4 System Overview - Installation 4231Scope of delivery LEONI:1: TCP-3D Sensor3: TCP-3D Controller with cable setpedestal optionalNot included:2. Torch Cleaner4. Robot Controller5. Robot5
5 System Overview - Assembly Robot controllerField busSupply voltage+24 DC
6 System Overview - Sensor Sensor inside dimensions in mm: 120 x 120Larger sensors available on request
7 System Overview – Controller Mounting bracket integrated
8 System Overview – Operation <OK>LEFTACKNOWLEDGERIGHT
9 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.
10 Systen Overview – Functional Description Procedure – Use of master tool and working toolStartStart calibrationProduction process with working tool1. Step:Working tool is saved as master toolMaster tool is copied into working toolCommissioningWorking tool is calibratedWorking tool is corrected
11 Systen Overview – What is new? Leoni update toolMilling optionTandem torch optionConnection of 2 additional sensors
12 Applications Measurable Geometries Wire, Nozzle Rotationally Symmetric ToolsMilling Tools with FlutesCutting Tools and Blades
15 Applications Activation codes for additional modes Required information for receiving an activation code:Hardware versionSerial numberWhere do I find the hardware version and the serial number?Version – HWRev. B 2.2/2.0Version – S.No.M31/42Main MenuSetupHardware VersionVersionSerial Number
16 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/O-Module.
17 ApplicationsSealingAutomated 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
18 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
19 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
20 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.
21 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.
22 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
23 Applications 6D Blade Calibration TCP position, orientation and cutting direction of a blade.
24 Features Available Interfaces DeviceNet CANopenInterbusProfibusProfinetEtherNet/IPEthernet TCP/IPEtherCATModbusTCPModbusRTUPowerlinkAdditional interfaces on request.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)
25 Features Calibration Times 2D-Calibration < 3 Seconds Calibration of the translational axes X and Y3D-Calibration < 5 SecondsCalibration of the translational axes X, Y and Z5D/6D-Calibration < 10 SecondsCalibration of the translational axes and the orientation X, Y, Z, Rx, Ry, Rz6D Gripper/Fixture Calibration >15 Secondsdepending on the application
26 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.
27 Technical Data - Overview advintec TCP-3Dadvintec TCP-5Dadvintec TCP-6DSensor type2 Channel Infra red 880 nm, pulsed 2kHzInterfaceSeial or field bus (DeviceNet, Profibus, Profinet, Interbus, etc.)Accuracy0,02 mmCalibration Time3 Sec. complete 2D calibration, 6 Sec. complete 3D calibration9 Sec. complete 5D calibration> 15 Sec. complete 6D calibrationProtection classIP67Useable in dirty environmentYesEnclosureAluminiumDimensions2 or 3 Translations5 (3 Translations, 2 Rotations)6 (3 Translations, 3 Rotations)Automatic correction of tool dataApplicationsArc Welding, Stud welding, Spot Welding, Laser Welding, TIG Welding, Sealing, MillingGripper Calibration, Calibration of Fixtures, Power Train Assembly, High Precision ApplicationsCE-MarkOperating Voltage10-34 V DCConnectorsIBS Plug, 5-pin, PE leading
28 Data Backup / UpdateWith 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.
29 Data Backup / Update Update Tool With this tool it is possible to perform a software update or install custom software onto the TCP-ControllerThe system settings are retained during an updatePower
30 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 toolAutomated 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.
31 Customer Value Advantages at a glance Simplified Integration in the production line due to the small footprintExternal system, the calculations are made in an external processor and the results are transferred to the robot controllerHigh process safetyNo external PC requiredLogging of calibration dataData analysis possible at all timesNo more touching up due to tool wear or change100% 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 movementsShort calibration timesSmall footprintIntegration in close proximity of the torch cleaneradvintec TCP-Sensors are unsensitive to anti-spatter spray, as they make use of infra red technologyReduction of costs due to reduced scrap and reworkElimination of possible sources of error due to dependance on own exact calibration valuesEasy to use and set up
32 LEONI TCP Systems Worldwide CustomerCountrySiteTotal TCPGermanySindelfingenBremenGaggenau420WorldwideVW WolfsburgVW HannoverVW KasselVW Coaching EmdenVW MoselVW Poznan PolandVW Slovakia BratislavaSkoda Mlada BolislavAudi NeckarsulmVW PortugalVW Mexico297BelgiumGenk50OthersGermanyFrance100LEONI TCP-Systems installed: > Status
33 Thank you for your attention EndThank you for your attention
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