FANUC > series

R-30*A/R-30*A Mate CONTROLLER

Coordinated Motion Function

OPERATOR'S MANUAL

B-82914EN/01
Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and understand
the content.

• No part of this manual may be reproduced in any form.

• All specifications and designs are subject to change without notice.

The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.

In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as “impossible”.
SAFETY
B-82914EN/01 1.SAFETY PRECAUTIONS

1 SAFETY PRECAUTIONS
This manual contains safety precautions against injury and property damage. Those precautions are
labeled “Warning” or “Caution,” according to the degree of importance. Supplementary explanation is
given under “Note.” Before starting to use a robot, carefully read the “Warning,” “Caution,” and
“Note.”

WARNING
Failure to follow the instruction given under “Warning” can cause fatal or serious
injury to the user. This information is indicated in bold type in a box so that it can be
easily distinguished from the main body of this manual.

CAUTION
Failure to follow the instruction given under “Caution” can cause injury to the user
or property damage. This information is indicated in a box so that it can be
easily distinguished from the main body of this manual.

NOTE
The information given under “Note” is a supplementary explanation, which is
neither a warning nor a caution.

Carefully read and save this manual.

1.1 WORKERS
A robot cannot do anything alone. The robot can operate only after it is equipped with a hand or other
device and connected with peripheral equipment to form a system.
Give considerations for the safety of not only the robot but also the entire system. When using the robot,
provide a safety fence and other safety measures. FANUC defines the system personnel as indicated
below. Check which worker should be trained in a specialist robot course.

Operator
The jobs of an operator are:
• Turning on and off the system
• Starting and stopping programs of a robot
• Recovering the system from an alarm state
The operator must not enter the area enclosed by the safety fence to do his or her work.

Programmer or teaching operator

The jobs of the programmer or teaching operator include the jobs of the operator and the following:
• Teaching of a robot, adjustment of the peripheral equipment, and other work that must be done in
the area enclosed by the safety fence
The programmer or teaching operator should be trained in a specialist robot course.

Maintenance engineer
The jobs of the maintenance engineer include the jobs of the programmer and the following:
• Repair and maintenance of the robot
The maintenance engineer should be trained in a specialist robot course.

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1.2 GENERAL SAFETY PRECAUTIONS

This section lists general safety precautions. Before starting to use the robot, read the precautions. The
subsequent sections of the manual indicate other precautions. Take each of the precautions.

General rules
WARNING
1 When the robot is used, the following precautions should be taken. Otherwise,
the robot and peripheral equipment can be adversely affected, or workers can be
severely injured.
- Avoid using the robot in a flammable environment.
- Avoid using the robot in an explosive environment.
- Avoid using the robot in an environment full of radiation.
- Avoid using the robot under water or at high humidity.
- Avoid using the robot to carry a person or animal.
- Avoid using the robot as a stepladder. (Never climb up on or hang from the
robot.)
2 Robot personnel must wear the following safety articles:
- Clothing suitable for each job
- Safety shoes
- Helmet

NOTE
Programmers and maintenance staff should be trained in a suitable course at
FANUC.

Notes on installation

WARNING
The robot should be transported and installed by accurately following the
procedures recommended by FANUC. Wrong transportation or installation may
cause the robot to fall, resulting in severe injury to workers.

CAUTION
In the first operation of the robot after installation, the operation should be
restricted to low speeds. Then, the speed should be gradually increased to
check the operation of the robot.

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Notes for Mechanism

NOTE
1 Keep the component cells of the robot system clean, and operate the robot in an
environment free of grease, water, and dust.
2 Use mechanical unit cable that have required user interface.
Please do not obstruct the movement of the mechanical unit cable when cables
are added. (Please never do the nylon band stop etc. of an external cable to the
mechanical unit cable.) Moreover, please do not interfere with the mechanical
unit cable when equipment is installed in the robot. If these precautions are not
observed there is a possibility that the mechanical unit cable is disconnected and
the trouble not anticipated occurs.
3 Employ a limit switch or mechanical stopper to limit the robot motion so that the
robot or cable does not encounter its peripheral devices or tools.

Notes on operation
WARNING
Before the robot is started, it should be checked that no one is in the area of the
safety fence. At the same time, a check must be made to ensure that there is
no risk of hazardous situations. If detected, such a situation should be
eliminated before the operation.

CAUTION
Operators should be ungloved while manipulating the operator’s panel or teach
pendant. Operation with gloved fingers could cause an operation error.

NOTE
Programs, system variables, and other information can be saved on external
storage. Be sure to save the data periodically in case the data is lost in an
accident. (See the file input/output section for saving the data.)

Notes on programming
WARNING
Programming should be done outside the area of the safety fence as far as
possible. If programming needs to be done in the area of the safety fence, the
programmer should take the following precautions:
- Before entering the area of the safety fence, ensure that there is no risk of
dangerous situations in the area.
- Be prepared to press the emergency stop button whenever necessary.
- Robot motions should be made at low speeds.
- Before starting programming, check the entire system status to ensure that no
remote instruction to the peripheral equipment or motion would be dangerous
to the user.

CAUTION
After programming is completed, a text execution should be given according to a
specified procedure. (See the section of program execution on this manual).
During the text execution, workers must stay out of the safety fence.

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NOTE
Programmers should be trained in a suitable course at FANUC.

Notes on maintenance
WARNING
1 During maintenance, the robot and system should be in the power-off state. If
the robot or system is in the power-on state, a maintenance operation could
cause a shock hazard. If necessary, a lock should be provided to prevent any
other person from turning on the robot or system. If maintenance needs to be
executed in the power-on state, the emergency stop button should be pressed.
2 When replacing a part, please contact FANUC service center. If a wrong
procedure is followed, an accident may occur, causing damage to the robot and
injury to the worker.
3 When entering the area enclosed by the safety fence, the maintenance worker
should check the entire system to make sure that no dangerous situations are
present. If the worker needs to enter the area of the fence while a dangerous
situation exists, the worker should always take extreme care and check the
current system status.
4 A part should be replaced with a part recommended by FANUC. If other parts
are used, malfunction or damage would occur. Especially, a fuse that is not
recommended by FANUC should not be used. Such a fuse may cause a fire.
5 When a motor or brake is removed, the robot arm should be supported with a
crane or other equipment beforehand so that the arm would not fall during the
removal.
6 If a robot motion is necessary during maintenance, the following precautions
should be taken:
- Reserve an escape route. During the maintenance, always check the motions
of the whole system so that the escape route will not be blocked by the robot
or peripheral equipment.
- Always pay attention to risk of dangerous situations and get prepared to press
the emergency stop button whenever necessary.
7 When a motor, decelerator, or other heavy load is handled, a crane or other
equipment should be used to protect maintenance workers from excessive load.
Otherwise, the maintenance workers would be severely injured.

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CAUTION
1 Whenever grease is spilled on the floor, it should be removed as quickly as
possible to prevent dangerous falls.
2 The robot should not be stepped on or climbed up during maintenance. If it is
attempted, the robot would be adversely affected. In addition, a misstep can
cause injury to the worker.
3 The following parts are heated. If a maintenance worker needs to touch such a
part in the heated state, the worker should wear heat-resistant gloves or use
other protective tools.
- Servo motor
- Inside the control unit
4 When a part is replaced, all bolts and other related components should put back
into their original places. A careful check must be given to ensure that no
components are missing or left unmounted.
5 Before the maintenance of the pneumatic system is started, the supply pressure
should be shut off and the pressure in the piping should be reduced to zero.
6 After a part is replaced, a text execution should be given for the robot according
to a predetermined method. (See the program execution of this manual.)
During the text execution, the maintenance staff should work outside the safety
fence.
7 After the maintenance is completed, spilled oil or water and metal chips should
be removed from the floor around the robot and within the safety fence.
8 When a part is replaced, care must be taken to prevent dust from entering the
robot.

NOTE
1 Each maintenance worker or inspection worker should be trained in a suitable
course at FANUC.
2 Maintenance should be done under suitable light. Care must be taken that the
light would not cause any danger.
3 The robot should be periodically inspected. (Refer to the controller and
mechanical manual.) A failure to do the periodical inspection can adversely
affect the performance or service life of the robot and may cause an accident.

1.3 SAFETY PRECAUTIONS

Safety precautions
Unlike ordinary automatic machines, robots have arms and wrists, which can be moved, in all operation
space. A robot is quite flexible, but on the other hand, it is quite dangerous. The robot is usually
connected with peripheral equipment to comprise an automated system. Users must take safety
precautions for the entire system.
The safety precautions are described below.

Safety precautions related to installation and layout

• Use warning lamps and other provisions to indicate that the robot is operating.

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Fig. 1.3 (a) Alarm Indications

• Put a protective fence with safety door around the system so that only the operator can enter the
operating area by the door. Design the system so that it will stop when the door is opened.

NOTE
Connect the *EAS1, *EAS11, *EAS2, *EAS22 (*FENCE1, *FENCE2 for single
chain controller) input signal to the safety door. Refer to the controller
maintenance manual for explanations about how to connect.

• Put a protective fence so that the motion range of the robot is surrounded completely. Moreover, put
the controller outside of the protective fence.

Fig. 1.3 (b) Safety fence

• Install an emergency stop button where it will be readily accessible to the operator.

NOTE
Upon receiving an emergency stop signal, the controller immediately stops the
robot.

Safety precautions related to system design

• Install a safety joint between robot wrists. If an abnormal external force is applied to the robot, the
safety joint breaks and the robot stops.

NOTE
When the hand break (*HBK) input signal goes off, the controller immediately
stops the robot.
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• Hand breakage detection can be disabled when the *HBK input signal is off. This can be set on the
system setting screen. See the section of the system config menu.
• Ground all peripheral units properly.
• When a desired operating area is smaller than the maximum operating area of the robot, the desired
area can be specified by parameters.
• The robot receives interlock signals sent from remote equipment. Upon receiving a signal indicating
the operating status of the remote equipment, the robot can stop or halt.
• When required, install a lock so that only authorized personnel can switch the power on.

NOTE
The circuit breaker on the control unit door is designed such that power-on can
be disabled by setting a padlock.

Fig. 1.3 (c) Locking the Circuit Breaker

Safety precautions related to inspection and maintenance

• Before starting the inspection or maintenance, turn off the controller. Lock the circuit breaker or
place a guard to prevent someone else from switching the power on.
• Before disconnecting the pneumatic system, release the supply pressure.
• Before starting an inspection in which the electrical system of the robot need not be operated, press
the emergency stop button.
• When carrying out an inspection in which the robot needs to be operated, carefully observe the
motion of the robot. Immediately press the emergency stop button whenever required.

Fig. 1.3 (d) Emergency Stop Button

Safety precautions related to transportation

• When carrying the robot or another unit on a carrier such as a crane or forklift, securely fasten the
robot to the carrier.
• Carefully inspect the crane, forklift, other carrying equipment, and carrying handle on the product.

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Fig. 1.3 (e) Carrying the Robot

Safety precautions related to operation

• All robot system operators are requested to attend FANUC training courses to learn the safety
precautions and functions of the robot.
• Before beginning to program the robot, make sure that there are no abnormal or dangerous
conditions around the robot and peripheral equipment.
• Before working within the operating area of the robot, even when the robot is not running, switch
the power off or press the emergency stop button. Place a guard to prevent someone else from
entering the operating area of the robot or activating the robot from the operator’s panel.
• While programming the robot in its operating area, place a guard so that the robot can be
immediately stopped in an emergency.

Fig. 1.3 (f) Danger Monitoring by Two Persons

Table 1.3 Safety precautions item

Operator Workshop Transportation and installation
Avoid dangerous behavior. Keep the workshop neat, tidy, and Keep the transportation lane free from
Wear working clothes, safety clean. Install a protective fence and obstacles. When carrying the robot or
shoes, and a safety helmet. warning indications. Provide another unit on a carrier such as a
ventilation. Never bring flammable forklift or crane, securely fasten it to the
material to the workshop. carrier. Keep a sufficient operating area.
Make connection s properly.
Operation Maintenance and inspection Hand
Attend training classes. Master Use only FANUC products for repair. Inspect and take care of cables. Check
the operating procedures. Before starting maintenance or the pneumatic pressure. Inspect the
Exclude unauthorized inspection, turn the power off. Close hand mechanism.
personnel. the controller door.
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Fig. 1.3 (g) Safety Clothes and Safety Helmet

• Before approaching the robot to program it, hold the teach pendant in your hand, press the deadman
switch, and set the teach pendant enable switch on.

NOTE
If the deadman switch is released while the teach pendant enable switch is on,
the robot immediately stops.

Fig. 1.3 (h) Deadman switch and Teach pendant enable switch

• Before moving the robot by jog feed, carefully observe the operation of the jog keys and the robot.
• Before moving the robot by jog feed, sufficiently lower the feedrate override of the robot.

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B-82914EN/01 TABLE OF CONTENTS

TABLE OF CONTENTS
SAFETY........................................................................................................... i
1 OVERVIEW ............................................................................................. 1
1.1 OVERVIEW ................................................................................................... 1
1.2 TERMINOLOGY ............................................................................................ 2
1.2.1 Overview ..................................................................................................................2
1.2.2 Motion Group ...........................................................................................................2
1.2.3 Leader Group............................................................................................................2
1.2.4 Follower Group ........................................................................................................2
1.2.5 Linear Axis ...............................................................................................................2
1.2.6 Rotary Axis ..............................................................................................................3
1.2.7 Axis Offset ...............................................................................................................3
1.2.8 Coordinated Frame ...................................................................................................3
1.2.9 Follower UFRAME..................................................................................................3
1.2.10 Follower UTOOL .....................................................................................................4
1.2.11 Leader UTOOL ........................................................................................................4
1.2.12 Leader UFRAME .....................................................................................................4
1.2.13 Leader World Frame.................................................................................................4
1.3 SETUP STEPS .............................................................................................. 4
2 INSTALLATION ...................................................................................... 5
2.1 OVERVIEW ................................................................................................... 5
2.2 INSTALLATION CONCEPTS ........................................................................ 5
2.2.1 Overview ..................................................................................................................5
2.2.2 Kinematics Type.......................................................................................................6
2.2.3 Axis Arrangement, Direction, and Assignment........................................................7
2.2.4 Offsets for Known Kinematics Types ....................................................................10

3 SETTING UP COORDINATED PAIRS.................................................. 11

3.1 OVERVIEW ................................................................................................. 11
3.2 RESTRICTIONS AND GUIDELINES........................................................... 11
3.3 SELECTING CD_PAIRS ............................................................................. 11
4 CALIBRATION ...................................................................................... 13
4.1 OVERVIEW ................................................................................................. 13
4.2 KNOWN FOUR POINT CALIBRATION ....................................................... 13
4.3 KNOWN DIRECT CALIBRATION................................................................ 18
4.4 UNKNOWN POINT CALIBRATION FOR POSITIONERS ........................... 19
4.5 LEADER FRAME SETUP ............................................................................ 29
4.6 Dynamic UFrame......................................................................................... 32
5 JOGGING .............................................................................................. 35
5.1 OVERVIEW ................................................................................................. 35
5.2 JOGGING DESIGNATION .......................................................................... 35
5.3 LEADER GROUP JOGGING (COORDINATED, FIXED ORIENTATION
COORDINATED) ......................................................................................... 36
5.3.1 Leader Frame (LDR) Jog Coordinate Mode...........................................................38
5.4 JOGGING EXAMPLES................................................................................ 39
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5.5 JOGGING PROCEDURE ............................................................................ 41

6 PROGRAMMING................................................................................... 44
6.1 OVERVIEW ................................................................................................. 44
6.2 PROGRAM HEADER INFORMATION ........................................................ 44
6.3 COORD COORDINATED MOTION OPTION .............................................. 45
6.4 COORD[ LDR ] COORDINATED MOTION OPTION................................... 45
6.5 SPEED DEFINITION ................................................................................... 48
6.6 LINEAR MOTION PROGRAMMING............................................................ 48
6.7 CIRCULAR MOTION PROGRAMMING ...................................................... 49
6.8 Relative motion and Simultaneous motion................................................... 50
7 TROUBLESHOOTING .......................................................................... 52
7.1 OVERVIEW ................................................................................................. 52
7.2 CALIBRATION ERRORS ............................................................................ 52
7.3 ERROR CODES .......................................................................................... 53

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B-82914EN/01 1.OVERVIEW

1 OVERVIEW
1.1 OVERVIEW
Coordinated motion is a motion control method in which the tool center point (TCP) speed and position
of a follower motion group is executed relative to a leader motion group. This method provides constant
relative speed between the two motion groups, and provides for path execution by the follower in a
moving frame of the leader.
See Fig. 1.1 .

Fig. 1.1 Coordinated Motion Overview

Benefits
You might want to use coordinated motion for the following reasons:
• It reduces the time required for workpiece programming because of the reduction in the number of
positions needed.
• It provides absolute relative speed between two moving motion groups.
• It allows you to arc weld more effectively:
• You can position welds more efficiently.
• You can weld significantly longer welds than the robot work envelope would normally permit.
• It eliminates the need for simultaneous motion welding paths.
• It provides for better utilization of gravity to focus penetration and for weld bead formation.
• It positions workpieces for subsequent welds during the execution of the current weld path.
• It provides an effective method for making continuous welds on positioner-mounted
workpieces.

Comparison with Simultaneous Motion

Coordinated motion differs from simultaneous motion in the following ways:
• Simultaneous motion addresses only starting and stopping motion groups at the same time.

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• In simultaneous motion, relative TCP speed is not controlled automatically. You must do this
manually by programming several regularly-spaced, time-based moves along the weld path,
generally every four to eight millimeters.

Operation
Coordinated motion occurs between coordinated motion group pairs, called CD_pairs . CD_pairs consist
of a leader motion group and a follower motion group. The leader group can be any kind of positioner,
such as a table. The follower group is usually the robot.
The leader group (for example, a positioner) must have FANUC Robotics motors and be controlled by the
robot as a separate motion group. This differs from the conventional positioner installation, which
typically uses extended axes or uses the multiple-motion group "Independent Axes" configuration.

Supported Options
Coordinated motion is supported for the following options:
• Touch Sensing
• Thru Arc Seam Tracking (TAST)
• Automatic Voltage Control Tracking (AVC)
• Root Pass Memorization (RPM)
• Multipass Welding (MPASS)

1.2 TERMINOLOGY

1.2.1 Overview
This section contains descriptions of terms that are used in coordinated motion. Become familiar with
these terms before you continue with coordinated motion setup, operation, and programming.

1.2.2 Motion Group

A motion group defines a set of motors and axes that are combined to accomplish a motion task. FANUC
Robotics robots are an example of a motion group, typically Group 1. Additional motion groups are
defined to control axes on a piece of equipment other than the robot.

When you use coordinated motion, the "coordination" that is performed is between two motion groups.

1.2.3 Leader Group

The leader group has independent motion during coordinated motions. Typically, the leader group is the
positioner.

1.2.4 Follower Group

The follower group executes motion with respect to the leader group. During coordinated jogging, for
example, when the leader group is moved, the follower group will maintain the same relative position
with respect to the leader. Typically, the follower group is the robot.

1.2.5 Linear Axis

Linear refers to the mechanical motion produced when the axis motor is run. Linear motion is straight line
motion. This motion occurs for lead screw-type drives and rack and pinion-type drives.

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1.2.6 Rotary Axis

Rotary refers to mechanical motion that rotates about a fixed point when the axis motor is run. Harmonic
drives typically have rotary motion output. The typical positioner has a rotary tabletop axis.

1.2.7 Axis Offset

The axis offset defines the x, y, and z coordinate difference between the center of rotation of two axes of
a multiple axis positioner device. The x, y, and z offsets are with respect to the positioner frame x, y, and
z origin. The offsets are calculated automatically when unknown kinematic calibration is performed.
The first axis of a multiple axis positioner will not have an offset. However, subsequent axes will have an
offset with respect to the first axis in a positioner group.

1.2.8 Coordinated Frame

The coordinated frame is the frame of the leader group. This frame is created when the leader and
follower are calibrated as a coordinated pair (CD_pair). For example, the coordinated frame is the frame
that is "connected" to the leader (positioner) table top, which moves when the table moves. The motion of
the follower is executed with respect to this moving frame.
The origin of the leader frame is expressed as a position in the robot WORLD frame. It is the
transformation from the robot origin to the leader origin.
The leader TCP is a position relative to the leader origin. It is expressed as a position in the leader
WORLD frame.

1.2.9 Follower UFRAME

The follower UFRAME has the effect of moving the coordinated frame, when used with coordinated
jogging or the program execution of coordinated motion. The UFRAME should be defined relative to the
leader WORLD coordinate system, for ease of programming, if UFRAME is to be used in coordinated
motion programs.
Changing the UFRAME will shift all of the programmed positions by the same amount for
non-coordinated motion programs. It has the effect of shifting the origin of the coordinated frame. When
applied to coordinated moves, this provides a convenient way to shift a coordinated motion program, if
the relationship between the positioner (leader) and the robot (follower) has been changed. This can occur
if the positioner is moved.
The follower UFRAME (user frame) performs the same function as the user frame in non-coordinated
motion.
The follower UFrame can be configured as a dynamic uframe. This frame moves with the leader and
corresponds to the leader frame at the current leader position. The dynamic uframe is useful when the
workpiece is shifted from the original taught position, for workcell cloning, or for transferring programs
between the controller and ROBOGUIDE.
Refer to Section 4.5 for more description of the dynamic uframe and setup of the leader frame.

CAUTION
Unless dynamic uframe is used, do not shift UFRAME to compensate for shifted
workpieces or programs. Otherwise, motion might not occur as expected relative
to the workpiece.

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1.2.10 Follower UTOOL

The follower UTOOL is the standard tool frame. This is the same as the tool frame used for the robot in
non-coordinated motion. Refer to the appropriate application-specific Setup and Operations Manual for
more information.
Use the 6-point method to define UTOOL. Ensure that you have defined the UTOOL correctly prior to
CD_pair calibration or programming.

1.2.11 Leader UTOOL

The leader UTOOL currently has no function in coordinated motion.

1.2.12 Leader UFRAME

The leader UFRAME currently has no function in coordinated motion.

1.2.13 Leader World Frame

The origin of the leader world frame is based on the positioner. This frame need not have any alignment
with the robot world frame. Refer to Section 1.2.8 for more information.

1.3 SETUP STEPS

To use coordinated motion, you must do the following:
1. Perform software setup for the positioner.
You must install the multiple motion group as a Positioner. Refer to Chapter 2 for more information.
2. Select motion group pairings as coordinated pairs (CD_pairs).
Refer to Chapter 3 .
3. Calibrate the CD_pairs.
Refer to Chapter 4 .
4. Verify coordinated motion by jogging the CD_pairs.
Refer to Chapter 5 .
5. Create coordinated motion teach pendant programs.
Refer to Chapter 6 .
6. Test coordinated motion programs.
Refer to the appropriate application-specific FANUC Robotics Setup and Operations Manual.
7. Run production with coordinated motion programs.
Refer to the appropriate application-specific FANUC Robotics Setup and Operations Manual.
8. Troubleshoot any problems.
Refer to Chapter 7 .

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B-82914EN/01 2.INSTALLATION

2 INSTALLATION
2.1 OVERVIEW
Before you can set up or use coordinated motion, you must install coordinated motion software and
hardware. This chapter describes how to install the software necessary to use coordinated motion.
Refer to the Extended Axis Connection and Maintenance Manual for information on how to install the
hardware associated with motion groups and extended axes when you use coordinated motion.

2.2 INSTALLATION CONCEPTS

2.2.1 Overview
In order to perform a proper installation, you must make several selections to define the axes of the leader
group. This section contains descriptions of some of the key concepts you must understand to define the
axes properly during installation:
For Standard Positioners:
• Kinematics type
• Axis arrangement, direction, assignment
• Axis offsets for known kinematics types
• Illegal axis configurations
Fig. 2.2.1 contains examples of leader devices you might install. Note that the "Robot" axes demonstrate
one possible robot location. Choose the robot location based on your positioner and application.

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Fig. 2.2.1 Leader Device Examples

2.2.2 Kinematics Type

Kinematics defines how a positioner will move in Cartesian space (x, y, and z) when the motors (axes) are
turned. This is determined by the Cartesian offset information of each axis to the next axis, and the gear
ratios supplied during positioner axis installation.
During installation, you must select the kinematics type. You can perform two kinds of setup, depending
on whether the kinematic information is known accurately:
• For a known kinematics type, the dimensions of the positioner axes are known exactly. In this case,
the offset information will be requested during axis setup.This also includes the case of setting up a
system in which calibration data is already known, such as when you upgrade software.
• For an unknown kinematics type, the dimensions of the positioner axes are not known. In this case,
the offset information will be calculated in the calibration procedure. This is the most common case.
See Fig. 2.2.2 for a description of the offset information involved in determining whether the kinematics
type is known or unknown. In Fig. 2.2.2 , x, y, and z are in the frame of the positioner and all axes are at
their 0°positions.

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Fig. 2.2.2 Known Kinematics Type and Offsets

NOTE
Assign axes and axes direction (+/-) in the most convenient manner for your
hardware and application setup and operation.

2.2.3 Axis Arrangement, Direction, and Assignment

During installation of a positioner, you must define the axis arrangement, direction, and assignment of the
leader group axes. The positioner (leader) frame is not dependent on the location and orientation of the
robot (follower) WORLD frame. The transformation from the robot frame to the positioner frame is
determined during CD_pair calibration.
You must assign an axis and direction (x, y, z, -x, -y, or -z) to each positioner axis. Assigning an axis of
the positioner frame to the positioner physical axis determines how motion of the follower will be
coordinated to the leader motion. In this installation, you must
• Make sure you have a positioner with a valid axis arrangement
• Determine the positive direction of each motion axis

Axis Arrangement
Standard positioner axes must be either parallel or perpendicular to the other axes in the positioner. See
Fig. 2.2.3(a) .
Axis assignment is arbitrary for single axis positioners. Choose the most convenient axis assignment for
your configuration. Axes are usually assigned according to the robot axes to which they are most closely
parallel.

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Fig. 2.2.3(a) Alignment of the Leader Frame

Axis Direction
You determine the positive direction of an axis differently for linear and rotary axes. The positive
direction of an axis is defined as the motion that occurs when the "+" jog key is pressed for the axis.
For a rotary axis , the right hand rule for electrical current is applied to determine the positive direction
of the rotary axis, as illustrated in Fig. 2.2.3(b) .
For linear axis , the positive direction is evident by which direction the axis moves when the "+" jog key
is pressed.
Usually, a positive leader frame axis (+x, +y, +z, for example) is assigned a positioner axis positive
direction. The choice of x, y, or z for the first axis is arbitrary. Select the direction of linear or rotary
motion relative to the frame you want to establish for the positioner device. The positioner frame is not
necessarily aligned with the robot world frame.

Fig. 2.2.3(b) Rotary Axis Selection

For a linear axis , see Fig. 2.2.3(c) .

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B-82914EN/01 2.INSTALLATION

Fig. 2.2.3(c) Linear Axis Selection

Axis Assignment
When you assign an axis, you must decide whether it will be x, y, or z of the leader (positioner) frame. It
might be more convenient to align the leader frame (positioner) axis with axes in one of the following
robot frames:
• World
• User
• Jog
NOTE
There might be a reason to assign -x, -y, or -z to the positive direction of rotation
or linear motion of the leader axis. This is permitted.
If the positive jog key direction needs to move the axis in the opposite direction, complete the following
steps:
1. Perform a Controlled start (START CTRL).
2. Press MENUS.
3. Select MAINTENANCE, Group 2.
4. Press MANUAL.
5. Modify the axis sign to the opposite: from TRUE to FALSE, or from FALSE to TRUE for any axis
that needs to be reversed.

Example Assignment
This example describes axis assignment as illustrated in Fig. 2.2.1 and Fig. 2.2.2 . Refer to Fig. 2.2.1 and
Fig. 2.2.2 as you read the descriptions in this example. Note that the robot placement in Fig. 2.2.1 and Fig.
2.2.2 is arbitrary. The "typical" assignment is based on the shown robot location.
For Fig. 2.2.1 , drawing 1, the axis assignment is arbitrary (x, y, z, -x, -y, or -z). In typical applications,
this axis would be assigned -z.
For Fig. 2.2.1 , drawing 2, select axis 1 arbitrarily (x, y, z, -x, -y, or -z). Axis 2 must not be the same as
axis 1 or its negative. In this drawing, a typical assignment is axis 1 as -y and axis 2 as -z.
For Fig. 2.2.1 , drawing 3, select axis 1 arbitrarily (x, y, z, -x, -y, or -z). Axis 2 must not be the same as
axis 1 or its negative. A typical assignment would be axis 1 as +x and axis 2 as -y.
For Fig. 2.2.1 , drawing 4, select axis 1 arbitrarily (x, y, z, -x, -y, or -z). Select axis 2 and axis 3 in the
same direction as each other, but not the same direction as axis 1 or its negative. A typical assignment
would be axis 1 as +y, axis 2 as +z, and axis 3 as +z.
For Fig. 2.2.2 , axis 1 and axis 2 must be the same axis assignment and in the same direction, and axis 3
must be the same axis assignment but in the opposite direction. A typical assignment would be axis 1 as
+z, axis 2 as +z, and axis 3 as -z.

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2.2.4 Offsets for Known Kinematics Types

During installation, if you selected a known kinematics type, you must enter offset information. See Fig.
2.2.4 .

Fig. 2.2.4 Axis Offset for Known Kinematics Types

For axis 1 of the positioner, the offset values should be

• Offset Axis1.X = 0
• Offset Axis1.Y = 0
• Offset Axis1.Z = 0
For axis 2 of the positioner, the offset values should be
• Offset Axis2.X = a
• Offset Axis2.Y = -b
• Offset Axis2.Z = c
For axis 3 of the positioner, the offset values should be
• Offset Axis3.X = d
• Offset Axis3.Y = 0
• Offset Axis3.Z = e
NOTE
Offset values a and d are parallel.

NOTE
Each axis is at 0°. Also, in the leader frame, the leader TCP is:
• X=a+d
• Y = -b
• Z=c+e

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3 SETTING UP COORDINATED PAIRS

3.1 OVERVIEW
After you have installed and set up the appropriate hardware and software, you must define specific
details about the coordinated pairs (CD_pairs). A coordinated pair consists of one leader and one follower
motion group that, together, perform coordinated motion.
Table 3.1 lists the motion group pairings that are available to define coordinated pairs. Each row in the
table makes up a coordinated pair.
Table 3.1 Coordinated Pair Configurations
Leader Group(s) Follower Group(s) CD_pairs

One table One robot 1 CD_pair

Two tables One robot 2 CD_pairs

One table One robot + one table (not 1 CD_pair

coordinated)

3.2 RESTRICTIONS AND GUIDELINES

When you select a coordinated pair, review the following restrictions and guidelines:
• Each motion group in a robotic system is either a leader or a follower (a group might not be used for
coordinated motion).
• Coordinated motion in a robotic system allows you to have multiple leaders and multiple followers.
• A CD_pair consists of a single leader and a single follower.
• A leader in one CD_pair can be a leader in another CD_pair with a different follower.
• A leader in one CD_pair cannot be a follower in another CD_pair.
• A follower in one CD_pair can be a follower in another CD_pair.
• Coordinated motion is supported for extended axes on leader and follower groups.
• Follower groups can be mounted to extended axes (such as on a swing arm, a track, or a combination.
These extended axes must be added sequentially to the robot, starting with axis 7 connected to the
robot, and following through the remaining connected extended axes. These must be “integrated
rotary” or “integrated linear” axes.
• Do not mount a leader group to an extended axis. Instead make this axis 1 of the positioner group.
• Coordinated motion is not supported when the follower group is mounted on the leader group. Also,
the leader group cannot be mounted on the follower group.

3.3 SELECTING CD_PAIRS

Use Procedure 3-1 to select CD_pairs.

Procedure 3-1 Selecting CD_pairs

Steps
1. Press MENUS.
2. Select SETUP.
3. Press F1, [TYPE].
4. Select Coord. You will see a screen similar to the following.

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SETUP Coord
Coord Pair Number : [ 1]
Leader Group : 2
Follower Group : 1
X: 800.000 Y:0.000 Z:0.000
W: 0.000 P:0.000 R:0.000
Follower orientation:ATTACHED
Use Leader Frame number: 1

5. To display setup information for another pair, move the cursor to Coord Pair Number and type the
CD_pair number.
NOTE
The group numbers you use depend on the number of groups defined and set up
on your controller at installation. If they have been set up, motion groups 1-5 are
available for coordinated motion leaders and followers.
6. Move the cursor to Leader group and type the group number of the leader.
7. Confirm the change:
• To confirm the change, press F4, YES.
• To cancel the change, press F5, NO.
8. Move the cursor to Follower group and type the group number of the follower.
9. Confirm the change:
• To confirm the change, press F4, YES.
• To cancel the change, press F5, NO.
NOTE
If you change the leader or follower of an existing CD_pair, the calibration data will
be set to zero. After the first calibration, the axis assignment can be changed at
CTRL start. This will also cause calibration data to be set to zero.

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4 CALIBRATION
4.1 OVERVIEW
After you have set up the CD_pairs you will use ( Chapter 3), you must calibrate each CD_pair. The
kinematics type of the CD_pair leader group you set up during installation will determine the kind of
calibration you must perform.

Kinematics Type
The kinematics type is determined when the leader group (positioner) is installed. Kinematics is
determined for the leader group through installation parameters. Two kinematics types are available:
• Known
• Unknown
Known kinematics type is applied to leader groups for which the arm length and offsets are known. This
information is required at the time the axes of the leader group are installed. This type can also be used
when you have existing calibration information that was defined previously for the CD_pair.
Unknown kinematics type is used for leader groups such as turntables or positioners for which the arm
length(s) and offset(s) are not known, or are not known accurately. Unknown kinematics type is the most
common kinematics type.
The kind of calibration you perform depends on the kinematics type you specified during leader group
installation. Refer to Chapter 2 for more information.

Calibration
CD_pair calibration defines the relationship between the leader and follower, by finding the motion
transformation from the follower group (robot) to the leader group (positioner). When you perform
calibration, you establish the location of the leader origin with respect to the follower origin. In addition,
for unknown kinematics cases, the kinematics of the leader are determined during calibration. Offset
information is installed when the axes are installed for "known" type calibration.
The kinematics type, which was established when the leader group axis was installed, will determine the
kind of calibration you must perform:
• Known four point - for known kinematics types
• Known direct - when previous calibration data is to be re-entered
• Unknown point - for unknown kinematics types
NOTE
After you have calibrated a CD_pair, you do not need to change the calibration
unless the relationship of the leader origin to follower origin changes, the CD_pair
groups is changed, the axis type is changed, or the calibration type is changed (at
a controlled start).

NOTE
After you have calibrated a CD_pair, you must perform a cold start for the data to
take effect.

4.2 KNOWN FOUR POINT CALIBRATION

Known four point calibration is the recommended method for CD_pairs with a known kinematics leader
group. Calibration determines the relationship of the follower to the leader origin, but, in most cases, the
origin of the leader group cannot be touched directly by the follower group (robot). This method is also
used when it is not possible to teach the x direction and y direction positions near the leader group TCP.
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Known four point calibration provides a method for calibrating the CD_pair without touching the leader's
origin point compared to three point frame setup. Known four point calibration uses three taught positions
to set the positioner frame alignment, and a fourth position to set the leader TCP location. The
transformation from robot origin to positioner origin will be calculated based on the TCP information
plus the axis offset data. The three frame positions must reflect the axis alignment selected during Coord
Independent Axes installation.
In known four point calibration, you define the following points:
• Leader's TCP.
• Orient origin point, which is a "temporary" origin point that can be located at any position within the
follower's working motion range.
• X direction point, which aligns with the position X axis.
• Y direction point, which aligns with the position Y axis.
The second, third, and fourth points are used to determine a temporary leader frame. This frame is
translated to the TCP position of the leader, which is then translated to the leader origin via the leader axis
offset values.

Guidelines
When you perform known four point calibration, use the following guidelines:
• Use this method only for known kinematics leader devices.
• The axis "direction" selected for each axis during the installation of the positioner axes and the axes'
offsets will determine the way that the follower (robot) motion will coordinate with the leader
(positioner) motion.
• The method will set only the leader (positioner) frame - the alignment is independent of the robot
world frame alignment - and will calculate the origin point of the positioner frame in robot space
(relative to the follower UFRAME).
• Correct alignment of the leader frame is essential. The positioner axis whose axis "direction" was
assigned as "+x" at axis installation should coincide with (or be parallel to) the "+x" axis in the
positioner frame.
The frame positions you define relative to the Orient Origin Point for the X Direction Point at this
time should be aligned exactly with the x-axis of the leader group; Y Direction Point corresponds to
the positive y direction (or axis). This will ensure that a "+x" motion of the leader (positioner) will
result in the correct follower (robot) motion in the leader's moving frame. See Fig. 4.2(a) .

NOTE
The positioner +z direction must be perpendicular to the +x - +y plane formed by
the X and Y Direction Points.

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Fig. 4.2(a) Defining Points

CAUTION
Be sure to align the Orient Origin, X Direction, and Y Direction positions carefully.
Otherwise, the calculated calibration frame will be incorrect and the coordinated
motion will not be accurate.

If you do not align these positions carefully, the calibration frame will be incorrect, but a calibration
frame will be calculated. In this case, the coordinated motion will not be accurate.
Use Procedure 4-1 to perform known four point calibration.

Procedure 4-1 Known Four Point Calibration

Conditions
• The follower group and leader group have been mastered and calibrated. (Refer to the appropriate
application-specific S etup and Operations Manual.)
• Axes in the leader group must be either parallel or perpendicular to each other. ( Fig. 2.2.1 )
• The selection of "axis direction" for the multiple-axis devices must be consistent with the right-hand
rule. ( Chapter 2 )
• The CD_pair has been set up ( Chapter 3 ).
Steps
1. Press MENUS.
2. Select SETUP.
3. Press F1, [TYPE].
4. Select Coord.
5. Press F3, [C_TYPE].
6. Select Known 4 Pt. You will see a screen similar to the following.

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NOTE
If you indicated "unknown kinematics" during installation, you cannot select Known
4 Pt or Known Direct for C_TYPE.

SETUP Coord
Known type calibration Coord Pair: 1
Group Number Leader: 3 Follower: 1
X: ******** Y: ******** Z: ********
W: ******** P: ******** R: ********
Leader's TCP point : UNINIT
Orient Origin point : UNINIT
X Direction Point : UNINIT
Y Direction Point : UNINIT

7. Define the leader's TCP point: ( Fig. 4.2(b) )

NOTE
The offset that was installed for your last axis during hardware setup of the leader
group is the point you need to touch during TCP Point recording.
a. Move the cursor to Leader's TCP Point.
b. Move the positioner axis (axes) to the zero angle position.On a tabletop, choose a position on
the table.
c. Jog the follower only, and touch the follower TCP to the leader TCP.
NOTE
The leader frame TCP and the follower tool frame must be defined accurately.
Torch orientation is not critical when recording this position.
d. Press and hold SHIFT and press F5, RECORD.
UNINIT is changed to RECORDED.

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Fig. 4.2(b) Defining Points

8. Define the orient origin point: ( Fig. 4.2(b) )

a. Move the cursor to Orient Origin Point.
NOTE
Jog only the follower in Step 8.b .
b. Jog the follower (robot) to a position that allows the other calibration positions to be set (point
3, X direction point, and point 4, Y direction point).
This is the "temporary" origin point.
c. Press and hold SHIFT and press F5, RECORD.
UNINIT is changed to RECORDED.
9. Define the x direction point: ( Fig. 4.2(b) )
NOTE
The +x direction is defined by the vector starting at the orient origin point and
going through the x-direction point.
a. Move the cursor to X Direction Point.
NOTE
Jog only the follower in Step 9.b .
b. Jog the follower (robot) along (or parallel to) the x-axis of the positioner.
c. Press and hold SHIFT and press F5, RECORD.
UNINIT is changed to RECORDED.
10. Define the y direction point: ( Fig. 4.2(b) )
a. Move the cursor to Y Direction Point.

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NOTE
Jog only the follower in Step 10.b and Step 10.c .
b. Jog the follower TCP to the Orient Origin Point.
c. Jog the follower to a position along (parallel to) the leader x-y plane in the positive y-axis of
the leader frame.
d. Press and hold SHIFT and press F5, RECORD.
UNINIT is changed to RECORDED.
11. Press F3, EXEC, to execute the calibration.
The leader coordinated frame is displayed in the SETUP Coord screen when this calculation is
complete.
If the calibration was not successful, or if a calibration message is displayed on the prompt line of the
teach pendant screen, refer to Table 7.2 in Chapter 7 .

4.3 KNOWN DIRECT CALIBRATION

Known direct calibration is used for systems that have known kinematics. This is useful if you need to
use previously defined calibration information, such as when a system software upgrade is performed.
Known direct calibration involves entering the following information manually into the calibration
screen:
• The Cartesian position of the leader origin in the robot WORLD frame
• Any frame rotations required to align the leader frame with the follower frame
For known direct calibration to be successful, you must have entered accurate offset values during the
installation of the leader group axes.
Use Procedure 4-2 to perform known direct calibration for positioners.

Procedure 4-2 Known Direct Calibration for Positioners

Conditions
• The follower group and leader group have been mastered and calibrated. (Refer to the appropriate
application-specific S etup and Operations Manual.)
• The leader group hardware configuration is correct.
• The CD_pair has been set up ( Chapter 3 ).
• The selection of "axis direction" for the multiple-axis devices must be consistent with
three-dimensional right hand rule conventions for axis labeling.
• The follower and the leader must be positioned in the workcell exactly. The relationship of the
leader origin and the follower origin, including frame rotation planes, must be calculated precisely.
or
Previous calibration data is known and is to be entered manually.
Steps
1. If you are using known direct calibration to restore calibration data (for example, after reloading
system software), set the following system variables to their previous values:
• $SCR_GRP[leader_group].$ofst[leader_axis].$X
• $SCR_GRP[leader_group].$ofst[leader_axis].$Y
• $SCR_GRP[leader_group].$ofst[leader_axis].$Z
2. Press MENUS.
3. Select SETUP.
4. Press F1, [TYPE].
5. Select Coord.
6. Press F2, [C_TYPE].
7. Select Known Direct and press ENTER. You will see a screen similar to the following.

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SETUP Coord
Known type calibration Coord Pair: 1
Group Number Leader: 3 Follower: 1
X: 0.000 Y: 0.000 Z: 0.000
W: 0.000 P: 0.000 R: 0.000
X: 0.0000
Y: 0.0000
Z: 0.0000
W: 0.0000
P: 0.0000
R: 0.0000

8. Move the cursor to X, type the x value of the leader frame origin point, and press ENTER.
9. Move the cursor to Y, type the y value of the leader frame origin point, and press ENTER.
10. Move the cursor to Z, type the z value of the leader frame origin point, and press ENTER.
11. Move the cursor to W, type the rotation about the follower x axis that the leader frame has relative to
the follower frame, and press ENTER.
12. Move the cursor to P, type the rotation about the follower y axis that the leader frame has relative to
the follower frame, and press ENTER.
13. Move the cursor to R, type the rotation about the follower z axis that the leader frame has relative to
the follower frame, and press ENTER.
14. When you have set all of the values, press F3, EXEC, to execute the calibration.
The leader coordinated frame is displayed in the SETUP Coord screen when this calculation is
complete.
If the calibration was not successful, or if a calibration message is displayed on the prompt line of the
teach pendant screen, refer to Table 7.2 in Chapter 7.

4.4 UNKNOWN POINT CALIBRATION FOR POSITIONERS

Unknown point calibration is used for all leader/follower pairs in which the leader group does not have
known kinematics. Most systems use unknown kinematics and unknown calibration type.
Calibration is required for each axis of an unknown kinematics device:
• Three points are defined on the circumference of a circle that is perpendicular to the axis of rotation.
• For linear motion axes, two points are taught along the line of motion.
Fig. 4.4(a) shows examples of linear and rotary axis unknown kinematics devices that are used as leaders
in coordinated motion.

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Fig. 4.4(a) Leader Device Examples

Conditions for Calibration

Before you perform unknown point calibration, the following conditions must be met:
• The number, direction, and order of axes for the leader group is set and known.
• The leader group hardware configuration is correct.
• The leader frame alignment has been determined. In calibration, a frame will be defined for the
leader group. The direction of the axes of the leader frame does not depend on the axis alignment of
the follower (robot).
The x, y, or z axis of the leader frame must be aligned with the first motor's axis of rotation or linear
axis:
• In a one-axis positioning device, the assignment and the direction of the axis is arbitrary.
• In a two-axis positioning device, the direction of the second axis is not arbitrary. The second
axis must align with respect to the first axis by being either parallel or perpendicular to the first
axis. The assignment of the leader frame axis (z, y, x) is made with respect to the axis one
assignment and the right-hand rule.
• The third motor of a three-axis positioning device must be either parallel or perpendicular to
one of the other axes.
In the case of three mutually perpendicular axes, one will be x, one y, and one z. The positive
direction of the axes must establish a correct Cartesian space frame. See Fig. 4.4(b).

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Fig. 4.4(b) Correct and Incorrect Axis Alignment

If possible, the alignment should reflect a logical alignment for leader frame x, y and z. Often,
it is best to align these with the follower (robot) WORLD axes, or with the UFRAME or
UTOOL axes of the follower.
For example, in Fig. 4.4(a) ,
• The one-axis rotary table can be any axis (x, y, z, -x, -y, or -z). See Drawing 1.
• Axis 1 of the two-axis rotary table can be any frame axis, such as y. However, the
perpendicular axes cannot be y or -y. See Drawings 2 and 3.
• Parallel axes with the same positive axis direction must be assigned the same. In the three-axis
parallel illustration, axis 2 and axis 3 must be defined as, for example, (x and x), (-x and -x), (y
and y), or (-y and -y). See Drawing 4.
• Mastering and calibration of the leader and follower groups has been completed.
• The CD_pair has been set up ( Chapter 3 ).
• The tool frame of the follower group has been defined.
• A mark or pointer has been placed on the last axis of the leader (positioner) device. This pointer
reference must be in the plane of rotation of the last axis, level with the surface (on the table top, for
example).
Use Procedure 4-3 to perform unknown point calibration for a rotary axis. Use Procedure 4-4 to perform
unknown point calibration for a linear axis. Use both Procedure 4-3 and Procedure 4-4 for positions with
linear and rotary axes.

Procedure 4-3 Unknown Point Calibration for a Rotary Axis

Conditions
• The number, direction, and order of axes for the leader group is set and known.
• The leader frame alignment has been determined.
• Mastering and calibration of the leader and follower groups has been completed.
• The tool frame and user frame (if applicable) of the follower group have been defined.
• A mark or pointer has been placed on the last axis of the leader device (positioner).
• The CD_pair has been set up ( Chapter 3 ).
Hint
It is recommended that you define the positions you use in the calibration in a program so that the
program can be executed later in the event that the CD_pair calibration data is lost. Add some JOINT
motion instructions between the calibration positions so that the robot does not hit the positioner. A
typical calibration program has 6 to 8 positions per axis. After you have created this program, you can
execute the program in single step mode while recording the CD_pair calibration positions in the

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coordinate calibration screen on the SETUP menu. Each axis will be calibrated. Note that all axes, except
the one being calibrated, must be at their zero positions.

NOTE
When you calibrate axes, you must start at the base axis and finish with the
tabletop or work surface axis. See Fig. 4.4(c).

Fig. 4.4(c) Unknown Point Calibration Overview for a Rotary Axis

Steps
1. Press MENUS.
2. Select SETUP.
3. Press F1, [TYPE].
4. Select Coord.
5. Press F2, [C_TYPE]. You will see a screen similar to the following.

SETUP Coord
Unknown type calibration Coord Pair: 1
Group Number Leader: 3 Follower: 1
X: 0.000 Y: 0.000 Z: 0.000
W: 0.000 P: 0.000 R: 0.000
Axis Number: 1 (Total:2)
Axis Type: ROTARY
Axis Direction: +Y
Point 1: UNINIT
Point 2: UNINIT
Point 3: UNINIT

6. Move all axes of the leader (positioner) to their zero positions.

7. Move the cursor to Axis Number and enter the number of the axis you are calibrating.
8. Move the cursor to Axis Direction and change it if necessary.
CAUTION
When recording calibration points for a positioner, move only that axis when
performing calibration on multi-group positioners. The other axes of the positioner
must remain at their zero positions, otherwise, an incorrect calibration can occur.
The follower (robot) can be moved freely during calibration.
9. Record Point 1:
a. Move the cursor to Point 1.
b. Jog the follower (robot) so that the pointing device touches the marked position on the leader.
See Fig. 4.4(d).
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c. Press and hold SHIFT and press F5, RECORD.

Fig. 4.4(d) Defining Point 1 for Axis 1

NOTE
For the next two points, if the total positive rotation is less than60°, split the
available angular motion into two portions of roughly equal size. Very small
angular moves of less than 20°might yield less accurate calibration information.

10. Record Point 2: ( Fig. 4.4(e) )

a. Move the cursor to Point 2.
b. Jog the first axis only of the leader from 30 to 90 degrees in the positive direction.
c. Jog the follower (robot) so that the pointing device touches the marked position on the leader.
d. Press and hold SHIFT and press F5, RECORD.

Fig. 4.4(e) Defining Point 2 for Axis 1

11. Record Point 3: ( Fig. 4.4(f) )

a. Move the cursor to Point 3.
b. Jog the first axis only of the leader another 30 to 90 degrees in the positive direction.
c. Jog the follower (robot) so that the pointing device touches the marked position on the leader.
d. Press and hold SHIFT and press F5, RECORD.

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Fig. 4.4(f) Defining Point 3 for Axis 1

12. If your positioner has a single axis, press F3, EXEC, to complete the CD_pair calibration. Otherwise,
go to Step 13.
13. Record Point 1 (Second Axis):
a. Move the cursor to Point 1.
b. Move the robot to Point 1 you defined in Step 9.
You can do this as follows: Move the robot clear of the positioner, change to Group 2, press
SHIFT and F4, MOVE_TO. This moves Group 2 to P[1]. Change to Group 1, press SHIFT and
F4, MOVE_TO.
Make sure axes 1 and 2 are each in the zero position. See Fig. 4.4(g).
NOTE
If you have written a calibration teach pendant program, move the cursor to the
position that is the Point 1 position, and press SHIFT and FWD.

NOTE
Use the same pointer or reference mark for all axes.
c. Press and hold SHIFT and press F5, RECORD.

Fig. 4.4(g) Defining Point 1 for Axis 2

14. Record Point 2 (Second Axis): ( Fig. 4.4(h) )

a. Move the cursor to Point 2.

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b. Jog the second axis only of the leader from 30 to 90 degrees in the positive direction.
c. Jog the follower (robot) so that the pointing device touches the marked position on the leader.
d. Press and hold SHIFT and press F5, RECORD.

Fig. 4.4(h) Defining Point 2 for Axis 2

15. Record Point 3 (Second Axis): ( Fig. 4.4(i) )

a. Move the cursor to Point 3.
b. Jog the second axis only of the leader another 30 to 90 degrees in the positive direction.
c. Jog the follower (robot) so that the pointing device touches the marked position on the leader.
d. Press and hold SHIFT and press F5, RECORD.

Fig. 4.4(i) Defining Point 3 for Axis 2

16. Repeat Step 6 through Step 15 for all of the rotary axes of the positioner.
17. Perform Procedure 4-4 for all of the linear axes of the positioner.
18. When all of the axes (rotary and linear) have been calibrated, press F3, EXEC, to execute the
calibration.

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The leader coordinated frame is displayed in the SETUP Coord screen when this calculation is
complete.
If the calibration was not successful, or if a calibration message is displayed on the prompt line of
the teach pendant screen, refer to Table 7.2 in Chapter 7.
19. Turn off the controller and then turn it on again to enable this data for system use.

Procedure 4-4 Unknown Point Calibration for a Linear Axis

Conditions
• The number, direction, and order of axes for the leader group is set and known.
• The leader frame alignment has been determined.
• Mastering and calibration of the leader and follower groups has been completed.
• The tool frame and user frame (if applicable) of the follower group have been defined.
• A mark or pointer has been placed on the last axis of the positioning device.
• The CD_pair has been set up ( Chapter 3 ).
NOTE
When you calibrate axes, you must start at the base axis and finish with the
tabletop or work surface axis. See Fig. 4.4(j).

Fig. 4.4(j) Unknown Point Calibration Overview for a Linear Axis

Steps
1. Press MENUS.
2. Select SETUP.
3. Press F1, [TYPE].
4. Select Coord.
5. Press F2, [C_TYPE]. You will see a screen similar to the following.
SETUP Coord
Unknown type calibration Coord Pair: 1
Group Number Leader: 3 Follower: 1
X: 0.000 Y: 0.000 Z: 0.000
W: 0.000 P: 0.000 R: 0.000
Axis Number: 2 (Total:2)
Axis Type: LINEAR
Axis Direction: +Y
Point 1: UNINIT
Point 2: UNINIT

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6. Move all axes of the leader (positioner) to their zero positions.

7. Move the cursor to Axis Number and enter the number of the axis you are calibrating.
8. Move the cursor to Axis Direction and change it if necessary.
CAUTION
When recording calibration points for a leader axis, move only that axis. The other
leader group axes must remain at their zero positions; otherwise, calibrations
might be incorrect.
9. Record Point 1:
a. Move the cursor to Point 1.
b. Jog the follower (robot) only so that the pointing device touches the marked position on the
leader. See Fig. 4.4(k).
c. Press and hold SHIFT and press F5, RECORD.

Fig. 4.4(k) Defining Point 1 for Axis 1

10. Record Point 2: ( Fig. 4.4(l) )

a. Move the cursor to Point 2.
b. Jog the first axis only of the leader 150 mm or more in the positive direction.
c. Jog the follower (robot) so that the pointing device touches the marked position on the leader.
d. Press and hold SHIFT and press F5, RECORD.

Fig. 4.4(l) Defining Point 2 for Axis 1

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11. Record Point 1 (second axis):

a. Move all axes to their zero positions.
b. Move the cursor to Axis Number and enter the number of the axis you are calibrating (2, for
example).
c. Move the cursor to Axis Direction and change it if necessary.
d. Move the cursor to Point 1.
e. Jog the follower (robot) so that the pointing device touches the marked position on the leader.
See Fig. 4.4(m).
f. Press and hold SHIFT and press F5, RECORD.
NOTE
Point 1 for the second axis can be the same as Point 1 for the first axis. Use
MOVE_TO to move the robot to Point 1 of the first axis, select the appropriate axis
number, and record the position. MOVE_TO will move only one group at a time.
To move another group, toggle the group number and press F4, MOVE_TO.

NOTE
Use the same pointer or reference mark for all axes.

Fig. 4.4(m) Defining Point 1 for Axis 2

12. Record Point 2 (second axis): ( Fig. 4.4(n) )

a. Move the cursor to Point 2.
b. Jog the second axis only of the leader 150 mm or more in the positive direction.
c. Jog the follower (robot) so that the pointing device touches the marked position on the leader.
d. Press and hold SHIFT and press F5, RECORD.

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Fig. 4.4(n) Defining Point 2 for Axis 2

13. Repeat Step 6 through Step 10 for all of the linear axes of the positioner.
14. Perform Procedure 4-3 for all of the rotary axes of the positioner.
15. When all of the axes (rotary and linear) have been calibrated, press F3, EXEC, to execute the
calibration.
The leader coordinated frame is displayed in the SETUP Coord screen when this calculation is
complete.
If the calibration was not successful, or if a calibration message is displayed on the prompt line of
the teach pendant screen, refer to Table 7.2 in Chapter 7.
16. Turn off the controller and then turn it on again to enable this data for system use.

4.5 LEADER FRAME SETUP

Leader frames function as TOOL frames of leader groups. You can use this frame to define the
orientation of the work piece that is mounted on the leader's face plate. Just as you teach a USER frame,
you will also want to teach a leader frame to assist you in the teaching process.
Use Procedure 4-5 to perform leader frame setup.
With leader frame jogging, when the leader (table) is rotated, the follower (robot) TCP will maintain its
relative distance and orientation along the current jog path. See Fig. 4.5(a) .

Fig. 4.5(a) Leader Frame Jogging

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Procedure 4-5 Leader Frame Setup

NOTE
In a table top coordination application, the leader is the table. It would be difficult to
define this leader frame by moving the leader position; therefore, use the follower
to teach the leader frames.
Conditions
• The coordinate pairs must be calibrated.
• The workpiece of the coordinate motion application is located on the leader group face plate.
Steps
1. Press MENUS.
2. Select SETUP.
3. Press F1, [TYPE].
4. Select Coord. You will see a screen similar to the following.

SETUP Coord
Coord Pair Number : [ 1]
Leader Group : 2
Follower Group : 1
X: 800.000 Y: 0.000 Z: 0.000
W: 0.000 P: 0.000 R: 0.000
Follower orientation: BOTH
Use Leader Frame number: 1

5. Press F2, [C_TYPE].

6. Select Leader Frame. You will see a screen similar to the following.

SETUP Coord
Leader's Frame Setup Coord Pair: 1
Group Number Leader: 2 Follower: 1
Leader Frame:
X: 0.000 Y: 0.000 Z: 0.000
W: 0.000 P: 0.000 R: 0.000
Leader Frame number: : 1
Origin Point: : UNINIT
X Direction Point: : UNINIT
Y Direction Point: : UNINIT

NOTE
If you do not see the option to select Leader Frame, you need to calibrate the
coordinate pair.

NOTE
The default value of all leader frames for x, y, z, w, p, and r, is zero.
7. You can select the leader frame whose values you wish to define:
a. Move the cursor to Leader Frame number.
b. Type the number of the leader frame and press ENTER.
8. Record Origin Point:
a. Move the cursor to Origin Point.
b. Jog the follower (robot) so that the pointing device touches the marked position on the leader.
See Fig. 4.5(b) .
c. Press and hold SHIFT and press F5, RECORD.
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Fig. 4.5(b) Defining the Origin Point

9. Record X Direction Point:

a. Move the cursor to X Direction Point.
b. Jog the follower (robot) so that the pointing device touches a point along the +x axis. See Fig.
4.5(c)
NOTE
If the follower (robot) TCP cannot touch a point along the +x axis, jog the leader to
a position where this can be done.

Fig. 4.5(c) Defining the X Direction Point

c. Press and hold SHIFT and press F5, RECORD.

10. Record Y Direction Point:
a. Move the cursor to Y Direction Point.
b. Jog the follower (robot) so that the pointing device touches a point along the +y axis. See Fig.
4.5(d) .
NOTE
If the follower (robot) TCP cannot touch a point along the +y axis, jog the leader to
a position where this can be done.

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Fig. 4.5(d) Defining the Y Direction Point

c. Press and hold SHIFT and press F5, RECORD.

11. To display the new leader frame values, press and hold SHIFT, and press F3, EXEC.

4.6 Dynamic UFrame

Abstract
When Coordinated Motion is used, Dynamic UFrame provides the method to record the follower’s
position in relative form not in absolute form. By enabling this function, when the leader moves, the
specified follower uframe varies. So, when the follower robot’s position is touched-up using the uframe,
the relative position based on the uframe (which is linked with leader frame) will be recorded. Since the
position data is stored in relative form, TPE Offset can work in relative frame. Before setting this function,
the operator needs to finish the calibration of Coordinated motion and the setting of Leader frame.
This function can be used on 7DA3/18 or later software and 7DA4 software.

Setting
1. To enable Dynamic UFrame on 7DA3/18 or later, set the following system variable and cycle
power.
$CD_PARAM.$DYN_UFRAME -> TRUE (default: FALSE)
After this setting and cycle power, the new item ‘Follower UFrame number’ appears on Coord pair
setting.
SETUP Coord
Coord Pair Number : [ 1]
Leader Group : 2
Follower Group : 1
X: 800.000 Y:0.000 Z:0.000
W: 0.000 P:0.000 R:0.000
Follower orientation : ATTACHED
Leader frame number : 1
Follower UFrame number : 0

In case of 7DA4 software, the option function “A05B-2500-R700 Dynamic UFrame” is needed
when the operator would like to use Dynamic UFrame. And when the above option is ordered, the
item “Follower UFrame number” appears on Coord pair setting without requiring the system
variable to be set manually.
2. Select “Leader frame number”. The selected leader frame is related with the following uframe.
Before this setting, you may need to define leader frame. For the procedure to define leader frame,
see the chapter of Section 4.5.
3. After setting “Follower UFrame number” and cycling power, the selected uframe of the follower is
treated as Dynamic Uframe. This means that the leader frame position based on the follower’s world

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frame will be set to the follower’s uframe. When this number is 0, Dynamic UFrame is disabled.
(default: 0)
For example, if Leader frame number is 1 and Follower Uframe number is 9, the position of the
leader frame 1 with respect to the follower’s world frame is set to the UF9 of the follower. So, UF9
content dynamically varies depending on the leader’s position.
And when one changes “Follower UFrame number” or “Leader frame number” setting, cycle power
operation is needed.

Programming
On the TPE program, use the uframe number set as Dynamic UFrame for the position to which you want
to apply TPE offset in relative frame.
On this TP program, we suppose Leader frame number is 1 and Follower Uframe number is 9. Here, note
that the position P[5], P[6], P[7], P[8] and P[9] are follower’s TCP position based on the leader frame 1.
And other positions are based on the follower’s world frame. Since P[5]-P[9] are relative form based on
the leader frame 1, i.e. work frame, the OFFSET, PR[100] works on the work frame.

1: UFRAME_NUM = 0 ; Initialize uframe number.

2: ;
3:J P[1] 100% CNT100 ;
4:J P[2] 100% CNT100 ;
5: ;
6: UFRAME_NUM = 9 ; The operation for calculating the
vision offset on UF9.
7: CALL VISTEST ;
(Calculation result is output to
8: UFRAME_NUM = 0 ; PR[100])
9: ;
10:J P[3] 100% CNT100 ;
11:J P[4] 100% CNT70 ;
12: ;
13: UFRAME_NUM = 9 ; Select Dynamic uframe.
14: ;
15:L P[5] 500mm/sec FINE OFFSET,PR[100] ;
16: Arc Start[23.0Volts,175.0Amps] ;
17:C P[6] OFFSET,PR[100]
P[7] 100cm/min CNT100 COORD OFFSET,PR[100] ;
18: Arc Start[22.0Volts,175.0Amps] ;
19:C P[8] OFFSET,PR[100]
P[9] 100cm/min FINE COORD OFFSET,PR[100] ;
20: Arc End[16.0Volts,125.0Amps,0.0s] ;
21: ;
22: UFRAME_NUM = 0 ; Back to original uframe.
23:L P[10] 500mm/sec CNT100 ;
24:L P[11] 2000mm/sec CNT70 ;

Restriction
This function can be used in the following versions of software.
• 7DA3/18 or later
• 7DA4/01 or later
This function cannot be used with the following motion.
• Weaving
• Multi-follower programs
• Remote TCP
• Tracking motion (Line Tracking, TAST etc.)
• Multi-Pass
• Any option that is not supported with Coordinated motion
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WARNING
The value of the User Frame that is used as Dynamic UFrame changes according
to the motion of the leader group. So if one operates the nomal motion by using
the User Frame that is used as Dynamic UFrame, the robot may move to
unexpected direction by the change of the leader robot’s position. Please don’t use
the User Frame that is used as Dynamic UFrame when operating the other
(nomal) motion.

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5 JOGGING
5.1 OVERVIEW
Coordinated jogging of a CD_pair allows one leader and its followers to be jogged in a coordinated
manner. The jog speed of the coordinated pair is determined by the speed of the leader group. The
relationship of the follower TCP to the leader frame is fixed during the jogging of the CD_pair.
How you jog CD_pairs depends on the kinds of groups used in the pairs:
• Fixed Orientation jogging is used to jog leader and follower groups together. Only the location of
the TCP of the follower is preserved with respect to the Leader frame. The orientation of the
follower remains constant with respect to the robot WORLD frame.
• Coordinated jogging is used to jog leader and follower groups together. The orientation and TCP of
the follower are maintained with respect to the leader frame is maintained.
• Coordinated sub-group jogging is used when integrated extended axes (sub-groups) are used in
leader groups. This type of jogging is only available in cases where auxiliary axes are included in
the leader group.
• Leader Frame (LDR) jogging is used to jog the follower group in the leader group frame.

WARNING
The farther the follower TCP is from the rotary leader axis center you are jogging,
the farther and faster the follower (robot) will move for the same override
percentage. Be aware of this when you jog; otherwise, you could injure personnel
or damage equipment.

5.2 JOGGING DESIGNATION

You select whether to perform coordinated motion jogging using the FCTN menu. The status line at the
top of the screen displays whether coordinated motion jogging will be performed when you press the jog
keys, and if it is used, the status line also indicates the type of coordinated jogging. The form is "C#*" or
"F#*", where # is the number of the leader group and * is the number of the follower group.
NOTE
You will not be able to switch between Coordinated jogging and Fixed orientation
coordinated jogging if the Follower Orientation field on the Setup Coord screen is
not set to BOTH. Refer to Procedure 5-1 to accomplish this task.
In Fig. 5.2(a) , the leader group is group 2, the follower group is group 1. If subgroup jogging is used, the
"C" is an "S," and will jog the extended axis of the leader group.
PROGRAM NAME C21 JOINT 10%
Fig. 5.2(a) Coordinated Jogging Display

In Fig. 5.2(b) , the leader group is group 2, the follower group is group 1. Subgroup jogging is used, so an
"S" is displayed instead of a "C."
PROGRAM NAME S21 JOINT 10%
Fig. 5.2(b) Coordinated Subgroup Jogging Display

In Fig. 5.2(c) , the leader group is group 2, the follower group is group 1. Fixed Orientation coordinated
jog is selected, so an "F" is displayed instead of a "C."
PROGRAM NAME F21 JOINT 10%
Fig. 5.2(c) Fixed Orientation Coordinated Jogging Display

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Table 5.2 lists various jogging designations for a leader group 2 and follower groups 1 and 3.

Table 5.2 Coordinated Motion Jogging Designations

Designation Description

C21 Jog leader (2) and follower (1), coordinated

F21 Jog leader (2) and follower (1), coordinated with fixed
orientation

G1 Jog follower (1) only, non-coordinated

G2 Jog leader (2) only, non-coordinated

S23 Sub-group jog leader (2) and follower (3), coordinated

G2/S Sub-group jog leader (2), non-coordinated

LDR2 Follower group is jogged in Leader frame.

Procedure 5-1 Enabling Toggle Coordinate Orientation

Conditions
• The coordinate pairs must be calibrated.
Steps
1. Press MENUS.
2. Select SETUP.
3. Press F1, [TYPE].
4. Select Coord. You will see a screen similar to the following.

SETUP Coord
Coord Pair Number : [ 1]
Leader Group : 2
Follower Group : 1
X: 800.000 Y: 0.000 Z: 0.000
W: 0.000 P: 0.000 R: 0.000
Follower orientation: BOTH
Use Leader Frame number: 1

5. Move the cursor to Follower orientation.

6. Press F4, [CHOICE], and select BOTH.

5.3 LEADER GROUP JOGGING (COORDINATED, FIXED

ORIENTATION COORDINATED)
In coordinate jogging applications, the work piece is located on the leader group and the follower group
(robot) performs an application on the workpiece. When you teach a program under these circumstances,
you would normally jog the workpiece, jog the follower to the new workpiece location, then teach the
position.
Leader Group coordinate jogging provides a simple coordinate frame which allows you to jog the
follower easily relative to the work piece. Two types of leader group jogging are available:
• Follower TCP maintains a relative position to the leader in location, and relative orientation is fixed.
See Fig. 5.3(a) and Fig. 5.3(b).
• Follower TCP maintains a relative position to the leader in location, but the relative orientation can
change. See Fig. 5.3(c) and Fig. 5.3(d).

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B-82914EN/01 5.JOGGING

NOTE
Before leader group jogging can be used, leader frames must be setup. Refer to
Section 4.5 for information on setting up leader frames.

Fig. 5.3(a) Rotary Leader Coordinated Jogging (C21)-Tilt (Attached Orientation)

Fig. 5.3(b) Rotary Leader Coordinated Jogging (C21)-Turn (Attached Orientation)

Fig. 5.3(c) Rotary Leader Coordinated Jogging (F21) - Tilt (Fixed Orientation)

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Fig. 5.3(d) Rotary Leader Coordinated Jogging (F21) - Turn (Fixed Orientation)

5.3.1 Leader Frame (LDR) Jog Coordinate Mode

In addition to the existing jog modes, JOINT, JOG, WORLD, USER, TOOL, and PATH, a new jog
coordinate mode called LDR (leader frame) is available for the robot (follower).
With leader frame jogging, when the leader (table) is rotated, the follower (robot) TCP will maintain its
relative distance and orientation along the current jog path. See Fig. 5.3.1(a).

Fig. 5.3.1(a) Leader Frame Jogging

If the jog group is a leader group, then leader frame jogging will be turned off and you will not be able to
use the LDR jog mode. If the jog group is a follower group, the LDR jog coordinate will be displayed in
the status bar as LDR 2, where 2 is the leader group number. See Fig. 5.3.1(b).
POSITION G1 LDR2 50%
Fig. 5.3.1(b) LDR Jogging Display

NOTE
When you select the leader group (robot) to jog, and LDR2 jog is displayed, the
jog direction for the TCP is defined in the Leader group WORLD frame. See Fig.
5.3.1(b).
G1 in the status bar indicates that the current jog group is Group 1.

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B-82914EN/01 5.JOGGING
If there is more than one leader group for the follower group, you can switch between leader groups using
the TOGGLE LDR GROUP function that is available on the FCTN menu. Refer to Section 5.5 for
information on jogging the robot.

5.4 JOGGING EXAMPLES

Table 5.4 lists the kinds of coordinated motion jogging that are available.

Table 5.4 Kinds of Coordinated Motion Jogging (Group 1: follower, Group 2: leader)
Display Description Effect of JOINT Jog Type Effect of WORLD, TOOL, or USER
Jog Type

C21 Coordinated group jog Coordinated frame of the leader No effect for coordinated
moves in JOINT Independent Axes
Follower moves with the coordinated
frame without changing relative
position in the leader frame

F21 Fixed orientation coordinated Coordinated frame of the leader No effect for coordinated
group jog moves in JOINT. Independent Axes
Follower moves with the coordinated
frame without changing relative
location in the leader frame, and
orientation remains the same

S21 Coordinated subgroup jog Coordinated frame of the leader Coordinated frame of the leader
(Integrated extended axes) moves in JOINT moves by only X, Y, or Z (dependent
Follower moves with the coordinated on axis assignment, effective for
frame without changing relative integrated linear axes)
position in the leader frame Follower moves with the coordinated
frame

G1 Follower group jog (robot) No coordinated motion No coordinated motion

Only the follower moves in JOINT Only the follower moves in WORLD,
TOOL, or USER frame

G2 Leader group jog (positioner) No coordinated motion No effect for coordinated

Only the leader moves in JOINT Independent Axes

LDR2(G1) Follower (robot) jog Follower jogging occurs with respect Appears to jog like a JOG frame or a
to the leader frame. USER frame, but this frame moves if
the leader group axes are moved.

Fig. 5.4(a) , through Fig. 5.4(e) show examples of the effect of coordinated jogging.

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Fig. 5.4(a) Linear Leader Coordinated Jogging

Fig. 5.4(b) Rotary Leader Coordinated Jogging - Tilt (Attached Orientation)

Fig. 5.4(c) Rotary Leader Coordinated Jogging - Turn (Attached Orientation)

NOTE
The tool orientation remains constant relative to the tabletop during jogging. You
can have coordinated motion on more than one axis being jogged at the same
time.

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B-82914EN/01 5.JOGGING

Fig. 5.4(d) Rotary Leader Coordinated Jogging - Tilt (Fixed Orientation)

Fig. 5.4(e) Rotary Leader Coordinated Jogging - Turn (Fixed Orientation)

WARNING
The farther the follower TCP is from the leader rotary axis center you are jogging,
the farther and faster the follower (robot) will move for the same override
percentage. Be aware of this when you jog; otherwise, you could injure personnel
or damage equipment.

5.5 JOGGING PROCEDURE

Use Procedure 5-2 to jog the robot using coordinated motion.

Procedure 5-2 Jogging Using Coordinated Motion

Conditions
• All personnel and unnecessary equipment are out of the workcell.
• All EMERGENCY STOP faults have been cleared.
• All other faults have been cleared and the fault light is not illuminated.

WARNING
Make certain that all safety requirements for your workplace have been followed;
otherwise, you could injure personnel or damage equipment.
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Steps
1. Hold the teach pendant and continuously press the DEADMAN switch on the back of the teach
pendant.

2. Turn the teach pendant ON/OFF switch to the ON position.

NOTE
If you release the DEADMAN switch while the teach pendant is ON, an error will
occur. To clear the error, continuously press the DEADMAN switch and then press
the RESET key on the teach pendant.

WARNING
The farther the follower TCP is from the leader axis you are jogging, the farther the
follower (robot) will move for the same override percentage. Be aware of this when
you jog; otherwise, you could injure personnel or damage equipment.

3. If you want to jog using coordinated motion,

For coordinated group jogging ,
a. Press FCTN.
b. Move the cursor to CHANGE GROUP and press ENTER.
c. Enter the number of the leader group.
d. Press FCTN.
e. Move the cursor to TOGGLE COORD JOG and press ENTER.

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B-82914EN/01 5.JOGGING
"C#*" or "F#*" will be displayed in the status line, where a "#" is the leader group, and a "*" is
the follower group. F indicates that the orientation of the follower group is fixed. You will see a
screen similar to the following.
PROGRAM NAME C21 JOINT 10%

f. To change the number of the follower group, press FCTN and select TOGGLE COORD JOG.
Do this until the CD_pair you want is displayed.
g. To change to a fixed orientation coordinate jogging mode (orientation does not change), select
TOGGLE COOR ORNT. For more information on the types of Leader coordinate jogging
modes available, refer to Section 5.3.
NOTE
If there is no follower group, TOGGLE COOR ORNT will not be displayed.

h. To end coordinated jogging, press FCTN and select TOGGLE COORD JOG.
NOTE
Set the jog speed to a low percentage (%) value if you are inexperienced in
jogging the robot, or if you are uncertain how the robot will move.

4. Select a jog speed by pressing and releasing the appropriate jog speed key until the jog speed you
want is displayed in the upper right hand corner of the teach pendant screen.
WARNING
In the next step, the robot will move. To stop the robot immediately any time during
jogging, release the DEADMAN switch or press the EMERGENCY STOP button.

5. To jog, press and hold the SHIFT key and continuously press the jog key that corresponds to the
positioner axis you want to move in a coordinated fashion with the follower (robot). To stop jogging,
release the jog key.
6. When you are finished jogging, turn the teach pendant ON/OFF switch to OFF, and release the
DEADMAN switch.

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6 PROGRAMMING
6.1 OVERVIEW
To use coordinated motion within a teach pendant program, you must include the COORD motion option
in the appropriate motion instructions. This chapter contains information on using coordinated motion in
a teach pendant program.
To use coordinated motion in a teach pendant program, you must
1. Modify the program header information.
2. Include the COORD coordinated motion option and define the speed in the motion instructions that
will perform coordinated motion.
3. Execute the program.

Benefits of Coordinated Motion Programming

Coordinated motion provides the following program execution enhancements:
• It allows continuous processing on long linear joints while maintaining tool orientation to the
workpiece. Path lengths can greatly exceed the maximum useable work envelope of the robot itself.
• It reduces the number of program points that would be required to execute simultaneous motion of a
table and robot. Simultaneous motion typically would require a point to be taught for every 6-8 mm.
The group of points is reduced to two points with coordinated motion programming for a linear
weld.
• It provides better or preferred positions on complex workpieces, especially for leaders (positioners)
with two or more axes.
• It reduces the non-productive motion (air cut moves) by use of continuous repositioning of the
workpiece, especially for workpieces that have processing on several planes.

Coordinated Motion Program Execution

In the example shown in Example 6.1 , G2 is the leader group, G1 is the follower group.

Example 6.1. Coordinated Motion Program Example

1: J P[1] 100% FINE
2: L P[2] 20mm/sec FINE COORD
3: L P[3] 20mm/sec CNT100 COORD
4: C P[4] P[5] 20mm/sec CNT100 COORD
5: L P[6] 20mm/sec FINE

In this example, coordinated motion will be performed in lines 2, 3, and 4. If the follower is a robot and
the leader is a single-axis tabletop, when line 2 of the program is executed, the leader and follower will
move together, and the TCP speed relative to the tabletop will be 20mm/sec. The two groups will start at
the same time and finish at the same time. The motion path of the follower, although it appears to be an
arc or circular, will travel along a straight line relative to the moving frame of the leader. The move to
P[6] will be a normal linear move.

6.2 PROGRAM HEADER INFORMATION

You must specify motion groups appropriately in the group mask portion of the program header for
programs in which you want to use coordinated motion. If more than one CD_pair is defined, the group
mask must contain only the groups in the CD_pair for which coordinated motion is to be executed.
You can use only one leader in a teach pendant program. You must indicate the motion groups of the one
leader and all followers in the group mask program header information. You must exclude other leader
groups not used in the program in the group mask.
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For example, for two positioners and one robot, CD_pair 1 = G1+G2 and CD_pair 2 = G1+G3. You
cannot have G1, G2, G3 in the header if you intend to use coordinated motion. If G1 and G2 are a
CD_pair, and G3 is not included in a CD_pair, then G1, G2, G3 can be included in the program header
and coordinated motion will execute.
You access the program header information on the DETAIL screen of the SELECT menu. You set the
group mask prior to recording any positions. Refer to the appropriate application-specific Setup and
Operations Manual for more information on modifying program header information.

6.3 COORD COORDINATED MOTION OPTION

You must include the COORD coordinated motion option in each motion instructions that will perform
coordinated motion, as follows:
L P[2] 20mm/sec FINE COORD

You can include the COORD motion option only in linear (L) and circular (C) motion instructions.

Conditions
Before you record coordinated motion instructions, make sure that the tool frame for the follower group
have been defined properly.

Limitations
Coordinated motion in a program has the following limitations:
• You cannot use the INC incremental motion option in motion instructions that contain the COORD
motion option.
• You cannot use wrist jogging.
• You cannot use the Wjnt wrist joint motion option in motion instructions that contain the COORD
motion option.
• You can execute weaving only on the follower group (robot).
• You cannot use program shift or mirror image copy.
• UTOOL and UFRAME for the leader group (positioner) are not supported.
• The COORD motion option can be applied to a robot-only move (when the positioner does not
move). The effect is the same as a non-coordinated linear or circular move.
• You cannot put a non-coordinated linear or circular motion instruction of termination type
CNT1-CNT100 before a coordinated motion instruction. See Example 6.2 .
• For Coordinated motion RPM and Multipass, the starting position for tracking and replay must be
linear and must contain the COORD option.

Example 6.2. Coordinated Motion Termination Type Example

Correct:
1: L P[1] 250mm/sec CNT0
2: L P[2] 20mm/sec FINE COORD
1: J P[1] 100% CNT100
2: L P[2] 20mm/sec FINE COORD

Incorrect:
1: L P[1] 250mm/sec CNT100
2: L P[2] 20mm/sec FINE COORD

6.4 COORD[ LDR ] COORDINATED MOTION OPTION

COORD[LDR] is a motion option that allows you to specify the leader group number. It can be used in
place of COORD when it is necessary to specify the leader group number.
L P[1] 25mm/sec CNT100 COORD [ 1 ]

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You can also use COORD [ R[ ] ] to specify the leader group number in a register.
In a multi-arm system, it is possible that one robot could function as a leader at one time, but then
function as a follower at another time. If the COORD option is used in a system where the program group
mask has more than one “potential leader”, the alarm CD-009 “More than one leader” is posted. An
example system shown in Table 6.4 is illustrated in Fig. 6.4(a) and Fig. 6.4(b) .

Table 6.4
CD_PAIR setup Leader Follower

CD_PAIR[1] G1 G3

CD_PAIR[2] G2 G4

CD_PAIR[3] G1 G2

CD_PAIR[4] G1 G4

In Fig. 6.4(a) , only one leader is possible for each program.

Fig. 6.4(a) One Possible Leader

In Fig. 6.4(b) , there are two potential leaders. In this case, you could use COORD[1] in Program C to
specify group 1 as the leader.

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B-82914EN/01 6.PROGRAMMING

Fig. 6.4(b) Two Possible Leaders

In the following example,

L P[1] 25mm/sec CNT100 COORD [ 1 ]

Group 1 is the leader group and

• the LDR group must be in the program group mask
• the LDR group will be the ONLY leader among the groups

Limitations
• If the leader group number changes within the same program
• they must be separated by at least one non-COORD motion
and
• the non-COORD motion immediately before the COORD[LDR] motion must use the FINE
termtype
L P[1] 25mm/sec CNT100 COORD [ m ]
L P[2] 25mm/sec FINE COORD [ m ]
….
L P[2] 1000mm/sec CNT100 <– reposition moves (non-COORD)
L P[3] 1000mm/sec FINE
L P[4] 25mm/sec CNT100 COORD [ n ] <– change leader group
L P[5] 25mm/sec FINE COORD [ n ]

• Dynamic switching of the leader group number in consecutive COORD [ LDR ] motion, as shown in
the following example, is not allowed.
The CD-029 “Illegal to switch leader” alarm will be posted.
L P[1] 25mm/sec CNT100 COORD [ m ]
L P[2] 25mm/sec CNT100 COORD [ n ]

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6.5 SPEED DEFINITION

Two speeds are controlled during the execution of coordinated motion: the leader speed and the follower
speed:
• The follower (robot) speed is continuously adjusted to maintain the TCP speed of the motion
instruction in the program. This speed is relative to the coordinated frame of the leader.
• For typical moves, the leader group runs at 100% of its speed and the follower speed is adjusted
continuously to maintain program speed.
• If the follower segment time is longer than the positioner move would take at 100%, then the
positioner speed is adjusted so that it takes the same amount of time as the follower to complete the
move. The follower (robot) segment time is the calculated time for the robot to move the distance
from P[n] to P[n+1] at the programmed speed. The follower's motion time is made equal to the
calculated segment time. This ensures that the motions begin and end simultaneously.
If the follower reaches an axis speed limit during coordinated motion, the coordinated path is maintained,
but the relative motion speed between the leader and follower will be slower than the speed specified in
the motion instruction. When this occurs, a warning is displayed.

6.6 LINEAR MOTION PROGRAMMING

Linear motions are executed in the coordinated frame at the programmed speed. For each linear segment,
record the start and end positions such that the position and orientation of the tool are correct for the
given weld joint. The position of the leader group can be changed between the start and end positions,
especially if the endpoint is not reachable by just moving the robot, or, for the case that tool orientation
can be maintained better via a movement of the workpiece.
When linear motion is executed, note that the speed is judged at the TCP relative to the workpiece, so the
axes might appear to be moving faster or slower than the programmed speed during coordinated motion.
Also note that most linear moves that are executed in a rotating coordinated frame will appear to be
circular, or elliptical when viewed.

Programming Guidelines
When programming a linear coordinated motion instruction, keep in mind the following guidelines:
• Divide the motion so that half is performed by the robot and half is performed by the table. This will
reduce the time required on that segment. Preferably, this will have the two groups moving in
opposite directions.
• Try to orient the workpiece so that a preferred (application-dependent) position is achieved.
• Try to arrange the leader and follower at the end position of the segment so that
• The next path segment can be executed without stopping the process.
• The next path segment is in a preferred position.
• The distance to the next path segment is minimized.

NOTE
A fast linear coordinated move can be used for an air cut move, which might be
quicker than a joint air cut move.
• You can minimize the motion of either the leader or follower group, especially in cases where the
leader or follower is close to an axis limit, or the follower group is approaching singularity or wrist
flip positions.
• A coordinated motion from P[n] to P[n+1] should not be defined by recording P[n], then coordinated
jogging to P[n+1]. The effect of doing this is that the follower motion in the coordinated frame will
be of zero length and the motion will be executed at the maximum speed of the leader group axis
(axes).
• Work and travel angles will be executed as though there were no leader group motion when viewed
with respect to the workpiece being welded. If torch orientation of the first and second positions is
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B-82914EN/01 6.PROGRAMMING
maintained relative to the workpiece, the entire path will maintain the torch orientation relative to
the workpiece.

6.7 CIRCULAR MOTION PROGRAMMING

Circular motions executed in the moving coordinated frame generally appear as circular motions, except
in cases where the motion is predominantly executed on the leader group (positioner).
As with linear motion, the relative positions of the positioner and robot for the START, VIA, and END
positions of the circular move are not critical except that the VIA position is located between the START
and END position with respect to the workpiece. When teaching the positions on circular weld paths,
ensure that the torch positions are correct for each point; changing the leader position between points is
permitted.
Orientation control at the VIA position is also provided in coordinated motion, but the plane in which the
circular move executes is determined by the start and end positions.

Programming Guidelines
When you program a circular coordination motion instruction, keep in mind the following guidelines:
• The smoothest execution tends to occur when the predominant motion occurs on the positioner.
• Try to orient the workpiece so that a preferred (application-dependent) position is achieved.
• Try to arrange the leader and follower positions at the end position of the segment so that
• The next path segment can be executed without stopping the process.
• The next path segment is in a preferred position.
• The distance to the next path segment is minimized.
• You use a fast linear coordinated move for an air cut move that might be quicker than a joint air
cut move.
NOTE
You minimize the motion of either the leader or follower group in cases where the
leader or follower is close to an axis limit, or the follower group is approaching
singularity or wrist flip positions.

It is possible to define circular positions that can not be executed in program mode. Typically, this is
caused by one or more joints going into singularity. In those cases, do the following:
1. Stop execution.
2. Select coordinated jogging mode.
3. Jog the leader group to a position in which the singularity no longer exists.
4. Touch up the position in this new position.
5. Re-teach the next position by the same method until the motion problem no longer exists.
6. Try a complete execution of the circular move.
7. If you cannot complete the move, rotate the leader axis only (G2) until the workpiece is in a section
of the robot work envelope that does not cause the motion problem to occur, then record the new
position.

WARNING
As with non-coordinated circular moves, if you abort a program during the
execution of a circular move, and if you jog the robot out of the plane of the
motion, the resumed motion will include the robot's current location. This might
cause the tool to hit the positioner or workpiece. Be sure to execute the program at
a low override for safety; otherwise, the robot could injure personnel or damage
equipment.
The (x,y,z) data of the VIA position is not used in the motion path execution, only for planning the circle.
The plane of execution of the circle will be determined by the start and end positions. The plane of
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6.PROGRAMMING B-82914EN/01

circular motion during program execution is not changed by re-teaching the VIA position, only by
changing the start and end positions.
The plane in which circular motion OCCURS is relative to the tabletop of the positioner. As the
positioner moves, the circular motion plane also moves. This will appear as a helical motion.
To perform a spiral or helical motion on a headstock-mounted workpiece, use circular motion training
positions approximately every 45°of headstock rotation.
In order to execute a circular motion that changes the motion plane during execution, two circular moves
must be defined for the circular path. In Fig. 6.7 , to rotate the table top (axis 2) while rotating axis 1, you
must program two arcs:
• The first arc is created using points [P1], P[2] (via), and P[3]
• The second arc is created using points P[3], P[4] (via), and P[5]
The VIA position Cartesian data is used during single step execution.

Fig. 6.7 Coordinated Circular Motion

6.8 Relative motion and Simultaneous motion

This section describes about Relative motion and Simultaneous motion. The purpose is to make user can
select ‘Relative motion’ or ‘Simultaneous motion’ automatically without conscious depending on the
situation.
Model case: the coordinated motion of three robots in one controller. A large work piece is held by two
handling robots. And the third arc robot welds the work piece. →Fig. 6.8

Fig. 6.8 The coordinated motion of three robots in one controller

• G1:arc robot
• G2:handling robot
• G3:handling robot
• Pair 1： G2 leader, G1 follower
• Pair 2： G2 leader, G3 follower
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B-82914EN/01 6.PROGRAMMING

For pair 1, much more attention will be paid to the follower’s relative motion than the leader’s one while
teaching. For pair 2, much more attention will be paid to the leader’s motion while teaching. Because the
relative motion is almost none. Pair 1's motion is called 'Relative motion', and pair 2's motion is called
'Simultaneous motion'.→Table 6.8

Table 6.8 Relative motion and Simultaneous motion

Relative motion Simultaneous motion

For example, the follower’s arc robot For example, a work piece is held by
Description
welds the work peace held by leader’s more than one robot in material
handling robot. In this case, the handling. In this case, the leader’s
follower’s relative motion is important. motion is important. Normally, robot
Normally, the coordinated motion is link is used.
used.

Leader’s motion type If motion type is CIRCULAR or ARC, Programmed motion type.
it’s changed to LINEAR.

Leader’s speed Maximum speed.*1 Program speed.

Follower’s relative motion type to Programmed motion type. If motion type is CIRCULAR or ARC,
leader it’s changed to LINEAR. *2

Coordinated jogging Anytime follower must follow.

If leader’s move time is dominant in The warning message "CD-020 Not No warning message.
coordinated motion planning. reach relative speed" is shown.

The speed of non-coordinated motion Maximum speed.*1 Program speed.

group in coordinated motion.

(*1)The move time of coordinated motion is the longest one among all groups.
(*2)Since folower's TCP realtive to leader don't move, this move is zero distance move.

On Fig. 6.8 both relative motion (pair 1) and simultaneous motion (pair 2) should be done at the same
time. But coordinated motion dose not support simultaneous motion regularly . So following setting
enables to use simultaneous motion.

Setting
On Fig. 6.8, Pair2 (G2, G3) motion is simultaneous motion. So G2 and G3 is handling robot.
1. For all handling robot、you calculate as below.
G2 2^(2-1) = 2
G3 2^(3-1) = 4
（For example, G1=1, G4=8, G5=16）
2. Next, you sum up all value. In this case, total is 6 (=2+4).
3. You set $CD_PARAM.$MH_ROB_GMSK to this value.

If all follower robots are handling robot, the leader is treated as the leader of simultaneous motion. If a
non-handling follower robot exists, the leader is treated as the leader of relative motion.
In the case of Fig. 6.8 G2 treated as the leader of relative motion, because G2 has non- handling follower
G1. So, if G2's motion type is CIRCULAR, G2's motion changes LINEAR and moves at a maximum
speed.(Table 6.8)
For coordinated jogging, a handling follower robot must follow about leader. For example, you can
toggle 'C21', 'C23', and 'C231' as coordinated jogging before simultaneous motion setting. But you cannot
toggle 'C21' after setting, because handling robot G3 don't follow about leader G2. This specification
prevent G2 and G3 from dropping their work piece.
If you want to toggle 'C21', please set '$CD_PARAM.$MH_JOG_ENB' to False.
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7.TROUBLESHOOTING B-82914EN/01

7 TROUBLESHOOTING
7.1 OVERVIEW
This section contains information on solving problems that arise when you are setting up and using
coordinated motion.
• Refer to the calibration error table in Section 7.2 if you have an error during calibration.
• Refer to the coordinated motion error codes listed in Section 7.3 if you want to look up a specific
coordinated motion error code.

7.2 CALIBRATION ERRORS

Refer to Table 7.2 for information on errors that can be displayed on the teach pendant prompt line during
calibration. These messages do not appear on the alarm log.

Table 7.2 Calibration Messages

Prompt Line Message Description

Record must be shifted The RECORD function key was pressed before or without
pressing the SHIFT key.

Move to must be shifted A MOVE_TO function key operation was attempted before or
without pressing the SHIFT key.

Cannot move to uninitialized point A MOVE_TO function key operation was attempted on a point
that has not been not recorded.

Point Not Recorded This will happen only under the following circumstances:
• An internal memory allocation error has occurred.
• The system is out of memory.
• The CD (coordinated motion) system variables have
not been loaded.
All points have to be recorded for calibration An EXEC calibration operation was attempted before all positions
were recorded.

Pair calibrated. Please cold start. A successful calibration matrix was calculated. In order for it to
take effect, the system requires a COLD START.

Position data will be cleared! This is the message normally displayed when changing the value
of either the leader or follower in a CD_pair. Verify the change,
and the CD_XF transform will be uninitialized.

Exec must be shifted An EXEC calibration operation was attempted before or without
pressing the SHIFT key.

Recorded points are on one line Rotary axis calibration positions all lie on a single line. Re-record
all calibration positions using the correct method.

Improper axis direction On a multiple-axis positioner, one or more axes have been
labelled incorrectly. Verify that the desired frame has been
defined, and that all axes have been labelled correctly.

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B-82914EN/01 7.TROUBLESHOOTING

Prompt Line Message Description

Recorded points are too close This will be displayed in the following cases:
• For a rotary axis, two positions have been recorded at
the same location.
• Three positions have been recorded at the same
location.
• The follower has been moved, but the leader has not
been moved, for calibration positions.
• For a linear axis, the positions are in the same
location.
Improper points are recorded This will be displayed in the following cases:
• One position has been recorded using a different
UTOOL.
• Rotary non-orthogonal axes have been defined.
• Rotary non-parallel axes have been defined.
• For a linear or rotary axis, the move on the robot is
not along the axis of the positioner.
• For an integrated linear extended axis of a leader, the
move on the robot is not along the axis of the
positioner.

7.3 ERROR CODES

Refer to the main CD error code table in Table 7.3. These messages appear on the alarm log.

Table 7.3 Main CD Error Code

error code Cause Remedy

CD-009 More than one leader There is more than one leader in the Check motion statement. Perform
coordinated motion Coordinated Motion SETUP and then
perform a COLD START.

CD-016 INC motion is not supported INCREMENTAL motion is not Delete INC instruction.
supported with coordinated motion.

CD-018 No calibration for CD Calibration for coordinated motion is Execute calibration of coordinated
not done. motion in SETUP screen.

CD-019 Illegal follower setting" Number of follower is zero or two or Set number of follower correctly or set
greater on this motion. group mask correctly.

CD-020 Not reach relative speed Follower can not reach relative speed Teach follower and leader position
in program. again to reach relative speed.

CD-021 No kinematics in CD group Attempt to perform coordinated motion Initialize robot library correctly.
with non-kinematics robot.

CD-023 Illegal CD setting. Setting of coordinated motion is not Check setting of coordinated motion in
correct. SETUP screen and set correctly.

CD-029 Illegal to switch leader Cannot switch leader group while in Use same leader group number.
coordinated motion. Change leader only when preceeded
by a non-coordinated motion.

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B-82914EN/01 INDEX

INDEX
<A> <O>
Axis Arrangement, Direction, and Assignment................7 Offsets for Known Kinematics Types............................ 10
Axis Offset .......................................................................3 Overview....................................................................... 2,5
OVERVIEW ........................................ 1,5,11,13,35,44,52
<C>
CALIBRATION.............................................................13 <P>
CALIBRATION ERRORS ............................................52 PROGRAM HEADER INFORMATION ...................... 44
CIRCULAR MOTION PROGRAMMING....................49 PROGRAMMING ......................................................... 44
COORD COORDINATED MOTION OPTION ............45
COORD[ LDR ] COORDINATED MOTION OPTION45 <R>
Coordinated Frame...........................................................3 Relative motion and Simultaneous motion .................... 50
RESTRICTIONS AND GUIDELINES ......................... 11
<D> Rotary Axis...................................................................... 3
Dynamic UFrame ...........................................................32
<S>
<E> SAFETY ...........................................................................i
ERROR CODES ............................................................53 SELECTING CD_PAIRS .............................................. 11
SETTING UP COORDINATED PAIRS ....................... 11
<F> SETUP STEPS................................................................. 4
Follower Group ................................................................2 SPEED DEFINITION.................................................... 48
Follower UFRAME..........................................................3
Follower UTOOL.............................................................4 <T>
TERMINOLOGY ............................................................ 2
<I> TROUBLESHOOTING................................................. 52
INSTALLATION.............................................................5
INSTALLATION CONCEPTS........................................5 <U>
UNKNOWN POINT CALIBRATION FOR POSITIONERS
<J> ....................................................................................... 19
JOGGING ......................................................................35
JOGGING DESIGNATION...........................................35
JOGGING EXAMPLES.................................................39
JOGGING PROCEDURE ..............................................41

<K>
Kinematics Type ..............................................................6
KNOWN DIRECT CALIBRATION .............................18
KNOWN FOUR POINT CALIBRATION ....................13

<L>
Leader Frame (LDR) Jog Coordinate Mode...................38
LEADER FRAME SETUP ............................................29
Leader Group ...................................................................2
LEADER GROUP JOGGING (COORDINATED, FIXED
ORIENTATION COORDINATED)..............................36
Leader UFRAME .............................................................4
Leader UTOOL ................................................................4
Leader World Frame ........................................................4
Linear Axis.......................................................................2
LINEAR MOTION PROGRAMMING .........................48

<M>
Motion Group...................................................................2

i-1
 FANUC Robot series R-30iA/R-30iA Mate CONTROLLER
Coordinated Motion Function OPERATOR’S MANUAL (B-82914EN)

01 Mar., 2009

Edition Date Contents Edition Date Contents

 B-82914EN/01

* B - 8 2 9 1 4 E N / 0 1 *