OPTION

KR C2

Fast Measurement

Functions for Measuring Components

Release 1.0

Issued: 20 Jun 2005 Version: 00

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e Copyright 2005

KUKA Roboter GmbH

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

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Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.1 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.2 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 About this documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Basic theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Activating Fast Measurement in robot type KR 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Upgrading other robot types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Start--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Connection of measuring sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Connector pin allocation X33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4 Connection examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Fast Measurement with one DSE and one RDC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Fast Measurement with two DSEs and two RDC2s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 System definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Checking the connected measuring inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.1 Viewing individual measuring inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.2 Viewing all measuring inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2.3 Cyclical display of the measuring inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 MeasureTech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1.1 Single--robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1.1.1 Program structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1.1.2 Program creation and reference measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1.1.3 Switching to measurement mode with the correction function active . . . . . . . . . . . . . . . . . . . 29
6.1.1.4 Reteaching points without a master component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1.1.5 Work envelope monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1.2 Two--robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.1.2.1 Measuring robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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 Fast Measurement

6.1.2.2 Processing robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.2 TouchSense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2.1 Single touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2.2 Double touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2.2.1 Calculating the center of a gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2.2.2 Calculating the position of a corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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1 Introduction

1 Introduction
1.1 General
This documentation describes the product “Fast Measurement”. The Fast Measurement
function package is a technology package for recording robot position data using fast
measuring inputs and digital sensors to measure components and subsequently correct
application programs.
The Fast Measurement function package is used to program search commands in the KR C2
for measuring components using digital sensors. The Fast Measurement option consists
essentially of an adapter kit, in the form of a modified connection cover on the RDC housing
in the base of the robot, and the familiar software packages MeasureTech and TouchSense.
The Fast Measurement option is generally ordered along with the robot, but can also be
retrofitted if required (KR C2 only). Compared with conventional digital inputs, the measuring
inputs have significantly shorter switching times thus resulting in greater accuracy and
reproducible measurement results. The new functions also allow the possibility of connecting
the measuring sensors directly to the base of the robot instead of in the robot controller.

1.2 System requirements

1.2.1 Software

The basic system requirements for “Fast Measurement” are:

-- KR C system software (KSS) 4.1 or higher

1.2.2 Hardware
-- RDC2
-- KUKA robot controller KR C2

While the configuration and programming of “Fast Measurement” applications requires no

special training, adequate knowledge of the KR C2 robot controller and its configuration
is necessary.
Knowledge of handling electronic components is also required.

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 Fast Measurement

1.3 About this documentation

This documentation contains a description of the optional “Fast Measurement” technology
package, including:
G Introduction
G Basic theory
G Start--up
G Configuration
G Application
It is assumed, for the hardware installation, that the user has adequate knowledge regarding
the installation and maintenance of industrial robots from KUKA Roboter GmbH.

All important procedural steps are recapitulated in tabular form at the end of each chapter.

For information about the technology packages MeasureTech and TouchSense, refer to
the relevant documentation modules.

Information about the robot controller can be found in the operating and programming
handbooks supplied with the robot.

1.4 Target group

G Programming and servicing personnel

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2 Basic theory

2 Basic theory
2.1 Functional description
The output signal of a digital proximity sensor (e.g. when the sensor passes over the edge
of a component) is read in the RDC in the base of the robot and transferred to the DSE in
the robot controller. In the robot program, an interrupt routine triggers a reaction,
e.g. detection of the robot position at the time the signal changed. Further evaluations and
calculations are made in the software technology packages MeasureTech and TouchSense;
a detailed description of these, however, goes beyond the scope of this documentation.

For information about the technology packages MeasureTech and TouchSense, refer to
the relevant documentation modules.

The Fast Measurement function usually calculates a sequence of several such interrupt
positions. Based on the number and respective positions of such measuring points, the
controller can detect and correct linear and rotational offsets of components in up to six
degrees of freedom. A maximum of six measuring points are required.
Corrections can be carried out in one or more steps, as required. In this way, a series of
search motions already executed can be corrected, thus making it possible to move to
specific measuring points on the component. Furthermore, the corrections can be carried
out either on the inspection robot itself, or on a second processing robot by means of serial
communication. The mathematical coupling of the robot systems is achieved simply by
calibrating a shared base system. As a result of the correction, the motion sequence relative
to the component always corresponds with the taught contour of the reference component.
There are five measuring inputs available on the RDC2.

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 Fast Measurement

2.2 Technical data

Signal level for the measuring inputs +24 V DC (--10%;

+20%)
Reaction time to change of signal 125 msec
Number of measuring inputs 5
Maximum RDC--DSE cable length (KR C2), see KR C2 50 m
documentation
Maximum RDC<-->sensor cable length depends on application
*)
Supply voltage to inputs (internal) +24 V DC internal
Maximum capacity of the supply voltage 500 mA incl. EMT
Connector for measuring inputs Harting HAN 8D
Recommended cable type for the measuring inputs depends on application
*)
RDC2 used as standard Series 2000
Retrofit possible Only with KR C2
Software requirements Software release 4.1 or
higher
Detailed requirement: software version 4.1.4, Service Pack
(SP)1, kernel system KS V4.48

*) If necessary, use shielded cable with shield gland

2.3 Activating Fast Measurement in robot type KR 2000

The hardware requirements must first be met before it is possible to use the Fast
Measurement option with the KR 2000. This is generally done by ordering a new robot
designed accordingly. It is also possible to upgrade machines with KR C2--generation
controllers. This is done by unscrewing the RDC housing cover in the base of the robot and
replacing it with a different cover with an integrated Harting HAN 8D connector for connecting
the sensor.

Further details on installing this cover can be found in Chapter 3 [Start--up] of this
documentation.

The corresponding technology package must also be loaded (included in basic KR C2

software package from software version 4.0 onwards). Measurement functions can also be
implemented by experienced programmers with expert knowledge, but an integrated
concept and reliable functionality are the responsibility of the user.
The measuring inputs are made available for program evaluation by configuring them
accordingly in the robot system.

See Chapter 3 [Start--up] of this documentation.

Activation of Fast Measurement is now completed.

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2 Basic theory (continued)

2.4 Upgrading other robot types

Use of the option “Fast Measurement” is reserved for KR 2000--series robots with the
KR C2 controller. Upgrading any other robot type requires consultation with Technical
Support at KUKA Roboter GmbH.

The Fast Measurement option described in this documentation can only be

used with the robot <--> controller combination specified; other combina-
tions may result in damage to components!

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 Fast Measurement

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3 Start--up

3 Start-- up
The robot system hardware preparations must be made first before this technology package
can be put into operation.
For a system with a single robot, this includes the mounting of a digital sensor on the robot
flange, or stationary installation in the work envelope of the robot, and the establishment of
an electrical connection to one of the fast measuring inputs on the RDC in the base of the
robot via the RDC housing cover.

3.1 Safety instructions

The steps described below for installing the sensor connection hardware
presuppose basic knowledge of handling electrical and electronic components.
Before the components are installed, the robot system must be completely
disconnected from the power supply and safeguarded against reconnection.
Before commencing installation, the person carrying out the work must connect
himself/herself to the ground using appropriate equipment in accordance with the
applicable ESD directives.
During the subsequent testing of the “Fast Measurement” function, the operator
must be outside the range of motion of the robot. Initial program tests must only
be executed in Test mode (T1/T2) with reduced override.

Further safety instructions can also be found in the [MeasureTech] and [TouchSense]
technology package documentation modules.

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 Fast Measurement

3.2 Hardware

Fig. 1 RDC housing open

In order to connect a digital sensor to the fast measuring inputs, the existing RDC housing
cover is removed along with the 4 fastening screws (see Fig. 1).

Observe ESD measures!

A connecting cable (Fig. 2/1) can be found inside the housing cover of the optional hardware
kit (Art. no. 00--110--296). It consists of individual wires of different colors. The connecting
cable has a premounted 7--pole Lumberg connector (2) at one end.

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3 Start--up (continued)

1 = Connecting cable
2 = 7--pole Lumberg connector

Fig. 2 Optional housing cover with internal connecting cable

The other end of the connecting cable terminates in connector X33 (Fig. 3/1), mounted
externally on the housing cover, to which the sensor cable will subsequently be connected.

1 = Connector X33
2 = Fastening screws

Fig. 3 Optional housing cover with connector X33

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 Fast Measurement

The loose end of the connecting cable with the 7--pole Lumberg connector (Fig. 2/2) is
plugged into the vacant socket X11 (Fig. 4/1) on the RDC. The connector locks itself in place.

1 = Sensor connector X11 on RDC

Fig. 4 RDC2 with connector X11

The new housing cover can now be put in position and fastened with the 4 fastening screws.

Care must be taken, when positioning the housing cover, not to pinch the wires of
the connecting cable or the resolver cables which are also located in the RDC
housing.

The installation of hardware on the robot is now completed.

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3 Start--up (continued)

3.3 Connection of measuring sensors

To connect a digital measuring sensor, a connecting cable must be connected to the sensor
at one end and the connector on the RDC housing at the other. The required connector is
contained in the hardware kit (see Fig. 5).

Fig. 5 Optional connector X33

The maximum possible length of the cable between the sensor and the RDC is determined
by the connection specification of the measuring input and is defined as follows:

Minimum switching voltage = 24 V DC (--10%; +20%)

The wire cross--section of the signal cable, the resistivity of the cable and the power
consumption of the measuring sensor determine the maximum cable length.

A smooth switching performance is ensured in the case of a measuring sensor mounted on

the robot tool with a standard shielded cable routed along the robot.
In the case of stationary measuring sensors (e.g. automatic TCP calibration), the cable is
routed directly from connector X33 on the RDC housing cover to the measuring sensor (see
Fig. 6).

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 Fast Measurement

Fig. 6 Stationary sensor cable

In the case of a robot--guided measuring sensor, the cable can be routed via axis 1 as shown
in Fig. 7.

Fig. 7 Robot--guided sensor cable routed via axis 1

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3 Start--up (continued)

In the case of a new order with the Fast Measurement option, the signal cable for Fast
Measurement via the robot is routed with the internal cable bundle through axis 1.
If a robot is upgraded with Fast Measurement, it may be necessary to exchange the cable
bundle routed through axis 1. It is always necessary to contact Technical Support for details
on cable routing in the case of an upgrade.

3.4 Connector pin allocation X33

Pin no. Assignment
1 0 V internal
2 +24 V DC internal
3 Measuring input 1
4 Measuring input 2
5 Measuring input 3
6 Measuring input 4
7 Measuring input 5

7
6 8
5 2
1
4 3

Fig. 8 Contact assignment of connector X33 (view: connection side)

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4 Connection examples

4 Connection examples
4.1 Fast Measurement with one DSE and one RDC2
There are two possible ways of supplying voltage to the sensors of the “Fast Measurement”
inputs (FM inputs). These are:
-- RDC2 supplies FM sensors (max. 500 mA)
-- FM sensors supplied externally
These two connection options are illustrated in Fig. 9 and Fig. 10.

RDC2

Fast Measurement 1

Fast Measurement 2

Fast Measurement 3

Fast Measurement 4

Fast Measurement 5

Fig. 9 FM sensors supplied with voltage by RDC2

RDC2

Fast Measurement 1

Fast Measurement 2

Fast Measurement 3

Fast Measurement 4

Fast Measurement 5

Fig. 10 FM sensors supplied externally with voltage

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 Fast Measurement

4.2 Fast Measurement with two DSEs and two RDC2s

If the function “Fast Measurement” with 2 DSEs and 2 RDC2s is used, each fast measuring
input must be connected in parallel to both RDCs.
Only in this way is the Fast Measurement signal present at both DSE measuring inputs at
the same time.
There are two possible ways of supplying voltage to the sensors of the “Fast Measurement”
inputs (FM inputs). These are:
-- RDC2 supplies FM sensors (max. 500 mA)
-- FM sensors supplied externally
These two connection options are illustrated in Fig. 11 and Fig. 12.

1st RDC2

Fast Measurement 1

Fast Measurement 2

Fast Measurement 3

Fast Measurement 4

Fast Measurement 5

2nd RDC2

Fast Measurement 1

Fast Measurement 2

Fast Measurement 3

Fast Measurement 4

Fast Measurement 5

Fig. 11 FM sensors supplied with voltage by first RDC2

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4 Connection examples (continued)

1st RDC2

Fast Measurement 1

Fast Measurement 2

Fast Measurement 3

Fast Measurement 4

Fast Measurement 5

2nd RDC2

Fast Measurement 1

Fast Measurement 2

Fast Measurement 3

Fast Measurement 4

Fast Measurement 5

Fig. 12 FM sensors supplied externally with voltage

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5 Configuration

5 Configuration
Configuration, in the sense of signal assignments in $CONFIG.DAT, is not necessary
for the use of fast measuring inputs. These are to be treated as controller inputs. The
signal states are displayed by means of the “Monitor – Variable” function.

5.1 System definitions

The fast measuring inputs are defined as follows in the control system:

Variable name Signal name

$MEAS_PULSE[1] Fast measuring input 1
$MEAS_PULSE[2] Fast measuring input 2
$MEAS_PULSE[3] Fast measuring input 3
$MEAS_PULSE[4] Fast measuring input 4
$MEAS_PULSE[5] Fast measuring input 5

5.2 Checking the connected measuring inputs

The switching performance of the fast measuring inputs can be checked as described below:

In order to check an input, it makes sense to switch the input to logic “1”, i.e. the connected
sensor is so positioned that it switches and connects the measuring input with 24 V.

5.2.1 Viewing individual measuring inputs

In order to view individual measuring inputs, select the menu “Monitor” on the KCP, then
select “Variable” followed by the menu item “Single”, then press the Enter key (see Fig. 13
and Fig. 14).

Fig. 13 Menu structure for viewing individual measuring inputs

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 Fast Measurement

Fig. 14 Variable display in the status window for one measuring input

$MEAS_PULSE[n] is entered in the box [Name], where [n] stands for the number of the
measuring input to be displayed. When the Enter key is pressed, the signal state of the input
(FALSE = logic 0, TRUE = logic 1) appears in the box [Current value].
The signal state of the measuring input at the time of the entry is displayed. The display is
refreshed by selecting the box [Name] again and pressing the Enter key.

5.2.2 Viewing all measuring inputs

If you wish to display the signal states of all measuring inputs simultaneously,
$MEAS_PULSE[ ] must be entered in the box [Name]. The numeric entry of the array stays
blank. When the Enter key is pressed, the resulting display in binary code indicates the signal
states of all five measuring inputs (see Fig. 15). The signal states of the measuring inputs
at the time of the entry are displayed. The display is refreshed by selecting the box [Name]
again and pressing the Enter key.

Fig. 15 Variable display in the status window (all measuring inputs)

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5 Configuration (continued)

5.2.3 Cyclical display of the measuring inputs

If the display of the signal states of the fast measuring inputs is to be refreshed automatically,
this is done by means of the keyboard shortcut [Ctrl]+[Shift]+[Enter] once the displays
described above have been activated. The display in the box [Current value] is now updated
automatically until a new selection is made.

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6 Application

6 Application
This chapter contains excerpts from the documentation modules of the MeasureTech and
TouchSense software packages illustrating typical applications of the Fast Measurement
function package. Detailed information on configuring, programming and using the
MeasureTech and TouchSense packages can be found in the respective documentation
modules.

6.1 MeasureTech
For each MeasureTech installation type three different program templates are available: for
main programs (Meas_Main), subprograms (Meas_Sub) and repositioning programs
(Back_Pos); this differentiation is merely a result of the automatic repositioning function.
When MeasureTech is installed, an empty subprogram and an empty repositioning program
are created by default in order to prevent the generation of an error message when a
newly--created main program is selected as these are integrated here.
The actual program creation, for both measurement and processing programs, is carried out
using the subprogram template (Meas_Sub). The repositioning template can be used,
furthermore, to teach a repositioning motion to the home position for any measuring or
installation position. In such a case, the main program merely contains the subprogram call
for the measuring or processing program and the call for the repositioning program to be
executed in the event of a measurement error.
If repositioning is not desired, it is sufficient to use the subprogram template and to select
these programs directly. It must be ensured that the variable AUTO_RETURN is set to
“FALSE”.

6.1.1 Single--robot system

The search and correction commands for a single--robot system and the work envelope
monitoring commands are described in the corresponding documentation module.

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 Fast Measurement

6.1.1.1 Program structure

The search and correction commands can be arranged sequentially within the program
structure or nested (see Fig. 16). This means that subsequent search motions can be
corrected in order to be able to address exact search points. The following limitation applies
here: offsets must always be corrected before rotations in order to achieve an exact
correction.

Fig. 16 Program example for a single--robot system

Search data sets 1 and 2 are used here to calculate the data for a two--dimensional
correction; the motion to search point 2 is already corrected with the offset calculated from
point one (see Fig. 16, line “correction.dim:1”).
The actual robot motion to be corrected, here a circular motion (line 13), is framed by the
“correction.dim:2” command (line 11) and the “correction.off” command (line 14).
This part of the program would be corrected in any case, even without this first correction
command, but care must be taken to ensure that the component surface for search point 2
is sufficiently large, as the programmed search point relative to the component is no longer
addressed exactly in the event of an offset.

6.1.1.2 Program creation and reference measurement

When creating programs, make sure that search commands are created in “reference:yes”
mode, as routines for saving the robot position, for example, are only started in this mode.
This ensures, at the same time, that the measured values from the first program execution
are saved as reference values. For a subsequent correction it is essential that the reference
values of the search points refer to the motion sequence taught on the master component.
In this mode, however, the correction commands, including the serial communication during
program execution, have no meaning.

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6 Application (continued)

6.1.1.3 Switching to measurement mode with the correction function active

Once the robot program has been completed and the reference values have been
determined by executing the program, each search command must be switched to
“reference:no” by changing the parameters in the inline form in order to activate the
correction function. This has the effect of saving the coordinates as measured values which
are then evaluated by the correction commands.

6.1.1.4 Reteaching points without a master component

If a search point or a processing point needs to be retaught without a master component,
reteaching can be carried out with the correction function active even for a component that
has been offset or rotated.
To do this, the robot system must execute the program up to and including the correction
command in order to acquire the correction currently valid. This is because an active
correction is reset both in the INI fold at the start of a program and by the command
“correction.off”.
The corresponding point can then be selected by block selection and retaught. The
correction value is automatically applied to the current robot position so the teaching process
is indirectly relative to the master component.
This process is indicated by the entry “Base_Corr” in a corresponding Touch Up dialog in the
message window.

Once again, it is important to note with this procedure that all points for which the correction
function is activated will be addressed. For this reason, care must be taken to ensure that
no points are selected for which correction is not desired.

6.1.1.5 Work envelope monitoring

In order to provide extra monitoring for the correction procedure, the program is expanded
as follows:

Fig. 17 Work envelope monitoring with a single--robot system

To ensure that the first point in the work envelope monitoring is not corrected, the correction
command must be positioned after the Workspace command.

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 Fast Measurement

6.1.2 Two--robot system

6.1.2.1 Measuring robot
All the information contained in the sections about the single--robot system applies equally
to the measuring robot in a two--robot system.
The only difference compared with the single--robot system is that the component is not
processed here; instead, the command “Correction.write to interface” is used to write a
correction, configured in advance and based on the joint base system, to the serial interface
(see Fig. 18, line 10). For this reason, no work envelope monitoring commands are available
here in the MeasureTech menu.

Fig. 18 Example program for a measuring robot

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6 Application (continued)

6.1.2.2 Processing robot

In the following example program, all points situated between the commands
“correction.read from interface” and “correction.off” and taught relative to the joint base
system (here Base:1) are corrected.

Fig. 19 Program example for a processing robot

Additionally, in this example, the work envelope monitoring function is used. As the correction
command is positioned before the Workspace activation command, P1 must not be taught
in base system 1 so that P2 is the first point to be corrected.
In this example, the robot path is monitored between points P1 and P2 with a maximum
permissible deviation of 100 mm.
As the activation and deactivation of work envelope monitoring trigger an advance run stop,
points P1 and P2 can only be addressed with exact positioning.
Here, once again, points can be retaught with the correction applied; this time, however, the
entry “M_Base_Corr” appears in the Touch Up dialog (see Section 6.1.1.4).

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 Fast Measurement

6.2 TouchSense
Two alternative procedures are available for the component search. These are “single touch”
and “double touch”. The selection is made in the “Search parameters” parameter list of the
corresponding search command.

6.2.1 Single touch

To search for a component, the robot moves the welding wire a defined distance from a
programmed point. The search direction is determined vectorially using an auxiliary point.

Distance

Auxiliary point
PTP

Search LIN
direction Start point
Touch point on the
master workpiece

Fig. 20 Single touch

If the wire reaches the component at the Touch point, a circuit is completed causing a relay
to pick up. This relay provides an electrically isolated input for “Fast Measurement”.
The robot controller registers this state and stops the robot. The axis measurements thus
determined are saved as a correction data set. The robot then returns to the start point.
Programmable tolerances are assigned to this search function. If these tolerances are
exceeded, the component search is aborted.
The number of search instructions depends on the possible changes in position of the
component. Up to six search instructions may be necessary (for the offset and rotation of
each axis) in order to adapt a path correctly to the changed component position.

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6 Application (continued)

6.2.2 Double touch

6.2.2.1 Calculating the center of a gap
In “Double touch” mode, the welding wire is positioned in a gap. The search direction is
defined using an auxiliary point in the same way as in “Single touch” mode. In order to be
able to calculate the center of the gap, the robot controller automatically generates a second,
opposite search direction for the return movement of the Touch procedure that has been
taught.

Auxiliary Start point

point

Center of gap

Auxiliary point
Start point

Center of gap

Search direction

Fig. 21 Calculating the center of a gap

The teaching start point does not have to be exactly in the center. The current gap width for
the component is measured and then saved at the end of the search run.

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 Fast Measurement

6.2.2.2 Calculating the position of a corner

This example illustrates the calculation of the exact position of a corner, e.g. in the case of
a fillet weld.
The procedure is essentially the same as that described above. The important thing in this
type of calculation is that the start point and auxiliary point of the search run are aligned
perpendicular to the bisector of the angle.

Auxiliary point Start point Bisector of the angle

Search direction
a
a/2 a/2

Touch point on the

master workpiece

Fig. 22 Calculating the position of a corner

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Index

A M
Activating Fast Measurement in robot type KR M_Base_Corr, 31
2000, 8 Meas_Main, 27
Application, 27 Meas_Sub, 27
AUTO_RETURN, 27 MeasureTech, 27
Measuring input, 20
Measuring robot, 30
B
Back_Pos, 27
Base_Corr, 29 P
Program creation and reference measurement,
28
C Program structure, 28
Checking the connected measuring inputs, 23
Component search, 32 R
Configuration, 23
RDC2, 14
Connection examples, 19
reference:no, 29
Connector pin allocation, 17
Repositioning, 27
correction.dim:1, 28
Reteaching points without a master component,
Correction.write to interface, 30 29
Cyclical display of the measuring inputs, 25

S
D Safety instructions, 11
Double touch, 33 Single touch, 32, 33
DSE measuring inputs, 20 Single--robot system, 27
Software, 5
Start--up, 11
F
Switching to measurement mode with the
Fast Measurement, 5 correction function active, 29
Fast Measurement with one DSE and one System definitions, 23
RDC2, 19
Fast Measurement with two DSEs and two
RDC2s, 20 T
FM sensors supplied externally with voltage, Technical data, 8
19, 21 Functional description, 7
FM sensors supplied with voltage by first TouchSense, 32
RDC2, 20
Two--robot system, 30
FM sensors supplied with voltage by RDC2, 19

U
H
Upgrading other robot types, 9
Hardware, 5, 12

V
K Viewing all measuring inputs, 24
KUKA robot controller KR C2, 5 Viewing individual measuring inputs, 23

Index -- i
 Index

W
Work envelope monitoring, 29

Index -- ii