I have a Keyence il-300 laser hooked up sidecar to a welding torch. We're looking for Robot Input 1 (or 9 in Robot 2's case) to come ON when it is in the GO Range. TCP's are set for the torch and the laser. The issue I"m seeing is the laser is finding the seam fine, but the Torch TCP is not going to that spot. It's consistently off by a couple mm's on both of my robots...On my duplicate cell, the lasers and torches work flawlessly. I cannot find any major difference between these two and have run out of ideas of what to look for. I've rechecked/retaught TCP's, mastering, checked reflection (turned lights in the cell off).
The weld seam looks something like a V, but one side of the V is straight, so more like this... I/ if you're looking at Robot 1 or \I if you're looking at Robot 2's. I'm doing a -X to look for the straight vertical drop. Then I'm going to a flat surface behind the angle and doing a -Z. This way I can get positional data of where the Seam is and send the torch TCP there. Customer wants to rely on the use of the laser to find the weld seam, so switching to a V-Groove pattern and doing a 1_D search isn't going to fly.
So when I take the Laser TCP to the saved positional data (lets say PR), the laser shines right at the inside edge of the vertical drop and at the bottom of the angle, where it should be. But when I switch to Torch TCP and take it to the same PR, the wire is usually off in -X from where the laser is.
I cannot wrap my head around WHY or WHAT is causing this. Especially since Welder A is working fine and I've taught the lasers and torches the same way (using Six Point (XY)).
Any ideas out there?
Edit: Forgot to include that I also thoguht it was a scanning time/speed issue, so I turned the search speed down to .5mm/sec and was still not able to bring Torch TCP to Laser TCP/Laser found seam....but the difference between Torch and Laser always seem to be consistent. I can't think of what that is actually telling me.