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Presentation advintec TCP-3D Calibration System Business Unit Industrial Solutions The Quality Connection Contents 1. Product portfolio Robotics 2. System Overview 3. Applications / Features 4. Technical Data 5. Data Backup / Update 6. Additional Features 7. Customer Value 8. References Business Unit Industrial Solutions 2017-03-26 2 Product Portfolio Robotics Business Unit Industrial Solutions 2017-03-26 3 System Overview - Installation 4 2 3 1 Scope of delivery LEONI: 1: TCP-3D Sensor 3: TCP-3D Controller with cable set - pedestal optional 5 Not included: 2. Torch Cleaner 4. Robot Controller 5. Robot Business Unit Industrial Solutions 2017-03-26 4 System Overview - Assembly Robot controller Field bus Supply voltage +24 DC Business Unit Industrial Solutions 2017-03-26 5 System Overview - Sensor Sensor inside dimensions in mm: 120 x 120 Larger sensors available on request Business Unit Industrial Solutions 2017-03-26 6 System Overview – Controller Mounting bracket integrated Business Unit Industrial Solutions 2017-03-26 7 System Overview – Operation Business Unit Industrial Solutions < OK > LEFT ACKNOWLEDGE RIGHT 2017-03-26 8 Systen Overview – Functional Description • advintec TCP-3D calibrates the tool electronically in 3 dimensions (X, Y, Z). • In addition it is possible to calibrate the tool orientation in the rotational axes (Rx, Ry, Rz). • The existing tool is referenced first, so that it is not neccessary to repeat the manual tool calibration. • The robot Trajectory is automatically offset according to the measured deviation in the tool position. • The tool always works in the correct position or path. Business Unit Industrial Solutions 2017-03-26 9 Systen Overview – Functional Description Procedure – Use of master tool and working tool Start Start calibration 1. Step: Working tool is saved as master tool Commissioning Master tool is copied into working tool Production process with working tool Working tool is calibrated Working tool is corrected Business Unit Industrial Solutions 2017-03-26 10 Systen Overview – What is new? Leoni update tool Milling option www.roboter-info.de Tandem torch option www.imperia.mi-verlag.de Business Unit Industrial Solutions Connection of 2 additional sensors 2017-03-26 11 Applications Measurable Geometries Wire, Nozzle Milling Tools with Flutes Cutting Tools and Blades Rotationally Symmetric Tools www.tragaskiss.com Business Unit Industrial Solutions www.lotex.de www.smdv.de 2017-03-26 12 Applications Calibration Modes Selectable Dimensions 2D 3D 5D/6D Additional Modes Stud Welding Business Unit Industrial Solutions Sealant Nozzles Milling Tools Tandem Torches 2017-03-26 13 Applications Additional Modes www.emhart.eu Stud Welding Business Unit Industrial Solutions www.sca-schucker.de Sealant Nozzles www.lotex.de Milling Tools www.imperia.mi-verlag.de Tandem Torches 2017-03-26 14 Applications Activation codes for additional modes Required information for receiving an activation code: 1. Hardware version 2. Serial number Where do I find the hardware version and the serial number? Main Menu Setup Setup Version Version – HW Rev. B 2.2/2.0 Hardware Version Business Unit Industrial Solutions Version – S.No. M31/42 Serial Number 2017-03-26 15 Applications Arc Welding • Automated torch calibration and correction of the TCP in 2D, 3D or 5D incl. wire centricity check. • Calibration system can be integrated directly into the torch cleaner. • As an option, the system can take over the control of the torch cleaner via an integrated I/OModule. Business Unit Industrial Solutions 2017-03-26 16 Applications Sealing • Automated calibration of sealant nozzles with special geometries. • Very accurate calibration of the position and orientation of the TCP as well as checking the geometry of the nozzle. • Detection of material build-up on the nozzle. Image: SCA Schucker Business Unit Industrial Solutions 2017-03-26 17 Applications Stud Welding • Automated calibration of stud welding heads. • Exact definition of the tool axis along the linear slide (5D-calbration of the TCP). Image: Tucker Business Unit Industrial Solutions 2017-03-26 18 Applications 6D Gripper Calibration • Automated 6D-calibration of the robot gripper. • Ideal for exchangeable grippers and high-precision applications such as power train assembly. • Compensation of temperature drift. Image: FZ Jülich Business Unit Industrial Solutions 2017-03-26 19 Applications Reference pins 6D Part/Gripper Calibration (Motor assembly) • Automated 6D-calibration of the robot gripper by using a reference part with calibration pins. • The calibration pins can also be mounted directly on the gripper. Business Unit Industrial Solutions 2017-03-26 20 Applications Spot Welding • Due to failures, welding guns often need to be replaced during production time. • The average down-time per gun change in a body shop can easily amount to approximately 90 minutes. • An early detection of gun defects is thus of principal interest. Business Unit Industrial Solutions 2017-03-26 21 Applications Drilling/Milling • Automated calibration of Milling tools and drill bits including tool breakage detection. • Ideal for use with an automatic tool changer. • Stores the dimensions of multiple tools and verifies whether the correct tool is loaded in the tool changer. Image: Fink Plexiglas Business Unit Industrial Solutions 2017-03-26 22 Applications 6D Blade Calibration • TCP position, orientation and cutting direction of a blade. Business Unit Industrial Solutions 2017-03-26 23 Features Available Interfaces • • • • • • • • • • • DeviceNet CANopen Interbus Profibus Profinet EtherNet/IP Ethernet TCP/IP EtherCAT ModbusTCP ModbusRTU Powerlink • Additional interfaces on request. Business Unit Industrial Solutions • The controller can manage up to 10 different tools. • The TCP Calibration System is fully independant of the robot brand. • Tools with a diameter of 0.3 mm – 35 mm can be calibrated (larger tools on request) 2017-03-26 24 Features Calibration Times • 2D-Calibration < 3 Seconds Calibration of the translational axes X and Y • 3D-Calibration < 5 Seconds Calibration of the translational axes X, Y and Z • 5D/6D-Calibration < 10 Seconds Calibration of the translational axes and the orientation X, Y, Z, Rx, Ry, Rz • 6D Gripper/Fixture Calibration >15 Seconds depending on the application Calibration of the translational axes and the orientation X, Y, Z, Rx, Ry, Rz Business Unit Industrial Solutions 2017-03-26 25 Features • Various calibration modes can be combined for the same tool. • Example: A welding torch can be quickly calibrated in 2D for small deviations during the production cycle. A more precise 5D-Calibration can be carried out after a tool change. Business Unit Industrial Solutions 2017-03-26 26 Technical Data - Overview advintec TCP-3D advintec TCP-5D advintec TCP-6D Sensor type 2 Channel Infra red 880 nm, pulsed 2kHz 2 Channel Infra red 880 nm, pulsed 2kHz 2 Channel Infra red 880 nm, pulsed 2kHz Interface Seial or field bus (DeviceNet, Profibus, Profinet, Interbus, etc.) Seial or field bus (DeviceNet, Profibus, Profinet, Interbus, etc.) Seial or field bus (DeviceNet, Profibus, Profinet, Interbus, etc.) Accuracy 0,02 mm 0,02 mm 0,02 mm Calibration Time 3 Sec. complete 2D calibration, 6 Sec. complete 3D calibration 9 Sec. complete 5D calibration > 15 Sec. complete 6D calibration Protection class IP67 IP67 IP67 Useable in dirty environment Yes Yes Yes Enclosure Aluminium Aluminium Aluminium Dimensions 2 or 3 Translations 5 (3 Translations, 2 Rotations) 6 (3 Translations, 3 Rotations) Automatic correction of tool data Yes Yes Yes Applications Arc Welding, Stud welding, Spot Welding, Laser Welding, TIG Welding, Sealing, Milling Arc Welding, Stud welding, Spot Welding, Laser Welding, TIG Welding, Sealing, Milling Gripper Calibration, Calibration of Fixtures, Power Train Assembly, High Precision Applications CE-Mark Yes Yes Yes Operating Voltage 10-34 V DC 10-34 V DC 10-34 V DC Connectors IBS Plug, 5-pin, PE leading IBS Plug, 5-pin, PE leading IBS Plug, 5-pin, PE leading Business Unit Industrial Solutions 2017-03-26 27 Data Backup / Update • With the LEONI Backup Interface the system settings can be backed up and restored. • In the event that a controller needs to be replaced, the settings of the old unit can be transferred to the replacement unit. Business Unit Industrial Solutions 2017-03-26 28 Data Backup / Update Update Tool •With this tool it is possible to perform a software update or install custom software onto the TCP-Controller •The system settings are retained during an update Power Business Unit Industrial Solutions 2017-03-26 29 Additional Features • Remote Configuration The configuration can be carried out via the field bus interface. Thus all settings required for the commisioning can be made via the teach pendant of the robot. • Initial calibration of a tool Automated initial calibration of an unknown tool. To this end only the starting point for the initial calibration needs to be recorded. The system then automatically calculates the tool data and transfers it to the robot controller. Business Unit Industrial Solutions 2017-03-26 30 Customer Value Advantages at a glance • Simplified Integration in the production line due to the small footprint • External system, the calculations are made in an external processor and the results are transferred to the robot controller High process safety No external PC required Logging of calibration data Data analysis possible at all times • No more touching up due to tool wear or change • 100% Quality assurance, that is higher process safety and better productivity due to the elimination of manual intervention or position related faults. • Calibration is carried out without contact or orientation movements Short calibration times Small footprint • Integration in close proximity of the torch cleaner advintec TCP-Sensors are unsensitive to anti-spatter spray, as they make use of infra red technology • Reduction of costs due to reduced scrap and rework Elimination of possible sources of error due to dependance on own exact calibration values • Easy to use and set up Business Unit Industrial Solutions 2017-03-26 31 LEONI TCP Systems Worldwide Customer Country Site Germany Sindelfingen Bremen Gaggenau 420 Worldwide 297 Belgium Others Germany France LEONI TCP-Systems installed: > 867 Business Unit Industrial Solutions Total TCP VW Wolfsburg VW Hannover VW Kassel VW Coaching Emden VW Mosel VW Poznan Poland VW Slovakia Bratislava Skoda Mlada Bolislav Audi Neckarsulm VW Portugal VW Mexico Genk 50 100 Status 2012-05 2017-03-26 32 End Thank you for your attention Business Unit Industrial Solutions 2017-03-26 33