Measurement error too big

    Hi.

    I was trying tool calibration TCP on XYZ 4 point procedure and each trial come in the end with Measurement error too big, more than 5 mm maximum tolerance, I got 7.98, 5.83,9.25.
    I repeated robot mastering and retried tool calibration.
    Same situation , measurement error more than 5 mm.
    I used a very sharp bolt, well fixed on a table. Each time I was very careful and I think I repositioned with good accuracy tool on sharp, less than 1 mm in my opinion.
    Manual says next to check should be machine data loaded.
    Last cause could be a mechanical problem, I hope won't be that.

    I think that I did well axis mastering, I used a dial gauge, I put each axe in premastering postion indicated by white marks, moving then the robot from + to - ( that means pressing -key , as I understood), when I met abrubt indicator change I set 0 and came again from + to - stopping to 0, and mastered postion.

    I mention that along tool calibration procedure even to 1-3 % speed,in cartesian coordinates, I observed on Z axiz moving , when short commands fallowed by short stops, tool was seeming to vibrate on stop command a little and not being very stiff.

    what to check? My robot came from BMW and has 13500 hours, year 2006 .

    Is that possible machine data loaded in controller to be wrong setted?

    thank you.

    Ensure your Load Data is correct for you tool.

    For each of the 4 positions in the 4-Point TCP creation, how many degrees of angle change do you have between each position? It should be 45deg, minimum, and the 4 positions should cover rotations at least that large around all 3 axes of rotation.

    you don't provide vital data like controller or robot version, kss etc.

    assuming this is KRC2, you can check robot model in one of following ways:
    1. read label/nameplate on the robot. normally it will include robot name, serial number etc and last one or two lines should specify MADA or transform.
    2. compare above with what controller thinks robot is. this means looking into one of following places:
    - Help, Info, Robot
    - Setup, Robot Data
    - R1\Mada\$robcor.dat (near top)

    when setting up robot it is essential to have correct machine data (mada), and that robot is mastered correctly.
    your description of dial mastering looks good except that you don't mention how precisely you got to mastering position. typically after you detect dial gage needle changing direction, you have to set lowest possible speed and go back and forth few times till you get it at the very center of V-notch

    axis not being stiff could mean few things like torque limits being changed, mechanical problem such as worn out motor brake...

    1) read pinned topic: READ FIRST...

    2) if you have an issue with robot, post question in the correct forum section... do NOT contact me directly

    3) read 1 and 2

    I don't think I respected what SkyeFire indicated, I used four different direction but not sure as large as asked by Skyefire.
    Where data tool should be loaded?

    I have installed a spindle on aluminium support having fallowing orientation Rz=-180;Ry=-45;Rx=180

    My robot is KR 210 L150-2 with KRC 2 controller. Version KSS 5.2.19.

    In Mada is setted

    $V_ROBCOR[]="V6.17.1/KUKA5.2" ;VERSIONSKENNUNG
    CHAR $MODEL_NAME[32]
    $MODEL_NAME[]="#KR2210L150 S C2 FLR ZH210"

    In Robot Setup , Robot data are ok, as on robot label

    I was very carefuly with finding V-notch, moving forth and back with 1% speed till I could find center, respecting procedure detailed above

    Panic mode,

    I have these folders in KRC/R1:

    BMW_std
    Mada
    Program
    System
    TP
    pos_home_mirror.dat
    pos_home_mirror.src

    I think that before robot was setted to work with PLC as gripper.
    sps.sub is defined so:

    DEF SPS ( )
    ;FOLD DECLARATIONS
    ;FOLD BASISTECH DECL
    ;Automatik extern
    DECL STATE_T STAT
    DECL MODUS_T MODE
    ;ENDFOLD (BASISTECH DECL)
    ;FOLD USER DECL
    ; Please insert user defined declarations
    DECL BOOL ABS_FLAG

    ;ENDFOLD (USER DECL)
    ;ENDFOLD (DECLARATIONS)
    ;FOLD INI
    ;FOLD DEFAULT MSG_T
    $MSG_T={MSG_T: VALID FALSE,RELEASE FALSE,TYP #NOTIFY,MODUL[] " ",KEY[] " ",PARAM_TYP #VALUE,PARAM[] " ",DLG_FORMAT[] " ",ANSWER 0}
    ;ENDFOLD (DEFAULT MSG_T)
    ;FOLD AUTOEXT INIT
    INTERRUPT DECL 91 WHEN $PRO_STATE1==#P_FREE DO RESET_OUT ()
    INTERRUPT ON 91
    $LOOP_MSG[]=" "
    MODE=#SYNC
    $H_POS=$H_POS
    ;Automatik extern
    ;IF $MODE_OP==#EX THEN ;Auskommentiert auf Wunsch der BMW Werke Regensburg, Muenchen
    ;CWRITE($CMD,STAT,MODE,"RUN /R1/CELL()")
    ;ENDIF
    ;ENDFOLD (AUTOEXT INIT)
    ;FOLD USER INIT
    ;FOLD BMW_STANDARD_GREIFER_INI
    SPS_STANDARD_INI ( )
    ;ENDFOLD (BMW_STANDARD_GREIFER_INI)
    ; Please insert user defined initialization commands
    ABS_FLAG=FALSE

    ;ENDFOLD (USER INIT)
    ;ENDFOLD (INI)

    LOOP
    WAIT FOR NOT($POWER_FAIL)

    ;FOLD GRIPPERTECH PLC;%{E}%MKUKATPGRP,%CSPS,%VSPS,%P
    IF (ZANGEN_FUNKT>0) THEN
    H50 (5,AKT_ZANGE,DUMMY,GDEFAULT )
    ZANGEN_FUNKT=0
    ENDIF
    ;ENDFOLD (GRIPPERTECH PLC)
    ;FOLD USER PLC
    ;Make your modifications here

    ;FOLD BMW_STANDARD_GREIFER_LOOP
    SPS_APPL ( )
    ;FOLD ABS_ACCUR_FLAG
    ; Ramacher 07.2007 Verhindert das der Roboter
    ; mit Abs_ACCUR=FALSE in Automatik gestartet wird
    IF NOT $ABS_ACCUR AND ($MODE_OP==#EX) THEN
    CWRITE($CMD,STAT,MODE,"STOP")
    IF ABS_FLAG==FALSE THEN
    $MSG_T={MSG_T: VALID FALSE,RELEASE FALSE,TYP #STATE,MODUL[] " ",KEY[] " ",PARAM_TYP #VALUE,PARAM[] " ",DLG_FORMAT[] " ",ANSWER 0}
    $MSG_T.MODUL[]="SUB"
    $MSG_T.KEY[]="Kein Start in AutoExt, Roboter nicht Absolutgenau"
    $MSG_T.VALID=TRUE
    ABS_FLAG=TRUE
    ENDIF
    ELSE
    IF ABS_FLAG==TRUE THEN
    $MSG_T.RELEASE=TRUE
    ABS_FLAG=FALSE
    ENDIF
    ENDIF
    ;ENDFOLD (ABS_ACCUR_FLAG)
    ;ENDFOLD (BMW_STANDARD_GREIFER_LOOP)
    ;ENDFOLD (USER PLC)
    ENDLOOP


    Unused program from Program folder I deleted. But I think is more than deleting some files.

    TP folder contain a folder:

    Griper_SpotTech

    How I can use my robot for milling?

    Gripper , yes has a H50.src file inside.

    I need help, I don't know how to fix it , I am loosing my enthusiasm.
    It seems simple but nobody so far could give me a certain solution.

    I am not familiar at all with Kuka software. It' a mess.I am tired.

    With TCP calibration I found a solution to load numeric input coordinates and orientation from my computer simulation, knowing the length of tool.

    But I still get R1/test-linking error 1327

    when I try to select Test module in R1/Program same window appear and say: Module Package not available 2031-APPL_STOPM_RESTART
    line -1, column-1

    In R1/System there is a IR_STOPM file and inside at the end it is a edited this APPL_STOPM_RESTART

    But I have no ideea what to do more.

    Edited once, last by signum (March 8, 2015 at 10:00 PM).

    working with robots is not like what one sees in the movies - it takes some effort and training. there is simply no quick way around it.

    if this is over your head, get training or simply hire someone trained (contractor) to do all setup and commissioning.

    if you do not want/need some tech package you can either ignore it or remove it. there is an option to uninstall tech packages.

    you can try posting your archive here or share link to it, depending on available time me or others may take a look at it... this will help identify some declarations you are struggling with.

    typically I would take archive, extract it on my laptop and use Agent Ransack to do full text search for things like declarations etc. then edit them using simple text editor (I like Notepad++).

    common practice is to read errors and use KCP feature Show Error to take you to problem line. if something does not work there could be several reasons:
    - typos
    - missing dependencies (programs, variables,...)
    - not initialized variable(s)
    etc.

    one strategy is to READ code and try to understand it, deactivate (comment out or delete) troublesome lines etc until you got no error.

    the other option is to give up and just create new program module (and/or Submit Interpreter) from scratch.

    of course this is easier done with access to affected robot because one can see effect of changes - it is MUCH easier to solve problem when it is interactive.

    that's about it...

    1) read pinned topic: READ FIRST...

    2) if you have an issue with robot, post question in the correct forum section... do NOT contact me directly

    3) read 1 and 2

    I had this same problem. I also noted that when I was jogging the robot around in the "World" mode, the robot jog directions would be slightly off. I.e. Pressing the +X jog button would cause the robot to move in the +X and +Z directions. It turns out I did not have the correct model of robot setup in work visual. After correcting it, I used this forum post to get rid of the machine data error:

    Machine data do not match robot type

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