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SOFTWARE
KR C2
Seminar workbookof …………………
Basic RobotProgramming
Release 4.1
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© Copyright KUKA Roboter GmbH This documentation or excerpts therefrommay not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, inthe case of a replacement or service work.We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepanciescannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on aregular basis, however, and necessary corrections will be incorporated in subsequent editions.Subject to technical alterations without an effect on the function.
handout GP KR C2 V4.1 01.03.01
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1. Contents and goals of this course ................................................................... 5
2. Safety .................................................................................................................. 7
3.
The robot system............................................................................................. 27
3.1. Basics at the robot system...................................................................... 27
3.2. System overview..................................................................................... 35
3.3.
Energy supply ......................................................................................... 41
4. Operation of the KUKA control panel (KCP) ................................................. 45
5. The coordinate systems at the robot ............................................................. 57
5.1. The axis coordinat system ...................................................................... 59
5.2. The world coordinate system .................................................................. 61
5.3.
The tool coordinate system..................................................................... 65
5.4. The base coordinate system................................................................... 67
6. Stop reactions of the robot ............................................................................. 69
7.
Master ing.......................................................................................................... 73
8. Tool calibration ................................................................................................ 79
8.1.
The calculation of the TCP's ................................................................... 79
8.1.1. The X Y Z - 4 Point method .........................................................................................83
8.1.2. The XYZ-reference method ......................................................................................... 85
8.2. Orientation calibration............................................................................. 87
8.2.1. The ABC-world 5D method..........................................................................................87
8.2.2. The ABC-world 6D method..........................................................................................89
8.2.3. The ABC-2 point method .............................................................................................91
8.3.
Tool - payload ......................................................................................... 95
9. Base calibration ............................................................................................... 97
10.
Motions programming at the robot .............................................................. 103 10.1. PTP – motion ........................................................................................ 105
10.2. LIN – motion.......................................................................................... 109
10.3.
CIRC – motion ...................................................................................... 113
10.4. Approximation of motion ....................................................................... 117
11. The navigator (program production)............................................................ 121
12. Logic programming ....................................................................................... 129
13. Gripper Tech H50........................................................................................... 139
13.1.
Gripper typ 1 ......................................................................................... 145
13.2. Gripper typ 2 ......................................................................................... 149
13.3. Gripper typ 3 ......................................................................................... 151
13.4.
Gripper typ 4 ......................................................................................... 153
13.5. Gripper typ 5 ......................................................................................... 155
14. Fixed tool calibration..................................................................................... 157
15. Programming with subprograms ................................................................. 165
16. The expert level.............................................................................................. 167
17. Loops and branches in programs ................................................................ 171
18. Automatik external ........................................................................................ 177
18.1.
Programnumber typ 1 ........................................................................... 189
18.2. Programnumber typ 2 ........................................................................... 191
18.3. Programnumber typ 3 ........................................................................... 193
18.4. Inputs.................................................................................................... 195
19.
Excercises ...................................................................................................... 202
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1. Contents and goals of this course
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Page 6 of 227 handout GP KR C2 V4.1 01.03.01
KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-40 00, Fax: +49 (0) 8 21/7 97-16 16, http://www.kuka-roboter.d e I 16.08.00 I College I ML I 1
Seminar goal
The Basic Robot Programming seminar is aimed at theprogramming personnel for KUKA industrial robots. Thisseminar provides training with regard to
• the proper and safety-conscious operation of a robot
in a production environment,• the modification and maintenance of robot application
programs,• and the creation of linear application programs.
Basic Robot Programming
Controller Type KR C2
KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-40 00, Fax: +49 (0) 8 21/7 97-16 16, http://www.kuka-roboter.d e I 16.08.00 I College I ML I 2
Topics covered
Basic Robot Programming
Controller Type KR C2
• Safety requirements for programmers• Components of the robot system
• Operation of the robot system (start-up, shut-down, manualmotion, program selection, automatic program execution)
• Commissioning the robot system (mastering, tool calibration)• Creation of simple application programs (programming of
motion instructions and predefined application technologyinstructions)
• Integration of application programs into the production process(interface between equipment controller (PLC) and robotcontroller)
• Archiving and maintenance of production programs
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handout GP KR C2 V4.1 01.03.01 Page 7 of 227
2. Safety
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Page 8 of 227 handout GP KR C2 V4.1 01.03.01
I 14.03.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Safety
Safety regulations for working with industrial robots
I 14.03.02 I College I ML I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Liability
• The robot system is built using state-of-the-art technology and in accordancewith the recognized safety rules. Nevertheless, improper use of the robotsystem or its employment for a purpose other than the intended one maycause danger to life and limb or damage to material property.
• The robot system may only be used in technically perfect condition inaccordance with its designated use and only by safety-conscious personswho are fully aware of the risks involved in its operation. Any functionaldisorders affecting the safety of the linear unit must be rectified immediately.
• The robot system is designed to comply with the EC Machinery Directiveand associated standards. These include, for example, EN 775, theEuropean norm for the safety of industrial robots.
The robot is always stronger than you!
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handout GP KR C2 V4.1 01.03.01 Page 9 of 227
I 14.03.02 I College I ML I 3KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Designated use
• The robot system is designed exclusively for the specified applications.
Applications for the KR 125/2 include:
– Spot welding
– Handling
– Assembly
– Application of adhesives, sealants and preservatives
– Machining – MIG/MAG welding
– YAG laser beam welding
Using the robot system for any other or additional purpose isconsidered contrary to its designated use. The manufacturer cannotbe held liable for any damage resulting from such use. The risk liesentirely with the user.
I 14.03.02 I College I ML I 4KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Safety symbols
This symbol is used where failure to fully and accurately observeoperating instructions, work instructions, prescribed sequencesand the like could result in injury or a fatal accident.
This symbol is used where failure to fully and accurately observeoperating instructions, work instructions, prescribed sequencesand the like could result in damage to the robot system.
This symbol is used to draw attention to a particular feature.Observance of the note will generally result in facilitation of thework concerned.
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Page 10 of 227 handout GP KR C2 V4.1 01.03.01
I 14.03.02 I College I ML I 5KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
General safety regulations
• Improper use of the robot system or its employment for apurpose other than the intended one may cause
– danger to life and limb
– danger to the robot system and other assets of the user
and – danger to the efficient working of the robot system or its
operator.
I 14.03.02 I College I ML I 6KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
General safety regulations
• Every person involved with the robot system must have read andunderstood these operating instructions, particularly the “ Safety” chapter ,paying special attention to the passages marked with the warning symbol .
• Installation, exchange, adjustment, operation, maintenance and repair mustbe performed only as specified in these operating instructions and only bypersonnel specially trained for this purpose.
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I 14.03.02 I College I ML I 7KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
General safety regulations
• The responsibilities involved in operation of the robot system and in all other work performed on the robot system or in its immediate vicinity must beclearly defined and observed by the user in order to prevent any uncertaintyregarding spheres of competence in matters of safety.
• The user and operating personnel must ensure that only authorized
personnel are permitted to work on the robot system.
• The user must clearly set out what the responsibilities of operating personnelactually entail and give them the authority to refuse to carry outinstructions from third parties which are contrary to safety procedures.
I 14.03.02 I College I ML I 8KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
General safety regulations
• The danger zones of the robot system must be safeguarded to preventpersons or objects from entering these zones. This safety facility is theresponsibility of the user.
• The switching times of the EMERGENCY STOP system must be takeninto account when determining the size of the danger zones.
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Page 12 of 227 handout GP KR C2 V4.1 01.03.01
I 14.03.02 I College I ML I 9KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Particular safety regulations for the user and the operating personnel
• The robot system must be switched off before maintenancework, i.e. the main switch on the control cabinet must be turned to“OFF”.
• Secure it with a padlock to prevent unauthorized persons from switching iton again.
• De-energize power supply lead and disconnect X1.
• Before exchanging the power unit (power module), wait at least 5 minutes.
• Work on the electrical equipment of the robot systemmay only be carried out by a skilled electrician.
• Skin contact with grease is to be avoided.
I 14.03.02 I College I ML I 10KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Particular safety regulations for the user and the operating personnel
• The operating personnel are obliged to inform the user immediately of any changes to the robot system which impair i ts safety.
• The user must ensure that the robot system is only ever operated infaultless condition.
• No functional safety equipment may be dismantled or taken out ofoperation.
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I 14.03.02 I College I ML I 11KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Particular safety regulations for the user and the operating personnel
• When work is carried out in the danger zone of the robot, thelatter may only, if absolutely essential, be operated at manualtraversing speed at the most.
• All persons situated in the environment of the robot must be informed ingood time that the robot is about to move.
• Wherever possible, only one person should work in the danger zone ofthe robot at any time.
I 14.03.02 I College I ML I 12KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Particular safety regulations for the user and the operating personnel
• In sensor-assisted operation, the robot is liable to performunexpected movements and path corrections if the mainswitch on the control cabinet has not been turned to “OFF”.
• Due regard must be paid to hazards posed by the peripheral systemcomponents of the robot such as grippers, conveyors, feeddevices or other robots in a multi-robot system.
• Any unauthorized conversion or modification of the robot system is notallowed.
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Page 14 of 227 handout GP KR C2 V4.1 01.03.01
I 14.03.02 I College I ML I 13KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Singularities of a 6-axis robot
• Singularities are points through which the robot cannot be movedusing Cartesian traversing . In the immediate vicinity of thesepoints, the affected axes are subjected to extreme acceleration.This results in the robot motion being stopped by the controller and the generation of an error message.
Alpha 5 Extended position
I 14.03.02 I College I ML I 14KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Safety features of the robot system: working space limitation
• The means of limiting the working space of the robot comprise:
– adjustable software limit switches for all axes and
– for some axes mechanical limit stops with a buffer function,
– working range monitoring by means of workspaces ($WORKSPACE),
– which as the working range limitation accessory are also adjustable.
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I 14.03.02 I College I ML I 15KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Safety features of the robot system: working space limitation
• Example: software limit switches for axis 1
$SOFTN _END[1] = -185°
$SOFTP _END[1] = 185°
Axis designation
I 14.03.02 I College I ML I 16KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Safety features of the robot system: working space limitation
• Examples: working range limitation on the KR 125
Axis 1
Axis 3
Axis 2
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I 14.03.02 I College I ML I 17KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Safety features of the robot system: counterbalancing system
• Some robot types are equipped with a hydropneumatic or mechanicalcounterbalancing system.
• Work on the hydropneumatic counterbalancing system may only be carriedout by persons having special knowledge and experience of hydraulic andpneumatic systems.
• If work is to be carried out onthe counterbalancing systems,the parts of the robot assistedby these systems must besecured so that they areunable to move.
I 14.03.02 I College I ML I 18KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Safety features of the robot system: temperature monitoring
• The motors are protected against overload by means of temperaturesensors in the motor windings.
• The motors reach temperatures during operation which cancause burns to the skin. Appropriate safety precautions must betaken.
• The temperatures inside the control cabinet (internaltemperature) are monitored. The controller is switchedoff if defined limits are exceeded.
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I 14.03.02 I College I ML I 19KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Safety features of the robot system: enabling switches
• The enabling switches on the KUKA Control Panel (KCP)
Enabling switches
I 14.03.02 I College I ML I 20KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Safety features of the robot system: jog mode
• Jog mode (deadman function). All programs can be executed manuallyin the test modes at reduced velocity. However, program execution is onlypossible as long as the “Start” key is held down. If the “Start” key isreleased, the robot stops. The program can only be continued by pressingthe “Start” key again.
“Start” keys
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Page 18 of 227 handout GP KR C2 V4.1 01.03.01
I 14.03.02 I College I ML I 21KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Release device for robot axes
• The robot can be moved after a malfunction via the main axis drive motorsand, depending on the type of robot, also via the wrist axis drive motors insome instances. It is only intended for use in emergencies.
• The release device may only be used if the robot control cabinet
has beenswitched off
.
• If a robot axis has been moved by the release device, all robotaxes must be remastered. The motor concerned must beexchanged.
I 14.03.02 I College I ML I 22KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Release device for robot axes
• The release device (reversible ratchet with size 12 socket wrench insert) ispushed onto the axle of the motor (remove protective cap), which can thenbe turned. It is necessary to overcome the resistance of the mechanicalmotor brake and any other loads acting on the axis.
• The motors reach temperatures during operation which cancause burns to the skin. Appropriate safety precautions must betaken.
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I 14.03.02 I College I ML I 23KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Planning and construction: safety and working zones
• Working zones are to be restricted to the necessary minimum size. On noaccount may persons or equipment be exposed to any danger.
• The danger zones must be safeguarded by means of protective barriersand indicated by means of paint markings on the floor.
• The safety fences must be high enough to prevent anybody from reachingover them. Design measures must be taken to prevent them from bending.The number of entrances must be kept to a minimum. All entrances must beconnected to the overall EMERGENCY STOP system operator safety on the gate, Emergency Stop on thesafety fencing.
I 14.03.02 I College I ML I 24KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Planning and construction
• The foundations and substructures must meet the quality specificationslaid down by KUKA.
• The loads to be expected when operating the robot system must lie withinthe permissible range.
• The operation of robots of normal design is not permitted inpotentially explosive areas.
• The robot can be equipped with a collision protection device (additionalequipment).
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I 14.03.02 I College I ML I 25KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Planning and construction
• Removal and installation stations must be provided to allow tools to bechanged. These stations must be accessible to the operator outside thedanger zone and the robot must be able to move to them by means of aspecial program step.
• If the presence of operating personnel in the work envelope of the robot isunavoidable (e.g. for loading components), the danger zone is to be isolatedby means of a safety mat or light curtain.
I 14.03.02 I College I ML I 26KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Planning and construction
• If the robot system is operated in conjunction with a higher-level controller ,the two EMERGENCY STOP circuits must be interconnected.
• Both these circuits must be of failsafe design (dual EMERGENCY STOPcontactors with reciprocal monitoring).
• It is particularly important that a regular check is made to ensure that that theEMERGENCY STOP devices are functioning correctly.
• Outputs are to be preset in accordance with the main project file, i.e. signalsfor hold functions must not be reset when the robot controller is switched off if personnel or equipment would be endangered as a result.
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I 14.03.02 I College I ML I 27KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
I nstallation and operation
• All persons working within the danger zone of the robot systemmust wear protective clothing. Of particular importance are safetyfootwear and closely fitting clothing.
• The prescribed transport positions for the robotmust be observed. Only suitable and technically
faultless lifting gear and load-bearing equipmentwith an adequate carrying capacity may be used.
• Never work or stand under suspendedloads!
I 14.03.02 I College I ML I 28KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
I nstallation and operation
• No welding may be carried out in the immediate vicinity of theopen control cabinet due, among other factors, to the risk ofEPROMs being erased by UV radiation. Foreign matter (e.g.
swarf, water, dust) must be prevented from entering the controlcabinet.
• During start-up , check that all protective devices are complete andfunctioning correctly. No persons or objects are allowed in the danger zoneduring start-up. It must be ensured that the correct machine data havebeen loaded before the system is put into operation for the first time.
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Page 22 of 227 handout GP KR C2 V4.1 01.03.01
I 14.03.02 I College I ML I 29KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
I nstallation and operation
• All safety regulations must be adhered to while the robot system is inoperation.
• Check the robot system at least once per working shift for obvious damageand defects.
• Never use the robot or the control cabinet as a climbing aid.
• The software must be checked for viruses.
I 14.03.02 I College I ML I 30KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
I nstallation and operation: safety instruction
• Personnel must be instructed before any work is commenced in the type ofwork involved and what exactly it entails as well as any hazards whichmay exist.
• Records are to be kept of the content and extent of the instruction.
• Personnel must be instructed oral ly every six months and in writingevery two years with regard to the observance of safety regulations andprecautions.
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I 14.03.02 I College I ML I 31KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Safety labeling
• All plates, labels, symbols and marks constitutesafety-relevant parts of the robot system.They must remain attached to the robot or control cabinet concerned for the whole of their service lives in their specified, clearly visiblepositions.
• It is forbiddento remove, cover, obliterate, paint over or alter in any other waydetracting from their clear visibility
- identification plates,- warning labels,- safety symbols,- designation labels and- cable marks.
I 14.03.02 I College I ML I 32KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Safety instructions for KUKA training cells
• Entering the motion range of the robot is only permitted with the robotoperated in “T1” mode (at reduced velocity) using a KCP.
• All persons situated in the environment of the robot (at its own or adjacentcells) must be informed in good time that the robot is about to move.
• On leaving the training cell, press the EMERGENCY STOP button on theKCP, set operating mode “ T1” and secure the KCP in its holder.
• Never lean over the safety fencing from outside!
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I 14.03.02 I College I ML I 33KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
Safety instructions for KUKA training cells
• When testing programs, always execute the program in “T1” mode firstand then in “T2” mode at reduced velocity.
• During program execution in “ T2” mode, no persons are permitted in the
cell and the gate to the cell must remain closed.
• The robot and its tooling must never touch or project beyond the safetyfence.
• Warning: memory dumps from KUKA College must not be loaded intomanufacturing systems.
I 14.03.02 I College I ML I 34KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
ESD directives
ESD = electrostatic sensitive devices
e.s.d. = electrostatic discharge
ESDs can be destroyed by voltages which are imperceptible to humans.
As well as causing complete failure of components, e.s.d. can also be responsiblefor partial damage to an IC or component, which can reduce its service life or leadto sporadic faults.
For these reasons, not only new modules, but alsodefective modules, must be handled very carefully in away suitable for ESDs.
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I 14.03.02 I College I ML I 35KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
ESD directives
16
14
12
10
8
6
4
2
20 40 60 80 100
synthetic
wool
antistatic
e.g. offices without air humidityregulation (in winter)
U/kV
Rel. air humidity/%15% 35%
Average values for electrical voltages to which aperson can be charged
Element
MOSFET
EPROM
JFET
OP amplifiersCMOS
Schottky diodes
Thick/thin-film circuits
Bipolar transistors
Schottky TTL
Voltage (V)
100-200
100
140-7000
100-2500250-3000
300-2500
300-3000
300-7000
1000-2500
e.s.d. vulnerability of semiconductor elements
I 14.03.02 I College I ML I 36KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.:+49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de(c) Copyright by KUKA Roboter GmbH College 1996-2002
ESD directives
Handling ESD modules:
• Components should only be unpacked if
a) you are wearing ESD shoes
or b) you are wearing ESD shoe grounding strips
or c) you are grounded by means of an ESD armband.
• Before touching an electronic module you should discharge the voltage
from your own body.
• Do not place electronic modules near monitors.
• Only measure with grounded measuring instruments or discharge the
measuring head before measuring.
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3. The robot system
3.1. Basics at the robot system
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I 14.03.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
KUKA Control Panel(KCP)
Components of a complete KUKA robot system
KUKA robot(e.g. KR 350/2 )
Robot controller (e.g. KR C2)
I 14.03.02 I College I ML I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
KUKA Control Panel (KCP)
• Large color graphic
display
• Softkeys around the
display
• Hardkeys for program
and display control
6D mouse
Numeric keypad, alphabetic keypad, cursor block with Enter key
• Keyswitch for mode selection• Drives on/off switch• Emergency Stop button
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I 14.03.02 I College I ML I 3KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
The model classification of KUKA industrial robots is based on the
rated payload.
The type designation is made up as follows:
KUKAindustrialr obot
Rated payloadof the robotin kilograms
Generation of the givenrobot type
K xxx / yR
Robot type designations
I 14.03.02 I College I ML I 4KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
KR 150 / 2KUKA industrial r obot
with a rated payload of 150 kg
of the 2nd generation
Example: Robot type designations
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I 14.03.02 I College I ML I 5KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Mechanical construction of a KUKA robot
Wrist
Link arm
Base frame
Arm
Rotatingcolumn
I 14.03.02 I College I ML I 6KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Axis designations of a KUKA robot
Axis 2
Axis 1
Axis 3
Axes 1, 2 and 3 are the main axes.
Axis 6
Axis 5
Axis 4
Axes 4, 5 and 6 are the wrist axes.
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I 14.03.02 I College I ML I 7KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
The work envelope of a KUKA robot (side view)
Can beexpanded usingan arm extension
Side view:work envelopeOverhead zone
I 14.03.02 I College I ML I 8KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
The work envelope of a KUKA robot (top view)
Top view:work envelope
Angle, axis 1:>360°
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I 14.03.02 I College I ML I 9KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Load distribution on a KUKA robot
Total Load = Payload + Supplementary Load
From the KR 2000 series onwards, it isalso possible to attach supplementaryloads to the link arm and rotating column.
Supplementary load
Payload
I 14.03.02 I College I ML I 10KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Loads on a KUKA robot (standard series)
Load center distance
Load center of gravity, P
Mass, M, of the payload(weight of tool)
Robot wrist
Robot flange
Axis 1
Axis 2
Axi s 3
PayloadSupplementaryload
Mass, M, and centerof gravity of thesupplementary load
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I 14.03.02 I College I ML I 11KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Payload diagram for KR 125/2
Lz (mm)
Lxy (mm)
100
200
300
400
500
600
100 200 300 400 500 600 700 800
125 kg
115 kg105 kg
95 kg85 kg
75 kg
65 kg
55 kg
45 kg
Nominal distance KR 125/2:LZ=210 mm
LXY=230 mm
230
210
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3.2. System overview
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I 14.03.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Control cabinet overview: KR C1, KR C1A and KR C2
Power supply connection 3x400 V PC technology Ambient temperature: 45 °C without cooling unit,
55 °C with cooling unit
I 14.03.02 I College I ML I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Technical data - KR C2
• Cabinet type: KR C2 – Control cabinet for max. 8 axes
• Permissible environmental conditions: – without cooling unit: max. 45 °C
– with cooling unit: max. 55 °C
• Weight: approx. 185 kg
• Power supply connection: 3x400 V
• Microprocessor: Celeron 433 MHz
• Main memory: 64 MB
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I 14.03.02 I College I ML I 3KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Hard drive
PC chassis - KR C2
Floppy disk drive
CD-ROM drive
I 14.03.02 I College I ML I 4KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Top view of the PC - KR C2
Keyboard
LPT1
COM1COM2Ethernet
Mouse
External monitor
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Page 38 of 227 handout GP KR C2 V4.1 01.03.01
I 14.03.02 I College I ML I 5KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Robot serial number
Serial number
I 14.03.02 I College I ML I 6KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Control cabinet serial number
Serial number
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I 14.03.02 I College I ML I 7KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Software concept
Main memory
Windows 95 VxWorks
Operation / visualization Kernel system
Drives
Robot programs
Control programs C
R O S S
Systems
communicate
with each other
KUKA GUIR1 / STEU
I 14.03.02 I College I ML I 8KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
User groups
User
• Start-up tasks (mastering,tool calibration)
• Simple application programs(programming using inlineforms, motion commands,technology commands, limitvalue checking, no syntax errors)
Administrator
• Configuration of the robotcontroller (external axes,technology packages)
• Configuration of the robotsystem (field buses, visionsystems, etc.)
• User-defined technology
commands with UserTECH
Expert
• Advanced programming usingthe KRL programming language
• Complex application programs(subprograms, interruptprogramming, loops, programbranches)
• Numeric motion programming
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3.3. Energy supply
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I 03.02.03 I College I DON I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Energy supply - Overview KR 2000
I 03.02.03 I College I DON I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Energy supply - Length attitude
Velcro fastener
Only as long asnecessary
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I 03.02.03 I College I DON I 3KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Energy supply - Hose routing
adjusting trumpet
adjusting compression spring
I 03.02.03 I College I DON I 4KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
If the protector is sanded off up to the redinterior, it is to be exchanged.
Energy supply - Attitude of the protectors
Robot-lateral p rotection device
Protector cannot beadjusted
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4. Operation of the KUKA control panel (KCP)
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I 19.03.02 I College I DON I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
KUKA Control Panel (KCP)
I 19.03.02 I College I DON I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Hardwired operator control elements
EMERGENCYSTOP
Drives OFF
Drives ON
Mode selectorswitch
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I 19.03.02 I College I DON I 3KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
T T
T1 (Test 1)T2 (Test 2)
AUTOMATIC AUTOMATIC EXTERNAL
Mode selector switch
I 19.03.02 I College I DON I 4KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Mode selector switch
T1 T2 AUTOMATIC AUTOMATICEXTERNAL
Manual motionusing
keysor
Space Mouse
250 mm/s 250 mm/s Manual motionnot active
Manual motionnot active
HOV
Enabling switch(dead manfunction)
Enabling switch(dead manfunction)
Programexecution
250 mm/s
POV
Prog.velocity
Prog. velocity Prog. velocity
Enabling switch(dead manfunction)
START keypressed
Enabling switch(dead manfunction)
START keypressed
Drives ONSTART key--> PULSE
Drives ONExternal start
Mode table
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I 19.03.02 I College I DON I 5KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
CAN bus operator control elements
Escape key
Window selection key
I 19.03.02 I College I DON I 6KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Display window
Programming window Status window
Message window
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I 19.03.02 I College I DON I 7KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Window selection key
I 19.03.02 I College I DON I 8KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Softkeys
Softkeys
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I 19.03.02 I College I DON I 9KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Status window
The status window isdisplayed as required.
The status window canbe closed at any time.
I 19.03.02 I College I DON I 10KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Message window
The controller communicates withthe operator via the message window.
Softkeys for acknowledgingmessages
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I 19.03.02 I College I DON I 11KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Message types
Hint - e.g. "Start key required"
Status - e.g. "EMERGENCY STOP"
Acknowl. - e.g. "Ackn. EMERGENCY STOP"
Wait - e.g. "Wait for $IN[1]==True"
Dialog - e.g. "Do you want to teach point?"
I 19.03.02 I College I DON I 12KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
CAN bus operator control elements
STOP key
Program start forwards
Program start backwards
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I 19.03.02 I College I DON I 13KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
CAN bus operator control elements
NUM key
Numeric keypad
I 19.03.02 I College I DON I 14KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Numeric keypad
HOMEJumps to thebeginning of the linein which the editcursor is positioned.
UNDOCancels the last entry.
ENDJumps to the end ofthe line in which theedit cursor ispositioned.
PGUPMoves one screentowards thebeginning of the file.
TABTab jump
PGDNMoves one screentowards the end ofthe file.
CTRLControl key
ArrowBackspace key;deletes thecharacter to the leftof the edit cursor.
LDELDeletes the line inwhich the editcursor is positioned.
DELDeletes thecharacter to the
right of the edit cursor.
INSSwitches betweeninsert and overwritemodes.
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I 19.03.02 I College I DON I 15KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
CAN bus operator control elements
ASCIIalphabetickeypad
I 19.03.02 I College I DON I 16KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
ASCII alphabetic keypad
SYM key
SHIFT key
ALT key
NUM key
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Page 54 of 227 handout GP KR C2 V4.1 01.03.01
I 19.03.02 I College I DON I 17KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
CAN bus operator control elements
RETURN key
CURSOR block
I 19.03.02 I College I DON I 18KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Menu keys
Menu keys
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I 19.03.02 I College I DON I 19KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Status keys
Status keys
I 19.03.02 I College I DON I 20KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Status bar
Selectedprogram Current line
number
Override
Time
Numeric keypad
Operating mode
Upper/lower-case letters
Robot name
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Page 56 of 227 handout GP KR C2 V4.1 01.03.01
I 19.03.02 I College I DON I 21KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Status bar
Submit interpreter deselectedSubmit interpreter stoppedSubmit interpreter running
Drives not readyDrives ready (600 ms)
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5. The coordinate systems at the robot
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I 14.03.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Coordinate systems
• Ax is-speci fic motionEach robot axis can be moved individually in a positiveor negative direction.
• WORLD coordinate systemFixed, rectangular coordinate system whose origin is locatedat the base of the robot.
• TOOL coordinate systemRectangular coordinate system, whose origin is located inthe tool.
• BASE coordinate systemRectangular coordinate system which has its origin onthe workpiece that is to be processed.
I 14.03.02 I College I ML I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Selecting a coordinate system
• Select manual motion
Motion keys
Motion with mouse
• Select the coordinate system
Axis-specific manual motion
WORLD coordinate system
TOOL coordinate system
BASE coordinate system
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5.1. The axis coordinat system
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I 08.04.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Axis-specific manual motion
Each robot axis can be moved individually in a positiveor negative direction.
I 08.04.02 I College I ML I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Axis-specific motion with the 6D mouse
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5.2. The world coordinate system
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I 08.04.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
WORLD coordinate system
Fixed, rectangular coordinate system whose origin islocated at the base of the robot.
I 08.04.02 I College I ML I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
+X
+Y
+Z
Assignment of the angles of rotation in Cartesian coordinates
X
Y
Z
A
B
C
A
Angle A Rotation about the Z-axis
B
Angle B Rotation about the Y-axis
C
Angle C Rotation about the X-axis
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I 08.04.02 I College I ML I 3KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
+Y
+Z
+X
Right hand rule (coordinate directions)
I 08.04.02 I College I ML I 4KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Right hand rule (direction of rotation)
+X, +Y or +Z
+C, +B or +A
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I 08.04.02 I College I ML I 5KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Cartesian motion with the 6D mouse
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5.3. The tool coordinate system
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I 08.04.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
TOOL coordinate system
Rectangular coordinate system, whose origin is locatedin the tool.
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5.4. The base coordinate system
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I 08.04.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
BASE coordinate system
Rectangular coordinate system which has its origin onthe workpiece that is to be processed.
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6. Stop reactions of the robot
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I 03.02.03 I College I DON I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Braking reactions of the KR C2
Emergency Stop
Enabling sw. released
Safety gate opened
Drives OFF
Mode change
Encoder error (DSE-RDC connection broken)
Move enable
Stop key
Path-oriented braking Path-maintaining braking
Path-oriented braking ---
--- Path-maintaining braking
Path-oriented braking
Path-oriented braking
Short-circuit braking
Ramp-down braking
Ramp-down braking
TEST (T1 or T2) AUTO or AUTOEXT
I 03.02.03 I College I DON I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Braking reactions of the KR C2
Short-circuitbraking
Path-maintainingbraking
Path-orientedbraking
Ramp-downbraking
Technicalterm
Reactionof drives
Intermediatecircuit
Short-circuitbraking relays
Brakes Software
Remain ON
High-speeddischarge
Appliedimmediately
---Switched off immediately
Only switchedoff after 1 s
hardwaredelay
Switched off immediately
Remainscharged
Discharged;high-speeddischarge if UIC < 50 V
Remainopen
Applied ifUIC < 50 V
Remain openfor 1 s,
then applied
Appliedimmediately
Remainopen
Appliedimmediately
Appliedafter 1 s
Normal ramp which is alsoused for normalacceleration and
deceleration at a point
The controller attempts tobrake the robot on the pathwith the remaining inter-mediate circuit voltage.When the intermediatecircuit voltage is no longersufficient, short-circuitbraking is activated.
In this time the controllerbrakes the robot on the path
using a steeper stop ramp.
Remainscharged for 1 s,
then high-speeddischarge
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7. Mastering
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I 14.03.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Why is mastering carried out?
A1=0°
A2=-90°
A3=+90°
A4, A5, A6=0°
• When the robot is mastered, the axesare moved into a defined mechanicalposition, the so-called mechanical zero
position.
• Once the robot is in this mechanicalzero position, the absolute encodervalue for each axis is saved.
I 14.03.02 I College I ML I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Mastering equipment
Electronic measuring tool (EMT)
Dial gauge
• In order to move the robotexactly to the mechanical zeroposition, a dial gauge orelectronic measuring tool(EMT) is used.
In EMT mastering, the axis isautomatically moved by therobot controller to themechanical zero position. If adial gauge is being used, thismust be carried out manually in
axis-specific mode.
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I 14.03.02 I College I ML I 3KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Cross-section of the gauge cartridge
EMTor
dial gauge
"Frontsight/rearsight" marker
Reference notchGauge pin
Gauge cartridge
I 14.03.02 I College I ML I 4KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Schematic representation of the mastering run
EMTor
dial gauge
Motion direction+ -
Mechanical zero position
EMTor
dial gauge
Motion direction+ -
Pre-mastering position
"Frontsight/rearsight" marker
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I 14.03.02 I College I ML I 5KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Reasons for remastering
... manually by the operator ... if the mastering values for the individual axes
are to be specifically deleted
Mastering is canceled...The robot can be unmastered...
1) If discrepancies are detected between the resolver data saved when shutting down the controller and thecurrent position, all mastering data are deleted for safety reasons.
... manually by the operator ...after a collision involving the tool or robot
... manually by the operator ...after an impact with a mechanical end stop at
more than manual velocity (25 cm/s)
... automatically on booting thesystem1)
...when the robot has been moved without thecontroller (e.g. hand crank)
... manually by the operator …replacement of a gear
... automatically on booting thesystem1)
...after repairs (e.g. replacement of a drivemotor or RDC)
Mastering is canceled...The robot is to be mastered...
I 14.03.02 I College I ML I 6KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Mastering with the EMT
M a s t e r i n g
l o s s / c h e c k Check
masteringMaster loadwith offset
Master loadwithout offset1)
Set mastering
Teach offset
First mastering
Mastering with the EMT
1) Only possible if the first mastering is still valid (i.e. no change to the drivetrain, e.g. replacement of a motor or parts, or following a collision, etc.)
S e t - u p
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I 14.03.02 I College I ML I 7KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Preparation for EMT mastering
!
OK
• Move axes to pre-mastering position(frontsight and rearsight aligned)
• Move axes manually in axis-specific mode
• Each axis is mastered individually
• Start with axis 1 and move upwards
• Always move axis from + to -
I 14.03.02 I College I ML I 8KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Preparation for EMT mastering
• Remove protective cap from gaugecartridge
• Attach EMT and connect signal cable(connection X32 on the junction box on
the rotating column)
• Three LEDs on the EMT:
red - error
green - falling edge
green - rising edge
Gaugecartridge
1 32
1
3
2
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I 14.03.02 I College I ML I 9KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Mastering menu
With load corr.With load corr.StandardStandard
Checkmastering
Checkmastering
Setmastering
Setmastering
Firstmastering
Firstmastering Teach offsetTeach offset Master loadMaster load
Without offsetWithout offsetWith offsetWith offset
Master Master
DialDial EMTEMT
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8. Tool calibration
8.1. The calculation of the TCP's
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I 02.05.02 I College I DON I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Tool calibration
What happens during too l calibration?
The tool receives a user-definedCartesian coord inate system
with its origin at a referencepoint specified by the user.
XZ
Y
I 02.05.02 I College I DON I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Tool calibration
What are the advantages of tool calibration?
1
2
3
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I 02.05.02 I College I DON I 3KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
General procedure for tool calibration
YFlange
XFlange
ZFlange
TCP withouttool calibration
1st step:
Calculation of the TCP relative to
the flange coordinate system
TCP withtool calibration
2nd step:
Definition of the rotation of the
Tool coordinate systemfrom the flange coordinatesystem
YTool
XTool
ZTool
I 02.05.02 I College I DON I 4KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Tool calibration methods
1. TCP calibration
2. Orientation calibration
or
or or
X Y Z - 4 PointX Y Z - Reference
A B C - World 5D A B C - World 6D
A B C - 2 Point
Flangeadapterpla teas referencetool
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I 02.05.02 I College I DON I 5KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Activating the tool
Pin
Blue
Enter the tool number TOOL_DATA[1-16]
Tool nameis displayed
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8.1.1. The X Y Z - 4 Point method
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The X Y Z - 4 Point method
In the XYZ - 4-point method, the TCP of the tool is moved to areference point from four different directions.
The TCP of the tool is then calculated from the different flangepositions and orientations.
I 14.03.02 I College I ML I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Diagram of the X Y Z - 4 Point method
P1
P2P3
P4
ZW
XT
Reference point
Unknowntool
• Move the tool to the referencepoint with 4 differentorientations (P1 to P4).
• Tip: Set the final orientation
(P4) so that +XT runs in thedirection of -ZW .
• Important: The orientationsof the tool positions (flangepositions) must differsufficiently from one another.
Reduce the velocity in the vicinity of the reference point in order toavoid a collision.
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8.1.2. The XYZ-reference method
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The X Y Z - Reference method
Reference point
Knowntool
Reference point
Unknowntool
In the X Y Z - Reference method, the TCP data are determined bymeans of a comparison with a known tool.
The unknown TCP can be calculated on the basis of the variouspositions and orientations of the robot flange and the dimensions of
the known tool.
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Example of the X Y Z - Reference method
Flangeadapter plateas referencetool
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8.2. Orientation calibration
8.2.1. The ABC-world 5D method
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The A B C - World 5D method
In this method, the tool mustbe oriented parallel to the Zaxis of the world coordinatesystem in the workingdirection. The Y and Z axesare oriented by the robot
controller. The orientation ofthese axes is not readilyforeseeable in this instance,but it is exactly the same ineach calibration procedure.
ZWorld
YWorldXWorld
Condition:
XTool parallel to ZWorld
XTool
YToolZTool
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8.2.2. The ABC-world 6D method
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The A B C - World 6D method
ZWorld
YWorld
XWorld
XTool
YToolZTool
Conditions:
XTool parallel to ZWorld
YTool parallel to YWorld
ZTool parallel to XWorld
In this method, the toolmust be oriented inalignment with the worldcoordinate system. Theaxes of the tool coordinatesystem must be parallel to
the axes of the worldcoordinate system.
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8.2.3. The ABC-2 point method
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I 14.03.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
The A B C 2 Point method 1st step (diagram 1)
• In the first step, the working
direction of the tool is definedfor the controller.
• This is done by moving theTCP (which has beencalibrated beforehand) to aknown reference point.
TCP
Reference point
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The A B C 2 Point method 1st step (diagram 2)
• It is now necessary to move apoint located opposite the TCPon the tool to the samereference point (in the reverseworking direction). The workingdirection of the tool is definedin this way.
• This is done by moving to apoint on the negative X axis ofthe tool to be calibrated.TCPReference point
XTool
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The A B C 2 Point method 2nd step
• The YZ plane can still rotatefreely about the X axis(working direction) of thetool and is defined in thesecond step.
• This is done by moving thetool so that the referencepoint is located with apositive Y value on thefuture XY plane of the tool.
TCP
Reference pointYTool
XTool
ZTool
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8.3. Tool - payload
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Tool load data
10 kg100
kg
Maximum acceleration / velocity
L o a d m o v e
d
In order to be able to move the robot as fast as possible,the load data of the tool/workpiece must be taken into consideration.
Do not forget supplementary loads on the robot!
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Tool load data parameters
YFlange
XFlange
ZFlange
M Weight of the tool
X, Y, Z Distance between the center of gravity of the tool and the origin of the robotflange coordinate system
A, B, C Rotational offset of the principal inertia axes of the tool (Z-Y-X Euler angles)from the robot flange coordinate system
JX, JY, JZ Mass moments of inertia about the principal inertia axes of the tool
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9. Base calibration
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Base calibration
The work surface (pallet, clamping table, workpiece...) receivesa user-defined Cartesian coordinate system with its origin at
a reference point specified by the user.
XBase
ZBase
YBase
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Purpose of base calibration
ZWorld
Tool
YWorldXWorld
Manual motion
Motion along theedges of the work
surface or workpiece.
Motion direction
Base
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Purpose of base calibration
Base
ZWorld
Tool
YWorldXWorld
Teaching points
The taught pointcoordinates refer to
the BASE coordinatesystem.
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Purpose of base calibration
Program mode
If the BASE coordinatesystem is offset, the
taught points move with it.
ZWorld
Tool
YWorldXWorld
Base
Base
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Purpose of base calibration
Program mode
It is possible to createseveral BASE coordinate
systems.
ZWorld
Tool
YWorld
XWorld
B a s e 2
B a s e 1
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The "3-Point" method: 1st step
Workpiece
Reference tool
Origin
• In the first step, theTCP of thereference tool ismoved to the originof the new BASEcoordinate system.
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The "3-Point" method: 2nd step
• In the second step,the TCP of the
reference tool ismoved to a point onthe positive X-axisof the new BASEcoordinate system.
Workpiece
Reference tool
Origin
XBase
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The "3-Point" method: 3rd step
• In the third step, theTCP of the referencetool is moved to apoint with a positive Yvalue on the XY-planeof the new BASEcoordinate system.
Workpiece
Reference tool
Origin
XBase
YBase
ZBase
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Calculating the BASE coordinate system indirectly
ZWorld
YWorld
XWorld
Reference point
Point 4
Point 1
Point 2
Point 3
• In the controller, enter thecoordinates of 4 pointsreferring to the BASE (e.g.from CAD).
• Move the TCP of the refer-ence tool to the four points.
• The robot controllercalculates the BASE.
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Pin
Blue
Activating a base
Enter the number ofthe baseBASE_DATA[1-16]
Name of the baseis displayed
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10. Motions programming at the robot
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Types of motion
P1
P2
LIN (Linear):The tool is guided at adefined velocity along astraight line.
P1
P2
CIRC (Circular):The tool is guided at adefined velocity along acircular path.
KUKA robot motion t ypes (interpolation types)
P2
P1
PTP (Point-to-point):The tool is movedalong the quickest pathto an end point.
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10.1. PTP – motion
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PTP motion
P1P2
Shortest distance
Fastest path
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SYNCHRO PTP
V max
Time t
Individual axis velocity v
P1 P2
Acceleration DecelerationConstant
e.g. axis 2: leading axis
P1
P2
e.g. axis 3: adaptede.g. axis 6: adapted
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Programming a PTP motion
Type of motion
Pointname
Velocity
Motionparameters
Approximatepositioning ON
Exact positioning
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Programming a PTP motion
ToolTool selection
Tool_Data[1]..[16], Nullframe
BaseWorkpiece coordinate systemselectionBase_Data[1]..[16], Nullframe
External TCPRobot guiding tool: FalseRobot guiding workpiece: True
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Programming a PTP motion
Accelerat ion Acceleration used for themotion.Range of values: 1...100%
Approximation distance*)
Size of approximate positioningrange for the motion.Range of values: 0...100%
*) The parameter "Approximation distance" is only displayed ifapproximate positioning has been selected (CONT).
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10.2. LIN – mot ion
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LIN motion without approximate positioning
P1
P2
P3shortest distance
LIN motion
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Velocity profile
P1
P2
Time t
Path velocity v
P1 P2
V prog
Acceleration DecelerationConstant
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Programming a LIN motion
Type of motion
Pointname
Velocity
Motionparameters
Approximatepositioning ON
Exact positioning
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Programming a LIN motion
ToolTool selection
Tool_Data[1]..[16], Nullframe
BaseWorkpiece coordinate systemselectionBase_Data[1]..[16], Nullframe
External TCPRobot guiding tool: FalseRobot guiding workpiece: True
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Programming a LIN motion
Accelerat ion Acceleration used for themotion.Range of values: 1...100%
Approximation distance*)
Size of approximate positioningrange for the motion.Range of values: 0...300 mm
*) The parameter "Approximation distance" is only displayed ifapproximate positioning has been selected (CONT).
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10.3. CIRC – motion
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CIRC motion without approximate positioning
CIRC motion
P1
P2 (AUX)
P3(END)
P2 is an auxiliary point (AUX),P3 is the end point (END)
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Programming a CIRC motion
Type of motion
Auxiliarypoint name
Velocity
Motionparameters
End pointname
Exact positioning
Approximate positioning ON
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Programming a CIRC motion
ToolTool selectionTool_Data[1]..[16], Nullframe
BaseWorkpiece coordinate systemselectionBase_Data[1]..[16], Nullframe
External TCPRobot guiding tool: FalseRobot guiding workpiece: True
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Programming a CIRC motion
Accelerat ion
Acceleration used for themotion.Range of values: 1...100%
Approximation distance*)
Size of approximate positioningrange for the motion.Range of values: 0...300 mm
*) The parameter "Approximation distance" is only displayed ifapproximate positioning has been selected (CONT).
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The 360° full circle
The full circle should be made upof at least two segments.
P2P1
P4=END
P3=AUX
P5=AUX
P2=END
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10.4. Approximation of motion
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Approximation of motions
During approximate positioning, the robot does not moveexactly to each programmed position, nor is it brakedcompletely. Advantage:
• reduced wear
• improved cycle timesP1
P2
P3
X
Y
Z
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Cycle time improvement by means of approximated motions
5 10 15 20 25 30
5 10 15 20 25 30
G e s c h w i n d i g k e i t
G e s c h w i n d i g k e i t
Zeit (sec)
Zeit (sec)
P2 P3 P4P1
P2 P3 P4P1
Vprog
Vprog
ohne Überschleifen
mit Überschleifen
without approximate positioning
Time (s)
Time (s)
with approximate positioning
V e l o c i t y
V e l o c i t y
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PTP motion with approximate positioning
P1
P2
P3shortest distance
possible PTP approx. positioning paths
PTP motion with P2 is an approx.approx. positioning positioning point
Approximate starts, if the leading axis reaches the middle ofthe angle of the shorter movement.
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LIN motion with approximate positioning
P1
P2
P3Two parabolic curves(symmetrical at constant velocity)
LIN motion with P2 is an approx.approx. positioning positioning point
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CIRC motion with approximate positioning
CIRC motion with P3 is an approx.approx. positioning positioning point
P4
P1
P2 (AUX)
P3(END)
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11. The navigator (program production)
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I 10.04.02 I College I DON I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Navigator (user)
Header
Directory structureDirectoryor file list
Status line
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Symbols in the Navigator (user)
Default p athTypeSymbol
Archive:\Backup drive
A:\Floppy
KRC:\Robot
Drives
MeaningTypeSymbol
Program with errors that cannot be
interpreted by the compiler.Module containing errors
Program at user levelModule
The contents of a directory are being readRead directory
ZIP file Archive
Open directoryDirectory open
Normal directoryDirectory
Directories and files
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Navigation using the keyboard
Focus
Select drive,
directory or file
Toggle betweendirectory structure / file list Open drive,
directory or file
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Please enter a name
New program
Confirm
Program name
Comment
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Program run modes (1)
Incremental Step (single block)The program is executed step by step, i.e. with aSTOP after each instruction (including blank lines).The program is executed without advanceprocessing.
ISTEP
Motion Step (motion block)
The program is executed one motion instruction at atime, i.e. with a STOP before each motioninstruction. The program is executed withoutadvance processing.
MSTEP
GO mode All instructions in the progam are executed up to theend of the program without a STOP.
GO
DescriptionRun
mode
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Program status
The block pointer is situated on the lastline of the selected program.
Black:
The selected and started program hasbeen stopped.
Red:
A program has been selected and iscurrently being executed.
Green:
The block pointer is situated on the firstline of the selected program.
Yellow:
No program is selected.Gray:
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Archive
This function allows you to save important data to floppy disk. All filesare saved in compressed form as ZIP files.
If you try to insert a file in an existing archive, therobot name is checked. The robot name in the archiveis compared with the name that is set in the
controller.If the two names are different, a request forconfirmation is generated asking if you really wish tooverwrite the existing archive.
I 10.04.02 I College I DON I 8KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Archive All
The menu item Archive "All" i s used to save to floppydisk all the data that are required to restore the robotsystem.These include
- machine data- tool/base data- all applications- etc.
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Archiving individual programs
The selected files are saved to floppy disk
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Restore All
Once the system has been restored, it must be shut down andrebooted.
Al l f il es, w ith the exception of log fi les , are loadedback onto the hard disk.
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Restoring individual programs
The selected files are loaded back onto the hard disk
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12. Logic programming
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Logic programming
Programming of inputs and outputs for communicationbetween the robot controller and its peripheral environment.
(e.g. tools, sensors, etc.)
Outputs:$OUT[1] ... $OUT[4096]
Inputs:$IN[1] ... $IN[4096]
$IN[1025]=TRUE$IN[1026]=FALSE
Robot controller Periphery
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Logic commands available
Time-dependentwait function
Signal-dependentwait function
Switching functions
Coupling/decouplingan Interbus segment
The following logic commands can be selected:
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Time-dependent wait function (WAIT)
If "WAIT" has been selected, the wait time can be specified:
Example:PTP P1 VEL=100% PDAT1PTP P2 VEL=100% PDAT2WAIT Time=1 sec
PTP P3 VEL=100% PDAT3
Wait time in seconds
P1
P2P3
Motion is interruptedfor 1 second at pointP2
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Signal-dependent wait function (WAIT FOR)
If "WAIT FOR" has been selected, the following parameters can bespecified:
Example:PTP P1 VEL=100% PDAT1PTP P2 VEL=100% PDAT2WAIT FOR IN 1 ‘ ‘ State=TRUE
PTP P3 VEL=100% PDAT3
State
Input/output number
P1
P2
P3
Motion is interrupted atpoint P2 until input 1 isset
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Switching functions
The following switching functions can be selected:
Simple switchingfunction
Simple pulse
function
Path-dependentswitching function
Path-dependentpulse function
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Simple switching function (OUT)
If "OUT" has been selected, the following parameters can bespecified:
StateOutput
Advance run stop on
Advance run stop off
Example:PTP P1 VEL=100% PDAT1PTP P2 CONT VEL=100% PDAT2PTP P3 CONT VEL=100% PDAT3
PTP P4 VEL=100% PDAT4P1
P2P3
P4
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Simple switching function (OUT)
If "OUT" has been selected, the following parameters can bespecified:
Example:PTP P1 VEL=100% PDAT1PTP P2 CONT VEL=100% PDAT2PTP P3 CONT VEL=100% PDAT3
PTP P4 VEL=100% PDAT4P1
P2 P3
P4
OUT 1 ‘ ‘ State=TRUE
StateOutput
Advance run stop on
Advance run stop off
Point P3becomes anexactpositioningpoint andoutput 1 is set
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Simple switching function (OUT)
If "OUT" has been selected, the following parameters can bespecified:
Example:PTP P1 VEL=100% PDAT1PTP P2 CONT VEL=100% PDAT2PTP P3 CONT VEL=100% PDAT3
PTP P4 VEL=100% PDAT4OUT 1 ‘ ‘ State=TRUE CONT
StateOutput
Advance run stop on
Advance run stop off
P1
P2P3
P4
CONT preventsan advance runstop from beingtriggered; output1 is set during theadvance run
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Simple pulse function (PULSE)
If "PULSE" has been selected, the following parameters can bespecified:
StateOutput
Advance run stop on
Advance run stop off
Pulse length
0
1
Time
OUT 1
Time 0
1
Time
OUT 1
Time
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Path-dependent switching function (SYN OUT)
If "SYN OUT" has been selected, the following parameters can bespecified:
StateOutput Switching point
Time
Example:LIN P1 VEL=0.3m/s CPDAT1LIN P2 VEL=0.3m/s CPDAT2
SYN OUT 1 ‘ ‘ State=TRUE at START Delay=20msSYN OUT 2 ‘ ‘ State=TRUE at END Delay=-20ms
LIN P3 VEL=0.3m/s CPDAT3
LIN P4 VEL=0.3m/s CPDAT4P1
P2
P3
P4
+
-
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Path-dependent switching function (SYN OUT)
If "SYN OUT" has been selected, the following parameters can bespecified:
StateOutput Switching point
Time
Example:LIN P1 VEL=0.3m/s CPDAT1LIN P2 VEL=0.3m/s CPDAT2
SYN OUT 1 ‘ ‘ State=TRUE at START Delay=20msSYN OUT 2 ‘ ‘ State=TRUE at END Delay=-20ms
LIN P3 CONT VEL=0.3m/s CPDAT3
LIN P4 VEL=0.3m/s CPDAT4P1
P2
P3
P4
+
-+
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Path-dependent switching function (SYN OUT)
If "SYN OUT" has been selected, the following parameters can bespecified:
StateOutput Switching point
Time
Example:LIN P1 VEL=0.3m/s CPDAT1LIN P2 CONT VEL=0.3m/s CPDAT2
SYN OUT 1 ‘ ‘ State=TRUE at START Delay=20msSYN OUT 2 ‘ ‘ State=TRUE at END Delay=-20ms
LIN P3 CONT VEL=0.3m/s CPDAT3
LIN P4 VEL=0.3m/s CPDAT4P1
P2
P3
P4
+
-+
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Path-dependent switching function (SYN OUT)
If "SYN OUT" has been selected, the following parameters can bespecified:
StateOutput Switching point
Time
Example:LIN P1 VEL=0.3m/s CPDAT1SYN OUT 1 ‘ ‘ State=TRUE PATH=20mm Delay=-5ms
LIN P2 CONT VEL=0.3m/s CPDAT2
LIN P3 CONT VEL=0.3m/s CPDAT3LIN P4 VEL=0.3m/s CPDAT4
P1
P2
P3
P4
+
-
20mm
-+
-5ms
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Path-dependent switching function (SYN OUT)
If "SYN OUT" has been selected, the following parameters can bespecified:
StateOutput Switching point
Time
Example:LIN P1 CONT VEL=0.3m/s CPDAT1SYN OUT 1 ‘ ‘ State=TRUE PATH=20mm Delay=-5ms
LIN P2 CONT VEL=0.3m/s CPDAT2
LIN P3 CONT VEL=0.3m/s CPDAT3LIN P4 VEL=0.3m/s CPDAT4
P1
P2
P4
+
-
20mm P3
-+
-5ms
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Path-dependent pulse function (SYN PULSE)
If "SYN PULSE" has been selected, the following parameters can bespecified:
State
Output Switching point
Time
Pulse length
0
1
Time
OUT 1
Time 0
1
Time
OUT 1
Time
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Coupling/decoupling Interbus segments
If "IBUS-Seg. on/off" has been selected, the following parameters canbe specified:
Coupling/
decoupling
3.0Bus terminal 3(fixed to the tool)
2.0
2.1
2.2
1.0
1.1
1.2
Bus terminal 1 Bus terminal 2
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13. Gripper Tech H50
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Gripper configuration
Up to 16 grippers can be configured via the "Configure"menu:
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Gripper configuration
Gripper <name>Name of the gripper; 24 characters
Gripper type <number>Function type of the gripper
Outputs <numbers> Assignment of robot controller outputs tothe gripper actuators
Inputs <numbers> Assignment of robot controller inputsfrom the gripper sensors
State <name>Designation of the gripper states,dependent on the gripper type; 11characters
11 22 33 44 55
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Gripper configuration
Gripper name
Gripper type (1...5)
Outputs
Inputs
States
OUT 1 OUT 2 IN 1 IN 2 IN 3 IN 4
TRUE FALSE TRUE FALSE TRUE A FALSE
FALSE TRUE FALSE TRUE FALSEB TRUE
State Activation Evaluation
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Programming gripper functions
The following gripper commands can be selected from the"Technology" menu:
Gripper function
Gripperinterrogation
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Gripper without approximate positioning
Once "GRIPPER" has been selected, the following parameters can bespecified:
Gripper name
Selectfunction
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Gripper with approximate positioning
Once "GRIPPER" has been selected, the following parameters can bespecified:
Approximate positioning on
Reference point
Delay
D e l a y
p o s i t i v
e D e l
a y
n e g a t i v
e
END
START
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Check Gripper
Once "CHECK GRIPPER" has been selected, the followingparameters can be specified:
Reference point
Delay
Gripper name
Selectfunction
This command is only executed if it is located before a motioninstruction.
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13.1. Gripper typ 1
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Basic types for gripper functions: TYPE 1
TYPE 1: 2 outputs, 4 inputs, 2 switching states
OUT 1 OUT 2 IN 1 IN 2 IN 3 IN 4
TRUE FALSE TRUE FALSE TRUE A FALSE
FALSE TRUE FALSE TRUE FALSEB TRUE
State Activation Evaluation
e.g. a simple gripper with the functions OPEN and CLOSE
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Example: TYPE 1 (functional principle)
IN 3IN 4
OUT 2
IN 1 IN 2
OUT 1
Gripper closed
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Example: TYPE 1 (functional principle)
Com-ponent
OUT 1
IN 1 IN 2 IN 3IN 4
OUT 2
Gripper open
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Example: TYPE 1 (functional principle)
Com-
ponent
IN 3IN 4
OUT 2
IN 1 IN 2
OUT 1
Component gripped
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13.2. Gripper typ 2
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Basic types for gripper functions: TYPE 2
TYPE 2: 2 outputs, 2 inputs, 3 switching states
OUT 1 OUT 2 IN 1 IN 2
TRUE FALSE TRUE FALSE A
FALSE TRUE FALSE TRUEB
State Activation Evaluation
FALSE FALSE FALSE FALSEC
e.g. a slide with a center position
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OUT 1 OUT 2
State: A C B
IN2 IN1
Example: TYPE 2
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13.3. Gripper typ 3
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Basic types for gripper functions: TYPE 3
TYPE 3: 2 outputs, 2 inputs, 3 switching states
OUT 1 OUT 2 IN 1 IN 2
TRUE FALSE TRUE FALSE A
FALSE TRUE FALSE TRUEB
State Activation Evaluation
FALSE FALSE FALSE FALSEC
e.g. a vacuum gripper with the functionsSUCTION, RELEASE and OFF
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OUT 1 OUT 2
< PIN1 > PIN2
Suction Release
Example: TYPE 3
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13.4. Gripper typ 4
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Basic types for gripper functions: TYPE 4
TYPE 4: 3 outputs, 2 inputs, 3 switching states
OUT 1 OUT 2 OUT 3 IN 1 IN 2
TRUE FALSE FALSE TRUE FALSE A
FALSE TRUE TRUE FALSE TRUEB
State Activation Evaluation
FALSE TRUE FALSE FALSE FALSE A
The same as type 3 but with three control outputs(type 3 has two outputs)
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< PIN1 > PIN2
OUT 1
Suction (A)
OUT 3
Release (B)
OUT 2
OFF (C)
Throttle
Example: TYPE 4
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13.5. Gripper typ 5
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Basic types for gripper functions: TYPE 5
TYPE 5: 2 outputs, 4 inputs, 2 switching states
OUT 1 OUT 2 IN 1 IN 2 IN 3 IN 4
TRUE FALSE TRUE FALSE TRUE A FALSE
FALSE TRUE FALSE TRUE FALSEB TRUE
State Activation Evaluation
The same as type 1 but with a pulse signal instead of acontinuous signal
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Example: TYPE 5
IN2 IN1
OUT1
OUT2
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14. Fixed tool calibration
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Fixed tool
X
Y
Z
• The workpiece is mountedon the robot flange andcalibrated as a BASE.
X
Y
Z
X
Y
Z
• Calculation of the distance
between the TCP of thefixed tool and the origin ofthe world coordinatesystem.
"Fixed tool" means that the robotguides a workpiece to one or morestationary tools that are integratedinto the cell. Calibration consists oftwo parts:
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Calibration of the fixed tool
The coordinates are saved asBASE_DATA[1]....[16].
1. Calibrate the fixed tool
+X
+Y+Z
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Calibration of the fixed tool 1st step
• First of all, a tool of knowndimensions is moved to the TCP(tool center point) of the fixedtool.
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Calibration of the fixed tool 2nd step
• In the second step, the robotflange is aligned perpendicularto the working direction of thetool (tool direction).
X
Y
Z
Tool
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Calibration of the movable workpiece
The coordinates are saved asTOOL_DATA[1]....[16].
2. Calibrate the workpiece
XY
Z
X
YZ
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Calibration of the movable workpiece 1st step
Origin at TCP
• The origin of the workpiece coordinate system must beshifted to the TCP of the fixed tool.
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Calibration of the movable workpiece 2nd step
• In the second step, the workpiece is moved so that the TCPof the fixed tool is positioned at a point on the positive X axisof the workpiece coordinate system.
XOrigin
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Calibration of the movable workpiece 3rd step
• In the final step, the workpiece is moved so that the TCP ofthe fixed tool is positioned at a point with a positive Y valuein the XY plane of the workpiece coordinate system.
Y
XOrigin
Z
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Kinematic chain with base-related interpolation
$TOOL
X
YZ
$IPO_MODE = #BASE
$POS_ACT
$ROBROOT
X
Y
Z
$WORLD
X
Y
Z
$BASE
X
Y
Z
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Kinematic chain with tool-related interpolation
$IPO_MODE = #TCP
$ROBROOT
X
Y
Z
$WORLD
X
Y
Z
$BASE
X
Y
Z
$TOOL
X
YZ
$POS_ACT
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Pen
Changing the $IPO_MODE
Pen
$IPO_MODE=#TCP
$IPO_MODE=#BASE
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Panel
not defined
Pen
Gripper
Blue
Red
Fixed pen
Tool and base type
Defined type
Name of the tool or base
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15. Programming with subprograms
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Subprograms
Subprograms are used for identical program sections that are repeatedfrequently.
• Subprograms reduce the amount of typing during programming.
• Subprograms reduce the program length thus making the programmore transparent.
• Subprograms can be reused in other programs.
• Subprograms can be used for structur ing a program.
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Global subprograms
DEF MAIN_PROG ( )
INI...
GLOBAL_SP1( )...
...
END
DEF MAIN_PROG ( )
INI...
GLOBAL_SP1( )...
...
END
DEF GLOBAL_SP1 ( )INI
...
...
END
DEF GLOBAL_SP1 ( )INI
...
...
END
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16. The expert level
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Navigator (expert)
System files and directories are displayed.
Drives aredisplayed
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Additional symbols in the Navigator (expert)
Default pathTypeSymbol
e.g. F:\, G:\, etc.Mapped network drive
E:\CD-ROM
e.g. Kukadisk (C:\) or Kukadata (D:\)Hard drive
Drives
Data list with errors that cannot be
interpreted by the compiler.DAT file contains errors
MeaningTypeSymbol
Binary filesOther files
Text file ASCII file
Data listDAT file
Program with errors that cannot be
interpreted by the compiler.SRC file contains errors
SubprogramSRC file
Program fileSRC file
Directories and files
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Error list
Short description
Error number
Line and column
Cursor is positioned onthe line containing errors
So that the line numbers in the error l ist correspond to those in the editor, theoptions "All FOLDs op" and "Detail view" must be activated.
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17. Loops and branches in programs
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Endless loop (LOOP)
Description
Cyclic executions can be programmed using LOOP. The statement block inthe LOOP is continually repeated. If you want to end the repeatedexecution of the statement block, you must call the EXIT statement.
Statements
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Endless loop
...PTP HOMELOOP
LIN P1LIN P2LIN P4
ENDLOOPPTP HOME...
...PTP HOMELOOP
LIN P1LIN P2LIN P4
ENDLOOPPTP HOME...
Syntax: LOOPStatement 1...Statement n
ENDLOOP
Statement 1
...
Statement n
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Conditional branch (IF..THEN..ELSE)
Description
Depending on a condition, either the first statement block (THEN block) orthe second statement block (ELSE block) is executed.
• There is no limit on the number of statements contained in the statementblocks.
• Several IF statements can be nested in each other.
• The keyword ELSE and the second statement block may be omitted.
• There must be an ENDIF for each IF.
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Conditional branch
...
IF $IN[22]==TRUE THEN
PTP HOMEELSE
$OUT[17]=TRUE$OUT[18]=FALSEPTP HOME
ENDIF...
Syntax: IF Execution_Condition THENStatement
ELSEStatement
ENDIF
StatementStatement
Condition met?
Yes
No
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Unconditional exit from loops (EXIT)
Description
The EXIT statement appears in the statement block of a loop. It may beused in any loop.
The EXIT statement can be used to exit the current loop. The program isthen continued after the ENDLOOP statement.
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Unconditional exit from loops
DEF EXIT_PRO ( )
PTP HOMELOOP ;Start of endless loopLIN P1
IF $IN[1] == TRUE THENEXIT ;Terminate when input 1 setENDIF
LIN P2ENDLOOP ;End of endless loopPTP HOME
END
DEF EXIT_PRO ( )
PTP HOMELOOP ;Start of endless loopLIN P1
IF $IN[1] == TRUE THENEXIT ;Terminate when input 1 setENDIF
LIN P2ENDLOOP ;End of endless loopPTP HOME
END
Syntax: EXIT
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Description
The SWITCH statement is a selection instruction for various programbranches. Only one program branch is executed and the program then
jumps immediately to the ENDSWITCH statement.
Selection?
Statements Statements Statements Statements
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Switch
...
SWITCH PROG_NR
CASE 1
Part1 ( ) ; if Prog_No = 1CASE 2
Part2 ( ) ; if Prog_No = 2DEFAULT
ERROR_SP () ; all other valuesENDSWITCH...
...
SWITCH PROG_NR
CASE 1
Part1 ( ) ; if Prog_No = 1CASE 2
Part2 ( ) ; if Prog_No = 2DEFAULT
ERROR_SP () ; all other valuesENDSWITCH...
Syntax: SWITCH VariableCASE 1
StatementCASE 2
StatementDEFAULT
ENDSWITCH
Selection1?
Statement
StatementSelection
n?
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18. Automatik external
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Automatic External inputs
Var
I/O
Functionaldescription
Variable name
VariableInput
Input number orvariable value
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Automatic External outputs - Start condition
Selection of the
variable groups
Functionaldescription
Function name
Output number
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I 08.04.02 I College I ML I 5KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
$NEAR_POSRET
The signal $NEAR_POSRET can be used to determine whether or not the robot issituated within a sphere about the position saved in $POS_RET. The radius of the spherecan be set in the file $CUSTOM.DAT using the system variable $NEARPATHTOL.
$POS_RET
P a t h
$NEARPATHTOL
$NEAR_POSRET=FALSE
TRUE
Deviation frompath caused, forexample, bydynamic braking
I 08.04.02 I College I ML I 6KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
..INITBAS INICHECK HOMEPTP HOME Vel= 100 % DEFAULT
AUTOEXT INILOOP
P00 (#EXT_PGNO,#PGNO_GET,DMY[],0 )SWITCH PGNO
CASE 1P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 );EXAMPLE1 ( )CASE 2P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 );EXAMPLE2 ( )CASE 3P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 );EXAMPLE3 ( )DEFAULTP00 (#EXT_PGNO,#PGNO_FAULT,DMY[],0 )
ENDSWITCHENDLOOP
Organization program: CELL.SRC
• Delete semicolon
• Substitute programname for EXAMPLEx
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I 08.04.02 I College I ML I 7KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Expanding CELL.SRC
• Insert new CASEbranch
• Proceed in thesame way for eachsubsequentprogram
...LOOP
P00 (#EXT_PGNO,#PGNO_GET,DMY[],0 )SWITCH PGNO
CASE 1P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )PROG1 ( )CASE 2P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )PROG2 ( )CASE 3P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )PROG3 ( )
CASE 4P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )PROG4 ( )DEFAULTP00 (#EXT_PGNO,#PGNO_FAULT,DMY[],0 )
ENDSWITCHENDLOOP
I 08.04.02 I College I ML I 8KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Overview of the "Automatic External" interface (not complete)
PLC O UT P UT S
I NP UT S
$STOPMESS
PGNO_REQ
APPL_RUN
$PERI_RDY
$ALARM_STOP
$USER_SAF
$I_O_ACTCONF(EXT)$ON_PATH
$IN_HOME
PGNO / PGNO_PARITY
PGNO_VALID
$EXT_START
$MOVE_ENABLE
$CONF_MESS
$DRIVES_ON
$DRIVES_OFF
$PRO_ACT
KRC
O U
T P U T S
I N P U T S
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I 08.04.02 I College I ML I 9KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Signal diagram example: Precondition
PLC O UT P UT S
I NP UT S
$ALARM_STOP (no E-STOP)
$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)
$IN_HOME (robot in HOME position)
$MOVE_ENABLE (motion enable)
$DRIVES_OFF (drives not deactivated)
$DRIVES_ON (activate drives)
$PERI_RDY (drives are on)
$STOPMESS (stop message)
KRC
O U T P U T S
I N P U T S
I 08.04.02 I College I ML I 10KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Signal diagram example: DRIVES_ON omitted
PLC O UT P UT S
I NP UT S
$ALARM_STOP (no E-STOP)
$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)
$IN_HOME (robot in HOME position)
$MOVE_ENABLE (motion enable)
$DRIVES_OFF (drives not deactivated)
$DRIVES_ON (activate drives)
$PERI_RDY (drives are on)
$STOPMESS (stop message)
KRC
O U
T P U T S
I N P U T S
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I 08.04.02 I College I ML I 13KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Signal diagram example: Start program
PLC O UT P UT S
I NP UT S
$ALARM_STOP (no E-STOP)
$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)
$IN_HOME (robot in HOME position)
$MOVE_ENABLE (motion enable)
$DRIVES_OFF (drives not deactivated)
$PERI_RDY (drives are on)
$EXT_START (start program)
$PRO_ACT (program is active)
$ON_PATH (robot is on path)
KRC
O U T P U T S
I N P U T S
I 08.04.02 I College I ML I 14KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Signal diagram example: EXT_START omitted
PLC O UT P UT S
I NP UT S
$ALARM_STOP (no E-STOP)
$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)
$IN_HOME (robot in HOME position)
$MOVE_ENABLE (motion enable)
$DRIVES_OFF (drives not deactivated)
$PERI_RDY (drives are on)
$EXT_START (start program)
$PRO_ACT (program is active)
$ON_PATH (robot is on path)
KRC
O U
T P U T S
I N P U T S
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I 08.04.02 I College I ML I 15KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Signal diagram example: Transfer program number
PLC O UT P UT S
I NP UT S
$ALARM_STOP (no E-STOP)
$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)
$IN_HOME (robot in HOME position)
$MOVE_ENABLE (motion enable)
$DRIVES_OFF (drives not deactivated)
$PERI_RDY (drives are on)
$PRO_ACT (program is active)
$ON_PATH (robot is on path)
PGNO_REQ (request)
PGNO (number + pari ty)
PGNO_VALID (read command)KRC
O U T P U T S
I N P U T S
I 08.04.02 I College I ML I 16KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Signal diagram example: Program running
PLC O UT P UT S
I NP UT S
$ALARM_STOP (no E-STOP)
$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)
$MOVE_ENABLE (motion enable)
$DRIVES_OFF (drives not deactivated)
$PERI_RDY (drives are on)
$PRO_ACT (program is active)
$ON_PATH (robot is on path)
APPL_RUN (program running)
PGNO_REQ (request)
PGNO (number + pari ty)
PGNO_VALID (read command)
$IN_HOME (robot in HOME position)
KRC
O U
T P U T S
I N P U T S
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I 08.04.02 I College I ML I 17KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Signal diagram example: Program running
PLC O UT P UT S
I NP UT S
$ALARM_STOP (no E-STOP)
$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)
$IN_HOME (robot in HOME position)
$MOVE_ENABLE (motion enable)
$DRIVES_OFF (drives not deactivated)
$PERI_RDY (drives are on)
$PRO_ACT (program is active)
$ON_PATH (robot is on path)
PGNO_REQ (request)
PGNO (number + pari ty)
PGNO_VALID (read command)
APPL_RUN (program running)
KRC
O U T P U T S
I N P U T S
I 08.04.02 I College I ML I 18KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Signal diagram example: End of program
PLC O UT P UT S
I NP UT S
$ALARM_STOP (no E-STOP)
$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)
$MOVE_ENABLE (motion enable)
$DRIVES_OFF (drives not deactivated)
$PERI_RDY (drives are on)
$PRO_ACT (program is active)
$ON_PATH (robot is on path)
APPL_RUN (program running)
$IN_HOME (robot in HOME position)
KRC
O U
T P U T S
I N P U T S
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I 08.04.02 I College I ML I 19KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Signal diagram example: End of program
PLC O UT P UT S
I NP UT S
$ALARM_STOP (no E-STOP)
$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)
$MOVE_ENABLE (motion enable)
$DRIVES_OFF (drives not deactivated)
$PERI_RDY (drives are on)
$PRO_ACT (program is active)
$ON_PATH (robot is on path)
APPL_RUN (program running)
$IN_HOME (robot in HOME position)
KRC
O U T P U T S
I N P U T S
I 08.04.02 I College I ML I 20KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Signal diagram example: New program request
PLC O UT P UT S
I NP UT S
$ALARM_STOP (no E-STOP)
$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)
$MOVE_ENABLE (motion enable)
$DRIVES_OFF (drives not deactivated)
$PERI_RDY (drives are on)
$PRO_ACT (program is active)
$ON_PATH (robot is on path)
$IN_HOME (robot in HOME position)
PGNO_REQ (request)
PGNO (number + pari ty)
PGNO_VALID (read command)KRC
O U
T P U T S
I N P U T S
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18.1. Programnumber typ 1
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I 08.04.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Display format of the program number: BINARY
Input: ... E8 E7 E6 E5 E4 E3 E2 E1
Values: 27= 26= 25= 24= 23= 22= 21= 20=
128 64 32 16 8 4 2 1
Example: 0 1 1 0 0 0 0 1
Prog. no.: 97 =0 + 64 + 32 + 0 + 0 + 0 + 0 + 1
Binary coded integer: PGNO_TYPE=1
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18.2. Programnumber typ 2
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I 08.04.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Display format of the program number: BCD
Binary coded decimal: PGNO_TYPE=2
Result: 2 7
Prog. no.: 27
Example: 0 0 1 0 0 1 1 1
Input: ... E8 E7 E6 E5 E4 E3 E2 E1
Values: 8 4 2 1 8 4 2 1
1st decimal place2nd decimal place
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18.3. Programnumber typ 3
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I 08.04.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Display format of the program number: "1 of N"
"1 of N" coded integer: PGNO_TYPE=3
Input (max. 16): ... E8 E7 E6 E5 E4 E3 E2 E1
Prog. no. 1 : 0 0 0 0 0 0 0 1
Prog. no. 2 : 0 0 0 0 0 0 1 0
Prog. no. 3 : 0 0 0 0 0 1 0 0
Prog. no. 4 : 0 0 0 0 1 0 0 0
Prog. no. 5 : 0 0 0 1 0 0 0 0
Prog. no. 6 : 0 0 1 0 0 0 0 0
Prog. no. 7 : 0 1 0 0 0 0 0 0
Prog. no. 8: 1 0 0 0 0 0 0 0
Only one input may be "TRUE" at any time. All other input combinations result in an invalid program number.
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18.4. Inputs
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I 08.04.02 I College I ML I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Program number format: PGNO_TYPE
*1 When using this transmission format, the values of PGNO_REQ, PGNO_PARITY and
PGNO_VALID are not evaluated and are thus of no significance.
The program number is transmittedby the higher-level controller or theperiphery as a "1 of n" coded value.
"1 of N" *13
The program number is transmitted
by the higher-level controller as abinary coded decimal.
BCD value2
The program number is transmittedby the higher-level controller as abinary coded integer .
Binary number 1
ExampleMeaningRead as ...PGNO_TYPE
ClickClick
ClickClick
ClickClick
This value determines the format in which the program number sent by the hostcomputer is read.
I 08.04.02 I College I ML I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Mirroring the program number: REFLECT_PROG_NR
This option allows you to decide whether or not the program number should bemirrored in a definable output area.
Activated0
Deactivated0FunctionREFLECT_PROG_NR
The output of the signal starts with the output defined using"PGNO_FBIT_REFL".
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I 08.04.02 I College I ML I 3KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Program number length in bits: PGNO_LENGTH
Its value determines the number of bits defining the program number sent by thehost computer.
PGNO_LENGTH = 1...16
Example:
PGNO_LENGTH = 6 ;the external program number is six bits long
While PGNO_TYPE has the value 2 (program number read as BCDvalue), only 4, 8, 12 and 16 are permissible values for the number of bits.
I 08.04.02 I College I ML I 4KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
First bit in the program number: PGNO_FBIT
Input representing the first bit of the program number.
PGNO_FBIT = 1...1024 (PGNO_LENGTH)
Example:
PGNO_FBIT = 5 ;the external program number begins with $IN[5]
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I 08.04.02 I College I ML I 5KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Parity bit: PGNO_PARITY
Input to which the parity bit is transferred from the host computer.
While PGNO_TYPE has the value 3 (program number read as "1of n" value), PGNO_PARITY is NOT evaluated.
Even parityPositive value
No evaluation0
Odd parityNegative value
FunctionInput
I 08.04.02 I College I ML I 6KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Program number valid: PGNO_VALID
Input to which the command to read the program number is transferred from thehost computer.
While PGNO_TYPE has the value 3 (program number read as "1of n" value), PGNO_PARITY is NOT evaluated.
Number is transferred at the rising edge of thesignal
Positive value
Number is transferred at the rising edge of thesignal on the EXT_START line0
Number is transferred at the falling edge of thesignal
Negative value
FunctionInput
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I 08.04.02 I College I ML I 7KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Program start: $EXT_START
If the I/O interface is active, this input can be set to start or continue a program.
Only the rising edge of the signal is evaluated.
There is no BCO run in Automatic External mode, so there is noprogram stop at the first programmed position.
I 08.04.02 I College I ML I 8KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Motion enable: $MOVE_ENABLE
This input is used by the host computer to check the robot drives.
If the drives have been switched off by the host computer, themessage "GENERAL MOTION ENABLE" appears in the messagewindow of the KCP. It is only possible to move the robot againonce this message has been reset and another external startsignal has been given.
All drives are stopped and all active commandsinhibited
FALSE
Manual motion and program execution are possibleTRUEFunctionSignal
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I 08.04.02 I College I ML I 9KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
MOVE_ENABLE monitoring: $CHCK_MOVENA
If the variable $CHCK_MOVENA has the value "FALSE", MOVE_ENABLE canbe bypassed. The value of the variable can only be changed in the file"C:\KRC\Roboter\KRC\Steu\MaDa\OPTION.DAT".
In order to be able to use MOVE_ENABLE monitoring,$MOVE_ENABLE must have been configured with the input"$IN[1025]". Otherwise, "$CHCK_MOVENA" has no effectwhatsoever.
MOVE_ENABLE monitoring is deactivatedFALSE
MOVE_ENABLE monitoring is activatedTRUE
FunctionSignal
I 08.04.02 I College I ML I 10KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Error acknowledgement: $CONF_MESS
Setting this input enables the host computer to reset (acknowledge) errormessages automatically.
Acknowledgement of the error messages is, of course, only possible once thecause of the error has been eliminated.
Only the rising edge of the signal is evaluated.
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I 08.04.02 I College I ML I 11KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Drives on/off: $DRIVES_ON / $DRIVES_OFF
DRIVES_ON
With a high-level pulse of at least 20 ms duration at this input, the hostcomputer can switch on the robot drives.
DRIVES_OFF
With a low-level pulse of at least 20 ms duration at this input, the hostcomputer can switch off the robot drives.
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19. Excercises
I 03.03.03 I College I DON I 1KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Overview: Exercises for the basic course
General exercises: 1-10Exercise 1: Operator control, joggingExercise 2: Robot masteringExercise 3: Tool calibration (pen and gripper)Exercise 4: BASE calibration (table)Exercise 5: “In-air” program (PTP motion)Exercise 6: CP motion, approximate positioning (waterjet cutting)Exercise 7: Component IExercise 8: BASE offset (tool mount offset)Exercise 9: BASE offset (two tool mounts)
Exercise 10: Component II (adhesive application, I/O’s)Exercises w ith external TCP: 11-14
Exercise 11: Gripper programming (plastic panel)Exercise 12: External TCP (tool calibration)Exercise 13: Adhesive application on windshield (plastic panel)Exercise 14: Subprograms (plastic panel)
Exercises wi thout external TCP: 15-16Exercise 15: Gripper programming (cube magazine)Exercise 16: Subprograms (CP motion)
Exercises for expert level: 17-18Exercise 17: Expert I (loop)Exercise 18: Automatic External
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I 03.03.03 I College I DON I 2KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercises: GP - KR C2
Expert exercises:
Basic exercises:
Advanced exercis es:
Exercises with external TCP:Exercise 11: Gripper programming (plastic panel)Exercise 12: External TCP (tool c alibration)
Exercise 13: Adhesive application on windshield(plastic panel)
Exercise 14: Subprograms (plastic panel)
Exercises without external TCP:Exercise 15: Gripper programming (cube magazine)Exercise 16: Subprograms (CP motion)
Exercises for expert level:Exercise 17: Expert I (loop)
Exercise 18: Automatic External
General exercises:Exercise 1: Operator control, manual motion
Exercise 2: Robot masteringExercise 3: Tool calibration (pen and gripper)Exercise 4: BASE calibration (table)Exercise 5: “In-air” program (PTP motion)Exercise 6: CP motion, approximate positioning (waterjetcutting)Exercise 7: Component IExercise 8: BASE offset (tool mount offset)Exercise 9: BASE offset (two tool mounts)Exercise 10: Component II (adhesive application, I/Os)
I 03.03.03 I College I DON I 3KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
General exercises: 1-10
Expert exercises:
Basic exercises:
Advanced exercis es:
General exercises:Exercise 1: Operator control, manual motion
Exercise 2: Robot masteringExercise 3: Tool calibration (pen and gripper)Exercise 4: BASE calibration (table)Exercise 5: “In-air” program (PTP motion)Exercise 6: CP motion, approximate positioning (waterjetcutting)Exercise 7: Component IExercise 8: BASE offset (tool mount offset)Exercise 9: BASE offset (two tool mounts)Exercise 10: Component II (adhesive application, I/Os)
Exercises with external TCP:Exercise 11: Gripper programming (plastic panel)Exercise 12: External TCP (tool c alibration)Exercise 13: Adhesive application on windshield
(plastic panel)Exercise 14: Subprograms (plastic panel)
Exercises without external TCP:Exercise 15: Gripper programming (cube magazine)Exercise 16: Subprograms (CP motion)
Exercises for expert level:Exercise 17: Expert I (loop)
Exercise 18: Automatic External
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Exercise 1: Operator control, joggingExercise 2: Robot mastering
Exercise 3: Tool calibration (pen and gripper)Exercise 4: BASE calibration (table)Exercise 5: “In-air” program (PTP motion)Exercise 6: CP motion, approximate positioning (waterjet cutting)Exercise 7: Component IExercise 8: BASE offset (tool mount offset)Exercise 9: BASE offset (two tool mounts)Exercise 10: Component II (adhesive application, I/Os)
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I 03.03.03 I College I DON I 4KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 1: Operator control, jogging
Exercise: Operator control, motion, jogging
Tasks:• Switch the control cabinet on and wait for the system to boot.• Check the robot type and software version.• Release the EMERGENCY STOP and acknowledge it.• Make sure that the mode selector switch is set to T1.• Activate manual motion for the joint (axis-specific) coordinate system.• Move the robot in joint (axis-specific) mode with various different manual (jog)
override settings (HOV) using the jog keys and Space Mouse.• Explore the range of motion of the individual axes. Be careful to avoid any
obstacles present, such as a table or cube magazine with fixed tool.(Accessibility investigation)
• On reaching the software limit switches, observe the message window.• Interpret the error message (Ch. 12).• Eliminate the error.• In joint (axis-specific) mode, move the gripper to a cube from several different
directions.• Repeat this procedure in the WORLD coordinate system.• Move the robot to the transport position and press the EMERGENCY STOP
button.
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I 03.03.03 I College I DON I 5KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 2: Robot mastering
• Carry out mastering in axis-specific jog mode
• Master each axis individually
• Begin with axis 1 and work upwards
• Always move from + to -
• Pre-mastering posi tion = frontsight and rearsight aligned
Exercise: Robot mastering
Tasks:• Unmaster all robot axes• Move all robot axes to the pre-mastering position in joint mode.• Master all axes with the electronic measuring tool (EMT).• Display the actual position in joint mode.
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I 03.03.03 I College I DON I 6KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 3: Tool calibration (pen and gripper)
Exercise: Tool calibration
Tasks:• Calibrate the TCP of the pen using the “XYZ 4-Point” method. Use the black
metal tip as the reference point. Assign the tool the TOOL number 2(TOOL_DATA[2])
• Calibrate the tool orientation using the “A B C - World (5D)” method. The toolcoordinate system is then situated on the tool as illustrated above.
• Save the TOOL data.•
Test the motion with the pen in the TOOL coordinate system.• Calibrate the gripper using the calibration cube (TOOL_DATA[3]). The
procedure here is the same as that for points 1 and 2.• Test the motion with the gripper in the TOOL coordinate system.
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I 03.03.03 I College I DON I 7KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 4: BASE calibration (table)
BASE_DATA[2]
BASE_DATA[1]
Exercise: BASE calibration
Tasks:• Calibrate the BASE system labeled on the worktable (blue) with the name
BASE_DATA[1] using the “3-Point” method.• Calibrate the BASE system labeled on the worktable (red) with the name
BASE_DATA[2] using the “3-Point” method.• Use the pen (TOOL_DATA[2]) as calibration tool.• Save the BASE data.•
Move the TCP in the BASE-specific system to the origin of the BASE_DATA[2]coordinate system.• Display the actual position in “Cartesian” mode.
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I 03.03.03 I College I DON I 8KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 5: “In-air” program (PTP motion)
shortest path
possible PTP path
Exercise: Dummy program
Tasks:• Teach 5 points in space as PTP motion points. Pay attention to interference
contours and obstacles caused by the workplace equipment.• Test your program in mode T1.• Following error-free execution of your program, run it again in mode T2 and
then in automatic mode.• Then archive your program.
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I 03.03.03 I College I DON I 9KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 6: CP motion, approximate positioning (waterjet cutting)
3D contour
BASE_DATA[1]
START
Exercise: CP motion, 3D contour
Tasks:
1. Program creation, motion programming, motion type, orientation control, jogging,archiving
• Teach the rectangular contour marked on the worktable, with reference toBASE_DATA[1] (blue, already calibrated), with the name “PATH_3D”.
•
Make sure that the jog velocity on the worktable is no greater than 0.15 m/s.• Make sure that the longitudinal axis of the pen is always perpendicular to thepath contour (orientation control).
• Test your program.
2. Copying the program, approximate positioning
• Create a duplicate of the program “PATH_3D” with the name “PATHCONT”.• Insert CONT instructions into the motion commands in the program
“PATHCONT” so that the robot follows the contour continuously without exactpositioning.
• The corners of the contour are to be approximated using differentapproximation parameters.
• Test your program.
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I 03.03.03 I College I DON I 10KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 7: Component I
Component contour
BASE_DATA[1]
START
Exercise: CP motion, 3D contour
Tasks:
1. Program creation, motion programming, motion type, orientation control, jogging,archiving
• Teach the component contour marked on the worktable, with reference toBASE_DATA[1] (blue, already calibrated), with the name “COMPONENT”.
•
Make sure that the jog velocity on the worktable is no greater than 0.15 m/s.• Make sure that the longitudinal axis of the pen is always perpendicular to thepath contour (orientation control).
• Test your program.
2. Copying the program, approximate positioning
• Create a duplicate of the program “COMPONENT” with the name“COMP_CONT”.
• Insert CONT instructions into the motion commands in the program“COMP_CONT” so that the robot follows the contour continuously without
exact positioning.• The corners of the contour are to be approximated using different
approximation parameters.• Test your program.
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I 03.03.03 I College I DON I 11KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 8: BASE offset (tool mount offset)
Triangular contour
New BASE_DATA[2]
Exercise: BASE offset (tool mount offset)
Tasks:
• Using the pen, “teach” the triangular contour marked on the worktable, withreference to BASE_DATA[2], with the program name “BAS_D”.
• Make sure that the jog velocity on the worktable is no greater than 0.15 m/s.• Test your program in mode T1.• Following error-free execution of your program, run it again in mode T2 and
then in automatic mode.• Then archive your program.• Calibrate the BASE system BASE_DATA[2] (blue) again (overwrite the
existing BASE 2).• Test your program in mode T1.• Run the program “BAS_SYS” once again.
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I 03.03.03 I College I DON I 12KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 9: BASE offset (two tool mounts)
BASE_DATA[6] Circular contour
BASE_DATA[5]
Exercise: BASE offset (two tool mounts)
Tasks:
• Calibrate the BASE system labeled on the worktable (blue) with the nameBASE_DATA[5] using the “3-Point” method.
• Using the pen, “teach” the circular contour marked on the worktable, withreference to BASE_DATA[5], with the program name “BAS_K1”.
• Make sure that the jog velocity on the worktable is no greater than 0.15 m/s.•
Test your program in mode T1.• Following error-free execution of your program, run it again in mode T2 and
then in automatic mode.• Then archive your program.• Calibrate the BASE system labeled on the worktable (blue, diagonal) with the
name BASE_DATA[6] using the “3-Point” method.• Create a duplicate of the program “BAS_K1” with the name “BAS_K2”.• In the motion commands, change the base to BASE_DATA[6].• Test your program in mode T1.• Run the program “BASE_K2”.
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• The end of the work on the component is to be signaled to the PLC. (Output 7for 2 seconds)
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I 03.03.03 I College I DON I 14KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercises with an external TCP: 11-14
Expert exercises:
Basic exercises:
Advanced exercis es:
Exercises with external TCP:Exercise 11: Gripper programming (plastic panel)Exercise 12: External TCP (tool c alibration)
Exercise 13: Adhesive application on windshield(plastic panel)
Exercise 14: Subprograms (plastic panel)
Exercises without external TCP:Exercise 15: Gripper programming (cube magazine)Exercise 16: Subprograms (CP motion)
Exercises for expert level:Exercise 17: Expert I (loop)
Exercise 18: Automatic External
General exercises:Exercise 1: Operator control, manual motion
Exercise 2: Robot masteringExercise 3: Tool calibration (pen and gripper)Exercise 4: BASE calibration (table)Exercise 5: “In-air” program (PTP motion)Exercise 6: CP motion, approximate positioning (waterjetcutting)Exercise 7: Component IExercise 8: BASE offset (tool mount offset)Exercise 9: BASE offset (two tool mounts)Exercise 10: Component II (adhesive application, I/Os)
Exercise 11: Gripper programming (plastic panel)Exercise 12: External TCP (tool calibration)Exercise 13: Adhesive application on windshield (plastic panel)Exercise 14: Subprograms (plastic panel)
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I 03.03.03 I College I DON I 15KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 11: Gripper programming (plastic panel)
Exercise: Gripper programming
Tasks:
• Create a program with the name “FETCH_PART”.• Teach the procedure “Fetch part” (black plastic panel)
(TOOL_DATA[3], BASE_DATA[1]).• Test your program.• Archive your program.•
Now create a program with the name “PART_DOWN”.• Teach the procedure “Part down”. The plastic panel is to be deposited back in
the fixture provided for this purpose.• Test your program.
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I 03.03.03 I College I DON I 16KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 12: External TCP (tool calibration)
Exercise: External TCP
Tasks:
• For the calibration of the fixed tool, the writing tool already calibrated(TOOL_DATA[2]) is to be used as a reference tool.
• Now calibrate the position and orientation of the external fixed tool.• Save the data as BASE_DATA[10].• Run the program “FETCH_PART”.•
Calibrate the workpiece guided by the robot.• Save the data as TOOL_DATA[15].
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I 03.03.03 I College I DON I 17KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 13: Adhesive application on windshield (plastic panel)
Exercise: Windshield
Tasks:
• Activate the external TCP and the movable workpiece for jogging.• Correct the interpolation mode ($IPO_MODE).• Move the coordinate origin of the movable workpiece to the TCP of the fixed
tool.• Display the actual position in “Cartesian” mode.•
Teach the contour on the plastic panel using the program name“PANEL_PATH”.• Make sure that the longitudinal axis of the fixed tool is always perpendicular to
the path contour (orientation control).• The adhesive is to be applied uniformly along the path.• Test your program.
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I 03.03.03 I College I DON I 18KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 14: Subprograms (plastic panel)
Exercise: Subprograms (complex program)
Tasks:
• The programs from exercises 11 and 13 are now to be expanded so that asingle program selection suffices to execute the entire procedure: fetch plasticpanel, apply adhesive and put plastic panel back down again.
• Create a new program “PANEL” in which all program sections are executed.• Proceed in the same way with the programs from exercises 6 and 7.•
Create a new program “COM_PATH” in which motions are executed for bothpaths.
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I 03.03.03 I College I DON I 19KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercises without an external TCP: 15-16
Expert exercises:
Basic exercises:
Advanced exercis es:
Exercises with external TCP:Exercise 11: Gripper programming (plastic panel)Exercise 12: External TCP (tool c alibration)
Exercise 13: Adhesive application on windshield(plastic panel)
Exercise 14: Subprograms (plastic panel)
Exercises without external TCP:Exercise 15: Gripper programming (cube magazine)Exercise 16: Subprograms (CP motion)
Exercises for expert level:Exercise 17: Expert I (loop)
Exercise 18: Automatic External
General exercises:Exercise 1: Operator control, manual motion
Exercise 2: Robot masteringExercise 3: Tool calibration (pen and gripper)Exercise 4: BASE calibration (table)Exercise 5: “In-air” program (PTP motion)Exercise 6: CP motion, approximate positioning (waterjetcutting)Exercise 7: Component IExercise 8: BASE offset (tool mount offset)Exercise 9: BASE offset (two tool mounts)Exercise 10: Component II (adhesive application, I/Os)
Exercise 15: Gripper programming (cube magazine)Exercise 16: Subprograms (CP motion)
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I 03.03.03 I College I DON I 20KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 15: Gripper programming (cube magazine)
Remove cube
Insert cube
Exercise: Gripper programming
Tasks:
• Create a program with the name “CUBE”.• Teach the procedure “Fetch cube” (from bottom of magazine).• Teach the procedure “Insert cube” (at top of magazine).• Test your program.• Archive your program.
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I 03.03.03 I College I DON I 21KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 16: Subprograms (CP motion)
Exercise: Subprograms (complex program)
Tasks:
• The programs from exercise 6 (“PATHCONT”) and exercise 7(“COMP_CONT”) are to be executed together as global subprograms in amain program.
• Create a new program “COM_PATH” in which motions are executed for bothpaths.
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I 03.03.03 I College I DON I 22KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercises for expert level: 17-18
Expert exercises:
Basic exercises:
Advanced exercis es:
Exercises with external TCP:Exercise 11: Gripper programming (plastic panel)Exercise 12: External TCP (tool c alibration)
Exercise 13: Adhesive application on windshield(plastic panel)
Exercise 14: Subprograms (plastic panel)
Exercises without external TCP:Exercise 15: Gripper programming (cube magazine)Exercise 16: Subprograms (CP motion)
Exercises for expert level:Exercise 17: Expert I (loop)
Exercise 18: Automatic External
General exercises:Exercise 1: Operator control, manual motion
Exercise 2: Robot masteringExercise 3: Tool calibration (pen and gripper)Exercise 4: BASE calibration (table)Exercise 5: “In-air” program (PTP motion)Exercise 6: CP motion, approximate positioning (waterjetcutting)Exercise 7: Component IExercise 8: BASE offset (tool mount offset)Exercise 9: BASE offset (two tool mounts)Exercise 10: Component II (adhesive application, I/Os)
Exercise 17: Expert I (loop)Exercise 18: Automatic External
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I 03.03.03 I College I DON I 23KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de© Copyright by KUKA Roboter GmbH College 1996-2002
Exercise 17: Expert I (loop)
Example:
DEF LOOP ( )PTP HOMELOOP
LIN P1CIRC P2, P3LIN P4
ENDLOOP
PTP HOMEEND
LOOPStatement 1...Statement n
ENDLOOP
Statement 1
...
Statement n
Exercise: LOOP
Tasks:
• Create a duplicate of the program “NEW_PART” from exercise 10. The newprogram is to be called “LOOP”.
• Execute the program section on the table as a LOOP.• Integrate the EXIT command at a sensible point in the program. The EXIT
command is to be executed when Input 16 is set.
Supplement:This exercise can alternatively be carried out using the program “CUBE” fromexercise 15.
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Host computer
E t h e
( a r c
Controls the entire systemand stores data
Exercise 18: Automatic External
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