In this video, we will go over a standard feature included with FANUC ServoGun software: tip wear measurement and compensation. Tip wear is a normal outcome of spot welding operations, but if it is not monitored and managed correctly, it can negatively impact weld quality, robot positioning, and production consistency. This video provides a practical overview of how ServoGun software measures tip wear, applies compensation, and supports long term reliability in servo welding applications.
We will begin by reviewing essential terminology related to servo welding, electrode caps, and gun motion to ensure the fundamentals are clearly understood. From there, we will explain what tip wear measurement is and how it differs from tip wear compensation. While these two functions are often used together, we will explore why each has its own purpose and how measurement alone may be sufficient in certain scenarios.
The video then covers the prerequisites required before running any tip wear measurement programs. Accurate wear detection depends on proper servo gun setup, and we will outline which configuration and calibration steps should already be completed. This context helps ensure the data gathered is meaningful and compensation behavior remains predictable during operation.
A key portion of the discussion focuses on the two available methods for measuring tip wear: the two step method and the one step method. We will compare how each approach works, what equipment or fixture requirements are involved, and how cycle time and available space influence method selection. We will also walk through how the default teach pendant programs provided with the ServoGun software option are used to establish a reference condition and perform ongoing wear updates.
Additional features are introduced toward the end of the video, including wear tracking options, alarm outputs, and how wear values are displayed within the ServoGun interface. We will also briefly touch on advanced use cases, such as combining measurement methods, without going into full implementation detail.
Prerequisites We Will Cover
- Servo gun and auxiliary axis setup
- Gun setup utility, auto tuning, and pressure calibration
- Installation of new weld tips for initial mastering
- Verification of gun direction and stroke limits
What We Will Learn
- How tip wear measurement and compensation function
- Differences between one step and two step methods
- How reference values and updates are used
- How wear ratios influence compensation behavior
- How to monitor wear and trigger alarms
By the end of this video, we will have a clear understanding of how tip wear measurement supports consistent weld quality, accurate positioning, and dependable servo welding performance.
