Hey guys - working on a machine tending cell that's got some serious hours on it, and I've run into an issue I can't seem to explain.
LR Mate 100i with an R-J2 controller. Loading a Fanuc Robodrill from a automated tray handler loading pallets. Pallet placement is good and consistent - loaded onto pins and is not moving, and is repeatable between pallets. Robot is securely fixtured and is not moving or rocking during installation. Both single axis moves and multi-axes moves have been tested and verified to repeat within original robot tolerance. (It's actually incredible how well this thing repeats, considering how old it is.) I checked everything with a dial test indicator on a mag base, set up to catch different points and different axis moves - I'm comfortable the robot is repeating well. It performs correctly within the machine, loading/unloading the fixture.
Where I run into trouble is the pallet work - if I had to guess, I'd say the X,Y coordinate of the robot is not aligned with the X,Y of the tray - sometimes the robot is off to one side or another, and sometimes it is dead nuts in line, depending on where it is in the pallet. The pallets have not been verified by me, but have been in service for years without issue - no new pallets, no changes to the program. But there was a pretty serious crash a couple of weeks ago, and they've been fighting with it ever since.
There is also some math to compensate for pallet locations, because they're not quite an even pattern, but again, they've run literally millions of parts through this system with all the same hardware and software, and are only have trouble after the crash. On the R-J2 (my first time working on one) there are no Tool/User/or Jog frames set up. The pallet system is...not what I'm used to on the newer stuff, but seems to be fairly straightforward and make sense.
I guess my question is: if we managed to crash this hard enough to throw off the X/Y alignment of the robot coordinate system to the tray coordinate system, and there aren't and have never been any frames set up in the robot, is there a way to re-teach/correct the alignment of the robot to the tray?
If this was a new robot running PalletTool or something similar, I know the process for teaching the pick point coordinate system (using the teach plate w/3 points) but this is all working in the same frame in the program.
I can get some screenshots of the TP in the portions where its looking at the pallet later if that helps.
Thanks all!
