Transcript Absolute Accuracy Presentation

Robotics
Motion Functions
WonderWyler
Alec Robertson – Department DMF – Confidential
Wyler
Robotics
Motion Functions
axis 4,6 0
• Levelling method
• no robot error
compensation
• low tool0 accuracy
compared to nominal
• innacurate recalibration
process
axis 3 0
axis 5 0
Z
Y
axis 2 90°
X
Key
foot 0°
Alec Robertson – Department DMF – Confidential
Wyler spread
Ideal tool0
Actual tool0
Wyler Errors
Robotics
Motion Functions
• Existing process
• error  0.9mm at tool0
• error  1.5mm at TCP (200, 200, 200)
• Error sources
• Placement of sensors and plates (55%)
• Tolerance of plates (35%)
• Stochastic (10%)
Alec Robertson – Department DMF – Confidential
WonderWyler
Robotics
Motion Functions
• Improve process repeatability
•
•
•
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•
No mounting plates
Highly accurate mounting cube
Absolute measurement not relative
Automated via RobComm/RAPID
tool0 deviation  0.4mm
Alec Robertson – Department DMF – Confidential
Main Unit
Robotics
Motion Functions
Control spheres
(magnetic)
Wyler Side
Wyler Front
Axis 2-6
Control spheres (magnetic)
Axis 1
Alec Robertson – Department DMF – Confidential
Prototype
Robotics
Motion Functions
LevelMeter 2000
• Step 1
Sensor B
Sensor A
RS232
RobComm
Alec Robertson – Department DMF – Confidential
• Automate via PC
• Serial comm. to LevelMeter
• RobComm comm. to S4C
• Step 2
• Plug into S4C
• RAPID automated calibration
Interface Plates
Robotics
Motion Functions
WonderWyler Unit
Interface Plate
Left
Face
Control
spheres
Control
cylinders
Alec Robertson – Department DMF – Confidential
Right
Face
Robot Flange
Control
pin
Control
surface
Robot
flange
holes
Control spheres magnetically attach
(kinematic coupling) to control cylinders
Interface Plates (cont.)
Robotics
Motion Functions
Robot flange
Interface plate
WonderWyler unit
 50mm
 63mm
 125mm
 160mm
 315mm
IRB140
IRB1400
IRB2400
IRB4400
IRB2400L
IRB6400
IRB6400R
Alec Robertson – Department DMF – Confidential
Voyager
Axis 1
Robotics
Motion Functions
Machined surface
50mm
50mm
60mm
50mm
60mm
Left or Right side of
robot base
Left or Right side of
robot base
No right angle surfaces
No right angle surfaces
IRB140
IRB2400L
IRB1400
IRB2400
IRB6400
Alec Robertson – Department DMF – Confidential
50mm
Left side of robot base
Right angle surfaces
IRB6400R
Control spheres magnetically attach
to axis 1 machined surface.
Axis 2
Robotics
Motion Functions
50mm
Front of arm 2
IRB1400
No right angle surfaces
50mm
50mm
Back of arm 2
IRB140
No right angle surfaces
50mm
Machined surface
60mm
60mm
Machined surface
Alec Robertson – Department DMF – Confidential
Back of arm 2
IRB2400L
Right angle surface
on right
IRB2400
IRB4400
Control spheres magnetically attach
to axis 2 machined surface
Axis 2 (cont.)
Robotics
Motion Functions
50mm
Back of arm 2
Right angle surface on
left and right
50mm
Front of arm 2
50mm
50mm
Alec Robertson – Department DMF – Confidential
IRB6400
Right angle surface
on left
IRB6400R
Sensors
Robotics
Motion Functions
57mm
90mm
24mm
Alec Robertson – Department DMF – Confidential
Summary
Robotics
Motion Functions
• Operator actions
Flange (axis 3–6)
g
Lower arm (axis 2)
Base (reference)
Alec Robertson – Department DMF – Confidential
• Axis 1 with mechanical fork
• Base, lower arm, flange
placements
• RobComm/RAPID automation
• Input angles via serial port
• Calculate axis adjustments
• Recalibrate resolvers
Procedure
Robotics
Motion Functions
• Connect to serial port on cabinet
• Run RAPID Program
• Prompts
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•
•
•
Installation
Axis 1
Axis 2
Axes 3–6
Alec Robertson – Department DMF – Confidential
Installation
Robotics
Motion Functions
g
• Place WonderWyler on base
reference plate
• Measure reference values
• Wyler Front (FR)
• Wyler Side (SR)
Wyler Front Reference Value (FR)
Wyler Side Reference Value (SR)
Alec Robertson – Department DMF – Confidential
Robotics
Axis 1 [1]
Motion Functions
Axis 2 housing
Base/Foot/Axis
1 housing
• Use mechanical fork
• Trim robot via RAPID
• Acceptable accuracy
Hollow cylinder to match  10
pin on axis 2 housing
 10 pin to fit hole in base
reference plate
Calibration tool
Alec Robertson – Department DMF – Confidential
Axis 1 [2]
Robotics
Motion Functions
• Improve existing design
• Connect axis 1 rocker arm
• Measure absolute values
• Front (F1), Side (S1 )
• Axis 1 adjustment
• 1 = F1 - FR
arm
hinge
Wyler Front Value (F1)
Wyler front
Wyler Side Value (S1)
Alec Robertson – Department DMF – Confidential
Axis 1 [3]
Robotics
Motion Functions
Wyler Front Value (F1)
Wyler Side Value (S1)
• Complete redesign
• Split kinematic coupling
• Determine axis 1 adjustment
from kinematic coupling
calculation
• Use for all axes?
Axis 1 adjustment
Axis 2
housing
WonderWyler kinematic coupling
Foot
Kinematic coupling grooves
Alec Robertson – Department DMF – Confidential
Wyler Front Value (F1)
Axis 2
Robotics
Motion Functions
CalPos2= (0,0,0,0,0,0)
• Connect to Axis 2
• Run robot to CalPos2
• Measure absolute values
• Front (F2), Side (S2 )
• Axis 2 adjustment
• 2 = F2 - FR
Wyler Front Value (F2)
Wyler Side Value (S2)
Alec Robertson – Department DMF – Confidential
Axis 3
Robotics
Motion Functions
CalPos3= (0,0,0,-90,0,90)
• Connect to flange
• Run robot to CalPos3
• Measure absolute value
• Front (F3)
• Axis 3 adjustment
Wyler Front Value (F3)
Wyler Side Value (S3)
Alec Robertson – Department DMF – Confidential
• 3 = F3 - FR
Axis 4
Robotics
Motion Functions
CalPos4= (0,0,0,-90,90,90)
• Run robot to CalPos4
• Measure absolute value
• Front (F4)
• Axis 4 adjustment
• 4 = F4 - SR
Wyler Front Value (F4)
Wyler Side Value (S4)
Alec Robertson – Department DMF – Confidential
Axis 5 and 6
Robotics
Motion Functions
CalPos5= (0,0,0,0,0,0)
• Run robot to CalPos5
• Measure absolute value
• Front (F5), Side (S5)
• Axis 5, 6 adjustments
• 5 = F5 - FR
• 6 = S5 - SR
Wyler Front Value (F5)
Wyler Side Value (S5)
Alec Robertson – Department DMF – Confidential
Quality Check
Robotics
Motion Functions
3=-1
3=0
3=+1
Axis 3 Error (with offset adjustment)
Parallelogram Effect on Axis 3 Error
Axis 3 Error
Wyler Measured (24-12401)
1.40
Parallel Arm Length OK!
1.20
Axis 3 Error (Degrees)
1.00
0.80
Parallel Bar Length OK!
0.60
0.40
Predicted Reorientation OK!
0.20
0.00
-60
-55
-50
-45
-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
15
20
25
30
35
40
45
50
55
60
-0.20
Axis 2 (degrees)
Parallelogram Model
Alec Robertson – Department DMF – Confidential
Quality Check