1. Robotics Motion Functions Alec Robertson – Department DMF – Confidential WonderWyler

2. Robotics Motion Functions Alec Robertson – Department DMF – Confidential axis 5 0  Wyler Levelling method no robot error compensation low tool0 accuracy compared to nominal innacurate recalibration process X Z Ideal tool0 Actual tool0 Key Y foot 0° axis 2 90° axis 3 0  axis 4,6 0  Wyler spread

3. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Wyler Errors 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%)

4. Robotics Motion Functions Alec Robertson – Department DMF – Confidential WonderWyler Improve process repeatability No mounting plates Highly accurate mounting cube Absolute measurement not relative Automated via RobComm/RAPID tool0 deviation   0.4mm

5. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Main Unit Axis 2-6 Axis 1 Wyler Side Wyler Front Control spheres (magnetic)

6. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Prototype Step 1 Automate via PC Serial comm. to LevelMeter RobComm comm. to S4C Step 2 Plug into S4C RAPID automated calibration LevelMeter 2000 Sensor A Sensor B RS232 RobComm

7. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Interface Plates Left Face Right Face Interface Plate Control spheres Robot flange holes Robot FlangeWonderWyler Unit Control spheres magnetically attach (kinematic coupling) to control cylinders Control cylinders Control surface Control pin

8. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Interface Plates (cont.) IRB140 IRB1400 IRB2400L  50mm  63mm  125mm  160mm IRB2400 IRB4400 IRB6400 IRB6400R WonderWyler unit Interface plate Robot flange  315mm Voyager

9. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Axis 1 IRB140 IRB1400 50mm IRB2400L IRB2400 IRB6400 IRB6400R 50mm Left or Right side of robot base No right angle surfaces 60mm Left or Right side of robot base No right angle surfaces 50mm Left side of robot base Right angle surfaces Machined surface Control spheres magnetically attach to axis 1 machined surface.

10. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Axis 2 IRB1400 Front of arm 2 No right angle surfaces Back of arm 2 No right angle surfaces 50mm IRB140 Back of arm 2 Right angle surface on right 60mm IRB2400L IRB2400 IRB4400 Machined surface Control spheres magnetically attach to axis 2 machined surface

11. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Axis 2 (cont.) Back of arm 2 Right angle surface on left and right 50mm IRB6400 Front of arm 2 Right angle surface on left IRB6400R 50mm

12. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Sensors 57mm 90mm  24mm

13. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Summary Operator actions Axis 1 with mechanical fork Base, lower arm, flange placements RobComm/RAPID automation Input angles via serial port Calculate axis adjustments Recalibrate resolvers Base (reference) g Lower arm (axis 2) Flange (axis 3–6)

14. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Procedure Connect to serial port on cabinet Run RAPID Program Prompts Installation Axis 1 Axis 2 Axes 3–6

15. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Installation 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 ) g

16. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Axis 1 [1] Use mechanical fork Trim robot via RAPID Acceptable accuracy Hollow cylinder to match  10 pin on axis 2 housing Axis 2 housing Base/Foot/Axis 1 housing  10 pin to fit hole in base reference plate Calibration tool

17. Robotics Motion Functions Alec Robertson – Department DMF – Confidential 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 Wyler front hinge Wyler Front Value (  F1 ) Wyler Side Value (  S1 )

18. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Axis 1 [3] Complete redesign Split kinematic coupling Determine axis 1 adjustment from kinematic coupling calculation Use for all axes? Wyler Front Value (  F1 ) Wyler Side Value (  S1 ) Wyler Front Value (  F1 ) Axis 1 adjustment WonderWyler kinematic coupling Axis 2 housing Foot Kinematic coupling grooves

19. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Axis 2 Wyler Front Value (  F2 ) Wyler Side Value (  S2 ) Connect to Axis 2 Run robot to CalPos2 Measure absolute values Front (  F2 ), Side (  S2 ) Axis 2 adjustment  2 =  F2 -  FR CalPos2= (0,0,0,0,0,0)

20. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Axis 3 Connect to flange Run robot to CalPos3 Measure absolute value Front (  F3 ) Axis 3 adjustment  3 =  F3 -  FR Wyler Front Value (  F3 ) Wyler Side Value (  S3 ) CalPos3= (0,0,0,-90,0,90)

21. Robotics Motion Functions Alec Robertson – Department DMF – Confidential 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 ) CalPos4= (0,0,0,-90,90,90)

22. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Axis 5 and 6 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 ) CalPos5= (0,0,0,0,0,0)

23. Robotics Motion Functions Alec Robertson – Department DMF – Confidential Quality Check Parallelogram Model  3 =0   3 =+1   3 =-1  Parallel Arm Length OK! Parallel Bar Length OK! Predicted Reorientation OK!