GlueTech V26 En

Issued: 21.11.2008

Version: KST GlueTech 2.6 V2 en

KUKA Roboter GmbHKUKA System Technology

KUKA.GlueTech 2.6

For KUKA System Software 5.2, 5.3, 5.4 or 5.5

© Copyright 2008

KUKA Roboter GmbHZugspitzstraße 140D-86165 AugsburgGermany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the KUKA Roboter GmbH.

Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work.

We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, how-ever, and necessary corrections will be incorporated in the subsequent edition.

Subject to technical alterations without an effect on the function.

Translation of the original operating instructions

KIM-PS5-DOC

KUKA.GlueTech 2.6

2 / 75 Issued: 21.11.2008 Version: KST GlueTech 2.6 V2 en

Publication: Pub KUKA.GlueTech 2.6 en

Book structure: KUKA.GlueTech 2.6 V1.1

Label: KST GlueTech 2.6 V2

Contents

Contents
1 Introduction .................................................................................................. 7
1.1 Target group .............................................................................................................. 7

1.2 Robot system documentation .................................................................................... 7

1.3 Terms used ................................................................................................................ 7

2 Product description ..................................................................................... 9

2.1 Overview of KUKA.GlueTech ..................................................................................... 9

2.2 Functional principle .................................................................................................... 10

2.3 Switching points and delay times ............................................................................... 10

3 Safety ............................................................................................................ 13

3.1 General ...................................................................................................................... 13

3.1.1 Liability .................................................................................................................. 13

3.1.2 Representation of warnings and notes ................................................................. 13

3.1.3 Designated use of the robot system ..................................................................... 14

3.1.4 EC declaration of conformity and declaration of incorporation ............................. 14

3.1.5 Description of the robot system ............................................................................ 14

3.1.6 Terms used ........................................................................................................... 15

3.2 Personnel ................................................................................................................... 16

3.3 Safety features of the robot system ........................................................................... 17

3.3.1 Overview of the safety features ............................................................................ 17

3.3.2 ESC safety logic ................................................................................................... 18

3.3.3 Mode selector switch ............................................................................................ 18

3.3.4 Stop reactions ....................................................................................................... 20

3.3.5 Workspace, safety zone and danger zone ........................................................... 21

3.3.6 Operator safety ..................................................................................................... 21

3.3.7 EMERGENCY STOP button ................................................................................. 22

3.3.8 Enabling switches ................................................................................................. 22

3.3.9 Connection for external enabling switch ............................................................... 23

3.3.10 Jog mode .............................................................................................................. 23

3.3.11 Mechanical end stops ........................................................................................... 23

3.3.12 Software limit switches ......................................................................................... 24

3.3.13 Overview of operating modes and active safety features ..................................... 24

3.3.14 Mechanical axis range limitation (option) .............................................................. 24

3.3.15 Axis range monitoring (option) .............................................................................. 24

3.3.16 Release device (option) ........................................................................................ 25

3.3.17 KCP coupler (optional) .......................................................................................... 25

3.3.18 External safeguards .............................................................................................. 25

3.3.19 Labeling on the robot system ................................................................................ 26

3.4 Safety measures ........................................................................................................ 27

3.4.1 General safety measures ...................................................................................... 27

3.4.2 Transportation ....................................................................................................... 28

3.4.3 Start-up ................................................................................................................. 28

3.4.4 Virus protection and network security ................................................................... 29

3.4.5 Programming ........................................................................................................ 29

3.4.6 Simulation ............................................................................................................. 29

3.4.7 Automatic mode .................................................................................................... 29

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3.4.8 Maintenance and repair ........................................................................................ 30

3.4.9 Decommissioning, storage and disposal .............................................................. 31

3.5 Applied norms and regulations .................................................................................. 31

4 Installation ................................................................................................... 33

4.1 System requirements ................................................................................................. 33

4.2 Installing KUKA.GlueTech ......................................................................................... 33

4.3 Reinstalling KUKA.GlueTech ..................................................................................... 33

4.4 Updating KUKA.GlueTech ......................................................................................... 33

5 Operation ...................................................................................................... 35

5.1 GlueTech operator control elements ......................................................................... 35

5.1.1 Change of state of status key Dry/Wet ................................................................. 36

6 Configuration ............................................................................................... 37

6.1 Overview of GlueTech configuration ......................................................................... 37

6.2 Configuring KUKA.GlueTech settings ....................................................................... 37

6.3 Configuring inputs ...................................................................................................... 38

6.4 Configuring outputs ................................................................................................... 39

6.5 Configuring delay times ............................................................................................. 40

6.6 Configuring adhesive profiles (bead data) ................................................................. 41

6.7 Configuring GlueTech PLC options ........................................................................... 42

6.8 Calibration routine (Calibrate_Equipment.src) ........................................................... 43

6.8.1 Testing the TCP ................................................................................................... 44

6.8.2 Determining the switching times of the adhesive gun (Gun On/Off) ..................... 45

6.8.3 Determining the material / air flow (Eq. Delay) ..................................................... 45

6.8.4 Determining the reaction time after a jump in the analog output (Ana. Switch) .... 45

6.8.5 Verifying and determining all configuration values (All) ........................................ 46

7 Programming ............................................................................................... 47

7.1 Overview of GlueTech motion commands ................................................................. 47

7.1.1 LIN with adhesive gun on - GLUE ON LIN ........................................................... 47

7.1.2 LIN with switch of gluing parameters - GLUE SWITCH LIN ................................. 48

7.1.3 LIN with adhesive gun off - GLUE OFF LIN ......................................................... 48

7.1.4 CIRC with adhesive gun on - GLUE ON CIRC ..................................................... 49

7.1.5 CIRC with switch of gluing parameters - GLUE SWITCH CIRC ........................... 49

7.1.6 CIRC with adhesive gun off - GLUE OFF CIRC ................................................... 49

7.1.7 PTP with adhesive gun on - GLUE ON PTP ........................................................ 50

7.1.8 PTP with adhesive gun off - GLUE OFF PTP ....................................................... 51

7.2 Overview of GlueTech gluing instructions ................................................................. 51

7.2.1 Init system command ............................................................................................ 52

7.2.2 Set program number command ............................................................................ 52

7.2.3 Set / reset motion parameter command ............................................................... 53

7.2.4 Dispense complete command .............................................................................. 53

7.2.5 Reload doser command ....................................................................................... 54

7.2.6 Error check command .......................................................................................... 54

7.2.7 Purge gun command ............................................................................................ 54

7.2.8 Monitor purge gun command ................................................................................ 55

7.2.9 Enable purge ........................................................................................................ 55

7.3 Teaching the purge position (MoveToPurge) ............................................................ 56

Issued: 21.11.2008 Version: KST GlueTech 2.6 V2 en

Contents

7.4 Program example ....................................................................................................... 57

8 System variables ......................................................................................... 59

8.1 Signal declarations ..................................................................................................... 59

8.2 GlueTech variables in $Config.dat ............................................................................. 60

8.3 GlueTech variables in Glue.dat .................................................................................. 61

9 Messages ..................................................................................................... 63

10 KUKA Service .............................................................................................. 65

10.1 Requesting support .................................................................................................... 65

10.2 KUKA Customer Support ........................................................................................... 65

Index ............................................................................................................. 71


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1. Introduction

1 Introduction

1.1 Target group

This documentation is aimed at users with the following knowledge and skills:

Advanced KRL programming skills

Advanced knowledge of the robot controller system

Advanced knowledge of the dispensing controller systems

Knowledge of field bus interfaces

1.2 Robot system documentation

The robot system documentation consists of the following parts:

Operating instructions for the robot

Operating instructions for the robot controller

Operating and programming instructions for the KUKA System Software

Documentation relating to options and accessories

Each of these sets of instructions is a separate document.

1.3 Terms used

The following terms are used in this documentation:

For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training pro-gram can be found at www.kuka.com or can be obtained directly from our subsidiaries.

Term Description

Bead data Data set with settings for speed and analog voltage for each adhesive profile.

Exact position-ing

Programmed position of the robot without approximate positioning. The robot stops at the position.

Handshaking Handshaking is a method used to check 2 devices dur-ing data transmission by means of direct acknowledge-ment signals.

Calibration rou-tine

The KUKA.GlueTech calibration routine verifies various configuration values using a defined linear path.

Seam number The seam number uniquely specifies the adhesive seam.

Switching point The switching point defines the switching position of the adhesive gun.

Switching times The programmable switching times compensate for the delay time of the adhesive gun.

Purging Function for clearing the adhesive gun.Purge position Defined position for clearing the adhesive gun. Motion parame-ters

Programmable parameters and machine data adapted specifically for adhesive application tasks.


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2. Product description

2 Product description

2.1 Overview of KUKA.GlueTech

KUKA.GlueTech is an add-on technology package with the following func-tions:

Functions Control of dispensing controllers SCA, Bielenberg, Kleinmichel ...

Staggered control of up to 3 dispensing controllers

KRL commands for the creation of dispensing applications (inline forms)

Configuration of up to 20 different adhesive profiles (bead data)

Calibration routine

Transmission of the seam number to the PLC

Diverse settings (I/Os, PLC, etc.)

Areas of appli-cation

Application of adhesive beads

Application of adhesive beads with 2-component adhesives

Bead shaping (electrical / pneumatic)

Thin-jet flatstream sealing

Extruded application of sound-insulating material

Communication The robot controller communicates with the dispensing controller via a field bus. Interbus, Profibus or DeviceNet can be used. There are different field bus cards for the robot controller. The drivers and the I/Os are configured in the bus configuration files and in IOSYS.INI.

Fig. 2-1: Example of an adhesive bonding cell

1 Dispensing controller 5 Pump controller2 Robot controller 6 Robot3 PLC 7 Dispenser4 Drum pump 8 Adhesive gun


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2.2 Functional principle

Description KUKA.GlueTech regulates the following parameters of the dispensing control-ler in proportion with the path velocity (TCP):

Delivery rate of the material

Delivery rate of the air spray

The parameters are regulated via the analog voltage of the outputs. The out-puts are configured via the field bus of the robot controller.

2.3 Switching points and delay times

Description In the dispensing process, time delays occur at the switching points (Glue On, Glue Switch, Glue Off) between the robot controller and the dispensing con-troller. This influences the material flow and the air supply. For this reason, the switching points must be adapted accordingly.

Further information about the field buses can be found in the corresponding KUKA documentation.

Fig. 2-2: Diagram: Analog voltage / speed

Fig. 2-3: Diagram: Delay times / offset


2. Product description

Example The following graphic shows a dispensing process with a straight seam. The angle of the adhesive nozzle to the workpiece should be between 70° and 90°, depending on the application. The start point of the robot is P1. At the switch-ing point On (Glue On LIN), the adhesive gun is switched on. The material flow begins after a delay.

At the switching point Off (Glue Off LIN), the adhesive gun is switched off. This material flow stops after a delay.

1 Material flow 5 Delay time2 Air supply 6 Delay time3 Robot motion 7 Offset4 Delay time

Fig. 2-4: Switching points, delay times during the dispensing process

1 Delay time2 Delay time


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3. Safety

3 Safety

3.1 General

3.1.1 Liability

The device described in these operating instructions is an industrial robot – called “robot system” in the following text – consisting of:

Robot

Connecting cables

Robot controller

Teach pendant

Linear unit (optional)

Positioner (optional)

Two-axis positioner (optional)

Top-mounted cabinet (optional)

The robot system is built using state-of-the-art technology and in accordance with the recognized safety rules. Nevertheless, impermissible misuse of the robot system may constitute a risk to life and limb or cause damage to the ro-bot system and to other material property.

The robot system may only be used in perfect technical condition in accord-ance with its designated use and only by safety-conscious persons who are fully aware of the risks involved in its operation. Use of the robot system is sub-ject to compliance with these operating instructions and with the declaration of incorporation supplied together with the robot system. Any functional disor-ders affecting the safety of the system must be rectified immediately.

Safety infor-mation

Safety information cannot be held against KUKA Roboter GmbH. Even if all safety instructions are followed, this is not a guarantee that the robot system will not cause personal injuries or material damage.

No modifications may be carried out to the robot system without the authori-zation of KUKA Roboter GmbH. Additional components (tools, software, etc.), not supplied by KUKA Roboter GmbH, may be integrated into the robot sys-tem. The user is liable for any damage these components may cause to the robot system or to other material property.

3.1.2 Representation of warnings and notes

Safety Warnings marked with this pictogram are relevant to safety and must be ob-served.

Danger!This warning means that death, severe physical injury or substantial material damage will occur, if no precautions are taken.

Warning!This warning means that death, severe physical injury or substantial material damage may occur, if no precautions are taken.

Caution!This warning means that minor physical injuries or minor material damage may occur, if no precautions are taken.


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Notes Notes marked with this pictogram contain tips to make your work easier or ref-erences to further information.

3.1.3 Designated use of the robot system

The robot system is designed exclusively for the specified applications.

Using the robot system or its options for any other or additional purpose is con-sidered impermissible misuse. The manufacturer cannot be held liable for any damage resulting from such use. The risk lies entirely with the user.

Operating the robot system and its options within the limits of its designated use also involves continuous observance of the operating instructions with particular reference to the maintenance specifications.

Impermissible misuse

Any use or application deviating from the designated use is deemed to be im-permissible misuse; examples of such misuse include:

Transportation of persons and animals

Use as a climbing aid

Operation outside the permissible operating parameters

Use in potentially explosive environments

3.1.4 EC declaration of conformity and declaration of incorporation

Declaration of conformity

The system integrator must issue a declaration of conformity for the overall system in accordance with the Machinery Directive. The declaration of con-formity forms the basis for the CE mark for the system. The robot system must be operated in accordance with the applicable national laws, regulations and standards.

The robot controller is CE certified under the EMC Directive and the Low Volt-age Directive.

Declaration of incorporation

A declaration of incorporation is provided for the robot system. This declara-tion of incorporation contains the stipulation that the robot system must not be commissioned until it complies with the provisions of the Machinery Directive.

3.1.5 Description of the robot system

The robot system consists of the following components:

Robot

Robot controller

KCP teach pendant

Connecting cables

Tips to make your work easier or references to further information.

Specific safety instructionsIn addition to the Safety chapter, the operating instructions for the robot sys-tem and its options contain further safety instructions. These must be ob-served.

Further information is contained in the technical data of the operating instruc-tions for the robot system and its options.


3. Safety

External axes, e.g. linear unit, two-axis positioner, positioner (optional)

Top-mounted cabinet (optional)

Software

Options, accessories

3.1.6 Terms used

Fig. 3-1: Example of a robot system

1 Linear unit 4 Connecting cables2 Robot 5 Robot controller3 Positioner 6 Teach pendant

Term Description

Axis range Range of an axis, in degrees, within which the robot may move The axis range must be defined for each axis that is to be monitored.

Working envelope The robot is allowed to move within its work-space. The workspace is derived from the indi-vidual axis ranges.

Operator(User)

The user of the robot system can be the man-agement, employer or delegated person respon-sible for use of the robot system.

Braking distance The braking distance is the distance covered by the robot and any optional external axes after the stop function has been triggered and before the robot comes to a standstill. The braking dis-tance is part of the danger zone.

Danger zone The danger zone consists of the workspace and the braking distances.

KCP The KCP (KUKA Control Panel) teach pendant has all the functions required for operating and programming the robot system.


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3.2 Personnel

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 ex-ist. Instruction must be repeated after particular incidents or technical modifi-cations.

Personnel include the system integrator responsible for integrating the robot system into the production cell, the user, and the operator or programmer of the robot system.

User The user of a robot system is responsible for its use. The user must ensure that it can be operated in complete safety and define all safety measures for personnel.

The user should check at specific intervals selected at his own discretion that the personnel attend to their work in a safety-conscious manner, are fully aware of the risks involved during operation and observe the operating instruc-tions for the robot system.

System integrator The robot system is safely integrated into a plant by the system integrator.

Robot system The robot system consists of the robot controller and robot, together with any options (e.g. KUKA linear unit, two-axis positioner, other positioner, top-mounted cabinet).

Safety zone The safety zone is situated outside the danger zone.

STOP 0(path-oriented braking)

In the case of a STOP 0, the drives are deacti-vated immediately and the brakes are applied. The robot and any external axes (optional) per-form path-oriented braking.

STOP 1(path-maintaining braking)

In the case of a STOP 1, the robot and any external axes (optional) perform path-maintain-ing braking. The drives are deactivated after 1 s and the brakes are applied.

STOP 2(ramp-down braking)

In the case of a STOP 2, the drives are not deac-tivated and the brakes are not applied. The robot and any external axes (optional) are braked with a normal braking ramp.

System integrator(plant integrator)

System integrators are people who safely inte-grate the robot system into a plant and commis-sion it.

T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)

T2 Test mode, Manual High Velocity (> 250 mm/s)External axis Motion axis which is not part of the robot but

which is controlled using the robot controller, e.g. KUKA linear unit, two-axis positioner, Posiflex

Term Description

All persons working with the robot system must have read and understood the robot system documentation, including the safety chapter.

Installation, exchange, adjustment, operation, maintenance and repair must be performed only as specified in the operating instructions for the relevant component of the robot system and only by personnel specially trained for this purpose.


3. Safety

The system integrator is responsible for the following tasks:

Installing the robot system

Connecting the robot system

Implementing the required facilities

Issuing the declaration of conformity

Attaching the CE mark

Operator The operator must meet the following preconditions:

The operator must have read and understood the robot system documen-tation, including the safety chapter.

The operator must be trained for the work to be carried out.

Work on the robot system must only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and ex-perience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential dangers.

Example The tasks can be distributed as shown in the following table.

3.3 Safety features of the robot system

3.3.1 Overview of the safety features

The following safety features are provided with the robot system:

For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training pro-gram can be found at www.kuka.com or can be obtained directly from our subsidiaries.

Tasks Operator ProgrammerSystem integrator

Switch robot controller on/off

x x x

Start program x x x

Select program x x x

Select operating mode x x x

Calibration (tool, base)

x x

Master robot x x

Configuration x x

Programming x x

Start-up x

Maintenance x

Repair x

Shutting down x

Transportation x

Work on the electrical and mechanical equipment of the robot system may only be carried out by specially trained personnel.


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Operator safety

EMERGENCY STOP pushbutton

Enabling switch

Mode selector switch

Jog mode

Mechanical limit stops

Software limit switches

Labeling on the robot system

Mechanical axis range limitation (optional)

Axis range monitoring (optional)

Release device (optional)

KCP coupler (optional)

The function and triggering of the electronic safety equipment are monitored by the ESC safety logic.

3.3.2 ESC safety logic

The ESC (Electronic Safety Circuit) safety logic is a dual-channel computer-aided safety system. It permanently monitors all connected safety-relevant components. In the event of a fault or interruption in the safety circuit, the pow-er supply to the drives is shut off, thus bringing the robot system to a standstill.

Depending on the operating mode of the robot system, the ESC safety logic triggers a different stop reaction.

The ESC safety logic monitors the following inputs:

Operator safety

Local EMERGENCY STOP

External EMERGENCY STOP

Enabling

Drives OFF

Drives ON

Operating modes

Qualifying inputs

3.3.3 Mode selector switch

The robot system can be operated in the following modes:

Manual Reduced Velocity (T1)

Manual High Velocity (T2)

Automatic (AUT)

Automatic External (AUT EXT)

The operating mode is selected using the mode selector switch on the KCP. The switch is activated by means of a key which can be removed. If the key is removed, the switch is locked and the operating mode can no longer be changed.

Danger!In the absence of functional safety equipment, the robot system can cause personal injury or material damage. If safety equipment is dismantled or de-activated, the robot system may not be operated.


3. Safety

If the operating mode is changed during operation, the drives are immediately switched off. The robot and any external axes (optional) are stopped with a STOP 0.

Fig. 3-2: Mode selector switch

1 T2 (Manual High Velocity)2 AUT (Automatic)3 AUT EXT (Automatic External)4 T1 (Manual Reduced Velocity)

Operating mode

Use Velocities

T1 For test operation

Program mode:

Programmed velocity, maxi-mum 250 mm/s

Jog mode:

Jog velocity, maximum 250 mm/s

T2 For test operation

Program mode:

Programmed velocity

Jog mode:

Jog velocity, maximum 250 mm/s

AUT

For robot systems without higher-level controllers

Only possible with a connected safety cir-cuit

Program mode:

Programmed velocity

Jog mode: not possible

AUT EXT

For robot systems with higher-level control-lers, e.g. PLC

Only possible with a connected safety cir-cuit

Program mode:

Programmed velocity

Jog mode: not possible


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3.3.4 Stop reactions

Stop reactions of the robot system are triggered in response to operator ac-tions or as a reaction to monitoring functions and error messages. The follow-ing table shows the different stop reactions according to the operating mode that has been set.

STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 60204.

Trigger T1, T2 AUT, AUT EXT

Safety gate opened - Path-maintaining braking (STOP 1)

EMERGENCY STOP pressed

Path-oriented braking(STOP 0)

Path-maintaining braking (STOP 1)

Enabling switch released


-

Start key released Ramp-down braking(STOP 2)

-

"Drives OFF" key pressed


STOP key pressed Ramp-down braking(STOP 2)

Operating mode changed


Encoder error (DSE-RDC connec-tion broken)

Short-circuit braking(STOP 0)

Motion enable can-celed

Ramp-down braking(STOP 2)

Robot controller switched off

Power failure


Stop reaction Drives Brakes Software Path

Ramp-down braking (STOP 2)

Drives remain on.

Brakes remain open.

Normal ramp which is used for acceleration and deceleration.

The path is maintained ex-actly.

Path-maintain-ing braking (STOP 1)

Drives are switched off after 1 second hardware delay.

Brakes are applied after 1 s at latest.

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

The path is maintained ex-actly.

Path-oriented braking (STOP 0)

Drives are switched off immediately.

Brakes are applied imme-diately.

The controller attempts to brake the robot on the path with the remaining energy. If the voltage is not sufficient, the robot leaves the programmed path.

The path is maintained approximately.


Drives are switched off immediately.

Brakes are applied imme-diately.

Stop initiated by the drive hardware. Energy present in the intermedi-ate circuit is used for braking.

The path is left.


3. Safety

3.3.5 Workspace, safety zone and danger zone

Workspaces are to be restricted to the necessary minimum size. A workspace must be safeguarded using appropriate safeguards.

The safeguards (e.g. safety gate) must be situated inside the safety zone. If a safeguard is triggered, the robot and external axes are braked and come to a stop within the workspace or the braking range.

The danger zone consists of the workspace and the braking distances of the robot and external axes (optional). It must be safeguarded by means of pro-tective barriers to prevent danger to persons or the risk of material damage.

3.3.6 Operator safety

The operator safety input is used for interlocking fixed guards. Safety equip-ment, such as safety gates, can be connected to the dual-channel input. If nothing is connected to this input, operation in Automatic mode is not possible. Operator safety is not active in the test modes T1 (Manual Reduced Velocity) and T2 (Manual High Velocity).

In the event of a loss of signal during Automatic operation (e.g. safety gate is opened), the drives are deactivated after 1 s and the robot and any external axes (optional) are stopped with a STOP 1. When the signal is applied again at the input (e.g. safety gate closed), Automatic operation can be resumed once the corresponding message has been acknowledged.

Operator safety can be connected via the peripheral interface on the robot controller.

Fig. 3-3: Example of axis range A1

1 Workspace 3 Braking distance2 Robot 4 Safety zone

The operator safety must be designed in such a way that it is only possible to acknowledge the message from outside.


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3.3.7 EMERGENCY STOP button

The EMERGENCY STOP button for the robot system is located on the KCP. If the EMERGENCY STOP button is pressed in the operating modes T1 (Man-ual Reduced Velocity) or T2 (Manual High Velocity), the drives are disconnect-ed immediately. The robot and any external axes (optional) are stopped with a STOP 0.

In the Automatic operating modes, the drives are disconnected after 1 s. The robot and any external axes (optional) are stopped with a STOP 1. The EMER-GENCY STOP button must be pressed as soon as persons or equipment are endangered. Before operation can be resumed, the EMERGENCY STOP but-ton must be turned to release it and the stop message must be acknowledged.

3.3.8 Enabling switches

There are 3 enabling switches installed on the KCP. The enabling switches have 3 positions:

Not pressed

Center position

Panic position

In the test modes T1 (Manual Reduced Velocity) and T2 (Manual High Veloc-ity), the robot can only be moved if one of the enabling switches is held in the central position. If the enabling switch is released or pressed fully down (panic position), the drives are deactivated immediately and the robot stops with a STOP 0.

Fig. 3-4: EMERGENCY STOP button on the KCP

1 EMERGENCY STOP button


3. Safety

3.3.9 Connection for external enabling switch

An external enabling switch is required if there is more than one person in the danger zone of the robot system.

The external enabling switch can be connected via the peripheral interface on the robot controller.

An external enabling switch is not included in the scope of supply of KUKA Ro-boter GmbH.

3.3.10 Jog mode

In the operating modes T1 (Manual Reduced Velocity) and T2 (Manual High Velocity), the robot can only execute programs in jog mode. This means that it is necessary to hold down an enabling switch and the Start key in order to execute a program. If the enabling switch is released or pressed fully down (panic position), the drives are deactivated immediately and the robot and any external axes (optional) stop with a STOP 0. Releasing the Start key causes the robot system to be stopped with a STOP 2.

3.3.11 Mechanical end stops

The axis ranges of main axes A 1 to A 3 and wrist axis A 5 of the robot are lim-ited by means of mechanical limit stops with a buffer.

Additional mechanical limit stops can be installed on the external axes.

Fig. 3-5: Enabling switches on the KCP

1 - 3 Enabling switches


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3.3.12 Software limit switches

The axis ranges of all robot and positioner axes are limited by means of ad-justable software limit switches. These software limit switches only serve as machine protection and must be adjusted in such a way that the robot/posi-tioner cannot hit the mechanical limit stops.

The software limit switches are set during commissioning of a robot system.

3.3.13 Overview of operating modes and active safety features

The following table indicates the operating modes in which the safety features are active.

3.3.14 Mechanical axis range limitation (option)

Most robots can be fitted with mechanical axis range limitation in main axes A 1 to A 3. Additional working range limitation can be installed on the position-er axes. The adjustable axis range limitation systems restrict the working range to the required minimum. This increases personal safety and protection of the system.

3.3.15 Axis range monitoring (option)

Most robots can be fitted with dual-channel axis range monitoring systems in main axes A 1 to A 3. The positioner axes may be fitted with additional axis

Danger!If the robot or an external axis hits an obstruction or a buffer on the mechan-ical end stop or axis range limitation, this can result in material damage to the robot system. KUKA Roboter GmbH must be consulted before the robot sys-tem is put back into operation (>>> 10 "KUKA Service" page 65). The affect-ed buffer must immediately be replaced with a new one. If a robot (or external axis) collides with a buffer at more than 250 mm/s, the robot (or external axis) must be exchanged or recommissioning must be carried out by the KUKA Roboter GmbH.

Further information is contained in the operating and programming instruc-tions.

Safety features T1 T2 AUT AUT EXT

Operator safety - - active active

EMERGENCY STOP button

active (STOP

0)

active (STOP

0)

active (STOP

1)

active (STOP 1)

Enabling switch active active - -

Reduced velocity in program mode

active - - -

Jog mode active active - -

Software limit switches active active active active

This option can be retrofitted.


3. Safety

range monitoring systems. The safety zone for an axis can be adjusted and monitored using an axis range monitoring system. This increases personal safety and protection of the system.

3.3.16 Release device (option)

Description The release device can be used to move the robot mechanically after an acci-dent or malfunction. The release device can be used for the main axis drive motors and, depending on the robot variant, also for the wrist axis drive mo-tors. It is only for use in exceptional circumstances and emergencies (e.g. for freeing people). After use of the release device, the affected motors must be exchanged.

Procedure 1. Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again.

2. Remove the protective cap from the motor

3. Push the release device onto the corresponding motor and move the axis in the desired direction.

The directions are indicated with arrows on the motors. It is necessary to overcome the resistance of the mechanical motor brake and any other loads acting on the axis.

3.3.17 KCP coupler (optional)

The KCP coupler allows the KCP to be connected and disconnected with the robot controller running.

3.3.18 External safeguards

EMERGENCY STOP

Additional EMERGENCY STOP devices can be connected via the peripheral interface on the robot controller or linked together by means of higher-level controllers (e.g. PLC).

This option can be retrofitted.

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

Warning!Moving an axis with the release device can damage the motor brake. This can result in personal injury and material damage. After using the release de-vice, the affected motor must be exchanged.

Further information is contained in the robot operating instructions.

Warning!If the KCP is disconnected, the system can no longer be deactivated by means of the EMERGENCY STOP button on the KCP. An external EMER-GENCY STOP must be connected to the peripheral interface to prevent per-sonal injury and material damage.

Further information is contained in the robot controller operating instructions.


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The input/output signals and any necessary external power supplies must en-sure a safe state in the case of an EMERGENCY STOP.

Safety fences Requirements on safety fences are:

Safety fences must withstand all forces that are likely to occur in the course of operation, whether from inside or outside the enclosure.

Safety fences must not, themselves, constitute a hazard.

It is imperative to comply with the minimum clearances from the danger zone.

Safety gates Requirements on safety gates are:

The number of safety gates in the fencing must be kept to a minimum.

All safety gates must be safeguarded by means of an operator safety sys-tem.

Automatic mode must be prevented until all safety gates are closed.

For additional protection in Automatic mode, the safety gate can be me-chanically locked by means of a safety system.

If a safety gate is opened in Automatic mode, it must trigger an EMER-GENCY STOP function.

If the safety gate is closed, the robot cannot be started immediately in Au-tomatic mode. The message on the control panel must be acknowledged.

Other safety equipment

Other safety equipment must be integrated into the system in accordance with the corresponding standards and regulations.

3.3.19 Labeling on the robot system

All plates, labels, symbols and marks constitute safety-relevant parts of the ro-bot system. They must not be modified or removed.

Labeling on the robot system consists of:

Rating plates

Warning labels

Safety symbols

Designation labels

Cable markings

Identification plates

Further information is contained in the corresponding standards and regula-tions.

Further information is contained in the corresponding standards and regula-tions.

Further information can be found in the operating instructions of the robot, lin-ear unit, positioner and robot controller.


3. Safety

3.4 Safety measures

3.4.1 General safety measures

The robot system may only be used in perfect technical condition in accord-ance with its designated use and only by safety-conscious persons. Operator errors can result in personal injury and damage to property.

It is important to be prepared for possible movements of the robot system even after the robot controller has been switched off and locked. Incorrect installa-tion (e.g. overload) or mechanical defects (e.g. brake defect) can cause the ro-bot or external axes to sag. If work is to be carried out on a switched-off robot system, the robot and external axes must first be moved into a position in which they are unable to move on their own, whether the payload is mounted or not. If this is not possible, the robot and external axes must be secured by appropriate means.

KCP If the KCP is not connected, it must be removed from the system, as the EMERGENCY STOP button on the KCP is not functional in such a case.

If there is more than one KCP in operation in the overall system, it must be en-sured that the KCPs and EMERGENCY STOP buttons can be unambiguously assigned to the corresponding robot system. There must be no possibility of mixing them up in an emergency situation.

External keyboard, external mouse

An external keyboard and/or external mouse may only be connected during service work (e.g. installation). If a keyboard and/or mouse is connected, the system can no longer be operated safely. If a keyboard and/or mouse is con-nected, the system must not be operated and there must be no persons within the system.

The KCP must not be used as long as an external keyboard and/or external mouse are connected.

The external keyboard and/or external mouse must be removed as soon as the service work is completed.

Faults The following tasks must be carried out in the case of faults to the robot sys-tem:

Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again.

Indicate the fault by means of a label with a corresponding warning (tag-out).

Keep a record of the faults.

Eliminate the fault and carry out a function test.

Danger!In the absence of functional safety equipment, the robot system can cause personal injury or material damage. If safety equipment is dismantled or de-activated, the robot system may not be operated.

Warning!The motors reach temperatures during operation which can cause burns to the skin. Contact should be avoided if at all possible. If necessary, appropri-ate protective equipment must be used.


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3.4.2 Transportation

Robot The prescribed transport position of the robot must be observed. Transporta-tion must be carried out in accordance with the robot operating instructions.

Robot controller The robot controller must be transported and installed in an upright position. Avoid vibrations and impacts during transportation in order to prevent damage to the robot controller.

Transportation must be carried out in accordance with the operating instruc-tions for the robot controller.

External axis (optional)

The prescribed transport position of the external axis (e.g. KUKA linear unit, two-axis positioner, etc.) must be observed. Transportation must be carried out in accordance with the operating instructions for the external axis.

3.4.3 Start-up

Function test It must be ensured that no persons or objects are present within the danger zone of the robot during the function test.

The following must be checked during the function test:

The robot system is installed and connected. There are no foreign bodies or destroyed, loose parts on the robot system.

All safety devices and protective measures are complete and fully func-tional.

All electrical connections are correct.

The peripheral devices are correctly connected.

The external environment corresponds to the permissible values indicated in the operating instructions.

Setting It must be ensured that the rating plate on the robot controller has the same machine data as those entered in the declaration of incorporation. The ma-chine data on the rating plate of the robot and the external axes (optional) must be entered during start-up.

The passwords for logging onto the KUKA System Software as “Expert” and “Administrator” must be changed before start-up and must only be communi-cated to authorized personnel.

Danger!The robot controller is preconfigured for the specific robot system. If cables are interchanged, the robot and the external axes (optional) may receive in-correct data and can thus cause personal injury or material damage. If a sys-tem consists of more than one robot, always connect the connecting cables to the robots and their corresponding robot controllers.

Caution!If the internal cabinet temperature of the robot controller differs greatly from the ambient temperature, condensation can form, which may cause damage to the electrical components. Do not put the robot controller into operation un-til the internal temperature of the cabinet has adjusted to the ambient temper-ature.

Caution!Incorrect machine data can result in material damage. Check that the correct machine data have been loaded; if not, load the correct machine data.


3. Safety

3.4.4 Virus protection and network security

The user of the robot system is responsible for ensuring that the software is always safeguarded with the latest virus protection. If the robot controller is in-tegrated into a network that is connected to the company network or to the In-ternet, it is advisable to protect this robot network against external risks by means of a firewall.

3.4.5 Programming

The following safety measures must be carried out during programming:

It must be ensured that no persons are present within the danger zone of the robot system during programming.

New or modified programs must always be tested first in Manual Reduced Velocity mode (T1).

If the drives are not required, they must be switched off to prevent the robot or the external axes (optional) from being moved unintentionally.

The robot, tooling or external axes (optional) must never touch or project beyond the safety fence.

Components, tooling and other objects must not become jammed due to the motion of the robot system, nor must they lead to short-circuits or be liable to fall off.

The following safety measures must be carried out during programming in the danger zone of the robot system:

The robot and the external axes (optional) must only be moved at Manual Reduced Velocity (max. 250 mm/s). In this way, persons have enough time to move out of the way of hazardous motions of the robot system or to stop the robot system.

To prevent other persons from being able to move the robot or external axes (optional), the KCP must be kept within reach of the programmer.

If two or more persons are working in the system at the same time, they must all use an enabling switch. While the robot or external axes (optional) are being moved, all persons must remain in constant visual contact and have an unrestricted view of the robot system.

3.4.6 Simulation

Simulation programs do not correspond exactly to reality. Robot programs cre-ated in simulation programs must be tested in the system in Manual Reduced Velocity mode (SSTEP T1). It may be necessary to modify the program.

3.4.7 Automatic mode

Automatic mode is only permissible in compliance with the following safety measures.

The prescribed safety equipment is present and operational.

There are no persons in the system.

The defined working procedures are adhered to.

For optimal use of our products, we recommend that our customers carry out a regular virus scan. Information about security updates can be found at www.kuka.com.


www.kuka.com

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If the robot or an external axis (optional) comes to a standstill for no apparent reason, the danger zone must not be entered until the EMERGENCY STOP function has been triggered.

3.4.8 Maintenance and repair

The purpose of maintenance and repair work is to ensure that the system is kept operational or, in the event of a fault, to return the system to an operation-al state. Repair work includes troubleshooting in addition to the actual repair itself.

The following safety measures must be carried out when working on the robot system:

Carry out work outside the danger zone. If work inside the danger zone is necessary, the user must define additional safety measures to ensure the safe protection of personnel.

Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. If it is necessary to carry out work with the robot controller switched on, the user must define addi-tional safety measures to ensure the safe protection of personnel.

If it is necessary to carry out work with the robot controller switched on, this may only be done in operating mode T1.

Label the system with a sign indicating that work is in progress. This sign must remain in place, even during temporary interruptions to the work.

The EMERGENCY STOP systems must remain active. If safety equip-ment is deactivated during maintenance or repair work, it must be reacti-vated immediately after the work is completed.

Faulty components must be replaced using new components with the same article numbers or equivalent components approved by KUKA Roboter GmbH for this purpose.

Cleaning and preventive maintenance work is to be carried out in accordance with the operating instructions.

Robot controller Even when the robot controller is switched off, parts connected to peripheral devices may still carry voltage. The external power sources must therefore be switched off or isolated if work is to be carried out on the robot controller.

The ESD regulations must be adhered to when working on components in the robot controller.

Voltages in excess of 50 V (up to 600 V) can be present in the KPS (KUKA Power Supply), the KSDs (KUKA Servo Drives) and the intermediate-circuit connecting cables several minutes after the robot controller has been switched off. To prevent life-threatening injuries, no work may be carried out on the robot system in this time.

Foreign matter, such as swarf, water and dust, must be prevented from enter-ing the robot controller.

Counterbal-ancing system

Some robot variants are equipped with a hydropneumatic, spring or gas cylin-der counterbalancing system.

The hydropneumatic and gas cylinder counterbalancing systems are pressure equipment and, as such, are subject to obligatory equipment monitoring. De-pending on the robot variant, the counterbalancing systems correspond to cat-egory II or III, fluid group 2, of the Pressure Equipment Directive

The user must comply with the applicable national laws, regulations and standards pertaining to pressure equipment.


3. Safety

Inspection intervals in Germany in accordance with Industrial Safety Order, Sections 14 and 15. Inspection by the user before commissioning at the instal-lation site.

The following safety measures must be carried out when working on the coun-terbalancing system:

The robot assemblies supported by the counterbalancing systems must be secured.

Work on the counterbalancing systems must only be carried out by quali-fied personnel.

Hazardous substances

The following safety measures must be carried out when handling hazardous substances:

Avoid prolonged and repeated intensive contact with the skin.

Avoid breathing in oil spray or vapors.

Clean skin and apply skin cream.

3.4.9 Decommissioning, storage and disposal

The robot system must be decommissioned, stored and disposed of in accord-ance with the applicable national laws, regulations and standards.

3.5 Applied norms and regulations

To ensure safe use of our products, we recommend that our customers reg-ularly request up-to-date safety data sheets from the manufacturers of haz-ardous substances.

Name Definition Edition

2006/95/EC Low Voltage Directive:

Directive of the European Parliament and the Council of 12 December 2006 on the harmonization of the laws of Member States relating to electrical equipment designed for use within cer-tain voltage limits

2006

89/336/EEC EMC Directive:

Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic com-patibility

1993

97/23/EC Pressure Equipment Directive:

Directive of the European Parliament and of the Council of 29 May 1997 on the approximation of the laws of the Member States concerning pressure equipment

1997

98/37/EC Machinery Directive:

Directive of the European Parliament and of the Council of 22 June 1998 on the approximation of the laws of the Member States relating to machinery

1998

EN ISO 13850 Safety of machinery:

E-STOP - Principles for design

2007


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EN ISO 13732-1 Ergonomics of thermal environment:

Methods for the assessment of human responses to contact with surfaces - Part 1: Hot surfaces

2006

EN 614-1 Safety of machinery:

Ergonomic design principles – Part 1: Terms and general principles

2006


Safety-related parts of control systems - Part 1: General principles for design

1997

EN 55011 Industrial, scientific and medical (ISM) radio-frequency equipment – Radio dis-turbance characteristics – Limits and methods of measurement

2003


Electrical equipment of machines - Part 1: General requirements

2007

EN 61000-4-4 Electromagnetic compatibility (EMC):

Part 4-4: Testing and measurement tech-niques; Electrical fast transient/burst immunity test

2005


Part 6-2: Generic standards; Immunity for industrial environments

2002


Part 6-4: Generic standards; Emission standard for industrial environments

2002

EN 61800-3 Adjustable speed electrical power drive systems:

Part 3: EMC product standard including specific test methods

2001

EN ISO 10218-1 Industrial robots:

Safety

2006

EN ISO 12100-1 Safety of machinery:

Basic concepts, general principles for design - Part 1: Basic terminology, meth-odology

2004

EN ISO 12100-2 Safety of machinery:

Basic concepts, general principles for design - Part 2: Technical principles

2004

Name Definition Edition


4. Installation

4 Installation

4.1 System requirements

Hardware KR C2

Dispensing controller SCA SYS S3000, SYS S4000, Kleinmichel, Bielen-berg, etc.

KUKA field bus cards (Interbus, Profibus, DeviceNet)

Specific components for the application:

Adhesive gun

Dispensing system (E, P, H dispenser)

2-component applications, etc.

Software KUKA System Software (KSS) 5.x

Timers 13...16 can be freely assigned by the user.

4.2 Installing KUKA.GlueTech

Precondition User group “Expert”

Windows interface (CTRL+ESC)

Procedure 1. Start the Setup program from the CD-ROM. The files are copied onto the hard drive.

2. Confirm the reboot prompt with OK.

3. Reboot the robot controller. The installation is resumed and completed.

LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.

4.3 Reinstalling KUKA.GlueTech

Precondition KUKA.GlueTech has been uninstalled.

Expert level

Windows interface (CTRL+ESC)

Procedure 1. Start the Reinst.exe program in the directory C:\KRC_OPTION\GLUE-TECH\REINST. Setup is prepared.


3. Reboot the robot controller.


4.4 Updating KUKA.GlueTech

Precondition A previous version is installed.

CD with technology package

Only required if there is no CD-ROM drive on the control cabinet: Bootable USB CD-ROM/DVD drive

User group “Expert”

Please consult KUKA Roboter if dispensing controllers other than SCA SYS S3000 or SYS S4000 are to be used.


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Procedure 1. Start the Setup program from the CD-ROM. The files are copied onto the hard drive.


3. Reboot the robot controller. Installation is resumed and completed.



5. Operation

5 Operation

5.1 GlueTech operator control elements

Overview The following menus and softkeys are extended:

Technology

GlueTech

Show dispense data

Gluing motion

Gluing instruction

Setup

GlueTech

Configure process data

I/O Configuration

Select calibration routine

Configure

Status keys

GlueTech

Description The following status keys are available:

Status key Description

Select dispensing controller 1, 2 or 3

Select adhesive gun 1, 2 or 3

Select dispenser 1 or 2

Purge dispensing controller

Clear adhesive gun

Reload doser

Execute program with material

Execute program without material

The content of this status key can vary.

(>>> 5.1.1 "Change of state of status key Dry/Wet" page 36)


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5.1.1 Change of state of status key Dry/Wet

Description If a number of dispensing controllers are configured in KUKA.GlueTech, these are shown numerically in this status key. For this, the robot controller must be in Automatic External mode. For example, if one dispensing controller is con-figured, a “1” is displayed in the status key, and if two dispensing controllers are configured, a “2” is displayed next to the “1”. If the input (With/without ma-terial under external control) is set for the dispensing controller, the number of the relevant dispensing controller is displayed crossed out. If the input is set for all dispensing controllers, then the dispensing gun on the status key is also displayed crossed out.

Example

Acknowledge dispensing controller messages

Change status key bar

Status key Description

This function is only available in KUKA System Software 5.5.

State DescriptionThree dispensing controllers configured. All dispensing controllers “Wet” (with material).

Three dispensing controllers configured. Dispensing con-troller 1 “Dry” (without material). Dispensing controllers 2 and 3 “Wet” (with material).

Three dispensing controllers configured. All dispensing controllers “Dry” (without material).


6. Configuration

6 Configuration

6.1 Overview of GlueTech configuration

Overview

6.2 Configuring KUKA.GlueTech settings

Precondition The dispensing controller and adhesive gun have been prepared.

Procedure 1. Select the menu sequence Setup > GlueTech > Show dispense data.

2. Press the Settings menu key.

3. Configure and save the settings.

Description The following parameters can be selected:

Step Description1 Install and prepare the dispensing controller.2 Configure the field bus between the robot controller and

the dispensing controller.3 Calibrate the tool and base.4 Configure the basic settings for GlueTech.

(>>> 6.2 "Configuring KUKA.GlueTech settings" page 37)5 Configure the inputs/outputs.

(>>> 6.3 "Configuring inputs" page 38)

(>>> 6.4 "Configuring outputs" page 39)6 Configure the delay times.

(>>> 6.5 "Configuring delay times" page 40)7 Configure the adhesive profiles.

(>>> 6.6 "Configuring adhesive profiles (bead data)" page 41)

8 Configure the PLC options.

(>>> 6.7 "Configuring GlueTech PLC options" page 42)9 Calibrate GlueTech.

(>>> 6.8 "Calibration routine (Calibrate_Equipment.src)" page 43)

Material flow is deactivated in mode T1.

Further settings and system responses can be configured via the system var-iables. (>>> 8 "System variables" page 59)


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6.3 Configuring inputs

Precondition The field bus connection between the robot controller and the dispensing controller has been configured.

Fig. 6-1: Settings tab

Parameter Description Range of values

Application type Selection of the adhesive type

#GLUE_1K - 1-component adhesive

#GLUE_2K - 2-component adhesive

#GLUE_1K, #GLUE_2K

Bead shaping Activation of bead shaping.

#NONE - Deactivated

#AIR - Air shaping

#SWIRL - Motor shaping

#NONE, #AIR, #SWIRL

With doser Number of dispensers 1, 2Fault acknowl-edge by PLC

Activation of fault acknowl-edgement by PLC

TRUE, FALSE

Program number mirroring by dis-pense controller

Activation of handshaking for the program number by the dispensing controller.

TRUE, FALSE

Bit width program number

Program number length in bits Freely selectable

Transmit single fault to PLC

Set output to PLC in the event of a single fault.

TRUE, FALSE

Number of gluing equipments

Number of dispensing control-lers

The configuration is automati-cally extended if there is more than one dispensing control-ler.

1, 2, 3


6. Configuration

The dispensing controller and adhesive gun have been prepared.

Procedure 1. Select the menu sequence Setup > GlueTech > I/O Configuration.

2. Press the Inputs menu key.

3. Configure and save the inputs.


(>>> 8.1 "Signal declarations" page 59)

6.4 Configuring outputs




2. Press the Outputs menu key.

3. Configure and save the outputs.


Fig. 6-2: Inputs tab

If the outputs of the dispensing controller are not present during the setup, the inputs of the robot controller can be bypassed using input 1025 (TRUE). This input should also be used if signals are not supported by the dispensing controller.


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(>>> 8.1 "Signal declarations" page 59)

6.5 Configuring delay times



2. Press the Timing menu key.

3. Configure and save the delay times.


Fig. 6-3: Outputs tab

Fig. 6-4: Delay time configuration window


6. Configuration

6.6 Configuring adhesive profiles (bead data)



2. Press the Bead menu key.

3. Configure and save the parameters.


Parameter Range of values

Gun1 (2, 3) on anticipation time msGun1 (2, 3) off anticipation time msGun1 (2, 3) material analog delay msGun1 (2, 3) material flow increase anticipation time

ms

Gun1 (2, 3) material flow decrease anticipation time

ms

The delay times can be determined automatically using the calibration rou-tine. (>>> 6.8 "Calibration routine (Calibrate_Equipment.src)" page 43)

Fig. 6-5: Adhesive profile configuration window


Bead Data set number 1 to 60Speed Additional velocity factor for

analog output

Default: deactivated

> 0

≤ 2000 mm/s

Material Factor Dynamic setpoint for the material

0 to 100%

Material Offset Static setpoint for the material 0 to 100%


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6.7 Configuring GlueTech PLC options

Precondition The field bus connection between the robot controller and the PLC has been configured.



2. Press the PLC-Set menu key.

3. Configure and save the parameters.


Material Analog type

Reference speed for analog output:

Current velocity ($VEL_ACT)

Programmed path velocity ($VEL.CP)

Independent of the veloci-ty

#TCP_SPEED

#PROG_SPEED

#SPEED_INDEP

Air Factor Dynamic setpoint for the air 0 to 100%Air Offset Static setpoint for the air 0 to 100%Air Analog type Reference speed for analog

output:

Current velocity ($VEL_ACT)

Programmed path velocity ($VEL.CP)

Independent of the veloci-ty

#TCP_SPEED

#PROG_SPEED

#SPEED_INDEP

Comment Comment Freely selectable


Fig. 6-6: PLC-Set tab


6. Configuration

6.8 Calibration routine (Calibrate_Equipment.src)

Overview The KUKA.GlueTech calibration routine verifies various configuration values using a defined linear path. These can then be optimized and adapted. The program interacts with the user via dialogs.

The following configuration values are verified:

The TCP is tested at a reference point by means of reorientation (visual check).

The switching times of the adhesive gun are tested and can be manually corrected.

The delay times of the material flow are tested and can be manually cor-rected.

The delay times of the air flow are tested and can be manually corrected.

The reaction times after a jump in the analog output are tested and can be manually corrected.

The values of the following machine data are checked:

Filter of the analog output $ANA_DEL_FLT ≠ #ON

Path acceleration $ACC_MA.CP < 10

Swivel acceleration $ACC_MA.ORI1 < 1000

Rotational acceleration $ACC_MA.ORI2 < 1000

Reduction factor for path and orientation acceleration $RED_ACC_CPC > 3

Description The user must teach the specified points at a distance of min. 400 mm in the calibration routine (Calibrate_Equipment.src). The calibration routine first moves to the points in T2 mode with 10% program override. The user marks the switching points with a pen. The program then moves once more along the path with 100% program override and the user can check the switching points and manually change them. The data can then be saved in the Timing table (>>> 6.5 "Configuring delay times" page 40).


Seam number transfer to PLC (active)

Activate seam number trans-fer to PLC

The parameter Seam No. is added to inline forms.

Activate, deacti-vate

1. Input The PLC activates or deacti-vates the request for the seam number via this input.

Input number

> 0 active, positive logic

< 0 active, nega-tive logic

2. Output The robot controller confirms the request for the seam number via this output.

Output number

= 0 deactivated

> 0 active, positive logic

< 0 active, nega-tive logic

3. Output Start/End Number of the start bit

Data width 8 bit/output, max. 256 seams

0...255


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KUKA.GlueTech 2.6

Program

6.8.1 Testing the TCP



The tool has been calibrated.

The adhesive profiles (bead data) have been configured.

The KUKA.GlueTech settings have been configured.

The reference point has been defined.

Procedure 1. Select the menu sequence Setup > GlueTech > Select calibration rou-tine. The program Calibrate_equipment is selected.

2. Start program with .

3. Follow program dialog and continue with 2x .

Result Tool correct: the tool orients about the TCP and the position remains the same.

Tool incorrect: the tool orients about the TCP but the position changes.

Fig. 6-7: Switching points, delay times during the dispensing process

1 Delay time2 Delay time

DEF CALIBRATE_EQUIPMENT( )

Do not edit - press START button

System program to install dispense equipment

---- Local Subroutines ---- LIN StartPath Vel= 0.8 m/s CalDat Tool[1] Base[0] LIN EndPath Vel= 0.8 m/s CalDat Tool[1] Base[0]

END


6. Configuration

6.8.2 Determining the switching times of the adhesive gun (Gun On/Off)






Tools required Pen for marking the switching points.




6.8.3 Determining the material / air flow (Eq. Delay)










6.8.4 Determining the reaction time after a jump in the analog output (Ana. Switch)





Danger!The robot moves at the programmed velocity in T2 mode with 100% program override. Risk of injury and damage to property!

It must be ensured that nobody is present within the working range of the robot!

The robot must be able to move freely without risk of collisions!





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6.8.5 Verifying and determining all configuration values (All)






The reference point has been defined.












7. Programming

7 Programming

7.1 Overview of GlueTech motion commands

Inline forms

7.1.1 LIN with adhesive gun on - GLUE ON LIN

Description The command executes a LIN motion and switches on the adhesive gun at the end point.

The following parameters can be selected:

Command DescriptionGLUE ON LIN LIN motion - adhesive gun on

(>>> 7.1.1 "LIN with adhesive gun on - GLUE ON LIN" page 47)

GLUE SWITCH LIN LIN motion - switch parameters

(>>> 7.1.2 "LIN with switch of gluing pa-rameters - GLUE SWITCH LIN" page 48)

GLUE OFF LIN LIN motion - adhesive gun off

(>>> 7.1.3 "LIN with adhesive gun off - GLUE OFF LIN" page 48)

GLUE ON CIRC CIRC motion - adhesive gun on

(>>> 7.1.4 "CIRC with adhesive gun on - GLUE ON CIRC" page 49)

GLUE SWITCH CIRC CIRC motion - switch parameters

(>>> 7.1.5 "CIRC with switch of gluing pa-rameters - GLUE SWITCH CIRC" page 49)

GLUE OFF CIRC CIRC motion - adhesive gun off

(>>> 7.1.6 "CIRC with adhesive gun off - GLUE OFF CIRC" page 49)

GLUE ON PTP PTP motion - adhesive gun on

(>>> 7.1.7 "PTP with adhesive gun on - GLUE ON PTP" page 50)

GLUE OFF PTP PTP motion - adhesive gun off

(>>> 7.1.8 "PTP with adhesive gun off - GLUE OFF PTP" page 51)

Fig. 7-1: Inline form Glue On LIN

Item Description Range of values

1 Select motion type. LIN, PTP, CIRC2 Teach end point and assign a name. Freely selectable3 Activate approximate positioning. CONT, blank4 Activate prepressure check. YES, NO5 Path velocity 0.001...2.0 m/s6 Data set with motion parameter Freely selectable


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7.1.2 LIN with switch of gluing parameters - GLUE SWITCH LIN

Description The command executes a LIN motion and switches the gluing parameters at the end point.


7.1.3 LIN with adhesive gun off - GLUE OFF LIN

Description The command executes a LIN motion and switches off the adhesive gun at the end point.


7 Enter a seam number (optional). 0...2558 Offset for switching point. -200...200 mm9 Select adhesive gun. 1...3


Fig. 7-2: Inline form Glue Switch LIN


1 Select motion type. LIN, PTP, CIRC2 Teach end point and assign a name. Freely selectable3 Activate approximate positioning. CONT, blank4 Select parameter board of dispensing

controller.0 to 31

5 Enter path velocity. 0.001 to 2.0 m/s6 Data set with motion parameter Freely selectable7 Select adhesive profile (bead data). 1 to 608 Offset for switching point. -200 to 200 mm

Fig. 7-3: Inline form Glue Off LIN


1 Select motion type. LIN, PTP, CIRC2 Teach end point and assign a name. Freely selectable3 Activate approximate positioning. CONT, blank4 End measurement of material applica-

tion (dispensing controller).YES, NO

5 Enter path velocity. 0.001...2.0 m/s6 Data set with motion parameter Freely selectable7 Change dispenser. YES, NO8 Offset for switching point. -200...200 mm


7. Programming

7.1.4 CIRC with adhesive gun on - GLUE ON CIRC

Description The command executes a CIRC motion and switches on the adhesive gun at the end point.


7.1.5 CIRC with switch of gluing parameters - GLUE SWITCH CIRC

Description The command executes a CIRC motion and switches the gluing parameters at the end point.


7.1.6 CIRC with adhesive gun off - GLUE OFF CIRC

Description The command executes a CIRC motion and switches off the adhesive gun at the end point.

Fig. 7-4: Inline form Glue On CIRC


1 Select motion type. LIN, PTP, CIRC2 Teach auxiliary point and end point, and

assign names.Freely selectable

3 Activate approximate positioning. CONT, blank4 Activate prepressure check. YES, NO5 Enter path velocity. 0.001...2.0 m/s6 Data set with motion parameter Freely selectable7 Enter a seam number (optional). 0...2558 Offset for switching point. -200...200 mm9 Select adhesive gun. 1...3

Fig. 7-5: Inline form Glue Switch CIRC




3 Activate approximate positioning. CONT, blank4 Select parameter board of dispensing

controller.0 to 31

5 CP velocity 0.001 to 2.0 m/s6 Data set with motion parameter Freely selectable7 Select adhesive profile (bead data). 1 to 608 Offset for switching point. -200 to 200 mm


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KUKA.GlueTech 2.6


7.1.7 PTP with adhesive gun on - GLUE ON PTP

Description The command executes a PTP motion and switches on the adhesive gun at the end point. The adhesive profile data (bead data) are not taken into account in this command. The command can be used to compensate for tolerances on the component.


Fig. 7-6: Inline form Glue Off CIRC




3 Activate approximate positioning. CONT, blank4 End measurement of material applica-

tion (dispensing controller).YES, NO

5 Path velocity 0.001...2.0 m/s6 Data set with motion parameter Freely selectable7 Change dispenser. YES, NO8 Offset for switching point. -200...200 mm

Fig. 7-7: Inline form Glue On PTP


1 Select motion type. LIN, PTP, CIRC2 Teach end point and assign a name. Freely selectable3 Activate approximate positioning. CONT, blank4 Setpoint for material quantity 0...100%

Default: 50%5 Velocity 1...100%6 Enter a seam number (optional). 0...2557 Data set with motion parameter Freely selectable8 Select adhesive gun. 1, 2, 39 Time offset for switching point. -0.1...1.0 s10 Time setpoint for gun on

Parameter is not taken into account with approximate positioning.

0...5.0 s


7. Programming

7.1.8 PTP with adhesive gun off - GLUE OFF PTP

Description The command executes a PTP motion and switches off the adhesive gun at the end point.


7.2 Overview of GlueTech gluing instructions

Inline forms

Fig. 7-8: Inline form Glue Off PTP


1 Select motion type. LIN, PTP, CIRC2 Teach end point and assign a name. Freely selectable3 Activate approximate positioning. CONT, blank4 Enter velocity. 1...100%5 Data set with motion parameter Freely selectable6 Time offset for switching point. -1.0...1.0 s

Command DescriptionInit system Initialize dispensing controller.

(>>> 7.2.1 "Init system command" page 52)

Set program number Send program number to dispensing con-troller.

(>>> 7.2.2 "Set program number com-mand" page 52)

Set / reset motion parameter Specific motion parameters are set or reset.

(>>> 7.2.3 "Set / reset motion parameter command" page 53)

Dispense complete Communication between robot controller and dispensing controller is reset.

(>>> 7.2.4 "Dispense complete command" page 53)

Reload doser Dispenser is filled.

(>>> 7.2.5 "Reload doser command" page 54)

Error check Communication between robot controller and dispensing controller is checked.

(>>> 7.2.6 "Error check command" page 54)

Purge gun Adhesive gun is purged.

(>>> 7.2.7 "Purge gun command" page 54)


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7.2.1 Init system command

Description The command initializes the communication between the robot controller and the dispensing controller.

The factor, offset and delay for the analog output are calculated from the adhesive profile data (bead data).

Cyclical analog output is started.

The program number for the dispensing controller is sent.

The handshake for the program number is checked. Precondition: the op-tion “Program number mirroring” is configured.

The output "Start" is set, causing the dispensing controller to be brought up to prepressure.

The input “Ready” is polled.

The input “Meter full” is polled. If the signal is not set, the dispenser is filled. Precondition: the option “With doser” is configured.

The timer or input is polled, then the program 'Move to Purge' is started. (>>> 7.3 "Teaching the purge position (MoveToPurge)" page 56)


7.2.2 Set program number command

Description The command sends the program number to the dispensing controller by handshaking.

Monitoring purge gun Purging of adhesive gun is monitored.

(>>> 7.2.8 "Monitor purge gun command" page 55)

Enable purge The enable signal for purging of the adhe-sive gun is set.

(>>> 7.2.9 "Enable purge" page 55)

Command Description

Fig. 7-9: Inline form Init system

Item DescriptionRange of values

1 Select parameter board of dispensing con-troller.

0 to 31

2 Select dispensing controller. 1, 2, 33 Select adhesive profile (bead data). 1 to 604 Select program number of dispensing con-

troller.0 to 31

Fig. 7-10: Inline form Set program number


7. Programming


7.2.3 Set / reset motion parameter command

Description The command increases the following parameters:

Swivel velocity $VEL_MA.ORI1

Rotational velocity $VEL_MA.ORI2

Path acceleration $ACC_MA.CP

Swivel acceleration $ACC_MA.ORI.1

Rotational acceleration $ACC_MA.ORI.2


7.2.4 Dispense complete command

Description The command resets the communication between the robot controller and the dispensing controller. No parameters can be selected.


1 Select program number of dispensing con-troller.

0 to 31

2 Select parameter board of dispensing con-troller.

0 to 31

3 Select adhesive profile (bead data). 1 to 60

Warning!The Motion parameter command must be reset before an exact positioning point, as the braking ramps are very steep with this command. If the com-mand is not reset, this could result in mechanical damage to the robot in the long term.

Depending on the programmed path and the parameters set, the Motion pa-rameter command can lead to acceleration errors. Either the path or the pa-rameters must be corrected in this case.

Fig. 7-11: Inline form Set / reset motion parameter

ItemDescription

Range of values

1 Activate / deactivate motion parameters. ON, OFF2 Increase path acceleration. 0...100 %3 Increase orientation velocity and accelera-

tion.0...100 %

Fig. 7-12: Inline form Dispense complete

The command contains trigger instructions and must therefore be placed be-fore a motion command.


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KUKA.GlueTech 2.6

7.2.5 Reload doser command

Description The command is used for filling the dispenser.


7.2.6 Error check command

Description The command checks the communication between the robot controller and the dispensing controller. No parameters can be selected.

The following inputs are checked:

Fault

Error material threshold high

Error material threshold low

Fault 1 (System)

Fault 2 (Material)

The following outputs are set if the inputs are not active:

Quit error system (optional)

Fault to PLC (optional)


7.2.7 Purge gun command

Description The command purges the dispensing system.

Fig. 7-13: Inline form Reload doser


1 Defines the procedure for ending the filling of the dispenser.

FULL - Filling is ended when the input "Meter full" is set.

TIME - Filling is ended after the time set. Duration 0.1...5.0 s

FULL, TIME

The command contains trigger instructions and must therefore be placed be-fore a motion command.

Fig. 7-14: Inline form Error check


1 Select dispensing controller. 1, 2, 3


7. Programming


7.2.8 Monitor purge gun command

Description The command starts monitoring of the time between 2 purge operations. Mon-itoring is restarted every time the command is called.


7.2.9 Enable purge

Description The command sets the enable signal for purging once the robot has reached the purge position.


Fig. 7-15: Inline form Purge gun


1 Defines the procedure for purging. Complete or by time.

COMPLETE - Purging is ended when the input "Purge passed" is set.

TIME - Purging is ended after the time set.

COMPLETE, TIME

2 Duration of the purging operation 0...10 s3 Select dispensing controller 1, 2, 34 Activate clearing YES, NO5 Select adhesive components. A, B, A+B6 Select adhesive gun. 1, 2, 3

Fig. 7-16: Inline form Monitoring purge gun


1 Maximum duration without material flow between 2 purge operations for dispensing controller 1.

0...10 min


0...10 min


0...10 min


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KUKA.GlueTech 2.6

7.3 Teaching the purge position (MoveToPurge)

Description The MoveToPurge program is used to move the robot to the purge position. The program is called by the input 'diSLxPurgeRequest' or after the timer 'iTimerSystemx'. In the program, the path to the purge position must be taught for each dispensing controller and the command 'Purge gun' must be entered. It consists of:

SRC file

DAT file

The program is called by the Init system command.

Program

Fig. 7-17: Inline form Enable purge

Item FunctionRange of values

1 Activate Enable purge. YES, NO

DEF MoveToPurge()... CASE 1 ; system number 1 ;Teach here the movement to purge position for system number 1

;Program here the purge command

;Teach here the movement to home position for system number 1

CASE 2 ; system number 2 ;Teach here the movement to purge position for system number 2



CASE 3 ; system number 3 ;Teach here the movement to purge position for system number 3



DEFAULT ENDSWITCH...


7. Programming

7.4 Program example

Program

Description

1 DEF GLUEING()2 INI3 Initialize And Start System 1 With BeadData 1 Set Program Number 2 Param Number 14 Check Purge System 1 Time 10 min System 2 Time 10 min System 3 Time 10 min5 PTP HOME Vel= 100% DEFAULT6 PTP P1 CONT Vel= 100% PDAT1 Tool[1] Base[0]7 Set High Motion Parameter ON PATH 10% ORIENTATION 25%8 LIN P3 CONT Vel= 0.5 m/s CPDAT2 Tool[1] Base[0]9 LIN P4 CONT Vel= 0.5 m/s CPDAT3 GlueOn Distance -10 mm Gun 1 Tool[1] Base[0]10 LIN P5 CONT Vel= 0.5 m/s CPDAT4 Tool[1] Base[0]11 LIN P6 CONT Vel= 0.5 m/s CPDAT5 Tool[1] Base[0]12 LIN P7 CONT Vel= 0.5 m/s CPDAT6 Tool[1] Base[0]13 LIN P8 CONT Vel= 0.5 m/s CPDAT7 GlueOff Distance -5 mm End Measurement Yes Change Doser No Tool[1] Base[0]14 LIN P9 CONT Vel= 0.5 m/s CPDAT8 Tool[1] Base[0]15 Set High Motion Parameter OFF16 PTP P10 CONT Vel= 100% PDAT2 Tool[1] Base[0]17 Process Complete18 PTP HOME Vel= 100% DEFAULT19 Error Check20 END

Pro-gram line

Description

3 Init system

4 Monitoring purge gun

(>>> 7.2.7 "Purge gun command" page 54)7 Set motion parameter

(>>> 7.2.3 "Set / reset motion parameter command" page 53)9 LIN with adhesive gun on

13 LIN with adhesive gun off

(>>> 7.1.1 "LIN with adhesive gun on - GLUE ON LIN" page 47)

15 Reset motion parameter

(>>> 7.2.3 "Set / reset motion parameter command" page 53)17 Finish gluing

(>>> 7.2.4 "Dispense complete command" page 53)19 Error check

(>>> 7.2.6 "Error check command" page 54)


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KUKA.GlueTech 2.6


8. System variables

8 System variables

8.1 Signal declarations

Description The signals listed refer to the first dispensing controller. The first number in the signal names refers to the number of the dispensing controller (1, 2, 3). The signals of the second and third dispensing controllers are therefore not listed.

ao: analog output

ai: analog input

do: digital output

di: digital input

Signal name Meaning I/O

aoSL1MatFlow Setpoint for material $ANOUT[1]aoSL1BeadShp Setpoint for air spray $ANOUT[2]doSL1StartSys Start application cycle $OUT[999]doSL1Gun1On Gun on $OUT[999]doSL1ReloadMeter Reload meter (Fill dis-

penser)$OUT[999]

doSL1AirOn Air on / Swirl $OUT[999]doSL1AutoExternal Automatic from extern $OUT[999]doSL1PrePurge Purge to record prepres-

sure$OUT[999]

doSL1Purge Purge $OUT[999]doSL1SystemReady System ready $OUT[999]doSL1ProgNo Program bit 0 $OUT[999] TO

$OUT[999]doSL1FinishMeasure Stop application cycle $OUT[999]doSL1PurgeEnable Decontrol purging $OUT[999]doSL1FaultAckn Quit error system $OUT[999]doSL1WithoutMaterial Without material $OUT[999]doSL1ParamNo Param table bit 0 $OUT[999] TO

$OUT[999]doSL1PistSelect1 Pist select W1 (Select gun

1)$OUT[999]

doSL1PistSelect2 Pist select W2 (Select gun 2)

$OUT[999]

doSL1DoserChange Change doser $OUT[999]doSL1HeatingUnitOn Heating unit on $OUT[999]doSL1HeatingUnitReset

Timer reset heating $OUT[999]

doSL1PumpReset Timer reset pump $OUT[999]doSL1FaultPeripheryAckn

Quit error periphery $OUT[999]

doSL1FaultToPLC Fault message to PLC $OUT[999]doSL1PurgeA Purge component A $OUT[999]doSL1PurgeB Purge component B $OUT[999]doSL1Purge2K Purge 2-component $OUT[999]doSL1ComponentBOff Component B off $OUT[999]diSL1Fault Fault $IN[1026]diSL1MatHigh Error material threshold

high$IN[1026]

diSL1MatLow Error material threshold low $IN[1026]


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8.2 GlueTech variables in $Config.dat

The file is located in the directory C:\KRC\Roboter\KRC\SYSTEM\.

diSL1Fault1 Fault 1 (system) $IN[1026]diSL1Fault2 Fault 2 (material) $IN[1026]diSL1Ready Ready $IN[1026]diSL1MeterFull Meter full (Dispenser full) $IN[1026]diSL1PurgePassed Purge passed $IN[1026]diSL1ProgRecieved Program quit bit 0 $IN[1026] TO

$IN[1026]diSL1MeasurePassed Measure passed $IN[1026]diSL1DispOk Application is ok $IN[1026]diSL1DoserNearlyEmpty

Doser nearly empty $IN[1026]

diSL1PrePressOk Prepressure ok $IN[1026]diSL1ParamRecieved Parameter table quit bit 0 $IN[1026] TO

$IN[1026]diSL1DoserSingleMode

Doser single mode $IN[1026]

diSL1DoserChangeAckn

Doser changed $IN[1026]

diSL1PurgeRequest Prepressure recording request

$IN[1026]

diSL1Automatic Automatic $IN[1026]diSL1PumpIsOn Pump is on $IN[1026]diSL1HydraulicIsOn Hydraulic is on $IN[1026]diSL1HeatingIsOn Heating is on $IN[1026]diSL1HeatingReady Heating reached tempera-

ture$IN[1026]

diSL1BarrelPreWarning

Barrel rest amount < 10% (Drum pre-warning)

$IN[1026]

diSL1FaultPeriphery Error periphery $IN[1026]diSL1DryByPLC Dry by PLC (With/without

material under external con-trol)

$IN[1026]

diSL1MixtureUndefined

Mixture undefined $IN[1026]

diSL1FaultMixture Fault mixture $IN[1026]diSL11KMode 1 K Mode (Single-compo-

nent mode)$IN[1026]

diSL11KInMixer 1K in mixer (1 component in mixer)

$IN[1026]

diSL12KInMixer 2K in mixer (2 components in mixer)

$IN[1026]

Signal name Meaning I/O

Name Description Range of values

dBlowTime Duration of the clearing time after purging

0..5 s

Default: 2 sGlueSetupMode Activate handshake for pro-

gram number.TRUE, FALSE

Default: FALSE


8. System variables

8.3 GlueTech variables in Glue.dat

Description The file is located in the directory C:\KRC\Roboter\KRC\R1\TP\GLUETECH\.

eGlueRestartMode Program resumption follow-ing a fault:

#GLUE_OFF - Gun is not switched on again

#GLUE_CONT - Gun is switched on

#GLUE_USER - User-specific, calls the program GLUE_UserRestart

#GLUE_OFF

#GLUE_CONT

#GLUE_USER

Default: #GLUE_OFF

bWithSpeed SPEED parameter of the bead data is taken into account.

TRUE, FALSE

Default: FALSE



iTimerGlueTech Variable defines the timer for time-programmed actions.

Reload Time, Purge Time, Glue On PTP

Free choice of timer.

Default: Timer 16

iTimerSystem1 Variable defines the timer for monitoring of the time between purge cycles for sys-tem 1.

Check Purge


Default: Timer 15


Check Purge


Default: Timer 14


Check Purge


Default: Timer 13


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KUKA.GlueTech 2.6


9. Messages

9 Messages

Errors may occur in the application due to incorrect configuration or operation.

Error messages Message Cause RemedySystem 1 (2, 3) not ready

Program execution is stopped. Input "Ready" from system 1 (2, 3) not set or incorrectly config-ured.

Check I/O configuration

Check I/O status

Doser system 1 (2, 3) will be filled

Output for filling the dis-penser is set, controller waits for input "Meter full". Input "Meter full" from system 1 not set or incor-rectly configured.


Check I/O status

Check dispensing system

No signal PRE-PRESSURE OK by system 1 (2, 3)

Program is stopped. Input "Prepressure ok" from system 1 not set or incor-rectly configured.


Check I/O status

Check dispensing systemFault controller system 1 (2, 3)

Program is stopped. The following inputs are not set or incorrectly config-ured:

Input "Fault"

Input "Fault 1"

Input "Fault 2"


Check dispensing system

Check material pressure

System 1 (2, 3): fault material high

Program is stopped. Input "Fault material high" of system 1 not set or incor-rectly configured.


Check material quantity

System 1 (2, 3): fault material low

Program is stopped. Input "Fault material low" of system 1 not set or incor-rectly configured.


Check material quantity

Variable SPEED is still initialized with the default value zero

Program is stopped. The component is still initial-ized with the default value 0.

Check bead data (speed)

Variable MATE-RIALFACTOR is still initialized with the default value zero

Program is stopped. The component is still initial-ized with the default value 0.

Check bead data (mate-rial)


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KUKA.GlueTech 2.6


10. KUKA Service

10 KUKA Service

10.1 Requesting support

Introduction The KUKA Robot Group documentation offers information on operation and provides assistance with troubleshooting. For further assistance, please con-tact your local KUKA subsidiary.

Information The following information is required for processing a support request:

Model and serial number of the robot

Model and serial number of the controller

Model and serial number of the linear unit (if applicable)

Version of the KUKA System Software

Optional software or modifications

Archive of the software

Application used

Any external axes used

Description of the problem, duration and frequency of the fault

10.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)Luis Angel Huergo 13 20Parque Industrial2400 San Francisco (CBA)ArgentinaTel. +54 3564 421033Fax +54 3564 [email protected]

Australia Marand Precision Engineering Pty. Ltd. (Agency)153 Keys RoadMoorabbinVictoria 31 89AustraliaTel. +61 3 8552-0600Fax +61 3 [email protected]

Faults leading to production downtime should be reported to the local KUKA subsidiary within one hour of their occurrence.


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KUKA.GlueTech 2.6

Belgium KUKA Automatisering + Robots N.V.Centrum Zuid 10313530 HouthalenBelgiumTel. +32 11 516160Fax +32 11 [email protected]

Brazil KUKA Roboter do Brasil Ltda.Avenida Franz Liszt, 80Parque Novo MundoJd. GuançãCEP 02151 900 São PauloSP BrazilTel. +55 11 69844900Fax +55 11 [email protected]

Chile Robotec S.A. (Agency)Santiago de ChileChileTel. +56 2 331-5951Fax +56 2 [email protected]

China KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd.Shanghai Qingpu Industrial ZoneNo. 502 Tianying Rd.201712 ShanghaiP.R. ChinaTel. +86 21 5922-8652Fax +86 21 [email protected]

Germany KUKA Roboter GmbHZugspitzstr. 14086165 AugsburgGermanyTel. +49 821 797-4000Fax +49 821 [email protected]


10. KUKA Service

France KUKA Automatisme + Robotique SASTechvallée6, Avenue du Parc91140 Villebon S/YvetteFranceTel. +33 1 6931660-0Fax +33 1 [email protected]

India KUKA Robotics, Private Limited621 Galleria TowersDLF Phase IV122 002 GurgaonHaryanaIndiaTel. +91 124 [email protected]

Italy KUKA Roboter Italia S.p.A.Via Pavia 9/a - int.610098 Rivoli (TO)ItalyTel. +39 011 959-5013Fax +39 011 [email protected]

Japan KUKA Robotics Japan K.K.Ogikubo TM Building 7F5-26-13 Ogikubo, Suginami-kuTokio167-0051JapanTel. +81 353 47-9831Fax +81 353 47-9835kuka.co.jp

Korea KUKA Robot Automation Korea Co. Ltd.4 Ba 806 Sihwa Ind. ComplexSung-Gok Dong, Ansan CityKyunggi Do425-110KoreaTel. +82 31 496-9937 or -9938Fax +82 31 [email protected]


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KUKA.GlueTech 2.6

Malaysia KUKA Robot Automation Sdn BhdSouth East Asia Regional OfficeNo. 24, Jalan TPP 1/10Taman Industri Puchong47100 PuchongSelangorMalaysiaTel. +60 3 8061-0613 or -0614Fax +60 3 [email protected]

Mexico KUKA de Mexico S. de R.L. de C.V.Rio San Joaquin #339, Local 5Colonia Pensil SurC.P. 11490 Mexico D.F.MexicoTel. +52 55 5203-8407Fax +52 55 [email protected]

Norway KUKA Sveiseanlegg + RoboterBryggeveien 92821 GjövikNorwayTel. +47 61 133422Fax +47 61 [email protected]

Austria KUKA Roboter Austria GmbHRegensburger Strasse 9/14020 LinzAustriaTel. +43 732 784752Fax +43 732 [email protected]

Portugal KUKA Sistemas de Automatización S.A.Rua do Alto da Guerra n° 50Armazém 042910 011 SetúbalPortugalTel. +351 265 729780Fax +351 265 [email protected]


10. KUKA Service

Russia OOO KUKA Robotics RusWebnaja ul. 8A107143 MoskauRussiaTel. +7 495 781-31-20Fax +7 495 781-31-19kuka-robotics.ru

Sweden KUKA Svetsanläggningar + Robotar ABA. Odhners gata 15421 30 Västra FrölundaSwedenTel. +46 31 7266-200Fax +46 31 [email protected]

Switzerland KUKA Roboter Schweiz AGRiedstr. 78953 DietikonSwitzerlandTel. +41 44 74490-90Fax +41 44 [email protected]

Spain KUKA Sistemas de Automatización S.A.Pol. IndustrialTorrent de la PasteraCarrer del Bages s/n08800 Vilanova i la Geltrú (Barcelona)SpainTel. +34 93 814-2353Fax +34 93 [email protected]

South Africa Jendamark Automation LTD (Agency)76a York RoadNorth End6000 Port ElizabethSouth AfricaTel. +27 41 391 4700Fax +27 41 373 3869www.jendamark.co.za


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Taiwan KUKA Robot Automation Taiwan Co. Ltd.136, Section 2, Huanjung E. RoadJungli City, TaoyuanTaiwan 320Tel. +886 3 4371902Fax +886 3 [email protected]

Thailand KUKA Robot Automation (M)SdnBhdThailand Officec/o Maccall System Co. Ltd.49/9-10 Soi Kingkaew 30 Kingkaew RoadTt. Rachatheva, A. BangpliSamutprakarn10540 ThailandTel. +66 2 7502737Fax +66 2 [email protected]

Hungary KUKA Robotics Hungaria Kft.Fö út 1402335 TaksonyHungaryTel. +36 24 501609Fax +36 24 [email protected]

USA KUKA Robotics Corp.22500 Key DriveClinton Township48036 MichiganUSATel. +1 866 8735852Fax +1 586 [email protected]

UK KUKA Automation + RoboticsHereward RiseHalesowenB62 8ANUKTel. +44 121 585-0800Fax +44 121 [email protected]


Index

Index

Symbols$ACC_MA.CP 43$ACC_MA.ORI1 43$ACC_MA.ORI2 43$ANA_DEL_FLT 43$RED_ACC_CPC 43

Numbers2-component adhesives 92006/95/EC 3189/336/EEC 3197/23/EC 3198/37/EC 31

AAccessories 15Adhesive bead application 9Adhesive profiles, configuration 41All configuration values, verifying/determining 46Analog voltage, proportional 10Applied norms and regulations 31Areas of application 9AUT 18, 19AUT EXT 18, 19Automatic 18, 19Automatic External 18, 19Automatic mode 29Axis range 15Axis range limitation 24Axis range monitoring 24

BBead data 7, 41, 61Bead shaping 9Brake defect 27Braking distance 15, 21Braking, path-maintaining 16, 20Braking, path-oriented 16, 20

CCalibrate_Equipment.src 43Calibration routine 7, 43CE mark 14Change of state of status key Dry/Wet 36Cleaning work 30Clearing 7Communication 9Configuration 37Connecting cables 14Connection for external enabling switch 23Counterbalancing system 30

DDanger zone 15Declaration of conformity 14Declaration of incorporation 13, 14Decommissioning 31Delay times 10

Delay times, air flow 43Delay times, configuration 40Delay times, material flow 43Designated use 14Dispense complete command 53Disposal 31Documentation, robot system 7Drives OFF 18Drives ON 18

EEC declaration of conformity 14EMC Directive 14, 31EMERGENCY STOP 20, 25EMERGENCY STOP button 22, 24EMERGENCY STOP function 30EN 55011 32EN 60204-1 32EN 61000-4-4 32EN 61000-6-2 32EN 61000-6-4 32EN 614-1 32EN 61800-3 32EN 954-1 32EN ISO 10218-1 32EN ISO 12100-1 32EN ISO 12100-2 32EN ISO 13732-1 32EN ISO 13850 31Enable purge 55Enabling 18Enabling switch 24Enabling switches 22, 23ESC 18Exact positioning 7External axes 15External axis 16External EMERGENCY STOP 18External safeguards 25Extruded application 9

FFaults 27Firewall 29Flatstream 9Function test 28Functional principle 10Functions 9

GGeneral safety measures 27GLUE OFF CIRC 49GLUE OFF LIN 48GLUE OFF PTP 51GLUE ON CIRC 49GLUE ON LIN 47GLUE ON PTP 50GLUE SWITCH CIRC 49


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KUKA.GlueTech 2.6

GLUE SWITCH LIN 48Gluing instructions, overview 51Guard interlock 21

HHandshaking 7Hazardous substances 31

IInit system command 52Inputs, configuration 38Installation 33Installing KUKA.GlueTech 33Introduction 7

JJog mode 23, 24

KKCP 14, 15, 27KCP coupler 25Keyboard, external 27KUKA Customer Support 65

LLabeling 26Liability 13Linear unit 15Local EMERGENCY STOP 18Low Voltage Directive 14, 31

MMachine data check 43Machinery Directive 14, 31Maintenance 30Manual High Velocity 18, 19Manual Reduced Velocity 18, 19Material / air flow determination 45Mechanical axis range limitation 24Mechanical end stops 23Messages 63Mode selector switch 18Motion commands, overview 47Motion parameters 7Mouse, external 27

NNetwork security 29

OOperating modes 18, 24Operation 35Operator 15, 17Operator safety 18, 21, 24Options 15Outputs, configuration 39Overload 27Overview of GlueTech configuration 37Overview of the safety features 17Overview, KUKA.GlueTech 9

PPanic position 22, 23Path-maintaining 16, 20Path-oriented 20path-oriented 16Personnel 16Plant integrator 16PLC options, configuration 42Positioner 15Pressure Equipment Directive 30, 31Preventive maintenance work 30Product description 9Program example 57Program mirroring 7Programming 29, 47Purge position 7Purge position, enable 55Purging 7

RRamp-down braking 16, 20Reaction time after jump in analog output 45Reaction time, analog output 43Reduced velocity, program mode 24Reinstalling KUKA.GlueTech 33Release device 25Repair 30Required knowledge and skills 7Reset motion parameter 53Robot 14, 21Robot controller 14, 29Robot system 13, 14, 16

SSafety 13Safety features 24Safety fences 26Safety gates 26Safety instructions 13Safety logic 18Safety zone 16, 21Safety, general 13Seam number 7Seam number transfer, configuration 42Service, KUKA Roboter 65Set motion parameter 53Set program number command 52Setting 28Settings, KUKA.GlueTech 37Short-circuit braking 20Signal declarations 59Simulation 29Software 15Software limit switches 24Sound-insulating material 9Speed, proportional 10Start-up 28STOP 0 16, 20STOP 1 16, 20STOP 2 16, 20Stop reactions 20


Index

Storage 31Support request 65Switching point 7Switching points 10Switching times 7Switching times, adhesive gun 43Switching times, gun 45System integrator 14, 16System requirements 33System variables 59

TT1 16, 18, 19T2 16, 18, 19Target group 7TCP test 43, 44Teach pendant 14Terms used 7, 15Thin-jet 9Top-mounted cabinet 15Training program 7, 17Transport position 28Transportation 28Two-axis positioner 15

UUpdating KUKA.GlueTech 33Use, contrary to designated use 13Use, improper 13User 15, 16

VVariables, $Config.dat 60Variables, Glue.dat 61Virus protection 29

WWarnings 13Working envelope 15Working range limitation 24Workspace 21


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KUKA.GlueTech 2.6



KUKA.GlueTech 2.6

GlueTech V26 En

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Transcript of GlueTech V26 En