Robotmaster Tutoriais passo a passo

Tutorial

ROBOTMASTER TUTORIAL SERIES Version 6 for Mastercam

Tutorial Title: Robotmaster Tutorial Series Date: April 1, 2013 Copyright Š2004-2013 by Jabez Technologies Inc. - All Rights Reserved.

ISBN: 978-0-9919274-0-1

Notice Jabez Technologies Inc. reserves the right to make improvements or change specifications to this manual at any time and without notice.

Disclaimer of All Warranties and Liability Jabez Technologies Inc. makes no warranties, either expressed or implied, with respect to this manual or with respect to the software described in this manual, its quality, performance, merchantability, or fitness for any particular purpose.

Copyrights The information contained within this document is the proprietary property of Jabez Technologies, Inc. and is protected under the copyright laws of Canada and the United Sates. This document, in whole or in part, may not be copied, reproduced, translated, reduced to any electronic medium or machine-readable form or transmitted to other parties without the expressed written authorization of Jabez Technologies, Inc.

Trademarks Robotmaster is a registered trademark licensed exclusively to Jabez Technologies Inc. MASTERCAM products and trademarks are property of CNC Software Inc. MICROSOFT FRAMEWORK V4.0 products and trademarks are property of Microsoft Corporation.

Tutorial

TUTORIAL 1 …………………………………………………….

INTRODUCTION TO ROBOTMASTER USING 2D CONTOUR TOOLPATHS

1.1

TUTORIAL 2 …………………………………………………….

MULTI-AXIS TOOLPATHS

2.1

TUTORIAL 3 …………………………………………………….

PROFILE TRACKING

3.1

TUTORIAL 4 ……………………………………………………

REPOSE POINTS

4.1

TUTORIAL 5 ……………………………………………………

OPTIMIZATION USING CURVE 5 AXIS TOOLPATH

5.1

TUTORIAL 6 ……………………………………………………

ROBOT ON A RAIL

6.1

TUTORIAL 7 ……………………………………………………

EXTERNAL ROTARY AXES

7.1

TUTORIAL 8 ……………………………….…….……………

PART TO TOOL

8.1

Tutorial 1

TUTORIAL 1 INTRODUCTION TO ROBOTMASTER USING 2D CONTOUR TOOLPATHS

1-1

Tutorial 1

Objectives: 1. The student will properly configure robot specific settings for a 2dimensional toolpath already created for a CNC machine by: a. Selecting the proper machine type through Mastercam; b. Understanding and mastering the basic features of Robotmaster; c. Entering Global Settings by:  Configuring the Robot page;  Configuring the Frame Data page;  Configuring the Approach/Retract data page;  Configuring the Tool and Configuration page; d. Entering Local Settings by:  Configuring the Axis Configuration page;

2. The student will simulate the process using the Robotmaster simulator.

This tutorial assumes that the student has the appropriate design and toolpath skills using Mastercam.

1-2

Tutorial 1 CUSTOMIZING THE TOOLBAR Before starting to work with Robotmaster, we should activate the toolbars required to use Robotmaster. See Robotmaster Quick Start Guide, pages 3 and 4.

STEP 1: OPEN THE MASTERCAM FILE The file Plate is located in the Robotmaster_V6\Samples\ directory.

File  Open.  Select the Plate file.

The file Plate contains one toolpath operation created for a standard 3 axis CNC machine as seen in the operations manager.

1-3

Tutorial 1 STEP 2: CHANGING THE ACTIVE MACHINE DEFINITION Before starting a new session with Robotmaster, we should select the proper machine definition in Mastercam. In this tutorial, we will use a Fanuc Robot machine.

See Robotmaster Quick Start Guide, pages 5 and 6 to add a robot to the machine list.

Operations Manager  Click on Properties - Generic Mill to expand the Machine Group settings.  Click on Files

 Click on Replace.

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Tutorial 1  Select ROBOTMASTER_V6_FANUC  Click on Open.

Notice the machine definition changed from Generic Mill to Fanuc Robot.

 Select the OK button to save and exit the Machine Group Properties window.

1-5

Tutorial 1 STEP 3: STARTING ROBOTMASTER GLOBAL SETTINGS INTERFACE The first step for any file is to enter the Global Settings. These settings are valid for all operations and include robot, tool process and environment information. ďƒ˜ Select the Robotmaster Global Settings from the main toolbar.

How do I know that Robotmaster is active and ready to use?

If the active machine definition is a Robotmaster_V6_[Robot_Type] and you are able to access the Global and Local Settings buttons, this confirms that the proper Robot definition is active and the Robotmaster features are enabled.

When does Robotmaster load up with default parameters?

When the Robotmaster Global or Local Settings interface is open for the first time in a Mastercam file, Robotmaster will load up with default values, which are predefined. Default values can be re-defined to your current parameter settings by using the Save as Global Defaults and Save as Local Defaults options in the Main Menu\Settings\.

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Tutorial 1 STEP 4: SETTING UP THE PARAMETERS IN THE ROBOT PAGE In this page we are selecting the robot and the tool that is attached to the end of the robot.

1-7

Tutorial 1  Click on the Robot pull down arrow and select ROBOTMASTER2.

 Click on the Tool pull down arrow and select GS_SPINDLE60.

1-8

Tutorial 1 STEP 5: SETTING UP THE PARAMETERS IN THE FRAME DATA PAGE In this page we need to determine where the part is located with respect to the origin of the robot.

Some robots have the origin at the intersection of the axis 1 and 2, and some robots have the origin at the bottom of the base.

Fig. 1 – Robot having the origin at the intersection of the axis 1 and 2

Fig. 2 – Robot having the origin at the bottom of the base

Note: The typical industrial robot has the coordinate axis in such a way that axis X is pointing straight out the front of the robot, axis Y is pointing to the left of the robot and axis Z is pointing to the top of the robot.

1-9

Tutorial 1  Select the Frame Data page.

The Base Data section represents the position and orientation of the part origin with respect to the robot.     

In the User Frame field, click the pull down arrow and select User defined.

Enter 1750 in the X value box.

Enter -250 in the Y value box.

Enter 250 in the Z value box.

Leave at 0 all the other values.

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Tutorial 1 The Tool Data section represents the position and orientation of the tool with respect to the end of the robot. ďƒ˜ In the Method field click the pull down arrow and select Use spindle definition.

The Use spindle definition option allows you to automatically calculate the coordinates X, Y, Z and the angles W, P, R of the tool, from the center of the robot flange to a reference point on the spindle. Robotmaster will read the holder and tool length from the Mastercam tool definition and add these values for total tool center point and orientation.

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Tutorial 1 STEP 6: SETTING UP THE PARAMETERS IN THE APPROACH/RETRACT PAGE The approach/retract points are the 6 joint values of the robot before the start and after the end of the program respectively.  Select the Approach/Retract page.

    

Enter 90 in the joint J1 value box.

Enter -45 in the joint J2 value box.

Enter -45 in the joint J3 value box.

Enter -90 in the joint J5 value box.

Leave at 0 J4 and J6.

 Then copy to the Retract section by clicking on the

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button.

Tutorial 1 STEP 7: SETTING UP THE PARAMETERS IN THE TOOL AND CONFIGURATION PAGE  Select the Tool and Configuration page.  In the Tool Call field, select the No tool call radio button.  In the Tool Activation field, select the No tool activation radio button.  Set the Robot Configuration settings as indicated in the screenshot below.

STEP 8: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 1 STEP 9: STARTING ROBOTMASTER LOCAL CONFIGURATION INTERFACE Local settings are used to set operation specific parameters. Only one operation can be selected to launch the Local Settings. Local Settings are compromised of axis configuration, optimization, safe retract, repose and external axis parameters.  Select the first operation in the operation manager.  Select the Robotmaster Local Settings from the main toolbar.

STEP 10: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE This page sets the orientation of the tool of the robot with respect to the part we are cutting.  Select the Axis Configuration page.  Select Spherical interpolation in the section Rotary Axis Calculation Method.  Adjust the Tool Rotation settings: o Enter 0 in the Tool Rotation numerical up down field.

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Tutorial 1 The axis configuration page selects the method of calculating 6 axis robot poses from 5-axis CAD/CAM toolpath data. In this first tutorial, the axis configuration is not addressed. In the two following tutorials, axis configuration will be addressed in detail.

STEP 11: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

STEP 12: SET UP OF SIMULATION PARAMETERS  Select the Robot Simulation Settings button from the Robotmaster toolbar.

 Set all parameters as shown below:

 Select the OK button to save and exit the Robot Simulation Settings window.

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Tutorial 1 Robot displays the active robot selected in the Robotmaster parameter window.

The robot cannot be changed through the Robot Simulation Settings window.

The Part option allows you to select the part geometries that will be displayed during the robot simulation.

The Settings button allows you to set up two tolerance values: o STL Tolerance, which is used to display the part during simulation. ďƒ˜ A good STL tolerance value for metric configuration is 0.1 ďƒ˜ A good STL tolerance value for inch configuration is 0.01 o Tolerance for collision checking during simulation.

When to use the Robot Simulation Settings button?

The Robot Simulation Settings is primarily used to set the part geometry that will be displayed during simulation. Once the initial simulation settings are done, unless the robot or part geometry is changed or that the part position or orientation is changed inside Mastercam, there is no need to use this feature.

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Tutorial 1 STEP 13: STARTING SIMULATION  Make sure the operation is selected. The Robotmaster simulation will not be launched properly unless at least one operation is selected.  Select the Robotmaster Simulation button from the Mastercam main toolbar.

 Select the Play button.

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Tutorial 1 OVERVIEW OF THE SIMULATION WINDOW  Calculate button: Process and validate the toolpaths.

 Progress bar: The progress bar can be used to quickly position the simulator to a specific location. Each operation is separated by tick marks on the progress bar.

 Point list: The list of points that corresponds to the toolpath trajectory that is being simulated. The active line is selected.

 Simulation control bar: To start the simulation select an operation and click on the Play button or step to the next move or operation by clicking the Next Point or Next Operation button in the simulation control bar.

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Tutorial 1  Simulation speed control: The simulation speed control allows the user to run the simulation faster/slower or to change the simulation step value for display on the screen.

 Axis control: Enables robot joint motion using the slider bars for each axis.

 Camera group: Fit to screen, Isometric, Top, Front, Right side, Bottom, Left side, Back.

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Tutorial 1 STEP 14: POSTING ROBOT CODES The Post button runs the Robotmaster post processor to generate a robot ready program file. The output type depends on the brand of robot selected.

ďƒ˜ Select the OK button to launch the postprocessor.

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Tutorial 2

TUTORIAL 2 MULTI-AXIS TOOLPATHS

2-1

Tutorial 2

Objectives: The student will understand how to set the robot tool orientations for multi-axis toolpaths by using the spherical interpolation method.

In this tutorial, the student will frequently be invited to go back and forth setting different tool orientations in order to further explore and understand the principles.

This tutorial assumes that the student has the appropriate design and toolpath skills using Mastercam.

2-2

Tutorial 2 CUSTOMIZING THE TOOLBAR  Before starting to work with Robotmaster, we should activate the toolbars required to use the simulation. See Robotmaster Quick Start Guide, pages 4 and 5.

STEP 1: OPEN THE MASTERCAM FILE The file Dome can be found in the Robotmaster_V6\Samples directory.

File  Open  Select the Dome file.

The file Dome has five toolpath operations created for a Fanuc Robot as seen in the Operations Manager.

2-3

Tutorial 2 STEP 2: CHANGING THE ACTIVE MACHINE DEFINITION The Machine definition for the file Dome is a Fanuc Robot machine. Please see Tutorial 1 for details on how to change the active robot brand if you would like to do this tutorial with another brand.

STEP 3: STARTING THE ROBOTMASTER PARAMETER INTERFACE  Select the Robotmaster Global Settings from the Robotmaster toolbar.

STEP 4: CONFIGURING THE ROBOT PAGE In this page we are selecting the robot and the tooling that is attached to the end of the robot.  Select the Robot page  Click on the Robot pull down arrow and select ROBOTMASTER2 generic robot.

This is a generic robot designed for use in this tutorial series.

 Click on the Tool selector button in order to select GS_SPINDLE60.

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Tutorial 2

2-5

Tutorial 2 STEP 5: SETTING UP PARAMETERS IN THE FRAME DATA PAGE  Select the Frame Data page and set the Base Data and Tool Data settings as indicated in the screenshot below:

     

In the User Frame field, click the pull down arrow and select User defined.

Enter 1500 in the X value box.

Enter 0 in the Y value box.

Enter 500 in the Z value box.

Leave at 0 all the other values.

In the Method field click the pull down arrow and select Use spindle definition.

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Tutorial 2 STEP 6: SETTING UP THE PARAMETERS IN THE APPROACH/RETRACT PAGE The approach/retract points are the 6 joint values of the robot before the start and after the end of the program respectively.  Select the Approach/Retract page.

    

Enter 90 in the joint J1 value box.

Enter -45 in the joint J2 value box.

Enter -45 in the joint J3 value box.

Enter -90 in the joint J5 value box.

Leave at 0 J4 and J6.

 Then copy to the Retract section by clicking on the

2-7

button.

Tutorial 2 STEP 7: SETTING UP THE TOOL AND CONFIGURATION PAGE  Select the Tool and Configuration page.  In the Tool Call field, select the No tool call radio button.  In the Tool Activation field, select the No tool activation radio button.  Set the Robot Configuration settings as indicated in the screenshot below:

STEP 8: SAVE THE GLOBAL PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 2 STEP 9: STARTING ROBOTMASTER LOCAL CONFIGURATION INTERFACE In this step, we will define the robot tool orientation scheme to be used for multi-axis toolpaths. ďƒ˜ Select the first operation in the operation manager. ďƒ˜ Select the Robotmaster Local Settings from the Robotmaster toolbar.

How are command points defined for robots?

A command point for CNC machines is comprised of a tool center position for a 3 axis machine. For 5 axis machines, the tool orientation is additionally defined by Mastercam as a tool vector which is resolved typically as two rotations in the post processor.

Fig. 1 - Typical positioning information required by 5axis CNC machines

Industrial robots typically have six axes therefore; there is one degree of redundancy that needs to be set in order to convert toolpath data to robot tool positions and orientations. Because the robot has the ability to rotate around the tool, each point is defined as a tool center position as well as an orientation matrix or three Euler angles which define a coordinate system.

Fig. 2 - Typical positioning information required by robots

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Tutorial 2 The Axis Configuration page sets the orientation of the tool of the robot with respect to the part we are cutting. The settings on this page manage the rotation around the tool vector.  Select the Axis Configuration page.  Choose Spherical interpolation in the Rotary Axis Calculation Method.

Once Spherical interpolation is selected, there are two methods available in the Type field:  Default with Z rotation.  Default no Z rotation.

In this tutorial we will look primarily into Default with Z rotation and Default no Z rotation and highlight the difference between both methods.  Choose Default with Z rotation in the Type field.  Choose TOP in the Orientation field.

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Tutorial 2 What is Orientation in Spherical Interpolation?

The orientation determines the plane on which the spherical dials are oriented with respect to the user frame as defined on the robot (which is also the current WCS). The three figures below will show how each plane is oriented.

Top

Front

Right

The three planes are oriented in such a way as to accommodate the three typical faces of the user frame most commonly accessed in a programming job.

However, each method wraps around to the other side of the plane if required.

The figure below shows a part as well as the user frame orientation. For this part, since all tool orientations can be thought of as in the top hemisphere then the top orientation is suitable for programming all cuts on this part.

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Tutorial 2 STEP10: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

STEP 11: SET UP OF THE SIMULATION PARAMETERS  Select the Robot Simulation Settings button from the Robotmaster toolbar.

 Set all parameters as shown below:

 Select the OK button to save and exit the Robot Simulation Settings window.

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Tutorial 2 STEP 12: STARTING THE SIMULATION PROCESS FOR OPERATION 1  Select operation 1.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

 Select the Play button.

The simulation will then start and the canvas will look like the screenshot below:

Run several times through the simulation and study the way in which the robot tool is oriented along the cut. In this first operation, we used the Default with Z rotation method which is further explained below.

During the simulation process of this first operation, you will notice that the X axis of the tool (red one) is always pointing relatively in the same direction.

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Tutorial 2 What is Spherical Interpolation, Default with Z rotation?

As the tool changes orientations, this method rotates around the tool Z axis to keep the X axis consistent with the way in which it is defined in the dials. The figure below shows an example where the tool is moving from one dial to the next and in this case, it rotates around the tool 90 degrees to proceed from one orientation (the blue one) to the next (yellow one).

STEP 13: TRYING DIFFERENT PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 1 We invite the student to come back to the Robotmaster parameter window and: ďƒ˜ Choose Default no Z rotation in the Type field.

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Tutorial 2 STEP 14: STARTING THE SIMULATION PROCESS FOR THE OPERATION 1 ďƒ˜ Make sure the operation is selected. ďƒ˜ Select the Robotmaster Simulation button from Robotmaster toolbar.

During simulation of this second parameter setting for operation 1, compare the way in which the robot tool is oriented along the toolpath versus the first approach.

During the simulation process, you will notice that there are no rotations anymore around the tool Z axis and therefore, the X (red) axis is always pointing in the same direction with respect to the cut.

What is Spherical Interpolation, Default no Z rotation?

As the tool changes orientations, this method does not rotate around the tool Z axis to keep the X axis consistent with the way in which it is defined in the dials.

The figure below shows an example where the tool is moving from one dial to the next and in this case there is no rotation around the tool Z axis to proceed from one orientation (the blue one) to the next (yellow one) as seen by the identical orientations of the X (red) axes along the trajectory.

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Tutorial 2 When to use Default no Z rotation versus Default with Z rotation?

Each method has specific advantages and disadvantages depending on the range of motion in the specific toolpath.

The method without rotation causes the tool X axis to point in relatively the same direction and this method is desirable when the tool orientation is far from vertical (away from the Z axis of the user frame or WCS). However, this method causes excessive rotation around the wrist of the robot when the tool orientation gets close to the vertical.

The method with rotation is constantly rotating around the tool Z as the tool orientation changes and this method is desirable when the tool orientation is close to the vertical (close to the Z axis of the user frame or WCS). However, this method causes excessive rotation around the wrist of the robot as the tool orientation gets farther from the vertical.

Note:  For operation 1, the best method is Default with Z rotation, thus we invite the student to return to the Robotmaster parameter window and set that option back to Default with Z rotation. By simulating again this first operation, you will notice that there is minimal wrist rotation.

It’s recommended to go back and forth between both methods in order to better understand the difference between with Z rotation and no Z rotation.

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Tutorial 2 STEP 15: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 2     

Select operation 2 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Default with Z rotation in the Type field.

Choose Top in the Orientation field.

STEP 16: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 2 STEP 17: STARTING THE SIMULATION PROCESS FOR OPERATION 2  Make sure the operation is selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

Note:  In this configuration, you will notice that the robot rotates a lot around the tool.

The elbow is going up and down around the tool as shown in the figures below:

This second operation contains toolpaths that are almost perpendicular to the vertical.

Therefore, Default no Z rotation will yield better results.

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Tutorial 2 STEP 18: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 2    

Select operation 2 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Default no Z rotation in the Type field.

STEP 19: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 2 STEP 20: STARTING SIMULATION PROCESS FOR THE OPERATION 2  Make sure the operation is selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

Note:  In this configuration, you will notice that the tool is always in the same orientation, it does not rotate anymore around the tool Z axis and the result is better. 

We invite the student to go back and try both methods and observe the difference between these two methods to help evaluate both methods.

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Tutorial 2 STEP 21: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 3     

Select operation 3 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Default no Z rotation in the Type field.

Choose Top in the Orientation field.

Note:  For operation 3, the best method is Default no Z rotation because we will not have excessive turning around the tool Z axis. 

As we had previously mentioned, anytime the toolpaths are oriented far from the vertical, or the tool is more or less cutting horizontally, it is always better to use the no Z rotation option.

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Tutorial 2 STEP 22: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

STEP 23: STARTING THE SIMULATION PROCESS FOR OPERATION 3  Make sure the operation is selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

We invite the student to go back and try both methods and observe the difference between these two methods for this third operation.

STEP 24: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 4 AND 5 Set Axis configurations of operations 4 and 5 with the same parameters given to operation 3.

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Tutorial 2 STEP 25: STARTING SIMULATION PROCESS FOR ALL FIVE OPERATIONS  Make sure all five operations are selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

Note:  Between the first and second operation, you will notice that the spindle is crashing into the part. To avoid this from happening we will have to use the safe Z retract height feature.

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Tutorial 2 STEP 26: SETTING UP PARAMETERS IN THE SAFE RETRACT PAGE FOR OPERATION 2  Select operation 2 in the operation manager.  Select the Robotmaster Local Settings from the Robotmaster toolbar.  Select the Safe Retract page.

 Check Use safe approach.  Select the Z axis.  Enter 250 in the value box.

This Z value represents the amount of safe Z retract height at the beginning of the second operation. This value will ensure that the robot will re-orient the wrist above the cutting zone and minimize the risk of robot to part collisions.  Select OK to save the parameters and exit the parameter window.

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Tutorial 2 How and when to use the Safe Z Retract Height settings?

The Safe Retract parameters can be used to move the robot head to a safe retract plane before and after an operation. This feature is useful when the robot head will perform a significant re-orientation between operations. At times, this re-orientation may cause a collision between the spindle and the part. This feature will move the robot head to a higher fixed plane to ensure that the robot has adequate space to re-orient the head without collisions.

STEP 27: STARTING SIMULATION PROCESS FOR ALL FIVE OPERATIONS  Make sure all five operations are selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

Note:  There are no more collisions between the first and the second operation because the robot re-orients the wrist by moving first to 250mm in Z from the user frame origin before engaging the second cut.

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Tutorial 2 NOTES:

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Tutorial 3

TUTORIAL 3 PROFILE TRACKING

3-1

Tutorial 3

Objectives: The student will understand how to set the robot tool orientations for multi-axis toolpaths by using the profile tracking method.

In this tutorial, the student will frequently be invited to go back and forth setting different tool orientations in order to further explore and understand the principles.

This tutorial assumes that the student has the appropriate design and toolpath skills using Mastercam.

3-2

Tutorial 3 CUSTOMIZING THE TOOLBAR  Before starting to work with Robotmaster, we should activate the toolbars required to use the simulation. See Robotmaster Quick Start Guide, pages 4 and 5.

STEP 1: OPEN THE MASTERCAM FILE The file Chair_Trimming is located in the Robotmaster_V6\Samples directory.

File  Open  Select the Chair_Trimming file.

The file Chair_Trimming has two toolpath operations created for a Fanuc Robot as seen in the Operations Manager.

3-3

Tutorial 3 STEP 2: CHANGING THE ACTIVE MACHINE DEFINITION The Machine definition for the file Chair_Trimming is a Fanuc Robot machine. Please see Tutorial 1 for details on how to change the active robot brand if you would like to do this tutorial with another brand.

STEP 3: STARTING THE ROBOTMASTER PARAMETER INTERFACE  Select the Robotmaster Global Settings from the Robotmaster toolbar.

STEP 4: CONFIGURING THE ROBOT PAGE In this page, we are selecting the robot and the tool that is attached to the flange of the robot.  Select the Robot page.  Click on the Robot pull down arrow and select ROBOTMASTER2 generic robot.

This is a generic robot designed for use in this tutorial series.  Click on the Tool selector button in order to select DEFAULT_KNIFE.

3-4

Tutorial 3 STEP 5: SETTING UP PARAMETERS IN THE FRAME DATA PAGE  Select the Frame Data page and set the Base Data and Tool Data settings as indicated in the screenshot below:

    

In the User Frame field, click the pull down arrow and select User defined.

Enter 2000 in the X value box.

Enter 550 in the Y value box.

Enter 500 in the Z value box.

Leave at 0 all the other values.

 In the Method field click the pull down arrow and select Use tool definition.  Enter 150 in the Z value box.  Leave at 0 all the other values.

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Tutorial 3 STEP 6: SETTING UP THE PARAMETERS IN THE APPROACH/RETRACT PAGE The approach/retract points are the 6 joint values of the robot before the start and after the end of the program respectively.  Select the Approach/Retract page.

    

Enter 90 in the joint J1 value box.

Enter -45 in the joint J2 value box.

Enter -45 in the joint J3 value box.

Enter -90 in the joint J5 value box.

Leave at 0 J4 and J6.

 Then copy to the Retract section by clicking on the

3-6

button.

Tutorial 3 STEP 7: SETTING UP THE TOOL AND CONFIGURATION PAGE  Select the Tool and Configuration page.  In the Tool Call field, select the No tool call radio button.  In the Tool Activation field, select the No tool activation radio button.  Set the Robot Configuration settings as indicated in the screenshot below.

STEP 8: SAVE THE GLOBAL PARAMETERS Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 3 STEP 9: STARTING ROBOTMASTER LOCAL CONFIGURATION INTERFACE  Select the first operation in the operation manager.  Select the Robotmaster Local Settings from the Robotmaster toolbar.

STEP 10: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 1  Select the Axis Configuration page.  Choose Profile Tracking in the Rotary Axis Calculation Method field.  Enter 0 in the Tool Rotation value box.

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Tutorial 3 What is Profile tracking?

Profile tracking is a method of setting the tool frame orientation relative to the direction of the trajectory. The tool frame orientation is varied based on the orientation of the next point on the trajectory to maintain a fixed relationship between the tool axis and the tangent to the trajectory.

STEP 11: SAVE THE PARAMETERS ďƒ˜ Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 3 STEP 12: SET UP OF THE SIMULATION PARAMETERS  Select the Robot Simulation Settings button from the Robotmaster toolbar.

 Set all parameters as shown below:

 Select the OK button to save and exit the Robot Simulation Settings window.

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Tutorial 3 STEP 13: STARTING THE SIMULATION PROCESS FOR OPERATION 1  Select operation 1.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

 Select the Play button.

The simulation will then start and the canvas will look like the screenshot below:

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Tutorial 3 Note:  In this configuration, you will notice that the flat part of the knife stays tangent to the trajectory allowing the trimming of the curved part contour with the edge of the blade.

STEP 14: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 2     

Select operation 2 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Profile Tracking in the Rotary Axis Calculation Method field.

Enter 0 in the Tool Rotation value box.

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Tutorial 3 STEP 15: STARTING THE SIMULATION PROCESS FOR OPERATION 2  Make sure the operation is selected. The Robotmaster simulation will not be launched properly unless at least one operation is selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

Note:  In this configuration, again you will notice that the flat part of the knife stays tangent to the trajectory allowing the trimming of the curved part contour with the edge of the blade.

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Tutorial 3 STEP 16: STARTING THE SIMULATION PROCESS FOR BOTH OPERATIONS  Make sure both operations are selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

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Tutorial 4

TUTORIAL 4 REPOSE POINTS

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Tutorial 4

Objectives: The student will understand how to change the robot posture between toolpath operations by using repose points.

In this tutorial, the student will frequently be invited to go back and forth setting different repose points in order to further explore and understand the principles.

This tutorial assumes that the student has the appropriate design and toolpath skills using Mastercam.

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Tutorial 4 CUSTOMIZING THE TOOLBAR  Before starting to work with Robotmaster, we should activate the toolbars required to use the simulation. See Robotmaster Quick Start Guide, pages 4 and 5.

STEP 1: OPEN THE MASTERCAM FILE The file Configuration_Change is located in the Robotmaster_V6\Samples directory.

File  Open  Select the Configuration_Change file.

The file Configuration_Change has four toolpath operations created for a Fanuc Robot as seen in the Operations Manager.

STEP 2: CHANGING THE ACTIVE MACHINE DEFINITION The Machine definition for the file Configuration_Change is a Fanuc Robot machine.

Please see Tutorial 1 for details on how to change the active robot brand if you would like to do this tutorial with another brand.

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Tutorial 4 STEP 3: STARTING ROBOTMASTER GLOBAL CONFIGURATION INTERFACE  Select the Robotmaster Global Settings from the Robotmaster toolbar.

STEP 4: CONFIGURING THE ROBOT PAGE In this page, we are selecting the robot and the tool that is attached to the flange of the robot.  Select the Robot page.  Click on the Robot pull down arrow and select ROBOTMASTER2 generic robot.

This is a generic robot designed for use in this tutorial series.  Click on the Tool selector button in order to select GS_SPINDLE60.

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Tutorial 4 STEP 5: SETTING UP PARAMETERS IN THE FRAME DATA PAGE  Select the Frame Data page and set the Base Data and Tool Data settings as indicated in the screenshot below:

    

In the User Frame field, click the pull down arrow and select User defined.

Enter 2000 in the X value box.

Enter -580 in the Y value box.

Enter 600 in the Z value box.

Leave at 0 all the other values.

 In the Method field click the pull down arrow and select Use spindle definition.

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Tutorial 4 STEP 6: SETTING UP THE PARAMETERS IN THE APPROACH/RETRACT PAGE The approach/retract points are the 6 joint values of the robot before the start and after the end of the program respectively.  Select the Approach/Retract page.

    

Enter 90 in the joint J1 value box.

Enter -45 in the joint J2 value box.

Enter -45 in the joint J3 value box.

Enter -90 in the joint J5 value box.

Leave at 0 J4 and J6.

 Then copy to the Retract section by clicking on the

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button.

Tutorial 4 STEP 7: SETTING UP THE TOOL AND CONFIGURATION PAGE  Select the Tool and Configuration page.  In the Tool Call field, select the No tool call radio button.  In the Tool Activation field, select the No tool activation radio button.  Set the Robot Configuration settings as indicated in the screenshot below.

What is ‘Same’ Robot Configuration?

When a robot configuration is set to any value other than Same, this configuration is maintained throughout the entire program. If orientation changes are required then the Same option needs to be used.

When the configuration is set to Same, the initial configuration is calculated automatically from the joint values set in the Approach point. Subsequently, if robot positions are programmed between operations by using the Repose option, then the robot configuration will be evaluated after each Repose point and this updated configuration will be used.

By using the Same configuration option and Repose points it is possible to program configuration changes between operations.

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Tutorial 4 STEP 8: SAVE THE GLOBAL PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

STEP 9: STARTING ROBOTMASTER LOCAL CONFIGURATION INTERFACE  Select the first operation in the operation manager.  Select the Robotmaster Local Settings from the Robotmaster toolbar.

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Tutorial 4 STEP 10: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 1  Select the Axis Configuration page.

   

Choose Spherical interpolation in the Rotary Axis Calculation Method field.

Choose Default no Z rotation in the Type field.

Choose Top in the Orientation field.

Set Tool Rotation to 0.

STEP 11: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 4 STEP 12: SET UP OF THE SIMULATION PARAMETERS  Select the Robot Simulation Settings button from the Robotmaster toolbar.

 Set all parameters as shown below:

 Select the OK button to save and exit the Robot Simulation Settings window.

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Tutorial 4 STEP 13: STARTING THE SIMULATION PROCESS FOR OPERATION 1  Make sure the operation is selected. The Robotmaster simulation will not launch unless at least one operation is selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

 Select the Play button.

The simulation will then start and the canvas will look like the screenshot below:

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Tutorial 4 STEP 14: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 2       

Select operation 2 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Spherical interpolation in the Rotary Axis Calculation Method field.

Choose Default no Z rotation in the Type field.

Choose Top in the Orientation field.

Set the Tool Rotation to 0.

STEP 15: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 4 STEP 16: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 3       

Select operation 3 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Spherical interpolation in the Rotary Axis Calculation Method field.

Choose Default with Z rotation in the Type field.

Choose Top in the Orientation field.

Set the Tool Rotation to 10.

STEP 17: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 4 STEP 18: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 4       

Select operation 4 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Spherical interpolation in the Rotary Axis Calculation Method field.

Choose Default with Z rotation in the Type field.

Choose Top in the Orientation field.

Set the Tool Rotation to 180.

STEP 19: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 4 STEP 20: STARTING THE SIMULATION PROCESS FOR ALL FOUR OPERATIONS  Make sure all four operations are selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

Note:  You will notice that the robot reorients the wrist inside the part. This might be dangerous, because a collision can occur especially if using fast joint motion settings.  To avoid a possible collision, we will send the robot to a position that will allow the tool to clear the part in a safe manner.

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Tutorial 4 STEP 21: SETTING UP PARAMETERS IN REPOSE PAGE FOR OPERATION 3    

Select operation 3 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Repose page.

Double click in the Repose joint values field, under Name, to add a repose position.  Type ClearPosition1 as the name of the 1st repose position.  Click on the Repose editor button.

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Tutorial 4  Simulate the toolpath to the last point of operation 3 using the track bar.  Enter 10 in the J1 value box.  By using the same method, enter the following values: o Enter -30 in the J2 value box. o Enter -20 in the J3 value box. o Enter -60 in the J4 value box. o Enter -10 in the J5 value box. o Enter -295 in the J6 value box.

   

Select the Repose tab.

Select the ClearPosition1 repose point.

Select the Set To Repose button to update the joint values of ClearPosition1.

Exit the Repose Editor by closing the current window.

Note:  The joint values entered will move the robot to a safe position that we will use to clear the part during a change of robot wrist re-orientation. 

This is our first repose point ClearPosition1 and it will be placed at the beginning of the third operation.



All individual joint values will be saved to repose point ClearPosition1 when the simulator is closed.

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Tutorial 4  Insert this Repose before the operation by clicking the Add button as shown in the screen shot below.

STEP 22: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 4 STEP 23: STARTING THE SIMULATION PROCESS FOR ALL FOUR OPERATIONS  Make sure all four operations are selected.  Select the Robot Simulation button from the Robotmaster toolbar.

Note:  You will notice that the robot reorients itself outside the part at the first repose position.

 



You will notice that the robot crashes into the part at the beginning of the fourth operation.

You will also notice that the robot is not in a desired configuration to work from underneath the part and that the 5th and 6th joints are close to their minimum limit.

To avoid the collision, we will send the robot to a safe position, change the configuration from Elbow-Up to Elbow-Down and unwind joints 5 and 6.

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Tutorial 4 STEP 24: SETTING UP PARAMETERS IN REPOSE PAGE FOR OPERATION 4      

Select operation 4 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Repose page.

Double click in the Repose joint values field to add a repose position.

Type SafePosition as the name of the 2nd repose position.

Select the Repose Editor button.

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Tutorial 4  Simulate the toolpath to the first point of operation 4 using the track bar.  Enter 25 in the J1 value box.  By using the same method, enter the following values: o Enter -20 in the J2 value box. o Enter 0 in the J3 value box. o Enter -75 in the J4 value box. o Enter 0 in the J5 value box. o Enter 0 in the J6 value box.

 Select the Repose tab.  Select the SafePosition repose point.  Select the Set To Repose button to update the joint values of SafePosition.

Note:  The joint values that are entered will move the robot to a safe position that we will use to clear the part during a change of robot orientation.  This is our second repose point SafePosition and it will be place at the beginning of the fourth operation. It will be used to position the robot to a safe position prior to changing its configuration.

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Tutorial 4  Double click in the Name field to add a repose position.  Type ChangeConfigurationPosition as the name of the 3rd repose position.

       

Enter 25 in the J1 value box.

Enter 135 in the J2 value box.

Enter 165 in the J3 value box.

Enter 175 in the J4 value box.

Enter -10 in the J5 value box.

Enter 0 in the J6 value box.

Select the ChangeConfigurationPosition repose point.

Select the Set To Repose button to update the joint values of ChangeConfigurationPosition.

Note:  This is our third repose point ChangeConfigurationPosition and should be placed before the fourth operation after the SafePosition repose. It will be used to change the robot to an elbow down configuration.

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Tutorial 4  Double click in the Name field to add a repose position.  Type ClearPosition2 as the name of the second 4th position.

        

Enter 0 in the J1 value box.

Enter 135 in the J2 value box.

Enter 165 in the J3 value box.

Enter 175 in the J4 value box.

Enter -10 in the J5 value box.

Enter 0 in the J6 value box.

Select the ClearPosition2 repose point.

Select the Set To Repose button to update the joint values of ClearPosition2.

Exit the Repose Editor by closing the current window.

Note:  This is our fourth and last repose point ClearPosition2 and should be placed before the fourth operation after the ChangeConfigurationPosition repose. It is used to approach the part in a safe manner.

Four robot postures (robot positions in joint values) were set by using the simulator and these positions will be required for successfully programming of the part.

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Tutorial 4 The repose option allows the user to define robot postures in joint coordinates and to sequentially place them before and/or after the current operation.

Some common reasons for use of repose points are:  Winding/unwinding one or more axis between operations to avoid reaching maximum joint limits.  Changing the robot posture between operations.  Managing configuration changes.  Insert repose ClearPosition1, SafePosition, ChangeConfigurationPosition and ClearPosition2 before the operation by clicking the Add button in the right order.  Insert repose ClearPosition2, ChangeConfigurationPosition and SafePosition after the operation by clicking the Add button in the right order.

Note:  We use the same repose points in the reverse order after operation 4 to re-set the robot to its initial configuration in a manner to avoid collisions with the part.

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Tutorial 4 STEP 25: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

STEP 26: STARTING THE SIMULATION PROCESS FOR ALL FOUR OPERATIONS  Make sure all four operations are selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

In summary, by adding the four repose points, the following has been accomplished: Before operation 3:  Collisions have been avoided during robot wrist re-orientations; Before operation 4:  Joint 6 was wound back to zero to avoid running out of joint limits;  The configuration of the robot has been changed from Elbow-Up to ElbowDown to successfully complete the path of the operation without collisions; After operation 4:  The configuration of the robot was reset after the last operation.

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Tutorial 4 NOTES:

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Tutorial 5

TUTORIAL 5 OPTIMIZATION USING CURVE 5 AXIS TOOLPATH

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Tutorial 5

Objectives: 1. The student will program a curve 5 axis trajectory and set robot specific parameters for a multiaxis toolpath by: a. Understanding and using the basic features of Mastercam;  Selecting the proper machine type through Mastercam;  Configuring the Tool page;  Configuring the Cut Parameters page;  Configuring the Lead Entry/Exit page;  Configuring the Linking Parameters page; b. Understanding and mastering the main features of Robotmaster;  Entering Global Settings by:  Configuring the Robot page;  Configuring the Frame Data page;  Configuring the Approach/Retract data page;  Configuring the Tool and Configuration page;  Entering Local Settings by:  Configuring the Axis Configuration page;  Configuring the Optimization page; 2. The student will simulate the process using the Robotmaster simulator.

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Tutorial 5 CUSTOMIZING THE TOOLBAR  Before starting to work with Robotmaster, we should activate the toolbars required to use the robot simulation. See Robotmaster Quick Start Guide, pages 3 and 4.

STEP 1: OPEN THE MASTERCAM FILE The file Seal_Trim_Optimization can be found in the Robotmaster_V6\Samples directory.

The file SEAL_TRIM_OPTIMIZATION_WITH_TOOLPATH can be used to complete this tutorial without toolpath creation. If you decide to skip toolpath creation, start this tutorial at step 7.

File  Open  Select the Seal_Trim_Optimization file.

The file Seal_Trim_Optimization contains all of the required geometry in order to create a curve 5 axis toolpath.

STEP 2: LOADING A ROBOT MACHINE DEFINITION Before starting a new session with Robotmaster, we should select the proper machine definition in Mastercam. Loading a robot machine definition is necessary in order to use Robotmaster’s features and functionalities. In this tutorial we will use a Fanuc Robot machine.

See Robotmaster Quick Start Guide, pages 4 and 5 to add a robot to the machine list.

Machine Type  Select Robotmaster_V6_fanuc from the menu Machine Type  Mill

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Tutorial 5 Notice the machine definition for Fanuc robots is now loaded in the Operations Manager.

STEP 3: GENERATING A CURVE 5 AXIS TRAJECTORY Now we will generate the robot trajectory using the Mastercam curve 5 axis toolpath.

This comprises of selecting geometry and setting trajectory and tool parameters.

Creating a curve 5 axis toolpath ďƒ˜ Select Multiaxis from the Toolpaths menu to create a curve 5 axis toolpath.

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Tutorial 5 Mastercam will prompt you to enter a NC name. This name will be used for the robot program file name.  Enter the robot program name.

Note: Please refer to your robot documentation for restrictions on program names.

 Click the OK button to confirm the NC name.

STEP 4: SELECTING THE TOOLPATH TYPE Now we will select the toolpath type.  Select the Toolpath Type page.  Select Calculation based on Classic and select Curve.

You will now be prompted to set tool and trajectory parameters.

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Tutorial 5 STEP 5: SELECT THE TOOL We will now select the tool from the Mastercam tool library.  Select the Tool page to set the tool parameters.  Click the Select library tool button to open the Mastercam tool library.

 Click the Filter button to open the tool filter window.

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Tutorial 5  Click the None button to clear any tool type selection.  Click the End mill button from Tool Types. Ensure only the End mill button is selected.

 Select the OK button to end the filter selection.  Select tool 216 7.0 FLAT ENDMILL for use in the trajectory.

 Select the OK button to end the tool selection.

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Tutorial 5 Now we will modify the tool parameters.  Uncheck Rapid Retract to use the Retract rate value for retract moves.  Right-click on the selected tool.  Select Edit tool to open the tool parameters window.

 Select the Endmill1 Flat tab.  Change the tool number to 1.

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Tutorial 5 Note: The tool number needs to be changed according to the actual tool number on the robot setup. Most robots have limits for tool numbers, please refer to your robot manufacturers documentation for more details.     

Select the Parameters tab to set tool specific parameters.

Change the Tool name to Tool1.

Change the Plunge rate to 10 mm/s.

Change the Feed rate and Retract rate to 20 mm/s.

Change the Spindle speed to 20000 RPM.

Note: All feed rates are defined as millimeters per second (mm/s) independently of the units selected in Mastercam.  Select the OK button to close the tool parameters window.

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Tutorial 5 STEP 6: SETTING TRAJECTORY PARAMETERS Now we will select the curve for the trajectory.  Select the Cut Pattern page to specify the geometry used in this trajectory.  Select the 3D Curves in the curve type selection drop menu.  Click the Select button to open the chaining window and select the curve.

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Tutorial 5  Select the Chain as the selection method.  Select the green contour as indicated in the picture below that defines the trajectory.

Select here

 Select the OK button to end the geometry selection.

Note: The green arrow indicates the starting point as the cut direction for the trajectory. Multiple chains can be selected in one trajectory.

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Tutorial 5 We will now set Cut Pattern parameters.  Select the Cut Pattern page to set the toolpath parameters.

 Enter 0.1 mm for the Cut Tolerance parameter.  Enter 50 mm for the Maximum step parameter.  Set Compensation type to Off to de-activate tool compensation.

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Tutorial 5 Now we will select the surface for the tool axis control. These steps will constraint the tool vector to stay perpendicular to the selected surface.  Select the Tool Axis Control page to specify the geometry used in this trajectory.  Select Surface in the tool axis control drop menu.  Click the Select button to open the surface selection window and select the surface.

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Tutorial 5 ďƒ˜ Select the green surface as indicated in the picture below. The tool vector will stay perpendicular to this surface while following the curve geometry.

Select here

ďƒ˜ Select the End Selection button to end the surface selection.

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Tutorial 5 We will now set Linking parameters.  Select the Linking page to set the approach and clearance parameters.

   

Uncheck the Clearance box to de-activate clearance moves.

Check the Retract box to activate retract moves.

Enter 150 mm for the Retract distance parameter.

Enter 50 mm for the Feed plane move parameter.

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Tutorial 5 We will now set all required parameters for the entry and exit moves.  Select the Entry/Exit page to set entry and exit parameters.

   

Check the Entry curve box to activate entry moves.

Enter 17.5 mm for the Length parameter.

Enter 0 mm for the Thickness parameter.

Enter 25 mm for the Height parameter.

 Click the

button to copy these parameters to Exit curve settings.

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Tutorial 5 We will now remove the multi passes from the roughing parameters.  Select the Roughing page to set the multi passes parameters.

 Uncheck the Multi Passes checkbox so that no roughing passes are created.  Select the OK button to save and exit the Multiaxis Toolpath Curve window.

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Tutorial 5 STEP 7: STARTING ROBOTMASTER GLOBAL SETTINGS INTERFACE The first step for any file is to enter the Global Settings. These settings are valid for all operations and include robot, tool process and environment information.  Select the Robotmaster Global Settings from the main toolbar.

STEP 8: SETTING UP THE PARAMETERS IN THE ROBOT PAGE In this page we are selecting the robot and the tool that is attached to the flange of the robot.  Select the Robot page.  Click on the Robot pull down arrow and select ROBOTMASTER.  Click on the Tool selector button in order to select GS_SPINDLE60.

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Tutorial 5 STEP 9: SETTING UP PARAMETERS IN THE FRAME DATA PAGE  Select the Frame Data page and set the Base Data and Tool Data settings as indicated in the screenshot below:

     

In the User Frame field, click the pull down arrow and select User defined.

Enter 850 in the X value box.

Enter -675 in the Y value box.

Enter -640 in the Z value box.

Leave at 0 all other values.

In the Method field click the pull down arrow and select Use spindle definition.

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Tutorial 5 STEP 10: SETTING UP THE PARAMETERS IN THE APPROACH/RETRACT PAGE The approach/retract points are the 6 joint values of the robot before the start and after the end of the program respectively.  Select the Approach/Retract page.

    

Enter 90 in the joint J1 value box.

Enter -45 in the joint J2 value box.

Enter -45 in the joint J3 value box.

Enter -90 in the joint J5 value box.

Leave at 0 J4 and J6.

 Then copy to the Retract section by clicking on the

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button.

Tutorial 5 STEP 11: SETTING UP THE PARAMETERS IN THE TOOL AND CONFIGURATION PAGE  Select the Tool and Configuration page.  In the Tool Call field, select the No tool call button.  In the Tool Activation field, select the No tool activation.  Set the Robot Configuration settings as indicated in the screenshot below.

STEP 12: STARTING ROBOTMASTER LOCAL CONFIGURATION INTERFACE Local settings are used to set operation specific parameters. Only one operation can be selected to launch the Local Settings. Local Settings are compromised of axis configuration, optimization, safe retract and external axis parameters.  Select the first operation in the operation manager.  Select the Robotmaster Local Settings from the main toolbar.

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Tutorial 5 STEP 13: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE This page sets the orientation of the tool of the robot with respect to the part we are cutting. Refer to tutorials 1, 2 and 3 for a detailed explanation of axis configurations.  Select the Axis Configuration page.  Select Spherical interpolation in the section Rotary Axis Calculation Method.  Adjust [Axis Layout] settings: o Enter 0 in the Tool Rotation numerical up down field.

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Tutorial 5 STEP 14: SETTING UP PARAMETERS IN THE SAFE RETRACT PAGE This page sets the safe approach / retract motion before and after an operation. Refer to tutorial 2 for a detailed explanation of safe retract.  Select the Safe Retract page.

 Check Use safe approach.  Select the Z axis.  Enter 800 in the value box.  Check Use safe retract.  Select the Z axis.  Enter 800 in the value box.

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Tutorial 5 STEP 15: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

STEP 16: SET UP OF SIMULATION PARAMETERS  Select the Robot Simulation Settings button from the Robotmaster toolbar.

 In the Robot Simulation Settings window, set all the parameters as shown below:

 Select the OK button to save and exit the Robot Simulation Settings window.

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Tutorial 5 STEP 17: STARTING SIMULATION PROCESS  Select the operation  Click the Robotmaster Simulation button.

 An error icon will be displayed beside the operation. This error is caused by a joint limit reached.

Joint limit reached on first point

The robot cannot reach the first point of the trajectory as J2 reaches its limit.

We notice the 2nd joint of the robot attains its minimum limit at the first point of the trajectory and the robot cannot complete the entire task. In this case, we can turn around the tool vector to bring joint 2 back in limit. This will be achieved using the Axis configuration page in the Robotmaster interface.

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Tutorial 5 STEP 18: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE Now we will increase the rotation around the tool vector in order to complete the task.     

Select the operation in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Select Spherical interpolation in the section Rotary Axis Calculation Method.

Adjust Configuration settings: Enter -90 in the Tool Rotation numerical up down field.

STEP 19: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 5 STEP 20: STARTING SIMULATION PROCESS  Make sure the operation is selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

 Select the Play button.  An error icon will be displayed beside the operation. This error is caused by a portion of the toolpath which is out-of-reach.

The robot attains its maximum reach at the 79th point and cannot complete the trajectory.

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Tutorial 5 We notice the robot starts the task but attains its maximum at point 79 and it cannot complete the entire trajectory. Fortunately, a 6-axis robot has the ability to turn around the tool and provide a variety of solutions for a given point. One way to avoid this issue is to turn around the tool vector to increase the reach for this trajectory. This tool rotation can be managed through the optimization page in the Robotmaster interface.

We also notice the arm of the robot is interfering with the part when point 78 is reached.

Therefore, the collision layer will be used in order to detect and avoid potential collisions.

Collision at point 78 Maximum reach at point 79

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Tutorial 5 STEP 21: OPTIMIZING THE OPERATION TO REMOVE ERRORS We will now optimize the trajectory in order to complete the task.  Select the operation in the operation manager.  Select the Robotmaster Local Settings from the Robotmaster toolbar.  Select the Optimization page.

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Tutorial 5 Enter the following parameters to optimize the trajectory. ďƒ˜ Check Singularity, Out-of-reach, Joint limits, Wrist flip, Over travel and Collision layers in the error layers group box.

When to activate the collision layer?

Collision errors are displayed when a collision is detected. Collisions are detected based on the current setup of collision groups in the simulator. A robot without any collision groups will not detect any collisions. For accurate collision detection the part needs to be updated in the simulator before running optimization.

Activating the collision layer increases the processing time. Therefore, the collision layer should be activated only if collisions are previously detected in the simulation module.

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Tutorial 5 ďƒ˜ Click the Calculate button to generate error layers for the given default curve.

The generated map will look like the following:

Point 132 Point 78

You will notice the robot is in interference with the part between point 78 and point 132 inclusively for the specified axis configuration settings. Therefore, this trajectory cannot be completed as a collision is detected at the 78th point of the trajectory.

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Tutorial 5 We will now hide the collision layer in order to analyze the reach error zones. ďƒ˜ Uncheck the Collision layers in the error layers group box.

Note: It is not necessary to click the Calculate button when layers are activated or de-activated.

The generated map will look like the following without the collision layer:

Point 132 Point 79

You will notice the robot is out of reach between point 79 and point 132 inclusively for the specified axis configuration settings. Therefore, this trajectory cannot be completed as the maximum reach is attained at the 79th point of the trajectory.

Changing the shape of the curve, to avoid Collision and Out of reach error zones, will enable us to find the optimal tool rotation value for each points of the trajectory to complete this task.

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Tutorial 5 We will now add a control point in the curve. This control point will be moved in order to change the shape of the curve to avoid the error zones. ďƒ˜ Enter 93 in the Modify Curve number field. ďƒ˜ Click the Add button to insert a control point in the tool rotation curve.

How to insert and remove control points inside the tool rotation curve?

Control points can be inserted inside the tool rotation curve using three methods: The first method consists of double-clicking the left mouse button on the tool rotation curve to insert a control point. A control point is then inserted at the current cursor position on the curve.

The second method consists of using the contextual menu. To insert a point using this method, press the right mouse button on the curve at the desired position and select Add point from the contextual menu.

The third method consists of using the Modify Curve dialog box (method used in this tutorial). Specify in the field a valid point number of the trajectory and click the Add button.

Control points can be removed from the tool rotation curve using two methods: The first method consists of using the keyboard. Select the control point to remove by pressing the left mouse button and then press the Delete key on the keyboard. The control point is now removed from the curve.

The second method consists of using the contextual menu. To remove a point using this method, select the desired control point pressing the left button of the mouse. Now, press the right button of the mouse and select Remove point from the contextual menu.

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Tutorial 5 When to use the Reset button?

The Reset button removes all inserted control points from the tool rotation curve.

It allows the user to revert back to the tool rotation defined by the axis configuration settings without any additional rotation.

Now we move the inserted control point in order to change the shape of the curve and avoid the error zones. ďƒ˜ Holding the Ctrl key of the keyboard, drag the control point below the Out of reach error zone using the left mouse button. Move this control at approximately -60 degrees on the additional tool rotation axis (Y axis). Holding the Ctrl key allows us to move the control point only vertically.

Note: The tool rotation curve is passing through a joint limits error zone.

Increasing the curvature of the first control point will allow the tool rotation curve to avoid the joint limits zones.

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Tutorial 5 Now we change the curvature of the first control point in order to change the shape of the curve and avoid the error zones.  Select the first control point of the tool rotation curve using the left mouse button.

The handle of the first control point now appears in the window.  Drag the endpoint of the handle using the left mouse button in order for the tool rotation curve to avoid the joint limits error zone. This should be approximately at point 70 on the point axis (X axis of the graph) and +30 degrees on the additional rotation axis (Y axis of the graph.)

Drag here

We will now update the error zones and validate the tool rotation curve.  Check the Collision layers in the error layers group box. This will allow us to validate that the trajectory is free of collision.  Click the Calculate button to update all error layers and to validate the tool rotation curve.

Note : The tool rotation curve turns green since all error zones were avoided. We now obtained an optimized trajectory without errors.

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Tutorial 5 STEP 22: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

STEP 23: STARTING SIMULATION PROCESS  Make sure the operation is selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

Note: The robot can now reach all the points of the trajectory. The arm of the robot is not interfering with the part and the robot can complete the entire task.

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Tutorial 5 STEP 24: POSTING ROBOT CODES The Post button runs the Robotmaster post processor to generate a robot ready program file. The output type depends on the type of robot selected.

ďƒ˜ Select the OK button to launch the postprocessor

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Tutorial 5 NOTES:

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Tutorial 6

TUTORIAL 6 ROBOT ON A RAIL

6-1

Tutorial 6

Objectives: The student will understand how to program a robot mounted on a rail.

This tutorial assumes that the student has the appropriate design and toolpath skills using Mastercam.

6-2

Tutorial 6 CUSTOMIZING THE TOOLBAR 

Before starting to work with Robotmaster, we should activate the toolbars required to use the simulation. See Robotmaster Quick Start Guide, pages 4 and 5.

STEP 1: OPEN THE MASTERCAM FILE The file Canoe_Trimming_Rail can be found in the Robotmaster_V6\Samples directory.

File  Open  Select the Canoe_Trimming_Rail file.

The file Canoe_Trimming_Rail has three toolpath operations created for a Fanuc Robot as seen in the operations manager.

STEP 2: CHANGING THE ACTIVE MACHINE DEFINITION The Machine definition for the file Canoe_Trimming_Rail_Finished is a Fanuc Robot machine. Please see Tutorial 1 for details on how to change the active robot brand if you would like to do this tutorial with another brand.

6-3

Tutorial 6 STEP 3: STARTING THE ROBOTMASTER PARAMETER INTERFACE  Select the Robotmaster Global Settings from the main toolbar.

STEP 4: CONFIGURING THE ROBOT PAGE In this page we are selecting the robot and the tool that is attached to the flange of the robot.  Select the Robot page.  Click on the Robot pull down arrow and select ROBOTMASTER2_LINEAR_RAIL generic robot. This is a generic robot designed for use in this tutorial series.  Click on the Tool selector button in order to select GS_SPINDLE60.

6-4

Tutorial 6 STEP 5: SETTING UP PARAMETERS IN THE FRAME DATA PAGE  Select the Frame Data page and set the Base Data and Tool Data settings as indicated in the screenshot below:

 In the User Frame field, click the pull down arrow and select User defined.

   

Enter 1960 in the X value box.

Enter -1650 in the Y value box.

Enter -950 in the Z value box.

Leave at 0 all the other values.

 In the Method field click the pull down arrow and select Use spindle definition.

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Tutorial 6 STEP 6: SETTING UP THE PARAMETERS IN THE APPROACH/RETRACT PAGE The approach/retract points are the 6 joint values of the robot before the start and after the end of the program respectively.  Select the Approach/Retract page.

 Set all values to 0.

What is the Rail value box used for?

The Rail value box in the Approach/Retract page is enabled if a robot with a rail is selected. The rail value boxes can be used to specify the position of the rail before the start and after the end of the program.

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Tutorial 6 STEP 7: SETTING UP THE TOOL AND CONFIGURATION PAGE  Select the Tool and Configuration page.  In the Tool Call field, select the No tool call radio button.  In the Tool Activation field, select the No tool activation radio button.  Set the Robot Configuration settings as indicated in the screenshot below.

 Select the OK button to close the Global Settings window.

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Tutorial 6 STEP 8: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 1      

Select operation 1 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Default no Z rotation in the Type field.

Choose Top in the Orientation field.

Enter 15 in the Tool Rotation value box.

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Tutorial 6 STEP 9: SETTING UP PARAMETERS IN THE RAIL PAGE FOR OPERATION 1  Select the Rail page.  Choose Fixed in the Rail value field.  Enter 0 in the Offset distance value box.

STEP 10: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 6 What is Fixed Rail value?

Fixed Rail value allows the user to index the robot to a specified position along the rail. This position is maintained throughout the whole operation resulting in a six axis motion for the robot. This method is useful to process small features, which would not require the contribution of the rail to maintain reach throughout the feature.

What is Variable Rail value?

Variable Rail allows the user to specify an offset distance, along the rail, from the tip of the tool to the base of the robot. This offset distance is maintained throughout the whole operation resulting in a full simultaneous seven axis motion.

This method is useful to process large features, such as contour cuts, which would normally be out of reach of the robot without the contribution of the rail.

STEP 11: SET UP OF THE SIMULATION PARAMETERS ďƒ˜ Select the Robot Simulation Settings button from the Mastercam main toolbar.

ďƒ˜ Set all parameters as shown below:

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Tutorial 6

ďƒ˜ Select the OK button to save and exit the Robot Simulation Settings window.

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Tutorial 6 STEP 12: STARTING THE SIMULATION PROCESS FOR OPERATION 1  Select operation 1.  Select the Robotmaster Simulation button from Mastercam main toolbar.

The simulation will then start and the canvas will look like the screenshot below:

Note:  In this configuration, you will notice that the robot doesn’t move along the rail for this operation using a fixed position at the origin of the rail.

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Tutorial 6 STEP 13: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 2      

Select operation 2 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Default no Z rotation in the Type field.

Choose Top in the Orientation field.

Enter 15 in the Tool Rotation value box.

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Tutorial 6 STEP 14: SETTING UP PARAMETERS IN THE RAIL PAGE FOR OPERATION 2  Select the Rail page.  Choose Fixed in the Rail value field.  Enter 3340 in the Offset distance value box.

STEP 15: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 6 STEP 16: STARTING THE SIMULATION PROCESS FOR OPERATION 2  Make sure the operation is selected..  Select the Robotmaster Simulation button from the Mastercam main toolbar.

Note:  In this configuration, you will notice that the robot is positioned using a fixed distance of 3.34 meters from the origin of the rail.

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Tutorial 6 STEP 17 SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 3    

Select the Axis Configuration page.

Choose Default no Z rotation in the Type field.

Choose Top in the Orientation field.

Enter 25 in the Tool Rotation value box.

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Tutorial 6 STEP 18: SETTING UP PARAMETERS IN THE RAIL PAGE FOR OPERATION 3     

Select operation 3 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Rail page.

Choose Variable in the Rail value field.

Enter 0 in the Offset distance value box.

STEP 19: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 6 STEP 20: STARTING THE SIMULATION PROCESS FOR OPERATION 3  Make sure the operation is selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

Note:  With Rail Value set to Variable, you will notice that the robot moves along the rail in a coordinated motion always keeping a fixed distance between the base of the robot and the tool center point.

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Tutorial 6 STEP 21: STARTING THE SIMULATION PROCESS FOR ALL OPERATIONS  Make sure all operations are selected.  Select the Robotmaster Simulation button from the Mastercam main toolbar.

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Tutorial 6 NOTES

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Tutorial 7

TUTORIAL 7 EXTERNAL ROTARY AXES

7-1

Tutorial 7

Objectives: The student will understand how to program a robot with an external rotary axis.

This tutorial assumes that the student has the appropriate design and toolpath skills using Mastercam.

7-2

Tutorial 7 CUSTOMIZING THE TOOLBAR 

Before starting to work with Robotmaster, we should activate the toolbars required to use the simulation. See Robotmaster Quick Start Guide, pages 4 and 5.

STEP 1: OPEN THE MASTERCAM FILE The file Thermoformed_Trimming_Rotary can be found in the Robotmaster_V6\Samples directory.

File  Open  Select the Thermoformed _Trimming_Rotary file.

The file Thermoformed _Trimming_Rotary has three toolpath operations created for a Fanuc Robot as seen in the operations manager.

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Tutorial 7 STEP 2: CHANGING THE ACTIVE MACHINE DEFINITION The Machine definition for the file Thermoformed _Trimming_Rotary is a Fanuc Robot machine. Please see Tutorial 1 for details on how to change the active robot brand if you would like to do this tutorial with another brand.

STEP 3: STARTING THE ROBOTMASTER PARAMETER INTERFACE ďƒ˜ Click on the Robotmaster Global Settings button.

7-4

Tutorial 7 STEP 4: CONFIGURING THE ROBOT PAGE In this page we are selecting the robot and the tool that is attached to the flange of the robot.  Select the Robot page.  Click on the Robot pull down arrow and select ROBOTMASTER2_ROTARY generic robot. This is a generic robot designed for use in this tutorial series.  Click on the Tool selector button in order to select GS_SPINDLE60.

7-5

Tutorial 7 STEP 5: SETTING UP PARAMETERS IN THE FRAME DATA PAGE  Select the Frame Data page and set the Base Data and Tool Data settings as indicated in the screenshot below:

     

In the User Frame field, click the pull down arrow and select User defined.

Enter 3250 in the X value box.

Enter 0 in the Y value box.

Enter 300 in the Z value box.

Leave at 0 all the other values.

In the Method field click the pull down arrow and select Use spindle definition.

7-6

Tutorial 7 STEP 6: SETTING UP THE PARAMETERS IN THE APPROACH / RETRACT PAGE The approach/retract points are the 6 joint values of the robot before the start and after the end of the program respectively.  Select the Approach/Retract page.  Enter -45 in J1 value box.  Leave at 0 all the value boxes.  Then copy to the Retract section by clicking on the

button.

What is the Rotary value box used for?

The Rotary value box in the Approach/Retract page is enabled if a robot with a rotary axis is selected. The rotary value boxes can be used to specify the position of the rotary table before the start and after the end of the program.

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Tutorial 7 STEP 7: SETTING UP THE TOOL AND CONFIGURATION PAGE  Select the Tool and Configuration page.  In the Tool Call field, select the No tool call radio button.  In the Tool Activation field, select the No tool activation radio button.  Set the Robot Configuration settings as indicated in the screenshot below.

 Select the OK button to close the Global Settings window.

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Tutorial 7 STEP 8: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 1      

Select operation 1 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Default with Z rotation in the Type field.

Choose Top in the Orientation field.

Enter 180 in the Tool Rotation value box.

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Tutorial 7 STEP 9: SETTING UP PARAMETERS IN THE ROTARY PAGE FOR OPERATION 1  Select the Rotary page.  Choose Index only in the Rotary type field.  Enter 180 in the Index value box.

STEP 10: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

What is Rotary type: Index only?

Index only allows the user to index the rotary table to a specified position from the origin of the rotary table. This position is maintained throughout the entire operation resulting in a six axis motion for the robot. This method is useful to process small features which would 7 - 10

Tutorial 7 not require the contribution of the rotary table to maintain reach throughout the trajectory.

STEP 11: SET UP OF THE SIMULATION PARAMETERS  Select the Robot Simulation Settings button from the Robotmaster toolbar.

 Set all parameters as shown below:

 Select the OK button to save and exit the Robot Simulation Settings window.

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Tutorial 7 STEP 12: STARTING THE SIMULATION PROCESS FOR OPERATION 1  Make sure the operation is selected. Robot simulation will not launch unless at least one operation is selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

The simulation will then start and the canvas will look like the screenshot below:

Note:  In this configuration, you will notice that the table indexes 180 degrees before the robot starts the operation. The table orientation is maintained throughout the cut.

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Tutorial 7 STEP 13: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 2      

Select operation 2 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Default no Z rotation in the Type field.

Choose Top in the Orientation field.

Enter 0 in the Tool Rotation value box.

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Tutorial 7 STEP 14: SETTING UP PARAMETERS IN THE ROATRY PAGE FOR OPERATION 2    

Select the Rotary page.

Choose Full rotary in the Rotary type field.

Choose Orientation in the Angle calculation field.

Enter -180 in the Tool orientation value box.

STEP 15: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 7

What is Rotary type: Full rotary?

Full rotary is a useful method to process large features, such as contour cuts, which would normally be out of reach of the robot without the contribution of simultaneous rotary table motion. There are three types of Angle calculations that can be used with this method.

Orientation allows the user to calculate a rotary table position by maintaining a fixed angle between the orientation of the tool vector projection on the rotary table and the rotation origin of the table. This constraint is maintained throughout the operation resulting in full simultaneous seven axis motion. This method works well when the tool vector is far from the orientation of the rotary axis (far from vertical). When the tool vector is near the orientation of the axis of rotation (of the rotary table) motion may be jerky and jumps can occur in the rotary table.

There are two angle calculation methods for the position: with rotation and without rotation Position angle calculation method allows the user to calculate a rotary table position by maintaining a fixed angle between a line defined from the origin of the rotary to the position of the tool tip projection on the rotary table (red dashed line in figure below) and the rotation origin of the table. This constraint is maintained throughout the operation resulting in full simultaneous seven-axis motion. This method is desirable when the orientation of the tool vector is near or parallel to the axis of rotation of the rotary axis (vertical). o Position with rotation compensates for the rotation of the table by adding the same rotation value to the programmed point. This approach is useful when the tool vector is far from the axis of rotation of the rotary table. o Position without rotation does not add any rotations to the tool orientation set by Axis Configurations. This approach is typically used for paths where the tool vector is parallel to the axis of rotation of the rotary table.

Orientation

Position without rotation

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Position with rotation

Tutorial 7 STEP 16: STARTING THE SIMULATION PROCESS FOR OPERATION 2  Select operation 2.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

Note:  In this configuration, you will notice that the rotary table and the robot move in simultaneous motion in order to keep the tool vector projection on the rotary table constant. Viewing the simulation of this operation from the top view may help to get a better understanding of this approach.

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Tutorial 7 STEP 17 SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 3      

Select operation 3 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Default with Z rotation in the Type field.

Choose Top in the Orientation field.

Enter 0 in the Tool Rotation value box.

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Tutorial 7 STEP 18: SETTING UP PARAMETERS IN THE ROTARY PAGE FOR OPERATION 3    

Select the Rotary page.

Choose Full rotary in the Rotary type field.

Choose Position without rotation in the Angle calculation field.

Enter -180 in the Tool orientation value box.

STEP 19: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

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Tutorial 7 STEP 20: STARTING THE SIMULATION PROCESS FOR OPERATION 3  Make sure the operation is selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

Note:  In this configuration, you will notice that the rotary table and the robot move in simultaneous motion in order to keep a fixed angle between the line defined from the origin of the rotary to the position of the tool tip projection on the rotary table and the rotation origin of the table. Viewing the simulation of this operation from the top view may help to get a better understanding of this approach.

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Tutorial 7 STEP 21: STARTING THE SIMULATION PROCESS FOR ALL OPERATIONS  Make sure all operations are selected.  Select Robotmaster Simulation button from the Robotmaster toolbar.

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Tutorial 8

TUTORIAL 8 PART TO TOOL

8-1

Tutorial 8

Objectives: The student will understand how to program part to tool applications.

This tutorial assumes that the student has the appropriate design and toolpath skills using Mastercam.

8-2

Tutorial 8 CUSTOMIZING THE TOOLBAR 

Before starting to work with Robotmaster, we should activate the toolbars required to use the simulation. See Robotmaster Quick Start Guide, pages 4 and 5.

STEP 1: OPEN THE MASTERCAM FILE The file Skateboard_Part_to_Tool can be found in the Robotmaster_V6\Samples directory.

File  Open  Select the Skateboard_Part_to_Tool file.

The file Skateboard_Part_to_Tool has two toolpath operations created for a Fanuc Robot as seen in the operations manager.

STEP 2: CHANGING THE ACTIVE MACHINE DEFINITION The Machine definition for the file Skateboard_Part_to_Tool is a Fanuc Robot machine. Please see Tutorial 1 for details on how to change the active robot brand if you would like to do this tutorial with another brand.

8-3

Tutorial 8 STEP 3: STARTING THE ROBOTMASTER PARAMETER INTERFACE  Click on the Robotmaster Global Settings button.

STEP 4: CONFIGURING THE ROBOT PAGE In this page we are selecting the robot and the tool that is attached to the flange of the robot.  Select the Robot page.  Click on the Robot pull down arrow and select the ROBOTMASTER2_PART_TO_TOOL robot. This is a generic robot designed for this tutorial.  Click on the Tooling pull down arrow in order to select DEFAULT_PART_TO_TOOL.

8-4

Tutorial 8 STEP 5: SETTING UP PARAMETERS IN THE FRAME DATA PAGE FOR OPERATION 1  Select the Frame Data page and set the Base Data and Tool Data settings as indicated in the screenshot below. You will notice in the screenshot below that the Frame Data graphics are changed when a Part to Tool robot is selected.

 In the User Frame field, click the pull down arrow and select User defined.  Set to 0 all the values boxes in the Base Data section.        

In the User Tool field click the pull down arrow and select Use tool definition.

Enter 1 in the Tool value box.

Enter 1520 in the X value box.

Enter 230 in the Y value box.

Enter 350 in the Z value box.

Enter -90 in the W value box.

Enter 0 in the P value box.

Enter 180 in the R value box.

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Tutorial 8 STEP 6: SETTING UP THE PARAMETERS IN THE APPROACH/RETRACT PAGE The approach/retract points are the 6 joint values of the robot before the start and after the end of the program respectively.  Select the Approach/Retract page.

 Enter -45 in the joint J1 value box.  Set to 0 all other value boxes.  Then copy to the Retract section by clicking on the

8-6

button.

Tutorial 8 STEP 7: SETTING UP THE TOOL AND CONFIGURATION PAGE  Select the Tool and Configuration page.  In the Tool Call field, select the No tool call radio button.  In the Tool Activation field, select the No tool activation.  Set the Robot Configuration settings as indicated in the screenshot below.

 Select the OK button to close the Global Settings window.

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Tutorial 8 STEP 8: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 1      

Select operation 2 in the operation manager.

Select the Robotmaster Local Settings from the Robotmaster toolbar.

Select the Axis Configuration page.

Choose Default no Z rotation in the Type field.

Choose Top in the Orientation field.

Enter 0 in the Tool Rotation value box.

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Tutorial 8

How Part to Tool works?

Part to tool is a setup where the part is mounted on the flange of the robot. The part is then moved to a stationary tool for processing. In a part to tool application, the user frame represents the origin of the part with respect to the flange of the robot. The tool frame represents the contact point of the part on the tool with respect to the base coordinate system of the robot.

The two figures below show the correlation of the axis configurations (top figure) and the actual part and tool setup (bottom figure).

Tool frame

User frame

Tool frame

User frame

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Tutorial 8

Can multiple tool frames be defined?

Only one user frame can be specified, however multiple tool frames can be defined to accommodate several stationary tools fixed around the robot.

Tool frame #2

Tool frame # 1

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Tutorial 8 STEP 9: SAVE THE PARAMETERS  Select OK to save the parameters and exit the Robotmaster parameter window.

STEP 10: SET UP OF THE SIMULATION PARAMETERS  Select the Robotmaster Simulation Settings button from the Robotmaster toolbar.

 Set all parameters as shown below:

 Select the OK button to save and exit the Robot Simulation Settings window.

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Tutorial 8 STEP 11: STARTING THE SIMULATION PROCESS FOR OPERATION 1  Make sure the operation is selected. The Robotmaster Simulation will not launch unless at least one operation is selected.  Select the Robotmaster Simulation button from the Robotmaster toolbar.

 Select the Play button.

The simulation will then start and the canvas will look like the screenshot below.

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Tutorial 8 STEP 12: SETTING UP PARAMETERS IN THE FRAME DATA PAGE FOR OPERATION 2  In Global Settings, select the Frame Data page and set the Tool Data settings as indicated in the screenshot below (for tool 2):      

Enter 2030 in the X value box.

Enter 230 in the Y value box.

Enter 350 in the Z value box.

Enter -90 in the W value box.

Enter 0 in the P value box.

Enter 180 in the R value box.

STEP 13: SETTING UP PARAMETERS IN THE AXIS CONFIGURATION PAGE FOR OPERATION 2  Select operation 2 in the operation manager.  Select the Robotmaster Local Settings from the Robotmaster toolbar.  Choose Default no Z rotation in the Type field.  Choose Top in the Orientation field.  Enter 0 in the Tool Rotation value box.

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Tutorial 8 STEP 14: STARTING THE SIMULATION PROCESS FOR BOTH OPERATIONS  Select both operations  Select the Robotmaster Simulation button from the Robotmaster toolbar.

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R o b o t ma s t