Presentation advintec TCP-3D Calibration System

1. Presentation advintec TCP-3D Calibration System

2. 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

3. Product Portfolio Robotics

4. System Overview - Installation 4 3 2 1 • Scope of delivery LEONI: • 1: TCP-3D Sensor • 3: TCP-3D Controller with cable set • pedestal optional • Not included: • 2. Torch Cleaner • 4. Robot Controller • 5. Robot 5

5. System Overview - Assembly Robot controller Field bus Supply voltage +24 DC

6. System Overview - Sensor Sensor inside dimensions in mm: 120 x 120 Larger sensors available on request

7. System Overview – Controller Mounting bracket integrated

8. System Overview – Operation

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 tool Start Start calibration Production process with working tool 1. Step: Working tool is saved as master tool Master tool is copied into working tool Commissioning Working tool is calibrated Working tool is corrected

11. Milling option www.roboter-info.de Leoni update tool Tandem torch option www.imperia.mi-verlag.de Connection of 2 additional sensors Systen Overview – What is new?

12. Applications • Measurable Geometries Wire, Nozzle Rotationally Symmetric Tools Milling Tools with Flutes Cutting Tools and Blades www.tragaskiss.com www.lotex.de www.smdv.de

13. Applications • Calibration Modes Selectable Dimensions 2D 3D 5D/6D Additional Modes Stud Welding Sealant Nozzles Milling Tools Tandem Torches

14. Applications • Additional Modes www.imperia.mi-verlag.de www.emhart.eu www.sca-schucker.de www.lotex.de Stud Welding Sealant Nozzles Milling Tools Tandem Torches

15. Main Menu Setup Setup Version Version – HW Rev. B 2.2/2.0 Version – S.No. M31/42 Hardware Version Applications • Activation codes for additional modes • Required information for receiving an activation code: • Hardware version • Serial number • Where do I find the hardware version and the serial number? Serial 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. 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

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 • 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) • Available Interfaces • DeviceNet • CANopen • Interbus • Profibus • Profinet • EtherNet/IP • Ethernet TCP/IP • EtherCAT • ModbusTCP • ModbusRTU • Powerlink • Additional interfaces on request.

25. 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

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

28. 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.

29. Power 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

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 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.

31. 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 safetyand 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

32. LEONI TCP Systems Worldwide Country Site Customer Total TCP • Germany • Sindelfingen • Bremen • Gaggenau 420 • Worldwide • 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 297 • Belgium • Genk 50 Others • Germany • France 100 LEONI TCP-Systems installed: > 867 Status 2012-05

33. End • Thank you for your attention