KST PalletTech 37 en PDF

KUKA System Technology KUKA Roboter GmbH
KUKA.PalletTech 3.7
For KUKA System Software 5.2, 5.4, 5.5 and 5.6
Issued: 21.01.2010
Version: KST PalletTech 3.7 V2 en

KUKA.PalletTech 3.7
© Copyright 2010
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of the KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
Publication: Pub KST PalletTech 3.7 en

Book structure: KST PalletTech 3.7 V2.1
Label: KST PalletTech 3.7 V2
2 / 107 Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en

Contents
Contents
1 Introduction .................................................................................................. 7
1.1 Target group .............................................................................................................. 7
1.2 Industrial robot documentation ................................................................................... 7
1.3 Representation of warnings and notes ...................................................................... 7
1.4 Terms used ................................................................................................................ 8
1.5 Trademarks ................................................................................................................ 9
2 Product description ..................................................................................... 11

2.1 Overview of KUKA.PalletTech ................................................................................... 11
2.2 Grippers ..................................................................................................................... 12
2.2.1 Physical gripper .................................................................................................... 12
2.2.2 Logical gripper ...................................................................................................... 14
2.2.2.1 Numbering convention for segments .................................................................... 14
2.2.2.2 Numbering convention for more than one row of segments ................................. 14
2.2.2.3 Logical offset in a vacuum grippers ...................................................................... 14
2.2.2.4 Logical offset in a clamp grippers ......................................................................... 15
2.3 Example of a palletizing cell ....................................................................................... 16
2.3.1 Conveyor stations ................................................................................................. 17
2.3.2 Pallet stations ....................................................................................................... 17
2.3.3 Slipsheet stations .................................................................................................. 17
2.3.4 Layer pattern ......................................................................................................... 17
2.4 Workflow with PalletTech ........................................................................................... 18
2.4.1 Cell integration ...................................................................................................... 18
2.4.2 Creating layer patterns ......................................................................................... 18
2.4.3 Runtime operation ................................................................................................ 19
3 Safety ............................................................................................................ 21
4 Installation ................................................................................................... 23
4.1 System requirements ................................................................................................. 23
4.2 Installing KUKA.PalletTech ........................................................................................ 23
4.3 Uninstalling KUKA.PalletTech .................................................................................... 23
4.4 Reinstalling KUKA.PalletTech .................................................................................... 23
5 Operation ...................................................................................................... 25
5.1 Menus ........................................................................................................................ 25
5.2 Status keys ................................................................................................................ 25
5.3 Status keys and softkeys in the configuration program ............................................. 25
6 Configuration ............................................................................................... 27
6.1 Overview of KUKA.PalletTech configuration .............................................................. 27
6.2 Calibrating the tool ..................................................................................................... 27
6.3 Calibrating conveyors and stations ............................................................................ 28
6.3.1 Calibrating the base of a station ........................................................................... 30
6.4 Overview of tabs in the configuration program .......................................................... 31
6.4.1 Configuring the robot cell in PalletTech ................................................................ 32
6.4.2 Configuring stations in the robot cell ..................................................................... 33
6.4.3 Defining the alignment of the items ...................................................................... 34
Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en 3 / 107

KUKA.PalletTech 3.7
6.4.4 Configuring the inputs and outputs of the stations ............................................... 37

6.4.5 Entering the load data of the gripper .................................................................... 38
6.4.6 Configuring the inputs and outputs for the gripper ............................................... 39
6.4.7 Configuring robot motions .................................................................................... 41
6.5 Dynamic height adaptation (dynamic repositioning) .................................................. 43
6.6 Configuring station relationships ............................................................................... 45
6.7 Configuring automatic product change ...................................................................... 46
6.8 Teaching perch positions ........................................................................................... 48
6.9 Configuring motion from and to perch position .......................................................... 48
6.10 Teaching safe positions between stations ................................................................. 49
6.10.1 Example: teaching a safe position ........................................................................ 50
6.10.2 Inline forms for safe positions ............................................................................... 51
6.11 Defining a directory for the layer pattern files ............................................................ 52
7 Programming ............................................................................................... 55
7.1 Overview: setting up production operation ................................................................ 55
7.2 Copying layer pattern files to the robot controller ...................................................... 55
7.3 Selecting and loading layer patterns for palletizing ................................................... 55
7.4 Starting production operation .................................................................................... 57
8 Diagnosis ...................................................................................................... 59
8.1 Unlocking a locked-out conveyor ............................................................................... 59
9 Troubleshooting .......................................................................................... 61
9.1 Fault strategy – Error during item pick-up ................................................................. 61
9.2 Fault strategy – Dropped item ................................................................................... 61
9.3 Fault strategy – Automatic unloading of rejects ......................................................... 61
10 Messages ...................................................................................................... 63
10.1 Error messages ......................................................................................................... 63
10.2 Error codes ................................................................................................................ 66
11 System variables ......................................................................................... 69

11.1 Variables .................................................................................................................... 69
12 Command interface ..................................................................................... 71

12.1 Functional description ................................................................................................ 71
12.2 Command interface signals ....................................................................................... 71
12.3 Function sequence of the command interface ........................................................... 72
12.4 Supported commands ............................................................................................... 74
12.4.1 Pallet reset ........................................................................................................... 74
12.4.2 Look-ahead function for conveyors ...................................................................... 75
12.4.3 Last Pick ............................................................................................................... 76
12.4.4 Unlock locked-out pallet ....................................................................................... 76
12.4.5 Unlock locked-out conveyor ................................................................................. 77
12.4.6 Reset slipsheet station ......................................................................................... 78
12.4.7 Item height factor .................................................................................................. 78
12.4.8 Reset program ...................................................................................................... 79
12.4.9 Deselect program ................................................................................................. 79
12.4.10 Change number of layers ..................................................................................... 80

Contents
12.4.11 Start Cell.src ......................................................................................................... 80

12.5 Error messages of the command interface ................................................................ 81
12.6 Debugging the command interface ............................................................................ 83
13 Integrating KUKA.PalletTech into an application ..................................... 85

13.1 Functions in the file UserMethods.SRC ..................................................................... 85
13.2 User-defined motions ................................................................................................. 86
13.2.1 Functions in the file PT_ConveyorMotion.SRC .................................................... 86
13.3 Reconfiguring the gripper ........................................................................................... 86
13.3.1 Defining the station for gripper reconfiguration ..................................................... 87
13.3.2 Communicating the required changes to PalletTech ............................................ 88
13.3.2.1 I/O settings ............................................................................................................ 88
13.3.2.2 Setting values for the gripper change ................................................................... 88
13.3.3 Example: reconfiguring a gripper .......................................................................... 89
13.4 Handling offsets of the pick-up position ..................................................................... 89
14 Appendix ...................................................................................................... 91
14.1 Example of sequence values ..................................................................................... 91
14.2 Look-ahead function .................................................................................................. 92
14.3 Motion to and from the conveyor ............................................................................... 92
14.4 Motion to and from the pallet station .......................................................................... 93
14.5 Motion to and from the slipsheet station .................................................................... 94
15 KUKA Service .............................................................................................. 97

15.1 Requesting support .................................................................................................... 97
15.2 KUKA Customer Support ........................................................................................... 97
Index ............................................................................................................. 105

KUKA.PalletTech 3.7

1. Introduction
1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and skills:
Advanced KRL programming skills
Advanced knowledge of the robot controller system
Advanced knowledge of palletizing
Knowledge of field bus interfaces
For optimal use of our products, we recommend that our customers take part
in a course of training at KUKA College. Information about the training pro-
gram can be found at www.kuka.com or can be obtained directly from our
subsidiaries.
1.2 Industrial robot documentation
The industrial robot documentation consists of the following parts:

Documentation for the manipulator
Documentation for the robot controller
Operating and programming instructions for the KUKA System Software
Documentation relating to options and accessories
Parts catalog on storage medium
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety Warnings marked with this pictogram are relevant to safety and must be ob-
served.
Danger!
This warning means that death, severe physical injury or substantial material
damage will occur, if no precautions are taken.
Warning!
This warning means that death, severe physical injury or substantial material
damage may occur, if no precautions are taken.
Caution!
This warning means that minor physical injuries or minor material damage
may occur, if no precautions are taken.
Notes Notes marked with this pictogram contain tips to make your work easier or ref-
erences to further information.
Tips to make your work easier or references to further information.

KUKA.PalletTech 3.7
1.4 Terms used
The following terms are used in this documentation:
Term Description
Reject station Pallet station in which item clusters with missing items
are set down
Conveyor sta- Defined area in the robot cell to which the item is trans-
tion ferred
Frame Coordinate system describing the position of a station
relative to the robot
Load The quantity of items and slipsheets placed on a pallet
Layer A group of items at the same height in a pattern on the
pallet
Layer pattern The horizontal pattern of items placed on the pallet, the
previous layer, or the slipsheet. The pattern may differ
from one layer to another.
Layer pattern File containing information about the item, pattern, and
file robot cell, which is required to create the palletizing
program.
This file is generated by KUKA.PalletEdit.
Look-ahead Function for outputting the orientation and number of
function packages required for the next pick action
Multi-cycle con- Extension of the look-ahead function to the next pick
veyor action by the offset of the pick action
MultiPick / Multi- All items in the gripper are set down at once.
Place
MultiPick / Sin- Items in the gripper can be set down individually.
glePlace
Item The object that is to be palletized. The item may or may
not be packaged. Within the palletizing system it is fed
to the robot via a conveyor station.
Item cluster / A group of items held in the gripper.
item block
Package Container for packaging the item, e.g. a wrapper, box
or bag. When an item is packaged, it acquires the
package’s physical dimensions and surface character-
istics.
Pallet Flat wooden contruction or similar, on which the goods
are packed
Pallet station Defined area in the robot cell in which the pallet is
located.
Palletizing sys- One or more robot cells in which palletizing programs
tem are executed
Palletizing pro- Program which can be executed to accomplish palletiz-
gram ing applications
Palletizing cycle Pick-up and setdown of an item, item cluster or slip-
sheet
Perch position Auxiliary position which must be defined for each sta-
tion
Station number Number assigned to a station (pallet station, conveyor
station or slipsheet station) as its identification number
Full load Maximum quantity of items and slipsheets which can
be placed on one pallet.
Slipsheet Sheet of paper, cardboard, etc., which is located under,
between and/or on top of the palletized layers

1. Introduction
1.5 Trademarks
Windows is a trademark of Microsoft Corporation.

KUKA.PalletTech 3.7

2. Product description
2 Product description
2.1 Overview of KUKA.PalletTech
Overview KUKA.PalletTech is an add-on technology package which simplifies the pro-

gramming of a KUKA robot for palletizing items from a conveyor onto a pallet.
KUKA.PalletTech is used if the robot is to palletize uniform (homogeneous)
layer patterns on a pallet.
2 components are used:
KUKA.PalletEdit is an offline tool for creating palletizing patterns.
KUKA.PalletTech is the technology package on the robot controller which
processes the layer patterns, and compiles and executes the KRL pro-
gram.
Fig. 2-1: KUKA.PalletTech concept
1 Offline PC with KUKA.PalletEdit

2 Transmission via Ethernet, or manually
3 KR C2 with KUKA.PalletTech
Functions Supports fork grippers, vacuum grippers and clamp grippers

Supports up to 64 stations in total:
Up to 30 conveyors for transferring the items to be palletized
Up to 30 palletizing stations
Up to 16 slipsheet stations
Multi-pick function and single-place
Multi-row pick (pick-up of several items simultaneously)
Dynamic repositioning calculates the height of the stations and moves the
robot over high stations without danger of collision
Multi-cycle conveyor preview enables optimized utilization of the system in
Automatic External mode
Look-ahead function
Automatic unloading of rejects (e.g. incorrectly gripped items)
Supports automatic product change

KUKA.PalletTech 3.7
2.2 Grippers
Overview In order to pick up, set down and monitor items with a gripper, KUKA.Pallet-
Tech must be able to control the inputs/outputs of the gripper. To this end, KU-
KA.PalletTech uses a number of conventions for the configuration of the
gripper.
Each gripper consists of a physical and a logical gripper. The physical gripper
is the mechanical gripper, including the gripper dimensions. For each physical
gripper, one or more logical grippers can be configured. A logical gripper de-
fines, for example, which valves and part sensors of the physical gripper are
used.
With the logical gripper, layer patterns can be generated with which a wide
range of different-sized items can be picked up with the same physical gripper.
Physical and logical grippers can only be configured using KUKA.PalletEdit.

Further information on configuration can be found in the KUKA.PalletEdit
documentation.
The following gripper types are supported:

Vacuum gripper
Clamp gripper
Fork gripper
2.2.1 Physical gripper
Description Irrespective of the gripper type used, every gripper must be able to grip and
release parts. In order to be able to monitor an item in a gripper, the physical
gripper must be equipped with part sensors which signal to the system when
there is a part in the gripper.
The physical gripper is mounted on the mounting flange and must be calibrat-
ed. During calibration, the TOOL coordinate system is moved from the flange
center point to a point on the gripper specified by the user, the TCP.
The TOOL coordinate system must be aligned as follows:
The Z coordinate must project out of the gripper.
The X coordinate must run parallel with the long side of the gripper.
Example The example shows a gripper with 21 suction cups. The X and Y coordinates
indicate the position of the TCP.
Fig. 2-2: Suction cups
Each valve controls one suction cup via an output.

Fig. 2-3: Outputs for controlling the suction cups
Part sensors on the gripper monitor the items held by the gripper.
Fig. 2-4: Items held in the gripper
Each part sensor is represented by an input.
Fig. 2-5: Part sensor inputs
The configured I/Os are displayed on the Gripper I/O tab of the configuration
program.
Fig. 2-6: Gripper I/O display

KUKA.PalletTech 3.7
2.2.2 Logical gripper
Description A physical gripper can generally grip a wide variety of different-sized items. A
logical gripper defines the I/Os of the physical gripper which are mapped onto
a segment, as well as the logical offset.
Segment A segment is a group of valves and part sensors which are required for picking
up an item. A logical gripper always consists of a number of segments. Up to
32 segments can be defined.
Logical offset The logical offset is the Cartesian position of segment 1 relative to the TCP of
the gripper. The gripper TCP is offset in the X, Y and Z directions toward the
item that is picked up by segment 1 (logical TCP). The position of the logical
TCP depends on the gripper type.
2.2.2.1 Numbering convention for segments
Description Segment 1 must always be the segment with the smallest X offset relative to
the TCP. The figure shows a group of 4 items on a conveyor. The position of
the TCP is indicated in red. Segment 1 has the smallest X offset relative to the
TCP, and segment 4 has the largest X offset. The TOOL coordinate system in
the gripper TCP is indicated in blue. The red coordinate system shows the log-
ical TCP after addition of the logical offset.
Fig. 2-7: Segment numbering
2.2.2.2 Numbering convention for more than one row of segments
Description Logical grippers can be configured with more than one row of segments. Seg-
ment 1 has the smallest X offset and the largest Y offset relative to the TCP.
The segments in one row are numbered in ascending order.
Fig. 2-8: Numbering of more than one row of segments
2.2.2.3 Logical offset in a vacuum grippers
Description The logical offset defines the offset of the TCP toward the center of the nearest
upper edge of the item (logical TCP). When the logical offset is measured, this
results in a positive X and Z offset and a negative Y offset. This is because
every component is measured relative to the TOOL coordinate system, the
TCP and the logical TCP.

Fig. 2-9: Logical offset in a vacuum gripper
1 Side view 3 Logical TCP

2 Top view 4 TCP
2.2.2.4 Logical offset in a clamp grippers
Description The logical offset defines the offset of the TCP toward a point on the rear sur-
face of the item in segment 1 that lies closest to the corner of the fixed edge
of the gripper (logical TCP). When the logical offset is measured, this results
in a negative X and Y offset and a positive Z offset.
Fig. 2-10: Logical offset in a clamp gripper
1 Side view
2 Top view
3 Fixed edge

KUKA.PalletTech 3.7
Fig. 2-11: Logical offset in a clamp gripper (front view)
2.3 Example of a palletizing cell
Overview KUKA.PalletTech supports 3 types of station within a cell:

Conveyor stations
Slipsheet stations
Pallet stations
Each station at which the robot works must be calibrated relative to the posi-
tion of the robot. During base calibration, the user assigns a BASE coordinate
system to the station.
Fig. 2-12: Example of a palletizing cell
1 Conveyor 7 Slipsheet station

2 Conveyor 8 Pallet station

5 Gripper with items 11 Pallet station

6 KR 180 PA with vacuum grip- 12 Reject station
per
2.3.1 Conveyor stations
The conveyor feeds items to the robot. All conveyors must signal to the indus-
trial robot via an input sensor when an item is ready to be picked up. The BASE
coordinate system of the station can be located at the center or the corners of
the pallet. A maximum of 30 conveyors can be configured per cell.
2.3.2 Pallet stations
After the pick action, the items are set down in the pallet station. The user as-
signs corresponding layer pattern files to the pallets. The BASE coordinate
system of the station can be located at the center or the corners of the pallet.
A maximum of 30 pallets can be configured per cell.
All pallet stations must signal to the industrial robot via an input sensor when
a pallet is ready for loading. Once a pallet is completely loaded, a signal is set.
The operator must then remove and acknowledge the pallet, and a new pallet
must be made ready.
It is possible to generate layer patterns that require the palletization of the
base pallet. A base pallet is picked up from the slipsheet station. If this option
is configured, the message “Pallet present” must be set.
2.3.3 Slipsheet stations
A slipsheet station feeds the robot with slipsheets for placing on a pallet. A slip-
sheet is an object which completes the palletization of a layer on a pallet. If a
base pallet is being palletized, the base pallet is considered a slipsheet.
All slipsheet stations must signal via an input sensor when a slipsheet is ready
to be picked up. A maximum of 16 slipsheet stations can be configured per
cell.
Slipsheet stations can be defined as either searchable or non-searchable
Searchable slipsheet stations are searched to determine the highest point
of the slipsheet stack. Thereafter, the grip position is reduced by the thick-
ness of the slipsheet to determine the next grip position. On starting a new
stack, the station must be reset and a new search begins.
In non-searchable slipsheet stations, the slipsheet is picked up at a fixed
position relative to the station frame.
2.3.4 Layer pattern
The layer pattern defines the complete pick-up and setdown process. The fol-
lowing information is stored in the layer pattern file:
Conveyor stations for feeding the items to be palletized
Properties of the items (length, width, height, weight and acceleration)
Number of items to be picked up (group)
Pallet station for setting down the items
Position and orientation of the items on setdown
Slipsheet station
Properties of the pallets (length, width, height, weight and acceleration)

KUKA.PalletTech 3.7
Properties of the slipsheets (length, width, height, weight and accelera-

tion)
2.4 Workflow with PalletTech
2.4.1 Cell integration
Description Here the cell is set up. Set-up involves the following work / elements:
the stations of the cell
the gripper
configuration of the inputs and outputs for communication with PalletTech
The tools and frames are taught with the KUKA System Software and the con-
figuration data are defined with the ConfigTool.
Overview Teaching the TCP

Teaching the perch positions assigned to the stations
Teaching the frames of the stations in the cell
Configuring PalletTech using the ConfigTool
Defining the number of stations in the cell (pallet, conveyor and slip-
sheet stations)
Assigning base frames to the individual stations and saving offsets
Defining inputs and outputs for the stations
Defining load data and inputs and outputs for the gripper
Defining inputs and outputs required for the PLC
Configuring the number of conveyors and pallet and slipsheet stations for
the cell
Configuring the layer pattern directory
Setting up and testing the interface
Setting up and testing automatic product change
2.4.2 Creating layer patterns
Description The following points are defined here:

Characteristics of the cell
Characteristics of the items
Characteristics of the logical gripper
Layer pattern to be executed
Overview Defining cell data with PalletEdit.
Further information on defining the cell data can be found in the KUKA.Pal-
letEdit documentation.
Defining the base pallet

Defining the item
Defining the layer pattern
Testing the layer pattern

2.4.3 Runtime operation
Description After configuration and creation of the layer patterns, set-up for production op-
eration starts.
Overview Making the layer patterns created available to the robot

Selecting layer patterns for conveyors/pallets within the cell
Using the status mask for monitoring the stations
Using the status masks for troubleshooting and for resetting the stations

KUKA.PalletTech 3.7

3. Safety
3 Safety
This documentation contains safety instructions which refer specifically to the

software described here. The fundamental safety information for the industrial
robot can be found in the “Safety” chapter of the Operating and Programming
Instructions for System Integrators or the Operating and Programming Instruc-
tions for End Users.
Warning!
The “Safety” chapter in the operating and programming instructions must be
observed. Death to persons, severe physical injuries or considerable dam-
age to property may otherwise result.

KUKA.PalletTech 3.7

4. Installation
4 Installation
4.1 System requirements
Hardware KR C2 or KR C2 edition2005 robot controller with network connection

(network card)
Gripper
Application-specific components
KUKA field bus card (Interbus, Profibus, DeviceNet)
Software KUKA System Software 5.2, 5.4, 5.5 or 5.6

KUKA.UserTech 2.3 or 2.4
4.2 Installing KUKA.PalletTech
Precondition User group “Expert”

Windows interface (CTRL+ESC)
Procedure 1. Start the Setup program from the CD-ROM. The files are copied onto the
hard drive.
2. A dialog regarding automatic product change appears. Select the required
option.
3. Confirm the reboot prompt with OK.
4. Reboot the robot controller. Installation is resumed and completed.
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.
4.3 Uninstalling KUKA.PalletTech
Precondition KUKA.PalletTech is installed.

Expert level.
Windows interface (CTRL+ESC).
Procedure 1. Start the Uninst.exe program in the directory C:\KRC_OPTION\PALLET-

TECH\UNINST. Uninstallation is prepared.
3. Reboot the robot controller.
4.4 Reinstalling KUKA.PalletTech
Precondition KUKA.PalletTech has been uninstalled.

Expert level
Procedure 1. Start the Reinst.exe program in the directory C:\KRC_OPTION\PALLET-

TECH\REINST. Setup is prepared.
3. Reboot the robot controller.

KUKA.PalletTech 3.7

5. Operation
5 Operation
5.1 Menus
The following menus and commands are specific to this technology package:
Configure
Status keys
PalletTech
Setup
PalletTech
Patterns
Config
ConfigTool
Relationships
Directory
Technology
PalletTech
Safe Position (Fixed Ori, Fixed Z)
Safe Position (Fixed Ori, Dynamic Z)
Safe Position (Target Ori, Fixed Z)
Safe Position (Source Ori, Fixed Z)
Safe Position (Target Ori, Dynamic Z)
Safe Position (Source Ori, Dynamic Z)
5.2 Status keys
The following status keys are available:
Status key Description

The status key PTech is used to exit the currently
selected program and select the program Pallet-
Tech.
The status key Home is used to exit the currently
selected program and select the program
PT_Home.
The program PT_Home moves the robot to the
home position.
The status key Service is used to exit the cur-
rently selected program and select the program
PT_Service.
The program PT_Service moves the robot to the
service position.
5.3 Status keys and softkeys in the configuration program
Procedure Select the menu sequence Setup > PalletTech > Config to open the con-
figuration program.

KUKA.PalletTech 3.7
Status keys The following status keys are available:
Status key Description

The status key Tab switches to the next element,
if more than one is available for selection.
The status keys Up and Down are for navigating
in lists and tables. The focus moves up or down
one line at a time.
The status key Change opens an input mask for
editing the selected line.
The status key OK is used to accept the settings
and changes.
The status key Save is used to save the settings
and changes.
Softkeys The following softkeys are available:
Softkey Description
The softkey Exit closes the configuration pro-
gram. Changes are not saved.
The softkey Save and exit closes the configura-
tion program. Changes are saved.
The softkey Save floppy saves the current con-
figuration data to a floppy disk.
The softkey Load floppy loads configuration
data from a floppy disk to the configuration pro-
gram.

6. Configuration
6 Configuration
6.1 Overview of KUKA.PalletTech configuration
Step Description
1 Set up the physical robot cell (stations, grippers, etc.).
2 Configure the field bus and I/Os.
3 Calibrate the tool (TCP).
(>>> 6.2 "Calibrating the tool" page 27)
4 Calibrate the stations and conveyors (BASE).
(>>> 6.3 "Calibrating conveyors and stations" page 28)
5 Configure the robot cell in KUKA.PalletTech.
(>>> 6.4.1 "Configuring the robot cell in PalletTech"
page 32)
6 Enter the load data of the gripper.
(>>> 6.4.5 "Entering the load data of the gripper" page 38)
7 Configure the inputs and outputs for the grippers.
(>>> 6.4.6 "Configuring the inputs and outputs for the grip-
per" page 39)
8 Configure the interface with I/Os to the PLC.
(>>> 6.4.4 "Configuring the inputs and outputs of the sta-
tions" page 37)
9 Configure the layer pattern with KUKA.PalletEdit.
10 Transfer the layer pattern to the robot controller via the net-
work or a storage medium (e.g. floppy disk, USB stick).
11 Set up production operation.
(>>> 7.1 "Overview: setting up production operation"
page 55)
6.2 Calibrating the tool
Overview The tool center point (TCP) specifies a point on the gripper at which the dis-
tance to the robot tool mounting flange is defined. KUKA.PalletTech always
uses the tool number 1 (TOOL[1]). With this tool, all motions and offsets are
executed with different items.
Description The TCP can be calibrated by various methods:

XYZ Reference
ABC 2-Point
ABC World
Numeric input
The following must be observed in the process:
The Z component must project out of the gripper.
The X component of the TCP must run parallel with the long side of the
gripper.

KUKA.PalletTech 3.7
Depending on the gripper type, the TCP must be calibrated at different posi-
tions.
With a vacuum gripper, TOOL[1] should be taught so that the TCP lies in
the same plane as the point on the items with which the vacuum gripper is
to engage.
With a clamp gripper, the TCP should be located on the fixed edge of the
clamp gripper.
With a fork gripper, the TCP should be located on the lower fixed edge of
the first prong.
Fig. 6-1: Example: TCP of a vacuum gripper
1 TCP of a vacuum gripper
Caution!
Tool number 16 (TOOL[16]) must not be used in connection with KUKA.Pal-
letTech. This number is used internally by KUKA.PalletTech and would
cause the values of the data to be lost.
Further information is contained in the operating and programming instruc-

tions.
6.3 Calibrating conveyors and stations
Calibrating The frame for conveyor stations must be taught so that it is right-handed and
conveyors the positive Z coordinate points upwards. The positive X coordinate must point
in the opposite direction to the direction of travel of the conveyor.
If the positive X coordinate does not point in the opposite direction to the di-
rection of travel of the conveyor, the gripper cannot pick up any items when
running KUKA.PalletTech.

6. Configuration
Fig. 6-2: Calibrating conveyors
1 Direction of travel of the conveyor
Calibrating The frame for pallet and slipsheet stations must be taught so that it is right-
stations handed and the positive Z coordinate points upwards.
The position of the frame when teaching the base specifies how the layer pat-
tern is created. The first setdown position for items is always located in the
opposite corner to the corner in which the base frame was taught.
Fig. 6-3: Calibrating stations
1 Taught base frame

2 Setdown position for the first item

KUKA.PalletTech 3.7
6.3.1 Calibrating the base of a station
Description The stations are calibrated using the 3-point method The robot moves to the
origin and 2 further points of the new base. These 3 points define the new
base.
Precondition A previously calibrated tool is mounted on the mounting flange.

Operating mode T1 or T2
Procedure 1. Select the menu Setup > Measure > Base > ABC 3-Point.
2. Assign a number and a name for the base. Confirm with OK.
3. Enter the number of the mounted tool. Confirm with OK.
4. Move the TCP to the origin of the new base. Confirm with OK.
5. Move the TCP to a point on the positive X axis of the new base. Confirm
with OK.
6. Move the TCP to a point in the XY plane with a positive Y value. Confirm
with OK.
7.
Press Save.
Further information is contained in the operating and programming instruc-

tions.
Fig. 6-4: Base calibration

6. Configuration
6.4 Overview of tabs in the configuration program

No program is selected in the Navigator.
Procedure Select the menu sequence Setup > PalletTech > Config to open the con-
figuration program.
Overview
Fig. 6-5: KUKA.PalletTech configuration program
Description
Tab Description
Config Defines the properties of the cell (number of convey-
ors, pallet stations and slipsheet stations)
Activates automatic unloading of rejects and dynamic
repositioning.
Stat. Data Defines the data (e.g. base frames) in order to be able
to use each individual station in the cell
Centering Defines where the items are located in relation to the
base frame of the conveyor station.
Defines where the pallets are located in relation to the
base frame of the pallet station.
Stat. I/O Defines the required inputs and outputs for each indi-
vidual station
GripData Defines the load data of the gripper used in the cell
Gripper I/O Defines the inputs and outputs for gripper control
The inputs and outputs are assigned in KUKA.PalletE-
dit.
Motion Specifies the runtime parameters, thereby defining the
motions of the palletizing cycle
Autom. Defines the signals required for communication with a
PLC, and configures automatic operation and auto-
matic product change

KUKA.PalletTech 3.7
6.4.1 Configuring the robot cell in PalletTech

The total number of stations (conveyors, pallet stations, slipsheet stations)

must not exceed 64.
Procedure 1. Select the menu sequence Setup > PalletTech > Config to open the con-
figuration program.
2. Select the menu key Configuration.
3. Make the desired settings.
4. Select the status key Save.
Overview
Parameter Description
Cell number Used with palletizing systems to identify the indi-
vidual robot cells.
Range of values: 0 … 15
Number of Conveyors Defines the number of conveyors in the robot
cell.
The layer pattern defines the alignment of the
packages.
Number of Pallets Defines the number of pallet stations in the robot
cell.
Each pallet in the cell is assigned a unique layer
pattern.
Reject stations are created as pallet stations.
Number of Slipsheets Defines the number of slipsheet stations in the
robot cell.
Automatic Reject Defines how the system should respond to
errors while picking up items or to errors due to
dropped items.
Activated: Rejects are automatically unloaded in
a reject station.
Not activated: Rejects must be removed manu-
ally.
NOTE: Dropped items must be removed manu-
ally.
(>>> 9.3 "Fault strategy – Automatic unloading
of rejects" page 61)

6. Configuration
Dynamic Reposition Defines how the robot should pass other stations
in the cell.
Activated: The robot automatically adapts the
height of the perch positions to the stations.
Not activated: The robot moves to the taught
perch positions.
Detented Valves Defines whether detented valves are used or
not.
Activated: Detented valves are used on the grip-
per
Not activated: No detented valves are used (per-
manent control)
6.4.2 Configuring stations in the robot cell
Precondition The stations have been calibrated

The robot cell has been configured
The configuration program is open
Procedure 1. Select the menu key Station Data.

If a number of different layer patterns are to be palletized for a pallet station,
the base and the sequence number of the pallet can be assigned more than
once.
Overview
Fig. 6-6: “Station Data” tab

KUKA.PalletTech 3.7
Base Number of the taught base system
Defines the position of the station in the robot
cell. This tells KUKA.PalletTech where the sta-
tions are situated relative to the robot position.
X offset Offsets the base frame to a different point in the
X direction
Y offset Offsets the base frame to a different point in the
Y direction
Z offset Offsets the base frame to a different point in the
Z direction
Seq. Must be entered if dynamic repositioning is acti-
vated
The sequence number tells KUKA.PalletTech
how the stations in the cell are arranged in rela-
tion to each other.
Search. Defines whether a slipsheet station is searchable
or not.
1: The slipsheet station is searchable. The robot
does not move to any predefined position to pick
up a slipsheet.
BLANK: The slipsheet station is not searchable.
The robot moves to a predefined position to pick
up a slipsheet.
Ori. The orientation specifies the orientation of a slip-
sheet.
1: The long side of the slipsheet runs parallel
with the positive X axis of the station frame.
2: The short side of the slipsheet runs parallel
with the positive X axis of the station frame.
Dynamic Specifies whether the X and Y coordinates of the
perch position for a station should be calculated
automatically.
Applies to conveyors and pallet stations.
0: The taught perch position is addressed.
1: The X and Y coordinates of the perch position
are calculated automatically.
MinHeight Specifies the minimum vertical distance in mm
with which the robot passes the station.
Precondition: Dynamic repositioning is activated.
6.4.3 Defining the alignment of the items
The alignment of the items on the conveyor and on the pallet station can be
defined.
Precondition The stations of the robot cell have been configured.
Procedure 1. Select the menu sequence Setup > PalletTech > Config.
2. Select the Centering tab.

6. Configuration
3. Set the parameters.

4. Save the settings.
Description
Fig. 6-7: “Centering” tab
Pkg/Pallet loca- 1: left-justified
tion
2: centered
3: right-justified
Pkg/Pallet Off- Offset, relative to the base of the station, on which the
set pallet or item is oriented.
Default: 0.0 mm
Offset types 1: X-axis offset
2: Y-axis offset
Alignment on The alignment of the packages on the conveyor station may be left-justified,
conveyor centered or right-justified in the direction of the Y axis of the BASE coordinate
system (base of the station).
Fork grippers can only pick up items at the sides of the conveyor. The align-
ment of the item on the conveyor defines from which side the robot picks up
the items. For example, if the items arrive left-justified, the robot picks up the
items on the left side of the conveyor.

KUKA.PalletTech 3.7
Fig. 6-8: Alignment of the items on the conveyor
A Left-justified alignment 2 Conveyor station

B Centered alignment 3 Item
C Right-justified alignment 4 Base of the station
1 Direction of item feed
Alignment on The alignment of the items on the pallet station may be left-justified, centered
pallet or right-justified in the direction of the X axis or Y axis of the BASE coordinate
system (base of the station).
The X axis of the BASE coordinate system can lie along the long or the short
side of the pallet.
Fig. 6-9: Alignment of the items on the pallet

6. Configuration
A Left-justified alignment with X-axis offset

B Centered alignment with X-axis offset
C Right-justified alignment with X-axis offset
D Left-justified alignment with Y-axis offset
E Centered alignment with Y-axis offset
F Right-justified alignment with Y-axis offset
1 Pallet station
2 Item
3 Pallet
4 Base of the station
6.4.4 Configuring the inputs and outputs of the stations
Description The inputs and outputs are used to communicate status messages to KU-
KA.PalletTech and where appropriate to the PLC.
Precondition The configuration program is open
Procedure 1. Select the menu key Station I/O.

Overview
Fig. 6-10: “Station I/O” tab
The following inputs and outputs must be defined:

KUKA.PalletTech 3.7
Inputs Range of
values
Conveyor Input signal of the conveyor -1, 1
Indicates that a package is ready Default value: 0
for pick-up.
Pallet Input signal of the pallet station -1, 1
Indicates that a pallet is situated in Default value: 0
the pallet station.
Outputs
Range of
values
Conveyor Output signal of the conveyor -1, 1
Indicates that a package has been Default value: 0
picked up by the gripper.
Pallet DONE Output signal of the pallet station -1, 1
Indicates that loading of the pallet in Default value: 0
the pallet station is complete.
A positive input or output value means that the station uses HIGH-active in-
puts and outputs. A negative input or output value means that the station
uses LOW-active inputs and outputs.
6.4.5 Entering the load data of the gripper
KUKA.PalletTech always uses the tool number 1 (TOOL[1]). With this tool,
all motions and offsets are executed with different items.

The following values are known:
Weight of the gripper
Offset of the gripper center of gravity from the robot flange coordinate
system.
Rotational offset of the gripper from the robot flange coordinate system
(Z-Y-X Euler angles)
Mass moments of inertia of the gripper
Procedure 1. Select the menu key Gripper data.

2. Enter the load data of the gripper.
The default value for the mass is -1.0. If this value is entered, the system as-
sumes the maximum payload of the robot.
Only positive mass parameters are taken into consideration.

6. Configuration
Overview
Fig. 6-11: “Gripper data” tab
M (kg) Weight of the gripper
X (mm), Offset of the gripper center of gravity from the
Y (mm), robot flange coordinate system in the X, Y and Z
Z (mm) directions
A (°), Rotational offset of the gripper from the robot
B (°), flange coordinate system about X, Y and Z
C (°)
JX (kg m2), Mass moments of inertia of the gripper
JY (kg m2),
JZ (kg m2)
6.4.6 Configuring the inputs and outputs for the gripper
Description Each gripper consists of a physical and a logical gripper. The physical gripper
is the mechanical gripper, including the gripper dimensions.
(>>> 6.4.5 "Entering the load data of the gripper" page 38)
Each gripper must be able to grip and release parts in order to palletize items.
All valves for gripping and releasing items, together with the sensors that sig-
nal to the robot controller when a part is located in the gripper, are configured
in the logical gripper. The data are mapped to inputs and outputs.
For each gripper, one or more logical grippers can be configured. The division
of a gripper into physical and logical grippers makes it possible to pick up a
wide range of items of different sizes with a single gripper.
The following describes how to configure the inputs and outputs with KU-
KA.PalletTech.
Procedure 1. Select the menu key Gripper I/O.


KUKA.PalletTech 3.7
Fig. 6-12: “Gripper I/O” tab
By default, the table has 50 lines. The number of lines can be configured by
changing the parameter PT_MaxNumberOfValves in the variable display.
Overview
Range of
values
Index The index numbers are assigned to
the segments of the logical gripper
in KUKA.PalletEdit.
Valve On Output for picking up the items to Output number
be palletized
Default value:
With vacuum grippers, the output BLANK
switches on the suction valves. The
output is switched off to release the
item.
With fork grippers and clamp grip-
pers, the output is switched on via a
pulse of 1 s in order to pick up an
item.
Valve Off Output for releasing the items in the Output number
case of fork grippers and clamp
Default value:
grippers
BLANK
The output is switched on via a
pulse of 1 s in order to release an
item.
Blowoff ($OFF) Output for releasing the items, for Output number
grippers with blow-off function
Default value:
The blow-off function is switched on BLANK
via a pulse of 1 s in order to release
the item onto the pallet.

6. Configuration
Range of
values
Part Present Part monitoring Input number
($IN)
Input for part sensors on the gripper Default value:
or for search sensors for picking up BLANK
slipsheets
If nothing is entered here, part mon-
itoring is deactivated.
Part Placed Input signaling that an item has Input number
($IN) been set down.
Default value:
BLANK
6.4.7 Configuring robot motions
Description The “Motion” tab allows the velocity and acceleration to be defined for the var-
ious motion sequences of the robot.
Fork grippers are unusual in that they can only pick up packages at the sides
of the conveyor. For fork grippers, it is therefore necessary to enter a Y and Z
offset on this tab, in order to specify:
how far the gripper must move towards the side of the conveyor
how far the gripper must move under the packages
Procedure 1. Select the menu key Motion.

2. Modify the data.
Overview
Fig. 6-13: “Motion” tab

KUKA.PalletTech 3.7
Range of
values
Vel. with item Velocity of the robot when an item is 1%-100% of the
located in the gripper max. velocity
Default: 100%
Acc. with item Acceleration of the robot when an 1%-100% of the
item is located in the gripper max. accelera-
tion
Default: 100%
Vel. with slip- Velocity of the robot when a slip- 1%-100% of the
sheet sheet is located in the gripper max. velocity
Default: 100%
Acc. with slip- Acceleration of the robot when a 1%-100% of the
sheet slipsheet is located in the gripper max. accelera-
tion
Default: 100%
Vel. without item Velocity of the robot without item or 1%-100% of the
slipsheet max. velocity
Default: 100%
Acc. without Acceleration of the robot without 1%-100% of the
item item or slipsheet max. accelera-
tion
Default: 100%
Fast search vel. Velocity of the robot when carrying 1%-100% of the
out a fast search run at a slipsheet max. velocity
station
Default: 100%
Fast search acc. Acceleration of the robot when car- 1%-100% of the
rying out a fast search run at a slip- max. accelera-
sheet station tion
Default: 100%
Slow search vel. Velocity of the robot when carrying 1%-100% of the
out a slow search run at a slipsheet max. velocity
station
Default: 100%
Slow search Acceleration of the robot when car- 1%-100% of the
acc. rying out a slow search run at a slip- max. accelera-
sheet station tion
Default: 100%
Vel. slipsheet Velocity of the robot when 1%-100% of the
approach approaching the pick-up position at max. velocity
the slipsheet station
Default: 100%
Acc. slipsheet Acceleration of the robot when 1%-100% of the
approach approaching the pick-up position at max. accelera-
the slipsheet station tion
Default: 100%
Vel. slipsheet Velocity of the robot when leaving 1%-100% of the
depart the pick-up position at the slipsheet max. velocity
station
Default: 100%

6. Configuration
Range of
values
Acc. slipsheet Acceleration of the robot when leav- 1%-100% of the
depart ing the pick-up position at the slip- max. accelera-
sheet station tion
Default: 100%
Pre-pick offset Position (X, Y, Z) of the gripper Default: 0 mm
before picking up the item
The pick-up position is relative to
the base frame system of the sta-
tion.
Post-pick offset Position (X, Y, Z) of the gripper after Default: 0 mm
picking up the item
The position is relative to the base
frame system of the station.
Delay after pick Defined wait time after picking up Default: 0 s
an item
Pre-drop offset Position (X, Y, Z) of the gripper Default: 50 mm
before setting down the item
The set-down position is relative to
the base frame system of the set-
down station.
Post-drop offset Position (X, Y, Z) of the gripper after Default for X
setting down the item and Y: 0 mm
The position is relative to the base Default for Z:
frame system of the set-down sta- 50 mm
tion.
Delay after drop Defined wait time after setting down Default: 0 s
an item
Z slip approach Value for calculating the position (Z) Default:
for setting down a slipsheet 200 mm
The position is relative to the base
frame system of the slipsheet sta-
tion.
Dynamic perch Distance between the underside of Default:
offset the item in the gripper and the high- 100 mm
est point on the loaded pallet
Pre-search off- Vertical position from which the Default:
set robot begins its search at a slip- 9,999 mm
sheet station
The robot must always move to this
position when it moves to a search-
able slipsheet station
Cycle stop input Input signaling that the robot should Default: 0
terminate the current palletizing
cycle and move to the HOME posi-
tion
6.5 Dynamic height adaptation (dynamic repositioning)
Description This function calculates the highest station on the basis of the source station
and target station. The perch positions of the source and target stations are
adapted so that the robot can move over all the stations without danger of col-
lision. Above a station, the robot always maintains a minimum distance be-

KUKA.PalletTech 3.7
tween the underside of the gripper (including the items held in the gripper) and
the uppermost point of the station.
Fig. 6-14: Robot motion with dynamic height adaptation
Procedure 1. Select the menu sequence Setup > PalletTech > Config.
2. Select the Config tab and activate the check box Dynamic Reposition.
3. Assign a unique sequence value to each station.
(>>> 6.4.2 "Configuring stations in the robot cell" page 33)
Example The stations surrounding the robot in the cell are numbered: clockwise in blue
numbers from 1 to 10, and counterclockwise in red numbers from 1 to 10.
For example, when the robot moves from conveyor 4 to pallet 3, KUKA.Pallet-
Tech determines the highest station on the robot’s motion path on the basis of
the sequence.
The source station (conveyor 4) is assigned the sequence value 7. The target
station (pallet 3) is assigned the sequence value 10. KUKA.PalletTech detects
the stations in the robotic cell whose sequence values lie between 7 and 10.
These are slipsheet station 1 and pallet 4, with the sequence values 8 and 9.
KUKA.PalletTech determines the highest of the 4 stations and automatically
adapts the perch positions of the source and target stations. In this way, the
robot moves at a height that ensures that these stations will be passed without
collisions.
Fig. 6-15: Numbering of the stations in an example of a robotic cell

6. Configuration
Once KUKA.PalletTech has determined the highest station, the program com-
pares the height of the station with the current height of the robot. If the current
height of the robot is below the highest point on the motion path, the robot po-
sition is automatically adapted upwards.
By default, the minimum offset for dynamic height adaptation is set to 25 mm

with the variable PT_MinAdjustment. If the value is too small, the robot will
not be able to approximate some motions. The variable can be displayed and
changed via the variable correction function.
6.6 Configuring station relationships
Description Station relationships must be configured for every pallet station configured in
the configuration program. At each pallet station that is configured, a particular
package type is palletized. The station relationships define which conveyor
stations and slipsheet stations are used for palletizing the package type.
Fig. 6-16: Option window: Pallet relationships
Precondition Expert user group

The robot cell has been configured
Procedure 1. Select the menu sequence Setup > PalletTech > Config > Relation-
ships.
An option window is opened. This shows the individual pallets and the con-
veyor stations and slipsheet stations from which they are served.
2. Select the pallet in the right-hand status key bar. The status key displays
the pallet for which relationships can be defined in the option window.
3. In the right-hand status key bar, select the station type for which relation-
ships are to be defined with the pallet station.
4. Using the arrow keys, mark the conveyor station or slipsheet station which
is to be linked to the pallet.
5. Press the Add softkey to create the link.
At least one conveyor station must be linked to the pallet station.

KUKA.PalletTech 3.7
6. Press the Close softkey to close the option window.
6.7 Configuring automatic product change
KUKA.PalletTech supports automatic product change. This function can be

used by a PLC to select the layer patterns for the next production cycle.
Precondition The robot cell has been configured

The I/Os are configured.
Procedure 1. Open the configuration program and select the Automatic tab.
2. Set the parameters.
3. Saving the configuration
Description
Fig. 6-17: “Automatic” tab
Signals for file selection

The following signals can be used by the PLC in automatic operation to select
the layer pattern files for the next production cycle:
Parameter Description Length

File Select ($IN) “File selection request” signal 1 bit
The “File selection complete”
signal indicates whether file
selection is completed:
HIGH: not completed
LOW: completed
Cell Number ($IN) Start address for the cell 4 bits
number
Conveyor Number ($IN) Start address for the con- 8 bits
veyor number
Pallet Number ($IN) Start address for the pallet 8 bits
number
Item ID ($IN) Start address for the item ID 24 bits

6. Configuration

Variant Number ($IN) Start address for the variant 4 bits
number
File Select Error ($OUT) Start address for the “File 8 bits
selection error” signal
Signals for file download

The following signals can be used by the PLC to download the selected layer
pattern files for the next production cycle:

Download ($IN) “Download request com- 1 bit
plete” signal
The “Download request com-
plete” signal indicates wheth-
er the download request is
completed:
HIGH: not completed
LOW: completed
Download Error ($OUT) Start address for the “Down- 8 bits
load request error” signal
Ready For Download ($OUT) Start address for the “Ready 1 bit
For Download” signal
Signals to the command interface

The following signals can be used by the PLC to send requests to the com-
mand interface and to control the robotic palletizing cell:

Command Input ($IN) “Command request com- 1 bit
plete” signal
The “Command request com-
plete” signal indicates wheth-
er the command request is
completed:
HIGH: not completed
LOW: completed
Command Number ($IN) Start address for the input 8 bits
signal “Command number”
Command Data 1 ($IN) Start address for the input 8 bits
signal “Data 1”
signal “Data 2”
signal “Data 3”
Command Number ($OUT) Start address for the output 8 bits
signal “Command number”
Command Data 1 ($OUT) Start address for the output 8 bits
signal “Data 1”
signal “Data 2”
signal “Data 3”

KUKA.PalletTech 3.7

Command Error ($OUT) Start address for the “Com- 8 bits
mand error” signal
KRC Occupied Signal Start address for the “KRC 1 bit
occupied” signal
6.8 Teaching perch positions
Description A perch position must be defined for every station of a robot cell. The robot
approaches and leaves each station via the perch position. By means of PTP
motions, the robot can move as quickly as possible between the individual
perch positions.
Precondition Tool[1] is set.

$NULLFRAME is set as the base.
Procedure 1. Select the program ConveyorData.src to teach the perch positions for the
conveyor stations. (This is found in the folder “R1\Program\PTPerch”.)
2. Carry out a BCO run:
Hold down the enabling switch. Then press the Start key and hold it down
until the message “Programmed path reached (BCO)” is displayed in the
message window.
Warning!
A BCO run is always executed as a PTP motion from the actual position to
the target position. Observe the motion to avoid collisions. The velocity is au-
tomatically reduced during the BCO run.
3. Move the robot to the desired perch position.

4. Select the desired station using the arrow keys.
5. Press the softkey Touch Up.
6. Repeat steps 3 to 5 for all stations.
7. Select the program PalletData.src to teach the perch positions for the pal-
let stations, and repeat steps 2 to 6. (This is found in the folder “R1\Pro-
gram\PTPerch”.)
8. Select the program SlipsheetData.src to teach the perch positions for the
slipsheet stations, and repeat steps 2 to 6. (This is found in the folder
“R1\Program\PTPerch”.)
9. Select the program RejectStationData.src to teach the perch positions
for the reject stations, and repeat steps 2 to 6. (This is found in the folder
“R1\Program\PTPerch”.)
6.9 Configuring motion from and to perch position
Description The robot approaches and leaves each station via the perch position. How the
robot moves to the perch position depends on two parameters:
Dynamic Reposition
Dynamic
Both parameters can be configured in the configuration program.
Overview A distinction is made between 3 different perch positions:

6. Configuration
Perch
Description Configuration
position
Fixed The robot moves to the taught “Dynamic Reposition”
perch position. and “Dynamic” are
deactivated
Dynamic The perch position is modified so “Dynamic” is activated
that it lies directly over the grip posi-
tion.
Height- The perch positions are modified so “Dynamic Reposition”
controlled that the robot can move over the is activated.
highest station without danger of
collision.
Dynamic perch positions cannot be configured for slipsheet stations.

figuration program.
2. Press the menu key Configuration.
3. Select “Dynamic Reposition” using the status keys Up and Down, and ac-
tivate or deactivate the check box using the Enter key.
Check box activated: Dynamic repositioning is activated.
Check box deactivated: Dynamic repositioning is deactivated.
4. Press the Station Data menu key.
5. Select the station using the status keys Up and Down.
6. Press the Change status key to edit the entry.
The entry is opened in the infobar.
7. Select the “Dynamic” parameter using the Tab status key.
Value 1: The “Dynamic” parameter is activated.
Value 0: The “Dynamic” parameter is deactivated.
8. Press the Save softkey to save the changes.
For detailed information on moving to perch positions, see
(>>> 14.3 "Motion to and from the conveyor" page 92)
(>>> 14.4 "Motion to and from the pallet station" page 93)
(>>> 14.5 "Motion to and from the slipsheet station" page 94)
6.10 Teaching safe positions between stations
Description Safe positions are defined points in the robot cell, which the robot must move
to in order to prevent collisions. Safe positions can be used, for example, if
there is a column in the robot cell. In order to avoid the column during the PTP
motions between two stations, safe positions must be taught.
Precondition Expert user group

The station numbers specified in the layer pattern files are known
Procedure 1. Open the directory KRC:\R1\PROGRAM\PTPERCH.

2.
Select PT_SAFEPOS.SCR.
3. Press the Open softkey.

KUKA.PalletTech 3.7
4. Enter the condition for motion to the safe position in the SafePos subpro-
gram.
(>>> 6.10.1 "Example: teaching a safe position" page 50)
5. Move the robot to the position that is to be taught as the safe position.
6. Select the menu sequence Technology > PalletTech > Safe Position.
7. Select the type of safe position and confirm with the Enter key.
(>>> 6.10.2 "Inline forms for safe positions" page 51)
6.10.1 Example: teaching a safe position
A column is situated between pallet station 2 and the corresponding conveyor

station 1.
Fig. 6-18: Cell layout with an obstacle to be avoided
1 Pallet station 1 4 Column

2 Pallet station 2 5 Conveyor station 1
3 Robot 6 Conveyor station 2
The robot is to move to a safe position when moving from the conveyor station
to the pallet station. The robot is to move to a taught safe position during the
palletizing process. The orientation of the gripper is to correspond to the ori-
entation of the gripper at the perch position of the target station (pallet station
2).
24 IF (Target.se_StationType == #PALLET) AND (Target.si_StationNum
== 2) THEN
25 PTSafety.TargetOriFixedZ Position 1
26 ENDIF

6. Configuration
Line Description
24 The target station type must be specified. The target station in
the example is a pallet station.
Station types:
Pallet station:
#PALLET
Conveyor station:
#CONVEYOR
Slipsheet station:
#SLIPSHEET
The target station number must be specified. The pallet station
in the example has the number 2.
The station number is specified by the layer pattern file.
(>>> Fig. 7-2)
25 Taught safe position
6.10.2 Inline forms for safe positions
Safe Position Motion to the safe position uses the taught position (X, Y, Z) and orientation.
(Fixed Ori, Fixed
Z)
Fig. 6-19: Inline form: Safe Position (Fixed Ori, Fixed Z)
Item Description
1 Number of the safe position
Safe Position Motion to the safe position uses the taught orientation and the taught X and Y
(Fixed Ori, positions. The Z position is adapted for the dynamic repositioning.
Dynamic Z) Precondition: Dynamic repositioning is activated for the selected station.
Fig. 6-20: Inline form: Safe Position (Fixed Ori, Dynamic Z)
Item Description
Safe Position Motion to the safe position uses the taught position (X, Y, Z) and the gripper
(Target Ori, Fixed orientation at the perch position of the target station.
Z)
Fig. 6-21: Inline form: Safe Position (Target Ori, Fixed Z)

KUKA.PalletTech 3.7
Item Description
Safe Position Motion to the safe position uses the taught position (X, Y, Z) and the gripper
(Source Ori, Fixed orientation at the perch position of the source station.
Z)
Fig. 6-22: Inline form: Safe Position (Source Ori, Fixed Z)
Item Description
Safe Position Motion to the safe position uses the taught X and Y positions. The Z position
(Target Ori, is adapted for the dynamic repositioning. The gripper orientation at the perch
Dynamic Z) position of the target station is used.
Precondition: Dynamic repositioning is activated for the selected station.
Fig. 6-23: Inline form: Safe Position (Target Ori, Dynamic Z)
Item Description
Safe Position Motion to the safe position uses the taught X and Y positions. The Z position
(Source Ori, is adapted for the dynamic repositioning. The gripper orientation at the perch
Dynamic Z) position of the source station is used.
Precondition: Dynamic repositioning is activated for the selected station.
Fig. 6-24: Inline form: Safe Position (Source Ori, Dynamic Z)
Item Description
6.11 Defining a directory for the layer pattern files
Procedure 1. Select the menu sequence Setup > PalletTech > Config > Directory.

6. Configuration
An option window is opened. The selected directory for the layer pattern
files and the tree structure of the C:\ drive is shown.
2. Select the directory C:\PATTERNS, if not already selected.
3. Press the Save softkey to confirm the selection.
4. Press the Close softkey to close the option window.
Fig. 6-25: Option window: Patterns Directory

KUKA.PalletTech 3.7

7. Programming
7 Programming
7.1 Overview: setting up production operation

The precondition for automatic product change is that layer patterns have
been selected and loaded for all pallet stations that are to be palletized.
Overview Step Description

1 Copy the layer patterns to the robot controller.
(>>> 7.2 "Copying layer pattern files to the robot control-
ler" page 55)
2 Select and load the layer patterns for palletizing.
(>>> 7.3 "Selecting and loading layer patterns for palletiz-
ing" page 55)
3 Start production operation.
(>>> 7.4 "Starting production operation" page 57)
4 Monitor production operation.
7.2 Copying layer pattern files to the robot controller
Description The layer patterns are created using KUKA.PalletEdit. Since KUKA.PalletEdit
does not run on the robot controller, the layer pattern files must be copied to
the robot controller.

A layer pattern has been created
Procedure 1. Make the layer pattern file available via the network or a data storage me-
dium.
2. Press the Windows Start button and select Run….
3. In the Open box, enter “explorer” and press OK. A Windows Explorer is
opened.
4. If necessary, create a directory C:\PATTERNS on the robot controller.
5. If necessary, connect the data storage medium (e.g. floppy disk, USB
stick).
6. Copy the layer patterns to the directory C:\PATTERNS on the robot con-
troller.
7. Select the second menu key on the top left, in order to select the menu bar
of the Windows Explorer.
8. Select the menu sequence File > Close to close the Explorer and return
to the KUKA.HMI.
7.3 Selecting and loading layer patterns for palletizing
Precondition The layer patterns have been copied to the robot controller
The station relationships have been configured

KUKA.PalletTech 3.7
A layer pattern file must have been assigned to at least one pallet station.
Otherwise no data can be loaded. That palletizing program cannot run in this
case.
Procedure 1. Select the menu sequence Setup > PalletTech > Patterns.
An option window is opened. The pallet stations configured in the config-
uration program are displayed.
Fig. 7-1: Option window: Patterns
2. Select the desired pallet station using the arrow keys.

3. Press the Pattern softkey.
An option window is opened. The layer pattern files found for the selected
pallet in the directory C:\PATTERNS are shown.
4. Select the layer pattern using the arrow keys and press the Select softkey.
If the layer pattern file matches the configuration of the pallet station, the
details of the layer pattern are displayed.
Fig. 7-2: Option window: Select pattern file
5.
Press OK to confirm the selection.
The option window is closed. The pallet stations configured in the config-
uration program are displayed.
6. Repeat steps 2 to 5 for all pallet stations.
7. Press the Apply softkey to load the layer pattern.
The layer patterns are available for palletizing as soon as they have been
successfully loaded.

7. Programming
7.4 Starting production operation

Precondition Layer patterns are selected and loaded for all stations.
The PALLETTECH.SRC program has been tested
The signals for automatic product change have been configured.
(>>> 6.7 "Configuring automatic product change" page 46)
Procedure 1. Select the PALLETTECH.SCR program in the Navigator. (This is found in

the folder “R1\Program\PTPerch”.)
2. Carry out a BCO run:
Hold down the enabling switch. Then press the Start key and hold it down
until the message “Programmed path reached (BCO)” is displayed in the
message window.
Warning!
A BCO run is always executed as a PTP motion from the actual position to
the target position. Observe the motion to avoid collisions. The velocity is au-
tomatically reduced during the BCO run.
3. Turn the mode selector switch to "Automatic External".

4. Start the program from a higher-level controller (PLC).
To stop a program that has been started in Automatic mode, press the STOP
key.

KUKA.PalletTech 3.7
Overview
Fig. 7-3: Flowchart for production operation
Production operation comprises the following steps:

1. Finding the next pick-up station (conveyor station or slipsheet station) that
is ready
2. Finding the next pallet station that is ready
3. Picking up the item from the pick-up station
4. Setting down the item on the pallet station
5. Updating the pallet data
The process is carried on until the operator executes a cycle stop. The robot
finishes its current pick-up and setdown cycle and then returns to the HOME
position.
If KUKA.PalletTech finds a station which is ready for the robot to pick up

items, it must find a pallet which needs items from this station. The program
remains in the subroutine “Find Next Station” until it finds a station.

8. Diagnosis
8 Diagnosis
8.1 Unlocking a locked-out conveyor
Caution!
Dropped items can cause collisions, which may result in damage to property.
Ensure that there are no dropped items in the robot cell.
Procedure 1. Select the menu sequence Monitor > PalletTech > Conveyor Status.
The “Conveyor Status” window opens.
2. Select the locked-out conveyor using the arrow keys.
3. Press the Unlock softkey.
4. Press the Retry or Increment softkey.

KUKA.PalletTech 3.7

9. Troubleshooting
9 Troubleshooting
9.1 Fault strategy – Error during item pick-up
Description Part monitoring is activated when an item is picked up from the conveyor sta-
tion, and remains active until the item is set down again.
If part monitoring detects that an item has not been correctly gripped, the robot
stops. An error message is displayed, prompting the operator to correct the er-
ror.
The operator can choose between the following options:
Fault strategy Description

Ignore Part monitoring is deactivated and the program
is resumed.
Retry The pick-up and setdown cycle is repeated.
NOTE:
The item or slipsheet must be removed by hand
before this option is selected.
9.2 Fault strategy – Dropped item
Description If part monitoring detects that an item has been dropped during the motion of
the robot from the pick-up to the setdown station, the robot stops. An error
message is displayed, prompting the operator to correct the error.
The operator can choose between the following options:
Fault strategy Description

Ignore Part monitoring is deactivated and the program
is resumed.
Retry The pick-up and setdown cycle is repeated.
NOTE:
Increment The current pick-up and setdown cycle is
skipped. The program is resumed from the next
pick-up and setdown cycle.
NOTE:
9.3 Fault strategy – Automatic unloading of rejects
Description The “Automatic Reject” option makes the system keep running if part monitor-
ing signals an error. The system no longer waits for the operator to intervene.
The robot moves incorrectly picked-up or incomplete item clusters to a reject
station and unloads them there. The station (conveyor station, pallet station,
slipsheet station) in which the error has occurred is locked out by the part mon-
itoring. This station remains locked out until it is unlocked again by the opera-
tor or the PLC.
If a station has been locked out, the robot no longer picks up or sets down
items or slipsheets there. KUKA.PalletTech continues the palletizing process
with the remaining, unlocked stations.

KUKA.PalletTech 3.7
If an item is dropped, the robot stops. The dropped item must be removed
manually from the robot cell. Operation can then be resumed once a mes-
sage has been acknowledged.

figuration program.
2. Press the menu key Configuration.
3. Activate the Automatic Reject option.
4. Press the softkey Save and exit.
5. Select the program R1\PROGRAM\PTPERCH\REJECTSTATIONDA-
TA.SRC.
6. Move the robot to the desired perch position.
7. Select the point RejectStationPerch.
8. Press the Touch Up softkey to teach the perch position of the reject sta-
tion.
9. Move the robot to the desired unloading position.
10. Select the point RejectStationPos.
11. Press the Touch Up softkey to teach the unloading position.

10. Messages
10 Messages
10.1 Error messages
Message Cause Remedy

File Request Failed The layer pattern file contains Create a new layer pattern
errors and is invalid file in KUKA.PalletEdit
File name is not unique The data entered for the Check which layer pattern
selected file apply to more file is the correct one
than one file in the Patterns Delete the incorrect layer
directory pattern files
The slip sheet search offset No “pre-search offset” has Configure the robot mo-
has not been initialized. been defined for the slip- tions with the configuration
Please set this value to a valid sheets. program and enter a new
offset. value for the parameter
“Pre-search offset”.
File select error - file not found The file has been deleted, Copy the layer pattern files
moved or renamed to the robot controller
The Patterns directory has Check which directory has
been changed been defined for the layer
pattern files
Invalid conveyor number The requested conveyor Ensure that the conveyor
number is invalid number lies within the
range of conveyor num-
bers defined in the config-
uration program
Gripper definition not consist- A number of selected layer Create new layer pattern
ent patterns contain different defi- files in KUKA.PalletEdit
nitions for the same logical Use the same gripper
gripper ID definition for all layer
patterns with the same
item
Copy the layer pattern file
to the robot controller
No patterns were selected None of the pallets defined for Select the layer pattern for
the cell has been linked to a palletizing
layer pattern.
No matching file found The data entered for the Copy the layer pattern file
selected file do not apply to to the robot controller
any file in the Patterns direc- Select the layer pattern file
tory again
Missing conveyor station defi- The layer pattern file contains Create a new layer pattern
nition errors and is invalid; the sec- file in KUKA.PalletEdit
tion for defining the conveyor Copy the layer pattern file
station is missing to the robot controller
Solution file contains invalid The selected layer pattern file Create a new layer pattern
conveyor station for the cell is not valid for the specified file in KUKA.PalletEdit
conveyor. The name of the Copy the layer pattern file
layer pattern file does not to the robot controller
match the data found in the
layer pattern file.

KUKA.PalletTech 3.7

Solution contains inconsistent The selected layer patterns Create new layer pattern
fork width have different fork thick- files in KUKA.PalletEdit
nesses. Select the same fork
gripper for all layer pat-
terns
Solution contains inconsistent The selected layer patterns Create new layer pattern
option for base pallet have different palletizing files in KUKA.PalletEdit
options. Select the same
In some of them, the pallets “Feeding base pallet”
are fed by the robot. In some option for all layer pat-
of them, the pallets are fed terns
automatically or by hand. Copy the layer pattern file
Solution contains invalid cell The selected layer pattern is Create a new layer pattern
ID not valid for the selected cell file in KUKA.PalletEdit
Select the correct cell
Activate the “Applica-
ble to all cells” option
Unable to compile pattens - The compiler is currently busy. Wait until the compiler is
compiler busy ready before issuing a new
download request
Solution contains no grippers The selected layer pattern file Create a new layer pattern
is invalid. It contains no grip- file in KUKA.PalletEdit
per definition Copy the layer pattern file
Solution missing base pallet The selected layer pattern file Create a new layer pattern
definition is invalid. It contains no base file in KUKA.PalletEdit
pallet definition Copy the layer pattern file
Solution missing layer defini- The selected layer pattern file Create a new layer pattern
tions is invalid. It contains no layer file in KUKA.PalletEdit
definition Copy the layer pattern file
Solution missing pattern data The selected layer pattern file Create a new layer pattern
is invalid. It contains no layer file in KUKA.PalletEdit
pattern data
Solution missing positions in The selected layer pattern file Create a new layer pattern
layer definition is invalid. It contains no layer file in KUKA.PalletEdit
positions Copy the layer pattern file
Solution missing layer refer- The selected layer pattern file Create a new layer pattern
ences is invalid. It contains no layer file in KUKA.PalletEdit
references
Solution missing item defini- The selected layer pattern file Create a new layer pattern
tions is invalid. It contains no item file in KUKA.PalletEdit
definition Copy the layer pattern file
Selected patterns not com- The download failed because Contact KUKA.Service
piled the selected files had not been and give a detailed de-
compiled. scription of the error

10. Messages

Missing pallet station definition The layer pattern file contains Create a new layer pattern
errors and is invalid; the sec- file in KUKA.PalletEdit
tion for defining the pallet sta- Copy the layer pattern file
tion is missing to the robot controller
The solution file is not valid for The selected layer pattern file Create a new layer pattern
the sected pallet is not valid for the specified file in KUKA.PalletEdit
pallet. The name of the layer Copy the layer pattern file
pattern file does not match the to the robot controller
data found in the layer pattern
file.
Solution file contains invalid The selected layer pattern file Check the station relation-
slipsheet station for the cell contains a slipsheet station ships
that is not valid for the cell. Correct if necessary
Check the layer pattern file
in KUKA.PalletEdit
If necessary, correct and
copy the new layer pattern
file to the robot controller
Item definition not consistent A number of selected layer Create new layer pattern
in selected patterns patterns contain different defi- files in KUKA.PalletEdit
nitions for the same item ID Use the same item def-
inition for all layer pat-
terns with the same
item.
Invalid pallet number The requested pallet number Ensure that the pallet
is invalid number lies within the
range of pallet numbers
defined in the configura-
tion program
Download failed because pro- A download request has failed Cancel or close active pro-
gram not canceled because a program is cur- grams
rently selected. Reissue download request
Robot not at home Robot is not in the HOME Move the robot to the
position HOME position
System error Internal error Contact KUKA.Service
and give a detailed de-
scription of the error
Conveyor has been assigned The selected conveyor has Delete the layer pattern
a different item already been assigned a dif- that is linked to the con-
ferent item. veyor
Select a different layer pat-
tern with the same item for
the selected conveyor
Slipsheet station has been The layer pattern file contains Check in KUKA.PalletEdit
assigned a different item a slipsheet station that is that all the layer pattern
already being used. files were generated with
the same data
Problem: The data of the slip-
sheet already used do not If necessary, correct and
match the data in the current copy the new layer pattern
layer pattern file. file to the robot controller

KUKA.PalletTech 3.7

Orientation for item on con- The pick-up orientation of the Delete the layer pattern
veyor is not consistent item in the configuration pro- that is linked to the con-
gram does not match the layer veyor
pattern Select a different layer pat-
tern with the same item ori-
entation for the selected
conveyor
Check the item orientation
in the configuration pro-
gram
Correct if necessary
Invalid pallet for conveyor The selected file contains an Select a different layer pat-
invalid pallet-conveyor combi- tern file
nation Reconfigure the station re-
lationships of the pallet:
Link conveyor to pallet
Invalid pallet for slipsheet The selected file contains an Select a different layer pat-
invalid pallet-slipsheet combi- tern file
nation Reconfigure the station re-
lationships of the pallet:
Link slipsheet to pallet
Invalid variant number The requested variant number Ensure that the variant
is invalid number lies between 0 and
15
Invalid cell number The requested cell number is Ensure that the cell
invalid number lies between 0 and
15
10.2 Error codes
File download Cause Parameter

1 Invalid data in the file PalletTech.DAT ———
2 Error when picking up items: dropped item. Segment number
3 Cycle stop request complete. ———
4 Error when picking up items: items not cor- Segment number
rectly gripped.
5 Error when setting down items: item still in the Segment number
gripper.
6 Uninitialized input/output ———
7 Submit interpreter is not active. ———
8 Internal error ———
9 Part sensor on pallet is not configured. Pallet number
10 Multi-row gripper is not supported. Conveyor number
11 Part sensor on conveyor is not configured. Conveyor number
12 The Increment option is selected. Conveyor number
13 Invalid acceleration value ———
14 Invalid velocity value ———
15 The Retry option is selected: the program must ———
be reset.
16 The Increment option is selected: the program ———
must be reset.
17 The Ignore option is selected. ———
18 Invalid number of stations ———

10. Messages
File download Cause Parameter

19 Input for cycle stop is not defined. ———
20 Part sensor on slipsheet station is not config- Slipsheet station
ured. number
21 Logical gripper with invalid ID ———
22 Output sensors for Pallet done are not config- Pallet number
ured.
23 Invalid item position on conveyor for fork grip- ———
per
24 Item presence status of the pallet is invalid. Pallet number
25 Segment: missing item Segment number
26 Segment: item picked up Segment number
27 Internal error: Invalid gripper orientation ———
28 Not assigned ———
29 Invalid gripper type ———
30 Invalid offset value for the item ———
31 Invalid pallet position ———
32 Invalid offset value for the pallet ———
33 Invalid offset type for the pallet ———
34 Invalid offset value for the pallet ———
35 Pallet sequence number is not unique. ———
36 Conveyor sequence number is not unique. Pallet number
37 Conveyor sequence number is not unique. Pallet number
38 Slipsheet sequence number is not unique. Pallet number
39 Internal error: invald logical gripper ———
40 Internal error: invalid segment size ———
41 Search sensor stop not defined. ———
42 Items in reject station are not released. ———
43 Pre-pick offset too large. ———
44 Internal error: Invalid station orientation ———
45 Internal error: invalid station orientation ———
46 Command interface: invalid pallet number ———
47 Post-pick offset too large. ———
48 Pre-drop offset too large. ———
49 Post-drop offset too large. ———
50 Pallet pattern has been changed. Pallet number
51 Perch position on conveyor has not been Conveyor number
taught.
52 Perch position on pallet has not been taught. Pallet number
53 Perch position on slipsheet station has not Slipsheet number
been taught.

KUKA.PalletTech 3.7

11. System variables
11 System variables
11.1 Variables
The following parameters can be adapted to the specific requirements by the

user.
The parameters are contained in the file PALLETTECH.DAT in the directory
C:\KRC\ROBOTER\ KRC\R1\TP\PALLETTECH. They can be displayed and
configured via the menu sequence Monitor > Variable > Single.
Variable Description Range of values

PT_APC_DEBUG Display the operations of the TRUE, FALSE
APC (automatic product
Default value: TRUE
change) in the message win-
dow of the user interface
PT_CI_LastEntry Index number of the diagnos- 1 ... 25
tic buffer field of the last com-
mand channel job to be
processed.
PT_DebugFlag If PT_DebugFlag is set to 16,
a debug flag with logged mes-
sages is activated. The mes-
sages indicate why a station is
not ready.
PT_DisableIncrement FALSE: The Increment TRUE, FALSE
softkey is displayed in the
Default value: FALSE
event of a part monitoring
error.
TRUE: The Increment softkey
is not displayed.
PT_DisableIgnore FALSE: The Ignore softkey is TRUE, FALSE
displayed in the event of a part
Default value: FALSE
monitoring error.
TRUE: The Ignore softkey is
not displayed.
PT_DEBOUNCE_DELAY Determines the sensitivity of 24 ms, 48 ms, 72 ms
the gripper monitoring.
Default value: 72 ms
The robot controller checks
the state of the part sensors
every 24 ms. If the current
state does not match the
expected state, an error mes-
sage is generated. By default,
an error message is gener-
ated after 3 consecutive
errors.
PT_SIMULATE Simulates part monitoring TRUE, FALSE
TRUE: Part monitoring is Default value: FALSE
deactivated and is simulated;
used e.g. when setting up a
cell.
FALSE: Part monitoring is
active.

KUKA.PalletTech 3.7
Variable Description Range of values

PT_MAX_CI_REQUESTS Maximum number of diagnos- 1 ... 25
tic buffer fields of the com-
mand channel
PT_MaxHeight Maximum value of the height ≤ 5%
correction for an item
PT_MaxNumberOfValves Maximum number of possible 1 ... 50
valve configurations in the
configuration tool
PT_MinAdjustment Minimum offset for dynamic Default value: 25 mm
repositioning
The gripper is offset upwards
by at least this value if the
gripper lies below the highest
point on the robot’s motion
path
If the value is too small, the
robot will not be able to
approximate some motions.
PT_HeightStep Increment for the height cor- 0.5 %
rection for an item

12. Command interface
12 Command interface
12.1 Functional description
Description With the command interface (CI) function, KUKA.PalletTech enables a robotic
palletizing cell to be controlled by a PLC. This PLC may be a SoftPLC running
directly on the robot controller or on an external PLC that is connected to the
robot controller via an I/O interface. The command interface provides an I/O
interface for calling commands which are useful during the normal palletizing
process and in response to error states in KUKA.PalletTech. These com-
mands include, for example, pallet reset, slipsheet reset, or the unlocking of
locked-out conveyors or pallets.
12.2 Command interface signals
Description The command interface exchanges data between the PLC and the robot con-
troller via corresponding inputs and outputs. The table below lists the input and
output signals that are used for executing commands via the command inter-
face.
Signal Description Direction Length

Command Input Signals to KUKA.PalletTech PLC - 1 bit
($IN) that all the data in the input KRC
signals are valid. Initializes
the command interface (com-
mand request)
Command For setting the number of the PLC - 8 bits
Number ($IN) command to be executed by KRC
KUKA.PalletTech.
Command Data For setting the value of the PLC - 8 bits
1 ($IN) signal. Depends on the com- KRC
mand selected (i.e. pallet /
conveyor / slipsheet
number).
Command Data For setting the value of the PLC - 8 bits
2 ($IN) signal. Depends on the com- KRC
mand selected (i.e. pallet /
conveyor / slipsheet
number).
Command Out- Signals to the PLC that the KRC - 1 bit
put ($OUT) selected command is com- PLC
pleted and that the data in
the output signals are valid.
Command Acknowledges the command KRC - 8 bits
Number ($OUT) number to the PLC PLC
Command Data Returns the same value as KRC - 8 bits
1 ($OUT) was set on initialization of the PLC
command by the PLC (i.e.
pallet / conveyor / slipsheet
number)
Command Data Returns command-specific KRC - 8 bits
2 ($OUT) data (e.g. number of items) PLC

KUKA.PalletTech 3.7
Signal Description Direction Length

Command Data Returns command-specific KRC - 8 bits
3 ($OUT) data (e.g. number of items) PLC
Command Error Set by KUKA.PalletTech if an KRC - 8 bits
($OUT) error occurred during execu- PLC
tion of the command (zero
signals that the command
was executed successfully)
12.3 Function sequence of the command interface
Description During the function sequence of the command interface, the PLC sets the data
on the signals and must then pulse a request bit. In this way, the command is
initialized in KUKA.PalletTech. KUKA.PalletTech then pulses a signal back to
the PLC to confirm that the command has been executed. The data in the sig-
nals are now valid and can be read. Via the command interface, KUKA.Pallet-
Tech returns the values transferred in the PLC for the purpose of cross
checking. For example, if the PLC requested a pallet reset for pallet 3, Pallet-
Tech returns the signal ‘Pallet reset’ (0000 0001) on the signal ‘Command
Number’, and the signal ‘Pallet 3’ (000 0011) on the signal ‘Data 1’. An error
signal with the value ZERO (0000 0000) indicates that the command has been
executed successfully.
Sequ Signal Precondi

Direction Description
ence designation tion
1 Command no. (8) PLC - These data must -
Command Data 1 KRC be set before the
($1. IN) (8) PLC sets ‘Com-
Command Data 2 mand Input’.
($IN) (8)
2 Command Input PLC - The PLC sets this Sequenc
($IN) (1) KRC signal to tell Pal- e1
letTech that the
data are correctly
set.
3 Command Output KRC - This bit is pulsed Sequenc
(1) PLC by PalletTech e2
when the
response to the
command request
is completed.
When this signal
is pulsed, the data
are ready.

Sequ Signal Precondi

Direction Description
ence designation tion
4 Command no. KRC - Number of the Sequenc
($OUT) (8) PLC requested com- e3
mand. Number is
mirrored so that it
can be confirmed
by the PLC
Command Data 1 KRC - Data set linked to
($OUT) (8) PLC the response. If
Command Data 2 the value for the
($OUT) (8) request is not
Command Data 3 valid, this value is
($OUT) (8) 0.
File Select Error KRC - Error value linked
($OUT) (8) PLC to the response. If
the request was
successful, this
value is 0; other-
wise an error code
is returned.
Fig. 12-1: Time sequence for requests and responses of the command in-
terface
Item Signal name Direction

1 Command Input ($IN) PLC - KRC
2 Command Number ($IN) PLC - KRC
3 Command Data 1 ($IN) PLC - KRC
4 Command Data 2 ($IN) PLC - KRC
5 KRC BUSY ($OUT) KRC - PLC
6 Command Number ($IN) KRC - PLC
7 Command Data 1 ($OUT) KRC - PLC
10 Command Error ($OUT) KRC - PLC

KUKA.PalletTech 3.7
Time Time Description

t1 During this time, the robot controller reads the ‘File
selection’ information from the PLC. The information
must be set continuously and must not change.
t2 The robot controller is busy. During this time, no
changes from the PLC are accepted by the robot con-
troller.
t3 During this time, the PLC can check whether any errors
have occurred on the robot controller during t2.
12.4 Supported commands
Description The following commands are supported by the command interface:
Command no. Command / function

1 Pallet reset
(>>> 12.4.1 "Pallet reset" page 74)
2 Look-ahead function for conveyors
(>>> 12.4.2 "Look-ahead function for conveyors"
page 75)
3 Last Pick
(>>> 12.4.3 "Last Pick" page 76)
4 Unlock locked-out pallet
(>>> 12.4.4 "Unlock locked-out pallet" page 76)
5 Unlock locked-out conveyor
(>>> 12.4.5 "Unlock locked-out conveyor" page 77)
6 Reset slipsheet station
(>>> 12.4.6 "Reset slipsheet station" page 78)
7 Item height factor
(>>> 12.4.7 "Item height factor" page 78)
8 Reset program
(>>> 12.4.8 "Reset program" page 79)
9 Deselect program
(>>> 12.4.9 "Deselect program" page 79)
10 Change number of layers
(>>> 12.4.10 "Change number of layers" page 80)
11 Start Cell.src
(>>> 12.4.11 "Start Cell.src" page 80)
12.4.1 Pallet reset
Description Once a pallet has been completely palletized, it must be removed from the cell
and reset before the robot can start palletizing the next load. After reset, a new
pallet can be brought into the cell and the robot can start palletizing the next
load.
The pallet can only be reset when the signal ‘Pallet present’ for the corre-
sponding pallet station is LOW. As soon as the requested pallet reset has
been successfully completed, the signal ‘Pallet done’ is set to LOW.

When a pallet reset is requested, the following command interface data sig-
nals are required from the PLC:
Signal designation Value / description of the value

Command Number 1
Command Data 1 Pallet number
Command Data 2 Not assigned
The following command interface data signals are sent to the robot by the ro-
bot controller when the requested pallet reset has been successfully complet-
ed:

Command Number 1
Error 0, if successfully completed.
Error number, if failed
12.4.2 Look-ahead function for conveyors
Description With the look-ahead function for conveyors, the PLC can determine how many
items are needed for the next pick-up and setdown cycle. It is possible to send
a request for a conveyor look-ahead for a given conveyor when the part sensor
for this conveyor signals LOW. The request can be sent as soon as the signal
‘Item gripped’ is set, thereby indicating that the items for the current cycle have
been successfully picked up.
If a conveyor look-ahead is to be requested, the following command interface
data signals are required from the PLC:

Command Number 2
Command Data 1 Conveyor number
Command Data 2 Next cycle to be processed.
0 = next cycle
1 = 1st cycle after the next cycle
2 = 2nd cycle after the next cycle
n = nth cycle after the next cycle
bot controller when the requested conveyor look-ahead has been successfully
completed:

Command Number 2
Command Data 2 Number of items to be picked up
Command Data 3 Orientation of the items during pick-
up.
1 = lengthwise
2 = widthwise
Error 0, if successfully completed.
Error number, if failed.

KUKA.PalletTech 3.7
If the robot drops any items while moving to a pallet, the cell controller is re-
sponsible for requesting a new conveyor look-ahead. The correct number of
items to be picked up is determined in the process. For the eventuality that
the number of items ready for pick-up does not match the number of items
required for the next cycle, the cell controller must be assigned a response
strategy. This can occur, for example, if a cycle is resumed after an error due
to a dropped item.
This function can only be used if the conveyor serves only one pallet station.
The function can not be used if the conveyor serves several pallet stations.
12.4.3 Last Pick
Description Last Pick causes the robot to pick up from the conveyor if the part sensor is
set to LOW. Normally, the robot picks up items from the conveyor when the
part sensor is HIGH, signaling that items are ready to be picked up. This func-
tion is used when there is a change to a new product on a particular conveyor.
When the command interface has successfully processed the request for a
Last Pick, this causes the robot to pick up items from the conveyor. On com-
pletion of the pick-up and setdown cycle, the output signal ‘Pallet done’ switch-
es to HIGH. The request for a Last Pick is unsuccessful if the conveyor part
sensor signals HIGH.
Item monitoring is deactivated during the request for a Last Pick, because the
number of items on the conveyor does not match the expected number of
items. If a Last Pick is to be requested, the following command interface data
signals are required from the PLC:

Command Number 3
bot controller when the requested Last Pick has been successfully completed:

Command Number 3
Error 0, if successfully completed
When the response is received from the command interface, this does not
mean that the Last Pick for the conveyor has already occurred. It means that
the robot will execute a Last Pick the next time it picks up from the conveyor.
12.4.4 Unlock locked-out pallet
Description If the robot drops an item while moving between a pick-up station and the pal-
let, and if the Automatic Reject function is activated, then KUKA.PalletTech
locks out the affected pallet. The robot does not pick up any more items for the
locked-out pallet until the locked-out pallet has been unlocked again.
The command ‘Unlock locked-out pallet’ can be used to unlock a locked-out
pallet. The following options exist for the unlock request:

Repeat the failed pick-up and setdown cycle

Skip the failed pick-up and setdown cycle and proceed to the next cycle
Risk of severe damage to the robot and its surroundings. Before the unlock
request is sent, it must be ensured that there are no dropped items on the
pallet.
If a pallet unlock is to be requested, the following command interface data sig-


Command Number 4
Command Data 2 Unlocking type
1 = repeat
2 = continue
bot controller when the requested pallet unlock has been successfully com-
pleted:

Command Number 4
12.4.5 Unlock locked-out conveyor
Description If the robot does not correctly grip an item in the conveyor station, and if the
‘Automatic Reject’ function is activated, KUKA.PalletTech locks out the affect-
ed conveyor. The robot does not pick up any more items from the locked-out
conveyor until this has been unlocked again.
Risk of severe damage to the robot and its surroundings. Before the unlock
request is sent, it must be ensured that there are no dropped items on the
pallet.
If a conveyor unlock is to be requested, the following command interface data


Command Number 5
bot controller when the requested conveyor unlock has been successfully
completed:

Command Number 5

KUKA.PalletTech 3.7

12.4.6 Reset slipsheet station
Description If a slipsheet station is defined as searchable, the PLC can request a reset of
this slipsheet station. After a slipsheet station has been reset, the robot carries
out a search the next time it approaches this station in order to find a slipsheet
to pick up.
If a slipsheet station reset is to be requested, the following command interface

Command Number 6
Command Data 1 Slipsheet station number
bot controller when the requested slipsheet station reset has been successful-
ly completed:

Command Number 6
Command Data 1 Slipsheet station number
12.4.7 Item height factor
Description With the item height factor, the PLC can adapt the height required for an item
on a particular conveyor. The numeric value of this height factor is the percent-
age by which the nominal height is increased or reduced. For example, if an
item with a height of 100 mm arrives on conveyor 1 and a height factor of 4%
is used, KUKA.PalletTech alters the item height to 104 mm. If a height factor
of -3% is used, KUKA.PalletTech alters the item height to 97 mm.
If an item height factor is to be requested, the following command interface

Command Number 7
Command Data 1 Conveyor station number
Command Data 2 Item height factor (percentage).
The most significant bit (bit 8) is
used to denote the factor sign. Only
integer values are supported.
bot controller when the requested item height factor has been successfully
completed:


Command Number 7
Command Data 1 Conveyor station number
12.4.8 Reset program
Description The program currently running can be reset via the command interface by re-
questing a program reset.
If a program reset is to be requested, the following command interface data

Command Number 8
The following command interface data signals are sent to the PLC by the robot
controller when the requested program reset has been successfully complet-
ed:

Command Number 8
12.4.9 Deselect program
Description The program currently running can be deselected via the command interface
by requesting a program deselect.
If a program deselect is to be requested, the following command interface data

Command Number 9
controller when the requested program deselect has been successfully com-
pleted:

Command Number 9

KUKA.PalletTech 3.7
12.4.10 Change number of layers
Description With this command, the PLC can change the number of layers that the robot
needs to palletize before the output signal ‘Pallet done’ is issued. For example,
a layer pattern can be generated that requires 10 layers of items. When exe-
cuting this layer pattern, the robot must therefore palletize these 10 layers be-
fore the ‘Pallet done’ signal is issued. If, during runtime, the pallets are to be
reduced so that only 5 layers of items need to be palletized before the ‘Pallet
done’ signal is issued, then this can be achieved using this command. Re-
questing a change in the number of layers enables the PLC to do this.
If a change in the number of layers is to be requested, the following command
interface data signals are required from the PLC:

Command Number 10
Command Data 2 Number of layers
controller when the requested change in the number of layers has been suc-
cessfully completed:

Command Number 10
12.4.11 Start Cell.src
Description This command is used to select Cell.src. This command can be used to restart
the cell program after KUKA.PalletTech has been terminated due to service
work on the robot.
If a Start Cell.src is to be requested, the following command interface data sig-

Command Number 11
controller when the requested Start Cell.src has been successfully completed:

Command Number 11

12.5 Error messages of the command interface
Error Cause Remedy

0 Requested command suc- -
cessfully executed
1 Requested command is not -
supported
2 Entered pallet number invalid Ensure that the pallet number
lies within the range specified
for pallets in the ConfigTool.
3 Entered conveyor number Ensure that the conveyor
invalid number lies within the range
specified for conveyors in the
ConfigTool.
4 The requested command Wait until the pallet is no
failed because the pallet is longer active. Then issue a
currently active new command request.
5 The requested command (pal- Ensure that the pallet has
let reset) failed because the been removed from the cell
pallet is present before the command is
issued.
6 The requested command Wait until there are no more
failed because items are items left on the conveyor
present on the conveyor before issuing the request.
7 Entered slipsheet number Ensure that the slipsheet
invalid number lies within the range
specified for slipsheets in the
ConfigTool.
8 A request for a Last Pick has Wait until the Last Pick
already been issued for the request has been completely
requested conveyor executed before requesting a
further Last Pick for this con-
veyor.
9 The item height factor lies out- Define a value that lies within
side the valid range defined in the defined range.
the file $config.dat (+/-
PT_MaxHeight)
10 The requested pallet has not Define all required data for the
yet been completely config- pallet before issuing a
ured request.
11 The requested conveyor has Define all required data for the
not yet been completely con- conveyor before issuing a
figured request.
12 The requested slipsheet has Define all required data for the
not yet been completely con- slipsheet before issuing a
figured request.
13 The request for unlocking the It is not necessary to unlock
pallet failed because the pallet this pallet.
concerned is not locked out.
14 The request for unlocking the It is not necessary to unlock
conveyor failed because the this conveyor
conveyor concerned is not
locked out.
15 The Last Pick failed because -
no pallets receive items from
this conveyor.

KUKA.PalletTech 3.7
Error Cause Remedy

16 The request for a slipsheet The slipsheet reset is only
reset failed because this is not possible for searchable sta-
a searchable station. tions
17 The request for program -
deselection failed because
there is currently no program
selected.
18 The request for program Before requesting program
deselection failed because no deselection, ensure that the
program is currently active. program is first stopped with a
cycle stop or by pressing the
stop button
19 Invalid unlocking type Carry out one of the following
unlocking types for pallet
unlocking:
1 - repeat
2 - continue
20 No pallet present A conveyor look-ahead is only
possible if the pallet is
present.
21 No pallet found Assign a layer pattern to the
requested conveyor.
22 Pallet done The pallet is complete – the
conveyor look-ahead must
wait until the pallet has been
reset.
23 The pallet linked to the con- Complete the conveyor cycle.
veyor is currently active Then request the look-ahead
function.
24 The requested number of lay- Adapt the number of layers
ers is less than the number of (the changed number of lay-
layers already palletized. ers must be greater than or
equal to the number of layers
already palletized)
25 Requested number of layers Set a different number of lay-
invalid. ers (the number of layers
must be greater than 0).
26 The requested number of lay- Set a different number of lay-
ers is greater than the number ers (the requested number of
of layers defined for the pallet. layers must not be greater
than the number of layers
defined for the layer pattern).
27 The command interface is -
currently processing a previ-
ously requested change in the
number of layers.
28 The data in the file Pallet- Load the selected layer pat-
Tech.dat do not match the terns to the controller before
data in the cell configuration. sending the request.
The selected layer patterns
must be loaded.

12.6 Debugging the command interface
Description If the value 4 is specified for the debug flag ‘PT_DebugFlag’, the command in-
terface can be debugged using the Variable display dialog box. If this flag is
activated, the commands received are logged by the KRC Logger. Logging of
requests increases the reaction time to commands. This method should only
be activated in order to check that commands are actually being received. Dur-
ing normal operation, the debug flag should be deactivated (setting 0).
It is also possible to retrieve the data for the last 25 command requests sent
by the PLC. The file R1\TP\PALLETTECH\COMMANDINTERFACE.DAT has
a ring buffer data structure. When the command interface processes a com-
mand, the request and the corresponding reaction are recorded in this data
structure.
The value of PT_CI_LastEntry defines which entry was last written where. The
request issued and the reaction from the controller can be seen from these en-
tries. The last element in the data structure represents a time in milliseconds.
The time difference between reactions can be calculated from the difference
between two consecutive entries.

KUKA.PalletTech 3.7

13. Integrating KUKA.PalletTech into an application
13 Integrating KUKA.PalletTech into an application
13.1 Functions in the file UserMethods.SRC
Description The file UserMethods.SRC contains a library of functions which are called
from the main program. By default, these functions are empty and do not ex-
ecute any actions. The sequences required for the specific application can be
programmed in the functions.
Function Description
GLOBAL DEF UserInitCom- This function is called after initialization of KUKA.PalletTech.
plete()
GLOBAL DEF UserErrorHan- This function is called after an error. Information about the error
dler(ErrorNum :IN, number and the severity of the error can be communicated to the
Parameter1: IN, Severity: IN) PLC. The parameter contains the relevant information about the
error.
GLOBAL DEF HandleConvey- This function is called when a conveyor is locked out. Sequences
orLock(ConveyorNumber :IN) can be programmed for locked-out conveyors.
GLOBAL DEF HandleConvey- This function is called when a locked-out conveyor is unlocked.
orUnLock(ConveyorNumber Sequences can be programmed for unlocking locked-out con-
:IN) veyors.
GLOBAL DEF HandlePallet- This function is called when a pallet is locked out. Sequences
Lock(PalletNumber :IN) can be programmed for locked-out pallets.
GLOBAL DEF HandlePalle- This function is called when a locked-out pallet is unlocked. Se-
tUnLock(PalletNumber :IN) quences can be programmed for unlocking locked-out pallets.
GLOBAL DEF HandlePart- This function is called when an individual setdown process is
sPlaced(PalletNumber :IN) completed on a pallet.
GLOBAL DEF HandleAllPart- This function is called when the setdown processes for a whole
sPlaced(PalletNumber :IN) cycle are completed on a pallet.
GLOBAL DEF UserInitialize() This function is called while KUKA.PalletTech is booting. Cell-
specific initializations can be programmed.
GLOBAL DEF UserCleanup() This function is called when the robot has moved to the HOME
position after a cycle stop. Cell-specific clean-ups can be pro-
grammed.
GLOBAL DEFFCT BOOL This function is called when a pallet is selected for the next pal-
CheckPalletConditions(Pallet- letizing process. Additional checks can be programmed in order
Number :IN) to decide which pallet should be palletized next.
TRUE: Pallet is palletized next.
FALSE: Pallet is not palletized next.
GLOBAL DEF HandlePart- This function is called when an item has been picked up and the
sPicked(ConveyorNumber :IN, robot has reached the first position after pick-up.
ItemId :IN)
GLOBAL DEF HandleSlip- This function is called when a slipsheet has been picked up and
sheetPicked(SlipsheetNum- the robot has reached the first position after pick-up.
ber :IN, ItemId :IN)
GLOBAL DEF HandlePost- This function is called when the robot has reached the setdown
PlaceAction() position. The actions required after setdown can be integrated.
GLOBAL DEFFCT INT Han- This function is called after an error during pick-up. Precondition:
dlePartPickError() The parameter Automatic Reject is deactivated.
GLOBAL DEFFCT INT Han- This function is called after an error due to a dropped item. Pre-
dlePartDroppedError() condition: The parameter Automatic Reject is deactivated.
GLOBAL DEFFCT BOOL This function is called after an error during pick-up or due to a
HandleRejectParts() dropped item. Precondition: The parameter Automatic Reject is
activated.
User-defined sequences can be programmed.

KUKA.PalletTech 3.7
GLOBAL DEF PrePickProc- This function is called before items are picked up from a convey-
ess(Target: IN) or. User-defined sequences can be programmed.
GLOBAL DEF PostPickProc- This function is called from the safe position on the pallet: after
ess(Source: IN, Target: IN) the items have been picked up from the conveyor (SOURCE)
and before the items are set down on the pallet (TARGET). User-
defined sequences can be programmed.
GLOBAL DEFFCT BOOL Trig- User-defined sequences can be programmed for searching for
gerGripperSearch(ItemId: IN) pallets or slipsheets. The return value of the function determines
whether the gripper valves are switched on before the search.
13.2 User-defined motions
Overview KUKA.PalletTech moves the robot along predefined positions in the stations.
The directory R1\PROGRAM\PTPERCH\ contains 2 files in which motions to
positions on the conveyor and the pallet are defined.
PT_ConveyorMotion.SRC
PT_PalletMotion.SRC
The robot moves to each of the positions with a LIN or PTP motion. The motion
type can be changed.
13.2.1 Functions in the file PT_ConveyorMotion.SRC
Description
GLOBAL DEF MotionToPre- This function contains the motion to the position before pick-up.
Pick(xPrePickPosition: IN) This motion is a PTP motion by default and can be changed into
a LIN motion.
GLOBAL DEF MotionToP- This function contains the motion to the grip position. This motion
ick(xPickPosition: IN) is a LIN motion by default and can be changed into a PTP mo-
tion.
GLOBAL DEF MotionToPost- This function contains the motion to the position after pick-up.
Pick(xPostPickPosition: IN) This motion is a PTP motion by default and can be changed into
a LIN motion.
13.3 Reconfiguring the gripper
Overview KUKA.PalletTech can pick up items lengthwise or widthwise relative to the

conveyor. The orientation of the item does not always exactly match the orien-
tation of the system.
Some grippers need to be reconfigured in order to pick up items. For example,
to pick up an item lengthwise with a clamp gripper, the fixed edge of the gripper
must be extended. By contrast, to pick up an item widthwise, the fixed edge of
the gripper must be retracted.
The following information must be communicated to KUKA.PalletTech to ena-
ble the pick-up and setdown positions to be correctly calculated for a reconfig-
ured gripper:
Station type
Station number
Orientation of the item
I/Os used by the reconfigured gripper
Change in gripper dimensions

Program The information for the reconfigured gripper can be defined in this function.
1 DECL cfdw_StationInfo Target
2 ; determine the station for which the customization is required.
3 IF (Target.se_StationType ==Station type required) AND
4 (Target.si_StationNum ==Station number from the configtool) THEN
5 ; Determine the orientation of the item in which the
customization is
6 required.
7 SWITCH (Target.si_StaOriType)
8 CASE 1,3 ; Lengthwise
9 ; Initiate Gripper extension by setting required IO
10 SetOutputCont(number of the output bit,required State)
11 ;Inform palletTech of the displacement.
12 ;When gripper is extended supply negative number for the
displacement
13 ;else supply positive number for the displacement
14 SetGripperDisplacement(X-displacement,Y-
Displacement,ZDisplacement)
15 ;If this orientation change is introducing offset in the pick
position
16 ; that is defined in the configtool then that offset must be
supplied
17 here.
18 SetPickOffsets(x-pick offset, y-pick offset)
19 CASE 2,4 ; Widthwise
21 SetOutputCont(number of the output bit, required State)
22 ; Inform palletTech of the displacement.
23 ; When gripper is extended supply negative number for the
displacement
24 ; else supply positive number for the displacement
25 SetGripperDisplacement(X-displacement, Y-Displacement,
ZDisplacement)
26 ; If this orientation change is introducing offset in the pick
position
supplied
28 here.
29 SetPickOffsets(x-pick offset, y-pick offset)
30 ENDSWITCH
31 ELSE
32 ; IF it is not the correct station to apply the offset the set
gripper to
33 normal
34 SetOutputCont(number of the output modified, normal state)
35 SetGripperDisplacement(0.0, 0.0, 0.0)
36 END
13.3.1 Defining the station for gripper reconfiguration
Description The station to which the gripper reconfiguration refers is defined with the argu-
ment Target.
The argument Target consists of the following elements:
.se_StationType: Station type
#Conveyor: Conveyor
#SlipSheet: Slipsheet station
#HOME: HOME position
#Pallet: Pallet station
#Reject: Reject station
#UNKNOWN: Unknown station
.si_StationNum: Station number from the configuration program
.si_StaOriType: Alignment of the item on the station
0: Invalid station

KUKA.PalletTech 3.7
1, 3: Lengthwise alignment
2, 4: Widthwise alignment
Fig. 13-1: Alignment of items
1 Lengthwise alignment 3 Lengthwise alignment

2 Widthwise alignment 4 Widthwise alignment
Items 1 and 3 differ in the orientation of the labeling, as do items 2 and 4.

In some cases, the exact determination of the alignment is not possible
due to the physical constraints of the cell or the gripper. In general, align-
ments 1 and 3 and alignments 2 and 4 can be combined.
13.3.2 Communicating the required changes to PalletTech
Description The required changes comprise the following:

Setting the appropriate I/O signals for implementing the physical change
(>>> 13.3.2.1 "I/O settings" page 88)
Communicating the gripper size or position change to the PalletTech pars-
er
(>>> 13.3.2.2 "Setting values for the gripper change" page 88)
To calculate the pick-up and drop-off points, the KRL element of PalletTech
requires information about the physical changes to the gripper.
Caution!
If the information about the changes is not specified, severe damage to the
robot and the cell may result.
13.3.2.1 I/O settings
Description 1 GLOBAL DEF SetOutputCont(iIndex :IN, bState: IN)

2 Description: Sets an output to the desired PalletTech bState
3 (with a CONTINUE)
4 iIndex - $OUT Index to set
5 bState - true (on), false (off)
6 GLOBAL DEF PulseOutputCont(iIndex :IN, bState: IN, Time: IN)

7 Descripion: Pulses an output to the desired PalletTech bState
8 (with a CONTINUE)
9 iIndex - input Index to pulse
10 bState - true (on), false (off)
11 Time - amount of time (sec) to pulse
13.3.2.2 Setting values for the gripper change
Description If a change to the gripper affects the size or dimensions of the gripper, this in-
formation must be communicated to PalletTech.

1 GLOBAL DEF SetGripperDisplacement(fXDist :IN, fYDist :IN, fZDist

:IN)
2 Description: Sets runtime changes to the gripper.
3 fxDist: Displacement in X direction.
4 fyDist: Displacement in Y direction. (Extending gripper affects –
5 ve Y and retracting gripper affects +ve y)
6 fzDist: Displacement in Z direction.
13.3.3 Example: reconfiguring a gripper
Description On conveyor 3, a clamp gripper must be extended by 25 mm in the Y direction

in order to pick up an item lengthwise. The extension is not necessary on other
conveyors. The extension of the gripper is initialized via output 40.
After the item has been set down, the reconfigured gripper must be reset.
Program 1 DECL cfdw_StationInfo Target

2 ; determine the station for which the customization is required.
3 IF (Target.se_StationType == #Conveyor) AND (Target.si_StationNum
== 3) THEN
4 ; Determine the orientation of the item in which the
customization is
5 required.
6 SWITCH (Target.si_StaOriType)
7 CASE 1,3 ; Lengthwise
9 SetOutputCont(40, TRUE)
10 ; Inform palletTech of the displacement.
11 ; When gripper is extended supply negative number for the
displacement
12 ; else supply positive number for the displacement
13 SetGripperDisplacement(0.0, -25.0, 0.0) ;extending gripper by
25mm
14 ; If this change is introducing offset in the pick position
because of
15 the turner functionality
supplied
17 here.
18 SetPickOffsets(0.0, 10.0)
19 CASE 2,4 ; widthwise
20 ; reset the gripper changes
21 SetOutputCont(40, FALSE)
24 DEFAULT
25 ENDSWITCH
26 ELSE
27 ; IF it is not the correct station to apply the offset then set
gripper to
28 normal
29 SetOutputCont(40,FALSE)
32 ENDIF
33 END
13.4 Handling offsets of the pick-up position
Description The function for lengthwise and widthwise pick-up makes it possible to modify
pick-up positions. Most systems use a turning mechanism to turn the item on
the conveyor from the lengthwise direction to the widthwise direction from one
pick-up to the next. This mechanism enables the alignment of the item on the
conveyor to be changed. This can lead to changes in the position on the con-

KUKA.PalletTech 3.7
veyor – particularly when the conveyor is wider than the item. For this reason,
it is not possible to move to the items, which are transported in a standard di-
rection defined in the editor, in the event of a change in their alignment. In or-
der to compensate for this change, a modification is made in the PalletTech
KRL.
Global DEF SetPickOffsets(XOffset :IN, YOffset :IN)
Description: This function applies custom pick offsets to the pick
positions.
XOffset: Offset to be applied in the X direction.
YOffset: Offset to be applied in the Y direction.

14. Appendix
14 Appendix
14.1 Example of sequence values
Overview If the “Dynamic Reposition” option is activated, every station must be assigned
a unique sequence value. If the robot moves within the cell from the source
station to the target station, KUKA.PalletTech uses the sequence value to de-
termine which stations the robot will cross.
When assigning the sequence values, ensure that the values are arranged
in ascending or descending order around the cell in accordance with the ro-
bot motion.
Example The following diagram shows an example of a numbering order for the se-
quence values.
Fig. 14-1: Example of sequence values
1 Pallet station 2, sequence value = 1

3 Slipsheet station 1, sequence value = 3
4 Conveyor station 1, sequence value = 4
8 Slipsheet station 2, sequence value = 8
Description If the robot moves from conveyor station 4 to pallet station 3, KUKA.PalletTech
determines which stations need to be crossed. In this example, the robot rec-
ognizes that conveyor station 4 has the sequence value 7. Pallet station 3 has
the sequence value 10. The robot crosses all the stations whose sequence
values lie between 7 and 10.
For dynamic repositioning, KUKA.PalletTech determines which of these sta-
tions (conveyor station 4, slipsheet station 2, pallet station 4 and pallet station

KUKA.PalletTech 3.7
3) is the highest. KUKA.PalletTech then automatically adapts the perch posi-

tions of the source and target stations, so that the robot moves at a height
which ensures that these stations are passed without collisions.
14.2 Look-ahead function
The look-ahead function is a signal to a conveyor. The look-ahead function

can be used if one pallet station is fed by a number of conveyors.
Description With the look-ahead function, the PLC can determine how many items are
needed for the next pick-up and setdown cycle. The PLC sends the conveyor
a request for the next item as soon as the “Item gripped” signal is set. The re-
quest to the conveyor is sent until the layer pattern is completely processed.
14.3 Motion to and from the conveyor
The motion types can be changed in the file C:\R1\PROGRAM\PT-

PERCH\PT_CONVEYORMOTION.SRC.
Motion to the When the robot has reached the perch position of the conveyor station, it car-
conveyor ries out the following motions:
1. PTP motion to the perch position of the conveyor station
2. PTP motion to the pre-pick position
3. LIN motion to the grip position
Fig. 14-2: Motion to the conveyor
A Motion with “Dynamic” parameter deactivated

B Motion with “Dynamic” parameter activated
1 Perch position
2 Pre-pick position
3 Grip position
4 Perch offset
5 Pre-pick offset
Motion from After picking up the item, the robot executes the following motions:
conveyor 1. LIN motion from the grip position to the post-pick position

14. Appendix
Fig. 14-3: Motion from the conveyor

1 Perch position
2 Post-pick position
3 Grip position
4 Perch offset
5 Post-pick offset
14.4 Motion to and from the pallet station
The motion types can be changed in the file C:\R1\PROGRAM\PT-

PERCH\PT_PALLETMOTION.SRC.
Motion to the When the robot has reached the perch position of the pallet station, it carries
pallet station out the following motions:
1. PTP motion to the perch position of the pallet station
2. PTP motion to the approach point
3. LIN motion to the pre-drop position
4. LIN motion to the setdown position
Fig. 14-4: Motion to the pallet

1 Perch position of the pallet station
2 Pre-drop position
3 Approach point
4 Setdown position
5 Perch offset
6 Pre-drop offset
Motion from the After setting down the item, the robot executes the following motions:
pallet station

KUKA.PalletTech 3.7
1. LIN motion from the grip position to the post-pick position

The following diagram shows the motions of the robot when it moves away
from the setdown position. If more than one setdown operation is necessary,
the robot moves to the next approach point from the post-drop position. The
robot moves to the perch position as soon as the last item has been set down.
Fig. 14-5: Motion from the pallet

1 Perch position
2 Post-drop position
4 Setdown position
5 Perch offset
6 Post-drop offset
14.5 Motion to and from the slipsheet station
Overview The motions required for the robot to pick up a slipsheet depend on the type
of slipsheet station. A slipsheet station can be searchable or non-searchable.
Motion away from the slipsheet station is equivalent to the motion of the robot
away from a conveyor station.
Searchable When the robot has reached the perch position of the pallet station, it carries
slipsheet station out the following motions:
1. PTP motion to the perch position
2. PTP motion to the above-pick position
3. LIN motion with fast search velocity and acceleration (search 1, until the
“slow” search sensor is tripped)
4. LIN motion with slow search velocity and acceleration (search 2, until the
stop sensor is tripped)
Grip position for the next approach to this station is saved
5. LIN motion to the above-pick position
Search 1 and search 2 are only necessary if no grip position is saved.

14. Appendix
Fig. 14-6: Motion to the slipsheet station
1 Perch position 5 Taught base frame

2 Pre-search position 6 Calculated base frame
3 Search 1 7 Pre-search offset
4 Search 2 8 Configured Z offset
Non-searchable When the robot has reached the perch position of the pallet station, it carries
slipsheet station out the following motions:
2. PTP motion to the above-pick position
3. LIN motion to the grip position
Grip position for the next approach to this station is saved
Fig. 14-7: Motion to the slipsheet station, non-searchable
1 Perch position 5 Calculated base frame

2 Pre-search position 6 Pre-search offset
3 Grip position 7 Configured Z offset
4 Taught base frame

KUKA.PalletTech 3.7

15. KUKA Service
15 KUKA Service
15.1 Requesting support
Introduction The KUKA Roboter GmbH documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.
Faults leading to production downtime should be reported to the local KUKA

subsidiary within one hour of their occurrence.
Information The following information is required for processing a support request:

Model and serial number of the robot
Model and serial number of the controller
Model and serial number of the linear unit (if applicable)
Version of the KUKA System Software
Optional software or modifications
Archive of the software
Application used
Any external axes used
Description of the problem, duration and frequency of the fault
15.2 KUKA Customer Support
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Argentina Ruben Costantini S.A. (Agency)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com
Australia Marand Precision Engineering Pty. Ltd. (Agency)

153 Keys Road
Moorabbin
Victoria 31 89
Australia
Tel. +61 3 8552-0600
Fax +61 3 8552-0605
robotics@marand.com.au

KUKA.PalletTech 3.7
Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be
Brazil KUKA Roboter do Brasil Ltda.

Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guançã
CEP 02151 900 São Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
info@kuka-roboter.com.br
Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl
China KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd.

Shanghai Qingpu Industrial Zone
No. 502 Tianying Rd.
201712 Shanghai
P.R. China
Tel. +86 21 5922-8652
Fax +86 21 5922-8538
Franz.Poeckl@kuka-sha.com.cn
www.kuka.cn
Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
info@kuka-roboter.de
www.kuka-roboter.de

15. KUKA Service
France KUKA Automatisme + Robotique SAS

Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
commercial@kuka.fr
www.kuka.fr
India KUKA Robotics, Private Limited

621 Galleria Towers
DLF Phase IV
122 002 Gurgaon
Haryana
India
Tel. +91 124 4148574
info@kuka.in
www.kuka.in
Italy KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it
Japan KUKA Robotics Japan K.K.

Daiba Garden City Building 1F
2-3-5 Daiba, Minato-ku
Tokio
135-0091
Japan
Tel. +81 3 6380-7311
Fax +81 3 6380-7312
info@kuka.co.jp
Korea KUKA Robot Automation Korea Co. Ltd.

4 Ba 806 Sihwa Ind. Complex
Sung-Gok Dong, Ansan City
Kyunggi Do
425-110
Korea
Tel. +82 31 496-9937 or -9938
Fax +82 31 496-9939
info@kukakorea.com

KUKA.PalletTech 3.7
Malaysia KUKA Robot Automation Sdn Bhd

South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
info@kuka.com.my
Mexico KUKA de Mexico S. de R.L. de C.V.

Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
Norway KUKA Sveiseanlegg + Roboter

Bryggeveien 9
2821 Gjövik
Norway
Tel. +47 61 133422
Fax +47 61 186200
geir.ulsrud@kuka.no
Austria KUKA Roboter Austria GmbH

Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
office@kuka-roboter.at
www.kuka-roboter.at
Poland KUKA Roboter Austria GmbH

Spólka z ograniczona odpowiedzialnoscia
Oddzial w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
ServicePL@kuka-roboter.de

15. KUKA Service
Portugal KUKA Sistemas de Automatización S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
kuka@mail.telepac.pt
Russia OOO KUKA Robotics Rus

Webnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
kuka-robotics.ru
Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se
Switzerland KUKA Roboter Schweiz AG

Riedstr. 7
8953 Dietikon
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch
Spain KUKA Sistemas de Automatización S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 814-2353
Fax +34 93 814-2950
Comercial@kuka-e.com
www.kuka-e.com

KUKA.PalletTech 3.7
South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za
Taiwan KUKA Robot Automation Taiwan Co. Ltd.

136, Section 2, Huanjung E. Road
Jungli City, Taoyuan
Taiwan 320
Tel. +886 3 4371902
Fax +886 3 2830023
info@kuka.com.tw
www.kuka.com.tw
Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
atika@ji-net.com
www.kuka-roboter.de
Czech Republic KUKA Roboter Austria GmbH

Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Pocernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
support@kuka.cz
Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu

15. KUKA Service
USA KUKA Robotics Corp.

22500 Key Drive
Clinton Township
48036 Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
info@kukarobotics.com
www.kukarobotics.com
UK KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
sales@kuka.co.uk

KUKA.PalletTech 3.7

Index
Index
A I
Appendix 91 I/O settings 88
Automatic operation, configuration 46 Inputs, configuration 37, 39
Automatic Reject 32, 61 Installation 23
Installation, KUKA.PalletTech 23
B Introduction 7
Base number 34 Item 8
Base, calibration 30 Item cluster 8
Item height factor 78
C Items, defining the alignment 34
Calibration, conveyor 28
Calibration, station 29 K
Cell integration 18 Knowledge, required 7
Cell number 32 KUKA Customer Support 97
Change number of layers 80 KUKA.PalletTech, integration into an application
Command interface 71 85
Command interface signals 71
Communicating the required changes to Pallet- L
Tech 88 Last Pick 76
Configuration 27 Layer 8
Configuration program, overview 31 Layer pattern 8
Configuration, overview 27 Layer pattern file 8
Conveyor station 8 Layer pattern files, copying to robot controller 55
Conveyor, calibration 28 Layer patterns, creation 18
Conveyor, unlocking 59 Layer patterns, loading 55
Layer patterns, selecting 55
D Load 8
Debugging the command interface 83 Load data, entering 38
Deselect program 79 Logical gripper 14
Detented Valves 33 Logical offset 14
Diagnosis 59 Logical offset in a clamp gripper 15
Directory for layer pattern files, defining 52 Logical offset in a vacuum gripper 14
Documentation, industrial robot 7 Look-ahead function 8
Dynamic 34 Look-ahead function for conveyors 75
Dynamic repositioning 33, 43
M
E Menus 25
Error codes 66 Messages 63
Error messages of the command interface 81 Motion, from the slipsheet station 94
Motion, to and from the conveyor 92
F Motion, to and from the pallet station 93
Frame 8 Motion, to non-searchable slipsheet station 95
Full load 8 Motion, to searchable slipsheet station 94
Function sequence of the command interface 72 Multi-cycle conveyor 8
Functional description, command interface 71 MultiPick / MultiPlace 8
Functions 11 MultiPick / SinglePlace 8
G N
Gripper change, setting values 88 Number of Conveyors 32
Gripper, configuring inputs 39 Number of Pallets 32
Gripper, configuring outputs 39 Number of Slipsheets 32
Gripper, reconfiguring 86
Grippers 12 O
Operation 25
H Orientation 34
Handling offsets of the pick-up position 89 Outputs, configuration 37, 39
Hardware 23 Overview of configuration, KUKA.PalletTech 27
Height, minimum 34 Overview, KUKA.PalletTech 11

KUKA.PalletTech 3.7
Overview, setting up production operation 55 System variables 69
P T
Package 8 Target group 7
Pallet 8 Terms used 8
Pallet reset 74 Trademarks 9
Pallet station 8 Training program 7
Palletizing cycle 8 Troubleshooting 61
Palletizing program 8
Palletizing system 8 U
Palletizing, starting 57 Uninstallation, KUKA.PalletTech 23
Perch position 8 Unlock locked-out pallet 76
Perch position, configuration 48 User-defined motions 86
Perch positions, teaching 48 UserMethods.SRC, functions 85
Physical gripper 12
Product change, automatic 46 W
Product description 11 Warnings 7
Production operation, starting 57 Workflow 18
Programming 55
PT_ConveyorMotion.SRC, functions 86 X
X offset 34
R
Reconfiguring a gripper, example 89 Y
Reinstallation, KUKA.PalletTech 23 Y offset 34
Reject station 8
Reset program 79 Z
Reset slipsheet station 78 Z offset 34
Robot cell, configuration 32
Robot cell, configuring stations 33
Robot motions, configuration 41
Runtime operation 19
S
Safe position, example 50
Safe positions, inline forms 51
Safe positions, teaching 49
Safety 21
Safety instructions 7
Searchable 34
Segment 14
Segments, numbering convention 14
Sequence 34
Sequence values, example 91
Service, KUKA Roboter 97
Slipsheet 8
Slipsheet station, non-searchable 95
Slipsheet station, searchable 94
Softkeys, configuration 26
Software 23
Start Cell.src 80
Station number 8
Station relationships, configuration 45
Station, calibration 29
Stations, configuration 33
Stations, configuring inputs 37
Stations, configuring outputs 37
Status keys, configuration 26
Stopping a program 57
Support request 97
Supported commands 74
System requirements 23

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KUKA System Technology KUKA Roboter GmbH

For KUKA System Software 5.2, 5.4, 5.5 and 5.6

Version: KST PalletTech 3.7 V2 en

Publication: Pub KST PalletTech 3.7 en

2 / 107 Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en

2 Product description ..................................................................................... 11

Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en 3 / 107

6.4.4 Configuring the inputs and outputs of the stations ............................................... 37

11 System variables ......................................................................................... 69

12 Command interface ..................................................................................... 71

4 / 107 Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en

12.4.11 Start Cell.src ......................................................................................................... 80

13 Integrating KUKA.PalletTech into an application ..................................... 85

15 KUKA Service .............................................................................................. 97

Index ............................................................................................................. 105

Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en 5 / 107

6 / 107 Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en

1.1 Target group

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

1.3 Representation of warnings and notes

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

Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en 7 / 107

1.4 Terms used

The following terms are used in this documentation:

8 / 107 Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en

Windows is a trademark of Microsoft Corporation.

Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en 9 / 107

10 / 107 Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en

2.1 Overview of KUKA.PalletTech

Overview KUKA.PalletTech is an add-on technology package which simplifies the pro-

Fig. 2-1: KUKA.PalletTech concept

1 Offline PC with KUKA.PalletEdit

Functions  Supports fork grippers, vacuum grippers and clamp grippers

Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en 11 / 107

Physical and logical grippers can only be configured using KUKA.PalletEdit.

The following gripper types are supported:

2.2.1 Physical gripper

Fig. 2-2: Suction cups

Each valve controls one suction cup via an output.

12 / 107 Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en

Fig. 2-3: Outputs for controlling the suction cups

Fig. 2-4: Items held in the gripper

Each part sensor is represented by an input.

Fig. 2-5: Part sensor inputs

Fig. 2-6: Gripper I/O display

Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en 13 / 107

2.2.2 Logical gripper

2.2.2.1 Numbering convention for segments

Fig. 2-7: Segment numbering

2.2.2.2 Numbering convention for more than one row of segments

Fig. 2-8: Numbering of more than one row of segments

2.2.2.3 Logical offset in a vacuum grippers

14 / 107 Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en

Fig. 2-9: Logical offset in a vacuum gripper

1 Side view 3 Logical TCP

2.2.2.4 Logical offset in a clamp grippers

Fig. 2-10: Logical offset in a clamp gripper

Issued: 21.01.2010 Version: KST PalletTech 3.7 V2 en 15 / 107

Fig. 2-11: Logical offset in a clamp gripper (front view)

2.3 Example of a palletizing cell

Overview KUKA.PalletTech supports 3 types of station within a cell:

Fig. 2-12: Example of a palletizing cell

Functions Supports fork grippers, vacuum grippers and clamp grippers

Properties of the slipsheets (length, width, height, weight and accelera-

Overview Teaching the TCP

Overview Defining cell data with PalletEdit.

Defining the base pallet

Overview Making the layer patterns created available to the robot

Hardware KR C2 or KR C2 edition2005 robot controller with network connection

Software KUKA System Software 5.2, 5.4, 5.5 or 5.6

Precondition User group “Expert”

Precondition KUKA.PalletTech is installed.

Precondition KUKA.PalletTech has been uninstalled.

Precondition A previously calibrated tool is mounted on the mounting flange.

Precondition User group “Expert”