SOFTWARE

KR C...

Function Generator

System Tech (KSS) 5.1

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e Copyright

KUKA Roboter GmbH

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers. Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in the case of a replacement or service work. We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in subsequent editions. Subject to technical alterations without an effect on the function.

PD Interleaf
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Contents
1
1.1 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.3

Characteristics, functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Correction direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The correction coordinate system TTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5
5 6 6 6 7 7 8

2
2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8 2.1.9 2.1.10 2.1.11 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.3 2.4

Programming, parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Structure variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $TECH[i], $TECH_C[i], i=1,...,6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $TECHIN[i], i = 1,...,6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $TECHPAR[i, j], i=1,...,6 , j=1,...,10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $TECHPAR_C[i, j], i = 1,...,6 , j=1,...,10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $TECHVAL[i], i = 1,...,6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $TECHSYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $TECHSYS_C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $TECHANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $TECHANGLE_C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $TSYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $DISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Correction direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing technology mode, correction variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conveyor synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Complex sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9
9 9 14 14 14 15 15 15 15 15 15 15 17 17 17 18 19 20 23

3
3.1 3.2 3.3

Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conveyor synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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25 26 27

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Function Generator

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Characteristics, functional description

1
1.1

Characteristics, functional description

Characteristics
The function generator included in the KRC software is easy to use and allows the user to implement the following functions: G G Mechanical weaving Thermal weaving The function values can be used at KRC analog outputs to modulate the weld current and the wire feed rate. Analog sensors Conveyor synchronization Coupling of intelligent sensors (META, SCOUT, ...).

G G G

The following diagram illustrates mechanical and thermal weaving using the function generator. Mechanical weaving Taking the example of a weld application Thermal weaving

Weave amplitude

Weld voltage (volts) Max. voltage

Length (1 period)

Torch

Min. voltage

Component plane

Weave plane

Weld direction Wire feed

Max. feed Min. feed

Weld direction

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Function Generator

1.2
1.2.1

Functional description
Basic principle
The user defines a function which is evaluated accordingly by the system and processed further. The input values of the function (distance, velocity, etc.), and also the further processing of the results of the function (output to an analog channel, path correction, etc.), can be selected and configured using variables.

1.2.2

Function definition
G G G The required function y(x) is defined in the interval [0,1] as a polygon. The polygon is defined unambiguously by entering function control points. A maximum of 50 control points (x,y) is permissible. They must be selected as follows: --x is a real number from the interval [0,1] y is a real number from the interval [--1,1] For control points 1 to max. 50, the following must be observed: x1 < x2 < ...<xN The first and last control points must be situated on the edge of the definition range (x1=0, xN=1). Example The control points (0,0), (0.3,0.5), (0.75,--0.5) and (1,0) result in the function illustrated below:

Y
(0,1) (1,1)

(0.3,0.5)

(0,0)

(1,0)

(0.75,--0.5)

(0,--1)

(1,--1)

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Characteristics, functional description (continued)

1.2.3

Correction direction
The correction direction is defined using a user--defined correction coordinate system (tool--based technological system, $TECHSYS): WORLD, BASE, ROBROOT, TCP and TTS The following definitions apply here: The correction coordinate system can be rotated using the variable $TECHANGLE: A: B: C: Rotation about the Z axis of the tool--based technological system in the mathematically positive direction. Rotation about the Y axis of the tool--based technological system in the mathematically positive direction. Rotation about the X axis of the tool--based technological system in the mathematically positive direction.

The definition can be made unambiguous by selecting an axis of the correction coordinate system by means of a GEOREF variable. Corrections are only possible in Cartesian space and not in axis space. This means that the function generator is only available for CP motions (LIN, CIRC).

1.2.4

The correction coordinate system TTS

TTS stands for tool--based technological system. This tool--based moving frame is defined as follows: X axis Y axis Unit vector in direction of path tangent. Unit vector in direction of vector product of path tangent and X axis of tool coordinate system. (Applying the right hand rule, the direction of the Y axis is that of the middle finger if the thumb is pointing in the direction of the path tangent and the index finger is pointing in the direction of the X axis of the tool coordinate system.) Unit vector in direction of vector product of path tangent and Y axis. Z axis Y axis (middle finger)

Z axis

TTS

(tool--based technological system)

X axis (thumb) XTOOL axis (index finger)

The correction coordinate system is calculated every time a CP motion is executed. If the X axis of the tool coordinate system and the path tangent are parallel, the TTS cannot be generated. The TTS is invalid in this case and results in the acknowledgement message TTS NOT EXISTING and dynamic braking when path correction is used. In this case, a corresponding reorientation of the tool is required as well as reprogramming of the motion.

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Function Generator

1.3

Configuration
The maximum number of programmable function generators is selected in the robot--specific machine data using the datum $TECH_MAX. $TECH_MAX can be set to values between 3 and 6 with 3 being the default setting.

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Programming, parameterization

Programming, parameterization
The function generator can be programmed using advance run and main run system variables. Advance run variables are copied into the main run variables internally in the system at the start of a motion or when changing block to an approximate positioning block. The function generator, which is only active for CP motions, only evaluates the main run variables. For this reason, when controlling the function generator using advance run variables, a CP motion block must then be executed so that the data are transferred to the main run data. A so--called zero block is also valid in this case.

2.1
2.1.1

Structure variables
$TECH[i], $TECH_C[i], i=1,...,6
These are structure variables for defining the function and programming the evaluation of the function. $TECH[i]. MODE The parameter MODE defines the type of evaluation of the function in the advance run. The parameter can be changed in the program and is block--specific. MODE #OFF #SINGLE #CYCLE Effect The function is not evaluated. The definition range of the function is run through just once when the function is evaluated. Cyclical evaluation of the function.

$TECH_C[i]. MODE The parameter MODE defines the type of evaluation of the function in the main run. The parameter can be changed using Trigger, Interrupt or the variable modification function and the changes take effect immediately. MODE #OFF #SINGLE #CYCLE Effect The function is not evaluated. The definition range of the function is run through just once when the function is evaluated. Cyclical evaluation of the function.

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Function Generator $TECH[i].CLASS The parameter CLASS can be used to define the technology class in the advance run. The parameter can be changed in the program and is block--specific. CLASS #PATH Effect The input variable for the function generator is the system variable $DISTANCE. The unit for the scaling and offset variables is [mm]. The input variable for the function generator is the path velocity ($VEL_ACT). The input variable for the function generator is the system variable $TECHIN[i], i=1..6. Depending on the input values, a corresponding position correction is carried out. The input variable for the function generator is the system variable $TECHIN[i], i=1..6. Depending on the input values, a corresponding tracking motion is executed by the robot. The input variable for the function generator is a correction frame that is set by the sensor task. Depending on the input values, a corresponding correction is carried out by the robot.

#VEL #SENSOR

#CONVEYOR

#DATALINK

$TECH_C[i].CLASS The parameter CLASS can be used to define the technology class in the main run. The parameter cannot be changed. CLASS #PATH Effect The input variable for the function generator is the system variable $DISTANCE. The unit for the scaling and offset variables is [mm]. The input variable for the function generator is the path velocity ($VEL_ACT). The input variable for the function generator is the system variable $TECHIN[i], i=1..6. Depending on the input values, a corresponding position correction is carried out. The input variable for the function generator is the system variable $TECHIN[i], i=1..6. Depending on the input values, a corresponding tracking motion is executed by the robot. The input variable for the function generator is a correction frame that is set by the sensor task. Depending on the input values, a corresponding correction is carried out by the robot.

#VEL #SENSOR

#CONVEYOR

#DATALINK

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2 $TECH[i].FCTCTRL

Programming, parameterization (continued)

This is a function control structure for setting the scaling and offset parameters in the advance run. The parameter can be changed in the program and is block--specific. FCTCTRL element OFFSET_IN OFFSET_OUT SCALE_IN SCALE_OUT Effect Real value which, depending on the parameter CLASS, can be used to offset the zero point of the definition range of the function. Real value which, depending on the parameter CLASS, can be used to offset the zero point of the value range of the function. Real value which can be used to scale the definition range of the function with reference to the parameter CLASS. Real value which can be used to scale the value range of the function with reference to the parameter CLASS.

$TECH_C[i].FCTCTRL Function control structure for setting the scaling and offset parameters in the main run. The parameter can be changed using Trigger, Interrupt or the variable modification function and the changes take effect immediately. FCTCTRL element OFFSET_IN OFFSET_OUT SCALE_IN SCALE_OUT Effect Real value which, depending on the parameter CLASS, can be used to offset the zero point of the definition range of the function. Real value which, depending on the parameter CLASS, can be used to offset the zero point of the value range of the function. Real value which can be used to scale the definition range of the function with reference to the parameter CLASS. Real value which can be used to scale the value range of the function with reference to the parameter CLASS.

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Function Generator GEOREF GEOREF If the technology class SBC is selected, the variable GEOREF is irrelevant. NONE This result of the function evaluation is only available as the system variable $TECHVAL. With the technology class SENSOR, this parameter has the effect that no function evaluation is carried out. In addition to the system variable, the calculated value is also included in the calculation of the TCP in the direction of the X axis of the TTS programmed using $TECHSYS and $TECHANGLE, or in the direction of the X BASE axis in the case of technology class CONVEYOR. In addition to the system variable, the calculated value is also included in the calculation of the TCP in the direction of the Y axis of the TTS programmed using $TECHSYS and $TECHANGLE, or in the direction of the Y BASE axis in the case of technology class CONVEYOR. In addition to the system variable, the calculated value is also included in the calculation of the TCP in the direction of the Z axis of the TTS programmed using $TECHSYS and $TECHANGLE, or in the direction of the Z BASE axis in the case of technology class CONVEYOR.

For technology classes SENSOR and CONVEYOR, the following parameters can also be programmed for GEOREF: A Significance for technology class SENSOR: Rotation about the Z axis of the tool--based technological system in the mathematically positive direction. Significance for technology class CONVEYOR: Tracking motion about the Z axis of the BASE coordinate system in the mathematically positive direction. Significance for technology class SENSOR: Rotation about the Y axis of the tool--based technological system in the mathematically positive direction. Significance for technology class CONVEYOR: Tracking motion about the Y axis of the BASE coordinate system in the mathematically positive direction. Significance for technology class SENSOR: Rotation about the X axis of the tool--based technological system in the mathematically positive direction. Significance for technology class CONVEYOR: Tracking motion about the X axis of the BASE coordinate system in the mathematically positive direction.

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2 Example

Programming, parameterization (continued)

$TECHVAL (output variable)

Y (0,1) (1,1) SCALE_OUT (1,0) (0,0) X

OFFSET_IN

(0,--1) OFFSET_OUT

(1,--1) Technology mode #CYCLE

SCALE_IN

e.g. length of arc for #PATH

(input variable) $DISTANCE (CLASS = #PATH) $VEL_ACT (CLASS = #VEL) $TECHIN (CLASS = #SENSOR, CLASS = #CONVEYOR) Correction frame (CLASS = #DATALINK)

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Function Generator $TECH[i].FCT Defines the function in the advance run. It can be changed in the program and is block--specific. $TECH_C[i].FCT Defines the function in the main run. It cannot be changed in the program. FCT element ORDER Effect Integer value specifying the degree of interpolation when the spline is evaluated. The only degree of interpolation currently implemented is 1. Total number of valid control points in the following five control point structures. The number of valid control points can be freely selected between 2 and 50; no gaps are allowed between valid control points. Control point list for control points 1 to 10 Control point list for control points 11 to 20 Control point list for control points 21 to 30 Control point list for control points 31 to 40 Control point list for control points 41 to 50

CPNUM

CPS1 CPS2 CPS3 CPS4 CPS5

2.1.2

$TECHIN[i], i = 1,...,6
The system variable $TECHIN forms the interface between the cyclical analog and digital inputs of the KR Cx and the function generator. The contents of this variable serve as the input variable for the function generator. The variable has the data type REAL and cannot be modified in the program.

2.1.3

$TECHPAR[i, j], i=1,...,6 , j=1,...,10

This is used for parameterization or output of the function generator (analog sensors, conveyor tracking, etc.) in the advance run. Ten input parameters and ten output parameters are available to each function generator (i). If a parameter is used to output function generator states, the parameter value that is current in the interpolation cycle can be found in the main run variable. The data type is REAL. The variable can be modified in the program and is block--specific.

2.1.4

$TECHPAR_C[i, j], i = 1,...,6 , j=1,...,10

This is used for parameterization or output of the function generator (analog sensors, conveyor tracking, etc.) in the main run. Ten input parameters and ten output parameters are available to each function generator (i). If a parameter is used to output function generator states, the parameter value that is current in the interpolation cycle can be found in the main run variable. The data type is REAL. The variable can be modified using Trigger, Interrupt or the variable modification function. The changes take effect immediately.

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Programming, parameterization (continued)

2.1.5

$TECHVAL[i], i = 1,...,6
This is an output variable of the function generator. SCALE_OUT and OFFSET_OUT are included in the calculations. This variable has the data type REAL and cannot be modified during program execution.

2.1.6

$TECHSYS
Used for programming the TTS in the advance run. The coordinate systems #WORLD, #BASE, #ROBROOT, #TCP and #TTS can be programmed. If GEOREF < > (is not equal to) #NONE, then the calculated function values refer to the programmed coordinate system. This variable can be modified in the program and is block--specific.

2.1.7

$TECHSYS_C
This variable is used for programming the TTS in the main run. The coordinate systems #WORLD, #BASE, #ROBROOT, #TCP and #TTS can be programmed. If GEOREF < > (is not equal to) #NONE, then the calculated function values refer to the programmed coordinate system. This variable can be modified using Trigger, Interrupt or the variable modification function and the changes take effect immediately.

2.1.8

$TECHANGLE
Used for programming the rotation of the TTS in the advance run. The rotation is specified in RPY angles. This variable can be modified in the program and is block--specific.

2.1.9

$TECHANGLE_C
Used for programming the rotation of the TTS in the main run. The rotation is specified in RPY angles. The variable can be modified using Trigger, Interrupt or the variable modification function and the changes take effect immediately.

2.1.10

$TSYS
For each interpolation cycle, this system variable contains the current TTS insofar as there is one available with reference to the base coordinate system. This variable is of type FRAME and cannot be modified.

2.1.11

$DISTANCE
This variable allows path--related function evaluation. During program execution, it represents the current arc length of a Cartesian motion in millimeters. $DISTANCE is set to zero at the start of an individual CP block or at the start of the CP motion in a PTP/CP approximate positioning motion. This variable is of type REAL and cannot be modified.

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Function Generator

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Programming, parameterization (continued)

2.2
2.2.1

Analog sensors
Interface
The system variables $TECHIN[i] (i = 1 .. 6) form the interface between the sensor inputs and the function generator. These variables are written to cyclically using the following statements and serve as the input variable for the function generator. Analog input: SIGNAL CORRECTION $ANIN[1] ANIN ON $TECHIN[2] = FACTOR * CORRECTION + OFFSET Digital input: Entry in $MACHINE.DAT SIGNAL $DIGIN1 $IN[20] TO $IN[27] DECL DIGINCODE $DIGIN1CODE=#UNSIGNED DIGIN ON $TECHIN[3] = FACTOR * $DIGIN1 + OFFSET

2.2.2

Parameterization
Elements of the array variable $TECHPAR[i,j] are used for parameterization and for outputting function generator states. Technology class SENSOR ($TECH[i].CLASS = #SENSOR) causes the function generator to use the variable $TECHIN[i] and thus the sensor signal as the input variable. For function generator class #SENSOR, the function definition describes a controller characteristic as illustrated in the following diagram. Correction velocity [mm/s] or [degrees/s] Y Controller characteristic (0,1) (1,1)

OFFSET_IN (0,0) (1,0) X

SCALE_OUT

(0,--1) OFFSET_OUT

(1,--1) Technology mode #CYCLE

SCALE_IN

$TECHIN
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Function Generator If the definition range SCALE_IN is exceeded, the corresponding limit value is maintained. For function generator class #SENSOR, the function generator calculates a correction velocity (mm/s or degrees/s) from the input values. This correction velocity is used to calculate a correction value (mm, degrees) which is added up in every interpolation cycle (sensor correction, initial value 0.0). With corresponding parameterization, the correction velocity is 0 (zero) and the sensor correction value remains constant in the balanced state. The correction velocity is smoothed before the correction value is calculated in order to avoid abrupt corrections. This smoothing can be set using $TECHPAR[i,1]. If the filter $TECHPAR[i,1] is set to less than the duration of an interpolation cycle, the unfiltered velocity value is used for calculating the correction.

2.2.3

Correction direction
The correction direction is defined, as is usual for the function generator, by means of the variables $TECHSYS, $TECHANGLE and GEOREF. Using the components #A, #B, and #C of the ENUM variable GEOREF, it is also possible to carry out an orientation correction to the corresponding angles. G G G #A: #B: #C: Rotation of the X axis of the tool about the Z axis of the tool--based technological system in the mathematically positive direction. Rotation of the X axis of the tool about the Y axis of the tool--based technological system in the mathematically positive direction. Rotation of the X axis of the tool about the X axis of the tool--based technological system in the mathematically positive direction.

Since the tool--based technological system changes its position when following a contour, the correction increase in the direction/orientation defined by GEOREF and calculated in the interpolation cycle is converted to the corresponding BASE components (dx, dy, dz or da, db, dc).

Z BASE

Y TSYS X TSYS

Y BASE

ds dx

Z TSYS dz dy

GEOREF X BASE

ds = correction velocity * t_ipo

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Programming, parameterization (continued)

The correction increase in the BASE components is added up (dX, dY, dZ or dA, dB, dC), included in the calculation of the TCP and can be accessed by the user via the TECHPAR variables. TECHPAR_C[i, TECHPAR_C[i, TECHPAR_C[i, TECHPAR_C[i, TECHPAR_C[i, TECHPAR_C[i, 3] 4] 5] 6] 7] 8] : : : : : : Correction Correction Correction Correction Correction Correction value value value value value value in in in in in in X Y Z A B C BASE BASE BASE BASE BASE BASE (dX) (dY) (dZ) (dA) (dB) (dC)

In the case of a TCP correction (GEOREF = #X, #Y or #Z), the value of the correction vector in BASE (unit = mm) is written to the output variable of the function generator ($TECHVAL[i]) and can then be used, with the aid of two interrupt declarations, for monitoring the sensor correction. INTERRUPT DECL 1 WHEN $TECHVAL[1] > 20.0 DO UPPER_LIMIT() INTERRUPT DECL 2 WHEN $TECHVAL[1] < --20.0 DO LOWER_LIMIT() In the case of an orientation correction (GEOREF = #A, #B or #C), the value is calculated using the correction angle in BASE (dA, dB, dC) and transferred to TECHVAL[i]. $TECHVAL[i] = SQRT(dA2 + dB2 + dC2)

All correction values that are made available to the user are interpolator command values and are not filtered, i.e. there is no reference to actual values.

2.2.4

Changing technology mode, correction variable

Switching the technology mode from #CYCLE to #SINGLE has the effect that the input variable $TECHIN[i] is no longer evaluated. The correction velocity is set to zero internally in the system thus keeping the established sensor correction vector constant. When an exact positioning point is reached, the correction variable is retained and is used for the subsequent CP motion. This applies also for the transition to the following block when a CP approximation contour is executed. Block selection, program reset and interrupt commands followed by the RESUME statement cause the start values of the motion block to be initialized and the correction value is lost. The sensor offset is set to 0 in the function generator. No sensor offset is permissible in the case of a PTP motion. If there is a correction value present, the acknowledgement message DEVIATION IN THE START POINT is generated. The instruction $TECH[i].MODE=#OFF triggers an advance run stop, deactivates the functionality of the sensors, sets the sensor offset to 0 and continues the motion from the current point in space.

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Function Generator

2.3

Conveyor synchronization
The system variables $TECHIN[i] (i = 1 .. 6) form the interface between the sensor inputs and the conveyor functionality. Data are written to these variables cyclically using the following statements: Analog input: SIGNAL CONVEYORVEL $ANIN[1] ANIN ON $TECHIN[2] = FACTOR * CONVEYORVEL + OFFSET Digital input: Entry in $MACHINE.DAT SIGNAL $DIGIN1 $IN[20] TO $IN[28] DECL DIGINCODE $DIGIN1CODE=#UNSIGNED DIGIN ON $TECHIN[3] = FACTOR * $DIGIN1 + OFFSET Elements of the array variable $TECHPAR[i,j] are used for parameterization and for outputting function generator states as described below. Two conveyor modes are possible. The robot tracks the conveyor in the case of translational or rotational motions of the part to be processed, e.g. with a conveyor belt or turntable. The coordinate system in which tracking motions are possible is defined by means of the first six TECHPAR variables of the next function generator. If, for example, function generator 1 has been configured for the conveyor function, $TECHPAR[2,1] to $TECHPAR[2,6] contain the tracking coordinate system (X, Y, Z, A, B, C) with reference to $WORLD. Function generator 2 should not be used for any other purpose in this case.

The TECH variable GEOREF defines the correction direction in this coordinate system. The parameters #X, #Y and #Z define a translational correction in the corresponding direction. For rotational tracking, the parameters #A, #B and #C of the GEOREF variable are used: #A --> about Z, #B --> about Y, #C --> about X. In the case of translational conveyor mode, it is of vital importance to ensure that the tracking direction corresponds to the direction of motion of the conveyor belt. In the case of rotational motions of the part, the correction axis must be located at the center of rotation, for example: GEOREF=#A where the Z axis of the conveyor (Z Conv.) is the rotational axis and the direction of rotation is mathematically positive.

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2 If the following is selected GEOREF=#NONE

Programming, parameterization (continued)

the tracking distance is calculated and is available to the user via the variable $TECHVAL[i] The robot does not carry out tracking, however. The conveyor function is defined by means of the technology class CONVEYOR ( $TECH[i].CLASS = #CONVEYOR) and activated with technology mode CYCLE. The parameter $TECHPAR[i,8] defines whether the variable $TECHIN[i] refers to a velocity value or a distance. $TECHPAR[i,8]=0 ----> $TECHIN[i] refers to a velocity $TECHPAR[i,8]=1 ----> $TECHIN[i] refers to a distance In the case of a conveyor synchronization with an absolute position sensing system, $TECHPAR[i,8] must be set to 1. Example: The synchronization switch enables the counting mode. At the end of the tracking operation, a digital output in the KRC ensures that the counter is set to 0 and that the enabling of the counting mode is withdrawn. The 16--bit values are scaled to [mm] using the FACTOR in the DIGIN statement. Synchronization switch X Conv. P2 P3

Conveyor
P1 P4 Z Conv. Incremental encoder Pulse Direction of rotation Direction of motion

Robot

Start counter (enable)

Reset counter (digital output)

KR C2

Counter 16 bits

Strobe (digital output)

16 digital inputs Start signal (digital input)

DIGIN ON $TECHIN[i]=FACTOR*$DIGIN1+OFFSET

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Function Generator If the parameter $TECHPAR[i,8] is set to 0, the tracking distance is calculated on the basis of the conveyor velocity which is assigned cyclically to $TECHIN[i] by means of an ANIN or DIGIN statement. Make sure that $TECHIN[i] contains the conveyor velocity value in mm/s or degrees/s. This is done by means of the factor in the ANIN/DIGIN statement. The system variable $TECHVAL[i] contains the absolute tracking distance in mm or degrees. This variable can be used to monitor the maximum permissible tracking distance, e.g. INTERRUPT DECL 1 WHEN $TECHVAL[i] > 2000.0 DO STOP_TRACK() The robot tracking motion is started by means of a synchronization signal which the conveyor system sends to the robot controller when the part enters the robots processing area. This synchronization input (user input) is transferred to the system via the variable $TECHPAR[i,7]. The program interpreter is stopped by means of a WAIT FOR $TECHVAL[i]>0.05 statement once the conveyor synchronization has been activated. The conveyor functionality is activated as soon as the technology mode is switched to CYCLE and the technology class CONVEYOR is selected. Once the robot has detected the synchronization signal it leaves its starting position and starts tracking and processing. For this kind of start from the rest position with the conveyor already running (so--called flying start), special precautions (smoothing) must be taken in order to ensure a smooth, but nonetheless sufficiently rapid, synchronization of the robot motion with the conveyor motion. The corresponding parameters are set using elements of $TECHPAR[i,j]: G G Distance gain $TECHPAR[i,1] in [1/s], Velocity gain $TECHPAR[i,2] in [1/s].

The following error between the conveyor and the robot caused by the smoothing and the system run times can be compensated for by the user by means of $TECHPAR[i,3] (rate time in s). As the function generator (interpolator) is not called during pauses between motions, no exact positioning motion should be programmed at any point in the tracking operation.

A programmed point can be reached exactly by setting the approximation radius to 0 (zero). If it is necessary for there to be pauses between robot motions, this can be achieved by setting the override to zero at the corresponding point in the program (TRIGGER in approximation zero block). The instruction $TECH[i].MODE=#OFF triggers an advance run stop, deactivates the conveyor functionality, sets the tracking distance to 0 and continues the motion from the current point in space.

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Programming, parameterization (continued)

2.4

Complex sensors Using an add--on controller task (sensor task), it is possible to couple an intelligent sensor to the controller and correct the robot motion in Cartesian space ($TECH[i].CLASS = #DATALINK).

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Function Generator

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Application examples

3
3.1

Application examples
Weaving
Example DECL TECH WEAVE1, WEAVE2 = #CYCLE = 2 ; Declare variables of type TECH ; Cartesian weaving is a cyclical ; function. ; Wavelength of the weave oscillation is ; 2 mm. ; Start of deflection is start of CP path. ; Weave amplitude is 3 mm. ; Focus of the weave oscillation is ; on the path: ; If amplitude = 0, path is followed without ; weaving. ; Argument of the weave pattern is the ; arc length, i.e. SCALE_IN the ; wavelength. ; Direction of the weave deflection in the Y ; direction in the TTS ; Create weave pattern from polygon using ; pairs of values in the function table. ; Rotate TTS WEAVE1.MODE

WEAVE1.FCTCTRL.SCALE_IN

WEAVE1.FCTCTRL.OFFSET_IN = 0 WEAVE1.FCTCTRL.SCALE_OUT = 3 WEAVE1.FCTCTRL.OFFSET_OUT = 0

WEAVE1.CLASS = #PATH WEAVE1.FCTCTRL.GEOREF = #Y WEAVE1.FCT.ORDER = 1 TECHANGLE.C = 10

; User--defined WEAVE1 is ready for assignment to the technology structure $TECH[1] ; Prepare FCTCTRL section of the structure WEAVE2 for structure ; assignment using TRIGGER command! WEAVE2.MODE = #CYCLE = 4 ; Cartesian weaving is a cyclical ; function. ; Wavelength of the weave oscillation is ; 4 mm. ; Start of deflection at start of CP path. ; Weave amplitude is 3 mm. ; Focus of the weave oscillation is ; the path. ; Weaving from next CP block onwards. ; PTP blocks always without weaving. ; Weaving with values of the structure ; WEAVE1. ; Weaving in the Z direction, i.e. perpendicular ; to the plane of the panels to be welded, ; from the start of this block onwards.

WEAVE2.FCTCTRL.SCALE_IN

WEAVE2.FCTCTRL.OFFSET_IN = 0 WEAVE2.FCTCTRL.SCALE_OUT = 3 WEAVE2.FCTCTRL.OFFSET_OUT = 0 $TECH[1] = WEAVE1 PTP X1 LIN L1 $TECH[1].FCTCTRL.GEOREF = #Z LIN L2 C_DIS

TRIGGER WHEN DISTANCE=1 DELAY=0 DO $TECH_C[1].FCTCTRL = WEAVE2.FCTCTRL LIN L3 C_DIS ; From the center of the intermediate ; block of the approximate positioning, ; weaving with new wavelength 4 mm. LIN L4 $TECH[1].MODE = #OFF LIN L5

; This motion block without weaving

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Function Generator

3.2

Analog sensor
Example Using a distance sensor, a correction is to be made in the Z direction of the TTS. Calibration is carried out using the offset variables. The maximum value for the correction vector should be +/-- 20 mm. The analog input delivers a voltage between --10 V and +10 V; this should be adjusted to 0 V. FACTOR = 0.1 OFFSET = 1.0 ; Sensor at analog input 2 SIGNAL CORRECTION $ANIN[2] ; Monitor sensor correction value INTERRUPT DECL 1 WHEN $TECHVAL[1] > 20.0 DO UPPER_LIMIT() INTERRUPT DECL 2 WHEN $TECHVAL[1] < -20.0 DO LOWER_LIMIT() ; Activate cyclical reading of the analog input and ; scaling of $TECHIN[1] to 0.0 - 2.0 ANIN ON $TECHIN[1] = FACTOR * CORRECTION + OFFSET ; Define correction direction $TECHSYS = #TTS $TECH[1].FCTCTRL.GEOREF = #Z ; Sensor correction using the function generator $TECH[1].CLASS = #SENSOR $TECH[1].FCTCTRL.SCALE_IN = 2.0 ; $TECH[1].FCTCTRL.OFFSET_IN = 0.0 ; $TECH[1].FCTCTRL.SCALE_OUT = 20.0; $TECH[1].FCTCTRL.OFFSET_OUT = 0.0; $TECH[1].FCT.ORDER = 1 ; $TECH[1].FCT.CPNUM = 3 ; $TECH[1].FCT.CPS1.X1 = 0.0 ; $TECH[1].FCT.CPS1.Y1 = -1.0 ; $TECH[1].FCT.CPS1.X2 = 0.5 ; $TECH[1].FCT.CPS1.Y2 = 0.0 ; $TECH[1].FCT.CPS1.X3 = 1.0 ; $TECH[1].FCT.CPS1.Y3 = 1.0 ; $TECHPAR[1,1] = 0.056 ; PTP BEFORE_PART INTERRUPT ON 1 INTERRUPT ON 2 ; Activate sensor correction TECH[1].MODE = #CYCLE LIN P1 C_DIS LIN P2 C_DIS LIN P3 ; Deactivate sensor correction TECH[1].MODE = #OFF LIN_REL {X 0.0} Definition of control parameters Smoothing constant in s

; Correction in Z direction

; Zero block for accepting advance run data ; in the main run data --> Deactivation of ; the function generator

; Deactivate cyclical analog input ANIN OFF CORRECTION

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Application examples (continued)

3.3

Conveyor synchronization
Example Synchronization switch X Conv. P2 P3

Conveyor
P1 Velocity measuring system Direction of motion P4 Z Conv.

KR C1
Digital input Analog input

Robot

A workpiece on a conveyor belt is moved past a robot. The velocity measuring system delivers a voltage of 10.0 V in the case of a maximum conveyor velocity of 0.08 m/s. The voltage range of the analog input is 0 V to 10.0 V. FACTOR = 80 OFFSET = 0.0 ; Number of the user input to which the synchronization switch is attached SYNCH_NO = 5 ; Velocity measuring system at analog input 2 SIGNAL CONVEYORVEL $ANIN[2] ; Monitor tracking distance INTERRUPT DECL 1 WHEN $TECHVAL[1] > 2000.0 DO STOP_TRACK() ; Define conveyor coordinate system relative to WORLD, Z axis points in ; direction of motion of the conveyor $TECHPAR[2,1] = ... ; X Conv. $TECHPAR[2,2] = ... ; Y Conv. $TECHPAR[2,3] = ... ; Z Conv. $TECHPAR[2,4] = ... ; A Conv. $TECHPAR[2,5] = ... ; B Conv. $TECHPAR[2,6] = ... ; C Conv. ; Activate cyclical reading of the analog input ANIN ON $TECHIN[1] = FACTOR * CONVEYORVEL + OFFSET

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Function Generator ; Conveyor synchronization using the function generator $TECH[1].CLASS = #CONVEYOR ; Tracking direction is the Z axis of the conveyor coordinate system $TECH[1].FCTCTRL.GEOREF = #Z ; Define control parameters $TECHPAR[1,1] = 0.6 $TECHPAR[1,2] = 0.7 $TECHPAR[1,3] = 0.084 $TECHPAR[1,7] = SYNCH_NO $TECHPAR[1,8] = 0 ; Distance gain in 1/s ; Velocity gain in 1/s ; Rate time in s ; Synchronization input ; $TECHIN[i] corresponds to a ; velocity value ; (measuring sensor is a tachometer)

PTP WAIT_POS INTERRUPT ON 1 ; Activate conveyor synchronization TECH[1].MODE = #CYCLE LIN_REL {X 0.0}

; Zero block for accepting advance run data ; in the main run data --> Activation of ; conveyor functionality ; Wait until the system has ; detected the synchronization signal ; --> $TECHVAL grows

; Wait for the synchronization signal WAIT FOR $TECHVAL[1]>0.05

; Process workpiece LIN P1 C_DIS LIN P2 C_DIS LIN P3 C_DIS LIN P4 C_DIS LIN AWAY_FROM_BELT ; Deactivate robot tracking TECH[1].MODE = #OFF LIN_REL {X 0.0}

; Zero block for accepting advance run data ; in the main run data --> Deactivation of ; the function generator

; Deactivate cyclical analog input ANIN OFF CONVEYORVEL

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Index

Symbols
#CYCLE, 19 #SENSOR, 17, 18 #SINGLE, 19 $ANIN[1], 17, 20 $DIGIN1, 17 $DISTANCE, 15 $MACHINE.DAT, 17, 20 $TECH[i]. MODE, 9 $TECH[i].CLASS, 17 $TECH[i].CLASS , 10 $TECH[i].FCT, 14 $TECH[i].FCTCTRL , 11 $TECH[i].MODE, 19, 22 $TECH[i], $TECH_C[i], 9 $TECH_C[i]. MODE, 9 $TECH_C[i].CLASS , 10 $TECH_C[i].FCT, 14 $TECH_C[i].FCTCTRL, 11 $TECH_MAX, 8 $TECHANGLE, 7, 15 $TECHANGLE_C, 15 $TECHIN[i], 14, 17, 19, 20 $TECHPAR, 17, 20, 22 $TECHPAR[i, j], 14 $TECHPAR[i,1, 18 $TECHPAR[i,1], 18 $TECHPAR[i,j], 20 $TECHPAR_C[i, j], 14 $TECHSYS, 7, 15, 18 $TECHSYS_C, 15 $TECHVAL[i], 15, 19, 21 $TSYS, 15

C
Configuration, 8 Control points, 6 Conveyor synchronization, 20 Correction coordinate system, 7 Correction coordinate system TTS, 7 Correction direction, 7 Correction value, 18 Correction velocity, 18 CYCLE, 21

D
DIGIN statement, 21

F
Function definition, 6 Functional description, 6

G
GEOREF, 7, 18, 20

M
Mechanical weaving, 5

O
OFFSET_OUT, 15

P
Parameterization, 9 Programming, 9

R
Reaching a programmed point, 22 RESUME, 19

A
Analog sensors, 17

S
SCALE_OUT, 15 Sensor correction value, 18 Sensor offset, 19 SIGNAL $DIGIN1, 17 SIGNAL CORRECTION, 17 Structure variables, 9

B
BASE, 19

Index -- i

Index

T
TCP correction, 19 TECHPAR variables, 20 TECHVAL[i], 19 Thermal weaving, 5 Tool--based technological system, 7 Tool--based technological system (TTS), 7, 15 TTS, 7

W
WAIT FOR $TECHVAL[i], 22

Index -- ii