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FANUC R-30iB Plus CONTROLLER, iRVision 2D Camera Application. OPERATOR'S MANUAL - page 6

Know-How

1. FRAME SETTING

1

17

17 While holding down the [SHIFT] key, press F5 [RECORD].

When all the touch-up points are taught, [Used] will be displayed. The user frame will be set.

18 Press the [PREV] key.

The User Frame list screen will appear.

19

19 Press F5 [SETIND] and enter a frame number.

The user frame that has been set will be set as the currently enabled user frame.

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Know-How

Four point method

Teach the following four points: the origin of the x−axis parallel to the frame, the point which specifies

the positive direction of the x−axis, a point on the x−y plane, and the origin of the frame. In the example

of the following figure, the user frame is set on the fixed calibration grid.

Z

Y

X

System origin

Example of setting a user frame on a fixed calibration grid

The following figure is a calibration grid. When perform the Grid Pattern Calibration for camera

calibration, it is necessary to set up a user frame such as shown in the following figure. Since it is

necessary to set a System origin on the center of a calibration grid, when the “Three point method” is used,

the distance from the System Origin to the X Direction Point or the Y Direction Point is near. By using

“Four point method”, the accuracy of user frame setting becomes better.

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1. FRAME SETTING

1

Y Direction

System Origin

Orient Origin

X Direction

Four point teaching method touch-up points for a calibration grid

1

On the teach pendant, after selecting the [MENU] key → [Setup], place the cursor over [Frame] and

press the [ENTER] key.

2

Press F3 [OTHER].

3

Place the cursor over [User] and press the [ENTER] key.

The list screen for user frames will appear.

4

5

4

Place the cursor over the line of the user frame number to set.

5

Press F2 [DETAIL].

The setup screen for the user frame for the selected frame number will appear

6

Press F2 [METHOD].

7

Place the cursor over [Four Point] and press the [ENTER] key.

A screen for user frame setting using the four point teaching method will appear.

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8

9

8

Enter a comment in the [Comment] field as required.

A comment to distinguish this frame from other user frames is recommended.

9

Place the cursor over [Orient Origin Point].

10

Jog the robot and touch up the X direction origin point with the pointer tool.

Orient Origin Point

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1. FRAME SETTING

1

12

11

11 While holding down the [SHIFT] key, press F5 [RECORD].

The current position data will be entered as the X-axis origin point.

For the taught [Orient Origin Point], [Used] will appear.

12 Place the cursor over [X Direction Point].

13 Jog the robot and touch up the X direction point of the frame with the pointer tool.

A line drawn between the orient origin point and the touched up X direction point will be the X-axis

of the frame.

Orient Origin Point

X Direction Point

X

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15

14

14 While holding down the [SHIFT] key, press F5 [RECORD].

The current position data will be entered as the X direction.

[USED] will be shown for the taught [X Direction Point].

15 Place the cursor over [Y Direction Point].

16 Jog the robot and touch up the Y direction point with the pointer tool.

Touching up the Y-axis direction will determine the X and Y plane of the frame.

Y Direction Point

Z

Y

X

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1. FRAME SETTING

1

18

17

17 While holding down the [SHIFT] key, press F5 [RECORD].

The current position data will be entered as the Y-axis direction.

[USED] will be shown for the taught [Y Direction Point].

18 Place the cursor over [ System Origin].

19 Jog the robot and touch up the orient origin point of the frame with the pointer tool.

System Origin

Z

Y

X

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20

20 While holding down the [SHIFT] key, press F5 [RECORD].

The current position data will be recorded as the orient origin of the frame.

When all the touch-up points are taught, [Used] will be displayed. The user frame will be set.

21 Press the [PREV] key.

The User Frame list screen will appear.

22 Press F5 [RECORD] and enter the frame number.

The user frame that has been set will be set as the currently enabled user frame.

1.1.2

Tool Frame Setting

This subsection is explained a tool frame setting on the calibration grid that the is mounted on the robot

end of arm tooling.

Fixed pointer

Z

Y

X

Calibration grid

Tool frame

Example of tool frame setting with a pointer tool

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Know-How

1. FRAME SETTING

After the pointer for touch-up is secured to a secured stand, select “Tool Frame Setup / Six Point(XY)” or

1

“Tool Frame Setup / Six Point(XZ)”, and teach the six points shown in the figure below by touch-up

operation. The position of fixed pointer is arbitrarily.

System Origin

X Direction

Approach point 1

Approach point 2

Approach point 3

Z

-

axis/Y

-

axis

Six point teaching method touch-up points for a calibration grid

The user tool set using the “Tool Frame Setup / Six Point(XZ)” method is rotated by 90 degrees about the

X-axis with respect to a desired coordinate system. Upon completion of setting the user tool frame by

touch-up operation, manually enter the value of W plus 90.

In the example of this subsection, “Tool Frame Setup / Six Point(XY)” is explained. Make sure that the

calibration grid is fixed securely to the robot end of arm tooling so that it remains in place while the robot

moves. Positioning pins or other appropriate means may be used so that the calibration grid can be

mounted at the same position for each measurement. Moreover, set the tool frame accurately on the

calibration grid. If the accuracy of this frame setting is low, the precision in handling of a workpiece by

the robot is also degraded.

1

On the teach pendant, after selecting the [MENU] key → [Setup], place the cursor over [Frame] and

press the [ENTER] key.

2

Press F3 [Frame].

3

Place the cursor over [Tool] and press the [ENTER] key.

The list screen for tool frames will appear.

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4

5

4

Place the cursor over the line of the tool frame number to set.

5

Press F2 [DETAILS].

The setup screen for the tool frame for the selected frame number will appear.

6

6

Press F2 [METHOD].

7

Place the cursor over [Six Point (XY)] and press the [ENTER] key.

A screen for tool frame setting using six points will appear.

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1. FRAME SETTING

1

8

9

8

Enter a comment in the [Comment] field as required.

A comment to distinguish this frame from other frames is recommended..

9

Place the cursor over [Approach point 1].

10

Jog the robot and touch up the reference point 1 with the pointer tool.

Approach point 1

Touch-up of approach point 1

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12

11

11 While holding down the [SHIFT] key, press F5 [RECORD].

The current value's data will be input as approach point 1.

For the taught [Approach point 1], [Used] will be displayed.

12 Place the cursor over [Approach point 2].

13 Jog the robot and touch up the reference point 2 with the pointer tool.

Touch up the same point as the reference point 1. However, change the robot attitude from that of

the reference point 1.

Approach point 2

Touch-up of approach point 2

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1. FRAME SETTING

1

15

14

14 Press and hold the [SHIFT] key and press F5 [RECORD] to record the data of current position as the

reference position. As for the [Approach point 2], [USED] is displayed.

15 Move the cursor to the [Approach point 2].

16 Jog the robot and touch up the [Approach point 2] with the fixed pointer. The position of

[Approach point 2] is same position as the approach point 1. However, the posture of approach

point 2 is different from the posture of approach point 1.

Approach point 3

Touch-up of approach point 3

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18

17

17 Press and hold the [SHIFT] key and press F5 [RECORD] to record the data of current position as the

reference position. As for the taught reference point, [USED]is displayed.

18 Move the cursor to the [Orient Origin Point].

19 Jog the robot and touch up the Orient Origin Point with the fixed pointer.

Orient Origin Point

Touch-up of the point for the Orient Origin Point

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1. FRAME SETTING

1

21

20

20 Press and hold the SHIFT key and press F5 RECORD to record the data of current position as the

reference position. As for the taught reference point, RECORED is displayed.

21 Move the cursor to the X Direction Point.

22 Jog the robot and touch up the X Direction Point with the fixed pointer.

X Direction Point

Touch-up of X direction point

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24

23

23 Press and hold the SHIFT key and press F5 RECORD to record the data of current position as the

reference position. As for the taught reference point, RECORED is displayed.

24 Move the cursor to the Y Direction Point.

25 Jog the robot and touch up the Y Direction Point with the fixed pointer.

Y Direction Point

Touch-up of Y direction point

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1. FRAME SETTING

1

26

26 Press and hold the SHIFT key and press F5 RECORD to record the data of current position as the

reference position. When all the reference points are taught, USED is displayed. The tool frame

has been set.

27 To display the tool frame list screen, press the PREV key.

28 Check the TCP is set accuracy. Press F5 [SETIND] and enter the frame number.

The tool frame that has been set will be set as the currently enabled tool frame.

29 Jog the robot to move the origin point of the calibration grid close to the tip of the fixed pointer tool.

Center of rotation

Check by moving the origin point of the calibration grid close to tip of fixed pointer tool

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30 Operate the robot by jog operation around the tool frame, and change the orientation of the

calibration grid (w, p, r). If the TCP is accurate, the tip of the pointer tool will always point toward

the origin point of the calibration grid.

1.2

FRAME SETTING WITH THE GRDI FRAME SSETTING

FUNCTION

Function overview

In the Grid Frame Setting Function, the robot holding the camera or the robot holding calibration grid

automatically moves to change relative position and orientation between the camera and the calibration

grid, and find the grid pattern repeatedly. Finally, the position of the calibration grid frame relative to

the robot base frame or the robot mechanical interface frame (the robot face place) is identified. When

the Grid Frame Setting Function is executed, a frame is set on the calibration grid, as shown in the

following figure.

Y

Origin

X

Example of frame using calibration grid

Compared with the manual touch-up setting method, the function offers a number of merits, including

accurate setting of the frame without requiring user skills, no need for touch-up pointers or to set the TCP

for touch-up setting, and semi-automatic easy-to-do operation.

CAUTION

The Grid Frame Setting Function is usable with 6-axis robots only. The function

cannot be used with 4-axis robots and 5-axis robots.

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1. FRAME SETTING

1.2.1

Setting procedure

1

Use the following setup procedure for the Grid Frame Setting Function:

1.

Mounting the calibration grid

2.

Camera data creation and teaching

3.

Setting the parameters

4.

Run Measurement

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1.2.1.1 Mounting the calibration grid

When the calibration grid is secured to a fixed surface

When the calibration grid is secured to fixed surface, a camera mounted on the robot end of arm tooling is

used to measure the position of the calibration grid frame. The Grid Frame Setting Function identifies

the position of the calibration grid frame relative to the robot base frame (world), and sets the results in a

user specified user frame. When use a robot-mounted camera, the Grid Frame Setting Function can be

performed with the camera currently used. When use a fixed camera, prepare another camera for the

Grid Frame Setting Function separately. Then, perform the Grid Frame Setting Function using the

camera attached to the arbitrary positions of the robot end of arm tooling.

Robot mounted-camera

User frame

Calibration grid

Example of a fixed calibration grid

When the calibration grid is mounted on the robot

When the calibration grid is mounted on the robot, a fixed camera is used to measure the position of the

calibration grid frame. The robot moves the calibration grid within the field of view of the fixed camera.

The Grid Frame Setting Function identifies the position of the calibration grid frame relative to the robot

mechanical interface frame (the robot face plate), and the results is written in a user defined user tool.

The Grid Frame Setting Function can be performed with the camera currently used. When there is not

sufficient space to perform Grid Frame Setting Function with the camera currently used, prepare another

fixed camera and Grid Frame Setting Function can be performed.

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1. FRAME SETTING

1

Camera

Calibration grid

Tool frame

Example of a calibration grid attached to the robot hand

Make sure that the calibration grid is fixed securely so that it does not move during measurement.

MEMO

To prevent unnecessary circles from being found, check that the calibration grid

is free of dirt and flaws. Spreading a plain sheet in the background is effective.

Also, make sure to cover the printed text on the calibration grid.

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1.2.1.2 Setting the parameters

Setup the parameters on [iRVision Utilities] screen of the teach pendant.

1

On the teach pendant, after selecting the [MENU] key → [iRVision], place the cursor over [Vision

Utilities] and press the [ENTER] key.

The iRVision Utilities screen will appear.

2

2

Place the cursor over [Automatic Grid Frame Set] and press the [ENTER] key.

The [Grid Frame Set] screen will appear.

CAUTION

The Grid Frame Set menu cannot be opened in more than one window at a time.

The following items will be displayed on the [Grid Frame Set] screen.

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Know-How

• Rotates ±45° around the camera's optical axis

• Slope (WP) rotates ±30° from the camera's optical axis at the robot's start position

• Slope (WP) rotates ±30° from the camera's optical axis when facing the calibration grid

If the motion range determined by the default setting cannot be secured, the motion range can be made

smaller by changing the value of each item. However, the accuracy of the frame that will be set will

depend on the motion amount at the time of measurement. If the workspace is made smaller, accuracy

of measurement may decrease, so it is recommended that you execute measurement with a workspace that

is as close to the initial setting as possible.

The following function keys will be displayed on the [Automatic Grid Frame Set] screen as common

functions.

F2 [DISP IMG]

The Automatic Grid Frame Set screen and Vision Runtime screen will be displayed as follows.

F3 [LIVE]

A live image for the selected camera will be displayed on the Vision Runtime screen. When a live

image is displayed, it changes to F3 [STOPLIVE] and if F3 [STOPLIVE] is pressed, live image display

will be stopped.

F4 [FIND]

Detect a grid pattern. The detection result will be displayed on the Vision Runtime screen.

F7 [RESET]

The set values will be changed to the initial values.

[Camera Name] and [Start Position] will be returned

to their initial values so that you can set them again.

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1. FRAME SETTING

1.2.1.3 Teaching start position

1

Teach the start position using the following procedure.

1

If Vision Runtime is not displayed, press F2 [DISP IMG].

2

Place the cursor over [Start Position].

3

Jog the robot so that the camera's optical axis is approximately perpendicular to the plate surface of

the calibration grid and that all of the four large black circles of the calibration grid are inside the

camera's field of view. The distance between the calibration grid and the camera should be

appropriate for the grid to come into focus, which is, under normal circumstances, roughly the same

as the distance at which camera calibration is performed.

MEMO

For Automatic Grid Frame Set, measurement is performed by panning and

rotating the camera attached to the robot's gripper or the calibration grid. It is

recommended that you set the field of view to something quite large in relation to

the calibration grid, so that the four large black dots will not be outside of the

field of view.

Camera field of view

Camera field of view

4

While holding down the [SHIFT] key, press F4 [RECORD].

The start position will be recorded, and [Start Position] changes to [Recorded].

5

To check the trained start position, press F3 POSITION. The value of each axis of the start

position is displayed, as shown below.

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To return to the previous menu, press PREV.

6

When moving the robot to the taught start position, press F5 [MOVE TO] while pressing the

[SHIFT] key.

1.2.1.4 Run measurement

Perform measurement as follows, using the taught start position as a reference.

1

If Vision Runtime is not displayed, press F2 [DISP IMG].

2

Check the parameter setup on the [Automatic Grid Frame Set] screen.

3

Check that the robot is at the start position.

4

While holding down the [SHIFT] key, press F5 [EXECUTE].

The robot will start the operation, and measurement will be executed. A message saying 'Now

executing' will appear during the operation.

CAUTION

1 The measurement will stop if you release the [SHIFT] key during measurement.

In such cases, redo the measurement. The measurement can be resumed

from where it was stopped.

2 The measurement will stop if you perform an operation that moves to another

screen during measurement, such as pressing the [SELECT] key on the teach

pendant. In such cases, open the [Automatic Grid Frame Set] screen and redo

the measurement. The measurement can be resumed from where it was

stopped.

3 Although the robot will perform the decided motion to some extent, depending on

the settings, it is possible that it will move with an unexpected motion range.

When executing measurement, check that the setup of parameters is correct,

and be careful to lower the override so that the robot will not interfere with

devices.

4 The robot may not be able to operate if other programs are in a paused state.

In such cases, press the [FCTN] key and end the programs.

When the measurement is successfully completed, a menu like the one shown below appears. The

robot stops after moving to a position where the camera directly faces the calibration grid and the

origin of the calibration grid comes to the center of the image.

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1. FRAME SETTING

1

5

If you press F4 [OK] is pressed, you will return to the Automatic Grid Frame Set screen.

Measurement check

The grid frame will be set depending on the measurement. The set frame can be checked using the

following procedure.

1

Set the manual feed frame as the frame for automatic grid frame set.

For a tool frame, press the [COORD] key and switch to [Tool].

For a user frame, press the [COORD] key to switch to [User], and specify the tool frame number that

was specified in [Camera User Tool] in [Tool] under the jog menu, using the number keys.

2

Press F3 [LIVE] to start the display of a live image, and move the robot by jog operation around the

WPR of the selected tool frame. There will be no problem unless the center position of the grid

pattern is significantly far from the center line of the image.

In the event of failure to measure

If measurement fails, the following message will appear.

If F4 [OK] is pressed, the screen will return to the original screen.

After changing the setup parameters, measurement can be redone by pressing F5 [EXECUTE] while

holding down the [SHIFT] key.

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2. CAMERA DATA SETTING

Know-How

2 CAMERA DATA SETTING

This chapter explains the settings for camera data.

Create camera data and perform camera setup and calibration. Camera calibration is the work of setting

where the camera is installed as seen from the robot. Complete calibration before teaching a vision

process. There are three methods to calibrate a camera. This chapter explains them using the

following structure.

• Know-how Edition Section 2.1, "GRID PATTERN CALIBRATION WITH A FIXED CAMERA".

• Know-how Edition Section 2.2, "GRID PATTERN CALIBRATION WITH A ROBOT-MOUNTED

CAMERA".

• Know-how Edition Section 2.3, "ROBOT-GENERATED GRID CALIBRATION".

2.1

GRID PATTERN CALIBRATION WITH A FIXED CAMERA

Grid pattern calibration is a general-purpose calibration method for cameras that uses a special jig called a

calibration grid. When using grid pattern calibration, prepare a calibration grid in advance. Usually,

prepare a calibration grid which is the bigger than a field of view. A standard calibration grid is

available from FANUC in several sizes. It is strongly recommended that you order a calibration grid as

well as a camera and lens.

It is not necessary to detect all the dots on the calibration grid. There are 11×11 dots in the standard

calibration grid of FANUC. If 7×7 dots are detected, the camera calibration is performed with sufficient

accuracy.

(The four big dots need to be detected.) In order to show all the dots in field of view, it is

not necessary to prepare a small calibration grid. In order to perform a calibration with accuracy

sufficient to the edge of the field of view, even if the number of detectable dots became fewer, prepare the

bigger calibration grid than a field of view.

Use the following setup procedure for 'GRID PATTERN CALIBRATION WITH A FIXED CAMERA':

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2. CAMERA DATA SETTING

1

Application Frame Setting

2

2

Camera Data Creation

3

Camera Setup

4

Calibration

5

Checking Calibration Point

6

Checking Calibration Result

For a robot system with multiple cameras, create camera data for each camera and perform calibration.

2.1.1

Application Frame Setting

Select a frame for the robot that will be the reference for calibration. Perform camera calibration using

the selected frame as the reference.

User frame [0: World frame] is selected as the default setting. In most cases, it does not need to be

changed. However, in the following cases, set up a user frame and perform calibration using that user

frame number as the application frame.

• In cases where the camera is attached to a robot other than the robot to be offset

• In cases where the calibration grid is attached to a robot other than the robot to be offset

• In cases where multiple robots are to be compensated using the same offset

Also, in cases like the above, it is necessary to carry out communication between robot controllers.

iRVision performs this communication when it is necessary, and for this, an interface function called

'ROS Interface Packet over Ethernet (RIPE)' is used internally. For robot systems to which the above

cases apply, refer to "12 ROS Interface Packet over Ethernet

(RIPE)" in "R-30iA/R-30iA

Mate/R-30iB/R-30iB Mate CONTROLLER Ethernet Function B-82974EN OPERATOR’S MANUAL"

when setting up the RIPE functions.

The figure below is an example of a situation in which the calibration grid is attached to a robot other

than the robot to be offset. When a camera is installed on the Robot 1 and a calibration grid is installed

on the Robot 2, set a common user frame for both robots, and use the frame as the application frame.

Also make the user frame number common.

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Know-How

Camera

Robot with a calibration grid

(Robot 2)

Z

Y

X

Common user frame= Application frame

Robot with a camera

(Set the same application frame number for each robot)

(Robot 1)

Example of a situation in which the calibration grid is attached to a robot other than the robot to be offset

For information on user frame settings, refer to Know-how Edition Section 1, "FRAME SETTING".

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