I am currently dry running a new robot setup at 100% and I have a few concerns as I'm getting Disturbance Excess alarms. I know I do not have accurate payload info, I have worked with the design guys and we even have calculators from our corporate office that is supposed to take the Solidworks model and output payload info, but the numbers never seem accurate or are obviously way off. I have a few questions:
1. I have ran Fanuc's built in auto-detect payload program and it never matches the payload values given to me by the design guys. Does anyone use the auto-detect and if so, does it match known good values?
2. Does anyone know of any easier ways to calculate the payload, the formulas in Fanuc's manual are a little hard to follow.
3. Are you using multiple payloads, i.e. payload#1 for carrying raw parts and then switch to payload#2 when carrying finished parts and so on? In my experience I have seen few programs like this, so I usually just set 1 payload while gripping raw and finished parts(worst case scenario) and I figured that was good, or is this some of my problem? I always figured it was better for the robot to expect more weight than actual, than to be surprised by extra weight?
4. Is there a general consensus on when to adjust the collision guard and how high to do you adjust, or is this always done by "feel"? I basically default to 100% and then when im going to pick or drop parts, anywhere Im anticipating a collision, I go up to 125-150%. Is that not ideal?
5. Normally I initially program a cell with no move at more than 50% of max possible speed and then ramp as needed by customer. In this cell the cycle time is quite critical so I have a lot of moves at 100% which im sure is making the robot more susceptible to errors due to my incorrect payload. Do most people start low and increase as I normally do or just leave the speed at 100% from the start unless there is an issue then slow down where needed?
Thanks in advance for any help.