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MOTOCAL V32 OPERATOR’S MANUAL VERSION 4.10 or LATER Upon receipt of the product and prior to initial operation, read these instructions thoroughly and retain for future reference. Part Number: Revision: 165139-1CD 1 MANUAL NO. HW9482359 4 1/61

General Precautions ・ Diagrams and photos in this manual are used as examples only and may differ from the actual delivered product. ・ This manual may be modified when necessary because of improvement of the product, modification, or changes in specifications. Such modification is made as a revision by renewing the manual No. ・ To order a copy of this manual, if your copy has been damaged or lost, contact your YASKAWA representative listed on the last page stating the manual No. on the front page. ・ YASKAWA is not responsible for any modification of the product made by the user since that will void our guarantee. ・ Software supplied with this manuals intended for use by licensed operators only and may only be used or copied according to the provisions of the license. ・ Reproduction of any part of this manual without the consent of YASKAWA is forbidden. ©YASKAWA, 1997 2/61

CONTENTS PREFACE ----------------------------------------------------------------- 4 4 4 4 Outline of MOTOVALV32 ----------------------------------------------------------------- Requirements for MOTOCALV32 Execution ----------------------------------------- MOTOCALV32 Setup --------------------------------------------------------------------- 1. TYPES OF CALIBRATION ---------------------------------------- 5 5 5 5 5 5 1.1 Robot Calibration ----------------------------------------------------------------------- 1.2 Tool Calibration ------------------------------------------------------------------------- 1.3 Tool Posture Calibration -------------------------------------------------------------- 1.4 Workpiece Calibration ----------------------------------------------------------------- 1.5 Layout Correction ---------------------------------------------------------------------- 2. OPERATION ----------------------------------------------------------- 2.1 Robot Calibration ------------------------------------------------------------------------ 2.1.1 Operation with Actual Robot --------------------------------------------------- 2.1.2 Operation on Personal Computer --------------------------------------------- 2.2 Tool Calibration ---------------------------------------------------------------------------- 2.2.1 Operation with Actual Robot --------------------------------------------------- 2.2.2 Operation on Personal Computer --------------------------------------------- 2.3 Tool Posture Calibration ---------------------------------------------------------------- 2.3.1 Operation with Actual Robot ---------------------------------------------------- 2.3.2 Operation on Personal Computer ---------------------------------------------- 2.4 Workpiece Calibration ------------------------------------------------------------------- 2.4.1 Workpiece Calibration ------------------------------------------------------------ 2.4.2 Job Conversion --------------------------------------------------------------------- 2.5 Layout Correction -------------------------------------------------------------------------- 2.5.1 Robot Layout Correction ---------------------------------------------------------- 2.5.2 Travel Axis Correction ------------------------------------------------------------- 6 6 6 9 16 16 17 20 20 21 24 24 29 34 34 40 APPENDIX ------------------------------------------------------------------ Appendix 1. Examples of Robot Calibration -------------------------------------------- Appendix 2. Examples of Tool Calibration ----------------------------------------------- 47 47 53 3/61

PREFACE Outline of MOTOCALV32 The MOTOCALV32 has been developed to improve positioning accuracy of YASKAWA’s industrial robot MOTOMAN. The MOTOCALV32 is an application software for MS-Windows, which offers excellent operability on various types of personal computers. Requirements for MOTOCALV32 Execution OS Required Memory CPU Hardware disk MS-Windows 95/98/NT4.0(SP3 or more)*2)/2000 *1 16 Mbytes or more Pentium90 MHz or more 15 Mbytes or more Capacity Screen Mouse Screen supported by Windows (256 colors or more) Mouse supported by Windows *1) MS-Windows95, MS-Windows98, MS-Windows NT4.0, MS-Windows 2000 are trade marks of Microsoft Corporation, U.S.A. *2) Service Packs 3 or more must be used for Microsoft Windows NT4.0. MOTOCALV32 Setup 1. Turn ON the power to the personal computer and screen. 2. Start the Windows. 3. 4. Select the [Control Panel] of [Setting] from the [Start] button in the menu of task bar, then select the Insert the install CD-ROM to the CD-ROM drive. [Add/Delete Application]. 5. Click the [Set-up] button and set "MOTOCALV32¥Disk1¥setup.exe" of the CD-ROM drive, following to the instructions displayed in the screen. 6. Clicking the [Complete] button starts the installation program. Follow the instructions displayed in the screen. 7. At the completion of setup, the [MOTOCALV32] icon is displayed in the [Start]-[Program]-[Motoman]-[MOTOCALV32]. 4/61

１．TYPES OF CALIBRATION The following types of calibrations are available for MOTOCALV32. 1.1 Robot Calibration Adjusts the absolute data and tool data, by teaching 5 postures each of 5 points (total 25 points) with robot. This calibration improves the absolute value accuracy of robot. 1.2 Tool Calibration Adjusts tool data by teaching 7 postures at 1 point (total 7 points) with robot. This calibration calculates the exact tool data (robot control point). 1.3 Tool Posture Calibration Adjusts tool data by teaching 1 posture at 1 point (total 1 point) with robot. This calibration calculates the exact tool positions (Rx, Ry, and Rz). 1.4 Workpiece Calibration Recognizes the positional difference between each robot and workpiece, by comparing the job created by offline system and the job created with the actual robot. Then converts the position data by offline system into the data for the actual robot, using the difference above. 1.5 Layout Correction The layout correction is composed of "Robot Layout Correction" and "Travel Axis Tilt Correction." "Robot Layout Correction" corrects the robot layout in the cell constructed by ROTSY for actual robot layout, by comparing the job created by offline system and the job created with the actual robot. "Travel Axis Tilt Correction" corrects the robot layout in the cell constructed by ROTSY for the actual robot layout, by calculating the positional difference between the travel axis and the robot positioned on the travel axis. 5/61

２．OPERATION This chapter explains the operation method of each calibration by MOTOCALV32. 2.1 Robot Calibration 2.1.1 Operation with Actual Robot 1) To perform robot calibration, prepare the data of tool to be mounted in advance. The following three methods are available for tool data. Performs the tool calibration with the actual robot controller. Performs the tool calibration by MOTOCALV32. (Refer to Section 2.2 "Tool Calibration.") Uses the values of mechanical dimensions if specified in the drawing, etc. 2) Mount an end-pointed tool on the robot flange. Use a tool with pointed-end part offset to the direction of X- or Y-axis on the tool coordinate. (Offset amount of approx. 200 mm is recommended.) 3) Using this tool, perform teaching of the job (job name: ROBOT) for 5 postures each of 5 points (total 25 points). The calibration job "ROBOT" is used for actual calculation by the calibration software. The teaching method is explained below. a) Using the same tool, perform teaching of 5 postures at each 5 point. (Use MOVJ or MOVL for interpolation type. On base of the taught positions, X, Y, and Z will be calculated internally.) Notes 1: For teaching of large-size robots of K60 and more, perform teaching with the wrist angle 45 or less, since the flexure by the robot arm weight may affect calibration, with the wrist posture largely inclined. For robot sizes below K60, incline the wrist 45 or more. 2: When the actual playback operation requires movement changing robot form, for example, the robot wrist axis rotating in reverse, perform teaching with the posture of that movement. 6/61

Fig. 2.1.1 Teaching the Same Point with 5 Postures b) With operation a), perform teaching of 1 point at 5 different points. The distance between each point should be kept to a minimum of 100 mm. If this condition is not kept, this function doesn’t work right. Perform teaching at five points from left upper side to right lower side with 5 postures each, so that the values of X, Y, and Z vary equally in a wide area of the robot front face, for teaching of correct calibration job. For robot postures at job teaching, refer to Appendix 1 "Examples of Robot Calibration." Robot Positioning job First posture Second posture Third posture Fourth posture Fifth posture 7/61

NOP *1 MOVJ C0000 VJ=0.78 PL=0 MOVJ C0001 VJ=0.78 PL=0 MOVJ C0002 VJ=0.78 PL=0 MOVJ C0003 VJ=0.78 PL=0 MOVJ C0004 VJ=0.78 PL=0 *2 MOVJ C0005 VJ=0.78 PL=0 MOVJ C0006 VJ=0.78 PL=0 MOVJ C0007 VJ=0.78 PL=0 MOVJ C0008 VJ=0.78 PL=0 MOVJ C0009 VJ=0.78 PL=0 *3 MOVJ C0010 VJ=0.78 PL=0 MOVJ C0011 VJ=0.78 PL=0 MOVJ C0012 VJ=0.78 PL=0 MOVJ C0013 VJ=0.78 PL=0 MOVJ C0014 VJ=0.78 PL=0 *4 MOVJ C0015 VJ=0.78 PL=0 MOVJ C0016 VJ=0.78 PL=0 MOVJ C0017 VJ=0.78 PL=0 MOVJ C0018 VJ=0.78 PL=0 MOVJ C0019 VJ=0.78 PL=0 *5 MOVJ C0020 VJ=0.78 PL=0 MOVJ C0021 VJ=0.78 PL=0 MOVJ C0022 VJ=0.78 PL=0 MOVJ C0023 VJ=0.78 PL=0 MOVJ C0024 VJ=0.78 PL=0 END Fig. 2.1.2 Teaching 5 Points with 5 Postures Positioning jigRobotP1P2P3P4P5RobotPositioning jig8/61

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