Kuka Krc2 Workbook

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SOFTWARE

KR C2

Seminar workbookof …………………

Basic RobotProgramming

Release 4.1



© Copyright KUKA Roboter GmbH This documentation or excerpts therefrommay not be reproduced or disclosed to third parties without the express permission of the publishers.

Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, 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



handout GP KR C2 V4.1 01.03.01 of 227

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




1. Contents and goals of this course



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




2. Safety




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


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!





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.


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.





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.



• 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.






• 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.



• 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.





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.



• 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.






• 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.



• 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.





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


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.






• Example: software limit switches for axis 1

$SOFTN _END[1] = -185°

$SOFTP _END[1] = 185°

Axis designation



• Examples: working range limitation on the KR 125

Axis 1

Axis 3

Axis 2





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.


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.





Safety features of the robot system: enabling switches

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

Enabling switches


Safety features of the robot system: jog mode

• Jog mode (deadman function). All programs can be executed 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





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.


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.





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.


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).






• 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.



• 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.





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!



• 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.






• 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 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.





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.


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!





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.


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.





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


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.




3. The robot system

3.1. Basics at the robot system




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)


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





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


KR 150 / 2KUKA industrial r obot

with a rated payload of 150 kg

of the 2nd generation

Example: Robot type designations





Mechanical construction of a KUKA robot

Wrist

Link arm

Base frame

Arm

Rotatingcolumn


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.





The work envelope of a KUKA robot (side view)

Can beexpanded usingan arm extension

Side view:work envelopeOverhead zone


The work envelope of a KUKA robot (top view)

Top view:work envelope

Angle, axis 1:>360°





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


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





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




3.2. System overview





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


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





Hard drive

PC chassis - KR C2

Floppy disk drive

CD-ROM drive


Top view of the PC - KR C2

Keyboard

LPT1

COM1COM2Ethernet

Mouse

External monitor





Robot serial number

Serial number


Control cabinet serial number

Serial number





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


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




3.3. Energy supply




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


Energy supply - Length attitude

Velcro fastener

Only as long asnecessary





Energy supply - Hose routing

adjusting trumpet

adjusting compression spring


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




4. Operation of the KUKA control panel (KCP)





KUKA Control Panel (KCP)


Hardwired operator control elements

EMERGENCYSTOP

Drives OFF

Drives ON

Mode selectorswitch





T T

T1 (Test 1)T2 (Test 2)

AUTOMATIC AUTOMATIC EXTERNAL

Mode selector switch


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)


Programexecution

250 mm/s

POV

Prog.velocity

Prog. velocity Prog. velocity


START keypressed


START keypressed

Drives ONSTART key--> PULSE

Drives ONExternal start

Mode table





CAN bus operator control elements

Escape key

Window selection key


Display window

Programming window Status window

Message window





Window selection key


Softkeys

Softkeys





Status window

The status window isdisplayed as required.

The status window canbe closed at any time.


Message window

The controller communicates withthe operator via the message window.

Softkeys for acknowledgingmessages





Message types

Hint - e.g. "Start key required"

Status - e.g. "EMERGENCY STOP"

Acknowl. - e.g. "Ackn. EMERGENCY STOP"

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

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



STOP key

Program start forwards

Program start backwards






NUM key

Numeric keypad


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.






ASCIIalphabetickeypad


ASCII alphabetic keypad

SYM key

SHIFT key

ALT key

NUM key






RETURN key

CURSOR block


Menu keys

Menu keys





Status keys

Status keys


Status bar

Selectedprogram Current line

number

Override

Time

Numeric keypad

Operating mode

Upper/lower-case letters

Robot name





Status bar

Submit interpreter deselectedSubmit interpreter stoppedSubmit interpreter running

Drives not readyDrives ready (600 ms)




5. The coordinate systems at the robot





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.


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




5.1. The axis coordinat system





Axis-specific manual motion

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


Axis-specific motion with the 6D mouse




5.2. The world coordinate system





WORLD coordinate system

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


+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





+Y

+Z

+X

Right hand rule (coordinate directions)


Right hand rule (direction of rotation)

+X, +Y or +Z

+C, +B or +A





Cartesian motion with the 6D mouse




5.3. The tool coordinate system





TOOL coordinate system

Rectangular coordinate system, whose origin is locatedin the tool.




5.4. The base coordinate system





BASE coordinate system

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




6. Stop reactions of the robot





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


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




7. Mastering





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.


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.





Cross-section of the gauge cartridge

EMTor

dial gauge

"Frontsight/rearsight" marker

Reference notchGauge pin

Gauge cartridge


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





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...


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





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 -


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





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




8. Tool calibration

8.1. The calculation of the TCP's





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


Tool calibration

What are the advantages of tool calibration?

1

2

3





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


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





Activating the tool

Pin

Blue

Enter the tool number TOOL_DATA[1-16]

Tool nameis displayed




8.1.1. The X Y Z - 4 Point method





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.


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.




8.1.2. The XYZ-reference method





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.


Example of the X Y Z - Reference method

Flangeadapter plateas referencetool




8.2. Orientation calibration

8.2.1. The ABC-world 5D method





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




8.2.2. The ABC-world 6D method





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.




8.2.3. The ABC-2 point method





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


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





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




8.3. Tool - payload





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!


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




9. Base calibration





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


Purpose of base calibration

ZWorld

Tool

YWorldXWorld

Manual motion

Motion along theedges of the work

surface or workpiece.

Motion direction

Base






Base

ZWorld

Tool

YWorldXWorld

Teaching points

The taught pointcoordinates refer to

the BASE coordinatesystem.



Program mode

If the BASE coordinatesystem is offset, the

taught points move with it.

ZWorld

Tool

YWorldXWorld

Base

Base






Program mode

It is possible to createseveral BASE coordinate

systems.

ZWorld

Tool

YWorld

XWorld

B a s e 2

B a s e 1


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.





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


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





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.


Pin

Blue

Activating a base

Enter the number ofthe baseBASE_DATA[1-16]

Name of the baseis displayed




10. Motions programming at the robot





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.




10.1. PTP – motion





PTP motion

P1P2

Shortest distance

Fastest path


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





Programming a PTP motion

Type of motion

Pointname

Velocity

Motionparameters

Approximatepositioning ON

Exact positioning



ToolTool selection

Tool_Data[1]..[16], Nullframe

BaseWorkpiece coordinate systemselectionBase_Data[1]..[16], Nullframe

External TCPRobot guiding tool: FalseRobot guiding workpiece: True






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).




10.2. LIN – mot ion





LIN motion without approximate positioning

P1

P2

P3shortest distance

LIN motion


Velocity profile

P1

P2

Time t

Path velocity v

P1 P2

V prog

Acceleration DecelerationConstant





Programming a LIN motion

Type of motion

Pointname

Velocity

Motionparameters

Approximatepositioning ON

Exact positioning



ToolTool selection

Tool_Data[1]..[16], Nullframe








Accelerat ion Acceleration used for themotion.Range of values: 1...100%


Size of approximate positioningrange for the motion.Range of values: 0...300 mm





10.3. CIRC – motion





CIRC motion without approximate positioning

CIRC motion

P1

P2 (AUX)

P3(END)

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


Programming a CIRC motion

Type of motion

Auxiliarypoint name

Velocity

Motionparameters

End pointname

Exact positioning

Approximate positioning ON






ToolTool selectionTool_Data[1]..[16], Nullframe





Accelerat ion

Acceleration used for themotion.Range of values: 1...100%


Size of approximate positioningrange for the motion.Range of values: 0...300 mm






The 360° full circle

The full circle should be made upof at least two segments.

P2P1

P4=END

P3=AUX

P5=AUX

P2=END




10.4. Approximation of motion





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


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





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.


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





CIRC motion with approximate positioning

CIRC motion with P3 is an approx.approx. positioning positioning point

P4

P1

P2 (AUX)

P3(END)




11. The navigator (program production)





Navigator (user)

Header

Directory structureDirectoryor file list

Status line


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





Navigation using the keyboard

Focus

Select drive,

directory or file

Toggle betweendirectory structure / file list Open drive,

directory or file


Please enter a name

New program

Confirm

Program name

Comment





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


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:





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.


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.





Archiving individual programs

The selected files are saved to floppy disk


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.





Restoring individual programs

The selected files are loaded back onto the hard disk




12. Logic programming





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


Logic commands available

Time-dependentwait function

Signal-dependentwait function

Switching functions

Coupling/decouplingan Interbus segment

The following logic commands can be selected:





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


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





Switching functions

The following switching functions can be selected:

Simple switchingfunction

Simple pulse

function

Path-dependentswitching function

Path-dependentpulse function


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








PTP P4 VEL=100% PDAT4P1

P2 P3

P4

OUT 1 ‘ ‘ State=TRUE

StateOutput

Advance run stop on


Point P3becomes anexactpositioningpoint andoutput 1 is set





PTP P4 VEL=100% PDAT4OUT 1 ‘ ‘ State=TRUE CONT

StateOutput

Advance run stop on


P1

P2P3

P4

CONT preventsan advance runstop from beingtriggered; output1 is set during theadvance run





Simple pulse function (PULSE)

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

StateOutput

Advance run stop on


Pulse length

0

1

Time

OUT 1

Time 0

1

Time

OUT 1

Time


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

+

-








Time

Example:LIN P1 VEL=0.3m/s CPDAT1LIN P2 VEL=0.3m/s CPDAT2


LIN P3 CONT VEL=0.3m/s CPDAT3


P2

P3

P4

+

-+





Time

Example:LIN P1 VEL=0.3m/s CPDAT1LIN P2 CONT VEL=0.3m/s CPDAT2




P2

P3

P4

+

-+








Time

Example:LIN P1 VEL=0.3m/s CPDAT1SYN OUT 1 ‘ ‘ State=TRUE PATH=20mm Delay=-5ms


LIN P3 CONT VEL=0.3m/s CPDAT3LIN P4 VEL=0.3m/s CPDAT4

P1

P2

P3

P4

+

-

20mm

-+

-5ms





Time

Example:LIN P1 CONT VEL=0.3m/s CPDAT1SYN OUT 1 ‘ ‘ State=TRUE PATH=20mm Delay=-5ms


LIN P3 CONT VEL=0.3m/s CPDAT3LIN P4 VEL=0.3m/s CPDAT4

P1

P2

P4

+

-

20mm P3

-+

-5ms





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


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




13. Gripper Tech H50





Gripper configuration

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



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






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


Programming gripper functions

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

Gripper function

Gripperinterrogation





Gripper without approximate positioning

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

Gripper name

Selectfunction


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





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.




13.1. Gripper typ 1





Basic types for gripper functions: TYPE 1

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





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


Example: TYPE 1 (functional principle)

IN 3IN 4

OUT 2

IN 1 IN 2

OUT 1

Gripper closed






Com-ponent

OUT 1

IN 1 IN 2 IN 3IN 4

OUT 2

Gripper open



Com-

ponent

IN 3IN 4

OUT 2

IN 1 IN 2

OUT 1

Component gripped




13.2. Gripper typ 2







OUT 1 OUT 2 IN 1 IN 2

TRUE FALSE TRUE FALSE A

FALSE TRUE FALSE TRUEB


FALSE FALSE FALSE FALSEC

e.g. a slide with a center position


OUT 1 OUT 2

State: A C B

IN2 IN1

Example: TYPE 2




13.3. Gripper typ 3







OUT 1 OUT 2 IN 1 IN 2

TRUE FALSE TRUE FALSE A

FALSE TRUE FALSE TRUEB


FALSE FALSE FALSE FALSEC

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


OUT 1 OUT 2

< PIN1 > PIN2

Suction Release

Example: TYPE 3




13.4. Gripper typ 4







OUT 1 OUT 2 OUT 3 IN 1 IN 2

TRUE FALSE FALSE TRUE FALSE A

FALSE TRUE TRUE FALSE TRUEB


FALSE TRUE FALSE FALSE FALSE A

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


< PIN1 > PIN2

OUT 1

Suction (A)

OUT 3

Release (B)

OUT 2

OFF (C)

Throttle

Example: TYPE 4




13.5. Gripper typ 5











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


Example: TYPE 5

IN2 IN1

OUT1

OUT2




14. Fixed tool calibration





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:


Calibration of the fixed tool

The coordinates are saved asBASE_DATA[1]....[16].

1. Calibrate the fixed tool

+X

+Y+Z





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.


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





Calibration of the movable workpiece

The coordinates are saved asTOOL_DATA[1]....[16].

2. Calibrate the workpiece

XY

Z

X

YZ


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.





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


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





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


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





Pen

Changing the $IPO_MODE

Pen

$IPO_MODE=#TCP

$IPO_MODE=#BASE


Panel

not defined

Pen

Gripper

Blue

Red

Fixed pen

Tool and base type

Defined type

Name of the tool or base




15. Programming with subprograms





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.


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




16. The expert level





Navigator (expert)

System files and directories are displayed.

Drives aredisplayed


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





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.




17. Loops and branches in programs





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


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





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.


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





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.


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





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


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?




18. Automatik external





Automatic External inputs

Var

I/O

Functionaldescription

Variable name

VariableInput

Input number orvariable value


Automatic External outputs - Start condition

Selection of the

variable groups

Functionaldescription

Function name

Output number





$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


..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





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


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





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


Signal diagram example: DRIVES_ON omitted

PLC O UT P UT S

I NP UT S



$I_O_ACTCONF(EXT)




$DRIVES_ON (activate drives)


$STOPMESS (stop message)

KRC

O U

T P U T S

I N P U T S





Signal diagram example: Start program

PLC O UT P UT S

I NP UT S



$I_O_ACTCONF(EXT)





$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


Signal diagram example: EXT_START omitted

PLC O UT P UT S

I NP UT S



$I_O_ACTCONF(EXT)





$EXT_START (start program)



KRC

O U

T P U T S

I N P U T S





Signal diagram example: Transfer program number

PLC O UT P UT S

I NP UT S



$I_O_ACTCONF(EXT)







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


Signal diagram example: Program running

PLC O UT P UT S

I NP UT S



$I_O_ACTCONF(EXT)






APPL_RUN (program running)

PGNO_REQ (request)


PGNO_VALID (read command)


KRC

O U

T P U T S

I N P U T S





Signal diagram example: Program running

PLC O UT P UT S

I NP UT S



$I_O_ACTCONF(EXT)







PGNO_REQ (request)


PGNO_VALID (read command)


KRC

O U T P U T S

I N P U T S


Signal diagram example: End of program

PLC O UT P UT S

I NP UT S



$I_O_ACTCONF(EXT)








KRC

O U

T P U T S

I N P U T S





Signal diagram example: End of program

PLC O UT P UT S

I NP UT S



$I_O_ACTCONF(EXT)








KRC

O U T P U T S

I N P U T S


Signal diagram example: New program request

PLC O UT P UT S

I NP UT S



$I_O_ACTCONF(EXT)







PGNO_REQ (request)


PGNO_VALID (read command)KRC

O U

T P U T S

I N P U T S




18.1. Programnumber typ 1





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





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





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.




18.4. Inputs





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.


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".





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.


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]





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


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





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.


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





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


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.





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.




19. Excercises


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





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)


General exercises: 1-10

Expert exercises:

Basic exercises:




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)







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)





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.





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.





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.





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.





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.





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.






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).


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.





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.





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”.




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





Exercises with an external TCP: 11-14

Expert exercises:

Basic exercises:










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)





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.





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].





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.






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.





Exercises without an external TCP: 15-16

Expert exercises:

Basic exercises:










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





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.





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.





Exercises for expert level: 17-18

Expert exercises:

Basic exercises:










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





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.



Host computer

E t h e

( a r c

Controls the entire systemand stores data


Kuka Krc2 Workbook

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