60-Point Link Length Calibration Operation Guide

1. Purpose of Calibration

The 60-point link length calibration is mainly used to correct the geometric relationship between the robot system and the external axis, ensuring that the robot’s trajectory coordinates remain consistent with the actual mechanical position during operation.

This operation is suitable for equipment installation, commissioning, maintenance, mechanical structure adjustment, or parameter recalibration after abnormal trajectory accuracy is detected.

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2. Preparation Before Calibration

Before starting the calibration, please confirm the following:

1. The calibration file is ready. The file name is:

   LINK_CALIB.XPL

2. The robot, external axis, and related mechanical structures are in normal condition.

3. The calibration area is clear of obstacles, and all personnel are away from the robot working range.

4. The teach pendant can normally open files, record variables, run programs, and view logs.

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3. Point Recording Requirements

This calibration requires a total of:

60 points

The points should be divided into:

3 groups

The recommended distance between each group is:

approximately 1 meter

In other words, the calibration points should not all be concentrated in the same position. They should be distributed in different areas to ensure more accurate link length calculation results.

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4. Operation Steps

Step 1: Import the Calibration File

Import the calibration file into the teach pendant:

LINK_CALIB.XPL

Confirm that the file has been successfully added to the file list of the teach pendant.

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Step 2: Open the Calibration File

Find and open the following file on the teach pendant:

LINK_CALIB.XPL

After entering the file, prepare to record the position variables.

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Step 3: Enter the Variable Page

After opening the file, click:

Variable

Enter the point variable list.

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Step 4: Select the Point Name and Record

In the variable list, select the point names one by one, for example:

p1, p2, p3 ... p60

After moving to each calibration position, select the corresponding point name and click:

Record

Complete the recording of all points in sequence.

Operation requirements:

• Each point must correspond to the correct variable name.
• Do not miss any point.
• Do not overwrite the wrong point.
• Keep an interval of approximately 1 meter between each group of points.
• When recording a point, the equipment position should be stable to avoid shaking or misoperation.

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Step 5: Save the Point Data

After all 60 points have been recorded, click:

Save

Confirm that the point data has been written into the file.

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Step 6: Enter the Code Page

After saving the point data, click:

Code

Enter the program code page.

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Step 7: Run the Calibration Program

Run the calibration program on the code page.

Important note:

The robot will not move during program execution.

This program mainly reads the recorded 60-point data and performs calculation. Therefore, it is normal that the robot remains stationary during operation.

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Step 8: View the Log Results

After the program finishes running, click:

Log

Check the calculation results.

The log usually displays:

• Zero-point errors of each axis
• Error values of each point group
• Link length calculation results
• Maximum error value
• Link length parameters to be referenced or entered

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5. Result Judgment Standard

After calibration, focus on the following item in the log:

Maximum Error

The judgment standard is as follows:

Maximum Error	Result
≤ 0.7	Calibration result is acceptable
> 0.7	Calibration result is abnormal and troubleshooting is required

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6. Troubleshooting If the Error Is Too Large

If the maximum error exceeds 0.7, check the following items:

1. Whether all 60 points have been recorded completely.
2. Whether the point variable names were selected correctly.
3. Whether the point recording sequence is correct.
4. Whether any point was repeatedly recorded or mistakenly overwritten.
5. Whether the three groups of points maintain an interval of approximately 1 meter.
6. Whether the robot or external axis has mechanical looseness.
7. Whether the equipment moved or shook during calibration.
8. Whether the correct calibration file was used.
9. Whether the save operation was completed on the teach pendant.
10. Whether the mechanical structure has installation deviation or abnormal deformation.

After troubleshooting, record the points again and rerun the calibration program.

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7. Link Length Parameter Activation Requirement

If the link length parameters are entered or modified according to the log results, the following operation must be performed:

Restart the equipment

The new link length parameters will officially take effect only after the equipment is restarted.

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8. Complete Operation Flow Summary

Import the LINK_CALIB.XPL file
↓
Open the file
↓
Enter the Variable page
↓
Record points p1 to p60 in sequence
↓
Divide 60 points into 3 groups, with about 1 meter between each group
↓
Save the point data
↓
Enter the Code page
↓
Run the program
↓
Check the Log
↓
Confirm whether the maximum error is ≤ 0.7
↓
If link length parameters are modified, restart the equipment