©Copyright 2004 KUKA Roboter GnbH Zugspitzstrate 1 D-86165 Augsbu “This documentation or bxcepis tharetiom may no be vpreduced or dscosed tod partis without tne express passion of he publishers. Diner nctions nt deferbed in this documertaton may be operable inthe conller The user has ne clsims to these functions, Inowever inthe case o replacement or service work. ‘We have checked the fontent of his docurnenation for conformity wih the hardware and sofware cescrbed. Neverthoess ‘screpancies cannot ip precludes, for wach reason we are not able to guaranie Iota conform. The information nts documentations cheched on a regular basis, however, and necessary corectors willbe incorporated in subsequent exons ‘Subject technica! alifratons without an eect onthe Recon. {KU Robcer Gi feces no abi whatsoever fo any errs in fcrvical formation comuricsed eral rin wring inthe traning courses e conics in ne documentation, Nor wl adilly be accepted for any resitantdamoge or conseqventa damage, Responsible otis fring documentation: Cllege Development (WVSC-10)Contents 1. The robot syste: 1.1. Robot syste} 1.2. System oepew 1.3. Energy sup basics ly 2. Coordinate syst4ms 2.1, Operation 2.2. Coordinate 2.3. Jogging axis the KUKA Control Panel (KCP) ystems of the robots specific 2.4. WORLD Coprdinate system 2.5. TOOL Coort 2.6. BASE Coor inate system inate system 2.7. Chioce of a Coordinate system 3. Setup 3.1. Mastering 3.2. Basics of the tool calibration 3.3. Methods of 3.3.1. Meth 3.3.2. Metht he tool calibration ds of the measurement of the TCP \ds of the measurement of the orientation 3.4. Activate a tdol 3.5. Tool eal ion 3.6. Base calibre 4, Programming 4.1, Motion prog} 4.2. PTP - moti 4.3. BCO- run 4.4, LIN - motio 4.5. CIRC - moti 4.6. Approximati 5. Navigator — Prog| tamming jn n of a motion am creation 13 7 7 29 31 33 39 a 43 45 45 51 57 59 63 69 71 79 85 85 87 93 97 103 109 1157. Fixed tool Logic programming 6.1. Program 6.2. Gripper p} ing of digital in-/outputs jogramming 8. Introduction tothe expert level 10. 8.1. Navigator |— Expert level 8.2. Introduction to sub programs 8.3. Introduction to loops and branches Automatic ext Exercises, inal mode 123 123 137 143 149 149 155 187 163 1691. The robot|system 1.1, Robot system basicsKUKA robot (e.g. KR 180) KUKA Control Panel robot controller (KCP) + Large color graphic display + Softkeys around the display + Hardkeys for program FE] and display control Pic) rrr ee) ry cm ric keypad, alphabetic keypad, cursor block with Enter key 6D mouseinne na oo ange re Rotating ‘overall number of components, column’ can be restricted. Base frame Link arm Counterbalancing system =_ ‘The modular design means that the number of robot assemblies, and thus the Axis 4] Axis 6, Axis 3 Axis 5) Aris 2 Ais 1 | ‘Axes 1, 2 anji 3 are the main axes 6 are the wrist axes.Top view: work envelope Angle, axis 360" ‘Arm extension, 200 mm, ‘Arm extension, 400 mmAEE RRR A RAO TANTO 1.2. System dverview(Genie chen Linear units KL 250 & KL 1500 a Connection of up to 2 extemal axes robot axes DKP 200 & DKP 400 ‘Two-axis positioner Floppy disk drive > CD-ROM driveSel boter GmbH 7 Germany. ial number Serial numbera * Human Machine Interface “Pom (as + Advanced programming using the KRL programming language + Complex application programs (subprograms, interrupt 33> programming, loops, program branches) + Numeric motion programming Robot programs Control programs uth Stara 4 HINES’. Energy supplyOKA ene iy supply systems « Seve 2000 robots @ interface At @ Intog:ated socon of dress package At-A3 ute on A2 @ Extemalsoction- ‘eit column - dross package A1-AS Interface AS @ dees package ARABca Enon Protector cannot be adjusted Protective devices on the robot=_— 2. Coordinate systems 2.1. Operation of the KUKA Control Panel (KCP)Cech Ene Mode selector switchAUTOMATIC] | AUTOMATIC EXTERNAL T2 (Test 2)| |T1 (Test 1) Jogging Jogging not active not active Ye Prog, velocity | Prog. velocity Drives ON Drives ON external {cad man START kay Extemal star functon) | —_functon) => PULSE STARTKey | STARTkey pressed | prossodGinna Be cxspsiey | Window selection key [J ei (} [+] 1 [+] a tet Slt aSoftkeysThe status window is displayed as required and can be closed at any time. The controller communicates with the | operator via the message window. | gases are a Softkeys for acknowledging messagesras message text using the arrow keys; the “Online help’ function will 1 explanation. provide Notify - e.g. “Start key required” Status - e.g. “EMERGENCY STOP” Acknowl. - e.g. “Ackn, EMERGENCY STOP” Wait - eg. “Wait for $IN[1]==True” e.g. “Do you want to teach point?”Eine eee bel tiietiietiiendiend [+] STOP key Cy a! Ci] Program start forwards f+] = aT Program start backwards led ee ee oe) ra) Cr) Ene f Numeric keypad ao’ ~ rem <”TERRE RRR IOI I 8 STE OT LDEL. PGUP | Deletes the line in ‘Moves one screen Rea e \\ which the edit towards the a eee cursor is positioned. beginning of the file. pre \ : _ cmon — B® @/ Baw ® UNDO Seeteobiteor, GG) @/ Semen towards the end of eH ~@ @@ ™ “ta OO @@ CTRL ihe tne mph the te nen Control key one pos ‘row | is Det eet Switches bptween Dates the Character tothe let Insert and verte character the ofthe edt cursor. modes, tight ofthe ed cursor, ‘CAN bus operat control elements ASCII alphabetic keypad ooco OB BE88 @CeIn eo) @G@GeOGOGROOO @e0edecd00d008 Q2®eO200068 EInnn ieee PYYTririer eB ap RETURN key eID yi] CURSOR block Fa NJ iit] Cee 3 as 3 a Cry) eos0 Cr)fin cs i) ie) i) eis Cie] 5 rte uvT [Numeric keypad Upperiiower- case letters Time Robot name: Selected prografn Current block number eT ier owt a | — Drives not ready — Drives ready (approx. 1 s) — Submit interpreter deselected — Submit interpreter stopped — Submit interpreter running \ ‘Operating mode Override| AAP AMT ARNT ERS ET OS 2.2. Coordihate systems of the robots+ Axis-specific motion Each robot axis can be moved individually in a positive or negative direction. + WORLD coordinate system Fixed, rectangular coordinate system whose origin is located at the base of the robot. + TOOL coordinate system Rectangular coordinate system, whose origin is located in the tool. + BASE coordinate system Rectangular coordinate system which has its origin on the workpiece that is to be processed.‘Ry EET EE 2.3, Jogging axis specificeee fach robot axis can be moved individually in a positive negative direction, iesRR AN UI NE EAE RT 2.4. WORLD Coordinate systembt é Fixed, rectangular coordinate system whose origin is located at the base of the robot (teen ns lle B_ =) Rotation about the ¥ axis Angle A) Rotation about the Z axis ie © =) Rotation about the X axisEnd Degrees of freedom of the mouse Bz] Unites funetionalty 2 ‘Only linear motions P| ‘Only rotational The mdau item "Mouse configuration” allows you to set the degrees of freedorh and adapt the dominance of the mouse ETIere inction is switched on, only the coordinate axis with ‘moved. In this example Current setting: “This function allows a superposed motion. Depending on the setting of the degrees of freadom, either 3 or 6 axes can be moved simuitaneousl. In this example, motion is possible in the X,Y and Z directions (the velocity depends on the deflection).Sm A os RENE a 8S oe caste tea 2.5. TOOL Coordinate systemRectangular coordinate system, whose origin is located in the toolee 2.5. TOOL Coordinate systemeons Rectangular coordinate system, whose origin is located in the tool,2.6. BASE Coordinate system‘angular coordinate system which has its origin the workpiece that is to be processed.Aca A AR NN a 2.7. Chioce of a Coordinate systemSee + Select jog mode ff) Axis-specific jogging WORLD coordinate system TOOL coordinate system BASE coordinate systemARTE TE sa a a aR 3. Setup 3.1. Mastering[ieee + When the robot is mastered, the axes are moved into a defined mechanical position, the so-called mechanical zero Position, + Once the robot is in this mechanical zero position, the absolute encoder value for each axis is saved. ‘Only a mastered robot can move to programmed positions and be moved using Cartesian coordinates; ‘a mastered robot also knows the positions of the software limit switches. + In order to move the robot exactly to the mechanical zero position, a dial gauge or electronic measuring tool (EMT) is used. ichanical zero position. Ifa ‘gauge is being used, this myst be carried out manually in axib-specific mode. STLET RT RE : Gauge cartridge “Fromtsigh:! rearsight”The robot is to be mastered... Mastering is canceled aie ais Ga mimes tate . automatically on booting the motol or RDC) system!) after duchanging a gear unit ‘manually bythe operator whenfne robot has been moved without the automatically on booting the contre (e.g. hand crank) system’) afer $n impact with a mechanical end stop at ‘morehan jog velocty (25 cms) manually by the operator after 4 colision involving the tool or robot manually by the operator 7 wah Leon nies are detacted between the resave the current poston, all masering data 5 data saved when shuting down the ats dolcted for safety reasons, astering valves forthe individual axes are tolbe specificaly deleted ‘manually by the operator Mastering with the EMT ERSGem + Move axes to pre-mastering position (frontsight and rearsight aligned) + Move axes manually in axis- specific mode + Each axis is mastered individually + Start yith axis 1 and move upwards: + Alway$ move axis from + to - + Only in TA! + Remove protective cap from gauge cartridge + Attach EMT and connect signal cable (connection X32 on the junction box on the rotating column) + Three LEDs on the EMT: @jed = - error @lsrcen - falling edge @lirecn rising edgeneedeT 3.2. Basics of the tool calibrationme The tool receives a user-defined Cartesian coordinate system with its origin at a reference point specified by the user. What are the advantages of tool calibration? io CP velocity a ntation 2 ree Tool directionoreo Reorientation about the tip of the tool (TCP) Emons + The tool can be oriented to any point around the TCP without changing the position of the TCP.2 EOE ORE CEES RS oe ee i Jogcirp using the jag keys Ising | the mouse *V rot “Zrt J “Zone ¥ Prat ‘Molioh along a straight wo *, in the foo! direction Eine + Component magazine is not aligned in the world coordinate system of the robot. + In order to move to the pick-up point in the world coordinate system itis always necessary to move in several different coordinate directions. + With a calibrated tool, the tool direction can be used for moving the tool.Since Poe eeeTE RETRO es ER SET 3.3. Methods Of the tool calibration(PaaS RR RRR CA 7A NT SR eee Ast step: ci ante of the TCP relative to the flange coordinate system 2nd step: Defeat of the rotation of the Tool chordinate system from tHe flange coordinate za system =f | er 2, Orientation calibration ABC-World 5D ABC-2-PointRac SORE RS EUATETRE ie SERB a oA ATED ESRI 3.3.1, Methods of the measurement of the TCP.In the X¥Z - 4-point method, the TCP of the tool is moved to a referenog point from four different directions. We le Te Sis The TCA of the tool is then calculated from the different flange positiong and orientations. + Move the tool to the reference point with 4 different orientations (P11 to P4). + Tip: Set the final orientation (P4) 50 that +X, runs in the direction of Zyy + Important: The orientations of the tool positions (flange positions) must differ sufficiently from one another. void a collision ev Reduce the velocity in the vicinity of the reference point in order to oe ERS RONIn the X|Y Z- Reference method, the TCP data are determined by means df a comparison with a known point on the wrist flange. Unknown fool i The unknown TCP can be calculated on the basis of the various postin and orientations of the robot flange and the dimensions of the kn n point. Flange adapter plate as Teference too! Calibrated TCP with the following values: X=50;Emons point ra Calibrated TCP must be moved to the reference ‘Once the reference point has been addressed, the TCP is calculated by the controllerTE TOT TUR COMR vee RRS FA 3.3.2, Methods of the measurement of the orientationEich In this method, the tool must be oriented parallel to the Z axis of the world coordinate system in the working direction. This calibration method is used if only the working direction (tool direction) of the tool is required for its positioning and manipulation (e.g. MIG/MAG welding, laser or waterjet cutting).lel 10 Zyray lel 10 Y ys lel 10 Kris In this method, the tool must be oriented in alignment with the world coordinate system. The axes of the tool coordinate system must be parallel to the axes of the world coordinate system. This method is used if the orientation of all three tool axes is required for positioning and manipulation (welding gun, gripper),ne ponent method This method is used if an exact orientation of the three tool axes is required for positioning and manipulation, e.g. in the case of vacuum grippers. + First of all, the TCP (which has been calibrated beforehand) is moved to a known reference point. + The TGP is now moved toa point on the negative X axis of the tool to be calibrated, The working direction of the tool is defined in this way.ian eee inne ae + The tool is now moved so that the reference point is located with a positive Y value on the future XY plane of the tool3.4. Activate ajtooles eee 3.5. Tool payloadWith thi | If the rok operate a v Each|robot is designed for : in its pntire work envelope with standard accelerations and velocities, causes premature failures and reduces the service life of the robot. Overionding the robot may even mean that the robot can no longer be fobot rated payload on the robot wrist, ith a specified load center distance, specified principal moment of inertia of the load and supplementary load on the robot (arm) is rated payload, the robot executes motions The permissible robot payload must not be exceeded! ot is overloaded, the wear on the robot is increased. This safely. If the static holding torque is exceeded, the robot can no longer be operated safely as the axes may sag! Use of incorrect load data nullfies all warranty obligations on the part of KUKA Roboter GmbH.‘Supplementary load, am Total load = payloall + supplementary load = max. 48 kg Payload Supplementary load, link arm”? + max. 20k9sprimentary toad “1 Calculation with KUKA Load; ‘rom KUKA homepage > download > software > KUKA.LOAD available err erm load center distance in direction of X axis Toad center distance in direction of ¥ axis load center distance in direction of Z axis, Toad canter distance in ‘wrist flange plane | =\LFeLF byPermissible mass inertia a o design point 0.36 kgm* (bg=120 mm.=150 mm) © _|Icaution: The mass inertia must be verified using KUKA Load. lIt is imperative for the load data to be entered in the controller! The value -1 is used as the default setting; this corresponds to the load specified in the machine datumIn order toloptimize use of the available maximum moments of acceleration of the robot gxes, it is necessary to enter the load data of the tool that is being used. SE | Caution: The load data must be entered for every geometrically calibrated tool. In additidn to the load on the robot wrist, the robot can also move a load mounted on the arm, link arm or rotating column, using the standard) dynamic values. This can|be a welding transformer or a terminal box with valve manifold for example. A value fpr the permissible supplementary load is specified by KUKA for each fobot. The supplementary load must not be exceeded, as there is otherwike a risk of the axes sagging, as in the case of exceeding the perinissible load on the wrist. Exceeding the permissible supplerpentary load generally increases wear and reduces the servicellife of the robot.Siena je distances L,. L,, L, ofthe supplementary d refer to the origin ofthe Robroot dinate system icin The value -1 1s used as this corresponds to los the default setting ‘supplementary ecified in the machine datumSten Ifthe value 0 is used, this indicates that there is no supplementary loed mounted on the specified axis. This also applies to the payload data.cs RR RR eS ESR Base calibrationE The work|surface (pallet, clamping table, workpiece...) receives a user- defined Cartesian coordinate system with its origin at a reference point specified by the user. Eien Jogging slong fi] the edges of the work surface oF workpiece. Jogging uging the jog ke a cinnoth somos, Motion directionfine Enea Progrm mode Ifthg BASE coordingte system is offset,|the taught points mpve with it. Base Tool : Pe *¥wortoPrdgram mode ua Itis| possible to create|several BASE coordihate systems. Base 1 Tool BASE cdordinate origin Abt point Tor, \ step, the TCP of the tool is moved to the origin of ASE coordinate system. 2 *% wort re *YworoPositfe X axis ‘2nd point +x referehce tool is moved to a point on the pobitive X axis of the new BASE coordihate system. In hen step, the TCP of the Positivg Y value on XY plane 3rd point TOP. \ step, the TCP of the reference \oved to a point with a positive ‘on the XY plane of the new BASE doordinate system.Top. \ 4Z +Y, x libration unambiguously defines ition of the BASE coordinate ‘Name of the is display Enter the number of the base BASE_DATAIAR ICR RNR EG A TT TT 4, Programming 4.4, Motion programmingKUKA robot mition types (interpolation types) PTP (Poin}-to-point): LIN (Linear): GIRG (Circular): The tool if moved The tool is guided at a | The tool is guided at a along the fuickest path | | defined velocity along a | | defined velocity along a to.an end point. straight line. | | circular path, Loa A eR ATES IO RTS CTI SAN eT 4.2. PTP-—motionIndi idual axis velocity v e.g. axis 2: leading avis, 9. axis 3: adapted 9, avis 6: adapted aN "Acceleration ' Constant ' Deceleration Time t is is the name given to the axis that takes longest to reach the ‘the velocity specified in the inline form is disregarded“The higher motion profile is used by defauit, Le. the permissible torques are optimally exploited at every point on the path the velocity is aways adapted to prevent the torques from being exceeded. Reduction in velocity because torque fo0 high Motion parameters Approximate positioning ONei aed Tool Tool selection Tool_Dataf1]..116], Nullframe Base Workpiece coordinate system selection Base_Data[1}.{32}, Nuliframe External TCP Robot guiding tool: False Robot guiding workpiece: True Po ee Acceleration Acceleration used for the motion. Range of values: 1.100% Approximation distance’ Size of approximate positioning range for the motion. Range of values: 0..100% The parameter “Approximation distance” is displayed if approximate positioning has been selected (CONT)defiled robot position where several different axis positions are possible for the same point in space. mice *S" and “T’ serve to select a specific, unambiguously The specification of Status and Tum is only evaluated for PTP motions. For this reason, the first motion in 2 program must be a PTP motion. Sea Status 41 Status = 2 Turn = 46 Tum = 43 Status 46 Status = 4 Turn = 99 Turn = 63 ee Te SS a a ER43. BCO-tunPeon For the purpose of ensuring that the robot position corresponds to the This is c4rried out at reduced velocity. The robot is moved to the coordinafes of the motion block in which the block pointer is situated. This is done: + after point + afer splection of the "CELL program before the Automatic External mode can b@ started + after ve program has been selected + after modifying a command + after j¢gging in programming mode ia A HOME run is recommended for both the first and Jock selection to the coordinates of the point at which the block : aloe reset by means of a BCO run to the home position is situated final motions as this represents an unambiguously defined uncritical positionhis is done by holding down the Start key after selecting the rogram, robot moves automatically at reduced velocity Ince the robot has reached the programmed path, the rogram can be continued by pressing the Start key again dpm [4.800 tun always takes place by the direct route from the current position to the destination position. It therefore important to make sure that there are no obstacles on this path in order to avoid damage to components, tools or the robot! No BCO run is carried out in Automatic External mode!4.4. LIN - motionean Ps P| Tep P2 The TCP is moved along a straight line to the end point The motion profile refers to Fab each the TCP of the selected tool es Haeaeeeeeeee eee ere reer ee eee eS eS SeProst LN === Birt [cont=|¥eref2 fisicpoart NV eeu ——f= -— Tool selection Tool_Dataf1}..[16}, Nulframe Base Workpiece coordinate system selection Base_Data[1]..(32), Nullframe External TCP Robot guiding tool: False Robot guiding workpiece: Trueerie ees eee Acceleration Acceleration used for the motion Range of values: 1.100% Approximation distance’ Size of approximate positioning range for the motion Range of values: 0.300 mm °) The parameter “Approximation distance displayed if approximate positioning has been selected (CONT), Orientation control - Standard End position During the path motion, the orientation of the tool changes continuously from the start position to the end position. This is achieved by rotating and pivoting the tool direction.During the path motion, the orientation of the tool changes continuously from the start position to the end position. This is done by linear transformation (axis- specific motion) of the wrist axis angles. The problem of the wrist singularity can be avoided using this option as there is no orientation control by rotating and pivoting the tool direction. Orientation control - Constant The orientation remains constant during the CP motion. The programmed orientation is disregarded for the end point and that of the start point is useda PTAA OLR MSR RLA ESET 4.5, CIRC - motionStart point} Auxiliary point ‘The TCP is moved along an arc to the end point Eicno Here, the TCP or workpiece reference point moves to the end point along ar arc. The path is defined using start, auxiliary and end points, The endpoint of a motion instruction serves as the start point for the subsequent motion Auxiliary point End point ; Start point ‘The orientation of the TCP is not taken into consideration at the auxiliary point and is not relevant for the teaching of coordinates.The motion profile refers to pat elec the TCP of the selected tool es Time t | ‘Acceleration Constant Deceleration Eon Velocity / lype of motion Exact positioning Approximate positioning ON End point nameGennes Gann The parameter “Approximation distance’ is only displayed if approximate positioning has been selected (CONT), Tool selection Tool_Datal'}.[16), Nullirame Base Workpiece coordinate system selection Base_Data[1]. {92}, Nullrame External TCP Robot guiding tool: False Robot guiding workpiece: True Acceleration Acceleration used for the motion, Range of values: 1...100% Approximation distance’ Size of approximate positioning range for the motion, Range of values: 0.00 mmOrientation control - Standard During the path motion, the orientation of the tool changes continuously ‘rom the start position to the end position. This is achieved by rotating and pivoting the tool direction Geen eenena During the path motion, the orientation of the tool ‘changes continuously from the start position to the end position. This is done by linear transformation (axis- ‘specific motion) of the wrist axis angles. The problem ofthe wrist singularity can be avoided using this option as there is no orientation control by rotating and pivoting the too} direction,Emi een onnis ‘The orientation remains constant during the CP motion. The programmed orientation is disregarded for the end point and that of the start point is used. ‘The full circle should be made up of at least two segments.ERRATA SST RRO 4.6. Approximation of a motionJuring approximate positioning, the robot does not move exactly each programmed position, nor is it braked completely. Advantage: reduced wear + improved cycle times Cement netpossible PTP approx. positioning paths shortest distance P41 ‘The value of "Approximation distance” specifies the size of the approximate positioning range. ‘The path cannot be set, nor is it predictable.P41 Two parabolic curves (symmetrical at constant velocity) LIN motion with ees ‘Approximabon distance in mm ‘The value entered for ‘Approximation distance” specifies the distance from the end point and the point at which the approximation motion commences. The resulting path is not an arc. ‘The same applies to the following CIRC command,Cone eneecen! s Jn run pointer (white bar), which can be seen on the graphical user interface program is running, always indicates the block that is currently being processed. The advance run pointer, on the other hand, is not visible and precedes the maih run pointer by up to three motion blocks (dafault setting), What if the function of the advance run pointer? In order|to be able to calculate the path, eg. of an approximation motion, itis ecess@ry to read the path planning data using the advance run pointer. itis not only motion fata that are processed, however, but also arithmetical data and commands. | for contfoling the periphery How ig the advance run pointer influenced? Instructipns and data that influence the periphery (e.g. inputoutput instructions) ‘rigger dn advance run stop. Ifthe advance run pointers stopped, approximate positionlng cannot be carried out.fe 1 ‘The advance run is stopped here Notification message generated in the event of an advence run stop Eo eco Cee eee aE erea 5. Navigator - Program creationNavigator (user) PR Directory structure Directory or file ist Symiol_ [type Default path imi HRC llaaas ae Directories and files symbpt | Type Meaning a] [omen Nomal recor Ea] | ovecory oven Open rectory GO| [Active 2 Ae (ee The contents ofa crectory ar bing rad @) [wow Prog a ereone Select drive, directory or file Toggle between directory structure / fie list if open dive, u directory or file ‘Comment Program nameGO mode {Al instructions inthe program are executed upto the end ofthe program without a STOP, Motion Step (motion block) USER “The program is executed one mation instruction at atime, Le. wth 2 STOP betore each motoninstcton “The program is executed wihout advance processing ISTEP | Incremental Step (single block) “The program is executed step by step, ie. with @ STOP after each instruction {including blank fines) “The program is executed without advance processing. EXPERT This flinction allows you to save important data to floppy disk. All files are saved in compressed form as ZIP files. CBP | Ifyou try to insert a fle in an existing archive, the robot name is checked. The robot name in the archive is compared with the name that is set in the controller. Ifthe two names are different, a request for confirmation is generated asking if you really wish to overwrite the existing archive.A — SSSA CST TNE «aD aioe acsndl Ps The menu item Ar-e > “All is used to save to floppy disk all the data that are \=: red to restore the robot system. ‘These include ~1 chine data -to-Vbase data 4 plications All files, with t! — ception of log files, are loaded back ‘onto the hard « eS Once the sy-i as been restored, it must be shut down and rebooted. TOTThis fiction allows you to save important data to floppy disk. All files are ed in compressed form as ZIP fs. If you try to insert a file in an existing archive, the robot name is checked. The robot name in the archiva is ‘compared with the name that is set in the controller. Ifthe two names are different, a request for confirmation is generated asking if you really wish to overwrite the existing archive. eeeeee The plected files are loaded back onto the hard disk | fw fhe —— cay No program is selected pot My wae IR) ——— Yelow: The lock pointers stuated on one ine of the selected program. > Green: Aprogram has been selected and is curently being executed. —— et: ‘The selected and stated program hes been stopped > Black The program has been executed and terminated6. Logic programming 6.1. Programming of digital in-/outputsThe polling of the inputs and setting of the outputs are used for munication between the robot controller and the periphery (e.g. tools, sensors, etc.) Robot controller Periphery Eien jling/decoupiing terbus segmentIF-WAIT" has been selected, the wait time can be specified. This comnjand always triggers an advance run stop, even with @ wait time gf 0 seconds. sec VEL=100% PDAT3 iain interrupted for 1 PA second at point P2 «“» T insertion of an external logic operation 1 (e.g, WAIT FOR (IN1) AND (IN2)) “NOT” __| Negation of the Boolean expression «» —Tinsertion of an internal iogic operation (e.g. WAIT FOR (IN1) AND (IN2)) “NOT | Negation of the Boolean expressioniin ‘The walt condition can be programmed, for exemple, in the following general form: WAIT FOR (IN1 OR IN2 OR IN3) AND (NOT OUT! OR OUT2) OR NOT (IN4) et External logic Mixed forms are possibi operation: the a maximum of 12 operands operator is, can be linked in a form. situated between the bracketed expressions. SRN If WAIT FOR” has been selected, the following parameters can be specified] Inputs/outouts, various flags, timers or user- defined names are possibleSmear! e Tne long text name can be programmed in 5 {Existing | Expert mode with the system lst activated long text name. =» | Execution with advanee run stop “CONT” | Execution in the advance run Si mn If WAIT|FOR” is selected with advance run stop activated, exact Positioning is always carried out, even if the event condition is met. ‘Advance run stop on Exampig: PTP P1VEL=100% PDATI PTP P2CONT VEL=100% PDAT2 WAIT FOR IN 4 i PTP P3\/EL=100% PDAT3 p2 Motion is interrupted at point P2 until input 1isset{SA CT RR RE ec AS NR Rae A Re IT FOR) if WAIT FDR’ is selected with “CONT”, the event is checked in the advance nin. If the event condition is met, then approximate positioning is carried out. Execution in the advance run In sit ‘Wconrs] Example: PTP Pt VEL=100% PDATT PTP P2 CDNT VEL=100% PDAT2 WAIT FOR IN 1 CONT re y PTP P3 VEL=100% PDAT3 P2 sequent signal a ges are not tected. Possible checking of input 4. advance run The following switching functions can be selected:aN CEREAL = SRT [ea ica all If "OUT" has been selected, the following parameters can be specified) 1 | 14096 ‘Output number RE The long text name can be progremmed in Expert 2 | Existing long | mode with the system list activated text name 3 | TRUE State to which the output is switched FALSE acid, Execution with advance run stop 4 “CONT” Execution in the advance run inure | Examples LIN P1 VEL=0.2 m/s PDAT1 LIN P2 GONT VEL=0.2 m/s PDAT2 LIN P3 GONT VEL=0.2 m/s PDAT3 OUT 1 ‘| State= TRUE LIN P4 VEL=0.2 m/s PDAT4 Output 1 is set at point 3 i ClSneed Point 3 is approxi LIN P1VEL=0.2 m/s PDATY 2 mls PDAT2 2 mls PDAT3 " State= TRUE CONT 2 m/s PDAT4 court Possible position at which output 1 is set by the advance im 1 || 1-4096 Output number Seay ‘The long text name can be programmed in Expert 2 |] Existing tong | mode with the system list activated text name 3 || TRE State fo which the output is switched FALSE eae Execution with advance run stop 4 “cont” Execution in the advance run, 5 |[ot..s Lenath of the pulse in seconds SISTER AAR aa a ai Afiona finan “HIGH” Jevel switching: STATE=TRUE. aT ae ours Time 1 5 ima LOW level switching: STATESFALSE ee Path-dependent switching (with PTP, LIN, CIRC) can be triggered relative to a start of end point. Such applications include, e.g. * Closing or opening the weld gun during spot welding ing the welding current on/off during arc welding ‘or stopping the flow of adhesive in bonding or sealing applications.enn I*SYNJOUT” has been selected, the following parameters can be specif Rng i: here end point with START or END ® [TRUE =] at[STARI>] Delay=[0 ms 1| | 4-096 Output number nee The long text name can be programmed in Expert 2| | Existing long | mode withthe system list activated toxt name 3 | | TRUE ‘State to which the output is switched FALSE “START” End point at which the switching function is 4 ‘executed “END” 8 | [1000 ... +1000 | Delay of the switching action Gn ms) Start poift and end point are exact positioning points: Pei eed State=|TRUE >] al[START=] Delay=[0 ms "| + P3 4 P 03 mis cPOATI : Live vaco03 ms SPOATS SYN OUT" Ststem TRUE a START Dety=20 ms Sy OUTP State TRUE at aN Dole 9) ne tits kms cross os ™ ca3ms Ceoars ‘Sutching init Ifthe spectied values are outside the ewitchngInits the controler aulomatialy swichos atthe switching limit(nnn en Start pint is exact positioning point, end point is approximated OUTTT [| State-[THOF =] a]STANT =] Delay-[0 ma Exameld: UN P1 VEL=0.3 m/s CPDATY P LIN P2 VEL=0.3 m/s CPDAT2 SYN OUV 1 ** State= TRUE at START Delay=20 ms ‘SYN OUP 2 * State= TRUE at END Delay=-20 ms LIN P3 CONT VEL=0.3 m/s CPDAT3 LIN P4 VEL=0.3 m/s CPDAT4 Genter of approximation range See Start polnt and end point are approximated: yn oui [— stete=[TRUE =] atfSTART =] Delay-[0 ms L ‘ye Example} LIN P1 VBL=0.3 m/s CPDAT1 Bay LIN P2 CONT VEL=0.3 m/s CPDAT2 j ‘SYN OUT|1 “ State= TRUE at START Delay=20 ms ‘SYN OUT)2 '' Stale= TRUE at END Delay=-20 ms LIN P3 CONT VEL=0.3 m/s CPDAT3 LIN P4 VEL=0.3 m/s CPDAT4 Py Center of approximation rangeGinn fees + Ifygu are using the path-related SYNOUT-PATH statement, you nape ‘the switching action at any position along the path by ifying a distance, =) 2a el sii actors tte ein ad en ee agar can | tionally be delayed or brought forward. + Thelpath-related switching action is only allowed with continuous- pat] motions (LIN or CIRC) + The|SYNOUT-PATH statement refers here to the next programmed motion block. Ifa SYNOUT-PATH statement with path specification is programmed for a PTP motion, this will be refused by the interpreter when the motion is executed, RIG enn ee If"SYN QUT” has been selected, the following parameters can be specified: here end point with PATH og" 6 9 @ @ BYNOGTT | Stoe=[TRUE =I[PAIN =1=0 mm Delay-[0 me 4098 Output number “The long text name ean be programmed in Expert 2 || Existing long | mode with the system list activated text name pata S| 3 | TRUE ‘State to which the outputs switched FALSE 4 | “PATH [End point at which the switching function is executed +2000 ... +2000 | Distance of the switching action from the end point 6 | 1000... +1000 | Delay of the switching action (in ms)AEE POSES RAOUL TEN AL TIO Preeennn the path Start poiht is exact positioning point, end point is approximated Sew oUTT | — Swe-|rAUE =IlpaTH I-[e0 wi Delay-PS me Ea LIN P1 VEL=0.3 m/s CPDATI SYN OUT|t ‘“ State= TRUE PATH=20 mm Delay=-5 ms; LIN P2 CONT VEL=0.3 m/s CPDAT2 LIN P3 CONT VEL=0.3 m/s CPDAT3 LIN P4 VEL=0.3 m/s CPDATA ‘Switching actinn at any point on the path ‘Start point and end point are approximated: Example: LIN P1 CONT VEL=0.3 m/s CPDAT1 SYN OUT *' State= TRUE PATH=20 mm Delay=-5 ms LIN P2 CNT VEL=0.3 m/s CPDAT2 LIN P3 CONT VEL=0.3 m/s CPDAT3 LIN P4 VEL=0.3 m/s CPDATA \20 mman If"SYN|PULSE” has been selected, the following parameters can be specifi: Coupling/dece iping inierbus segments If*IBUS}Seq. on/off’ has been selected, the following parameters can be spectfied: Bus eine 3 (heateneton)ee RRR C . Gripper ProgrammingGE eae) [| Up to 16 grippers can be configured via the “Configure” menu eed Gripper Name of the ripper; 24 characters Gripper type Function type of the gripper Overview of types 1.5 Outputs Assignment of robot controller outputs to the gripper actuators Inputs Assignment of robot controller inputs from the gripper sensors State Designation of the gripper states, dependent on the gripper type; 11 charactersGin oi 4 Further freely definable ypes of gripper function ion (ed Type 5) Gripper type (1.5) (UE EES EWTenet toe soe. | Activate the gripper status key ‘The labeling of the gripper keys is defined in the gripper configuration. ‘Amaximum of 5 characters are displayed on the gripper keys. Ifthe ‘ripper name exceeds 5 characters, the system automatically switches to the ripper number instead. Ee ce fas] ip (obeins oem cecal eee hnology” menu: Gripper function Gripper interrogationOnce “GRIPPER’ has been selected, the following parameters cen be specified: Ctl \ Approxi positioning off [[ Select function Gripper name | ‘OFF: Once the wait time has elapsed, the program Is resumed. ‘The program is not resumed until the ‘gripper sensors are set Gripper with ipproximate positioning RIPPER’ has been selected, the following parameters can‘Oned “CHECK GRIPPER” has been selected, the following ters can be specified Reference point function Gripper nam ‘This command is only executed if its located before a motion struction.7. Fixed tool“Fixed tool” means that the robot guides a workpiece to one or more stationary tools that are integrated into the cell. Calibration consists of two parts: + Calculation of the distance between the TCP of the fixed tool and the origin of the world coordinate system, + The workpiece is mounted nn the robot flange and calibrated +x ‘ Y z 42. The coordinates are saved as BASE_DATAI1]....[32]. et er ee eee see eee rather than handled by the robot.Ciro + First of all, a tool of known dimensions is moved to the TCP (tool center point) of the fixed tool, Wrist{flange Ib + Inthe second az step, the robot wy flange is bx aligned perpendicular to the working direction of the tool (tool direction) the 5D or 6DCee (2. Calibrate the workpiece ‘The coordinates are saved as TOOL_DATAI1)....[16]. his method is used to determine the reference point of a workpiece junted on the robot lange. + The ofgin of the workpiece coordinate system must be shifted}to the TCP of the fixed tool.Carne peed + In|the second step, a point on the positive X axis of the wdrkpiece coordinate system is addressed. Sinn es + In the final step, a point with a positive Y value in the XY plahe of the workpiece coordinate system is addressed, |8. Introduction to the expert level 8.1. Navigatot - Expert levelGia When the softkey “Expert” is pressed, the user is prompted to enter a password. The preset password is "kuka’, ‘System files and directories are displayed.Symbol [Tape Defaut path | BB | | Hardarve 2.9. Kukadlsk (C:\) or Kukadata (O') le Flopey AN co-Rom = Ay | [Marpedneworaive [eg FAGA ote Ree ee Directoties and files ‘Symbol | Type Meaning ‘seh Program fle a Sub-Program Program with errors that cannot be interproied by the compler Data ist SRC-fte containg enor Sale DATSie ‘Data fst with eror that cannot be DAT fie contain erors | imarpretc by the compiler ASCII ate Binary fies | 5) e|e othe esAKRL program can be made up of SRC and DAT fies. ‘SRC - contains program code DAT - contains specific program data call ‘Skeleton program for control via a PLC Efpert ‘SRC and DAT fle without a skeleton program Expert Submit _| SUB fle without a skeleton program em nese wie ERG and DAT le wth selon program sfomit UB le with tletonproaran J scree ira [reat sa Program containing omors f= Ee = ley , =~ 1 OF tad | —_ eI If fhe focus is moved toa file marked as containing errors, the appearance of the softkey bar changes as follows:‘Short description Error number Ling and column Cursor is positioned on the tin containing errors jumbers in the error list correspond to those in th ions “All FOLDs op” and “Detail view” must be activated.8.2. Introduction to sub programsGeka emt | ‘Subprograms are used for identical program sections that are repeated frequently. + §ubprograms reduce the amount of typing during programming. + $ubprograms reduce the program length thus making the program jore transparent. + $ubprograms can be reused in other programs. + $ubprograms can be used for structuring a program. Program name, program header oO ‘Subprogram call [__ Global subprogram8.3. Introduction to loops and brancheslic executions can be programmed using LOOP. The statement block in LOOP is continually repeated. If you want to end the repeated cution of the statement block, you must call the EXIT statement.Description spending on a condition, either the first statement block (THEN black) the second statement block (ELSE block) is executed, ‘There is no limit on the number of statements contained in the statement blocks. ‘Several IF statements can be nested in each other. The keyword ELSE and the second statement block may be omitted ‘There must be an ENDIF for each IF. IF Execution Condition THEN Statement ELSE Statement ENDIFDescription ‘The EXIT statement appears in the statement block of a loop. It may be used in any loop. ‘The EXIT statement can be used to exit the current loop, The program is thenlcontinued after the ENDLOOP statement Syntax:| | EXITDescription ‘The SWITCH statement is a selection instruction for various program irjuches, Only ane program Bench In mci are the rogram en jurhps immediately to the ENDSWITCH statement ‘SWITCH Variable CASE 4 ‘Statement CASE 2 ‘Statement DEFAULT ENDSWITCH ‘SistomantRNR TY RETURN RN MaRE EE ITT 9. Automati¢ external modeControls the entire a system ard saves | ,E= Host computer data Nae [organization program for selecting the motion programs ‘Automatic External: ‘Operating mode in which a host computer or PLC ‘assumes control ofthe robot system, Signal exchange \\ Information about operating and ‘The entire robot process, € 9, fait states are transmitted to the motion enable, fault Pl acknowledgement, program start, is controlled by the PLCoes ‘The signals of the Automatic External interface must be assigned physical inputs and oufputs of the robot controller. eee Variable name Sex START | 105 SHOVE ENABLE | 1088 SON MESS | 025 18 Input number or variable value Var) Variable HE input‘Automatic Ex eral outputs -Stan condition [Function name 1018 iSERL SAF OTT | SPER OY tore Be Output number The sign! SNEAR_POSRET can be used to determine whether or not the robot is situated fithin a sphere about the position saved in $POS_RET"). The radius of the sphere chin be set in the le SCUSTOM.DAT using the system variable §NEARPATHTOL. SNEAR |POSRET=FALSE SNEAR_POSRET=TRUE Deviation from path caused, ‘or example, by SnearpaTuron ‘vnamlc braking *) $POS|RET: Position at which the robot left the path (|scHecK AUTOR) ‘LOOP si Eines }+ cursor key and insert copied branch din the same way for Ibsequent program program number and corresponding program name BASISTECH INI TP HOME Vele 100 % DEFAULT + P00 (#exT_PGNO,#PGNO_GET,OMY) ENDLOOP, HOME XTINI SWITCH PGNO- TASET 00 (HEXT_PGNO,SPGNO_ACKN,OMYI}0) ‘CASE? P00 (#EXT_PGNO.#PGNO_ACKN,DMYI}0) DEFAULT P00 (#EXT_PGNO#PGNO_FAULT,OMYT10 ENDSWITCH Loop 0 (He) =XT_PGNO#PGNO_GET,OMYI0) SWITCH PGNO ASE 00 BEXT_PGNO#PGNO_ACKN,DMY1}.0) ROG P00 (#EXT_PGNO,#PGNO_ACKN,OMYIL0) PROG2() CASES P00 (#EXT_PGNO,#PGNO_ACKN.OMYIL0 ) PROGS, ASE 4 (WEXT_PGNO.PGNO_ACKN.DMYI}.0) os4, ‘DEFAULT P00 (#EXT_PGNO.APGNO_FAULT,OMYILO ) ENDSWITCH ENDLOOP,(pssamenseamescn 10. Exerdises Exercise: Exercise: Exercise: Exercise: Exercise: Exercise: Exercise: Exercise’ Exercise’ Exercise: Exercise’ Exercise’ Exercise’ Operptor control, jogging Robot mastering ‘Tool dalibration (pen — gripper) BASE calibration (table) “In-air! program (PTP motion) CP mation, approximate positioning (water jet cutting) Adhes|ve application (I/Os) Gripper programming: pen magazine Gripper programming (plastic panel) Extern@l TCP (tool calibration) Adhesive application on windshield (plastic panel) ‘Subproprams (plastic panel, component contour), endless loop Automatic External 170 172 174 17 179 181 184 186 188 190 192 194 197Exercise: Operator control, jogging Aim of the exercise: (On successful complet Prerequisites: ‘Switch the cor Basic operatot Jog the robot Initial interpret Jon of this exercise, you will be able to carry out the following activities: roller onloft Control of the robot using the KCP Joint, World coordinate system) by means of the jog keys and Space Mouse tion of messages and troubleshooting * Have received and understood KUKA College safety instructions Necessary equipment: Theoretical kn Axis-specific Axis-specificj Training robot wedge of the general operator control of a KUKA industrial robot ging and motion in the World coordinate system. 6 a& ing World coordinate system “A. ll‘© Switch the cdntrol cabinet on and wait for the system to boot © Check the ro ot type and software version '* Release andjacknowledge the EMERGENCY STOP. © Make sure th tthe mode selector switch is set to Tt © Activate axis specific jogging © Move the rot the jog keys. © Explore the asa table or in joint axis-specific) mode with various different jog override settings (HOV) using Ind Space Mouse Inge of motion ofthe individual axes. Be careful to avoid any obstacles present, such sube magazine with fixed tool (accessibilty investigation) '* On reaching {he software limit switches, observe the message window '* In joint (axis-pecific) mode, move the gripper to the reference tool (black metal tip) from several different diredtions, Repeat this procedure in the World coordinate system What you should now know: 1, How does the rot 2. Which keys are r¢ t brake when the enabling switch is released in test mode? ited for acknowledging messages? 3. Which icon repregents the world coordinate system? a) 4, Whats the nama} a lof the velocity setting for jog mode? 5. What operating modes are there?Exercise: Robot mastering (On successful com; Prerequisites: Necessary equipm Tasks: Aim of the cg Move to pr etion of this exercise, you will be able to carry out the following activities: mastering position Select cot mastering mens Correct ope} Master all a ‘Theoretical Proper con Mastering v Connection] EMT Unmaster al Move al rt Master alia Display the fation of the electronic mastering tool (EMT) (es by means of EMT wedge of the general procedure for mastering lection of the EMT to the robot fp the Setup menu x32, Pre-mastering position I cobot axes ‘axes to the pre-mastering position in joint mode Jes using the EMT ‘ctual postion in “Joint” modeSe EE ENO Ar aT TS What you should) Inow know: 4. Why is mgstering carried out? 2. How is the) 3. What must 4. What mast 5. What is th mechanical zero position defined? be taken into consideration with an unmastered robot? ring equipment exists and what is it used for? danger of moving the robot with the EMTT (dial gauge) screwed in place?Exercise: Tool calibration (pen — gripper) Aim of the exercise! (On successful completion ofthis exercise, you will be able to carry out the following activities: © Calibrate the|desired too! © Activate the a to be calibrated '* Move the selected tool in the tool direction and reorientation about the tool center point Prorequisites: ‘© Theoretical Knowledge of the various calibration methods to determine a Tool Center Point (TCP) Theoretical knowledge of the various calibration methods to determine the orientation of the TCP. TCP calibrator Orientation calibration Necessary equipmeht: ‘+ Reference top (back metal tp), pen, gripperTask Calibrating pent Calibrate tHe TCP of the pen using the "XYZ ~ 4-Point’ method. Use the black metal ti as the reference the tool nu int. Remove the uppermost pen from the pen magazine and clamp it inthe gripper. Use ber 2 and assign the name “pent”. The tolerance should not exceed 0.96 mm. Save your gata before exiting the menu Calibrate te tool orientation using the "A B C - World (5D)" method Payload gn kgrn?: JY=t per + pen: M=7,32 kg; X=20mm; Y=21mm; Z=23mm; A=48°; B=-76"; C=108"; JX=0 12 kgm?; JZ=0,3 kgm? ‘Save the Tao! data and test the traversing with the pen in the Tool coordinate system Calibrating the gripper Calibrate th ‘gripper’. The calibration data are: X=132.08, Y=171.3, 2=173,0, A=45 Payload gr J 4 kant TCP of the gripper using “numeric input’. Assign tool number 3 and the name 80° 7-128"; JX=0 kgm '=41mm; A=25°; per : M=6,68kg; » Z=0,48 kgm 23mm; Y=t1mm; ‘Save the Tdol data and test the traversing with the gripper in the Tool coordinate system Gripper TCP‘What you should how know: 1. Why shoulf a robot-guided tool be calibrated? 2. Whats calpulated using the XYZ method? 3, Which icon|represents the tool coordinate system? el b) & 4, What tool chlibration methods are there? 5. What is the|maximum number of tools that the controller can manage? 6. What doas {he value -1 in the payload data mean?ees aed Exercise: BASE calibration (table) peton of tis exercise, you wll be abe to carry out the folowing activites * Determing and calibrate any desired base + Activate tT base tobe calibrated ro Jog the root (base coordinate system): move along the coordinate axes using the selacted base Prerequisites: ‘* Theoretical knowledge of the various base calibration methods Necessary equipm © PenUse the penfi which has already been calibrated (TOOL 2) as the calibration tool © Calibrate thq BASE system marked in blue on the worktable using the 3-Point method and assign Base numbgr 1 with the name “blue”. Save the data of the calibrated Base Calibrate th BASE system marked in red on the worktable using the 3-Point method and assign 2 with the name ‘red”, Save the calibrated Base, ccenter point tothe origin ofthe biue coordinate system, thus causing the actual position to bp displayed in "Cartesian" mode Base number: 1 Base name: blue bese numberi2 Base name: red What you should npw know: 1. Why should h base be calibrated? 2. When is the }ndirect method used? Which icon rppresents the base coordinate system? a & 4. What base cplibration methods are there? ‘What isthe thaximum number of base systems that the controller can manage?Exercise: |‘In-air” program (PTP motion) Aim of the exerci (On successful completion ofthis exercise, you will be able to carry out the following activities: Prerequisites: Create a ndw robot program (program folder / program) Select a root program and execute, stop and reset iin the required operating modes Move betwen points in space by means of programmed PTP motion commands Change thd program run mode and step-by-step movement fo programmed points Camry out alBCO run (block selection) Theoreticallknowledge of the PTP motion type Knowledge pf the Navigator Fastest path Necessary equipmpnt: oT Training robpt cellTas Select the a) Program ole program test rogram withthe name “Air Test your prbgram in the mode T1 with diferent Program overrides (POV). Observe the relevant safety instafations. Test your prbgram in the mode T2 with diferent Program overrides (POV). Observe the relevant safety intretions. Test your prpgram in the mode Automatic. Observe the relevant safety instructions, b) a aeeal a ‘© Correct sonfe positions by using the softkey TouchUp Set various ete fr your space pons Cal te arf point several imesh th program Delete tin Bcks and inser new nes a a fret gintin the program Carry out a block selection Minus Key) Testyourpiforam nthe medes 71, T2 and Automat: Observe te clevant safety insuctons What you should nbw know: 1 ‘What is the pifference between selecting a program and opening it? What program run modes are there and what are they used for? ‘What is @ BGO run? How can yo} influence the program velocity? What are the characteristics of 2 PTP motion?Sree eS Design a robdt program using all ofthe available motion commands (PTP, LIN, CIRC) Approximate gxact positioning points Modify the HME position (global position) Duplicate or qopy a robot program ‘Save robot prpgrams to floppy disk 19 ofthe robot Direction of motion Component contour 4 nna Blue base reference system Necessary equipme Training robotcell Floppy diskTasks: Program creation Create @ new data program with the name ‘Component _contourt” Copying the program, Additional task ‘Teach the com} “The traversing] ynent contour 1 marked on the worktable, using the blue base and pent as the tool jelocity on the worktable is 0.3 m/s. Make sure that the longitudinal axis of the pen is always perpendicular to the path contour (orientation coptral) Test your progfam in the modes T1, T2 and Automatic. Observe the relevant safely instructions. Create a dupli Insert the apy the robot fol approximate positioning te of the program "Component_contourt" with the name *Component!_CONT" xximate positioning instruction into the motion commands of the new program so that the contour continuously ‘The comers of|the contour are to be approximated using different approximation parameters: ‘Test your progfam in the modes T', T2 and Automatic. Observe the relevant safety instructions, Create a seco: same tool, data program with the name “Component _contour2". Use the same base and the ‘The traversing|velocity on the worktable is 0.3 mis Note the orienfation control of the pen relative to the worktable Test your prog Create a dupli Insert the app in the modes T1, T2 and Automatic, Observe the relevant safely instructions. te of the program “Component_contour2" with the name “Component2_CONT* imate positioning instruction into the motion commands of the new program so that, the robot follows the contour continuously Test your new Instructions. gram in the modes T1, 12 and Automatic. Observe the relevant safetyWhat you should né 1. What are the} know: haracteristcs of a LIN or CIRC motion? 2. How is the vefocity specified for PTP, LIN and CIRC motions and what does this velocity refer to? 3. How is the agproximation distance specified for PTP, LIN and CIRC commands? 4, What must bq 5. Why isthe IN 6. What must bq 7. What must bg taken into consideration when programming new CONT commands? line important? taken into consideration when changing the HOME position? taken into consideration when correcting or modifying programmed points?Exercise: Adhesive application (I/Os) ‘Aim of the exercise: (On successful complétion ofthis exercise, you will be able to carry out the following activities: ‘+ Execute switching actions (simple and path-related) = Integrate waitlfunctions into the program sequence ‘Knowledge of simple switching and pulse functions. . jpath-degendent switching and pulse functions ‘+ Knowledge of wait functions (signal-dependent, time-dependent) Necessary equipment: © Training robot cellTasks: © Create 2 dul © Add the fol The} Tre (out Asi part the The| eee licate of the program *Component1_CONT* with the name “Adhesive_contour’ ing logic functions to the program: IPLC is to issue an enabling signal (input 11) before the robot leaves the HOME position ladhesive nozzle must be activated 0.5 seconds before it reaches the component ut 13) nal lamp is to be activated at the transition from the flat part ofthe table to the curved. lof the component and deactivated again at the transition from the curved part back to lat part of the table (output 12) ladhesive nozzle must be deactivated again 0.75 seconds before itleaves the ‘component (output 13) Acti cor © Testyour pr Additional task © Enter the pl ‘= Modify your’ What you should ni 1. Whatis the cconsiderati 2. Whatis the 3. When are S 4. What are th 5. What is the ished’ signal is to be sent to the PLC 50mm before the end af work on the jonent. This signal (output 11) for the PLC is to be active for 2 seconds. gram in accordance with the instructions. intext names of the inputs and outputs being used in the 1/0 table (I11, 011, 012, 013) rogram so that the long texts are saved in your inline form, know: jifference between the commands OUT and OUT CONT? What must be taken into when using these commands? ference between the commands PULSE and OUT? 'N OUT statements used? restrictions when using SYN OUT Path commands in mation programming? fanger of using the WAIT FOR command with a CONT statement?ze Exercise: Gripper programming: pen magazine Aim of the exercise: (On successful complefon of this exercise, you will be able to carry out the following activities: * Integrate into 4 program the technology-specific commands for controlling and checking a gripper ‘+ Activate and tHus work with the status keys for the installed technology package Prerequisites: '* Knowledge of fhe GripperTech technology package Necessary equipment: ® Training robot}oet! * Pen magazingTasks: Exercise: pen magazine with pent Additional tas! Create two 2w programs with the names "Fetch_pent” and "Set_down_pen'” (duplicate) During progr¢mming, make use of the advantages of jogging in the tool direction Make sure the pen mag} Before fetchi tthe jog velocity when fetching pens from the pen magazine or setting them down in ine does not exceed 0.3 mis 19 @ pen, carry out a safety query with regard to the gripper position eH magazine with pen2 and pen3 Using "Numefic input", specify the following values for pen?2 (TOOL §) and pen3 (TOOL 6): pen? is 10 mm short¢r than pen’; pen3 is 20 mm shorter than pent Create two aliditional programs each for pen? and pen3 as previously described in task a) above. What you should ndw know: 1 2. 3 4. How many sthndard KUKA gripper types are there? ‘What is the df ‘What is the of You receive t this? ference between the ‘Wait time” and “Gripper monitoring ON/OFF*? ly time the gripper command "Check Gripper’ is executed? 1@ notification message “Approximation not possible’. What are the possible causes ofot foo a RRO IT Exercise: Gripper programming (plastic panel) Aim of the exercise: (On successful completion of this exercise, you will be able to carry out the following activities: ‘Integrate into f program the technology-specific commands for controling and checking a gripper * Activate and thus work with the status keys for the installed technology package Prerequisites: '* Knowledge ofthe GripperTech technology package Pick-up and set-down position Necossary equipmer © Training robot cell Panel© Create ane program with the name ‘Fetch_panel’, using the gripper tool and the biue base © Teach the cis |_pane!” process in such a way that the pick-up positions are as shown in the ilustration at ve © Test your new program in the modes T1, 12 and Automatic. Observe the relevant safety instructions. © Createa sec nd program with the name “Set_down_pane’, using the necessary base and too! ‘Teach the prdoess "Set_down_panet" * Test your new program in the modes T1, T2 and Automatic. Observe the relevant safety Instructions. ‘© Archive your rograms What you should noWw know: 1. When should] 2. What isthe [safety instruction be carried out? lease device on a KUKA robot? 3. What is meant by the designation "KR 180 L150 "?‘SESE PT Exercis: Aim of the exerct ‘On successful com = Calibrate © Calibrate a} © Activate any Prerequisit © Knowledge} Necessary equipm © Training cell © Panel © Extemal pep Reading materials} External TCP (tool calibration) de: etion of this exercise, you will be able to carry out the following activities: ‘external fool in terms of position and orientation Imovable work piece lextemal too! for jogging of calibration options for external tools, jont: Standard docurpentation: © Chapter Training docu © Workbook, rt-up" tation: hapter "Calibration of an external tootFor the calibration of the fixed tool, the pent (TOOL 2) already calibrated is to be used asa reference Fool; assign the tool number 10 and the name "Nozzle" » Besure to ® Calibrate th panel » Payload gri JX=0,3 kgm * Once calibrat Base or Too! ve your data each lime you carry out calibration workpiece guided by the robot, assigning the workpiece number 12 and the name [54 kg; X=46mm; 8 kgm* jon is complete, activate the external tool for jogging. Make appropriate use of the ordinate system to move the robot * Move the TCP to the BASE coordinate origin ofthe tool being measured, causing the actual position tobe display in “Cartesian” mode you should nojy know: How is @ basd calibrated for 2 workpiece mounted on the robot flange? How is the TCP of an external tool determined? Why do you n What settings fed an external TCP? re required to move in the tool direction with an extemal TCP?Exercise: Adhesive application on windshield (plastic panel) ‘Aim of the exercis (On successful compton ofthis exercise, you willbe able to carry out the folowing activites: ‘+ Program a cohtour using an external TCP and a workpiece Prorequisites ‘+ Knowledge of how to activate an external tool when programming motions Froo.osrar x] Start adhesive contour Necessary equipm © Training robe © Panel ‘© External penTasks: Inner adhesive apy Teach the SS lication contour ntour on the plastic panel using the program name “Glue_panel’. Do this using your calibrated eternal tool "Nozzle" and workpiece "Pane'’ Make sure application ‘The traversi Test your py Archive you atthe longitudinal axis ofthe fixed too is always perpendicular to the adhesive tour 19 velocity on the panel is 0.25 mis am in accordance with the instructions program Additional task: Precess optimization What you should né 1 2 3 Create threg Optimize the [copies of your programs Fetch’Set_down/Giue_panel ‘complete sequence of the three programs Test your neWw programs in the modes T1, T2 and Automatic. Observe the relevant safety instructions. What does How do you ‘Which icon if 8 know: 1e “adhesive velocity" you have programmed refer to? petivate the external tool in your program? necessary for moving on the workpiece with the depicted coordinate system? a & meExercise: Sara (plastic panel, component contour), endless logp {Aim of the exercise} (On successful complption ofthis exercise, you will be able to carryout the following activites: = Program Ce calis + Program an gress loop Prerequisites: + Knowledge of the Navigator at Expert level + Knowledge of subprogram and loop programming Necessary equipment: © Training robe cell Tasks: ‘At the Exper evel, create a new module with the name "Procedure". All program sections will be called and this executed from this program, Use the follofing program flowchart as a guide Test your ney program ‘Procedure’ in the modes T1, T2 and Automatic. Observe the relevant safely Instructions. FEFetch_pen() Pathcont() ‘Set_down_pen() Fetch_panel() Al Glue_panel() Set_down_panel( ENDLOOPWhat you should fow know: 41. What do th KUKA filename extensions SRC and DAT mean?” 2. What comrand can you use to leave an endless loop? 3, What syntakis required for a SWITCH statement? 4. What are te preconditions for expanding a freely-selected program to include an endless loop?REESE HO LORE Exercise: Automatic External Aim of the exerci On successful cor + Targeted it + Adaptation Necessary equipr © Training r © PLC statig ‘Tasks: © Prepare yi oP oP oP © Ensure thi © Use a PO\ etion of this exercise, you will be able to carry out the following activities: tegration of a robot program into Automatic External operation of the “Cell” program of the Navigator at Expert level of how to edit the “Cell” program ent: ot cell lur cell program for the following applications: yam number 1: call the subprograms for fetching and setting down the first pen am number 2: call for fetching and setting down the panel yam number 3: call the program “Procedure” the programs being used function 100% error-free (crash-free) ‘of 30% and increase it gradually ® Start your frograms from the PLC computer, observing the relevant safety instructions What you should 4. What i the jow know: Call program? 2. What is th difference between a BCO run in T1 made and a BCO run in Automatic Extemal mode? 3. How does the robot system brake when a safety gate is opened in Autornatic External mode? What must 1@ operator do to the robot system if the robot leaves the path during braking in ‘Automatic xtemal mode?