Dual Gear Assembly Phase Search (Gear 3)

In this video, we will go over the final step in assembling two gears: the phase search process. This is part three of our multipart series on gear assembly using force control technology. Building on what we covered in the previous videos, we’ll walk through how to create and configure a new force control schedule specifically for phase matching.

We’ll start by setting up the schedule parameters, including the tool and user frames, and explain why these frames are critical for accurate alignment. You’ll learn how to define insertion direction, manage force limits, and configure key settings like phase match angular velocity, torque, and angle limits. These adjustments ensure smooth gear engagement and prevent common errors such as alarms caused by incorrect torque or rotation values.

To make this process efficient, we’ll also discuss how to skip auto-tuning when the gear is already partially inserted, and how to leverage continuous execution for multiple force control schedules without clearing active forces. This approach is essential for complex assemblies and error handling scenarios.

Requirements for Following Along:

• Familiarity with previous steps in gear assembly (shaft insert)
• Basic understanding of force control principles
• Access to FANUC robot programming interface

What You Will Learn:

• How to create and configure a phase search schedule
• Best practices for setting phase match parameters (velocity, torque, angle)
• How to use continuous execution for successive force control operations
• Tips for combining FANUC technologies like iRVision with force control for faster alignment

By the end of this video, you’ll have a clear understanding of how to execute a phase search and integrate it seamlessly into your gear assembly process. This knowledge will help you improve cycle time, reduce errors, and optimize robotic assembly performance.