Kuka Krc2 Workbook

SOFTWARE

KR C2 Seminar workbook of …………………

Basic Robot Programming Release 4.1

© Copyright

KUKA Roboter GmbH

This documentation or excerpts therefrommay not be reproduced or disclosed to third parties without the express permission of the publishers. Other functions not described in this documentation may be operable in the controller. The user has no claim 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 subsequent editions. Subject to technical alterations without an effect on the function.

handout GP KR C2 V4.1 01.03.01

1. 2. 3.

Contents and goals of this course ................................................................... 5 Safety.................................................................................................................. 7 The robot system............................................................................................. 27 3.1. Basics at the robot system ...................................................................... 27 3.2. System overview..................................................................................... 35 3.3. Energy supply ......................................................................................... 41 4. Operation of the KUKA control panel (KCP) ................................................. 45 5. The coordinate systems at the robot ............................................................. 57 5.1. The axis coordinat system ...................................................................... 59 5.2. The world coordinate system .................................................................. 61 5.3. The tool coordinate system ..................................................................... 65 5.4. The base coordinate system ................................................................... 67 6. Stop reactions of the robot ............................................................................. 69 7. Mastering.......................................................................................................... 73 8. Tool calibration ................................................................................................ 79 8.1. The calculation of the TCP's ................................................................... 79 8.1.1. 8.1.2.

8.2. 8.2.1. 8.2.2. 8.2.3.

The X Y Z - 4 Point method ......................................................................................... 83 The XYZ-reference method ......................................................................................... 85

Orientation calibration ............................................................................. 87 The ABC-world 5D method.......................................................................................... 87 The ABC-world 6D method.......................................................................................... 89 The ABC-2 point method ............................................................................................. 91

8.3. Tool - payload ......................................................................................... 95 9. Base calibration ............................................................................................... 97 10. Motions programming at the robot .............................................................. 103 10.1. PTP – motion ........................................................................................ 105 10.2. LIN – motion.......................................................................................... 109 10.3. CIRC – motion ...................................................................................... 113 10.4. Approximation of motion ....................................................................... 117 11. The navigator (program production)............................................................ 121 12. Logic programming ....................................................................................... 129 13. Gripper Tech H50........................................................................................... 139 13.1. Gripper typ 1 ......................................................................................... 145 13.2. Gripper typ 2 ......................................................................................... 149 13.3. Gripper typ 3 ......................................................................................... 151 13.4. Gripper typ 4 ......................................................................................... 153 13.5. Gripper typ 5 ......................................................................................... 155 14. Fixed tool calibration..................................................................................... 157 15. Programming with subprograms ................................................................. 165 16. The expert level.............................................................................................. 167 17. Loops and branches in programs ................................................................ 171 18. Automatik external ........................................................................................ 177 18.1. Programnumber typ 1 ........................................................................... 189 18.2. Programnumber typ 2 ........................................................................... 191 18.3. Programnumber typ 3 ........................................................................... 193 18.4. Inputs .................................................................................................... 195 19. Excercises...................................................................................................... 202


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1. Contents and goals of this course


Page 5 of 227

Seminar goal

Basic Robot Programming Controller Type KR C2 The Basic Robot Programming seminar is aimed at the programming personnel for KUKA industrial robots. This seminar provides training with regard to • the proper and safety-conscious operation of a robot in a production environment, • the modification and maintenance of robot application programs, • and the creation of linear application programs.

KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-40 00, Fax: +49 (0) 8 21/7 97-16 16, http://www.kuka-roboter.de I 16.08.00 I College I ML I 1

Topics covered

Basic Robot Programming Controller Type KR C2 • Safety requirements for programmers • Components of the robot system • Operation of the robot system (start-up, shut-down, manual motion, program selection, automatic program execution) • Commissioning the robot system (mastering, tool calibration) • Creation of simple application programs (programming of motion instructions and predefined application technology instructions) • Integration of application programs into the production process (interface between equipment controller (PLC) and robot controller) • Archiving and maintenance of production programs

KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-40 00, Fax: +49 (0) 8 21/7 97-16 16, http://www.kuka-roboter.de I 16.08.00 I College I ML I 2

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2. Safety


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Safety

Safety regulations for working with industrial robots

KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de (c) Copyright by KUKA Roboter GmbH College 1996-2002

I 14.03.02 I College I ML I 1

Liability

• The robot system is built using state-of-the-art technology and in accordance with the recognized safety rules. Nevertheless, improper use of the robot system or its employment for a purpose other than the intended one may cause danger to life and limb or damage to material property.

The robot is always stronger than you! • The robot system may only be used in technically perfect condition in accordance with its designated use and only by safety-conscious persons who are fully aware of the risks involved in its operation. Any functional disorders affecting the safety of the linear unit must be rectified immediately. • The robot system is designed to comply with the EC Machinery Directive and associated standards. These include, for example, EN 775, the European norm for the safety of industrial robots.


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Designated use

• The robot system is designed exclusively for the specified applications. Applications for the KR 125/2 include: – Spot welding – Handling – Assembly – Application of adhesives, sealants and preservatives – Machining – MIG/MAG welding – YAG laser beam welding Using the robot system for any other or additional purpose is considered contrary to its designated use. The manufacturer cannot be held liable for any damage resulting from such use. The risk lies entirely with the user. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de (c) Copyright by KUKA Roboter GmbH College 1996-2002


Safety symbols

This symbol is used where failure to fully and accurately observe operating instructions, work instructions, prescribed sequences and the like could result in injury or a fatal accident.

This symbol is used where failure to fully and accurately observe operating instructions, work instructions, prescribed sequences and the like could result in damage to the robot system.

This symbol is used to draw attention to a particular feature. Observance of the note will generally result in facilitation of the work concerned.




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General safety regulations

• Improper use of the robot system or its employment for a purpose other than the intended one may cause – danger to life and limb – danger to the robot system and other assets of the user and – danger to the efficient working of the robot system or its operator.




• Every person involved with the robot system must have read and understood these operating instructions, particularly the “Safety” chapter, paying special attention to the passages marked with the warning symbol .

• Installation, exchange, adjustment, operation, maintenance and repair must be performed only as specified in these operating instructions and only by personnel specially trained for this purpose.


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• The responsibilities involved in operation of the robot system and in all other work performed on the robot system or in its immediate vicinity must be clearly defined and observed by the user in order to prevent any uncertainty regarding spheres of competence in matters of safety. • The user and operating personnel must ensure that only authorized personnel are permitted to work on the robot system. • The user must clearly set out what the responsibilities of operating personnel actually entail and give them the authority to refuse to carry out instructions from third parties which are contrary to safety procedures.




• The danger zones of the robot system must be safeguarded to prevent persons or objects from entering these zones. This safety facility is the responsibility of the user. • The switching times of the EMERGENCY STOP system must be taken into account when determining the size of the danger zones.




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Particular safety regulations for the user and the operating personnel

• The robot system must be switched off before maintenance work, i.e. the main switch on the control cabinet must be turned to “OFF”. • Secure it with a padlock to prevent unauthorized persons from switching it on again. • De-energize power supply lead and disconnect X1. • Before exchanging the power unit (power module), wait at least 5 minutes. • Work on the electrical equipment of the robot system may only be carried out by a skilled electrician. • Skin contact with grease is to be avoided.




• The operating personnel are obliged to inform the user immediately of any changes to the robot system which impair its safety. • The user must ensure that the robot system is only ever operated in faultless condition. • No functional safety equipment may be dismantled or taken out of operation.


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• When work is carried out in the danger zone of the robot, the latter may only, if absolutely essential, be operated at manual traversing speed at the most. • All persons situated in the environment of the robot must be informed in good time that the robot is about to move. • Wherever possible, only one person should work in the danger zone of the robot at any time.




• In sensor-assisted operation, the robot is liable to perform unexpected movements and path corrections if the main switch on the control cabinet has not been turned to “OFF”. • Due regard must be paid to hazards posed by the peripheral system components of the robot such as grippers, conveyors, feed devices or other robots in a multi-robot system. • Any unauthorized conversion or modification of the robot system is not allowed.




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Singularities of a 6-axis robot

• Singularities are points through which the robot cannot be moved using Cartesian traversing. In the immediate vicinity of these points, the affected axes are subjected to extreme acceleration. This results in the robot motion being stopped by the controller and the generation of an error message.

Alpha 5

Extended position



Safety features of the robot system: working space limitation

• The means of limiting the working space of the robot comprise:

– adjustable software limit switches for all axes and – for some axes mechanical limit stops with a buffer function, – working range monitoring by means of workspaces ($WORKSPACE), – which as the working range limitation accessory are also adjustable.


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• Example: software limit switches for axis 1

$SOFTN_END[1] = -185° Axis designation

$SOFTP_END[1] = 185°




• Examples: working range limitation on the KR 125

Axis 1

Axis 3

Axis 2




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Safety features of the robot system: counterbalancing system

• Some robot types are equipped with a hydropneumatic or mechanical counterbalancing system. • Work on the hydropneumatic counterbalancing system may only be carried out by persons having special knowledge and experience of hydraulic and pneumatic systems. • If work is to be carried out on the counterbalancing systems, the parts of the robot assisted by these systems must be secured so that they are unable to move. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de (c) Copyright by KUKA Roboter GmbH College 1996-2002


Safety features of the robot system: temperature monitoring

• The motors are protected against overload by means of temperature sensors in the motor windings.

• The motors reach temperatures during operation which can cause burns to the skin. Appropriate safety precautions must be taken. • The temperatures inside the control cabinet (internal temperature) are monitored. The controller is switched off if defined limits are exceeded.


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Safety features of the robot system: enabling switches

• The enabling switches on the KUKA Control Panel (KCP)

Enabling switches



Safety features of the robot system: jog mode

• Jog mode (deadman function). All programs can be executed manually in the test modes at reduced velocity. However, program execution is only possible as long as the “Start” key is held down. If the “Start” key is released, the robot stops. The program can only be continued by pressing the “Start” key again.

“Start” keys




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Release device for robot axes

• The robot can be moved after a malfunction via the main axis drive motors and, depending on the type of robot, also via the wrist axis drive motors in some instances. It is only intended for use in emergencies.

• The release device may only be used if the robot control cabinet has been switched off.

• If a robot axis has been moved by the release device, all robot axes must be remastered. The motor concerned must be exchanged.



Release device for robot axes

• The release device (reversible ratchet with size 12 socket wrench insert) is pushed onto the axle of the motor (remove protective cap), which can then be turned. It is necessary to overcome the resistance of the mechanical motor brake and any other loads acting on the axis.

• The motors reach temperatures during operation which can cause burns to the skin. Appropriate safety precautions must be taken.


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Planning and construction: safety and working zones

• Working zones are to be restricted to the necessary minimum size. On no account may persons or equipment be exposed to any danger. • The danger zones must be safeguarded by means of protective barriers and indicated by means of paint markings on the floor. • The safety fences must be high enough to prevent anybody from reaching over them. Design measures must be taken to prevent them from bending. The number of entrances must be kept to a minimum. All entrances must be connected to the overall EMERGENCY STOP system operator safety on the gate, Emergency Stop on the safety fencing.



Planning and construction

• The foundations and substructures must meet the quality specifications laid down by KUKA. • The loads to be expected when operating the robot system must lie within the permissible range.

• The operation of robots of normal design is not permitted in potentially explosive areas. • The robot can be equipped with a collision protection device (additional equipment).




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• Removal and installation stations must be provided to allow tools to be changed. These stations must be accessible to the operator outside the danger zone and the robot must be able to move to them by means of a special program step.

• If the presence of operating personnel in the work envelope of the robot is unavoidable (e.g. for loading components), the danger zone is to be isolated by means of a safety mat or light curtain.




• If the robot system is operated in conjunction with a higher-level controller, the two EMERGENCY STOP circuits must be interconnected. • Both these circuits must be of failsafe design (dual EMERGENCY STOP contactors with reciprocal monitoring). • It is particularly important that a regular check is made to ensure that that the EMERGENCY STOP devices are functioning correctly. • Outputs are to be preset in accordance with the main project file, i.e. signals for hold functions must not be reset when the robot controller is switched off if personnel or equipment would be endangered as a result. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de (c) Copyright by KUKA Roboter GmbH College 1996-2002

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I nstallation and operation

• All persons working within the danger zone of the robot system must wear protective clothing. Of particular importance are safety footwear and closely fitting clothing. • The prescribed transport positions for the robot must be observed. Only suitable and technically faultless lifting gear and load-bearing equipment with an adequate carrying capacity may be used. • Never work or stand under suspended loads!




• No welding may be carried out in the immediate vicinity of the open control cabinet due, among other factors, to the risk of EPROMs being erased by UV radiation. Foreign matter (e.g. swarf, water, dust) must be prevented from entering the control cabinet. • During start-up, check that all protective devices are complete and functioning correctly. No persons or objects are allowed in the danger zone during start-up. It must be ensured that the correct machine data have been loaded before the system is put into operation for the first time.




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• All safety regulations must be adhered to while the robot system is in operation. • Check the robot system at least once per working shift for obvious damage and defects. • Never use the robot or the control cabinet as a climbing aid. • The software must be checked for viruses.



I nstallation and operation: safety instruction

• 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. • Records are to be kept of the content and extent of the instruction.

• Personnel must be instructed orally every six months and in writing every two years with regard to the observance of safety regulations and precautions.


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Safety labeling

• All plates, labels, symbols and marks constitute safety-relevant parts of the robot system. They must remain attached to the robot or control cabinet concerned for the whole of their service lives in their specified, clearly visible positions. • It is forbidden to remove, cover, obliterate, paint over or alter in any other way detracting from their clear visibility - identification plates, - warning labels, - safety symbols, - designation labels and - cable marks. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de (c) Copyright by KUKA Roboter GmbH College 1996-2002


Safety instructions for KUKA training cells

• Entering the motion range of the robot is only permitted with the robot operated in “T1” mode (at reduced velocity) using a KCP. • All persons situated in the environment of the robot (at its own or adjacent cells) must be informed in good time that the robot is about to move. • On leaving the training cell, press the EMERGENCY STOP button on the KCP, set operating mode “T1” and secure the KCP in its holder. • Never lean over the safety fencing from outside!




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Safety instructions for KUKA training cells

• When testing programs, always execute the program in “T1” mode first and then in “T2” mode at reduced velocity. • During program execution in “T2” mode, no persons are permitted in the cell and the gate to the cell must remain closed. • The robot and its tooling must never touch or project beyond the safety fence. • Warning: memory dumps from KUKA College must not be loaded into manufacturing systems. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de (c) Copyright by KUKA Roboter GmbH College 1996-2002


ESD directives

ESD = electrostatic sensitive devices e.s.d. = electrostatic discharge

ESDs can be destroyed by voltages which are imperceptible to humans. As well as causing complete failure of components, e.s.d. can also be responsible for partial damage to an IC or component, which can reduce its service life or lead to sporadic faults. For these reasons, not only new modules, but also defective modules, must be handled very carefully in a way suitable for ESDs. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de (c) Copyright by KUKA Roboter GmbH College 1996-2002

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ESD directives

U/kV

e.g. offices without air humidity regulation (in winter)

16 14 12

synthetic

10 wool

8 6

antistatic

4 2 20 40 60 80 100 Rel. air humidity/% 15% 35% Average values for electrical voltages to which a person can be charged

Element

Voltage (V)

MOSFET

100-200

EPROM

100

JFET

140-7000

OP amplifiers

100-2500

CMOS

250-3000

Schottky diodes

300-2500

Thick/thin-film circuits

300-3000

Bipolar transistors

300-7000

Schottky TTL

1000-2500

e.s.d. vulnerability of semiconductor elements



ESD directives

Handling ESD modules: • Components should only be unpacked if a) you are wearing ESD shoes or b) you are wearing ESD shoe grounding strips or c) you are grounded by means of an ESD armband. • Before touching an electronic module you should discharge the voltage from your own body. • Do not place electronic modules near monitors. • Only measure with grounded measuring instruments or discharge the measuring head before measuring.




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3. The robot system 3.1.

Basics at the robot system


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Components of a complete KUKA robot system

KUKA robot (e.g. KR 350/2 )

Robot controller (e.g. KR C2) KUKA Control Panel (KCP) KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


KUKA Control Panel (KCP)

• Keyswitch for mode selection • Drives on/off switch • Emergency Stop button

• Large color graphic display • Softkeys around the display • Hardkeys for program and display control

6D mouse

Numeric keypad, alphabetic keypad, cursor block with Enter key KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

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Robot type designations

The model classification of KUKA industrial robots is based on the rated payload. The type designation is made up as follows:

K R xxx / y KUKA industrial robot

Rated payload of the robot in kilograms

Generation of the given robot type

KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Example: Robot type designations

KR 150 / 2 KUKA industrial robot with a rated payload of 150 kg of the 2nd generation




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Mechanical construction of a KUKA robot

Arm

Wrist

Rotating column

Link arm

Base frame



Axis designations of a KUKA robot

Axis 4 Axis 3

Axis 5 Axis 6

Axes 1, 2 and 3 are the main axes.

Axis 1

Axis 2

Axes 4, 5 and 6 are the wrist axes. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

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The work envelope of a KUKA robot (side view)

Overhead zone

Side view: work envelope Can be expanded using an arm extension



The work envelope of a KUKA robot (top view)

Top view: work envelope

Angle, axis 1: >360°




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Load distribution on a KUKA robot Supplementary load

Payload

Total Load = Payload + Supplementary Load From the KR 2000 series onwards, it is also possible to attach supplementary loads to the link arm and rotating column. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Loads on a KUKA robot (standard series) Supplementary load

Payload

Mass, M, and center of gravity of the supplementary load Load center distance

Robot wrist

Axis 3

Robot flange

Mass, M, of the payload (weight of tool) Load center of gravity, P

Axis 2

Axis 1


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Payload diagram for KR 125/2

Lxy (mm)

Nominal distance KR 125/2: 45 kg LZ=210 mm LXY=230 mm 55 kg

600 500 65 kg 75 kg 85 kg 95 kg 105 kg 115 kg

400 300 230 200

125 kg

100

100

210 200

Lz (mm) 300

400

500

600

700

800




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3.2.

System overview


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Control cabinet overview: KR C1, KR C1A and KR C2

Power supply connection 3x400 V PC technology Ambient temperature: 45 °C without cooling unit, 55 °C with cooling unit KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Technical data - KR C2

• Cabinet type:

KR C2

– Control cabinet for max. 8 axes

• Permissible environmental conditions: – without cooling unit: – with cooling unit:

• Weight:

max. 45 °C max. 55 °C

approx. 185 kg

• Power supply connection: 3x400 V • Microprocessor:

Celeron 433 MHz

• Main memory:

64 MB


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PC chassis - KR C2

Hard drive

Floppy disk drive

CD-ROM drive



Top view of the PC - KR C2 LPT1 External monitor Keyboard Ethernet

COM2

COM1

Mouse




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Robot serial number

Serial number



Control cabinet serial number

Serial number


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Software concept

Drives

Main memory

Windows 95

VxWorks

CROSS

KUKA GUI R1 / STEU

Robot programs Systems communicate with each other

Control programs Kernel system

Operation / visualization



User groups

• Configuration of the robot controller (external axes, technology packages) • Configuration of the robot system (field buses, vision systems, etc.) • User-defined technology commands with UserTECH

Administrator

• Advanced programming using the KRL programming language • Complex application programs (subprograms, interrupt programming, loops, program branches) • Numeric motion programming

Expert • Start-up tasks (mastering, tool calibration) • Simple application programs (programming using inline forms, motion commands, technology commands, limit value checking, no syntax errors)

User




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3.3.

Energy supply


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Energy supply - Overview KR 2000


I 03.02.03 I College I DON I 1

Energy supply - Length attitude

Velcro fastener

Only as long as necessary


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Energy supply - Hose routing adjusting trumpet

adjusting compression spring KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Energy supply - Attitude of the protectors If the protector is sanded off up to the red interior, it is to be exchanged.

Protector cannot be adjusted

Robot-lateral protection device KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002



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Page 44 of 227


4. Operation of the KUKA control panel (KCP)


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KUKA Control Panel (KCP)



Hardwired operator control elements

Mode selector switch Drives ON Drives OFF EMERGENCY STOP


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Mode selector switch

AUTOMATIC

AUTOMATIC EXTERNAL

T

T

T2 (Test 2)

T1 (Test 1)



Mode table

Mode selector switch

T1

Manual motion using keys or Space Mouse

250 mm/s

T2

250 mm/s

AUTOMATIC

AUTOMATIC EXTERNAL

Manual motion not active

Manual motion not active

Prog. velocity

Prog. velocity

Drives ON START key --> PULSE

Drives ON External start

Enabling switch Enabling switch (dead man (dead man function) function)

HOV Program execution POV

250 mm/s

Prog. velocity

Enabling switch Enabling switch (dead man (dead man function) function) START key START key pressed pressed




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CAN bus operator control elements

Escape key Window selection key



Display window

Programming window

Status window

Message window


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Window selection key



Softkeys

Softkeys KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002



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Status window

The status window is displayed as required.

The status window can be closed at any time.



Message window

The controller communicates with the operator via the message window.

Softkeys for acknowledging messages


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Message types

Hint

-

e.g. "Start key required"

Status

-

e.g. "EMERGENCY STOP"

Acknowl.

-

e.g. "Ackn. EMERGENCY STOP"

Wait

-

e.g. "Wait for $IN[1]==True"

Dialog

-

e.g. "Do you want to teach point?"




STOP key Program start forwards Program start backwards




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Numeric keypad

NUM key KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Numeric keypad

HOME Jumps to the beginning of the line in which the edit cursor is positioned.

LDEL Deletes the line in which the edit cursor is positioned.

TAB Tab jump PGDN Moves one screen towards the end of the file.

UNDO Cancels the last entry. END Jumps to the end of the line in which the edit cursor is positioned. INS Switches between insert and overwrite modes.

PGUP Moves one screen towards the beginning of the file.

CTRL Control key

DEL Deletes the character to the right of the edit cursor.

Arrow Backspace key; deletes the character to the left of the edit cursor.


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ASCII alphabetic keypad



ASCII alphabetic keypad

NUM key

SYM key

SHIFT key ALT key KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002



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RETURN key CURSOR block



Menu keys

Menu keys


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Status keys

Status keys



Status bar

Numeric keypad Time

Upper/lowercase letters

Selected program

Robot name

Override Current line number Operating mode




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Status bar

Drives not ready Drives ready (600 ms)

Submit interpreter deselected Submit interpreter stopped Submit interpreter running KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 56 of 227



5. The coordinate systems at the robot


Page 57 of 227

Coordinate systems

• Axis-specific motion Each robot axis can be moved individually in a positive or negative direction. • WORLD coordinate system Fixed, rectangular coordinate system whose origin is located at the base of the robot. • TOOL coordinate system Rectangular coordinate system, whose origin is located in the tool. • BASE coordinate system Rectangular coordinate system which has its origin on the workpiece that is to be processed. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Selecting a coordinate system

• Select manual motion Motion keys Motion with mouse • Select the coordinate system Axis-specific manual motion WORLD coordinate system TOOL coordinate system BASE coordinate system KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 58 of 227



5.1.

The axis coordinat system


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Axis-specific manual motion

Each robot axis can be moved individually in a positive or negative direction.



Axis-specific motion with the 6D mouse


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5.2.

The world coordinate system


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WORLD coordinate system

Fixed, rectangular coordinate system whose origin is located at the base of the robot.



Assignment of the angles of rotation in Cartesian coordinates

Angle A Angle B Angle C

Rotation about the Z-axis Rotation about the Y-axis Rotation about the X-axis +Y

X

B

Y Z C

A B C

+X A +Z


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Right hand rule (coordinate directions)

+Z

+X

+Y KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Right hand rule (direction of rotation)

+X, +Y or +Z

+C, +B or +A




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Cartesian motion with the 6D mouse


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5.3.

The tool coordinate system


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TOOL coordinate system

Rectangular coordinate system, whose origin is located in the tool.


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5.4.

The base coordinate system


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BASE coordinate system

Rectangular coordinate system which has its origin on the workpiece that is to be processed.


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6. Stop reactions of the robot


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Braking reactions of the KR C2

TEST (T1 or T2)

AUTO or AUTOEXT

Emergency Stop

Path-oriented braking

Path-maintaining braking

Enabling sw. released


---

Safety gate opened

---

Path-maintaining braking

Drives OFF


Mode change


Encoder error

Short-circuit braking

(DSE-RDC connection broken)

Move enable

Ramp-down braking

Stop key

Ramp-down braking



Braking reactions of the KR C2

Technical term Shortcircuit braking

Reaction of drives Switched off immediately

Only switched Pathmaintaining off after 1 s hardware braking delay Pathoriented braking

Switched off immediately

Ramp-down Remain ON braking

Intermediate circuit High-speed discharge

Short-circuit Brakes braking relays Applied immediately

--Applied immediately

Remains charged for 1 s, then high-speed discharge

Remain open for 1 s, then applied

Applied after 1 s

Discharged; high-speed discharge if UIC < 50 V

Applied if UIC < 50 V

Remains charged

Remain open

The controller attempts to Applied immediately brake the robot on the path with the remaining intermediate circuit voltage. When the intermediate circuit voltage is no longer sufficient, short-circuit braking is activated. Normal ramp which is also Remain used for normal open acceleration and deceleration at a point

Software

In this time the controller brakes the robot on the path using a steeper stop ramp.


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Page 71 of 227

7. Mastering


Page 73 of 227

Why is mastering carried out? A3=+90° A4, A5, A6=0°

• When the robot is mastered, the axes are moved into a defined mechanical position, the so-called mechanical zero position. A2=-90°

• Once the robot is in this mechanical zero position, the absolute encoder value for each axis is saved.

A1=0°



Mastering equipment

• In order to move the robot exactly to the mechanical zero position, a dial gauge or electronic measuring tool (EMT) is used.

Electronic measuring tool (EMT) In EMT mastering, the axis is automatically moved by the robot controller to the mechanical zero position. If a dial gauge is being used, this must be carried out manually in axis-specific mode. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 74 of 227

Dial gauge I 14.03.02 I College I ML I 2


Cross-section of the gauge cartridge

EMT or dial gauge

Gauge cartridge

"Frontsight/ rearsight" marker Gauge pin

Reference notch



Schematic representation of the mastering run

Motion direction + -

Motion direction + -

EMT or dial gauge

EMT or dial gauge

"Frontsight/ rearsight" marker

Pre-mastering position

Mechanical zero position




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Reasons for remastering

Mastering is canceled...

The robot is to be mastered... ...after repairs (e.g. replacement of a drive motor or RDC)

... automatically on booting the system1)

…replacement of a gear

... manually by the operator

...when the robot has been moved without the controller (e.g. hand crank)

... automatically on booting the system1)

...after an impact with a mechanical end stop at more than manual velocity (25 cm/s)


...after a collision involving the tool or robot


1)

If discrepancies are detected between the resolver data saved when shutting down the controller and the current position, all mastering data are deleted for safety reasons.

The robot can be unmastered...

Mastering is canceled...

... if the mastering values for the individual axes are to be specifically deleted




Mastering with the EMT

Set-up

Mastering with the EMT

Set mastering

First mastering

Mastering loss / check

Teach offset

Check mastering 1)

Master load with offset

Master load without offset1)

Only possible if the first mastering is still valid (i.e. no change to the drive train, e.g. replacement of a motor or parts, or following a collision, etc.)


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Preparation for EMT mastering

• Move axes to pre-mastering position (frontsight and rearsight aligned)

!

• Move axes manually in axisspecific mode • Each axis is mastered individually

• Start with axis 1 and move upwards

OK

• Always move axis from + to -



Preparation for EMT mastering

Gauge cartridge

• Remove protective cap from gauge cartridge • Attach EMT and connect signal cable (connection X32 on the junction box on the rotating column)

• Three LEDs on the EMT: error 1 red 2 green 3 green

-

falling edge

-

rising edge

1



2

3


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Mastering menu

Master Master

Dial Dial

EMT EMT

Standard Standard

Set Set mastering mastering

Check Check mastering mastering

With With load load corr. corr.

First First mastering mastering

Teach Teach offset offset

Master Master load load

With With offset offset

Without Without offset offset


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8. Tool calibration 8.1.

The calculation of the TCP's


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Tool calibration

What happens during tool calibration?

The tool receives a user-defined Cartesian coordinate system with its origin at a reference point specified by the user.

Y Z

X



Tool calibration

What are the advantages of tool calibration?

3 1

2


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General procedure for tool calibration

1st step: Calculation of the TCP relative to the flange coordinate system

TCP without tool calibration

2nd step: YFlange

Definition of the rotation of the Tool coordinate system from the flange coordinate ZFlange system

XFlange YTool

ZTool

TCP with tool calibration

XTool KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Tool calibration methods

1. TCP calibration

or Flange adapter plate as reference tool

X Y Z - Reference X Y Z - 4 Point 2. Orientation calibration

or

or A B C - 2 Point

A B C - World 5D A B C - World 6D




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Activating the tool

Pin

Tool name is displayed

Enter the tool number TOOL_DATA[1-16]

Blue


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8.1.1. The X Y Z - 4 Point method


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The X Y Z - 4 Point method

In the XYZ - 4-point method, the TCP of the tool is moved to a reference point from four different directions.

The TCP of the tool is then calculated from the different flange positions and orientations.



Diagram of the X Y Z - 4 Point method

Unknown tool

• Move the tool to the reference point with 4 different orientations (P1 to P4).

P1

P4

• Tip: Set the final orientation (P4) so that +XT runs in the direction of -ZW . XT

P3

P2

Reference point

ZW

• Important: The orientations of the tool positions (flange positions) must differ sufficiently from one another.

Reduce the velocity in the vicinity of the reference point in order to avoid a collision. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 84 of 227



8.1.2. The XYZ-reference method


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The X Y Z - Reference method

In the X Y Z - Reference method, the TCP data are determined by means of a comparison with a known tool.

Known tool

Reference point

Unknown tool

Reference point

The unknown TCP can be calculated on the basis of the various positions and orientations of the robot flange and the dimensions of the known tool. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Example of the X Y Z - Reference method

Flange adapter plate as reference tool KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 86 of 227



8.2.

Orientation calibration

8.2.1. The ABC-world 5D method


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The A B C - World 5D method

Condition: XTool parallel to ZWorld ZWorld YTool

ZTool XTool

XWorld

In this method, the tool must be oriented parallel to the Z axis of the world coordinate system in the working direction. The Y and Z axes are oriented by the robot controller. The orientation of these axes is not readily foreseeable in this instance, but it is exactly the same in each calibration procedure. YWorld


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8.2.2. The ABC-world 6D method


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The A B C - World 6D method

In this method, the tool must be oriented in alignment with the world coordinate system. The axes of the tool coordinate system must be parallel to the axes of the world coordinate system.

ZWorld ZTool

YTool XTool

Conditions: XTool parallel to ZWorld YTool parallel to YWorld

XWorld

YWorld

ZTool parallel to XWorld KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 90 of 227



8.2.3. The ABC-2 point method


Page 91 of 227

The A B C 2 Point method

1st step (diagram 1)

• In the first step, the working direction of the tool is defined for the controller.

TCP

• This is done by moving the TCP (which has been calibrated beforehand) to a known reference point.

Reference point




1st step (diagram 2)

• It is now necessary to move a point located opposite the TCP on the tool to the same reference point (in the reverse working direction). The working direction of the tool is defined in this way.

Reference point

TCP

• This is done by moving to a point on the negative X axis of the tool to be calibrated.


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2nd step

ZTool

Reference point

YTool TCP

• The YZ plane can still rotate freely about the X axis (working direction) of the tool and is defined in the second step. • This is done by moving the tool so that the reference point is located with a positive Y value on the future XY plane of the tool.




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8.3.

Tool - payload


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Tool load data

In order to be able to move the robot as fast as possible, the load data of the tool/workpiece must be taken into consideration.

10 kg

Load moved

100 kg

Maximum acceleration / velocity

Do not forget supplementary loads on the robot! KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Tool load data parameters

M

Weight of the tool

X, Y, Z

Distance between the center of gravity of the tool and the origin of the robot flange coordinate system

YFlange ZFlange A, B, C

XFlange

Rotational offset of the principal inertia axes of the tool (Z-Y-X Euler angles) from the robot flange coordinate system

JX, JY, JZ Mass moments of inertia about the principal inertia axes of the tool KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 96 of 227



9. Base calibration


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Base calibration

The work surface (pallet, clamping table, workpiece...) receives a user-defined Cartesian coordinate system with its origin at a reference point specified by the user.

ZBase YBase

XBase



Purpose of base calibration

Manual motion ZWorld

Motion along the edges of the work surface or workpiece.

Tool XWorld

YWorld

Base Motion direction KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 98 of 227




Teaching points ZWorld

The taught point coordinates refer to the BASE coordinate system. Tool XWorld

YWorld

Base




Program mode ZWorld

If the BASE coordinate system is offset, the taught points move with it.

Tool XWorld

YWorld

Base Base KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002



Page 99 of 227


Program mode ZWorld

It is possible to create several BASE coordinate systems.

Bas e

Tool

1

YWorld XWorld

B as

e2



The "3-Point" method: 1st step

Reference tool

Origin Workpiece

• In the first step, the TCP of the reference tool is moved to the origin of the new BASE coordinate system.


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The "3-Point" method: 2nd step

Reference tool

XBase Origin Workpiece

• In the second step, the TCP of the reference tool is moved to a point on the positive X-axis of the new BASE coordinate system.



The "3-Point" method: 3rd step

Reference tool

YBase

XBase Origin Workpiece

ZBase

• In the third step, the TCP of the reference tool is moved to a point with a positive Y value on the XY-plane of the new BASE coordinate system.




Page 101 of 227

Calculating the BASE coordinate system indirectly

• In the controller, enter the coordinates of 4 points referring to the BASE (e.g. from CAD). • Move the TCP of the reference tool to the four points. • The robot controller calculates the BASE.

ZWorld Point 1 Point 2

Point 4 Point 3

XWorld Reference point KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

YWorld I 14.03.02 I College I ML I 9

Activating a base

Pin

Blue

Name of the base is displayed

Enter the number of the base BASE_DATA[1-16]


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10. Motions programming at the robot


Page 103 of 227

Types of motion

KUKA robot motion types (interpolation types) PTP (Point-to-point): The tool is moved along the quickest path to an end point.

LIN (Linear): The tool is guided at a defined velocity along a straight line.

CIRC (Circular): The tool is guided at a defined velocity along a circular path.

P2

P2

P2

P1 P1 P1


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10.1.

PTP – motion


Page 105 of 227

PTP motion

Fastest path

P2

P1

Shortest distance



SYNCHRO PTP

P1

Individual axis velocity v e.g. axis 2: leading axis

P2

V max e.g. axis 3: adapted e.g. axis 6: adapted

P1

P2 Acceleration

Constant

Time t

Deceleration


Page 106 of 227



Programming a PTP motion

Velocity Motion parameters

Type of motion

Exact positioning Approximate positioning ON Point name KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002



Tool Tool selection Tool_Data[1]..[16], Nullframe

Base Workpiece coordinate system selection Base_Data[1]..[16], Nullframe

External TCP Robot guiding tool: False Robot guiding workpiece: True KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002



Page 107 of 227


Acceleration Acceleration used for the motion. Range of values: 1...100%

Approximation distance*) Size of approximate positioning range for the motion. Range of values: 0...100% *)

The parameter "Approximation distance" is only displayed if approximate positioning has been selected (CONT).


Page 108 of 227



10.2.

LIN – motion


Page 109 of 227

LIN motion without approximate positioning

LIN motion

P2

P3

shortest distance

P1



Velocity profile

P1

Path velocity v

P2

V prog

P1

P2 Acceleration

Constant


Page 110 of 227

Time t

Deceleration



Programming a LIN motion


Type of motion

Exact positioning Approximate positioning ON Point name KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002








Page 111 of 227



Approximation distance*) Size of approximate positioning range for the motion. Range of values: 0...300 mm *)



Page 112 of 227



10.3.

CIRC – motion


Page 113 of 227

CIRC motion without approximate positioning

CIRC motion

P2 (AUX)

P2 is an auxiliary point (AUX), P3 is the end point (END)

P3 (END)

P1



Programming a CIRC motion


Type of motion

Exact positioning Approximate positioning ON End point name Auxiliary point name KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 114 of 227










Approximation distance*) Size of approximate positioning range for the motion. Range of values: 0...300 mm *)





Page 115 of 227

The 360° full circle

The full circle should be made up of at least two segments. P3=AUX P1

P2 P2=END

P4=END

P5=AUX


Page 116 of 227



10.4.

Approximation of motion


Page 117 of 227

Approximation of motions

During approximate positioning, the robot does not move exactly to each programmed position, nor is it braked completely. Advantage: • reduced wear • improved cycle times

P1

Z P2 Y

P3 X KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Geschwindigkeit Velocity

Cycle time improvement by means of approximated motions

P1 Vprog

P2

P3

P4

ohne Überschleifen without approximate positioning

Zeit (sec) Time (s)

Geschwindigkeit Velocity

5

Vprog

10

15

20

25

30

20

25

30

mit Überschleifen with approximate positioning

Zeit (sec) Time (s) 5 P1

10 P2

15 P3

P4


Page 118 of 227



PTP motion with approximate positioning

PTP motion with approx. positioning

P2 is an approx. positioning point

possible PTP approx. positioning paths

P2

shortest distance

P1

P3

Approximate starts, if the leading axis reaches the middle of the angle of the shorter movement. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


LIN motion with approximate positioning

LIN motion with approx. positioning

P2 is an approx. positioning point

P2

P1

P3 Two parabolic curves (symmetrical at constant velocity)




Page 119 of 227

CIRC motion with approximate positioning

CIRC motion with approx. positioning

P3 is an approx. positioning point P4 P2 (AUX)

P3 (END) P1 KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 120 of 227



11. The navigator (program production)


Page 121 of 227

Navigator (user)

Header

Directory or file list

Directory structure

Status line



Symbols in the Navigator (user) Drives Symbol

Type

Default path

Robot

KRC:\

Floppy

A:\

Backup drive

Archive:\

Directories and files Symbol

Type

Meaning

Directory

Normal directory

Directory open

Open directory

Archive

ZIP file

Read directory

The contents of a directory are being read

Module

Program at user level

Module containing errors

Program with errors that cannot be interpreted by the compiler.


Page 122 of 227



Navigation using the keyboard

Focus

Select drive, directory or file

Toggle between directory structure / file list

Open drive, directory or file



New program

Comment Program name

Please enter a name

Confirm KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002



Page 123 of 227

Program run modes (1)

Run mode GO

MSTEP

ISTEP

Description GO mode All instructions in the progam are executed up to the end of the program without a STOP.

Motion Step (motion block) The program is executed one motion instruction at a time, i.e. with a STOP before each motion instruction. The program is executed without advance processing. Incremental Step (single block) The program is executed step by step, i.e. with a STOP after each instruction (including blank lines). The program is executed without advance processing.



Program status

Gray:

No program is selected.

Yellow:

The block pointer is situated on the first line of the selected program.

Green:

A program has been selected and is currently being executed.

Red:

The selected and started program has been stopped.

Black:

The block pointer is situated on the last line of the selected program.


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Archive

This function allows you to save important data to floppy disk. All files are saved in compressed form as ZIP files.

If you try to insert a file in an existing archive, the robot name is checked. The robot name in the archive is compared with the name that is set in the controller. If the two names are different, a request for confirmation is generated asking if you really wish to overwrite the existing archive.



Archive All

The menu item Archive "All" is used to save to floppy disk all the data that are required to restore the robot system. These include - machine data - tool/base data - all applications - etc. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002



Page 125 of 227

Archiving individual programs

The selected files are saved to floppy disk



Restore All

All files, with the exception of log files, are loaded back onto the hard disk.

Once the system has been restored, it must be shut down and rebooted.


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Restoring individual programs

The selected files are loaded back onto the hard disk




Page 127 of 227

12. Logic programming


Page 129 of 227

Logic programming

Programming of inputs and outputs for communication between the robot controller and its peripheral environment. (e.g. tools, sensors, etc.)

Outputs: $OUT[1] ... $OUT[4096]

Inputs: $IN[1] ... $IN[4096] $IN[1025]=TRUE $IN[1026]=FALSE

Robot controller

Periphery



Logic commands available

The following logic commands can be selected:

Time-dependent wait function Signal-dependent wait function Switching functions Coupling/decoupling an Interbus segment


Page 130 of 227



Time-dependent wait function (WAIT)

If "WAIT" has been selected, the wait time can be specified:

Wait time in seconds

P3

Example: PTP P1 VEL=100% PDAT1 PTP P2 VEL=100% PDAT2 WAIT Time=1 sec PTP P3 VEL=100% PDAT3

P2 Motion is interrupted for 1 second at point P2

P1



Signal-dependent wait function (WAIT FOR)

If "WAIT FOR" has been selected, the following parameters can be specified:

State Input/output number

Example: PTP P1 VEL=100% PDAT1 PTP P2 VEL=100% PDAT2 WAIT FOR IN 1 ‘ ‘ State=TRUE PTP P3 VEL=100% PDAT3

P1

P3 P2 Motion is interrupted at point P2 until input 1 is set




Page 131 of 227

Switching functions

The following switching functions can be selected:

Simple switching function Simple pulse function Path-dependent switching function Path-dependent pulse function



Simple switching function (OUT)

If "OUT" has been selected, the following parameters can be specified:

Advance run stop on Output

State

Advance run stop off

Example: PTP P1 VEL=100% PDAT1 PTP P2 CONT VEL=100% PDAT2 PTP P3 CONT VEL=100% PDAT3

P2

P3

PTP P4 VEL=100% PDAT4

P1


Page 132 of 227

P4






State


Example: PTP P1 VEL=100% PDAT1 PTP P2 CONT VEL=100% PDAT2 PTP P3 CONT VEL=100% PDAT3 OUT 1 ‘ ‘ State=TRUE PTP P4 VEL=100% PDAT4

P3

P2 Point P3 becomes an exact positioning point and output 1 is set

P1


P4





State


Example: PTP P1 VEL=100% PDAT1 PTP P2 CONT VEL=100% PDAT2 PTP P3 CONT VEL=100% PDAT3 OUT 1 ‘ ‘ State=TRUE CONT PTP P4 VEL=100% PDAT4

P3

P2

P1

CONT prevents an advance run stop from being triggered; output 1 is set during the advance run



P4


Page 133 of 227

Simple pulse function (PULSE)

If "PULSE" has been selected, the following parameters can be specified:

Pulse length Advance run stop on Output

State

OUT 1


OUT 1

Time

Time

1

1

0

Time 0

Time



Path-dependent switching function (SYN OUT)

If "SYN OUT" has been selected, the following parameters can be specified:

Time Output

State

Example: LIN P1 VEL=0.3m/s CPDAT1 LIN P2 VEL=0.3m/s CPDAT2 SYN OUT 1 ‘ ‘ State=TRUE at START Delay=20ms SYN OUT 2 ‘ ‘ State=TRUE at END Delay=-20ms LIN P3 VEL=0.3m/s CPDAT3 LIN P4 VEL=0.3m/s CPDAT4

Switching point

+

P3

P2

-

P1


Page 134 of 227

P4





Time Output

State

Switching point

P3

+

Example: LIN P1 VEL=0.3m/s CPDAT1 LIN P2 VEL=0.3m/s CPDAT2 SYN OUT 1 ‘ ‘ State=TRUE at START Delay=20ms SYN OUT 2 ‘ ‘ State=TRUE at END Delay=-20ms LIN P3 CONT VEL=0.3m/s CPDAT3 LIN P4 VEL=0.3m/s CPDAT4

P2

-

+

P1

P4





Time Output

State

Example: LIN P1 VEL=0.3m/s CPDAT1 LIN P2 CONT VEL=0.3m/s CPDAT2 SYN OUT 1 ‘ ‘ State=TRUE at START Delay=20ms SYN OUT 2 ‘ ‘ State=TRUE at END Delay=-20ms LIN P3 CONT VEL=0.3m/s CPDAT3 LIN P4 VEL=0.3m/s CPDAT4

Switching point

+ P2

P1



P3

-

+

P4


Page 135 of 227



Time Output

State

Switching point P3

20mm P2 + Example: LIN P1 VEL=0.3m/s CPDAT1 SYN OUT 1 ‘ ‘ State=TRUE PATH=20mm Delay=-5ms LIN P2 CONT VEL=0.3m/s CPDAT2 LIN P3 CONT VEL=0.3m/s CPDAT3 LIN P4 VEL=0.3m/s CPDAT4

+

-

-5ms

P4

P1 KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002




Time Output

State

Switching point

20mm

P3

P2 + Example: LIN P1 CONT VEL=0.3m/s CPDAT1 SYN OUT 1 ‘ ‘ State=TRUE PATH=20mm Delay=-5ms LIN P2 CONT VEL=0.3m/s CPDAT2 LIN P3 CONT VEL=0.3m/s CPDAT3 LIN P4 VEL=0.3m/s CPDAT4

-

+ -5ms

P1 KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 136 of 227

P4 I 14.03.02 I College I ML I 14


Path-dependent pulse function (SYN PULSE)

If "SYN PULSE" has been selected, the following parameters can be specified:

State

Time

Output

Pulse length

OUT 1

Switching point

OUT 1

Time

Time

1

1

0

Time 0

Time



Coupling/decoupling Interbus segments

If "IBUS-Seg. on/off" has been selected, the following parameters can be specified:

Coupling/ decoupling 3.0 Bus terminal 3 (fixed to the tool)

Bus terminal 1 Bus terminal 2

1.0

2.0

1.1

2.1

1.2

2.2




Page 137 of 227

13. Gripper Tech H50


Page 139 of 227

Gripper configuration

Up to 16 grippers can be configured via the "Configure" menu:




Gripper Name of the gripper; 24 characters Gripper type Function type of the gripper 11

22

33

44

55

Outputs Assignment of robot controller outputs to the gripper actuators Inputs Assignment of robot controller inputs from the gripper sensors State Designation of the gripper states, dependent on the gripper type; 11 characters KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 140 of 227




Gripper name

Gripper type (1...5)

States Outputs State

Activation OUT 1 OUT 2

Evaluation IN 1

IN 2

IN 3

IN 4

A

TRUE FALSE TRUE FALSE TRUE FALSE

B

FALSE TRUE FALSE TRUE FALSE TRUE

Inputs KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Programming gripper functions

The following gripper commands can be selected from the "Technology" menu:

Gripper function Gripper interrogation




Page 141 of 227

Gripper without approximate positioning

Once "GRIPPER" has been selected, the following parameters can be specified:

Select function Gripper name



Gripper with approximate positioning

Once "GRIPPER" has been selected, the following parameters can be specified:

Delay

Approximate positioning on Reference point

END lay De itive s po

lay De ative neg

START


Page 142 of 227



Check Gripper

Once "CHECK GRIPPER" has been selected, the following parameters can be specified:

Delay Select function

Reference point

Gripper name

This command is only executed if it is located before a motion instruction.




Page 143 of 227

13.1.

Gripper typ 1


Page 145 of 227

Basic types for gripper functions: TYPE 1

TYPE 1: 2 outputs, 4 inputs, 2 switching states State

Activation

Evaluation

OUT 1

OUT 2

IN 1

IN 2

IN 3

IN 4

A

TRUE

FALSE

TRUE

FALSE

TRUE

FALSE

B

FALSE

TRUE

FALSE

TRUE

FALSE

TRUE

e.g. a simple gripper with the functions OPEN and CLOSE



Example: TYPE 1 (functional principle)

Gripper closed IN 1 IN 2

OUT 1

IN 4 IN 3

OUT 2


Page 146 of 227




Gripper open IN 1 IN 2

IN 4 IN 3 Component

OUT 1

OUT 2




Component gripped IN 1 IN 2

IN 4 IN 3 Component

OUT 1

OUT 2




Page 147 of 227

13.2.

Gripper typ 2


Page 149 of 227


TYPE 2: 2 outputs, 2 inputs, 3 switching states Activation

State

Evaluation

OUT 1

OUT 2

IN 1

IN 2

A

TRUE

FALSE

TRUE

FALSE

B

FALSE

TRUE

FALSE

TRUE

C

FALSE FALSE FALSE FALSE

e.g. a slide with a center position



Example: TYPE 2

IN2

IN1

OUT 1

State:

OUT 2

A

C

B


Page 150 of 227



13.3.

Gripper typ 3


Page 151 of 227



Activation

Evaluation

OUT 1

OUT 2

IN 1

IN 2

A

TRUE

FALSE

TRUE

FALSE

B

FALSE

TRUE

FALSE

TRUE

C

FALSE FALSE FALSE FALSE

e.g. a vacuum gripper with the functions SUCTION, RELEASE and OFF



Example: TYPE 3

IN1

OUT 1

Suction

IN2

>P

OUT 2

Release


Page 152 of 227



13.4.

Gripper typ 4


Page 153 of 227



Activation OUT 1

OUT 2

A

TRUE

B A

Evaluation OUT 3

IN 1

IN 2

FALSE FALSE

TRUE

FALSE

FALSE

TRUE

TRUE

FALSE

TRUE

FALSE

TRUE

FALSE FALSE FALSE

The same as type 3 but with three control outputs (type 3 has two outputs)



Example: TYPE 4

IN1

OUT 1

IN2

OUT 2

>P

OUT 3

Throttle Suction (A)

OFF (C)

Release (B)


Page 154 of 227



13.5.

Gripper typ 5


Page 155 of 227



Activation

Evaluation

OUT 1

OUT 2

IN 1

IN 2

IN 3

IN 4

A

TRUE

FALSE

TRUE

FALSE

TRUE

FALSE

B

FALSE

TRUE

FALSE

TRUE

FALSE

TRUE

The same as type 1 but with a pulse signal instead of a continuous signal



Example: TYPE 5

IN2

IN1

OUT1 OUT2


Page 156 of 227



14. Fixed tool calibration


Page 157 of 227

Fixed tool

"Fixed tool" means that the robot guides a workpiece to one or more stationary tools that are integrated into the cell. Calibration consists of two parts:

Z Y Z

X

X

• Calculation of the distance between the TCP of the fixed tool and the origin of the world coordinate system.

Z Y X Y

• The workpiece is mounted on the robot flange and calibrated as a BASE.



Calibration of the fixed tool

1. Calibrate the fixed tool

+X +Y +Z

The coordinates are saved as BASE_DATA[1]....[16]. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 158 of 227




1st step

• First of all, a tool of known dimensions is moved to the TCP (tool center point) of the fixed tool.




2nd step

X Z Y

Tool

• In the second step, the robot flange is aligned perpendicular to the working direction of the tool (tool direction).




Page 159 of 227

Calibration of the movable workpiece

2. Calibrate the workpiece

Z Y Z X

The coordinates are saved as TOOL_DATA[1]....[16]. X

Y




1st step

• The origin of the workpiece coordinate system must be shifted to the TCP of the fixed tool.

Origin at TCP


Page 160 of 227




2nd step

• In the second step, the workpiece is moved so that the TCP of the fixed tool is positioned at a point on the positive X axis of the workpiece coordinate system.

Origin

X




3rd step

• In the final step, the workpiece is moved so that the TCP of the fixed tool is positioned at a point with a positive Y value in the XY plane of the workpiece coordinate system.

Z Y

Origin

X




Page 161 of 227

Kinematic chain with base-related interpolation

$IPO_MODE = #BASE

X Y $TOOL Z $POS_ACT Z Y X

Z Z

Y

Y

X $ROBROOT

$BASE

X $WORLD



Kinematic chain with tool-related interpolation

$IPO_MODE = #TCP

X Y $TOOL Z Z

$POS_ACT Y X

Z Z

Y

Y

X $ROBROOT

X $WORLD

$BASE


Page 162 of 227



Changing the $IPO_MODE

$IPO_MODE=#BASE Pen

$IPO_MODE=#TCP Pen



Tool and base type

Name of the tool or base

Blue Red

not defined Pen Gripper

Fixed pen

Panel

Defined type




Page 163 of 227

15. Programming with subprograms


Page 165 of 227

Subprograms

Subprograms are used for identical program sections that are repeated frequently.

• Subprograms reduce the amount of typing during programming. • Subprograms reduce the program length thus making the program more transparent. • Subprograms can be reused in other programs. • Subprograms can be used for structuring a program.



Global subprograms

DEF DEFMAIN_PROG MAIN_PROG(()) INI INI ... ... GLOBAL_SP1( GLOBAL_SP1()) ... ...

DEF DEFGLOBAL_SP1 GLOBAL_SP1(()) INI INI

... ...

... ... ... ...

END END

END END


Page 166 of 227



16. The expert level


Page 167 of 227

Navigator (expert) System files and directories are displayed.

Drives are displayed



Additional symbols in the Navigator (expert) Drives Symbol

Type

Default path

Hard drive

e.g. Kukadisk (C:\) or Kukadata (D:\)

CD-ROM

E:\

Mapped network drive

e.g. F:\, G:\, etc.

Directories and files Symbol

Type

Meaning

SRC file

Program file

SRC file

Subprogram

SRC file contains errors

Program with errors that cannot be interpreted by the compiler.

DAT file

Data list

DAT file contains errors

Data list with errors that cannot be interpreted by the compiler.

ASCII file

Text file

Other files

Binary files


Page 168 of 227



Creating a new module (expert)

A KRL program can be made up of SRC and DAT files. • SRC - contains program code • DAT - contains specific program data

Cell

Skeleton program for control via a PLC

Expert

SRC and DAT file without a skeleton program

Expert Submit

SUB file without a skeleton program

Function

SRC file without a skeleton program

Module

SRC and DAT file with a skeleton program

Submit

SUB file with a skeleton program



Error display

Program containing errors

If the focus is moved to a file marked as containing errors, the appearance of the softkey bar changes as follows:




Page 169 of 227

Error list Cursor is positioned on the line containing errors Short description Error number Line and column

So that the line numbers in the error list correspond to those in the editor, the options "All FOLDs op" and "Detail view" must be activated.


Page 170 of 227



17. Loops and branches in programs


Page 171 of 227

Endless loop (LOOP)

Description Cyclic executions can be programmed using LOOP. The statement block in the LOOP is continually repeated. If you want to end the repeated execution of the statement block, you must call the EXIT statement.

Statements



Endless loop

Syntax:

LOOP Statement 1 ... Statement n ENDLOOP

... ... PTP PTPHOME HOME LOOP LOOP LIN LINP1 P1 LIN LINP2 P2 LIN P4 LIN P4 ENDLOOP ENDLOOP PTP PTPHOME HOME ... ...

Statement 1

...

Statement n


Page 172 of 227



Conditional branch (IF..THEN..ELSE)

Description Depending on a condition, either the first statement block (THEN block) or the second statement block (ELSE block) is executed. • There is no limit on the number of statements contained in the statement blocks. • Several IF statements can be nested in each other. • The keyword ELSE and the second statement block may be omitted. • There must be an ENDIF for each IF.



Conditional branch

Syntax:

IF Execution_Condition THEN Statement ELSE Statement ENDIF

... IF $IN[22]==TRUE THEN PTP HOME ELSE $OUT[17]=TRUE $OUT[18]=FALSE PTP HOME ENDIF ...

No Condition met?

Yes Statement



Statement


Page 173 of 227

Unconditional exit from loops (EXIT)

Description The EXIT statement appears in the statement block of a loop. It may be used in any loop. The EXIT statement can be used to exit the current loop. The program is then continued after the ENDLOOP statement.



Unconditional exit from loops

Syntax:

EXIT DEF DEFEXIT_PRO EXIT_PRO(()) PTP PTPHOME HOME LOOP ;Start LOOP ;Startofofendless endlessloop loop LIN P1 LIN P1 IF IF$IN[1] $IN[1]== ==TRUE TRUETHEN THEN EXIT ;Terminate EXIT ;Terminatewhen wheninput input11set set ENDIF ENDIF LIN LINP2 P2 ENDLOOP ;End ENDLOOP ;Endofofendless endlessloop loop PTP HOME PTP HOME END END


Page 174 of 227



Description The SWITCH statement is a selection instruction for various program branches. Only one program branch is executed and the program then jumps immediately to the ENDSWITCH statement.

Selection?

Statements

Statements

Statements

Statements



Switch

Syntax: SWITCH Variable CASE 1 Statement CASE 2 Statement DEFAULT ENDSWITCH ... ... SWITCH SWITCHPROG_NR PROG_NR CASE CASE11 Part1 Part1(()) ; ;ififProg_No Prog_No==11 CASE 2 CASE 2 Part2 Part2(()) ; ;ififProg_No Prog_No==22 DEFAULT DEFAULT ERROR_SP ERROR_SP()(); ;all allother othervalues values ENDSWITCH ENDSWITCH ... ...

Selection 1?

Statement

Selection n?

Statement




Page 175 of 227

18. Automatik external


Page 177 of 227

System structure

Controls the entire system and saves data

Host computer

Control system components (robots and periphery)

PLCs

Robots Execute application programs KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Configuring the interface

The signals of the Automatic External interface must be assigned physical inputs and outputs of the robot controller.


Page 178 of 227



Automatic External inputs Functional description

Var I/O

Variable name

Variable Input

Input number or variable value



Automatic External outputs - Start condition Functional description

Function name

Output number Selection of the variable groups KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002



Page 179 of 227

$NEAR_POSRET

The signal $NEAR_POSRET can be used to determine whether or not the robot is situated within a sphere about the position saved in $POS_RET. The radius of the sphere can be set in the file $CUSTOM.DAT using the system variable $NEARPATHTOL.

$NEAR_POSRET=FALSE

TRUE $POS_RET

th Pa

$NEARPATHTOL

Deviation from path caused, for example, by dynamic braking



Organization program: CELL.SRC

• •

.. INIT BAS INI CHECK HOME PTP HOME Vel= 100 % DEFAULT AUTOEXT INI LOOP P00 (#EXT_PGNO,#PGNO_GET,DMY[],0 ) SWITCH PGNO CASE 1 P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 ) ;EXAMPLE1 ( ) Delete semicolon CASE 2 P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 ) ;EXAMPLE2 ( ) Substitute program CASE 3 name for P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 ) EXAMPLEx ;EXAMPLE3 ( ) DEFAULT P00 (#EXT_PGNO,#PGNO_FAULT,DMY[],0 ) ENDSWITCH ENDLOOP


Page 180 of 227



Expanding CELL.SRC ... LOOP

• •

P00 (#EXT_PGNO,#PGNO_GET,DMY[],0 ) SWITCH PGNO CASE 1 P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 ) PROG1 ( ) CASE 2 P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 ) PROG2 ( ) CASE 3 Insert new CASE P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 ) PROG3 ( ) branch CASE 4 Proceed in the P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 ) same way for each PROG4 ( ) DEFAULT subsequent P00 (#EXT_PGNO,#PGNO_FAULT,DMY[],0 ) program ENDSWITCH ENDLOOP



Overview of the "Automatic External" interface (not complete) $STOPMESS PGNO_REQ

$USER_SAF $I_O_ACTCONF(EXT) $ON_PATH

INPUTS

KRC

$EXT_START $MOVE_ENABLE $CONF_MESS $DRIVES_ON $DRIVES_OFF

OUTPUTS

$PRO_ACT $IN_HOME PGNO / PGNO_PARITY PGNO_VALID

INPUTS

OUTPUTS

APPL_RUN $PERI_RDY $ALARM_STOP

PLC




Page 181 of 227

Signal diagram example: Precondition

$PERI_RDY (drives are on) $ALARM_STOP (no E-STOP) $USER_SAF (safety gate closed) $I_O_ACTCONF(EXT)

INPUTS

OUTPUTS

$STOPMESS (stop message)

$IN_HOME (robot in HOME position)

INPUTS

$MOVE_ENABLE (motion enable) $DRIVES_ON (activate drives) $DRIVES_OFF (drives not deactivated)

OUTPUTS

KRC

PLC



Signal diagram example: DRIVES_ON omitted


INPUTS

OUTPUTS



INPUTS

$MOVE_ENABLE (motion enable) $DRIVES_ON (activate drives) $DRIVES_OFF (drives not deactivated)

OUTPUTS

KRC

PLC


Page 182 of 227



Signal diagram example: Acknowledge messages


INPUTS

OUTPUTS



INPUTS

$MOVE_ENABLE (motion enable) $CONF_MESS (ackn. messages)

OUTPUTS

KRC

PLC

$DRIVES_OFF (drives not deactivated) KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Signal diagram example: Acknowledge messages


INPUTS

OUTPUTS



INPUTS

$MOVE_ENABLE (motion enable) $CONF_MESS (ackn. messages)

OUTPUTS

KRC

PLC




Page 183 of 227

$PERI_RDY (drives are on) $ALARM_STOP (no E-STOP) $USER_SAF (safety gate closed) $I_O_ACTCONF(EXT) $ON_PATH (robot is on path)

INPUTS

OUTPUTS

Signal diagram example: Start program

$PRO_ACT (program is active) $IN_HOME (robot in HOME position)

INPUTS

$EXT_START (start program) $MOVE_ENABLE (motion enable)

OUTPUTS

KRC

PLC




INPUTS

OUTPUTS

Signal diagram example: EXT_START omitted


INPUTS

$EXT_START (start program) $MOVE_ENABLE (motion enable)

OUTPUTS

KRC

PLC


Page 184 of 227



Signal diagram example: Transfer program number


INPUTS

KRC

$MOVE_ENABLE (motion enable)

OUTPUTS

$PRO_ACT (program is active) $IN_HOME (robot in HOME position) PGNO (number + parity) PGNO_VALID (read command)

INPUTS

OUTPUTS

PGNO_REQ (request)

PLC



Signal diagram example: Program running

PGNO_REQ (request) $PERI_RDY (drives are on) $ALARM_STOP (no E-STOP) $USER_SAF (safety gate closed) $I_O_ACTCONF(EXT) $ON_PATH (robot is on path)

INPUTS

KRC


OUTPUTS


INPUTS

OUTPUTS

APPL_RUN (program running)

PLC




Page 185 of 227

Signal diagram example: Program running

PGNO_REQ (request) $PERI_RDY (drives are on) $ALARM_STOP (no E-STOP) $USER_SAF (safety gate closed) $I_O_ACTCONF(EXT) $ON_PATH (robot is on path)

INPUTS

KRC


OUTPUTS


INPUTS

OUTPUTS


PLC



Signal diagram example: End of program


INPUTS

OUTPUTS



INPUTS


OUTPUTS

KRC

PLC


Page 186 of 227



Signal diagram example: End of program


INPUTS

OUTPUTS



INPUTS


OUTPUTS

KRC

PLC



Signal diagram example: New program request


INPUTS

KRC


OUTPUTS


INPUTS

OUTPUTS

PGNO_REQ (request)

PLC




Page 187 of 227

18.1.

Programnumber typ 1


Page 189 of 227

Display format of the program number: BINARY

Binary coded integer: PGNO_TYPE=1

Input:

... E8

E7

E6

E5

E4

E3

E2

E1

Values:

27= 26= 25= 24= 23= 22= 21= 20= 128 64 32 16 8 4 2 1

Example:

0

Prog. no.:

1

1

0

0

0

1

97 =0 + 64 + 32 + 0 + 0 + 0 + 0 + 1


Page 190 of 227

0



18.2.

Programnumber typ 2


Page 191 of 227

Display format of the program number: BCD

Binary coded decimal: PGNO_TYPE=2 2nd decimal place

Input:

1st decimal place

... E8

E7

E6

E5

E4

E3

E2

E1

Values:

8

4

2

1

8

4

2

1

Example:

0

0

1

0

0

1

1

1

Result:

Prog. no.:

2

7

27


Page 192 of 227



18.3.

Programnumber typ 3


Page 193 of 227

Display format of the program number: "1 of N"

"1 of N" coded integer: PGNO_TYPE=3 Input (max. 16): ...

E8

E7

E6

E5

E4

E3

E2

E1

Prog. no. 1 :

0

0

0

0

0

0

0

1

Prog. no. 2 :

0

0

0

0

0

0

1

0

Prog. no. 3 :

0

0

0

0

0

1

0

0

Prog. no. 4 :

0

0

0

0

1

0

0

0

Prog. no. 5 :

0

0

0

1

0

0

0

0

Prog. no. 6 :

0

0

1

0

0

0

0

0

Prog. no. 7 :

0

1

0

0

0

0

0

0

Prog. no. 8 :

1

0

0

0

0

0

0

0

Only one input may be "TRUE" at any time. All other input combinations result in an invalid program number. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

Page 194 of 227



18.4.

Inputs


Page 195 of 227

Program number format: PGNO_TYPE

This value determines the format in which the program number sent by the host computer is read. PGNO_TYPE

Read as ...

1

Binary number

The program number is transmitted by the higher-level controller as a binary coded integer.

Click Click

2

BCD value

The program number is transmitted by the higher-level controller as a binary coded decimal.

Click Click

3

*1

*1

"1 of N"

Meaning

The program number is transmitted by the higher-level controller or the periphery as a "1 of n" coded value.

Example

Click Click

When using this transmission format, the values of PGNO_REQ, PGNO_PARITY and PGNO_VALID are not evaluated and are thus of no significance.



Mirroring the program number: REFLECT_PROG_NR

This option allows you to decide whether or not the program number should be mirrored in a definable output area.

REFLECT_PROG_NR

Function

0

Deactivated

0

Activated

The output of the signal starts with the output defined using "PGNO_FBIT_REFL".


Page 196 of 227



Program number length in bits: PGNO_LENGTH

Its value determines the number of bits defining the program number sent by the host computer.

PGNO_LENGTH = 1...16 Example: PGNO_LENGTH = 6 ;the external program number is six bits long

While PGNO_TYPE has the value 2 (program number read as BCD value), only 4, 8, 12 and 16 are permissible values for the number of bits.



First bit in the program number: PGNO_FBIT

Input representing the first bit of the program number.

PGNO_FBIT = 1...1024 (PGNO_LENGTH) Example: PGNO_FBIT = 5 ;the external program number begins with $IN[5]




Page 197 of 227

Parity bit: PGNO_PARITY

Input to which the parity bit is transferred from the host computer.

Input

Function

Negative value

Odd parity

0

No evaluation

Positive value

Even parity

While PGNO_TYPE has the value 3 (program number read as "1 of n" value), PGNO_PARITY is NOT evaluated.



Program number valid: PGNO_VALID

Input to which the command to read the program number is transferred from the host computer. Input Negative value

0

Positive value

Function Number is transferred at the falling edge of the signal Number is transferred at the rising edge of the signal on the EXT_START line Number is transferred at the rising edge of the signal

While PGNO_TYPE has the value 3 (program number read as "1 of n" value), PGNO_PARITY is NOT evaluated.


Page 198 of 227



Program start: $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, so there is no program stop at the first programmed position.



Motion enable: $MOVE_ENABLE

This input is used by the host computer to check the robot drives.

Signal

Function

TRUE

Manual motion and program execution are possible

FALSE

All drives are stopped and all active commands inhibited

If the drives have been switched off by the host computer, the message "GENERAL MOTION ENABLE" appears in the message window of the KCP. It is only possible to move the robot again once this message has been reset and another external start signal has been given. KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002



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MOVE_ENABLE monitoring: $CHCK_MOVENA

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

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 whatsoever.



Error acknowledgement: $CONF_MESS

Setting this input enables the host computer to reset (acknowledge) error messages automatically.

Only the rising edge of the signal is evaluated.

Acknowledgement of the error messages is, of course, only possible once the cause of the error has been eliminated.


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Drives on/off: $DRIVES_ON / $DRIVES_OFF

DRIVES_ON With a high-level pulse of at least 20 ms duration at this input, the host computer can switch on the robot drives.

DRIVES_OFF With a low-level pulse of at least 20 ms duration at this input, the host computer can switch off the robot drives.




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19. Excercises Overview: Exercises for the basic course General exercises: 1-10 Exercise 1: Operator control, jogging Exercise 2: Robot mastering Exercise 3: Tool calibration (pen and gripper) Exercise 4: BASE calibration (table) Exercise 5: “In-air” program (PTP motion) Exercise 6: CP motion, approximate positioning (waterjet cutting) Exercise 7: Component I Exercise 8: BASE offset (tool mount offset) Exercise 9: BASE offset (two tool mounts) Exercise 10: Component II (adhesive application, I/O’s) Exercises with external TCP: 11-14 Exercise 11: Gripper programming (plastic panel) Exercise 12: External TCP (tool calibration) Exercise 13: Adhesive application on windshield (plastic panel) Exercise 14: Subprograms (plastic panel) Exercises without external TCP: 15-16 Exercise 15: Gripper programming (cube magazine) Exercise 16: Subprograms (CP motion) Exercises for expert level: 17-18 Exercise 17: Expert I (loop) Exercise 18: Automatic External KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

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Exercises: GP - KR C2

Basic exercises: General exercises: Exercise 1: Operator control, manual motion Exercise 2: Robot mastering Exercise 3: Tool calibration (pen and gripper) Exercise 4: BASE calibration (table) Exercise 5: “In-air” program (PTP motion) Exercise 6: CP motion, approximate positioning (waterjet cutting) Exercise 7: Component I Exercise 8: BASE offset (tool mount offset) Exercise 9: BASE offset (two tool mounts) Exercise 10: Component II (adhesive application, I/Os)

Advanced exercises: Exercises with external TCP: Exercise 11: Gripper programming (plastic panel) Exercise 12: External TCP (tool calibration) Exercise 13: Adhesive application on windshield (plastic panel) Exercise 14: Subprograms (plastic panel)

Exercises without external TCP: Exercise 15: Gripper programming (cube magazine) Exercise 16: Subprograms (CP motion)

Expert exercises: Exercises for expert level: Exercise 17: Expert I (loop) Exercise 18: Automatic External



General exercises: 1-10








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Exercise 1: Exercise 2: Exercise 3: Exercise 4: Exercise 5: Exercise 6: Exercise 7: Exercise 8: Exercise 9: Exercise 10:

Operator control, jogging Robot mastering Tool calibration (pen and gripper) BASE calibration (table) “In-air” program (PTP motion) CP motion, approximate positioning (waterjet cutting) Component I BASE offset (tool mount offset) BASE offset (two tool mounts) Component II (adhesive application, I/Os)

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Exercise 1: Operator control, jogging



Exercise: Operator control, motion, jogging Tasks: • Switch the control cabinet on and wait for the system to boot. • Check the robot type and software version. • Release the EMERGENCY STOP and acknowledge it. • Make sure that the mode selector switch is set to T1. • Activate manual motion for the joint (axis-specific) coordinate system. • Move the robot in joint (axis-specific) mode with various different manual (jog) override settings (HOV) using the jog keys and Space Mouse. • Explore the range of motion of the individual axes. Be careful to avoid any obstacles present, such as a table or cube magazine with fixed tool. (Accessibility investigation) • On reaching the software limit switches, observe the message window. • Interpret the error message (Ch. 12). • Eliminate the error. • In joint (axis-specific) mode, move the gripper to a cube from several different directions. • Repeat this procedure in the WORLD coordinate system. • Move the robot to the transport position and press the EMERGENCY STOP button.


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Exercise 2: Robot mastering

• Carry out mastering in axis-specific jog mode • Master each axis individually • Begin with axis 1 and work upwards • Always move from + to • Pre-mastering position = frontsight and rearsight aligned



Exercise: Robot mastering Tasks: • Unmaster all robot axes • Move all robot axes to the pre-mastering position in joint mode. • Master all axes with the electronic measuring tool (EMT). • Display the actual position in joint mode.

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Exercise 3: Tool calibration (pen and gripper)



Exercise: Tool calibration Tasks: • Calibrate the TCP of the pen using the “XYZ 4-Point” method. Use the black metal tip as the reference point. Assign the tool the TOOL number 2 (TOOL_DATA[2]) • Calibrate the tool orientation using the “A B C - World (5D)” method. The tool coordinate system is then situated on the tool as illustrated above. • Save the TOOL data. • Test the motion with the pen in the TOOL coordinate system. • Calibrate the gripper using the calibration cube (TOOL_DATA[3]). The procedure here is the same as that for points 1 and 2. • Test the motion with the gripper in the TOOL coordinate system.


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Exercise 4: BASE calibration (table)

BASE_DATA[1] BASE_DATA[2] KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Exercise: BASE calibration Tasks: • Calibrate the BASE system labeled on the worktable (blue) with the name BASE_DATA[1] using the “3-Point” method. • Calibrate the BASE system labeled on the worktable (red) with the name BASE_DATA[2] using the “3-Point” method. • Use the pen (TOOL_DATA[2]) as calibration tool. • Save the BASE data. • Move the TCP in the BASE-specific system to the origin of the BASE_DATA[2] coordinate system. • Display the actual position in “Cartesian” mode.

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Exercise 5: “In-air” program (PTP motion)

possible PTP path

shortest path



Exercise: Dummy program Tasks: • Teach 5 points in space as PTP motion points. Pay attention to interference contours and obstacles caused by the workplace equipment. • Test your program in mode T1. • Following error-free execution of your program, run it again in mode T2 and then in automatic mode. • Then archive your program.


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Exercise 6: CP motion, approximate positioning (waterjet cutting)

3D contour

START

BASE_DATA[1] KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Exercise: CP motion, 3D contour Tasks: 1. Program creation, motion programming, motion type, orientation control, jogging, archiving • • • •

Teach the rectangular contour marked on the worktable, with reference to BASE_DATA[1] (blue, already calibrated), with the name “PATH_3D”. Make sure that the jog velocity on the worktable is no greater than 0.15 m/s. Make sure that the longitudinal axis of the pen is always perpendicular to the path contour (orientation control). Test your program.

2. Copying the program, approximate positioning • • • •

Create a duplicate of the program “PATH_3D” with the name “PATHCONT”. Insert CONT instructions into the motion commands in the program “PATHCONT” so that the robot follows the contour continuously without exact positioning. The corners of the contour are to be approximated using different approximation parameters. Test your program.

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Exercise 7: Component I

Component contour

START

BASE_DATA[1] KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Exercise: CP motion, 3D contour Tasks: 1. Program creation, motion programming, motion type, orientation control, jogging, archiving • • • •

Teach the component contour marked on the worktable, with reference to BASE_DATA[1] (blue, already calibrated), with the name “COMPONENT”. Make sure that the jog velocity on the worktable is no greater than 0.15 m/s. Make sure that the longitudinal axis of the pen is always perpendicular to the path contour (orientation control). Test your program.

2. Copying the program, approximate positioning • • • •

Create a duplicate of the program “COMPONENT” with the name “COMP_CONT”. Insert CONT instructions into the motion commands in the program “COMP_CONT” so that the robot follows the contour continuously without exact positioning. The corners of the contour are to be approximated using different approximation parameters. Test your program.


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Exercise 8: BASE offset (tool mount offset)

Triangular contour

New BASE_DATA[2]



Exercise: BASE offset (tool mount offset) Tasks: • • • • • • • •

Using the pen, “teach” the triangular contour marked on the worktable, with reference to BASE_DATA[2], with the program name “BAS_D”. Make sure that the jog velocity on the worktable is no greater than 0.15 m/s. Test your program in mode T1. Following error-free execution of your program, run it again in mode T2 and then in automatic mode. Then archive your program. Calibrate the BASE system BASE_DATA[2] (blue) again (overwrite the existing BASE 2). Test your program in mode T1. Run the program “BAS_SYS” once again.


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Exercise 9: BASE offset (two tool mounts)

BASE_DATA[5]

BASE_DATA[6]

Circular contour



Exercise: BASE offset (two tool mounts) Tasks: • • • • • • • • • • •

Calibrate the BASE system labeled on the worktable (blue) with the name BASE_DATA[5] using the “3-Point” method. Using the pen, “teach” the circular contour marked on the worktable, with reference to BASE_DATA[5], with the program name “BAS_K1”. Make sure that the jog velocity on the worktable is no greater than 0.15 m/s. Test your program in mode T1. Following error-free execution of your program, run it again in mode T2 and then in automatic mode. Then archive your program. Calibrate the BASE system labeled on the worktable (blue, diagonal) with the name BASE_DATA[6] using the “3-Point” method. Create a duplicate of the program “BAS_K1” with the name “BAS_K2”. In the motion commands, change the base to BASE_DATA[6]. Test your program in mode T1. Run the program “BASE_K2”.

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Exercise 10: Component II (adhesive application, I/Os)

COMPONENT

BASE_DATA[1]



Exercise: Component 1. Copying the program, modifying/correcting positions Tasks: • Create a duplicate of the program “COMPONENT” with the name “NEW_PART”. • Select and execute the program “NEW_PART”. • Now carry out position corrections in this program so that the robot follows the real component contour when the program is executed. (TOOL_DATA[2], BASE_DATA[1]) • Archive your corrected program. 2. Programming logic commands Tasks: • The PLC is to issue an enabling signal before the adhesive nozzle is positioned to the starting point on the component. (Input 14) • The adhesive nozzle must be activated ½ second before it reaches the component. (Output 5) • A signal lamp is to be activated at the transition from the flat part of the table to the curved part of the component and deactivated again at the transition from the curved part back to the flat part of the table. (Output 6) • The adhesive nozzle must be deactivated again 0.75 seconds before it leaves the component.


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•

The end of the work on the component is to be signaled to the PLC. (Output 7 for 2 seconds)

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Exercises with an external TCP: 11-14







Exercise 11: Gripper programming (plastic panel) Exercise 12: External TCP (tool calibration) Exercise 13: Adhesive application on windshield (plastic panel) Exercise 14: Subprograms (plastic panel)


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Exercise 11: Gripper programming (plastic panel)



Exercise: Gripper programming Tasks: • • • • • • •

Create a program with the name “FETCH_PART”. Teach the procedure “Fetch part” (black plastic panel) (TOOL_DATA[3], BASE_DATA[1]). Test your program. Archive your program. Now create a program with the name “PART_DOWN”. Teach the procedure “Part down”. The plastic panel is to be deposited back in the fixture provided for this purpose. Test your program.

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Exercise 12: External TCP (tool calibration)



Exercise: External TCP Tasks: • • • • • •

For the calibration of the fixed tool, the writing tool already calibrated (TOOL_DATA[2]) is to be used as a reference tool. Now calibrate the position and orientation of the external fixed tool. Save the data as BASE_DATA[10]. Run the program “FETCH_PART”. Calibrate the workpiece guided by the robot. Save the data as TOOL_DATA[15].


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Exercise 13: Adhesive application on windshield (plastic panel)



Exercise: Windshield Tasks: • • • • • • • •

Activate the external TCP and the movable workpiece for jogging. Correct the interpolation mode ($IPO_MODE). Move the coordinate origin of the movable workpiece to the TCP of the fixed tool. Display the actual position in “Cartesian” mode. Teach the contour on the plastic panel using the program name “PANEL_PATH”. Make sure that the longitudinal axis of the fixed tool is always perpendicular to the path contour (orientation control). The adhesive is to be applied uniformly along the path. Test your program.

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Exercise 14: Subprograms (plastic panel)



Exercise: Subprograms (complex program) Tasks: • • • •

The programs from exercises 11 and 13 are now to be expanded so that a single program selection suffices to execute the entire procedure: fetch plastic panel, apply adhesive and put plastic panel back down again. Create a new program “PANEL” in which all program sections are executed. Proceed in the same way with the programs from exercises 6 and 7. Create a new program “COM_PATH” in which motions are executed for both paths.


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Exercises without an external TCP: 15-16







Exercise 15: Gripper programming (cube magazine) Exercise 16: Subprograms (CP motion)

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Exercise 15: Gripper programming (cube magazine)

Insert cube

Remove cube



Exercise: Gripper programming Tasks: • • • • •

Create a program with the name “CUBE”. Teach the procedure “Fetch cube” (from bottom of magazine). Teach the procedure “Insert cube” (at top of magazine). Test your program. Archive your program.


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Exercise 16: Subprograms (CP motion)



Exercise: Subprograms (complex program) Tasks: • •

The programs from exercise 6 (“PATHCONT”) and exercise 7 (“COMP_CONT”) are to be executed together as global subprograms in a main program. Create a new program “COM_PATH” in which motions are executed for both paths.

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Exercises for expert level: 17-18







Exercise 17: Expert I (loop) Exercise 18: Automatic External


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Exercise 17: Expert I (loop)

LOOP Statement 1 ... Statement n ENDLOOP Example: DEF LOOP ( ) PTP HOME LOOP LIN P1 CIRC P2, P3 LIN P4 ENDLOOP PTP HOME END

Statement 1

...

Statement n



Exercise: LOOP Tasks: • • •

Create a duplicate of the program “NEW_PART” from exercise 10. The new program is to be called “LOOP”. Execute the program section on the table as a LOOP. Integrate the EXIT command at a sensible point in the program. The EXIT command is to be executed when Input 16 is set.

Supplement: This exercise can alternatively be carried out using the program “CUBE” from exercise 15.

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Exercise 18: Automatic External

Controls the entire system and stores data

Host computer t Etherne g) (archivin

PLCs

Control the system components (robots and periphery)

Execute application programs Robot controllers KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002


Exercise: Automatic External Tasks: • • • •

Integrate the programs you have created into the cell program as global subprograms. Configure the KRC inputs for Aut.Ext. mode. Simulate the signal exchange (handshake) between the KRC and the PLC for automatic system start and normal operation with program number acknowledgement using PGNO_VALID. Observe the message window. Select various program numbers.


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Kuka Krc2 Workbook

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