Absolute Accuracy Presentation

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 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 Automate via PC Serial comm. to LevelMeter RobComm comm. to S4C Step 2

Plug into S4C RAPID automated calibration RS232 RobComm Alec Robertson Department DMF Confidential Interface Plates Robotics Motion Functions WonderWyler Unit Control spheres Interface Plate Left Face 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 IRB2400L IRB4400 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 No right angle surfaces IRB1400 50mm 50mm Back of arm 2

No right angle surfaces 50mm IRB140 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 Right angle surface on left IRB6400 IRB6400R Sensors Robotics

Motion Functions 57mm 90mm 24mm Alec Robertson Department DMF Confidential Summary Robotics Motion Functions Operator actions Flange (axis 36) 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 Installation Axis 1 Axis 2 Axes 36 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 Motion Functions Axis 2 housing Base/Foot/Axis 1 housing Axis 1 [1] 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 Robotics Motion Functions Axis 1 [2] 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 Alec Robertson Department DMF Confidential Wyler Front Value (F1) Wyler Side Value (S1) 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 Robotics Motion Functions CalPos4= (0,0,0,-90,90,90) Axis 4 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 Parallel Bar Length OK! 0.80 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 (de gree s)

Parallelogram Model Alec Robertson Department DMF Confidential Quality Check

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