This may be long I apologize but am not getting any help from the powers that be. We recently purchased an older Genesis CRZ system with A Fanuc 100iBe robot and Rj3iC. Upon purchase it had a broken connector on J4 so the unit needed to be rewired, so I purchased a new harness and did this. After I performed tic mark master along with master enhancement on J4 J5 and set up a new TCP. The following week we had a company come in and take my TCP and there calibrated table points and put them into a virtual OLP ( OCTOPUZ). I set up my first programs and was AMAZED at how close I could program and get away with virtually no touchups. Now 2 weeks go by and I am performing touch-ups on a part and was watching the head not the tail and I collided the J2/J3on the back wall. it cracked the servo which lost mastering. I had to remove the robot from the base and swivel the robot just to remove the servo. FAST FORWARD. Servo replaced robot bolted back down ( NO PINS WERE EVER THERE ) but again it has to be remastered again and start from scratch. SO I perform the above all over again and actually get a better TCP than the first time. I give all the data to OCTOPUZ and they calibrate the table and send it back. But every program is way off. This leads me to measure the points I sent them in the cad. I picked all 4 corners of the table with a teach pointer and they are perfect to all corners. The table measures 36" deep and 58" My cad is made to match table. Now when we import the points into Octopuz and you measure between them they measure 35.625" x 57.3125". If we measure the table in cad it matches reality. SO my question is how can the robot travel the same distance and not match the true measurement? hope I made sense. Octopuz insists its a poor mastering of the robot and Genesis insists they have a dam near perfect TCP. I can verify the TCP is spot on less than a mm I am stumped and not sure what to look at next. I am FAR from an expert and know plenty to get me in trouble. And if I had not written a previous program I could believe that this is a good as it can get but I have seen how accurate we were. ANY HELP OR ADVISE IS GREATLY APPRECIATED
-Scott