Fanuc Touch Sensing

B-82594EN-3/03 13.
ARC TOOL UTILITY
13.10 TOUCH SENSING
13.10.1 Overview
Touch sensing (optional feature) allows the robot to change a path
automatically to compensate for object displacement.
Touch sensing consists of:

- Moving the robot tool center point (TCP) toward the object using
pre-defined robot motion, speed, and direction.
- Using an input signal to indicate that the robot has come into
contact with the object.
- Storing the found location of the object, or position offset
information, in position registers.
- Using the stored position to move the robot to the stored position,
or using the stored position offset information to shift one or
more positions in your welding program.
To use touch sensing you must:

- Set up the robot Tool Center Point (TCP) properly.
- Set up touch sensing hardware. The hardware monitors an
input signal to determine when the robot comes into contact with
the object.
- Assign I/O to enable and use the electrical interface circuit.
- Set up how the robot moves to the object and the type of position
offset information that is stored.
- Set up a coordinated motion pair for coordinated motion touch
sensing
- Create a touch sensing program.
See Fig.13.10.1 for an example of a program that includes touch

sensing.
This function is an option. (A05B-××××-J536)
Fig. 13.10.1 Example program including touch sensing routine
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13.ARC TOOL UTILITY B-82594EN-3/03
13.10.2 Assigning Touch Sensing I/O

To use touch sensing you must assign the
- Input signal that the touch sensing circuit monitors to indicate
when the robot has reached the object.
- Output signal that enables and disables the touch sensing circuit.
NOTE
You must wire the necessary connections for the
input and output signals to be used for touch
sensing. The wire stick detection circuit on the
process I/O board also can be used for touch
sensing.
The controller supports numerous I/O options. If you decide to use

an I/O point other than the standard, (such as a modular I/O), then the
controller must be wired and configured correctly.
NOTE
Some welding power supplies, such as the Lincoln
Electric PowerWave 450 provide internal touch
sensing circuitry. These power supplies can be
automatically set up for the appropriate inputs and
outputs when software configuration is performed.
Touch Sensing Input Signal

The touch sensing input signal indicating contact with a part is
monitored by the touch sensing circuit. When the input is received,
the current robot position is stored in a position register.
Any of the following can be used as the touch sensing input signal:
- Welding Digital Inputs (WI) 1-8, found on the CRW1 Connector

of the process I/O board.
- Digital Inputs (DI) 1-22, found on the CRM2A and CRM2B
connectors of the process I/O board.
- Wire stick detection circuit input WSI (WI+, WI-), found on the
CRWI connector of the process I/O board.
- Robot Digital Inputs (RI) 1-16, found on the Axis Control PCB.
CAUTION
If a WI is assigned as the touch sensing input signal,
the dedicated function it performs must be disabled.
Refer to Section 12.2 Welding Input/Output Signals.
You can also set up touch sensing to monitor the condition of any RO
or DO signal as an input signal. When the selected output turns on
during a touch sensing routine, the controller reads this as a received
input signal.
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B-82594EN-3/03 13.ARC TOOL UTILITY
Touch Sensing Enable/Disable Output Signal

Any of the following can be used to enable the touch sensing circuit:
- Robot Digital Outputs (RO) 1-20 found on the digital output
(DO) 1-16, found on the Axis Control PCB.
- Digital Outputs (DO) 1-20 as an option for additional digital
outputs.
- Welding Digital Outputs (WO) 1-8 found on the CRW1
Connector of the Process I/O Board.
- Wire stick detection circuit enable WSE is an internal output on
the process I/O board that enables the detection circuit and
allows it to be used for touch sensing.
CAUTION
If a WO is assigned as the touch sensing input
signal, the dedicated function it performs must be
disabled. Refer to Section 2 Welding Input/Output
Signals.
NOTE
To use touch sensing, the weld interface cable must
be installed. If you are using the Lincoln
PowerWave 450 weld power supply, the power
source must be turned on for touch sensing to work.
Assigning the Touch Sensing Inputs and Outputs

You must assign touch sensing inputs and outputs to match the
hardware interface at your site. This involves assigning both input
and output type and port number.
Touch sensing inputs are shown as sensor ports in the ArcTool

software. Touch sensing outputs are shown as circuit ports in the
ArcTool software.
NOTE
After you have decided what I/O to use for touch
sensing, you should add a comment to the selected
I/O indicating that the I/O has been assigned to
touch sensing. This is done using the SETUP menu.
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Procedure 13-16 Assigning touch-sensing inputs and outputs

Step
1 Press MENUS.
2 Select SETUP.
3 Press F1, [TYPE]
4 Select Touch I/O. You will see a screen similar to the
followings.
Touch I/O Setup JOINT 10 %
1/4
NAME VALUE
1 Sensor port type: RI

2 Sensor port number: 1
3 Circuit port type: RO
4 Circuit port number: 1
[ TYPE ] [CHOICE] HELP
NOTE
This screen shows the settings of the currently
selected motion group. To view the settings of
another motion group, change the motion group
by selecting an auxiliary menu item CHANGE
GROUP.
5 Assign Sensor (input) and Circuit (output) types as follows:

a Move the cursor to the line you want to assign.
b Press CHOICE, [F4].
c Move the cursor to the desired input/output type.
d Press ENTER.
NOTE
The allowable input range for the sensor and
circuit ports is from 1 to 256. The ArcTool
software checks the validity of the port type and
port number when running your program that
includes touch sensing. If the port type or
number is invalid, the system displays an I/O
invalid error message.
6 Assign Sensor and Circuit number:

a Move the cursor to the line you want to assign.
b Type the value and press ENTER.
NOTE
After the input signal has been wired and
assigned, perform a test to verify that it is
connected properly. The input signal condition
can be monitored from the I/O Menu.
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13.10.3 Setting Up Touch Sensing

Search motions locate an object and store the found location, or
position offset information, of the object in a position register.
Search motions use
- Touch frames
- Touch patterns
- Touch schedules
A touch frame determines the direction of the search motion. The

search motion is actually a programmed move along the x, y or z axis
of a selected touch frame.
For touch sensing with coordinated motion, you can select the touch
frame relative to the UFRAME of the robot (follower) or the
coordinated frame of the reference group (leader). If the reference
group is set for the leader group, the search direction will be relative
to that group.
Typically, only one search motion is used for each search direction.
Some search patterns require two search motions in each of two search
directions for the ArcTool software to calculate an angular offset.
Search patterns determine the type of information stored in the
position register. The stored information is either the found position
or position offset information depending on the search pattern used.
Touch schedules allow you to set up the conditions that define the
search motions. These conditions include the position register, touch
frame and search pattern to use; the robot speed and motion type; and
other conditions.
Fig. 13.10.3(a), Fig. 13.10.3(b), and Fig. 13.10.3 (c) represent how
search motions are used in a program.
Touch Sense installation is a "semi-automatic" function. Touch

Sense defaults to using the position register 32. Typically, systems
have only 10 position registers available.
A Second Controlled Start is required after you install Touch Sense

before the system will "automatically" increase the number of position
registers to 32.
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Fig. 13.10.3 (a) Search using searches in one direction
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Fig.13.10.3(b) Search using offsets in two dimensions
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Fig. 13.10.3 (c) Search using 2 search motions in 2 different directions to

obtain X and Y offset and rotation about Z
The characteristics of a search motion are controlled by variables set

in touch schedules. The x, y, or z movements in a search motion are
aligned with an object by using one of the touch frames.
Touch Frames
A touch frame determines the motion direction of the robot TCP. A
touch frame is defined by three points. The first point defines the
origin, or starting point. The second point defines the positive x
direction of the touch frame. The third point defines the positive x-y
plane.
Fig. 13.10.3 (d) shows a touch frame and how it is used in a touch
sensing program. The orientation of the touch frame to the object is
arbitrary in Fig. 13.10.3(d).
The positive x axis could be aligned with the current z direction.
This would re-define positive z to be in the opposite direction of the
current positive x direction.
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Fig. 13.10.3 (d)Touch frame used in a program
NOTE
You can set up a maximum of 32 touch frames.
Touch frames are set up using the touch frame
screen in the Setup menu.
NOTE
You must define a touch frame before you perform a
search motion in a program.
There are two ways to define touch frames: The teaching method
and the direct entry method. The teaching method defines the touch
frame by recording three points. The direct entry method defines the
touch frame by the rotation angle value you enter in the touch sense
setup screen.
Table13.10.3(a) lists and describes the items you must set to define the
touch frame.
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Table 13.10.3 (a) Touch frame setup items

ITEM DESCRIPTION
Frame Number This item specifies the number of the touch frame you want to define.
Reference Group This item specifies the reference group to which the touch frame is relative:
-1: Touch frame is relative to the UFRAME of the robot (follower)
-2: Touch frame is relative to the coordinated frame of robot group 2 (leader)
Robot Group This item specifies a motion group for which the touch frame is set.
Direct Entry (Procedure 13-18)
Rotate about X This item specifies the rotation about X for the touch frame.
Rotate about Y This item specifies the rotation about Y for touch frame.
Rotate about Z This item specifies the rotation about Z for touch frame.
Teach Method (Procedure 13-17)
Origin This item allows you to record the origin of the touch frame.
+X direction This item allows you to define the +X direction of the touch frame.
+Y direction This item allows you to define the +Y direction of the touch frame.
NOTE
When Reference Group is not equal to 1, the touch
frame changes with the coordinate frame, but the
display of the Rotate about X, Y, and Z items
remains unchanged.
Use Procedure 13-17 to define your touch frame by using the teaching
method. Use Procedure 13-18 to define your touch frame by using the
direct entry method
Procedure 13-17 Setting up a touch frame using the teaching method

Step
1 Press MENUS.
2 Select Setup.
3 Press F1, [TYPE].
4 Select Touch Frame. You will see a screen similar to the
following.
Touch Frame Setup JOINT 10 %
5/7
Frame #: 1 Ref Grp: 1 Robot Grp: 1
Direct Entry:
Rotate about X : 0.000
Rotate about Y : 0.000
Rotate about Z : 0.000
Teach Method:
Origin : UNINIT
+X direction : UNINIT
+Y direction : UNINIT
[ TYPE ] RECORD DONE
5 Move the cursor to Frame Number. Type the number of the

frame to define and press ENTER.
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6 Move the cursor to Reference Grp. Type the number of the

reference group and press ENTER. Move the cursor to Robot
Grp. Type the robot group number and press ENTER.
7 Define the origin point of the Touch Frame
a Move the cursor to Origin.
b Jog the Robot TCP to the desired starting point (origin).
c Press F2, RECORD.
8 Define the +X direction
a Move the cursor to X.
b Jog the robot TCP to a point along the +X axis of the touch
frame.
c Press F2, Record.
9 Define the +Y direction
a Move the cursor to Y.
b Jog the robot in the +Y direction of the touch frame, to a
point on the X-Y plane.
c Press F2, RECORD.
10 Press F5, DONE to complete the definition of the frame.
NOTE
Do not forget this operation. If you forget this
operation, touch frame can not be defined.
Procedure 13-18 Setting up a touch frame using the direct entry method
Step
1 Press MENUS.
2 Select SETUP.
3 Press F1, [TYPE].
4 Select Touch Frame. You will see a screen similar to the
following.
Touch Frame Setup JOINT 10 %
1/7
Frame #: 1 Ref Grp: 1 Robot Grp: 1
Direct Entry:
Rotate about X : 0.000
Rotate about Y : 0.000
Rotate about Z : 0.000
Teach Method:
Origin : UNINIT
+X direction : UNINIT
+Y direction : UNINIT
[ TYPE ] RECORD DONE
5 Move the cursor to Frame Number. Type the number of the

frame to define and press ENTER.
6 Move the cursor to Reference Grp. Type the number of the
reference group and press ENTER.
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NOTE
If you change the value of Reference Grp for an
initialized frame, the following warning message will
be displayed:
If you press F3, Yes, the frame data will be

reinitialized.
If you set Reference Grp > 1, but no leader group
matches the selected reference group, or it has not
been calibrated for coordinated motion, the value of
Reference Grp will not change and the following
warning message will be displayed:
7 Move the cursor to Robot Grp. Type the robot group

number and press ENTER.
8 Define the rotation angle about X.
a Move the cursor to Rotate about X.
b Enter the value (in degrees).
9 Define the rotation angle about Y.
a Move the cursor to Rotate about Y.
10 Define the rotation angle about Z.
a Move the cursor to Rotate about Z.
11 Press F5, DONE to complete the definition of the frame.
Search Pattern
Search patterns determine the kind of information stored in the
position register. The stored information is either the found position,
or the position offset information depending on the search pattern used
and the reference group specified in the touch schedule. Four types
of search patterns are available:
- Simple search
- Fillet/lap search
- V-Groove search
- Outside/inside diameter search
Simple Search
For a simple search, a two-dimensional search is executed to find the
actual location of one position on an object. A simple search stores
the found position (x, y, z, w, p, r) into a position register PR[ ].
Once completed, the robot is programmed to move to the position
stored in that position register.
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CAUTION
Do not use simple search when you use the
multipass option with touch sensing because both
simple search and multipass use position registers.
Simple search stores the computed position in a
position register. Multipass cannot use position
registers to plan paths. Use the 2D fillet search
pattern when using multipass with touch sensing.
Simple search requires:

- That the surfaces being searched are perpendicular to each other.
- Searches to be done in two different directions.
- The second search motion to be performed with the desired torch
angle.
The first search defines the positional information for that search
direction only (x, for example). The second search defines the other
direction positional information (z, for example). The starting
position of the second search defines the remaining positional
information, (y, w, p, r, for example) that determines the torch angle
for welding and, in this case, the y value.
Simple search is typically used to find the starting point of a weld path
that uses the Thru-Arc Seam Tracking(TAST) option or Automatic
Voltage Control (AVC) Tracking option.
A two-dimensional search is programmed in the software as the only

valid search pattern type when a simple search is used. Changing the
search pattern type has no effect.
The two-dimensional search that Simple Search does is called a

pattern type. The two-dimensional search is the only valid pattern type
for a simple search.
Refer to Table 13.10.3(b) for information on search patterns and valid

pattern types for each search pattern.
Refer to Section 13.10.4 for example programs using simple search.

See Fig. 13.10.3 (e) for an illustration of a simple search routine.
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Fig. 13.10.3 (e) Simple search routine using searches in two directions
Fillet/Lap Search
For a Fillet/Lap Search a one, two, or three dimensional search is
executed to obtain positional offset information. A Fillet/Lap Search
stores positional offset information in a positional register PR[ ].
This offset can be applied to one or more positions in a programmed
path.
The offset can be in one, two or three directions. The offset can also
be in two directions plus rotation about the axis of which no searching
is performed. For example, if the object is being searched for offset in
both x and y directions, a fillet search can offset for a rotation about
the z axis.
Another type of offset can be in one direction plus rotation about an

axis of which no searching is performed. For example, if the object
is being searched for offset in x, a fillet search can offset for a rotation
about z. Note that is this type of search, the first touch point is used
as the arc start point. See Fig. 13.10.3 (f).
Fig. 13.10.3(f) Fillet search in one direction (x) with rotation about z
Another type of offset can be in three directions plus rotation about

the axis of which no searching is performed. For example, if the
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object is being searched for offset in x, y, and z directions, a fillet

search can offset for a rotation about the z axis.
A fillet search stores an offset into a position register [PR]. The
robot program then uses the touch offset commands to begin and end
the offset.
The type of searches that a Fillet/Lap Search does is called a pattern
type. See Fig. 13.10.3 (g) for information on search patterns and valid
pattern types for each search pattern.
Refer to Section 13.10.4 for example programs using Fillet/Lap

Search. See Fig. 13.10.3 (g) and Fig. 13.10.3 (h) for illustrations of
Fillet/Lap Searches.
Fig. 13.10.3 (g) Fillet search in two directions (x and y) with rotation about z
Fig. 13.10.3 (h) Fillet search in three directions (x, y, z) with rotation about z
V-Groove Search
For V-Groove Search a one-dimensional search is executed to obtain
positional offset information. A V-Groove Search stores positional
offset information in a positional register [PR]. This offset can be
applied to one or more positions in a programmed path.
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The types of searches that a V-Groove Search does is called a pattern

type. Refer to Fig. 13.10.3 (i) for information on search patterns and
valid pattern types for each search pattern.
Refer to Section 13.10.4 for example programs using V-Groove

Search. See Fig. 13.10.3 (i) for an illustration of a V-Groove Search.
Fig. 13.10.3 (i) V-groove search
Outside/Inside Diameter Search (OD/ID)

For Outside/Inside Diameter Search (OD/ID Search) a two
dimensional search is executed to obtain the positional offset
information of the center point of a circular path relative to the
original (master) location. An Outside/Inside Diameter Search stores
positional offset information in a positional register [PR]. This offset
can be applied to one or more positions in a programmed path.
The types of searches that an Outside/Inside Search does is called a

pattern type. Refer to Fig. 13.10.3 (j) for information on search
patterns and valid pattern types for each search pattern.
Refer to Section 13.10.4 for example programs using OD/ID Search.

See Fig. 13.10.3 (j) for an illustration of a OD/ID Search.
Fig. 13.10.3 (j) OD/ID search in two directions (x and y)
Table 13.10.3 (b) shows a matrix of possible search pattern and valid
pattern types. Select a combination that you would like to use on your
application and verify that it will provide the proper results.
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Table 13.10.3 (b) Search pattern and valid search type

Search Search Type Search Type Search Type Search Type Search Type Search Type
Patterns 1_D 2_D 3_D 1_D and 2_D and 3_D and
Rotation Rotation Rotation
Simple Search Not Valid Requires 2 Not Valid Not Valid Not Valid Not Valid
different
search
directions.
1 search per
direction.
Fillet/Lap Requires 1 Requires 2 Requires 3 Requires 1 Requires 2 Requires 3
search different different search different different
direction. search search direction. search search
1 search. directions, x directions, x,y, 2 searches per directions. directions. 3
and y, x and z, and z. direction. 2 searches per searches in
y and z. 1 search per direction. one direction
1 search per direction. (usually -z) 2
direction. searches in
each of the
remaining
directions.
V-Groove Requires 1 Not Valid Not Valid Not Valid Not Valid Not Valid
search
direction.
1 search
OD/ID Not Valid Requires 3 Not Valid Not Valid Not Valid Not Valid
different
searches in 2
different
directions.
For example,
+x,-x,+y, NOT
x,y,z.
1 search per
direction.
Touch Schedule
A touch schedule is a series of conditions that control how the search
motion is completed. Thirty-two touch schedules are available.
You access touch schedules from the DATA menu. There are two
screens associated with touch schedules: the SCHEDULE screen and
the DETAIL screen.
The SCHEDULE screen allows you to view and set limited

information for all schedules at once. DETAIL allows you to view
and set the complete information for a single schedule. You display
the schedule screen by pressing the PREV
MENU key. You display the detail screen by pressing the function
key F2, DETAIL.
Table 13.10.3 (c) lists and describes each DETAIL screen condition.
The items of SCHEDULE screen are also included in touch sensing
DETAIL screen.
Use Procedure 13-19 to define touch schedules.
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Table 13.10.3 (c) Touch sensing SCHEDULE screen conditions

ITEM DESCRIPTION
Touch Schedule This item indicates the number of the displayed schedule. A comment can be
entered.
Master Flag This item enables the search routine to be used as a mastering routine for those
Default=OFF touch sensing programs that generate position offset information. If set to ON, when
the search routine is executed, the touched positions are recorded as the reference
positions to be used by future searches. This flag must be set to OFF after the
master search is completed in order to generate position offset informatin on the
objects to be searched.
Also , when the search is performed, the position offset information in the position
register is set to all zero values. This means the when touch sensing finds the
object in its master position, no offset is to be applied to the weld path.
NOTE The Master Flag condition has no effect on simple searches.
Search Speed This item specifies how fast the robot will move when performing a Search Motion.
Default = 50.0 mm/sec
CAUTION
A search motion is programmed as a motion option at the end of a
position instruction. The speed at which the robot will move is
determined by the search speed, not by what is indicated in the
position instruction. During testing, when dry run is in effect, this
search speed is also used. The dry run speed has no effect.
Search Distance This item defines how far the robot can move when it is performing a search. Error
Default = 100 mm code THSR-017 Pause No contact with part. is displayed when this distance is
reached without making contact with the object.
Touch Frame This item defines the touch frame to be used in the touch schedule. This
Default = 1 determines the x, y, and z directions for the search motion. The same touch frame
can be used in more than one touch schedule.
Search Patterns This item defines the type of object to be searched and causes the Arctool software
Default = SIMPLE to compute the found position or positional offset information dependent on the
search pattern selected. The computed data is stored in a position register.
There are four available search patterns:
-Simple Search
-Fillet Search
-V-Groove Search
-OD/I D Search
Refer to the description of search patterns.
Pattern Type This item selects the type of offset to be stored in the position register.
Default = 1_D Shift Six pattern types are available:
1_D Shift Stores a one dimensional offset. Offsets can be in the x, y, or z direction.
2_D Shift Stores a two dimensional offset. Offsets can be in two of the x, y, or z direction.
3_D Shift Stores a three dimensional offset to a program. Offsets are in the x, y, or z
1_D Offset direction. Stores a one dimensional offset with rotation about the axis of which the
2_D Offset search is not performed.
3_D Offset Stores a two dimensional offset with rotation about the axis of which no searches are
performed. For example, if the object is being searched for an offset in both the x
and y directions, a 2_D Shift & Rotate search can offset for a rotation about the z
axis. Stores a three dimensional offset with rotation about the axis of which no
searches are performed. For example, if the object is being searched for an offset
in both the x and y directions, a 3_D Shift & Rotate search can offset for a rotation
about the z axis. NOTE Simple, OD/ID, and V-Groove search patterns are
pre-defined. Changing the pattern type for these searches has no effect. See
13.10.3 for valid pattern types for selected search patterns.
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ITEM DESCRIPTION
Incremental Search Offsets the starting position of the second etc. search in a search routine by the
Default = ON amount of offset found by the first search motion. If set to OFF, the robot returns to
the original starting position. The following illustration shows how the incremental
search affects the search routine. Incremental search requires a separate
SEARCH START point for each search.
Without incremental search, the robot found the x-offset but cannot find the z-offset.
NOTE: Simple search does not support incremental search
Auto Return This item moves the robot back to the search start position when contact is made
Default = ON with the object. If set to OFF, the robot stops at the contact point and moves
straight to the next position.
Return Speed This item specifies the speed at which the robot will return to the search start
Default = 100 mm/sec position upon making contact with the part.
Return Term Type This item specifies the termination type the robot will use to return to the search start
Default = Fine position. Five Return Term Types are available:
-FINE
-CNT20
-CNT40
-CNT100
Return Distance When Auto Return is set to ON, Return Distance specifies the distance the robot will
Default = 2000 mm return automatically. If the return distance passes the initial search start position,
Minimum = 0 mm the robot will return to the initial start position.
Maximum = 2000 mm
Reference Group This item specifies how the offset is recorded:
If the specified number is the same as the number specified in the robot group item,
which will be described later, OFFSET is recorded with respect to the user
coordinate system of the robot group of the number. (no coordination) If the
specified number is different from the number specified in the robot group item,
OFFSET is recorded with respect to the coordinated frame of the robot group
specified in the robot group item and the robot group (leader) specified in this item.
NOTE For searches other than simple search, Reference Group must equal the
frame Reference Group. Otherwise, an error message, "Reference grp
mismatch," will be displayed. For simple search, Reference Group must
be same as the specified number of Robot Grp. Otherwise an error
message, "Illegal motion ref. grp," will be displayed.
Contact Record PR The search output position register is used as a temporary buffer to hold the last
Default = 32 search contact position. The purpose for this temporary position register buffer is to
provide the ability to look at the positional data of an individual search, or to extract
data from the buffer in a program. By default, this register is position register 32.
Search output position register should be assigned to the last position register
number in your system.
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ITEM DESCRIPTION
CAUTION
The data in the position register is overwritten at each search motion
so the same position register should not be used to store the final
positional data from the search motion. Also, the contents of this
temporary buffer is a real position, not an offset. Do not program
motion instructions to use this position register data as an offset.
Error on Failure This item posts error code THSR - 017( PAUSE) No contact with part, if the search
Default = ON move exceeds the distance set in Search Distance. When OFF, the program
execution continues with the next instruction if the Search Distance is exceeded;
Programming Hint: If this is set to OFF, the next instruction in the program looks at
the contents of the Error Register and branch accordingly.
Error Register Number When Error On Failure is set to OFF, this register is set to 1 when the search
Default = 32 distance is exceeded. A successful search sets this register to 0.
Robot Group This item specifies the robot group which uses the touch sensing schedule.
Default = [1,∗,∗,∗,∗,∗,∗, ∗]
Procedure 13-19 Defining touch schedules

Step
1 Press DATA.
2 Press F1, [TYPE].
3 Select Touch Sched. You will see a screen similar to the
following.
DATA Touch Sched JOINT 10 %
1/32
(mm/sec) (mm) FRAME MASTER GMASK
1 50.0 100.0 1 OFF 1
2 50.0 100.0 1 OFF 1
3 50.0 100.0 1 OFF 1
4 50.0 100.0 1 OFF 1
5 50.0 100.0 1 OFF 1
6 50.0 100.0 1 OFF 1
7 50.0 100.0 1 OFF 1
8 50.0 100.0 1 OFF 1
9 50.0 100.0 1 OFF 1
[ TYPE ] DETAIL HELP >
[ TYPE ] COPY CLEAR >
4 To copy schedule information from one schedule to another:

a Press NEXT, >.
b Move the cursor to the schedule you want to copy.
c Press F2, COPY.
d Enter the schedule number to which you want to copy the
data.
Enter schedule number to copy to:
e Press ENTER. The data will be copied, but the comment
will not be copied.
5 To clear the information you have entered for a schedule:
Clear this schedule? [NO]
YES NO
a Move the cursor to the schedule.
b Press NEXT, >.
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c Press F2, CLEAR. The data will be cleared, but the

comment will remain.
6 Move the cursor to the desired schedule number.
7 To display more information about the schedule, press F2,
DETAIL. See the following screen for an example.
DATA Touch Sched JOINT 10 %
1/17
1 Touch Schedule:1 [ Touch Schdule 1]
2 Master flag: OFF

3 Search speed 50.0 mm/sec
4 Search distance: 100.0 mm
5 Touch frame: 1
6 Search pattern: Simple
7 Pattern type: 1_D Shift
8 Incremental search: ON
9 Auto return: ON
10 Return speed: 100.0 mm/sec
11 Return distance: 2000.0 mm
12 Reference Group: 1
13 Return term type: Fine
14 Contact record PR: 32
15 Error on failure: ON
16 Error register num: 32
17 Robot Group Mask: [1,*,*,*,*,*,*,*]
[ TYPE ]SCHEDULE HELP >
8 Set each schedule item as desired.

9 To add a comment:
a Move the cursor to the to the comment line and press
ENTER.
b Select a method of naming the comment.
c Press the appropriate function keys to add the comment.
d When you are finished, press ENTER.
10 To select [Search pattern], [Pattern type], [Return Term Type]:
a Move the cursor to each item and press F4, SELECT.
b Select the item and press ENTER.
13.10.4 Touch Sensing Programming

A touch sensing routine consists of search instructions to locate an
object, and offset instructions to displace programmed positions.
NOTE
Any changes to the tool frame affects the touch start
position.
CAUTION
Recorded positions and position registers are
affected by UFRAME, and UFRAME has an affect
during playback. If you change UFRAME, any
recorded positions and position registers will also
change.
- 1031 -
Touch Sensing Instructions

Touch sensing instructions are used to implement touch sensing
programming. Four touch sensing instructions are provided:
- Search Start [ ] PR [ ]
- Search End
- Touch Offset PR[ ]
- Touch Offset End
- Search [ ]
Touch Sensing Motion Option
There is one Touch Sensing motion option: Search [ ]..The Search
[ ] motion option directs the motion of the robot (in a positive or
negative x,y or z direction) to search for the object. The x, y and z
vectors are defined by the touch frame assigned in the touch schedule.
When contact is made
Search [ ] Motion Option

J P[1] 50% Fine Search [ ]
with the object, the robot's current TCP position is stored and robot
motion is stopped.
The Search [ ] motion option is entered at the end of a motion

instruction.
NOTE
Search and Search Start must use FINE termination
type.
The recorded position that has the search motion option is not
executed, so motion to the search start position must be recorded in a
separate motion instruction. See Fig.13.10.4(a).
Fig.13.10.4(a) Touch sensing motion option example
Use Procedure 13-20 to enter the Search[ ] instruction.
Procedure 13-20 Entering a search [ ] instruction into a program

Step
1 Jog the robot to the search start position and record the position.
2 Record another position at the same location. This second
motion instruction will be controlled by the touch sensing
software during the search.
- 1032 -
3 Move the cursor to the end of the motion instruction line of the
selected position.
4 Press F4, [CHOICE] to view the motion option choices.
5 Select 8, Next Page
6 Select Search and press ENTER.
7 Select the direction of the search to be performed and press
ENTER.
Motion Instructions Used with Touch Sensing

Touch sensing routines, using a simple search, apply the positional
data by using a motion instruction. A simple search stores an actual
position in the specified position register.
After a "simple" search routine, the touch sense software will calculate
a real position (x,y,z,w,p,r) and put the data in the position register
defined by the SEARCH START[1] PR[x] instruction. Since this is
a real position, the robot will be commanded to move to the position
in the position register instead of to a recorded position.
Example: J PR [4] 100% FINE ARC START [1]
J PR[4] 100% FINE ARC START[1] shows where position register

4 is the position register specified in the simple search routine.
Executing a Touch Sensing Program

When executing a touch sensing program, all testing and cautions
must be followed. Refer to Chapter 6. EXECUTING A PROGRAM
for more information about testing programs and running production.
For Fillet/Lap, V-Groove, OD/ID search pattern programs you must

establish master positions for all search motion by:
1 Setting the master flag in the touch schedule that is specified in
the SEARCH START command used to ON.
2 Running the program to establish master positions for all search
motions.
3 Setting the master flag in the touch schedule that is specified in
the SEARCH START command to OFF.
Touch Sensing Robot Position Touchup

You can use the function key F5, TOUCHUP when editing your
program to modify the recorded robot position. When you use the
TOUCHUP function with touch sensing, the new position information
is added to the offset information to determine the weld path. Use
Procedure 13-21 to touchup robot positions in a touch sensing
program.
Fig. 13.10.4(b) shows an example of points that require touching up.
- 1033 -
Fig. 13.10.4 (b) Points that require touching up
13-24
In order to correctly touch up Touch Offset positions, follow

Procedure 13-21 .
Procedure 13-21 Touching up robot positions in a touch sensing program

Step
1 Execute the program so that the search data is complete and the
position register contains the offset information.
2 Execute the line of your program that contains the Touch Offset
instruction.
CAUTION
Do not execute a Touch Offset End instruction and
then use backward execution to move to the
program line that contains the robot position you
want to touchup. Otherwise, the offset data will be
incorrect.
3 Single step to a line in the program that contains the first robot
position that you want to touchup.
4 Jog the robot to the new position, press and hold in the SHIFT
key and press F5, TOUCHUP.
5 Touch up all necessary robot positions between the Touch Offset
Start and Offset End positions.
Programming Examples
Example programs contained in this section include:
- Simple search – Fig. 13.10.4 (c)
- One-dimensional search (Fillet/Lap, V-Groove)– Fig. 13.10.4 (d)
- Two-dimensional with rotation – Fig. 13.10.4 (e)
- Two-dimensional with coordinated motion – Fig. 13.10.4 (f), Fig.
13.10.4 (g), and Fig. 13.10.4 (h)
- Simple search with coordinated motion – Fig. 13.10.4 (i)
- 1034 -
CAUTION
Do not use a continuous term type (CNT) for motion
that is right before a Search. Instead, use the FINE
term type. See line 3 in the Simple Search
Example Program. If you use continuous, the
search cannot compute a valid offset.
Fig. 13.10.4 (c) Simple search example program
CAUTION
Simple search is different from all other searches in
three aspects: First, the master flag in the
schedule is always set to off. Second, the position
register contains an absolute position instead of an
offset. Third, TOUCH OFFSET instruction is not
used.
Fig. 13.10.4 (d) One-dimensional search ex. prog. (Fillet/Lap, V-Groove)
- 1035 -
Fig. 13.10.4 (e) Two dimensional search example program
Fig. 13.10.4 (f) Two dimensional search with coordinated motion example program
(See Fig. 13.10.4(g) and Fig. 13.10.4 (h) for illustrations)
NOTE
The search direction is part relative as shown in
Fig.13.10.4(g). When the part moves, the search
direction does not change.
Offset PR[2] is part relative as shown in
Fig.13.10.4(h)
Motions between searches are allowed.
- 1036 -
Fig. 13.10.4 (g) First illustration of two dimensional search with coordinated motion program example
Fig. 13.10.4 (h) Second illustration of two dimensional search with coordinated motion program example
Fig. 13.10.4 (i) Simple search with coordinated motion example program
NOTE
The simple search frame can be relative to the
follower or to the leader group. The stored position is
relative to the follower.
The leader is not allowed to move between the
searches.
- 1037 -
Three Dimensional Search Example Program

The 3D search is very similar to the 2D search. To do a 3D search, add
searches in the Z-direction.
Fig.13.10.4 (j) Three dimensional search with rotation example program (See Fig. 13.10.4(k) for an illustration)
Fig.13.10.4(k) Illustration of three dimensional search with rotation program example (Fig. 13.10.4(j))
13.10.5 Touch Sensing Mastering

Touch sensing provides a method for determining part location and
automatic adjustment of the robot path, to compensate for part
displacement. This section contains the details of mastering a part
for touch sensing with the following items
- Mastering
- Remastering
- 1038 -
- Offsets
- Patterns
- Master Flag
- Touching up Path Positions and Incorrect Touch Up
- Adding New Positions
- Multiple Searches
- Touching Up Search Start Positions
Mastering
Mastering refers to defining taught positions in a program as the
expected locations of positions. When the robot follows the taught
positions of the master path, then the offset is zero. An example is
shown in Fig. 13.10.5(a).
Fig. 13.10.5(a) Part in mastered position and offset applied illustration
Remastering
The touch up procedure described in Section 13.10.5 should work for
most instances where the search start positions do not need to be
moved or if the parts do not change drastically.
Remastering is required if the search start positions must be retaught.

Also, if the path must be altered significantly, it is recommended to
remaster to ensure a correct path.
Remastering is accomplished by turning the Master Flag ON and

running through the program. The path followed will be the master
path with no offset applied. Points not in the correct location must be
touched up. After executing the program, the Master Flag is turned
OFF. For Touching up path positions refer to Section 13.10.5.
In addition, if the specific schedule reference group is not equal to 1

(follower), all of the mastering information is stored with respect to
- 1039 -
the reference group. If you change the reference group in a schedule,

you will have to remaster.
NOTE
Complex parts with multiple searches might only
require remastering of specific portions of the path.
Offsets
Offsets generated by touch sensing are relative to the position found
while mastering. An offset is computed by comparing the location of
the part with the stored location. Fig.13.10.5(b) illustrates the offset
value.
- The search performed during mastering establishes the expected
location (which is indicated by the small straight line).
- This location is stored when mastering the part.
- An offset is computed by comparing the location of the part with
this stored location.
- The offset is part relative when the schedule reference group is
not equal to 1.
Fig13.10.5(b). Offset Value Illustration
• Master Flag ON
• Master Flag OFF
Patterns
Mastering is needed for search patterns that generate offset data. The
search patterns that require mastering are as follows:
- Fillet/Lap
- V-Groove
- Outside and Inside diameter searches
- 1040 -
NOTE
A simple search does not require mastering since it
produces an actual location stored in a position
register.
Program Example
The following program example describes a part with a search start
location and three points along a straight path.
- The points are numbered according to the program example.
- The search is a two dimensional search, one in the X direction
and the second in the -Z direction.
- A 2_D Fillet/Lap search was performed.
- The type of search and other details are defined in Touch Sense
Schedule 3.
- Both searches were started at point 2 and the offset information is
stored in position register 1.
- Points 5, 6, and 7 are offset according to the results of the search.
To perform Incremental searches, each search must have its own start
point. In the example program, line 5 was included so the Incremental
search feature could be used for the second search. If Incremental is
turned off, line 5 could be removed and both searches would start at
the taught location of position 2.
Master Flag
The first time the program is executed the part must be mastered.
- Mastering is done by turning on the Master Flag in the Touch
Sense Schedule 3.
- Execute the program.
- The search is performed and the path is followed according to the
taught positions.
- Once the program is completed, the Master Flag is turned OFF.
- According to search result, correct P[5], [6], [7] by touch Touch
offset instruction.
- 1041 -
NOTE
Incremental search is disabled while the Master Flag
is turned ON.
Fig.13.10.5(c) Part with one touch sense start position, 2, and three points along a path, 5, 6, 7
The following explanation is program execution after finishing

Mastering.
- The path represented by points 5, 6, and 7 will be offset by the
amount stored in position register 1.
- Fig. 13.10.5(d) shows the position of the master path.
- The search is performed and the offset from the master location
is computed and stored in position register 1.
- The offset is then applied to the master path to produce the new,
offset path.
Fig.13.10.5(d) Illustration of the path when an offset is applied
Touching Up Path Positions

Occasionally the part or its placement on a fixture will change
requiring adjustment of the path. The entire process of remastering
is not need to accommodate these changes. Refer to Fig.13.10.5(e)
for an illustration of offset path touchup to adjust the location of
points.
NOTE
Touch up must be performed after a successful
touch sense and at the same time the offset is being
applied. Fig.13.10.5(f) illustrates the result of the
touch up process.
- 1042 -
Fig.13.10.5(e) Offset path touch up to adjust location of points 6 and 7
Fig.13.10.5(f) New master touch up illustration
Incorrect Touch Up
A common error is to alter the path without the correct offset being
applied. Touching up must be done after executing the search and
while the Touch Offset is applied.
Example An example of a incorrect touch up is as follows:

- You can move through the program without executing the touch
sense.
- You can touch up point 6 to place it on the part. Refer to
Fig.13.10.5(g).
- The master path has been altered as shown by the new master
path. It was originally intended for the path to be straight and
follow the part.
Fig. 13.10.5(g) Incorrect touch up of a path
- 1043 -
- The part will not be followed correctly when the program is run.
Refer to Fig. 13.10.5(g).
- The offset shifts points 5 and 7 to the correct location along the
part. Point 6 will not be along the part since the master path
was incorrectly touched up.
- Fig.13.10.5(h) exhibits the path that was followed after altering
one point. It shows that the part is not followed correctly.
Fig.13.10.5(h) Path followed after altering 1 point
Adding New Positions

Additional points can be added in the same manner as touching up.
- The search must be completed.
- An accurate offset must be generated.
- Points can then be added to the offset path.
- The program is executed by first performing the search and then
generating a valid offset.
Fig.13.10.5 (i) illustrates adding a point to a path. The offset must be

actively applied for the master path to be correctly updated.
NOTE
If the program is ABORTED while adding new
positions, the offset is cancelled. New positions will
be taught as actual locations rather than positions
with an offset applied. The results would be similar
to what is shown in Fig.13.10.5(h).
Fig. 13.10.5 (i) New point taught while executing the offset path.
- 1044 -
Multiple Searches
Complex programs can have multiple searches generating several
offsets as shown in Fig.13.10.5(j).
The following program example shown in Fig.13.10.5(j) exhibits two

searches that can be performed for complex shapes.
- The first search stores the offset data in position register 1 with
positions 10, 11, and 12 using the offset.
- The second search stores offset data in position register 2 with
If a position of the taught path is to be touched up, the corresponding

search must be performed. Fig.13.10.5 (k) shows the complex part
with a section moved and the path represented by positions, 10, 11,
and 12 which must be touched up.
- The first search must be executed to obtain an accurate offset.
- The offset is applied and the positions, 10, 11, and 12 can be
touched up as normal.
- The master will be correctly updated.
If the path using positions 13, 14, and 15 must be touched up, the
second search must be executed.
- The second search stores offset data in position register 2 with
NOTE
Using this method can reduce the amount of time
required to adjust a small section of the program.
See the following screen for an example.
- 1045 -
Fig. 13.10.5(j) Multiple searches can be performed for complex shapes
Fig. 13.10.5 (k) Illustration of part shape change and the effect on multiple searches performed
Touching Up Search Start Positions

Touching up a search start position is different from touching up the
path position. If the search start position is moved, then the search
and affected path positions must be remastered. There is one
exception:
- Moving the search start position along the axis of the search.
Program Example 1
The following program example shown in Fig.13.10.5(l) exhibits a
part and search start position.
If the search start position is too close to the part due to poor
programming, changes in the part, or a change in the part location,
then
- The search start position needs only to be moved back along the
search direction.
- This can be accomplished with no effect on the path positions
and remastering will not be required.
Program Example 2
The program example shown in Fig. 13.10.5(m) shows the search start
position moved to a new location off the axis of the search direction.
If the search position is moved off the axis of the search direction,
then:
- Remastering is required. To remaster refer to Section 13.10.5.
- 1046 -
Fig.13.10.5(l) Moving a search start position along the search direction
Fig. 13.10.5(m) Search start position moved to a new location off the axis of the search direction
- 1047 -

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B-82594EN-3/03 13.

ARC TOOL UTILITY

13.10 TOUCH SENSING

Touch sensing consists of:

To use touch sensing you must:

See Fig.13.10.1 for an example of a program that includes touch

Fig. 13.10.1 Example program including touch sensing routine

13.10.2 Assigning Touch Sensing I/O

The controller supports numerous I/O options. If you decide to use

Touch Sensing Input Signal

- Welding Digital Inputs (WI) 1-8, found on the CRW1 Connector

Touch Sensing Enable/Disable Output Signal

Assigning the Touch Sensing Inputs and Outputs

Touch sensing inputs are shown as sensor ports in the ArcTool

Procedure 13-16 Assigning touch-sensing inputs and outputs

1 Sensor port type: RI

[ TYPE ] [CHOICE] HELP

5 Assign Sensor (input) and Circuit (output) types as follows:

6 Assign Sensor and Circuit number:

13.10.3 Setting Up Touch Sensing

A touch frame determines the direction of the search motion. The

Touch Sense installation is a "semi-automatic" function. Touch

A Second Controlled Start is required after you install Touch Sense

Fig. 13.10.3 (a) Search using searches in one direction

Fig.13.10.3(b) Search using offsets in two dimensions

Fig. 13.10.3 (c) Search using 2 search motions in 2 different directions to

The characteristics of a search motion are controlled by variables set

Fig. 13.10.3 (d)Touch frame used in a program

Table 13.10.3 (a) Touch frame setup items

Procedure 13-17 Setting up a touch frame using the teaching method

[ TYPE ] RECORD DONE

5 Move the cursor to Frame Number. Type the number of the

6 Move the cursor to Reference Grp. Type the number of the

[ TYPE ] RECORD DONE

5 Move the cursor to Frame Number. Type the number of the

If you press F3, Yes, the frame data will be

7 Move the cursor to Robot Grp. Type the robot group

Simple search requires:

A two-dimensional search is programmed in the software as the only

The two-dimensional search that Simple Search does is called a

Refer to Table 13.10.3(b) for information on search patterns and valid

Refer to Section 13.10.4 for example programs using simple search.

Another type of offset can be in one direction plus rotation about an

Another type of offset can be in three directions plus rotation about

object is being searched for offset in x, y, and z directions, a fillet

Refer to Section 13.10.4 for example programs using Fillet/Lap

The types of searches that a V-Groove Search does is called a pattern

Refer to Section 13.10.4 for example programs using V-Groove

Fig. 13.10.3 (i) V-groove search

Outside/Inside Diameter Search (OD/ID)

The types of searches that an Outside/Inside Search does is called a

Refer to Section 13.10.4 for example programs using OD/ID Search.

Fig. 13.10.3 (j) OD/ID search in two directions (x and y)

Table 13.10.3 (b) Search pattern and valid search type

The SCHEDULE screen allows you to view and set limited

Table 13.10.3 (c) Touch sensing SCHEDULE screen conditions

Procedure 13-19 Defining touch schedules

[ TYPE ] DETAIL HELP >

[ TYPE ] COPY CLEAR >

4 To copy schedule information from one schedule to another:

c Press F2, CLEAR. The data will be cleared, but the

1 Touch Schedule:1 [ Touch Schdule 1]

2 Master flag: OFF

[ TYPE ]SCHEDULE HELP >