How are folks creating disk images to help recover from a disk failure without having to re-calibrate their robots? I realize I can get an image from UR and the field calibrate.  Field calibrations are never as good as a 2 robot calibration.

You can always request the calibration.conf file from UR, generally takes them just a couple of hours to send it to us when we need it, all you need is the serial number. You’d request this from your local distributor and they can get it from UR.  The other way is to mount the drive to your laptop, you will need something that can mount a Linux drive and then copy the file from the drive and store it for safe keeping.  We’ve also had several times where the robot will not boot from the USB but we could still mount it on the laptop and get files off of it regardless. 

Matthew, are all of the calibration files located in the /root/.urcontrol   directory or are there more hiding places?

Yes, there’s just one file that you need, calibration.conf. The remainder of the files will come with the disk image from UR

On a UR3 I removed the drive and on a linux machine used dd to archive the entire disk.

If your robot is connected to your network, you can also use software such as filezilla to download/upload files to the controller

We just create an image of the USB using a tool like Passmark's ImageUSB (Wintel environment).