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13.10.1 Overview
Touch sensing (optional feature) allows the robot to change a path
automatically to compensate for object displacement.
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NOTE
You must wire the necessary connections for the
input and output signals to be used for touch
sensing. The wire stick detection circuit on the
process I/O board also can be used for touch
sensing.
NOTE
Some welding power supplies, such as the Lincoln
Electric PowerWave 450 provide internal touch
sensing circuitry. These power supplies can be
automatically set up for the appropriate inputs and
outputs when software configuration is performed.
CAUTION
If a WI is assigned as the touch sensing input signal,
the dedicated function it performs must be disabled.
Refer to Section 12.2 Welding Input/Output Signals.
You can also set up touch sensing to monitor the condition of any RO
or DO signal as an input signal. When the selected output turns on
during a touch sensing routine, the controller reads this as a received
input signal.
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CAUTION
If a WO is assigned as the touch sensing input
signal, the dedicated function it performs must be
disabled. Refer to Section 2 Welding Input/Output
Signals.
NOTE
To use touch sensing, the weld interface cable must
be installed. If you are using the Lincoln
PowerWave 450 weld power supply, the power
source must be turned on for touch sensing to work.
NOTE
After you have decided what I/O to use for touch
sensing, you should add a comment to the selected
I/O indicating that the I/O has been assigned to
touch sensing. This is done using the SETUP menu.
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NOTE
This screen shows the settings of the currently
selected motion group. To view the settings of
another motion group, change the motion group
by selecting an auxiliary menu item CHANGE
GROUP.
NOTE
The allowable input range for the sensor and
circuit ports is from 1 to 256. The ArcTool
software checks the validity of the port type and
port number when running your program that
includes touch sensing. If the port type or
number is invalid, the system displays an I/O
invalid error message.
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For touch sensing with coordinated motion, you can select the touch
frame relative to the UFRAME of the robot (follower) or the
coordinated frame of the reference group (leader). If the reference
group is set for the leader group, the search direction will be relative
to that group.
Typically, only one search motion is used for each search direction.
Some search patterns require two search motions in each of two search
directions for the ArcTool software to calculate an angular offset.
Search patterns determine the type of information stored in the
position register. The stored information is either the found position
or position offset information depending on the search pattern used.
Touch schedules allow you to set up the conditions that define the
search motions. These conditions include the position register, touch
frame and search pattern to use; the robot speed and motion type; and
other conditions.
Fig. 13.10.3(a), Fig. 13.10.3(b), and Fig. 13.10.3 (c) represent how
search motions are used in a program.
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Touch Frames
A touch frame determines the motion direction of the robot TCP. A
touch frame is defined by three points. The first point defines the
origin, or starting point. The second point defines the positive x
direction of the touch frame. The third point defines the positive x-y
plane.
Fig. 13.10.3 (d) shows a touch frame and how it is used in a touch
sensing program. The orientation of the touch frame to the object is
arbitrary in Fig. 13.10.3(d).
The positive x axis could be aligned with the current z direction.
This would re-define positive z to be in the opposite direction of the
current positive x direction.
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NOTE
You can set up a maximum of 32 touch frames.
Touch frames are set up using the touch frame
screen in the Setup menu.
NOTE
You must define a touch frame before you perform a
search motion in a program.
There are two ways to define touch frames: The teaching method
and the direct entry method. The teaching method defines the touch
frame by recording three points. The direct entry method defines the
touch frame by the rotation angle value you enter in the touch sense
setup screen.
Table13.10.3(a) lists and describes the items you must set to define the
touch frame.
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NOTE
When Reference Group is not equal to 1, the touch
frame changes with the coordinate frame, but the
display of the Rotate about X, Y, and Z items
remains unchanged.
Use Procedure 13-17 to define your touch frame by using the teaching
method. Use Procedure 13-18 to define your touch frame by using the
direct entry method
Teach Method:
Origin : UNINIT
+X direction : UNINIT
+Y direction : UNINIT
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NOTE
Do not forget this operation. If you forget this
operation, touch frame can not be defined.
Procedure 13-18 Setting up a touch frame using the direct entry method
Step
1 Press MENUS.
2 Select SETUP.
3 Press F1, [TYPE].
4 Select Touch Frame. You will see a screen similar to the
following.
Touch Frame Setup JOINT 10 %
1/7
Frame #: 1 Ref Grp: 1 Robot Grp: 1
Direct Entry:
Rotate about X : 0.000
Rotate about Y : 0.000
Rotate about Z : 0.000
Teach Method:
Origin : UNINIT
+X direction : UNINIT
+Y direction : UNINIT
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NOTE
If you change the value of Reference Grp for an
initialized frame, the following warning message will
be displayed:
Search Pattern
Search patterns determine the kind of information stored in the
position register. The stored information is either the found position,
or the position offset information depending on the search pattern used
and the reference group specified in the touch schedule. Four types
of search patterns are available:
- Simple search
- Fillet/lap search
- V-Groove search
- Outside/inside diameter search
Simple Search
For a simple search, a two-dimensional search is executed to find the
actual location of one position on an object. A simple search stores
the found position (x, y, z, w, p, r) into a position register PR[ ].
Once completed, the robot is programmed to move to the position
stored in that position register.
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CAUTION
Do not use simple search when you use the
multipass option with touch sensing because both
simple search and multipass use position registers.
Simple search stores the computed position in a
position register. Multipass cannot use position
registers to plan paths. Use the 2D fillet search
pattern when using multipass with touch sensing.
The first search defines the positional information for that search
direction only (x, for example). The second search defines the other
direction positional information (z, for example). The starting
position of the second search defines the remaining positional
information, (y, w, p, r, for example) that determines the torch angle
for welding and, in this case, the y value.
Simple search is typically used to find the starting point of a weld path
that uses the Thru-Arc Seam Tracking(TAST) option or Automatic
Voltage Control (AVC) Tracking option.
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Fig. 13.10.3 (e) Simple search routine using searches in two directions
Fillet/Lap Search
For a Fillet/Lap Search a one, two, or three dimensional search is
executed to obtain positional offset information. A Fillet/Lap Search
stores positional offset information in a positional register PR[ ].
This offset can be applied to one or more positions in a programmed
path.
The offset can be in one, two or three directions. The offset can also
be in two directions plus rotation about the axis of which no searching
is performed. For example, if the object is being searched for offset in
both x and y directions, a fillet search can offset for a rotation about
the z axis.
Fig. 13.10.3(f) Fillet search in one direction (x) with rotation about z
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Fig. 13.10.3 (g) Fillet search in two directions (x and y) with rotation about z
Fig. 13.10.3 (h) Fillet search in three directions (x, y, z) with rotation about z
V-Groove Search
For V-Groove Search a one-dimensional search is executed to obtain
positional offset information. A V-Groove Search stores positional
offset information in a positional register [PR]. This offset can be
applied to one or more positions in a programmed path.
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Table 13.10.3 (b) shows a matrix of possible search pattern and valid
pattern types. Select a combination that you would like to use on your
application and verify that it will provide the proper results.
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Touch Schedule
A touch schedule is a series of conditions that control how the search
motion is completed. Thirty-two touch schedules are available.
You access touch schedules from the DATA menu. There are two
screens associated with touch schedules: the SCHEDULE screen and
the DETAIL screen.
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CAUTION
A search motion is programmed as a motion option at the end of a
position instruction. The speed at which the robot will move is
determined by the search speed, not by what is indicated in the
position instruction. During testing, when dry run is in effect, this
search speed is also used. The dry run speed has no effect.
Search Distance This item defines how far the robot can move when it is performing a search. Error
Default = 100 mm code THSR-017 Pause No contact with part. is displayed when this distance is
reached without making contact with the object.
Touch Frame This item defines the touch frame to be used in the touch schedule. This
Default = 1 determines the x, y, and z directions for the search motion. The same touch frame
can be used in more than one touch schedule.
Search Patterns This item defines the type of object to be searched and causes the Arctool software
Default = SIMPLE to compute the found position or positional offset information dependent on the
search pattern selected. The computed data is stored in a position register.
There are four available search patterns:
-Simple Search
-Fillet Search
-V-Groove Search
-OD/I D Search
Refer to the description of search patterns.
Pattern Type This item selects the type of offset to be stored in the position register.
Default = 1_D Shift Six pattern types are available:
1_D Shift Stores a one dimensional offset. Offsets can be in the x, y, or z direction.
2_D Shift Stores a two dimensional offset. Offsets can be in two of the x, y, or z direction.
3_D Shift Stores a three dimensional offset to a program. Offsets are in the x, y, or z
1_D Offset direction. Stores a one dimensional offset with rotation about the axis of which the
2_D Offset search is not performed.
3_D Offset Stores a two dimensional offset with rotation about the axis of which no searches are
performed. For example, if the object is being searched for an offset in both the x
and y directions, a 2_D Shift & Rotate search can offset for a rotation about the z
axis. Stores a three dimensional offset with rotation about the axis of which no
searches are performed. For example, if the object is being searched for an offset
in both the x and y directions, a 3_D Shift & Rotate search can offset for a rotation
about the z axis. NOTE Simple, OD/ID, and V-Groove search patterns are
pre-defined. Changing the pattern type for these searches has no effect. See
13.10.3 for valid pattern types for selected search patterns.
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ITEM DESCRIPTION
Incremental Search Offsets the starting position of the second etc. search in a search routine by the
Default = ON amount of offset found by the first search motion. If set to OFF, the robot returns to
the original starting position. The following illustration shows how the incremental
search affects the search routine. Incremental search requires a separate
SEARCH START point for each search.
Without incremental search, the robot found the x-offset but cannot find the z-offset.
NOTE: Simple search does not support incremental search
Auto Return This item moves the robot back to the search start position when contact is made
Default = ON with the object. If set to OFF, the robot stops at the contact point and moves
straight to the next position.
Return Speed This item specifies the speed at which the robot will return to the search start
Default = 100 mm/sec position upon making contact with the part.
Return Term Type This item specifies the termination type the robot will use to return to the search start
Default = Fine position. Five Return Term Types are available:
-FINE
-CNT20
-CNT40
-CNT100
Return Distance When Auto Return is set to ON, Return Distance specifies the distance the robot will
Default = 2000 mm return automatically. If the return distance passes the initial search start position,
Minimum = 0 mm the robot will return to the initial start position.
Maximum = 2000 mm
Reference Group This item specifies how the offset is recorded:
If the specified number is the same as the number specified in the robot group item,
which will be described later, OFFSET is recorded with respect to the user
coordinate system of the robot group of the number. (no coordination) If the
specified number is different from the number specified in the robot group item,
OFFSET is recorded with respect to the coordinated frame of the robot group
specified in the robot group item and the robot group (leader) specified in this item.
NOTE For searches other than simple search, Reference Group must equal the
frame Reference Group. Otherwise, an error message, "Reference grp
mismatch," will be displayed. For simple search, Reference Group must
be same as the specified number of Robot Grp. Otherwise an error
message, "Illegal motion ref. grp," will be displayed.
Contact Record PR The search output position register is used as a temporary buffer to hold the last
Default = 32 search contact position. The purpose for this temporary position register buffer is to
provide the ability to look at the positional data of an individual search, or to extract
data from the buffer in a program. By default, this register is position register 32.
Search output position register should be assigned to the last position register
number in your system.
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ITEM DESCRIPTION
CAUTION
The data in the position register is overwritten at each search motion
so the same position register should not be used to store the final
positional data from the search motion. Also, the contents of this
temporary buffer is a real position, not an offset. Do not program
motion instructions to use this position register data as an offset.
Error on Failure This item posts error code THSR - 017( PAUSE) No contact with part, if the search
Default = ON move exceeds the distance set in Search Distance. When OFF, the program
execution continues with the next instruction if the Search Distance is exceeded;
Programming Hint: If this is set to OFF, the next instruction in the program looks at
the contents of the Error Register and branch accordingly.
Error Register Number When Error On Failure is set to OFF, this register is set to 1 when the search
Default = 32 distance is exceeded. A successful search sets this register to 0.
Robot Group This item specifies the robot group which uses the touch sensing schedule.
Default = [1,∗,∗,∗,∗,∗,∗, ∗]
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NOTE
Any changes to the tool frame affects the touch start
position.
CAUTION
Recorded positions and position registers are
affected by UFRAME, and UFRAME has an affect
during playback. If you change UFRAME, any
recorded positions and position registers will also
change.
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with the object, the robot's current TCP position is stored and robot
motion is stopped.
NOTE
Search and Search Start must use FINE termination
type.
The recorded position that has the search motion option is not
executed, so motion to the search start position must be recorded in a
separate motion instruction. See Fig.13.10.4(a).
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3 Move the cursor to the end of the motion instruction line of the
selected position.
4 Press F4, [CHOICE] to view the motion option choices.
5 Select 8, Next Page
6 Select Search and press ENTER.
7 Select the direction of the search to be performed and press
ENTER.
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13-24
CAUTION
Do not execute a Touch Offset End instruction and
then use backward execution to move to the
program line that contains the robot position you
want to touchup. Otherwise, the offset data will be
incorrect.
3 Single step to a line in the program that contains the first robot
position that you want to touchup.
4 Jog the robot to the new position, press and hold in the SHIFT
key and press F5, TOUCHUP.
5 Touch up all necessary robot positions between the Touch Offset
Start and Offset End positions.
Programming Examples
Example programs contained in this section include:
- Simple search – Fig. 13.10.4 (c)
- One-dimensional search (Fillet/Lap, V-Groove)– Fig. 13.10.4 (d)
- Two-dimensional with rotation – Fig. 13.10.4 (e)
- Two-dimensional with coordinated motion – Fig. 13.10.4 (f), Fig.
13.10.4 (g), and Fig. 13.10.4 (h)
- Simple search with coordinated motion – Fig. 13.10.4 (i)
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CAUTION
Do not use a continuous term type (CNT) for motion
that is right before a Search. Instead, use the FINE
term type. See line 3 in the Simple Search
Example Program. If you use continuous, the
search cannot compute a valid offset.
CAUTION
Simple search is different from all other searches in
three aspects: First, the master flag in the
schedule is always set to off. Second, the position
register contains an absolute position instead of an
offset. Third, TOUCH OFFSET instruction is not
used.
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Fig. 13.10.4 (f) Two dimensional search with coordinated motion example program
(See Fig. 13.10.4(g) and Fig. 13.10.4 (h) for illustrations)
NOTE
The search direction is part relative as shown in
Fig.13.10.4(g). When the part moves, the search
direction does not change.
Offset PR[2] is part relative as shown in
Fig.13.10.4(h)
Motions between searches are allowed.
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Fig. 13.10.4 (g) First illustration of two dimensional search with coordinated motion program example
Fig. 13.10.4 (h) Second illustration of two dimensional search with coordinated motion program example
Fig. 13.10.4 (i) Simple search with coordinated motion example program
NOTE
The simple search frame can be relative to the
follower or to the leader group. The stored position is
relative to the follower.
The leader is not allowed to move between the
searches.
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Fig.13.10.4 (j) Three dimensional search with rotation example program (See Fig. 13.10.4(k) for an illustration)
Fig.13.10.4(k) Illustration of three dimensional search with rotation program example (Fig. 13.10.4(j))
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- Offsets
- Patterns
- Master Flag
- Touching up Path Positions and Incorrect Touch Up
- Adding New Positions
- Multiple Searches
- Touching Up Search Start Positions
Mastering
Mastering refers to defining taught positions in a program as the
expected locations of positions. When the robot follows the taught
positions of the master path, then the offset is zero. An example is
shown in Fig. 13.10.5(a).
Remastering
The touch up procedure described in Section 13.10.5 should work for
most instances where the search start positions do not need to be
moved or if the parts do not change drastically.
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NOTE
Complex parts with multiple searches might only
require remastering of specific portions of the path.
Offsets
Offsets generated by touch sensing are relative to the position found
while mastering. An offset is computed by comparing the location of
the part with the stored location. Fig.13.10.5(b) illustrates the offset
value.
- The search performed during mastering establishes the expected
location (which is indicated by the small straight line).
- This location is stored when mastering the part.
- An offset is computed by comparing the location of the part with
this stored location.
- The offset is part relative when the schedule reference group is
not equal to 1.
• Master Flag ON
Patterns
Mastering is needed for search patterns that generate offset data. The
search patterns that require mastering are as follows:
- Fillet/Lap
- V-Groove
- Outside and Inside diameter searches
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NOTE
A simple search does not require mastering since it
produces an actual location stored in a position
register.
Program Example
The following program example describes a part with a search start
location and three points along a straight path.
- The points are numbered according to the program example.
- The search is a two dimensional search, one in the X direction
and the second in the -Z direction.
- A 2_D Fillet/Lap search was performed.
- The type of search and other details are defined in Touch Sense
Schedule 3.
- Both searches were started at point 2 and the offset information is
stored in position register 1.
- Points 5, 6, and 7 are offset according to the results of the search.
To perform Incremental searches, each search must have its own start
point. In the example program, line 5 was included so the Incremental
search feature could be used for the second search. If Incremental is
turned off, line 5 could be removed and both searches would start at
the taught location of position 2.
Master Flag
The first time the program is executed the part must be mastered.
- Mastering is done by turning on the Master Flag in the Touch
Sense Schedule 3.
- Execute the program.
- The search is performed and the path is followed according to the
taught positions.
- Once the program is completed, the Master Flag is turned OFF.
- According to search result, correct P[5], [6], [7] by touch Touch
offset instruction.
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NOTE
Incremental search is disabled while the Master Flag
is turned ON.
Fig.13.10.5(c) Part with one touch sense start position, 2, and three points along a path, 5, 6, 7
NOTE
Touch up must be performed after a successful
touch sense and at the same time the offset is being
applied. Fig.13.10.5(f) illustrates the result of the
touch up process.
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Incorrect Touch Up
A common error is to alter the path without the correct offset being
applied. Touching up must be done after executing the search and
while the Touch Offset is applied.
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- The part will not be followed correctly when the program is run.
Refer to Fig. 13.10.5(g).
- The offset shifts points 5 and 7 to the correct location along the
part. Point 6 will not be along the part since the master path
was incorrectly touched up.
- Fig.13.10.5(h) exhibits the path that was followed after altering
one point. It shows that the part is not followed correctly.
NOTE
If the program is ABORTED while adding new
positions, the offset is cancelled. New positions will
be taught as actual locations rather than positions
with an offset applied. The results would be similar
to what is shown in Fig.13.10.5(h).
Fig. 13.10.5 (i) New point taught while executing the offset path.
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Multiple Searches
Complex programs can have multiple searches generating several
offsets as shown in Fig.13.10.5(j).
If the path using positions 13, 14, and 15 must be touched up, the
second search must be executed.
- The second search stores offset data in position register 2 with
positions 13, 14, and 15 using the offset.
NOTE
Using this method can reduce the amount of time
required to adjust a small section of the program.
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Fig. 13.10.5 (k) Illustration of part shape change and the effect on multiple searches performed
Program Example 1
The following program example shown in Fig.13.10.5(l) exhibits a
part and search start position.
If the search start position is too close to the part due to poor
programming, changes in the part, or a change in the part location,
then
- The search start position needs only to be moved back along the
search direction.
- This can be accomplished with no effect on the path positions
and remastering will not be required.
Program Example 2
The program example shown in Fig. 13.10.5(m) shows the search start
position moved to a new location off the axis of the search direction.
If the search position is moved off the axis of the search direction,
then:
- Remastering is required. To remaster refer to Section 13.10.5.
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Fig. 13.10.5(m) Search start position moved to a new location off the axis of the search direction
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