I am currently using a Fanuc ArcMate100i with a R-J3 controller. It is an older robot/controller and I have just been introduced to it last week. Mounted on the robot face plate is a torch holder which holds a TIG torch. I am trying to make the sharpened tip of the tungsten the tool center point. The tungsten is at a ~45 degree angle to the face plate pointing away from it. The tip is near the center of the face plate but it is not dead center. I am trying to program a ~1/2" diameter circular weld with a circular move, however, the tool center point for whatever reason is not at the tip of the tungsten.
I have tried setting up the tool frame using the six point method several times with no luck. I am making Approach Point 1 and the origin point where the tip of the tungsten touches the reference point with the tungsten parallel to the Z axis. For Approach Point 2, I rotate J6 in JOINT 180 degrees and jog in world so that the tip of the tungsten is back at the reference point. Then I return it to the origin. For Approach Point 3, I rotate J4 in WORLD about 60 degrees, jog the tip of the tungsten to the reference point, and then move it back to the origin. Then I program my X and Z offset points. When I select the new tool frame and go into TOOL coordinates, it is obvious that the tip of the tungsten is not the TCP after attempting to rotate.
My question is whether I'm not setting up the tool frame correctly or if there could be other issues with this robot.
I've attached a napkin drawing of the tool situation.