Industry Introduction
In industrial robot welding, the accuracy of the welding torch TCP (Tool Center Point) directly determines weld quality. After a torch change or a collision, the TCP must be recalibrated; traditional manual teaching is inefficient, inconsistent and carries safety risks.
Video Demonstration
---Industry Pain Points
- Time-consuming calibration: manual calibration takes 10~15 minutes per session, frequently eating into production time
- Inconsistent results: dependent on operator experience, results vary between people and shifts
- Wire deformation: traditional contact-type flat-plate calibration bends and deforms the welding wire, affecting accuracy
- Safety hazards: manual teaching requires entering the welding cell, exposing operators to high temperatures, arc light and spatter
Our Advantages
The iNexBot TCP automatic calibration system uses a cross-laser sensor + five-point automatic calibration algorithm:
| Metric | Manual Calibration | Automatic Calibration | Improvement |
|---|---|---|---|
| Calibration time | 10~15 min | 5~7 min | ↓50% |
| Accuracy around A axis | 1.0 mm | 0.1 mm | ↓10× |
| Accuracy around B axis | 1.0 mm | 0.3 mm | — |
| Accuracy around C axis | 2.0 mm | 0.5 mm | — |
| Combined pivot-point error | 3.0mm | 0.59 mm | — |
| Consistency | Experience-dependent, highly variable | Fully automatic and standardized, highly consistent | — |
| Probing method | Contact flat plate (wears out) | Non-contact laser (zero wear) | — |
Our Solution
One-touch start from the teach pendant; the system automatically completes: trajectory generation → motion acquisition → tool calculation → write to tool frame, with no manual intervention at any step.
The operator only needs to teach 5 calibration points on the teach pendant the first time; every subsequent calibration (after torch changes or collisions) is triggered with one touch. No additional host computer is required — the development and debugging interface runs directly on the teach pendant and is enabled by a software upgrade, at zero hardware cost.
Hardware Used
| Hardware | Description |
|---|---|
| Cross-laser sensor | Laser beam diameter 0.3~1.0mm, compatible with wire diameters ≥0.6mm; 120mm and 220mm beam-distance versions available |
| Robot controller | [Compatible with multiple of our controller models] |
| Teach pendant | [T30], with a natively integrated calibration interface |
Robot Types
Supports mainstream 6-axis industrial robots and suits all types of arc welding applications (gas-shielded welding, TIG welding, etc.), as well as welding carriages and dedicated welding machines.
Communication Methods
| Method | Scenario |
|---|---|
| EtherCAT | Controller ↔ sensor direct connection |
| PROFINET / EtherNet/IP | PLC-triggered calibration |
| Modbus TCP | Data exchange |
| Hardwired I/O | Start/complete/alarm signals |
FAQ
Q1: What calibration accuracy can be achieved?
±0.1mm around the A axis, ±0.3mm around the B axis and ±0.5mm around the C axis, with a combined pivot-point error of 0.59mm — far beyond manual calibration levels.
Q2: Are there requirements for wire diameter?
Supports wire diameters of 0.6mm and above. The laser beam diameter is 0.3~1.0mm; non-contact probing means the wire never deforms.
Q3: What is needed for first deployment? Does every subsequent calibration require re-teaching?
Teach 5 points on the teach pendant during initial deployment and the system saves them. Subsequent calibrations are triggered with one touch — no re-teaching needed.
Q4: Is an additional host computer required?
No. The system is integrated directly into the teach pendant; it is enabled by a software upgrade, at zero hardware cost.
Q5: How long does installation and commissioning take?
For the hardware, simply place the cross-laser sensor roughly parallel to the work platform and keep it stable. The initial 5-point teaching takes just a few minutes.
Q6: Will welding arc light interfere with the laser?
No. Modulated laser technology is used, immune to interference from arc light, ambient light and spatter.
Q7: How long does the sensor last? Does it need frequent maintenance?
Non-contact measurement involves no mechanical wear; daily upkeep is just keeping the lens clean, with no consumables.
Q8: Does calibration require stopping the line?
No. Online calibration is supported — after a torch change, trigger it with one touch and it completes automatically in 5~7 minutes.
Q9: After a torch collision, does the sensor need to be reinstalled or recalibrated?
No. The sensor can be fixed in the cell; the robot automatically executes the calibration to restore accuracy.
Q10: How is after-sales and technical support guaranteed?
Remote debugging + on-site support. For product specification updates, please contact iNexBot technical support.
