Robot KUKA KRC4 Instrukcje obsługi "Manual" w PDF ver.English
KUKA System Software
KUKA Roboter GmbH
KUKA System Software 8.2
Operating and Programming Instructions for System Integrators
Issued: 02.11.2011
Version: KSS 8.2 SI V3 en
KUKA System Software 8.2
© Copyright 2011
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
Publication:
Bookstructure:
KSS 8.2 SI V3.2
Version:
2 / 391
Pub KSS 8.2 SI en
KSS 8.2 SI V3 en
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Contents
Contents
1
Introduction ..................................................................................................
13
1.1
Target group ..............................................................................................................
13
1.2
Industrial robot documentation ...................................................................................
13
1.3
Representation of warnings and notes ......................................................................
13
1.4
Trademarks ................................................................................................................
14
2
Product description .....................................................................................
15
2.1
Overview of the industrial robot .................................................................................
15
2.2
Overview of the software components .......................................................................
15
2.3
Overview of KUKA System Software (KSS) ..............................................................
15
3
Safety ............................................................................................................
17
3.1
General ......................................................................................................................
17
3.1.1
Liability ..................................................................................................................
17
3.1.2
Intended use of the industrial robot ......................................................................
17
3.1.3
EC declaration of conformity and declaration of incorporation .............................
18
3.1.4
Terms used ...........................................................................................................
18
3.2
Personnel ...................................................................................................................
20
3.3
Workspace, safety zone and danger zone .................................................................
21
3.4
Triggers for stop reactions .........................................................................................
22
3.5
Safety functions .........................................................................................................
23
3.5.1
Overview of the safety functions ...........................................................................
23
3.5.2
Safety controller ....................................................................................................
23
3.5.3
Mode selection ......................................................................................................
24
3.5.4
Operator safety .....................................................................................................
24
3.5.5
EMERGENCY STOP device ................................................................................
25
3.5.6
Logging off the higher-level safety controller ........................................................
25
3.5.7
External EMERGENCY STOP device ..................................................................
25
3.5.8
Enabling device ....................................................................................................
26
3.5.9
External enabling device .......................................................................................
26
3.5.10
External safe operational stop ..............................................................................
26
3.5.11
External safety stop 1 and external safety stop 2 .................................................
26
3.5.12
Velocity monitoring in T1 ......................................................................................
27
Additional protective equipment .................................................................................
27
3.6.1
Jog mode ..............................................................................................................
27
3.6.2
Software limit switches .........................................................................................
27
3.6.3
Mechanical end stops ...........................................................................................
27
3.6.4
Mechanical axis range limitation (optional) ...........................................................
27
3.6.5
Axis range monitoring (optional) ...........................................................................
28
3.6.6
Release device (optional) .....................................................................................
28
3.6
3.6.7
Labeling on the industrial robot .............................................................................
29
3.6.8
External safeguards ..............................................................................................
29
3.7
Overview of operating modes and safety functions ...................................................
30
3.8
Safety measures ........................................................................................................
30
3.8.1
General safety measures ......................................................................................
30
3.8.2
Transportation .......................................................................................................
31
3.8.3
Start-up and recommissioning ..............................................................................
32
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KUKA System Software 8.2
3.8.3.1
Start-up mode .......................................................................................................
33
3.8.4
Manual mode ........................................................................................................
34
3.8.5
Simulation .............................................................................................................
35
3.8.6
Automatic mode ...................................................................................................
35
3.8.7
Maintenance and repair ........................................................................................
35
3.8.8
Decommissioning, storage and disposal ..............................................................
37
3.8.9
Safety measures for “single point of control” ........................................................
37
3.9
Applied norms and regulations ..................................................................................
39
4
Operation ......................................................................................................
41
4.1
KUKA smartPAD teach pendant ................................................................................
41
4.1.1
Front view .............................................................................................................
41
4.1.2
Rear view .............................................................................................................
43
4.1.3
Disconnecting and connecting the smartPAD ......................................................
44
KUKA smartHMI user interface .................................................................................
45
4.2
4.2.1
Status bar .............................................................................................................
46
4.2.2
Keypad .................................................................................................................
47
4.2.3
Minimizing KUKA smartHMI .................................................................................
48
4.3
Switching on the robot controller and starting the KSS .............................................
48
4.4
Calling the main menu ...............................................................................................
48
4.5
Defining the start type for KSS ..................................................................................
49
4.6
Exiting or restarting KSS ...........................................................................................
49
4.7
Switching the robot controller off ...............................................................................
52
4.8
Setting the user interface language ...........................................................................
52
4.9
Changing user group .................................................................................................
52
4.10 Changing operating mode .........................................................................................
53
4.11 Coordinate systems ...................................................................................................
54
4.12 Jogging the robot .......................................................................................................
55
4.12.1
“Jog options” window ............................................................................................
56
4.12.1.1
4.12.1.2
4.12.1.3
4.12.1.4
4.12.1.5
“General” tab ........................................................................................................
“Keys” tab .............................................................................................................
“Mouse” tab ..........................................................................................................
“KCP pos.” tab ......................................................................................................
“Cur. tool/base” tab ...............................................................................................
57
57
58
59
59
4.12.2
Activating the jog mode ........................................................................................
60
4.12.3
Setting the jog override (HOV) .............................................................................
60
4.12.4
Selecting the tool and base ..................................................................................
60
4.12.5
Axis-specific jogging with the jog keys .................................................................
61
4.12.6
Cartesian jogging with the jog keys ......................................................................
61
4.12.7
Configuring the Space Mouse ..............................................................................
61
4.12.8
Defining the alignment of the Space Mouse .........................................................
63
4.12.9
Cartesian jogging with the Space Mouse .............................................................
64
4.12.10 Incremental jogging ..............................................................................................
65
4.13 Jogging external axes ................................................................................................
66
4.15 Monitor functions .......................................................................................................
67
4.15.1
Displaying the actual position ...............................................................................
67
4.15.2
Displaying digital inputs/outputs ...........................................................................
67
4.15.3
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66
4.14 Bypassing workspace monitoring ..............................................................................
Displaying analog inputs/outputs ..........................................................................
69
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Contents
4.15.4
Displaying inputs/outputs for Automatic External .................................................
69
4.15.5
Displaying and modifying the value of a variable ..................................................
70
4.15.6
Displaying the state of a variable ..........................................................................
71
4.15.7
Displaying the variable overview and modifying variables ....................................
72
4.15.8
Displaying cyclical flags ........................................................................................
73
4.15.9
Displaying flags .....................................................................................................
74
4.15.10 Displaying counters ..............................................................................................
75
4.15.11 Displaying timers ..................................................................................................
76
4.15.12 Displaying calibration data ....................................................................................
77
4.15.13 Displaying information about the robot and robot controller .................................
78
4.15.14 Displaying/editing robot data ................................................................................
78
4.16 Displaying the battery state ........................................................................................
80
5
Start-up and recommissioning ...................................................................
83
5.1
Start-up wizard ...........................................................................................................
83
5.2
Checking the machine data .......................................................................................
83
5.3
Defining hardware options .........................................................................................
84
5.4
Changing the safety ID of the PROFINET device ......................................................
85
5.5
Jogging the robot without a higher-level safety controller ..........................................
86
5.6
Checking the activation of the positionally accurate robot model ..............................
87
5.7
Activating palletizing mode ........................................................................................
87
5.8
Copying machine data ...............................................................................................
88
5.9
Mastering ...................................................................................................................
89
5.9.1
Mastering methods ...............................................................................................
90
5.9.2
Moving axes to the pre-mastering position ...........................................................
91
5.9.3
Mastering with the EMD ........................................................................................
92
5.9.3.1
5.9.3.2
5.9.3.3
First mastering with the EMD ................................................................................
Teach offset ..........................................................................................................
Master load with offset ..........................................................................................
92
95
96
5.9.4
Mastering with the dial gauge ...............................................................................
97
5.9.5
Mastering external axes ........................................................................................
98
5.9.6
Reference mastering ............................................................................................
98
5.9.7
Manually unmastering axes ..................................................................................
99
5.10 Modifying software limit switches ...............................................................................
100
5.11 Calibration ..................................................................................................................
102
5.11.1
Defining the tool direction .....................................................................................
102
5.11.2
Tool calibration .....................................................................................................
102
5.11.2.1
5.11.2.2
5.11.2.3
5.11.2.4
5.11.2.5
TCP calibration: XYZ 4-point method ...................................................................
TCP calibration: XYZ Reference method ..............................................................
Defining the orientation: ABC World method ........................................................
Defining the orientation: ABC 2-point method ......................................................
Numeric input ........................................................................................................
104
106
107
107
109
5.11.3
Base calibration ....................................................................................................
109
5.11.3.1 3-point method ......................................................................................................
5.11.3.2 Indirect method .....................................................................................................
5.11.3.3 Numeric input ........................................................................................................
110
111
112
5.11.4
Fixed tool calibration .............................................................................................
112
5.11.4.1 Calibrating an external TCP ..................................................................................
5.11.4.2 Entering the external TCP numerically .................................................................
5.11.4.3 Workpiece calibration: direct method ....................................................................
113
114
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KUKA System Software 8.2
5.11.4.4 Workpiece calibration: indirect method .................................................................
116
5.11.5
Renaming the tool/base .......................................................................................
117
5.11.6
Linear unit .............................................................................................................
117
5.11.6.1 Checking whether the linear unit needs to be calibrated ......................................
5.11.6.2 Calibrating the linear unit ......................................................................................
5.11.6.3 Entering the linear unit numerically ......................................................................
117
118
119
5.11.7
Calibrating an external kinematic system .............................................................
120
5.11.7.1
5.11.7.2
5.11.7.3
5.11.7.4
5.11.7.5
5.11.7.6
Calibrating the root point ......................................................................................
Entering the root point numerically .......................................................................
Workpiece base calibration ..................................................................................
Entering the workpiece base numerically .............................................................
Calibrating an external tool ...................................................................................
Entering the external tool numerically ..................................................................
120
122
122
124
124
125
5.12 Load data ...................................................................................................................
126
5.12.1
Checking loads with KUKA.Load ..........................................................................
126
5.12.2
Calculating payloads with KUKA.LoadDataDetermination ...................................
126
5.12.3
Entering payload data ..........................................................................................
126
5.12.4
Entering supplementary load data ........................................................................
127
5.12.5
Online load data check (OLDC) ............................................................................
127
5.13 Maintenance handbook .............................................................................................
129
5.13.1
Logging maintenance ...........................................................................................
130
5.13.2
Displaying a maintenance log ...............................................................................
131
6
Configuration ...............................................................................................
133
6.1
Configuring the KUKA Line Interface (KLI) ................................................................
133
6.1.1
Configuring the Windows interface (without PROFINET) .....................................
133
6.1.2
Configuring the Windows PROFINET interface and creating the Windows interface
134
6.1.3
Displaying ports of the Windows interface or enabling an additional port ............
136
6.1.4
Displaying or modifying filters ...............................................................................
136
6.1.5
Displaying the subnet configuration of the robot controller ...................................
137
6.1.6
Error display in the Address and Subnet boxes ...................................................
138
6.1.7
Configuring DNS ...................................................................................................
138
6.2
Reconfiguring the I/O driver .......................................................................................
141
6.3
Checking the safety configuration of the robot controller ..........................................
141
6.4
Configuring the variable overview .............................................................................
142
6.5
Changing the password .............................................................................................
143
6.6
Configuring workspaces ............................................................................................
143
6.6.1
Configuring Cartesian workspaces .......................................................................
144
6.6.2
Configuring axis-specific workspaces ...................................................................
146
6.6.3
Mode for workspaces ...........................................................................................
148
6.7
Warm-up ....................................................................................................................
149
6.7.1
Configuring warm-up ............................................................................................
149
6.7.2
Warm-up sequence ..............................................................................................
149
6.7.3
System variables for warm-up ..............................................................................
150
6.8
151
Calculating the tolerance range and activating collision detection .......................
153
6.8.2
Defining an offset for the tolerance range ............................................................
154
6.8.3
Option window “Collision detection” .....................................................................
155
6.8.4
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Collision detection .....................................................................................................
6.8.1
Torque monitoring ................................................................................................
156
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Contents
6.8.4.1
6.8.4.2
6.9
Determining values for torque monitoring .............................................................
Programming torque monitoring ...........................................................................
157
157
Defining calibration tolerances ...................................................................................
158
6.10 Configuring Automatic External .................................................................................
158
6.10.1
Configuring CELL.SRC .........................................................................................
159
6.10.2
Configuring Automatic External inputs/outputs .....................................................
160
6.10.2.1 Automatic External inputs .....................................................................................
6.10.2.2 Automatic External outputs ...................................................................................
162
164
6.10.3
Transmitting error numbers to the higher-level controller .....................................
166
6.10.4
Signal diagrams ....................................................................................................
168
6.11 Torque mode ..............................................................................................................
174
6.11.1
Overview of torque mode ......................................................................................
174
6.11.1.1 Using torque mode ...............................................................................................
6.11.1.2 Robot program example: setting A1 to “soft” in both directions ............................
174
176
6.11.2
Activating torque mode: SET_TORQUE_LIMITS() ...............................................
177
6.11.3
Deactivating torque mode: RESET_TORQUE_LIMITS() .....................................
180
6.11.4
Interpreter specifics ..............................................................................................
180
6.11.5
Diagnostic variables for torque mode ...................................................................
181
6.11.5.1
6.11.5.2
6.11.5.3
6.11.5.4
6.11.5.5
6.11.5.6
$TORQUE_AXIS_ACT .........................................................................................
$TORQUE_AXIS_MAX_0 ....................................................................................
$TORQUE_AXIS_MAX ........................................................................................
$TORQUE_AXIS_LIMITS .....................................................................................
$HOLDING_TORQUE ..........................................................................................
Comparison: $TORQUE_AXIS_ACT and $HOLDING_TORQUE .......................
181
182
182
182
183
183
6.11.6
Other examples ....................................................................................................
184
6.11.6.1
6.11.6.2
6.11.6.3
6.11.6.4
6.11.6.5
Robot program: setting axis to “soft” in both directions ........................................
Robot program: avoiding damage in the event of collisions .................................
Robot program: torque mode in the interrupt ........................................................
Robot program: servo gun builds up pressure ......................................................
Submit program: servo gun builds up pressure ....................................................
184
184
186
187
188
6.12 Event planner .............................................................................................................
188
6.12.1
Configuring a data comparison .............................................................................
188
6.12.2
Configuring T1 and T2 Consistency, AUT and EXT Consistency .........................
189
6.12.3
Configuring Logic Consistency .............................................................................
190
6.13 Brake test ...................................................................................................................
191
6.13.1
Overview of the brake test ....................................................................................
191
6.13.2
Programs for the brake test ..................................................................................
192
6.13.3
Signal diagram of the brake test ...........................................................................
193
6.13.4
Configuring input and output signals ....................................................................
194
6.13.5
Teaching positions for the brake test ....................................................................
195
6.13.6
Performing a manual brake test ............................................................................
196
6.13.7
Checking that the brake test is functioning correctly ............................................
197
7
Program management .................................................................................
199
7.1
Navigator file manager ...............................................................................................
199
7.1.1
Selecting filters .....................................................................................................
200
7.1.2
Creating a new folder ............................................................................................
200
7.1.3
Creating a new program .......................................................................................
201
7.1.4
Renaming a file .....................................................................................................
201
Selecting or opening a program .................................................................................
201
7.2
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KUKA System Software 8.2
7.2.1
Selecting and deselecting a program ...................................................................
202
7.2.2
Opening a program ..............................................................................................
203
7.2.3
Toggling between the Navigator and the program ...............................................
203
Structure of a KRL program .......................................................................................
204
HOME position .....................................................................................................
205
Displaying/hiding program sections ...........................................................................
205
7.4.1
Displaying/hiding the DEF line ..............................................................................
205
7.4.2
Activating detail view ............................................................................................
205
7.4.3
Activating/deactivating the line break function ......................................................
206
7.4.4
Displaying Folds ...................................................................................................
206
Starting a program .....................................................................................................
207
7.5.1
Selecting the program run mode ..........................................................................
207
7.5.2
Program run modes ..............................................................................................
208
7.5.3
Advance run .........................................................................................................
208
7.5.4
Setting the program override (POV) .....................................................................
209
7.5.5
Switching drives on/off ..........................................................................................
209
7.5.6
Robot interpreter status indicator .........................................................................
209
7.5.7
Starting a program forwards (manual) ..................................................................
210
7.5.8
Starting a program forwards (automatic) ..............................................................
210
7.5.9
Carrying out a block selection ..............................................................................
211
7.5.10
Starting a program backwards ..............................................................................
211
7.5.11
Resetting a program .............................................................................................
211
7.5.12
Starting Automatic External mode ........................................................................
212
7.3
7.3.1
7.4
7.5
7.6
Editing a program ......................................................................................................
212
7.6.1
Inserting a comment or stamp ..............................................................................
213
7.6.2
Deleting program lines ..........................................................................................
214
7.6.3
Creating Folds ......................................................................................................
214
7.6.4
Additional editing functions ...................................................................................
215
7.7
Printing a program .....................................................................................................
216
7.8
Archiving and restoring data ......................................................................................
216
7.8.1
Archiving overview ................................................................................................
216
7.8.2
Archiving to a USB stick .......................................................................................
217
7.8.3
Archiving on the network ......................................................................................
218
7.8.4
Archiving the logbook ...........................................................................................
218
7.8.5
Restoring data ......................................................................................................
219
7.9
Project management .................................................................................................
219
7.9.1
Pinning a project on the robot controller ...............................................................
219
7.9.2
Activating a project ...............................................................................................
220
7.9.3
Project management window .............................................................................
221
8
Basic principles of motion programming ..................................................
223
8.1
Overview of motion types ..........................................................................................
223
8.2
Motion type PTP ........................................................................................................
223
8.3
Motion type LIN .........................................................................................................
223
8.4
Motion type CIRC ......................................................................................................
224
8.5
Approximate positioning ............................................................................................
224
8.6
Orientation control LIN, CIRC ....................................................................................
226
Combinations of $ORI_TYPE and $CIRC_TYPE .................................................
227
Motion type “Spline” ...................................................................................................
229
8.6.1
8.7
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Contents
8.7.1
Velocity profile for spline motions .........................................................................
231
8.7.2
Block selection with spline motions ......................................................................
232
8.7.3
Modifications to spline blocks ...............................................................................
233
8.7.4
Approximate positioning of spline motions ...........................................................
235
8.7.5
Replacing an approximated motion with a spline block ........................................
236
8.7.5.1
SLIN-SPL-SLIN transition .....................................................................................
239
Orientation control SPLINE ........................................................................................
239
8.8.1
SCIRC: reference system for the orientation control ............................................
241
8.8.2
SCIRC: orientation behavior .................................................................................
242
Status and Turn .........................................................................................................
244
8.9.1
Status ....................................................................................................................
245
8.9.2
8.8
8.9
Turn ......................................................................................................................
247
8.10 Singularities ...............................................................................................................
248
9
251
Programming for user group “User” (inline forms) .................................
9.1
Names in inline forms ................................................................................................
251
9.2
Programming PTP, LIN and CIRC motions ...............................................................
251
9.2.1
Programming a PTP motion .................................................................................
251
9.2.2
Inline form “PTP” ...................................................................................................
252
9.2.3
Programming a LIN motion ...................................................................................
252
9.2.4
Inline form “LIN” ....................................................................................................
253
9.2.5
Programming a CIRC motion ................................................................................
253
9.2.6
Inline form “CIRC” .................................................................................................
254
9.2.7
Option window: Frames .......................................................................................
255
9.2.8
Option window: Motion parameters (PTP) ..........................................................
255
9.2.9
Option window: Motion parameters (LIN, CIRC) ................................................
256
Spline motions ...........................................................................................................
257
9.3
9.3.1
Programming tips for spline motions ....................................................................
257
9.3.2
Programming a SLIN motion (individual motion) ..................................................
258
9.3.2.1
9.3.2.2
Inline form “SLIN” ..................................................................................................
Option window “Motion parameters” (SLIN) .........................................................
258
259
9.3.3
Programming a SCIRC motion (individual motion) ...............................................
260
9.3.3.1
9.3.3.2
Inline form “SCIRC” ..............................................................................................
Option window “Motion parameters” (SCIRC) ......................................................
260
261
9.3.4
Programming a spline block .................................................................................
262
9.3.4.1
9.3.4.2
9.3.4.3
9.3.4.4
9.3.4.5
9.3.4.6
9.3.4.7
9.3.4.8
9.3.4.9
9.3.4.10
9.3.4.11
9.3.4.12
9.3.4.13
9.3.4.14
Inline form for spline block ....................................................................................
Option window “Frames” (spline block) ................................................................
Option window “Motion parameters” (spline block) ...............................................
Programming an SPL or SLIN segment ...............................................................
Programming an SCIRC segment ........................................................................
Inline form for spline segment ...............................................................................
Option window “Frames” (spline segment) ...........................................................
Option window “Motion parameters” (spline segment) .........................................
Programming triggers in the spline block ..............................................................
Inline form for spline trigger type “Set output” .......................................................
Inline form for spline trigger type “Set pulse output” .............................................
Inline form for spline trigger type “Trigger assignment” ........................................
Inline form for spline trigger type “Trigger function call” ........................................
Limits for functions in the spline trigger ................................................................
263
263
264
265
265
266
267
267
268
269
270
271
271
272
9.3.5
Copying spline inline forms ...................................................................................
273
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KUKA System Software 8.2
9.3.6
Converting spline inline forms from 8.1 ................................................................
273
9.4
Modifying motion parameters ....................................................................................
274
9.5
Modifying the coordinates of a taught point ...............................................................
274
9.6
Programming logic instructions .................................................................................
274
9.6.1
Inputs/outputs .......................................................................................................
274
9.6.2
Setting a digital output - OUT ...............................................................................
275
9.6.3
Inline form “OUT” ..................................................................................................
275
9.6.4
Setting a pulse output - PULSE ............................................................................
276
9.6.5
Inline form “PULSE” ..............................................................................................
276
9.6.6
Setting an analog output - ANOUT .......................................................................
276
9.6.7
Inline form “ANOUT” (static) .................................................................................
277
9.6.8
Inline form “ANOUT” (dynamic) ............................................................................
277
9.6.9
Programming a wait time - WAIT ..........................................................................
278
9.6.10
Inline form “WAIT” ................................................................................................
278
9.6.11
Programming a signal-dependent wait function - WAITFOR ................................
278
9.6.12
Inline form “WAITFOR” .........................................................................................
279
9.6.13
Switching on the path - SYN OUT ........................................................................
280
9.6.14
Inline form “SYN OUT”, option “START/END” ......................................................
280
9.6.15
Inline form “SYN OUT”, option “PATH” .................................................................
283
9.6.16
Setting a pulse on the path - SYN PULSE ...........................................................
285
9.6.17
Inline form “SYN PULSE” .....................................................................................
285
9.6.18
Modifying a logic instruction .................................................................................
286
Programming for user group “Expert” (KRL syntax) ...............................
287
10.1 Overview of KRL syntax ............................................................................................
287
10.2 Symbols and fonts .....................................................................................................
288
10.3 Important KRL terms .................................................................................................
289
10
10.3.1
SRC files and DAT files ........................................................................................
289
10.3.2
Subprograms and functions ..................................................................................
289
10.3.3
Naming conventions and keywords ......................................................................
290
10.3.4
Data types ............................................................................................................
291
10.3.5
Areas of validity ....................................................................................................
292
10.3.6
Constants .............................................................................................................
293
10.4 Variables and declarations ........................................................................................
293
10.4.1
DECL ....................................................................................................................
293
10.4.2
ENUM ...................................................................................................................
295
10.4.3
STRUC .................................................................................................................
296
10.5 Motion programming: PTP, LIN, CIRC ......................................................................
297
10.5.1
297
PTP ......................................................................................................................
10.5.2
PTP_REL .............................................................................................................
298
10.5.3
LIN ........................................................................................................................
299
10.5.4
LIN_REL ...............................................................................................................
300
10.5.5
CIRC .....................................................................................................................
302
10.5.6
303
304
10.6.1
Higher motion profile for spline motions ...............................................................
304
10.6.2
SPLINE ... ENDSPLINE .......................................................................................
305
10.6.3
SLIN .....................................................................................................................
306
10.6.4
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CIRC_REL ............................................................................................................
10.6 Motion programming: spline ......................................................................................
SCIRC ..................................................................................................................
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Contents
10.6.5
SPL .......................................................................................................................
309
10.6.6
TIME_BLOCK .......................................................................................................
309
10.6.7
System variables that affect the spline? ...............................................................
313
10.7 Program execution control .........................................................................................
314
10.7.1
CONTINUE ...........................................................................................................
314
10.7.2
EXIT ......................................................................................................................
314
10.7.3
FOR ... TO ... ENDFOR ........................................................................................
315
10.7.4
GOTO ...................................................................................................................
315
10.7.5
HALT .....................................................................................................................
316
10.7.6
IF ... THEN ... ENDIF ............................................................................................
316
10.7.7
LOOP ... ENDLOOP .............................................................................................
317
10.7.8
REPEAT ... UNTIL ................................................................................................
317
10.7.9
SWITCH ... CASE ... ENDSWITCH ......................................................................
318
10.7.10 WAIT FOR ............................................................................................................
319
10.7.11 WAIT SEC ............................................................................................................
320
10.7.12 WHILE ... ENDWHILE ..........................................................................................
320
10.8 Inputs/outputs ............................................................................................................
321
10.8.1
ANIN .....................................................................................................................
321
10.8.2
ANOUT .................................................................................................................
322
10.8.3
PULSE ..................................................................................................................
323
10.8.4
SIGNAL .................................................................................................................
326
10.9 Subprograms and functions .......................................................................................
327
10.9.1
327
RETURN ...............................................................................................................
10.10 Interrupt programming ...............................................................................................
328
10.10.1 BRAKE ..................................................................................................................
328
10.10.2 INTERRUPT ... DECL ... WHEN ... DO ................................................................
329
10.10.3 INTERRUPT .........................................................................................................
330
10.10.4 RESUME ..............................................................................................................
332
10.11 Path-related switching actions (=Trigger) ..................................................................
333
10.11.1 TRIGGER WHEN DISTANCE ..............................................................................
333
10.11.2 TRIGGER WHEN PATH .......................................................................................
336
10.11.3 TRIGGER WHEN PATH (for SPLINE) .................................................................
339
10.11.3.1Spline: trigger point in the case of approximate positioning .................................
341
10.12 Communication ..........................................................................................................
343
10.13 System functions ........................................................................................................
343
10.13.1 VARSTATE() ........................................................................................................
343
10.13.2 ROB_STOP() and ROB_STOP_RELEASE() .......................................................
345
10.14 Editing string variables ...............................................................................................
346
10.14.1 String variable length in the declaration ................................................................
346
10.14.2 String variable length after initialization ................................................................
346
10.14.3 Deleting the contents of a string variable ..............................................................
347
10.14.4 Extending a string variable ...................................................................................
347
10.14.5 Searching a string variable ...................................................................................
348
10.14.6 Comparing the contents of string variables ..........................................................
349
10.14.7 Copying a string variable ......................................................................................
349
11
351
Submit interpreter .......................................................................................
11.1 Function of the Submit interpreter ..............................................................................
351
11.2 Manually stopping or deselecting the Submit interpreter ...........................................
352
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KUKA System Software 8.2
11.3 Manually starting the Submit interpreter ....................................................................
352
11.4 Modifying the program SPS.SUB ..............................................................................
353
11.5 Creating a new SUB program ....................................................................................
353
11.6 Programming .............................................................................................................
354
12
Diagnosis ......................................................................................................
357
12.1 Logbook .....................................................................................................................
357
12.1.1
Displaying the logbook .........................................................................................
357
12.1.2
“Log” tab ...............................................................................................................
357
12.1.3
“Filter” tab .............................................................................................................
358
12.1.4
Configuring the logbook .......................................................................................
359
12.2 Displaying the caller stack .........................................................................................
360
12.3 Displaying interrupts ..................................................................................................
361
12.4 Displaying diagnostic data about the kernel system ..................................................
362
12.5 Compressing data for error analysis at KUKA ...........................................................
362
13
Installation ...................................................................................................
363
13.1 Overview of the software components ......................................................................
363
13.2 Installing Windows and KSS (from image) ................................................................
363
13.3 Installing additional software .....................................................................................
364
13.4 KSS update ...............................................................................................................
365
13.4.1
Update from the KUKA USB stick ........................................................................
365
13.4.2
Update from the network ......................................................................................
366
Messages ......................................................................................................
369
14.1 Automatic External error messages ..........................................................................
369
14.2 Brake test messages .................................................................................................
370
14.3 Error messages of the positionally accurate robot model ..........................................
372
15
KUKA Service ...............................................................................................
375
15.1 Requesting support ...................................................................................................
375
15.2 KUKA Customer Support ...........................................................................................
375
Index .............................................................................................................
383
14
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1 Introduction
1
Introduction
1.1
Target group
This documentation is aimed at users with the following knowledge and skills:
Advanced knowledge of the robot controller system
Advanced KRL programming skills
For optimal use of our products, we recommend that our customers
take part in a course of training at KUKA College. Information about
the training program can be found at www.kuka.com or can be obtained directly from our subsidiaries.
1.2
Industrial robot documentation
The industrial robot documentation consists of the following parts:
Documentation for the manipulator
Documentation for the robot controller
Operating and programming instructions for the KUKA System Software
Documentation relating to options and accessories
Parts catalog on storage medium
Each of these sets of instructions is a separate document.
1.3
Safety
Representation of warnings and notes
These warnings are relevant to safety and must be observed.
These warnings mean that it is certain or highly probable
that death or severe physical injury will occur, if no precautions are taken.
These warnings mean that death or severe physical injury may occur, if no precautions are taken.
These warnings mean that minor physical injuries may
occur, if no precautions are taken.
These warnings mean that damage to property may occur, if no precautions are taken.
These warnings contain references to safety-relevant information or
general safety measures. These warnings do not refer to individual
hazards or individual precautionary measures.
Hints
These hints serve to make your work easier or contain references to further
information.
Tip to make your work easier or reference to further information.
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KUKA System Software 8.2
1.4
Trademarks
Windows is a trademark of Microsoft Corporation.
WordPad is a trademark of Microsoft Corporation.
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2 Product description
2
Product description
2.1
Overview of the industrial robot
The industrial robot consists of the following components:
Manipulator
Robot controller
Teach pendant
Connecting cables
Software
Options, accessories
Fig. 2-1: Example of an industrial robot
1
3
Robot controller
2
2.2
Manipulator
Connecting cables
4
Teach pendant
Overview of the software components
Overview
The following software components are used:
2.3
KUKA System Software 8.2
Windows XPe V3.0.0
Overview of KUKA System Software (KSS)
Description
The KUKA System Software (KSS) is responsible for all the basic operator
control functions of the industrial robot.
Path planning
I/O management
Data and file management
etc.
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KUKA System Software 8.2
Additional technology packages, containing application-specific instructions
and configurations, can be installed.
smartHMI
The user interface of the KUKA System Software is called KUKA smartHMI
(smart Human-Machine Interface).
Features:
User administration
Program editor
KRL (KUKA Robot Language)
Inline forms for programming
Message display
Configuration window
etc.
( & gt; & gt; & gt; 4.2 " KUKA smartHMI user interface " Page 45)
Depending on customer-specific settings, the user interface may vary
from the standard interface.
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3 Safety
3
Safety
3.1
General
3.1.1
Liability
The device described in this document is either an industrial robot or a component thereof.
Components of the industrial robot:
Manipulator
Robot controller
Teach pendant
Connecting cables
External axes (optional)
e.g. linear unit, turn-tilt table, positioner
Software
Options, accessories
The industrial robot is built using state-of-the-art technology and in accordance with the recognized safety rules. Nevertheless, misuse of the industrial
robot may constitute a risk to life and limb or cause damage to the industrial
robot and to other material property.
The industrial robot may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons who are fully aware of the risks involved in its operation. Use of the industrial robot is
subject to compliance with this document and with the declaration of incorporation supplied together with the industrial robot. Any functional disorders affecting the safety of the industrial robot must be rectified immediately.
Safety information
Safety information cannot be held against KUKA Roboter GmbH. Even if all
safety instructions are followed, this is not a guarantee that the industrial robot
will not cause personal injuries or material damage.
No modifications may be carried out to the industrial robot without the authorization of KUKA Roboter GmbH. Additional components (tools, software,
etc.), not supplied by KUKA Roboter GmbH, may be integrated into the industrial robot. The user is liable for any damage these components may cause to
the industrial robot or to other material property.
In addition to the Safety chapter, this document contains further safety instructions. These must also be observed.
3.1.2
Intended use of the industrial robot
The industrial robot is intended exclusively for the use designated in the “Purpose” chapter of the operating instructions or assembly instructions.
Further information is contained in the “Purpose” chapter of the operating instructions or assembly instructions of the industrial robot.
Using the industrial robot for any other or additional purpose is considered impermissible misuse. The manufacturer cannot be held liable for any damage
resulting from such use. The risk lies entirely with the user.
Operating the industrial robot and its options within the limits of its intended
use also involves observance of the operating and assembly instructions for
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KUKA System Software 8.2
the individual components, with particular reference to the maintenance specifications.
Misuse
Any use or application deviating from the intended use is deemed to be impermissible misuse. This includes e.g.:
Use as a climbing aid
Operation outside the permissible operating parameters
Use in potentially explosive environments
Operation without additional safeguards
3.1.3
Transportation of persons and animals
Outdoor operation
EC declaration of conformity and declaration of incorporation
This industrial robot constitutes partly completed machinery as defined by the
EC Machinery Directive. The industrial robot may only be put into operation if
the following preconditions are met:
The industrial robot is integrated into a complete system.
Or: The industrial robot, together with other machinery, constitutes a complete system.
Or: All safety functions and safeguards required for operation in the complete machine as defined by the EC Machinery Directive have been added
to the industrial robot.
Declaration of
conformity
The complete system complies with the EC Machinery Directive. This has
been confirmed by means of an assessment of conformity.
The system integrator must issue a declaration of conformity for the complete
system in accordance with the Machinery Directive. The declaration of conformity forms the basis for the CE mark for the system. The industrial robot must
be operated in accordance with the applicable national laws, regulations and
standards.
The robot controller is CE certified under the EMC Directive and the Low Voltage Directive.
Declaration of
incorporation
The industrial robot as partly completed machinery is supplied with a declaration of incorporation in accordance with Annex II B of the EC Machinery Directive 2006/42/EC. The assembly instructions and a list of essential
requirements complied with in accordance with Annex I are integral parts of
this declaration of incorporation.
The declaration of incorporation declares that the start-up of the partly completed machinery remains impermissible until the partly completed machinery
has been incorporated into machinery, or has been assembled with other parts
to form machinery, and this machinery complies with the terms of the EC Machinery Directive, and the EC declaration of conformity is present in accordance with Annex II A.
The declaration of incorporation, together with its annexes, remains with the
system integrator as an integral part of the technical documentation of the
complete machinery.
3.1.4
Terms used
STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 602041:2006.
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3 Safety
Term
Description
Axis range
Range of each axis, in degrees or millimeters, within which it may move.
The axis range must be defined for each axis.
Stopping distance
Stopping distance = reaction distance + braking distance
Workspace
The manipulator is allowed to move within its workspace. The workspace is derived from the individual axis ranges.
Operator
(User)
The user of the industrial robot can be the management, employer or
delegated person responsible for use of the industrial robot.
Danger zone
The danger zone consists of the workspace and the stopping distances.
KCP
The KCP (KUKA Control Panel) teach pendant has all the operator control and display functions required for operating and programming the
industrial robot.
The stopping distance is part of the danger zone.
The KCP variant for the KR C4 is called KUKA smartPAD. The general
term “KCP”, however, is generally used in this documentation.
Manipulator
The robot arm and the associated electrical installations
Safety zone
The safety zone is situated outside the danger zone.
Safe operational stop
The safe operational stop is a standstill monitoring function. It does not
stop the robot motion, but monitors whether the robot axes are stationary. If these are moved during the safe operational stop, a safety stop
STOP 0 is triggered.
The safe operational stop can also be triggered externally.
When a safe operational stop is triggered, the robot controller sets an
output to the field bus. The output is set even if not all the axes were stationary at the time of triggering, thereby causing a safety stop STOP 0 to
be triggered.
Safety STOP 0
A stop that is triggered and executed by the safety controller. The safety
controller immediately switches off the drives and the power supply to
the brakes.
Safety STOP 1
A stop that is triggered and monitored by the safety controller. The braking process is performed by the non-safety-oriented part of the robot
controller and monitored by the safety controller. As soon as the manipulator is at a standstill, the safety controller switches off the drives and
the power supply to the brakes.
Note: This stop is called safety STOP 0 in this document.
When a safety STOP 1 is triggered, the robot controller sets an output to
the field bus.
The safety STOP 1 can also be triggered externally.
Note: This stop is called safety STOP 1 in this document.
Safety STOP 2
A stop that is triggered and monitored by the safety controller. The braking process is performed by the non-safety-oriented part of the robot
controller and monitored by the safety controller. The drives remain activated and the brakes released. As soon as the manipulator is at a standstill, a safe operational stop is triggered.
When a safety STOP 2 is triggered, the robot controller sets an output to
the field bus.
The safety STOP 2 can also be triggered externally.
Note: This stop is called safety STOP 2 in this document.
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KUKA System Software 8.2
Term
Description
Stop category 0
The drives are deactivated immediately and the brakes are applied. The
manipulator and any external axes (optional) perform path-oriented
braking.
Note: This stop category is called STOP 0 in this document.
Stop category 1
The manipulator and any external axes (optional) perform path-maintaining braking. The drives are deactivated after 1 s and the brakes are
applied.
Stop category 2
The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a pathmaintaining braking ramp.
Note: This stop category is called STOP 1 in this document.
Note: This stop category is called STOP 2 in this document.
System integrator
(plant integrator)
System integrators are people who safely integrate the industrial robot
into a complete system and commission it.
T1
Test mode, Manual Reduced Velocity ( & lt; = 250 mm/s)
T2
Test mode, Manual High Velocity ( & gt; 250 mm/s permissible)
External axis
Motion axis which is not part of the manipulator but which is controlled
using the robot controller, e.g. KUKA linear unit, turn-tilt table, Posiflex.
3.2
Personnel
The following persons or groups of persons are defined for the industrial robot:
User
Personnel
All persons working with the industrial robot must have read and understood the industrial robot documentation, including the safety
chapter.
User
The user must observe the labor laws and regulations. This includes e.g.:
Personnel
The user must comply with his monitoring obligations.
The user must carry out instructions at defined intervals.
Personnel must be instructed, before any work is commenced, in the type of
work involved and what exactly it entails as well as any hazards which may exist. Instruction must be carried out regularly. Instruction is also required after
particular incidents or technical modifications.
Personnel includes:
System integrator
Operators, subdivided into:
Start-up, maintenance and service personnel
Operating personnel
Cleaning personnel
Installation, exchange, adjustment, operation, maintenance and repair must be performed only as specified in the operating or assembly
instructions for the relevant component of the industrial robot and only
by personnel specially trained for this purpose.
System integrator
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The industrial robot is safely integrated into a complete system by the system
integrator.
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3 Safety
The system integrator is responsible for the following tasks:
Connecting the industrial robot
Performing risk assessment
Implementing the required safety functions and safeguards
Issuing the declaration of conformity
Attaching the CE mark
Operator
Installing the industrial robot
Creating the operating instructions for the complete system
The operator must meet the following preconditions:
Example
The operator must be trained for the work to be carried out.
Work on the industrial robot must only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and
experience, and their familiarization with the relevant standards, are able
to assess the work to be carried out and detect any potential hazards.
The tasks can be distributed as shown in the following table.
Tasks
Operator
Programmer
System integrator
Switch robot controller
on/off
x
x
x
Start program
x
x
x
Select program
x
x
x
Select operating mode
x
x
x
Calibration
(tool, base)
x
x
Master the manipulator
x
x
Configuration
x
x
Programming
x
x
Start-up
x
Maintenance
x
Repair
x
Decommissioning
x
Transportation
x
Work on the electrical and mechanical equipment of the industrial robot may only be carried out by specially trained personnel.
3.3
Workspace, safety zone and danger zone
Workspaces are to be restricted to the necessary minimum size. A workspace
must be safeguarded using appropriate safeguards.
The safeguards (e.g. safety gate) must be situated inside the safety zone. In
the case of a stop, the manipulator and external axes (optional) are braked
and come to a stop within the danger zone.
The danger zone consists of the workspace and the stopping distances of the
manipulator and external axes (optional). It must be safeguarded by means of
physical safeguards to prevent danger to persons or the risk of material damage.
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KUKA System Software 8.2
Fig. 3-1: Example of axis range A1
1
3
Stopping distance
2
3.4
Workspace
Manipulator
4
Safety zone
Triggers for stop reactions
Stop reactions of the industrial robot are triggered in response to operator actions or as a reaction to monitoring functions and error messages. The following tables show the different stop reactions according to the operating mode
that has been set.
Trigger
Start key released
T1, T2
AUT, AUT EXT
STOP 2
-
STOP key pressed
STOP 2
Drives OFF
STOP 1
“Motion enable” input
drops out
STOP 2
Robot controller switched
off (power failure)
STOP 0
Internal error in nonsafety-oriented part of the
robot controller
STOP 0 or STOP 1
(dependent on the cause of the error)
Operating mode changed
during operation
Safety stop 2
Safety gate opened (operator safety)
-
Safety stop 1
Enabling switch released
Safety stop 2
-
Enabling switch pressed
fully down or error
Safety stop 1
-
E-STOP pressed
Error in safety controller
or periphery of the safety
controller
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Safety stop 1
Safety stop 0
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3 Safety
3.5
Safety functions
3.5.1
Overview of the safety functions
The following safety functions are present in the industrial robot:
Mode selection
Operator safety (= connection for the guard interlock)
EMERGENCY STOP device
Enabling device
External safe operational stop
External safety stop 1
External safety stop 2
Velocity monitoring in T1
The safety functions of the industrial robot have the following performance:
Category 3 and Performance Level d in accordance with EN ISO 138491:2008. This corresponds to SIL 2 and HFT 1 in accordance with EN 62061.
This performance only applies under the following conditions, however:
The EMERGENCY STOP button is pressed at least once every 6 months.
The following components are involved in the safety functions:
Safety controller in the control PC
KUKA Control Panel (KUKA smartPAD)
Cabinet Control Unit (CCU)
Resolver Digital Converter (RDC)
KUKA Power Pack (KPP)
KUKA Servo Pack (KSP)
Safety Interface Board (SIB) (if used)
There are also interfaces to components outside the industrial robot and to
other robot controllers.
In the absence of operational safety functions and safeguards, the industrial robot can cause personal injury or
material damage. If safety functions or safeguards are dismantled or deactivated, the industrial robot may not be operated.
During system planning, the safety functions of the overall system
must also be planned and designed. The industrial robot must be integrated into this safety system of the overall system.
3.5.2
Safety controller
The safety controller is a unit inside the control PC. It links safety-relevant signals and safety-relevant monitoring functions.
Safety controller tasks:
Switching off the drives; applying the brakes
Monitoring the braking ramp
Standstill monitoring (after the stop)
Velocity monitoring in T1
Evaluation of safety-relevant signals
Setting of safety-oriented outputs
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KUKA System Software 8.2
3.5.3
Mode selection
The industrial robot can be operated in the following modes:
Manual Reduced Velocity (T1)
Manual High Velocity (T2)
Automatic (AUT)
Automatic External (AUT EXT)
Do not change the operating mode while a program is running. If the
operating mode is changed during program execution, the industrial
robot is stopped with a safety stop 2.
Operating mode
Use
Velocities
T1
For test operation, programming and teaching
Programmed velocity, maximum 250 mm/s
Jog mode:
Jog velocity, maximum 250 mm/
s
T2
Program verification:
For test operation
Program verification:
Programmed velocity
AUT
AUT EXT
3.5.4
Jog mode: Not possible
For industrial robots
without higher-level
controllers
Program mode:
Jog mode: Not possible
For industrial robots
with higher-level controllers, e.g. PLC
Program mode:
Programmed velocity
Programmed velocity
Jog mode: Not possible
Operator safety
The operator safety signal is used for interlocking physical safeguards, e.g.
safety gates. Automatic operation is not possible without this signal. In the
event of a loss of signal during automatic operation (e.g. safety gate is
opened), the manipulator stops with a safety stop 1.
Operator safety is not active in the test modes T1 (Manual Reduced Velocity)
and T2 (Manual High Velocity).
Following a loss of signal, automatic operation must not
be resumed merely by closing the safeguard; it must first
additionally be acknowledged. It is the responsibility of the system integrator
to ensure this. This is to prevent automatic operation from being resumed inadvertently while there are still persons in the danger zone, e.g. due to the
safety gate closing accidentally.
24 / 391
The acknowledgement must be designed in such a way that an actual
check of the danger zone can be carried out first. Acknowledgement
functions that do not allow this (e.g. because they are automatically triggered by closure of the safeguard) are not permissible.
Failure to observe this may result in death to persons, severe physical injuries or considerable damage to property.
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3 Safety
3.5.5
EMERGENCY STOP device
The EMERGENCY STOP device for the industrial robot is the EMERGENCY
STOP button on the KCP. The button must be pressed in the event of a hazardous situation or emergency.
Reactions of the industrial robot if the EMERGENCY STOP button is pressed:
The manipulator and any external axes (optional) are stopped with a safety stop 1.
Before operation can be resumed, the EMERGENCY STOP button must be
turned to release it.
Tools and other equipment connected to the manipulator
must be integrated into the EMERGENCY STOP circuit
on the system side if they could constitute a potential hazard.
Failure to observe this precaution may result in death, severe physical injuries or considerable damage to property.
There must always be at least one external EMERGENCY STOP device installed. This ensures that an EMERGENCY STOP device is available even
when the KCP is disconnected.
( & gt; & gt; & gt; 3.5.7 " External EMERGENCY STOP device " Page 25)
3.5.6
Logging off the higher-level safety controller
If the robot controller is connected to a higher-level safety controller, switching
off the robot controller inevitably terminates this connection.
If an SIB interface is used, this triggers an EMERGENCY STOP for the
overall system.
If the PROFIsafe interface is used, the KUKA safety controller generates
a signal that prevents the higher-level controller from triggering an EMERGENCY STOP for the overall system.
If the PROFIsafe interface is used: In his risk assessment, the system integrator must take into consideration
whether the fact that switching off the robot controller does not trigger an
EMERGENCY STOP of the overall system could constitute a hazard and, if
so, how this hazard can be countered.
Failure to take this into consideration may result in death to persons, severe
physical injuries or considerable damage to property.
If a robot controller is switched off, the E-STOP button on
the KCP is no longer functional. The user is responsible
for ensuring that the KCP is either covered or removed from the system. This
serves to prevent operational and non-operational EMERGENCY STOP facilities from becoming interchanged.
Failure to observe this precaution may result in death to persons, severe
physical injuries or considerable damage to property.
3.5.7
External EMERGENCY STOP device
There must be EMERGENCY STOP devices available at every operator station that can initiate a robot motion or other potentially hazardous situation.
The system integrator is responsible for ensuring this.
There must always be at least one external EMERGENCY STOP device installed. This ensures that an EMERGENCY STOP device is available even
when the KCP is disconnected.
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External EMERGENCY STOP devices are connected via the customer interface. External EMERGENCY STOP devices are not included in the scope of
supply of the industrial robot.
3.5.8
Enabling device
The enabling devices of the industrial robot are the enabling switches on the
KCP.
There are 3 enabling switches installed on the KCP. The enabling switches
have 3 positions:
Not pressed
Center position
Panic position
In the test modes, the manipulator can only be moved if one of the enabling
switches is held in the central position.
Releasing the enabling switch triggers a safety stop 2.
Pressing the enabling switch down fully (panic position) triggers a safety
stop 1.
It is possible, for a short time, to hold 2 enabling switches in the center position simultaneously. This makes it possible to adjust grip from one enabling switch to another one. If 2 enabling switches are held
simultaneously in the center position for a longer period of time, this triggers a safety stop after several seconds.
If an enabling switch malfunctions (jams), the industrial robot can be stopped
using the following methods:
Press the enabling switch down fully
Actuate the EMERGENCY STOP system
Release the Start key
The enabling switches must not be held down by adhesive tape or other means or manipulated in any other
way.
Death, serious physical injuries or major damage to property may result.
3.5.9
External enabling device
External enabling devices are required if it is necessary for more than one person to be in the danger zone of the industrial robot. They are connected to the
robot controller via interface X11 or PROFIsafe.
External enabling devices are not included in the scope of supply of the industrial robot.
3.5.10
External safe operational stop
The safe operational stop can be triggered via an input on the customer interface. The state is maintained as long as the external signal is FALSE. If the
external signal is TRUE, the manipulator can be moved again. No acknowledgement is required.
3.5.11
External safety stop 1 and external safety stop 2
Safety stop 1 and safety stop 2 can be triggered via an input on the customer
interface. The state is maintained as long as the external signal is FALSE. If
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the external signal is TRUE, the manipulator can be moved again. No acknowledgement is required.
3.5.12
Velocity monitoring in T1
The velocity at the TCP is monitored in T1 mode. If, due to an error, the velocity exceeds 250 mm/s, a safety stop 0 is triggered.
3.6
Additional protective equipment
3.6.1
Jog mode
In the operating modes T1 (Manual Reduced Velocity) and T2 (Manual High
Velocity), the robot controller can only execute programs in jog mode. This
means that it is necessary to hold down an enabling switch and the Start key
in order to execute a program.
Pressing the enabling switch down fully (panic position) triggers a safety
stop 1.
3.6.2
Releasing the enabling switch triggers a safety stop 2.
Releasing the Start key triggers a STOP 2.
Software limit switches
The axis ranges of all manipulator and positioner axes are limited by means of
adjustable software limit switches. These software limit switches only serve as
machine protection and must be adjusted in such a way that the manipulator/
positioner cannot hit the mechanical end stops.
The software limit switches are set during commissioning of an industrial robot.
Further information is contained in the operating and programming instructions.
3.6.3
Mechanical end stops
The axis ranges of main axes A1 to A3 and wrist axis A5 of the manipulator
are limited by means of mechanical end stops with buffers.
Additional mechanical end stops can be installed on the external axes.
If the manipulator or an external axis hits an obstruction
or a buffer on the mechanical end stop or axis range limitation, this can result in material damage to the industrial robot. KUKA Roboter GmbH must be consulted before the industrial robot is put back into
operation. ( & gt; & gt; & gt; 15 " KUKA Service " Page 375)
The affected buffer must be replaced with a new one before operation of the
industrial robot is resumed. If a manipulator (or external axis) collides with a
buffer at more than 250 mm/s, the manipulator (or external axis) must be exchanged or recommissioning must be carried out by KUKA Roboter GmbH.
3.6.4
Mechanical axis range limitation (optional)
Some manipulators can be fitted with mechanical axis range limitation in axes
A1 to A3. The adjustable axis range limitation systems restrict the working
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range to the required minimum. This increases personal safety and protection
of the system.
In the case of manipulators that are not designed to be fitted with mechanical
axis range limitation, the workspace must be laid out in such a way that there
is no danger to persons or material property, even in the absence of mechanical axis range limitation.
If this is not possible, the workspace must be limited by means of photoelectric
barriers, photoelectric curtains or obstacles on the system side. There must be
no shearing or crushing hazards at the loading and transfer areas.
This option is not available for all robot models. Information on specific robot models can be obtained from KUKA Roboter GmbH.
3.6.5
Axis range monitoring (optional)
Some manipulators can be fitted with dual-channel axis range monitoring systems in main axes A1 to A3. The positioner axes may be fitted with additional
axis range monitoring systems. The safety zone for an axis can be adjusted
and monitored using an axis range monitoring system. This increases personal safety and protection of the system.
This option is not available for all robot models. Information on specific robot models can be obtained from KUKA Roboter GmbH.
3.6.6
Release device (optional)
Description
The release device can be used to move the manipulator manually after an accident or malfunction. The release device can be used for the main axis drive
motors and, depending on the robot variant, also for the wrist axis drive motors. It is only for use in exceptional circumstances and emergencies (e.g. for
freeing people).
The motors reach temperatures during operation which
can cause burns to the skin. Contact must be avoided.
Appropriate safety precautions must be taken, e.g. protective gloves must be
worn.
Procedure
1. Switch off the robot controller and secure it (e.g. with a padlock) to prevent
unauthorized persons from switching it on again.
2. Remove the protective cap from the motor.
3. Push the release device onto the corresponding motor and move the axis
in the desired direction.
The directions are indicated with arrows on the motors. It is necessary to
overcome the resistance of the mechanical motor brake and any other
loads acting on the axis.
Moving an axis with the release device can damage the
motor brake. This can result in personal injury and material damage. After using the release device, the affected motor must be exchanged.
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3.6.7
Labeling on the industrial robot
All plates, labels, symbols and marks constitute safety-relevant parts of the industrial robot. They must not be modified or removed.
Labeling on the industrial robot consists of:
Identification plates
Warning labels
Safety symbols
Designation labels
Cable markings
Rating plates
Further information is contained in the technical data of the operating
instructions or assembly instructions of the components of the industrial robot.
3.6.8
External safeguards
The access of persons to the danger zone of the industrial robot must be prevented by means of safeguards. It is the responsibility of the system integrator
to ensure this.
Physical safeguards must meet the following requirements:
They meet the requirements of EN 953.
They prevent access of persons to the danger zone and cannot be easily
circumvented.
They are sufficiently fastened and can withstand all forces that are likely
to occur in the course of operation, whether from inside or outside the enclosure.
They do not, themselves, represent a hazard or potential hazard.
The prescribed minimum clearance from the danger zone is maintained.
Safety gates (maintenance gates) must meet the following requirements:
They are reduced to an absolute minimum.
The interlocks (e.g. safety gate switches) are linked to the operator safety
input of the robot controller via safety gate switching devices or safety
PLC.
Switching devices, switches and the type of switching conform to the requirements of Performance Level d and category 3 according to EN ISO
13849-1.
Depending on the risk situation: the safety gate is additionally safeguarded
by means of a locking mechanism that only allows the gate to be opened
if the manipulator is safely at a standstill.
The button for acknowledging the safety gate is located outside the space
limited by the safeguards.
Further information is contained in the corresponding standards and
regulations. These also include EN 953.
Other safety
equipment
Other safety equipment must be integrated into the system in accordance with
the corresponding standards and regulations.
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3.7
Overview of operating modes and safety functions
The following table indicates the operating modes in which the safety functions
are active.
Safety functions
T1
T2
AUT
AUT EXT
Operator safety
-
-
active
active
EMERGENCY STOP device
active
active
active
active
Enabling device
active
active
-
-
Reduced velocity during program verification
active
-
-
-
Jog mode
active
active
-
-
Software limit switches
active
active
active
active
3.8
Safety measures
3.8.1
General safety measures
The industrial robot may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons. Operator
errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial robot
even after the robot controller has been switched off and locked. Incorrect installation (e.g. overload) or mechanical defects (e.g. brake defect) can cause
the manipulator or external axes to sag. If work is to be carried out on a
switched-off industrial robot, the manipulator and external axes must first be
moved into a position in which they are unable to move on their own, whether
the payload is mounted or not. If this is not possible, the manipulator and external axes must be secured by appropriate means.
In the absence of operational safety functions and safeguards, the industrial robot can cause personal injury or
material damage. If safety functions or safeguards are dismantled or deactivated, the industrial robot may not be operated.
Standing underneath the robot arm can cause death or
serious physical injuries. For this reason, standing underneath the robot arm is prohibited!
The motors reach temperatures during operation which
can cause burns to the skin. Contact must be avoided.
Appropriate safety precautions must be taken, e.g. protective gloves must be
worn.
KCP
The user must ensure that the industrial robot is only operated with the KCP
by authorized persons.
If more than one KCP is used in the overall system, it must be ensured that
each KCP is unambiguously assigned to the corresponding industrial robot.
They must not be interchanged.
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The operator must ensure that decoupled KCPs are immediately removed from the system and stored out of
sight and reach of personnel working on the industrial robot. This serves to
prevent operational and non-operational EMERGENCY STOP facilities from
becoming interchanged.
Failure to observe this precaution may result in death, severe physical injuries or considerable damage to property.
External
keyboard,
external mouse
An external keyboard and/or external mouse may only be used if the following
conditions are met:
Start-up or maintenance work is being carried out.
The drives are switched off.
There are no persons in the danger zone.
The KCP must not be used as long as an external keyboard and/or external
mouse are connected.
The external keyboard and/or external mouse must be removed as soon as
the start-up or maintenance work is completed or the KCP is connected.
Faults
The following tasks must be carried out in the case of faults in the industrial
robot:
Indicate the fault by means of a label with a corresponding warning (tagout).
Keep a record of the faults.
Modifications
Switch off the robot controller and secure it (e.g. with a padlock) to prevent
unauthorized persons from switching it on again.
Eliminate the fault and carry out a function test.
After modifications to the industrial robot, checks must be carried out to ensure
the required safety level. The valid national or regional work safety regulations
must be observed for this check. The correct functioning of all safety circuits
must also be tested.
New or modified programs must always be tested first in Manual Reduced Velocity mode (T1).
After modifications to the industrial robot, existing programs must always be
tested first in Manual Reduced Velocity mode (T1). This applies to all components of the industrial robot and includes modifications to the software and
configuration settings.
3.8.2
Transportation
Manipulator
The prescribed transport position of the manipulator must be observed. Transportation must be carried out in accordance with the operating instructions or
assembly instructions of the manipulator.
Robot controller
The robot controller must be transported and installed in an upright position.
Avoid vibrations and impacts during transportation in order to prevent damage
to the robot controller.
Transportation must be carried out in accordance with the operating instructions or assembly instructions of the robot controller.
External axis
(optional)
The prescribed transport position of the external axis (e.g. KUKA linear unit,
turn-tilt table, etc.) must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the external axis.
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3.8.3
Start-up and recommissioning
Before starting up systems and devices for the first time, a check must be carried out to ensure that the systems and devices are complete and operational,
that they can be operated safely and that any damage is detected.
The valid national or regional work safety regulations must be observed for this
check. The correct functioning of all safety circuits must also be tested.
The passwords for logging onto the KUKA System Software as “Expert” and “Administrator” must be changed before start-up and must
only be communicated to authorized personnel.
The robot controller is preconfigured for the specific industrial robot. If cables are interchanged, the manipulator and the external axes (optional) may receive incorrect data and can thus
cause personal injury or material damage. If a system consists of more than
one manipulator, always connect the connecting cables to the manipulators
and their corresponding robot controllers.
If additional components (e.g. cables), which are not part of the scope
of supply of KUKA Roboter GmbH, are integrated into the industrial
robot, the user is responsible for ensuring that these components do
not adversely affect or disable safety functions.
If the internal cabinet temperature of the robot controller
differs greatly from the ambient temperature, condensation can form, which may cause damage to the electrical components. Do not
put the robot controller into operation until the internal temperature of the
cabinet has adjusted to the ambient temperature.
Function test
The following tests must be carried out before start-up and recommissioning:
General test:
It must be ensured that:
The industrial robot is correctly installed and fastened in accordance with
the specifications in the documentation.
There are no foreign bodies or loose parts on the industrial robot.
All required safety equipment is correctly installed and operational.
The power supply ratings of the industrial robot correspond to the local
supply voltage and mains type.
The ground conductor and the equipotential bonding cable are sufficiently
rated and correctly connected.
The connecting cables are correctly connected and the connectors are
locked.
Test of the safety functions:
A function test must be carried out for the following safety functions to ensure
that they are functioning correctly:
External EMERGENCY STOP device (input and output)
Enabling device (in the test modes)
Operator safety
All other safety-relevant inputs and outputs used
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Local EMERGENCY STOP device (= EMERGENCY STOP button on the
KCP)
Other external safety functions
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Test of reduced velocity control:
This test is to be carried out as follows:
1. Program a straight path with the maximum possible velocity.
2. Calculate the length of the path.
3. Execute the path in T1 mode with the override set to 100% and time the
motion with a stopwatch.
It must be ensured that no persons are present within the
danger zone during path execution. Death or severe
physical injuries may result.
4. Calculate the velocity from the length of the path and the time measured
for execution of the motion.
Control of reduced velocity is functioning correctly if the following results are
achieved:
Machine data
The calculated velocity does not exceed 250 mm/s.
The manipulator executes the path as programmed (i.e. in a straight line,
without deviations).
It must be ensured that the rating plate on the robot controller has the same
machine data as those entered in the declaration of incorporation. The machine data on the rating plate of the manipulator and the external axes (optional) must be entered during start-up.
The industrial robot must not be moved if incorrect machine data are loaded. Death, severe physical injuries or
considerable damage to property may otherwise result. The correct machine
data must be loaded.
Following modifications to the machine data, the safety configuration must be
checked.
Further information is contained in the Operating and Programming
Instructions for System Integrators.
Following modifications to the machine data, control of the reduced velocity
must be checked.
3.8.3.1
Start-up mode
Description
The industrial robot can be set to Start-up mode via the smartHMI user interface. In this mode, the manipulator can be moved in T1 or CRR mode in the
absence of the safety periphery. (CRR is an operating mode specifically for
use with SafeOperation.)
If an SIB interface is used:
Start-up mode is always possible if all input signals have the state “logic
zero”. If this is not the case, the robot controller prevents or terminates
Start-up mode.
If the PROFIsafe interface is used:
If a connection to a higher-level safety system exists or is established, the
robot controller prevents or terminates Start-up mode.
Hazards
Possible hazards and risks involved in using Start-up mode:
A person walks into the manipulator’s danger zone.
An unauthorized person moves the manipulator.
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In a hazardous situation, a disabled external EMERGENCY STOP device
is actuated and the manipulator is not shut down.
Additional measures for avoiding risks in Start-up mode:
If there is no safety fence, other measures must be taken to prevent persons from entering the manipulator’s danger zone, e.g. use of warning
tape.
Use
Cover disabled EMERGENCY STOP devices or attach a warning sign indicating that the EMERGENCY STOP device is out of operation.
Use of Start-up mode must be minimized – and avoided where possible –
by means of organizational measures.
Intended use of Start-up mode:
Only service personnel who have received safety instruction may use
Start-up mode.
Start-up in T1 mode or CRR mode when the external safeguards have not
yet been installed or put into operation. The danger zone must be delimited at least by means of warning tape.
Fault localization (periphery fault).
Use of Start-up mode disables all external safeguards.
The service personnel are responsible for ensuring that
there is no-one in or near the danger zone of the manipulator as long as the
safeguards are disabled.
Failure to observe this may result in death to persons, physical injuries or
damage to property.
Misuse
Any use or application deviating from the designated use is deemed to be impermissible misuse. This includes, for example, use by any other personnel.
KUKA Roboter GmbH accepts no liability for damage or injury caused thereby.
The risk lies entirely with the user.
3.8.4
Manual mode
Manual mode is the mode for setup work. Setup work is all the tasks that have
to be carried out on the industrial robot to enable automatic operation. Setup
work includes:
Jog mode
Teach
Programming
Program verification
The following must be taken into consideration in manual mode:
If the drives are not required, they must be switched off to prevent the manipulator or the external axes (optional) from being moved unintentionally.
New or modified programs must always be tested first in Manual Reduced
Velocity mode (T1).
Workpieces, tooling and other objects must not become jammed as a result of the industrial robot motion, nor must they lead to short-circuits or be
liable to fall off.
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The manipulator, tooling or external axes (optional) must never touch or
project beyond the safety fence.
All setup work must be carried out, where possible, from outside the safeguarded area.
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If the setup work has to be carried out inside the safeguarded area, the following must be taken into consideration:
In Manual Reduced Velocity mode (T1):
If it can be avoided, there must be no other persons inside the safeguarded area.
If it is necessary for there to be several persons inside the safeguarded area, the following must be observed:
All persons must have an unimpeded view of the industrial robot.
Each person must have an enabling device.
Eye-contact between all persons must be possible at all times.
The operator must be so positioned that he can see into the danger area
and get out of harm’s way.
In Manual High Velocity mode (T2):
Teaching and programming are not permissible in this operating mode.
Before commencing the test, the operator must ensure that the enabling
devices are operational.
The operator must be positioned outside the danger zone.
3.8.5
This mode may only be used if the application requires a test at a velocity
higher than Manual Reduced Velocity.
There must be no other persons inside the safeguarded area. It is the responsibility of the operator to ensure this.
Simulation
Simulation programs do not correspond exactly to reality. Robot programs created in simulation programs must be tested in the system in Manual Reduced
Velocity mode (T1). It may be necessary to modify the program.
3.8.6
Automatic mode
Automatic mode is only permissible in compliance with the following safety
measures:
All safety equipment and safeguards are present and operational.
There are no persons in the system.
The defined working procedures are adhered to.
If the manipulator or an external axis (optional) comes to a standstill for no apparent reason, the danger zone must not be entered until an EMERGENCY
STOP has been triggered.
3.8.7
Maintenance and repair
After maintenance and repair work, checks must be carried out to ensure the
required safety level. The valid national or regional work safety regulations
must be observed for this check. The correct functioning of all safety circuits
must also be tested.
The purpose of maintenance and repair work is to ensure that the system is
kept operational or, in the event of a fault, to return the system to an operational state. Repair work includes troubleshooting in addition to the actual repair
itself.
The following safety measures must be carried out when working on the industrial robot:
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Carry out work outside the danger zone. If work inside the danger zone is
necessary, the user must define additional safety measures to ensure the
safe protection of personnel.
Switch off the industrial robot and secure it (e.g. with a padlock) to prevent
it from being switched on again. If it is necessary to carry out work with the
robot controller switched on, the user must define additional safety measures to ensure the safe protection of personnel.
If it is necessary to carry out work with the robot controller switched on, this
may only be done in operating mode T1.
Label the system with a sign indicating that work is in progress. This sign
must remain in place, even during temporary interruptions to the work.
The EMERGENCY STOP systems must remain active. If safety functions
or safeguards are deactivated during maintenance or repair work, they
must be reactivated immediately after the work is completed.
Before work is commenced on live parts of the robot system, the main switch must be turned off and secured
against being switched on again. The system must then be checked to ensure that it is deenergized.
It is not sufficient, before commencing work on live parts, to execute an
EMERGENCY STOP or a safety stop, or to switch off the drives, as this does
not disconnect the robot system from the mains power supply in the case of
the drives of the new generation. Parts remain energized. Death or severe
physical injuries may result.
Faulty components must be replaced using new components with the same
article numbers or equivalent components approved by KUKA Roboter GmbH
for this purpose.
Cleaning and preventive maintenance work is to be carried out in accordance
with the operating instructions.
Robot controller
Even when the robot controller is switched off, parts connected to peripheral
devices may still carry voltage. The external power sources must therefore be
switched off if work is to be carried out on the robot controller.
The ESD regulations must be adhered to when working on components in the
robot controller.
Voltages in excess of 50 V (up to 780 V) can be present in various components
for several minutes after the robot controller has been switched off! To prevent
life-threatening injuries, no work may be carried out on the industrial robot in
this time.
Water and dust must be prevented from entering the robot controller.
Counterbalancing system
Some robot variants are equipped with a hydropneumatic, spring or gas cylinder counterbalancing system.
The hydropneumatic and gas cylinder counterbalancing systems are pressure
equipment and, as such, are subject to obligatory equipment monitoring. Depending on the robot variant, the counterbalancing systems correspond to category 0, II or III, fluid group 2, of the Pressure Equipment Directive.
The user must comply with the applicable national laws, regulations and standards pertaining to pressure equipment.
Inspection intervals in Germany in accordance with Industrial Safety Order,
Sections 14 and 15. Inspection by the user before commissioning at the installation site.
The following safety measures must be carried out when working on the counterbalancing system:
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Hazardous
substances
The manipulator assemblies supported by the counterbalancing systems
must be secured.
Work on the counterbalancing systems must only be carried out by qualified personnel.
The following safety measures must be carried out when handling hazardous
substances:
Avoid prolonged and repeated intensive contact with the skin.
Avoid breathing in oil spray or vapors.
Clean skin and apply skin cream.
To ensure safe use of our products, we recommend that our customers regularly request up-to-date safety data sheets from the manufacturers of hazardous substances.
3.8.8
Decommissioning, storage and disposal
The industrial robot must be decommissioned, stored and disposed of in accordance with the applicable national laws, regulations and standards.
3.8.9
Safety measures for “single point of control”
Overview
If certain components in the industrial robot are operated, safety measures
must be taken to ensure complete implementation of the principle of “single
point of control” (SPOC).
Components:
Submit interpreter
PLC
OPC Server
Remote control tools
Tools for configuration of bus systems with online functionality
KUKA.RobotSensorInterface
External keyboard/mouse
The implementation of additional safety measures may be required.
This must be clarified for each specific application; this is the responsibility of the system integrator, programmer or user of the system.
Since only the system integrator knows the safe states of actuators in the periphery of the robot controller, it is his task to set these actuators to a safe
state, e.g. in the event of an EMERGENCY STOP.
T1, T2
In the test modes, the components referred to above (with the exception of the
external keyboard/mouse) may only access the industrial robot if the following
signals have the following states:
Signal
$USER_SAF
TRUE
$SPOC_MOTION_ENABLE
Submit interpreter, PLC
State required for SPOC
TRUE
If motions, (e.g. drives or grippers) are controlled with the Submit interpreter
or the PLC via the I/O system, and if they are not safeguarded by other means,
then this control will take effect even in T1 and T2 modes or while an EMERGENCY STOP is active.
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If variables that affect the robot motion (e.g. override) are modified with the
Submit interpreter or the PLC, this takes effect even in T1 and T2 modes or
while an EMERGENCY STOP is active.
Safety measures:
In the test modes, the system variable $OV_PRO must not be written to
by the Submit interpreter or the PLC.
Do not modify safety-relevant signals and variables (e.g. operating mode,
EMERGENCY STOP, safety gate contact) via the Submit interpreter or
PLC.
If modifications are nonetheless required, all safety-relevant signals and
variables must be linked in such a way that they cannot be set to a dangerous state by the Submit interpreter or PLC.
OPC server,
remote control
tools
These components can be used with write access to modify programs, outputs
or other parameters of the robot controller, without this being noticed by any
persons located inside the system.
Safety measures:
KUKA stipulates that these components are to be used exclusively for diagnosis and visualization.
Programs, outputs or other parameters of the robot controller must not be
modified using these components.
Tools for configuration of bus
systems
If these components are used, outputs that could cause a hazard must be
determined in a risk assessment. These outputs must be designed in such
a way that they cannot be set without being enabled. This can be done using an external enabling device, for example.
If these components have an online functionality, they can be used with write
access to modify programs, outputs or other parameters of the robot controller, without this being noticed by any persons located inside the system.
WorkVisual from KUKA
Tools from other manufacturers
Safety measures:
External
keyboard/mouse
In the test modes, programs, outputs or other parameters of the robot controller must not be modified using these components.
These components can be used to modify programs, outputs or other parameters of the robot controller, without this being noticed by any persons located
inside the system.
Safety measures:
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Only use one operator console at each robot controller.
If the KCP is being used for work inside the system, remove any keyboard
and mouse from the robot controller beforehand.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
3 Safety
3.9
Applied norms and regulations
Name
Definition
Edition
2006/42/EC
Machinery Directive:
2006
Directive 2006/42/EC of the European Parliament and of
the Council of 17 May 2006 on machinery, and amending
Directive 95/16/EC (recast)
2004/108/EC
EMC Directive:
2004
Directive 2004/108/EC of the European Parliament and of
the Council of 15 December 2004 on the approximation of
the laws of the Member States relating to electromagnetic
compatibility and repealing Directive 89/336/EEC
97/23/EC
Pressure Equipment Directive:
1997
Directive 97/23/EC of the European Parliament and of the
Council of 29 May 1997 on the approximation of the laws
of the Member States concerning pressure equipment
(Only applicable for robots with hydropneumatic counterbalancing system.)
EN ISO 13850
Safety of machinery:
EN ISO 13849-1
Safety of machinery:
2008
Emergency stop - Principles for design
2008
Safety-related parts of control systems - Part 1: General
principles of design
EN ISO 13849-2
Safety of machinery:
2008
Safety-related parts of control systems - Part 2: Validation
EN ISO 12100-1
Safety of machinery:
2003
Basic concepts, general principles for design - Part 1:
Basic terminology, methodology
EN ISO 12100-2
Safety of machinery:
2003
Basic concepts, general principles for design - Part 2:
Technical principles
EN ISO 10218-1
Industrial robots:
2008
Safety
EN 614-1
Safety of machinery:
2006
Ergonomic design principles - Part 1: Terms and general
principles
EN 61000-6-2
Electromagnetic compatibility (EMC):
2005
Part 6-2: Generic standards; Immunity for industrial environments
EN 61000-6-4
Electromagnetic compatibility (EMC):
2007
Part 6-4: Generic standards; Emission standard for industrial environments
EN 60204-1
Safety of machinery:
2006
Electrical equipment of machines - Part 1: General
requirements
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
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4 Operation
4
Operation
4.1
KUKA smartPAD teach pendant
4.1.1
Front view
Function
The smartPAD is the teach pendant for the industrial robot. The smartPAD has
all the operator control and display functions required for operating and programming the industrial robot.
The smartPAD has a touch screen: the smartHMI can be operated with a finger or stylus. An external mouse or external keyboard is not necessary.
The general term “KCP” (KUKA Control Panel) is often used in this
documentation for the smartPAD.
Overview
Fig. 4-1: KUKA smartPAD, front view
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KUKA System Software 8.2
Item
1
Description
Button for disconnecting the smartPAD
( & gt; & gt; & gt; 4.1.3 " Disconnecting and connecting the smartPAD "
Page 44)
2
Keyswitch for calling the connection manager. The switch can only
be turned if the key is inserted.
The connection manager is used to change the operating mode.
( & gt; & gt; & gt; 4.10 " Changing operating mode " Page 53)
3
EMERGENCY STOP button. Stops the robot in hazardous situations. The EMERGENCY STOP button locks itself in place when it
is pressed.
4
Space Mouse. For moving the robot manually.
( & gt; & gt; & gt; 4.12 " Jogging the robot " Page 55)
5
Jog keys. For moving the robot manually.
( & gt; & gt; & gt; 4.12 " Jogging the robot " Page 55)
6
Key for setting the program override
7
Key for setting the jog override
8
Main menu key. Shows the menu items on the smartHMI.
( & gt; & gt; & gt; 4.4 " Calling the main menu " Page 48)
9
Status keys. The status keys are used primarily for setting parameters in technology packages. Their exact function depends on the
technology packages installed.
10
Start key. The Start key is used to start a program.
11
Start backwards key. The Start backwards key is used to start a
program backwards. The program is executed step by step.
12
STOP key. The STOP key is used to stop a program that is running.
13
Keyboard key
Displays the keyboard. It is generally not necessary to press this
key to display the keyboard, as the smartHMI detects when keyboard input is required and displays the keyboard automatically.
( & gt; & gt; & gt; 4.2.2 " Keypad " Page 47)
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4 Operation
4.1.2
Rear view
Overview
Fig. 4-2: KUKA smartPAD, rear view
1
4
USB connection
Start key (green)
5
Enabling switch
3
Description
Enabling switch
2
Enabling switch
6
Identification plate
Element
Description
Identification
plate
Identification plate
Start key
The Start key is used to start a program.
The enabling switch has 3 positions:
Enabling
switch
Not pressed
Center position
Panic position
The enabling switch must be held in the center position
in operating modes T1 and T2 in order to be able to jog
the manipulator.
In the operating modes Automatic and Automatic External, the enabling switch has no function.
USB connection
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
The USB connection is used, for example, for archiving
and restoring data.
Only for FAT32-formatted USB sticks.
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KUKA System Software 8.2
4.1.3
Disconnecting and connecting the smartPAD
Description
The smartPAD can be disconnected while the robot controller is running.
If the smartPAD is disconnected, the system can no longer be switched off by means of the EMERGENCY
STOP button on the smartPAD. For this reason, an external EMERGENCY
STOP must be connected to the robot controller.
The operator must ensure that disconnected smartPADs are immediately removed from the system and stored out of sight and reach of personnel working on the industrial robot. This serves to prevent operational and nonoperational EMERGENCY STOP facilities from becoming interchanged.
Failure to observe these precautions may result in death to persons, severe
physical injuries or considerable damage to property.
Procedure
Disconnection:
1. Press the disconnect button on the smartPAD.
A message and a counter are displayed on the smartHMI. The counter
runs for 30 s. During this time, the smartPAD can be disconnected from
the robot controller.
If the smartPAD is disconnected without the counter running, this triggers an EMERGENCY STOP. The EMERGENCY STOP can only be
canceled by plugging the smartPAD back in.
2. Disconnect the smartPAD from the robot controller.
If the counter expires without the smartPAD having been disconnected,
this has no effect. The disconnect button can be pressed again at any time
to display the counter again.
Connection:
Connect the smartPAD to the robot controller.
A smartPAD can be connected at any time. Precondition: Same smartPAD
variant as the disconnected device. The EMERGENCY STOP and enabling
switches are operational again 30 s after connection. The smartHMI is automatically displayed again. (This may take longer than 30 s.)
The connected smartPAD assumes the current operating mode of the robot
controller.
The current operating mode is not, in all cases, the same as that before the smartPAD was disconnected: if the robot controller is part of
a RoboTeam, the operating mode may have been changed after disconnection, e.g. by the master.
The user connecting a smartPAD to the robot controller
must subsequently stay with the smartPAD for at least
30 s, i.e. until the EMERGENCY STOP and enabling switches are operational once again. This prevents another user from trying to activate a non-operational EMERGENCY STOP in an emergency situation, for example.
Failure to observe this may result in death to persons, physical injuries or
damage to property.
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4 Operation
4.2
KUKA smartHMI user interface
Fig. 4-3: KUKA smartHMI user interface
Item
Description
1
Status bar ( & gt; & gt; & gt; 4.2.1 " Status bar " Page 46)
2
Message counter
The message counter indicates how many messages of each message type are active. Touching the message counter enlarges the
display.
3
Message window
By default, only the last message is displayed. Touching the message window expands it so that all active messages are displayed.
An acknowledgeable message can be acknowledged with OK. All
acknowledgeable messages can be acknowledged at once with
All OK.
4
Space Mouse status indicator
This indicator shows the current coordinate system for jogging with
the Space Mouse. Touching the indicator displays all coordinate
systems, allowing a different one to be selected.
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KUKA System Software 8.2
Item
5
Description
Space Mouse alignment indicator
Touching this indicator opens a window in which the current alignment of the Space Mouse is indicated and can be changed.
( & gt; & gt; & gt; 4.12.8 " Defining the alignment of the Space Mouse "
Page 63)
6
Jog keys status indicator
This indicator shows the current coordinate system for jogging with
the jog keys. Touching the indicator displays all coordinate systems, allowing a different one to be selected.
7
Jog key labels
If axis-specific jogging is selected, the axis numbers are displayed
here (A1, A2, etc.). If Cartesian jogging is selected, the coordinate
system axes are displayed here (X, Y, Z, A, B, C).
Touching the label causes the selected kinematics group to be displayed.
8
Program override
( & gt; & gt; & gt; 7.5.4 " Setting the program override (POV) " Page 209)
9
Jog override
( & gt; & gt; & gt; 4.12.3 " Setting the jog override (HOV) " Page 60)
10
Button bar. The buttons change dynamically and always refer to
the window that is currently active in the smartHMI.
At the right-hand end is the Edit button. This can be used to call
numerous commands relating to the Navigator.
11
Clock
The clock displays the system time. Touching the clock displays
the system time in digital format, together with the current date.
12
WorkVisual icon
If no project can be opened, the icon has a small red X in the bottom left-hand corner. This is the case, for example, if the files belonging to the project are missing. In such a case, the system is
only partially available, e.g. the safety configuration cannot be
opened.
4.2.1
Status bar
The status bar indicates the status of certain central settings of the industrial
robot. In most cases, touching the display opens a window in which the settings can be modified.
Overview
Fig. 4-4: KUKA smartHMI status bar
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4 Operation
Item
1
Description
Main menu key. Shows the menu items on the smartHMI.
( & gt; & gt; & gt; 4.4 " Calling the main menu " Page 48)
2
Robot name. The robot name can be changed.
3
If a program has been selected, the name is displayed here.
4
Submit interpreter status indicator
5
Drives status indicator. The drives can be switched on or off here.
( & gt; & gt; & gt; 4.15.14 " Displaying/editing robot data " Page 78)
( & gt; & gt; & gt; 11 " Submit interpreter " Page 351)
( & gt; & gt; & gt; 7.5.5 " Switching drives on/off " Page 209)
6
Robot interpreter status indicator. Programs can be reset or canceled here.
( & gt; & gt; & gt; 7.5.6 " Robot interpreter status indicator " Page 209)
( & gt; & gt; & gt; 7.2.1 " Selecting and deselecting a program " Page 202)
( & gt; & gt; & gt; 7.5.11 " Resetting a program " Page 211)
7
Current operating mode
( & gt; & gt; & gt; 4.10 " Changing operating mode " Page 53)
8
POV/HOV status indicator. Indicates the current program override
and the current jog override.
( & gt; & gt; & gt; 7.5.4 " Setting the program override (POV) " Page 209)
( & gt; & gt; & gt; 4.12.3 " Setting the jog override (HOV) " Page 60)
9
Program run mode status indicator. Indicates the current program
run mode.
( & gt; & gt; & gt; 7.5.2 " Program run modes " Page 208)
10
Tool/base status indicator. Indicates the current tool and base.
11
Incremental jogging status indicator.
( & gt; & gt; & gt; 4.12.4 " Selecting the tool and base " Page 60)
( & gt; & gt; & gt; 4.12.10 " Incremental jogging " Page 65)
4.2.2
Keypad
The smartPAD has a touch screen: the smartHMI can be operated with a finger or stylus.
There is a keypad on the smartHMI for entering letters and numbers. The smartHMI detects when the entry of letters or numbers is required and automatically displays the keypad.
The keypad only ever displays the characters that are required. If, for example,
a box is edited in which only numbers can be entered, then only numbers are
displayed and not letters.
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KUKA System Software 8.2
Fig. 4-5: Example keypad
4.2.3
Minimizing KUKA smartHMI
Procedure
4.3
User group " Expert " .
Precondition
Operating mode T1 or T2.
Select Start-up & gt; Service & gt; Minimize HMI in the main menu.
Switching on the robot controller and starting the KSS
Procedure
Turn the main switch on the robot controller to ON.
The operating system and the KSS start automatically.
If the KSS does not start automatically, e.g. because the Startup function has
been disabled, execute the file StartKRC.exe in the directory C:\KRC.
If the robot controller is logged onto the network, the start may take longer.
4.4
Calling the main menu
Procedure
Press “Main menu” key on the KCP. The Main menu window is opened.
The display is always the same as that which was in the window before it
was last closed.
Description
Properties of the Main Menu window:
The main menu is displayed in the left-hand column.
Touching a menu item that contains an arrow opens the corresponding
submenu (e.g. Configure).
Depending on how many nested submenus are open, the Main Menu column may no longer be visible, with only the submenus remaining visible.
The arrow key in the top right-hand corner closes the most recently
opened submenu.
The Home key in the top right-hand corner closes all open submenus.
The most recently selected menu items are displayed in the bottom section (maximum 6).
This makes it possible to select these menu items again directly without
first having to close other submenus that might be open.
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The white cross on the left-hand side closes the window.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
4 Operation
Fig. 4-6: Example: Configuration submenu is open.
4.5
Defining the start type for KSS
This function defines how the KSS starts after a power failure. A power failure
and start are generally triggered by switching the main switch on the robot controller off and on.
By default, the KSS boots with Hibernate.
Precondition
Procedure
1. In the main menu, select Shutdown. A window opens.
Expert user group
2. Select the start type: Cold start or Hibernate.
( & gt; & gt; & gt; " Start types " Page 52)
3. Close the window. The selected start type is applied.
Following installation or update of the KUKA System Software, the robot controller always performs an initial cold start.
4.6
Exiting or restarting KSS
Precondition
For certain options: “Expert” user group
Procedure
1. Select the menu item Shutdown in the main menu.
2. Select the desired options.
3. Press Shut down control PC or Reboot control PC.
4. Confirm the request for confirmation with Yes. The KSS is terminated and
restarted in accordance with the selected option.
After the restart, the following message is displayed:
Cold start of controller
Or, if Reload files has been selected: Initial cold start of controller
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KUKA System Software 8.2
If, on shutting down, the option Reboot control PC was
selected, the main switch on the robot controller must not
be pressed until the reboot has been completed. System files may otherwise
be destroyed.
If this option was not selected on shutting down, the main switch can be
pressed once the controller has shut down.
Description
Fig. 4-7: Shutdown window
Option
Description
Default settings for switching off the controller via main switch
Cold start
After a power failure, the robot controller starts
with a cold start.
(A power failure and start are generally triggered
by switching the main switch on the robot controller off and on.)
Can only be selected in the “Expert” user group.
( & gt; & gt; & gt; " Start types " Page 52)
Hibernate
After a power failure, the robot controller starts
with Hibernate.
Can only be selected in the “Expert” user group.
( & gt; & gt; & gt; " Start types " Page 52)
Power-off delay time
Wait time before the robot controller is shut
down. This ensures that the system does not
immediately shut down, for example, in the event
of very brief power failures, but bridges the
power failure.
Can only be changed in the “Expert” user group.
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4 Operation
Option
Description
Settings valid next time the system is switched off using the main
switch
These settings only apply to the next start.
Force cold start
Activated: The next start is a cold start.
Reload files
Activated: The next start is an initial cold start.
Only available if Hibernate has been selected.
This option must be selected in the following
cases:
If XML files have been changed directly, i.e.
the user has opened the file and modified it.
(Any other changes to XML files, e.g. if the robot controller modifies them in the background, are irrelevant.)
If hardware components are to be exchanged
after shutdown.
Can only be selected in the “Expert” user group.
Only available if Cold start or Force cold start
has been selected.
Depending on the hardware, the initial cold start
takes approx. 30 to 150 seconds longer than a
normal cold start.
Power-off delay time
Activated: The wait time is adhered to the next
time the system is shut down.
Deactivated: The wait time is ignored the next
time the system is shut down.
Instant actions
Shut down control
PC
Only available in operating modes T1 and T2.
Reboot control PC
Only available in operating modes T1 and T2.
The robot controller is shut down
The robot controller is shut down and then
restarted.
Drive bus
Only available in operating modes T1 and T2.
OFF / ON
The drive bus can be switched off or on.
Drive bus status indicator:
Red: Drive bus is off.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Green: Drive bus is on.
Gray: Status of the drive bus is unknown.
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KUKA System Software 8.2
Start types
Start type
Description
Cold start
After a cold start the robot controller displays the Navigator. No program is selected. The robot controller is
reinitialized, e.g. all user outputs are set to FALSE.
Note: If XML files have been changed directly, i.e. the
user has opened the file and modified it, these changes
are taken into consideration in the case of a cold start
with Reload files. This cold start is called an “initial
cold start”.
In the case of a cold start without Reload files, these
changes are not taken into consideration.
Hibernate
After a start with Hibernate, the previously selected
robot program can be resumed. The state of the kernel
system: programs, block pointer, variable contents and
outputs, is completely restored.
Additionally, all programs that were open parallel to the
robot controller are reopened and have the same state
that they had before the system was shut down. The
last state of Windows is also restored.
4.7
Switching the robot controller off
Procedure
Turn the main switch on the robot controller to OFF.
The robot controller automatically backs up data.
The main switch on the robot controller must not be operated if the KSS has been exited with the option Reboot
control PC and the reboot has not yet been completed. System files may
otherwise be destroyed.
4.8
Setting the user interface language
Procedure
1. In the main menu, select Configuration & gt; Miscellaneous & gt; Language.
2. Select the desired language. Click OK to confirm.
4.9
Changing user group
Procedure
1. Select Configuration & gt; User group in the main menu. The current user
group is displayed.
2. Press Default to switch to the default user group. (Default is not available
if the default user group is already selected.)
Press Login... to switch to a different user group. Select the desired user
group.
3. If prompted: Enter password and confirm with Log-on.
Description
Different functions are available in the KSS, depending on the user group. The
following user groups are available:
Operator
User group for the operator. This is the default user group.
User
User group for the operator. (By default, the user groups “Operator” and
“User” are defined for the same target group.)
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4 Operation
Expert
User group for the programmer. This user group is protected by means of
a password.
Safety recovery
This user group can activate and configure the safety configuration of the
robot. This user group is protected by means of a password.
Safety maintenance
This user group is only relevant if KUKA.SafeOperation or KUKA.SafeRangeMonitoring is used. The user group is protected by means of a
password.
Administrator
The range of functions is the same as that for the user group “Expert”. It is
additionally possible, in this user group, to integrate plug-ins into the robot
controller.
This user group is protected by means of a password.
The default password is “kuka”. The password can be changed.
( & gt; & gt; & gt; 6.5 " Changing the password " Page 143)
When the system is booted, the default user group is selected.
If the mode is switched to AUT or AUT EXT, the robot controller switches to
the default user group for safety reasons. If a different user group is desired,
this must be selected subsequently.
If no actions are carried out in the user interface within a certain period of time,
the robot controller switches to the default user group for safety reasons. The
default setting is 300 s.
4.10
Changing operating mode
Do not change the operating mode while a program is running. If the
operating mode is changed during program execution, the industrial
robot is stopped with a safety stop 2.
Precondition
The robot controller is not executing a program.
Procedure
Key for the switch for calling the connection manager
1. On the smartPAD, turn the switch for the connection manager. The connection manager is displayed.
2. Select the operating mode.
3. Return the switch for the connection manager to its original position.
The selected operating mode is displayed in the status bar of the smartPAD.
Operating mode
Use
Velocities
T1
For test operation, programming and teaching
Programmed velocity, maximum 250 mm/s
For test operation
Program verification:
Programmed velocity
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Jog mode:
Jog velocity, maximum 250 mm/
s
T2
Program verification:
Jog mode: Not possible
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KUKA System Software 8.2
Operating mode
AUT
AUT EXT
4.11
Use
Velocities
For industrial robots
without higher-level
controllers
Jog mode: Not possible
For industrial robots
with higher-level controllers, e.g. PLC
Program mode:
Program mode:
Programmed velocity
Programmed velocity
Jog mode: Not possible
Coordinate systems
Overview
The following Cartesian coordinate systems are defined in the robot controller:
WORLD
ROBROOT
BASE
TOOL
Fig. 4-8: Overview of coordinate systems
Description
WORLD
The WORLD coordinate system is a permanently defined Cartesian coordinate system. It is the root coordinate system for the ROBROOT and BASE coordinate systems.
By default, the WORLD coordinate system is located at the robot base.
ROBROOT
The ROBROOT coordinate system is a Cartesian coordinate system, which is
always located at the robot base. It defines the position of the robot relative to
the WORLD coordinate system.
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By default, the ROBROOT coordinate system is identical to the WORLD coordinate system. $ROBROOT allows the definition of an offset of the robot relative to the WORLD coordinate system.
BASE
The BASE coordinate system is a Cartesian coordinate system that defines
the position of the workpiece. It is relative to the WORLD coordinate system.
By default, the BASE coordinate system is identical to the WORLD coordinate
system. It is offset to the workpiece by the user.
( & gt; & gt; & gt; 5.11.3 " Base calibration " Page 109)
TOOL
The TOOL coordinate system is a Cartesian coordinate system which is located at the tool center point.
By default, the origin of the TOOL coordinate system is located at the flange
center point. (In this case it is called the FLANGE coordinate system.) The
TOOL coordinate system is offset to the tool center point by the user.
( & gt; & gt; & gt; 5.11.2 " Tool calibration " Page 102)
Angles of rotation of the robot coordinate systems
Angle
Rotation about axis
Angle A
Rotation about the Z axis
Angle B
4.12
Rotation about the Y axis
Angle C
Rotation about the X axis
Jogging the robot
Description
There are 2 ways of jogging the robot:
Cartesian jogging
The TCP is jogged in the positive or negative direction along the axes of a
coordinate system.
Axis-specific jogging
Each axis can be moved individually in a positive and negative direction.
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KUKA System Software 8.2
Fig. 4-9: Axis-specific jogging
There are 2 operator control elements that can be used for jogging the robot:
Jog keys
Space Mouse
Overview
Cartesian jogging
Axis-specific jogging
Jog keys
( & gt; & gt; & gt; 4.12.5 " Axis-specific
jogging with the jog keys "
Page 61)
Space
Mouse
4.12.1
( & gt; & gt; & gt; 4.12.6 " Cartesian jogging with the jog keys "
Page 61)
( & gt; & gt; & gt; 4.12.9 " Cartesian jogging with the Space Mouse "
Page 64)
Axis-specific jogging with
the Space Mouse is possible, but is not described
here.
“Jog options” window
Description
All parameters for jogging the robot can be set in the Jogging Options window.
Procedure
Open the Jogging Options window:
1. Open a status indicator on the smartHMI, e.g. the POV status indicator.
(Not possible for the Submit interpreter, Drives and Robot interpreter
status indicators.)
A window opens.
2. Press Options. The Jogging Options window is opened.
For most parameters, it is not necessary to open the Jogging Options window. They can be set directly via the smartHMI status indicators.
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4 Operation
4.12.1.1 “General” tab
Fig. 4-10: General tab
Description
Item
1
Description
Set program override
( & gt; & gt; & gt; 7.5.4 " Setting the program override (POV) " Page 209)
2
Set jog override
( & gt; & gt; & gt; 4.12.3 " Setting the jog override (HOV) " Page 60)
3
Select the program run mode
( & gt; & gt; & gt; 7.5.2 " Program run modes " Page 208)
4.12.1.2 “Keys” tab
Fig. 4-11: Keys tab
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Description
Item
1
Description
Activate jog mode “Jog keys”
( & gt; & gt; & gt; 4.12.2 " Activating the jog mode " Page 60)
2
Select a kinematics group. The kinematics group defines the axes
to which the jog keys refer.
Default: Robot axes (= A1 to A6)
Depending on the system configuration, other kinematics groups
may be available.
( & gt; & gt; & gt; 4.13 " Jogging external axes " Page 66)
3
Select the coordinate system for jogging with the jog keys
4
Incremental jogging
( & gt; & gt; & gt; 4.12.10 " Incremental jogging " Page 65)
4.12.1.3 “Mouse” tab
Fig. 4-12: Mouse tab
Description
Item
1
Description
Activate jog mode “Space Mouse”
( & gt; & gt; & gt; 4.12.2 " Activating the jog mode " Page 60)
2
Configure the Space Mouse
( & gt; & gt; & gt; 4.12.7 " Configuring the Space Mouse " Page 61)
3
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Select the coordinate system for jogging with the Space Mouse
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4.12.1.4 “KCP pos.” tab
Fig. 4-13: Kcp Pos. tab
Description
Item
1
Description
( & gt; & gt; & gt; 4.12.8 " Defining the alignment of the Space Mouse "
Page 63)
4.12.1.5 “Cur. tool/base” tab
Fig. 4-14: Act. Tool/Base tab
Description
Item
1
Description
The current tool is displayed here. A different tool can be selected.
( & gt; & gt; & gt; 4.12.4 " Selecting the tool and base " Page 60)
The display Unknown [?] means that no tool has yet been calibrated.
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Item
2
Description
The current base is displayed here. A different base can be selected.
( & gt; & gt; & gt; 4.12.4 " Selecting the tool and base " Page 60)
The display Unknown [?] means that no base has yet been calibrated.
3
Select the interpolation mode:
4.12.2
Flange: The tool is mounted on the mounting flange.
ext. Tool: The tool is a fixed tool.
Activating the jog mode
Procedure
1. Open the Jogging Options window.
( & gt; & gt; & gt; 4.12.1 " “Jog options” window " Page 56)
2. To activate the jog mode “Jog keys”:
On the Keys tab, activate the Activate Keys check box.
To activate the jog mode “Space Mouse”:
On the Mouse tab, activate the Activate Mouse check box.
Description
4.12.3
Both jog modes “Jog keys” and “Space Mouse” can be activated simultaneously. If the robot is jogged using the keys, the Space Mouse is disabled until
the robot comes to a standstill. If the Space Mouse is actuated, the keys are
disabled.
Setting the jog override (HOV)
Description
Jog override is the velocity of the robot during jogging. It is specified as a percentage and refers to the maximum possible jog velocity. This is 250 mm/s.
Procedure
1. Touch the POV/HOV status indicator. The Overrides window is opened.
2. Set the desired jog override. It can be set using either the plus/minus keys
or by means of the slide controller.
Plus/minus keys: The value can be set to 100%, 75%, 50%, 30%,
10%, 3%, 1%
Slide controller: The override can be adjusted in 1% steps.
3. Touch the POV/HOV status indicator again. (Or touch the area outside the
window.)
The window closes and the selected override value is applied.
The Jog options window can be opened via Options in the Overrides window.
Alternative
procedure
Alternatively, the override can be set using the plus/minus key on the righthand side of the KCP.
The value can be set to 100%, 75%, 50%, 30%, 10%, 3%, 1%.
4.12.4
Selecting the tool and base
Description
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A maximum of 16 TOOL and 32 BASE coordinate systems can be saved in
the robot controller. One tool (TOOL coordinate system) and one base (BASE
coordinate system) must be selected for Cartesian jogging.
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Procedure
1. Touch the Tool/base status indicator. The Act. Tool/Base window is
opened.
2. Select the desired tool and base.
3. The window closes and the selection is applied.
4.12.5
Axis-specific jogging with the jog keys
Precondition
The jog mode “Jog keys” is active.
Procedure
Operating mode T1
1. Select Axes as the coordinate system for the jog keys.
2. Set jog override.
3. Hold down the enabling switch.
Axes A1 to A6 are displayed next to the jog keys.
4. Press the Plus or Minus jog key to move an axis in the positive or negative
direction.
The position of the robot during jogging can be displayed: select Display & gt; Actual position in the main menu.
4.12.6
Cartesian jogging with the jog keys
Precondition
The jog mode “Jog keys” is active.
Operating mode T1
Tool and base have been selected.
( & gt; & gt; & gt; 4.12.4 " Selecting the tool and base " Page 60)
Procedure
1. Select World, Base or Tool as the coordinate system for the jog keys.
2. Set jog override.
3. Hold down the enabling switch.
The following designations are displayed next to the jog keys:
X, Y, Z: for the linear motions along the axes of the selected coordinate
system
A, B, C: for the rotational motions about the axes of the selected coordinate system
4. Press the Plus or Minus jog key to move the robot in the positive or negative direction.
The position of the robot during jogging can be displayed: select Display & gt; Actual position in the main menu.
4.12.7
Configuring the Space Mouse
Procedure
1. Open the Jogging Options window and select the Mouse tab.
( & gt; & gt; & gt; 4.12.1 " “Jog options” window " Page 56)
2. Mouse Settings group:
Dominant check box:
Activate or deactivate dominant mode as desired.
6D/XYZ/ABC option box:
Select whether the TCP is to be moved using translational motions, rotational motions, or both.
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3. Close the Jogging Options window.
Description
Fig. 4-15: Mouse settings
Dominant check box:
Depending on the dominant mode, the Space Mouse can be used to move just
one axis or several axes simultaneously.
Check box
Description
Active
Dominant mode is activated. Only the coordinate axis
with the greatest deflection of the Space Mouse is
moved.
Inactive
Dominant mode is deactivated. Depending on the axis
selection, either 3 or 6 axes can be moved simultaneously.
Option
Description
6D
The robot can be moved by pulling, pushing, rotating or
tilting the Space Mouse.
The following motions are possible with Cartesian jogging:
XYZ
Translational motions in the X, Y and Z directions
Rotational motions about the X, Y and Z axes
The robot can only be moved by pulling or pushing the
Space Mouse.
The following motions are possible with Cartesian jogging:
ABC
Translational motions in the X, Y and Z directions
The robot can only be moved by rotating or tilting the
Space Mouse.
The following motions are possible with Cartesian jogging:
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Rotational motions about the X, Y and Z axes
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Fig. 4-16: Pushing and pulling the Space Mouse
Fig. 4-17: Rotating and tilting the Space Mouse
4.12.8
Defining the alignment of the Space Mouse
Description
The functioning of the Space Mouse can be adapted to the location of the user
so that the motion direction of the TCP corresponds to the deflection of the
Space Mouse.
The location of the user is specified in degrees. The reference point for the
specification in degrees is the junction box on the base frame. The position of
the robot arm or axes is irrelevant.
Default setting: 0°. This corresponds to a user standing opposite the junction
box.
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Fig. 4-18: Space Mouse: 0° and 270°
Precondition
Operating mode T1
Procedure
1. Open the Jog options window and select the KCP pos. tab.
Fig. 4-19: Defining the alignment of the Space Mouse
2. Drag the KCP to the position corresponding to the location of the user (in
45° steps).
3. Close the Jog options window.
Switching to Automatic External mode automatically resets the alignment of the Space Mouse to 0°.
4.12.9
Cartesian jogging with the Space Mouse
Precondition
The jog mode “Space Mouse” is active.
Operating mode T1
Tool and base have been selected.
The Space Mouse is configured.
( & gt; & gt; & gt; 4.12.4 " Selecting the tool and base " Page 60)
( & gt; & gt; & gt; 4.12.7 " Configuring the Space Mouse " Page 61)
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The alignment of the Space Mouse has been defined.
( & gt; & gt; & gt; 4.12.8 " Defining the alignment of the Space Mouse " Page 63)
Procedure
1. Select World, Base or Tool as the coordinate system for the
Space Mouse.
2. Set jog override.
3. Hold down the enabling switch.
4. Move the robot in the desired direction using the Space Mouse.
The position of the robot during jogging can be displayed: select Display & gt; Actual position in the main menu.
4.12.10 Incremental jogging
Description
Incremental jogging makes it possible to move the robot a defined distance,
e.g. 10 mm or 3°. The robot then stops by itself.
Incremental jogging can be activated for jogging with the jog keys. Incremental
jogging is not possible in the case of jogging with the Space Mouse.
Areas of application:
Positioning of equidistant points
Moving a defined distance away from a position, e.g. in the event of a fault
Mastering with the dial gauge
The following options are available:
Setting
Description
Continuous
Incremental jogging is deactivated.
100 mm / 10°
1 increment = 100 mm or 10°
10 mm / 3°
1 increment = 10 mm or 3°
1 mm / 1°
1 increment = 1 mm or 1°
0.1 mm / 0.005°
1 increment = 0.1 mm or 0.005°
Increments in mm:
Valid for Cartesian jogging in the X, Y or Z direction.
Increments in degrees:
Procedure
Valid for axis-specific jogging.
The jog mode “Jog keys” is active.
Precondition
Valid for Cartesian jogging in the A, B or C direction.
Operating mode T1
1. Select the size of the increment in the status bar.
2. Jog the robot using the jog keys. Jogging can be Cartesian or axis-specific.
Once the set increment has been reached, the robot stops.
If the robot motion is interrupted, e.g. by releasing the enabling
switch, the interrupted increment is not resumed with the next motion;
a new increment is started instead.
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4.13
Jogging external axes
External axes cannot be moved using the Space Mouse. If “Space Mouse”
mode is selected, only the robot can be jogged with the Space Mouse. The external axes, on the other hand, must be jogged using the jog keys.
Precondition
The jog mode “Jog keys” is active.
Procedure
Operating mode T1
1. Select the desired kinematics group, e.g. External axes, on the Keys tab
in the Jog options window.
The type and number of kinematics groups available depend on the system configuration.
2. Set jog override.
3. Hold down the enabling switch.
The axes of the selected kinematics group are displayed next to the jog
keys.
4. Press the Plus or Minus jog key to move an axis in the positive or negative
direction.
Description
Depending on the system configuration, the following kinematics groups may
be available.
Kinematics group
Description
Robot Axes
The robot axes can be moved using the jog keys.
The external axes cannot be jogged.
External Axes
All configured external axes (e.g. external axes
E1 to E5) can be moved using the jog keys.
NAME /
The axes of an external kinematics group can be
moved using the jog keys.
External Kinematics
Groupn
[User-defined kinematics group]
The name is taken from the system variable
$ETn_NAME (n = number of the external kinematic system). If $ETn_NAME is empty, the default
name External Kinematics Groupn is displayed.
The axes of a user-defined kinematics group can
be moved using the jog keys.
The name corresponds to the name of the userdefined kinematics group.
4.14
Bypassing workspace monitoring
Description
Workspaces can be configured for a robot. Workspaces serve to protect the
system.
There are 2 types of workspace:
The workspace is an exclusion zone.
The robot may only move outside the workspace.
Only the workspace is a permitted zone.
The robot may not move outside the workspace.
Exactly what reactions occur when the robot violates a workspace depends on
the configuration. ( & gt; & gt; & gt; 6.6 " Configuring workspaces " Page 143)
One possible reaction, for example, is that the robot stops and an error message is generated. The workspace monitoring must be bypassed in such a
case. The robot can then move back out of the prohibited workspace.
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Precondition
User group “Expert”
Procedure
Operating mode T1
1. In the main menu, select Configuration & gt; Miscellaneous & gt; Workspace
monitoring & gt; Override.
2. Move the robot manually out of the prohibited workspace.
Once the robot has left the prohibited workspace, the workspace monitoring is automatically active again.
4.15
Monitor functions
4.15.1
Displaying the actual position
Procedure
1. In the main menu, select Display & gt; Actual position. The Cartesian actual
position is displayed.
2. To display the axis-specific actual position, press Axis-specific.
3. To display the Cartesian actual position again, press Cartesian.
Description
Actual position, Cartesian:
The current position (X, Y, Z) and orientation (A, B, C) of the TCP are displayed. Status and Turn are also displayed.
Actual position, axis-specific:
The current position of axes A1 to A6 is indicated. If external axes are being
used, the position of the external axes is also displayed.
The actual position can also be displayed while the robot is moving.
Fig. 4-20: Actual position, axis-specific
4.15.2
Displaying digital inputs/outputs
Procedure
1. In the main menu, select Display & gt; Inputs/outputs & gt; Digital I/O.
2. To display a specific input/output:
Click on the Go to button. The Go to: box is displayed.
Enter the number and confirm with the Enter key.
The display jumps to the input/output with this number.
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Description
Fig. 4-21: Digital inputs
Fig. 4-22: Digital outputs
Item
Description
1
Input/output number
2
Value of the input/output. The icon is red if the input or output is
TRUE.
3
SIM entry: The input/output is simulated.
SYS entry: The value of the input/output is saved in a system variable. This input/output is write-protected.
4
Name of the input/output
The following buttons are available:
Button
-100
Toggles back 100 inputs or outputs in the display.
+100
Toggles forward 100 inputs or outputs in the display.
Go to
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Description
The number of the input or output being searched
for can be entered.
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Button
Description
Value
Toggles the selected input/output between TRUE
and FALSE. Precondition: The enabling switch is
pressed.
This button is not available in AUT EXT mode,
and is only available for inputs if simulation is activated.
Name
4.15.3
The name of the selected input or output can be
changed.
Displaying analog inputs/outputs
Procedure
1. In the main menu, select Display & gt; Inputs/outputs & gt; Analog I/O.
2. To display a specific input/output:
Click on the Go to button. The Go to: box is displayed.
Enter the number and confirm with the Enter key.
The display jumps to the input/output with this number.
The following buttons are available:
Button
Description
Go to
The number of the input or output being searched
for can be entered.
Voltage
A voltage can be entered for the selected output.
-10 … 10 V
This button is only available for outputs.
Name
4.15.4
The name of the selected input or output can be
changed.
Displaying inputs/outputs for Automatic External
Procedure
In the main menu, select Display & gt; Inputs/outputs & gt; Automatic External.
Description
Fig. 4-23: Automatic External inputs (detail view)
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Fig. 4-24: Automatic External outputs (detail view)
Item
Description
1
Number
2
Status
Gray: inactive (FALSE)
Red: active (TRUE)
3
Long text name of the input/output
4
Type
Green: input/output
Yellow: variable or system variable ($...)
5
Name of the signal or variable
6
Input/output number or channel number
Columns 4, 5 and 6 are only displayed if Details has been pressed.
The following buttons are available:
Button
Config.
Switches to the configuration of the Automatic
External interface. ( & gt; & gt; & gt; 6.10.2 " Configuring Automatic External inputs/outputs " Page 160)
Inputs/Outputs
Toggles between the windows for inputs and outputs.
Details/Normal
4.15.5
Description
Toggles between the Details and Normal views.
Displaying and modifying the value of a variable
Precondition
To modify a variable:
Procedure
“Expert” user group
1. In the main menu, select Display & gt; Variable & gt; Single.
The Variable Overview - Single window is opened.
2. Enter the name of the variable in the Name box and confirm with the Enter
key.
3. If a program has been selected, it is automatically entered in the Module
box.
If a variable from a different program is to be displayed, enter the program
as follows:
/R1/Program name
Do not specify a folder between /R1/ and the program name. Do not add
a file extension to the file name.
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In the case of system variables, no program needs to be specified in
the Module box.
4. The current value of the variable is displayed in the Current value box. If
nothing is displayed, no value has yet been assigned to the variable.
To modify the variable:
5. Enter the desired value in the New value box.
6. Press the Set value button. The new value is displayed in the Current value box.
Description
Fig. 4-25: Variable Overview - Single window
Item
Description
1
Name of the variable to be modified.
2
New value to be assigned to the variable.
3
Program in which the search for the variable is to be carried out.
In the case of system variables, the Module box is irrelevant.
4
This box has two states:
: The displayed value is not refreshed automatically.
: The displayed value is refreshed automatically.
Switching between the states:
4.15.6
Press Refresh.
Displaying the state of a variable
Description
Variables can have the following states:
DECLARED: The variable is declared.
Procedure
UNKNOWN: The variable is unknown.
INITIALIZED: The variable is initialized.
1. In the main menu, select Display & gt; Variable & gt; Single.
The Variable Overview - Single window is opened.
2. In the Name box, enter: =VARSTATE( " name " )
name = name of the variable whose state is to be displayed.
3. If a program has been selected, it is automatically entered in the Module
box.
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If a variable from a different program is to be displayed, enter the program
as follows:
/R1/Program name
Do not specify a folder between /R1/ and the program name. Do not add
a file extension to the file name.
In the case of system variables, no program needs to be specified in
the Module box.
4. Press Refresh.
The current state of the variable is displayed in the Current value box.
4.15.7
Displaying the variable overview and modifying variables
In the variable overview, variables are displayed in groups. The variables can
be modified.
The number of groups and which variables they contain are defined in the configuration.
( & gt; & gt; & gt; 6.4 " Configuring the variable overview " Page 142)
Variables can only be displayed and modified in the user group “User”
if these functions have been enabled in the configuration.
Procedure
1. In the main menu, select Display & gt; Variable & gt; Overview & gt; Display.
The Variable overview - Display window is opened.
2. Select the desired group.
3. Select the cell to be modified. Carry out modification using the buttons.
4. Press OK to save the change and close the window.
Description
Fig. 4-26: Variable overview - Monitor window
Item
1
Description
Arrow symbol
: If the value of the variable changes, the display
is automatically refreshed.
No arrow symbol: The display is not automatically refreshed.
2
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Descriptive name
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Item
Description
3
Value of the variable. In the case of inputs/outputs, the state is indicated:
4
Gray: inactive (FALSE)
Red: active (TRUE)
There is one tab per group.
The following buttons are available:
Button
Description
Config.
Switches to the configuration of the variable overview.
( & gt; & gt; & gt; 6.4 " Configuring the variable overview "
Page 142)
This button is not available in the user group “User”.
Refresh all
Refreshes the display.
Cancel info
Deactivates the automatic refreshing function.
Start info
Activates the automatic refreshing function.
A maximum of 12 variables per group can be refreshed automatically.
Edit
Switches the current cell to edit mode so that the
name or value can be modified. In the Value column, this button changes the state of inputs/outputs (TRUE/FALSE).
This button is only available in the user group
“User” if it has been enabled in the configuration.
Note: The values of write-protected variables
cannot be changed.
4.15.8
Displaying cyclical flags
Procedure
1. In the main menu, select Display & gt; Variable & gt; Cyclical flags. The Cyclical flags window is opened.
2. To display a specific flag:
Click on the Go to button. The Go to: box is displayed.
Enter the number and confirm with the Enter key.
The display jumps to the flag with this number.
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Description
Fig. 4-27: Cyclical flags
Item
Description
1
Number of the flag
2
Value of the flag. The icon is red if a flag is set.
3
Name of the flag
4
The conditions linked to the setting of a cyclical flag are indicated
here.
The following buttons are available:
Button
-100
Toggles back 100 flags in the display.
+100
Toggles forward 100 flags in the display.
Go to
The number of the flag being searched for can be
entered.
Name
4.15.9
Description
The name of the selected flag can be modified.
Displaying flags
Procedure
1. In the main menu, select Display & gt; Variable & gt; Flags. The Flags window
is opened.
2. To display a specific flag:
Click on the Go to button. The Go to: box is displayed.
Enter the number and confirm with the Enter key.
The display jumps to the flag with this number.
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Description
Fig. 4-28: Flags
Item
Description
1
Number of the flag
2
Value of the flag. The icon is red if a flag is set.
3
Name of the flag
The following buttons are available:
Button
Description
-100
Toggles back 100 flags in the display.
+100
Toggles forward 100 flags in the display.
Go to
The number of the flag being searched for can be
entered.
Value
Toggles the selected flag between TRUE and
FALSE. Precondition: The enabling switch is
pressed.
This button is not available in AUT EXT mode.
Name
The name of the selected flag can be modified.
4.15.10 Displaying counters
Procedure
1. In the main menu, select Display & gt; Variable & gt; Counter. The Counter
window is opened.
2. To display a specific counter:
Click on the Go to button. The Go to: box is displayed.
Enter the number and confirm with the Enter key.
The display jumps to the counter with this number.
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Description
Fig. 4-29: Counter
Item
Description
1
Counter number
4
Value of the counter.
5
Name of counter
The following buttons are available:
Button
Description
Go to
The number of the counter being searched for
can be entered.
Value
A value can be entered for the selected counter.
Name
The name of the selected counter can be modified.
4.15.11 Displaying timers
Procedure
1. In the main menu, select Display & gt; Variable & gt; Timer. The Timer window
is opened.
2. To display a specific timer:
Click on the Go to button. The Go to: box is displayed.
Enter the number and confirm with the Enter key.
The display jumps to the timer with this number.
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Description
Fig. 4-30: Timer
Item
Description
1
Number of the timer
2
Status of the timer
3
If the timer is activated, this is indicated in green.
If the timer is deactivated, this is indicated in red.
State of the timer
If the value of the timer is & gt; 0, the timer flag is set (red check
mark).
If the value of the timer is ≤ 0, no timer flag is set.
4
Value of the timer (unit: ms)
5
Name of timer
The following buttons are available:
Button
Description
Go to
The number of the timer being searched for can
be entered.
State
Toggles the selected timer between TRUE and
FALSE. Precondition: The enabling switch is
pressed.
Value
A value can be entered for the selected timer.
Name
The name of the selected timer can be modified.
4.15.12 Displaying calibration data
Procedure
1. In the main menu, select Start-up & gt; Calibrate & gt; Calibration points and
the desired menu item:
Tool type
Base type
External axis
2. Enter the number of the tool, base or external kinematic system.
The calibration method and the calibration data are displayed.
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4.15.13 Displaying information about the robot and robot controller
Procedure
Description
The information is required, for example, when requesting help from KUKA
Customer Support.
Select Help & gt; Info in the main menu.
The tabs contain the following information:
Tab
Description
Info
Robot controller type
Robot controller version
User interface version
Kernel system version
Robot name
Robot type and configuration
Service life
Robot
The operating hours meter is running as long as the
drives are switched on. Alternatively, the operating
hours can also be displayed via the variable $ROBRUNTIME.
List of external axes
Machine data version
Control PC name
Operating system versions
System
Number of axes
Storage capacities
Options
Additionally installed options and technology packages
Comments
Additional comments
Modules
Names and versions of important system files
The Save button exports the contents of the Modules
tab to the file C:\KRC\ROBOTER\LOG\OCXVER.TXT.
4.15.14 Displaying/editing robot data
Precondition
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T1 or T2 operating mode
Procedure
No program is selected.
Select Start-up & gt; Robot data in the main menu.
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Description
Fig. 4-31: Robot data window
Item
Description
1
Serial number
2
Operating hours. The operating hours meter is running as long as
the drives are switched on. Alternatively, the operating hours can
also be displayed via the variable $ROBRUNTIME.
3
Machine data name
4
Robot name. The robot name can be changed.
5
Robot controller data can be archived to a network path.
( & gt; & gt; & gt; 7.8.3 " Archiving on the network " Page 218)
The archive path is defined here.
6
This box is only displayed if the check box Incorporate robot
name into
archive name. is not activated.
A name for the archive file can be defined here.
7
Check box active: The robot name is used as the name for the
archive file. If no robot name is defined, the name archive is
used.
Check box not active: A separate name can be defined for
the archive file.
The following buttons are available in the user group “Expert”:
Button
Description
Transfer PID & gt; & gt; RDC
Only relevant for positionally accurate robots: the XML file with
the data for the positionally accurate robot can be transferred
manually to the RDC.
Pressing this button displays the directory structure. The directory containing the file with the current serial number is selected
here. The file can be selected and transferred to the RDC.
Transfer MAM & gt; & gt; RDC
Only relevant for robots with fixed mastering marks: the MAM file
with the robot-specific mastering offset data can be transferred
manually to the RDC.
Pressing this button displays the directory structure. The directory containing the file with the current serial number is selected
here. The file can be selected and transferred to the RDC.
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Button
Description
Transfer CAL & gt; & gt; RDC
The CAL file with the EMD mastering data can be transferred
manually to the RDC.
Pressing this button displays the directory structure. The directory containing the file with the current serial number is selected
here. The file can be selected and transferred to the RDC.
Save RDC data
The data on the RDC can be backed up temporarily in the directory C:\KRC\Roboter\RDC by pressing this button.
Note: The directory is deleted when the robot controller is rebooted or data are archived. If the RDC data are to be retained
permanently, they must be backed up elsewhere.
4.16
Displaying the battery state
Description
If the robot controller is switched off at the main switch, or if the power fails,
the robot controller is backed up by a battery and is shut down in a controlled
manner (without loss of data). The battery charge can be displayed for the user. The user can also transfer it to the PLC.
The battery charge is displayed by means of the system variable
$ACCU_STATE.
The state can only be displayed and not modified.
The charging current characteristic is monitored every time the robot controller
is booted. An additional battery test is carried out cyclically. The state indicated
by $ACCU_STATE is derived from the information regarding the charging current and the battery test.
States
Possible states for $ACCU_STATE:
The user must configure the info to the PLC himself.
Information about exchanging the battery can be found in the operating instructions for the robot controller.
#CHARGE_OK
Meaning: The charging current dropped as required after booting and/or
the battery tested positive in the battery test.
Action required by the user: Do not exchange the battery.
Info to PLC: Supply voltage disconnection OK.
Message: No message.
#CHARGE_OK_LOW
Meaning: The charging current dropped as required after booting and/or
the battery tested positive in the battery test. The battery is not fully
charged, however, after the maximum charging time.
Action required by the user: Exchange the battery.
Info to PLC: Supply voltage disconnection OK.
Message: Battery warning - full charge not possible
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#CHARGE_UNKNOWN
Meaning: The battery is being charged. Or the battery has not yet been
checked since the controller was booted. Or the charging current has not
yet dropped sufficiently.
Action required by the user: Do not exchange the battery.
Info to PLC: Supply voltage disconnection can cause errors in Hibernate
mode.
Message: No message
#CHARGE_TEST_NOK
Meaning: The result of the battery test was negative.
Action required by the user: Exchange the battery.
Info to PLC: Supply voltage disconnection can cause errors in Hibernate
mode.
Message: Battery defective - load test failed
#CHARGE_NOK
Meaning: No battery test possible. The battery is not fully charged after
the maximum charging time.
Action required by the user: Exchange the battery.
Info to PLC: Supply voltage disconnection can cause errors in the case of
a warm start.
Message: Battery defective - reliable backup cannot be assured
#CHARGE_OFF
Meaning: There is no battery present or the battery is defective.
Action required by the user: Exchange the battery.
Info to PLC: Supply voltage disconnection can cause errors in the case of
a warm start.
Message: Battery defective - backup not possible
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5 Start-up and recommissioning
5
Start-up and recommissioning
5.1
Start-up wizard
Description
Start-up can be carried out using the Start-up wizard. This guides the user
through the basic start-up steps.
Precondition
No program is selected.
Operating mode T1
Select Start-up & gt; Start-up wizard in the main menu.
Procedure
5.2
Checking the machine data
Description
The correct machine data must be loaded. This must be checked by comparing the loaded machine data with the machine data on the rating plate.
If machine data are reloaded, the version of the machine data must correspond exactly to the KSS version. This is ensured if the machine data supplied
together with the KSS release are used.
The industrial robot must not be moved if incorrect machine data are loaded. Death, severe physical injuries or
considerable damage to property may otherwise result. The correct machine
data must be loaded.
Fig. 5-1: Rating plate
Precondition
T1 or T2 operating mode
Procedure
No program is selected.
1. In the main menu, select Start-up & gt; Robot data.
The Robot Data window is opened.
2. Compare the following entries:
In the Robot data window: the entry in the Machine data box
On the rating plate on the base of the robot: the entry in the line $TRAFONAME()=“# ..... ”
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The file path of the machine data on the CD is specified on the rating
plate in the line ...\MADA\.
5.3
Defining hardware options
Precondition
User group “Safety recovery”
Procedure
1. Select Configuration & gt; Safety configuration in the main menu.
2. Press Hardware options.
3. Modify hardware options and press Save.
Description
Fig. 5-2: Hardware options
Parameter
Description
Customer interface
Select here which interface is used:
ProfiSafe
SIB
SIB, SIB extended
SIB with operating mode output
SIB with operating mode output, SIB extended
This option is available with System Software
version 8.2.4 or higher.
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Parameter
Description
Peripheral contactor
circuit (US2)
Main contactor 2 can be used as a peripheral
contactor, i.e. as a switching element for the
power supply to peripheral devices.
Deactivated: Peripheral contactor is not used.
(Default)
By external PLC: The peripheral contactor is
switched by an external PLC via input US2.
By KRC: The peripheral contactor is switched in
accordance with the motion enable. If motion
enable is present, the contactor is energized.
Operator safety
acknowledgement
If the Operator Safety signal is lost and reset in
Automatic mode, it must be acknowledged
before operation can be continued.
By acknowledgement button: Acknowledgement is given e.g. by an acknowledgement button (situated outside the cell). Acknowledgement
is communicated to the safety controller. The
safety controller re-enables automatic operation
only after acknowledgement.
External unit: Acknowledgement is given by the
system PLC.
5.4
Changing the safety ID of the PROFINET device
Description
If multiple KUKA robot controllers are operated with a single PROFIsafe master PLC, each PROFINET device must have a unique safety ID. The default
ID is always 7.
Precondition
User group “Safety recovery”
If one of the options KUKA.SafeOperation or KUKA.SafeRangeMonitoring is installed on the robot controller, different user groups may
apply. Information can be found in the documentation for these op-
tions.
Procedure
1. Select Configuration & gt; Safety configuration in the main menu.
2. Press Device management.
3. In the column New safety ID, press the ID to be modified and change the
ID.
4. Press Apply safety IDs.
5. A request for confirmation is displayed, asking if the change should be
saved. Confirm the request with Yes.
6. A message is displayed, indicating that the change has been saved. Confirm the message with OK.
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This procedure can only be used to save changes to the safety ID. If
other unsaved changes have been made elsewhere in the safety configuration, these are not saved here.
If an attempt is now made to close the safety configuration, a query is generated asking whether you wish to reject the changes or cancel the action. To
save the changes, proceed as follows:
1. Cancel the action.
2. In the safety configuration, press Save. (If the Save button is not available, first go back a level by pressing Back.)
3. A request for confirmation is displayed, asking if all the changes should
be saved. Confirm the request with Yes.
4. A message is displayed, indicating that the change has been saved. Confirm the message with OK.
All changes in the safety configuration are saved.
5.5
Jogging the robot without a higher-level safety controller
Description
To jog the robot without a higher-level safety controller, Start-up mode must
first be activated. The robot can then be jogged in T1 mode. If SafeOperation
is used, the robot can also be jogged in CRR.
If the RoboTeam option is used, it is only possible to activate Start-up mode
and jog the robot using the local smartPAD.
External safeguards are disabled in Start-up mode. Observe the safety instructions relating to Start-up mode.
( & gt; & gt; & gt; 3.8.3.1 " Start-up mode " Page 33)
The robot controller automatically deactivates Start-up mode in the following
cases:
If no operator action has been carried out within 30 min of activation.
If the smartPAD is switched to passive mode or disconnected from the robot controller.
If the PROFIsafe interface is used: when a connection to a higher-level
safety controller is established.
If an SIB interface is used: when some input signals no longer have the
state “logic zero”.
In Start-up mode, the system switches to the following simulated input image:
The external EMERGENCY STOP is not active.
The safety gate is open.
No safety stop 1 has been requested.
No safety stop 2 has been requested.
No safe operational stop has been requested.
Only for VKR C4: E2 is closed.
If SafeOperation or SafeRangeMonitoring is used, Start-up mode also influences other signals.
Information about the effects of Start-up mode in conjunction with SafeOperation or SafeRangeMonitoring can be found in the documentation SafeOperation and SafeRangeMonitoring.
Precondition
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If the PROFIsafe interface is used: No connection to a higher-level safety
controller
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Operating mode T1 or CRR
In the case of VKR C4: no E2/E7 signals are activated via a USB stick or
retrofit interface.
Procedure
If an SIB interface is used: all input signals have the state “logic zero”.
In the case of RoboTeam: the local smartPAD is used.
In the main menu, select Start-up & gt; Service & gt; Start-up mode.
Menu
Description
Start-up mode is active. Touching
the menu item deactivates the
mode.
Start-up mode is not active. Touching the menu item activates the
mode.
5.6
Checking the activation of the positionally accurate robot model
Description
If a positionally accurate robot is used, it must be checked that the positionally
accurate robot model is activated.
In the case of positionally accurate robots, position deviations resulting from
workpiece tolerances and elastic effects of the individual robots are compensated for. The positionally accurate robot positions the programmed TCP anywhere in the Cartesian workspace within the tolerance limits. The model
parameters of the positionally accurate robot are determined at a calibration
station and permanently saved on the robot (RDC).
The positionally accurate robot model is only valid for the robot as delivered.
Following conversion or retrofitting of the robot, e.g. with an arm extension or a new wrist, the robot must be recalibrated.
Functions
A positionally accurate robot has the following functions:
Increased positioning accuracy, approximately by the factor 10
Increased path accuracy
A precondition for the increased positioning and path accuracy is the
correct input of the load data into the robot controller.
Procedure
Simplified transfer of programs if the robot is exchanged (no reteaching)
Simplified transfer of programs after offline programming with WorkVisual
(no reteaching)
1. In the main menu, select Help & gt; Info.
2. Check on the Robot tab that the positionally accurate robot model is activated. (= specification Positionally accurate robot).
5.7
Activating palletizing mode
Description
Only relevant for palletizing robots with 6 axes!
In the case of palletizing robots with 6 axes, palletizing mode is deactivated by
default and must be activated. When palletizing mode is active, A4 is locked
at 0° and the mounting flange is parallel to the floor.
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Precondition
The robot is mastered.
Procedure
There is no load on the robot; i.e. there is no tool, workpiece or supplementary load mounted.
Activate palletizing mode in the program as follows:
$PAL_MODE = TRUE
Alternative
procedure
1. Set $PAL_MODE to TRUE via the variable correction function.
2. The following message is displayed: Palletizing mode: Move axis A4 [direction]
into position.
Move A4 in the direction specified in the message [+/-].
3. Once A4 has reached its position, the following message is displayed:
Palletizing mode: Move axis A5 [direction] into position.
Move A5 in the direction specified in the message [+/-].
Restrictions
After every cold restart of the robot controller, $PAL_MODE is automatically set to FALSE.
Recommendation: Integrate $PAL_MODE = TRUE into the initialization section of all programs for the palletizing robot.
In the case of robots with palletizing mode active, payload determination
with KUKA.LoadDataDetermination is not possible.
In the case of robots with palletizing mode active, payload determination with KUKA.LoadDataDetermination
must not be carried out. Physical injuries or damage to property may result.
If palletizing mode is active, the robot cannot be mastered. If mastering is
nonetheless required, proceed as follows:
a. Remove all loads from the robot.
b. Set $PAL_MODE to FALSE via the variable correction function.
c. Master the robot.
d. Set $PAL_MODE to TRUE.
(Not necessary if $PAL_MODE = TRUE is in the initialization section
of all programs for the palletizing robot.)
e. Move the robot to the palletizing position.
f.
5.8
Re-attach all loads to the robot.
Copying machine data
Description
This function can be used to copy machine data to the robot controller, e.g. if
a robot has been exchanged.
If machine data are reloaded, the version of the machine
data must correspond exactly to the KUKA System Software (KSS) version. This is ensured if only machine data supplied together
with the KSS release used (e.g. on a USB stick) are loaded.
The robot must not be moved if incorrect machine data are loaded. Personal
injuries or damage to property may result in this case.
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Following modifications to the machine data, all safety
measures specified in the “Safety” chapter of the operating and programming instructions must be carried out. This includes at least
the following safety measures:
1. The safety configuration must be updated.
2. Reduced velocity control must be tested.
3. All programs must be tested in Manual Reduced Velocity mode (T1).
Failure to observe this may result in death to persons, severe physical injuries or damage to property.
Precondition
The System Software release is available on the local drive or network.
No program is selected.
T1 or T2 operating mode
Procedure
“Expert” user group
1. In the main menu, select Start-up & gt; Copy machine data. A directory
structure is displayed.
2. Navigate to the System Software release.
3. Navigate to the desired machine data within the release and select the directory.
4. Press Copy. The machine data are copied. The message Reconfiguration
in progress ... is displayed.
The copying operation is successfully completed when this message is no
longer displayed and the message Copying of machine data completed is displayed.
The following icons are displayed in the directory structure:
Icon
Description
Red check mark
All directories containing valid data that can be copied
are labeled with a red check mark.
Green arrow
If a directory is labeled with a red check mark, the icon
changes to a green arrow. Furthermore, the complete
path of the selected directory is displayed underneath
the directory structure.
This directory can now be copied using the Copy button.
The following buttons are available:
Button
Description
Refresh
Refreshes the directory structure.
Copy
Copies the selected directory.
Precondition: the selected directory is labeled with the
green arrow.
5.9
Mastering
Overview
Every robot must be mastered. Only if the robot has been mastered can it
move to programmed positions and be moved using Cartesian coordinates.
During mastering, the mechanical position and the electronic position of the robot are aligned. For this purpose, the robot is moved to a defined mechanical
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position, the mastering position. The encoder value for each axis is then
saved.
The mastering position is similar, but not identical, for all robots. The exact positions may even vary between individual robots of a single robot type.
Fig. 5-3: Mastering position – approximate position
A robot must be mastered in the following cases:
Case
Comments
During commissioning
---
After maintenance work during
which the robot loses its mastering,
e.g. exchange of motor or RDC
( & gt; & gt; & gt; 5.9.6 " Reference mastering "
Page 98)
When the robot has been moved
without the robot controller (e.g.
with the release device)
---
After exchanging a gear unit
Before carrying out a new mastering procedure, the old mastering
data must first be deleted! Mastering data are deleted by manually
unmastering the axes.
After an impact with an end stop at
more than 250 mm/s
After a collision
( & gt; & gt; & gt; 5.9.7 " Manually unmastering
axes " Page 99)
5.9.1
Mastering methods
Overview
A robot can be mastered in the following ways:
With the EMD (Electronic Mastering Device)
( & gt; & gt; & gt; 5.9.3 " Mastering with the EMD " Page 92)
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With the dial gauge
( & gt; & gt; & gt; 5.9.4 " Mastering with the dial gauge " Page 97)
The axes must be moved to the pre-mastering position before every mastering
operation.
EMD mastering is recommended.
Another method is “reference mastering”. It is only used for mastering the robot after certain maintenance tasks.
( & gt; & gt; & gt; 5.9.6 " Reference mastering " Page 98)
5.9.2
Moving axes to the pre-mastering position
Description
Each axis is moved so that the mastering marks line up.
Fig. 5-4: Moving an axis to the pre-mastering position
The mastering marks are situated in the following positions on the robot:
Fig. 5-5: Mastering marks on the robot
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Depending on the specific robot model, the positions of the mastering
marks may deviate slightly from those illustrated.
Precondition
The jog mode “Jog keys” is active.
Procedure
Operating mode T1
1. Select Axes as the coordinate system for the jog keys.
2. Hold down the enabling switch.
Axes A1 to A6 are displayed next to the jog keys.
3. Press the Plus or Minus jog key to move an axis in the positive or negative
direction.
4. Move each axis, starting from A1 and working upwards, so that the mastering marks line up.
If A4 and A6 are moved to the pre-mastering position,
ensure that the energy supply system – if present – is in
its correct position and not rotated through 360°.
5.9.3
Mastering with the EMD
Overview
In EMD mastering, the axis is automatically moved by the robot controller to
the mastering position. Mastering is carried out first without and then with a
load. It is possible to save mastering data for different loads.
EMD mastering consists of the following steps:
Step
1
Description
First mastering
( & gt; & gt; & gt; 5.9.3.1 " First mastering with the EMD " Page 92)
First mastering is carried out without a load.
2
Teach offset
( & gt; & gt; & gt; 5.9.3.2 " Teach offset " Page 95)
“Teach offset” is carried out with a load. The difference from
the first mastering is saved.
3
If required: Master load with offset
( & gt; & gt; & gt; 5.9.3.3 " Master load with offset " Page 96)
“Load mastering with offset” is carried out with a load for
which an offset has already been taught.
Area of application:
5.9.3.1
Checking first mastering
Restoring first mastering if it has been lost (e.g. following exchange of motor or collision). Since an offset that
has been taught is retained, even if mastering is lost, the
robot controller can calculate the first mastering.
First mastering with the EMD
Precondition
There is no load on the robot; i.e. there is no tool, workpiece or supplementary load mounted.
All axes are in the pre-mastering position.
No program is selected.
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Operating mode T1
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Procedure
The EMD must always be screwed onto the gauge cartridge without the signal cable attached. Only then may
the signal cable be attached to the EMD. Otherwise, the signal cable could
be damaged.
Similarly, when removing the EMD, the signal cable must always be removed
from the EMD first. Only then may the EMD be removed from the gauge cartridge.
After mastering, remove the signal cable from connection X32. Failure to do
so may result in interference signals or damage.
1. Select Start-up & gt; Master & gt; EMD & gt; With load correction & gt; First mastering in the main menu.
A window opens. All axes to be mastered are displayed. The axis with the
lowest number is highlighted.
2. Remove the cover from connection X32.
Fig. 5-6: Removing cover from X32
3. Connect the signal cable to X32.
Fig. 5-7: Connecting signal cable to X32
4. Remove the protective cap of the gauge cartridge on the axis highlighted
in the window. (Turned around, the EMD can be used as a screwdriver.)
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Fig. 5-8: Removing protective cap from gauge cartridge
5. Screw the EMD onto the gauge cartridge.
Fig. 5-9: Screwing EMD onto gauge cartridge
6. Attach the signal cable to the EMD, aligning the red dot on the connector
with the groove in the EMD.
Fig. 5-10: Attaching signal cable to EMD
7. Press Master.
8. Press an enabling switch and the Start key.
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When the EMD has passed through the reference notch, the mastering position is calculated. The robot stops automatically. The values are saved.
The axis is no longer displayed in the window.
9. Remove the signal cable from the EMD. Then remove the EMD from the
gauge cartridge and replace the protective cap.
10. Repeat steps 4 to 9 for all axes to be mastered.
11. Close the window.
12. Remove signal cable from connection X32.
5.9.3.2
Teach offset
Description
“Teach offset” is carried out with a load. The difference from the first mastering
is saved.
If the robot is operated with different loads, “Teach offset” must be carried out
for every load. In the case of grippers used for picking up heavy workpieces,
“Teach offset” must be carried out for the gripper both with and without the
workpiece.
Precondition
Same ambient conditions (temperature, etc.) as for first mastering.
The load is mounted on the robot.
All axes are in the pre-mastering position.
No program is selected.
Procedure
Operating mode T1
The EMD must always be screwed onto the gauge cartridge without the signal cable attached. Only then may
the signal cable be attached to the EMD. Otherwise, the signal cable could
be damaged.
Similarly, when removing the EMD, the signal cable must always be removed
from the EMD first. Only then may the EMD be removed from the gauge cartridge.
After mastering, remove the signal cable from connection X32. Failure to do
so may result in interference signals or damage.
1. Select Start-up & gt; Master & gt; EMD & gt; With load correction & gt; Teach offset
in the main menu.
2. Enter tool number. Confirm with Tool OK.
A window opens. All axes for which the tool has not yet been taught are
displayed. The axis with the lowest number is highlighted.
3. Remove the cover from connection X32 and connect the signal cable.
4. Remove the protective cap of the gauge cartridge on the axis highlighted
in the window. (Turned around, the EMD can be used as a screwdriver.)
5. Screw the EMD onto the gauge cartridge.
6. Attach the signal cable to the EMD, aligning the red dot on the connector
with the groove in the EMD.
7. Press Learn.
8. Press an enabling switch and the Start key.
When the EMD has passed through the reference notch, the mastering position is calculated. The robot stops automatically. A window opens. The
deviation of this axis from the first mastering is indicated in degrees and
increments.
9. Click OK to confirm. The axis is no longer displayed in the window.
10. Remove the signal cable from the EMD. Then remove the EMD from the
gauge cartridge and replace the protective cap.
11. Repeat steps 4 to 10 for all axes to be mastered.
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12. Close the window.
13. Remove signal cable from connection X32.
5.9.3.3
Master load with offset
Description
Area of application:
Checking first mastering
Restoring first mastering if it has been lost (e.g. following exchange of motor or collision). Since an offset that has been taught is retained, even if
mastering is lost, the robot controller can calculate the first mastering.
An axis can only be checked if all axes with lower numbers have been
mastered.
Precondition
Same ambient conditions (temperature, etc.) as for first mastering.
A load for which “Teach offset” has been carried out is mounted on the robot.
All axes are in the pre-mastering position.
No program is selected.
Procedure
Operating mode T1
The EMD must always be screwed onto the gauge cartridge without the signal cable attached. Only then may
the signal cable be attached to the EMD. Otherwise, the signal cable could
be damaged.
Similarly, when removing the EMD, the signal cable must always be removed
from the EMD first. Only then may the EMD be removed from the gauge cartridge.
After mastering, remove the signal cable from connection X32. Failure to do
so may result in interference signals or damage.
1. In the main menu, select Start-up & gt; Master & gt; EMD & gt; With load correction & gt; Master load & gt; With offset.
2. Enter tool number. Confirm with Tool OK.
A window opens. All axes for which an offset has been taught with this tool
are displayed. The axis with the lowest number is highlighted.
3. Remove the cover from connection X32 and connect the signal cable.
4. Remove the protective cap of the gauge cartridge on the axis highlighted
in the window. (Turned around, the EMD can be used as a screwdriver.)
5. Screw the EMD onto the gauge cartridge.
6. Attach the signal cable to the EMD, aligning the red dot on the connector
with the groove in the EMD.
7. Press Check.
8. Hold down an enabling switch and press the Start key.
When the EMD has passed through the reference notch, the mastering position is calculated. The robot stops automatically. The difference from
“Teach offset” is displayed.
9. If required, press Save to save the values. The old mastering values are
deleted.
To restore a lost first mastering, always save the values.
Axes A4, A5 and A6 are mechanically coupled. This means:
If the values for A4 are deleted, the values for A5 and A6 are also deleted.
If the values for A5 are deleted, the values for A6 are also deleted.
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10. Remove the signal cable from the EMD. Then remove the EMD from the
gauge cartridge and replace the protective cap.
11. Repeat steps 4 to 10 for all axes to be mastered.
12. Close the window.
13. Remove signal cable from connection X32.
5.9.4
Mastering with the dial gauge
Description
In dial mastering, the axis is moved manually by the user to the mastering position. Mastering is always carried out with a load. It is not possible to save
mastering data for different loads.
Fig. 5-11: Dial gauge
Precondition
The load is mounted on the robot.
All axes are in the pre-mastering position.
The jog mode “Jog keys” is active and the coordinate system Axis has
been selected.
No program is selected.
Procedure
Operating mode T1
1. In the main menu, select Start-up & gt; Master & gt; Dial.
A window opens. All axes that have not been mastered are displayed. The
axis that must be mastered first is selected.
2. Remove the protective cap from the gauge cartridge on this axis and
mount the dial gauge on the gauge cartridge.
Using the Allen key, loosen the screws on the neck of the dial gauge. Turn
the dial so that it can be viewed easily. Push the pin of the dial gauge in as
far as the stop.
Using the Allen key, tighten the screws on the neck of the dial gauge.
3. Reduce jog override to 1%.
4. Jog axis from “+” to “-”. At the lowest position of the reference notch, recognizable by the change in direction of the pointer, set the dial gauge to 0.
If the axis inadvertently overshoots the lowest position, jog the axis backwards and forwards until the lowest position is reached. It is immaterial
whether the axis is moved from “+” to “-” or from “-” to “+”.
5. Move the axis back to the pre-mastering position.
6. Move the axis from “+” to “-” until the pointer is about 5-10 scale divisions
before zero.
7. Switch to incremental jogging.
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8. Move the axis from “+” to “-” until zero is reached.
If the axis overshoots zero, repeat steps 5 to 8.
9. Press Master. The axis that has been mastered is removed from the window.
10. Remove the dial gauge from the gauge cartridge and replace the protective cap.
11. Switch back from incremental jogging to the normal jog mode.
12. Repeat steps 2 to 11 for all axes to be mastered.
13. Close the window.
5.9.5
Mastering external axes
Description
KUKA external axes can be mastered using either the EMD or the dial
gauge.
Procedure
Non-KUKA external axes can be mastered using the dial gauge. If mastering with the EMD is desired, the external axis must be fitted with gauge
cartridges.
The procedure for mastering external axes is the same as that for mastering robot axes. Alongside the robot axes, the configured external axes now
also appear in the axis selection window.
Fig. 5-12: Selection list of axes to be mastered
Mastering in the case of industrial robots with more than 2 external
axes: if the system contains more than 8 axes, it may be necessary
to connect the signal cable of the EMD to the second RDC.
5.9.6
Reference mastering
Reference mastering must not be used when commissioning the robot.
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Description
Reference mastering is suitable if maintenance work is due on a correctly
mastered robot and it is to be expected that the robot will lose its mastering.
Examples:
Exchange of RDC
Exchange of motor
The robot is moved to the $MAMES position before the maintenance work is
commenced. Afterwards, the axis values of this system variable are reassigned to the robot by means of reference mastering. The state of the robot is
then the same as before the loss of mastering. Taught offsets are retained. No
EMD or dial gauge is required.
In the case of reference mastering, it is irrelevant whether or not there is a load
mounted on the robot. Reference mastering can also be used for external axes.
Preparation
Move the robot to the $MAMES position before commencing the maintenance work. To do so, program a point PTP $MAMES and move the robot
to it. This is only possible in the user group “Expert”!
The robot must not move to the default HOME position
instead of to $MAMES. $MAMES may be, but is not always, identical to the default HOME position. Only in the $MAMES position
will the robot be correctly mastered by means of reference mastering. If the
robot is reference mastered at any position other than $MAMES, this may result in physical injury and material damage.
Precondition
No program is selected.
Operating mode T1
The position of the robot was not changed during the maintenance work.
If the RDC has been exchanged: the robot data have been transferred
from the hard drive to the RDC (this can only be done in the user group
“Expert”!)
( & gt; & gt; & gt; 4.15.14 " Displaying/editing robot data " Page 78)
Procedure
1. In the main menu, select Start-up & gt; Master & gt; Reference.
The option window Reference mastering is opened. All axes that have
not been mastered are displayed. The axis that must be mastered first is
selected.
2. Press Master. The selected axis is mastered and removed from the option
window.
3. Repeat step 2 for all axes to be mastered.
5.9.7
Manually unmastering axes
Description
The mastering values of the individual axes can be deleted. The axes do not
move during unmastering.
Axes A4, A5 and A6 are mechanically coupled. This means:
If the values for A4 are deleted, the values for A5 and A6 are also deleted.
If the values for A5 are deleted, the values for A6 are also deleted.
The software limit switches of an unmastered robot are
deactivated. The robot can hit the end stop buffers, thus
damaging the robot and making it necessary to exchange the buffers. An unmastered robot must not be jogged, if at all avoidable. If it must be jogged,
the jog override must be reduced as far as possible.
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Precondition
No program is selected.
Procedure
Operating mode T1
1. In the main menu, select Start-up & gt; Master & gt; Unmaster. A window
opens.
2. Select the axis to be unmastered.
3. Press Unmaster. The mastering data of the axis are deleted.
4. Repeat steps 2 and 3 for all axes to be unmastered.
5. Close the window.
5.10
Modifying software limit switches
There are 2 ways of modifying the software limit switches:
Enter the desired values manually.
Or automatically adapt the limit switches to one or more programs.
The robot controller determines the minimum and maximum axis positions
occurring in the program. These values can then be set as software limit
switches.
Precondition
“Expert” user group
Procedure
T1, T2 or AUT mode
Modifying software limit switches manually:
1. In the main menu, select Start-up & gt; Service & gt; Software limit switch. The
Software limit switch window is opened.
2. Modify the limit switches as required in the columns Negative and Positive.
3. Save the changes with Save.
Adapting software limit switches to a program:
1. In the main menu, select Start-up & gt; Service & gt; Software limit switch. The
Software limit switch window is opened.
2. Click on Auto detection. The following message is displayed: Auto detection is running.
3. Start the program to which the limit switches are to be adapted. Execute
the program completely and then cancel it.
The maximum and minimum position reached by each axis is displayed in
the Software limit switch window.
4. Repeat step 3 for all programs to which the limit switches are to be adapted.
The maximum and minimum position reached by each axis in all executed
programs is displayed in the Software limit switch window.
5. Once all desired programs have been executed, press End in the Software limit switch window.
6. Press Save to save the determined values as software limit switches.
7. If required, modify the automatically determined values manually.
Recommendation: Reduce the determined minimum values by 5°. Increase the determined maximum values by 5°.
This margin prevents the axes from reaching the limit switches during
program execution and thus triggering a stop.
8. Save the changes with Save.
Description
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Software limit switch window:
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Fig. 5-13: Before automatic determination
Item
Description
1
Current negative limit switch
2
Current position of the axis
3
Current positive limit switch
Fig. 5-14: During automatic determination
Item
4
Minimum position of the axis since the start of determination
5
Buttons
Description
Maximum position of the axis since the start of determination
The following buttons are available (only in the “Expert” user group):
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Button
Description
Auto detection
Starts the automatic determination:
The robot controller writes the minimum and
maximum positions adopted by the axes from
now on to the columns Minimum and Maximum
in the Software limit switch window.
End
Ends the automatic determination. Transfers the
calculated minimum/maximum positions to the
columns Negative and Positive, but does not yet
save them.
Save
Saves the values in the columns Negative and
Positive as software limit switches.
5.11
Calibration
5.11.1
Defining the tool direction
Description
By default, the X axis is defined in the system as the tool direction. The tool
direction can be changed using the system variable $TOOL_DIRECTION.
The change relates only to spline motions. For LIN and CIRC motions, the
tool direction is the X axis and cannot be changed.
The change applies to all tools. It is not possible to define different tool directions for different tools.
The tool direction must be defined before calibration and
before program creation. It cannot be modified subsequently. Failure to observe this may result in unexpected changes to the motion characteristics of the robot. Death to persons, severe physical injuries or
considerable damage to property may result.
Precondition
Expert user group
Procedure
Set the system variable $TOOL_DIRECTION to the desired value in the
file $CUSTOM.DAT, located in the directory KRC\Steu\MaDa.
Possible values: #X (default); #Y; #Z
It is not possible to modify $TOOL_DIRECTION by means of the variable correction function or by writing to the variable from the program.
5.11.2
Tool calibration
Description
During tool calibration, the user assigns a Cartesian coordinate system (TOOL
coordinate system) to the tool mounted on the mounting flange.
The TOOL coordinate system has its origin at a user-defined point. This is
called the TCP (Tool Center Point). The TCP is generally situated at the working point of the tool.
In the case of a fixed tool, the type of calibration described here must
not be used. A separate type of calibration must be used for fixed
tools. ( & gt; & gt; & gt; 5.11.4 " Fixed tool calibration " Page 112)
Advantages of tool calibration:
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The tool can be moved in a straight line in the tool direction.
The tool can be rotated about the TCP without changing the position of the
TCP.
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In program mode: The programmed velocity is maintained at the TCP
along the path.
A maximum of 16 TOOL coordinate systems can be saved. Variable:
TOOL_DATA[1…16].
The following data are saved:
X, Y, Z:
Origin of the TOOL coordinate system relative to the FLANGE coordinate
system
A, B, C:
Orientation of the TOOL coordinate system relative to the FLANGE coordinate system
Fig. 5-15: TCP calibration principle
Overview
Tool calibration consists of 2 steps:
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Step
1
Description
Definition of the origin of the TOOL coordinate system
The following methods are available:
XYZ 4-point
( & gt; & gt; & gt; 5.11.2.1 " TCP calibration: XYZ 4-point method "
Page 104)
XYZ Reference
( & gt; & gt; & gt; 5.11.2.2 " TCP calibration: XYZ Reference method "
Page 106)
2
Definition of the orientation of the TOOL coordinate system
The following methods are available:
ABC 2-point
( & gt; & gt; & gt; 5.11.2.4 " Defining the orientation: ABC 2-point
method " Page 107)
ABC World
( & gt; & gt; & gt; 5.11.2.3 " Defining the orientation: ABC World method " Page 107)
If the calibration data are already known, they can be entered directly.
( & gt; & gt; & gt; 5.11.2.5 " Numeric input " Page 109)
5.11.2.1 TCP calibration: XYZ 4-point method
The XYZ 4-point method cannot be used for palletizing robots.
Description
The TCP of the tool to be calibrated is moved to a reference point from 4 different directions. The reference point can be freely selected. The robot controller calculates the TCP from the different flange positions.
The 4 flange positions at the reference point must be sufficiently different from one another.
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Fig. 5-16: XYZ 4-Point method
Precondition
The tool to be calibrated is mounted on the mounting flange.
Procedure
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; Tool & gt; XYZ 4-point.
2. Assign a number and a name for the tool to be calibrated. Confirm with
Next.
3. Move the TCP to a reference point. Press Calibrate. Answer the request
for confirmation with Yes.
4. Move the TCP to the reference point from a different direction. Press Calibrate. Answer the request for confirmation with Yes.
5. Repeat step 4 twice.
6. Enter the payload data. (This step can be skipped if the payload data are
entered separately instead.)
( & gt; & gt; & gt; 5.12.3 " Entering payload data " Page 126)
7. Confirm with Next.
8. If required, coordinates and orientation of the calibrated points can be displayed in increments and degrees (relative to the FLANGE coordinate system). For this, press Meas. points. Then return to the previous view by
pressing Back.
9. Either: press Save and then close the window via the Close icon.
Or: press ABC 2-point or ABC World. The previous data are automatically saved and a window is opened in which the orientation of the TOOL coordinate system can be defined.
( & gt; & gt; & gt; 5.11.2.4 " Defining the orientation: ABC 2-point method " Page 107)
( & gt; & gt; & gt; 5.11.2.3 " Defining the orientation: ABC World method " Page 107)
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5.11.2.2 TCP calibration: XYZ Reference method
Description
In the case of the XYZ Reference method, a new tool is calibrated with a tool
that has already been calibrated. The robot controller compares the flange positions and calculates the TCP of the new tool.
Fig. 5-17: XYZ Reference method
Precondition
A previously calibrated tool is mounted on the mounting flange.
Preparation
Operating mode T1
Calculate the TCP data of the calibrated tool:
1. In the main menu, select Start-up & gt; Calibrate & gt; Tool & gt; XYZ Reference.
2. Enter the number of the calibrated tool.
3. The tool data are displayed. Note the X, Y and Z values.
4. Close the window.
Procedure
1. In the main menu, select Start-up & gt; Calibrate & gt; Tool & gt; XYZ Reference.
2. Assign a number and a name for the new tool. Confirm with Next.
3. Enter the TCP data of the calibrated tool. Confirm with Next.
4. Move the TCP to a reference point. Press Calibrate. Answer the request
for confirmation with Yes.
5. Move the tool away and remove it. Mount the new tool.
6. Move the TCP of the new tool to the reference point. Press Calibrate. Answer the request for confirmation with Yes.
7. Enter the payload data. (This step can be skipped if the payload data are
entered separately instead.)
( & gt; & gt; & gt; 5.12.3 " Entering payload data " Page 126)
8. Confirm with Next.
9. If required, coordinates and orientation of the calibrated points can be displayed in increments and degrees (relative to the FLANGE coordinate system). For this, press Meas. points. Then return to the previous view by
pressing Back.
10. Either: press Save and then close the window via the Close icon.
Or: press ABC 2-point or ABC World. The previous data are automatically saved and a window is opened in which the orientation of the TOOL coordinate system can be defined.
( & gt; & gt; & gt; 5.11.2.4 " Defining the orientation: ABC 2-point method " Page 107)
( & gt; & gt; & gt; 5.11.2.3 " Defining the orientation: ABC World method " Page 107)
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5.11.2.3 Defining the orientation: ABC World method
Description
The axes of the TOOL coordinate system are aligned parallel to the axes of
the WORLD coordinate system. This communicates the orientation of the
TOOL coordinate system to the robot controller.
There are 2 variants of this method:
5D: Only the tool direction is communicated to the robot controller. By default, the tool direction is the X axis. The directions of the other axes are
defined by the system and cannot be detected easily by the user.
Area of application: e.g. MIG/MAG welding, laser cutting or waterjet cutting
6D: The directions of all 3 axes are communicated to the robot controller.
Area of application: e.g. for weld guns, grippers or adhesive nozzles
Precondition
The tool to be calibrated is mounted on the mounting flange.
The TCP of the tool has already been measured.
Operating mode T1
The following procedure applies if the tool direction is the default tool
direction (= X axis). If the tool direction has been changed to Y or Z,
the procedure must also be changed accordingly.
( & gt; & gt; & gt; 5.11.1 " Defining the tool direction " Page 102)
Procedure
1. In the main menu, select Start-up & gt; Calibrate & gt; Tool & gt; ABC World.
2. Enter the number of the tool. Confirm with Next.
3. Select a variant in the box 5D/6D. Confirm with Next.
4. If 5D is selected:
Align +XTOOL parallel to -ZWORLD. (+XTOOL = tool direction)
If 6D is selected:
Align the axes of the TOOL coordinate system as follows.
+XTOOL parallel to -ZWORLD. (+XTOOL = tool direction)
+YTOOL parallel to +YWORLD
+ZTOOL parallel to +XWORLD
5. Press Calibrate. Answer the request for confirmation with Yes.
The following two steps are eliminated if the procedure is not called
via the main menu, but by means of the ABC World button after TCP
calibration.
6. Enter the payload data. (This step can be skipped if the payload data are
entered separately instead.)
( & gt; & gt; & gt; 5.12.3 " Entering payload data " Page 126)
7. Confirm with Next.
8. If required, coordinates and orientation of the calibrated points can be displayed in increments and degrees (relative to the FLANGE coordinate system). For this, press Meas. points. Then return to the previous view by
pressing Back.
9. Press Save.
5.11.2.4 Defining the orientation: ABC 2-point method
Description
The axes of the TOOL coordinate system are communicated to the robot controller by moving to a point on the X axis and a point in the XY plane.
This method is used if it is necessary to define the axis directions with particular precision.
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Fig. 5-18: ABC 2-Point method
Precondition
The tool to be calibrated is mounted on the mounting flange.
The TCP of the tool has already been measured.
Operating mode T1
The following procedure applies if the tool direction is the default tool
direction (= X axis). If the tool direction has been changed to Y or Z,
the procedure must also be changed accordingly.
( & gt; & gt; & gt; 5.11.1 " Defining the tool direction " Page 102)
Procedure
1. In the main menu, select Start-up & gt; Calibrate & gt; Tool & gt; ABC 2-point.
2. Enter the number of the mounted tool. Confirm with Next.
3. Move the TCP to any reference point. Press Calibrate. Answer the request for confirmation with Yes.
4. Move the tool so that the reference point on the X axis has a negative X
value (i.e. move against the tool direction). Press Calibrate. Answer the
request for confirmation with Yes.
5. Move the tool so that the reference point in the XY plane has a negative Y
value. Press Calibrate. Answer the request for confirmation with Yes.
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The following two steps are eliminated if the procedure is not called
via the main menu, but by means of the ABC 2-point button after
TCP calibration.
6. Enter the payload data. (This step can be skipped if the payload data are
entered separately instead.)
( & gt; & gt; & gt; 5.12.3 " Entering payload data " Page 126)
7. Confirm with Next.
8. If required, coordinates and orientation of the calibrated points can be displayed in increments and degrees (relative to the FLANGE coordinate system). For this, press Meas. points. Then return to the previous view by
pressing Back.
9. Press Save.
5.11.2.5 Numeric input
Description
The tool data can be entered manually.
Possible sources of data:
CAD
Externally calibrated tool
Tool manufacturer specifications
In the case of palletizing robots with 4 axes, e.g. KR 180 PA, the tool
data must be entered numerically. The XYZ and ABC methods cannot be used as reorientation of these robots is highly restricted.
Precondition
The following values are known:
Procedure
X, Y and Z relative to the FLANGE coordinate system
A, B and C relative to the FLANGE coordinate system
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; Tool & gt; Numeric input.
2. Assign a number and a name for the tool to be calibrated. Confirm with
Next.
3. Enter the tool data. Confirm with Next.
4. Enter the payload data. (This step can be skipped if the payload data are
entered separately instead.)
( & gt; & gt; & gt; 5.12.3 " Entering payload data " Page 126)
5. If online load data verification is available (this depends on the robot type):
configure as required.
( & gt; & gt; & gt; 5.12.5 " Online load data check (OLDC) " Page 127)
6. Confirm with Next.
7. Press Save.
5.11.3
Base calibration
Description
During base calibration, the user assigns a Cartesian coordinate system
(BASE coordinate system) to a work surface or the workpiece. The BASE coordinate system has its origin at a user-defined point.
If the workpiece is mounted on the mounting flange, the type of calibration described here must not be used. A separate type of calibration must be used for workpieces mounted on the mounting flange.
( & gt; & gt; & gt; 5.11.4 " Fixed tool calibration " Page 112)
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Advantages of base calibration:
The TCP can be jogged along the edges of the work surface or workpiece.
Points can be taught relative to the base. If it is necessary to offset the
base, e.g. because the work surface has been offset, the points move with
it and do not need to be retaught.
A maximum of 32 BASE coordinate systems can be saved. Variable:
BASE_DATA[1…32].
Overview
There are 2 ways of calibrating a base:
3-point method ( & gt; & gt; & gt; 5.11.3.1 " 3-point method " Page 110)
Indirect method ( & gt; & gt; & gt; 5.11.3.2 " Indirect method " Page 111)
If the calibration data are already known, they can be entered directly.
( & gt; & gt; & gt; 5.11.3.3 " Numeric input " Page 112)
5.11.3.1 3-point method
Description
The robot moves to the origin and 2 further points of the new base. These 3
points define the new base.
Fig. 5-19: 3-point method
Precondition
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A previously calibrated tool is mounted on the mounting flange.
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Procedure
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; Base & gt; ABC 3-point.
2. Assign a number and a name for the base. Confirm with Next.
3. Enter the number of the mounted tool. Confirm with Next.
4. Move the TCP to the origin of the new base. Press Calibrate. Answer the
request for confirmation with Yes.
5. Move the TCP to a point on the positive X axis of the new base. Press Calibrate. Answer the request for confirmation with Yes.
6. Move the TCP to a point in the XY plane with a positive Y value. Press Calibrate. Answer the request for confirmation with Yes.
7. If required, coordinates and orientation of the calibrated points can be displayed in increments and degrees (relative to the FLANGE coordinate system). For this, press Meas. points. Then return to the previous view by
pressing Back.
8. Press Save.
5.11.3.2 Indirect method
Description
The indirect method is used if it is not possible to move to the origin of the
base, e.g. because it is inside a workpiece or outside the workspace of the robot.
The TCP is moved to 4 points in the base, the coordinates of which must be
known. The robot controller calculates the base from these points.
Fig. 5-20: Indirect method
Precondition
A calibrated tool is mounted on the mounting flange.
The coordinates of 4 points in the new base are known, e.g. from CAD data. The 4 points are accessible to the TCP.
Procedure
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; Base & gt; Indirect.
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2. Assign a number and a name for the base. Confirm with Next.
3. Enter the number of the mounted tool. Confirm with Next.
4. Enter the coordinates of a known point in the new base and move the TCP
to this point. Press Calibrate. Answer the request for confirmation with
Yes.
5. Repeat step 4 three times.
6. If required, coordinates and orientation of the calibrated points can be displayed in increments and degrees (relative to the FLANGE coordinate system). For this, press Meas. points. Then return to the previous view by
pressing Back.
7. Press Save.
5.11.3.3 Numeric input
Precondition
The following numerical values are known, e.g. from CAD data:
Distance between the origin of the base and the origin of the WORLD coordinate system
Rotation of the base axes relative to the WORLD coordinate system
Procedure
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; Base & gt; Numeric input.
2. Assign a number and a name for the base. Confirm with Next.
3. Enter data. Confirm with Next.
4. Press Save.
5.11.4
Fixed tool calibration
Overview
Calibration of a fixed tool consists of 2 steps:
Step
1
Description
Calibration of the TCP of the fixed tool
The TCP of a fixed tool is called an external TCP.
( & gt; & gt; & gt; 5.11.4.1 " Calibrating an external TCP " Page 113)
If the calibration data are already known, they can be entered
directly.
( & gt; & gt; & gt; 5.11.4.2 " Entering the external TCP numerically "
Page 114)
2
Calibration of the workpiece
The following methods are available:
Direct method
( & gt; & gt; & gt; 5.11.4.3 " Workpiece calibration: direct method "
Page 114)
Indirect method
( & gt; & gt; & gt; 5.11.4.4 " Workpiece calibration: indirect method "
Page 116)
The robot controller saves the external TCP as the BASE coordinate system
and the workpiece as the TOOL coordinate system. A maximum of 32 BASE
coordinate systems and 16 TOOL coordinate systems can be saved.
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5.11.4.1 Calibrating an external TCP
Description
First of all, the TCP of the fixed tool is communicated to the robot controller.
This is done by moving a calibrated tool to it.
Then, the orientation of the coordinate system of the fixed tool is communicated to the robot controller. For this purpose, the coordinate system of the calibrated tool is aligned parallel to the new coordinate system. There are 2
variants:
5D: Only the tool direction of the fixed tool is communicated to the robot
controller. By default, the tool direction is the X axis. The orientation of the
other axes is defined by the system and cannot be detected easily by the
user.
6D: The orientation of all 3 axes is communicated to the robot controller.
Fig. 5-21: Moving to the external TCP
Fig. 5-22: Aligning the coordinate systems parallel to one another
Precondition
A previously calibrated tool is mounted on the mounting flange.
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Operating mode T1
The following procedure applies if the tool direction is the default tool
direction (= X axis). If the tool direction has been changed to Y or Z,
the procedure must also be changed accordingly.
( & gt; & gt; & gt; 5.11.1 " Defining the tool direction " Page 102)
Procedure
1. In the main menu, select Start-up & gt; Calibrate & gt; Fixed tool & gt; Tool.
2. Assign a number and a name for the fixed tool. Confirm with Next.
3. Enter the number of the calibrated tool. Confirm with Next.
4. Select a variant in the box 5D/6D. Confirm with Next.
5. Move the TCP of the calibrated tool to the TCP of the fixed tool. Press Calibrate. Answer the request for confirmation with Yes.
6. If 5D is selected:
Align +XBASE parallel to -ZFLANGE.
(i.e. align the mounting flange perpendicular to the tool direction of the
fixed tool.)
If 6D is selected:
Align the mounting flange so that its axes are parallel to the axes of the
fixed tool:
+XBASE parallel to -ZFLANGE
(i.e. align the mounting flange perpendicular to the tool direction.)
+YBASE parallel to +YFLANGE
+ZBASE parallel to +XFLANGE
7. Press Calibrate. Answer the request for confirmation with Yes.
8. If required, coordinates and orientation of the calibrated points can be displayed in increments and degrees (relative to the FLANGE coordinate system). For this, press Meas. points. Then return to the previous view by
pressing Back.
9. Press Save.
5.11.4.2 Entering the external TCP numerically
Precondition
The following numerical values are known, e.g. from CAD data:
Procedure
Distance between the TCP of the fixed tool and the origin of the
WORLD coordinate system (X, Y, Z)
Rotation of the axes of the fixed tool relative to the WORLD coordinate
system (A, B, C)
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; Fixed tool & gt; Numeric input.
2. Assign a number and a name for the fixed tool. Confirm with Next.
3. Enter data. Confirm with Next.
4. Press Save.
5.11.4.3 Workpiece calibration: direct method
Description
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The origin and 2 further points of the workpiece are communicated to the robot
controller. These 3 points uniquely define the workpiece.
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Fig. 5-23
Fig. 5-24: Workpiece calibration: direct method
Precondition
The workpiece is mounted on the mounting flange.
A previously calibrated fixed tool is mounted.
Procedure
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; Fixed tool & gt; Workpiece
& gt; Direct calibration.
2. Assign a number and a name for the workpiece. Confirm with Next.
3. Enter the number of the fixed tool. Confirm with Next.
4. Move the origin of the workpiece coordinate system to the TCP of the fixed
tool. Press Calibrate. Answer the request for confirmation with Yes.
5. Move a point on the positive X axis of the workpiece coordinate system to
the TCP of the fixed tool. Press Calibrate. Answer the request for confirmation with Yes.
6. Move a point with a positive Y value in the XY plane of the workpiece coordinate system to the TCP of the fixed tool. Press Calibrate. Answer the
request for confirmation with Yes.
7. Enter the load data of the workpiece. (This step can be skipped if the load
data are entered separately instead.)
( & gt; & gt; & gt; 5.12.3 " Entering payload data " Page 126)
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8. Confirm with Next.
9. If required, coordinates and orientation of the calibrated points can be displayed in increments and degrees (relative to the FLANGE coordinate system). For this, press Meas. points. Then return to the previous view by
pressing Back.
10. Press Save.
5.11.4.4 Workpiece calibration: indirect method
Description
The robot controller calculates the workpiece on the basis of 4 points whose
coordinates must be known. The robot does not move to the origin of the workpiece.
Fig. 5-25: Workpiece calibration: indirect method
Precondition
A previously calibrated fixed tool is mounted.
The workpiece to be calibrated is mounted on the mounting flange.
The coordinates of 4 points of the new workpiece are known, e.g. from
CAD data. The 4 points are accessible to the TCP.
Procedure
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; Fixed tool & gt; Workpiece
& gt; Indirect calibration.
2. Assign a number and a name for the workpiece. Confirm with Next.
3. Enter the number of the fixed tool. Confirm with Next.
4. Enter the coordinates of a known point on the workpiece and move this
point to the TCP of the fixed tool. Press Calibrate. Answer the request for
confirmation with Yes.
5. Repeat step 4 three times.
6. Enter the load data of the workpiece. (This step can be skipped if the load
data are entered separately instead.)
( & gt; & gt; & gt; 5.12.3 " Entering payload data " Page 126)
7. Confirm with Next.
8. If required, coordinates and orientation of the calibrated points can be displayed in increments and degrees (relative to the FLANGE coordinate sys-
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tem). For this, press Meas. points. Then return to the previous view by
pressing Back.
9. Press Save.
5.11.5
Renaming the tool/base
Precondition
Procedure
1. In the main menu, select Start-up & gt; Calibrate & gt; Tool or Base & gt; Change
name.
Operating mode T1
2. Select the tool or base and press Name.
3. Enter the new name and confirm with Save.
5.11.6
Linear unit
The KUKA linear unit is a self-contained, one-axis linear unit mounted on the
floor or ceiling. It is used for linear traversing of the robot and is controlled by
the robot controller as an external axis.
The linear unit is a ROBROOT kinematic system. When the linear unit is
moved, the position of the robot in the WORLD coordinate system changes.
The current position of the robot in the WORLD coordinate system is defined
by the vector $ROBROOT_C.
$ROBROOT_C consists of:
$ERSYSROOT (static component)
Root point of the linear unit relative to $WORLD. The root point is situated
by default at the zero position of the linear unit and is not dependent on
$MAMES.
#ERSYS (dynamic component)
Current position of the robot on the linear unit relative to the $ERSYSROOT
Fig. 5-26: ROBROOT kinematic system – linear unit
5.11.6.1 Checking whether the linear unit needs to be calibrated
Description
The robot is standing on the flange of the linear unit. Ideally, the ROBROOT
coordinate system of the robot should be identical to the FLANGE coordinate
system of the linear unit. In reality, there are often slight discrepancies which
mean that positions cannot be moved to correctly. Calibration allows mathe-
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matical correction of these discrepancies. (Rotations about the direction of
motion of the linear unit cannot be corrected. They do not, however, cause errors when moving to positions.)
If there are no discrepancies, the linear unit does not need to be calibrated.
The following procedure can be used to determine whether calibration is required.
Precondition
The machine data of the linear unit have been configured and loaded into
the robot controller.
A previously calibrated tool is mounted on the mounting flange.
No program is open or selected.
Procedure
Operating mode T1
1. Align the TCP against a freely selected point and observe it.
2. Execute a Cartesian (not axis-specific!) motion with the linear unit.
If the TCP stops: the linear unit does not require calibration.
If the TCP moves: the linear unit does require calibration.
( & gt; & gt; & gt; 5.11.6.2 " Calibrating the linear unit " Page 118)
If the calibration data are already known (e.g. from CAD), they can be entered
directly. ( & gt; & gt; & gt; 5.11.6.3 " Entering the linear unit numerically " Page 119)
5.11.6.2 Calibrating the linear unit
Description
During calibration, the TCP of a tool that has already been calibrated is moved
to a reference point 3 times.
The reference point can be freely selected.
The position of the robot on the linear unit from which the reference point
is approached must be different all 3 times. The 3 positions must be far
enough apart.
The correction values determined by the calibration are factored into the system variable $ETx_TFLA3.
Precondition
The machine data of the linear unit have been configured and loaded into
the robot controller.
A previously calibrated tool is mounted on the mounting flange.
No program is open or selected.
Procedure
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; External kinematic system & gt; Linear unit.
The robot controller detects the linear unit automatically and displays the
following data:
Ext. kinematic system no.: number of the external kinematic system
(1 … 6) ($EX_KIN)
Axis: number of the external axis (1 … 6) ($ETx_AX)
Name of the external kinematic system ($ETx_NAME)
(If the robot controller is unable to determine these values, e.g. because
the linear unit has not yet been configured, calibration cannot be continued.)
2. Move the linear unit with the jog key “+”.
3. Specify whether the linear unit is moving to “+” or “-”. Confirm with Next.
4. Move the TCP to the reference point.
5. Press Calibrate.
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6. Repeat steps 4 and 5 twice, but move the linear unit first each time in order
to address the reference point from different positions.
7. Press Save. The calibration data are saved.
8. The system asks whether the positions that have already been taught are
to be corrected.
If no positions have been taught prior to the calibration, it makes no difference whether the question is answered with Yes or No.
If positions have been taught prior to the calibration:
Answering Yes will cause positions with base 0 to be corrected automatically. Other positions will not be corrected!
Answering No will cause no positions to be corrected.
After calibration of a linear unit, the following safety measures must be carried out:
1. Check the software limit switches of the linear unit and adapt them if required.
2. Test programs in T1.
Damage to property may otherwise result.
5.11.6.3 Entering the linear unit numerically
Precondition
The machine data of the linear unit have been configured and loaded into
the robot controller.
No program is open or selected.
The following numerical values are known, e.g. from CAD data:
Procedure
Distance between the robot base flange and the origin of the ERSYSROOT coordinate system (X, Y, Z)
Orientation of the robot base flange relative to the ERSYSROOT coordinate system (A, B, C)
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; External kinematic system & gt; Linear unit (numeric).
The robot controller detects the linear unit automatically and displays the
following data:
Ext. kinematic system no.: number of the external kinematic system
(1 … 6)
Axis: number of the external axis (1 … 6)
Name of the kinematic system
(If the robot controller is unable to determine these values, e.g. because
the linear unit has not yet been configured, calibration cannot be continued.)
2. Move the linear unit with the jog key “+”.
3. Specify whether the linear unit is moving to “+” or “-”. Confirm with Next.
4. Enter data. Confirm with Next.
5. Press Save. The calibration data are saved.
6. The system asks whether the positions that have already been taught are
to be corrected.
If no positions have been taught prior to the calibration, it makes no difference whether the question is answered with Yes or No.
If positions have been taught prior to the calibration:
Answering Yes will cause positions with base 0 to be corrected automatically. Other positions will not be corrected!
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Answering No will cause no positions to be corrected.
After calibration of a linear unit, the following safety measures must be carried out:
1. Check the software limit switches of the linear unit and adapt them if required.
2. Test programs in T1.
Damage to property may otherwise result.
5.11.7
Calibrating an external kinematic system
Description
Calibration of the external kinematic system is necessary to enable the motion
of the axes of the kinematic system to be synchronized and mathematically
coupled with the robot axes. An external kinematic system can be a turn-tilt table or positioner, for example.
For linear units, the type of calibration described here must not be
used. A separate type of calibration must be used for linear units.
( & gt; & gt; & gt; 5.11.6 " Linear unit " Page 117)
Overview
Calibration of an external kinematic system consists of 2 steps:
Step
1
Description
Calibrate the root point of the external kinematic system.
( & gt; & gt; & gt; 5.11.7.1 " Calibrating the root point " Page 120)
If the calibration data are already known, they can be entered
directly.
( & gt; & gt; & gt; 5.11.7.2 " Entering the root point numerically " Page 122)
2
If there is a workpiece on the external kinematic system: calibrate the base of the workpiece.
( & gt; & gt; & gt; 5.11.7.3 " Workpiece base calibration " Page 122)
If the calibration data are already known, they can be entered
directly.
( & gt; & gt; & gt; 5.11.7.4 " Entering the workpiece base numerically "
Page 124)
If there is a tool mounted on the external kinematic system:
calibrate the external tool.
( & gt; & gt; & gt; 5.11.7.5 " Calibrating an external tool " Page 124)
If the calibration data are already known, they can be entered
directly.
( & gt; & gt; & gt; 5.11.7.6 " Entering the external tool numerically "
Page 125)
5.11.7.1 Calibrating the root point
Description
In order to be able to move the robot with a mathematical coupling to a kinematic system, the robot must know the precise location of the kinematic system. This location is determined by means of root point calibration.
The TCP of a tool that has already been calibrated is moved to a reference
point on the kinematic system 4 times. The position of the reference point must
be different each time. This is achieved by moving the axes of the kinematic
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system. The robot controller uses the different positions of the reference point
to calculate the root point of the kinematic system.
In the case of external kinematic systems from KUKA, the reference point is
configured in the system variable $ETx_TPINFL in the machine data. This
contains the position of the reference point relative to the FLANGE coordinate
system of the kinematic system. (x = number of the kinematic system.) The reference point is also marked on the kinematic system. During calibration, this
reference point must be addressed.
In the case of non-KUKA external kinematic systems, the reference point must
be configured in the machine data.
The robot controller saves the coordinates of the root point as the BASE coordinate system.
Fig. 5-27: Root point calibration principle
Precondition
The machine data of the kinematic system have been configured and loaded into the robot controller.
The number of the external kinematic system is known.
A previously calibrated tool is mounted on the mounting flange.
If $ETx_TPINFL is to be modified: user group “Expert”
Procedure
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; External kinematic system & gt; Root point.
2. Select the number of the BASE coordinate system the root point is to be
saved as. Confirm with Next.
3. Enter the number of the external kinematic system.
4. Assign a name for the external kinematic system. Confirm with Next.
5. Enter the number of the reference tool. Confirm with Next.
6. The value of $ETx_TPINFL is displayed.
If the value is not correct: the value can be modified here in the user
group “Expert”.
If the value is correct: confirm with Next.
7. Move the TCP to the reference point.
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8. Press Calibrate. Confirm with Next.
9. Repeat steps 7 and 8 three times. Each time, move the kinematic system
first so that the reference point is approached from different positions.
10. Press Save.
5.11.7.2 Entering the root point numerically
Precondition
The following numerical values are known, e.g. from CAD data:
Distance between the origin of the ROOT coordinate system and the
origin of the WORLD coordinate system (X, Y, Z)
Orientation of the ROOT coordinate system relative to the WORLD coordinate system (A, B, C)
Procedure
The number of the external kinematic system is known.
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; External kinematic system & gt; Root point (numeric).
2. Select the number of the BASE coordinate system the root point is to be
saved as. Confirm with Next.
3. Enter the number of the external kinematic system.
4. Assign a name for the external kinematic system. Confirm with Next.
(The name is automatically also assigned to the BASE coordinate system.)
5. Enter the data of the ROOT coordinate system. Confirm with Next.
6. Press Save.
5.11.7.3 Workpiece base calibration
Description
During this calibration, the user assigns a BASE coordinate system to a workpiece located on the kinematic system. This BASE coordinate system is relative to the FLANGE coordinate system of the kinematic system. The base is
thus a moving base that moves in the same way as the kinematic system.
It is not strictly necessary to calibrate a base. If none is calibrated, the
FLANGE coordinate system of the kinematic system is taken as the base.
During calibration, the TCP of a calibrated tool is moved to the origin and 2 other points of the desired base. These 3 points define the base. Only one base
can be calibrated per kinematic system.
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Fig. 5-28: Base calibration principle
Precondition
The machine data of the kinematic system have been configured and loaded into the robot controller.
A previously calibrated tool is mounted on the mounting flange.
The root point of the external kinematic system has been calibrated.
The number of the external kinematic system is known.
Procedure
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; External kinematic system & gt; Offset.
2. Enter the number of the BASE coordinate system the root point was saved
as. The name of the BASE coordinate system is displayed.
Confirm with Next.
3. Enter the number of the external kinematic system. The name of the external kinematic system is displayed.
Confirm with Next.
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4. Enter the number of the reference tool. Confirm with Next.
5. Move the TCP to the origin of the workpiece base. Press Calibrate and
confirm with Next.
6. Move the TCP to a point on the positive X axis of the workpiece base.
Press Calibrate and confirm with Next.
7. Move the TCP to a point in the XY plane with a positive Y value. Press Calibrate and confirm with Next.
8. Press Save.
5.11.7.4 Entering the workpiece base numerically
Precondition
The following numerical values are known, e.g. from CAD data:
Distance between the origin of the workpiece base and the origin of the
FLANGE coordinate system of the kinematic system (X, Y, Z)
Rotation of the axes of the workpiece base relative to the FLANGE coordinate system of the kinematic system (A, B, C)
The number of the external kinematic system is known.
Procedure
The root point of the external kinematic system has been calibrated.
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; External kinematic system & gt; Offset (numeric).
2. Enter the number of the BASE coordinate system the root point was saved
as. The name of the BASE coordinate system is displayed.
Confirm with Next.
3. Enter the number of the external kinematic system. The name of the external kinematic system is displayed.
Confirm with Next.
4. Enter data. Confirm with Next.
5. Press Save.
5.11.7.5 Calibrating an external tool
Description
During calibration of the external tool, the user assigns a coordinate system to
the tool mounted on the kinematic system. This coordinate system has its origin in the TCP of the external tool and is relative to the FLANGE coordinate
system of the kinematic system.
First of all, the user communicates to the robot controller the TCP of the tool
mounted on the kinematic system. This is done by moving a calibrated tool to
the TCP.
Then, the orientation of the coordinate system of the tool is communicated to
the robot controller. For this purpose, the user aligns the coordinate system of
the calibrated tool parallel to the new coordinate system. There are 2 variants:
5D: The user communicates the tool direction to the robot controller. By
default, the tool direction is the X axis. The orientation of the other axes is
defined by the system and cannot be influenced by the user.
The system always defines the orientation of the other axes in the same
way. If the tool subsequently has to be calibrated again, e.g. after a crash,
it is therefore sufficient to define the tool direction again. Rotation about
the tool direction need not be taken into consideration.
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6D: The user communicates the direction of all 3 axes to the robot controller.
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If 6D is selected: it is advisable to document the alignment of all axes.
If the tool subsequently has to be calibrated again, e.g. after a crash,
the axes must be aligned the same way as the first time in order to be
able to continue moving to existing points correctly.
The robot controller saves the coordinates of the external tool as the BASE coordinate system.
Precondition
The machine data of the kinematic system have been configured and loaded into the robot controller.
A previously calibrated tool is mounted on the mounting flange.
The root point of the external kinematic system has been calibrated.
The number of the external kinematic system is known.
Operating mode T1
The following procedure applies if the tool direction is the default tool
direction (= X axis). If the tool direction has been changed to Y or Z,
the procedure must also be changed accordingly.
( & gt; & gt; & gt; 5.11.1 " Defining the tool direction " Page 102)
Procedure
1. In the main menu, select Start-up & gt; Calibrate & gt; Fixed tool & gt; External kinematic offset.
2. Enter the number of the BASE coordinate system the root point was saved
as. The name of the BASE coordinate system is displayed.
Confirm with Next.
3. Enter the number of the external kinematic system. The name of the external kinematic system is displayed.
Confirm with Next.
4. Enter the number of the reference tool. Confirm with Next.
5. Select a variant in the box 5D/6D. Confirm with Next.
6. Move the TCP of the calibrated tool to the TCP of the external tool. Press
Calibrate and confirm with Next.
7. If 5D is selected:
Align +XBASE parallel to -ZFLANGE.
(i.e. align the mounting flange perpendicular to the tool direction of the external tool.)
If 6D is selected:
Align the mounting flange so that its axes are parallel to the axes of the
external tool:
+XBASE parallel to -ZFLANGE
(i.e. align the mounting flange perpendicular to the tool direction of the
external tool.)
+YBASE parallel to +YFLANGE
+ZBASE parallel to +XFLANGE
8. Press Calibrate and confirm with Next.
9. Press Save.
5.11.7.6 Entering the external tool numerically
Precondition
The following numerical values are known, e.g. from CAD data:
Distance between the TCP of the external tool and the origin of the
FLANGE coordinate system of the kinematic system (X, Y, Z)
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Procedure
Rotation of the axes of the external tool relative to the FLANGE coordinate system of the kinematic system (A, B, C)
Operating mode T1
1. In the main menu, select Start-up & gt; Calibrate & gt; Fixed tool & gt; Numeric input.
2. Assign a number and a name for the external tool. Confirm with Next.
3. Enter data. Confirm with Next.
4. Press Save.
5.12
Load data
The load data are factored into the calculation of the paths and accelerations
and help to optimize the cycle times. The load data must be entered in the robot controller.
Sources
Load data can be obtained from the following sources:
Manufacturer information
Manual calculation
5.12.1
Software option KUKA.LoadDataDetermination (only for payloads on the
flange)
CAD programs
Checking loads with KUKA.Load
All load data (payload and supplementary loads) must be checked with the
KUKA.Load software. Exception: If the payload is checked with KUKA.LoadDataDetermination, it is not necessary to check it with KUKA.Load.
A sign-off sheet can be generated for the loads with KUKA.Load. KUKA.Load
can be downloaded free of charge, complete with the documentation, from the
KUKA website www.kuka.com.
More information is contained in the KUKA.Load documentation.
5.12.2
Calculating payloads with KUKA.LoadDataDetermination
Description
KUKA.LoadDataDetermination can be used to calculate payloads exactly and
transfer them to the robot controller.
Precondition
T1 or T2 operating mode
No program is selected.
In the main menu, select Start-up & gt; Service & gt; Load data determination.
Procedure
More information is contained in the KUKA.LoadDataDetermination
documentation.
5.12.3
Entering payload data
Description
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The payload data must be entered in the robot controller and assigned to the
correct tool.
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Exception: If the payload data have already been transferred to the robot controller by KUKA.LoadDataDetermination, no manual entry is required.
Precondition
Procedure
1. In the main menu, select Start-up & gt; Calibrate & gt; Tool & gt; Payload data.
The payload data have been checked with KUKA.Load or KUKA.LoadDataDetermination and the robot is suitable for these payloads.
2. Enter the number of the tool in the box Tool no.. Confirm with Next.
3. Enter the payload data:
Box M: Mass
Boxes X, Y, Z: Position of the center of gravity relative to the flange
Boxes A, B, C: Orientation of the principal inertia axes relative to the
flange
Boxes JX, JY, JZ: Mass moments of inertia
(JX is the inertia about the X axis of the coordinate system that is rotated relative to the flange by A, B and C. JY and JZ are the analogous
inertia about the Y and Z axes.)
Or, if the default values for this robot type are to be used: press Default.
4. If online load data verification is available (this depends on the robot type):
configure as required.
( & gt; & gt; & gt; 5.12.5 " Online load data check (OLDC) " Page 127)
5. Confirm with Next.
6. Press Save.
5.12.4
Entering supplementary load data
Description
The supplementary load data must be entered in the robot controller.
Reference systems of the X, Y and Z values for each supplementary load:
Load
Reference system
Supplementary load
A1
ROBROOT coordinate system
Supplementary load
A2
ROBROOT coordinate system
Supplementary load
A3
FLANGE coordinate system
A1 = 0°
A2 = -90°
A4 = 0°, A5 = 0°, A6 = 0°
Precondition
Procedure
1. In the main menu, select Setup & gt; Measure & gt; Supplementary load data.
The supplementary loads have been verified with KUKA.Load and are
suitable for this robot type.
2. Enter the number of the axis on which the supplementary load is to be
mounted. Confirm with Continue.
3. Enter the load data. Confirm with Continue.
4. Press Save.
5.12.5
Online load data check (OLDC)
Description
For many robot types, the robot controller monitors whether or not there is an
overload or underload during operation. This monitoring is called “Online load
data check” (OLDC).
If the OLDC detects an underload, for example, the robot controller reacts, e.g.
by displaying a message. The reactions can be configured.
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The results of the check can be polled using the system variable
$LDC_RESULT. ( & gt; & gt; & gt; " $LDC_RESULT " Page 129)
OLDC is available for those robot types for which KUKA.LoadDataDetermination can also be used. Whether or not OLDC is available for the current robot
type can be checked by means of $LDC_LOADED (TRUE = yes).
Overload
Underload
Configuration
There is an overload if the actual load is greater than
the configured load.
There is an underload if the actual load is less than the
configured load.
OLDC can be configured as follows:
During manual entry of the tool data
During separate entry of the payload data
( & gt; & gt; & gt; 5.11.2.5 " Numeric input " Page 109)
( & gt; & gt; & gt; 5.12.3 " Entering payload data " Page 126)
The following boxes are displayed in the same window in which the payload
data are also entered:
Fig. 5-29: Online load data check
Item
1
Description
TRUE: OLDC is activated for the tool displayed in the same window. The defined reactions are carried out in the case of an overload or underload.
FALSE: OLDC is deactivated for the tool displayed in the same
window. There is no reaction in the case of an overload or underload.
2
The overload reaction can be defined here.
Warning: The robot controller generates the following status
message: Check of robot load (Tool (Tool number)) calculated overload.
3
None: No reaction.
Stop robot: The robot controller generates an acknowledgement message with the same content as that generated under
Warning. The robot stops with a STOP 2.
The underload reaction can be defined here. The possible reactions are analogous to those for an overload.
The reactions can be modified in the KRL program using the system variable
$LDC_CONFIG. ( & gt; & gt; & gt; " $LDC_CONFIG " Page 129)
NULLFRAME
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OLDC cannot be configured for motions to which the tool NULLFRAME has
been assigned. The reactions are defined for this case and cannot be influenced by the user.
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5 Start-up and recommissioning
Overload reaction: Stop robot
The following acknowledgement message is generated: Overload calculated when checking robot load (no tool defined) and the set load data. The robot stops with a STOP 2.
Underload reaction: Warning
The following status message is generated: Underload calculated when
checking robot load (no tool defined) and the set load data.
$LDC_CONFIG
$LDC_CONFIG[Index]= {UNDERLOAD Reaction, OVERLOAD Reaction}
Element
Description
Index
Type: INT
Tool number
1 … 32
Type: CHAR
Reaction
#NONE (= None)
#WARNONLY (= Warning)
#STOPROBOT (= Stop robot)
Example:
1
2
3
4
5
...
$LDC_CONFIG[1]={UNDERLOAD #NONE, OVERLOAD #NONE}
...
$LDC_CONFIG[1]={UNDERLOAD #WARNONLY, OVERLOAD #WARNONLY}
...
Line
The reaction for both underload and overload is set to None.
4
$LDC_RESULT
Description
2
The reaction is set to Warning. If there is an underload or
overload, the corresponding status messages will be displayed in the message window.
$LDC_RESULT[Index]= Result
Element
Description
Index
Type: INT
Tool number
Result
1 … 32
Type: CHAR
#OVERLOAD: There is an overload.
#UNDERLOAD: There is an underload.
#CHECKING
5.13
#OK: The payload is OK. (Neither overload nor underload.)
#NONE: There are currently no results, e.g. because
the tool has been changed.
Maintenance handbook
The Maintenance handbook functionality is available in the KUKA System
Software. The maintenance handbook enables logging of the maintenance
work. The logged maintenance work can be displayed in an overview.
The robot controller uses messages to indicate when maintenance is due:
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KUKA System Software 8.2
A message is generated one month before the maintenance work is due.
This message can be acknowledged.
At the end of the month, the robot controller generates a message indicating that the maintenance is now due. This message cannot be acknowledged. Additionally, LED4 on the Controller System Panel flashes (= first
LED from the left in the bottom row).
Only when the corresponding maintenance work has been logged does
the robot controller reset the message and the LED stops flashing.
The due dates are determined by the maintenance intervals specified in the
KUKA maintenance agreements. The intervals are counted from the initial
start-up of the robot controller. The operating hours of the robot are counted.
5.13.1
Logging maintenance
Description
It is not possible to log multiple maintenance activities of the same kind on one
day.
Once saved, changes can no longer be made.
Precondition
Procedure
1. In the main menu, select Start-up & gt; Service & gt; Maintenance handbook.
The Maintenance handbook window is opened.
Expert user group
2. Select the Maintenance input tab and enter the maintenance details. Entries must be made in all boxes.
3. Press Save. A request for confirmation is displayed.
4. If all entries are correct, answer the request for confirmation with Yes.
The entries are now saved. Switching to the Maintenance overview tab
causes the maintenance to be displayed there.
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5 Start-up and recommissioning
Fig. 5-30: Maintenance input
Item
Description
1
Select which type of maintenance has been carried out.
2
Enter who performed the maintenance.
3
For maintenance carried out and logged by KUKA employees: enter the order number.
4
Enter a comment.
For other maintenance: enter any number.
Maintenance
types
By default, the following maintenance types can be selected:
Basic inspection
In-line wrist maintenance
Main axis maintenance
Gear backlash measurement
Minor electrical maintenance
Major electrical maintenance
Data backup with spare hard drive
Repair
These maintenance types correspond to those in the KUKA maintenance
agreements. Depending on the options used (e.g. linear axis or technology
packages), other maintenance types may be available for selection.
5.13.2
Displaying a maintenance log
Description
The logged maintenance work can be displayed in an overview.
If the KUKA System Software is updated (e.g. from KSS 8.2.3 to KSS 8.2.4),
this overview is retained.
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KUKA System Software 8.2
When archiving is carried out, the maintenance logs are also archived. If,
when the data are restored, other maintenance work has been logged on the
robot controller in the meantime, these logs are not overwritten; instead, the
restored logs are added to the overview.
Procedure
1. In the main menu, select Start-up & gt; Service & gt; Maintenance handbook.
The Maintenance handbook window is opened.
2. Select the Maintenance overview tab.
Fig. 5-31: Maintenance overview
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6 Configuration
6
Configuration
6.1
Configuring the KUKA Line Interface (KLI)
The KLI is the Ethernet interface of the robot controller for external communication. It is a physical interface and can contain multiple virtual interfaces.
In order for external PCs to be able to connect to the robot controller via a network, the KLI must be configured accordingly. This is a precondition, for example, for being able to transfer WorkVisual projects to the robot controller via
the network.
The following address ranges are used by default by the
robot controller for internal purposes. IP addresses from
this range must not therefore be assigned by the user.
172.16.0.0 … 172.16.255.255
6.1.1
192.168.0.0 … 192.168.0.255
172.17.0.0 … 172.17.255.255
Configuring the Windows interface (without PROFINET)
Description
The Windows interface is a virtual interface of the KLI.
From Build 48 onwards, KSS 8.2 is supplied with a preconfigured static IP address for the Windows interface:
IP address: 172.31.1.147
Subnet mask: 255.255.0.0
These values can be modified by the user. If required, it is also possible to
switch to dynamic address assignment. Similarly, it is also possible to switch
back from a dynamic address to a static address.
Precondition
PROFINET is not used.
If the address type Dynamic IP address is to be selected: there is a DHCP
server present in the network.
No program is selected.
T1 or T2 operating mode
Procedure
“Expert” user group
The Address and Subnet boxes may be displayed with a red frame.
This means that there is an error.
( & gt; & gt; & gt; 6.1.6 " Error display in the Address and Subnet boxes "
Page 138)
1. In the main menu, select Start-up & gt; Network configuration. The Network configuration window is opened. The active Windows interface is
displayed. (Default: “virtual5”)
2. Select the desired type in the Address type box: Dynamic IP address or
Fixed IP address
The other types in this box (e.g. Real-time IP address) must not be
selected.
3. Only for Dynamic IP address:
The following boxes are deactivated, as the values are automatically assigned by the DHCP server: IP address, Subnet mask, Standard gateway
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4. Only for Fixed IP address: Fill out the following boxes:
IP address : enter the IP address of the robot controller.
Subnet mask: the selected subnet mask must match the IP network.
Standard gateway (if required): specifies the IP address that can be
used to leave the network.
“0.0.0.0” is admissible and is ignored by the system.
5. Press Save.
6. Reboot the robot controller so that the change takes effect.
Fig. 6-1: Example: Fixed IP address
6.1.2
Configuring the Windows PROFINET interface and creating the Windows interface
Description
PROFINET automatically occupies the virtual interface “virtual5”. This must be
adapted to PROFINET.
“Virtual5” can also be used as a Windows interface, but the static IP address
of PROFINET must then be used for Windows access.
If a different IP configuration is to be used for the Windows interface, an additional virtual interface, e.g. “virtual6” must be added and configured for this
purpose.
Precondition
PROFINET is used.
PROFINET device naming has been completed.
Information about device naming can be found in the documentation
KR C4 PROFINET.
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T1 or T2 operating mode
Procedure
No program is selected.
“Expert” user group
The Address and Subnet boxes may be displayed with a red frame.
This means that there is an error.
( & gt; & gt; & gt; 6.1.6 " Error display in the Address and Subnet boxes "
Page 138)
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6 Configuration
1. In the main menu, select Start-up & gt; Network configuration. The Network configuration window is opened. The “virtual5” interface is displayed.
2. If it has not already been selected: select the type Fixed IP address in the
box Address type.
3. Fill out the boxes IP address and Subnet mask. Enter the address and
mask that are also assigned by the PROFINET PLC.
4. Press Activate. The window for advanced network configuration opens.
5. Select the Interfaces tab.
6. Select the entry “virtual5” in the Configured interfaces area and enter
“PROFINET” in the Interface name box.
7. Several “Queue” entries are displayed under the entry “virtual5”. Select the
bottom one.
8. The Reception filter box indicates Accept all. Change the entry to Target
IP address.
Fig. 6-2
9. Select the entry “virtual5” and press the Add interface button. The entry
“virtual6” is automatically created.
10. Select the entry “virtual6” and enter “WINDOWS” in the Interface name
box.
11. Select the type Dynamic IP address in the Address type box.
Fixed IP address can also be selected here if a static IP address is
desired. The static address must be in a different address range,
however, than the address of “virtual5”.
12. Set the check mark in the check box Windows interface.
Fig. 6-3: Interface “virtual6”
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13. Several the “Queue” entry under the entry “virtual6”.
14. If not already the case, change the Reception filter box to Accept all.
15. Press Save.
16. Close the Network configuration window using the Close icon.
17. Reboot the robot controller. For this, select Shutdown in the main menu
and select the option Reload files.
The check mark in the check box Windows interface cannot be removed. Deselection is only possible by defining a different interface
as the Windows interface.
6.1.3
Displaying ports of the Windows interface or enabling an additional port
It is not generally necessary to enable additional ports. If this is nevertheless to be done, KUKA Roboter GmbH must be contacted beforehand.
The ports enabled by KUKA by default must not be removed. Doing so may result in the loss of functions of the
robot controller.
Precondition
User group “Expert”
Operating mode T1 or T2.
Procedure
No program is selected.
1. In the main menu, select Start-up & gt; Network configuration. The Network configuration window is opened.
2. Press Activate. The window for advanced network configuration opens.
3. Select the NAT tab. A list of all the enabled ports of the Windows interface
is displayed in the Available ports area.
4. Only if a port is to be enabled:
a. Press Add port. A new port with the number “0” is added to the list.
b. Complete the boxes Port number and Permitted protocols.
c. Press Save.
A maximum total of 40 ports can be enabled.
5. Close the Network configuration window using the Close icon.
6. Only if modifications have been made:
Reboot the robot controller so that the changes take effect. To do so, if
PROFINET is used, select Shutdown in the main menu and select the option Reload files.
6.1.4
Displaying or modifying filters
It is not generally necessary to modify the filters. If this is nevertheless
to be done, KUKA Roboter GmbH must be contacted beforehand.
The filters set by KUKA by default must not be modified
or removed. Doing so may result in the loss of functions
of the robot controller.
Precondition
User group “Expert”
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Operating mode T1 or T2.
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6 Configuration
Procedure
No program is selected.
1. In the main menu, select Start-up & gt; Network configuration. The Network configuration window is opened.
2. Press Activate. The window for advanced network configuration opens.
3. Select the Internal subnets tab. The filters of the KUKA Line Interface and
their properties are displayed here.
4. Only if modifications are required: Carry them out and press Save.
5. Close the Network configuration window using the Close icon.
6. Only if modifications have been made:
Reboot the robot controller so that the changes take effect. To do so, if
PROFINET is used, select Shutdown in the main menu and select the option Reload files.
6.1.5
Displaying the subnet configuration of the robot controller
Description
The subnet configuration of the robot controller can be displayed. This makes
it possible to compare it with the subnets of the customer network.
The subnet configuration of the robot controller may be
modified only in consultation with KUKA Roboter GmbH.
Modifications carried out without consultation may result in the loss of functions of the robot controller.
Precondition
User group “Expert”
Operating mode T1 or T2.
Procedure
No program is selected.
1. In the main menu, select Start-up & gt; Network configuration. The Network configuration window is opened.
2. Press Activate. The window for advanced network configuration opens.
3. Select the Internal subnets tab. The subnet configuration of the robot
controller is displayed.
Only the network address is displayed. The range containing the address
of the device is indicated by an “x”.
The Address and Subnet boxes may be displayed with a red frame.
This means that there is an error.
( & gt; & gt; & gt; 6.1.6 " Error display in the Address and Subnet boxes "
Page 138)
Fig. 6-4: Example: Internal subnets
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6.1.6
Error display in the Address and Subnet boxes
Description
The Address and Subnet boxes may be displayed with a red frame. This indicates an error and may have the following causes:
Cause
Possible remedy
The entry does not conform to the
IP system.
Check the box with the red frame
and correct it.
Example: The number ranges of the
IP address and subnet do not
match.
The red frame disappears.
This address is already used in one
of the internal subnets.
Change the actual address.
Or change the address of the internal subnet.
In this case, both the address and
the corresponding box on the Internal subnets tab are displayed with
a red frame.
The red frame disappears.
The subnet configuration of the robot controller may be
modified only in consultation with KUKA Roboter GmbH.
Modifications carried out without consultation may result in the loss of functions of the robot controller.
Example
Example of an entry that is not system-compliant:
In the binary display, subnet masks may only contain closed groups of leading
ones.
The subnet mask “255.255.208.0” is entered.
The box is now displayed with a red frame.
Reason: The binary representation of “208” corresponds to “11010000”
and is thus not a valid entry.
Possible remedy: enter 255.255.240.0.
The binary representation of “240” corresponds to “11110000” and is thus
a valid entry.
6.1.7
Configuring DNS
Description
If the robot controller is connected to the IT network, name resolution of the
devices can be carried out via the DNS server address. (In other words, the
DNS server receives a query with a device name and responds with the corresponding IP address.)
In KSS 8.2, this configuration must be carried out manually. This is not dependent on whether the address type Dynamic IP address or Fixed IP address
has been selected.
Precondition
User group " Expert " .
Procedure
Operating mode T1 or T2.
1. Select Start-up & gt; Service & gt; Minimize HMI in the main menu.
2. Open the Windows Start menu and select Network Connections.
The Network Connections window is opened and the LAN connection is
displayed.
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Fig. 6-5: “Network Connections” window
3. Right-click on the LAN connection and select Properties.
The Local Area Connection properties window is opened.
Fig. 6-6: “Local Area Connection Properties” window
4. Select Internet Protocol (TCP/IP) and select the Properties button.
The Internet Protocol (TCP/IP) Properties window is opened.
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Fig. 6-7: “Internet Protocol Properties” window, example
5. Activate the radio button Use the following DNS server addresses.
Enter the preferred DNS server address. An alternative DNS server address can also be entered.
6. Press the Advanced... button.
The Advanced TCP/IP Settings window opens.
7. Select the WINS tab.
Fig. 6-8: “Advanced TCP/IP Settings” window
8. Press the Add... button.
The TCP/IP WINS Server window opens.
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Fig. 6-9: “TCP/IP WINS Server” window
9. Enter the WINS server address. The WINS server address must match the
DNS server address entered in step 4.
10. Press the Add button.
The WINS server address is applied and displayed in the Advanced TCP/
IP Settings window.
11. Close the Advanced TCP/IP Settings window with OK.
12. Close the Internet Protocol (TCP/IP) Properties window with OK.
13. Close the Local Area Connection properties window with OK.
6.2
Reconfiguring the I/O driver
Precondition
User group " Expert " .
Operating mode T1 or T2.
Procedure
All outputs are reset!
6.3
In the main menu, select Configuration & gt; Inputs/outputs & gt; Reconfigure
I/O driver.
Checking the safety configuration of the robot controller
Description
The safety configuration of the robot controller must be checked in the following cases:
After activation of a WorkVisual project on the robot controller
Generally after changes to the machine data (independent of WorkVisual).
If the safety configuration is not checked and updated
where necessary, it may contain incorrect data. Death to
persons, severe physical injuries or considerable damage to property may
result.
Precondition
User group Expert or higher
If one of the options KUKA.SafeOperation or KUKA.SafeRangeMonitoring is installed on the robot controller, different user groups may
apply. Information can be found in the documentation for these op-
tions.
Procedure
1. Select the menu sequence Configuration & gt; Safety configuration.
2. The safety configuration checks whether there are any relevant deviations
between the data in the robot controller and those in the safety controller.
3. The following situations can now occur:
a. If there are no deviations, the Safety configuration window is
opened. No message is displayed. No further action is necessary.
b. If there are deviations regarding the machine data, a dialog message
is displayed. This indicates which machine data in the robot controller
deviate from those in the safety controller.
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The message asks whether the safety controller should be updated.
Confirm the request with Yes.
The system asks whether the deviations should now be accepted.
Confirm the request with Yes.
c. The safety configuration also checks whether there are any other deviations (other than in the machine data) between the robot controller
and the safety controller.
If so, the Troubleshooting wizard window is opened. A description of
the problem and a list of possible causes is displayed. The user can
select the applicable cause. The wizard then suggests a solution.
6.4
Configuring the variable overview
This is where the variables to be displayed in the variable overview and the
number of groups are defined. A maximum of 10 groups is possible. A maximum of 25 variables per group is possible. System variables and user-defined
variables can be displayed.
Precondition
Procedure
1. In the main menu, select Display & gt; Variable & gt; Overview & gt; Configuration.
Expert user group
The Variable overview - Configuration window is opened.
2. Make the desired settings. To edit a cell, select it.
3. Press OK to save the configuration and close the window.
Description
Fig. 6-10: Variable overview - Configuration
Item
1
Description
Arrow symbol
: If the value of the variable changes, the display
is automatically updated.
No arrow symbol: The display is not automatically updated.
2
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Descriptive name
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6 Configuration
Item
3
Description
Path and name of the variable
Note: For system variables, the name is sufficient. Other variables
must be specified as follows:
/R1/Program name/Variable name
Do not specify a folder between /R1/ and the program name. Do
not add a file extension to the file name.
4
Lowest user group in which the variable overview can be modified.
5
Lowest user group in which the variable overview can be displayed.
6
Column width in mm. Enter the desired value via the keypad and
confirm it with the Enter key.
7
Row height in mm. Enter the desired value via the keypad and confirm it with the Enter key.
The following buttons are available:
Button
Description
Display
Switches to the variable overview.
( & gt; & gt; & gt; 4.15.7 " Displaying the variable overview
and modifying variables " Page 72)
Insert
Displays additional buttons:
Row below: Inserts a new row below the one
currently selected.
Group before: Inserts a new group to the left
of the one currently selected.
Delete
Row above: Inserts a new row above the one
currently selected.
Group after: Inserts a new group to the right
of the one currently selected.
Displays additional buttons:
6.5
Row: The selected row is deleted.
Group: The current group is deleted.
Changing the password
Procedure
1. Select Configuration & gt; User group in the main menu. The current user
group is displayed.
2. Press Login....
3. Select the user group for which the password is to be changed.
4. Press Password ....
5. Enter the old password. Enter the new password twice.
For security reasons, the entries are displayed encrypted. Upper and lower case are taken into consideration.
6. Press OK. The new password is valid immediately.
6.6
Configuring workspaces
Workspaces can be configured for a robot. These serve to protect the system.
A maximum of 8 Cartesian (=cubic) and 8 axis-specific workspaces can be
configured at any one time. The workspaces can overlap.
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( & gt; & gt; & gt; 6.6.1 " Configuring Cartesian workspaces " Page 144)
( & gt; & gt; & gt; 6.6.2 " Configuring axis-specific workspaces " Page 146)
There are 2 types of workspace:
Non-permitted spaces. The robot may only move outside such a space.
Permitted spaces. The robot must not move outside such a space.
Exactly what reactions occur when the robot violates a workspace depends on
the configuration.
6.6.1
Configuring Cartesian workspaces
In the case of Cartesian workspaces, only the position of the TCP is
monitored. It is not possible to monitor whether other parts of the robot violate the workspace.
Description
The following parameters define the position and size of a Cartesian workspace:
Origin of the workspace relative to the WORLD coordinate system
Dimensions of the workspace, starting from the origin
Fig. 6-11: Cartesian workspace, origin U
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Fig. 6-12: Cartesian workspace, dimensions
Precondition
User group " Expert " .
Procedure
Operating mode T1 or T2.
1. In the main menu, select Configuration & gt; Miscellaneous & gt; Workspace
monitoring & gt; Configuration.
The Cartesian workspaces window is opened.
2. Enter values and press Save.
3. Press Signal. The Signals window is opened.
4. In the Cartesian group: next to the number of the workspace, enter the
output that is to be set if the workspace is violated.
5. Press Save.
6. Close the window.
Fig. 6-13: Configuring a Cartesian workspace
Item
Description
1
Number of the workspace (max. 8)
2
Designation of the workspace
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Item
3
Description
Origin and orientation of the workspace relative to the WORLD coordinate system
4
Dimensions of the workspace in mm
5
Mode ( & gt; & gt; & gt; 6.6.3 " Mode for workspaces " Page 148)
Fig. 6-14: Workspace signals
Item
Description
1
Outputs for the monitoring of the Cartesian workspaces
2
Outputs for the monitoring of the axis-specific workspaces
If no output is to be set when the workspace is violated, the value FALSE must
be entered.
6.6.2
Configuring axis-specific workspaces
Description
Axis-specific workspaces can be used to restricted yet further the areas defined by the software limit switches in order to protect the robot, tool or workpiece.
Fig. 6-15: Example of axis-specific workspaces for A1
Precondition
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User group " Expert " .
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6 Configuration
Procedure
Operating mode T1 or T2.
1. In the main menu, select Configuration & gt; Miscellaneous & gt; Workspace
monitoring & gt; Configuration.
The Cartesian workspaces window is opened.
2. Press Axis-spec. to switch to the window Axis-specific workspaces.
3. Enter values and press Save.
4. Press Signal. The Signals window is opened.
5. In the Axis-specific group: next to the number of the workspace, enter the
output that is to be set if the workspace is violated.
6. Press Save.
7. Close the window.
Fig. 6-16: Configuring an axis-specific workspace
Item
Description
1
Number of the workspace (max. 8)
2
Designation of the workspace
3
Lower limit for axis angle
4
Upper limit for axis angle
5
Mode ( & gt; & gt; & gt; 6.6.3 " Mode for workspaces " Page 148)
If the value 0 is entered for an axis under Item 3 and Item 4, the axis is not
monitored, irrespective of the mode.
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Fig. 6-17: Workspace signals
Item
Description
1
Outputs for the monitoring of the Cartesian workspaces
2
Outputs for the monitoring of the axis-specific workspaces
If no output is to be set when the workspace is violated, the value FALSE must
be entered.
6.6.3
Mode for workspaces
Mode
Description
#OFF
Workspace monitoring is deactivated.
#INSIDE
Cartesian workspace: The defined output is set if
the TCP or flange is located inside the workspace.
Axis-specific workspace: The defined output is set if
the axis is located inside the workspace.
Cartesian workspace: The defined output is set if
the TCP or flange is located outside the workspace.
Axis-specific workspace: The defined output is set if
the axis is located outside the workspace.
#OUTSIDE
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Mode
#INSIDE_STOP
Description
Cartesian workspace: The defined output is set if
the TCP, flange or wrist root point is located inside
the workspace. (Wrist root point = center point of
axis A5)
Axis-specific workspace: The defined output is set if
the axis is located inside the workspace.
The robot is also stopped and messages are displayed.
The robot cannot be moved again until the workspace
monitoring is deactivated or bypassed.
( & gt; & gt; & gt; 4.14 " Bypassing workspace monitoring "
Page 66)
#OUTSIDE_ST
OP
Cartesian workspace: The defined output is set if
the TCP or flange is located outside the workspace.
Axis-specific workspace: The defined output is set if
the axis is located outside the workspace.
The robot is also stopped and messages are displayed.
The robot cannot be moved again until the workspace
monitoring is deactivated or bypassed.
( & gt; & gt; & gt; 4.14 " Bypassing workspace monitoring "
Page 66)
6.7
Warm-up
Description
If a robot is started in low ambient temperatures, this results in increased friction in the gear unit. This can cause the motor current of an axis (or of more
than one axis) to reach its maximum value. This stops the robot and the robot
controller generates the error message Regulator limit exceeded & lt; axis number & gt; .
To avoid this, the motor current can be monitored during the warm-up phase.
If a defined value is reached, the robot controller reduces the motion velocity.
This, in turn, reduces the motor current.
The monitoring refers to PTP motions and PTP-CP approximate positioning blocks. CP motions (including Spline) are not monitored and
their velocity is not reduced.
6.7.1
Configuring warm-up
Precondition
Procedure
1. Open the file R1\Mada\$machine.dat.
Expert user group
2. Set the corresponding system variables to the desired values.
( & gt; & gt; & gt; 6.7.3 " System variables for warm-up " Page 150)
3. Close the file. Respond to the request for confirmation asking whether the
changes should be saved by pressing Yes.
6.7.2
Warm-up sequence
Precondition
$WARMUP_RED_VEL =TRUE
Operating mode AUT or AUT EXT
The robot is considered to be cold. This applies in the following cases:
Cold start
Or $COOLDOWN_TIME has expired.
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KUKA System Software 8.2
Example
Or $WARMUP_RED_VEL has been set from FALSE to TRUE.
Sequence on the basis of the following example values in $machine.dat:
BOOL $WARMUP_RED_VEL = TRUE
REAL $WARMUP_TIME = 30.0
REAL $COOLDOWN_TIME = 120.0
INT $WARMUP_CURR_LIMIT = 95
INT $WARMUP_MIN_FAC = 60
REAL $WARMUP_SLEW_RATE = 5.0
1. The cold robot starts. The motor currents are monitored for 30 minutes
($WARMUP_TIME).
2. If the motor current of an axis exceeds 95% ($WARMUP_CURR_LIMIT)
of the maximum permissible motor current, the monitoring is triggered.
The robot controller then generates the message Warm-up active and reduces the internal override. The robot slows down and the motor current
drops. The program override on the KCP remains unchanged!
The internal override is reduced to a maximum of 60%
($WARMUP_MIN_FAC) of the programmed override. There is no way of
influencing how quickly the internal override is reduced.
3. Once the monitoring is no longer triggered, the robot controller increases
the internal override again. This is generally the case before the minimum
$WARMUP_MIN_FAC has been reached! The robot accelerates again.
Once a second, the robot controller edges back up towards the programmed override. $WARMUP_SLEW_RATE determines the rate of increase. In the example, the internal override is increased by 5% per
second.
4. It is possible that the robot is still not warm enough and that the motor current thus exceeds the maximum $WARMUP_CURR_LIMIT once again.
The robot controller reacts (within $WARMUP_TIME) the same way as the
first time.
5. If the robot is warm enough for the robot controller to increase the internal
override all the way back up to the programmed override, the robot controller deactivates the message Warm-up active.
6. After 30 minutes ($WARMUP_TIME), the robot is deemed to be warmed
up and the motor currents are no longer monitored.
LOG file
The following events are logged in the file “Warmup.LOG” (path “KRC:\Roboter\Log\”):
Entry
Meaning
Monitoring active
The motor currents are monitored.
Monitoring inactive
The motor currents are not monitored.
Controlling active
The velocity is reduced.
Controlling inactive
The velocity corresponds to the programmed
override once again.
Example:
...
Date:
Date:
Date:
Date:
...
6.7.3
21.08.08
21.08.08
21.08.08
21.08.08
Time:
Time:
Time:
Time:
14:46:57
14:54:06
14:54:07
18:23:43
State:
State:
State:
State:
Monitoring active
Controlling active
Controlling inactive
Monitoring inactive
System variables for warm-up
The system variables for the warm-up can only be modified in the file $Machine.dat (path KRC:\R1\MADA).
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6 Configuration
If one of the values is outside the permissible range, the warm-up
function is not active and the velocity is not reduced.
System variable
Description
$WARMUP_RED_VEL
TRUE: Warm-up functionality is activated.
FALSE: Warm-up functionality is deactivated (default).
If $WARMUP_RED_VEL is set from FALSE to TRUE, this sets the
runtime of the robot to zero. The robot is deemed to be cold, irrespective of how long it was previously under servo control.
$WARMUP_TIME
Time during which the motor currents are monitored by the warmup function.
If the cold robot is started, a runtime value is incremented. If the
robot is not under servo control, the value is decremented. If the
runtime is greater than $WARMUP_TIME, the robot is deemed to
be warmed up and the motor currents are no longer monitored.
$COOLDOWN_TIME
& gt; 0.0 min
If the warm robot is not under servo control, a standstill value is
incremented. If the robot is under servo control, the value is decremented. If the standstill time is greater than
$COOLDOWN_TIME, the robot is deemed to be cold and the
motor currents are monitored. (Precondition:
$WARMUP_RED_VEL = TRUE.)
If the controller of a warm robot is shut down and restarted with a
warm restart, the time the controller was switched off is counted
as standstill time.
$WARMUP_CURR_LIMIT
& gt; 0.0 min
Maximum permissible motor current during warm-up (relative to
the regular maximum permissible motor current)
Regular maximum permissible motor current =
($CURR_LIM * $CURR_MAX) / 100
$WARMUP_MIN_FAC
0 … 100%
Minimum for the override reduction due to the warm-up function
The internal override is reduced at most to the factor of the programmed override defined here.
$WARMUP_SLEW_RATE
0 … 100%
Rate of increase for the increase in velocity
Once the monitoring is no longer triggered, the robot controller
increases the internal override again. The rate of increase is
defined here.
6.8
& gt; 0.0%/s
Collision detection
Collision detection is an extension and improvement of the torque
monitoring function.
The torque monitoring function remains available. Programs in which
torque monitoring is already defined can still be executed as before.
Alternatively, the lines with the torque monitoring in such programs can be
deleted and collision detection can be used instead. Collision detection must
not be used together with torque monitoring in a program.
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KUKA System Software 8.2
Description
If the robot collides with an object, the robot controller increases the axis
torques in order to overcome the resistance. This can result in damage to the
robot, tool or other objects.
Collision detection reduces the risk of such damage. It monitors the axis
torques. If these deviate from a specified tolerance range, the following reactions are triggered:
The robot stops with a STOP 1.
The robot controller calls the program tm_useraction. This is located in the
Program folder and contains the HALT statement. Alternatively, the user
can program other reactions in the program tm_useraction.
The robot controller automatically calculates the tolerance range. (Exception:
no values are calculated in T1 mode.) A program must generally be executed
2 or 3 times before the robot controller has calculated a practicable tolerance
range. The user can define an offset via the user interface for the tolerance
range calculated by the robot controller.
If the robot is not operated for a longer period (e.g. over the weekend), the motors, gear units, etc., cool down. Different axis torques are required in the first
few runs after such a break than in the case of a robot that is already at operating temperature. The robot controller automatically adapts the collision detection to the changed temperature.
Precondition
In order to be able to use the collision detection function, acceleration adaptation must be activated.
Acceleration adaptation is activated when system variable $ADAP_ACC
is not equal to #NONE. (This is the default setting.) The system variable
can be found in the file C:\KRC\Roboter\KRC\R1\MaDa\$ROBCOR.DAT.
The tolerance range is only calculated for motion blocks that have been
executed completely.
To activate collision detection for a motion, the parameter Collision detection must be set to TRUE during programming. This can be seen from
the addition CD in the program code:
PTP P2
Vel= 100 % PDAT1 Tool[1] Base[1] CD
The parameter Collision detection is only available if the motion is
programmed via an inline form.
Information about collision detection for motions programmed without
inline forms can be found in the documentation “KUKA.ExpertTech”.
Restrictions
Collision detection is not possible for HOME positions and other global positions.
Collision detection is not possible for external axes.
Collision detection is not possible during backward motion.
Collision detection is not possible in T1 mode.
High axis torques arise when the stationary robot starts to move. For this
reason, the axis torques are not monitored in the starting phase (approx.
700 ms).
The collision detection function reacts much less sensitively for the first 2
or 3 program executions after the program override value has been modified. Thereafter, the robot controller has adapted the tolerance range to
the new program override.
System variables
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System variable
Description
$TORQ_DIFF
The values of $TORQ_DIFF (torque) and $TORQ_DIFF2
(impact) are automatically calculated during program execution.
These values are compared with the values from the previous
program execution or with the default values. The highest value
is saved. The values are always calculated, even when collision
detection is deactivated.
$TORQ_DIFF2
If collision detection is active, the system compares the values
of $TORQ_DIFF and $TORQ_DIFF2 with the saved values during the motion.
$TORQMON_DEF[1] …
$TORQMON_DEF[6]
Values for the tolerance range in program mode (per axis)*
$TORQMON_COM_DEF[1]
…
$TORQMON_COM_DEF[6]
Values for the tolerance range in jog mode (per axis)*
$COLL_ENABLE
Signal declaration. This output is set if the value of one of the
$TORQMON_DEF[…] variables is less than 200.
File C:\KRC\Roboter\KRC\MaDa\$CUSTOM.DAT
File C:\KRC\Roboter\KRC\MaDa\$CUSTOM.DAT
File: KRC:\STEU\Mada\$machine.dat
$COLL_ALARM
Signal declaration. This output is set if message 117 “Collision
Detection axis & lt; axis number & gt; ” is generated. The output
remains set as long as $STOPMESS is active.
File: KRC:\STEU\Mada\$machine.dat
$TORQMON_TIME
Response time for the collision detection. Unit: milliseconds.
Default value: 0.0
File: C:\KRC\Roboter\KRC\Steu\MaDa\$CUSTOM.DAT.
*The width of the tolerance range is equal to the maximum torque [Nm] multiplied by the value in $TORQMON_... . The default value is 200. Unit: percent.
6.8.1
Calculating the tolerance range and activating collision detection
Precondition
The acceleration adaptation is switched on.
The load data have been entered correctly.
In the program, the parameter Collision detection is set to TRUE for all
motions that are to be monitored.
Procedure
If required: the desired collision response has been programmed in the
program tm_useraction.
1. In the main menu, select Configuration & gt; Miscellaneous & gt; Collision detection.
( & gt; & gt; & gt; 6.8.3 " Option window “Collision detection” " Page 155)
2. The box KCP must contain the entry MonOff. If this is not the case, press
Deactivate.
3. Start the program and execute it several times. After 2 or 3 program executions, the robot controller has calculated a practicable tolerance range.
4. Press Activate. The box KCP in the Collision detection window now
contains the entry MonOn.
Save the configuration by pressing Close.
If required, the user can define an offset for the tolerance range.
( & gt; & gt; & gt; 6.8.2 " Defining an offset for the tolerance range " Page 154)
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KUKA System Software 8.2
The tolerance range must be recalculated in the following cases:
The
velocity has been modified.
Points
6.8.2
have been changed, added or removed.
Defining an offset for the tolerance range
Description
An offset for the torque and for the impact can be defined for the tolerance
range. The lower the offset, the more sensitive the reaction of the collision detection. The higher the offset, the less sensitive the reaction of the collision detection.
Torque: The torque is effective if the robot meets a continuous resistance. Examples:
The robot collides with a wall and pushes against the wall.
The robot collides with a container. The robot pushes against the container
and moves it.
Impact: The impact is effective if the robot meets a brief resistance. Example:
The robot collides with a panel which is sent flying by the impact.
If the collision detection reacts too sensitively, do not immediately increase the offset. Instead, recalculate the tolerance range first and
test whether the collision detection now reacts as desired.
( & gt; & gt; & gt; 6.8.1 " Calculating the tolerance range and activating collision detection " Page 153)
Procedure
1. Select program.
2. In the main menu, select Configuration & gt; Miscellaneous & gt; Collision detection.
( & gt; & gt; & gt; 6.8.3 " Option window “Collision detection” " Page 155)
3. The offset for a motion can be modified while a program is running:
If the desired motion is displayed in the Collision detection window,
press an arrow key in the Torque or Impact box. The window remains focused on the motion and the offset can be modified.
Alternatively, a block selection to the desired motion can be carried out.
4. Save the change by pressing Save.
5. Save the configuration by pressing Close.
6. Set the original operating mode and program run mode.
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6.8.3
Option window “Collision detection”
Fig. 6-18: Option window “Collision detection”
The values in the option window Collision detection do not always
refer to the current motion. Deviations are particularly possible in the
case of points which are close together and approximated motions.
Item
1
Description
Indicates the status of the current motion:
Green: the current motion is monitored.
Orange: an arrow key has been pressed in the Torque or Impact box. The window remains focused on the motion and the
offset can be modified. The change can then be applied by
pressing Save.
2
Red: the current motion is not monitored.
Pixelated: a program must generally be executed 2 or 3 times
before the robot controller has calculated a practicable tolerance range. This display is pixelated during this learning
phase.
Number of the TMx variable
The robot controller creates a TMx variable for each motion block
in which the parameter Collision detection is set to TRUE. TMx
contains all the values for the tolerance range of this motion block.
If 2 motion blocks refer to the same point Px, the robot controller
creates 2 TMx variables.
3
Path and name of the selected program
4
Point name
5
This box is only active in “Automatic External” mode. It appears
gray in all other modes.
MonOn: collision detection has been activated by the PLC.
If collision detection is activated by the PLC, the PLC sends the
input signal sTQM_SPSACTIVE to the robot controller. The robot
controller responds with the output signal sTQM_SPSSTATUS.
The signals are defined in the file $config.dat.
Note: Collision detection is only active in Automatic External
mode if both the PLC box and the KCP box show the entry
MonOn.
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KUKA System Software 8.2
Item
6
Description
MonOn: collision detection has been activated from the KCP.
Note: Collision detection is only active in Automatic External
mode if both the PLC box and the KCP box show the entry
MonOn.
7
Offset for the torque. The lower the offset, the more sensitive the
reaction of the collision detection. Default value: 20.
If an arrow key is pressed, the window remains focused on the
motion and the offset can be modified. The change can then be
applied by pressing Save.
8
N.A.: the option Collision detection in the inline form is set to
FALSE for this motion.
Offset for the impact. The lower the offset, the more sensitive the
reaction of the collision detection. Default value: 30.
If an arrow key is pressed, the window remains focused on the
motion and the offset can be modified. The change can then be
applied by pressing Save.
N.A.: the option Collision detection in the inline form is set to
FALSE for this motion.
Button
Description
Activate
Activates collision detection.
This button is not displayed if the torque or impact
has been changed, but the changes have not yet
been saved.
Deactivate
Deactivates collision detection.
This button is not displayed if the torque or impact
has been changed, but the changes have not yet
been saved.
Save
Cancel
6.8.4
Saves changes to the torque and/or impact.
Rejects changes to the torque and/or impact.
Torque monitoring
Collision detection is an extension and improvement of the torque
monitoring function.
The torque monitoring function remains available. Programs in which
torque monitoring is already defined can still be executed as before.
Alternatively, the lines with the torque monitoring in such programs can be
deleted and collision detection can be used instead. Collision detection must
not be used together with torque monitoring in a program.
Description
Differences between torque monitoring and collision detection:
The tolerance range only refers to the torque. No values can be defined
for the impact.
The robot controller cannot automatically adapt the tolerance range to
changed temperatures.
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The tolerance range is not automatically calculated by the robot controller,
but must be defined by the user.
If a collision is detected, the robot stops with a STOP 1. It is not possible
to call a user-defined program.
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6 Configuration
Overview
Step
1
Description
Determine suitable values for torque monitoring.
( & gt; & gt; & gt; 6.8.4.1 " Determining values for torque monitoring "
Page 157)
2
Program torque monitoring.
( & gt; & gt; & gt; 6.8.4.2 " Programming torque monitoring " Page 157)
6.8.4.1
Determining values for torque monitoring
Description
The maximum torque deviation that has occurred can be determined as a percentage by means of the system variable $TORQ_DIFF[...].
Procedure
1. In the main menu, select Display & gt; Variable & gt; Single.
2. Set the value of the variable $TORQ_DIFF[…] to 0.
3. Execute the motion block and read the variable again. The value corresponds to the maximum torque deviation.
4. Set the variable for the monitoring of the axis to this value plus a safety
margin of 5 - 10%.
Only the value 0 can be assigned to the variables $TORQ_DIFF[...].
6.8.4.2
Programming torque monitoring
Precondition
In order to be able to use the collision detection function, acceleration adaptation must be activated. Acceleration adaptation is activated when system variable $ADAP_ACC is not equal to #NONE. (This is the default
setting.) The system variable can be found in the file C:\KRC\Roboter\KRC\R1\MaDa\$ROBCOR.DAT.
Procedure
A program is selected.
1. Position the cursor in the line before the motion for which the torque monitoring is to be programmed.
2. Select the menu sequence Commands & gt; Motion parameters & gt; Torque
monitoring. An inline form is opened.
Fig. 6-19
3. In the TORQMON box, select the entry SetLimits.
Fig. 6-20
4. For each axis, enter the amount by which the command torque may deviate from the actual torque.
5. Press Cmd OK.
6. If a response time for the torque monitoring is to be defined:
Set the variable $TORQMON_TIME to the desired value. Unit: milliseconds. Default value: 0.
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KUKA System Software 8.2
The values are automatically reset to the default value 200 in the following cases:
Reset
6.9
Block selection
Program deselection
Defining calibration tolerances
Only modify the default values in exceptional cases. Otherwise, increased error messages and inaccuracy may result.
Precondition
Expert user group
Procedure
In the main menu, select Start-up & gt; Calibrate & gt; Tolerances.
Description
Fig. 6-21: Default error tolerances
Item
1
Description
The minimum distance for tool calibration.
2
The minimum distance for base calibration.
3
0 … 200 mm
The minimum angle between the straight lines through the 3 calibration points in base calibration.
4
0 … 200 mm
0 … 360°
Maximum error in calculation.
0 … 200 mm
The following buttons are available:
Button
Default
6.10
Restores the default settings. The data must then
be saved by pressing OK.
Configuring Automatic External
Description
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Description
If robot processes are to be controlled centrally by a higher-level controller
(e.g. a PLC), this is carried out using the Automatic External interface.
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6 Configuration
The higher-level controller transmits the signals for the robot processes (e.g.
motion enable, fault acknowledgement, program start, etc.) to the robot controller via the Automatic External interface. The robot controller transmits information about operating states and fault states to the higher-level controller.
Overview
To enable use of the Automatic External interface, the following configurations
must be carried out:
Step
Description
1
Configuration of the CELL.SRC program.
( & gt; & gt; & gt; 6.10.1 " Configuring CELL.SRC " Page 159)
2
Configuration of the inputs/outputs of the Automatic External interface.
( & gt; & gt; & gt; 6.10.2 " Configuring Automatic External inputs/outputs " Page 160)
3
Only if error numbers are to be transmitted to the higher-level controller: configuration of the P00.DAT file.
( & gt; & gt; & gt; 6.10.3 " Transmitting error numbers to the higher-level
controller " Page 166)
6.10.1
Configuring CELL.SRC
Description
Program
In Automatic External mode, programs are called using the program
CELL.SRC.
1
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
DEF CELL ( )
…
INIT
BASISTECH INI
CHECK HOME
PTP HOME Vel= 100 % DEFAULT
AUTOEXT INI
LOOP
P00 (#EXT_PGNO,#PGNO_GET,DMY[],0 )
SWITCH PGNO ; Select with Programnumber
CASE 1
P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )
;EXAMPLE1 ( ) ; Call User-Program
CASE 2
P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )
;EXAMPLE2 ( ) ; Call User-Program
CASE 3
P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )
;EXAMPLE3 ( ) ; Call User-Program
DEFAULT
P00 (#EXT_PGNO,#PGNO_FAULT,DMY[],0 )
ENDSWITCH
ENDLOOP
END
Line
Description
12
The robot controller calls the program number from the
higher-level controller.
15
CASE branch for program number = 1
16
Receipt of program number 1 is communicated to the higherlevel controller.
17
The user-defined program EXAMPLE1 is called.
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KUKA System Software 8.2
Line
Description
27
DEFAULT = the program number is invalid.
28
Error treatment in the case of an invalid program number
Precondition
Expert user group
Procedure
1. Open the program CELL.SRC in the Navigator. (This program is located
in the folder " R1 " .)
2. In the section CASE 1, replace the name EXAMPLE1 with the name of the
program that is to be called via program number 1. Delete the semicolon
in front of the name.
…
15
16
17
…
CASE 1
P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )
MY_PROGRAM ( ) ; Call User-Program
3. For all further programs, proceed as described in step 2. If required, add
additional CASE branches.
4. Close the program CELL.SRC. Respond to the request for confirmation
asking whether the changes should be saved with Yes.
6.10.2
Configuring Automatic External inputs/outputs
Procedure
1. In the main menu, select Configuration & gt; Inputs/outputs & gt; Automatic
External.
2. In the Value column, select the cell to be edited and press Edit.
3. Enter the desired value and save it by pressing OK.
4. Repeat steps 2 and 3 for all values to be edited.
5. Close the window. The changes are saved.
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Description
Fig. 6-22: Configuring Automatic External inputs
Fig. 6-23: Configuring Automatic External outputs
Item
Description
1
Number
2
Long text name of the input/output
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KUKA System Software 8.2
Item
3
Description
Type
Green: Input/output
Yellow: variable or system variable ($...)
4
Name of the signal or variable
5
Input/output number or channel number
6
The outputs are thematically assigned to tabs.
( & gt; & gt; & gt; 6.10.2.1 " Automatic External inputs " Page 162)
( & gt; & gt; & gt; 6.10.2.2 " Automatic External outputs " Page 164)
6.10.2.1 Automatic External inputs
PGNO_TYPE
Type: variable
This variable defines the format in which the program number sent by the higher-level controller is read.
Value
00100111
= & gt; PGNO = 39
Read as BCD value.
00100111
= & gt; PGNO = 27
Read as “1 of n”*.
00000001
The program number is transmitted by the
higher-level controller or the periphery as a
" 1 of n " coded value.
3
Example
The program number is transmitted by the
higher-level controller as a binary coded
decimal.
2
Description
Read as binary number.
The program number is transmitted by the
higher-level controller as a binary coded
integer.
1
= & gt; PGNO = 1
00001000
= & gt; PGNO = 4
* When using this transmission format, the values of PGNO_REQ,
PGNO_PARITY and PGNO_VALID are not evaluated and are thus of no significance.
REFLECT_PROG
_NR
Type: variable
This variable defines whether the program number is to be mirrored to an output range. The output of the signal starts with the output defined using
PGNO_FBIT_REFL. ( & gt; & gt; & gt; 6.10.2.2 " Automatic External outputs " Page 164)
Value
Description
0
1
PGNO_LENGTH
Function deactivated
Function activated
Type: variable
This variable determines the number of bits in the program number sent by the
higher-level controller. Range of values: 1 … 16.
Example: PGNO_LENGTH = 4 = & gt; the external program number is 4 bits long.
If PGNO_TYPE has the value 2, only 4, 8, 12 and 16 are permissible values
for the number of bits.
PGNO_FBIT
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Input representing the first bit of the program number. Range of values:
1 … 4096.
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6 Configuration
Example: PGNO_FBIT = 5 = & gt; the external program number begins with the
input $IN[5].
PGNO_PARITY
Input to which the parity bit is transferred from the higher-level controller.
Input
Function
Negative value
Odd parity
0
No evaluation
Positive value
Even parity
If PGNO_TYPE has the value 3, PGNO_PARITY is not evaluated.
PGNO_VALID
Input to which the command to read the program number is transferred from
the higher-level controller.
Input
Function
Negative value
Number is transferred at the falling edge of the signal.
0
Number is transferred at the rising edge of the signal on
the EXT_START line.
Positive value
Number is transferred at the rising edge of the signal.
If PGNO_TYPE has the value 3, PGNO_VALID is not evaluated.
$EXT_START
If the I/O interface is active, this input can be set to start or continue a program.
Only the rising edge of the signal is evaluated.
There is no BCO run in Automatic External mode. This
means that the robot moves to the first programmed position after the start at the programmed (not reduced) velocity and does not
stop there.
$MOVE_ENABLE
This input is used by the higher-level controller to check the robot drives.
Signal
Function
TRUE
Jogging and program execution are possible.
FALSE
All drives are stopped and all active commands inhibited.
If the drives have been switched off by the higher-level controller, the
message “GENERAL MOTION ENABLE” is displayed. It is only possible to move the robot again once this message has been reset and
another external start signal has been given.
During commissioning, the variable $MOVE_ENABLE is often configured with the value $IN[1025]. If a different input is not subsequently
configured, no external start is possible.
$CHCK_MOVENA
Type: variable
If the variable $CHCK_MOVENA has the value FALSE, $MOVE_ENABLE
can be bypassed. The value of the variable can only be changed in the file
C:\KRC\ROBOTER\KRC\STEU\Mada\$OPTION.DAT.
Signal
Function
TRUE
MOVE_ENABLE monitoring is activated.
FALSE
MOVE_ENABLE monitoring is deactivated.
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In order to be able to use MOVE_ENABLE monitoring,
$MOVE_ENABLE must have been configured with the input
$IN[1025]. Otherwise, $CHCK_MOVENA has no effect.
$CONF_MESS
Setting this input enables the higher-level controller to acknowledge error
messages automatically as soon as the cause of the error has been eliminated.
Only the rising edge of the signal is evaluated.
$DRIVES_OFF
If there is a low-level pulse of at least 20 ms duration at this input, the higherlevel controller switches off the robot drives.
$DRIVES_ON
If there is a high-level pulse of at least 20 ms duration at this input, the higherlevel controller switches on the robot drives.
$I_O_ACT
If this input is TRUE, the Automatic External interface is active. Default setting:
$IN[1025].
6.10.2.2 Automatic External outputs
$RC_RDY1
Ready for program start.
$ALARM_STOP
This output is reset in the following EMERGENCY STOP situations:
The EMERGENCY STOP button on the KCP is pressed.
External E-STOP
In the case of an EMERGENCY STOP, the nature of the EMERGENCY STOP can be recognized from the states of the outputs
$ALARM_STOP and Int. E-Stop:
Both outputs are FALSE: the EMERGENCY STOP was triggered on the
KCP.
$ALARM_STOP is FALSE, Int. E-Stop is TRUE: external EMERGENCY
STOP.
$USER_SAF
This output is reset if the safety fence monitoring switch is opened (AUTO
mode) or an enabling switch is released (T1 or T2 mode).
$PERI_RDY
By setting this output, the robot controller communicates to the higher-level
controller the fact that the robot drives are switched on.
$ROB_CAL
The signal is FALSE as soon as a robot axis has been unmastered
$I_O_ACTCONF
This output is TRUE if Automatic External mode is selected and the input
$I_O_ACT is TRUE.
$STOPMESS
This output is set by the robot controller in order to communicate to the higherlevel controller any message occurring which requires the robot to be stopped.
(Examples: EMERGENCY STOP, Driving condition or Operator safety)
PGNO_FBIT_REF
L
Output representing the first bit of the program number. Precondition: The variable REFLECT_PROG_NR has the value 1. ( & gt; & gt; & gt; 6.10.2.1 " Automatic External inputs " Page 162)
The size of the output area depends on the number of bits defining the program number (PGNO_LENGTH).
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If a program selected by the PLC is deselected by the user, the output area
starting with PGNO_FBIT_REFL is set to FALSE. In this way, the PLC can
prevent a program from being restarted manually.
PGNO_FBIT_REFL is also set to FALSE if the interpreter is situated in the
CELL program.
Int. E-Stop
This output is set to FALSE if the EMERGENCY STOP button on the KCP is
pressed.
In the case of an EMERGENCY STOP, the nature of the EMERGENCY STOP can be recognized from the states of the outputs
$ALARM_STOP and Int. E-Stop:
$PRO_ACT
Both outputs are FALSE: the EMERGENCY STOP was triggered on the
KCP.
$ALARM_STOP is FALSE, Int. E-Stop is TRUE: external EMERGENCY
STOP.
This output is always set if a process is active at robot level. The process is
therefore active as long as a program or an interrupt is being processed. Program processing is set to the inactive state at the end of the program only after
all pulse outputs and all triggers have been processed.
In the event of an error stop, a distinction must be made between the following
possibilities:
If interrupts have been activated and processed at the time of the error
stop, the process is regarded as active ($PRO_ACT=TRUE) until the interrupt program is completed or a STOP occurs in it
($PRO_ACT=FALSE).
PGNO_REQ
If interrupts have been activated but not processed at the time of the error
stop, the process is regarded as inactive ($PRO_ACT=FALSE).
If interrupts have been activated and a STOP occurs in the program, the
process is regarded as inactive ($PRO_ACT=FALSE). If, after this, an interrupt condition is met, the process is regarded as active
($PRO_ACT=TRUE) until the interrupt program is completed or a STOP
occurs in it ($PRO_ACT=FALSE).
A change of signal at this output requests the higher-level controller to send a
program number.
If PGNO_TYPE has the value 3, PGNO_REQ is not evaluated.
APPL_RUN
By setting this output, the robot controller communicates to the higher-level
controller the fact that a program is currently being executed.
$PRO_MOVE
Means that a synchronous axis is moving, including in jog mode. The signal is
thus the inverse of $ROB_STOPPED.
$IN_HOME
This output communicates to the higher-level controller whether or not the robot is in its HOME position.
$ON_PATH
This output remains set as long as the robot stays on its programmed path.
The output ON_PATH is set after the BCO run. This output remains set until
the robot leaves the path, the program is reset or block selection is carried out.
The ON_PATH signal has no tolerance window, however; as soon as the robot
leaves the path the signal is reset.
$NEAR_POSRET
This signal allows the higher-level controller to determine whether or not the
robot is situated within a sphere about the position saved in $POS_RET. The
higher-level controller can use this information to decide whether or not the
program may be restarted.
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The user can define the radius of the sphere in the file $CUSTOM.DAT using
the system variable $NEARPATHTOL.
$ROB_STOPPED
The signal is set when the robot is at a standstill. In the event of a WAIT statement, this output is set during the wait.
The signal is thus the inverse of $PRO_MOVE.
$T1, $T2, $AUT,
$EXT
6.10.3
These outputs are set when the corresponding operating mode is selected.
Transmitting error numbers to the higher-level controller
Error numbers of the robot controller in the range 1 to 255 can be transmitted
to the higher-level controller. To transmit the error numbers, the file P00.DAT,
in the directory C:\KRC\ROBOTER\KRC\R1\TP, must be configured as follows:
1
2
3
4
5
6
7
8
9
10
11
12
13
26
30
35
36
37
96
97
DEFDAT
P00
BOOL PLC_ENABLE=TRUE ; Enable error-code transmission to plc
INT I
INT F_NO=1
INT MAXERR_C=1 ; maximum messages for $STOPMESS
INT MAXERR_A=1 ; maximum messages for APPLICATION
DECL STOPMESS MLD
SIGNAL ERR $OUT[25] TO $OUT[32]
BOOL FOUND
STRUC PRESET INT OUT,CHAR PKG[3],INT ERR
DECL PRESET P[255]
…
P[1]={OUT 2,PKG[] " P00 " ,ERR 10}
…
P[128]={OUT 128,PKG[] " CTL " ,ERR 1}
…
STRUC ERR_MESS CHAR P[3],INT E
DECL ERR_MESS ERR_FILE[64]
ERR_FILE[1]={P[] " XXX " ,E 0}
…
ERR_FILE[64]={P[] " XXX " ,E 0}
ENDDAT
Line
Description
3
PLC_ENABLE must be TRUE.
6
Enter the number of controller errors for the transmission of
which parameters are to be defined.
7
Enter the number of application errors for the transmission of
which parameters are to be defined.
9
Specify which robot controller outputs the higher-level controller should use to read the error numbers. There must be 8
outputs.
13
In the following section, enter the parameters of the errors.
P[1] … P[127]: range for application errors
P[128] … P[255]: range for controller errors
26
Example of parameters for application errors:
PKG[] " P00 " = technology package
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OUT 2 = error number 2
ERR 10 = error number in the selected technology package
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6 Configuration
Line
Description
30
Example of parameters for controller errors:
PKG[] " CTL " = technology package
37 … 96
OUT 128 = error number 128
ERR 1 = error number in the selected technology package
The last 64 errors that have occurred are stored in the
ERR_FILE memory.
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6.10.4
Signal diagrams
Fig. 6-24: Automatic system start and normal operation with program
number acknowledgement by means of PGNO_VALID
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Fig. 6-25: Automatic system start and normal operation with program
number acknowledgement by means of $EXT_START
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Fig. 6-26: Restart after dynamic braking (operator safety and restart)
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Fig. 6-27: Restart after path-maintaining EMERGENCY STOP
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Fig. 6-28: Restart after motion enable
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Fig. 6-29: Restart after user STOP
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6.11
Torque mode
6.11.1
Overview of torque mode
Description
The “torque mode” function consists of the sub-functionalities “torque limitation” and “deactivation of monitoring functions”.
Torque limitation:
The torques, i.e. the motor current, can be limited for individual axes or multiple axes. Torque limitation enables the following applications:
The axis can push or pull with a defined torque against a resistance.
Example:
application of a defined pressure on the workpiece by an electric motordriven spot welding gun.
The axis can be set to “soft”. It can then be moved by application of an external force. It can be pushed away, for example.
Examples:
The robot must grip a workpiece in a press that is then ejected by the
press. In order for the robot to be able to yield and absorb the ejector
stroke, the affected axis is set to “soft”.
The robot must set a workpiece down at a point from which it can be pulled
into exactly the right position by means of clamps. The robot must be compliant for this.
Deactivation of monitoring functions:
The torque limitation generally results in a relatively large deviation between
the command position and the actual position. Certain monitoring functions
are triggered by this deviation, although this is undesirable with torque limitation. These regular monitoring functions can thus be deactivated.
Restriction
The following restriction must be taken into consideration if axes are to absorb
ejector motions:
A diagonal ejector motion cannot generally be absorbed by switching a single
axis to “soft”. Remedy:
In the case of slightly diagonal ejector motions, a possible remedy is to install the robot with a slight inclination.
Or contact KUKA Roboter GmbH.
Inclined installation of the robot is only permissible up to a certain angle of inclination. Further information is contained in the robot operating or assembly instructions.
6.11.1.1 Using torque mode
Torque mode is only possible in program mode, not in manual mode.
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6 Configuration
By default, the robot controller is configured so that only
limits that exceed the holding torque of the axis
($HOLDING_TORQUE) can be set. It is nonetheless possible that the axis
with limited torque is no longer able to achieve the necessary torque for braking, holding or moving the axis. This can be the case, for example, if the default configuration of the robot controller has been changed or incorrect load
data are used.
Incorrectly set values can result in unexpected behavior of the robot controller, e.g. motion in a different direction or with different acceleration.
For this reason:
Only ever limit the torque in small steps, gradually approaching the required limit.
Do not limit the torque further than necessary.
Failure to observe this may result in death to persons, severe physical injuries or considerable damage to property.
If an application requires torque limits that no longer exceed the holding torque of the axis, KUKA Roboter GmbH must be contacted.
Procedure
1. Set the torque limits for the desired axis and/or deactivate the regular monitoring functions.
( & gt; & gt; & gt; 6.11.2 " Activating torque mode: SET_TORQUE_LIMITS() "
Page 177)
If the regular monitoring functions are deactivated, other monitoring functions specially adapted to torque mode are automatically activated.
( & gt; & gt; & gt; " Monitoring functions " Page 176)
2. If the axis is to be set to “soft”: move the axis so that the torque limit becomes active. At the end of the motion, the brakes of this axis remain
open.
Alternatively, a “motion” to the current position can be executed. The robot
does not move, but the brakes are released.
3. Optionally: generate a signal indicating that the axis is stationary (e.g. signal to an injection molding machine).
4. Perform the desired action, e.g. move to workpiece and build up pressure
or push the axis away.
5. Optionally: wait for a signal to end torque mode.
6. Deactivate torque mode again.
( & gt; & gt; & gt; 6.11.3 " Deactivating torque mode: RESET_TORQUE_LIMITS() "
Page 180)
The torque limits are canceled and the regular monitoring functions are reactivated. Furthermore, the command position is adjusted to the actual position.
Activated/deactivated
Torque mode is considered to be activated in the following case:
If the upper torque limit is less than or equal to the upper value of the
$TORQUE_AXIS_MAX interval.
And/or: If the lower torque limit is greater than or equal to the lower value
of the $TORQUE_AXIS_MAX interval.
And/or: If the regular monitoring functions are deactivated.
( & gt; & gt; & gt; 6.11.5.3 " $TORQUE_AXIS_MAX " Page 182)
Torque mode is considered to be deactivated in the following case:
If no limits are set or if the limits are invalid. A limit is invalid if it is outside
the $TORQUE_AXIS_MAX interval.
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And: If the regular monitoring functions are deactivated.
Automatic deactivation
Torque mode is automatically deactivated in the following cases:
End of program
Program reset
Program deselection
Block selection (but no deactivation if the target of the block selection is in
an interrupt program)
RESUME (but no deactivation if the RESUME statement returns to an interrupt program)
Monitoring
functions
Manual mode is activated. Planning is carried out from the current actual
position and motion is resumed with full torque.
Torque mode generally results in a relatively large deviation between the command position and the actual position. Certain monitoring functions are triggered by this deviation, although this is undesirable in torque mode. These
regular monitoring functions can thus be deactivated using
SET_TORQUE_LIMITS().
If the regular monitoring functions are deactivated, other monitoring functions
specially adapted to torque mode are automatically activated for the actual velocity and following error. If required, user-defined values can be set for these
special monitoring functions using SET_TORQUE_LIMITS().
The following messages belong to the regular monitoring functions. They are
no longer displayed if the regular monitoring functions are deactivated.
Monitoring
Message no. / message
Following error monitoring
26024: Ackn. Max. following error
exceeded (Drive).
Standstill monitoring
1100: Stopped (Axis number)
Positioning monitoring
1105: Positioning monitoring (Axis number)
Monitoring whether motor
blocked
26009: Motor blocked (Drive).
It is also possible, however, to retain the regular monitoring functions in torque
mode. This may be useful, for example, if torque mode is used to avoid damage in the case of collisions.
( & gt; & gt; & gt; 6.11.6.2 " Robot program: avoiding damage in the event of collisions "
Page 184)
6.11.1.2 Robot program example: setting A1 to “soft” in both directions
Description
This simple example illustrates the basic principle of torque mode.
In this example, A1 is to be set to “soft” in both directions. For this purpose,
both the positive and negative current limits are set to 0 Nm. This allows A1 to
be moved by application of an external force.
Program
1
2
3
4
5
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...
PTP {A1 10}
SET_TORQUE_LIMITS(1, {lower 0, upper 0, monitor #off})
PTP {A1 11}
...
RESET_TORQUE_LIMITS(1)
PTP {A1 -20}
...
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6 Configuration
Line
Description
2
Negative and positive current limit of A1 are set to 0; the regular monitoring functions are deactivated.
(The actual velocity and the following error are now monitored
with special monitoring functions.)
3
A “motion” is executed to activate torque limitation. (Since both
current limits are set to 0, the robot will not actually move.)
4
Deactivate torque mode again for A1.
A1 can now be moved by application of an external force.
Torque limitation is canceled and the regular monitoring functions are reactivated. Furthermore, the command position is
automatically adjusted to the actual position.
5
The robot moves to the next position.
(The motion from line 4 is not belatedly executed now, as the
command-actual adjustment has been carried out in line 5.)
It is only for A1 that the holding torque is 0 Nm. The limits can therefore not generally be set to 0 for setting an axis to “soft”.
A more detailed example that can also be applied to other axes can
be found here: ( & gt; & gt; & gt; 6.11.6.1 " Robot program: setting axis to “soft” in both
directions " Page 184)
6.11.2
Activating torque mode: SET_TORQUE_LIMITS()
Description
This function can be used to perform the following actions for a specific axis:
Deactivate the regular monitoring functions that would be triggered by a
higher following error.
Function
Limit the torques in the positive and/or negative direction.
If the regular monitoring functions are deactivated: modify the values for
the special monitoring functions.
SET_TORQUE_LIMITS (axis: in, values: in)
Element
axis
Description
Type: INT
Axis to which the statement applies
values
Type: TorqLimitParam
Values set for the axis
TorqLimitParam
STRUC TorqLimitParam REAL lower, upper, SW_ONOFF monitor,
REAL max_vel, max_lag
Element
lower
Description
Lower torque limit
Unit: Nm (for linear axes: N)
Default value: -1E10 (i.e. unlimited)
upper
Upper torque limit
Unit: Nm (for linear axes: N)
Default value: 1E10 (i.e. unlimited)
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Element
monitor
Description
#ON (Default): activates the regular monitoring functions.
max_vel
#OFF: deactivates the regular monitoring functions. Instead, the monitoring functions max_vel and max_lag
are activated.
Maximum permissible actual velocity in torque mode (only
relevant if the regular monitoring functions are deactivated)
Only a positive value may be programmed.
Unit: Degrees (for linear axes: mm)
Default value (valid for all operating modes): T1 jog velocity
* internal safety factor
In T1, the maximum velocity with which jogging can be carried out is the default value, even if a higher value is programmed.
Note: Only set a higher value than the default value if
absolutely necessary.
max_lag
Maximum permissible following error in torque mode (only
relevant if the regular monitoring functions are deactivated)
Only a positive value may be programmed.
Unit: Degrees (for linear axes: mm)
Default value: 5 degrees (for linear axes: 100 mm)
Note: Only set a higher value than the default value if
absolutely necessary.
lower/upper
When must the upper torque be limited and when must the lower torque be
limited?
General: The direction in which the following error is building up must always
be limited.
Example: The robot is to be moved up against an obstacle and then stop there.
The torque that is thus built up is to be limited.
If the obstacle appears in the negative direction, lower must be set.
SET_TORQUE_LIMITS() can be used in robot programs and in submit
programs.
Advance run stop: In the robot program, the statement triggers an advance run stop.
Values may remain partially non-initialized. The non-initialized components
mean that the existing values are to remain unchanged.
If both limits are set, upper must be & gt; = lower.
Characteristics
If the obstacle appears in the positive direction, upper must be set.
If one limit (or both) is already set and the other limit is then set, and if the
new limit would result in an empty interval, the new limit value becomes
the value for both limits. Example:
Already set: {lower 1, upper 2}
Newly set: {lower 3}
This results in: {lower 3, upper 3}
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It is permissible to set a positive lower or a negative upper limit.
The limits set must be greater than the current holding torque
$HOLDING_TORQUE. If they are set differently, the robot controller generates an error message that must be acknowledged by the user.
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6 Configuration
If an application requires torque limits that no longer exceed the holding torque of the axis, KUKA Roboter GmbH must be contacted.
lower must be less than or equal to the upper value of the
$TORQUE_AXIS_MAX_0 interval.
upper must be greater than or equal to the lower value of the
$TORQUE_AXIS_MAX_0 interval.
If the limits are set differently, the robot controller generates an error message that must be acknowledged by the user.
Examples
Example 1:
For A1, the permissible torque range is limited to the interval 800 … 1,400 Nm.
SET_TORQUE_LIMITS(1, {lower 800, upper 1400} )
Example 2:
For A3, the upper torque limit is set to 1,200 Nm.
SET_TORQUE_LIMITS(3, {upper 1200} )
Example 3:
For A1, the regular monitoring functions are (re)activated.
SET_TORQUE_LIMITS(1, {monitor #on} )
Example 4:
For A1, the permissible torque range is limited to the interval -1,000 …
1,000 Nm. Furthermore, the regular monitoring functions are deactivated and
the special monitoring functions are set to user-defined values.
SET_TORQUE_LIMITS(1, {lower -1000, upper 1000, monitor #off, max_vel
10, max_lag 20} )
Example 5:
For A1, the permissible torque range is set to -1E10 … 1E10, i.e. the range is
unlimited. The regular monitoring functions are (re)activated.
SET_TORQUE_LIMITS(1, {lower -1E10, upper 1E10, monitor #on} )
This all corresponds to RESET_TORQUE_LIMITS(1), with the difference that
in example 5, the command position is not to adapted to the actual position.
Example 6:
For A1, the lower torque limit is set to a calculated value.
The value has been calculated with the function myCalc() and transferred with
the variable myLimits. (In the concrete application, the user must write his own
function for this.)
In order for the other components to be non-initialized, the value is pre-initialized with a partially initialized aggregate.
DECL TorqLimitParam myParams
...
myParams = {lower 0}
myParams.lower = myCalc()
SET_TORQUE_LIMITS(1, myParams)
Example 7:
In this case, the limits are also set to a value that has been calculated with a
function. (In the concrete application, the user must write his own function for
this.)
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The return value of the function is transferred directly, however.
DEFFCT TorqLimitParam myCalcLimits()
DECL TorqLimitParam myLimits
...
RETURN myLimits
ENDFCT
...
SET_TORQUE_LIMITS(1, myCalcLimits())
6.11.3
Deactivating torque mode: RESET_TORQUE_LIMITS()
Description
This function has the following effect on the selected axis:
It reactivates the regular monitoring functions insofar as they were deactivated.
Function
It cancels the limitation of the torques insofar as they were limited.
It adapts the command position to the actual position.
RESET_TORQUE_LIMITS (axis: in)
Element
Description
Type: INT
axis
Axis to which the statement applies
Characteristics
The statement can be used in robot programs and in submit programs.
Alternative
Advance run stop: In the robot program, the statement triggers an advance run stop. This cannot be masked with CONTINUE!
If no command/actual value adjustment is required, torque mode can also be
deactivated with SET_TORQUE_LIMITS instead of
RESET_TORQUE_LIMITS:
SET_TORQUE_LIMITS(1, {lower -1E10, upper 1E10, monitor #on} )
Advantage: Can be used during a motion (“on the fly”).
Disadvantage: If the torque limitation has resulted in a relatively large following error, the robot accelerates very fast. This can trigger monitoring
functions and stop the program.
Deactivation by means of SET_TORQUE_LIMITS is not suitable in
most cases.
6.11.4
Interpreter specifics
Description
SET_TORQUE_LIMITS() and RESET_TORQUE_LIMITS() can be used
in robot programs and in submit programs.
The statements are interpreter-specific, i.e. they only work in the interpreter in which they have been used.
SET_TORQUE_LIMITS() first takes effect when the axis is moved for the
interpreter that generates the statement. Example:
a. Torque mode is activated in the robot program for an external axis.
b. The external axis is moved by a submit program. Torque mode has no
effect.
c. The external axis is moved by a robot program. Torque mode takes effect.
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If torque mode is already active, SET_TORQUE_LIMITS() takes effect immediately.
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6 Configuration
SET_TORQUE_LIMITS() works immediately if a motion is active. For this
reason, the torque limits can be set at any time in robot programs, both inside and outside an interrupt, and the monitoring functions can be activated and deactivated.
It is also possible to use torque mode inside an interrupt program only. (If
RESET_TORQUE_LIMITS() is used, it may subsequently be necessary to
return to the interrupt position with PTP $AXIS_RET.)
( & gt; & gt; & gt; 6.11.6.3 " Robot program: torque mode in the interrupt " Page 186)
When a torque-driven axis “changes owner”, the command position is adjusted to the actual position.
“Change of owner” means: an interpreter has moved the axis in torque
mode (and thus “owns” it). While torque mode is active, the axis is moved
by a different interpreter.
The main application here is: jogging after a program has been interrupted
in torque mode.
Example
The following example shows when SET_TORQUE_LIMITS() is effective, depending on whether torque mode is already active or not.
Initial situation (default): the monitoring functions are activated.
1
2
3
4
5
6
7
SET_TORQUE_LIMITS(1, {monitor #off})
HALT
PTP_REL {A1 10}
HALT
SET_TORQUE_LIMITS(1, {monitor #on})
HALT
PTP_REL {A1 15}
Line
1
The monitoring functions for A1 are deactivated.
2
Here the monitoring functions are still activated.
3
The axis is moved. From here on, the statement
SET_TORQUE_LIMITS is effective.
4
The monitoring functions are deactivated.
5
The monitoring functions are activated.
6
6.11.5
Description
Here the monitoring functions are already activated. Because
torque limitation was already active, the statement took effect
immediately and not just after the next motion of this axis.
Diagnostic variables for torque mode
All these variables and constants are write-protected.
Their value is not dependent on the interpreter.
6.11.5.1 $TORQUE_AXIS_ACT
Variable
$TORQUE_AXIS_ACT[axis number]
Data type: REAL
Description
Current motor torque for axis [axis number]
Unit: Nm (for linear axes: N)
The value is only relevant if the brakes are released. If the brakes are applied,
it is virtually zero. (The state of the brakes can be displayed by means of the
system variable $BRAKE_SIG. The value of $BRAKE_SIG is a bit array: bit 0
corresponds to A1, bit 6 corresponds to E1.)
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Advance run stop: In the robot program, the variable triggers an advance run
stop.
( & gt; & gt; & gt; 6.11.5.6 " Comparison: $TORQUE_AXIS_ACT and
$HOLDING_TORQUE " Page 183)
6.11.5.2 $TORQUE_AXIS_MAX_0
Constant
$TORQUE_AXIS_MAX_0[axis number]
Data type: REAL
Description
Maximum permanent motor torque for axis [axis number] at velocity 0
The value specifies an interval: from -value to +value.
Unit: Nm (for linear axes: N)
Advance run stop: does not trigger an advance run stop.
lower must be less than or equal to the upper value of the
$TORQUE_AXIS_MAX_0 interval.
upper must be greater than or equal to the lower value of the
$TORQUE_AXIS_MAX_0 interval.
If the limits are set differently, the robot controller generates an error message that must be acknowledged by the user.
6.11.5.3 $TORQUE_AXIS_MAX
Constant
$TORQUE_AXIS_MAX[axis number]
Data type: REAL
Description
Absolute maximum motor torque for axis [axis number]
The value specifies an interval: from -value to +value.
Unit: Nm (for linear axes: N)
Advance run stop: does not trigger an advance run stop.
6.11.5.4 $TORQUE_AXIS_LIMITS
Variable
$TORQUE_AXIS_LIMITS[axis number]
Data type: TorqLimitParam
Description
Currently active motor torque limitation for axis [axis number]
Unit: Nm (for linear axes: N)
The variable is primarily intended for diagnosis via the variable correction function or variable overview.
Characteristics:
If there are currently no limits active, upper and lower remain non-initialized.
The component monitor is always initialized unless the axis does not exist.
This is relevant, for example, in the case of 4-axis and 5-axis robots: if the
entire array is displayed, the non-existent axes can be easily identified.
Non-existent external axes are simply not displayed when the entire array
is displayed.
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6 Configuration
Max_vel and max_lag are non-initialized if monitor = #ON, as the regular monitoring functions are active in this case.
If monitor = #OFF, the values of max_vel and max_lag are displayed, irrespective of whether they have been set explicitly in the current program
or whether the default values are being used.
The fact that certain components may remain non-initialized simplifies diagnosis for the user.
If the variable is accessed via KRL, however, the robot controller may
regard the access as “invalid”. Recommendation: Check the state of the variable with VARSTATE() prior to access.
Advance run stop: In the robot program, the variable triggers an advance run
stop.
6.11.5.5 $HOLDING_TORQUE
Variable
$HOLDING_TORQUE[axis number]
Data type: REAL
Description
Holding torque for the robot axis [axis number]
Unit: Nm
The holding torque refers to the current actual position of the axis and the current load.
(For external axes, the value 0 N is always returned.)
Advance run stop: In the robot program, the variable triggers an advance run
stop.
( & gt; & gt; & gt; 6.11.5.6 " Comparison: $TORQUE_AXIS_ACT and
$HOLDING_TORQUE " Page 183)
If the upper and lower torque limits are set to $HOLDING_TORQUE
for all axes, the robot must remain stationary when the brakes are released.
If this is not the case, i.e. if the robot drifts, the load is not correctly configured.
6.11.5.6 Comparison: $TORQUE_AXIS_ACT and $HOLDING_TORQUE
In the case of a robot that is stationary with the brakes released,
$TORQUE_AXIS_ACT is not equal to $HOLDING_TORQUE, although this
might be assumed.
Characteristics of $HOLDING_TORQUE:
A calculated value that does not take friction into consideration. Control effects have no influence on the value.
Is only dependent on the current position of the axis. Thus remains unchanged if the position remains constant.
Characteristics of $TORQUE_AXIS_ACT:
Calculated from the actual currents. Friction and control effects thus affect
the value.
Can change if the position remains constant.
The discrepancy between $HOLDING_TORQUE and $TORQUE_AXIS_ACT
is less than or equal to the current friction if the robot remains stationary for at
least 1 second. A precondition is that the load data are correct.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
6.11.6
Other examples
6.11.6.1 Robot program: setting axis to “soft” in both directions
Description
The robot must grip a workpiece in a press that is then ejected by the press.
In order for the robot to be able to yield and absorb the ejector stroke, the axis
is set to “soft”.
For this, the torque limits must be set to a very small interval around the holding torque. (It is only for A1 that the holding torque = 0 Nm. The limits can
therefore not generally be set to 0 for setting an axis to “soft”.)
Assumption for this example: a rotation about the axis [ideal_axis] move the
gripper almost exactly in the ejector direction.
Program
1 DECL TorqLimitParam myLimits
2 DECL INT ideal_axis
...
3 myLimits.monitor = #off
4 myLimits.lower = $holding_torque[ideal_axis] - 10
5 myLimits.upper = $holding_torque[ideal_axis] + 10
6 SET_TORQUE_LIMITS(ideal_axis, myLimits)
7 PTP $AXIS_ACT
8 OUT_SIGNAL_SOFT = TRUE
9 WAIT FOR IN_SIGNAL_EJECTED
10 RESET_TORQUE_LIMITS(i)
11 OUT_SIGNAL_SOFT = FALSE
12 WAIT FOR IN_SIGNAL_NEXTMOVE
...
Line
Description
3 …6
For the axis [ideal_axis], the regular monitoring functions are
deactivated and the torques are limited to a very small interval
around the holding torque.
7
Execute a “motion” to the current position to activate reduction
of the current limits. The axis [ideal_axis] can now be moved
by the ejector of the press.
8
Signal to the press controller that the axis is ready for the ejection.
9
Wait for signal from press controller that the workpiece has
been ejected.
10
Cancels torque limitation and reactivates the regular monitoring functions. Furthermore, adjusts the command position the
actual position.
11
Signal to the press controller that the axis is no longer ready
for an ejection.
12
If required:
Wait for a signal that motion away from the position is allowed.
6.11.6.2 Robot program: avoiding damage in the event of collisions
Description
Torque limitation can be used to avoid damage in the event of collisions. Compared with the Collision detection function that can be activated in the inline
forms of the motion instructions, this has the following advantage and disadvantage:
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Advantage: It is assured that the robot only presses against the obstacle
with a defined, limited force.
Disadvantage: The robot becomes sluggish. High accelerations are no
longer possible.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
6 Configuration
Program
The robot fetches workpieces from a box. During the motion to points P7, P8
and P9, the possibility cannot be ruled out of the robot with the workpiece colliding with the box. It must be ensured that the robot does not press so hard
that damage can result. For this, the forces are limited before the critical
points.
The regular monitoring functions are deactivated. This is not because they
would otherwise be triggered unnecessarily; on the contrary, they are not strict
enough for this example. Instead, one of the special monitoring functions is set
to a very low value. (Depending on the specific application, it may also be useful to use the regular monitoring functions.)
...
1 DECL TorqLimitParam myParams
...
2 FOR i = 1 to 6
3
myParams.lower = $holding_torque[i] - 500
4
myParams.upper = $holding_torque[i] + 500
5
myParams.monitor = #off
6
myParams.max_lag = 0.1
7 SET_TORQUE_LIMITS(i, myParams)
8 ENDFOR
9 $acc.cp = my_low_acceleration
10 $vel.cp = my_low_velocity
11 LIN P7
12 LIN P8
13 LIN P9
14 FOR i = 1 to 6
15
myParams.lower = -1E10
16
myParams.upper = 1E10
17
myParams.monitor = #on
18 SET_TORQUE_LIMITS(i, myParams)
19 ENDFOR
20 $acc.cp = my_high_acceleration
21 $vel.cp = my_high_velocity
22 LIN P10
...
Line
Description
2…7
The torques for A1 ... A6 are limited.
3, 4
The limits are set to a relatively small interval centered on the
holding torque.
5, 6
The regular monitoring functions are deactivated. Max_lag =
0.1 has the effect of triggering a stop in the case of a following
error as low as 0.1°.
9, 10
Acceleration and velocity are reduced so that the robot approaches the critical point slowly.
11 …13
Points at which a collision could occur.
If a collision occurs, the monitoring function max_lag is triggered and the system operator can intervene.
After the critical section:
14 …19
Torque mode is deactivated.
SET_TORQUE_LIMITS can be used here: the robot only
reaches this point if it has passed the critical points without collision. In this case, no following error has built up and command/actual value adjustment is not required.
20, 21
Acceleration and velocity are reset to the previous higher values.
22
Uncritical point
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
6.11.6.3 Robot program: torque mode in the interrupt
Description
This demonstrates that torque mode can be used completely inside an interrupt program. The example is not primarily a practical one, but is intended to
show that this use is generally possible.
Program
The robot is to determine the position of a workpiece whose possible location
is known, but not its exact position. First, a proximity sensor signals to the robot controller when the robot is in the vicinity of the workpiece. On the basis of
this sensor signal, an interrupt program is then called.
The actual search is carried out in the interrupt program: A1 moves towards
the workpiece. Torque mode is activated for A1 beforehand. The robot comes
to a standstill where it makes contact with the workpiece due to the reduced
torques: the workpiece has been “found”. This position can now be saved as
the position of the workpiece.
...
LIN P1
INTERRUPT DECL 1 WHEN sensor_signal==true DO search()
INTERRUPT ON 1
LIN P2
INTERRUPT OFF 1
...
------------------------6 DEF search()
7 ...
8 BRAKE
9 SET_TORQUE_LIMITS(1,{lower 1000, upper 1000, monitor #off})
10 PTP_REL {A1 10}
11 RESET_TORQ_LIMITS(1)
12 piece_found = $POS_ACT_MES
13 PTP $AXIS_RET
14 END
1
2
3
4
5
Line
Description
1…4
On the way to P2, the sensor is to signal when the robot is in
the vicinity of the workpiece.
2
When the sensor signal is received, the subprogram search()
is called.
In the subprogram:
8
The current motion is stopped as soon as search() is executed.
9
Sets torque limits for A1, deactivates regular monitoring functions.
10
A1 moves. The robot comes to a standstill where it makes contact with the workpiece due to the reduced torques.
Once the robot has reached its command position {A1 10}, the
next program line is executed. (The fact that the actual position
deviates from the command position has no effect, as the regular monitoring functions have been deactivated.)
11
12
The current position of the robot now indicates the position of
the workpiece. This is saved here in a variable.
13
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Cancels torque limitation and reactivates the regular monitoring functions. Furthermore, adjusts the command position the
actual position.
Returns to the position at which the robot left the path in the
main program.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
6 Configuration
6.11.6.4 Robot program: servo gun builds up pressure
Description
This program shows how torque mode can be activated by means of a trigger.
(Comparable programs are used in the background in the KUKA.ServoGun
technology packages. They thus do not need to be programmed by the user.)
Program
Main program:
1 DEF SPOT()
2 DECL BOOL error_occurred
...
3 Interrupt DECL 1 WHEN $stopmess DO resume_subprog()
4 Interrupt ON 1
5 REPEAT
6 error_occurred = false
7 SPOT_MOVE()
8 UNTIL error_occurred == false
...
Line
Description
3
If an error occurs, resume_subprog() is to be called.
7
The weld program SPOT_MOVE() is called.
5…8
If an error has occurred (i.e. if error_occurred == true),
SPOT_MOVE() is repeated.
Weld program:
1 DEF SPOT_MOVE()
...
2 TorqLimWeld = {lower -1000, upper 1000 , monitor #off}
3 i = 6+EG_EXTAX_ACTIVE
...
4 LIN P_APPROX C_DIS
5 $VEL_EXTAX[EG_EXTAX_ACTIVE]=EG_MAX_CONST_VEL[EG_EXTAX_ACTIVE]
6 LIN P_APPROX C_DIS
7 TRIGGER WHEN DISTANCE=0 DELAY=50 DO SET_TORQUE_LIMITS(i,
TorqLimWeld) PRIO = -1
8 LIN P_PART C_DIS
9 TRIGGER WHEN DISTANCE=0 DELAY=50 DO START_TIMER_SPOT() PRIO=82
10 LIN P_PRESSURE C_DIS
11 LIN P_WELD
12 WAIT FOR EG_TRIGGER_END
13 RESET_TORQUE_LIMITS(i)
14 Interrupt OFF 1
15 LIN P_PART C_DIS
16 END
Line
Description
7
Shortly before the gun touches the workpiece, the torques are
reduced.
9 … 11
Build up pressure and then weld.
12
The weld timer signals the end of welding.
13
Cancels torque limitation and reactivates the regular monitoring functions. Furthermore, adjusts the command position the
actual position.
Interrupt program in the event of an error:
1
2
3
4
5
6
7
DEF resume_subprog()
BRAKE
Suppress_repositioning()
HALT
error_occurred = true
RESUME
END
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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Line
Description
3
Normally, in the case of a restart after HALT, the robot is repositioned to the position at which the interrupt was triggered.
(This is because of $STOPMESS.) Suppress_repositioning()
prevents this repositioning.
Suppress_repositioning() may be useful, depending on the application, but not necessarily.
5
Set error_occurred to TRUE so that the REPEAT loop in the
main program is repeated.
6
RESUME deactivates torque mode. Jump back to line 8 in the
main program.
6.11.6.5 Submit program: servo gun builds up pressure
Precondition
E1 is already asynchronous with ASYPTP {E1 10}.
Or: $ASYNC_MODE is configured in such a way (bit 0 = 1) that the axis is
implicitly set to synchronous mode in the case of ASYPTP in the submit
program.
Program
...
1 IF $PRO_STATE1==#P_FREE
2
SET_TORQUE_LIMITS(7,{upper 1000, monitor #off })
3
ASYPTP {E1 10}
...
4
RESET_TORQUE_LIMITS(7)
5
ASYPTP {E1 -10}
6 ENDIF
...
Line
Description
1
Ensure that no robot program is selected.
2
Limit the positive torque and deactivate the regular monitoring
functions.
3
Motion towards end point {E1 10} behind the workpiece. The
pressure on the workpiece builds up.
4
Cancels torque limitation and reactivates the regular monitoring functions. Furthermore, adjusts the command position the
actual position.
The interpreter waits in RESET_TORQUE_LIMITS(7) until the
asynchronous motion has been completed. Only then does it
perform the command/actual value adjustment. It is therefore
not necessary to program WAIT FOR $ASYNC_STATE ==
#IDLE before “RESET…”.
5
6.12
Reopen the gun.
Event planner
This function can be used for time-related or action-related control of the data
comparison between the kernel system and the hard drive. During data comparison, the kernel system data are written to the hard drive.
6.12.1
Configuring a data comparison
Precondition
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Expert user group
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
6 Configuration
Procedure
1. In the main menu, select Configuration & gt; Miscellaneous & gt; Event planner.
2. Open the tree structure in the left-hand part of the window.
3. Select the desired action:
T1 and T2 consistency: Compare data in operating modes T1 and T2
at regular intervals.
AUT and EXT consistency: Compare data in operating mode Automatic External at regular intervals.
Logic consistency: Compare data after a change of operating mode
or after online optimizing.
Online optimizing is the modification of the parameters of a program
during operation.
4. Make the desired settings in the right-hand part of the window.
( & gt; & gt; & gt; 6.12.2 " Configuring T1 and T2 Consistency, AUT and EXT Consistency " Page 189)
( & gt; & gt; & gt; 6.12.3 " Configuring Logic Consistency " Page 190)
5. Press Save.
6.12.2
Configuring T1 and T2 Consistency, AUT and EXT Consistency
The following settings are possible here:
Definition of the date and time that a comparison will first be made between the data in the kernel system and those on the hard drive.
Definition of the interval at which this operation is to be repeated.
Description
Fig. 6-30: Configuring T1 and T2 Consistency
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
Item
Description
1
Check box active: data comparison is activated.
Check box not active: data comparison is deactivated.
2
Enter date and time in the format indicated.
3
Check box active: interval is activated.
Check box not active: interval is deactivated.
If the intervals selected are too small, this can result in
damage to the hard drive. An interval of several minutes
is recommended.
6.12.3
Configuring Logic Consistency
Description
The following settings are possible here:
Fig. 6-31: Configuring Logic Consistency
Item
1
Description
Check box active: data are compared when operating mode
is switched to T1.
Check box not active: data comparison is deactivated.
Check box activated: data are compared when operating mode
is switched to T2.
Check box not active: data comparison is deactivated.
Check box active: data are compared when operating mode
is switched to Automatic.
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4
Check box not active: data comparison is deactivated.
3
Check box active: data comparison is activated.
2
Check box not active: data comparison is deactivated.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
6 Configuration
Item
5
Description
Check box active: data are compared when operating mode
is switched to Automatic External.
Check box not active: data comparison is deactivated.
Check box active: data are compared after online optimizing.
6
Check box not active: data comparison is deactivated.
6.13
Brake test
6.13.1
Overview of the brake test
Description
Each robot axis has a holding brake integrated into the motor. The brake test
checks every axis at low speed and at the current temperature to see if the
braking torque exceeds a certain minimum value. The absolute value of the
braking torque is not calculated. The minimum braking torque for the individual
axes is stored in the machine data.
The braking torque in the machine data may vary from the information
in the data sheet of the brake manufacturer.
Performance of the brake test
A precondition for the brake test is that the robot is at operating temperature.
This is the case after approx. 1 h in normal operation.
The brake test is carried out using the program BrakeTestReq.SRC. It can be
carried out in the following ways:
Automatically
Integrate BrakeTestReq.SRC into the application program in such a way
that it is cyclically called as a subprogram. If a brake test is requested, the
robot detects this and performs the brake test immediately.
Manually
Start the program BrakeTestReq.SRC manually.
Brake test request
The following events cause a brake test to be requested.
Input $BRAKETEST_REQ_EX is set externally, e.g. by a PLC (external
request)
Brake test cycle time has elapsed (internal request)
Robot controller is rebooted (internal request)
Manual start of the program BrakeTestReq.SRC (external request)
Function test of the brake test (internal request)
In the main menu by means of Configuration & gt; Inputs/outputs & gt; Reconfigure I/O driver (external request)
Functional principle of the brake test
The brake test checks all brakes one after the other.
1. The robot accelerates to a defined velocity. (The velocity cannot be influenced by the user.)
2. Once the robot has reached the velocity, the brake is applied and the result for this braking operation is displayed in the message window.
3. If a brake has been identified as being defective, the brake test can be repeated for confirmation or the robot can be moved to the parking position.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
If a brake has reached the wear limit, the robot controller indicates this by
means of a message. A worn brake will soon be identified as defective.
Until then, the robot can be moved without restrictions.
If a brake has been identified as being defective, the drives remain
under servo-control for 2 hours following the start of the brake test (=
monitoring time). The robot controller then switches the drives off.
Cycle time
The cycle time is 46 h. It is deemed to have elapsed when the drives have
been under servo-control for a total of 46 h. The robot controller then requests
a brake test and generates the following message: Brake test required. The robot can be moved for another 2 hours. It then stops and the robot controller
generates the following acknowledgement message: Test cycle for brake test request exceeded. Once the message has been acknowledged, the robot can be
moved for another 2 hours.
Overview
Step
1
Description
Assign input and output signals for the brake test.
( & gt; & gt; & gt; 6.13.4 " Configuring input and output signals "
Page 194)
2
Teach positions for the brake test.
The parking position must be taught. The start position and
end position can be taught.
( & gt; & gt; & gt; 6.13.5 " Teaching positions for the brake test "
Page 195)
3
If the brake test is to be carried out automatically:
Integrate BrakeTestReq.SRC into the application program
in such a way that it is cyclically called as a subprogram.
4
If the brake test is to be carried out manually:
Start the program BrakeTestReq.SRC manually.
( & gt; & gt; & gt; 6.13.6 " Performing a manual brake test " Page 196)
6.13.2
Programs for the brake test
The programs are located in the directory C:\KRC\ROBOTER\KRC\R1\TP\BrakeTest.
Program
Description
BrakeTestReq.SRC
This program performs the brake test.
It can be performed in the following ways:
Execute the program manually.
BrakeTestPark.SRC
Integrate the program into the application program in such a way that
it is cyclically called as a subprogram. If a brake test is requested, the
robot detects this and performs the brake test immediately.
Test the function of the brake test. The robot controller executes BrakeTestReq.SRC with special parameterization.
The parking position of the robot must be taught in this program.
The robot can be moved to the parking position if a brake has been
identified as being defective. Alternatively, the brake test can be
repeated for confirmation.
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Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
6 Configuration
Program
Description
BrakeTestStart.SRC
The start position of the brake test can be taught in this program. The
robot starts the brake test from this position.
If the start position is not taught, the robot performs the brake test at the
actual position.
BrakeTestBack.SRC
The end position of the brake test can be taught in this program. The
robot moves to this position after the brake test.
If the end position is not taught, the robot remains at the actual position
after the brake test.
BrakeTestSelfTest.SRC
6.13.3
The program checks whether the brake test has correctly detected a
defective brake. For this purpose, the robot controller executes BrakeTestReq.SRC with special parameterization.
Signal diagram of the brake test
Example 1
The signal diagram for the brake test applies in the following case:
No brake has reached the wear limit.
No brake is defective.
Fig. 6-32: Signal diagram: brakes OK
Item
Description
1
The brake test is requested.
2
Automatic call of the program BrakeTestReq.SRC
Start of the brake test
3
Example 2
The brake test is completed.
The signal diagram for the brake test applies in the following case:
Brake A2 is worn.
Brake A4 is defective.
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KUKA System Software 8.2
Fig. 6-33: Signal diagram: brakes not OK
Item
1
Description
The brake test is requested.
($BRAKETEST_REQ_INT is not set to FALSE again until a brake
test is carried out with a positive result.)
2
Automatic call of the program BrakeTestReq.SRC
3
Brake A2 is tested: brake is worn.
4
Brake A4 is tested: brake is defective.
5
The robot has been moved to the parking position or the program
has been canceled.
Start of the brake test
6.13.4
Configuring input and output signals
Description
All signals for the brake test are declared in the file $machine.dat in the directory C:\KRC\ROBOTER\KRC\STEU\MADA.
These signals are not redundant in design and can supply incorrect information. Do not use these signals for
safety-relevant applications.
By default, the input signal is routed to $IN[1026], i.e. there is no active request
for a brake test.
The output signals are preset to FALSE. There is no compelling need to assign
outputs to them. It is only necessary to assign outputs if there is a need to be
able to read the signals (e.g. via the variable correction function or program
execution.)
Precondition
Procedure
1. Open the file $machine.dat.
Expert user group
2. Assign inputs and outputs.
3. Save and close the file.
$machine.dat
Extract from the file $machine.dat (with default settings, without comments):
...
SIGNAL
SIGNAL
SIGNAL
SIGNAL
SIGNAL
SIGNAL
...
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$BRAKETEST_REQ_EX $IN[1026]
$BRAKETEST_MONTIME FALSE
$BRAKETEST_REQ_INT FALSE
$BRAKETEST_WORK FALSE
$BRAKES_OK FALSE
$BRAKETEST_WARN FALSE
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
6 Configuration
Signals
Signal
Description
$BRAKETEST_REQ_EX
Input
$BRAKETEST_MONTIME
TRUE = brake test is being requested externally (e.g. by
PLC). The robot controller confirms the signal with
$BRAKETEST_REQ_INT = TRUE and generates message 27004.
FALSE = brake test is not being requested externally.
Output
$BRAKETEST_REQ_INT
TRUE = robot was stopped due to elapsed monitoring
time. Acknowledgement message 27002 is generated.
FALSE = acknowledgement message 27002 is not active. (Not generated, or has been acknowledged.)
Output
TRUE = message 27004 is active.
The signal is not set to FALSE again until a brake test is
carried out with a positive result, i.e. with message
27012.
$BRAKETEST_WORK
FALSE = brake test is not requested (either internally or
externally).
Output
TRUE = brake test is currently being performed.
FALSE = brake test is not being performed.
If no defective brakes have been detected, message
27012 is generated.
Edge TRUE -- & gt; FALSE:
Or at least 1 defective brake was detected and the robot
has moved to the parking position.
$BRAKES_OK
Test was successfully completed. No brake is defective.
Message 27012 is generated.
Or the program was canceled during execution of the
brake test.
Output
$BRAKETEST_WARN
Edge FALSE -- & gt; TRUE: Output was set to FALSE by the
previous brake test. The brake test was carried out again
and no defective brake was detected.
Edge TRUE -- & gt; FALSE: A brake has just been detected
as defective. Message 27007 is generated.
Output
6.13.5
Edge FALSE -- & gt; TRUE: At least 1 brake has been detected as having reached the wear limit. Message 27001
is generated at the same time.
Edge TRUE -- & gt; FALSE: Output was set to TRUE by the
previous brake test. The brake test was carried out again
and no worn brake was detected.
Teaching positions for the brake test
Description
The parking position must be taught.
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KUKA System Software 8.2
The start position and end position can be taught.
Parking position
If the start position is not taught, the robot performs the brake test at the
actual position.
If the end position is not taught, the robot remains at the actual position after the brake test.
If a brake is identified as being defective, the robot can be moved to the parking position. The parking position must be selected in a position where no persons are endangered if the robot sags because of the defective brake.
The parking position can correspond to the transport position, for example.
Further information about the transport position is contained in the robot operating or assembly instructions.
Precondition
All output signals are assigned to outputs.
User group “Expert”
Procedure
Operating mode T1
1. Open the program BrakeTestStart.SRC in the directory R1\TP\BrakeTest.
2. Teach the motions to the start position of the brake test.
The motions must be taught in such a way that the robot cannot cause
a collision on the way to the start position.
In the start position, every robot axis must have an available motion
range of ±10°.
3. Save and close the program.
4. Open the program BrakeTestBack.SRC in the directory R1\TP\BrakeTest.
5. Teach the motions from the start position to the end position of the brake
test.
The start and end position of the brake test can be identical.
6. Save and close the program.
7. Open the program BrakeTestPark.SRC in the directory R1\TP\BrakeTest.
8. Program the motions from the end position to the parking position of the
robot.
9. Save and close the program.
6.13.6
Performing a manual brake test
If a brake is defective and the drives are deactivated, the
robot may sag. For this reason, no stop may be triggered
during the motion to the parking position. The monitoring functions that can
trigger a stop in this range (e.g. monitoring spaces) must be deactivated beforehand. No safety functions may be executed that would trigger a stop (e.g.
E-STOP, opening the safety gate, change of operating mode, etc.).
Precondition
No persons or objects are present within the motion range of the robot.
In the start position, every robot axis has an available motion range of
±10°. (Or, if no start position has been taught, in the actual position.)
The parking position has been taught in the program BrakeTestPark.SRC.
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6 Configuration
AUT mode
Procedure
Program run mode GO
The robot is at operating temperature (= after approx. 1 h in normal operation).
1. Select the program BrakeTestReq.SRC in the directory R1\TP\BrakeTest
and press the Start key.
2. The following message is displayed: acknowledge to manually perform brake
test. Acknowledge the message.
3. Press the Start key. The message Programmed path reached (BCO) is displayed.
4. Press the Start key. The brakes are tested, starting with A1.
Program override is automatically set to 100%. The robot
moves at high velocity. Make sure that the robot cannot
collide and that no persons are in the motion range of the robot.
5. Possible results:
If a brake is OK, this is indicated by the following message: Brake X OK.
If all brakes are OK, this is indicated after the brake test by the following message: Brake test successful. (It is possible that one or more
brakes may have reached the wear limit. This is also indicated by a
message.)
Deselect the program BrakeTestReq.SRC.
If a brake is defective, this is indicated by the following message: Insufficient holding torque of brake X.
Once all brakes have been tested, either press Repeat to repeat the
brake test for checking purposes
or press Park pos. to move the robot to the parking position.
If a brake has been identified as being defective, the drives remain
under servo-control for 2 hours following the start of the brake test (=
monitoring time). The robot controller then switches the drives off.
6.13.7
Checking that the brake test is functioning correctly
Description
It is possible to check whether the brake test has correctly detected a defective
brake: the program BrakeTestSelfTest.SRC simulates a fault in the brakes
and triggers a brake test. If the brake test detects the simulated fault, it is functioning correctly.
If the function of the brake test is being tested, the meaning of the messages is different from that in a normal
brake test. The following applies to the function test:
Message Insufficient holding torque of brake 3:
The brake test has correctly detected the simulated fault. The brake test
is functioning correctly.
Any other message, or no message, means:
The brake test has not detected the simulated fault. The brake test is not
functioning correctly. The robot must no longer be moved. KUKA Roboter
GmbH must be contacted.
Precondition
No persons or objects are present within the motion range of the robot.
In the start position, every robot axis has an available motion range of
±10°. (Or, if no start position has been taught, in the actual position.)
The parking position has been taught in the program BrakeTestPark.SRC.
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Program run mode GO
AUT mode
Procedure
“Expert” user group
The robot is at operating temperature (= after approx. 1 h in normal operation).
1. Select the program BrakeTestSelfTest.SRC in the directory C:\KRC\ROBOTER\KRC\R1\TP\SAFEROBOT and press the Start key.
2. The following message is displayed: Performing self-test for brake test - please
acknowledge. Confirm the message by pressing Ackn..
3. Press the Start key.
Program override is automatically set to 100%. The robot
moves at high velocity. Make sure that the robot cannot
collide and that no persons are in the motion range of the robot.
4. Result of the function test:
Message Insufficient holding torque of brake 3: The brake test has correctly detected the simulated fault. The brake test is functioning correctly.
Deselect the program BrakeTestSelfTest.SRC.
Perform a manual brake test. This ensures that the simulated fault
does not remain active.
Any other message, or no message, means: The brake test has not
detected the simulated fault. The brake test is not functioning correctly.
If the function test establishes that the brake test is not
functioning correctly:
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The robot must no longer be moved.
KUKA Roboter GmbH must be contacted.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
7 Program management
7
Program management
7.1
Navigator file manager
Overview
Fig. 7-1: Navigator
1
3
File list
2
Description
Header
Directory structure
4
Status bar
In the Navigator, the user manages programs and system-specific files.
Header
Left-hand area: the selected filter is displayed.
( & gt; & gt; & gt; 7.1.1 " Selecting filters " Page 200)
Right-hand area: the directory or drive selected in the directory structure
is displayed.
Directory structure
Overview of directories and drives. Exactly which directories and drives are
displayed depends on the user group and configuration.
File list
The contents of the directory or drive selected in the directory structure are displayed. The manner in which programs are displayed depends on the selected
filter.
The file list has the following columns:
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Column
Description
Name
Directory or file name
Extension
File extension
This column is not displayed in the user group “User”.
Comment
Comment
Attributes
Attributes of the operating system and kernel system
This column is not displayed in the user group “User”.
Size
File size in kilobytes
This column is not displayed in the user group “User”.
#
Number of changes made to the file
Changed
Date and time of the last change
Created
Date and time of file creation
This column is not displayed in the user group “User”.
Status bar
The status bar can display the following information:
Action in progress
User dialogs
User entry prompts
7.1.1
Selected objects
Requests for confirmation
Selecting filters
Description
This function is not available in the user group “User”.
The filter defines how programs are displayed in the file list. The following filters are available:
Detail
Programs are displayed as SRC and DAT files. (Default setting)
Modules
Programs are displayed as modules.
Precondition
Procedure
1. Select the menu sequence Edit & gt; Filter.
Expert user group
2. Select the desired filter in the left-hand section of the Navigator.
3. Click OK to confirm.
7.1.2
Creating a new folder
Precondition
Procedure
1. In the directory structure, select the folder in which the new folder is to be
created, e.g. the folder R1.
The Navigator is displayed.
Not all folders allow the creation of new folders within them. In the user
groups “Operator” and “User”, new folders can only be created in the folder
R1.
2. Press New.
3. Enter a name for the folder and confirm it with OK.
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7 Program management
7.1.3
Creating a new program
Precondition
Procedure
1. In the directory structure, select the folder in which the program is to be
created, e.g. the folder Program. (Not all folders allow the creation of programs within them.)
The Navigator is displayed.
2. Press New.
3. Only in the user group “Expert”:
The Template selection window is opened. Select the desired template
and confirm with OK.
4. Enter a name for the program and confirm it with OK.
It is not possible to select a template in the user group “User”. By default, a program of type “Module” is created.
7.1.4
Renaming a file
Precondition
Procedure
1. In the directory structure, select the folder in which the file is located.
The Navigator is displayed.
2. Select the file in the file list.
3. Select Edit & gt; Rename.
4. Overwrite the file name with the new name and confirm with OK.
7.2
Selecting or opening a program
Overview
A program can be selected or opened. Instead of the Navigator, an editor is
then displayed with the program.
( & gt; & gt; & gt; 7.2.1 " Selecting and deselecting a program " Page 202)
( & gt; & gt; & gt; 7.2.2 " Opening a program " Page 203)
It is possible to toggle backwards and forwards between the program display
and the Navigator.
( & gt; & gt; & gt; 7.2.3 " Toggling between the Navigator and the program " Page 203)
Differences
Program is selected:
The block pointer is displayed.
The program can be started.
The program can be edited to a certain extent.
Selected programs are particularly suitable for editing in the user group
“User”.
Example: KRL instructions covering several lines (e.g. LOOP … ENDLOOP) are not permissible.
When the program is deselected, modifications are accepted without a request for confirmation. If impermissible modifications are programmed, an
error message is displayed.
Program is opened:
The program cannot be started.
The program can be edited.
Opened programs are particularly suitable for editing in the user group
“Expert”.
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7.2.1
A request for confirmation is generated when the program is closed. Modifications can be accepted or rejected.
Selecting and deselecting a program
If a selected program is edited in the user group “Expert”, the cursor
must then be removed from the edited line and positioned in any other
line!
Only in this way is it certain that the editing will be applied when the program
is deselected again.
Precondition
Procedure
1. Select the program in the Navigator and press Select.
T1, T2 or AUT mode
The program is displayed in the editor. It is irrelevant whether a module,
an SRC file or a DAT file is selected. It is always the SRC file that is displayed in the editor.
2. Start or edit the program.
3. Deselect the program again:
Select Edit & gt; Cancel program.
Or: In the status bar, touch the Robot interpreter status indicator. A window opens. Select Cancel program.
When the program is deselected, modifications are accepted without
a request for confirmation!
If the program is running, it must be stopped before it can be deselected.
Description
If a program is selected, this is indicated by the Robot interpreter status indicator.
( & gt; & gt; & gt; 7.5.6 " Robot interpreter status indicator " Page 209)
Fig. 7-2: Program is selected
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7 Program management
1
2
Cursor
3
Program path and file name
4
Position of the cursor in the program
5
7.2.2
Block pointer
The icon indicates that the program is selected.
Opening a program
Precondition
T1, T2 or AUT mode
A program can be opened in AUT EXT mode, but not edited.
Procedure
1. Select the program in the Navigator and press Open. The program is displayed in the editor.
If a module has been selected, the SRC file is displayed in the editor. If an
SRC file or DAT file has been selected, the corresponding file is displayed
in the editor.
2. Edit the program.
3. Close the program.
4. To accept the changes, answer the request for confirmation with Yes.
Description
Fig. 7-3: Program is open
1
2
Program path and file name
3
7.2.3
Cursor
Position of the cursor in the program
Toggling between the Navigator and the program
Description
If a program is selected or open, it is possible to display the Navigator again
without having to deselect or close the program. The user can then return to
the program.
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Procedure
Program is selected:
Toggling from the program to the Navigator: select the menu sequence
Edit & gt; Navigator.
Toggling from the Navigator to the program: press PROGRAM.
Program is open:
Toggling from the program to the Navigator: select the menu sequence
Edit & gt; Navigator.
Toggling from the Navigator to the program: press EDITOR.
Programs that are running or have been interrupted must first be
stopped before the menu sequences and buttons referred to above
are available.
7.3
Structure of a KRL program
1
2
3
4
DEF my_program( )
INI
PTP
...
8 LIN
...
14 PTP
...
20 PTP
21
22 END
HOME
Vel= 100 % DEFAULT
point_5 CONT Vel= 2 m/s CPDAT1 Tool[3] Base[4]
point_1 CONT Vel= 100 % PDAT1 Tool[3] Base[4]
HOME
Vel= 100 % DEFAULT
Line
Description
1
The DEF line indicates the name of the program. If the program is a function, the DEF line begins with “DEFFCT” and
contains additional information. The DEF line can be displayed or hidden.
( & gt; & gt; & gt; 7.4.1 " Displaying/hiding the DEF line " Page 205)
2
The INI line contains initializations for internal variables and
parameters.
4
HOME position
( & gt; & gt; & gt; 7.3.1 " HOME position " Page 205)
8
LIN motion
( & gt; & gt; & gt; 9.2.3 " Programming a LIN motion " Page 252)
14
PTP motion
( & gt; & gt; & gt; 9.2.1 " Programming a PTP motion " Page 251)
20
HOME position
22
The END line is the last line in any program. If the program is
a function, the wording of the END line is “ENDFCT”. The
END line must not be deleted!
The first motion instruction in a KRL program must define an unambiguous
starting position. The HOME position, which is stored by default in the robot
controller, ensures that this is the case.
If the first motion instruction is not the default HOME position, or if this position
has been changed, one of the following statements must be used:
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Complete PTP instruction of type POS or E6POS
Complete PTP instruction of type AXIS or E6AXIS
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7 Program management
“Complete” means that all components of the end point must be specified.
If the HOME position is modified, this affects all programs in which it is used. Physical injuries or damage to
property may result.
In programs that are used exclusively as subprograms, different statements
can be used as the first motion instruction.
7.3.1
HOME position
The HOME position is not program-specific. It is generally used as the first and
last position in the program as it is uniquely defined and uncritical.
The HOME position is stored by default with the following values in the robot
controller:
Axis
A1
A2
A3
A4
A5
A6
Position
0°
- 90°
+ 90°
0°
0°
0°
Additional HOME positions can be taught. A HOME position must meet the following conditions:
Good starting position for program execution
Good standstill position. For example, the stationary robot must not be an
obstacle.
If the HOME position is modified, this affects all programs in which it is used. Physical injuries or damage to
property may result.
7.4
Displaying/hiding program sections
7.4.1
Displaying/hiding the DEF line
Description
By default, the DEF line is hidden. Declarations can only be made in a program
if the DEF line is visible.
The DEF line is displayed and hidden separately for opened and selected programs. If detail view (ASCII mode) is activated, the DEF line is visible and does
not need to be activated separately.
Precondition
User group “Expert”
Procedure
Program is selected or open.
Select the menu sequence Edit & gt; View & gt; DEF line.
Check mark activated in menu: DEF line is displayed.
Check mark not activated in menu: DEF line is hidden.
7.4.2
Activating detail view
Description
Detail view (ASCII mode) is deactivated by default to keep the program transparent. If detail view is activated, hidden program lines, such as the FOLD and
ENDFOLD lines and the DEF line, are displayed.
Detail view is activated and deactivated separately for opened and selected
programs.
Precondition
Expert user group
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Procedure
Select the menu sequence Edit & gt; View & gt; Detail view (ASCII).
Check mark activated in menu: detail view is activated.
Check mark not activated in menu: detail view is deactivated.
7.4.3
Activating/deactivating the line break function
Description
If a line is wider than the program window, the line is broken by default. The
part of the line after the break has no line number and is marked with a black,
L-shaped arrow. The line break function can be deactivated.
Fig. 7-4: Line break
The line break function is activated and deactivated separately for opened and
selected programs.
Precondition
User group “Expert”
Procedure
Program is selected or open.
Select the menu sequence Edit & gt; View & gt; Line break.
Check mark activated in menu: line break function is activated.
Check mark not activated in menu: line break function is deactivated.
7.4.4
Displaying Folds
Description
Folds are used to hide sections of the program. In this way, Folds make programs more transparent. The hidden program sections are processed during
program execution in exactly the same way as normal program sections.
In the user group “User”, Folds are always closed. In other words, the contents of the Folds are not visible and cannot be edited.
In the user group “Expert”, Folds are closed by default. They can be
opened and edited. New Folds can be created.
( & gt; & gt; & gt; 7.6.3 " Creating Folds " Page 214)
If a program is deselected, all Folds are automatically closed.
Fig. 7-5: Example of a closed Fold
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7 Program management
Fig. 7-6: Example of an open Fold
Color coding of Folds:
Color
Description
Dark red
Closed fold
Light red
Closed sub-Fold
Light blue
Opened sub-Fold
Green
Precondition
Opened fold
Dark blue
Contents of the Fold
User group “Expert”
Procedure
Program is selected or open.
1. Select the line containing the Fold.
2. Press Open/close fold. The Fold then opens.
3. To close the fold, press Open/close fold again.
Alternatively, use the menu sequence Edit & gt; FOLD & gt; Open all FOLDs or
Close all FOLDs to open or close all the Folds in a program at once.
7.5
Starting a program
7.5.1
Selecting the program run mode
Procedure
1. Touch the Program run mode status indicator. The Program run mode
window is opened.
2. Select the desired program run mode.
( & gt; & gt; & gt; 7.5.2 " Program run modes " Page 208)
The window closes and the selected program run mode is applied.
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7.5.2
Program run modes
Program run mode
Go
Description
The program is executed through to the
end without stopping.
#GO
Motion
#MSTEP
Single Step
#ISTEP
The program is executed with a stop after
each motion block. The Start key must be
pressed again for each motion block.
The program is executed with a stop after
each program line. Program lines that cannot be seen and blank lines are also taken
into consideration. The Start key must be
pressed again for each line.
Single Step is only available to the user
group “Expert”.
Backward
#BSTEP
This program run mode is automatically
selected if the Start backwards key is
pressed.
In Motion Step and Single Step modes, the program is executed
without an advance run.
The following additional program run modes are available for systems integrators.
These program run modes can only be selected via the variable correction
function. System variable for the program run mode: $PRO_MODE.
Program run mode
Program Step
#PSTEP
Continuous Step
#CSTEP
Description
The program is executed step by step without an advance run. Subprograms are executed completely.
Approximate positioning points are executed with advance processing, i.e. they
are approximated.
Exact positioning points are executed without an advance run and with a stop after
the motion instruction.
7.5.3
Advance run
The advance run is the maximum number of motion blocks that the robot controller calculates and plans in advance during program execution. The actual
number is dependent on the capacity of the computer.
The advance run refers to the current position of the block pointer. It is set via
the system variable $ADVANCE:
Default value: 3
Maximum value: 5
The advance run is required, for example, in order to be able to calculate approximate positioning motions. If $ADVANCE = 0 is set, approximate positioning is not possible.
Certain statements trigger an advance run stop. These include statements
that influence the periphery, e.g. OUT statements.
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7 Program management
7.5.4
Setting the program override (POV)
Description
Program override is the velocity of the robot during program execution. The
program override is specified as a percentage of the programmed velocity.
In T1 mode, the maximum velocity is 250 mm/s, irrespective of the
value that is set.
Procedure
1. Touch the POV/HOV status indicator. The Overrides window is opened.
2. Set the desired program override. It can be set using either the plus/minus
keys or by means of the slide controller.
Plus/minus keys: The value can be set to 100%, 75%, 50%, 30%,
10%, 3%, 1%
Slide controller: The override can be adjusted in 1% steps.
3. Touch the POV/HOV status indicator again. (Or touch the area outside the
window.)
The window closes and the selected override value is applied.
The Jog options window can be opened via Options in the Overrides window.
Alternative
procedure
Alternatively, the override can be set using the plus/minus key on the righthand side of the KCP.
The value can be set to 100%, 75%, 50%, 30%, 10%, 3%, 1%.
7.5.5
Switching drives on/off
The status of the drives is indicated in the status bar. The drives can also be
switched on or off here.
Icon
Description
Green
Drives ready.
Red
7.5.6
Color
Drives not ready.
Robot interpreter status indicator
Icon
Description
Gray
No program is selected.
Yellow
The block pointer is situated on the first line
of the selected program.
Green
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Color
The program is selected and is being executed.
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Icon
Description
Red
The selected and started program has been
stopped.
Black
7.5.7
Color
The block pointer is situated at the end of
the selected program.
Starting a program forwards (manual)
Precondition
Program is selected.
Procedure
Operating mode T1 or T2.
1. Select the program run mode.
2. Hold the enabling switch down and wait until the status bar indicates
“Drives ready”:
Fig. 7-7
3. Carry out a BCO run: Press Start key and hold it down until the message
“Programmed path reached (BCO)” is displayed in the message window. The
robot stops.
A BCO run is always executed as a PTP motion from the
actual position to the target position. Observe the motion
to avoid collisions. The velocity is automatically reduced during the BCO run.
4. Press Start key and hold it down.
The program is executed with or without stops, depending on the program
run mode.
To stop a program that has been started manually, release the Start key.
7.5.8
Starting a program forwards (automatic)
Precondition
A program is selected.
Procedure
Operating mode Automatic (not Automatic External)
1. Select the program run mode Go.
2. Switch on the drives.
3. Carry out a BCO run:
Press Start key and hold it down until the message “Programmed path
reached (BCO)” is displayed in the message window. The robot stops.
A BCO run is always executed as a PTP motion from the
actual position to the target position. Observe the motion
to avoid collisions. The velocity is automatically reduced during the BCO run.
4. Press the Start key. The program is executed.
To stop a program that has been started in Automatic mode, press the STOP
key.
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7 Program management
7.5.9
Carrying out a block selection
Description
A program can be started at any point by means of a block selection.
Precondition
Program is selected.
Operating mode T1 or T2.
Procedure
1. Select the program run mode.
2. Select the motion block at which the program is to be started.
3. Press Block selection. The block pointer indicates the motion block.
4. Hold the enabling switch down and wait until the status bar indicates
“Drives ready”:
5. Carry out a BCO run: Press Start key and hold it down until the message
“Programmed path reached (BCO)” is displayed in the message window. The
robot stops.
A BCO run is always executed as a PTP motion from the
actual position to the target position. Observe the motion
to avoid collisions. The velocity is automatically reduced during the BCO run.
6. The program can now be started manually or automatically. It is not necessary to carry out a BCO run again.
7.5.10
Starting a program backwards
Description
In the case of backward motion, the robot stops at every point. Approximate
positioning is not possible.
Precondition
Program is selected.
Operating mode T1 or T2.
Procedure
1. Hold the enabling switch down and wait until the status bar indicates
“Drives ready”:
2. Carry out a BCO run: Press Start key and hold it down until the message
“Programmed path reached (BCO)” is displayed in the message window. The
robot stops.
A BCO run is always executed as a PTP motion from the
actual position to the target position. Observe the motion
to avoid collisions. The velocity is automatically reduced during the BCO run.
3. Press Start backwards key.
4. Press Start backwards key again for each motion block.
7.5.11
Resetting a program
Description
In order to restart an interrupted program from the beginning, it must be reset.
This returns the program to the initial state.
Precondition
Program is selected.
Procedure
Select the menu sequence Edit & gt; Reset program.
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Alternative
procedure
In the status bar, touch the Robot interpreter status indicator. A window
opens.
Select Reset program.
7.5.12
Starting Automatic External mode
There is no BCO run in Automatic External mode. This
means that the robot moves to the first programmed position after the start at the programmed (not reduced) velocity and does not
stop there.
Precondition
Operating mode T1 or T2
Procedure
Inputs/outputs for Automatic External and the program CELL.SRC are
configured.
1. Select the program CELL.SRC in the Navigator. (This program is located
in the folder “R1”.)
2. Set program override to 100%. (This is the recommended setting. A different value can be set if required.)
3. Carry out a BCO run:
Hold down the enabling switch. Then press the Start key and hold it down
until the message “Programmed path reached (BCO)” is displayed in the
message window.
A BCO run is always executed as a PTP motion from the
actual position to the target position. Observe the motion
to avoid collisions. The velocity is automatically reduced during the BCO run.
4. Select “Automatic External” mode.
5. Start the program from a higher-level controller (PLC).
To stop a program that has been started in Automatic mode, press the STOP
key.
7.6
Editing a program
Overview
A running program cannot be edited.
Programs cannot be edited in AUT EXT mode.
If a selected program is edited in the user group “Expert”, the cursor
must then be removed from the edited line and positioned in any other
line!
Only in this way is it certain that the editing will be applied when the program
is deselected again.
Action
Insert comment or
stamp
Possible in user group …?
User: Yes
Expert: Yes
Delete lines
User: Yes
Expert: Yes
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Action
Possible in user group …?
Create folds
User: No
Expert: Yes
Copy
User: No
Expert: Yes
Paste
User: No
Expert: Yes
Insert blank lines
(press the Enter key)
User: No
Expert: Yes
Cut
User: No
Expert: Yes
Find
User: Yes
Expert: Yes
Possible for all user groups in an open program,
even in AUT EXT mode.
Replace
User: No
Expert: Yes (program is open, not
selected)
Programming with
inline forms
User: Yes
Expert: Yes
KRL programming
User: Possible to a certain extent. KRL
instructions covering several lines (e.g.
LOOP … ENDLOOP) are not permissible.
Expert: Yes
7.6.1
Inserting a comment or stamp
Precondition
Program is selected or open.
Procedure
T1, T2 or AUT mode
1. Select the line after which the comment or stamp is to be inserted.
2. Select the menu sequence Commands & gt; Comment & gt; Normal or Stamp.
3. Enter the desired data. If a comment or stamp has already been entered
previously, the inline form still contains the same entries.
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In the case of a comment, the box can be cleared using New text
ready for entry of a new text.
In the case of a stamp, the system time can also be updated using
New time and the NAME box can be cleared using New name.
4. Save with Cmd Ok.
Description
Comment
Fig. 7-8: Inline form “Comment”
Item
1
Description
Stamp
Description
Any text
A stamp is a comment that is extended to include the system date and time
and the user ID.
Fig. 7-9: Inline form “Stamp”
Item
1
Description
System date (cannot be edited)
2
Name or ID of the user
4
7.6.2
System time
3
Any text
Deleting program lines
Precondition
Program is selected or open.
Procedure
T1, T2 or AUT mode
1. Select the line to be deleted. (The line need not have a colored background. It is sufficient for the cursor to be in the line.)
If several consecutive lines are to be deleted: drag a finger or stylus across
the desired area. (The area must now have a colored background.)
2. Select the menu sequence Edit & gt; Delete.
3. Confirm the request for confirmation with Yes.
Lines cannot be restored once they have been deleted!
If a program line containing a motion instruction is deleted, the point
name and coordinates remain saved in the DAT file. The point can be
used in other motion instructions and does not need to be taught
again.
7.6.3
Syntax
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Creating Folds
;FOLD Name
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7 Program management
Statements
;ENDFOLD & lt; Name & gt;
The ENDFOLD lines can be assigned more easily if the name of the Fold is
entered here as well. Folds can be nested.
Precondition
User group “Expert”
Procedure
Program is selected or open.
1. Enter Fold in program. A double semicolon prevents the Fold from closing
when edited.
Fig. 7-10: Creating a sample Fold, step 1
2. Delete the second semicolon.
Fig. 7-11: Creating a sample Fold, step 2
3. Position the cursor in a line outside the Fold. The Fold closes.
Fig. 7-12: Creating a sample Fold, step 3
7.6.4
Additional editing functions
The following additional program editing functions can be called using Edit:
Copy
Precondition:
Program is selected or open.
Expert user group
T1, T2 or AUT mode
Paste
Precondition:
Program is selected or open.
Expert user group
T1, T2 or AUT mode
Cut
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KUKA System Software 8.2
Precondition:
Program is selected or open.
Expert user group
T1, T2 or AUT mode
Find
Precondition:
Program is selected or open.
Replace
Precondition:
7.7
Program has been opened.
Expert user group
Printing a program
Procedure
1. Select the program in the Navigator. Multiple program selection is also
possible.
2. Select the menu sequence Edit & gt; Print.
7.8
Archiving and restoring data
7.8.1
Archiving overview
Target locations
Archiving can be performed to the following target destinations:
Menu items
USB stick in KCP or robot controller
Network
The following menu items are available:
( " *.* " means all files and subdirectories.)
Menu item
Archives the directories/files
All
KRC:\*.*
C:\KRC\Roboter\Config\User\*.*
C:\KRC\Roboter\Config\System\Common\Mada\*.*
C:\KRC\Roboter\Init\*.*
C:\KRC\Roboter\lr_Spec\*.*
C:\KRC\Roboter\Template\*.*
C:\KRC\Roboter\Rdc\*.*
C:\KRC\User\*.*
C:\KRC\Roboter\log\Mastery.log
Some additional log data
KRC:\R1\Program\*.*
KRC:\R1\System\*.*
KRC:\R1\cell*.*
KRC:\Steu\$config*.*
Applications
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Menu item
Archives the directories/files
System data
KRC:\R1\Mada\*.*
KRC:\R1\System\*.*
KRC:\R1\TP\*.*
KRC:\Steu\Mada\*.*
C:\KRC\Roboter\Config\User\*.*
C:\KRC\Roboter\Config\System\Common\Mada\*.*
C:\KRC\Roboter\Init\*.*
C:\KRC\Roboter\lr_Spec\*.*
C:\KRC\Roboter\Template\*.*
C:\KRC\Roboter\Rdc\*.*
C:\KRC\User\*.*
C:\KRC\Roboter\log\*.*
Log data
Except: Poslog.xsl and files with the extension DMP
KrcDiag
Some additional log data
If it is necessary for an error to be analyzed by KUKA
Roboter GmbH, this menu item can be used to compress the data for sending to KUKA.
In addition to the menu sequence File & gt; Archive, there
are other methods available for compressing these
data.
( & gt; & gt; & gt; 12.5 " Compressing data for error analysis at
KUKA " Page 362)
If archiving is carried out using the menu item All and there is an existing archive present, this will be overwritten.
If archiving is carried out using a menu item other than All or KrcDiag and an
archive is already available, the robot controller compares its robot name with
that in the archive. If the names are different, a request for confirmation is generated.
If archiving is carried out repeatedly via KrcDiag, a maximum of 10 archives
can be created. Further archives will overwrite the oldest existing archive.
The logbook can also be activated. ( & gt; & gt; & gt; 7.8.4 " Archiving the logbook "
Page 218)
7.8.2
Archiving to a USB stick
Description
This procedure generates a ZIP file on the stick. By default, this file has the
same name as the robot. A different name can be defined for the file, however,
under Robot data.
( & gt; & gt; & gt; 4.15.14 " Displaying/editing robot data " Page 78)
The archive is displayed in the ARCHIVE:\ directory in the Navigator. Archiving
is also carried out automatically to D:\ as well as to the stick. The file INTERN.ZIP is generated here.
Special case KrcDiag:
This menu item generates the folder KRCDiag on the stick. This contains a
ZIP file. The ZIP file is also automatically archived in C:\KUKA\KRCDiag.
Use only a KUKA.USB data stick: if a different USB stick
is used, data may be lost or changed.
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Precondition
A KUKA.USB data stick is connected.
The stick can be connected to the KCP or robot controller.
Procedure
1. In the main menu, select File & gt; Archive & gt; USB (KCP) or USB (cabinet)
and then the desired menu item.
2. Confirm the request for confirmation with Yes. The archive is created.
Once the archiving is completed, this is indicated in the message window.
Special case KrcDiag: If archiving is carried out using this menu item, a
separate window indicates when archiving has been completed. The window is then automatically hidden again.
3. The stick can be removed when the LED on the stick is no longer lit.
7.8.3
Archiving on the network
Description
This procedure generates a ZIP file on the network path. By default, this file
has the same name as the robot. A different name can be defined for the file,
however, under Robot data.
The network path to which archiving is to be carried out must be configured
under Robot data.
( & gt; & gt; & gt; 4.15.14 " Displaying/editing robot data " Page 78)
The archive is displayed in the ARCHIVE:\ directory in the Navigator. Archiving
is also carried out automatically to D:\ as well as to the network path. The file
INTERN.ZIP is generated here.
Special case KrcDiag:
This menu item generates the folder KRCDiag on the network path. This contains a ZIP file. The ZIP file is also automatically archived in C:\KUKA\KRCDiag.
Precondition
Procedure
1. In the main menu, select File & gt; Archive & gt; Network and then the desired
menu item.
The network path to which the data are to be archived is configured.
2. Confirm the request for confirmation with Yes. The archive is created.
Once the archiving is completed, this is indicated in the message window.
Special case KrcDiag: If archiving is carried out using this menu item, a
separate window indicates when archiving has been completed. The window is then automatically hidden again.
7.8.4
Archiving the logbook
Description
The file “Logbuch.txt” is generated as an archive in the directory C:\KRC\ROBOTER\LOG.
Procedure
In the main menu, select File & gt; Archive & gt; Logbook.
The archive is created. Once the archiving is completed, this is indicated
in the message window.
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7.8.5
Restoring data
Description
Only KSS 8.2 archives may be loaded into KSS 8.2. If
other archives are loaded, the following may occur:
Error messages
Robot controller is not operable.
Personal injury and damage to property.
The following menu items are available for restoring data:
All
Applications
System data
If the archived files are not the same version as the files present in the system,
an error message is generated during restoration.
Similarly, if the version of the archived technology packages does not match
the installed version, an error message is generated.
Precondition
If data are to be restored from the USB stick: A KUKA.USB data stick with
the archive is connected.
The stick can be connected to the KCP or robot controller.
Procedure
1. In the main menu, select File & gt; Restore and then the desired subitems.
2. Confirm the request for confirmation with Yes. Archived files are restored
to the robot controller. A message indicates completion of the restoration
process.
3. When data have been restored from the USB stick: remove the stick when
the LED on the stick is no longer lit.
4. Reboot the robot controller.
7.9
Project management
7.9.1
Pinning a project on the robot controller
Description
Projects that are present on the robot controller can be pinned. A project can
be pinned directly on the robot controller or in WorkVisual.
Pinned projects cannot be changed, activated or deleted. They can be copied
or unpinned, however. A project can thus be pinned e.g. to prevent it from being accidentally deleted.
Information about how projects can be pinned via WorkVisual can be
found in the WorkVisual documentation.
Precondition
Procedure
1. Select the menu sequence File & gt; Project management.
Expert user group
2. Select the desired project and press the Pin button. The project is pinned
and labeled with a pin symbol in the project list.
( & gt; & gt; & gt; 7.9.3 " Project management window " Page 221)
3. The project can be unpinned again by pressing the Unpin button.
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7.9.2
Activating a project
Precondition
User group Expert or higher
Restriction: If the activation would cause changes in the area Safety-relevant communication parameters, the user group “Safety recovery” or
higher must be selected.
If the operating mode AUT or AUT EXT is selected: The project can only
be activated if this affects only KRL programs. If the project contains settings that would cause other changes, it cannot be activated.
If one of the options KUKA.SafeOperation or KUKA.SafeRangeMonitoring is installed on the robot controller, different user groups may
apply. Information can be found in the documentation for these op-
tions.
Procedure
1. Select the menu sequence File & gt; Project management. The Project
management window is opened.
( & gt; & gt; & gt; 7.9.3 " Project management window " Page 221)
2. Select the desired project and activate it using the Activate button.
3. The KUKA smartHMI displays the request for confirmation Do you want to
activate the project […]?. In addition, a message is displayed as to whether
the activation would overwrite a project, and if so, which.
If no relevant project will be overwritten: Confirm with Yes within 30 minutes.
4. An overview is displayed of the changes which will be made in comparison
to the project that is still active on the robot controller. The check box Details can be used to display details about the changes.
If changes are listed in the overview under the heading
Safety-relevant communication parameters, this
means that the behavior of the Emergency Stop and “Operator safety” signal
may have changed compared with the previous project.
After activation of the project, the Emergency Stop and the “Operator safety”
signal must be checked for safe functioning. If the project is activated on several robot controllers, this check must be carried out for every robot controller. Failure to carry out this check may result in death to persons, severe
physical injuries or considerable damage to property.
5.
The overview displays the request for confirmation Do you want to continue?. Confirm with Yes. The project is activated on the robot controller.
After activation of a project on the robot controller, the
safety configuration must be checked there! If this is not
done, the robot will possibly be operated with incorrect data. Death to persons, severe physical injuries or considerable damage to property may result.
( & gt; & gt; & gt; 6.3 " Checking the safety configuration of the robot controller "
Page 141)
If the activation of a project fails, an error message is displayed. In this case, one of the following measures must
be carried out:
Either: Activate a project again (the same one or a different one).
Or: Reboot the robot controller with a cold restart.
In the case of a KSS/VSS update (e.g. from 8.2.3 to 8.2.4), the initial
project and base project are overwritten by copies of the active project.
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7.9.3
Project management window
Overview
In addition to the regular projects, the Project management window contains
the following special projects:
Project
Description
Initial project
The initial project is always present. It cannot be
changed by the user. It contains the initial state of the
robot controller as shipped.
Base project
The user can save the active project as the base project. This functionality is generally used to save a functional, tried-and-tested project state.
The base project cannot be activated, but copied. The
base project can no longer be changed by the user. It
can, however, be overwritten by saving a new base
project (after a request for confirmation).
If a project is activated which does not contain all the
configuration files, the missing information is inserted
from the base project. This is the case e.g. if a project
is activated from an earlier version of WorkVisual. (The
configuration files include machine data files, safety
configuration files and many others.)
In the case of a KSS/VSS update (e.g. from 8.2.3 to 8.2.4), the initial
project and base project are overwritten by copies of the active project.
Description
Fig. 7-13: “Projects management” window
Item
Description
1
The initial project is displayed.
2
Restores the factory settings of the robot controller.
Only available to the user group “Expert” or higher.
3
The base project is displayed.
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Item
4
Description
Creates a copy of the base project.
Only available to the user group “Expert” or higher.
5
The active project is displayed.
6
Saves the active project as the base project. The active project remains active.
Only available to the user group “Expert” or higher.
7
Creates a pinned copy of the active project.
8
List of projects. The active project is not displayed here.
Only available to the user group “Expert” or higher.
With all copying operations, a window opens in which a name and a description can be entered for the copy.
Buttons
The following buttons are available:
Button
Description
Activate
Activates the selected project.
If the selected project is pinned: Creates a copy of the
selected project. (A pinned project cannot be activated
itself, only a copy of it.) The user can then decide
whether to activate this copy or whether the current
project should remain active.
Only available to the user group “Expert” or higher.
Pin
( & gt; & gt; & gt; 7.9.1 " Pinning a project on the robot controller "
Page 219)
Only available if an unpinned project is selected. Only
available to the user group “Expert” or higher.
Unpin
Unpins the project.
Only available if a pinned project is selected. Only
available to the user group “Expert” or higher.
Copy
Copies the selected project.
Only available to the user group “Expert” or higher.
Delete
Deletes the selected project.
Only available if a non-activated, unpinned project is
selected. Only available to the user group “Expert” or
higher.
Edit
Opens a window in which the name and/or description
of the selected project can be changed.
Only available if an unpinned project is selected. Only
available to the user group “Expert” or higher.
Refresh
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Refreshes the project list. This enables e.g. projects to
be displayed which have been transferred to the robot
controller since the display was opened.
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8 Basic principles of motion programming
8
Basic principles of motion programming
8.1
Overview of motion types
The following motion types can be programmed:
Point-to-point motions (PTP)
( & gt; & gt; & gt; 8.2 " Motion type PTP " Page 223)
Linear motions (LIN)
( & gt; & gt; & gt; 8.3 " Motion type LIN " Page 223)
Circular motions (CIRC)
( & gt; & gt; & gt; 8.4 " Motion type CIRC " Page 224)
Spline motions
( & gt; & gt; & gt; 8.7 " Motion type “Spline” " Page 229)
LIN, CIRC and spline motions are also known as CP (“Continuous Path”) motions.
The start point of a motion is always the end point of the previous motion.
8.2
Motion type PTP
The robot guides the TCP along the fastest path to the end point. The fastest
path is generally not the shortest path and is thus not a straight line. As the
motions of the robot axes are rotational, curved paths can be executed faster
than straight paths.
The exact path of the motion cannot be predicted.
Fig. 8-1: PTP motion
8.3
Motion type LIN
The robot guides the TCP at a defined velocity along a straight path to the end
point.
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Fig. 8-2: LIN motion
8.4
Motion type CIRC
The robot guides the TCP at a defined velocity along a circular path to the end
point. The circular path is defined by a start point, auxiliary point and end point.
Fig. 8-3: CIRC motion
8.5
Approximate positioning
Approximate positioning means that the motion does not stop exactly at the
programmed point. Approximate positioning is an option that can be selected
during motion programming.
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Approximate positioning is not possible if the motion instruction is followed by an instruction that triggers an advance run stop.
PTP motion
The TCP leaves the path that would lead directly to the end point and moves
along a faster path. During programming of the motion, the maximum distance
from the end point at which the TCP may deviate from its original path is defined.
The path of an approximated PTP motion cannot be predicted. It is also not
possible to predict which side of the approximated point the path will run.
Fig. 8-4: PTP motion, P2 is approximated
LIN motion
The TCP leaves the path that would lead directly to the end point and moves
along a shorter path. During programming of the motion, the maximum distance from the end point at which the TCP may deviate from its original path
is defined.
The path in the approximate positioning range is not an arc.
Fig. 8-5: LIN motion, P2 is approximated
CIRC motion
The TCP leaves the path that would lead directly to the end point and moves
along a shorter path. During programming of the motion, the maximum distance from the end point at which the TCP may deviate from its original path
is defined.
The motion always stops exactly at the auxiliary point.
The path in the approximate positioning range is not an arc.
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Fig. 8-6: CIRC motion, PEND is approximated
8.6
Orientation control LIN, CIRC
Description
The orientation of the TCP can be different at the start point and end point of
a motion. There are several different types of transition from the start orientation to the end orientation. A type must be selected when a CP motion is programmed.
The orientation control for LIN and CIRC motions is defined as follows:
In the option window Motion parameter
( & gt; & gt; & gt; 9.2.9 " Option window: Motion parameters (LIN, CIRC) " Page 256)
Or via the system variable $ORI_TYPE
LIN motion
Orientation control
Description
Option window:
Constant orientation
The orientation of the TCP remains constant during the motion.
$ORI_TYPE = #CONSTANT
The programmed orientation is disregarded
for the end point and that of the start point
is retained.
Option window:
Standard
The orientation of the TCP changes continuously during the motion.
$ORI_TYPE = #VAR
Note: If, with Standard, the robot passes
through a wrist axis singularity, use Wrist
PTP instead.
Option window:
Wrist PTP
$ORI_TYPE = #JOINT
The orientation of the TCP changes continuously during the motion. This is done by
linear transformation (axis-specific motion)
of the wrist axis angles.
Note: Use Wrist PTP if, with Standard, the
robot passes through a wrist axis singularity.
The orientation of the TCP changes continuously during the motion, but not uniformly.
Wrist PTP is thus not suitable if a specific
orientation must be maintained exactly, e.g.
in the case of laser welding.
If a wrist axis singularity occurs with Standard and the desired orientation cannot be maintained exactly enough with Wrist PTP, the following remedy is recommended:
Re-teach start and/or end point. Select orientations that prevent a wrist axis
singularity from occurring and allow the path to be executed with Standard.
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8 Basic principles of motion programming
Fig. 8-7: Orientation control - Constant
Fig. 8-8: Standard or Wrist PTP
CIRC motion
During CIRC motions, the robot controller only takes the programmed orientation of the end point into consideration. The programmed orientation of the
auxiliary point is disregarded.
The same orientation control options are available for selection for CIRC motions as for LIN motions.
It is also possible to define for CIRC motions whether the orientation control is
to be base-related or path-related. This is defined via the system variable
$CIRC_TYPE.
Orientation control
Description
$CIRC_TYPE = #BASE
Base-related orientation control during the
circular motion
$CIRC_TYPE = #PATH
Path-related orientation control during the
circular motion
$CIRC_TYPE is meaningless if $ORI_TYPE = #JOINT.
( & gt; & gt; & gt; 8.6.1 " Combinations of $ORI_TYPE and $CIRC_TYPE " Page 227)
8.6.1
Combinations of $ORI_TYPE and $CIRC_TYPE
$ORI_TYPE = #CONSTANT, $CIRC_TYPE = #PATH:
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Fig. 8-9: Constant orientation, path-related
$ORI_TYPE = #VAR, $CIRC_TYPE = #PATH:
Fig. 8-10: Variable orientation, path-related
$ORI_TYPE = #CONSTANT, $CIRC_TYPE = #BASE:
Fig. 8-11: Constant orientation, base-related
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$ORI_TYPE = #VAR, $CIRC_TYPE = #BASE:
Fig. 8-12: Variable orientation, base-related
8.7
Motion type “Spline”
“Spline” is a Cartesian motion type that is suitable for particularly complex,
curved paths. Such paths can generally also be generated using approximated LIN and CIRC motions, but Spline nonetheless has advantages.
Disadvantages of approximated LIN and CIRC motions:
The path is defined by means of approximated points that are not located
on the path. The approximate positioning ranges are difficult to predict.
Generating the desired path is complicated and time-consuming.
In many cases, the velocity may be reduced in a manner that is difficult to
predict, e.g. in the approximate positioning ranges and near points that are
situated close together.
The path changes if approximate positioning is not possible, e.g. for time
reasons.
The path changes in accordance with the override setting, velocity or acceleration.
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Fig. 8-13: Curved path with LIN
Advantages of Spline:
The path is defined by means of points that are located on the path. The
desired path can be generated easily.
The programmed velocity is maintained. There are few cases in which the
velocity is reduced.
( & gt; & gt; & gt; 8.7.1 " Velocity profile for spline motions " Page 231)
The path always remains the same, irrespective of the override setting, velocity or acceleration.
Circles and tight radii are executed with great precision.
Fig. 8-14: Curved path with spline block
A spline motion can consist of several individual motions: spline segments.
These are taught separately. The segments are grouped together to form the
overall motion in a so-called spline block. A spline block is planned and executed by the robot controller as a single motion block.
Furthermore, individual SLIN and SCIRC motions are possible (without spline
block).
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Further characteristics of all spline motions:
8.7.1
If all points are situated on a plane, then the path is also situated in this
plane.
If all points are situated on a straight line, then the path is also a straight
line.
Velocity profile for spline motions
The path always remains the same, irrespective of the override setting, velocity or acceleration. Only dynamic effects can cause deviations at different velocities.
The programmed acceleration is valid not only for the direction along the path,
but also perpendicular to the path. The same applies to the jerk limitation. Effects include the following:
In the case of circles, the centrifugal acceleration is taken into consideration. The velocity that can be achieved thus also depends on the programmed acceleration and the radius of the circle.
In the case of curves, the maximum permissible velocity is derived from
the radius of the curve, the acceleration and the jerk limitation.
Reduction of the velocity
In the case of spline motions, the velocity may, under certain circumstances,
fall below the programmed velocity. This occurs particularly in the case of:
Tight corners
Major reorientation
Large motions of the external axes
If the points are close together, the velocity is not reduced.
Reduction of the velocity to 0
This is the case for:
Successive points with the same Cartesian coordinates.
Successive SLIN and/or SCIRC segments. Cause: inconstant velocity direction.
In the case of SLIN-SCIRC transitions, the velocity is also reduced to 0 if
the straight line is a tangent of the circle, as the circle, unlike the straight
line, is curved.
Fig. 8-15: Exact positioning at P2
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Fig. 8-16: Exact positioning at P2
Exceptions:
In the case of successive SLIN segments that result in a straight line and
in which the orientations change uniformly, the velocity is not reduced.
Fig. 8-17: P2 is executed without exact positioning.
In the case of a SCIRC-SCIRC transition, the velocity is not reduced if both
circles have the same center point and the same radius and if the orientations change uniformly. (This is difficult to teach, so calculate and program
points.)
Circles with the same center point and the same radius are sometimes programmed to obtain circles ≥ 360°. A simpler method is to
program a circular angle.
8.7.2
Block selection with spline motions
Spline block
A spline block is planned and executed by the robot controller as a single motion block. Block selection to the spline segments is nonetheless possible. The
BCO run is executed as a LIN motion. This is indicated by means of a message that must be acknowledged.
If the second segment in the spline block is an SPL segment, a modified path
is executed in the following cases:
Block selection to the first segment in the spline block
Block selection to the spline block
Block selection to a line before the spline block if this does not contain a
motion instruction and if there is no motion instruction before the spline
block
If the Start key is pressed after the BCO run, the modified path is indicated by
means of a message that must be acknowledged.
Example:
1 PTP P0
2 SPLINE
3
SPL P1
4
SPL P2
5
SPL P3
6
SPL P4
7
SCIRC P5, P6
8
SPL P7
9
SLIN P8
10 ENDSPLINE
Line
2
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Description
Start of the spline block
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Line
3…9
10
Description
Spline segments
End of the spline block
Fig. 8-18: Example: modified path in the case of block selection to P1
SCIRC
In the case of block selection to a SCIRC instruction for which a circular angle
has been programmed, the motion is executed to the end point including the
circular angle, provided that the robot controller knows the start point. If this is
not possible, the motion is executed to the programmed end point. In this case,
a message is generated, indicating that the circular angle is not being taken
into consideration.
Position/type of SCIRC instruction
SCIRC segment is 1st segment in
the spline block
Circular angle is not taken into consideration
Other SCIRC segments in the
spline block
Circular angle is taken into consideration
Individual SCIRC motions
8.7.3
End point for block selection
Circular angle is not taken into consideration
Modifications to spline blocks
Description
Modification of the position of the point:
If a point within a spline block is offset, the path is modified, at most, in the
2 segments before this point and the 2 segments after it.
Small point offsets generally result in small modifications to the path. If,
however, very long segments are followed by very short segments or vice
versa, small modifications can have a very great effect, as the tangents
and curves can change very greatly in such cases.
Modification of the segment type:
If an SPL segment is changed into an SLIN segment or vice versa, the
path changes in the previous segment and the next segment.
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Example 1
PTP P0
SPLINE
SPL P1
SPL P2
SPL P3
SPL P4
SCIRC P5, P6
SPL P7
SLIN P8
ENDSPLINE
Fig. 8-19: Original path
P3 is offset. This causes the path to change in segments P1 - P2, P2 - P3 and
P3 - P4. Segment P4 - P5 is not changed in this case, as it belongs to an
SCIRC and a circular path is thus defined.
Fig. 8-20: Point has been offset
In the original path, the segment type of P2 - P3 is changed from SPL to SLIN.
The path changes in segments P1 - P2, P2 - P3 and P3 - P4.
PTP P0
SPLINE
SPL P1
SPL P2
SLIN P3
SPL P4
SCIRC P5, P6
SPL P7
SLIN P8
ENDSPLINE
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Fig. 8-21: Segment type has been changed
Example 2
...
SPLINE
SPL {X 100,
SPL {X 102,
SPL {X 104,
SPL {X 204,
ENDSPLINE
Y
Y
Y
Y
0, ...}
0}
0}
0}
Fig. 8-22: Original path
P3 is offset. This causes the path to change in all the segments illustrated.
Since P2 - P3 and P3 - P4 are very short segments and P1 - P2 and P4 - P5
are long segments, the slight offset causes the path to change greatly.
...
SPLINE
SPL {X 100,
SPL {X 102,
SPL {X 104,
SPL {X 204,
ENDSPLINE
Y
Y
Y
Y
0, ...}
1}
0}
0}
Fig. 8-23: Point has been offset
Remedy:
8.7.4
Distribute the points more evenly
Program straight lines (except very short ones) as SLIN segments
Approximate positioning of spline motions
Approximate positioning between spline motions (individual SLIN and SCIRC
motions and spline blocks) is possible.
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Approximate positioning between spline motions and LIN, CIRC or PTP is not
possible.
Approximation not possible due to time or advance run stop:
If approximation is not possible for reasons of time or due to an advance run
stop, the robot waits at the start of the approximate positioning arc.
In the case of time reasons: the robot moves again as soon as it has been
possible to plan the next block.
In the case of an advance run stop: the end of the current block is reached
at the start of the approximate positioning arc. This means that the advance run stop is canceled and the robot controller can plan the next block.
Robot motion is resumed.
In both cases, the robot now moves along the approximate positioning arc. Approximate positioning is thus technically possible; it is merely delayed.
This response differs from that for LIN, CIRC or PTP motions. If approximate
positioning is not possible for the reasons specified, the motion is executed to
the end point with exact positioning.
No approximate positioning in MSTEP and ISTEP:
In the program run modes MSTEP and ISTEP, the robot stops exactly at the
end point, even in the case of approximated motions.
In the case of approximate positioning from one spline block to another spline
block, the result of this exact positioning is that the path is different in the last
segment of the first block and in the first segment of the second block from the
path in program run mode GO.
In all other segments of both spline blocks, the path is identical in MSTEP,
ISTEP and GO.
8.7.5
Replacing an approximated motion with a spline block
Description
In order to replace conventional approximated motions with spline blocks, the
program must be modified as follows:
Replace LIN - LIN with SLIN - SPL - SLIN.
Replace LIN - CIRC with SLIN - SPL - SCIRC.
Recommendation: Allow the SPL to project a certain way into the original
circle. The SCIRC thus starts later than the original CIRC.
In approximated motions, the corner point is programmed. In the spline block,
the points at the start and end of the approximation are programmed instead.
The approximate positioning arc of the approximated motions varies
according to the override. For this reason, when reproducing an approximated motion, it must be ensured that it is executed with the desired override.
The following approximated motion is to be reproduced:
LIN P1 C_DIS
LIN P2
Spline motion:
SPLINE
SLIN P1A
SPL P1B
SLIN P2
ENDSPLINE
P1A = start of approximation, P1B = end of approximation
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Fig. 8-24: Approximated motion - spline motion
Ways of determining P1A and P1B:
Execute the approximated path and save the positions at the desired point
by means of Trigger.
Calculate the points in the program with KRL.
The start of the approximation can be determined from the approximate
positioning criterion. Example: If C_DIS is specified as the approximate
positioning criterion, the distance from the start of the approximation to the
corner point corresponds to the value of $APO.CDIS.
The end of the approximation is dependent on the programmed velocity.
The SPL path does not correspond exactly to the approximate positioning arc,
even if P1A and P1B are exactly at the start/end of the approximation. In order
to recreate the exact approximate positioning arc, additional points must be inserted into the spline. Generally, one point is sufficient.
Example
The following approximated motion is to be reproduced:
$APO.CDIS=20
$VEL.CP=0.5
LIN {Z 10} C_DIS
LIN {Y 60}
Spline motion:
SPLINE WITH $VEL.CP=0.5
SLIN {Z 30}
SPL {Y 30, Z 10}
SLIN {Y 60}
ENDSPLINE
The start of the approximate positioning arc has been calculated from the approximate positioning criterion.
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Fig. 8-25: Example: Approximated motion - spline motion 1
The SPL path does not yet correspond exactly to the approximate positioning
arc. For this reason, an additional SPL segment is inserted into the spline.
SPLINE WITH $VEL.CP=0.5
SLIN {Z 30}
SPL {Y 15, Z 15}
SPL {Y 30, Z 10}
SLIN {Y 60}
ENDSPLINE
Fig. 8-26: Example: Approximated motion - spline motion 2
With the additional point, the path now corresponds to the approximate positioning arc.
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8.7.5.1
SLIN-SPL-SLIN transition
In the case of a SLIN-SPL-SLIN segment sequence, it is usually desirable for
the SPL segment to be located within the smaller angle between the two
straight lines. Depending on the start and end point of the SPL segment, the
path may also move outside this area.
Fig. 8-27: SLIN-SPL-SLIN
The path remains inside if the following conditions are met:
The extensions of the two SLIN segments intersect.
2/3 ≤ a/b ≤ 3/2
a = distance from start point of the SPL segment to intersection of the SLIN
segments
b = distance from intersection of the SLIN segments to end point of the
SPL segment
8.8
Orientation control SPLINE
Description
The orientation of the TCP can be different at the start point and end point of
a motion. When a CP motion is programmed, it is necessary to select how to
deal with the different orientations.
The orientation control for SLIN and SCIRC motions is defined as follows:
If programming with KRL syntax: by means of the system variable
$ORI_TYPE
If programming with inline forms: in the option window Motion parameters
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Orientation control
Description
Option window:
Constant orientation
The orientation of the TCP remains constant during the motion.
$ORI_TYPE = #CONSTANT
The orientation of the start point is retained.
The programmed orientation of the end
point is not taken into consideration.
Option window:
Standard
$ORI_TYPE = #VAR
The orientation of the TCP changes continuously during the motion. At the end point,
the TCP has the programmed orientation.
Option window:
Ignore orientation
$ORI_TYPE = #IGNORE
This option is only available for spline segments (not for the spline block or for individual spline motions).
It is used if no specific orientation is
required at a point.
( & gt; & gt; & gt; " #IGNORE " Page 240)
Fig. 8-28: Orientation control - Constant
Fig. 8-29: Standard
#IGNORE
$ORI_TYPE = #IGNORE is used if no specific orientation is required at a point.
If this option is selected, the taught or programmed orientation of the point is
ignored. Instead, the robot controller calculates the optimal orientation for this
point on the basis of the orientations of the surrounding points.
Example:
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SPLINE
SPL XP1
SPL XP2
SPL XP3 WITH $ORI_TYPE=#IGNORE
SPL XP4 WITH $ORI_TYPE=#IGNORE
SPL XP5
SPL XP6
ENDSPLINE
The taught or programmed orientation of XP3 and XP4 is ignored.
Characteristics of $ORI_TYPE = #IGNORE:
In the program run modes MSTEP and ISTEP, the robot stops with the orientations calculated by the robot controller.
In the case of a block selection to a point with #IGNORE, the robot adopts
the orientation calculated by the robot controller.
$ORI_TYPE = #IGNORE is not allowed for the following segments:
The last segment in a spline block
SCIRC segments with $CIRC_TYPE=#PATH
Segments followed by a SCIRC segment with $CIRC_TYPE=#PATH
Segments followed by a segment with $ORI_TYPE=#CONSTANT
SCIRC
The first segment in a spline block
In the case of successive segments with identical Cartesian end points,
#IGNORE is not allowed for the first and last segments.
It is also possible to define for SCIRC motions whether the orientation control
is to be space-related or path-related.
( & gt; & gt; & gt; 8.8.1 " SCIRC: reference system for the orientation control " Page 241)
It is also possible to define for SCIRC motions whether, and to what extent, the
orientation of the auxiliary point is to be taken into consideration. The orientation behavior at the end point can also be defined.
( & gt; & gt; & gt; 8.8.2 " SCIRC: orientation behavior " Page 242)
8.8.1
SCIRC: reference system for the orientation control
It is possible to define for SCIRC motions whether the orientation control is to
be space-related or path-related. This can be defined as follows:
If programming with inline forms: in the option window Motion parameter
If programming with KRL syntax: by means of the system variable
$CIRC_TYPE
Orientation control
Option window:
Base-related
$CIRC_TYPE = #BASE
Option window:
Path-related
Description
$CIRC_TYPE = #PATH
Base-related orientation control during the
circular motion
Path-related orientation control during the
circular motion
$CIRC_TYPE = #PATH is not allowed for the following motions:
SCIRC segments for which $ORI_TYPE = #IGNORE
SCIRC motions preceded by a spline segment for which $ORI_TYPE =
#IGNORE
( & gt; & gt; & gt; 8.6.1 " Combinations of $ORI_TYPE and $CIRC_TYPE " Page 227)
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8.8.2
SCIRC: orientation behavior
Description
During SCIRC motions, the robot controller can take the programmed orientation of the auxiliary point into consideration. $CIRC_MODE can be used to define whether and to what extent it is taken into consideration.
In the case of SCIRC statements with circular angles, $CIRC_MODE can also
be used to define whether the end point is to have the programmed orientation
or whether the orientation is to be scaled according to the circular angle.
$CIRC_MODE can only be written to by means of a SCIRC statement.
$CIRC_MODE cannot be read.
Syntax
For auxiliary points:
$CIRC_MODE.AUX_PT.ORI = BehaviorAUX
For end points:
$CIRC_MODE.TARGET_PT.ORI = BehaviorEND
Explanation of
the syntax
Element
Description
BehaviorAUX
Data type: ENUM
#IGNORE: The transition from the start orientation to
the end orientation is carried out over the shortest possible distance. The programmed orientation of the auxiliary point is disregarded.
BehaviorEND
#INTERPOLATE: The programmed orientation is accepted in the auxiliary point.
#CONSIDER (default): The transition from the start orientation to the end orientation passes through the programmed orientation of the auxiliary point, i.e. the
orientation of the auxiliary point is accepted at some
point during the transition, but not necessarily at the
auxiliary point.
Data type: ENUM
#INTERPOLATE: The programmed orientation of the
end point is accepted at the actual end point.
(Only possibility for SCIRC without specification of circular angle. If #EXTRAPOLATE is set, #INTERPOLATE is nonetheless executed.)
#EXTRAPOLATE: The programmed orientation is accepted at the programmed end point. The orientation at
the actual end point is scaled according to the circular
angle.
(Default for SCIRC with specification of circular angle.)
Restrictions
If $ORI_TYPE = #IGNORE for a SCIRC segment, $CIRC_MODE is not
evaluated.
If a SCIRC segment is preceded by a SCIRC or SLIN segment with
$ORI_TYPE = #IGNORE, #CONSIDER cannot be used in this SCIRC
segment.
For SCIRC with circular angle:
If $ORI_TYPE = #IGNORE, #EXTRAPOLATE must not be set for the end
point.
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#INTERPOLATE must not be set for the auxiliary point.
If it is preceded by a spline segment with $ORI_TYPE = #IGNORE, #EXTRAPOLATE must not be set for the end point.
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Example:
Auxiliary point
The TCP executes an arc with a Cartesian angle of 192°.
The orientation at the start point is 0°.
The orientation at the auxiliary point is 98°.
The orientation at the end point is 197°.
The re-orientation is thus 197° if the auxiliary point is taken into consideration.
If the orientation at the auxiliary point is ignored, the end orientation can also
be achieved by means of a re-orientation of 360° - 197° = 163°.
#INTERPOLATE:
The programmed orientation of 98° is accepted in the auxiliary point. The
re-orientation is thus 197°.
#IGNORE:
The programmed orientation of the auxiliary point is disregarded. The
shorter re-orientation through 163° is used.
#CONSIDER:
The distance traveled includes the orientation of the auxiliary point, in this
case the re-orientation through 197°, i.e. the 98° are accepted at some
point during the transition, but not necessarily at the auxiliary point.
Example:
End point
The example schematically illustrates the behavior of #INTERPOLATE and
#EXTRAPOLATE.
The pale, dotted arrows show the programmed orientation.
The dark arrows show the actual orientation where this differs from the
programmed orientation.
#INTERPOLATE:
At TP, which is situated before TP_CA, the programmed orientation has not
yet been reached. The programmed orientation is accepted at TP_CA.
Fig. 8-30: #INTERPOLATE
SP
Start point
AuxP
Auxiliary point
TP
Programmed end point
TP_CA
Actual end point. Determined by the circular angle.
#EXTRAPOLATE:
The programmed orientation is accepted at TP. For TP_CA, this orientation is
scaled in accordance with the circular angle.
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Fig. 8-31: #EXTRAPOLATE
8.9
Status and Turn
Overview
The position (X, Y, Z) and orientation (A, B, C) values of the TCP are not sufficient to define the robot position unambiguously, as different axis positions
are possible for the same TCP. Status and Turn serve to define an unambiguous position that can be achieved with different axis positions.
Fig. 8-32: Example: Same TCP position, different axis position
Status (S) and Turn (T) are integral parts of the data types POS and E6POS:
STRUC POS REAL X, Y, Z, A, B, C, INT S, T
STRUC E6POS REAL X, Y, Z, A, B, C, E1, E2, E3, E4, E5, E6, INT S, T
KRL program
The robot controller only takes the programmed Status and Turn values into
consideration for PTP motions. They are ignored for CP motions.
The first motion instruction in a KRL program must therefore be one of the following instructions so that an unambiguous starting position is defined for the
robot:
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A complete PTP instruction of type POS or E6POS
Or a complete PTP instruction of type AXIS or E6AXIS
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“Complete” means that all components of the end point must be specified. The
default HOME position is always a complete PTP instruction.
Status and Turn can be omitted in the subsequent instructions:
8.9.1
The robot controller retains the previous Status value.
The Turn value is determined by the path in CP motions. In the case of
PTP motions, the robot controller selects the Turn value that results in the
shortest possible path.
Status
The Status specification prevents ambiguous axis positions.
Bit 0
Bit 0 specifies the position of the intersection of the wrist axes (A4, A5, A6).
Position
Value
Overhead area
Bit 0 = 1
If the x-value of the intersection of the wrist axes, relative to the A1 coordinate system, is negative, the robot
is in the overhead area.
Basic area
Bit 0 = 0
If the x-value of the intersection of the wrist axes, relative to the A1 coordinate system, is positive, the robot
is in the basic area.
The A1 coordinate system is identical to the $ROBROOT coordinate system if
axis 1 is at 0°. For values not equal to 0°, it moves with axis 1.
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Fig. 8-33: Example: The intersection of the wrist axes (red dot) is in the
basic area.
Bit 1
Bit 1 specifies the position of axis 3. The angle at which the value of bit 1
changes depends on the robot type.
For robots whose axes 3 and 4 intersect, the following applies:
Position
Value
A3 ≥ 0°
Bit 1 = 1
A3 & lt; 0°
Bit 1 = 0
For robots with an offset between axis 3 and axis 4, the angle at which the value of bit 1 changes depends on the size of this offset.
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Fig. 8-34: Offset between A3 and A4 – example: KR 30
Bit 2
Bit 2 specifies the position of axis 5.
Position
Value
A5 & gt; 0
Bit 2 = 1
A5 ≤ 0
Bit 2 = 0
Bit 3
Bit 3 is not used and is always 0.
Bit 4
Bit 4 specifies whether or not the point was taught using an absolutely accurate robot.
Depending on the value of the bit, the point can be executed by both absolutely accurate robots and non-absolutely-accurate robots. Bit 4 is for information
purposes only and has no influence on how the robot calculates the point. This
means, therefore, that when a robot is programmed offline, bit 4 can be ignored.
Description
The point was not taught with an absolutely accurate
robot.
Bit 4 = 0
The point was taught with an absolutely accurate robot.
8.9.2
Value
Bit 4 = 1
Turn
Description
The Turn specification makes it possible to move axes through angles greater
than +180° or less than -180° without the need for special motion strategies
(e.g. auxiliary points). With rotational axes, the individual bits determine the
sign before the axis value in the following way:
Bit = 0: angle ≥ 0°
Bit = 1: angle & lt; 0°
Value
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0
A6 ≥ 0°
A5 ≥ 0°
A4 ≥ 0°
A3 ≥ 0°
A2 ≥ 0°
A1 ≥ 0°
1
Example
Bit 5
0
A6 & lt; 0°
A5 & lt; 0°
A4 & lt; 0°
A3 & lt; 0°
A2 & lt; 0°
A1 & lt; 0°
DECL POS XP1 = {X 900, Y 0, Z 800, A 0, B 0, C 0, S 6, T 19}
T 19 corresponds to T 'B010011'. This means:
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Axis
Angle
A1
negative
A2
positive
A4
positive
A5
negative
A6
8.10
negative
A3
positive
Singularities
KUKA robots with 6 degrees of freedom have 3 different singularity positions.
Overhead singularity
Extended position singularity
Wrist axis singularity
A singularity position is characterized by the fact that unambiguous reverse
transformation (conversion of Cartesian coordinates to axis-specific values) is
not possible, even though Status and Turn are specified. In this case, or if very
slight Cartesian changes cause very large changes to the axis angles, one
speaks of singularity positions.
Overhead
In the overhead singularity, the wrist root point (intersection of axes A4, A5 and
A6) is located vertically above axis 1.
The position of axis A1 cannot be determined unambiguously by means of reverse transformation and can thus take any value.
If the end point of a PTP motion is situated in this overhead singularity position,
the robot controller may react as follows by means of the system variable
$SINGUL_POS[1]:
Extended
position
0: The angle for axis A1 is defined as 0 degrees (default setting).
1: The angle for axis A1 remains the same from the start point to the end
point.
In the extended position singularity, the wrist root point (intersection of axes
A4, A5 and A6) is located in the extension of axes A2 and A3 of the robot.
The robot is at the limit of its work envelope.
Although reverse transformation does provide unambiguous axis angles, low
Cartesian velocities result in high axis velocities for axes A2 and A3.
If the end point of a PTP motion is situated in this extended position singularity,
the robot controller may react as follows by means of the system variable
$SINGUL_POS[2]:
Wrist axes
0: The angle for axis A2 is defined as 0 degrees (default setting).
1: The angle for axis A2 remains the same from the start point to the end
point.
In the wrist axis singularity position, the axes A4 and A6 are parallel to one another and axis A5 is within the range ±0.01812°.
The position of the two axes cannot be determined unambiguously by reverse
transformation. There is an infinite number of possible axis positions for axes
A4 and A6 with identical axis angle sums.
If the end point of a PTP motion is situated in this wrist axis singularity, the robot controller may react as follows by means of the system variable
$SINGUL_POS[3]:
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0: The angle for axis A4 is defined as 0 degrees (default setting).
1: The angle for axis A4 remains the same from the start point to the
end point.
In the case of SCARA robots, only the extended position singularity
can arise. In this case, the robot starts to move extremely fast.
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9 Programming for user group “User” (inline forms)
9
Programming for user group “User” (inline forms)
Inline forms are available in the KSS for frequently used instructions. They
simplify programming.
Instructions can also be programmed without inline forms. Information is contained in the description of the KRL syntax.
( & gt; & gt; & gt; 10 " Programming for user group “Expert” (KRL syntax) "
Page 287)
In the case of programs with the following axis motions
or positions, the film of lubricant on the gear units of the
axes may break down:
Motions & lt; 3°
Oscillating motions
Areas of gear units permanently facing upwards
It must be ensured that the gear units have a sufficient supply of oil. For this,
in the case of oscillating motions or short motions ( & lt; 3°), programming must
be carried out in such a way that the affected axes regularly move more than
40° (e.g. once per cycle).
In the case of areas of gear units permanently facing upwards, sufficient oil
supply must be achieved by programming re-orientations of the in-line wrist.
In this way, the oil can reach all areas of the gear units by means of gravity.
Required frequency of re-orientations:
With low loads (gear unit temperature & lt; +35 °C): daily
With medium loads (gear unit temperature +35 °C to 55 °C): hourly
With heavy loads (gear unit temperature & gt; +55 °C): every 10 minutes
Failure to observe this precaution may result in damage to the gear units.
9.1
Names in inline forms
Names for data sets can be entered in inline forms. These include, for example, point names, names for motion data sets, etc.
The following restrictions apply to names:
Maximum length 23 characters
No special characters are permissible, with the exception of $.
The first character must not be a number.
The restrictions do not apply to output names.
Other restrictions may apply in the case of inline forms in technology packages.
9.2
Programming PTP, LIN and CIRC motions
9.2.1
Programming a PTP motion
When programming motions, it must be ensured that the
energy supply system is not wound up or damaged during program execution.
A program is selected.
Precondition
Operating mode T1
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Procedure
1. Move the TCP to the position that is to be taught as the end point.
2. Position the cursor in the line after which the motion instruction is to be inserted.
3. Select the menu sequence Commands & gt; Motion & gt; PTP.
4. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.2.2 " Inline form “PTP” " Page 252)
5. Save instruction with Cmd Ok.
9.2.2
Inline form “PTP”
Fig. 9-1: Inline form for PTP motions
Item
Description
1
Motion type PTP
2
Name of the end point
The system automatically generates a name. The name can be
overwritten.
( & gt; & gt; & gt; 9.1 " Names in inline forms " Page 251)
Touch the arrow to edit the point data. The corresponding option
window is opened.
( & gt; & gt; & gt; 9.2.7 " Option window: Frames " Page 255)
3
CONT: end point is approximated.
[Empty box]: the motion stops exactly at the end point.
4
Velocity
5
1 … 100%
Name for the motion data set
The system automatically generates a name. The name can be
overwritten.
Touch the arrow to edit the point data. The corresponding option
window is opened.
( & gt; & gt; & gt; 9.2.8 " Option window: Motion parameters (PTP) " Page 255)
9.2.3
Programming a LIN motion
When programming motions, it must be ensured that the
energy supply system is not wound up or damaged during program execution.
Precondition
A program is selected.
Procedure
Operating mode T1
1. Move the TCP to the position that is to be taught as the end point.
2. Position the cursor in the line after which the motion instruction is to be inserted.
3. Select the menu sequence Commands & gt; Motion & gt; LIN.
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9 Programming for user group “User” (inline forms)
4. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.2.4 " Inline form “LIN” " Page 253)
5. Save instruction with Cmd Ok.
9.2.4
Inline form “LIN”
Fig. 9-2: Inline form for LIN motions
Item
Description
1
Motion type LIN
2
Name of the end point
The system automatically generates a name. The name can be
overwritten.
( & gt; & gt; & gt; 9.1 " Names in inline forms " Page 251)
Touch the arrow to edit the point data. The corresponding option
window is opened.
( & gt; & gt; & gt; 9.2.7 " Option window: Frames " Page 255)
3
CONT: end point is approximated.
[Empty box]: the motion stops exactly at the end point.
4
Velocity
5
Name for the motion data set
0.001 … 2 m/s
The system automatically generates a name. The name can be
overwritten.
Touch the arrow to edit the point data. The corresponding option
window is opened.
( & gt; & gt; & gt; 9.2.9 " Option window: Motion parameters (LIN, CIRC) "
Page 256)
9.2.5
Programming a CIRC motion
When programming motions, it must be ensured that the
energy supply system is not wound up or damaged during program execution.
Precondition
A program is selected.
Procedure
Operating mode T1
1. Move the TCP to the position that is to be taught as the auxiliary point.
2. Position the cursor in the line after which the motion instruction is to be inserted.
3. Select the menu sequence Commands & gt; Motion & gt; CIRC.
4. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.2.6 " Inline form “CIRC” " Page 254)
5. Press Teach Aux.
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6. Move the TCP to the position that is to be taught as the end point.
7. Save instruction with Cmd Ok.
9.2.6
Inline form “CIRC”
Fig. 9-3: Inline form for CIRC motions
Item
Description
1
Motion type CIRC
2
Name of the auxiliary point
The system automatically generates a name. The name can be
overwritten.
( & gt; & gt; & gt; 9.1 " Names in inline forms " Page 251)
3
Name of the end point
The system automatically generates a name. The name can be
overwritten.
Touch the arrow to edit the point data. The corresponding option
window is opened.
( & gt; & gt; & gt; 9.2.7 " Option window: Frames " Page 255)
4
CONT: end point is approximated.
5
[Empty box]: the motion stops exactly at the end point.
Velocity
6
0.001 … 2 m/s
Name for the motion data set
The system automatically generates a name. The name can be
overwritten.
Touch the arrow to edit the point data. The corresponding option
window is opened.
( & gt; & gt; & gt; 9.2.9 " Option window: Motion parameters (LIN, CIRC) "
Page 256)
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9.2.7
Option window: Frames
Fig. 9-4: Option window: Frames
Item
1
Description
Tool selection.
If True in the box External TCP: workpiece selection.
Range of values: [1] … [16]
2
Base selection.
If True in the box External TCP: fixed tool selection.
Range of values: [1] … [32]
3
Interpolation mode
9.2.8
True: The tool is a fixed tool.
True: For this motion, the robot controller calculates the axis
torques. These are required for collision detection.
4
False: The tool is mounted on the mounting flange.
False: For this motion, the robot controller does not calculate
the axis torques. Collision detection is thus not possible for this
motion.
Option window: Motion parameters (PTP)
Fig. 9-5: Option window: Motion parameters (PTP)
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Item
Description
1
Acceleration
Refers to the maximum value specified in the machine data. The
maximum value depends on the robot type and the selected operating mode.
2
1 … 100 %
This box is only displayed if CONT was selected in the inline form.
Furthest distance before the end point at which approximate positioning can begin.
Maximum distance 100%: half the distance between the start
point and the end point relative to the contour of the PTP motion
without approximate positioning
9.2.9
1 … 100 %
Option window: Motion parameters (LIN, CIRC)
Fig. 9-6: Option window: Motion parameters (LIN, CIRC)
Item
Description
1
Acceleration
Refers to the maximum value specified in the machine data. The
maximum value depends on the robot type and the selected operating mode.
2
Furthest distance before the end point at which approximate positioning can begin
The maximum permissible value is half the distance between the
start point and the end point. If a higher value is entered, this is
ignored and the maximum value is used.
This box is only displayed if CONT was selected in the inline form.
3
Orientation control selection.
Standard
Wrist PTP
Constant orientation control
( & gt; & gt; & gt; 8.6 " Orientation control LIN, CIRC " Page 226)
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9.3
Spline motions
9.3.1
Programming tips for spline motions
A spline block should cover only 1 process (e.g. 1 adhesive seam). More
than one process in a spline block leads to a loss of structural clarity within
the program and makes changes more difficult.
Use SLIN and SCIRC segments in cases where the workpiece necessitates straight lines and arcs. (Exception: use SPL segments for very short
straight lines.) Otherwise, use SPL segments, particularly if the points are
close together.
Procedure for defining the path:
a. First teach or calculate a few characteristic points. Example: points at
which the curve changes direction.
b. Test the path. At points where the accuracy is still insufficient, add
more SPL points.
Avoid successive SLIN and/or SCIRC segments, as this often reduces the
velocity to 0.
Program SPL segments between SLIN and SCIRC segments. The length
of the SPL segments must be at least & gt; 0.5 mm. Depending on the actual
path, significantly larger SPL segments may be required.
Avoid successive points with identical Cartesian coordinates, as this reduces the velocity to 0.
The parameters (tool, base, velocity, etc.) assigned to the spline block
have the same effect as assignments before the spline block. The assignment to the spline block has the advantage, however, that the correct parameters are read in the case of a block selection.
Use the option Ignore Orientation if no specific orientation is required at
a point. The robot controller calculates the optimal orientation for this point
on the basis of the orientations of the surrounding points. This way, even
large changes in orientation between two points are optimally distributed
over the points in between.
Jerk limitation can be programmed. The jerk is the change in acceleration.
Procedure:
a. Use the default values initially.
b. If vibrations occur at tight corners: reduce values.
If the velocity drops or the desired velocity cannot be reached: increase values or increase acceleration.
If the robot executes points on a work surface, a collision with the work surface is possible when the first point is addressed.
Fig. 9-7: Collision with work surface
In order to avoid a collision, observe the recommendations for the SLINSPL-SLIN transition.
( & gt; & gt; & gt; 8.7.5.1 " SLIN-SPL-SLIN transition " Page 239)
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Fig. 9-8: Avoiding a collision with the work surface
9.3.2
Programming a SLIN motion (individual motion)
When programming motions, it must be ensured that the
energy supply system is not wound up or damaged during program execution.
Precondition
A program is selected.
Procedure
Operating mode T1
1. Move the TCP to the end point.
2. Position the cursor in the line after which the motion is to be inserted.
(But not within a spline block. This opens another inline form.)
( & gt; & gt; & gt; 9.3.4.6 " Inline form for spline segment " Page 266)
3. Select Commands & gt; Motion & gt; SLIN.
4. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.3.2.1 " Inline form “SLIN” " Page 258)
5. Press Cmd OK.
9.3.2.1
Inline form “SLIN”
Fig. 9-9: Inline form “SLIN” (individual motion)
Item
Description
1
Motion type SLIN
2
Point name for end point. The system automatically generates a
name. The name can be overwritten.
( & gt; & gt; & gt; 9.1 " Names in inline forms " Page 251)
Touch the arrow to edit the point data. The corresponding option
window is opened.
( & gt; & gt; & gt; 9.2.7 " Option window: Frames " Page 255)
3
CONT: end point is approximated.
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[Empty box]: the motion stops exactly at the end point.
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9 Programming for user group “User” (inline forms)
Item
Description
4
Velocity
5
0.001 … 2 m/s
Name for the motion data set. The system automatically generates a name. The name can be overwritten.
Touch the arrow to edit the point data. The corresponding option
window is opened.
( & gt; & gt; & gt; 9.3.2.2 " Option window “Motion parameters” (SLIN) "
Page 259)
9.3.2.2
Option window “Motion parameters” (SLIN)
Fig. 9-10: Option window “Motion parameters” (SLIN)
Item
Description
1
Path acceleration. The value refers to the maximum value specified in the machine data.
2
1 … 100%
Jerk limitation. The jerk is the change in acceleration.
The value refers to the maximum value specified in the machine
data.
3
1 … 100%
This box is only displayed if CONT was selected in the inline form.
Furthest distance before the end point at which approximate positioning can begin.
The maximum permissible value is half the distance between the
start point and the end point. If a higher value is entered, this is
ignored and the maximum value is used.
4
Axis velocity. The value refers to the maximum value specified in
the machine data.
5
Axis acceleration. The value refers to the maximum value specified in the machine data.
6
1 … 100%
1 … 100%
Orientation control selection.
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9.3.3
Programming a SCIRC motion (individual motion)
When programming motions, it must be ensured that the
energy supply system is not wound up or damaged during program execution.
Procedure
A program is selected.
Precondition
Operating mode T1
1. Move the TCP to the auxiliary point.
2. Position the cursor in the line after which the motion is to be inserted.
(But not within a spline block. This opens another inline form.)
( & gt; & gt; & gt; 9.3.4.6 " Inline form for spline segment " Page 266)
3. Select the menu sequence Commands & gt; Motion & gt; SCIRC.
4. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.3.3.1 " Inline form “SCIRC” " Page 260)
5. Press Teach Aux.
6. Move the TCP to the end point.
7. Press Cmd OK.
9.3.3.1
Inline form “SCIRC”
Fig. 9-11: Inline form “SCIRC” (individual motion)
Item
Description
1
Motion type SCIRC
2
Point names for auxiliary and end point. The system automatically
assigns names. The names can be overwritten.
( & gt; & gt; & gt; 9.1 " Names in inline forms " Page 251)
Touch the arrow to edit the point data. The corresponding option
window is opened.
( & gt; & gt; & gt; 9.2.7 " Option window: Frames " Page 255)
3
CONT: end point is approximated.
4
[Empty box]: the motion stops exactly at the end point.
Velocity
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Item
Description
5
Name for the motion data set. The system automatically generates a name. The name can be overwritten.
Touch the arrow to edit the point data. The corresponding option
window is opened.
( & gt; & gt; & gt; 9.3.3.2 " Option window “Motion parameters” (SCIRC) "
Page 261)
6
Specifies the overall angle of the circular motion. This makes it
possible to extend the motion beyond the programmed end point
or to shorten it. The actual end point thus no longer corresponds
to the programmed end point.
Positive circular angle: the circular path is executed in the direction Start point › Auxiliary point › End point.
Negative circular angle: the circular path is executed in the direction Start point › End point › Auxiliary point.
- 9,999° … + 9,999°
If a circular angle less than -400° or greater than +400° is entered,
a request for confirmation is generated when the inline form is
saved asking whether entry is to be confirmed or rejected.
9.3.3.2
Option window “Motion parameters” (SCIRC)
Fig. 9-12: Option window “Motion parameters” (SCIRC)
Item
Description
1
Path acceleration. The value refers to the maximum value specified in the machine data.
2
1 … 100%
Jerk limitation. The jerk is the change in acceleration.
The value refers to the maximum value specified in the machine
data.
1 … 100%
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Item
Description
3
Furthest distance before the end point at which approximate positioning can begin.
The maximum permissible value is half the distance between the
start point and the end point. If a higher value is entered, this is
ignored and the maximum value is used.
This box is only displayed if CONT was selected in the inline form.
4
Axis velocity. The value refers to the maximum value specified in
the machine data.
5
1 … 100%
Axis acceleration. The value refers to the maximum value specified in the machine data.
1 … 100%
6
7
Orientation control reference system selection.
8
9.3.4
Orientation control selection
Circular parameters are displayed on this tab. The parameters
cannot be changed.
Programming a spline block
Description
A spline block can be used to group together several SPL, SLIN and/or SCIRC
segments to an overall motion. A spline block that contains no segments is not
a motion statement.
A spline block may contain the following:
Spline segments (only limited by the memory capacity.)
PATH trigger
Comments and blank lines
Inline commands from technology packages that support the spline functionality
A spline block must not include any other instructions, e.g. variable assignments or logic statements. A spline block does not trigger an advance run
stop.
Precondition
A program is selected.
Procedure
Operating mode T1
1. Position the cursor in the line after which the spline block is to be inserted.
2. Select the menu sequence Commands & gt; Motion & gt; SPLINE block.
3. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.3.4.1 " Inline form for spline block " Page 263)
4. Press Cmd OK.
5. Press Open/close fold. Spline segments and other lines can now be inserted into the spline block.
( & gt; & gt; & gt; 9.3.4.4 " Programming an SPL or SLIN segment " Page 265)
( & gt; & gt; & gt; 9.3.4.5 " Programming an SCIRC segment " Page 265)
( & gt; & gt; & gt; 9.3.4.9 " Programming triggers in the spline block " Page 268)
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9.3.4.1
Inline form for spline block
Fig. 9-13: Inline form for spline block
Item
Description
1
Name of the spline block. The system automatically generates a
name. The name can be overwritten.
( & gt; & gt; & gt; 9.1 " Names in inline forms " Page 251)
Position the cursor in this box to edit the motion data. The corresponding option window is opened.
( & gt; & gt; & gt; 9.3.4.2 " Option window “Frames” (spline block) " Page 263)
2
CONT: end point is approximated.
[Empty box]: the motion stops exactly at the end point.
3
The velocity is valid by default for the entire spline block. It can
also be defined separately for individual segments.
4
0.001 … 2 m/s
Name for the motion data set. The system automatically generates a name. The name can be overwritten.
Position the cursor in this box to edit the motion data. The corresponding option window is opened.
( & gt; & gt; & gt; 9.3.4.3 " Option window “Motion parameters” (spline block) "
Page 264)
The motion data are valid by default for the entire spline block.
They can also be defined separately for individual segments.
9.3.4.2
Option window “Frames” (spline block)
Fig. 9-14: Option window “Frames” (spline block)
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Item
1
Description
Tool selection.
If True in the box External TCP: workpiece selection.
2
[1] … [16]
Base selection.
If True in the box External TCP: fixed tool selection.
3
[1] … [32]
Interpolation mode
9.3.4.3
False: The tool is mounted on the mounting flange.
True: The tool is a fixed tool.
Option window “Motion parameters” (spline block)
Fig. 9-15: Option window “Motion parameters” (spline block)
Item
Description
1
Path acceleration. The value refers to the maximum value specified in the machine data.
2
Jerk limitation. The jerk is the change in acceleration.
1 … 100%
The value refers to the maximum value specified in the machine
data.
3
1 … 100%
This box is only displayed if CONT was selected in the inline form.
Furthest distance before the end point at which approximate positioning can begin.
The maximum distance is that of the last segment in the spline. If
there is only one segment present, the maximum distance is half
the segment length. If a higher value is entered, this is ignored
and the maximum value is used.
4
Axis velocity. The value refers to the maximum value specified in
the machine data.
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9 Programming for user group “User” (inline forms)
Item
Description
5
Axis acceleration. The value refers to the maximum value specified in the machine data.
1 … 100%
6
Orientation control selection.
7
Orientation control reference system selection.
This parameter only affects SCIRC segments (if present) in the
spline block.
9.3.4.4
Programming an SPL or SLIN segment
When programming motions, it must be ensured that the
energy supply system is not wound up or damaged during program execution.
A program is selected.
Operating mode T1
Procedure
Precondition
The spline block fold is open.
1. Move the TCP to the end point.
2. Position the cursor in the line after which the segment is to be inserted in
the spline block.
3. Select the menu sequence Commands & gt; Motion & gt; SPL or SLIN.
4. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.3.4.6 " Inline form for spline segment " Page 266)
5. Press Cmd OK.
9.3.4.5
Programming an SCIRC segment
When programming motions, it must be ensured that the
energy supply system is not wound up or damaged during program execution.
Precondition
A program is selected.
Operating mode T1
Procedure
The spline block fold is open.
1. Move the TCP to the auxiliary point.
2. Position the cursor in the line after which the segment is to be inserted in
the spline block.
3. Select the menu sequence Commands & gt; Motion & gt; SCIRC.
4. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.3.4.6 " Inline form for spline segment " Page 266)
5. Press Teach Aux.
6. Move the TCP to the end point.
7. Press Cmd OK.
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9.3.4.6
Inline form for spline segment
Fig. 9-16: Inline form for spline segment
The boxes in the inline form can be displayed or hidden one by one with Toggle parameters.
Item
Description
1
Motion type
SLIN
2
SPL
SCIRC
Point name for end point. Only for SCIRC: point names for auxiliary point and end point.
The system automatically generates a name. The name can be
overwritten.
( & gt; & gt; & gt; 9.1 " Names in inline forms " Page 251)
Touch the arrow to edit the point data. The corresponding option
window is opened.
( & gt; & gt; & gt; 9.3.4.7 " Option window “Frames” (spline segment) "
Page 267)
3
Velocity
This only refers to the segment to which it belongs. It has no effect
on subsequent segments.
4
0.001 … 2 m/s
Name for the motion data set. The system automatically generates a name. The name can be overwritten.
Touch the arrow to edit the point data. The corresponding option
window is opened.
( & gt; & gt; & gt; 9.3.4.8 " Option window “Motion parameters” (spline segment) " Page 267)
The motion data only refer to the segment to which they belong.
They have no effect on subsequent segments.
5
Only available if the motion type SCIRC has been selected.
Specifies the overall angle of the circular motion. This makes it
possible to extend the motion beyond the programmed end point
or to shorten it. The actual end point thus no longer corresponds
to the programmed end point.
Positive circular angle: the circular path is executed in the direction Start point › Auxiliary point › End point.
Negative circular angle: the circular path is executed in the direction Start point › End point › Auxiliary point.
- 9,999° … + 9,999°
If a circular angle less than -400° or greater than +400° is entered,
a request for confirmation is generated when the inline form is
saved asking whether entry is to be confirmed or rejected.
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9.3.4.7
Option window “Frames” (spline segment)
Fig. 9-17: Option window “Frames” (spline segment)
Item
True: For this motion, the robot controller calculates the axis
torques. These are required for collision detection.
9.3.4.8
Description
1
False: For this motion, the robot controller does not calculate
the axis torques. Collision detection is thus not possible for this
motion.
Option window “Motion parameters” (spline segment)
Fig. 9-18: Option window “Motion parameters” (spline segment)
Item
Description
1
Path acceleration. The value refers to the maximum value specified in the machine data.
2
Jerk limitation. The jerk is the change in acceleration.
1 … 100 %
The value refers to the maximum value specified in the machine
data.
3
1 … 100 %
Axis velocity. The value refers to the maximum value specified in
the machine data.
1 … 100 %
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Item
Description
4
Axis acceleration. The value refers to the maximum value specified in the machine data.
1 … 100 %
5
6
Only in the case of SCIRC segments: Orientation control reference system selection.
7
9.3.4.9
Orientation control selection
Only in the case of SCIRC segments: Circular parameters are displayed on this tab. The parameters cannot be changed.
Programming triggers in the spline block
Precondition
A program is selected.
Operating mode T1
Procedure
The spline block fold is open.
1. Position the cursor in the line after which the trigger is to be inserted in the
spline block.
2. Select the menu sequence Commands & gt; Logic & gt; Spline trigger.
3. The inline form Set output is displayed by default. A different inline form
can be displayed by pressing the Toggle type button.
4. Set the parameters in the inline form.
5. Press Cmd OK.
Description
The specific inline form that is displayed depends on which type has been selected using Toggle type.
Inline form type
Description
Set output
The trigger sets an output.
( & gt; & gt; & gt; 9.3.4.10 " Inline form for spline trigger type
“Set output” " Page 269)
Set pulse output
The trigger sets a pulse of a defined length.
( & gt; & gt; & gt; 9.3.4.11 " Inline form for spline trigger type
“Set pulse output” " Page 270)
Trigger assignment
The trigger assigns a value to a variable. Only
available in the user group “Expert”.
( & gt; & gt; & gt; 9.3.4.12 " Inline form for spline trigger type
“Trigger assignment” " Page 271)
Trigger function call
The trigger calls a subprogram. Only available in
the user group “Expert”.
( & gt; & gt; & gt; 9.3.4.13 " Inline form for spline trigger type
“Trigger function call” " Page 271)
Further information on triggers, on offsetting the switching point and
on the offset limits can be found here:
( & gt; & gt; & gt; 10.11 " Path-related switching actions (=Trigger) " Page 333)
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9.3.4.10 Inline form for spline trigger type “Set output”
Fig. 9-19: Inline form for spline trigger type Set output
Item
Description
1
If the statement is to be shifted in space, the desired distance from
the start or end point must be specified here. If no shift in space is
desired, enter the value 0.
Positive value: shifts the statement towards the end of the motion.
Negative value: shifts the statement towards the start of the
motion.
Only for the user group “Expert”: Toggle path makes it possible to
enter a variable, constant or function in this box. The functions are
subject to constraints.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger " Page 272)
2
Toggle OnStart can be used to set or cancel the parameter
ONSTART.
3
Without ONSTART: the PATH value refers to the end point.
With ONSTART: the PATH value refers to the start point.
If the statement is to be shifted in time (relative to the value in item
1), the desired duration must be specified here. If no shift in time
is desired, enter the value 0.
Positive value: shifts the statement towards the end of the motion. Maximum: 1,000 ms
Negative value: shifts the statement towards the start of the
motion.
Only for the user group “Expert”: Toggle Delay makes it possible
to enter a variable, constant or function in this box. The functions
are subject to constraints.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger " Page 272)
4
Output number
5
1 … 4096
State to which the output is switched
TRUE
FALSE
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9.3.4.11 Inline form for spline trigger type “Set pulse output”
Fig. 9-20: Inline form for spline trigger type Set pulse output
Item
Description
1
If the statement is to be shifted in space, the desired distance from
the start or end point must be specified here. If no shift in space is
desired, enter the value 0.
Positive value: shifts the statement towards the end of the motion.
Negative value: shifts the statement towards the start of the
motion.
Only for the user group “Expert”: Toggle path makes it possible to
enter a variable, constant or function in this box. The functions are
subject to constraints.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger " Page 272)
2
Toggle OnStart can be used to set or cancel the parameter
ONSTART.
3
Without ONSTART: the PATH value refers to the end point.
With ONSTART: the PATH value refers to the start point.
If the statement is to be shifted in time (relative to the value in item
1), the desired duration must be specified here. If no shift in time
is desired, enter the value 0.
Positive value: shifts the statement towards the end of the motion. Maximum: 1,000 ms
Negative value: shifts the statement towards the start of the
motion.
Only for the user group “Expert”: Toggle Delay makes it possible
to enter a variable, constant or function in this box. The functions
are subject to constraints.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger " Page 272)
4
Output number
5
1 … 4096
State to which the output is switched
6
TRUE: “High” level
FALSE: “Low” level
Length of the pulse
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0.10 … 3.00 s
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
9 Programming for user group “User” (inline forms)
9.3.4.12 Inline form for spline trigger type “Trigger assignment”
Fig. 9-21: Inline form for spline trigger type Trigger assignment
Item
Description
1
If the statement is to be shifted in space, the desired distance from
the start or end point must be specified here. If no shift in space is
desired, enter the value 0.
Positive value: shifts the statement towards the end of the motion.
Negative value: shifts the statement towards the start of the
motion.
Only for the user group “Expert”: Toggle path makes it possible to
enter a variable, constant or function in this box. The functions are
subject to constraints.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger " Page 272)
2
Toggle OnStart can be used to set or cancel the parameter
ONSTART.
3
Without ONSTART: the PATH value refers to the end point.
With ONSTART: the PATH value refers to the start point.
If the statement is to be shifted in time (relative to the value in item
1), the desired duration must be specified here. If no shift in time
is desired, enter the value 0.
Positive value: shifts the statement towards the end of the motion. Maximum: 1,000 ms
Negative value: shifts the statement towards the start of the
motion.
Only for the user group “Expert”: Toggle Delay makes it possible
to enter a variable, constant or function in this box. The functions
are subject to constraints.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger " Page 272)
4
Variable to which a value is to be assigned
Note: Runtime variables cannot be used.
5
Value to be assigned to the variable
9.3.4.13 Inline form for spline trigger type “Trigger function call”
Fig. 9-22: Inline form for spline trigger type Trigger function call
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
Item
Description
1
If the statement is to be shifted in space, the desired distance from
the start or end point must be specified here. If no shift in space is
desired, enter the value 0.
Positive value: shifts the statement towards the end of the motion.
Negative value: shifts the statement towards the start of the
motion.
Only for the user group “Expert”: Toggle path makes it possible to
enter a variable, constant or function in this box. The functions are
subject to constraints.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger " Page 272)
2
Toggle OnStart can be used to set or cancel the parameter
ONSTART.
3
Without ONSTART: the PATH value refers to the end point.
With ONSTART: the PATH value refers to the start point.
If the statement is to be shifted in time (relative to the value in item
1), the desired duration must be specified here. If no shift in time
is desired, enter the value 0.
Positive value: shifts the statement towards the end of the motion. Maximum: 1,000 ms
Negative value: shifts the statement towards the start of the
motion.
Only for the user group “Expert”: Toggle Delay makes it possible
to enter a variable, constant or function in this box. The functions
are subject to constraints.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger " Page 272)
4
Name of the subprogram to be called
5
A priority must be entered in the PRIO box. Priorities 1, 2, 4 to 39
and 81 to 128 are available. Priorities 3 and 40 to 80 are reserved
for cases in which the priority is automatically assigned by the
system. If the priority is to be assigned automatically by the system, the following is programmed: PRIO = -1.
If several triggers call subprograms at the same time, the trigger
with the highest priority is processed first, then the triggers of
lower priority. 1 = highest priority.
9.3.4.14 Limits for functions in the spline trigger
The values for PATH and DELAY can be assigned using functions. The following constraints apply to these functions:
The KRL program containing the function must have the attribute Hidden.
The function must be globally valid.
The functions may only contain the following statements or elements:
IF statements
Comments
Blank lines
RETURN
Read system variable
272 / 391
Value assignments
Call predefined KRL function
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
9 Programming for user group “User” (inline forms)
9.3.5
Copying spline inline forms
Overview
The following copying operations can be carried out:
Copy a spline segment to another spline block
Copy a spline segment out of a spline block
Expert user group
Program is selected or open.
Copy
Copy a spline block
Precondition
Copy an individual motion into a spline block
T1, T2 or AUT mode
Copy an individual motion into a spline block:
The following individual motions can be copied and pasted into a spline block:
SLIN
SCIRC
LIN
CIRC
Precondition:
The following frame data (= data in the option window Frames) of the individual motion and the block are identical: Tool, Base and Interpolation
mode
Copy spline block:
A spline block can be copied and pasted at a different point in the program.
Only the empty block is pasted. It is not possible to copy a block and its contents at the same time.
The contents must be copied and pasted separately.
Copy a spline segment to another spline block:
One or more spline segments can be copied and pasted to another block.
Precondition:
The following frame data (= data in the option window Frames) of the
spline blocks are identical: Tool, Base and Interpolation mode
Copy a spline segment out of a spline block:
One or more spline segments can be copied and pasted outside a spline
block. The motion types change as follows:.
Spline segment…
... becomes an individual motion
SLIN
SLIN
SCIRC
SCIRC
SPL
PTP
9.3.6
For individual SLIN, SCIRC motions: the frame and motion data from the
segment are applied if available; otherwise, the data from the spline block
are applied.
For individual PTP motion: the position and frame data from the SPL are
applied to the PTP. Motion data are not applied.
Converting spline inline forms from 8.1
Description
More parameters can be set in spline inline forms in KSS 8.2 than in KSS 8.1.
This allows more detailed determination of the motion characteristics.
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KUKA System Software 8.2
Programs with inline forms from 8.1 can be used in 8.2. For this, values must
be assigned to the new parameters. This is done by opening the inline form
and closing it again. Default values are automatically assigned to all new parameters.
Precondition
A program is selected.
Procedure
Operating mode T1
1. Position the cursor in the line with the inline form.
2. Press Change. The inline form is opened. The default values are automatically set for all new parameters.
3. If required, modify the values.
4. Press Cmd OK.
5. Repeat steps 1 to 4 for all spline inline forms in the program.
9.4
Modifying motion parameters
Precondition
A program is selected.
Procedure
Operating mode T1
1. Position the cursor in the line containing the instruction that is to be
changed.
2. Press Change. The inline form for this instruction is opened.
3. Modify parameters.
4. Save changes by pressing Cmd Ok.
9.5
Modifying the coordinates of a taught point
Description
The coordinates of a taught point can be modified. This is done by moving to
the new position and overwriting the old point with the new position.
Precondition
A program is selected.
Operating mode T1
Procedure
1. Move the TCP to the desired position.
2. Position the cursor in the line containing the motion instruction that is to be
changed.
3. Press Change. The inline form for this instruction is opened.
4. For PTP and LIN motions: Press Touch Up to accept the current position
of the TCP as the new end point.
For CIRC motions:
Press Teach Aux to accept the current position of the TCP as the new
auxiliary point.
Or press Teach End to accept the current position of the TCP as the
new end point.
5. Confirm the request for confirmation with Yes.
6. Save change by pressing Cmd Ok.
9.6
Programming logic instructions
9.6.1
Inputs/outputs
Digital inputs/outputs
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9 Programming for user group “User” (inline forms)
The robot controller can manage up to 4096 digital inputs and 4096 digital outputs. The configuration is customer-specific.
Analog inputs/outputs
The robot controller can manage 32 analog inputs and 32 analog outputs. The
configuration is customer-specific.
Permissible range of values for inputs/outputs: -1.0 to +1.0. This corresponds
to a voltage range from -10 V to +10 V. If the value is exceeded, the input/output takes the maximum value and a message is displayed until the value is
back in the permissible range.
The inputs/outputs are managed via the following system variables:
Inputs
Outputs
Digital
$OUT[1] … $OUT[4096]
Analog
9.6.2
$IN[1] … $IN[4096]
$ANIN[1] … $ANIN[32]
$ANOUT[1] … $ANOUT[32]
Setting a digital output - OUT
Precondition
A program is selected.
Procedure
Operating mode T1
1. Position the cursor in the line after which the logic instruction is to be inserted.
2. Select the menu sequence Commands & gt; Logic & gt; OUT & gt; OUT.
3. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.6.3 " Inline form “OUT” " Page 275)
4. Save instruction with Cmd Ok.
9.6.3
Inline form “OUT”
The instruction sets a digital output.
Fig. 9-23: Inline form “OUT”
Item
1
Description
Output number
2
1 … 4096
If a name exists for the output, this name is displayed.
Only for the user group “Expert”:
A name can be entered by pressing Long text. The name is freely
selectable.
3
State to which the output is switched
FALSE
CONT: Execution in the advance run
4
TRUE
[Empty box]: Execution with advance run stop
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
9.6.4
Setting a pulse output - PULSE
Precondition
A program is selected.
Procedure
Operating mode T1
1. Position the cursor in the line after which the logic instruction is to be inserted.
2. Select the menu sequence Commands & gt; Logic & gt; OUT & gt; PULSE.
3. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.6.5 " Inline form “PULSE” " Page 276)
4. Save instruction with Cmd Ok.
9.6.5
Inline form “PULSE”
The instruction sets a pulse of a defined length.
Fig. 9-24: Inline form “PULSE”
Item
Description
1
Output number
2
If a name exists for the output, this name is displayed.
1 … 4096
Only for the user group “Expert”:
A name can be entered by pressing Long text. The name is freely
selectable.
3
State to which the output is switched
5
FALSE: “Low” level
CONT: Execution in the advance run
4
TRUE: “High” level
[Empty box]: Execution with advance run stop
Length of the pulse
9.6.6
0.10 … 3.00 s
Setting an analog output - ANOUT
Precondition
A program is selected.
Procedure
Operating mode T1
1. Position the cursor in the line after which the instruction is to be inserted.
2. Select Commands & gt; Analog output & gt; Static or Dynamic.
3. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.6.7 " Inline form “ANOUT” (static) " Page 277)
( & gt; & gt; & gt; 9.6.8 " Inline form “ANOUT” (dynamic) " Page 277)
4. Save instruction with Cmd Ok.
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9 Programming for user group “User” (inline forms)
9.6.7
Inline form “ANOUT” (static)
This instruction sets a static analog output.
A maximum of 8 analog outputs (static and dynamic together) can be used at
any one time. ANOUT triggers an advance run stop.
The voltage is set to a fixed level by means of a factor. The actual voltage level
depends on the analog module used. For example, a 10 V module with a factor of 0.5 provides a voltage of 5 V.
Fig. 9-25: Inline form “ANOUT” (static)
Item
1
Description
Number of the analog output
2
Factor for the voltage
9.6.8
CHANNEL_1 … CHANNEL_32
0 … 1 (intervals: 0.01)
Inline form “ANOUT” (dynamic)
This instruction activates or deactivates a dynamic analog output.
A maximum of 4 dynamic analog outputs can be activated at any one time.
ANOUT triggers an advance run stop.
The voltage is determined by a factor. The actual voltage level depends on the
following values:
Velocity or function generator
For example, a velocity of 1 m/s with a factor of 0.5 results in a voltage of
5 V.
Offset
For example, an offset of +0.15 for a voltage of 0.5 V results in a voltage
of 6.5 V.
Fig. 9-26: Inline form “ANOUT” (dynamic)
Item
1
Description
Activation or deactivation of the analog output
2
ON
OFF
Number of the analog output
3
CHANNEL_1 … CHANNEL_32
Factor for the voltage
0 … 10 (intervals: 0.01)
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KUKA System Software 8.2
Item
4
Description
VEL_ACT: The voltage is dependent on the velocity.
5
TECHVAL[1] … TECHVAL[6]: The voltage is controlled by a
function generator.
Value by which the voltage is increased or decreased
6
Time by which the output signal is delayed (+) or brought forward
(-)
9.6.9
-1 … +1 (intervals: 0.01)
-0.2 … +0.5 s
Programming a wait time - WAIT
Procedure
A program is selected.
Precondition
Operating mode T1
1. Position the cursor in the line after which the logic instruction is to be inserted.
2. Select the menu sequence Commands & gt; Logic & gt; WAIT.
3. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.6.10 " Inline form “WAIT” " Page 278)
4. Save instruction with Cmd Ok.
9.6.10
Inline form “WAIT”
WAIT can be used to program a wait time. The robot motion is stopped for a
programmed time. WAIT always triggers an advance run stop.
Fig. 9-27: Inline form “WAIT”
Item
1
Description
Wait time
9.6.11
≥0s
Programming a signal-dependent wait function - WAITFOR
Precondition
A program is selected.
Procedure
Operating mode T1
1. Position the cursor in the line after which the logic instruction is to be inserted.
2. Select the menu sequence Commands & gt; Logic & gt; WAITFOR.
3. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.6.12 " Inline form “WAITFOR” " Page 279)
4. Save instruction with Cmd Ok.
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9 Programming for user group “User” (inline forms)
9.6.12
Inline form “WAITFOR”
The instruction sets a signal-dependent wait function.
If required, several signals (maximum 12) can be linked. If a logic operation is
added, boxes are displayed in the inline form for the additional signals and
links.
Fig. 9-28: Inline form “WAITFOR”
Item
1
Description
Add external logic operation. The operator is situated between the
bracketed expressions.
AND
OR
EXOR
Add NOT.
NOT
[Empty box]
Enter the desired operator by means of the corresponding button.
2
Add internal logic operation. The operator is situated inside a
bracketed expression.
AND
OR
EXOR
Add NOT.
NOT
[Empty box]
Enter the desired operator by means of the corresponding button.
3
Signal for which the system is waiting
OUT
CYCFLAG
TIMER
4
IN
FLAG
Number of the signal
5
1 … 4096
If a name exists for the signal, this name is displayed.
Only for the user group “Expert”:
A name can be entered by pressing Long text. The name is freely
selectable.
6
CONT: Execution in the advance run
[Empty box]: Execution with advance run stop
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9.6.13
Switching on the path - SYN OUT
Precondition
A program is selected.
Procedure
Operating mode T1
1. Position the cursor in the line after which the logic instruction is to be inserted.
2. Select the menu sequence Commands & gt; Logic & gt; OUT & gt; SYN OUT.
3. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.6.14 " Inline form “SYN OUT”, option “START/END” " Page 280)
( & gt; & gt; & gt; 9.6.15 " Inline form “SYN OUT”, option “PATH” " Page 283)
4. Save instruction with Cmd Ok.
9.6.14
Inline form “SYN OUT”, option “START/END”
A switching action can be triggered relative to the start or end point of a motion
block. The switching action can be delayed or brought forward. The motion
block can be a LIN, CIRC or PTP motion.
Possible applications include:
Closing or opening the weld gun during spot welding
Switching the welding current on/off during arc welding
Starting or stopping the flow of adhesive in bonding or sealing applications.
Fig. 9-29: Inline form “SYN OUT”, option “START/END”
Item
1
Description
Output number
2
1 … 4096
If a name exists for the output, this name is displayed.
Only for the user group “Expert”:
A name can be entered by pressing Long text. The name is freely
selectable.
3
State to which the output is switched
4
TRUE
FALSE
Point at which switching is carried out
END: Switching is carried out at the end point of the motion
block.
5
START: Switching is carried out at the start point of the motion
block.
PATH:
Switching action delay
-1,000 … +1,000 ms
Note: The time specification is absolute. The switching point varies according to the velocity of the robot.
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9 Programming for user group “User” (inline forms)
Example 1
Start point and end point are exact positioning points.
LIN
LIN
SYN
SYN
LIN
LIN
P1 VEL=0.3m/s CPDAT1
P2 VEL=0.3m/s CPDAT2
OUT 1 '' State= TRUE at START Delay=20ms
OUT 2 '' State= TRUE at END Delay=-20ms
P3 VEL=0.3m/s CPDAT3
P4 VEL=0.3m/s CPDAT4
Fig. 9-30
OUT 1 and OUT 2 specify approximate positions at which switching is to occur. The dotted lines indicate the switching limits.
Switching limits:
START: The switching point can be delayed, at most, as far as exact positioning point P3 (+ ms).
END: The switching point can be brought forward, at most, as far as exact
positioning point P2 (- ms).
If greater values are specified for the delay, the controller automatically switches at the switching limit.
Example 2
Start point is exact positioning point, end point is approximated.
LIN
LIN
SYN
SYN
LIN
LIN
P1 VEL=0.3m/s CPDAT1
P2 VEL=0.3m/s CPDAT2
OUT 1 '' State= TRUE at START Delay=20ms
OUT 2 '' State= TRUE at END Delay=-20ms
P3 CONT VEL=0.3m/s CPDAT3
P4 VEL=0.3m/s CPDAT4
Fig. 9-31
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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OUT 1 and OUT 2 specify approximate positions at which switching is to occur. The dotted lines indicate the switching limits. M = middle of the approximate positioning range.
Switching limits:
START: The switching point can be delayed, at most, as far as the start of
the approximate positioning range of P3 (+ ms).
END: The switching point can be brought forward, at most, as far as the
start of the approximate positioning range of P3 (-).
The switching point can be delayed, at most, as far as the end of the approximate positioning range of P3 (+).
If greater values are specified for the delay, the controller automatically switches at the switching limit.
Example 3
Start point and end point are approximated
LIN
LIN
SYN
SYN
LIN
LIN
P1 VEL=0.3m/s CPDAT1
P2 CONT VEL=0.3m/s CPDAT2
OUT 1 '' State= TRUE at START Delay=20ms
OUT 2 '' State= TRUE at END Delay=-20ms
P3 CONT VEL=0.3m/s CPDAT3
P4 VEL=0.3m/s CPDAT4
Fig. 9-32
OUT 1 and OUT 2 specify approximate positions at which switching is to occur. The dotted lines indicate the switching limits. M = middle of the approximate positioning range.
Switching limits:
START: The switching point can be situated, at the earliest, at the end of
the approximate positioning range of P2.
The switching point can be delayed, at most, as far as the start of the approximate positioning range of P3 (+ ms).
END: The switching point can be brought forward, at most, as far as the
start of the approximate positioning range of P3 (-).
The switching point can be delayed, at most, as far as the end of the approximate positioning range of P3 (+).
If greater values are specified for the delay, the controller automatically switches at the switching limit.
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9 Programming for user group “User” (inline forms)
9.6.15
Inline form “SYN OUT”, option “PATH”
A switching action can be triggered relative to the end point of a motion block.
The switching action can be shifted in space and delayed or brought forward.
The motion block can be a LIN or CIRC motion. It must not be a PTP motion.
Fig. 9-33: Inline form “SYN OUT”, option “PATH”
Item
1
Description
Output number
2
1 … 4096
If a name exists for the output, this name is displayed.
Only for the user group “Expert”:
A name can be entered by pressing Long text. The name is freely
selectable.
3
State to which the output is switched
4
TRUE
FALSE
Point at which switching is carried out
START: ( & gt; & gt; & gt; 9.6.14 " Inline form “SYN OUT”, option “START/
END” " Page 280)
5
PATH: Switching is carried out at the end point of the motion
block.
END: ( & gt; & gt; & gt; 9.6.14 " Inline form “SYN OUT”, option “START/
END” " Page 280)
Distance from the switching point to the end point
-2,000 … +2,000 mm
This box is only displayed if PATH has been selected.
6
Switching action delay
-1,000 … +1,000 ms
Note: The time specification is absolute. The switching point varies according to the velocity of the robot.
Example 1
Start point is exact positioning point, end point is approximated.
LIN
SYN
LIN
LIN
LIN
P1 VEL=0.3m/s CPDAT1
OUT 1 '' State= TRUE at START PATH=20mm Delay=-5ms
P2 CONT VEL=0.3m/s CPDAT2
P3 CONT VEL=0.3m/s CPDAT3
P4 VEL=0.3m/s CPDAT4
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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Fig. 9-34
OUT 1 specifies the approximate position at which switching is to occur. The
dotted lines indicate the switching limits. M = middle of the approximate positioning range.
Switching limits:
The switching point can be brought forward, at most, as far as exact positioning point P1.
The switching point can be delayed, at most, as far as the next exact positioning point P4. If P3 was an exact positioning point, the switching point
could be delayed, at most, as far as P3.
If greater values are specified for the shift in space or time, the controller automatically switches at the switching limit.
Example 2
Start point and end point are approximated
LIN
SYN
LIN
LIN
LIN
P1 CONT VEL=0.3m/s CPDAT1
OUT 1 '' State= TRUE at START PATH=20mm Delay=-5ms
P2 CONT VEL=0.3m/s CPDAT2
P3 CONT VEL=0.3m/s CPDAT3
P4 VEL=0.3m/s CPDAT4
Fig. 9-35
OUT 1 specifies the approximate position at which switching is to occur. The
dotted lines indicate the switching limits. M = middle of the approximate positioning range.
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9 Programming for user group “User” (inline forms)
Switching limits:
The switching point can be brought forward, at most, as far as the start of
the approximate positioning range of P1.
The switching point can be delayed, at most, as far as the next exact positioning point P4. If P3 was an exact positioning point, the switching point
could be delayed, at most, as far as P3.
If greater values are specified for the shift in space or time, the controller automatically switches at the switching limit.
9.6.16
Setting a pulse on the path - SYN PULSE
Precondition
A program is selected.
Procedure
Operating mode T1
1. Position the cursor in the line after which the logic instruction is to be inserted.
2. Select the menu sequence Commands & gt; Logic & gt; OUT & gt; SYN PULSE.
3. Set the parameters in the inline form.
( & gt; & gt; & gt; 9.6.17 " Inline form “SYN PULSE” " Page 285)
4. Save instruction with Cmd Ok.
9.6.17
Inline form “SYN PULSE”
A pulse can be triggered relative to the start or end point of a motion block. The
pulse can be delayed or brought forward and shifted in space.
Fig. 9-36: Inline form “SYN PULSE”
Item
Description
1
Output number
2
If a name exists for the output, this name is displayed.
1 … 4096
Only for the user group “Expert”:
A name can be entered by pressing Long text. The name is freely
selectable.
3
State to which the output is switched
4
TRUE
FALSE
Duration of the pulse
0.1 … 3 s
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Item
5
Description
START: The pulse is triggered at the start point of the motion
block.
END: The pulse is triggered at the end point of the motion
block.
See SYN OUT for examples and switching limits.
( & gt; & gt; & gt; 9.6.14 " Inline form “SYN OUT”, option “START/END” "
Page 280)
PATH: The pulse is triggered at the end point of the motion
block.
See SYN OUT for examples and switching limits.
( & gt; & gt; & gt; 9.6.15 " Inline form “SYN OUT”, option “PATH” " Page 283)
6
Distance from the switching point to the end point
-2,000 … +2,000 mm
This box is only displayed if PATH has been selected.
7
Switching action delay
-1,000 … +1,000 ms
Note: The time specification is absolute. The switching point varies according to the velocity of the robot.
9.6.18
Modifying a logic instruction
Procedure
A program is selected.
Precondition
Operating mode T1
1. Position the cursor in the line containing the instruction that is to be
changed.
2. Press Change. The inline form for this instruction is opened.
3. Change the parameters.
4. Save changes by pressing Cmd Ok.
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10
Programming for user group “Expert” (KRL syntax)
In the case of programs with the following axis motions
or positions, the film of lubricant on the gear units of the
axes may break down:
Motions & lt; 3°
Oscillating motions
Areas of gear units permanently facing upwards
It must be ensured that the gear units have a sufficient supply of oil. For this,
in the case of oscillating motions or short motions ( & lt; 3°), programming must
be carried out in such a way that the affected axes regularly move more than
40° (e.g. once per cycle).
In the case of areas of gear units permanently facing upwards, sufficient oil
supply must be achieved by programming re-orientations of the in-line wrist.
In this way, the oil can reach all areas of the gear units by means of gravity.
Required frequency of re-orientations:
With low loads (gear unit temperature & lt; +35 °C): daily
With medium loads (gear unit temperature +35 °C to 55 °C): hourly
With heavy loads (gear unit temperature & gt; +55 °C): every 10 minutes
Failure to observe this precaution may result in damage to the gear units.
If a selected program is edited in the user group “Expert”, the cursor
must then be removed from the edited line and positioned in any other
line!
Only in this way is it certain that the editing will be applied when the program
is deselected again.
10.1
Overview of KRL syntax
Variables and declarations
DECL
( & gt; & gt; & gt; 10.4.1 " DECL " Page 293)
ENUM
( & gt; & gt; & gt; 10.4.2 " ENUM " Page 295)
STRUC
( & gt; & gt; & gt; 10.4.3 " STRUC " Page 296)
Motion programming
PTP
( & gt; & gt; & gt; 10.5.1 " PTP " Page 297)
PTP_REL
( & gt; & gt; & gt; 10.5.2 " PTP_REL " Page 298)
LIN
( & gt; & gt; & gt; 10.5.3 " LIN " Page 299)
LIN_REL
( & gt; & gt; & gt; 10.5.4 " LIN_REL " Page 300)
CIRC
( & gt; & gt; & gt; 10.5.5 " CIRC " Page 302)
CIRC_REL
( & gt; & gt; & gt; 10.5.6 " CIRC_REL " Page 303)
SPLINE … ENDSPLINE
( & gt; & gt; & gt; 10.6.2 " SPLINE ... ENDSPLINE " Page 305)
SLIN
( & gt; & gt; & gt; 10.6.3 " SLIN " Page 306)
SCIRC
( & gt; & gt; & gt; 10.6.4 " SCIRC " Page 307)
SPL
( & gt; & gt; & gt; 10.6.5 " SPL " Page 309)
TIME_BLOCK
( & gt; & gt; & gt; 10.6.6 " TIME_BLOCK " Page 309)
Program execution control
CONTINUE
( & gt; & gt; & gt; 10.7.1 " CONTINUE " Page 314)
EXIT
( & gt; & gt; & gt; 10.7.2 " EXIT " Page 314)
FOR … TO … ENDFOR
( & gt; & gt; & gt; 10.7.3 " FOR ... TO ... ENDFOR " Page 315)
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Program execution control
GOTO
( & gt; & gt; & gt; 10.7.4 " GOTO " Page 315)
HALT
( & gt; & gt; & gt; 10.7.5 " HALT " Page 316)
IF … THEN … ENDIF
( & gt; & gt; & gt; 10.7.6 " IF ... THEN ... ENDIF " Page 316)
LOOP … ENDLOOP
( & gt; & gt; & gt; 10.7.7 " LOOP ... ENDLOOP " Page 317)
REPEAT … UNTIL
( & gt; & gt; & gt; 10.7.8 " REPEAT ... UNTIL " Page 317)
SWITCH … CASE … ENDSWITCH
( & gt; & gt; & gt; 10.7.9 " SWITCH ... CASE ... ENDSWITCH "
Page 318)
WAIT … FOR
( & gt; & gt; & gt; 10.7.10 " WAIT FOR " Page 319)
WAIT … SEC
( & gt; & gt; & gt; 10.7.11 " WAIT SEC " Page 320)
WHILE … ENDWHILE
( & gt; & gt; & gt; 10.7.12 " WHILE ... ENDWHILE " Page 320)
Inputs/outputs
ANIN
( & gt; & gt; & gt; 10.8.1 " ANIN " Page 321)
ANOUT
( & gt; & gt; & gt; 10.8.2 " ANOUT " Page 322)
PULSE
( & gt; & gt; & gt; 10.8.3 " PULSE " Page 323)
SIGNAL
( & gt; & gt; & gt; 10.8.4 " SIGNAL " Page 326)
Subprograms and functions
RETURN
( & gt; & gt; & gt; 10.9.1 " RETURN " Page 327)
Interrupt programming
BRAKE
( & gt; & gt; & gt; 10.10.1 " BRAKE " Page 328)
INTERRUPT
( & gt; & gt; & gt; 10.10.3 " INTERRUPT " Page 330)
INTERRUPT … DECL … WHEN … DO
( & gt; & gt; & gt; 10.10.2 " INTERRUPT ... DECL ... WHEN ... DO "
Page 329)
RESUME
( & gt; & gt; & gt; 10.10.4 " RESUME " Page 332)
Path-related switching actions (=Trigger)
TRIGGER WHEN DISTANCE
( & gt; & gt; & gt; 10.11.1 " TRIGGER WHEN DISTANCE " Page 333)
TRIGGER WHEN PATH
( & gt; & gt; & gt; 10.11.2 " TRIGGER WHEN PATH " Page 336)
TRIGGER WHEN PATH (for spline)
( & gt; & gt; & gt; 10.11.3 " TRIGGER WHEN PATH (for SPLINE) "
Page 339)
Communication
( & gt; & gt; & gt; 10.12 " Communication " Page 343)
System functions
VARSTATE()
( & gt; & gt; & gt; 10.13.1 " VARSTATE() " Page 343)
ROB_STOP()
( & gt; & gt; & gt; 10.13.2 " ROB_STOP() and
ROB_STOP_RELEASE() " Page 345)
Manipulating string variables
( & gt; & gt; & gt; 10.14 " Editing string variables " Page 346)
10.2
Symbols and fonts
The following symbols and fonts are used in the syntax descriptions:
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Syntax element
Representation
KRL code
Courier font
Upper-case letters
Examples: GLOBAL; ANIN ON; OFFSET
Elements that must be
replaced by program-specific entries
Italics
Upper/lower-case letters
Optional elements
Examples: Distance; Time; Format
In angle brackets
Example: & lt; STEP Increment & gt;
Elements that are mutually
exclusive
10.3
Separated by the " | " symbol
Example: IN |OUT
Important KRL terms
10.3.1
SRC files and DAT files
A KRL program generally consists of an SRC file and a DAT file of the same
name.
SRC file: contains the program code.
DAT file: contains permanent data and point coordinates. The DAT file is
also called a data list.
The SRC file and associated DAT file together are called a module.
Depending on the user group, programs in the Navigator are displayed as
modules or individual files:
User group " User "
A program is displayed as a module. The SRC file and the DAT file exist
in the background. They are not visible for the user and cannot be edited
individually.
User group " Expert "
By default, the SRC file and the DAT file are displayed individually. They
can be edited individually.
10.3.2
Subprograms and functions
Subprograms
Subprograms are programs which are accessed by means of branches from
the main program. Once the subprogram has been executed, the main program is resumed from the line directly after the subprogram call.
Local subprograms are contained in the same SRC file as the main program. They can be made to be recognized globally using the keyword
GLOBAL .
Global subprograms are programs with a separate SRC file of their own,
which is accessed from another program by means of a branch.
Functions
Functions, like subprograms, are programs which are accessed by means of
branches from the main program. In addition, however, they also have a data
type and always return a value to the main program.
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10.3.3
Naming conventions and keywords
Names
Examples of names in KRL: variable names, program names, point names
Names in KRL can have a maximum length of 24 characters.
Names in KRL can consist of letters (A-Z), numbers (0-9) and the signs “_”
and “$”.
Names in KRL must not begin with a number.
Names in KRL must not be keywords.
The names of all system variables begin with the “$” sign. To avoid
confusion, do not begin the names of user-defined variables with this
sign.
Keywords
Keywords are sequences of letters having a fixed meaning. They must not be
used in programs in any way other than with this meaning. No distinction is
made between uppercase and lowercase letters. A keyword remains valid irrespective of the way in which it is written.
Example: The sequence of letters CASE is an integral part of the KRL syntax
SWITCH … CASE … ENDSWITCH. For this reason, CASE must not be used
in any other way, e.g. as a variable name.
The system distinguishes between reserved and non-reserved keywords:
Reserved keywords
These may only be used with their defined meaning.
Non-reserved keywords
With non-reserved keywords, the meaning is restricted to a particular context. Outside of this context, a non-reserved keyword is interpreted by the
compiler as a name.
In practice, it is not helpful to distinguish between reserved and nonreserved keywords. To avoid error messages or compiler problems,
keywords are thus never used other than with their defined meaning.
Overview of important keywords:
All elements of the KRL syntax described in this documentation that are not
program-specific are keywords.
The following important keywords are worth a particular mention:
AXIS
ENDFCT
BOOL
ENDFOR
CHAR
ENDIF
CAST_FROM
ENDLOOP
CAST_TO
ENDSWITCH
CCLOSE
ENDWHILE
CHANNEL
EXT
CIOCTL
FALSE
CONST
FRAME
COPEN
GLOBAL
CREAD
INT
CWRITE
MAXIMUM
DEF
MINIMUM
DEFAULT
POS
DEFDAT
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EXTFCT
CONFIRM
PRIO
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DEFFCT
E6AXIS
SREAD
E6POS
SWRITE
END
REAL
ENDDAT
10.3.4
PUBLIC
TRUE
Data types
Overview
There are 2 kinds of data types:
User-defined data types
User-defined data types are always derived from the data types ENUM or
STRUC.
Predefined data types, e.g.:
Simple data types
Data types for motion programming
The following simple data types are predefined:
Data type
Keyword
Description
Integer
INT
Integer
-2³¹-1 … 2³¹-1
Examples: 1; 32; 345
Real
REAL
Floating-point number
+1.1E-38 … +3.4E+38
Examples: 1.43; 38.50; 300.25
Boolean
BOOL
Logic state
Character
CHAR
TRUE
FALSE
1 character
ASCII character
Examples: " A " ; " 1 " ; " q "
The following data types for motion programming are predefined:
Structure type AXIS
A1 to A6 are angle values (rotational axes) or translation values (translational
axes) for the axis-specific movement of robot axes 1 to 6.
STRUC AXIS REAL A1, A2, A3, A4, A5, A6
Structure type E6AXIS
E1 to E6 are angle values or translation values of the external axes 7 to 12.
STRUC E6AXIS REAL A1, A2, A3, A4, A5, A6, E1, E2, E3, E4, E5, E6
Structure type FRAME
X, Y and Z are space coordinates, while A, B and C are the orientation of the
coordinate system.
STRUC FRAME REAL X, Y, Z, A, B, C
Structure types POS and E6POS
S (Status) and T (Turn) define axis positions unambiguously.
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STRUC POS REAL X, Y, Z, A, B, C, INT S, T
STRUC E6POS REAL X, Y, Z, A, B, C, E1, E2, E3, E4, E5, E6, INT S, T
10.3.5
Areas of validity
Local
Data object
Area of validity
Variable
Valid in the program code between DEF
and END containing the declaration of the
variables.
Constant
Valid in the module to which the data list in
which the constant was declared belongs.
User-defined data type
If the data type has been defined in an SRC
file: valid at, or below, the program level in
which it was declared.
If the data type has been defined in a DAT
file: valid in the SRC file that belongs to the
DAT file.
Subprogram
Function
Valid in the main program of the shared
SRC file.
Interrupt
Global
Valid in the main program of the shared
SRC file.
Valid at, or below, the programming level in
which it was declared.
The data objects referred to under “Local” are globally valid if they are declared using the keyword GLOBAL.
GLOBAL can only be used for variables and user-defined data types
if they have been declared in a data list.
Variables and user-defined data types are also globally valid if they were declared in the section USER GLOBALS in $CONFIG.DAT.
If there are local and global variables with the same name, the compiler uses
the local variable within its area of validity.
Always globally valid:
Predefined data types
KRL system variables
Examples
The first program in an SRC file. By default, it bears the name of the SRC
file.
Variables declared in $CONFIG.DAT
The examples show where the keyword GLOBAL must be positioned.
Declaration of a global variable (only in a data list):
& lt; DECL & gt; GLOBAL Data type Variable name
Declaration of a global subprogram:
Main program
GLOBAL DEF Subprogram name ()
Restriction
292 / 391
Data types defined using the keyword GLOBAL must not be used in
$CONFIG.DAT.
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Example:
In DEFDAT PROG(), the enumeration type SWITCH_TYP has been defined
with the keyword GLOBAL:
DEFDAT PROG()
GLOBAL ENUM SWITCH_TYP ON, OFF
...
If this data type is used in $CONFIG.DAT, the compiler signals the error “Type
unknown: *** DECL SWITCH_TYP MY_VAR”.
DEFDAT $CONFIG
DECL SWITCH_TYP MY_VAR
...
10.3.6
Constants
The value of a constant can no longer be modified during program execution
after initialization. Constants can be used to prevent a value from being
changed accidentally during program execution.
Constants must be declared and, at the same time, initialized in a data list. The
data type must be preceded by the keyword CONST.
DECL & lt; GLOBAL & gt; CONST Data type Variable name = Value
The keyword CONST must only be used in data lists.
10.4
Variables and declarations
10.4.1
DECL
Description
Declaration of variables, arrays and constants
Syntax
Declaration of variables
Declaration of variables in programs:
& lt; DECL & gt; Data type Name1 & lt; , ..., NameN & gt;
Declaration of variables in data lists:
& lt; DECL & gt; & lt; GLOBAL & gt; Data type Name1 & lt; , ..., NameN & gt;
Declaration of variables in data lists with simultaneous initialization:
& lt; DECL & gt; & lt; GLOBAL & gt; Data type Name = Value
In the case of declaration with simultaneous initialization, a separate DECL
declaration is required for each variable. It is not possible to declare and initialize several variables with a single DECL declaration.
Declaration of arrays
Declaration of arrays in programs:
& lt; DECL & gt; Data type Name1 [Dimension1 & lt; , ..., Dimension3 & gt; ] & lt; , ..., NameN
[DimensionN1 & lt; ,..., DimensionN3 & gt; ] & gt;
Declaration of arrays in data lists:
& lt; DECL & gt; & lt; GLOBAL & gt; Data type Name1 [Dimension1 & lt; , ..., Dimension3 & gt; ] & lt; , ...,
NameN [DimensionN1 & lt; ,..., DimensionN3 & gt; ] & gt;
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For the declaration of arrays or constant arrays in data lists with simultaneous
initialization:
It is not permissible to declare and initialize in a single line. The initialization must, however, follow directly after the line containing the declaration.
There must be no lines, including blank lines, in between.
If several elements of an array are initialized, the elements must be specified in ascending sequence of the array index (starting from the right-hand
array index).
If the same character string is to be assigned to all of the elements of an
array of type CHAR as a default setting, it is not necessary to initialize each
array element individually. The right-hand array index is omitted. (No index
is written for a one-dimensional array index.)
Declaration of arrays in data lists with simultaneous initialization:
& lt; DECL & gt; & lt; GLOBAL & gt; Data type Name [Dimension1 & lt; ,..., Dimension3 & gt; ]
Name [1 & lt; , 1, 1 & gt; ] = Value1
& lt; Name [1 & lt; , 1, 2 & gt; ] = Value2 & gt;
...
Name [Dimension1 & lt; , Dimension2, Dimension3 & gt; ] = ValueN
Declaration of constant arrays in data lists with simultaneous initialization:
DECL & lt; GLOBAL & gt; CONST Data type Name [Dimension1 & lt; ,..., Dimension3 & gt; ]
Name [1 & lt; , 1, 1 & gt; ] = Value1
& lt; Name [1 & lt; , 1, 2 & gt; ] = Value2 & gt;
...
Name [Dimension1 & lt; , Dimension2, Dimension3 & gt; ] = ValueN
Explanation of
the syntax
Element
DECL
Description
DECL can be omitted if Data type is a predefined data type.
If Data type is a user-defined data type, then DECL is obligatory.
GLOBAL
( & gt; & gt; & gt; 10.3.5 " Areas of validity " Page 292)
CONST
The keyword CONST must only be used in data lists.
Data type
Specification of the desired data type
Name
Name of the object (variable, array or constant) that is
being declared.
Dimension
Type: INT
Dimension defines the number of array elements for the
dimension in question. Arrays have a minimum of 1 and a
maximum of 3 dimensions.
Value
Example 1
The data type of Value must be compatible with Data type,
but not necessarily identical. If the data types are compatible, the system automatically matches them.
Declarations with predefined data types. The keyword DECL can also be omitted.
DECL INT X
DECL INT X1, X2
DECL REAL ARRAY_A[7], ARRAY_B[5], A
Example 2
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Declarations of arrays with simultaneous initialization (only possible in data
lists).
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INT A[7]
A[1]=27
A[2]=313
A[6]=11
CHAR TEXT1[80]
TEXT1[]= " message "
CHAR TEXT2[2,80]
TEXT2[1,]= " first message "
TEXT2[2,]= " second message "
10.4.2
ENUM
Description
Definition of an enumeration type (= ENUM data type)
Syntax
& lt; GLOBAL & gt; ENUM NameEnumType Constant1 & lt; , ..., ConstantN & gt;
Explanation of
the syntax
Element
GLOBAL
Description
( & gt; & gt; & gt; 10.3.5 " Areas of validity " Page 292)
Note: Data types defined using the keyword GLOBAL must
not be used in $CONFIG.DAT.
NameEnumType
Constant
Example 1
Name of the new enumeration type.
The constants are the values that a variable of the enumeration type can take. Each constant may only occur once in
the definition of the enumeration type.
Recommendation: For user-defined data types, assign
names ending in _TYPE, to distinguish them from variable
names.
Definition of an enumeration type with the name COUNTRY_TYPE.
ENUM COUNTRY_TYP SWITZERLAND, AUSTRIA, ITALY, FRANCE
Declaration of a variable of type COUNTRY_TYPE:
DECL COUNTRY_TYP MYCOUNTRY
Initialization of the variable of type COUNTRY_TYPE:
MYCOUNTRY = #AUSTRIA
Example 2
An enumeration type with the name SWITCH_TYPE and the constants ON
and OFF is defined.
DEF PROG()
ENUM SWITCH_TYP ON, OFF
DECL SWITCH_TYP GLUE
IF A & gt; 10 THEN
GLUE=#ON
ELSE
GLUE=#OFF
ENDIF
END
Restriction
Data types defined using the keyword GLOBAL must not be used in
$CONFIG.DAT.
Example:
In DEFDAT PROG(), the enumeration type SWITCH_TYP has been defined
with the keyword GLOBAL:
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DEFDAT PROG()
GLOBAL ENUM SWITCH_TYP ON, OFF
...
If this data type is used in $CONFIG.DAT, the compiler signals the error “Type
unknown: *** DECL SWITCH_TYP MY_VAR”.
DEFDAT $CONFIG
DECL SWITCH_TYP MY_VAR
...
10.4.3
STRUC
Description
Definition of a structure type (= STRUC data type). Several data types are
combined to form a new data type.
Syntax
& lt; GLOBAL & gt; STRUC NameStructureType Data type1 Component1A & lt; ,
Component1B, ... & gt; & lt; , Data type2 Component2A & lt; , Component2B, ... & gt; & gt;
Explanation of
the syntax
Element
GLOBAL
Description
( & gt; & gt; & gt; 10.3.5 " Areas of validity " Page 292)
Note: Data types defined using the keyword GLOBAL must
not be used in $CONFIG.DAT.
NameStructureType
Name of the new structure type. The names of userdefined data types should end in _TYPE, to distinguish
them from variable names.
Data type
TYPE: Any data type
Structure types are also permissible as data types.
Component
Name of the component. It may only be used once in the
structure type.
Arrays can only be used as components of a structure type
if they have the type CHAR and are one-dimensional. In
this case, the array limit follows the name of the array in
square brackets in the definition of the structure type.
Value assignment
There are 2 ways of assigning values to variables based on a STRUC data
type:
Assignment of values to several components of a variable: with an aggregate
Assignment of a value to a single component of a variable: with the point
separator
Information regarding the aggregate:
The components do not need to be specified in the order in which they
have been defined.
Each component may only be contained once in an aggregate.
296 / 391
Not all components of the structure have to be specified in an aggregate.
Example 1
The values of an aggregate can be simple constants or themselves aggregates; they may not, however, be variables (see also Example 3).
The name of the structure type can be specified at the beginning of an aggregate, separated by a colon.
Definition of a structure type CAR_TYPE with the components AIR_COND,
YEAR and PRICE.
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STRUC CAR_TYP BOOL AIR_COND, INT YEAR, REAL PRICE
Declaration of a variable of type CAR_TYPE:
DECL CAR_TYP MYCAR
Initialization of the variable MYCAR of type CAR_TYPE with an aggregate:
A variable based on a structure type does not have to be initialized
with an aggregate. It is also possible to initialize the components individually with the point separator.
MYCAR = {CAR_TYP: PRICE 15000, AIR_COND TRUE, YEAR 2003}
Modification of an individual component using the point separator:
MYCAR.AIR_COND = FALSE
Example 2
Definition of a structure type S_TYPE with the component NUMBER of data
type REAL and of the array component TEXT[80] of data type CHAR.
STRUC S_TYP REAL NUMBER, CHAR TEXT[80]
Example 3
Example of aggregates as values of an aggregate:
STRUC INNER_TYP INT A, B, C
STRUC OUTER_TYP INNER_TYP Q, R
DECL OUTER_TYP MYVAR
...
MYVAR = {Q {A 1, B 4}, R {A 3, C 2}}
10.5
Motion programming: PTP, LIN, CIRC
10.5.1
PTP
Description
Executes a point-to-point motion to the end point. The coordinates of the end
point are absolute.
Syntax
PTP End point & lt; C_PTP & lt; CP approximation & gt; & gt;
Explanation of
the syntax
Element
End point
Description
Type: POS, E6POS, AXIS, E6AXIS, FRAME
The end point can be specified in Cartesian or axis-specific
coordinates. Cartesian coordinates refer to the BASE coordinate system.
If not all components of the end point are specified, the
controller takes the values of the previous position for the
missing components.
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Element
C_PTP
Description
Causes the end point to be approximated.
The specification C_PTP is sufficient for PTP-PTP approximate positioning. In the case of PTP-CP approximation, i.e.
if the approximated PTP block is followed by a LIN or CIRC
block, CP approximation must also be specified.
CP approximation
Only for PTP-CP approximate positioning. This parameter
defines the earliest point at which the approximate positioning can begin. The possible specifications are:
C_DIS
Distance parameter (default): Approximation starts, at
the earliest, when the distance to the end point falls below the value of $APO.CDIS.
C_ORI
Orientation parameter: Approximation starts, at the earliest, when the dominant orientation angle falls below
the value of $APO.CORI.
C_VEL
Velocity parameter: Approximation starts, at the earliest, when the velocity in the deceleration phase to the
end point falls below the value of $APO.CVEL.
Example 1
End point specified in Cartesian coordinates.
PTP {X 12.3,Y 100.0,Z 50,A 9.2,B 50,C 0,S ’B010’,T ’B1010’}
Example 2
End point specified in axis-specific coordinates. The end point is approximated.
PTP {A1 10,A2 -80.6,A3 -50,A4 0,A5 14.2, A6 0} C_PTP
Example 3
End point specified with only 2 components. For the rest of the components,
the controller takes the values of the previous position.
PTP {Z 500,X 123.6}
10.5.2
PTP_REL
Description
Executes a point-to-point motion to the end point. The coordinates of the end
point are relative to the current position.
A REL statement always refers to the current position of the robot. For
this reason, if a REL motion is interrupted, the robot executes the entire REL motion again, starting from the position at which it was interrupted.
Syntax
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PTP_REL End point & lt; C_PTP & lt; CP approximation & gt; & gt;
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10 Programming for user group “Expert” (KRL syntax)
Explanation of
the syntax
Element
End point
Description
Type: POS, E6POS, AXIS, E6AXIS
The end point can be specified in Cartesian or axis-specific
coordinates. The controller interprets the coordinates as
relative to the current position. Cartesian coordinates refer
to the BASE coordinate system.
If not all components of the end point are specified, the
controller sets the value of the missing components to 0. In
other words, the absolute values of these components
remain unchanged.
C_PTP
Causes the end point to be approximated.
The specification C_PTP is sufficient for PTP-PTP approximate positioning. In the case of PTP-CP approximation, i.e.
if the approximated PTP block is followed by a LIN or CIRC
block, CP approximation must also be specified.
CP approximation
Only for PTP-CP approximate positioning. This parameter
defines the earliest point at which the approximate positioning can begin. The possible specifications are:
C_DIS
Distance parameter (default): Approximation starts, at
the earliest, when the distance to the end point falls below the value of $APO.CDIS.
C_ORI
Orientation parameter: Approximation starts, at the earliest, when the dominant orientation angle falls below
the value of $APO.CORI.
C_VEL
Velocity parameter: Approximation starts, at the earliest, when the velocity in the deceleration phase to the
end point falls below the value of $APO.CVEL.
Example 1
Axis 2 is moved 30 degrees in a negative direction. None of the other axes
moves.
PTP_REL {A2 -30}
Example 2
The robot moves 100 mm in the X direction and 200 mm in the negative Z direction from the current position. Y, A, B, C and S remain constant. T is calculated in relation to the shortest path.
PTP_REL {X 100,Z -200}
10.5.3
LIN
Description
Executes a linear motion to the end point. The coordinates of the end point are
absolute.
Syntax
LIN End point & lt; CP approximation & gt;
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KUKA System Software 8.2
Explanation of
the syntax
Element
End point
Description
Type: POS, E6POS, FRAME
If not all components of the end point are specified, the
controller takes the values of the previous position for the
missing components.
The Status and Turn specifications for an end point of type
POS or E6POS are ignored in the case of LIN (and CIRC)
motions.
The coordinates refer to the BASE coordinate system.
CP apprioximation
This parameter causes the end point to be approximated. It
also defines the earliest point at which the approximate
positioning can begin. The possible specifications are:
C_DIS
Distance parameter: Approximation starts, at the earliest, when the distance to the end point falls below the
value of $APO.CDIS.
C_ORI
Orientation parameter: Approximation starts, at the earliest, when the dominant orientation angle falls below
the value of $APO.CORI.
C_VEL
Velocity parameter: Approximation starts, at the earliest, when the velocity in the deceleration phase to the
end point falls below the value of $APO.CVEL.
Example
End point with two components. For the rest of the components, the controller
takes the values of the previous position.
LIN {Z 500,X 123.6}
10.5.4
LIN_REL
Description
Executes a linear motion to the end point. The coordinates of the end point are
relative to the current position.
A REL statement always refers to the current position of the robot. For
this reason, if a REL motion is interrupted, the robot executes the entire REL motion again, starting from the position at which it was interrupted.
Syntax
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LIN_REL End point & lt; CP approximation & gt; & lt; #BASE|#TOOL & gt;
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10 Programming for user group “Expert” (KRL syntax)
Explanation of
the syntax
Element
End point
Description
Type: POS, E6POS, FRAME
The end point must be specified in Cartesian coordinates.
The controller interprets the coordinates as relative to the
current position. The coordinates can refer to the BASE or
TOOL coordinate system.
If not all components of the end point are specified, the
controller automatically sets the value of the missing components to 0. In other words, the absolute values of these
components remain unchanged.
The Status and Turn specifications for an end point of type
POS or E6POS are disregarded in the case of LIN motions.
CP approximation
This parameter causes the end point to be approximated. It
also defines the earliest point at which the approximate
positioning can begin. The possible specifications are:
C_DIS
Distance parameter: Approximation starts, at the earliest, when the distance to the end point falls below the
value of $APO.CDIS.
C_ORI
Orientation parameter: Approximation starts, at the earliest, when the dominant orientation angle falls below
the value of $APO.CORI.
C_VEL
Velocity parameter: Approximation starts, at the earliest, when the velocity in the deceleration phase to the
end point falls below the value of $APO.CVEL.
#BASE,
#TOOL
#BASE
Default setting. The coordinates of the end point refer to
the BASE coordinate system.
#TOOL
The coordinates of the end point refer to the TOOL coordinate system.
The specification of #BASE or #TOOL refers only to the
corresponding LIN_REL statement. It has no effect on subsequent statements.
Example 1
The TCP moves 100 mm in the X direction and 200 mm in the negative Z direction from the current position in the BASE coordinate system. Y, A, B, C
and S remain constant. T is determined by the motion.
LIN_REL {X 100,Z -200}
Example 2
The TCP moves 100 mm from the current position in the negative X direction
in the TOOL coordinate system. Y, Z, A, B, C and S remain constant. T is determined by the motion.
This example is suitable for moving the tool backwards against the tool direction. The precondition is that the tool direction has been calibrated along the
X axis.
LIN_REL {X -100} #TOOL
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10.5.5
CIRC
Description
Executes a circular motion. An auxiliary point and an end point must be specified in order for the controller to be able to calculate the circular motion.
The coordinates of the auxiliary point and end point are absolute.
Syntax
Explanation of
the syntax
CIRC Auxiliary point, End point & lt; , CA Circular angle & gt; & lt; CP approximation & gt;
Element
Auxiliary point
Description
Type: POS, E6POS, FRAME
If not all components of the auxiliary point are specified, the
controller takes the values of the previous position for the
missing components.
The orientation angles and the Status and Turn specifications for an auxiliary point are always disregarded.
The auxiliary point cannot be approximated. The motion
always stops exactly at this point.
The coordinates refer to the BASE coordinate system.
End point
Type: POS, E6POS, FRAME
If not all components of the end point are specified, the
controller takes the values of the previous position for the
missing components.
The Status and Turn specifications for an end point of type
POS or E6POS are ignored in the case of CIRC (and LIN)
motions.
The coordinates refer to the BASE coordinate system.
Circular angle
Specifies the overall angle of the circular motion. This
makes it possible to extend the motion beyond the programmed end point or to shorten it. The actual end point
thus no longer corresponds to the programmed end point.
Unit: degrees. There is no limit; in particular, a circular
angle greater than 360° can be programmed.
CP approximation
Positive circular angle: the circular path is executed in
the direction Start point › Auxiliary point › End point.
Negative circular angle: the circular path is executed in
the direction Start point › End point › Auxiliary point.
This parameter causes the end point to be approximated. It
also defines the earliest point at which the approximate
positioning can begin. The possible specifications are:
C_DIS
Distance parameter: Approximation starts, at the earliest, when the distance to the end point falls below the
value of $APO.CDIS.
C_ORI
Orientation parameter: Approximation starts, at the earliest, when the dominant orientation angle falls below
the value of $APO.CORI.
C_VEL
Velocity parameter: Approximation starts, at the earliest, when the velocity in the deceleration phase to the
end point falls below the value of $APO.CVEL.
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Example
The end point of the circular motion is defined by a circular angle of 260°. The
end point is approximated.
CIRC {X 5,Y 0, Z 9.2},{X 12.3,Y 0,Z -5.3,A 9.2,B -5,C 20}, CA 260
C_ORI
10.5.6
CIRC_REL
Description
Executes a circular motion. An auxiliary point and an end point must be specified in order for the controller to be able to calculate the circular motion.
The coordinates of the auxiliary point and end point are relative to the current
position.
A REL statement always refers to the current position of the robot. For
this reason, if a REL motion is interrupted, the robot executes the entire REL motion again, starting from the position at which it was interrupted.
Syntax
Explanation of
the syntax
CIRC_REL Auxiliary point, End point & lt; , CA Circular angle & gt; & lt; CP approximation & gt;
Element
Auxiliary point
Description
Type: POS, E6POS, FRAME
The auxiliary point must be specified in Cartesian coordinates. The controller interprets the coordinates as relative
to the current position. The coordinates refer to the BASE
coordinate system.
If $ORI_TYPE, Status and/or Turn are specified, these
specifications are ignored.
If not all components of the auxiliary point are specified, the
controller sets the value of the missing components to 0. In
other words, the absolute values of these components
remain unchanged.
The orientation angles and the Status and Turn specifications for an auxiliary point are disregarded.
The auxiliary point cannot be approximated. The motion
always stops exactly at this point.
End point
Type: POS, E6POS, FRAME
The end point must be specified in Cartesian coordinates.
The controller interprets the coordinates as relative to the
current position. The coordinates refer to the BASE coordinate system.
If not all components of the end point are specified, the
controller sets the value of the missing components to 0. In
other words, the absolute values of these components
remain unchanged.
The Status and Turn specifications for an end point of type
POS or E6POS are disregarded.
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Element
Description
Circular angle
Specifies the overall angle of the circular motion. This
makes it possible to extend the motion beyond the programmed end point or to shorten it. The actual end point
thus no longer corresponds to the programmed end point.
Unit: degrees. There is no limit; in particular, a circular
angle & gt; 360° can be programmed.
CP approximation
Positive circular angle: the circular path is executed in
the direction Start point › Auxiliary point › End point.
Negative circular angle: the circular path is executed in
the direction Start point › End point › Auxiliary point.
This parameter causes the end point to be approximated. It
also defines the earliest point at which the approximate
positioning can begin. The possible specifications are:
C_DIS
Distance parameter: Approximation starts, at the earliest, when the distance to the end point falls below the
value of $APO.CDIS.
C_ORI
Orientation parameter: Approximation starts, at the earliest, when the dominant orientation angle falls below
the value of $APO.CORI.
C_VEL
Velocity parameter: Approximation starts, at the earliest, when the velocity in the deceleration phase to the
end point falls below the value of $APO.CVEL.
Example
The end point of the circular motion is defined by a circular angle of 500°. The
end point is approximated.
CIRC_REL {X 100,Y 3.2,Z -20},{Y 50},CA 500 C_VEL
10.6
Motion programming: spline
10.6.1
Higher motion profile for spline motions
There are 2 motion profiles available for spline motions. The motion profile is
selected using the system variable $SPL_VEL_MODE.
Overview
$SPL_VEL_MODE:
$SPL_VEL_MODE = #OPT: higher motion profile
This motion profile is activated by default when the System Software is installed for the first time.
$SPL_VEL_MODE = #CART: conventional motion profile
This motion profile is activated by default if a System Software version
& lt; 8.2 had previously been installed.
The higher motion profile enables the robot controller already to take axis-specific restrictions into consideration during path planning, and not wait until they
are detected by monitoring functions during execution. All applications can
generally be executed faster with the higher motion profile.
If a path is executed with the different motion profiles, the time response of the
robot changes, but not the path in space.
$SPL_VEL_RESTR:
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If $SPL_VEL_MODE = #OPT, it is possible to activate additional Cartesian restrictions by means of $SPL_VEL_RESTR. These are:
Maximum orientation velocity (component ORI_VEL)
Maximum Cartesian acceleration (component CART_ACC)
Maximum orientation acceleration (component ORI_ACC)
Maximum Cartesian jerk (component CART_JERK)
Maximum orientation jerk (component ORI_JERK)
Maximum robot axis acceleration (component ROB_ACC)
Maximum robot axis jerk (component ROB_JERK)
The restrictions are deactivated by default. #ON activates them; #OFF deactivates them. Example:
$SPL_VEL_RESTR={ORI_VEL=#OFF, CART_ACC=#ON, …, ROB_JERK=#OFF}
Changes:
Changing $SPL_VEL_MODE or $SPL_VEL_RESTR triggers an advance run
stop.
$SPL_VEL_MODE and $SPL_VEL_RESTR can be changed as follows:
Directly during program execution
In the WITH line of a spline block
In the WITH line of an individual spline motion
By means of the variable correction function
It is not possible to change $SPL_VEL_MODE or $SPL_VEL_RESTR in the
WITH line of a segment within a spline block.
10.6.2
SPLINE ... ENDSPLINE
Description
A spline block may contain the following:
Spline segments (only limited by the memory capacity.)
PATH trigger
1 time block
( & gt; & gt; & gt; 10.6.6 " TIME_BLOCK " Page 309)
Comments
Blank lines
A spline block must not include any other instructions, e.g. variable assignments or logic statements. There must be no trigger between the last segment
and ENDSPLINE.
A spline block does not trigger an advance run stop.
The following components must be specified for the first point in a spline block:
X, Y, Z
A, B, C
E1 to E6 (if present)
This also applies if the first point of the auxiliary point is a SCIRC segment.
Syntax
SPLINE & lt; WITH SysVarSpline = Value1 & lt; ,Value2 , …, ValueN & gt; & gt;
Spline segment1
& lt; Trigger & gt;
…
& lt; Spline segmentN-1
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& lt; Trigger & gt; & gt;
& lt; Spline segmentN & gt;
ENDSPLINE & lt; C_DIS & gt;
Explanation of
the syntax
Element
SysVarSpline
Description
The following system variables may be used:
$ACC, $ACC_AXIS, $ACC_EXTAX, $APO, $BASE,
$CIRC_TYPE, $IPO_MODE, $GEAR_JERK, $JERK,
$LOAD, $ORI_TYPE, $SPL_VEL_MODE,
$SPL_VEL_RESTR, $TOOL, $VEL, $VEL_AXIS,
$VEL_EXTAX
( & gt; & gt; & gt; 10.6.7 " System variables that affect the spline? "
Page 313)
Value
Value assignment to the system variable. The value is valid
for every segment in the spline block except segments to
which a value is assigned separately.
A value can also be assigned to the system variables
$ACC_EXTAX, $GEAR_JERK, $JERK, $VEL and
$VEL_EXTAX via a function. The same restrictions apply
to these functions as to functions in the spline trigger.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger "
Page 272)
C_DIS
Approximate the end point of the spline block (= last point
in the block).
$APO is used to define the earliest point at which the
approximate positioning can begin.
Example
10.6.3
SPLINE
SPL P1
TRIGGER WHEN PATH=GET_PATH() ONSTART DELAY=0 DO & lt; subprog & gt; PRIO=-1
SPL P2
SLIN P3
SPL P4
SCIRC P5, P6 WITH $VEL.CP=0.2
SPL P7 WITH $ACC={CP 2.0, ORI1 200, ORI2 200}
SCIRC P8, P9
SPL P10
ENDSPLINE
SLIN
Description
Syntax
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SLIN can be programmed as an individual block or as a segment in a spline
block. It is possible to copy an individual SLIN motion into a spline block, but
only if it does not contain an assignment to system variables that are not permissible there.
SLIN End point & lt; WITH SysVarSlin = Value1 & lt; ,Value2 , …, ValueN & gt; & gt; & lt; C_DIS & gt;
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10 Programming for user group “Expert” (KRL syntax)
Explanation of
the syntax
Element
End point
Description
Type: POS, E6POS, FRAME
The coordinates refer to the BASE coordinate system.
SysVarSlin
The following applies for spline segments: If not all components of the end point are specified, the controller
takes the values of the previous segment for the missing components. The first segment in the spline block
must be specified completely.
The following applies for individual motions: If not all
components of the end point are specified, the controller takes the values of the previous position for the missing components. If the previous position is the end point
of a circle with a circular angle, the values of the programmed end point are applied, not the values resulting
from the circular angle. If no previous position is known
(in the case of a block selection), the missing components are taken from the current robot position.
The following system variables may be used:
$ACC, $ACC_AXIS, $ACC_EXTAX, $GEAR_JERK,
$JERK, $ORI_TYPE, $VEL, $VEL_AXIS, $VEL_EXTAX
The following may also be used for SLIN in the spline
block: $EX_AX_IGNORE
The following may also be used for individual SLIN motions: $APO, $BASE, $IPO_MODE, $LOAD,
$SPL_VEL_MODE, $SPL_VEL_RESTR, $TOOL
( & gt; & gt; & gt; 10.6.7 " System variables that affect the spline? "
Page 313)
Value
Value assignment to the system variable.
In the case of SLIN segments: The assignment applies
only for this segment. It has no effect on subsequent segments.
A value can also be assigned to the system variables
$ACC_EXTAX, $GEAR_JERK, $JERK, $VEL and
$VEL_EXTAX via a function. The same restrictions apply
to these functions as to functions in the spline trigger.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger "
Page 272)
C_DIS
Only possible for individual SLIN motions: Approximate the
end point.
$APO is used to define the earliest point at which the
approximate positioning can begin.
10.6.4
SCIRC
Description
SCIRC can be programmed as an individual block or as a segment in a spline
block. It is possible to copy an individual SCIRC motion into a spline block, but
only if it does not contain an assignment to system variables that are not permissible there.
Syntax
SCIRC Auxiliary point, End point & lt; , CA Auxiliary point & gt; & lt; WITH SysVarScirc =
Value1 & lt; ,Value2 , …, ValueN & gt; & gt; & lt; C_DIS & gt;
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Explanation of
the syntax
Element
Auxiliary
point
End point
Description
Type: POS, E6POS, FRAME
The coordinates refer to the BASE coordinate system.
The following applies for spline segments: If not all components of the point are specified, the controller takes
the values of the previous segment for the missing components. The first segment in the spline block must be
specified completely.
Circular
angle
The following applies for individual motions: If not all
components of the point are specified, the controller
takes the values of the previous position for the missing
components. If the previous position is the end point of
a circle with a circular angle, the values of the programmed end point are applied, not the values resulting
from the circular angle. If no previous position is known
(in the case of a block selection), the missing components are taken from the current robot position.
Specifies the overall angle of the circular motion. This
makes it possible to extend the motion beyond the programmed end point or to shorten it. The actual end point
thus no longer corresponds to the programmed end point.
Unit: degrees. There is no limit; in particular, a circular
angle greater than 360° can be programmed.
SysVarScirc
Positive circular angle: the circular path is executed in
the direction Start point › Auxiliary point › End point.
Negative circular angle: the circular path is executed in
the direction Start point › End point › Auxiliary point.
The following system variables may be used:
$ACC, $ACC_AXIS, $ACC_EXTAX, $CIRC_MODE,
$CIRC_TYPE, $GEAR_JERK, $JERK, $ORI_TYPE,
$VEL, $VEL_AXIS, $VEL_EXTAX
The following may also be used for SCIRC in the spline
block: $EX_AX_IGNORE
The following may also be used for individual SCIRC
motions: $APO, $BASE, $IPO_MODE, $LOAD,
$SPL_VEL_MODE, $SPL_VEL_RESTR, $TOOL
( & gt; & gt; & gt; 10.6.7 " System variables that affect the spline? "
Page 313)
Value
Value assignment to the system variable.
In the case of SCIRC segments: The assignment applies
only for this segment. It has no effect on subsequent segments.
A value can also be assigned to the system variables
$ACC_EXTAX, $GEAR_JERK, $JERK, $VEL and
$VEL_EXTAX via a function. The same restrictions apply
to these functions as to functions in the spline trigger.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger "
Page 272)
C_DIS
Only possible for individual SCIRC motions: Approximate
the end point.
$APO is used to define the earliest point at which the
approximate positioning can begin.
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Example
10.6.5
SCIRC P2, P3 WITH $CIRC_TYPE=#PATH
SPL
Description
SPL can only be programmed as a segment in a spline block. It is not possible
to program an individual SPL motion.
Syntax
SPL End point & lt; WITH SysVarSpl = Value1 & lt; ,Value2 , …, ValueN & gt; & gt;
Explanation of
the syntax
Element
End point
Description
Type: POS, E6POS, FRAME
The coordinates refer to the BASE coordinate system.
If not all components of the end point are specified, the
controller takes the values of the previous segment for the
missing components. The first segment in the spline block
must be specified completely.
SysVarSpl
The following system variables may be used:
$ACC, $ACC_AXIS, $ACC_EXTAX, $CIRC_TYPE,
$EX_AX_IGNORE, $GEAR_JERK, $JERK, $ORI_TYPE,
$VEL, $VEL_AXIS, $VEL_EXTAX
( & gt; & gt; & gt; 10.6.7 " System variables that affect the spline? "
Page 313)
Value
Value assignment to the system variable. The assignment
applies only for this segment. It has no effect on subsequent segments.
A value can also be assigned to the system variables
$ACC_EXTAX, $GEAR_JERK, $JERK, $VEL and
$VEL_EXTAX via a function. The same restrictions apply
to these functions as to functions in the spline trigger.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger "
Page 272)
Example
10.6.6
SPL P4 WITH $ACC={CP 2.0, ORI1 200, ORI2 200}
TIME_BLOCK
Description
TIME_BLOCK can be used to execute a spline block or part of one in a defined
time. It is also possible to allocate time components to areas of TIME_BLOCK.
Points can be modified in, added to or removed from the spline block without
changing the time specifications. This enables the user to correct the Cartesian path and retain the existing timing.
A spline block may include 1 time block, i.e. 1 statement of the type
TIME_BLOCK START … TIME_BLOCK END. This, in turn, may contain any
number of TIME_BLOCK PART statements. The time block can only be used
in spline blocks.
Syntax
SPLINE
& lt; Spline segment… & gt;
…
TIME_BLOCK START
& lt; Spline segment…
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...
& lt; TIME_BLOCK PART = Component[1] & gt; & gt;
…
Spline segmentN
...
& lt; TIME_BLOCK PART = Component[N] & gt;
TIME_BLOCK END = Overall time
& lt; Spline segmentN+1 & gt;
…
ENDSPLINE
Explanation of
the syntax
It is not essential for there to be spline segments before TIME_BLOCK START
and after TIME_BLOCK END. It is nonetheless advisable to program as follows:
There is at least 1 spline segment between SPLINE and TIME_BLOCK
START.
There is at least 1 spline segment between TIME_BLOCK END and ENDSPLINE.
Advantages:
In the case of a block selection, the original velocity profile is maintained if
there is at least 1 spline segment between SPLINE and TIME_BLOCK
START.
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The programmed overall time is maintained exactly even in the case of approximate positioning.
Segments before TIME_BLOCK START make it possible to accelerate to
the desired velocity.
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10 Programming for user group “Expert” (KRL syntax)
Element
Component[x]
Description
Type: INT or REAL; constant, variable or function
Desired time component [x] for the following distance:
From the point before TIME_BLOCK PART = Component[x-1]
to the point before TIME_BLOCK PART = Component[x]
If TIME_BLOCK PART = Component[x-1] does not exist:
From the point before TIME_BLOCK START
to the point before TIME_BLOCK PART = Component[x]
The time components are maintained as accurately as possible by the robot controller. Generally, however, they are
not maintained exactly.
The user can assign the components in such a way that
they add up to 100. The components can then be considered as percentages. The components do not have to add
up to 100, however, and can have any sum! The robot controller always equates Overall time to the sum of the components. This allows the components to be used very flexibly
and also changed.
If time components are assigned, there must always be a
TIME_BLOCK PART before TIME_BLOCK END. There
must be no segments in between.
Overall time
Type: INT or REAL; constant, variable or function; unit: s
Time in which the following distance is traveled:
From the point before TIME_BLOCK START
to the point before TIME_BLOCK END
The value must be greater than 0. The overall time is maintained exactly. If this time cannot possibly be maintained,
e.g. because too short a time has been programmed, the
robot executes the motion in the fastest possible time. In
T1 and T2, a message is also displayed.
If the value for Component[x] or Overall time is assigned via a function, the same
restrictions apply as for the functions in the spline trigger.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger " Page 272)
Example
SPLINE
SLIN P1
SPL P2
TIME_BLOCK START
SLIN P3
TIME_BLOCK PART = 12.7
SPL P4
SPL P5
SPL P6
TIME_BLOCK PART = 56.4
SCIRC P7, P8
SPL P9
TIME_BLOCK PART = 27.8
TIME_BLOCK END = 3.9
SLIN P10
ENDSPLINE
Points P2 to P9 are executed exactly in the programmed time of 3.9 s.
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The robot controller equates the overall time of 3.9 s to the sum of the components, i.e. 96.9. This gives the value of the components in seconds.
Fig. 10-1: Example TIME_BLOCK
Block selection
If $SPL_VEL_MODE = #OPT: in the case of a block selection, the robot controller ignores the time block and generates the following message: Time block ignored due to BCO run..
In the case of a block selection, the original velocity profile is maintained if
there is at least 1 spline segment between SPLINE and TIME_BLOCK
START.
(A block selection to TIME_BLOCK is the equivalent of a block selection to the
subsequent motion block.)
Example: Block selection with segment before TIME_BLOCK START
LIN P1
SPLINE
SPL P2
TIME_BLOCK
SLIN P3
TIME_BLOCK
SPL P4
SPL P5
SPL P6
TIME_BLOCK
TIME_BLOCK
...
START
PART = 0.5
PART = 2.2
END = 2.7
The defined overall time applies from the point before TIME_BLOCK
START, i.e. P2.
A block selection is now made to P5.
For continued motion from P5, the robot controller plans the velocity for the
entire spline block.
The first point in the spline block is P2. The velocity is thus planned from
the same point as if the spline were to be executed during normal program
execution (= from P1).
Example: Block selection without segment before TIME_BLOCK START
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LIN P1
SPLINE
TIME_BLOCK
SLIN P2
TIME_BLOCK
SPL P3
SPL P4
SPL P5
TIME_BLOCK
TIME_BLOCK
...
START
PART = 0.5
PART = 2.2
END = 2.7
The defined overall time applies from the point before TIME_BLOCK
START, i.e. P1.
A block selection is now made to P5.
For continued motion from P5, the robot controller plans the velocity for the
entire spline block.
The first point in the spline block is P2. P1 is situated before the spline
block and can thus no longer be taken into consideration by the robot controller.
It is thus not possible to plan the velocity for the spline block as exactly as
if it were to be executed during normal program execution (= from P1).
System variable
The data of the time-based spline can be read via the system variable $PATHTIME. $PATHTIME is filled with the data as soon as the robot controller has
completed the planning of the spline block. The data are retained until the next
spline block has been planned.
$PATHTIME is a structure and consists of the following components:
Component
Description
REAL $PATHTIME.TOTAL
Overall time actually required (s)
REAL $PATHTIME.SCHEDULED
Overall time programmed (s)
INT $PATHTIME.N_SECTIONS
Number N of time components
REAL $PATHTIME.MAX_DEV
Maximum deviation of all time components between the programmed
time and the planned time (%)
INT $PATHTIME.MAX_DEV_SECTION
10.6.7
Overall time planned (s)
REAL $PATHTIME.PROGRAMMED
Number of the time component with
the greatest deviation between the
programmed time and the planned
time
System variables that affect the spline?
In the case of some system variables that can be set in WITH lines with
splines, it depends on the state of $SPL_VEL_MODE whether or not the system variable has an effect on spline motions.
System variable
$SPL_VEL_MODE=#OPT
$SPL_VEL_MODE=#CART
$ACC.CP
By default no, but can be activated
using $SPL_VEL_RESTR
Yes
$ACC.ORI1
By default no, but can be activated
using $SPL_VEL_RESTR
Yes
$ACC_AXIS[]
Yes
No
$GEAR_JERK
Yes
No
$JERK.AX.E1 …
$JERK.AX.E6
Yes
No
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System variable
$SPL_VEL_MODE=#OPT
$SPL_VEL_MODE=#CART
$JERK.AX.A1 …
$JERK.AX.A6
By default no, but can be activated
using $SPL_VEL_RESTR
Yes
$JERK.CP
By default no, but can be activated
using $SPL_VEL_RESTR
Yes
$JERK.ORI
By default no, but can be activated
using $SPL_VEL_RESTR
Yes
$SPL_VEL_RESTR
Yes
No
$VEL.CP
Yes
Yes
$VEL.ORI1
By default no, but can be activated
using $SPL_VEL_RESTR
Yes
$VEL_AXIS[]
Yes
No
10.7
Program execution control
10.7.1
CONTINUE
Description
Prevents an advance run stop that would otherwise occur in the following program line.
CONTINUE always applies to the following program line, even if this
is a blank line!
Syntax
CONTINUE
Example
Preventing both advance run stops:
CONTINUE
$OUT[1]=TRUE
CONTINUE
$OUT[2]=FALSE
In this case, the outputs are set in the advance run. The exact point
at which they are set cannot be foreseen.
10.7.2
EXIT
Description
Exit from a loop. The program is then continued after the loop. EXIT may be
used in any loop.
Syntax
EXIT
Example
The loop is exited when $IN[1] is set to TRUE. The program is then continued after ENDLOOP.
DEF EXIT_PROG()
PTP HOME
LOOP
PTP POS_1
PTP POS_2
IF $IN[1] == TRUE THEN
EXIT
ENDIF
CIRC HELP_1, POS_3
PTP POS_4
ENDLOOP
PTP HOME
END
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10.7.3
FOR ... TO ... ENDFOR
Description
A statement block is repeated until a counter exceeds or falls below a defined
value.
After the last execution of the statement block, the program is resumed with
the first statement after ENDFOR. The loop execution can be exited prematurely with EXIT.
Loops can be nested. In the case of nested loops, the outer loop is executed
completely first. The inner loop is then executed completely.
Syntax
FOR Counter = Start TO End & lt; STEP Increment & gt;
& lt; Statements & gt;
ENDFOR
Explanation of
the syntax
Element
Counter
Description
Type: INT
Variable that counts the number of times the loop has been
executed. The preset value is Start. The variable must first
be declared.
The value of Counter can be used in statements inside and
outside of the loop. Once the loop has been exited, Counter
retains its most recent value.
Start; End
Type: INT
Counter must be preset to the value Start. Each time the
loop is executed, the value of Counter is automatically
increased by the increment. If the value exceeds or falls
below the End value, the loop is terminated.
Increment
Type: INT
Value by which Counter is changed every time the loop is
executed The value may be negative. Default value: 1.
Positive value: the loop is ended if Counter is greater
than End.
Negative value: the loop is ended if Counter is less than
End.
The value may not be either zero or a variable.
Example
The variable B is incremented by 1 after each of 5 times the loop is executed.
INT A
...
FOR A=1 TO 10 STEP 2
B=B+1
ENDFOR
10.7.4
GOTO
Description
Unconditional jump to a specified position in the program. Program execution
is resumed at this position.
The destination must be in the same subprogram or function as the GOTO
statement.
The following jumps are not possible:
Into an IF statement from outside.
Into a loop from outside.
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From one CASE statement to another CASE statement.
GOTO statements lead to a loss of structural clarity within a program.
It is better to work with IF, SWITCH or a loop instead.
Syntax
GOTO Label
...
Label:
Explanation of
the syntax
Example 1
Element
Description
Position to which a jump is made. At the destination position, Label must be followed by a colon.
Label
Unconditional jump to the program position GLUESTOP.
GOTO GLUESTOP
...
GLUESTOP:
Example 2
Unconditional jump from an IF statement to the program position END.
IF X & gt; 100 THEN
GOTO ENDE
ELSE
X=X+1
ENDIF
A=A*X
...
ENDE:
END
10.7.5
HALT
Description
Stops the program. The last motion instruction to be executed will, however,
be completed.
Execution of the program can only be resumed using the Start key. The next
instruction after HALT is then executed.
In an interrupt program, program execution is only stopped after the
advance run has been completely executed.
Syntax
10.7.6
HALT
IF ... THEN ... ENDIF
Description
Conditional branch. Depending on a condition, either the first statement block
(THEN block) or the second statement block (ELSE block) is executed. The
program is then continued after ENDIF.
The ELSE block may be omitted. If the condition is not satisfied, the program
is then continued at the position immediately after ENDIF.
There is no limit on the number of statements contained in the statement
blocks. Several IF statements can be nested in each other.
Syntax
IF Condition THEN
Statements
& lt; ELSE
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Statements & gt;
ENDIF
Explanation of
the syntax
Element
Condition
Description
Type: BOOL
Possible:
Function of type BOOL
Example 1
Variable of type BOOL
Logic operation, e.g. a comparison, with a result of type
BOOL
IF statement without ELSE
IF A==17 THEN
B=1
ENDIF
Example 2
IF statement with ELSE
IF $IN[1]==TRUE THEN
$OUT[17]=TRUE
ELSE
$OUT[17]=FALSE
ENDIF
10.7.7
LOOP ... ENDLOOP
Description
Loop that endlessly repeats a statement block. The loop execution can be exited with EXIT.
Loops can be nested. In the case of nested loops, the outer loop is executed
completely first. The inner loop is then executed completely.
Syntax
LOOP
Statements
ENDLOOP
Example
The loop is executed until input $IN[30] is set to true.
LOOP
LIN P_1
LIN P_2
IF $IN[30]==TRUE THEN
EXIT
ENDIF
ENDLOOP
10.7.8
REPEAT ... UNTIL
Description
Non-rejecting loop. Loop that is repeated until a certain condition is fulfilled.
The statement block is executed at least once. The condition is checked after
each loop execution. If the condition is met, program execution is resumed at
the first statement after the UNTIL line.
Loops can be nested. In the case of nested loops, the outer loop is executed
completely first. The inner loop is then executed completely.
Syntax
REPEAT
Statements
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UNTIL Termination condition
Explanation of
the syntax
Element
Termination
condition
Description
Type: BOOL
Possible:
Variable of type BOOL
Function of type BOOL
Example 1
Logic operation, e.g. a comparison, with a result of type
BOOL
The loop is to be executed until $IN[1] is true.
R=1
REPEAT
R=R+1
UNTIL $IN[1]==TRUE
Example 2
The loop is executed once, even though the termination condition is already
fulfilled before the loop execution, because the termination condition is not
checked until the end of the loop. After execution of the loop, R has the value
102.
R=101
REPEAT
R=R+1
UNTIL R & gt; 100
10.7.9
SWITCH ... CASE ... ENDSWITCH
Description
Selects one of several possible statement blocks, according to a selection criterion. Every statement block has at least one identifier. The block whose identifier matches the selection criterion is selected.
Once the block has been executed, the program is resumed after ENDSWITCH.
If no identifier agrees with the selection criterion, the DEFAULT block is executed. If there is no DEFAULT block, no block is executed and the program is
resumed after ENDSWITCH.
The SWITCH statement cannot be prematurely exited using EXIT.
Syntax
SWITCH Selection criterion
CASE Identifier1 & lt; ,Identifier2,... & gt;
Statement block
& lt; CASE IdentifierM & lt; ,IdentifierN,... & gt;
Statement block & gt;
& lt; DEFAULT
Default statement block & gt;
ENDSWITCH
There must be no blank line or comment between the SWITCH line and the
first CASE line. DEFAULT may only occur once in a SWITCH statement.
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Explanation of
the syntax
Element
Description
Selection criterion
Type: INT, CHAR, ENUM
Identifier
Type: INT, CHAR, ENUM
This can be a variable, a function call or an expression of
the specified data type.
The data type of the identifier must match the data type of
the selection criterion.
A statement block can have any number of identifiers. Multiple block identifiers must be separated from each other by
a comma.
Example 1
Selection criterion and identifier are of type INT.
INT VERSION
...
SWITCH VERSION
CASE 1
UP_1()
CASE 2,3
UP_2()
UP_3()
UP_3A()
DEFAULT
ERROR_UP()
ENDSWITCH
Example 2
Selection criterion and identifier are of type CHAR. The statement SP_5() is
never executed here because the identifier C has already been used.
SWITCH NAME
CASE " A "
UP_1()
CASE " B " , " C "
UP_2()
UP_3()
CASE " C "
UP_5()
ENDSWITCH
10.7.10 WAIT FOR
Description
Stops the program until a specified condition is fulfilled. Program execution is
then resumed.
If, due to incorrect formulation, the expression can never take the value TRUE, the compiler does not recognize this. In this case, execution of the program will be permanently halted because the program
is waiting for a condition that cannot be fulfilled.
Syntax
Explanation of
the syntax
WAIT FOR Condition
Element
Condition
Description
Type: BOOL
Condition, the fulfillment of which allows program execution to be resumed.
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If the condition is already TRUE when WAIT is called,
program execution is not halted.
If the condition is FALSE, program execution is stopped
until the condition is TRUE.
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Example
Interruption of program execution until $IN[17] is TRUE:
WAIT FOR $IN[17]
Interruption of program execution until BIT1 is FALSE:
WAIT FOR BIT1==FALSE
10.7.11 WAIT SEC
Description
Halts execution of the program and continues it after a wait time. The wait time
is specified in seconds.
Syntax
WAIT SEC Wait time
Explanation of
the syntax
Element
Wait time
Description
Type: INT, REAL
Number of seconds for which program execution is to be
interrupted. If the value is negative, the program does not
wait. With small wait times, the accuracy is determined by
a multiple of 12 ms.
Example
Interruption of program execution for 17.156 seconds:
WAIT SEC 17.156
Interruption of program execution in accordance with the variable value of
V_WAIT in seconds:
WAIT SEC V_ZEIT
10.7.12 WHILE ... ENDWHILE
Description
Rejecting loop. Loop that is repeated as long as a certain condition is fulfilled.
If the condition is not met, program execution is resumed at the first statement
after the ENDWHILE line. The condition is checked before each loop execution. If the condition is not already fulfilled beforehand, the statement block is
not executed.
Loops can be nested. In the case of nested loops, the outer loop is executed
completely first. The inner loop is then executed completely.
Syntax
WHILE Repetition condition
Statement block
ENDWHILE
Explanation of
the syntax
Element
Repetition
condition
Description
Type: BOOL
Possible:
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Function of type BOOL
Example 1
Variable of type BOOL
Logic operation, e.g. a comparison, with a result of type
BOOL
The loop is executed 99 times. After execution of the loop, W has the value 100.
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W=1
WHILE W & lt; 100
W=W+1
ENDWHILE
Example 2
The loop is executed as long as $IN[1] is true.
WHILE $IN[1]==TRUE
W=W+1
ENDWHILE
10.8
Inputs/outputs
10.8.1
ANIN
Description
Cyclical reading (every 12 ms) of an analog input.
ANIN triggers an advance run stop.
Syntax
Starting cyclical reading:
ANIN ON Value = Factor * Signal name * & lt; ±Offset & gt;
Ending cyclical reading:
ANIN OFF Signal name
The robot controller has 32 analog inputs ($ANIN[1] … $ANIN[32]).
A maximum of three ANIN ON statements can be used at the same
time.
Explanation of
the syntax
A maximum of two ANIN ON statements can use the same variable Value
or access the same analog input.
All of the variables used in an ANIN statement must be declared in data
lists (locally or in $CONFIG.DAT).
Element
Value
Description
Type: REAL
The result of the cyclical reading is stored in Value. Value
can be a variable or a signal name for an output.
Factor
Type: REAL
Any factor. It can be a constant, variable or signal name.
Signal name
Type: REAL
Specifies the analog input. Signal name must first have been
declared with SIGNAL . It is not possible to specify the analog input $ANIN[x] directly instead of the signal name.
The values of an analog input $ANIN[x] range between
+1.0 and -1.0 and represent a voltage of +10 V to -10 V.
Offset
Type: REAL
It can be a constant, variable or signal name.
Example
In this example, the program override (= system variable $OV_PRO) is defined by means of the analog input $ANIN[1].
$ANIN[1] must first be linked to a freely selected signal name, in this case
SIGNAL_1, in the declaration section.
SIGNAL SIGNAL_1 $ANIN[1]
...
ANIN ON $OV_PRO = 1.0 * SIGNAL_1
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The cyclical scanning of SIGNAL_1 is ended using the ANIN OFF statement.
ANIN OFF SIGNAL_1
10.8.2
ANOUT
Description
Cyclical writing (every 12 ms) to an analog output.
ANOUT triggers an advance run stop.
Syntax
Starting cyclical writing:
ANOUT ON Signal name = Factor * Control element & lt; ±Offset & gt; & lt; DELAY =
±Time & gt; & lt; MINIMUM = Minimum value & gt; & lt; MAXIMUM = Maximum value & gt;
Ending cyclical writing:
ANOUT OFF Signal name
The robot controller has 32 analog outputs
($ANOUT[1] … $ANOUT[32]).
A maximum of four ANOUT ON statements can be used at the same
time.
Explanation of
the syntax
All of the variables used in an ANOUT statement must be declared in
data lists (locally or in $CONFIG.DAT).
Element
Signal name
Description
Type: REAL
Specifies the analog output. Signal name must first have
been declared with SIGNAL . It is not possible to specify
the analog output $ANOUT[x] directly instead of the signal
name.
The values of an analog output $ANOUT[x] range between
+1.0 and -1.0 and represent a voltage of +10 V to -10 V.
Factor
Type: REAL
Any factor. It can be a constant, variable or signal name.
Control
element
Type: REAL
Offset
Type: REAL
It can be a constant, variable or signal name.
It can be a constant, variable or signal name.
Time
Type: REAL
Unit: seconds. By using the keyword DELAY and entering a
positive or negative amount of time, the output signal can
be delayed (+) or set early (-).
Minimum
value,
Maximum
value
Type: REAL
Minimum and/or maximum voltage to be present at the output. The actual value does not fall below/exceed these values, even if the calculated values fall outside this range.
Permissible values: -1.0 to +1.0 (corresponds to -10 V to
+10 V).
It can be a constant, variable, structure component or array
element. The minimum value must always be less than the
maximum value. The sequence of the keywords MINIMUM
and MAXIMUM must be observed.
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Example
In this example, the output $ANOUT[5] controls the adhesive output.
A freely selected name, in this case GLUE, is assigned to the analog output in
the declaration section. The amount of adhesive is to be dependent on the current path velocity (= system variable $VEL_ACT). Furthermore, the output signal is to be generated 0.5 seconds early. The minimum voltage is to be 3 V.
SIGNAL GLUE $ANOUT[5]
...
ANOUT ON GLUE = 0.5 * $VEL_ACT DELAY=-0.5 MINIMUM=0.30
The cyclical analog output is ended by using ANOUT OFF:
ANOUT OFF GLUE
10.8.3
PULSE
Description
Sets a pulse. The output is set to a defined level for a specified duration. The
output is then reset automatically by the system. The output is set and reset
irrespective of the previous level of the output.
At any one time, pulses may be set at a maximum of 16 outputs.
If PULSE is programmed before the first motion block, the pulse duration also
elapses if the Start key is released again and the robot has not yet reached the
BCO position.
The PULSE statement triggers an advance run stop. It is only executed concurrently with robot motion if it is used in a TRIGGER statement.
The pulse is not terminated in the event of an EMERGENCY STOP,
an operator stop or an error stop!
Syntax
Explanation of
the syntax
PULSE (Signal, Level, Pulse duration)
Element
Signal
Description
Type: BOOL
Output to which the pulse is to be fed. The following are
permitted:
Level
OUT[No]
Signal variable
Type: BOOL
Logic expression:
Pulse duration
TRUE represents a positive pulse (high).
FALSE represents a negative pulse (low).
Type: REAL
Range of values: 0.1 to 3.0 seconds. Pulse durations outside this range trigger a program stop.
Pulse interval: 0.1 seconds, i.e. the pulse duration is
rounded up or down. The PULSE statement is executed in
the controller at the low-priority clock rate. This results in a
tolerance in the order of the pulse interval (0.1 seconds).
The time deviation is about 1% - 2% on average. The deviation is about 13% for very short pulses.
$OUT+PULSE
If an output is already set before the pulse, it will be reset by the falling edge
of the pulse.
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$OUT[50] = TRUE
PULSE($OUT[50],TRUE,0.5)
Actual pulse characteristic at output 50:
Fig. 10-2: $OUT+PULSE, example 1
If a negative pulse is applied to an output that is set to Low, the output remains
Low until the end of the pulse and is then set to High:
$OUT[50] = FALSE
PULSE($OUT[50],FALSE,0.5)
Actual pulse characteristic at output 50:
Fig. 10-3: $OUT+PULSE, example 2
PULSE+$OUT
If the same output is set during the pulse duration, it will be reset by the falling
edge of the pulse.
PULSE($OUT[50],TRUE,0.5)
$OUT[50] = TRUE
Actual pulse characteristic at output 50:
Fig. 10-4: PULSE+$OUT, example 1
If the output is reset during the pulse duration, the pulse duration is reduced
accordingly:
PULSE($OUT[50],TRUE,0.5)
$OUT[50] = FALSE
Actual pulse characteristic at output 50:
Fig. 10-5: PULSE+$OUT, example 2
If an output is set to FALSE during a pulse and then back to TRUE, the pulse
is interrupted and then resumed when the output is set to TRUE. The overall
duration from the first rising edge to the last falling edge (i.e. including the duration of the interruption) corresponds to the duration specified in the PULSE
statement.
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PULSE($OUT[50],TRUE,0.8)
$OUT[50]=FALSE
$OUT[50]=TRUE
Actual pulse characteristic at output 50:
Fig. 10-6: PULSE+$OUT, example 3
The actual pulse characteristic is only specified as above if $OUT[x]=TRUE is
set during the pulse. If $OUT[x]=TRUE is not set until after the pulse (see line
3), then the actual pulse characteristic is as follows (line 4):
Fig. 10-7: PULSE+$OUT, example 4
PULSE+PULSE
If several PULSE statements overlap, it is always the last PULSE statement
that determines the end of the overall pulse duration.
If a pulse is activated again before the falling edge, the duration of the second
pulse starts at this moment. The overall pulse duration is thus shorter than the
sum of the values of the first and second pulses:
PULSE($OUT[50],TRUE,0.5)
PULSE($OUT[50],TRUE,0.5)
Actual pulse characteristic at output 50:
Fig. 10-8: PULSE+PULSE, example 1
If, during the pulse duration of a positive pulse, a negative pulse is sent to the
same output, only the second pulse is taken into consideration from this moment onwards:
PULSE($OUT[50],TRUE,0.5)
PULSE($OUT[50],FALSE,0.5)
Actual pulse characteristic at output 50:
Fig. 10-9: PULSE+PULSE, example 2
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PULSE($OUT[50],TRUE,3.0)
PULSE($OUT[50],FALSE,1.0)
Actual pulse characteristic at output 50:
Fig. 10-10: PULSE+PULSE, example 3
PULSE+END
If a pulse is programmed before the END statement, the duration of program
execution is increased accordingly.
PULSE($OUT[50],TRUE,0.8)
END
Program active
Actual pulse characteristic at output 50:
Fig. 10-11: PULSE+END, example
PULSE+RESET/
CANCEL
If program execution is reset (RESET) or aborted (CANCEL) while a pulse is
active, the pulse is immediately reset:
PULSE($OUT[50],TRUE,0.8)
RESET or CANCEL
Actual pulse characteristic at output 50:
Fig. 10-12: PULSE+RESET, example
10.8.4
SIGNAL
Description
SIGNAL declarations must appear in the declaration section.
SIGNAL links predefined signal variables for inputs or outputs with a
name.
A SIGNAL declaration is required in order to be able to address an analog
input or output. An input or output may appear in several SIGNAL declarations.
SIGNAL declarations that are predefined in the system can be deactivated
by means of SIGNAL in conjunction with the keyword FALSE.
Can only be used in KRC:\STEU:\MADA:\$machine.dat.
Syntax
Declaration of signal names for inputs and outputs:
SIGNAL Signal name Signal variable & lt; TO Signal variable & gt;
Deactivation of a SIGNAL declaration predefined in the system:
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SIGNAL System signal name FALSE
Explanation of
the syntax
Element
Description
Signal name
Any name
Signal
variable
Predefined signal variable. The following types are available:
$IN[x]
$OUT[x]
$ANIN[x]
$ANOUT[x]
TO
Groups together several consecutive binary inputs or outputs (max. 32) to form a digital input or output. The combined signals can be addressed with a decimal name, a
hexadecimal name (prefix H) or with a bit pattern name
(prefix B). They can also be processed with Boolean operators.
System signal
name
Signal name predefined in the system, e.g. $T1.
FALSE
Deactivates a SIGNAL declaration predefined in the system. The inputs or outputs to which the SIGNAL declaration refers are thus available again for other purposes.
FALSE is not a Boolean value here, but a keyword. The
option TRUE is not available. If the SIGNAL declaration
that has been deactivated by means of FALSE is to be
reactivated, the program line containing the entry FALSE
must be deleted.
Example 1
The output $OUT[7] is assigned the name START_PROCESS. The output
$OUT[7] is set.
SIGNAL START_PROCESS $OUT[7]
START_PROCESS = TRUE
Example 2
The outputs $OUT[1] to $OUT[8] are combined to form one digital output under the name OUTWORT. The outputs $OUT[3], $OUT[4], $OUT[5] and
$OUT[7] are set.
SIGNAL OUTWORT $OUT[1] TO $OUT[8]
OUTWORT = 'B01011100'
10.9
Subprograms and functions
10.9.1
RETURN
Description
Jump from a subprogram or function back to the program from which the subprogram or function was called.
Subprograms
RETURN can be used to return to the main program if a certain condition is
met in the subprogram. No values from the subprogram can be transferred to
the main program.
Functions
Functions must be ended by a RETURN statement containing the value that
has been determined. The determined value is hereby transferred to the program from which the function was called.
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Syntax
For subprograms:
RETURN
For functions:
RETURN Function value
Explanation of
the syntax
Element
Function
value
Description
Type: The data type of Function value must match the data
type of the function.
Function value is the value determined by the function. The
value can be specified as a constant, a variable or an
expression.
Example 1
Return from a subprogram to the program from which it was called, dependent
on a condition.
DEF PROG_2()
...
IF $IN[5]==TRUE THEN
RETURN
...
END
Example 2
Return from a function to the program from which it was called. The value X is
transferred.
DEFFCT INT CALCULATE(X:IN)
INT X
X=X*X
RETURN X
ENDFCT
10.10
Interrupt programming
10.10.1 BRAKE
Description
BRAKE stops the robot.
BRAKE may only be used in an interrupt program.
The interrupt program is not continued until the robot has come to a stop. The
robot motion is resumed as soon as the interrupt program has been completed.
Syntax
Explanation of
the syntax
BRAKE & lt; F & gt;
Element
F
Description
F triggers a STOP 1.
In the case of a BRAKE statement without F, the robot
brakes with a STOP 2.
Example
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( & gt; & gt; & gt; 10.10.3 " INTERRUPT " Page 330)
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10.10.2 INTERRUPT ... DECL ... WHEN ... DO
Description
In the case of a defined event, e.g. an input, the controller interrupts the current program and executes a defined subprogram. The event and the subprogram are defined by INTERRUPT ... DECL ... WHEN ... DO.
Once the subprogram has been executed, the interrupted program is resumed
at the point at which it was interrupted. Exception: RESUME.
A subprogram called by an interrupt is called an interrupt program.
A maximum of 32 interrupts may be declared simultaneously. An interrupt declaration may be overwritten by another at any time.
The interrupt declaration is a statement. It must be situated in the
statements section of the program and not in the declaration section!
When first declared, an interrupt is deactivated. The interrupt must be
activated before the system can react to the defined event!
( & gt; & gt; & gt; 10.10.3 " INTERRUPT " Page 330)
Syntax
Explanation of
the syntax
& lt; GLOBAL & gt; INTERRUPT DECL Prio WHEN Event DO Subprogram
Element
Description
GLOBAL
An interrupt is only recognized at, or below, the level in
which it is declared. In other words, an interrupt declared in
a subprogram is not recognized in the main program (and
cannot be activated there). If an interrupt is also to be recognized at higher levels, the declaration must be preceded
by the keyword GLOBAL.
Prio
Type: INT
If several interrupts occur at the same time, the interrupt
with the highest priority is processed first, then those of
lower priority. 1 = highest priority.
Priorities 1, 2, 4 to 39 and 81 to 128 are available.
Note: Priorities 3 and 40 to 80 are reserved for use by the
system. They must not be used by the user because this
would cause system-internal interrupts to be overwritten
and result in errors.
Event
Type: BOOL
Event that is to trigger the interrupt. Structure components
are impermissible. The following are permitted:
a signal name
a comparison
Example 1
a Boolean variable
Subprogram
a Boolean constant
a simple logic operation: NOT, OR, AND or EXOR
The name of the interrupt program to be executed. Runtime variables may not be transferred to the interrupt program as parameters, with the exception of variables
declared in a data list.
Declaration of an interrupt with priority 23 that calls the subprogram SP1 if
$IN[12] is true. The parameters 20 and VALUE are transferred to the subprogram.
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INTERRUPT DECL 23 WHEN $IN[12]==TRUE DO UP1(20,WERT)
Example 2
Two objects, the positions of which are detected by two sensors connected to
inputs 6 and 7, are located on a programmed path. The robot is to be moved
subsequently to these two positions.
For this purpose, the two detected positions are saved as points P_1 and P_2.
These points are then addressed in the second section of the main program.
If the robot controller detects an event defined by means of INTERRUPT ...
DECL ... WHEN ... DO, it always saves the current robot position in the system
variables $AXIS_INT (axis-specific) and $POS_INT (Cartesian).
Main program:
DEF PROG()
...
INTERRUPT DECL 10 WHEN $IN[6]==TRUE DO UP1()
INTERRUPT DECL 20 WHEN $IN[7]==TRUE DO UP2()
...
INTERRUPT ON
LIN START
LIN END
INTERRUPT OFF
LIN P_1
LIN P_2
...
END
Local interrupt program 1:
DEF UP1()
P_1=$POS_INT
END
Local interrupt program 2:
DEF UP2()
P_2=$POS_INT
END
10.10.3 INTERRUPT
Description
Executes one of the following actions:
Activates an interrupt.
Deactivates an interrupt.
Disables an interrupt.
Enables an interrupt.
The interrupt must previously have been declared. ( & gt; & gt; & gt; 10.10.2 " INTERRUPT ... DECL ... WHEN ... DO " Page 329)
Syntax
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INTERRUPT Action & lt; Number & gt;
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Explanation of
the syntax
Element
Description
OFF: Deactivates an interrupt.
DISABLE: Disables an activated interrupt.
Number
ON: Activates an interrupt.
Action
ENABLE: Enables a disabled interrupt.
Type: INT
Number (= priority) of the interrupt to which the Action is to
refer.
Number can be omitted. In this case, ON or OFF refers to all
declared interrupts, while DISABLE or ENABLE refers to all
active interrupts.
Up to 16 interrupts may be active at any one time. In this regard, particular attention must be paid to the following:
If, in the case of INTERRUPT ON, the Number is omitted, all declared
interrupts are activated. The maximum permissible total of 16 may not be
exceeded, however.
If a trigger calls a subprogram, it counts as an active interrupt until the
subprogram has been executed.
If, in the interrupt declaration, a Boolean variable, e.g. an input, has
been defined as the Event:
In this case, the interrupt is triggered by a change of state, e.g. in the
case of $IN[x]==TRUE by the change from FALSE to TRUE. The state
must therefore not already be present at INTERRUPT ON, as the interrupt is not then triggered!
Furthermore, the following must also be considered in this case: the
change of state must not occur until at least one interpolation cycle after
INTERRUPT ON.
(This can be achieved by programming a WAIT SEC 0.012 after INTERRUPT ON. If no advance run stop is desired, a CONTINUE command
can also be programmed before the WAIT SEC.)
The reason for this is that INTERRUPT ON requires one interpolation cycle (= 12 ms) before the interrupt is actually activated. If the state changes before this, the interrupt cannot detect the change.
Example 1
The interrupt with priority 2 is activated. (The interrupt must already be declared.)
INTERRUPT ON 2
Example 2
A non-path-maintaining EMERGENCY STOP is executed via the hardware
during application of adhesive. The application of adhesive is stopped by the
program and the adhesive gun is repositioned onto the path after enabling (by
input 10).
DEF PROG()
...
INTERRUPT DECL 1 WHEN $STOPMESS DO STOP_PROG()
LIN P_1
INTERRUPT ON
LIN P_2
INTERRUPT OFF
...
END
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DEF STOP_PROG()
BRAKE F
GLUE=FALSE
WAIT FOR $IN[10]
LIN $POS_RET
GLUE=TRUE
END
10.10.4 RESUME
Description
RESUME may only occur in interrupt programs. (Not in interrupt programs,
however, that are called by an interrupt that is declared as GLOBAL.) RESUME cancels all running interrupt programs and subprograms up to the level
at which the current interrupt was declared.
When the RESUME statement is activated, the advance run pointer must not
be at the level where the interrupt was declared, but at least one level lower.
Changing the variable $BASE in the interrupt program only has an effect there.
The computer advance run, i.e. the variable $ADVANCE, must not be modified
in the interrupt program.
The behavior of the robot controller after RESUME depends on the following
motion instruction:
PTP instruction: is executed as a PTP motion.
LIN instruction: is executed as a LIN motion.
CIRC instruction: is always executed as a LIN motion!
Following a RESUME statement, the robot is not situated at the original
start point of the CIRC motion. The motion will thus differ from how it was
originally planned; this can potentially be very dangerous, particularly in
the case of CIRC motions.
If the first motion instruction after RESUME is a CIRC
motion, this is always executed as LIN! This must be taken into consideration when programming RESUME statements. The robot
must be able to reach the end point of the CIRC motion safely, by means of
a LIN motion, from any position in which it could find itself when the RESUME
statement is executed.
Failure to observe this may result in death to persons, physical injuries or
damage to property.
Syntax
RESUME
Example
The robot is to search for a part on a path. The part is detected by means of a
sensor at input 15. Once the part has been found, the robot is not to continue
to the end point of the path, but to return to the interrupt position and pick up
the part. The main program is then to be resumed.
Motions that are to be canceled by means of BRAKE and RESUME must be
programmed in a subprogram. (Here SEARCH().)
Main program:
DEF PROG()
INI
...
INTERRUPT DECL 21 WHEN $IN[15] DO FOUND()
PTP HOME
...
SEARCH()
$ADVANCE=3
...
END
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Subprogram with search path:
When the RESUME statement is activated, the advance run pointer must not
be at the level where the current interrupt was declared. To prevent this, the
advance run is set to 0 here in the subprogram.
DEF SEARCH()
INTERRUPT ON 21
LIN START_SEARCH
LIN END_SEARCH
$ADVANCE=0
...
END
Interrupt program:
LIN $POS_INT is the return motion to the position at which the interrupt was
triggered. After LIN $POS_INT (in the example: …), the robot grips the part.
RESUME causes the main program to be resumed after the part has been
gripped. Without the RESUME statement, the subprogram SEARCH would be
resumed after END.
DEF FOUND()
INTERRUPT OFF
BRAKE
LIN $POS_INT
...
RESUME
END
10.11
Path-related switching actions (=Trigger)
10.11.1 TRIGGER WHEN DISTANCE
Description
The Trigger triggers a defined statement. The statement refers to the start
point or end point of the motion block in which the Trigger is situated in the program. The statement is executed parallel to the robot motion.
The statement can be shifted in time. It is then not triggered exactly at the start
or end point, but brought forward or delayed.
Syntax
TRIGGER WHEN DISTANCE=Position DELAY=Time DO Statement & lt; PRIO=Priority & gt;
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Explanation of
the syntax
Element
Position
Description
Type: INT; variable or constant
Defines the point at which the statement is triggered. Possible values: 0 or 1.
Time
0: The statement is triggered at the start point of the motion block. If the start point is approximated, the statement is triggered at the end of the approximate
positioning arc.
1: The statement is triggered at the end point. If the end
point is approximated, the statement is triggered in the
middle of the approximate positioning arc.
Type: REAL; variable or constant; unit: ms
Shifts the statement in time. Obligatory specification: if no
time shift is desired, set Time = 0.
The statement cannot be shifted freely in time. The shifts
that are available depend on the value selected for Position:
Position = 0 (start point)
In this case, the statement can only be triggered with a
delay, i.e. it is only possible to select a positive value for
Time. The statement can be delayed, at most, as far as
the end point. If the end point is approximated, the
statement can be delayed, at most, as far as the start of
the approximate positioning arc.
Position = 1 (end point)
In this case, a distinction must be made as to whether
the end point is an exact positioning point or an approximate positioning point.
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Exact positioning point: In this case, the statement can only be triggered earlier, i.e. it is only possible to select a negative value for Time. The
statement can be brought forward, at most, as far
as the start point. If the start point is approximated,
the statement can be brought forward, at most, as
far as the end of the approximate positioning arc.
Approximate positioning point: In this case, the
statement can be triggered earlier or with a delay,
i.e. it is possible to select a negative or positive value for Time. The statement can be shifted, at most,
as far as the start or end of the approximate positioning arc of the end point.
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Element
Statement
Description
Possible:
Assignment of a value to a variable
Note: There must be no runtime variable on the lefthand side of the assignment.
OUT statement
PULSE statement
Subprogram call. In this case, Priority must be specified.
Type: INT; variable or constant
Priority
Priority of the trigger. Only relevant if Statement calls a subprogram, and then obligatory.
Priorities 1, 2, 4 to 39 and 81 to 128 are available. Priorities
3 and 40 to 80 are reserved for cases in which the priority
is automatically assigned by the system. If the priority is to
be assigned automatically by the system, the following is
programmed: PRIO = -1.
If several triggers call subprograms at the same time, the
trigger with the highest priority is processed first, then the
triggers of lower priority. 1 = highest priority.
If a trigger calls a subprogram, it counts as an active interrupt until the
subprogram has been executed. Up to 16 interrupts may be active at
any one time.
System variables
Useful system variables for working with triggers:
System variable
Description
$DIST_NEXT
REAL
Distance to next point. Value
is negative or 0. This system
variable can be used for
teaching triggers.
$DISTANCE
Example 1
Data type
REAL
Overall length of current CP
motion
130 milliseconds after P_2, $OUT[8] is set to TRUE.
LIN P_2
TRIGGER WHEN DISTANCE=0 DELAY=130 DO $OUT[8]=TRUE
LIN P_3
Example 2
In the middle of the approximate positioning arc of P_5, the subprogram
MY_SUBPROG with priority 5 is called.
PTP P_4
TRIGGER WHEN DISTANCE=1 DELAY=0 DO MY_SUBPROG() PRIO=5
PTP P_5 C_DIS
Example 3
Explanation of the diagram:
In the diagram, the approximate positions in which the Triggers would be triggered are indicated by arrows.
In addition to these points, the start, middle and end of each approximate positioning arc are indicated.
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
DEF PROG()
...
PTP P_0
TRIGGER WHEN DISTANCE=0
...
TRIGGER WHEN DISTANCE=1
...
LIN P_1
TRIGGER WHEN DISTANCE=0
...
TRIGGER WHEN DISTANCE=1
...
LIN P_2 C_DIS
TRIGGER WHEN DISTANCE=0
...
TRIGGER WHEN DISTANCE=1
...
LIN P_3 C_DIS
TRIGGER WHEN DISTANCE=0
...
TRIGGER WHEN DISTANCE=1
...
LIN P_4
...
END
DELAY=40 DO A=12
DELAY=-20 DO UP1() PRIO=10
DELAY=10 DO UP2(A) PRIO=5
DELAY=15 DO B=1
DELAY=10 DO UP2(B) PRIO=12
DELAY=0 DO UP(A,B,C) PRIO=6
DELAY=50 DO UP2(A) PRIO=4
DELAY=-80 DO A=0
Line
Description
4
Switching range: 0 - 1
6
Switching range: 0 - 1
9
Switching range: 1 - 2*start
11
Switching range: 2*start - 2*end
14
Switching range: 2*end - 3*start
16
Switching range: 3*start - 3*end
19
Switching range: 3*end - 4
21
Switching range: 3*end - 4
Fig. 10-13: Example of TRIGGER WHEN DISTANCE
10.11.2 TRIGGER WHEN PATH
Description
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The Trigger triggers a defined statement. The statement refers to the end point
of the motion block in which the Trigger is situated in the program. It is possible
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10 Programming for user group “Expert” (KRL syntax)
to shift the statement in time and/or space so that it is not triggered exactly at
the end point, but before or after it.
The end point must be LIN or CIRC. It must not be PTP.
The statement is executed parallel to the robot motion.
Syntax
TRIGGER WHEN PATH =Distance DELAY=Time DO Statement & lt; PRIO=Priority & gt;
Explanation of
the syntax
Element
Distance
Description
Type: REAL; variable or constant; unit: mm
Obligatory specification. If no shift in space is desired, set
Distance = 0.
If the statement is to be shifted in space, the desired distance from the end point must be specified here. If this end
point is approximated, Distance is the distance to the position on the approximate positioning arc closest to the end
point.
Positive value: shifts the statement towards the end of
the motion.
Negative value: shifts the statement towards the start of
the motion.
The statement cannot be shifted freely. Maximum possible
shift: see below, section “Switching range”.
Time
Type: REAL; variable or constant; unit: ms
Obligatory specification. If no shift in time is desired, set
Time = 0.
If the statement is to be shifted in time (relative to PATH),
the desired duration must be specified here.
Positive value: shifts the statement towards the end of
the motion.
Negative value: shifts the statement towards the start of
the motion.
The statement cannot be shifted freely. Maximum possible
shift: see below, section “Switching range”.
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Element
Statement
Description
Possible:
Assignment of a value to a variable
Note: There must be no runtime variable on the lefthand side of the assignment.
OUT statement
PULSE statement
Subprogram call. In this case, Priority must be specified.
Type: INT; variable or constant
Priority
Priority of the trigger. Only relevant if Statement calls a subprogram, and then obligatory.
Priorities 1, 2, 4 to 39 and 81 to 128 are available. Priorities
3 and 40 to 80 are reserved for cases in which the priority
is automatically assigned by the system. If the priority is to
be assigned automatically by the system, the following is
programmed: PRIO = -1.
If several triggers call subprograms at the same time, the
trigger with the highest priority is processed first, then the
triggers of lower priority. 1 = highest priority.
If a trigger calls a subprogram, it counts as an active interrupt until the
subprogram has been executed. Up to 16 interrupts may be active at
any one time.
System variables
Useful system variables for working with triggers:
System variable
REAL
Distance to next point. Value
is negative or 0. This system
variable can be used for
teaching triggers.
$DISTANCE
Description
$DIST_NEXT
Switching range
Data type
REAL
Overall length of current CP
motion
Shift towards the end of the motion:
A statement can be shifted, at most, as far as the next exact positioning
point after TRIGGER WHEN PATH (skipping all approximate positioning
points).
In other words, if the end point is an exact positioning point, the statement
cannot be shifted beyond the end point.
Shift towards the start of the motion:
A statement can be shifted, at most, as far as the start point of the motion block (i.e. as far as the last point before TRIGGER WHEN PATH).
If the start point is an approximated LIN or CIRC point, the statement can
be brought forward, at most, as far as the start of its approximate positioning arc.
If the start point is an approximated PTP point, the statement can be
brought forward, at most, as far as the end of its approximate positioning
arc.
Example
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LIN P_2
TRIGGER
LIN P_3
LIN P_4
LIN P_5
C_DIS
WHEN PATH = -20.0 DELAY= -10 DO $OUT[2]=TRUE
C_DIS
C_DIS
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10 Programming for user group “Expert” (KRL syntax)
In the diagram, the approximate position in which the $OUT[2]=TRUE statement would be triggered is indicated by an arrow.
Fig. 10-14: Example of TRIGGER WHEN PATH
Switching range: P_2*start to P_5.
If P_2 were not approximated, the switching range would be P_2 to P_5.
The switching range goes to P_5 because P_5 is the next exact positioning
point after the TRIGGER statement. If P_3 were not approximated, the switching range would be P_2 to P_3, as P_3 is the next exact positioning point in
the program after the Trigger statement.
10.11.3 TRIGGER WHEN PATH (for SPLINE)
Description
This trigger can only be used in spline blocks.
The Trigger triggers a defined statement. The statement refers to the start
point or end point of the motion block in which the Trigger is situated in the program. The statement is executed parallel to the robot motion.
The statement can be shifted in time and/or space. It is then not triggered exactly at the start or end point, but beforehand or afterwards.
In the negative direction, the statement can be shifted, at most, as far as
the first point before the spline block.
In the positive direction, the statement can be shifted as far as the last
point of the spline block if this is an exact positioning point. If this point is
approximated, the statement can be shifted, at most, as far as the next exact positioning point.
Syntax
TRIGGER WHEN PATH = Distance & lt; ONSTART & gt; DELAY = Time DO Statement
& lt; PRIO = Priority & gt;
Functions
PATH and DELAY can call functions. The functions are subject to constraints.
( & gt; & gt; & gt; 9.3.4.14 " Limits for functions in the spline trigger " Page 272)
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Explanation of
the syntax
Element
Distance
Description
Type: REAL; variable, constant or function; unit: mm
Obligatory specification. If no shift in space is desired, set
Distance = 0.
If the statement is to be shifted in space, the desired distance from the start or end point must be specified here.
ONSTART
Positive value: shifts the statement towards the end of
the motion.
Negative value: shifts the statement towards the start of
the motion.
The PATH value refers to the start point.
Without ONSTART: the PATH value refers to the end point.
( & gt; & gt; & gt; 10.11.3.1 " Spline: trigger point in the case of approximate positioning " Page 341)
Type: REAL; variable, constant or function; unit: ms
Time
Obligatory specification. If no shift in time is desired, set
Time = 0.
If the statement is to be shifted in time (relative to PATH),
the desired duration must be specified here.
Statement
Positive value: shifts the statement towards the end of
the motion. Maximum: 1,000 ms
Negative value: shifts the statement towards the start of
the motion.
Possible:
Assignment of a value to a variable
Note: There must be no runtime variable on the lefthand side of the assignment.
PULSE statement
Priority
OUT statement
Subprogram call. In this case, Priority must be specified.
Type: INT; variable or constant
Priority of the trigger. Only relevant if Statement calls a subprogram, and then obligatory.
Priorities 1, 2, 4 to 39 and 81 to 128 are available. Priorities
3 and 40 to 80 are reserved for cases in which the priority
is automatically assigned by the system. If the priority is to
be assigned automatically by the system, the following is
programmed: PRIO = -1.
If several triggers call subprograms at the same time, the
trigger with the highest priority is processed first, then the
triggers of lower priority. 1 = highest priority.
If a trigger calls a subprogram, it counts as an active interrupt until the
subprogram has been executed. Up to 16 interrupts may be active at
any one time.
System variables
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Useful system variables for working with triggers:
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System variable
Description
$DIST_NEXT
REAL
Distance to next point. Value
is negative or 0. This system
variable can be used for
teaching triggers.
$DISTANCE
Example
Data type
REAL
Overall length of current CP
motion
1 PTP P0
2 SPLINE
3
SPL P1
4
SPL P2
5
SPL P3
6
SPL P4
7
TRIGGER WHEN PATH=0 ONSTART DELAY=10 DO $OUT[5]=TRUE
8
SCIRC P5, P6
9
SPL P7
10 TRIGGER WHEN PATH=-20.0 DELAY=0 DO SUBPR_2() PRIO=-1
11 SLIN P8
12 ENDSPLINE
The Trigger in line 10 would have the same result if it was positioned directly
before the spline block (i.e. between line 1 and line 2). In both cases, it refers
to the last point of the spline motion: P8.
Fig. 10-15: Example of TRIGGER WHEN PATH (for spline)
10.11.3.1Spline: trigger point in the case of approximate positioning
The point at which the trigger is triggered is the end point of the motion block
in which the trigger is situated. If ONSTART is used, it is the start point.
If this end or start point is approximated, the trigger point is transferred onto
the approximate positioning arc by a distance corresponding to the approximation distance.
The trigger point is not generally in the middle of the approximate positioning arc.
Triggers that are triggered at the same point in the case of exact positioning are triggered at different points in the case of approximate positioning.
The trigger that refers to the end point is triggered later than the trigger that
refers to the start point
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Example
Trigger 1 and trigger 2 would be triggered at the same point if P3 was not approximated.
Trigger 1 refers to the end point of the block in which it is situated, i.e. P3.
Trigger 2 (= with ONSTART) refers to the start point of the block in which
it is situated, i.e. also P3.
Trigger 1:
SPLINE
...
SLIN P2
TRIGGER WHEN PATH=0 DELAY=0 DO ...
SLIN P3
ENDSPLINE C_DIS
SPLINE
SLIN4
...
ENDSPLINE
Trigger 2:
SPLINE
...
SLIN P2
SLIN P3
ENDSPLINE C_DIS
SPLINE
TRIGGER WHEN PATH=0 ONSTART DELAY=0 DO ...
SLIN4
...
ENDSPLINE
P3 is approximated, however. It is transferred onto the approximate positioning arc by a distance corresponding to the approximation distance (= P3').
Trigger 1:
Trigger 1 is situated in the block P2 -- & gt; P3 and refers to the end point. The robot controller calculates how far the distance would be from the start of the approximate positioning arc to the end point with exact positioning. This distance
is then applied to the approximate positioning arc.
The distance PStartApprox -- & gt; P3' is the same as PStartApprox -- & gt; P3.
Fig. 10-16: Trigger 1: Trigger point in the case of approximate positioning
P3
P3'
Trigger point in the case of approximate positioning
PStartApprox
Start of the approximate positioning arc
PEndApprox
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Trigger point in the case of exact positioning
End of the approximate positioning arc
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10 Programming for user group “Expert” (KRL syntax)
Trigger 2:
Trigger 2 is situated in the block P3 -- & gt; P4 and refers to the start point. The
robot controller calculates how far the distance would be from the end of the
approximate positioning arc back to the start point with exact positioning. This
distance is then applied to the approximate positioning arc.
The distance PEndApprox -- & gt; P3' is the same as PEndApprox -- & gt; P3.
Fig. 10-17: Trigger 2: Trigger point in the case of approximate positioning
10.12
Communication
Information about the following statements is contained in the Expert documentation CREAD/CWRITE.
CAST_TO
CCLOSE
CHANNEL
CIOCTL
COPEN
CREAD
CWRITE
SREAD
10.13
CAST_FROM
SWRITE
System functions
10.13.1 VARSTATE()
Description
VARSTATE() can be used to monitor the state of a variable.
VARSTATE() is a function with a return value of type VAR_STATE.
VAR_STATE is an enumeration type that is defined as follows in the system:
ENUM VAR_STATE DECLARED, INITIALIZED, UNKNOWN
VARSTATE is defined as follows in the system:
VAR_STATE VARSTATE(CHAR VAR_STR[80]:IN)
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Example 1
DEF PROG1()
INT MYVAR
...
IF VARSTATE( " MYVAR " )==#UNKNOWN THEN
$OUT[11]=TRUE
ENDIF
...
IF VARSTATE( " MYVAR " )==#DECLARED THEN
$OUT[12]=TRUE
ENDIF
...
IF VARSTATE( " ANYVAR " )==#UNKNOWN THEN
$OUT[13]=TRUE
ENDIF
...
MYVAR=9
...
IF VARSTATE( " MYVAR " )==#DECLARED THEN
$OUT[14]=TRUE
ENDIF
...
IF VARSTATE( " MYVAR " )==#INITIALIZED THEN
$OUT[15]=TRUE
ENDIF
...
END
Explanation of the state monitoring:
The second IF condition is true, as MYVAR has been declared. Output 12
is set.
The third IF condition is true, on the condition that there is also no variable
with the name ANYVAR in $CONFIG.DAT. Output 13 is set.
The fourth IF condition is false, as MYVAR has not only been declared, but
has also already been initialized here. Output 14 is not set.
Example 2
The first IF condition is false, as MYVAR has already been declared. Output 11 is not set.
The fifth IF condition is true, as MYVAR has been initialized. Output 15 is
set.
DEF PROG2()
INT MYVAR
INT YOURVAR
DECL VAR_STATE STATUS
...
STATUS=VARSTATE( " MYVAR " )
UP()
...
STATUS=VARSTATE( " YOURVAR " )
UP()
...
END
DEF UP()
...
IF VARSTATE( " STATUS " )==#DECLARED THEN
$OUT[100]=TRUE
ENDIF
...
END
Explanation of the state monitoring:
In this example, the state is monitored indirectly, i.e. via an additional variable.
The additional variable must be of type VAR_STATE. The keyword DECL
must not be omitted in the declaration. The name of the additional variable
may be freely selected. In this example it is STATUS.
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10.13.2 ROB_STOP() and ROB_STOP_RELEASE()
Description
The statement ROB_STOP() stops the robot and prevents further motions.
This affects all possible motions, irrespective of whether they arise from program execution, manual jogging or command mode.
The statement ROB_STOP_RELEASE() cancels a blockade caused by
ROB_STOP().
ROB_STOP() and ROB_STOP_RELEASE() can only be used in submit programs, not robot programs.
If ROB_STOP() is called several times in succession without a
ROB_STOP_RELEASE() in between, only the first call has any effect. The
subsequent calls have no effect, i.e. they do not trigger a stop or cause a message to be generated.
If ROB_STOP_RELEASE() is called without ROB_STOP() being called first,
this has no effect.
Messages
ROB_STOP() triggers the following status message: Robot stopped by submit
ROB_STOP_RELEASE() in a Test mode triggers the following acknowledgement message: Ackn. Robot stopped by submit
ROB_STOP_RELEASE() in an Automatic mode triggers no message.
Syntax
result = ROB_STOP (stop_type: IN)
Explanation of
the syntax
Element
result
Description
Type: BOOL
Variable for the return value. Return value:
stop_type
TRUE: The stop has been executed.
FALSE: An invalid parameter has been transferred for
stop_type.
Type: ROB_STOP_T
Stop type to be used to stop the robot:
#RAMP_DOWN: ramp stop
#PATH_MAINTAINING: path-maintaining EMERGENCY STOP
Other stop types are not possible.
ProConOS
The “Robot stop” function can also be used from ProConOS. The following
functions are available for this:
PLC_ROB_STOP()
The desired stop type is defined with PLC_ROB_STOP_RAMP_DOWN or
PLC_ROB_STOP_PATH_MAINT.
PLC_ROB_STOP_RELEASE()
The effect is the same, irrespective of whether a stop is triggered by submit or
by ProConOS. ProConOS generates its own message texts; these are:
Robot stopped by SoftPLC (Name of the task calling it)
Ackn. Robot stopped by SoftPLC
If a stop is requested by both submit and ProConOS, this is indicated in each
case by a status message. A maximum of 2 status messages can thus be dis-
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played for an executed stop. In this case, robot motion cannot be resumed until the blockade has been canceled by both submit and ProConOS.
If different stop types are requested by submit and ProConOS, the type actually carried out is generally the one that was requested first.
A stop triggered by ProConOS cannot be canceled by a submit program and vice versa.
10.14
Editing string variables
Various functions are available for editing string variables. The functions can
be used in SRC files, in SUB files and in the variable correction function.
10.14.1 String variable length in the declaration
Description
The function StrDeclLen() determines the length of a string variable according to its declaration in the declaration section of a program.
Syntax
Length = StrDeclLen(StrVar[])
Explanation of
the syntax
Element
Length
Description
Type: INT
Variable for the return value. Return value: Length of the
string variable as declared in the declaration section
StrVar[]
Type: CHAR array
String variable whose length is to be determined
Since the string variable StrVar[ ] is an array of type CHAR,
individual characters and constants are not permissible for
length determination.
Example
1
2
3
4
CHAR ProName[24]
INT StrLength
…
StrLength = StrDeclLen(ProName)
StrLength = StrDeclLen($Trace.Name[ ])
Line
Description
3
StrLength = 24
4
StrLength = 64
10.14.2 String variable length after initialization
Description
Syntax
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The function StrLen() determines the length of the character string of a
string variable as defined in the initialization section of the program.
Length = StrLen(StrVar)
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10 Programming for user group “Expert” (KRL syntax)
Explanation of
the syntax
Element
Description
Length
Type: INT
Variable for the return value. Return value: Number of characters currently assigned to the string variable
StrVar
Type: CHAR
Character string or variable whose length is to be determined
Example
1
2
3
4
CHAR PartA[50]
INT AB
…
PartA[] = " This is an example "
AB = StrLen(PartA[])
Line
Description
4
AB = 18
10.14.3 Deleting the contents of a string variable
Description
The function StrClear() deletes the contents of a string variable.
Syntax
Result = StrClear(StrVar[])
Explanation of
the syntax
Element
Result
Description
Type: BOOL
Variable for the return value. Return value:
StrVar[]
The contents of the string variable have been deleted:
TRUE
The contents of the string variable have not been deleted: FALSE
Type: CHAR array
Variable whose character string is to be deleted
Example
IF (NOT StrClear($Loop_Msg[])) THEN
HALT
ENDIF
The function can be used within IF branches without the return value
being explicitly assigned to a variable. This applies to all functions for
editing string variables.
10.14.4 Extending a string variable
Description
The function StrAdd() can be used to expand a string variable with the contents of another string variable.
Syntax
Sum = StrAdd(StrDest[], StrToAdd[])
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Explanation of
the syntax
Element
Description
Sum
Type: INT
Variable for the return value. Return value: Sum of StrDest[ ] and StrToAdd[ ]
If the sum is longer than the previously defined length of
StrDest[ ], the return value is 0. This is also the case if the
sum is greater than 470 characters.
StrDest[]
Type: CHAR array
The string variable to be extended
Since the string variable StrDest[ ] is an array of type
CHAR, individual characters and constants are not permissible.
StrToAdd[]
Type: CHAR array
The character string by which the variable is to be
extended
Example
1
2
3
4
5
DECL CHAR A[50], B[50]
INT AB, AC
…
A[] = " This is an "
B[] = " example "
AB = StrAdd(A[],B[])
Line
5
Description
A[ ] = “This is an example”
AB = 18
10.14.5 Searching a string variable
Description
The function StrFind() can be used to search a string variable for a character string.
Syntax
Result = StrFind(StartAt, StrVar[], StrFind[], CaseSens)
Explanation of
the syntax
Element
Result
Description
Type: INT
Variable for the return value. Return value: Position of the
first character found. If no character is found, the return
value is 0.
StartAt
Type: INT
The search is started from this position.
StrVar[]
Type: CHAR array
The string variable to be searched
StrFind[]
Type: CHAR array
The character string that is being looked for.
CaseSens
#CASE_SENS: Upper and lower case are taken into
consideration.
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#NOT_CASE_SENS: Upper and lower case are ignored.
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10 Programming for user group “Expert” (KRL syntax)
Example
1
2
3
4
5
6
7
DECL CHAR A[5]
INT B
A[]= " ABCDE "
B = StrFind(1,
B = StrFind(1,
B = StrFind(1,
B = StrFind(1,
A[],
A[],
A[],
A[],
" AC " , #CASE_SENS)
" a " , #NOT_CASE_SENS)
" BC " , #Case_Sens)
" bc " , #NOT_CASE_SENS)
Line
Description
4
B=0
5
B=1
6
B=2
7
B=2
10.14.6 Comparing the contents of string variables
Description
The function StrComp() can be used to compare two string variables.
Syntax
Comp = StrComp(StrComp1[], StrComp2[], CaseSens)
Explanation of
the syntax
Element
Description
Comp
Type: BOOL
Variable for the return value. Return value:
StrComp1[]
The character strings match: TRUE
The character strings do not match: FALSE
Type: CHAR array
String variable that is compared with StrComp2[].
StrComp2[]
Type: CHAR array
String variable that is compared with StrComp1[].
CaseSens
1
2
3
4
5
6
7
#CASE_SENS: Upper and lower case are taken into
consideration.
Example
#NOT_CASE_SENS: Upper and lower case are ignored.
DECL CHAR A[5]
BOOL B
A[]= " ABCDE "
B = StrComp(A[],
B = StrComp(A[],
B = StrComp(A[],
B = StrComp(A[],
" ABCDE " , #CASE_SENS)
" abcde " , #NOT_CASE_SENS)
" abcd " , #NOT_CASE_SENS)
" acbde " , #NOT_CASE_SENS)
Line
Description
4
B = TRUE
5
B = TRUE
6
B = FALSE
7
B = FALSE
10.14.7 Copying a string variable
Description
The function StrCopy() can be used to copy the contents of a string variable
to another string variable.
Syntax
Copy = StrCopy(StrDest[], StrSource[])
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Explanation of
the syntax
Element
Description
Copy
Type: BOOL
Variable for the return value. Return value:
StrDest[]
The string variable was copied successfully: TRUE
The string variable was not copied: FALSE
Type: CHAR array
The character string is copied to this string variable.
Since StrDest[ ] is an array of type CHAR, individual characters and constants are not permissible.
StrSource[]
Type: CHAR array
The contents of this string variable are copied.
Example
1
2
3
4
5
DECL CHAR A[25], B[25]
DECL BOOL C
A[] = " "
B[] = " Example "
C = StrCopy(A[], B[])
Line
5
Description
A[ ] = “Example”
C = TRUE
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11 Submit interpreter
11
Submit interpreter
11.1
Function of the Submit interpreter
Function
2 tasks run in parallel on the robot controller:
Robot interpreter
The motion program runs in the robot interpreter.
Submit interpreter
A SUB program runs in the Submit interpreter.
A SUB program can perform operator control or monitoring tasks. Examples: monitoring of safety equipment; monitoring of a cooling circuit.
This means that no PLC is required for smaller applications, as the robot
controller can perform such tasks by itself.
The Submit interpreter starts automatically when the robot controller is
switched on. The program defined in the file KRC/STEU/MADA/$custom.dat
is started. By default, this is SPS.SUB.
$PRO_I_O[]= " /R1/SPS() "
The Submit interpreter can be stopped or deselected manually and can also
be restarted. It is also possible to start a SUB program other than the one entered in $custom.dat.
( & gt; & gt; & gt; 11.2 " Manually stopping or deselecting the Submit interpreter "
Page 352)
( & gt; & gt; & gt; 11.3 " Manually starting the Submit interpreter " Page 352)
SUB programs are always files with the extension *.SUB. The program
SPS.SUB can be modified and new SUB programs can be created.
( & gt; & gt; & gt; 11.4 " Modifying the program SPS.SUB " Page 353)
( & gt; & gt; & gt; 11.5 " Creating a new SUB program " Page 353)
The Submit interpreter must not be used for time-critical
applications! A PLC must be used in such cases. Reasons:
The Submit interpreter shares system resources with the robot interpreter, which has the higher priority. The Submit interpreter is thus not executed at the robot controller’s interpolation cycle rate of 12 ms.
Furthermore, the runtime of the Submit interpreter is irregular.
The runtime of the Submit interpreter is influenced by the number of lines
in the SUB program. Even comment lines and blank lines have an effect.
If a system file, e.g. $config.dat or $custom.dat, is modified in such a
way that errors are introduced, the Submit interpreter is automatically
deselected. Once the error in the system file has been rectified, the
Submit interpreter must be reselected manually.
Display
The program SPS.SUB can be found in the “System” folder in the Navigator.
SUB files are only visible in the Navigator in the user group “Expert”.
By default, the execution of a selected SUB program is not displayed. This can
be changed using the system variable $INTERPRETER. The SUB program
can only be displayed, however, if a motion program is selected at the same
time.
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Value of $INTERPRETER
Description
1
0
11.2
The selected motion program is displayed in
the editor (default).
The selected SUB program is displayed in
the editor.
Manually stopping or deselecting the Submit interpreter
Precondition
User group " Expert " .
Operating mode T1 or T2.
Procedure
In the main menu, select Configuration & gt; SUBMIT interpreter & gt; Stop or
Deselect.
Alternative
procedure
In the status bar, touch the Submit interpreter status indicator. A window
opens.
Select Stop or Deselect.
Description
Command
Description
Stop
The Submit interpreter is stopped. When it is restarted, the
SUB program is resumed at the point at which it was
stopped.
Deselect
The Submit interpreter is deselected. A different SUB program can now be selected.
Once the Submit interpreter has been stopped or deselected, the corresponding icon in the status bar is red or gray.
Icon
Color
Description
Red
Gray
11.3
Submit interpreter has been stopped.
Submit interpreter is deselected.
Manually starting the Submit interpreter
Precondition
User group “Expert”
Operating mode T1 or T2
Submit interpreter has been stopped or deselected.
Procedure
In the main menu, select Configuration & gt; SUBMIT interpreter & gt; Start/
select.
Alternative
procedure
In the status bar, touch the Submit interpreter status indicator. A window
opens.
Select Start/select.
Description
If the Submit interpreter is deselected, the command Start/Select selects the
SUB program defined in the file $custom.dat.
If the Submit interpreter has been stopped, the command Start/Select resumes the selected SUB program at the point at which it was stopped.
Once the Submit interpreter has been started, the corresponding icon in the
status bar is green.
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11 Submit interpreter
Icon
Description
Yellow
Submit interpreter is selected. The block
pointer is situated on the first line of the selected SUB program.
Green
11.4
Color
Submit interpreter is running.
Modifying the program SPS.SUB
Precondition
The program SPS.SUB is not selected or has been stopped.
Procedure
User group “Expert”
1. Select the program SPS.SUB in the Navigator and press Open.
2. Enter changes.
Enter initializations in the USER INIT Fold. This Fold is located in the
INI Fold.
USER INIT
; Please insert user defined initialization commands
Enter all other changes in the USER PLC Fold.
USER PLC
; Make your modifications here
3. Close the program. Respond to the request for confirmation asking whether the changes should be saved by pressing Yes.
4. The program SPS.SUB can now be started via the main menu with Configuration & gt; SUBMIT interpreter & gt; Start.
Description
Structure of the program SPS.SUB:
1
2
3
4
5
6
7
8
9
10
DEF SPS ( )
DECLARATIONS
INI
LOOP
WAIT FOR NOT($POWER_FAIL)
TORQUE_MONITORING()
USER PLC
ENDLOOP
Line
Description
2
Declaration section
3
Initialization section. For statements that are only to be executed once after the system has booted.
5 … 10
LOOP statement. For programs that are to run continuously in
the background.
9
Fold for user-specific adaptations
The program SPS.SUB may also contain Folds for user-specific adaptations
for technology packages, e.g. the Fold GRIPPERTECH PLC. The Folds that
are actually present depend on what technologies are installed.
11.5
Creating a new SUB program
Precondition
Expert user group
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Procedure
1. In the directory structure, select the folder in which the program is to be
created. (Not all folders allow the creation of programs within them.)
2. Press New.
The Template selection window is opened.
3. Select the template Submit or Expert Submit and confirm with OK.
4. Enter a name for the program and confirm it with OK.
Description
Newly created SUB programs contain no Folds for the installed technology
packages.
These Folds are present by default in the program SPS.SUB. If the program
SPS.SUB is to be replaced with a new SUB program, these Folds must be
copied into the new program. The technology packages are otherwise no longer fully operational.
The template Submit generates a SUB file with the following structure:
1
2
3
4
5
6
7
DECLARATIONS
INI
LOOP
USER PLC
ENDLOOP
USER SUBROUTINE
Line
Description
1
Declaration section
2
Initialization section. For statements that are only to be executed once after the system has booted.
4, 5, 6
LOOP statement containing the Fold USER PLC. The Fold is
for programs that are to run continuously in the background.
7
For user-specific subroutines
The template Expert Submit generates an empty SUB file. With this template, everything has to be programmed by the user.
Use a LOOP statement when programming. SUB programs without a
LOOP statement are only executed once by the Submit interpreter. It
is then automatically deselected.
11.6
Programming
KRL code
Almost all KRL instructions can be used in a SUB program. The following
statements are not possible, however:
Statements for robot motions
Robot motions can only be interpreted by the robot interpreter. For this
reason, SRC programs containing motion commands cannot be called as
subprograms from a SUB program.
Statements referring to robot motions
These include BRAKE and all TRIGGER statements.
Motion commands for external axes can be used in a SUB program. Example:
IF (($IN[12] == TRUE) AND ( NOT $IN[13] == TRUE)) THEN
ASYPTP {E2 45}
ASYPTP {E3 200}
...
IF ((NOT $IN[12] == TRUE) AND ($IN[13] == TRUE)) THEN
ASYPTP {E2 0}
ASYPTP {E3 90}
External axes E2 and E3 are moved in accordance with specific inputs.
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11 Submit interpreter
WAIT statements or wait loops stop the cycle.
System variables
The Submit interpreter has read-access to all system variables and write-access to many of them. Access works even if the system variables are being
used in parallel by a motion program.
If a system variable to which the Submit interpreter does not have write-access
is modified in a SUB program, an error message is generated when the program is started and the Submit interpreter stops.
System variables that are frequently required in SUB programs:
$MODE_OP = Value
Value
Description
#T1
Robot controller is in T1 mode.
#T2
Robot controller is in T2 mode.
#AUT
Robot controller is in Automatic mode.
#EX
Robot controller is in Automatic External mode.
#INVALID
Robot controller has no defined state.
$OV_PRO = Value
Element
Data type
Description
Value (%)
INT
Program override value
Example:
If the programmed velocity is not reached, output 2 is set to FALSE.
…
IF (($MODE_OP == #T1) OR ($OV_PRO & lt; 100)) THEN
$OUT[2] = FALSE
ENDIF
…
In the test modes, $OV_PRO must not be written to by
the Submit interpreter, because the change may be unexpected for operators working on the industrial robot. Death to persons, severe physical injuries and considerable damage to property may result.
If possible, do not modify safety-relevant signals and
variables (e.g. operating mode, EMERGENCY STOP,
safety gate contact) via the Submit interpreter.
If modifications are nonetheless required, all safety-relevant signals and variables must be linked in such a way that they cannot be set to a dangerous
state by the Submit interpreter or PLC.
Inputs/outputs
The Submit interpreter can access the inputs and outputs of the robot controller.
No check is made to see if the robot interpreter and Submit interpreter are accessing the same output simultaneously, as this may even be desired in certain cases.
The user must therefore carefully check the assignment of the outputs. Otherwise, unexpected output signals may be generated, e.g. in safety equipment. Death, serious physical injuries or major damage to property may
result.
Subprograms
Other programs can be called as subprograms in a SUB program. The following are possible:
Other SUB programs
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SRC programs without statements for robot motions
Example:
CELL.SRC can be called from the program SPS.SUB with a CWRITE statement and RUN. The call only takes effect in the case of a cold start.
Fig. 11-1: SPS.SUB calls CELL.SRC
Further information about the program CELL.SRC can be found in
this documentation.
( & gt; & gt; & gt; 6.10.1 " Configuring CELL.SRC " Page 159)
Further information about CWRITE statements can be found in the Expert
documentation CREAD/CWRITE.
Communication
356 / 391
The flags of the robot controller can be used to enable the exchange of binary
information between a running motion program and a SUB program. A flag is
set by the Submit interpreter and read by the robot interpreter.
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12 Diagnosis
12
Diagnosis
12.1
Logbook
12.1.1
Displaying the logbook
The operator actions on the KCP are automatically logged. The command
Logbook displays the logbook.
Procedure
In the main menu, select Diagnosis & gt; Logbook & gt; Display.
The following tabs are available:
12.1.2
Log ( & gt; & gt; & gt; 12.1.2 " “Log” tab " Page 357)
Filter ( & gt; & gt; & gt; 12.1.3 " “Filter” tab " Page 358)
“Log” tab
Fig. 12-1: Logbook, Log tab
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KUKA System Software 8.2
Item
1
Description
Type of log event
Example
: Filter type " Note " + filter class " System " = note
originated by the kernel system of the robot.
The individual filter types and filter classes are listed on the Filter
tab.
2
Log event number
3
Date and time of the log event
4
Brief description of the log event
5
Detailed description of the selected log event
6
Indication of the active filter
The following buttons are available:
Button
Description
Export
Exports the log data as a text file.
( & gt; & gt; & gt; 12.1.4 " Configuring the logbook "
Page 359)
Update
12.1.3
Refreshes the log display.
“Filter” tab
The Filter tab is only displayed if the log User-defined has been selected.
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12 Diagnosis
Fig. 12-2: Logbook, Filter tab
12.1.4
Configuring the logbook
Precondition
Procedure
1. In the main menu, select Diagnosis & gt; Logbook & gt; Configuration. A window opens.
Expert user group
2. Make the desired settings.
3. Press OK to save the configuration and close the window.
Description
Fig. 12-3: Logbook configuration window
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Item
Description
1
Check box active: the log events selected with the filter are
saved in the text file.
Check box not active: all log events are saved in the text file.
2
Enter the path and name of the text file.
Default path: C:\KRC\ROBOTER\LOG\LOGBUCH.TXT
3
Check box active: log data deleted because of a buffer overflow are indicated in gray in the text file.
12.2
Check box not active: log data deleted because of a buffer
overflow are not indicated in the text file.
Displaying the caller stack
This function displays the data for the process pointer ($PRO_IP).
Precondition
User group " Expert "
Procedure
Program is selected.
In the main menu, select Diagnosis & gt; Caller stack.
Description
Fig. 12-4: Caller Stack window
Item
1
Description
None: Call not initiated by interrupt
[No.]: Call initiated by interrupt with the number [No.]
2
This file contains the call.
3
The program line with this number contains the call.
Preconditions in the program for the correct line to be determined
using the number:
Detail view (ASCII mode) is activated.
All Point PLCs are open.
4
5
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Source line
Detailed information about the entry selected in the list
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
12 Diagnosis
12.3
Displaying interrupts
Assumption
“Expert” user group
Procedure
In the main menu, select Display & gt; Diagnosis & gt; Interrupts.
Description
Fig. 12-5: Interrupts
Item
1
Description
Status of the interrupt
Interrupt ON or ENABLE
Interrupt DISABLE
Interrupt OFF or not activated
2
Number/priority of the interrupt
3
Validity range of the interrupt: global or local
4
Type of interrupt, dependent on the defined event in the interrupt
declaration
Error stop: $STOPMESS
EMERGENCY STOP: $ALARM_STOP
Measurement (Fast Measurement): $MEAS_PULSE[1…5]
5
Default: e.g. $IN[1…4096]
Trigger: Trigger subprogram
Module and program line of the interrupt declaration
The following buttons are available:
Button
Description
Submit/Robot
Toggles between the displays for robot interrupts and
Submit interrupts.
Update
Refreshes the display.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
12.4
Displaying diagnostic data about the kernel system
Description
The menu item Diagnostic Monitor makes it possible to display a wide range
of diagnostic data concerning numerous software modules of the kernel system.
Examples:
Module Kcp3 Driver (= drive for the smartPAD)
Network driver
The data displayed depend on the selected module. The display includes
states, fault counters, message counters, etc.
Procedure
1. Select Diagnosis & gt; Diagnostic monitor in the main menu.
2. Select a software module in the Module box.
Diagnostic data are displayed for the selected module.
12.5
Compressing data for error analysis at KUKA
Description
If it is necessary for an error to be analyzed by KUKA Roboter GmbH, this procedure can be used to compress the data for sending to KUKA. The procedure
generates a ZIP file in the directory C:\KUKA\KRCDiag. This contains the data
required by KUKA Roboter GmbH to analyze an error (including information
about system resources, screenshots, and much more.)
Procedure via
“Diagnosis”
Procedure via
smartPAD
This procedure uses keys on the smartPAD instead of menu items. It can thus
also be used if the smartHMI is not available, due to Windows problems for example.
In the main menu, select Diagnosis & gt; KrcDiag.
The data are compressed. Progress is displayed in a window. Once the
operation has been completed, this is also indicated in the window. The
window is then automatically hidden again.
Precondition:
The smartPAD is connected to the robot controller.
The robot controller is switched on.
The keys must be pressed within 2 seconds. Whether or not the main
menu and keypad are displayed in the smartHMI is irrelevant.
1. Press the “Main menu” key and hold it down.
2. Press the keypad key twice.
3. Release the “Main menu” key.
The data are compressed. Progress is displayed in a window. Once the
operation has been completed, this is also indicated in the window. The
window is then automatically hidden again.
Procedure via
“Archive”
Alternatively, the data can also be compressed via File & gt; Archive & gt; [...]. In this
way, the data can be stored on a USB stick or network path.
( & gt; & gt; & gt; 7.8 " Archiving and restoring data " Page 216)
362 / 391
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
13 Installation
13
Installation
The robot controller is supplied with a Windows operating system and an operational version of the KUKA System Software (KSS). Therefore, no installation is required during initial start-up.
Installation becomes necessary, for example, in the event of the hard drive being damaged and exchanged.
The robot controller may only be operated using the software provided with the controller by KUKA.
KUKA Roboter GmbH must be consulted if different software is to be
used. ( & gt; & gt; & gt; 15 " KUKA Service " Page 375)
13.1
Overview of the software components
Overview
The following software components are used:
13.2
KUKA System Software 8.2
Windows XPe V3.0.0
Installing Windows and KSS (from image)
Precondition
KUKA.USBSystem stick with an image of the robot controller
The stick can be purchased from KUKA Roboter GmbH.
1 GB RAM
The robot controller is switched off.
Only the KUKA.USBSystem stick can be used. Installation from a different stick is not possible.
Procedure
1. Connect the USB stick to the robot controller.
2. Switch on the robot controller. The Windows installation starts.
3. Disconnect the USB stick when all 6 LEDs on the CSP are permanently lit.
The robot controller restarts.
4. Select the desired language. Confirm with Next.
5. Information about the installation and copyright are displayed. Confirm
with Next.
6. Specifiy whether the robot controller is an Office PC. This is generally not
the case. (Office PC = PC for KUKA personnel for tests.) Confirm with
Next.
7. Only if a KSS version is already installed: It is possible to select whether
data are to be retained from the existing installation. Confirm with Next.
8. The system suggests a robot type. Confirm with Next.
Or: If the suggested type does not correspond to the type that is being
used, select a different type. Then confirm with Next.
If, under step 7, the data from an existing installation have been retained,
the system does not suggest a robot type, but retains the previous one.
9. A summary of the setup settings is displayed. Confirm with Next. The KSS
installation starts.
10. A prompt to enter a unique computer name is displayed. A unique name
is always suggested. The suggestion can be either accepted or altered.
Confirm with Run Now.
The robot controller restarts. When it has booted, installation is complete.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
Following installation or update of the KUKA System Software, the robot controller always performs an initial cold start.
13.3
Installing additional software
This function can be used to install additional software, e.g. technology packages. New programs and updates can be installed. The software is installed
from a USB stick. Alternatively, it can also be installed via a network path.
Use only a KUKA.USB data stick: if a different USB stick
is used, data may be lost or changed.
The system checks whether the additional software is relevant for the KSS. If
not, the system rejects the installation. If a software package that the system
has rejected is nonetheless to be installed, KUKA Roboter GmbH must be
contacted. ( & gt; & gt; & gt; 15 " KUKA Service " Page 375)
This function can also be used to uninstall additional software. Multiple additional programs can be installed or uninstalled one after the other.
This function is also used to select the path for a KSS update from the network.
This function cannot be used, however, to install the KSS update.
( & gt; & gt; & gt; 13.4 " KSS update " Page 365)
Precondition
Software on KUKA.USBData stick
No program is selected.
T1 or T2 operating mode
Procedure
“Expert” user group
1. Plug in USB stick.
2. Select Start-up & gt; Install additional software in the main menu.
3. Press New software. If a software package that is on the USB stick is not
yet displayed, press Refresh.
4. Select the software to be installed and press Install. Reply to the request
for confirmation with Yes. The files are copied onto the hard drive.
5. Repeat step 4 if another software package is to be installed from this stick.
6. Remove the USB stick when the LED on the stick is no longer lit.
7. It may be necessary to reboot the controller, depending on the additional
software. In this case, a corresponding prompt is displayed. Confirm with
OK and reboot the robot controller. Installation is resumed and completed.
Description
The following buttons are available:
Button
Description
New software
All programs available for installation are displayed.
Back
Additional software already installed is displayed.
Refresh
Refreshes the display, e.g. after a USB stick has
been connected.
Install
Displays additional buttons:
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Yes: The selected software is installed. If it is
necessary to reboot the controller, this is indicated by a message.
No: The software is not installed.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
13 Installation
Button
Description
Configuration
This button is only displayed if New software has
been pressed.
Paths for the installation of additional software or
KSS updates can be selected and saved here.
Displays additional buttons:
Uninstall
Browse: A new path can be selected.
Save: Saves the displayed paths.
Displays additional buttons:
13.4
Yes: The selected software is uninstalled.
No: The software is not uninstalled.
KSS update
Description
This function can be used to install KSS updates, e.g. from KSS 8.2.0 to KSS
8.2.1.
It is advisable to archive all relevant data before updating a software package.
If necessary, the old version can be restored in this way. It is also advisable to
archive the new version after carrying out the update.
This function cannot be used to install new versions, e.g. from KSS
8.1 to KSS 8.2. KUKA Roboter GmbH must be consulted before a
new version is installed.
( & gt; & gt; & gt; 15 " KUKA Service " Page 375)
This function cannot be used to install updates of additional software, such
as technology packages.
( & gt; & gt; & gt; 13.3 " Installing additional software " Page 364)
If machine data are reloaded after an update, the version
of the machine data must correspond exactly to the KSS
version. This is ensured if the machine data supplied together with the KSS
release are used.
The robot must not be moved if incorrect machine data are loaded. Personal
injuries or damage to property may result in this case.
Overview
There are 2 ways of installing a KSS update:
From KUKA.USBData stick
( & gt; & gt; & gt; 13.4.1 " Update from the KUKA USB stick " Page 365)
From the network
( & gt; & gt; & gt; 13.4.2 " Update from the network " Page 366)
Following installation or update of the KUKA System Software, the robot controller always performs an initial cold start.
13.4.1
Update from the KUKA USB stick
Use only a KUKA.USB data stick: if a different USB stick
is used, data may be lost or changed.
Precondition
Software on KUKA.USBData stick
The software must be copied onto the stick with the file Setup.exe at the
highest level (i.e. not in a folder).
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
Procedure
No program is selected.
T1 or T2 operating mode
1. Plug in USB stick.
2. In the main menu, select Start-up & gt; Software update & gt; Automatic.
3. A request for confirmation is displayed, asking if the update should be carried out. Confirm by pressing Yes.
4. A message is displayed, indicating that a cold start will be forced next time
the system is booted. Switch the controller off.
5. Wait until the computer has shut down completely.
6. Remove the USB stick when the LED on the stick is no longer lit.
7. Switch the controller back on
Once the update has been completed, the computer is automatically shut
down and rebooted.
13.4.2
Update from the network
Description
In the case of an update from the network, the installation data are copied from
the network to the local drive D:\. If there is already a copy of a system software version present on drive D:\, that copy will now be overwritten.
Installation is started on completion of the copying operation.
Precondition
For the preparation:
No program is selected.
T1 or T2 operating mode
“Expert” user group
For the procedure:
Preparation
No program is selected.
T1 or T2 operating mode
Configure the network path from which the update installation is to be carried
out:
1. Select Start-up & gt; Install additional software in the main menu.
2. Press New software.
3. Press Configuration.
4. Select the Installation path for KRC update via the network box. Press
Browse.
5. Select the desired network path. Press Save.
6. The selected path is displayed in the Installation path for KRC update
via the network box. Press Save.
7. Close the window.
It is only necessary to configure the network path once. It remains
saved for subsequent updates.
Procedure
1. In the main menu, select Start-up & gt; Software update & gt; Net.
2. A request for confirmation is displayed, asking if the update should be carried out. Confirm by pressing Yes.
Depending on the network utilization, the procedure may take up to
15 min.
3. A message is displayed, indicating that a cold start will be forced next time
the system is booted. Switch the controller off.
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Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
13 Installation
4. Wait until the computer has shut down completely. Then switch the controller back on.
5. Once the update has been completed, the computer is automatically shut
down and rebooted.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
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Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
14 Messages
14
Messages
14.1
Automatic External error messages
No.
Message text
Cause
P00:1
PGNO_TYPE incorrect value
permissible values (1,2,3)
The data type for the program
number was entered incorrectly.
P00:2
PGNO_LENGTH incorrect value
Range of values 1 ≤ PGNO_LENGTH ≤
16
The selected program number
length in bits was too high.
P00:3
PGNO_LENGTH incorrect value
permissible values (4,8,12,16)
If BCD format was selected for
reading the program number, a
corresponding number of bits must
also be set.
P00:4
PGNO_FBIT incorrect value
not in the $IN range
The value “0” or a non-existent
input was specified for the first bit
of the program number.
P00:7
PGNO_REQ incorrect value
not in the $OUT range
The value “0” or a non-existent
output was specified for the output
via which the program number is
to be requested.
P00:10
Transmission error
incorrect parity
Discrepancy detected when
checking parity. A transmission
error must have occurred.
P00:11
Transmission error
incorrect program number
The higher-level controller has
transferred a program number for
which there is no CASE branch in
the file CELL.SRC.
P00:12
Transmission error
incorrect BCD encoding
The attempt to read the program
number in BCD format led to an
invalid result.
P00:13
Incorrect operating mode
The I/O interface output has not
been activated, i.e. the system
variable $I_O_ACTCONF currently has the value FALSE. This
can have the following causes:
The mode selector switch is
not in the “Automatic External”
position.
The signal $I_O_ACT currently
has the value FALSE.
P00:14
Move to Home position in operating
mode T1
The robot has not reached the
HOME position.
P00:15
Incorrect program number
More than one input set with “1 of
n”.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
369 / 391
KUKA System Software 8.2
14.2
No.
27001
Brake test messages
Message
Brake X has reached the
wear limit
Description
Cause: The brake is worn. It will soon be identified as
defective. Until then, the robot can be moved without
restrictions.
Remedy:
27002
Cyclical check for brake
test request not made
Repeat the brake test for confirmation. If the same result is obtained, exchange the brake now and perform
a brake test again.
Or leave the message until the brake has been tested
as defective and then exchange the brake
Cause: The brake test has been requested. No brake
test was performed within 2 hours of the request.
Remedy:
27004
Brake test required
Integrate the program BrakeTestReq.SRC into the
application program in such a way that it is cyclically
called as a subprogram. If a brake test is requested,
the robot detects this and performs the brake test immediately.
Or acknowledge the motion enables and perform a
brake test.
Cause: The brake test cycle time has elapsed, the robot
controller has been rebooted or the brake test has been
requested externally.
Remedy: Perform brake test.
27007
Insufficient holding torque
of brake X
Cause: The brake for axis X is defective.
27009
Brake X OK
Cause: Brake X has been tested and is OK.
27010
Unable to verify performance of brake X
Cause: The start position of the brake test is not suitable
for testing the performance of the brake.
27011
Test of brake X not completed
Cause: The test was aborted, either by the operator or
due to a fault not attributable to the brake test.
Remedy: If no additional message is displayed for which
a different remedy is specified, exchange the brake and
perform a brake test again.
Remedy: Change the start position.
Remedy: Repeat the test.
27012
Brake test successful
Cause: No brake is defective. Message 27009 has been
displayed for all brakes.
It is possible that one or more brakes may have reached
the wear limit. This is also indicated by message 27001.
27017
Friction impedes verification of brake X
May be generated as an additional message with 27007
or 27023.
Cause: The brake cannot be tested due to friction.
Remedy: Warm up the robot and repeat the test.
27018
370 / 391
No application of brake X
observed
May be generated as an additional message with 27007.
Cause: The brake application time is significantly longer
than specified.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
14 Messages
No.
27019
Message
Full torque of brake X
could not be verified, but
holding torque is reached
Description
May be generated as an alternative to 27009.
Cause: Brake X has been tested and is OK. The braking
torque in the machine data is greater than the required
holding torque and cannot be verified due to the limited
power of the drive.
Remedy: No remedy required.
27020
Asynchronous axes prevent execution of brake
test
Cause: At least one axis has been switched to asynchronous mode with $ASYNC_AXIS or $EX_AXIS_ASYNC.
Remedy:
In the case of $EX_AX_ASYNC, exclude the axis
from the test.
In the case of $ASYNC_AXIS, the cyclical call of the
brake test must be shifted to a point at which all axes
are switched to synchronous mode.
27021
Simulated axes prevent
execution of brake test
Cause: At least one axis has been switched to simulation
with $SIMULATED_AXIS.
27022
T1 mode prevents brake
test execution
Cause: The test cannot be executed with the required
velocity.
Remedy: Deactivate axis simulation.
Remedy: Change operating mode.
27023
Automatic safety factor
reduction for brake X
Cause:
The start position of the brake test is not suitable for
early detection of brake wear.
Or unfavorable ratio between braking torque and rated motor torque.
Effect: Worn brakes may be detected later than usual.
Remedy:
---
Maximum motion of axis X
exceeded
If worn brakes are to be detected as early as possible,
change the start position of the test.
If it is not relevant whether or not worn brakes are detected as early as possible, no remedy is required.
Cause: During the brake test, the robot exceeded the
maximum motion range of axis X.
Remedy: Contact KUKA Roboter GmbH.
---
If you trigger a safety function (E-Stop, operating
mode change, opening the
safety gate) that causes
the drives to be switched
off, the robot may sag.
Select strategy.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Cause: One or more brakes have been detected as
defective.
Remedy:
Press Repeat to repeat the brake test.
Press Park pos. to move the robot to the parking position.
371 / 391
KUKA System Software 8.2
No.
---
Message
Performing manual brake
test - please acknowledge
Description
Cause: The program BrakeTestReq.SRC has been
started manually. It must be confirmed that the test is to
be performed.
Remedy: Confirm the message by pressing Ackn.. Press
the Start key to resume the program and perform the test.
---
Performing self-test for
brake test - please
acknowledge
Cause: The program BrakeTestSelfTest.SRC has been
started. It must be confirmed that the test is to be performed.
Remedy: Confirm the message by pressing Ackn.. Press
the Start key to resume the program and perform the test.
14.3
Error messages of the positionally accurate robot model
No.
Message
Description
272
No robot number programmed
Cause: The file ROBOTINFO.XML is missing on the RDC,
e.g. after exchange of the RDC memory chip.
Remedy: Create the file ROBOTINFO.XML on the RDC
again.
276
Wrong machine data for
this robot type
Cause: The machine data loaded in the robot controller do
not correspond to the robot type. The robot must not be
moved.
Remedy: Load the correct machine data.
384
Not enough memory: Cannot load precision robot
model
Cause: It was not possible to create the positionally accurate robot model due to insufficient memory capacity. Positioning accuracy is not possible.
417
Absolute accuracy model
not active
Cause: The positionally accurate robot model was deactivated.
Remedy: Increase the memory capacity.
Remedy: Contact KUKA Roboter GmbH. ( & gt; & gt; & gt; 15 " KUKA
Service " Page 375)
1446
Value assignment inadmissible
Cause:
A system variable was assigned an inadmissible value, e.g. $SPEED.ORI1 ≤0.0 or & gt; $SPEED_MA.ORI1.
An inadmissible value was assigned to $BASE or
$TOOL.
Remedy: Check the system variables and assign a correct value. Acknowledge the message.
2972
Checksum error File %1
Cause: Error in the file indicated: The parameters are not
applied.
2973
Precision Robot Model Parameterfile wrong Serialnumber
Cause: The XPid file PREC_ROBXXXXXXXXXX.XML
contains a serial number that does not match the robot.
The positionally accurate robot model cannot be initialized.
Remedy: Install the correct file.
Remedy:
372 / 391
Use the correct XPid file.
Use the correct serial number.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
14 Messages
No.
Message
Description
2974
Precision robot: Model parameter not consistent with
machine data
Cause: The machine data have been modified. The positionally accurate robot model cannot be initialized.
Error loading high precision
model. Reason code
0x1011
Cause: The positionally accurate robot model could not
be loaded during the update because the robot moved.
Error loading high precision
model. Reason code
0x1012
Cause: The positionally accurate robot model could not
be accepted during loading because the robot moved.
Error loading high precision
model. Reason code
0x1013
Cause: The positionally accurate robot model could not
be accepted because it was not possible to allocate the
memory.
3047
Remedy: Recalibrate the robot with KUKA.XROB RCS.
Remedy: Stop the robot and repeat the update.
Remedy: Stop the robot and load the model.
Remedy: Reboot the robot controller with a cold restart
and load the model.
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
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Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
15 KUKA Service
15
KUKA Service
15.1
Requesting support
Introduction
The KUKA Roboter GmbH documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please contact your local KUKA subsidiary.
Information
The following information is required for processing a support request:
Model and serial number of the robot
Model and serial number of the controller
Model and serial number of the linear unit (if applicable)
Version of the KUKA System Software
Optional software or modifications
Archive of the software
For KUKA System Software V8: instead of a conventional archive, generate the special data package for fault analysis (via KrcDiag).
Any external axes used
15.2
Application used
Description of the problem, duration and frequency of the fault
KUKA Customer Support
Availability
KUKA Customer Support is available in many countries. Please do not hesitate to contact us if you have any questions.
Argentina
Ruben Costantini S.A. (Agency)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com
Australia
Headland Machinery Pty. Ltd.
Victoria (Head Office & Showroom)
95 Highbury Road
Burwood
Victoria 31 25
Australia
Tel. +61 3 9244-3500
Fax +61 3 9244-3501
vic@headland.com.au
www.headland.com.au
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
Belgium
Brazil
KUKA Roboter do Brasil Ltda.
Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guançã
CEP 02151 900 São Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
info@kuka-roboter.com.br
Chile
Robotec S.A. (Agency)
Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl
China
KUKA Automation Equipment (Shanghai) Co., Ltd.
Songjiang Industrial Zone
No. 388 Minshen Road
201612 Shanghai
China
Tel. +86 21 6787-1808
Fax +86 21 6787-1805
info@kuka-sha.com.cn
www.kuka.cn
Germany
376 / 391
KUKA Automatisering + Robots N.V.
Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be
KUKA Roboter GmbH
Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
info@kuka-roboter.de
www.kuka-roboter.de
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
15 KUKA Service
France
KUKA Automatisme + Robotique SAS
Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
commercial@kuka.fr
www.kuka.fr
India
KUKA Robotics India Pvt. Ltd.
Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
info@kuka.in
www.kuka.in
Italy
KUKA Roboter Italia S.p.A.
Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it
Japan
KUKA Robotics Japan K.K.
Daiba Garden City Building 1F
2-3-5 Daiba, Minato-ku
Tokyo
135-0091
Japan
Tel. +81 3 6380-7311
Fax +81 3 6380-7312
info@kuka.co.jp
Korea
KUKA Robotics Korea Co. Ltd.
RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
info@kukakorea.com
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
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KUKA System Software 8.2
Malaysia
Mexico
KUKA de Mexico S. de R.L. de C.V.
Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
Norway
KUKA Sveiseanlegg + Roboter
Bryggeveien 9
2821 Gjövik
Norway
Tel. +47 61 133422
Fax +47 61 186200
geir.ulsrud@kuka.no
Austria
KUKA Roboter Austria GmbH
Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
office@kuka-roboter.at
www.kuka-roboter.at
Poland
378 / 391
KUKA Robot Automation Sdn Bhd
South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
info@kuka.com.my
KUKA Roboter Austria GmbH
Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
ServicePL@kuka-roboter.de
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
15 KUKA Service
Portugal
KUKA Sistemas de Automatización S.A.
Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
kuka@mail.telepac.pt
Russia
OOO KUKA Robotics Rus
Webnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
kuka-robotics.ru
Sweden
KUKA Svetsanläggningar + Robotar AB
A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se
Switzerland
KUKA Roboter Schweiz AG
Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch
Spain
KUKA Robots IBÉRICA, S.A.
Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
Fax +34 93 8142-950
Comercial@kuka-e.com
www.kuka-e.com
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
379 / 391
KUKA System Software 8.2
South Africa
Taiwan
KUKA Robot Automation Taiwan Co., Ltd.
No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
info@kuka.com.tw
www.kuka.com.tw
Thailand
KUKA Robot Automation (M)SdnBhd
Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
atika@ji-net.com
www.kuka-roboter.de
Czech Republic
KUKA Roboter Austria GmbH
Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Počernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
support@kuka.cz
Hungary
380 / 391
Jendamark Automation LTD (Agency)
76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za
KUKA Robotics Hungaria Kft.
Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
15 KUKA Service
USA
KUKA Robotics Corp.
22500 Key Drive
Clinton Township
48036
Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
info@kukarobotics.com
www.kukarobotics.com
UK
KUKA Automation + Robotics
Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
sales@kuka.co.uk
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
381 / 391
KUKA System Software 8.2
382 / 391
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Index
Index
Symbols
_TYP 295
_TYPE 296
#BSTEP 208
#CSTEP 208
#IGNORE 240
#ISTEP 208
#MSTEP 208
#PSTEP 208
$ 290
$ACCU_STATE 80
$ADAP_ACC 152, 157
$ADVANCE 208
$ANIN 275
$ANOUT 275
$BRAKE_SIG 181
$BRAKES_OK 195
$BRAKETEST_MONTIME 195
$BRAKETEST_REQ_EX 195
$BRAKETEST_REQ_INT 195
$BRAKETEST_WARN 195
$BRAKETEST_WORK 195
$CIRC_MODE 242, 308
$CIRC_TYPE 241
$COLL_ALARM 153
$COLL_ENABLE 153
$COOLDOWN_TIME 151
$HOLDING_TORQUE 183
$IN 275
$LDC_CONFIG 129
$LDC_LOADED 128
$LDC_RESULT 129
$ORI_TYPE 226, 239
$OUT 275
$PAL_MODE 87
$PATHTIME 313
$PRO_IP 360
$PRO_MODE 208
$ROBRUNTIME 78, 79
$SPL_VEL_MODE 304, 313
$SPL_VEL_RESTR 314
$TOOL_DIRECTION 102
$TORQ_DIFF 153, 157
$TORQ_DIFF2 153
$TORQMON_COM_DEF 153
$TORQMON_DEF 153
$TORQMON_TIME 153, 157
$TORQUE_AXIS_ACT 181, 183
$TORQUE_AXIS_LIMITS 182
$TORQUE_AXIS_MAX 182
$TORQUE_AXIS_MAX_0 182
$WARMUP_CURR_LIMIT 151
$WARMUP_MIN_FAC 151
$WARMUP_RED_VEL 151
$WARMUP_SLEW_RATE 151
$WARMUP_TIME 151
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Numbers
2004/108/EC 39
2006/42/EC 39
3-point method 110
89/336/EEC 39
95/16/EC 39
97/23/EC 39
A
ABC 2-point method 107
ABC World method 107
Accessories 15, 17
Actual position 67
Administrator 53
Advance run 208
Advance run stop 314
Analog inputs 321
Analog outputs 322
ANIN 321
ANOUT 276, 322
Applied norms and regulations 39
Approximate positioning 224, 256
Archiving overview 216
Archiving, logbook 218
Archiving, network 218
Archiving, to USB stick 217
Areas of validity 292
AUT and EXT Consistency 189
AUT and EXT consistency 189
Automatic External error messages 369
Automatic mode 35
Auxiliary point 224, 302, 303
Axis range 19
Axis range limitation 27
Axis range monitoring 28
B
Backward motion 211
Base calibration 109
BASE coordinate system 54, 109
Battery state 80
Block pointer 203
Block selection 211, 232
BRAKE 328
Brake defect 30
Brake test 191
Brake test cycle time 192
Brake test, function test 197
Brake test, messages 370
Brake test, programs 192
Brake test, signals 193, 194
Brake test, teaching positions 195
Brake, defective 196
BrakeTestBack.SRC 193, 196
BrakeTestPark.SRC 192, 196
BrakeTestReq.SRC 192, 197
BrakeTestSelfTest.SRC 193, 198
BrakeTestStart.SRC 193, 196
383 / 391
KUKA System Software 8.2
Braking distance 19
Branch, conditional 316
C
Calibrating an external kinematic system 120
Calibration 102
Calibration points (menu item) 77
Calibration tolerances, defining 158
Calibration, base 109
Calibration, external TCP 113
Calibration, fixed tool 112
Calibration, linear unit 118
Calibration, root point, kinematic system 120
Calibration, tool 102
Calibration, TOOL kinematic system 124
Calibration, workpiece 112
Caller stack 360
Caller stack (menu item) 360
CASE 318
CAST_FROM 343
CAST_TO 343
CCLOSE 343
CE mark 18
CELL.SRC 212
CHANNEL 343
CIOCTL 343
CIRC 302
CIRC motion 253
CIRC_REL 303
CIRC, motion type 224
Circular angle 261, 266, 302, 304
Circular motion 302, 303
Cleaning work 36
Close all FOLDs (menu item) 207
Cold start 52
Cold start, initial 49, 51, 52, 364, 365
Collision detection 151, 153
Collision detection (menu item) 153, 154
Collision detection, Automatic External 155
Collision detection, offset 154
Collision detection, system variables 152
Collision detection, variable 155
Comment 213
Comparison, data from kernel system and hard
drive 188
Conditional branch 316
Configuration 133
Configuration (menu item) 142
Configuring CELL.SRC 159
Connecting cables 15, 17
Connection manager 42
Constants 293
CONTINUE 314
Continuous Path 223
Coordinate system for jog keys 46
Coordinate system for Space Mouse 45
Coordinate systems 54
Coordinate systems, angles 55
Coordinate systems, orientation 55
COPEN 343
Copy 215
384 / 391
Counterbalancing system 36
Counters, displaying 75
CP motions 223
CREAD 343
Creating a new folder 200
Creating a new program 201
Cut 215
CWRITE 343
D
Danger zone 19
DAT 289
Data list 289
Data types 291
Data, restoring 219
DECL 293
Declaration of conformity 18
Declaration of incorporation 17, 18
Decommissioning 37
DEF line (menu item) 205
DEF line, displaying/hiding 205
DEFAULT 318
Deleting mastering 99
Description, signal declarations 194
Deselecting a program 202
Detail view (ASCII) (menu item) 206
Detail view, activating 205
Diagnosis 357
Diagnostic monitor (menu item) 362
Dial gauge 97
Directory structure 199
Display (menu item) 72
Displaying a variable, single 70, 71
Displaying the logbook 357
Displaying variables, in overview 72
Displaying, robot controller information 78
Displaying, robot information 78
Disposal 37
DISTANCE 333
DNS, configuring 138
Documentation, industrial robot 13
Drive bus 51
E
EC declaration of conformity 18
Edit (button) 46
Editing a program 212
Editor 201
Electronic Mastering Device 92
ELSE 316
EMC Directive 18, 39
EMD 92
EMERGENCY STOP 42
EMERGENCY STOP button 25, 32
EMERGENCY STOP device 25, 30
EMERGENCY STOP, external 25, 32
EMERGENCY STOP, local 32
EN 60204-1 39
EN 61000-6-2 39
EN 61000-6-4 39
EN 614-1 39
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Index
EN ISO 10218-1 39
EN ISO 12100-1 39
EN ISO 12100-2 39
EN ISO 13849-1 39
EN ISO 13849-2 39
EN ISO 13850 39
Enabling device 26, 30
Enabling device, external 26
Enabling switch 43
Enabling switches 26
ENDFOR 315
ENDIF 316
Endless loop 317
ENDLOOP 317
ENDSPLINE 305
ENDSWITCH 318
ENDWHILE 320
ENUM 295
Enumeration type 295
error messages, Automatic External 369
Error messages, positionally accurate robot 372
Event planner (menu item) 188
EXIT 314, 317
Exiting, KSS 49
External axes 17, 20, 67, 78
External kinematic system, calibration 120
F
F 328
FALSE 327
Faults 31
File list 199
File, renaming 201
Filter 200
Find 216
First mastering 92
Fixed tool, calibration 112
Flags, displaying 73, 74
FLANGE coordinate system 55, 103
Folder, creating 200
Folds 206
Folds, creating 214
Folds, displaying 206
Fonts 288
FOR 319
FOR ... TO ... ENDFOR 315
Function test 32
Functions 289
G
General safety measures 30
Global 292
GLOBAL (interrupt declaration) 329
GOTO 315
Guard interlock 24
H
HALT 316
Hardware, options 84
Hazardous substances 37
Header 199
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Hibernate 52
Higher motion profile 304
HOME position 205
HOV 60
I
I/O driver, reconfiguring 141
I/Os, reconfiguring 141
Identification plate 43
IF ... THEN ... ENDIF 316
Impact 153, 154
Increment 65
Incremental jogging 65
Indirect method 111
Industrial robot 15, 17
Info (menu item) 78
Inline forms 251
Inputs/outputs, analog 69, 275
Inputs/outputs, Automatic External 69, 160
Inputs/outputs, digital 67, 274
Installation 363
Intended use 17
INTERN.ZIP 217, 218
Interpolation mode 255, 264
INTERRUPT 329, 330
Interrupt 328
Interrupt program 329
Interrupts 361
Introduction 13
IP addresses 133
J
Jerk 259, 261, 264, 267
Jerk limitation 259, 261, 264, 267
Jog keys 42, 56, 61
Jog mode 27, 30
Jog mode “Jog keys” 58
Jog mode “Space Mouse” 58
Jog mode, activating 60
Jog override 60
Jogging, axis-specific 55, 61
Jogging, Cartesian 55, 61, 64
Jogging, external axes 66
Jogging, robot 55
Jump 315
K
KCP 19, 30, 41
Keyboard 42
Keyboard key 42
Keyboard, external 31
Keypad 47
Keywords 290
Kinematics group 46, 58
KLI, configuring 133
KRL syntax 287
KUKA Control Panel 41
KUKA Customer Support 78, 375
KUKA Line Interface, configuring 133
KUKA smartHMI 45
KUKA smartPAD 19, 41
385 / 391
KUKA System Software 8.2
KUKA.Load 126
KUKA.LoadDataDetermination 126
L
Labeling 29
Language 52
Liability 17
LIN 299
LIN motion 252
LIN_REL 300
LIN, motion type 223
Line break (menu item) 206
Linear motion 299, 300
Linear unit 17, 117
Load data 126
Logbook 357
Logbook, configuring 359
Logic Consistency 190
Logic consistency 189
LOOP ... ENDLOOP 317
Loss of mastering 92, 96
Low Voltage Directive 18
M
Machine data 33, 78, 79, 83, 88, 365
Machine data, copying 88
Machinery Directive 18, 39
Main menu, calling 48
Maintenance 35, 129
Manipulator 15, 17, 19, 22
Manual mode 34
Mastering 89
Mastering after maintenance work 98
Mastering marks 91
Mastering methods 90
Mechanical axis range limitation 27
Mechanical end stops 27
Messages 369
Messages, brake test 370
Minimizing smartHMI 48
Mode selection 23, 24
Modifying a logic instruction 286
Modifying a variable 70
Modifying coordinates 274
Modifying motion parameters 274
Modifying variables 72
Module 289
Monitoring, velocity 27
Motion profile, conventional 304
Motion programming, basic principles 223
Motion types 223
Motor, exchange 99
Mouse, external 31
N
Name, archive 79
Name, control PC 78
Name, robot 78, 79
Names 290
Navigator 199
Non-rejecting loop 317
386 / 391
Numeric entry, external TCP 114
Numeric entry, external tool 125
Numeric entry, linear unit 119
Numeric entry, root point, kinematic system 122
Numeric input, base 112
Numeric input, tool 109
O
Offset 92, 95, 277
OLDC 127
Online load data check 127
Online optimizing 189, 191
Open all FOLDs (menu item) 207
Opening a program 201
Operating hours 79
Operating hours meter 79
Operating mode, changing 53
Operation 41
Operator 19, 21, 52
Operator safety 23, 24, 30
Operator safety acknowledgement 85
Options 15, 17
Orientation control 256
Orientation control (spline) 262, 265, 268
Orientation control, LIN, CIRC 226
Orientation control, SPLINE 239
OUT 275
Output, analog 276
Output, digital 275
Overload 30
Override 60, 209
Override (menu item) 67
Overview of the industrial robot 15
P
Palletizing robots 87, 104, 109
Panic position 26
Password, changing 143
Paste 215
PATH 336, 339
Payload data 126
Payload data (menu item) 127
Performance Level 23
Performing a manual brake test 196
Peripheral contactor 85
Personnel 20
Pinning 219, 222
Plant integrator 20
PLC_ROB_STOP_RELEASE() 345
PLC_ROB_STOP() 345
Point-to-point 223
Point-to-point motion 297, 298
Positionally accurate robot, checking activation
87
Positionally accurate robot, error messages 372
Positioner 17, 120
POV 209
Pre-mastering position 91
Pressure Equipment Directive 36, 39
Preventive maintenance work 36
Printing a program 216
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Index
Priority 329, 335, 338, 340
Product description 15
PROFINET interface 134
Program lines, deleting 214
Program management 199
Program override 209
Program run mode, selecting 207
Program run modes 208
Program, closing 203
Program, creating 201
Program, deselecting 202
Program, opening 201
Program, selecting 201
Program, starting 210
Program, stopping 210, 212
Programmer 53
Programming, Expert 287
Programming, inline forms 251
Programming, KRL syntax 287
Programming, User 251
Project management (window) 221
Protective equipment 27
PTP 297
PTP motion 251
PTP_REL 298
PTP, motion type 223
PULSE 276, 323
Pulse 276, 323
Pulse, path-related 285
R
Rating plate 83
RDC, exchange 99
Reaction distance 19
Recommissioning 32, 83
Reference mastering 98
Rejecting loop 320
Release device 28
Renaming a file 201
Renaming the base 117
Renaming the tool 117
Repair 35
REPEAT ... UNTIL 317
Replace 216
Resetting a program 211
RESUME 332
RETURN 327
ROB_STOP_RELEASE() 345
ROB_STOP() 345
Robot controller 15, 17
Robot data (menu item) 78
ROBROOT coordinate system 54
S
Safe operational stop 19, 26
Safeguards, external 29
Safety 17
Safety controller 23
Safety functions 30
Safety functions, overview 23
Safety instructions 13
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Safety STOP 0 19
Safety STOP 1 19
Safety STOP 2 19
Safety STOP 0 19
Safety STOP 1 19
Safety STOP 2 19
Safety stop, external 26, 27
Safety zone 19, 21, 22
Safety, general 17
SCIRC 307
SCIRC motion, programming 260
SCIRC segment, programming 265
SEC 320
Selecting a program 201
Selecting the base 60
Selecting the tool 60
Serial number 79
Service life 78
Service, KUKA Roboter 375
SET_TORQUE_LIMITS 177, 180
Shutdown (menu item) 49
SIGNAL 326
Signal diagrams 168
Signals, brake test 194
Signals,brake test 193
Simulation 35
Single (menu item) 70, 71, 157
Single point of control 37
Singularities 248
SLIN 306
SLIN motion, programming 258
SLIN segment, programming 265
smartHMI 16, 45
smartPAD 19, 41
Soft axes 174
Software 15, 17
Software components 15, 363
Software limit switches 27, 30, 99
Software limit switches, modifying 100
Space Mouse 42, 56, 61, 63, 64
Special characters 251
SPL 309
SPL segment, programming 265
SPLINE 339
SPLINE ... ENDSPLINE 305
Spline block, programming 262
Spline motion, orientation control 262, 265, 268
Spline, motion type 229
SPOC 37
SPS.SUB, modifying 353
SRC 289
SREAD 343
Stamp 213
Start backwards key 42
Start key 42, 43
Start type, KSS 49
Start types 52
Start-up 32, 83
Start-up mode 33
Start-up wizard 83
Starting a program, automatic 210
387 / 391
KUKA System Software 8.2
Starting a program, backwards 211
Starting a program, manual 210
Starting Automatic External mode 212
Starting the KSS 48
Status 244
Status bar 45, 46, 199
Status keys 42
STEP 315
STOP 0 18, 20
STOP 1 18, 20
STOP 2 18, 20
Stop category 0 20
Stop category 1 20
Stop category 2 20
STOP key 42
Stop reactions 22
Stopping a program 210, 212
Stopping distance 19, 22
Stopping the robot 328, 345
Storage 37
Storage capacities 78
String variable length after initialization 346
String variable length in the declaration 346
String variable, deleting contents 347
String variables 346
String variables, comparing contents 349
String variables, copying 349
String variables, extending 347
String variables, searching 348
STRUC 296
Structure type 296
Submit interpreter 47, 351
Submit interpreter, modifying SPS.SUB 353
Submit interpreter, starting 352
Submit interpreter, stopping 352
Subprograms 289
Supplementary load data (menu item) 127
Support request 375
SWITCH ... CASE ... ENDSWITCH 318
Switching action, path-related 280
Switching on the robot controller 48
SWRITE 343
Symbols 288
SYN OUT 280
SYN PULSE 285
System integrator 18, 20
T
T1 20
T1 and T2 Consistency 189
T1 and T2 consistency 189
T2 20
TCP 102
TCP, external 112
Teach pendant 15, 17
Teaching 274
Technology packages 16, 78, 251
Terms used, safety 18
Time block 309
TIME_BLOCK 309
Timers, displaying 76
388 / 391
tm_useraction 152
TMx 155
Tool calibration 102
Tool Center Point 102
TOOL coordinate system 54, 102
Tool direction 102
Tool, external 124
Torque 153, 154
Torque mode, diagnosis 181
Torque mode, examples 176, 184
Torque mode, overview 174
Torque monitoring 156
Torque monitoring (menu item) 157
Touch screen 41, 47
Trademarks 14
Training 13
Transport position 31
Transportation 31
TRIGGER 333, 336
TRIGGER, for spline 268, 339
Turn 244
Turn-tilt table 17, 120
Type, robot 78
Type, robot controller 78
U
Unmastering 99
UNTIL 317
Update 365
USB connection 43
Use, contrary to intended use 17
Use, improper 17
User 19, 20
User group, changing 52
User group, default 52
User interface 45
V
Variable overview, configuring 142
VARSTATE() 71, 343
Velocity 60, 209
Velocity monitoring 27
Version, kernel system 78
Version, operating system 78
Version, robot controller 78
Version, user interface 78
Voltage 69, 275, 277
W
WAIT 278, 319, 320
WAIT FOR 319
Wait function, signal-dependent 278
WAIT SEC 320
Wait time 278, 320
WAITFOR 278
Warm-up 149
Warnings 13
WHILE ... ENDWHILE 320
Windows interface 133, 134
Working range limitation 27
Workpiece base calibration 122
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
Index
Workpiece base, numeric entry 124
Workspace 19, 21, 22
Workspace monitoring, bypassing 66
Workspaces, axis-specific 143
Workspaces, Cartesian 143
Workspaces, cubic 143
Workspaces, mode 148
WORLD coordinate system 54
Wrist root point 149
X
XYZ 4-point method 104
XYZ Reference method 106
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
389 / 391
KUKA System Software 8.2
390 / 391
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
KUKA System Software 8.2
Issued: 02.11.2011 Version: KSS 8.2 SI V3 en
391 / 391