MT45315 S 141 Adv Robotics

SIEMENS
Process Simulate
Standalone (eMS)
Advanced Robotics
Student Guide
October 2018
MT45315 ‒ Version 14.1
MT45315-S-141
Tecnomatix copyright, proprietary, and restricted rights notice
Proprietary and restricted rights notice

This software and related documentation are proprietary to Siemens Product Lifecycle
Management Software 2 (IL) Ltd.
© 2018 Siemens Product Lifecycle Management Software Inc.
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2 Process Simulate Standalone (eMS) Advanced Robotics MT45315-S-141

Contents
Tecnomatix copyright, proprietary, and restricted rights notice . . . . . . . . . . . . . . . . . . . . . 2
Advanced robotics (OLP) course overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Advanced robotics prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Advanced robotics audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Learning tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Introduction to OLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

OLP Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Business process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Allocating a Worker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Data model basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Operation Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Robotic simulative operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
OLP software packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Robot models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Robot model basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
More on robot models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Getting robot models from GTAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Advanced kinematic definitions (MotionParameters.e file) . . . . . . . . . . . . . . . . . . . . . . . 1-11
Introduction to the MotionParameters.e file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
MotionParameters.e units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
MotionParameters.e motion types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
MotionParameters.e configurations and turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
MotionParameters.e zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Defining zones in the MotionParameters.e file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Cloos specific MotionParameters.e for zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Epson specific MotionParameters.e for zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Kawasaki specific MotionParameters.e for speed and accuracy . . . . . . . . . . . . . . . . . . . 1-17
NC specific MotionParameters.e for zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Panasonic specific MotionParameters.e for zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Reis specific MotionParameters.e for zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Staubli specific MotionParameters.e for zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Universal specific MotionParameters.e for zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Motion planning (Introduction to MOP, RCS, and RRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Motion planning basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
What is MOP? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Process Simulate motion planning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
What is RRS? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
MOP, RRS, and ESRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
MT45315-S-141 Process Simulate Standalone (eMS) Advanced Robotics 3

Contents
Contents
ESRC history and content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Contents of ESRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Robots as integrated production resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Robotics: Information exchange between PLC and robot . . . . . . . . . . . . . . . . . . . . . . . 1-28
Setting up the RCS (part 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Business process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Process Simulate access to RCS/RRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Setting up MOP versus RCS robot controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Setting up the robot controller (part 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Robot controller setup basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Setting up the RRS.XML file and more (part 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
RRS setup basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
Process overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Process generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Process to program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
OLP in process design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
Problems that can occur without considering OLP issues . . . . . . . . . . . . . . . . . . . . . . . 1-44
How to take OLP into consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
Do the up-front work required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
Include relevant information at each step of the process . . . . . . . . . . . . . . . . . . . . . . . . 1-45
Supply information needed in later steps of the process . . . . . . . . . . . . . . . . . . . . . . . . 1-45
What should be considered for OLP? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
Study preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
Error sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49
Five major sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50
Robot programming background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Basic motion attributes (default controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Do I do this . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Motion attributes basics (default controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Motion types (default controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Motion termination for the default controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Location reference frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Other default controller examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Viewing and editing location attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Robotic configuration selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Robot configuration selection basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Solution and turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Contents
Using the Robot Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

External axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Review of robot programs and robot signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Robot programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Robot signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Status signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Robot path reference operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Robot program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Creating robot programs (default controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Robot program basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Methods to create and edit a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Creating a robotic program from a compound operation . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
ESRC setup and motion parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Process Simulate OLP introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

MOP-based and RCS-based controller set up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
ABB supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cloos supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Comau supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Denso supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Duerr supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Epson supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Fanuc supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
IGM supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Kawasaki supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Kuka supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Nachi supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
NC supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Panasonic supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Reis supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Staubli supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Trallfa supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Universal supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Yaskawa supported configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Basic study setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Process Simulate robot controller application support . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Study basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Robot controller selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Robot controller selection basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
How to figure out the manipulator type for an RRS controller? . . . . . . . . . . . . . . . . . . . . 3-13
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Contents
Contents
Robot controller setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Robot controller setup basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Accessing Robot Setup using method 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Accessing Robot Setup using method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
ABB Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Comau Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Denso Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Duerr Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Epson Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Fanuc Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
IGM Robot Setup dialog box — first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Kawasaki Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Kuka Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Nachi Robot Setup dialog box — first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
NC Code Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Panasonic Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Reis Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Staubli Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
(ABB) Trallfa Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Universal Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Yaskawa Robot Setup dialog box – first buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Testing the RCS connection and fixing setup problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
RCS connection testing basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
RCS shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
RCS logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
RCS management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
RCS management basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Reset RCS module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Disconnecting from the RCS (RCS decoupling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Limitations of decouple mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Methods to define TCPF positions for a robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
TCPF definition basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Robot Toolbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Robot controller specific frames and setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Robot setup basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Accessing robot setup using method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Accessing robot setup using method 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Robot system frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
ABB Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Comau Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Denso Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
Duerr Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Contents
Epson Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Fanuc Robot Setup dialog box – continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
IGM Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Kawasaki Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Kuka Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Nachi Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
NC Code Robot Setup dialog box – continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Panasonic Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Reis Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Staubli Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
(ABB) Trallfa Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Universal Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Yaskawa Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Controller specific frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
Setting controller specific motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Do I do this . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Basic controller specific motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
ABB motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Cloos motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Comau motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Denso motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Duerr motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Epson motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Fanuc motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
IGM motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Kawasaki motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Kuka motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Nachi motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
NC motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Panasonic motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Reis motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
Staubli motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
(ABB) Trallfa motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
Universal motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
Yaskawa motion attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Program creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Program creation basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Process simulation and robot configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
Robot configuration basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
Teaching and clearing robot configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Simulate robot paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
Upload and download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Contents
Contents
Program templates for downloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Program template basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Editing program templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Program template selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Template locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Example robot specific template keywords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Example download template use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Process download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Download basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Downloaded files for each controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Examining output files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Output file basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Downloaded files for each controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Direct process upload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Upload basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Overview of Robotic Operation Merge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Robotic Operation Merge basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
ESRC OLP commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Standard OLP commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

OLP command basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Basic OLP commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Free text standard commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Free text basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
OLP command conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Entering robot specific comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Defining robot specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
ABB signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Cloos signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Comau signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Denso signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Duerr signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Epson signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Fanuc signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
IGM signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Kawasaki signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Kuka signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Nachi signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Contents
Panasonic signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Reis signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Trallfa signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Universal signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Yaskawa signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Sending and waiting for robot specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
ABB: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Cloos: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Comau: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Denso: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Duerr: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Epson: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fanuc: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
IGM: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Kawasaki: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Kuka: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Nachi: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Panasonic: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Reis: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Trallfa: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Universal: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Yaskawa: Sending and waiting for signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
More controller specific OLP commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Controller specific OLP command basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Class discussion to put it all together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
ABB-Rapid — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . . . 5-31
Cloos-Carola - Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . . . 5-35
Comau-Pdl — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . . . 5-36
Denso-PacScript - Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . 5-40
Duerr-EcoTalk — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . 5-41
Epson — Beyond signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Fanuc-RJ — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . . . . 5-46
IGM-Ins — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Kawasaki-As — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . . 5-51
Kuka-Krc — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Nachi-Slim — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . . . 5-58
NC-Code — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Panasonic-Csr - Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . . 5-62
Reis-Robstar — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . . 5-63
Staubli-Val — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Trallfa-Robtalk — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . . 5-71
Universal-URScript - Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . 5-73
Yaskawa-Inform — Beyond signals and send/wait commands . . . . . . . . . . . . . . . . . . . . 5-74
Robot Program Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
Robot Program Viewer basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78

Contents
Contents
Use the viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80

Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Calibration introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Calibration basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
What is calibration? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Calibration sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
The math behind calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Calibration results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Robot to part calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Robot to part calibration basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Calibration steps overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
OLP command customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Overview of customizing robot controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

OLP command customization basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
The customizable user interface's layers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Dialog standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Custom OLP commands XML file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Customized XML basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
OLP configuration file basic elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Robotic parameters section of the file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Robotic params dection basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Defining a list of values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
More on TxObject ValueTypes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
OLP commands section of the file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
OLP commands section basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Layers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
OLP dialogs section of the file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
OLP dialogs section basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
OLP command XML structure example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Signal example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Send signal and wait signal basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Custom OLP command and macro example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Macro file example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
OLP command XML file requirement for example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Motion and robotic path template customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Motion command customization introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2


Contents
Motion customization basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Custom motion type configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Additional elements of motion command files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Motion command basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Motion command customization example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Motion example basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Robotic path template customization introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Path template basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Path template customization example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Path template example basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Example path template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Other XML customization topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Custom XML debugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Multi editing of customized motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Picture attribute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Add online help to customized dialogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Centralize all XML files in a shared folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Encryption of customized XML files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Simulation keywords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Other customizations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Attributes of mfg features and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Basic data flow for locations and mfg features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Importing weld points or rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Configuring a mapping file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Mapping attributes from mfg features to locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Adding attributes to the Mfg Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Showing custom attributes in the Path Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Setting up the Path Editor for custom attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Training sample file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Adding attributes to the Path Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Final comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Creating an OLP procedure (putting it all together) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
A multi-step OLP procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Putting it all together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Where do you go from here? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Final notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

Contents
Contents
Appendix — Optional topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Segmentizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Segmentizer basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Comparison of various methods for handling robot macros . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Entering OLP commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Entering OLP commands method comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Notes on conditional statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Process upload from Robcad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Robcad upload basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Overview of the Robotic Parameters Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Robotic Parameters Viewer basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Overview of Robot Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16
Robot Modules basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

Advanced robotics (OLP) course overview
Course description
The Process Simulate Standalone Advanced Robotics course provides step-by-step instruction
on how to use Process Simulate to configure, simulate, and upload/download (OLP) using MOP,
realistic robot simulation (RRS), RCS (Robot Controller Software), and ESRC (Emulated Robot
Specific Controllers).
Course objectives
Learn about:
• Introduction to Robotic Off-Line Programming (OLP)
• Introduction to MOP, RCS, RRS, and the Process Simulate robot controllers
• Setting up the RCS, RRS, and the Process Simulate robot controllers
• Creating Robot Programs
• Inverse Kinematics Solution Selections (Robot Configurations)
• Robot Controller Selection and Setup
• Testing the Teach Pendant and Fixing Setup Problems
• RCS Management
• Robot Controller Specific Signals, Commands, Frames, Setup, and Motion Attributes
• Templates, Uploading, and Downloading
• ESRC OLP Commands
• OLP Command XML Customization

Advanced
Advanced robotics
robotics (OLP)
(OLP) course
course overview
overview
• Motion XML Customization
• Robotic Path Template XML Customization
• Other XML Customization Topics
• Other Related OLP Topics
Advanced robotics prerequisites

Knowledge of a robot language: such as those from ABB, Cloos, Comau, Duerr, Epson, Fanuc,
IGM, Kawasaki, Kuka, Nachi, NC machining, NC riveting,Reis,Staubli, (ABB) Trallfa,, Universal, or
Yaskawa/Motoman. Please specify two desired robot languages when signing up for this course.
Required courses:
• TR45115 – Process Simulate Standalone Basic Robotic Simulation
• TR45215 – Process Simulate Standalone Intermediate Robotics
Advanced robotics audience

Individuals who would like to use Process Simulate to configure, simulate, and upload/download
(OLP) using realistic robot simulation (RRS/RCS) or MOP, and use ESRC (Emulated Robot Specific
Controllers).
Learning tracks
Learning tracks for the Tecnomatix application are found on the Siemens PLM Software training
website: training.industrysoftware.automation.siemens.com/index.cfm
Related Courses
• TR45101 – Process Simulate Standalone (eMServer Compatible) Part Flow Simulation
• TR45106 – Process Simulate Standalone (eMServer Compatible) Human Simulation
• TR45115 – Process Simulate Standalone (eMServer Compatible) Basic Robotic Simulation
• TR45215 – Process Simulate Standalone (eMServer Compatible) Intermediate Robotics
• TR45315 – Process Simulate Standalone (eMServer Compatible) Advanced Robotics

Lesson 1: Introduction
Purpose
To discuss the basics of Off-Line Programming with Process Simulate.
Objectives
After you complete this chapter, you should be familiar with:

• An overview of OLP.
• An overview of the Process Simulate data model.
• The basics of robot models.
• The basics of RRS, RCS, and the ESRC (Emulated Robot Specific Controllers).
• How to setup the RCS, RRS, and robot controller.
• The steps for process generation and process to program.
• The problems that can occur if OLP is not considered.
• How to prepare the study for OLP.
• Some sources of error in OLP.
MT45315-S-141 Process Simulate Standalone (eMS) Advanced Robotics 1-1

Lesson
Lesson 1: 1: Introduction
Introduction
Introduction to OLP
Purpose
In this topic, you are introduced to OLP.
Objectives
After you complete this topic, you should be able to:

• Get some basic background in OLP.
OLP Basics
This course focuses on portion of Process Simulate known as Process Simulate Robotics. Process
Simulate Robotics contains a set of tools for performing OLP.
• OLP (also known as Off-line programming) — the process of designing, modifying, and testing
a robot program in an external system without the need of the actual robot. Once the program
is created it can be downloaded from the external system and uploaded into the actual robot
controller.
• Downloading — the process of exporting a text file of the program from a system or robot
controller.
o For example: Downloading from a real robot exports a file from the real robot controller.
o For example: Downloading from Process Simulate exports a file from the system.
• Uploading — the process of importing a text file of the program into a system or robot controller.
o For example: Uploading to a real robot imports a file into the real robot controller.
o For example: Uploading to Process Simulate imports a file into the system.
Here is the basic process. A program can be originated in Process Simulate or directly on the real
robot (controller). After that, it can be cycled through this continuous loop:
• Path — A path (also known as a robotic operation) is a representation of the robot work plan in the
Process Simulate world. It consists of locations, sequence of locations, and location attributes.
• Program — A collection of paths (and or locations) used for downloading.
• Program File — A task is a textual format of the robot work plan which includes motion
commands and parameters.
Business process
This is an overview of the steps to off-line program robots and of the topics in the first half of this
training. The last part of this training describes how to customize and make your use of the robot
controller more efficient.
1-2 Process Simulate Standalone (eMS) Advanced Robotics MT45315-S-141

Introduction

Lesson
Introduction
Allocating a Worker
Purpose
In this topic, you add a worker to the station.
Objectives

• Add a worker to the stations.
Data model basics

The center of the Process Simulate universe is the operation tree of the loaded study.
Studies can contain four types of data. The actual content depends on the shortcuts that have been
added to the study and the relationships of the data to objects in the operation tree:
• Product
• Operation
• Resources
• Manufacturing Features
• “Engineering Data”
In general, the data can be initially found in these viewers:

• Product, Resources, and Engineering Data can be found in the Object Tree viewer.
• Operations are found in the Operation Tree viewer.
• Manufacturing Features can be found in the Mfg Viewer.
Operation Tree
The operation tree contains a structure that typically starts with a station. This station contains several
compound operations sequenced together. . This is done by adding simulative operations to the
desired compound operations. There are several types of simulative operations:
• Object flow operation - a simulative operation consisting of the movement of a part along
its assembly path. It is represented using the icon. (Covered in the TR45101, TR45106,
TR45115, and TR45215 courses).
• Device operation - a simulative operation consisting of any mechanical device (for example a
robot, human, clamps, cart, etc.) moving from one pose to another. It is represented using the
icon. (Covered in the TR45115 and TR45215 courses).

Introduction
• Robotic operation - a simulative operation consisting of a sequence of locations (positions) for

the Robot TCPF. This type can be used for material handling or welding. It is represented using
these , , icons. (Covered in the TR45115 and TR45215 courses)
• Human operation - a simulative operation consisting of a single human motion or a series of

motions. It is represented using these , , , , icons. (Covered in the TR45106
course).
• Non-sim operation - a simulative operation detailing an activity requiring time (but is not
simulated) that you want to include. It is represented using the icon.
Robotic simulative operations

A robotic operation can be made up of:
• Weld locations — each is linked to a weld point (manufacturing feature). The weld gun is
actuated at each weld location.
• Pick and Place Locations
• Seam Locations — locations that move the robot along the contour of the part
• Via Locations — general movement or clearance moves
Robotic operations can be visualized as a path (also known as a sequence of locations) in the
Graphic Viewer.
Robotic properties of locations and robotic operation:
There are several types of properties that can be stored on a location or robotic operation.
• Motion Type (interpolation)
• Speed
• Zone
• Tool
• Process parameters
• OLP commands
• Configuration and turns
Some of this information can be mapped from a generic (default) controller (for example for something
simple like motion type). Much of the information that is robot manufacturer (or sometimes robot)
specific is done differently (for example how configurations are represented).
Instead it is typically better to work directly in the language of the robot, within Process Simulate,
rather than to work in a generic language and then translate it later. However, you could work with the
default controller if needed (no RRS), and get about 80% motion accuracy.

Lesson
Introduction
The motion planning, how the joint motions of the robot are synchronized, cannot have the accuracy
of the real robot because of the real robot’s smoothing algorithms may be different than the default
controller’s (for example motion from down to up may use a different motion than from up to down).
OLP software packages

An OLP software package contains the following:
• A user interface to set parameters
• RRS Simulation access to the RCS
you discuss this topics in detail starting in lesson 4, however these are two core
technologies of robotic offline programming:
o RRS — Realistic Robot Simulation
o RCS — Robot Controller Software
• Downloads — create a program file to run on the real robot
• Uploads — the most complex since some things needed to run a simulation are only defined
(exist) in Process Simulate and cannot be extracted from the program file.
Standard OLP software packages are released with the Process Simulate software. Currently there
are packages for robot manufacturers.
Each controller has its own OLP package executable. Files are installed
under the C:\Program Files\Tecnomatix\eMPower and C:\Program
Files\Tecnomatix\eMPower\Robotics\OLP folders.

Introduction
A specific license is required from Siemens PLM Software and the robot vendor to activate
each controller (and underlying robot specific abilities).

Lesson
Introduction
Robot models
Purpose
In this topic, you learn about robot models used in this system, including the MotionParameters.e file.
Objectives

• Know where to find the robot models you need.
• Make them ready to use for OLP.
• Know a little about the MotionParameters.e file
Business process

Introduction
Robot model basics

One of the first factors that must be considered when doing OLP is the robot model. There are
several questions that can be asked. For example:
Does a robot model for my real robot already exist in Process Simulate? Answer: There are several
places to go to find robot models:
• Method 1: In Robcad data you may have from old projects. The advantage here is that you
may already have the proper robot models and related configuration files already gathered in
one place.
Similarly, the RCS install used by Robcad can be reused with Process Simulate by
adding the related TUNE bridge file. This is discussed in more detail later in this course.
• Method 2: Software install DVD (Robcad and RobotExpert only).
• Method 3: GTAC (Many robot models are available for download from the Siemens PLM
Software Global Technical Access Center at support.industrysoftware.automation.siemens.com
or 1–800-955-0000.
You learn more about downloading files from GTAC later in this course.
The Robcad .CO formatted robots found here need to be converted to .COJT format
before it can be used in this system.
• Method 4: Given to you by an OEM.
• Method 5: Most robot models must be gotten directly from the robot manufacturer, for intellectual
property reasons. Typically robot manufacturers, such as Duerr, Fanuc, or Yaskawa/Motoman,
provide a robot model to a customer that purchases the real robot. Here the are robot
manufacturer websites:
o ABB Robotics: http://new.abb.com/products/robotics
o Cloos Robotic Welding: http://cloosrobot.com/
o Comau Robotics: http://www.robotics.comau.com/
o Denso Robots: http://densorobotics.com/
o Duerr Paint Systems: http://www.durr-paint.com/
o Epson Robots: http://robots.epson.com/
o Fanuc Global Network: http://www.fanuc.com/
o IGM Robotersysteme: http://www.igm-group.com/en

Lesson
Introduction
o Kawasaki Robotics: https://robotics.kawasaki.com/en/index.html?language_id=1
o Kuka Robotics: http://www.kuka-robotics.com/en/
o Panasonic Robotics:
https://eu.industrial.panasonic.com/products/robot-welding-system-solutions
o Staubli Robotics: http://www.staubli.com/en/robotics/
o (ABB) Trallfa (robot

history):http://www.abb.com/product/ap/seitp327/583a073bb0bb1922c12570c1004d3e6b.aspx
o Universal Robots: http://www.universal-robots.com/
o Yaskawa/Motoman Robotics: http://www.motoman.com/
More on robot models
Here are some additional questions:
Does the robot model have a MotionParameters.e file?
• This file has many uses, which include helping set the proper speed, acceleration, and selecting
robot configurations; especially when disconnected from the RCS.
Does the robot model include other robot controller files in the robot model that are needed to
establish a proper RCS connection?
• Typically, there is a file or group of files from the robot manufacturer, that describe how a specific
robot is to move. They can be provided as part of the RCS install or as part of the robot model.
You learn later in this course, on a case-by-case basis, which files are needed to make the robot
work with the RCS since it is different for every robot manufacturer.

Introduction
The robot model selected should have geometry and kinematics which closely represents
the robot you use in the plant. This allows you to have the same reach envelope in this
system as in reality and get a accurate robot configurations from the RCS.
Getting robot models from GTAC

Here is an example of the steps required to bring a new robot into the system:
1. Browse to https://download.industrysoftware.automation.siemens.com.
2. Select Tecnomatix Products.
3. Browse to Product updates/Robot_Models.
4. Browse into a folder such as the ABB or KUKA folder.
5. Right click the desired robot and save a copy to your computer.
For the sake of your discussion, assume that you have locally saved (downloaded) a
robot model named abb_irb2400_10.co.tar.gz into a temporary folder named C:\temp
and that this folder is empty.
A Robcad formatted .CO robot model is downloaded. It is compressed (zipped) using

.tar and .gz formats. In most situations you need to convert to a .COJT format. This
can be done by running tools like Upgrade to Version or Import CAD Files.
6. Uncompress (unzip) the contents of the abb_irb2400_10.co.tar.gz file to the C:\temp folder.
If the downloaded file is in the .zip format, simply uncompres (unzip) it and go to the
next page.
A folder named C:\temp\ROBOTS_ABB is created and contains the

abb_irb2400_10.co.tar file.
7. Uncompress (unzip) the contents of the abb_irb2400_10.co.tar file and move the resulting
abb_irb2400_10.co folder directly to the C:\temp folder.
8. Continue to the next page to see how to use the robot model in the system.
Advanced kinematic definitions (MotionParameters.e file)

Functionality
• In Process Simulate the motionparameters.e file is used during simulation. It must benamed
motionparameters.e

Lesson
Introduction
In Robcad, the motionparameters.e file was known as the .e file.
The motionparameters.e file, pronounced “motion parameters dot e” file, is an ASCII

text file stored under the robot model’s .COJT folder containing measured robot motion
parameters such as speed, accel/decel, zones, configurations, and delay/settle times.
Simulation packages contain only limited knowledge about the robot’s technical
capabilities such as reach, speed, limits etc. Other information such as payloads,
momentum, acceleration, and similar parameters where limited. The .e file was the
initial solution for this problem (for example it was the pre-RRS technique). Tecnomatix
engineers performed measurements on the robots themselves in order to determine
specific parameters (for example a very long process requiring intimate knowledge
of the robot).
The syntax for this file can be found in the Motion Planning Definition File Reference
Guide included on the Process Simulate DVD.
• Allows the use and editing of former Robcad .e files when renamed to motionparameters.e
Upgrade to Version creates the motionparameters.e file (which is a duplication of the

original .e file) in the .cojt folder. Comments in the original .e file are not copied to the
new motionparameters.e file unless they are wrapped with begin text/end text tags.
• Uses Microsoft Windows legal file naming format
Process Simulate can read motionparameters.e files located under .cojt folders.
There are cases where users open a device for modeling from the object folder (but not
directly from a .jt file) with integrated .e file data. If there is no motionparameters.e
file under the folder, the system creates it with the .e content when saving the modeled
device in the study/library.

Introduction
Why is this important to you?

• More accurate behavior of devices
• Reuse legacy Robcad data
Getting into the details within a motionparameters.e file is a very advanced topic and is
behind the scope of this course. However, some additional information can be found by
reviewing the online help for the motionparameters.e file found on the install DVD.
Introduction to the MotionParameters.e file

Motionparameters.e (dot-e) files are produced from data obtained by performing measurements
on actual robots. The files model the behavior of robots that are simulated with Process Simulate
motion-planning capabilities. As in Robcad, the .e file is mainly required in MOP-based and
default controllers but the config/turn part is also required in RCS-based controllers for storing the
configuration at the location.

Lesson
Introduction
A motionparameters.e file can be written for a robot either with or without an inverse
solution, and also for a device. However, many statements, particularly those pertaining to
Cartesian motion, apply only to robots having an inverse solution.
MotionParameters.e units
For both joint and Cartesian motion, velocity, acceleration, deceleration and jerk values are assigned
to each joint in the units shown in the table below. “Jerk” is the rate of change of the acceleration the
derivative of the acceleration.
Rotational Motion Linear Motion

Velocity radians per second millimeters per second
Acceleration radians per second squared millimeters per second squared
Deceleration radians per second squared millimeters per second squared
Jerk radians per second cubed millimeters per second cubed
A common error is to supply rotational values in degrees, resulting in very high speeds
producing extremely short cycle times.
MotionParameters.e motion types

All robot motion is planned mathematically. Two basic plans, or types, of motion exist for both actual
and simulated robots: joint motion and Cartesian motion.
Joint motion
For joint motion, the mechanism moves according to motion parameters specified individually for
each joint. It applies to all mechanisms: devices and robots both with and without an inverse solution.
The manner in which the specified values apply to the joints during actual motion depends on whether
the type of the motion is synchronous or slew.
• Synchronous motion — In synchronous motion, the more common type, all of the joints begin
together and also complete their motion together. The joint which requires the most time to
complete its motion (usually because it moves the farthest) moves at its specified velocity. The
other joints move at speeds correspondingly slower than their specified speeds, in order to
complete their motion together with the fastest-moving joint.
• Slew motion — In slew motion, all of the joints begin together but complete their motion
separately. Each joint moves at its specified velocity. The joint which requires the least time
(usually because it moves the smallest distance) completes its motion first, with the other joints
following behind. The joint requiring the longest time to complete its motion (usually because it
moves the farthest) completes its motion last.
Cartesian motion
Cartesian motion is effected by commands directed to the TCP of a robot. The system then uses
inverse algorithms for the robot to calculate the required motion of each joint from the TCP data

Introduction
contained both in the various kinematic and motion-planning files in the motion command itself. It
thus applies only to robots having an inverse solution.
Cartesian motion occurs by means of interpolations between the start and finish locations of the
frame at the robot TCP (the TCPF). Both the position and the orientation are interpolated. Various
types of Cartesian motion are possible:
• Linear-type Cartesian motion causes the robot to move its TCP in a straight-line trajectory
to a target location.
• Circular-type Cartesian motion causes the robot to move its TCP in a circular arc through an
intermediate location to the target location.
MotionParameters.e configurations and turns

The inverse algorithm used to effect Cartesian motion usually produces two or more solutions,
combinations of joint values which enable the robot to superimpose its TCPF on the target location.
Each such combination of joint values, or configuration, can be stored with a location in order to
require the robot to reach the location with the desired configuration. This consideration pertains only
to Cartesian motion.
In addition, a rotational joint capable of multiple turns may produce for the same location many
inverse solutions which are actually the same, but with the values of the joint differing by multiples of
360 degrees. In order to distinguish between these solutions, the range of such a joint is divided into
subranges of 360 degrees (a full turn) which themselves are identified by names. The desired turn for
a joint when the robot arrives at a location can be stored with the location. Moving to these locations
by joint motion only puts the joints in the position corresponding to the turns recorded with the location.
The recorded turns are ignored during Cartesian motion; the motion itself determines the actual turns.
MotionParameters.e zones
Most robot controllers accommodate the definition of zones around target positions.
When a robot arrives at its specified zone from the target position, it sends a zone reached signal
which can inform the controller immediately to plan the next motion. The robot thus does not reach
precisely the target position and does not need to come to a full stop, reducing cycle time where
precise arrivals are not necessary.
It can also facilitate synchronizing other tasks by informing them of impending arrival at the target.
The zone type can be defined as an absolute or relative distance either constituting a sphere around
a working point or measured from a target joint position, or as a condition on the speed of the robot as
it approaches the destination. For example, the zone can be defined to begin when all of the joints
have decelerated to half of their steady-state speed during the motion. When during motion a robot
arrives at its specified zone from the target position, it sends a zone signal to its controller.
Zones apply both to joint motion and to Cartesian motion.
Defining zones in the MotionParameters.e file

The zone_define parameter specifies controller-dependent zone information. Its full syntax is:
zone_define name type space parameters;

Lesson
Introduction
Name is usually one of fine, medium, coarse or nodecel, or one of sp_zone# where # is an integer
from 1 to 6; however, it may be any user-specified character string that does not contain spaces.
A motion command in the robot program specifies the desired zone by referring to its name. The
names are arbitrary and serve only to allow the robot program to reference the desired zone. It is
thus desirable but not necessary to use fine as the name for the most precise zone. The nodecel
name can likewise be used for a zone that causes the robot to move to a point but continue to
the subsequent point without decelerating. The sp_zone# values can be used when more than
four zone types are needed.
Type is one of:
• dist
• rel_dist
• speed
• time
• min
• max
• no_decel
• no_smooth
• no_settle_time
A dist zone type defines a distance constituting for Cartesian motion the radius of a sphere around a
target location, or for joint motion the linear or angular deviation from a target joint position. A rel_dist
type permits defining zones as a percentage of the total distance for each motion. A speed zone
type begins the zone at a specified percentage of the speed of the robot as it decelerates toward the
destination. A time zone type similarly begins the zone at a specified time before the robot reaches its
destination. A min or max zone type permits defining a zone as either the smaller or larger of two
previously defined zones, respectively. A no_decel zone type begins the zone when the motion profile
begins to decelerate. And no_smooth can be specified to require the robot to reach its destination
precisely. The no_settle_time value is used by only a few robots.
Space is either joints or Cartesian. It specifies the space in which the zone is defined by means of
the corresponding parameters; they are specified in the unit of measure corresponding to the zone
type. For joints space, parameters is a list of values separated by spaces; one value is specified for
each joint in the mechanism.
For Cartesian space, parameter is a single value. If a zone is defined in Cartesian space,
Cartesian-motion commands using that zone use the zone parameters as defined by zone_define.
For joint motion using that zone, motion planning generates values in joint space approximately
equivalent to the value defined in Cartesian space. Likewise, when a zone is defined in joints space,
joint-motion commands using that zone use the zone parameters as defined by zone_define.
For Cartesian motion using that zone, motion planning generates a value in Cartesian space
approximately equivalent to those defined in joint space.

Introduction
Cloos specific MotionParameters.e for zones
All zones that can be used on the locations should be defined in the MotionParameters.e
file of the Cloos robot component with a special naming:
• Joint Zones: stv<SmoothTransitionValue> For example:
o zone_define stv1 rel_dist cartesian 25;
• Cartesian Zones: setdd<Dist1>_<Dist2> For example:

o zone_define setdd10_20 rel_dist cartesian 65;
o zone_define setdd50_50 rel_dist cartesian 65;
Although the exact MotionParameters.e zone name are internally stored on the location, in
the Teach Pendant and Path Editor, zone information appears in Carola terms, for example:
• Zone stv10 maps to STV(10) on the controller.
• Zone setdd10_20 maps to SETDD(10,20) on the controller.
The available zones are filtered using the location motion type:
• For GP, only stv zones are available.
• For GC and ARC. only setdd zones are available.
STV(0) and SETDD(0,0) are mapped to the fine zone.
Epson specific MotionParameters.e for zones

For robot configurations, you should enter these motionparameters.e config and turns entries to
properly record the configurations on the locations:
• config_family cf_over_head_pos;
• joint_config_family j3 joint_cf_elbow_up;
• joint_config_family j5 joint_cf_pos;
• default_turns j1 0 -90.0, j2 0 -180, j4 0 -180.0, j6 0 -180.0;
Kawasaki specific MotionParameters.e for speed and accuracy

• Speed:

Lesson
Introduction
o Speed value in % is converted to mm/s (via cart_max_lin_speed entry in

MotionParameters.e) for linear motions.
• Accuracy: If ACCU<i> zone is defined in the MotionParameters.e file, this actual zone is used.
Otherwise conversion from accuracy value (in mm) to default zones is as follows:
o 0 < val < 5: fine
o 5 < val < 30: medium
o 30 < val < 75: coarse
o 75 < val: nodecel
NC specific MotionParameters.e for zones

Zone (must be defined in the robot’s MotionParameters.e file)
Zone name is selected from the list of allowed zones by reading the MotionParameters.e file under
the robot component directory. For example:
zone_define G93 no_smooth;
zone_define G92 no_decel;
The zone is shown in the teach pendant as:

G92
G93
G194
Zone fine is downloaded as first no_smooth zone in the list of available zones
Otherwise zone fine is downloaded as G09
Panasonic specific MotionParameters.e for zones

For other motion types besides no decel, it uses the closest distance Cartesian zone defined in
the MotionParameters.e file.
zone_define fine no_smooth;
zone_define z1 dist speed cartesian 10.0;

Introduction

fine
z1
z2
z3
z4
z5
z6
z7
z8
z9
The default smoothing is z4.
Reis specific MotionParameters.e for zones

zone_define medium speed cartesian 5.0;
zone_define sp_zone1 speed cartesian 10.0;
zone_define coarse speed cartesian 75.0;
zone_define nodecel speed cartesian 99.5;
zone_define nodecel speed joints 99.0 99.0 99.0 99.0 99.0 99.0;

fine
medium
sp_zone1
sp_zone2
sp_zone3
sp_zone4

Lesson
Introduction
sp_zone5
sp_zone6
course
nodecel
Staubli specific MotionParameters.e for zones

All zones that can be used in the trajectories should be defined in the MotionParameters.e file of the
Staubli robot component with a special naming convention: fine or z<Blend>l<Leave>r<reach>
For example:
• fine: zone fine (Blend off)
• zcl10r15: zone with Cartesian blend (flyby type), leave value of 10mm and reach value of 15mm
• zjl15r10: zone with Joint blend (flyby type), leave value of 15mm and reach value of 10mm
Although the exact MotionParameters.e zone name is internally stored on the location, in the Teach
Pendant and Path Editor, zone information should appear in Staubli terms, for example:
zone_define zcl10r15 dist cartesian 12;
zone_define zjl15r20 dist cartesian 17;
The zones are shown in the teach pendant as:

fine
zcl10r15
zjl15r20
zcl20r30
Zone fine is shown as first no_smooth zone in the list of available zones
Universal specific MotionParameters.e for zones

zone_define z1 dist cartesian 1;
zone_define z2 dist speed cartesian 2;

Introduction

fine
z1
z2
z10
z20
z50
z100
z200
z500
z1000
Universal joint speed and acceleration are defined in deg/s and deg/s2.The simulation converts those
values into joint speed values into percent max speed (the only unit supported by MOP).
The following motionparameters.e entries are used:
• cart_max_rot_speed <speedInRadS2>
• cart_max_rot_acc <accInRadS2>
Example of motionparameters.e file speed entries:

cart_max_lin_speed 2000;
cart_max_lin_acc 2000;
* 100 deg/s
cart_max_rot_speed 1.74533;
* 2500 deg/s2
cart_max_rot_acc 43.6332313;

Lesson
Introduction
Motion planning (Introduction to MOP, RCS, and RRS)

Purpose
In this topic, you get introduced to the concepts of MOP, RCS, and RRS.
Objectives

• Better understand MOP, RCS, and RRS.
Motion planning basics

Process Simulate’s motion planner controls the trajectory and cycle-time of all motions. It also
determines if a motion is possible, and also can give error messages if a motion request exceeds the
capability of the modeled mechanism.
There are several different types of robot controllers available:
• DCM (also known as MOP) – the default robot controller. No RCS license is required.
DCM – Dynamic Controller Model
• DCM with RRS – the most accurate robot motion
RRS – Realistic Robot Simulation
What is MOP?
MOP stands for MOtion Planner. Process Simulate uses it to process motion requests from the
user, and passes the results back to the Graphic Viewer. It is the motion planner of the Process
Simulate default robot controller. It can be used by all robots. It uses a robot’s MotionParameters.e
file to create robot specific motion.

Introduction
Process Simulate motion planning flowchart
Description:
• Siemens PLM Software’s patented path-based simulation based on a selected Process Simulate
robot controller
Advantages:
• User designs, simulates, and optimizes a path using the related Process Simulate teach pendant.
• Automatic creation of a robot program file from Process Simulate path
• The created program is an accurate translation of the designed path
• Only a few modifications may be required
What is RRS?
RRS – In a combined effort, initiated by the European Car Manufacturers Association, robot
manufacturers, and software simulation vendors worked together to form an accurate representation
of robot algorithms for each robot in production engineering simulation packages (for example
Process Simulate).
Basically RRS is the interface used by Process Simulate to access a virtual robot controller (RCS).

Lesson
Introduction
• Realistic Robot Simulation (RRS) - An international standard developed by robot manufacturers

and robotic CAD/CAM companies. The standard specifies communication algorithms and
protocols, used by Process Simulate, or any other system, to communicate with a software model
of a robot controller. The standard defines a software model of a robot controller as a "Black Box"
with a specific input and output scheme. Siemens PLM Software develops an RRS interfaces for
Process Simulate to access the RCS.
• RCS Module - A software model of a robot controller (for example virtual robot controller), which
knows how to deal with RRS inputs and outputs. It is developed by the robot manufacturer
to behave just like the real robot controller.

Introduction
MOP, RRS, and ESRC

Purpose
In this topic, you see the connection from MOP and RRS to ESRC.
Objectives
• Know the history of RRS and ESRC.
• Know the contents of ESRC.
• Recall the information exchange between a PLC and a robot.
ESRC history and content

RRS1:
• Developed a long time ago (around 1990).
• Motion planning of robot to communicate to simulation software

o Interpolation
o Transformation
o Kinematics modeling
o Machine data
o External axes
o Conveyor synchronization
o Internal event generation
o Error messages
o RCS Validated (accurate) robot path
o RCS Verified (accurate) motion time
• About 97% motion accuracy including (payload) dynamics
• All process parameters are included / can be downloaded
• Need a configuration file
• Good for standard, non-complex, configurations (for example no servo gun, non-rail robot, etc.)
• But cannot provide accurate cell cycle time because of the following reasons:
o Waiting for devices

Lesson
Introduction
o Robot interlocks
o Path optimization cannot take into account any synchronization of devices
RRS2:
• Good for local changes after robot commissioning
• Too complex
• Gives full controller
• Motion and logic
• Need real controller available
• Need to know all sorts of information to set it up that is not known when the paths are developed
in Process Simulate or it won’t run (for example temperatures, sensor signal registers, how
many I/O boards, how may servo motors, etc.)
• Not the best for project lifecycle (for example want to do robot simulations two years before
commissioning)
• Performance problems (controller needs to “boot” and start everything)
ESRC:
• Emulated Specific Robot Controller
• Easier to use and configure than RRS2
• ESRC = (RRS1 or MOP) + desired logic + robot specific commands
• It is used in the Process Simulate Cyclic Event Evaluator environment (CEE is covered in the
TR45215 Process Simulate Standalone Intermediate Robotics (CEE) course)
• Subset of robot language used to get accurate cycle time
• Can create XML customization files (OLP commands and motion commands).

Introduction
Contents of ESRC
• Command recognition (send/wait signals, etc.)
• Edit robotic commands
• Non-boolean signals
• Comment robotic command
• Free text command
• Boolean/analog evaluation
• Under program/call path (conditional).
• Macro
• Simulates robot commands without the need of RRS2.
• Enhances the usage of RRS1 or MOP with internal robot logic.
• Enables a better design.
• Enables checking alternatives at an early stage.
Robots as integrated production resources

Lesson
Introduction
All RRS papers identify clearly two very important points:

• Robots never are standalones in a production station – they need all the relevant production and
control devices (conveyors, tools, sensors etc.).
• An external Controller (PLC or similar) is a must in order to make the VRC (virtual robot controller)
work.
Robotics: Information exchange between PLC and robot

There are three categories of information to be exchanged:
• Synchronization signals (Wait, Continue) on locations
• Program (path) number and GO/End
• Status Information even on “in between location” positions (for example on each simulation cycle)
Setting up the Process Simulate OPC connection to a PLC was described in the
TR44215 Process Simulate Standalone Intermediate Robotics (CEE) course.

Introduction
Setting up the RCS (part 1)

Purpose
In this topic, you learn how to setup the RCS.
Objectives

• Configure Process Simulate to access the RCS/RRS
Business process
Process Simulate access to RCS/RRS

Process Simulate interfaces with robot manufacturer supplied RCS modules. Each robot interface is
customized to use the functionality of the RCS module as defined by the robot manufacturer.
In order to use RRS to perform a simulation in Process Simulate:

Lesson
Introduction
• You must have the RCS module from the robot manufacturer installed and licensed in the
computer. This is referenced, before starting Process Simulate, in the rrs.xml file.
The specifics of each RCS module covered in the activities. In general you should get
the proper version of the RCS directly from the robot manufacturer. However, a few
versions of some RCS modules are available on the Siemens PLM Software GTAC
website.
• You must use a RCS robot and compatible RRS controller (its motion can be controlled in
Process Simulate using an installed RCS module). This is setup in a specific study in the Robot
Properties dialog box.
For example:
Robot Manufacturer Language Controller RCS or MOP

S4, S4C, S4C+, IRC5,
ABB Rapid RCS
RW6
S4, S4C, S4C+, IRC5,
ABB Volvo (Volvo only) Rapid RCS
RW6
Cloos Carola Qirox MOP
Comau PDL C3G+, C4G, C5G RCS
Comau Volvo (Volvo only) PDL C3G+, C4G, C5G RCS
Denso PacScript RC8 MOP
Duerr EcoTalk EcoRC2, EcoRPC RCS
Epson Spel RC+ 7.0 MOP
F100iA also known as
Fanuc F100iA F100iA RCS
CFLEX
RJ3, RJ3iB, R30iA, TPE (teach pendant
Fanuc RCS
R30iB (RJ13ic) editor)
Fanuc Japan (Japan RJ3, RJ3iB, R30iA, TPE (teach pendant
RCS
customers only) R30iB (RJ13ic) editor)
RJ3, RJ3iB, R30iA, TPE (teach pendant
Fanuc VW (VW only) RCS
R30iB (RJ13ic) editor)
IGM INS K4 MOP
C, D, E (block step
Kawasaki AS RCS
motion format)
KRC1, KRC2, KRC3,
Kuka KRC RCS
KRC4
KRC1, KRC2, KRC3,
Kuka BMW (BMW only) KRC RCS
KRC4
KRC1, KRC2, KRC3,
Kuka Volvo (Volvo only) KRC RCS
KRC4
VKRC1, VKRC2,
Kuka VKRC (VW only) VKRC RCS
VKRC3, VKRC4
Nachi SLIM FD, AW RCS
NC Machining G Code G Code MOP

Introduction
NC Machining BMW (BMW

G Code G Code MOP
only)
NC Machining Danobat
G Code G Code MOP
(Danobat only)
NC Riveting G Code G Code MOP
NC Riveting Embraer
G Code G Code MOP
(Embraer only)
Panasonic CSR G3 MOP
Reis Robstar Robstar5 MOP
Staubli Val Val3 MOP
(ABB) Trallfa Robtalk Robtalk3 RCS
Universal (planned release
URScript v3.1 MOP
Q4 2015)
XRC, NX, DX100,
Yaskawa/ Motoman INFORM RCS
DX200
Setting up MOP versus RCS robot controllers

Since this lesson deals specifically with setting up the RCS, nothing needs to be done for MOP-based
robot controllers. By definition, only RCS-based controllers have an RCS.
For RCS-based controllers, each robot manufacturer has implemented their RCS differently. Each
has some software in a folder under the rrs_bin folder. In some cases, the entire RCS is found here.
In other cases, this folder many contain the RCS client with the RCS server and license server in
different folder or on other computers (such as a centralized server).
From the perspective of Process Simulate, the RCS is considered 3rd party software. this means that
it is developed and supported directly by the robot manufacturer.
Activities
In the Setting up the RCS and RRS (Part 1) section, do the following activities:
• ABB — Setting up the RCS (Discussion Only)
• Cloos — Setting up the RCS (Discussion Only)
• Comau — Setting up the RCS (Discussion Only)
• Duerr — Setting up the RCS (Discussion Only)
• Epson — Setting up the RCS (Discussion Only)
• Fanuc — Setting up the RCS (Discussion Only)
• IGM — Setting up the RCS (Discussion Only)
• Kawasaki — Setting up the RCS (Discussion Only)
• Kuka — Setting up the RCS (Discussion Only)
• Nachi — Setting up the RCS (Discussion Only)

Lesson
Introduction
• Trallfa — Setting up the RCS (Discussion Only)
• Yaskawa — Setting up the RCS (Discussion Only)

Introduction
Setting up the robot controller (part 2)

Purpose
In this topic, you learn how to setup the ESRC robot controllers.
Objectives
• Setup the robot controller.
Business process
Robot controller setup basics

In this lesson, you discuss downloading and installing the latest robot controller from the GTAC site.
For example:
Robot Manufacturer Language

Lesson
Introduction
ABB Rapid
ABB Volvo (Volvo only) Rapid
Cloos Carola
Comau PDL
Comau Volvo (Volvo only) PDL
Denso PacScript
Duerr EcoTalk
Epson Spel
Fanuc F100iA F100iA
Fanuc RJ3, RJ3iB, R30iA (RJ13ic)
Fanuc Japan (Japan customers only) RJ3, RJ3iB, R30iA (RJ13ic)
Fanuc VW (VW only) RJ3, RJ3iB, R30iA (RJ13ic)
IGM K4
Kawasaki AS
Kuka KRC
Kuka BMW (BMW only) KRC
Kuka Volvo (Volvo only) KRC
Kuka VKRC (VW only) VKRC
Nachi Slim
NC Code machining G Code
NC Code machining BMW (BMW only) G Code
NC Code machining Danobat (Danobat only) G Code
NC Code riveting G Code
NC Code riveting Embraer (Embraer only) G Code
Panasonic CSR
Reis Robstar
Staubli Val
(ABB) Trallfa Robtalk
Universal UR Script
Yaskawa/ Motoman INFORM
** In Process Simulate the Cloos, Denso, Epson, Fanuc F100iA, IGM, NC Code machining, NC Code
riveting, Panasonic, Reis, Staubli, Trallfa, and Universal robot controllers are currently license free.
Terminology note:
You can install various Process Simulate robot controllers, which include a teach pendant and an
interface to the related RCS. The RCS is the virtual robot controller (software and license) from the
robot manufacturer. A Process Simulate robot controller and teach pendant together are your interface
to various features of the real robot controller. It is not required to have a real robot controller or teach
pendant from the robot manufacturer to use the Process Simulate robot controller and teach pendant.

Introduction
Pictured: A real robot controller and teach pendant from Kawasaki Robotics, Inc.

Whether the Process Simulate robot controller is MOP-based or RCS-based, you must download
and install it separately from Process Simulate.
This robot controller is developed and supported by Siemens PLM Software and can be referred
to as the ESRC.
Activities
In the Setting up the robot controller (part 2) section, do the following activities:
• ABB — Setting up the Latest Process Simulate robot controller (discussion only)
• Cloos — Setting up the Latest Process Simulate robot controller (discussion only)
• Comau — Setting up the Latest Process Simulate robot controller (discussion only)
• Default — Setting up the Latest Process Simulate robot controller (discussion only)
• Denso — Setting up the Latest Process Simulate robot controller (discussion only)
• Duerr — Setting up the Latest Process Simulate robot controller (discussion only)
• Epson — Setting up the Latest Process Simulate robot controller (discussion only)

Lesson
Introduction
• Fanuc — Setting up the Latest Process Simulate robot controller (discussion only)
• IGM — Setting up the Latest Process Simulate robot controller (discussion only)
• Kawasaki — Setting up the Latest Process Simulate robot controller (discussion only)
• Kuka — Setting up the Latest Process Simulate robot controller (discussion only)
• Nachi — Setting up the Latest Process Simulate robot controller (discussion only)
• NC — Setting up the Latest Process Simulate robot controller (discussion only)
• Panasonic — Setting up the Latest Process Simulate robot controller (discussion only)
• Reis — Setting up the Latest Process Simulate robot controller (discussion only)
• Staubli — Setting up the Latest Process Simulate robot controller (discussion only)
• Trallfa — Setting up the Latest Process Simulate robot controller (discussion only)
• Universal — Setting up the Latest Process Simulate robot controller (discussion only)
• Yaskawa — Setting up the Latest Process Simulate robot controller (discussion only)

Introduction
Setting up the RRS.XML file and more (part 3)
Purpose
In this topic, you learn how to setup the RRS.
Objectives
• Set the basic RRS.
Business process
RRS setup basics
• Setup the RCS before setting up this file, if working with RCS-based controllers.

Lesson
Introduction
• The Process Simulate robot controller must be setup in the rrs.xml file. This includes where the
RCS is located, where the custom XML is located, and whether it should try to connect to the
RCS. This file is located in the C:\Program Files\Tecnomatix\eMPower\Robotics\OLP folder.
Basic syntax for the RRS.xml file:

The rrs.xml file can have several lines. Typical parameters are:
• ControllerName — the RRS name used to reference the RCS from within Process Simulate.
The default value for decoupling can also be setup in the rrs.xml file on the
controller line (in class located in the N:\sysroot\OLP_config_files\ folder).
For example to be disconnected by default: <Controller Name="Fanuc-Rj"
RCSDecoupleSimulationAction="True" RCSDecoupleNonSimulationAction="True">
• VersionName — the version of the RCS module.
You can place all the customer specific controller files under a shared folder in single
location, allowing all users to just point to this folder by adding the CustomizedPath
attribute to the Version element in the rrs.xml file. Typically this folder would be a
shared drive such asN:\sysroot\OLP\Kuka-Krc or \\ilhzsomebody\Kuka-Krc. You
learn more about this at the end of this course.
• ModuleName — the absolute path and name of the executable that is the RCS.
• ModulePathName — the absolute path where the RCS module is located.

Introduction
For example:
Example RCS Module Example Version
Controller Name Required Decoupling
Name Names
C:\Tecnomatix
\rrs_bin\rcs_abb\ 5.0 IRC5
ABB-Rapid
rcsabb_rw5.61.01.irc5\ (rw5.61.01)
rcsabb_tune.exe
C:\Tecnomatix
\rrs_bin\rcs_abb\ 5.0 IRC5
ABB-Rapid-Volvo
rcsabb_rw5.61.01.irc5\ (rw5.61.01)
rcsabb_tune.exe
Cloos-Carola N/A v1
C:\Tecnomatix
\rrs_bin\rcs_comau\
Comau-Pdl C4G (3.12)
rcs_cm_c4g_3.12\
cm_3.12.01_tune.exe
C:\Tecnomatix
\rrs_bin\rcs_comau\
Comau-Pdl-Volvo C4G (3.12)
rcs_cm_c4g_3.12\
cm_3.12.01_tune.exe
default N/A v1 Not supported
Denso N/A v1
C:\Tecnomatix
Duerr-Ecotalk \rrs_bin\rcs_ecopc\v5\ RPC (v5.1.7)
rcsdb01_tune.exe
Epson-Spel N/A v1
V8.2d (fr13.v5.0),
Fanuc-F100iA
debug
C:\Tecnomatix
\rrs_bin\rcsfr13\ V8.2d (fr13.v5.0),
Fanuc-RJ
robcad.bin\ debug
rj3_rcs_tune.exe
C:\Tecnomatix
Fanuc-Rj-Japan
robcad.bin\ debug
rj3_rcs_tune.exe
C:\Tecnomatix
Fanuc-Rj-Vw
robcad.bin\ debug
rj3_rcs_tune.exe
Igm-Ins N/A v1 Must be set to True.
C:\Tecnomatix C (KW07), D
Kawasaki_As \rrs_bin\rcskw\ (KW08),
rcsKW09_tune.exe E (KW09)
C:\Tecnomatix
\rrs_bin\rcs_krc1\
Kuka-Krc V52 (r02)
krc5.2_r02\bin\
rcskrc1_tune.exe

Lesson
Introduction
C:\Tecnomatix
\rrs_bin\rcs_krc1\
Kuka-Krc-Volvo V52 (r02)
krc5.2_r02\bin\
rcskrc1_tune.exe
C:\Tecnomatix
\rrs_bin\rcs_krc1\
Kuka-vKrc V52 (r02)
krc5.2_r02\bin\
rcskrc1_tune.exe
C:\Tecnomatix
Nachi-Slim \rrs_bin\rcsnf_ax\ FD
rcs_main_ax_tune.exe
NC-Code N/A v1 Must be set to True.
NC-Code-BMW N/A v1 Must be set to True.
NC-Code-Danobat N/A v1 Must be set to True.
NC-Code-Riveting N/A v1 Must be set to True.
Panasonic N/A v1
Reis-Robstar N/A v1 Not supported
C:\Tecnomatix
Trallfa-Robtalk \rrs_bin\rcstr\ v2.1.2
rcstr01_tune.exe
Universal-URScript N/A v1 (TBD)
C:\Tecnomatix
Yaskawa-Inform \rrs_bin\rcsyma\ DX
rcsmainDX_tune.exe
The rrs.xml file is a mapping file. It must be edited to reflect your environment (for example the
version of the RCS used, the folder it is installed in, decoupling mode, custom XML folder, etc.).
A section must exist in this file for every RCS and RCS module version that is used, but not for every
RCS supported by Process Simulate.
An example of the rrs.xml which matches the exercises in this course is included with the
training data. Some modifications may need to be done to the file in order to use it in
your training environment.

The major step covered in these activities is the configuration of the RRS.xml file. The configuration
of this file is required for RCS-based robot controllers, but is optional for MOP-based robot controllers.
For RCS-based controllers, it is used to reference the RCS under the rrs_bin folder. For most
RCS-based robot controllers you need to add a section to this file for each robot controller and for
each version of the controller (accept for Fanuc).
One reason to setup a section in this file for MOP-based controllers is if you would like to place your
customer specific configuration files for a robot controller in a different folder other than the default.

Introduction
In this case a Version section is added to the file and can be named anything. This is what you
have done in these activities by naming it v1.
Activities
In the Setting up the RRS.XML file and more (Part 3) section, do the following activities:
• ABB — Preparing to setup the RRS (discussion only)
• Cloos — Preparing to setup the RRS.xml (discussion only)
• Comau — Preparing to setup the RRS (discussion only)
• Default — Preparing to setup the RRS.xml (discussion only)
• Denso — Preparing to setup the RRS.xml (discussion only)
• Duerr — Preparing to Setup the RRS (discussion only)
• Epson — Preparing to setup the RRS.xml (discussion only)
• Fanuc — Preparing to Setup the RRS (discussion only)
• IGM — Preparing to setup the RRS.xml (discussion only)
• Kawasaki — Preparing to Setup the RRS (discussion only)
• Kuka — Preparing to Setup the RRS (discussion only)
• Nachi — Preparing to setup the RRS (discussion only)
• NC — Preparing to setup the RRS.xml (discussion only)
• Panasonic — Preparing to setup the RRS.xml (discussion only)
• Reis — Preparing to Setup the RRS.xml (discussion only)
• Staubli — Preparing to setup the RRS.xml (discussion only)
• Trallfa — Preparing to setup the RRS (discussion only)
• Universal — Preparing to setup the RRS.xml (discussion only)
• Yaskawa — Preparing to Setup the RRS (discussion only)

Lesson
Introduction
Process overview
Purpose
In this topic, you get an overview of the process.
Objectives

• Get a basic overview of the steps to create a process and then output it as a program for the
real robot.
Process generation
1. Basic Process Roughed Out.
• Setup of basic structure of data
2. Detailed process motion completed and verified. (Topic covered in TR45115 Process Simulate
Standalone Basic Robotic Simulation)
• Create Process Locations
• Select Robot Tool
• Place Robot
• Create Via Locations
• Optimize the Process
• Simulate the Process
3. Logic added and verified (Topic covered in TR45215 Process Simulate Standalone Intermediate
Robotics)
• Setup sensors
• Flexible tooling for variants logic
• Verify robotic zone signaling
• Conveyor setup
• Simulate the process logic
4. Fully verified robot programs are completed and ready for downloading. (Topic covered in
TR45315 Process Simulate Standalone Advanced Robotics)
• Sending a process to a robot using OLP
• Etc.

Introduction
Process to program
1. Verify collision free simulation.
2. Add process logic attributes.
3. Teach local locations for process using correct motion type at each location.
4. Download the program.

Lesson
Introduction
OLP in process design

Purpose
In this topic, you learn about using OLP to design a process.
Objectives

• Know problems that can occur without considering OLP issues
• Take OLP into consideration.
• Do the up-front work required.
• Include relevant information at each step of the process.
• Supply information needed in later steps of the process.
• Know what should be considered for OLP.
Problems that can occur without considering OLP issues
If no Off-Line Programming considerations are made by the process designer, it is assured

that the shop floor engineer has major problems with the Process Simulate generated
programs. In many cases these problems may justify discarding the OLP deliverables.
Some of the types of problems are:

1. Robot pose configurations (impossible, senseless, etc.).
• Example: The robot moves from a FLIP to NO-FLIP.
2. Dangerous (to man and machine) singularity problems.

• Example: Joint 4 & 6 move in an unpredictable, high-speed rotation.
3. Elements of the program are missing.

• Example: The robot controller doesn’t have good editing capabilities.
4. The shop floor engineer does not understand the total control scheme.
5. Need to calibrate? Need to maintain?
6. No flexibility in the design to compensate for mechanical and build inaccuracies.

• Example: A change is required, but the robot is already working on a joint limit!
7. No obvious way to "dress" the robot with this program.

Introduction
How to take OLP into consideration
At each processing stage, a good designer can make many of the OLP shopfloor decisions
without venturing out of their office. Also, a good designer is responsible for ensuring
successful OLP by making their design intent clear
Do the up-front work required

Example:
• Using the required robot controller, test a sample of the programs you generate. Identify a
program certification process/authority. What is the required program structure?
Include relevant information at each step of the process

Example:
• What robot is used?
• What is the maximum cycle time allowed?
• How many robots does the cell include?
• What about zones clearance?
• What about joint limits?
Supply information needed in later steps of the process

Example:
• Setup kinematic devices and robot tools.
• Enter signals information.
• Create the sequencing.
• Add notes for shop floor engineers.
Always be alert, and check the design against common robotic constraints.
What should be considered for OLP?

At the concept design stage:
1. Robotic welding? Human operations? Fixed automation?
2. Do not position robots close to each other.
3. Make the part accessible - Shop floor personnel need to work there safely.

Lesson
Introduction
4. Is the robot required to pick and place as well as weld? Remember: The tooling on this robot
makes it harder to manipulate and less flexible.
5. What robot is designated for use? Can it do the job (weight, speed, etc.)?
6. Go and see the actual robot you are working with. Request a presentation of the unique
capabilities of this robot.
7. Where is calibration performed? Maintenance?
At the initial (rough) processing stage:

1. Assign a robot only those locations it can actually reach. Check extreme cases with the ACTUAL
robot.
2. Make sure the location orientation makes sense.
3. Color-code the location assignment. This makes it easier to see what is happening.
4. Use naming conventions from the very beginning (weld locations, via points, pounce, home,
maintenance, safe, tip dress, etc.).
5. Sequence the locations assigned to a robot in a consistent fashion, according to plant

specifications as well as the concept sequence (for example a robot that is assigned a pick &
place and weld combination).
6. When sequencing welds, consider orientation changes as well as geometric properties. It

may be easier and faster for a robot to work on a further out (geometrically) weld than to twist
it’s configuration.
7. Make realistic gun size assumptions.
8. Process for a smooth gun motion. This, in turn, leads to a smooth robot motion and an easy
program.
9. Immediately (by default) assign a linear motion type to all segments where the gun tip is close
to the part.
10. Immediately (by default) assign zone type fine to all segments where the gun tip is close to the
part.
At the layout and integration stage:

1. Position the robot such that not only can it reach all the locations, but also comply with the
shop floor soft limit set up.
2. Position the robot such that not only can it reach all locations, but also have a +/- 10 degrees of
freedom for future changes.
3. Position the robot such that not only 1 and 2 are covered, but also all segments of motion in
between welds are considered for 1 and 2, and all possible configurations.
4. Optimize for bottlenecks.

Introduction
5. Optimize for cycle time, but indicate possible changes.
6. Include all robot specific commands you find relevant to maintain the design intent, such as :
speed instructions, signal and control instructions, etc.
7. Duplicate locations if it makes program structure easier for the shop floor engineers to manipulate.
8. Approve and certify the program/database (by a shop floor representative).
At the detail process design stage:

1. Keep the gun motion smooth. Do not force big gun orientation changes.
2. Avoid using large envelope stretches. This causes difficulty in positioning the robot.
3. Avoid complicated control schemes if possible (for example opening and closing clamps to make
welds). Request a change as early as possible for such conditions. If you don not, the shop
floor engineers need to do it later.
4. Mirror situations, where the left robot and right robot are performing a mirror image of the same
path, are preferable.
5. Mark optional calibration data (use naming and color conventions).
6. Add via locations the way the robot would naturally move - not how you think it should.
7. Immediately, (by default) assign jointed motion type to all segments where the gun is moving
between via locations.
8. Immediately, (by default) assign zone type coarse to all segments where the gun is moving
between via locations.
9. Add your comments of design intent for the shop floor engineer.
At the documentation stage:

1. Create OLP outputs. Set up as follows:
• Create a Snapshot, displaying only relevant data. Blank data used for presentation needs.
Blank all irrelevant details. Include Notes and Labels in the image to document the location
names or other relevant information.
• Include screen shots of problematic areas.
• Create AVI of the simulation, so shop floor can understand the complete design.
• Create robot program files (OLP downloads).
2. Prepare the media for the program (diskette, files, etc.).
3. Test problematic programs locally before they are shipped to the plant.

Lesson
Introduction
Study preparation
Purpose
In this topic, you get an overview of how to prepare the environment.
Objectives

• Get an idea of now to prepare the environment.
Overview
1. CAD geometry is latest revision of workpiece.
2. Study components are modeled to a sufficient level of detail to verify collision avoidance.
3. Robot model chosen according to job requirements.
4. Robot is positioned to reach all target locations.
5. Study layout of components is matched to real-world conditions.
Activity: Verify and adjust your study as required per previous instruction.

Introduction
Error sources
Purpose
In this topic, you learn several major sources of error in OLP.
Objectives
• Know about five major sources of errors in the process.
Five major sources

Robot inaccuracies:
• Geometric model (link lengths, joint limits, joint direction)
• Elasticity (gravity effects)
• Zero positions
• Conversion coefficients
• Motor and gear performance
• Every robot on the factory floor is slightly different from each other and from the Process Simulate
"ideal" model.
Tool inaccuracies:
• Manufacturing tolerances
• Geometric model
• Mounting frame
Workpiece:
• CAD model variances
• Manufacturing tolerances
• Deformations during the process
Layout:
• Installation errors
• Tolerances
External devices:
(positioner, gantry, rotary tables, 7th axis, etc.)

Lesson
Introduction
Summary
Subjects learned in this topic:
• An overview of OLP.
• An overview of the Process Simulate data model.
• The basics of robot models.
• The basics of RRS, RCS, and ESRC.
• How to setup the RCS and RRS.
• The steps for process generation and process to program.
• The problems that can occur if OLP is not considered.
• How to prepare the study for OLP.
• Some sources of error in OLP.

Lesson 2: Robot programming background
Purpose
To provide information on the default controller, ESRC’s (Emulated Specific Robot Controller) and
robot programs.
Objectives

• The basic motion attributes.
• Robot configuration, 7th axis, and the Robot Viewer.
• Where and how to store signals and conditional statements.
• Robot program basics and robot signals.
• Robot program creation and usage.

Lesson
Lesson 2: 2: Robot
Robot programming
programming background
background
Basic motion attributes (default controller)

Purpose
In this topic, you learn how modify basic motion attributes using the default controller.
Objectives

• Motion attributes basics.
• Robot controller.
• Know about basic motion types.
• Know about basic motion termination (accuracy/zones).
• Know about basic default controller examples.
• View and edit location attributes.
Do I do this

Robot programming background
Motion attributes basics (default controller)

You start by using the default controller to talk about the basic theory of motion attributes. Later in
this course, you revisit this topic using robot specific motion attributes. Much of the information in
this lesson is a review from previous Process Simulate training.
Robot controller
The robot controller can be set or viewed from the Controller tab of the Robot Properties dialog box
(Robotics→Robot Properties ) in Process Simulate. It is used to assign a Process Simulate
controller and machine data to a robot; which sets the teach pendant (containing robot specific
motion parameters) and motion planner for a robot.
For this portion of the course, you use the default controller. Later, you switch to an ESRC
one.
Motion types (default controller)

On the Default controller, motion type refers to joint motion, linear motion, or circular motion. Proper
selection of motion type is very important in the design of the process.
• Motion Type — Describes how a robot moves to this location. For example here are two most
common motion types found in the default controller:
o Joint (PTP) — Typically causes the robot to move the quickest between locations (usually
resulting in a curved path).
o Linear (LIN) — Causes the robot to move straight to this location.
When to use a motion type:

• Joint (PTP) motion should be used where high speed and low accuracy of the TCP trajectory
is allowed.
• Linear (LIN) motion should be used where high accuracy of the TCP track is required; robot
speed may be somewhat curtailed.
• Circular (CIRC) motion is used when the robot TCP is required to move along a circular arc;
most often in an arc-welding or sealing process.

Lesson
Lesson 2: 2: Robot
Robot programming
background
Motion type constraints:

The process designer must take this into account during layout of a robot path, or the robot may want
to "unwind" the wrist in a critical portion of the process.
• Linear (LIN) and Circular (CIRC) motion place constraints on how the robot is allowed to reach
the target locations.
• Configuration refers to the specific wrist pose the robot is required to attain in reaching a location.
Configuration only applies to locations that have been taught.
Motion termination for the default controller

A "zone" (also known as termination zone or accuracy) in Process Simulate determines how closely
the TCPF approaches the target location. Zone types include "fine" (accurate positioning), by
distance (window), by relative distance, by speed, or by time. Zones have different effects on TCP
trajectory based on the motion type.
An absolute or relative distance constituting the radius of a sphere around the working
point, or a condition on speed or deceleration as it approaches the destination point.
When the robot reaches the zone around a location, it immediately begins execution of the
next instruction of the program.
• Zone (Called Accuracy or Term Type on various ESRC controllers) — Describes how the robot
approach/arrive at a location. For example here are four zones found in the default controller.

Each can be mapped to a range of values on the ESRC controllers (you discuss this later). The
two most common are Fine and No Decel:
o Fine — causes the robot to slow and “arrive” at the location.
o Course and Medium in between Fine and No Decel.
o No Decel — cause the robot to not slow and “approach” the location (However, arrival is
not a requirement).
Curvature effect on a linear path because of a "nodecel" zone

Lesson
Lesson 2: 2: Robot
Robot programming
background
Zone determines the precision by which the robot’s TCPF reaches intermediate locations
as it performs motion commands. Intermediate locations (via locations) are those through
which the robot passes without stopping. These are all of the locations except the last
location in a path, as well as all the locations where, when reached by the robot, a delay or
wait command is specified. The numeric values of the different zones are defined in the
robot motionparameters.e file under the robot .cojt component directory.
Using UpgradeToVersion to convert an old .co component to a .cojt component,

automatically convert the .e file within the component to a motionparameters.e file.
Location reference frames

Scenarios for location reference frames
• Method 1: Defined when the gun is mounted to the robot (for gun on robot) or when External
TCP is checked on the Operation Properties (for remote TCP). All locations in the path use this
same default TCPF position.
• Method 2: A different TCPF position can be set for each location in the path using the Tool
Frame, Remote TCP Frame, or Work Frame location attributes. In this case there is no default
TCPF position. There is only the current TCPF position. A path can even contain a combination
of locations with different location attributes (for example one path with gun on robot locations
and remote TCP locations). However, it is recommended that each location have a specific TCPF
position defined. This is much closer to how the real robot operates.
When a gun is mounted to a robot, the default TCPF position is also set. Alternately if this is not
desired, a different TCPF position can be set on each location. Tool Frame and Remote TCP
Frame locations.
Location Attributes for Frame References:
• Tool Frame (for gun on robot) — this is the typical place for defining the TCPF position on a
location. Pick any frame in the Object Tree or Graphic Viewer. Make sure the frame name is
unique in the study.
• Remote TCP Frame (for an external TCP) — this box is used when the TCPF should be on an
object which is not mounted to the robot. Pick any frame in the Object Tree or Graphic Viewer.
Make sure the frame name is unique in the study.
• Work Frame — can be used if you know the gun device that has to be used with a given TCP.
Select the tool from the list of values. This list of values is populated with the list of defined tools
for this robot created by choosing Control tab→Setup group→Robot Toolbox (More on
this later).

Other default controller examples

• Speed
o Speed for Joint (PTP) motion is measured as a percent of the maximum speed.
o Speed for Linear (LIN) or Circular (CIRC) motion is measured in mm/sec.
• Wait Time is measured in seconds.
Viewing and editing location attributes

These attributes can be viewed and edited in several ways in Process Simulate:
• Teach Pendant dialog box
• Path Editor dialog box
Both of these techniques were covered in the TR45115 Process Simulate Standalone
Basic Robotic Simulation course. You use these techniques throughout this course.
Activities
In the Basic motion attributes (default controller) section, do the following activities:
• Set up the macro folder
• Set up some basic robotic operations
• View simulation differences

Lesson
Lesson 2: 2: Robot
Robot programming
background
Robotic configuration selection

Purpose
In this topic, you learn how to view and select robotic configurations.
Objectives
• Select a solution (robot configuration).
• Identify solution and turns for a location.
• Use the Robot Viewer.
• Understand how an external axis effects solution selection.
Business process
Robot configuration selection basics

In several cases, a robot has more than one choice for inverse kinematics (robotic joint angle
selection to reach a specific location with its TCPF). This lesson investigates some of the factors
affecting inverse kinematics solution selection. In robotics, the inverse kinematic solution is also
known as a robot configuration.
Solution and turns
Configuration — A specific combination of joint values obtained as a solution of inverse

kinematics.
Turns — A condition related to joints with greater than 360 degrees of travel.
Solutions (also known as the Robot Configuration) and turns can be accessed in several places
in Process Simulate. In cases where multiple inverse kinematics solutions are available to reach a
location, it allows the viewing and selection of specific solutions. Configuration information is read

from the controller, stored on a local location (our solution), and downloaded (controller specific
solution) to the program file.
In most common robots there are 23 = 8 possible solutions for each location. However,
some are ruled by limitations of the robot:
• J1 — Overhead or not overhead
• J2, J3 elbow up or elbow down
• J4, J5 flipped or not flipped
The solution also affects cable rap (entanglement).
Controller selection of solutions:

For each robot there are criteria to sort out which solution to select (specific configuration bits). For
example, flip or no flip, overhead or not overhead, and in general where the robot is within a 360
degree area divided into four sections, etc. The controller translates this information into a string,
depending on robot type, which is placed in the downloaded program file. Each robot family has
different key words. Process Simulate needs to have access to the RCS for the selected robot.
Otherwise, it won’t be able to get the robot configuration string for the real robot (critical).
Communication between Process Simulate and the RCS:
• Process Simulate gives the location information to the RCS
• The RCS gives back configuration results
• RCS can have a tolerance for configuration selection
• In some cases (for example Fanuc rj2ic) the RCS may have special syntax flags to say which
one to use
• You auto teach and store your configuration on a location which may be diffident than the RCS.
The Robot tab→Reach group→Jump to location command uses simple

kinematics (not RCS) to calculate the configuration.

Lesson
Lesson 2: 2: Robot
Robot programming
background
• If not connected to the RCS then it writes the solution from the default controller. Not having a
connection also causes it to not understand that the controller specific OLP commands during
download.
The guy on the floor doesn’t see different solutions because he teaches the
configuration solution. You are trying to solve it each time.
Solution information can be viewed or edited using:

• Robot Configuration dialog box
• Teach Pendant dialog box
• Path Editor
Teaching a solution for a location (also known as creating a local location in Robcad):
1. Select a location.
2. From the ribbon, choose Robot tab→Setup group→Robot Configuration .
The current location configuration is bold. A MotionParameters.e file must exist in the
robot .COJT for this command and the simulation engine to function properly. There is
an entire guide dedicated to this file. However, it contains various definitions for how
the robot moves and is required by default controller (MOP) and RRS simulation.
3. Select a configuration from the list
4. Click Teach.
5. OR you can select a turn by clicking Turn (+/-)
OH = overhead

In the Robot Configuration dialog box, in the Joint Turns area, if the joint name is different than
the joint index, the joint name is added in parentheses.
If you download with an RCS connection, Process Simulate writes the translated stored version of
the configuration. It should be the same as what is stored on the local location except if there was a
problem with the mapping (The connection allows the validation of what you put in the mapping). If
there is a problem, it would show in the log file.
Joint value defined locations don’t have a configuration
Using the Robot Viewer
This tool was discussed in the TR45115 Process Simulate Standalone Basic Robotic
Simulation and TR45215 Process Simulate Standalme Intermediate Robotics (CEE)
courses.
The Robot Viewer can be found by picking a robot and choosing Robot tab→Play group→Robot
Viewer .

Lesson
Lesson 2: 2: Robot
Robot programming
background
• Can be used to view joints moving along the path
• Can be used to look for steep or radical joint value changes (winding)
• Can export to excel or various picture formats
• Can gather statistics on min/max (values or %) including the applied software limits
A key OLP issue is the engineering judgment of the robot behavior over time and not only at a
specific point. The Robot Integrated Development Environment (RIDE), available for multiple robots,
contains several tools essential to robot programming and debugging:
• Trend-like graphical presentation of robot joint values
• “Historical view” — the values of the information are visible over time
The Robot Viewer contains the following panels:
• Joint Monitor — It generates and displays a graphical representation of their values at all points
of time in the simulation. The trace for each joint of the selected robot is displayed in a different
color. Each trace is comprised of finite points in time where measurements are taken. The higher
the sampling rate, the more accurate is the trace.
You can display the lower and upper limits for each joint as a dashed line, providing a visual
impression of the state of the joint (but does not generate alarms).
The Joint Monitor panel also displays statistics concerning joint values during simulation. The
Statistics section shows the minimum and maximum values for each joint of the selected robot
during the current simulation. When the joint value enters one of the working limits, its value is
displayed in orange and when it reaches its minimum or maximum value, it is displayed in red.
• Joint Status — shows the current value for each joint of the selected robot (including external
joints). Alternatively, you can display the current joint value as a percentage of the joint range.

• TCPF Speed Monitor — Displays a graph of the speed of the robot TCPF. In the Legend
section, you can set the color of the trace. The Statistics section displays the minimum and
maximum speeds of the robot TCPF.
• Joint Speed & Acceleration — Displays graphs of joint speed and acceleration.
• Power Consumption — The graph above shows the current Power Consumption of a robot
during simulation in units of kW (kilowatts). The Statistics section on the right of the graph
displays the following: Overall energy — The total energy consumption (in Joules) of the robot
during simulation. This is the sum of all the RCS updates until the simulation ends (or pauses).
Peak power — The peak power consumption (in kilowatts) as sampled during the simulation.
The system also notes the time at which the peak energy consumption occurred. Currently, this
feature is only supported by robots connected to the KUKA KRC8.3 RCS (or higher version).
External axis
For more information on external axis usage and kinematic definition, see the TR45115
Process Simulate Standalone Basic Robotics Simulation course.
External axis — (for example 7th axis). A typical example is a robot on a rail, where the rail is the
external axis. This allows multiple solutions to a location, based on the position of the robot on the
external axis. This information is stored on the compound location.
External Axis process overview:
• The external device (for example rail) is created as a separate component with (at least) one joint.
• The robot base must be attached to the carriage (for example slider) entity of the external device.
• The robot is made the active mechanism by selecting it.
• Add the joints from the external device to the robot’s joint list.
• Mark compound locations (for example to store the position of the robot on the external device’s
joints onto the location that is being reached)
Activities
In the Robotic configuration selection section, do the following activities:
• Viewing and setting robot configurations
• Robot Viewer

Lesson
Lesson 2: 2: Robot
Robot programming
background
Review of robot programs and robot signals

This topic reviews some of the robot programs and robot signal topics from the TR45215 Process
Simulate Standalone Intermediate Robotics (CEE) course.

It contains the following subtopics:

• Robot Programs
• Robot Signals
• Status Signals
• Robot Path Reference Operation
• Robot Program
Business process

Lesson
Lesson 2: 2: Robot
Robot programming
background
Robot programs
RCS/RSS simulation does require the definition of a Process Simulate program. It can be
used with just one simple robotic operation (for example one path). A Process Simulate
program is used when switching, during simulation, between several robotic operations
using logic, or when downloading.
A robot has as task to be executed. Normally it is made up of motion tasks and logic instructions
organized in a robot program. Almost all robot programs have the same basic skeleton:
To guarantee correct behavior all robot vendors enforce a predefined sequence of signal exchange:
• To prevent the robot from starting to move in an uncontrolled way.
• To continue its motion until the end of its task.
The Siemens PLM Software default behavior doesn’t simulate all of the signals used by a real robot.
Those significant signals for the correct process behavior are included in the default behavior.
Specific behavior may be implemented in the relevant ESRC (Emulated Specific Robot Controller),
which has to be purchased separately and has its own documentation.

In the TR42215 Process Simulate on eMS Intermediate Robotics (CEE) course, you
discussed how to create a simulation where logic is used to switch between the different
robot paths (for example trigger them) that are part of a robot program (for example when
to run path 1, path 2, etc.).
Robot signals
In the TR42215 Process Simulate on eMS Intermediate Robotics (CEE) course, you
discussed how create and use robot signals and associate them to signals on a PLC in
order to control the simulation (for example trigger the execution of various events).
A robot program is a series of instructions to the robot. For example:
It’s easy to see that some of the signal values are only checked when a specific location is reached.
Such signals are called robot signals (might be of type Input, Output, or Memory).
In the example it can be seen that the value of $OUT [17] is set only on the on “POINT2” location (for
example it is a robot signal).
Status signals
Status signals play a different role. They are continuously evaluated by the robot controller (either
input signals, for example emergency stop, or output signals, for example pose signal). They are a
way of simulating behavior that can be downloaded. Using status signals, paths can be simulated like
robot programs using path numbers inside the program.
Default (PLC) output signals:
• startProgram (signal function = Starting Program)
• programNumber (signal function = Program Number)
• emergencyStop (signal function = Program Emergency Stop)
• programPause (signal function = Program Pause)
Default (PLC) input signals:

• programEnded (signal function = Ending Program)
• mirrorProgramNumber (signal function = Mirror Program Number)

Lesson
Lesson 2: 2: Robot
Robot programming
background
• errorProgramNumber (signal function = Error Program Number)
• robotReady (signal function = Robot Ready)
• HOME (signal function = Pose Signal)
Robot path reference operation
The New Operation →New Robot Path Reference Operation command enables you to
run robotic operations of a robotic program in a line simulation.
• A robot path reference operation activates one or more specific operations within a robotic
program via the path number.
• You can run it in a line simulation.
• Because the robot path reference operation refers to the robotic operation only by its path number,
you can change the target of it by re-assigning a path number to a different robotic operation.
Creating robot path reference operation:

• Keeps the part associated to a material flow alive
• Allows full flexibility in changing paths without changing anything in the Gantt chart
• Are only be executed using robot program parameters (robot status signals)

Robot program
The following schematic diagram shows the general robot behavior based on a path view:

Lesson
Lesson 2: 2: Robot
Robot programming
background

Creating robot programs (default controller)

Purpose
In this topic, you learn how to create robot programs using the default controller.
Objectives

• Use a couple methods to create and edit a program.
• Create a robotic program from a compound operation.
Business process
Robot program basics

In order to download paths you need to make a program. The robot program is used to organize the
robot operations in a specific order and enumerate them.
• A program is an object
• It can be downloaded and simulated
• It can contain several paths and can be edited
Program features in the Path Editor:

• The Path Editor supports opening robot programs and robotic paths
• Used to set up robot programs as an executable program – like on a real robot
• Used to add robot paths to a program by drag and drop to the program
• A program can be renamed by selecting it in the Path Editor, pressing F2, and entering a new
name.

Lesson
Lesson 2: 2: Robot
Robot programming
background
Methods to create and edit a program

Methods to create a robotic program:
• Manually create it using a combination of the Program Inventory dialog box and the Path Editor.
This technique is described in this lesson.
• Select a compound operation containing the desired robotic operations and choose Robot
tab→Program group→Create Robotic Program for Compound Operation .
Alternately, you can right-click a compound operation in the Operation Tree and choose
Create Robotic Program for Compound Operation .
• Use the Segmentizer (a separately installed command that is discussed in the appendix)
View or edit the contents of a robotic program:
In the Program Inventory dialog box, select the program and click Open in Program Editor to
edit or show a program’s contents in the Path Editor.
A robot program is stored as part of the study and is specific to one robot .
Creating a robotic program from a compound operation
The Create Robotic Program for Compound Operation command searches for robotic paths
in the selected compound operation. If all the paths it locates are assigned to the same robot, the
system creates a new robotic program for the robot and names it after the name of the selected
compound operation with an _program suffix. The system then inserts all the paths from the
compound operation under the new robotic program. The order of paths in the new robotic program is
the order in which the paths run in the compound operation. The command is enabled when you
select one or more compound operations (or PrStationProcess objects).
• If you select multiple compound operations, the system repeats the process for each one and
creates a new robotic program for each one.
• The compound operation remains unchanged.
• Paths inserted in the new robotic program are retained by the robotic programs to which they
have previously been assigned.

• If there is no robotic path under the selected compound(s), the system does not create a program.
No error message is issued.
• The system ignores operations that are not robotic paths. No error message is issued.
• If you select paths assigned to different robots, the system does not create a program and
issues the following message: "The system was unable to create a Robotic Program for one or
more Compound Operations, which contain operations performed by different robots: < list of
compound_operation_names>".
Activities
In the Creating robot programs (default controller) section, do the following activities:
• Creating a robot program and using default signals (review)
• Creating an Excel spreadsheet of a path (review)

Lesson
Lesson 2: 2: Robot
Robot programming
background
Summary
• The basic motion attributes.
• Robot configuration, 7th axis, and the Robot Viewer.
• Where and how to store signals and conditional statements.
• Robot program basics and robot signals.
• Robot program creation and usage.

Lesson 3: ESRC setup and motion parameters
Purpose
To describe how to setup and setup and add motion parameters to paths using emulated robot
specific controllers (ESRC).
Objectives
• Got an overview of OLP features.
• How to setup a basic robotic study that you can use to learn about ESRC.
• How to select a controller and view the teach pendant.
• How to do some basic setup of a robot and robot controller.
• How to test a teach pendant and fix some setup problem.
• How to reset the RCS and decouple it.
• How to setup and use the robot toolbox.
• How to setup specific controller frames using the Teach Pendant and other specific setup.
• How to set specific controllers motion attributes using the teach pendant.
• How to create a program.
• How to simulate a process and create configurations.

Lesson
Lesson 3: 3: ESRCESRC
setupsetup and motion
and motion parameters
parameters
Process Simulate OLP introduction

Purpose
In this topic, you learn how using a specific controller differs from using the default controller.
Objectives
• Overview the basic steps to setup a robot controller
MOP-based and RCS-based controller set up

There are several steps required to setup up MOP-based and RCS-based robot controllers.
Overview of setting up a MOP-based simulation

1. Select a supported robot configuration (for example a robot with a gripper mounted) as described
later in this lesson.
2. Setup and configure all guns that can be mounted on the robot. Tell which is gun1 and gun2
and if is it a pneumatic or servo gun.
3. Verify the setup of the rrs.xml file for all robots by vendor. This file contains configuration
information for all robot vendor RCS modules. It contains information such as where the RCS
installed and which version is installed. (for example for ABB the Module Path would be:
C:\Tecnomatix\rrs_bin\rcs_abb\rcsabb\rcsabb_tune.exe). This information needs to be
maintained manually (for example as new versions of the RCS are installed, this file needs
to be updated accordingly).
4. Configure the robot controller for a specific robot instance: Right-click the robot and choose
Robot Properties. Select the Controller tab. Select the Controller, RCS Version (optional),
and Controller version. This is stored in the study data.
5. If the robot is using specific machine data (ex : robot with external axes): In Setup dialog box,
choose Robot Settings, choose Load Machine data, and import the desired file from the robot.
6. Choose Robot Settings then choose Create/Update System frames to create all required
frames (for example world, tool, wobj, etc.)
7. Setup the tool frame and base frame definitions. They are stored at the study level.
8. Setup the desired attributes on the teach pendant and run the simulation.
Overview of setting up a RCS-based simulation

1. Select a supported robot configuration (for example a robot with a gripper mounted) as described
later in this lesson.
2. Setup and configure all guns that can be mounted on the robot. Tell which is gun1 and gun2
(can have two for Fanuc) and if is it a pneumatic or servo gun.

ESRC setup and motion parameters
3. Verify the setup of the rrs.xml file for all robots by vendor. This file contains configuration
information for all robot vendor RCS modules. It contains information such as where the RCS
installed and which version is installed. (for example for ABB the Module Path would be:
C:\Tecnomatix\rrs_bin\rcs_abb\rcsabb\rcsabb_tune.exe). This information needs to be
maintained manually (for example as new versions of the RCS are installed, this file needs
to be updated accordingly).
4. Configure the robot controller for a specific robot instance: Right-click the robot and choose
Robot Properties. Select the Controller tab. Select the Controller, RCS Version, and
Controller version. Enter the Manipulator Type (the machine data entered must be precise).
Usually in the syntax of RCS software version and robot description (robot model, arm
configuration, 7th axis, servo, etc.). This is stored in the study data.
5. If the robot is using specific machine data (ex : robot with external axes): In Setup dialog box,
choose Robot Settings, choose Load Machine data, and import the desired file from the robot.
6. Choose Robot Settings then choose Create/Update System frames to create all required
frames (for example world, tool, wobj, etc.)
7. Setup the tool frame and base frame definitions. They are stored at the study level.
8. Start the RCS (if required) and connect to it
9. Setup the desired attributes on the teach pendant and run the simulation.
ABB supported configurations

Process Simulate supports these ABB configurations:
• Robot with one or two mounted pneumatic guns
• Robot with gripper and one or two pedestal pneumatic guns
• Robot on rail with one or two mounted pneumatic guns
• Robot with gripper on rail with one or two pedestal pneumatic guns
• Robot with one or two mounted servo guns
• Robot with gripper and one or two pedestal servo guns
• Robot on rail with one or two mounted servo guns
• Robot with gripper on rail with one or two pedestal servo guns
• Robot with moving object frame (object attached to an external mechanical unit, like a turn table)
Cloos supported configurations

Process Simulate supports these Cloos configurations:
• Robot with mounted gun

Lesson
parameters
• Robot with mounted workpiece
• Robot on rail
Comau supported configurations

Process Simulate supports these Comau configurations:
• Robot with a mounted gun
• Robot with a mounted workpiece
• Robot on a rail
• Robot with one servo gun
• Robot on rail with one servo gun
Denso supported configurations

Process Simulate supports these Denso configurations:
• Fixed robot with fixed part
External axes are not supported for the Denso controller.
Duerr supported configurations

Process Simulate supports these Duerr configurations:
• Multiples robots on rail with a conveyor
Epson supported configurations

Process Simulate supports these Epson configurations:
External axes are not supported for the Epson controller.
Fanuc supported configurations

Process Simulate supports these Fanuc configurations:
• Robot with one or two mounted pneumatic guns
• Robot with gripper and one or two pedestal pneumatic guns
• Robot on rail with one or two mounted pneumatic guns

• Robot with gripper on rail with one or two pedestal pneumatic guns
• Robot with one or two mounted servo guns
• Robot with gripper and one or two pedestal servo guns
• Robot on rail with one or two mounted servo guns
• Robot with gripper on rail with one or two pedestal servo guns
IGM supported configurations

Process Simulate supports these IGM configurations:
• Fixed robot with part mounted on an external manipulator
• Robot on gantry with fixed part
Kawasaki supported configurations

Process Simulate supports these Kawasaki configurations:
• Robot on a rail
Kuka supported configurations

Process Simulate supports these Kuka configurations:
• Robot on a rail
• Moving bases (bases attached to an external manipulator)
Nachi supported configurations

Process Simulate supports these Nachi configurations:

Lesson
parameters
• Robot on a rail
NC supported configurations
Process Simulate supports these NC configurations for machining:
• “Robot” or NC machine with an external axis
Process Simulate supports these NC configurations for drilling and riveting:

• GemCor machines G86 and G2000
• Brotje machine
Panasonic supported configurations

Process Simulate supports these Panasonic configurations:
• Fixed robot with positioner
• Robot on rail or gantry with fixed part
• Robot on rail or gantry with positioner
Reis supported configurations

Process Simulate supports these Reis configurations:
• Robot on a gantry
• Robot with a positioner (dynamic user frames)
Staubli supported configurations

Process Simulate supports these Staubli configurations:
• Fixed robot with a fixed part
Trallfa supported configurations

Process Simulate supports these Trallfa configurations:
• Robot on a rail
• Robot with one conveyor

Universal supported configurations

Process Simulate supports these Universal configurations:
External axes are not supported for the Universal controller.
Yaskawa supported configurations

Process Simulate supports these Yaskawa configurations:
• Robot with a pneumatic mounted gun
• Robot with a mounted workpiece with pneumatic remote gun
• Robot on a rail
• Robot with one external positioner (1 or 2-axes positioner)
• Multiples robots with conveyor

Lesson
parameters
Basic study setup

Purpose
In this topic, you learn how to a basic study.
Objectives

• Setup a Study to access a controller.
Business process

Process Simulate robot controller application support

Material Continuous
(Robot) Arc Spot
Handling App.
Controller Support Support
Support Support
Abb-Rapid Yes Yes Yes Paint, Dispensing
Paint, Dispensing,
Abb-Rapid- Laser Weld, Laser
Yes Yes Yes
Volvo Braze, Nut Run,
Seal, Stud
Cloos-Carola Yes —- —- —-
Comau-Pdl —- Yes Yes —-
Comau-Pdl- Stud, Nut, Glue,
—- Yes Yes
Volvo Laser Weld
Duerr-Ecotalk —- —- —- Paint
Epson-Spel —- Yes —- —-
Fanuc-F100iA —- Yes —- —-
Fanuc-RJ Yes Yes Yes Sealing
Fanuc-Japan Yes Yes Yes Sealing
Fanuc-Vw Yes Yes Yes Sealing
IGM-Ins Yes —- —- —-
Kawaski-As Yes —- Yes —-
Kuka-Krc —- Yes Yes —-
Kuka-Krc-
—- Yes Yes Nut, Glue
Volvo
Kuka-Vkrc —- Yes Yes —-
Nachi-Slim —- —- Yes —-
NC-Code —- —- —- Machining
NC-Riveting —- —- —- Riveting
Reis-Robstar Yes Yes —- —-
Staubli-Val —- Yes —- —-
Trallfa-
—- —- —- Paint
Robtalk
Universal-URScipt —- Yes —- —-
Yaskawa-
Yes —- Yes Paint
Inform
Study basics
In this lesson, you load a study, mount the gun, and create a small path that you later download. All
the steps covered in this lesson should be a review of what was learned in the TR45115 Process
Simulate Standalone Basic Robotics Simulation course.

Lesson
parameters
Activities
In the Basic Process Simulate Setup section, do the following activities:
• Basic Study Setup

Robot controller selection

Purpose
In this topic, you learn how to select the robot controller for a specific robot.
Objectives

• Select a robot controller.
• Figure out the manipulator type for a robot.
Business process
Robot controller selection basics

Selecting the Controller affects this information for the selected robot instance:
• The motion planner used during simulation (for example RCS-based or MOP-based)
• Teach Pendant
• Robot Setup

Lesson
parameters
• Download to Robot
• Upload Programs
• Simulation
• Path Editor dialog box
On the Controller tab of the Robot Properties dialog box, there are four parameters that are typically
related to Selecting a controller for a specific robot instance:
• Controller
o This list is populated based on which Process Simulate controllers (teach pendants) have
been installed (development specified). (Each is a separate install, as you have seen in
earlier in this course)
o As you have seen earlier in this course: For RCS-based controllers, an entry for each
controller in this list should be in the rrs.xml file (user specified)
• RCS version
o Comes from the rrs.xml file (user specified)
o Set on the Robot Properties dialog box
o Only used to select which RCS to use during simulation
• Manipulator type
o For RCS-based controllers, it is user specified and must match a valid value on the RCS
• Controller version
o Hard-coded in the controller (development specified)
o Set either on the Robot Properties dialog box or the Robot Setup →Controller version
dialog box.
o Handles any slight difference in the software such as features available in the teach pendant,
download syntax, simulation, etc.
Other Controller Topics:

• Connect / Disconnect — used to decide whether to connect to the specified RCS.
• Validate RCS — located on the Controller tab of the Robot Properties dialog box, it
becomes available when connected to the RCS. It checks the compatibility between the selected
RCS Version and selected Controller Version.
As of v10.0, this feature is not currently supported for all controllers. However, it does
work for the Fanuc controller.

• Robot Setup — This is described in the coming lessons.
Opening the Controller tab of the Robot Properties dialog box:
• Choose a robot and choose Robot tab→Setup group→Robot Properties or right-click

the robot and choose Robot Properties .
How to figure out the manipulator type for an RRS controller?
The Manipulator Type is only needed by RRS-based controllers. If you are using a MOP
controller, this is not needed.
Check the .rrs file located under the N:\sysroot\libraries\robots\robot-prototype.co\rrs folder.
The file is used by Robcad and may not available if the .CO was converted to .COJT
Abb:

Lesson
parameters
• For a Robcad cell connected to Process Simulate, just look at the .rrs file either under the
<cell>/<robot>_rrs folder or robot prototype folder and use same value as defined for
ManipulatorType
• For a new study: See the s4c.cfg, s4cplus.cfg, or irc5.cfg files under the ABB RCS install folder.
Comau:
Leave the manipulator type box blank. It figured out a different way.
• Typically it is the name of the .rcs file located in the N:\sysroot\libraries\robot-prototype.co\rrs
folder.
Fanuc:
• For a temp robot: see the C:\Tecnomatix\rrs_bin\rcsfr13\robcad.bin\VERSION\<RCS
Version>/standard.cfg file inside RCS module folder (client)
o In the standard.cfg file enter: <Temp Robot>. For example: R2000IF-165KG (as specified
in the Fanuc robot setup wizard).
o In the Manipulator Type box in Process Simulate, select: <RCS Version>,<Temp Robot>
from the list. For example: V7.40,R2000IF-165KG
• For a named robot, use following manipulator type format :

o In the specific.cfg file enter: <Named Robot>. For example: R2000IF-165KG (as specified
in the Fanuc robot setup wizard).
o In the Manipulator Type box in Process Simulate, select: <RCS Version>@<Named

Robot> from the list. For example: V7.40@R2000IF-165KG.
Kuka:
• Later you browse and select several files from the MADA folder under the Kuka RCS install.
Nachi:
• Check the manipulators.cfg file in the FD folder for the right name under the Nachi RCS client
install folder.
Tralfa:
Yaskawa:
• Check your Yaskawa RCS license file for the right name.
Activities
In the Robot controller selection section, do the following activities:
• Robot controller selection

Robot controller setup

Purpose
In this topic, you learn how to set up various robot controllers.
Objectives
• Setup a robot controller for a robot.
• Access Robot setup using method 1.
Business process
Robot controller setup basics

In this lesson you discuss basic controller setup using the Robot Setup dialog box. This button
can be found in two places:
• Method 1: Click Robot Setup on the Robot Properties dialog box opened for a specific robot.

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• Method 2: Click Robot Setup on the relevant robot controller specific Teach Pendant dialog
box opened for a specific robotic operation.
• Method 3: From the ribbon, choose Robot tab→Setup group→Robot Setup to access it
directly instead of inside other dialog boxes.
Setup must be done to define / upload:

• Machine data (for example must always be done for Kuka and Comau)
• System data (Tool, Base, Load, …)
• Creation / Update of system frames
• Simulation & Download settings
• Program template definition
Accessing Robot Setup using method 1
Robot Setup is located on the Robot Properties dialog box. To open this dialog box:
1. Right-click a robot in the Graphic Viewer and Selecting Robot Properties .
2. In the Robot Properties dialog box, click the Controller tab
The controller information must be filled in.
3. Click the Robot Setup button.
Accessing Robot Setup using method 2

Robot Setup is located in every Teach Pendant dialog box. To open this dialog box:
• Right-click a robotic path in the Operation Tree (the robot must be assigned to operation) and
choose Teach Pendant .
A robot must be assigned to the operation and a robot controller, besides the Default,
assigned to the assigned robot.

• From the Teach Pendant dialog box, click Robot Setup .
ABB Robot Setup dialog box – first buttons
• Load Machine Data – If the robot is using specific machine data (ex : robot with external axes):
In Setup dialog box, choose Load Machine data. In Load Machine Data dialog box, select the
desired moc.CFG file. (There are some samples on GTAC for a 7th axis). Close the dialog
box by clicking OK.
• Create / Update System Frames – Creates all ABB system frames (if not already existing) and
places them in the study with respect to the machine data:
o <robot>.w - robot controller world frame created in the Frames folder of the Object Tree.
o <robot>_<mechUnit>_base and <robot>_<mechUnit> - system frames for external

manipulators. Only available for robot with external manipulators (turn table,...)
configurations.

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o In case of a conflict in the robot orientation on the rail, the user is prompted whether he would
like the application to align the robot position in the cell with the Machine data definition, or
update the Machine data.
o Pushing this button resets the tool frame and wobj frame in the study to its initial positions
corresponding to data definition
Comau Robot Setup dialog box – first buttons

For C3G version of controller:


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• Load Machine Data – Used to load the .rcs file related to this robot. Typically it is located in
the N:\sysroot\libraries\robot-prototype.co\rrs folder. (The file is used by Robcad and might
not available if the .co was converted to .cojt).
• Create/Update System Frames - Creates all Comau system frames (if not already existing) and
like the application to align the robot position in the cell with the Machine data definition, or
update the Machine data.
o Pushing this button resets tool frame and wobj frame in the cell on its initial positions

Denso Robot Setup dialog box – first buttons
• Create/Update System Frames - Creates all Denso system frames (if not already existing) and
like the application to align the robot position in the cell with the machine data definition, or
update the machine data.
• Work Definition - Create, edit, and remove robot user frames. The naming convention for a
work frame is <robot>.w<num>.
• Tool Definition - Create, edit, and remove robot tool frames. The naming convention for a tool
frame is <robot>.w<num>.

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Duerr Robot Setup dialog box – first buttons
• Load Machine Data — If the robot is using specific machine data (for example a robot with
external axes): In the Setup dialog box, choose Load Machine Data. Select the relevant
const.RC and device.CFG files. Close the dialog box by clicking OK.
• Create/Update System Frames — Creates all Duerr system frames (if not already existing) and

Epson Robot Setup dialog box – first buttons
• Create/Update System Frames - Creates all Epson system frames (if not already existing) and

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Fanuc Robot Setup dialog box – first buttons
• Create/Update system frames — Creates all Fanuc system frames (if not already existing) and
o <robot>.w — robot controller world frame created in the Frames folder of the Object Tree.
o Potential conflict between robot orientation on rail (between cell and machine data) is NOT
checked

IGM Robot Setup dialog box — first buttons
• Load Machine Data — In the Setup dialog box, choose Load Machine Data. Select the relevant
param.ini file. This is a critical step for this controller. Close the dialog box by clicking OK.
There is no generic PARAM.INI file since it is a file from the real robot. However, the
actual type of the robot is not important to Process Simulate. The robot controller is
only reading the externals layout, tools, and process configurations from this file.
• Create/Update System Frames — Creates all IGM system frames (if not already existing) and
o <robot>.w — the robot world frame.
o <robot>.w1 — Robot base frame created in the Frames folder of the Object Tree.
o <robot>.w2 — predefined external work object frames. These system frames are linked to
each ExtAxRef external axis (as defined in param.ini) and are automatically attached to the
relevant link of the relevant robot external device. They are named using the ExtAxRef order.
o All tools in the study (modeled as either robot system frames or Robot Toolbox work tools)
are set to their nominal position (as defined in the param.ini).
Names for locations to be downloaded cannot exceed 8 characters in length.
Potential conflict between robot orientation on rail (between cell and param.ini) is not
checked.

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IGM robots MUST have an external axis.
Kawasaki Robot Setup dialog box – first buttons
• Create/Update System Frames — Creates all Kawasaki system frames (if not already existing)
and places them in the study with respect to the machine data:

Kuka Robot Setup dialog box – first buttons
• Load Machine Data — In Robot Setup dialog box, choose Load Machine data. In the Load
Machine Data dialog box, Browse and select the R1 and STEU folders (mandatory).

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Selecting the $config.dat file is optional.
If using the version 5.2, 5.4, or 5.6 of the Kuka controller, you do not have the Config
folder box on the Load Machine Data dialog box.
• Create/Update System Frames — Creates all Kuka system frames (if not already existing) and
o <robot>.bf0 — robot controller world frame created in the Frames folder of the Object
Tree.
o <robot>.sim_bf0 — rail base frame (also known as the ERSYSROOT frame). Only available
for robot on rail configurations.
o <robot>.base_easys, <robot>.object_easys ... <robot>.base_efsys,

<robot>.object_efsys — system frames for external manipulators. Only available for robot
with external manipulators (for example a turn table) configurations.
o In case of major conflict between Process Simulate layout and the MADA layout (number/type
of external axes), a warning message is displayed.
o In case of conflict between robot orientation on rail, the user is prompt whether he would like
the application to align the robot position in the cell with the MADA definition.

Nachi Robot Setup dialog box — first buttons
• Create/Update System Frames — Creates all Nachi system frames (if not already existing) and
• Gun Definition — assign a gun number to the guns you use in simulation. The type of gun is also
set, such as pneumatic or servo. If this is not set, a warning message is shown during download.

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NC Code Robot Setup dialog box – first buttons
• Origin Definition (for machining, but not riveting) — used to setup origin frames (which are like
robot base frames). Origin frames can be named G54 through G59 with the “defined” keyword if
the origin is already defined. Euler angle is used for the orientation (phi, theta, psi).
o <robot>.g54 — robot controller world frame created in the Frames folder of the Object
Tree.
• Create/Update System Frames — (Not currently used) Creates all NC Code system frames (if
not already existing) and places them in the study with respect to the machine data:
o <robot>.of_g53 — robot controller world frame created in the Frames folder of the Object
Tree.

Panasonic Robot Setup dialog box – first buttons
• Create/Update System Frames - Creates all Panasonic system frames (if not already existing)
• Tool Definition - Tool numbers range from 1 to 30. The tool coordinates are relative to the robot
TOOLFRAME. The naming convention for tools is <robot>.t<toolNum> for a robot system
frame and Tool<number> for a work tool. Optionally, a tool name can be associated with the
tool number.
• User Frame Definition - Frame numbers range from 1 to 32. The frame coordinates are relative
to the robot WORLDFRAME. The naming convention for user frames is <robot>.uf<frameNum>.
Optionally, a frame name can be associated with the frame number. A user frame is only
downloaded in the header section and it cannot be changed within a program. An error message
is reported if more than one user frame is used in a robotic operation.

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Reis Robot Setup dialog box – first buttons
• Create/Update System Frames — Creates all Reis Robstar system frames (if not already
existing) and places them in the study with respect to the machine data:
o <robot>.uf0 — robot controller world frame created in the Frames folder of the Object
Tree. This frame is the reference for the user frames and is superimposed on the robot
BASEFRAME.
• Tools Definition - Only mounted tool configurations are supported. Tools are defined by name
and should start with an uppercase T. Space or special characters are not supported. Here are
some examples of valid tool names: T_time, Tcp, or T1. The naming convention for frames is
_t_<Toolname> and <ToolName> for work tools. The frame coordinates are relative to the
robot ToolFrame.
• User Frame Definition -

You can define user frames by name. The naming convention for user frames is _uf_<name>.
User frames can be either STATIC and DYNAMIC. The dynamic option is available only for
robot with an external axis. If the dynamic type is selected, the created frame is attached to
the last link of the selected external device. The user frame coordinates are relative to the
robot RrsWorldFrame.

Staubli Robot Setup dialog box – first buttons
• Create/Update System Frames — Creates all Staubli system frames (if not already existing)
• Tool Definition - Use it to create, edit, and delete tools. The tool position is relative to the robot
TOOLFRAME. The naming convention for robot frames is <robot>.ut_<tool>. The naming
convention for Robot Toolbox work tools is <tool>.
• Frame Definition - Use it to create, edit, and delete user frames. The frame position is relative to
the robot WORLD (BASEFRAME). The naming convention for frames is <robot>.of_<frame>.

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(ABB) Trallfa Robot Setup dialog box – first buttons
• Load Machine Data — In Robot Setup dialog box, choose Load Machine data. In the Load
Machine Data dialog box, click Add and choose a .i01 machine data file (mandatory).
• Create/Update System Frames — Creates all Trallfa system frames (if not already existing)
o <robot>.bf — robot controller world frame created in the Frames folder of the Object Tree.
o <robot>.uf — UserFrame (Disp Base from a robot.i01 MADA file)
o <robot>.of — TrackFrame for conveyor
o <robot>.ut<n> or <robot>.t<n> — TcpFrame
o <robot>.uf<n> — DispFrame

Universal Robot Setup dialog box – first buttons
• Create/Update System Frames - Creates all Universal system frames (if not already existing)
• Tool Definition - Use it to create, edit, or delete tools. The tool position is relative to the robot
TOOLFRAME. The orientation is displayed in native Universal Rotation Vector representation.
The naming convention for robot frames is <robot>.t_<toolName>. The naming convention
for Robot Toolbox work tools is <toolName>.

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Yaskawa Robot Setup dialog box – first buttons
• Load Machine Data — If the robot is using specific machine data (for example a robot with
external axes): In the Setup dialog box, choose Load Machine data. Select the relevant
all.PRM, tool.CND, uframe.CMD, sgun.DAT, spress.cnd, and clearnce.DAT files. Close the
dialog box by clicking OK.
• Create/Update System Frames — Creates all Yaskawa system frames (if not already existing)
Activities
In the Robot controller setup section, do the following activities:
• ABB — Setting up the controller
• Cloos — Setting up the controller
• Comau — Setting up the controller
• Denso — Setting up the controller
• Duerr — Setting up the controller

• Epson — Setting up the controller
• Fanuc — Setting up the controller
• IGM — Setting up the controller
• Kawasaki — Setting up the controller
• Kuka — Setting up the controller
• Nachi — Setting up the controller
• NC — Setting up the controller
• Panasonic — Setting up the controller
• Reis — Setting up the controller
• Staubli — Setting up the controller
• Trallfa — Setting up the controller
• Universal — Setting up the controller
• Yaskawa — Setting up the controller

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Testing the RCS connection and fixing setup problems

Purpose
In this topic, you learn how to test the RCS connection and fix setup problems for RCS-based robot
controllers. For MOP-based robot controllers, this does not apply.
Objectives
• Open the teach pedant for the robot associated to a robotic path and see if the related RCS
can be accessed.
• Use the RCS shell.
• Use RCS logs.
RCS connection testing basics

There are several ways to find problems in the setup:
• Look over your installation again (for example the information from earlier in this course).
• Turn on log files and look at the resulting logs
• Look at the messages shown in the error dialog box during simulation.
• Turn on the RCS console dialog box and view the messages.
• Finally, work with GTAC to help resolve the problem.
RCS shell
First turn it on:
• From the ribbon, choose Robot tab→OLP group→Visible Shell On/Off .
Then view the results in the RCS shell dialog box:

• This dialog box opens whenever the Robot Setup or Teach Pendant dialog boxes are opened.
RCS logs
First turn them on using the Robot Setup dialog box:
Simulation Settings:

• RRS Debug - turn on/off RRS debug mode. If on, simulation creates a debug file named
rcs<RobotVendor>.<robotName> with the dialog between Process Simulate and the RCS.
View the resulting log file in the C:\temp folder.
• Simulation Debug Trace - activate/deactivate debug trace mode
• Reset Conveyor Position - reset conveyor to zero position (might be require after using Jump
To Location on tracking locations). Available on some controllers such as Abb-Rapid.
Activities
In the Testing the RCS connection and fixing setup problems section, do the following activities:
• Testing the RCS connection
• Using the RCS shell
• Using the RCS logs

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RCS management
Purpose
In this topic, you learn how to manage the connection to the RCS for RCS-based robot controllers.
For MOP-based robot controllers, this does not apply.
Objectives
• Manage the RCS module.
• Reset RCS module.
• Decouple the RCS module.
• Know limitations on decouple mode.
RCS management basics

In order to simulate, use some functions of an RCS-based teach pendant, or upload/download the
RCS module must be loaded. Normally, it is loaded in several ways:
• When the Teach Pendant dialog box is opened.
• When the Robot Properties dialog boxes is opened.
• When a robotic simulation is run which uses a non-default controller robot.
Reset RCS module

Drops and reestablishes the connection to the RCS (for example stops and restarts the RCS
module). This is useful if the RCS connection hangs. The other way to do this is to use the Controller
Settings dialog box.
This does not release the RCS license.
Using Reset RCS module:

1. Select the robot using a loaded RCS robot controller.
2. From the Quick access toolbar choose Reset RCS Module .
The Reset RCS Module command is not located in the ribbon. To add it to the
Quick access toolbar, choose Customize Quick Access Toolbar command.
Unloading and load the RCS using Controller Settings:

1. From the ribbon, choose Robot tab→Setup group→Controller Settings (or it can be found
on the Controller tab of the Robot Settings dialog box).
2. Select a robot controller in the Controller Settings dialog box.
3. From the Controller Settings toolbar, choose Terminate RCS to terminate the selected
RCS connection.
Choose Terminate All RCS to end all the active RCS connections.
4. From the Controller Settings toolbar, choose Initialize RCS to start an RCS connection
to the selected RCS.
Choose Initialize All RCS to start RCS connection for all listed RCS.
Disconnecting from the RCS (RCS decoupling)

For RCS-based controllers, you can perform several actions disconnected (decoupled) from the RCS
that normally require the RCS to be work. The main caveat is that the motion is performed using the
default controller instead of the RCS.
It is possible to run robot-customized, non-RCS actions without launching the RCS module and
without an RCS license, since this is Siemens PLM development, not dependent on the robot
manufacturer.
For each robot controller, check or clear the following: in either the Robot Controllers dialog box
or the Robot Properties dialog box:
• Non Simulation Actions — For example, teach pendant and downloading programs.
• Simulation Actions — For example, OLP commands, RCS simulation, and ESRC functionality.
Not all RCS modules support decoupling. Grayed out boxes do not support decoupling.
For exact motion, the RCS module is still mandatory for all controllers. For example,
circular motion is replaced with linear motion in decouple mode.

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The default value for decoupling can also be setup in the rrs.xml file on the controller line (in
class located in the N:\sysroot\OLP_config_files\ folder). For example to be disconnected
by default: <Controller Name="Fanuc-Rj" RCSDecoupleSimulationAction="True"
RCSDecoupleNonSimulationAction="True">
To break the connection to the RCS:

2. Deselect either the Simulation or Non Simulation check boxes, depending on the action you
want too perform.
3. Check Close.
To reestablish the connection to the RCS:

2. Select either the Simulation or Non Simulation check boxes, depending on the action you
want too perform.
3. Check Close.
Limitations of decouple mode

Limitations in the Robot Setup dialog box
• External axes mapping definition is not available
• When performing Create/Update System Frames, transformation from robot WORLD frame to
the robot BASE frame cannot be retrieved from the RCS module, therefore this information is
assumed to be Identity Matrix. If this assumption is wrong, it might be necessary to manually
relocate the robot WORLD frame in the study.
• In moving frames configuration, when performing Create/Update System Frames, the

information on the moving frames cannot be retrieved from the RCS module. These system
frames should therefore be created, located and attached manually.

Limitations during downloading:

• Logical Axes Map information from the RCS module cannot be used. As a consequence,
external axes are downloaded in the same order and with same indices as they are defined in
Process Simulate. It might be necessary to post-process the robot targets in the download file
in case this assumption is wrong.
• Conversion from Process Simulate to RCS configuration string is done manually
Limitations during uploading:

• Logical Axes Map information from the RCS module cannot be used. As a consequence, the
following work around is implemented for the upload of external axes:
• The application looks for defined external axes in the ABB externals string (the ones which
value is not 9E9)
• The nth axis that is defined is supposed to be mapped to the nth external axis in Process Simulate.
• Conversion from RCS configuration string to Process Simulate configuration to is done manually.
Activities
In the RCS management section, do the following activities:
• RCS management

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Methods to define TCPF positions for a robot controller

Purpose
In this topic, you learn how to define TCPF positions for a robot controller.
Objectives
• Understand some tools and definitions related to the TCPF.
• Use the Robot Toolbox.
Business process
TCPF definition basics

Currently, there are two ways to define the TCPF positions for a robot controller:
• Method 1 and Method 2: Using the Teach Pendant (or Robot Properties ) – Defines it as
engineering data stored in the study. This is the way that Robcad used to do it. you describe
this method in more detail in the next lesson.
• Method 3: Using the Robot Toolbox — Defines it as an object stored with the robot, which is
not dependent on the robot’s name. This is the newer, preferred technique.

Currently, there is only one way to define the BASEFRAME (REF FRAME) positions for the RCS:
• Using the Robot Setup from Teach Pendant (or Robot Properties)
Robot Toolbox
The Robot Toolbox command is used to assign tools (TCPF positions) to a robot and view sets
of tools assigned to robots. The assigned tools are available to the robot throughout the simulation.
The Robot Toolbox includes information about the tools assigned to the robot and buttons to perform
functions on the tools.
Often, it is useful to include tools that are not yet fully-designed in a simulation. The Robot
Toolbox is used to assign incomplete tools, requiring only the tool's TCP frame
information. Incomplete tools included in the Robot Toolbox are called virtual tools.
The Robot Tools list displays the tools assigned to the selected robot. For each tool, a Mounted
check box indicates whether the tool is mounted on the robot. Use the Mount or Unmount buttons to
mount or unmount a tool on the robot.
In order to use the tools you have defined in the Robot Toolbox, you must define a specific tool to be
used in an operation. This is done by adding a Work Tool to the default Teach Pendant.
To open the Robot Toolbox:
1. Select a robot in the Graphic Viewer or Object Tree.
2. From the ribbon, choose Robot tab→Setup group→Robot Toolbox .
3. The Robot Toolbox dialog box appears, displaying the tools associated with the selected robot.
Activities
In the Methods to define TCPF positions for the RCS section, do the following activities:
• Using the Robot Toolbox

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Robot controller specific frames and setup

Purpose
In this topic, you learn how to setup robot controller specific frames.
Objectives
• Access Robot Setup using method 2.
• Access Robot Setup using method 3.
• Continue learning about specific controller Robot Setup dialog boxes.
• Continue learning about the controller specific frames.
Business process
Robot setup basics

In this lesson you discuss controller specific frame creation and other specific setup tasks. In this
lesson you reference Method 1 and Method 2 as briefly described in the previous lesson: clicking
Robot Setup . This command can be found in several places:
• Method 1: The Robot Properties dialog box.

• Method 2: The relevant Teach Pendant dialog box (for example ABB-Rapid, ABB-Rapid-Volvo,
Cloos-Carola, Comau-Pdl, Comu-Pdl-Volvo, Default, Duerr, Epson-Spel, Fanuc-F100ia,
Fanuc-Rj, Fanuc-Rj-Japan, Fanuc-Vw, Igm-Ins, Kawsasaki-As, Kuka-krc, Kuka-Krc-Volvo,
Kuka-Vkrc, Nachi-Slim, NC-Code, Reis-Robstar, Staubli-Val, Trallfa-Robtalk,
Universal-URScript or YaskawaTeach Pendant dialog boxes).
• Method 3: From the ribbon, choose Robot tab→Setup group→Robot Setup .
Robot controller created frames:

• Controller and instance specific frames are created in the Frames folder of the Object Tree.
• Word reference frame — Process Simulate creates a robot system frame named <robot>.w
(before it created a study frame <robot>_w). It is superimposed on the robot BASEFRAME
when all external axes are set to zero. Although robot system frames are shown in the Object
Tree, they are stored with the robot instance (meaning they come with the robot if you put the
same robot instance in another study).
• User reference frames — Some controllers all you to create a additional reference frames, for
example on the part.
• Tool frames — Tools, which may be superimposed on the TCPF, are referenced by a controller
either by a name or a number. There position is stored relative to the robot TOOLFRAME. During
simulation the tool frame is placed on the locations in the path. The location’s downloaded position
is relative to a reference frame such as the world reference frame or a user reference frame.
The robot must be setup before simulating, uploading, or downloading:

• Machine data must be setup for all RRS-based controllers (Although how it is done is a bit
different for each controller)
• Create system frames such as a the world (w) frame.
• System data such as tool frames, base frames
• Setup controller or robot specific simulation and download settings (needed for downloading and
accurate simulation)
• Setup basic motion parameters (needed for downloading and accurate simulation)
• Teach robot configurations to each location (needed for downloading and accurate simulation)
• Setup a program download template (needed for downloading only)

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Accessing robot setup using method 2

Robot Setup is located on the Robot Properties dialog box. To open this dialog box:
• Right-click a robot in the Graphic Viewer and choosing Robot Properties .
• In the Robot Properties dialog box, select the Controller tab. The controller information must
be filled in. For example:
• Choose the Robot Setup command.
Accessing robot setup using method 3

Robot Setup is located in every Teach Pendant dialog box. To open this dialog box:
• Right-click a robotic path in the Operation Tree (the robot must be assigned to operation) and
• From the Teach Pendant dialog box, choose Robot Setup . For example:

Robot system frames

Robot system frames make up a large number of global frames in any robotics study.
When system frames are created or updated, using the Create\Update System Frames command,
the frames are created or moved under a folder structure named according to the robot instance
name. The world frame is placed in this folder while tool and base frames are separated into different
sub-folders named according to the RCS standard naming. The following pictures provide an
example of the folder structure that is created.
The Create\Update System Frames command only copies frames under this folder structure if the
world frame was not manually moved under another folder already.

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ABB Robot Setup dialog box — continued
• Download Settings – Set the type of program to download.

• Explicit Data Upload – Used to:

o Import data definition files (for instance the base.sys that is located under the robot
component folder in Robcad) into Process Simulate
o Maintain the list of explicitly uploaded files
o The selected files are copied under the robot private folder (same folder as the one used to
copy the machine data file needed for the RCS)
o The list of explicitly uploaded files are stored as a robot parameter
• Load Local Data Definitions – Used to import the Robcad .robdata.sys file definitions into
Process Simulate. The definitions are stored as a robot parameter.

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• Down Local Data Definitions – Copies all local data definitions into the LocalDataDefinition.sys
file in the N:\sysroot\libraries\RobotsMachineDataFiles/<RobotExtId>/SystemFiles folder.
• Base Data Definition

o All data definition interface:
■ Edit existing (local) data by selecting from a list of data.
■ Create new data: select data from list for display by values, replace the data name with a
new data name, and validate it by clicking Enter.
■ Add new data by clicking Store.
■ Delete ( local) data by clicking Delete.
o Tool data, Wobj data:

■ Robcad tools are supported (frame <robot>_<tooldata>_tf)
■ Robcad object frames are supported (frame <robot>_<wobjdata>_of)
■ RobotToolBox WorkTool are also supported.
■ Naming convention for ABB is that WorkTool name should match the ABB tool data
name. For a given tool data, WorkTools have priority upon Process Simulate frame tools.
• Process Data Definition – Spot data, Gun data, Bead data, Arc Data, etc.
o Spot data definition is different for pneumatic or servo guns.

o You can select between these two possibilities of parameters.
o Gun data is the same for pneumatic and servo guns.
• Custom Data Definition – described later in this course
• External Axis Map Setup

o For each Mechanical unit, you can define a device from devices list.
o For each Mechanical unit, logical axes can be associated the joint of the selected device.
Program Templates – described later in this course
Comau Robot Setup dialog box — continued

For C3G:

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For C4G:

For C5G:

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The Comau has three controller versions: C3G, C4G, and C5G. The C4G and C5G versions support
glue and stud process. they also support defining tool data and frame data instead of UFrame
and UTool. The C5G version also supports: two active guns, Base Data, eMotion, Servo Flyby,
and SpotWare type selection.
• Program Templates — described later in this course
• User Frame & Tool Data (for C3G)

o <robot name>_uf1
o <robot name>_ut1
• Base Data (for C5G only)

o Creates or edits base frames named: <robot name>.wf<number>. For example
myrobot.wf1.
• Frame Data (for C4G and C5G only)

o Creates user frames name: <robot name>.of<number>. For example myrobot.of1.
• Tool Data (for C4G and C5G only)

o Creates or edits tool frames: <robot name>.t<number>. For example myrobot.t1.
• Download Settings — Can be used to filter what is output to the resulting file output for the robot.

• Explicit Data Upload — Used to explicitly upload a tool file tt_tool1.lsv, frame file tu_frame.lsv,
base file tb_base.lsv, or servo distance file SwD_dist_data.lsv.
• Robot World Setup — Setup the position and orientation of the robot world frame.
Denso Robot Setup dialog box — continued
• Tools Definition — Create, edit, or delete tools. The tool position is relative to the robot
TOOLFRAME. The naming convention for robot tool frames is <robot>.t<number>. For example
myrobot.t1. The naming convention for Robot Toolbox WorkTools is Tool<toolNumber>.
• Works Definition — Create, edit, or delete robot user frames with the corresponding
<robot>.w<num> frame.

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Duerr Robot Setup dialog box — continued
• Explicitly Uploaded Data Files — allows uploading system (.TID) files.
This file is needed in order to initialize the RCS.
• Profile Data — allows defining velocity, acceleration, overlap, ramp, jerk, and interpolation list
of values data.
• Process Data — allows defining triggerPar (brush) data.
• Frame Data — allows defining tool frame, base frame, and object frame data.
o Creates or edits base frames named: <robot>.bf<number>. For example myrobot.bf_1.
o Creates or edits object frames named: <robot>.of<number>. For example myrobot.of_1.
o Creates or edits tool frames named: <robot>.tf<number>. For example myrobot.tf_1.
• Local Machine Data — allows specifying const (.RC), device (.CFG), and motion (.CFG) files.

The const (.RC) and device (.CFG) files are needed in order to initialize the RCS.
Robcad tool frames are supported (frame <robot>_ut<num>) and base frames have the
same naming convention as in Robcad (frame <robot>_uf<num>).
Epson Robot Setup dialog box — continued
• Local Coordinate Systems Definition — Create, edit, or delete user frames The frame
position is relative to the robot WORLD (BASEFRAME). The naming convention for frames is
<robot>.lcs<number>. For example myrobot.lcs1.

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Fanuc Robot Setup dialog box – continued
• Download Settings — several options for downloading such as simulation commands, download
point frame, RTCP location coordinates, Utool/Uframe declaration insertion, and aborting
download on error. These values are stored in the user DownloadSettings.xml file located in the
.\eMPower\Olp\Robotics\Fanuc-Rj\Settings folder.
• Robot And Guns Setup

o Definition of the robot ID
o Definition of 2 guns with, for each gun:

■ Name (entered or picked)
■ Type: Pneumatic or Servo Gun (automatically deduced)
■ MultiPressure: YES / NO for Servo Gun and NONE / LOW-HIGH / LOW-MEDIUM-HIGH

for Pneumatic guns

■ Backup: YES / NO
■ Backup Mapping
o The gun definitions are used in the Teach Pendant to show or not show some process
parameters.
o As for these definitions, the following rules apply:

■ You cannot define one pneumatic gun and one servo gun.
■ If you define one servo gun, it must be the gun 1.
■ You cannot use the same device to define the 2 guns.
• External Axis Mapping — this option is available when an external axis is present on the robot.
• Tool & Base Definition

o Utool
■ Creates tool frames named: <robot>.ut<number>. For example myrobot.ut1.
■ Robcad tools are supported (frame <robot>_ut<num>)
■ Robot ToolBox WorkTools are also supported. The naming convention for FanucRj is
Tool<Num>. For a given tool number, WorkTools have priority over Robcad frame tools.
o Uframe
■ Creates or edits user frames named: <robot>.uf<number>. For example myrobot.uf1.
■ Same naming convention as in Robcad (frame <robot>_uf<num>)
• Payload Definitions — used to either define or upload a payload definition for the robot.
• Armload Definitions — used to define an arm load for the robot.
• Export Definitions — used to export tool data to a .LS file.
• Explicit Data Upload — used to upload a .VA file (for example upload payload definitions from a
SYMOTN.VA or SYSTEM.VA file)

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IGM Robot Setup dialog box — continued
• Program Templates — described later in this course.
• Work Object Definition — Create work object frames. Work object numbers after 1 are reserved
for predefined external work objects. You can create, edit, or delete the user defined work objects.
o Creates user frames named: <robot>.w<number>. For example myrobot.w1.
• Tool Definition — Create tool frames.

o Creates or edits tool frames named: <robot>.t<number>. For example myrobot.t1.
o Robcad tools are supported (frame <robot>.t<num>, or Robot Toolbox Worktool Tool<num>).
Only tool numbers defined in the param.ini file are available (tool numbers start from 1).

Kawasaki Robot Setup dialog box — continued
• Download Settings — Used to setup the default clamp command in pneumatic or servo gun
contexts.
• Gun Definition — allows the user to map a gun number to a specific gun device in the study
• Data Definition — allows removing, loading, and exporting the AUX data file. Also allows editing
speed, accuracy, timer, clamp application, clamp condition, and gun parameters.
• Tool Setup
o Creates or edits tool frames named: <robot>.tl<number>. For example myrobot.tl1.
o Robot Toolbox Worktools are also supported with the following naming convention:
Tool<num>
o Users can upload one or all Tool definitions from a robot.aux file
• Work Setup
o Creates or edits user frames named: <robot>.w<number>. For example myrobot.w1.
o User can upload one or all work definitions from loaded robot.aux file
• FTool Setup
o Creates or edits FTool frames named: <robot>.ftl<number>. For example myrobot.ftl1.
o Robot Toolbox Worktools are also supported with following naming convention: FTool<num>
o Users can upload one or all FTool definitions from a robot.aux file

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Kuka Robot Setup dialog box — continued
• Load Robot Backup — Reads a robot backup .ZIP file and copies the files to the robot private
folder.

• Tool & Base Definition (VKRC only) or Tool & Base (KRC only)
o Creates or edits base frame named: <robot>.bf<number>. For example myrobot.bf1.
o Creates or edits object frames named: <robot>.b<number>. For example myrobot.b1.
o Upload base or tool from MADA by clicking Upload.
• External Manipulator Setup — This option is available when an external axis is defined for the
robot. The display and edit external moving bases attached to an external manipulator.
• Settings — contains download, upload, and display settings.

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• Download Settings — (VKRC only) set the type of program to download.
• Load Definition — Setup the payload
• Gun Definitions — allows defining a gun.

Nachi Robot Setup dialog box — continued
• Tool Definition — Create tool frames.

o Upload base or tool by clicking Upload.
• Stationary Tool Definition — Stationary tool numbers are from 0 to 3 and are named
rt<number> for a robot system frame or RemoteTool<number> for a work tool.
o Tool definitions can be uploaded (selected one or all) from ROBOT.CON file.
• Accuracy Definition — If accuracy definitions are not available on robot instance, then values
are loaded from machine data file (if such file is available). When Restore values is clicked

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values are loaded form machine data file (if such file is available) Simulation Settings /
Synchronize RCS should be run after manually changing an accuracy definition.
• Axis Load Definition — If axis load definitions are not available on robot instance then values
are loaded from machine data file (if such file is available). Simulation Settings / Synchronize
RCS should be run after manually changing an axis load definition.
• Smooth Definition — If smoothness definitions are not available on robot instance then values
are loaded from machine data file (if such file is available). Simulation Settings / Synchronize
RCS should be run after manually changing a smooth definition.
• Acceleration Definition — If acceleration definitions are not available on robot instance then
values are loaded from machine data file (if such file is available). Simulation Settings /
Synchronize RCS should be run after manually changing an acceleration definition.
• Servo Gun Welding Conditions — If servo gun welding definitions are not available on robot
instance then values are loaded from machine data file (if such file is available).
• Welding Sequences — Different dialog boxes are shown depending on if a servo gun or
pneumatic gun is mounted on the robot. Welding sequences can be between 1 and 64.
• Simulation Settings — For this portion of the course, you only learn about Synchronize RCS in
the Simulation Settings dialog box:
o When clicked, axis loads, tool payloads, accuracy, acceleration and smooth definitions,
defined on the robot instance, are sent to the RCS module.
o This command should be used whenever payloads or motion parameter definitions are
manually changed in Robot Setup, in order that the Nachi RCS module is using the updated
definitions. The Nachi RCS module is storing those updated definitions in its RCS machine
data files.
o It might be a good practice to use it once after loading a study to ensure the definitions from
Robot Setup are identical to the ones defined in the RCS machine data files (a discrepancy
may happen in case the study was not saved after changing some data definitions and
synchronizing the RCS).

NC Code Robot Setup dialog box – continued
• Origin Definition (for machining, but not riveting) — used to setup origin frames (which are like
robot base frames). Origin frames can be named G54 through G59 with the “defined” keyword if
the origin is already defined. Euler angles are used for the orientation (phi, theta, psi).
o Creates a base frame named: <robot>.g53. For example myrobot.g53.
o Creates a user frames named <robot>.g53 through <robot>.g59. For example myrobot.g54.
• Download Settings — there are various download settings such as circular interpolation method,
robot number, line numbering, program file extension, coordinate mapping, and multi-file settings.
Tools must be defined using Robot Toolbox WorkTools (not as a robot frame) using the naming
convention Tool1 for tool number 1.

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Panasonic Robot Setup dialog box — continued
• User Frame Definition — Create, edit, or delete user frames Frame numbers are from 1 to
32. Coordinates are relative to robot WORLDFRAME. The naming convention for user frames
is<robot>.uf<frameNum>. Optionally, a frame name can be associated using the frame number.
A user frame is only downloaded in the header section and cannot be changed within a program.
An error message will be reported in case more than 1 User Frame is used in a robotic operation

Reis Robot Setup dialog box — continued
• Download Settings – Allows setting various settings for download including language and
the display of comments.
• Tool Definition
o Creates or edits tool frames named: <robot>.t_T<number>. For example myrobot.t_T1.
o Only mounted tool configuration is supported.
o Tool Coordinates are relative to the robot ToolFrame
• User Frame Definition

o Creates or edits user frames named: <robot>.uf<number>. For example myrobot.uf_1.
o Reis controller supports User Frames defined by name.
o There are two types of UserFrames: STATIC and DYNAMIC. The dynamic option is available
only for a robot with external axis. If the dynamic type is selected, the created frame should
be attached to the selected external device’s last link
o User Frame Coordinates are relative to the robot World Frame

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Staubli Robot Setup dialog box — continued
• Download Settings – several options for downloading such as simulation commands.

These values are stored in the user DownloadSettings.xml file located in the
.\eMPower\Olp\Robotics\Staubli-Val\Settings folder.
• Tools Definition — create, edit, and delete tool frames. The tool position is relative to the
robot TOOLFRAME.
o Creates or edits tool frames named: <robot>.ut<number>. For example myrobot.ut_1.
o Robot Toolbox work tools are named <number>
• Frames Definition — create, edit, and delete user reference frames. The frame position is
relative to the WORLD (BASEFRAME).
o Creates or edits user frames named: <robot>.of<number>. For example myrobot.of_1.

(ABB) Trallfa Robot Setup dialog box — continued
• Download Settings — Select the ROBOT_ID to select the system files and set the binary file
name of the downloaded file.
• Tcp Tool Definition

o Update all or one tool from the robot.i01 MADA file.
• Disp Base Definition

o Creates or edits base frames named: <robot>.uf<number>. For example myrobot.uf1.
o Update all or one disp from the robot.i01 MADA file.

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Universal Robot Setup dialog box — continued
TOOLFRAME. The orientation is displayed in native Universal Rotation Vector representation.
The naming convention for robot tool frames is <robot>.tf_<number>. For example myrobot.t1.
The naming convention for Robot Toolbox WorkTools is Tool<toolNumber>.

Yaskawa Robot Setup dialog box — continued
• UTool/UFrame Definition
o Creates or edits tool frames named: <robot>.tl<number>. For example myrobot.tl1.
o Creates or edits user frames named: <robot>.user<number>. For example myrobot.user1.
o Robot Toolbox Worktools named Tool<num>.
o UFrames have the same naming convention as in Robcad (frame <robot>.user<num>)
• Robot and External Axes Setup — This option is available for robots with an external axis
defined.
• System Information — Allows entering or editing pulse (encoder) factors, offsets, and order.
• Gun Definition — Allows associating a gun device with a gun file number.
Controller specific frames

Almost every controller needs a different frame created to represent the TCPF. The TCPF information
must exist in the study and in the teach pendant. There are several ways to define the TCPF:

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• The frame can either be directly created in the study and then the coordinates read from the
study to the teach pendant.
• The TCPF can defined in the teach pendant which creates the frame in the study automatically.
• The information can be read from files output from the actual robot controller (with many Process
Simulate teach pendants).
o <Robot name>_.wf — robot world frame created automatically when the RCS is
initialized. It is the robot origin frame and is typically at the intersection of J1 and
J2. It’s not needed for downloading.
o BASEFRAME — robot origin frame that is part of the robot’s kinematic definition.
It should match the <Robot name>_.wf.
o REFFRAME — part of the robot’s kinematic definition and is related to the

BASEFRAME. The Robot Setup dialog box is used to define a special ESRC frame
at the desired position) of the reference frame. The positions of all downloaded
locations are according to the reference frame. The car part origin, or somewhere
on the tooling, are good places for this. Two stations serviced by one robot may
each have their own reference frame or a moving line may have multiple reference
frames.
o TCPF — frame that is part of the robot’s kinematic definition. The Robot Setup
dialog box is used to define a special ESRC frame at the exact position of the TCP.
Here are example ESRC frames used in the activities:

ESRC user/object
ESRC base frame (for TCPF (name of special
reference name (for
Robot (controller) example default is ESRC frame attached
example default is
BASEFAME) to the TCPF)
REFFRAME)
Abb irb6600_wobj0_uf irb6600_tool1_tf
Cloos cloos_cls76swr.t1
Comau comau_sm_nh3_ comau_sm_nh3_ comau_sm_nh3
(C4G and C5G) 165_30.wf1 165_30.of1 _165_30.t1
Denso my_robot.w1 my_robot.t1
Duerr duerr_rp125160.bf_1 duerr_rp125160.of_1 duerr_rp125160.tf_1

Epson epson_c4_a901.lcs1 epson_c4_a901.t1
fanuc_r2000ia fanuc_r2000ia
Fanuc
_165f_if.uf1 _165f_if.ut1
IGM igm_330_1.w1 igm_330_1.t1
Kawasaki kawasaki_zzx300s.w1 kawasaki_zzx300s.tl1
kuka_kr200l150 kuka_kr200l150 kuka_kr200l150
Kuka
.bf1 .b1 .t1
Nachi nachi_sra210_01a_fd.t1
sim01_mill_3ax sim01_mill_3ax
NC (machining)
_head.of_g53 _head.of_g54
NC (riveting)
Panasonic panasonic_tm_1800.uf1 panasonic_tm_1800.t1
Reis reis_rv16_0699.uf0 reis_rv16_0699.uf_1 reis_rv16_0699.t_T1
Staubli staubli_rx170.of_1 staubli_rx170.ut_1
(ABB) Trallfa trallfa_tr5003.bf trallfa_tr5003.uf1 trallfa_tr5003.t1
Universal universal_ur5.tf_1
yaskawa_es200n yaskawa_es200n
Yaskawa
_a00.user1 _a00.tl1
Use this table as reference to perform the activities. Note that each robot 's settings and teach
pendant have several differences. Reference the online help for setup, configuration and usage
details of specific controllers.
It is the users’ responsibility to set these frames on the real robot (It is not done
automatically since two programs could use the same def file. The tool definition could be
added to program download template as well as the home pose.
Activities
In the Robot controller specific frames and setup section, do the following activities:
• ABB — Tool and base data setup
• Cloos — Tool and base data setup
• Comau — Tool and base data setup

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• Denso — Tool and base data setup
• Duerr — Tool and base data setup
• Epson — Tool and base data setup
• Fanuc — Tool and base data setup
• IGM — Tool and base data setup
• Kawasaki — Tool and base data setup
• Kuka — Tool and base data setup
• Nachi — Tool and base data setup
• NC — Tool and base data setup
• Panasonic — Tool and base data setup
• Reis — Tool and base data setup
• Staubli — Tool and base data setup
• Trallfa — Tool and base data setup
• Universal — Tool and base data setup
• Yaskawa — Tool and base data setup

Setting controller specific motion attributes

Purpose
In this topic, you learn how to set controller specific motion attributes.
Objectives
• Know the available methods to edit controller specific motion attributes.
• Edit controller specific attributes in the Path editor.
• Know the basic robot controller specific motion attributes.
Do I do this
Basic controller specific motion attributes

In this lesson, you look at setting up controller specific motion attributes required for downloading.
There are several ways to do this:
• In the Teach Pendant edit locations one at a time.
• In the Path Editor edit a single location.
• In the Teach Pendant or Path Editor simultaneously edit several locations.

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• By applying a path template. (This is described in a lesson later in this training).
Disclaimer: This lesson provides selected details for each specific teach pendant. It should not be
considered a replacement to the online help or other more complete reference sources for these robot
controllers or the robotic languages themselves
ABB motion attributes

• Motion Type — Four choices including:
o MoveJ — use joint motion
o MoveL— use linear motion
o MoveC — use circular motion
o MoveABSJ Home
• Zone Data — Several choices:

o Fine Point — like fine on the default controller
o z0 — like fine on the default controller
o z1 to z29 — like medium on the default controller
o z30 to z119 — like coarse on the default controller
o z120 and up — like no decel on the default controller
• Speed Data — Two ways to record speed:

o V (Tcp Speed) v5, v10, v20, etc., v7000, vmax
These definitions can come from your SYS file.
o T (Motion Time) measured in seconds
• Tool Data — ESRC TCP frame definitions
• Wobj Data — ESRC location reference frame definitions
These definitions can come from your SYS file.
Cloos motion attributes

• Motion Type — Three choices including:
o GP — use joint motion (only on via locations)

o GC— use linear motion
o ARC — use circular motion (full circle motion not supported)
• Zone — Several choices:

o fine — like fine on the default controller
o stv1 — like medium on the default controller
o stv5 — like course on the default controller
o stv10 — like no-decel on the default controller
o setdd10_20 — like no-decel on the default controller
o setdd50_50 — like no-decel on the default controller
All zones that can be used on the locations should be defined in the
MotionParameters.e file of the Cloos robot component with a special naming:
o Joint Zones: stv<SmoothTransitionValue> For example:
■ zone_define stv1 rel_dist cartesian 25;
o Cartesian Zones: setdd<Dist1>_<Dist2> For example:

■ zone_define setdd10_20 rel_dist cartesian 65;
■ zone_define setdd50_50 rel_dist cartesian 65;
Although the exact MotionParameters.e zone name is internally stored on the

location, in the Teach Pendant and Path Editor, zone information appears in Carola
terms, for example:
o Zone stv10 maps to STV(10) on the controller.
o Zone setdd10_20 maps to SETDD(10,20) on the controller.
The available zones are filtered using the location motion type:
o For GP, only stv zones are available.
o For GC and ARC. only setdd zones are available.
STV(0) and SETDD(0,0) are mapped to the fine zone.
• Speed — Ways to record speed:

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o For GP joint speed can range from 0.1 to 100
o For GC and ARC linear speed in mm/sec can range from 0.1 to 1000.
• Tool — ESRC TCP frame definitions
Comau motion attributes

• Motion Type – Several choices:
o Joint – use joint motion
o Joint POS : Home
o Linear – use linear motion
o Circular – use circular motion
• Term Type (Zone/Termination Type) – Three choices:

o Fine
o Course
o No Settle
• FlyType (Zone/Termination Type) – Several choices:

o Off – like fine on the default controller
o For cart FlyParam (in mm) of Norm (in %):
o 1 to 4 – like fine on the default controller
o 6 to 29 – like medium on the default controller
o 31 to 74 – like coarse on the default controller
o 76 to 99 – like nodecel on the default controller
• Speed — After setting the Speed Control, you can enter the speed.
• Speed Control – Several choices:

o Const (in %) - Percent of max speed.
o Lin (in m/s)
o Rot (in rad/s)
• Tool Data — ESRC TCP frame definitions
• Frame Data — ESRC location reference frame definitions

Denso motion attributes

o MoveP — use point-to-point motion (joint motion).
o DriveA — use point-to-point motion (joint motion) and select a robot pose.
o MoveL— use linear motion
o MoveC — use circular motion (full circle motion not supported)
• Zone — Enter the number (in mm) for the zone. This is how many mm away the robot can stop
near the target location and still have “arrived”.
o 0 — uses no smoothing and is like fine on the default controller.
o 1 to 30 — like medium on the default controller.
o 31 to 120 — like course on the default controller.
o A value greater than 120 is like no-decel on the default controller.
No section is required in the motionparameters.e file for zones, since the above
mapping is automatic.
• Speed — Enter as a percent
Duerr motion attributes

• Motion Type
o PTP – use joint motion
o LIN – use linear motion
o CIRC – use circular motion
• Overlap (Zone)
These definitions can come from your TID file.
o FINE
o LOW
o MID
o COURSE

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o NODEC50
o NODEC100
o NODEC150
o NODEC200
• Vel (Velocity or Speed)
These definitions can come from your TID file.
o V200
o V300
o etc.
o V1400
o V1500
• Object — ESRC location reference frame definitions
Epson motion attributes

• Motion Type – Three choices including:
o Go – use joint motion
o Move– use linear motion
o Arc3 – use circular motion
• Zone – Several choices:

o Fine (no param) – like fine on the default controller
o CP – like no decel on the default controller
• Speed
• Speed Type – Joint speed is recorded as a percentage of the max speed, linear speed is
recorded in mm/s, and rotational speed is recorded in deg/s.
• Tool — ESRC TCP frame definitions. Tool 0 is the robot TOOLFRAME.

• Local CS — ESRC location reference frame definitions. Coordinate system 0 is the robot
World Frame.
• Config — You should enter these motionparameters.e config and turns entries to properly
record the configurations on the locations:
o config_family cf_over_head_pos;
o joint_config_family j3 joint_cf_elbow_up;
o joint_config_family j5 joint_cf_pos;
o default_turns j1 0 -90.0, j2 0 -180, j4 0 -180.0, j6 0 -180.0;
Fanuc motion attributes

• Motion Type – Three choices:
o Joint – use joint motion
o Linear – use linear motion
o Circular – use circular motion
• Def Type (Location type)

o Pose — Download location as joint values
o Cartesian — Download location as the XYZ values for the TCPF. However for locations
linked to robot poses, the Coord Type is forces to Pose.
• Term Type (Zone/Termination Type) – Several choices:

o CNT0 to CNT10 (or Fine) – like fine on default controller
o CNT11 to CNT40 - like medium on default controller
o CNT41 to CNT80 - like course on default controller
o CNT81 to CNT100 (or CD) - like no decel on default controller
• Speed
• Speed Type – Two ways to record speed:

o Percent of max speed.
o Time measured in seconds.
• UTool — ESRC TCP frame definitions
• UFrame — ESRC location reference frame definitions

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IGM motion attributes

• Motion Mode (Motion Type)
o Non-linear – uses joint motion with joint speed in % for jog (via) locations.
o Linear – uses linear motion with Cartesian position speed for for jog (via) or work (seam)
locations.
o Circular – uses circular motion with Cartesian orientation speed for work (seam) locations.
• Passpoint (Zone) — flyby in percent:

o 0–10 — fine (0 means no flyby)
o 10–25 — medium
o 25–45 — course
o 45–100 — no-decel
• Velocity (Speed in cm/min)
• Torch — ESRC TCP frame definition. This is set only once for the continuous feature operation.
• WRK-Co — ESRC location reference frame (work object) definitions.
• Location type
o For via locations the Location type is set to Jog by default. By default, Jog locations have a
Non-Linear Motion Mode, a Velocity of 100%, and you can set the Passpoint (zone).
o For seam locations the Location type is set to Work by default. By default, Work locations
have a Linear Motion Mode, Velocity in cm/min must be set, and you cannot set the
Passpoint (except on the first location in a seam) since the default Passpoint is 0% (fine).
• Substation — This is set only once for the continuous feature operation. If it is not set, you
get an warning message during download.
• Library — This is set only once for the continuous feature operation. If it is not set, you get an
warning message during download. It is placed in the initialization section of the downloaded
program. It is the name of the library step program to be referenced by this step program. All
welding sequence calls, such as the WSC function, are taken from this library by the real robot
controller. If it is left blank, no library reference is used.
Kawasaki motion attributes

• Move (Motion Type) – Two choices:
o AC_JOINT – use joint motion
o AC_LINEAR – use linear motion
• Acc/Accu (Accuracy/Zone) – Several choices:

o 1 mm to 4 mm – like fine on default controller
o 6 to 29 – like medium on default controller
o 31 to 74 – like course on default controller
o 76 and up – like no decel on default controller
• Speed – One way to record speed:

o Index value – 0 through 9 (where 9 is 100%).
• Work — ESRC location reference frame definitions
Kuka motion attributes

• Motion (Motion type) – Four choices:
o Ptp – use joint motion
o Ptp axis : Home
o Lin – use linear motion
o Circ – use circular motion
• Zone – Several choices:

o C_PTP
■ 0 to 10 – like fine on default controller
■ 10 to 40 – like medium on default controller
■ 40 to 80 – like course on default controller
■ 80 to 100 – like no decel on default controller
o C_DIS
■ 0 to 2 – like fine on default controller
■ 2 to 7 – like medium on default controller
■ 7 to 15 – like course on default controller
■ Greater than 15 – like no decel on default controller
o C_VEL – like no decel on default controller
o C_ORI – like no decel on default controller
• Speed (Velocity) – One way to record speed:

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o Joint Speed measured as a percentage
o Linear Speed measured in mm/sec.
• Tool Nr — ESRC TCP frame definitions
• Base Nr — ESRC location reference frame definitions
Nachi motion attributes

• Motion Type
o MOVE P – use joint motion
o MOVE L – use linear motion
o MOVE C – use circular motion
• Coord Type (Location type)

o Joints — Download location as joint values
linked to robot poses, the Coord Type is forces to Joints.
• Accuracy (Zone)
o 1 (0 mm, 0 %) — similar to fine on the default controller. Downloaded as ACCU1.
o 2 (5 mm, 5 %) to 4 (25 mm, 15 %) — similar to medium on the default controller. Downloaded

as ACCU2–ACCU4
o 5 (50 mm, 25 %) to 7 (200 mm, 75 %) — similar to course on the default controller.

Downloaded as ACCU5–ACCU7
o 8 (500 mm, 100 %) — similar to no nodecel on the default controller. Downloaded as ACCU8
• Speed
• Speed Type
o Joint Speed — Sets the unit for Speed to %.
o Linear Speed — Sets the unit for Speed to mm/s.
o Rotation Speed — Sets the unit for Speed to deg/s.
o Time — Sets the unit for Speed to sec.
• Stationary Tool — ESRC location reference frame definitions

NC motion attributes
• Interp (Motion type)
o G00 - PTP
o G01 - LIN
o G02/G03 - CIRC
■ G02 = CW circle
■ G03 = CCW circle
• Abs/Incr (Coordinate Mode)

o G90 – ABS coordinates are be downloaded as absolute values
o G91 - INCR coordinates are be downloaded as offset from the precedent value
• Zone (must be defined in the robot’s MotionParameters.e file)

Zone name is selected from the list of allowed zones by reading the MotionParameters.e file
under the robot component directory. For example:
zone_define G93 no_smooth;

G92
G93
G194
Zone fine is downloaded as the first no_smooth zone in the list of available zones
Otherwise the fine zone is downloaded as G09
• Feed — Integer speed in feed rate unit mm per min (available only on linear locations) which
ranges from 1 to 150,000.
• Tool — ESRC TCP frame definitions must be created by user as Robot Toolbox work tools ( not
as robot frame) with the naming convention Tool1 for tool number 1, Tool2 for tool number 2 ...
Tool64 for tool number 64
• Origin — ESRC location reference frame definitions selected from defined origins
G292_1-G292_10 and default origin G53
Panasonic motion attributes

• Motion Type — Three choices including:
o MoveP — use point-to-point motion (joint motion).

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o MoveL — use linear motion .
o MoveC — use circular motion (full circle motion not supported).
• Smooth — it is like zone on the default controller and can range between -1 and 9. These
values are defined in the motionparameters.e file. For example, a smooth value of 6 is defined in
the file as zone z6.
o -1 — means to use the default smooth value of 4. The default smooth value can be changed
by the user changing the definition of the medium zone in the motionparameters.e file.
o 0 (z0) — uses no smoothing and is like fine on the default controller.
o 4 (z4) — uses a Cartesian speed of 40 and is like medium on the default controller.
o z7 has a Cartesian speed of 70 and is like course on the default controller, but it not mapped
to course when switching to the default controller.
o z9 has a Cartesian speed of 99.5 and is like no-decel on the default controller, but it not
mapped to no-decel when switching to the default controller.
All other zones are defined as z<smooth value> in the MotionParameters.e file of
the Panasonic robot component.
• Cartesian zones: For example:

o zone_define fine no_smooth;
o zone_define medium speed cartesian 40.0 ;
o zone_define z0 no_smooth;
o zone_define z1 speed cartesian 10.0 ;
• Speed Type — Select the type of speed

• Speed — Enter the speed
Reis motion attributes

• Motion Type
o #PTP — use joint motion
o #CP_LIN — use linear motion
o #CP_CIRC — use circular motion
• FlyBy (Zone)
o #OFF — like fine on default controller (for all motion types)
o #ON — like nodecel on default controller for #PTP motion type. For other motion types it
uses the closest distance Cartesian zone defined in the MotionParameters.e file.
zone_define medium speed cartesian 5.0;
zone_define coarse speed cartesian 75.0;
zone_define nodecel speed cartesian 99.5;
zone_define nodecel speed joints 99.0 99.0 99.0 99.0 99.0 99.0;

fine
medium
sp_zone1
sp_zone2
sp_zone3
sp_zone4
sp_zone5
sp_zone6
course

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nodecel
• Speed types:
o PTP Speed — speed for joint motion in %.
o CP Speed — speed for linear or circular motion in mm/sec.
o Tool — ESRC TCP frame definitions
o Frame — ESRC location reference frame definitions
Staubli motion attributes

o PTP — use joint motion
o LIN— use linear motion
o CIRC — use circular motion
• Coord Type (Location type)

o Joints — Download location as joint values
linked to robot poses, the Coord Type is forces to Joints.
• Zone — Several choices:

o fine — like fine on the default controller
o zcl10r15 — like medium on the default controller
o zjl15r20 — like course on the default controller
o zcl20r30 — like no-decel on the default controller

All zones that can be used in the trajectories should be defined in the
MotionParameters.e file of the Staubli robot component with a special naming
convention: fine or z<Blend>l<Leave>r<reach>
For example:
fine: zone fine (Blend off)
zcl10r15: zone with Cartesian blend (flyby type), leave value of 10mm and reach
value of 15mm
zjl15r10: zone with Joint blend (flyby type), leave value of 15mm and reach value
of 10mm
Although the exact MotionParameters.e zone name are internally stored on the
location, in the Teach Pendant and Path Editor, zone information appears in Staubli
terms, for example:
zone_define zjl15r20 dist cartesian 17;
The zone name appears as:

fine
zcl10r15
zjl15r20
zcl20r30
Zone fine is downloaded as first no_smooth zone in the list of available zones
• Ways to record speed:

o Joint Speed percent max speed
o Lin Speed measured in mm/s
o Rot Speed measured in deg/s
• User Frame — ESRC location reference frame definitions
(ABB) Trallfa motion attributes

• Motion Type
o RC — joint motion

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o CC — linear motion
o CIRC — circular motion
• Interpolation Type — Zone

o Int0: Fine
o Int1: NoDecel
• Vel — Speed
• Tcp Nr. — ESRC TCP frame definitions
• Disp Nr. — ESRC location reference frame definitions
Universal motion attributes

o MoveJ — use joint motion (only on via locations)
o MoveL— use linear motion with an option blend. The default is no blend (fine).
o MoveP — use linear motion with a mandatory blend.
o MoveC — use circular motion (full circle motion not supported)
• Blend — it is like zone on the default controller and can range between 0 and 1000. These
values are defined in the motionparameters.e file. For example, a blend value of 50 is defined in
the file as zone z50.
o 0 (z0) — uses no blend and is like fine on the default controller.
o z50 has a Cartesian speed of 50 and is like medium on the default controller.
o z500 has a Cartesian speed of 500 and is like course on the default controller, but it not
mapped to course when switching to the default controller.
o z1000 has a Cartesian speed of 1000 and is like no-decel on the default controller, but it not
mapped to no-decel when switching to the default controller.

All zones that can be used on the locations should be defined in the
MotionParameters.e file of the Denso robot component with a special naming:
o Cartesian Zones: For example:
■ zone_define fine no_smooth;
■ zone_define z1 dist cartesian 1;
• Speed — Enter in degrees per second
Yaskawa motion attributes

There are some differences between XRC, NX, and DX versions of the Yaskawa controller, such as
supported robots. However, the motion attributes are the same:
• Motion Type
o MOVJ — move joint
o MOVL — move linear
o MOVC — move circular
o MOVC (start) — move circular start
o MOVS — move s
• Destination Type
o ABS, P1, P2, P3, etc.
• Fly Level (Level\Zone)

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o Cont — like no decel on default controller
o PL=0 — like fine on default controller
o PL=1 — like medium on default controller
o PL=2 to PL=8 — like coarse on default controller
• Speed
• Speed Type Speed types:

o VJ — for joint motion type (a % of maximum speed)
o V — for linear or circular motion type (Cartesian position speed)
o VR — for linear or circular motion type (Cartesian orientation speed)
• User — ESRC location reference frame definitions
Activities
In the Setting controller specific motion attributes section, do the following activities:
• ABB — Specific Teach Pendant motion attributes
• Cloos — Specific Teach Pendant motion attributes
• Comau — Specific Teach Pendant motion attributes
• Denso — Specific Teach Pendant motion attributes
• Duerr — Specific Teach Pendant motion attributes
• Epson — Specific Teach Pendant motion attributes
• Fanuc — Specific Teach Pendant motion attributes
• IGM — Specific Teach Pendant motion attributes
• Kawasaki — Specific Teach Pendant motion attributes
• Kuka — Specific Teach Pendant motion attributes
• Nachi — Specific Teach Pendant motion attributes
• NC — Specific Teach Pendant motion attributes
• Panasonic — Specific Teach Pendant motion attributes
• Reis — Specific Teach Pendant motion attributes

• Staubli — Specific Teach Pendant motion attributes
• (ABB) Trallfa — Specific Teach Pendant motion attributes
• Universall — Specific Teach Pendant motion attributes
• Yaskawa — Specific Teach Pendant motion attributes

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Program creation
Purpose
In this topic, you learn how to create a program.
Objectives
• Create a robotic program in this system.
Business process
Program creation basics
You create a program for the default controller earlier in this training. You know create a program for
the robot specific controller and used for other portions of this training.
Activities
In the Program creation section, do the following activities:
• Creating a robot program and using default signals (review)

Process simulation and robot configurations

Purpose
To learn more about robot configurations and how to view and modify them.
Objectives
• Robot configurations
• Teaching and clearing robot configurations
• Simulating robot paths
Business process
Robot configuration basics

Process or motion attributes are simulated in the same way as they would appear on the factory floor.
The creation of robot configurations is critical to the download process, since they store the robot
configuration from the RCS and are tied to the robot BASEFRAME (or user reference frame specified
on the location). Whereas, global locations are in reference to the working frame of the study and
do not store the robot configuration.
To prepare for download, the process must be "taught". This step must be performed in order to
apply the configuration data to the locations.
There are multiple techniques to generate robot configurations (attributes on top of the locations). All
process attributes are preserved on the location, and all configuration parameters (turns, flips) are
stored as well.
The configuration can also be viewed on the Teach Pendant or Path Editor.
After teaching a solution, the robot uses it during subsequent simulations and downloads.

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Teaching and clearing robot configurations

To add robot configurations to locations, use one of these methods:
1. Method 1: Select a location, choose Robotics→Robot Configuration , select a configuration,

and click Teach.
2. Method 2: Add the path to the Sequence Editor or Path Editor, click Auto Teach , and then
run the simulation as usual
When running Auto Teach from the Sequence Editor, you must first select the
robot, choose Robotics→Set Robots for Auto Teach , and click OK.
To remove robot configurations from locations, use one of these methods:
1. Method 1: Select a location, choose Robotics→Robot Configuration , select a configuration,

and click Clear.
2. Method 2: Select one or many locations, choose Robotics→Clear Teach Location , and
click OK. The Robotics→Clear Teach Location option clears turns and solutions, causing
simulations as well as downloads to use the locations' initial, pre-taught values
Simulate robot paths

• Analyze path and cycle time
• Teach
o Configuration and turns
o Needed for download

Activities
In the Process simulation and robot configurations section, do the following activities:
• Process Simulate and robot configurations

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Summary
• Got an overview of OLP features.
• How to setup a basic robotic study that you can use to learn about ESRC.
• How to select a controller and view the teach pendant.
• How to do some basic setup of a robot and robot controller.
• How to test a teach pendant and fix some setup problem.
• How to reset the RCS and decouple it.
• How to setup and use the robot toolbox.
• How to setup specific controller frames using the Teach Pendant and other specific setup.
• How to set specific controllers motion attributes using the teach pendant.
• How to create a program.
• How to simulate a process and create configurations.

Lesson 4: Upload and download
Purpose
To describe how to upload and download.
Objectives

• How to select and create program templates for downloading.
• How to download a process.
• How to look at the files produced by the Download command.
• How to upload a process directly in Process Simulate.

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Program templates for downloading

Purpose
In this topic, you get an overview of program templates used to format downloaded files.
Objectives

• Edit program templates.
• Know how to select a program template.
• Know the template locations.
• Use example robot specific template keywords.
• Use example templates.
Business process
Program template basics

In this lesson you discuss program templates. The template defines the header format including
which keywords is included. It can describe some elements you want in program (for example who
generates/when/from which study). Several key words are provided (listed in the documentation).
Editing program templates

Usage:
1. Click the Robot Setup from the Controller tab of the Robot Properties dialog box.
2. From the Robot Setup dialog box, click Program Templates Edition.

Upload and download
3. Edit the template by double-clicking on the file.

• Use this menu to edit the available program templates or to add/remove program templates.
There are two levels of templates:

• Global templates — by default are stored in the C:\Program
Files\Tecnomatix\eMPowerRobotics\OLP\<Controller
Name>\Templates\Programs folder. However, this can be changed by specifying
a CustomizedPath in the rrs.xml file for the version of the controller used like
the training course (for example N:\sysroot\OLP_config_files\<Controller
Name>\Templates\Programs).
• Private templates — stored in the

N:\sysroot\RobotsMachineDataFiles\<RobotExtId>\
Templates\Programs folder.
Program template selection

Usage:
1. Click the Robot Setup from the Controller tab of the Robot Properties dialog box.
2. From the Robot Setup dialog box, click Program Template Selection.

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3. Select the active program template.
4. Click Close.
If no specific templates are selected, the defaults shipped with the software are used
during download.
Template locations
The download file templates are located in specific folders depending on the controller used:
• ABB
By default, located in C:\Program
Files\Tecnomatix\eMPower\Robotics\OLP\Abb-Rapid\Templates\
programs folder (unless the CustomizedPath is defined in the rrs.xml file).
o default.tprg — default template for a prog file (contains the main program)
o default.tmod— default template for a mod file (contains a module of the program)
• ABB (Volvo)
Files\Tecnomatix\eMPower\Robotics\OLP\Abb-Rapid-Volvo\Templates\.
programs folder (unless the CustomizedPath is defined in the rrs.xml file) and is named either
*.tmod, default.tmod or default.tpl.
• Cloos
Files\Tecnomatix\eMPower\Robotics\OLP\Cloos-Carola\Templates\
o default.ttxt — default template for a txt file (contains the program)
o default.tpkt — default template for a pkt file (contains the locations)
• Comau
Files\Tecnomatix\eMPower\Robotics\OLP\Comau-Pdl\Templates\

Upload and download
There are separate templates for C3G, C4G, and C5G versions of the controller. There
are also separate templates for applications such as glue, spot, stud.
o default.tpdl — default template for a pdl file (contains the program)
o default.tlsv — default template for a lsv file
o default.tolp — default template for a olp file (contains the tool, frame, and base definitions)
• Comau (Volvo)
Files\Tecnomatix\eMPower\Robotics\OLP\Comau-Pdl-Volvo \Templates\
*.proc, *.tolp, *.tpl, *.tpdl, *.tlsv, default.tpdl, or default.tlsv.
• Default
Files\Tecnomatix\eMPower\Robotics\OLP\Default\Templates\
o default.tpl — default template for a pl file (contains the program and locations)
• Denso
Files\Tecnomatix\eMPower\Robotics\OLP\Denso-PacScript\Templates\
o default.tpcs — default template for a prog file (contains the program)
o default.tolp — default template for a olp file (contains the tool definitions)
• Duerr
Files\Tecnomatix\eMPower\Robotics\OLP\Duerr-Ecotalk\Templates\
There are different templates for the RPC and RC2 versions of the controller.
o default.ttis — default template for a tis file (contains the program)
o default.ttid — default template for a tid file (contains the locations and tool definitions)
• Epson

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Files\Tecnomatix\eMPower\Robotics\OLP\Epson-Spel\Templates\
o default.tprg — default template for a prog file (contains the program)
o default.tpts — default template for a pts file (contains the locations)
• Fanuc
Files\Tecnomatix\eMPower\Robotics\OLP\Fanuc-Rj\Templates\
There are different templates for the applicatiosn such as arc and seal.
o default.tls — default template for a ls file (contains the program)
• IGM
Files\Tecnomatix\eMPower\Robotics\OLP\Igm-Ins\Templates\
o default.tipa — default template for a ipa file (contains the program and locations)
• Kawasaki
Files\Tecnomatix\eMPower\Robotics\OLP\Kawasaki-As\Templates\
o default.tprg — default template for a prg file (contains the program)
o default.tolp — default template for a olp file (contains the tool, ftool, and work definitions)
• Kuka
Files\Tecnomatix\eMPower\Robotics\OLP\Kuka-Krc\Templates\
o default.tsrc — default template for a src file (contains the program)
o default.tdat — default template for a dat file (contains the locations)

Upload and download
o default.tolp — default template for a olp file (contains the tool, base, and load definitions)
• Kuka (Volvo)
By default, located in C:\Program Files\Tecnomatix\eMPower\Robotics\OLP\Kuka-Krc-Volvo
\Templates\
default.tpl, default.tdat, or default.tsrc.
• Nachi
Files\Tecnomatix\eMPower\Robotics\OLP\Nachi-Slim\Templates\
o default.tpl — default template for an A file (contains the program)
• NC Machining
Files\Tecnomatix\eMPower\Robotics\OLP\NC-Code\Templates\
o default.tsi — default template for a si file (contains the program)
o default.tolp — default template for a olp file (contains the tools used)
• NC Riveting
Files\Tecnomatix\eMPower\Robotics\OLP\NC-Code-Riveting\Templates\
o default.tA01 — default template for a A file (contains the program)
o default.tpro — default template for a pro file (contains the program with a different header)
o default.tolp — default template for a olp file (contains the tools used)
• Panasonic
Files\Tecnomatix\eMPower\Robotics\OLP\APanasonic-Csr\Templates\
o default.tcsr — default template for a prog file (contains the program)
• Reis

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Files\Tecnomatix\eMPower\Robotics\OLP\Reis-Robstar\Templates\
o default.tsrc — default template for a src file (contains the program)
• Staubli
Files\Tecnomatix\eMPower\Robotics\OLP\Staubli-Val\Templates\
o default.tpjx — default template for a pjx file (contains the program)
o default.tpgx — default template for a pgx file (contains the path)
o default.tdx — default template for a tdx file (contains the path)
• Trallfa (ABB)
Files\Tecnomatix\eMPower\Robotics\OLP\Trallfa-Robtalk\Templates\
o default.trt3 — default template for a rt3 file (contains the program)
o default.tpos — default template for a pos file (contains the locations)
• Universal
– By default, located in C:\Program
Files\Tecnomatix\eMPower\Robotics\OLP\Universal-URScript\Templates\
o default.tscript — default template for a x file (contains the program)
• Yaskawa
Files\Tecnomatix\eMPower\Robotics\OLP\Yaskawa-Inform\Templates\
o default.tjbi — default template for a jbi file (contains the main program)
o default.tpl — default template for a pl file (contains a sub program)

Upload and download
Template keywords
The sample templates shipped with the controllers are a reference for the available keywords. Some
keywords are common to all controllers (for example <RobotName>), some are specific to the
controller (these ones should be in the sample templates). Here are the common keywords:
• Body
• Data
• Date
• FileBaseName
• ProgName
• Study
• TecnomatixSoftware
• TecnomatixControllerVersion
• Time
• RobotName
• UserName
Example robot specific template keywords

Additional ABB template keywords:
• Robtarget
• GundataTitle
• Gundata
• SpotdataTime
• Spotdata
• SpeeddataTitle
• Speeddata
• ZonedataTitle
• Zonedata
• TooldataTitle
• Tooldata

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• LoaddataTitle
• Loaddata
• WobjdataTitle
• Wobjdata
• BeaddataTitle
• Beaddata
• WelddataTitle
• Welddata
• WeavedataTitle
• Weavedata
• CustomdataTitle
• Customdata
• MainBlockBody
• MoveBlockBody
• Robtarget
• JointTarget
Additional Comau template keywords:

• LocVar
• DataVar
• SchedulerCalls
• JointPosition
• CartPosition
• AllAxesNumber
• ExtAxesNumber
• JointMask
• ToolNumbers
• ToolNumbersRmt

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• FrameNumbers
• FrameNumbersRmt
• ImplPayLoadMass
• ImplPayLoadCenter
• ImplinertiaX
• ImplinertiaY
• ImplinertiaZ
• ImplPayLoadMassRmt
• ImplPayLoadCenterRmt
• ImplinertiaXRmt
• ImplinertiaYRmt
• ImplinertiaZRmt
Additional Duerr template keywords:

• Velocitydata
• AccelerationData
• InterpolationData
• OverlapDclData
• GTriggerParData
• RampDclData
• JerkDclData
• BaseData
• ToolData
• ObjectData
• PointData
• TriggerPointData
• TriggerFrameData
Additional Epson template keywords:

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• FirstExtAxis
• JointsNumber
• Points
• PointsNumber
• SecondExtAxis
• ThirdExtAxis
• Tools
Additional Fanuc template keywords:

• LineCount
• DefaultGroup
• ControlCode
• GunNumber
• MainBlockBody
• PosBlockBody
Additional IGM template keywords:

• StartStep
• WorkObjects
• Tool
Additional Kawasaki template keywords:

• Tool
• FTool
• Work
• Load
Additional Kuka template keywords:

• TecnomatixControllerVersion
• E6Pos
• E6Axis
• BaseData

Upload and download
• MovingBaseData
• ToolData
• LoadData
Additional Nachi template keywords:

• ToolDefinitions
• StationaryToolDefinitions
Aditional NC (machining)template keywords:

• Tools
• Origins
• FileName
• ProgramNumber
Additional NC Riveting template keywords:

• Tools
Additional Reis template keywords:

• Tools
• UserFrames
• ToolDefinitions
Additional Staubli template keywords:

• FileBaseName
• toolSection
• frameSection
• mdescSection
• jointSection
• jointSection
• programsSection
• databaseSection
Additional Trallfa template keywords:

• DispBase

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• Tcp
Additional Yaskawa / Motoman template keywords:

• NPos
• Coords
• ProgComment
• Attr
• Group
• Main
Example download template use

In this Fanuc example a header and footer in the template with line number is setup like this:
/MN
1:UFRAME_NUM = 1;
2:UTOOL_NUM = 1;
3:PAYLOAD[1];
4:! Start Program;
<MainBlockBody>
<FOOTER_LINE_N_1>:! End Program;
<FOOTER_LINE_N_2>:ABORT;
/POS
In order to have the following downloaded text:
/MN
1:UFRAME_NUM = 1;
2:UTOOL_NUM = 1;
3:PAYLOAD[1];
4:! Start Program;
5:J P[1:"lo1"] 100% FINE;
6:L P[2:"lo2"] 500mm/sec FINE SPOT[S=1];
7:L P[3:"lo3"] 500mm/sec FINE;
8:L P[4:"lo4"] 500mm/sec FINE;
10:J P[6:"lo6"] 100% FINE;

Upload and download
12:J P[8:"lo8"] 100% FINE;

13:J P[9:"lo9"] 100% FINE BACKUP=O;
14:L P[10:"lo10"] 100mm/sec FINE;
15:L P[11:"lo11"] 100mm/sec FINE;
16:L P[12:"lo12"] 500mm/sec FINE;
17:! End Program;
18:ABORT;
/POS
Activities
In the Program templates for downloading section, do the following activities:
• Creating a new program template
• Selecting a program template

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Lesson 4: 4: Upload
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and download
Process download
Purpose
In this topic, you learn how to download a program.
Objectives
• Perform a basic download.
Business process
Download basics
To download a program, you must have ESRC robot configurations and minimum motion
attributes on each location in the path (program). This is what was done in the previous
activities in the training. To download to an RRS-based controller, you also need to
connect to the RCS.
Any process created in a Process Simulate application can be transformed into a robot program by
downloading it to a text file (robot program) in the robot controller’s language. The robot programs
include:
• Custom file layouts and content from templates
• Header
• Process attributes (per path or location)
• Motion attributes (for example tool, motion type, and zone/accuracy)
• Control statements (for example If, Then, and For)
• Logic statements (for example send signal and wait signal)
• Other statements that are part of the ESRC or added through XML customization
Thus, the work put into process design is automatically reflected in fully-verified robot programs. The
generated programs may be further edited if desired, and then downloaded to the actual robots on
the factory floor.

Upload and download
To download:
1. Set the robot specific robot controller for the path. (Done in a previous activity in this training).
2. Setup robot specific required TCP frames, reference frames, and base frames. (Done in a
previous activity in this training).
3. With the robot specific robot controller set, open the Teach Pendant or Path Editor.
4. Make sure that you have specified the required attributes such as TCP frame, motion type, and
zone on the locations. (Done in a previous activity in this training).
5. From the ribbon, choose Robot tab→Program group→ Robotic Program Inventory .
6. From the Robotic Program Inventory, create a robot program and set it as the default program for
the robot. (Done in a previous activity in this training).
The program can contain one or several paths.
7. With the robot specific robot controller set, auto teach all locations to store the robot configurations
(solutions) on the locations. (Done in previous activities in this training)
8. From the Robotic Program Inventory, and select the program from the list.
9. Start the download: From the Robot Program Inventory click Download Program
10. Check the contents in the Download dialog box and store results.

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Your Download dialog box may look different than this graphic, depending on the robot language
you use.
The previously selected template is automatically applied.
Downloaded files for each controller

Each controller has different files that are downloaded. these files a specific to the real robot controller.
ABB Controller
• <prog>.prg contains the main program
• <prog>.mod contains a module of the program
Cloos Controller
• <prog>.txt contains the program (including the definition of the arc data lists, main procedure,
and local procedures). Main and local procedures are modeled as robotic operationsIf you
download only one robotic operation, only a main procedure is generated. If you download a
robotic program, the operation named main (not case sensitive) becomes the main procedure,
and all others are local procedures.
• <prog>.pkt contains the coordinates and assigned number for each location. Cloos robots use
same RPY angles as Process Simulate. During download and upload only encoder coordinates
are supported.
• <prog>.olp contains the definition of the tools used.

Upload and download
Comau Controller
• <prog>.pdl contains the program
• <prog>.lsv
• <prog>.olp contains the tool, frame, and base definitions.
Default Controller
• <prog>.pl contains the program
Duerr Controller
• <prog>.tis contains the program
• <prog>.tid contains the locations and tool definitions
Epson Controller
• <prog>.prg contains the program, and paths, divided into several “function” section. Robotic
operations with locations are represent “functions with motion instructions. Scheduler robotic
operations are used to represent “functions without motion instructions.
• <prog>.pts contains the coordinates of the locations
• <prog>.olp contains the definition of the used tools
Fanuc Controller
• <prog>.ls contains the program
IGM Controller
• <prog>.ipa contains the program (including the definitions of all locations)
Kawasaki Controller
• <prog>.prg contains the program
• <prog>.olp contains (in .AUX syntax) the current definitions of the TOOL, FTOOL and WORK
used in the program.
Kuka Controller
• <prog>.src contains the program
• <prog>.dat
• <prog>.olp contains the tool, base, and load definitions.

Lesson
Lesson 4: 4: Upload
Upload and download
and download
Nachi Controller
• <progName>-A.(progNumber) contains the program structure
• < progName>-P.(progNumber) optional file contains the positions defined as “Storage type” =
“Pose File”
• <progName>.(progNumber).olp contains the definition of the tool and stationary tool used.
NC Maching Controller
• <progName>.si contains the program.
• <progName>.(progNumber).olp contains the definition of the tools used.
NC Riveting Controller
• <progName>.A(progNumber) contains the program.
• <progName>.pro contains the program with a different header.
Reis Controller
• <prog>.src contains the program.
• <prog>.olp contains the definition of the tools and UFiles used in the program.
Staubli Controller
• <prog>.pjx contains the program in XML format
• <prog>.pgx and <prog>.dtx contains the path in XML format. Each downloaded operation
produces separate .pgx and .dtx files.
• <prog>.olp contains the definition of the tools used in the program.
Trallfa Controller
• <prog>.rt3 contains the program structure
• <prog>.pos contains the location coordinates
• <prog>.off
• <prog>.olp contains the definition of the used TCP and DISP BASE
Yaskawa Controller
• <prog>.jbi contains the main program
• <prog>.pl contains a sbu program

Upload and download
Activities
In the Process Download section, do the following activities:
• Process Download

Lesson
Lesson 4: 4: Upload
Upload and download
and download
Examining output files

Purpose
In this topic, you examine the files output by the download of the program.
Objectives
• Look at the contents of some files downloaded from the system.
Output file basics

In this lesson you examine the files output from the download. The same procedure could be used to
examine files from the robot to be uploaded into Process Simulate.
Downloaded files for each controller

Each controller has different files that are downloaded. these files a specific to the real robot controller.
ABB Controller
• <prog>.prg contains the main program
• <prog>.mod contains a module of the program
Cloos Controller
• <prog>.txt contains the program (including the definition of the arc data lists, main procedure,
and local procedures). Main and local procedures are modeled as robotic operationsIf you
download only one robotic operation, only a main procedure is generated. If you download a
robotic program, the operation named main (not case sensitive) becomes the main procedure,
and all others are local procedures.
• <prog>.pkt contains the coordinates and assigned number for each location. Cloos robots use
same RPY angles as Process Simulate. During download and upload only encoder coordinates
are supported.
Comau Controller
• <prog>.pdl contains the program
• <prog>.lsv
• <prog>.olp contains the tool, frame, and base definitions.
Default Controller
• <prog>.pl contains the program

Upload and download
Duerr Controller
• <prog>.tis contains the program
• <prog>.tid contains the locations and tool definitions
Epson Controller
• <prog>.prg contains the program, and paths, divided into several “function” section. Robotic
operations with locations are represent “functions with motion instructions. Scheduler robotic
operations are used to represent “functions without motion instructions.
• <prog>.pts contains the coordinates of the locations
• <prog>.olp contains the definition of the used tools
Fanuc Controller
• <prog>.ls contains the program
IGM Controller
• <prog>.ipa contains the program (including the definitions of all locations)
Kawasaki Controller
• <prog>.prg contains the program
• <prog>.olp contains (in .AUX syntax) the current definitions of the TOOL, FTOOL and WORK
used in the program.
Kuka Controller
• <prog>.src contains the program
• <prog>.dat
• <prog>.olp contains the tool, base, and load definitions.
Nachi Controller
• <progName>-A.(progNumber) contains the program structure
• < progName>-P.(progNumber) optional file contains the positions defined as “Storage type” =
“Pose File”
• <progName>.(progNumber).olp contains the definition of the tool and stationary tool used.
NC Maching Controller
• <progName>.si contains the program.

Lesson
Lesson 4: 4: Upload
Upload and download
and download
NC Riveting Controller
• <progName>.A(progNumber) contains the program.
• <progName>.pro contains the program with a different header.
Reis Controller
• <prog>.src contains the program.
• <prog>.olp contains the definition of the tools and UFiles used in the program.
Staubli Controller
• <prog>.pjx contains the program in XML format
• <prog>.pgx and <prog>.dtx contains the path in XML format. Each downloaded operation
produces separate .pgx and .dtx files.
• <prog>.olp contains the definition of the tools used in the program.
Trallfa Controller
• <prog>.rt3 contains the program structure
• <prog>.pos contains the location coordinates
• <prog>.off
• <prog>.olp contains the definition of the used TCP and DISP BASE
Yaskawa Controller
• <prog>.jbi contains the main program
• <prog>.pl contains a sbu program
Activities
In the Examining output files section, do the following activities:
• ABB — Examining a PRG file
• Cloos — Examining a PKT file
• Comau — Examining a PDL file
• Denso — Examining a file
• Duerr — Examining a TIS file
• Epson — Examining a PRG file

Upload and download
• Fanuc — Examining a LS file
• IGM — Examining a IPA file
• Kawasaki — Examining a PG file
• Kuka — Examining a SRC file
• Nachi — Examining a -A file
• NC — Examining a SI file
• Panasonic — Examining a file
• Reis — Examining a SRC file
• Trallfa — Examining a RT3 file
• Universal — Examining a PKT file
• Yaskawa — Examining a JBI file

Lesson
Lesson 4: 4: Upload
Upload and download
and download
Direct process upload

Purpose
In this topic, you learn how to upload a program into this system.
Objectives
• Upload a real robotic path into this system.
• Use Robot Operation Merge .
Upload basics
The Upload Program command receives information from a robot (in specific controller syntax)
and saves it as robotic operation and/or program.
Here is how (NOT an activity):
1. Select a robot from the Graphic Viewer.
A robot controller other than Default must be chosen.
2. From the ribbon, choose Robot tab→Program group→ Robotic Program Inventory .
Do NOT select a program in the list.
3. From the Program Inventory dialog box, click Upload Programs .
This picture shows the file types for Fanuc-Rj. The file types shown depend on the
controller chosen.
4. In the Open dialog box, browse to the desired folder and select the desired file.

Upload and download
The available Files of type are specific to the chosen robot controller.
5. Click Open.
For each file, Process Simulate runs the upload mechanism to read the file and create
a robotic operation and/or robotic program.
Overview of Robotic Operation Merge
The Robotic Operation Merge command, on the Robot tab of the ribbon, is used to merge
two robotic operations into a single operation. After merging the source operation with the target
operation, the updated target operation contains the new set of information.
This is useful if, for example, you have used Download Program to load your program on a
shop-floor robot. You can then edit and fine-tune the program on the robot itself and use Upload
Program to store the updated program back to Process Simulate. In order to make use of
your shop-floor improvements, you can merge the changes in the shop-floor program (the source)
into your original program (the target).
The Robotic Operation Merge dialog box enables you to manually select which source locations
to merge with which target locations. Alternatively, you can perform an automatic merge of the
entire source operation with the target operation. The automatic merge may be performed either by
merging source and target locations sharing the same name or merging locations in close proximity.
You can also edit the order of locations in the target operation. Additionally, you can specify which
source data to merge with the target.
Robotic Operation Merge basics
1. From the ribbon, choose Robot tab→OLP group→Robotic Operation Merge .

Lesson
Lesson 4: 4: Upload
Upload and download
and download
If you select an operation before picking Robotic Operation Merge , this

operation appears in Target Operation.
2. Click in Target operation and select the target operation in the Operation Tree (or other relevant
viewer). This is the operation you wish to update with information from another operation.
Robotic Operation Merge can be performed on several operation types

including weld operations, seams, and continuous operations.
3. Click in Source operation and select the source operation in the Operation Tree. This is the
operation from which you wish to retrieve information.
4. Click OK. The Robotic Operation Merge dialog box appears displaying the Target Operation
as a tree together with its locations in blue text in the left pane and the Source Operation tree
together with its locations in red text in the right pane.
5. Click Select Operations to replace the selected operations with a different source and
target operation.
6. Configure either manual or automatic matching, as follows: If you wish to match locations
manually, select a source location and a target location and click Match .
7. If you wish to match source operations with target operations automatically, click Automatic
Match . The system matches up pairs of locations either by name or by distance (depending
on the criteria set in Robotic Operation Merge Settings ) and displays them as matched
pairs.

Upload and download
If you set manual matches before invoking automatic match, the system retains your
manual matches and matches all the other locations automatically.
8. If necessary, click Erase Match to unmatch selected matched pairs. For each matched pair,
the source location is removed from Match, the distance from Distance, Merge is cleared, and is
removed from the source location (unless this is still matched with another target location).
9. Click Execute. The system performs the merge and the Robotic Operation Merge dialog box
reloads the target operation.

Lesson
Lesson 4: 4: Upload
Upload and download
and download
Summary
• How to select and create program templates for downloading.
• How to download a process.
• How to look at the files produced by the Download command.
• How to upload a process directly in Process Simulate.

Lesson 5: ESRC OLP commands
Purpose
To describe how to use the OLP commands section of the emulated robot specific controllers (ESRC).
Objectives

• How use the standard OLP commands of emulated robot specific controllers (ESRC).
• Various commands supported in simulation on all controllers which must be entered as free text.
• The list of the supported OLP commands for several of the robot controllers.
• Compared the various methods available in Process Simulate.

Lesson
OLP OLP commands
commands
Standard OLP commands

Purpose
In this topic, you learn about the standard OLP commands.
Objectives
• Be aware of Basic OLP commands and be able to use some of them.
Business process
OLP command basics

Much of what is downloaded is stored on the locations in the path as OLP commands. This is where
logic statements are placed for download to the program file. In this lesson, you learn all sorts of OLP
commands which can be used in Process Simulate. While some commands can only be simulated,
others can be simulated and downloaded.
Here are some examples of OLP commands:
• Boolean output signals could have a value of 0 or 1 (different syntax for each controller described
later)
• Analog output signals could have a value such as 5 or 1.4 (different syntax for each controller
described later)
• Macros
• Other commands
o payload
o pause, abort
o send Boolean signals

ESRC OLP commands
o send analog signals
o wait delay or signal expressions
o register assignment
o call, if call
o if jump label (LBL)
Basic OLP commands

On the Teach Pendant after clicking Add, the Standard Commands menu is available. These
commands are available during simulation, but either do not download or download as comments.
They work the same as their default controller equivalent.
Several examples of OLP commands were discussed in the TR45115 Process Simulate
Standalone Basic Robotic Simulation and TR45215 Process Simulate Standalone
Intermediate Robotics (CEE) courses.
The Standard Commands Menu:
Standard commands not mentioned here are described later in this course.
• File submenu:
o # OpenFile — Opens a file for editing. The Mode setting enables you to Append or
Overwrite file content. Also, set a Handle to be used in the next WriteLine and CloseFile
commands and a Name for the path to the file to be opened.
o # CloseFile — Closes an open file. Set the Handle of the file that was opened with the
OpenFile command.
o # WriteLine — Enables you to write a line of text in an open file. Set the Handle of the file
that was opened with the OpenFile command and write the text in the Expression box. Use
double quotes to print the value of a variable or a signal, for example, type "E1" to write the
value of signal E1.
• Graphics submenu:
o # Blank — Blank an object during simulation.
o # Display — Display an object during simulation.
o # TCP Tracker — Enables you to start, pause, resume, or stop the TCP Tracker for the
robot assigned to the current operation during simulation.

Lesson
OLP OLP commands
commands
• Paint submenu: (Review from the TR45115 Process Simulate Standalone Basic Robotic
Simulation course)
o # OpenPaintGun — Marks the location where painting should start.
o # ClosePaintGun — Marks the location where painting should stop.
o # ChangeBrush — Marks the location where the painting style should be changed
(for example paint fan 1, 2, 3, etc.)
• PartHandling submenu:
o # Attach — Attach a selected component to another component or link during simulation.
o # Detach - Attach a selected component to another component or link during simulation.
o # Grip — moves the gripper to the specified pose and attaches the part to it. This OLP
command is automatically added to grip locations in Pick and Place Operations and is
preferable to the Attach command for part handling. (Review from the TR45215 Process
Simulate Standalone Intermediate Robotics (CEE) course).
o # Release — moves the gripper to the specified pose and detaches the part from it. This OLP
command is automatically added to release locations in Pick and Place Operations and is
preferable to the Detach command for part handling. (Review from the TR45215 Process
Simulate Standalone Intermediate Robotics (CEE) course).
• ProgramFlow submenu:
o # Macro — executes the specified macro located in the <robot controller>.macros file
located in the Macros folder defined in File→Options . The file can contain any OLP
command for the selected robot controller. (Review from the TR45215 Process Simulate
Standalone Intermediate Robotics (CEE) course).
o # CallPath — in the middle of executing a path (for example pa1), another path (for example
pa2) can be executed. Once pa2 is finished, it selects up where it left off in pa1. (Review
from the TR45215 Process Simulate Standalone Intermediate Robotics (CEE) course).
o # CallProg — similar to CallPath, except for programs instead of paths.
• RobotCycleTime submenu:
o # CycleStart — specify when the cycle time calculation should begin.
o # CycleEnd — specify when the cycle time calculation should end.
o # TimerOn — Define when a user defined timer should start track time associated to a
certain part of the simulation. Each timer includes a user-defined name.

ESRC OLP commands
Internal (built-in) timers include motion to location time, wait device time, weld time,
weld count, wait time, and wait signal time.
o # TimerOff — Define when a certain timer should be stopped during a specific cycle.
• Synchronization submenu:
o # SendSignal — In line simulation mode, the robot sends a robot signal to the PLC (PLC
input). (Review from the TR45115 and TR45215 courses).
Both boolean and analog signals are supported. Any integer value can be assigned
to a signal. In event-based simulations the Destination is always left blank.
o # SetSignal — Enables you to compose an expression for the value of the selected robot
output signal.
o # WaitSignal — In line simulation mode, the robot waits for a robot signal from the PLC (PLC
output). (Review from the TR45115 and TR45215 courses)
o # WaitTime — The robot waits the specified number of seconds before the next command is
performed.
• ToolHanding submenu:
o # Connect — (add an external axis to the robot during simulation) connect the specified joint
from the specified device as an external axis of the robot. For example, when simulating a
grinding robot with a tool changer with several sized grinding tools.
o # Disconnect — (remove an external axis of the robot during simulation) disconnect all
external axis joints of the specified device from the robot. For example, when simulating a
o # DriveDevice — Moves the selected device to the selected target pose. (Review from
the TR42115 course)
o # GunToState — Instructions for moving the gun to its specified pose, as specified in the
Gun State parameter. TR45115 Process Simulate Standalone Basic Robotic Simulation and
TR45215 Process Simulate Standalone Intermediate Robotics (CEE) courses
In the case of a servo gun, this moves the servo gun to the position specified by
the external axis depart value. If no depart value is defined, the servo gun moves
using the Gun State parameter.
o # Mount — Mount a new tool on the robot. For example, when simulating a grinding
robot with a tool changer with several sized grinding tools.

Lesson
OLP OLP commands
commands
o # UnMount — Unmount the existing tool on the robot. For example, when simulating a
o # WaitDevice — The robot waits until the selected device reaches the selected target pose.
(Review from the TR42115 course). (Review from the TR45115 course).
o # Drive Device Joints — Move the selected joint(s) of the selected kinematic device to
the specified joint value(s).
Activities
In the Standard OLP commands section, do the following activities:
• Looking at and using a basic OLP command

ESRC OLP commands
Free text standard commands

Purpose
In this topic, you learn how to enter standard commands as free text in the OLP commands section
of the controller teach pendant.
Objectives

• Have an ideas of some of the OLP commands that can be entered as standard.
• Enter basic OLP commands as free text.
Business process
Free text basics

This lesson describes various commands supported in simulation on all controllers which must be
entered as free text.
Other simulation supported Default controller commands:
These commands can be entered as free text:
• ; <String> – Allows textual comments to be inserted into the OLP command list.
• #DriveDeviceToValues <DeviceName> – Drive the specified joint of the specified device.
• # DriveDeviceToValuesSync <DeviceName> – Like # DriveDeviceToValues except, the device

motion can be synchronized with the robot’s movement to the next location in the path.
• # CallToolPath <opName> <toolName> - Calls the specified operation while verifying that the
assigned tool on this operation is the specified tool.

Lesson
OLP OLP commands
commands
• # Note <message> - Displays the message in the Process Simulate error window after the
simulation is stopped including the location where it was executed. Use double quotes to
evaluate variables and signals
• Setting the value of signals and variables with expressions

o # SetSignal <signal> <expression> (or # SetSignal <signal> = <expression> )
o # SetVariable <var> <expression>
OLP command conditions
The information referenced here is for the default controller. Each robot controller supports
these conditions and may support additional options as well. For example the Fanuc
controller Process Simulate also supports Jump to label abilities.
Basic syntax
The following basic syntax is supported in the condition commands:
• Logic operators: AND, OR, NOT (case sensitive)
• Parentheses
• Robot signals (case sensitive)
• False
• Decimal and integer values
• Arithmetic operators: +, - , *, /
OLP commands are not case sensitive.
(default controller) If then else syntax

Use the #If command to make the execution of a command depend on the result of a condition. If
the condition returns true, the lines between Then and #Elseif are executed. If the condition returns
false, the #Elseif commands are executed, otherwise it executes the #Else commands. If you do
not need it, you can also omit the #Else and #Elseif commands.
Most controllers support the IF statement natively, but each controller has its own syntax
for it that is described later in this training.
• # If <condition> Then
• # Elsif <condition> Then
• # Else

ESRC OLP commands
• # Endif
• For example:
o # If (a + b) > c Then
o # callPath pa1
o # Elsif a OR b Then
o # callPath pa2
o # Else
o # callPath pa3
o # Endif
Switch syntax
The #Switch command enables you to make easier and clearer choices when presented with several
possibilities. This way you do not have to use lengthy if-then-elseif chains.
This is similar to the case statement in the C programming language.
• # Switch <expression>
• # Case <val1>, <val2>
• # Default
• # Endswitch
• For example:
o # Switch (a+b)
o # Case 1
o # callPath pa1
o # Case 2, 3
o # callPath pa2
o # Default
o # callPath pa3
o # Endswitch

Lesson
OLP OLP commands
commands
For loop syntax

The #For loop passes over a range between a beginning and an end value using the specified step
size. The loop variable has to be of data type integer.
• # For <var> From <start> To <end> Step <step> Do
• # For <var> From <start> To <end> Do
• # Endfor
• For example:
o # For j From 1 To 10 Step 2 Do
o # callPath pa1
o # callPath pa2
o # Endfor
While loop syntax

The #While loop is executed as long as the condition is true.
If the condition never becomes false, it runs forever.
• # While <expression> Do
• # Endwhile
• For example:
o # While a < 100 Do
o # callPath pa1
o # Endwhile
Entering robot specific comments

(Robot) Controller Comments begin with
ABB-Rapid !# (exclamation mark and pound sign)
Cloos-Carola ! (exclamation mark)
Comau-Pdl - - (two minus signs)
Default // (two slashes)
Denso-PacScript ‘ (single quote/apostrophe)
Duerr-Ecotalk - - (two minus signs)
Epson-Spel ‘ (single quote/apostrophe)
Fanuc-Rj // (two slashes)

ESRC OLP commands
Igm-Ins # (pound sign)

Kawasaki-As ; (semi-colon)
Kuka-Krc ; (semi-colon)
Nachi-Slim ‘# (single quote/apostrophe and pound sign)
Nc-Code (machining) ( ) (comments within parenthesis)
Nc-Code-Rivieting ( ) (comments within parenthesis)
Panasonic-Csr / (one slash)
Reis-Robstar C # (the letter C and a pound sign)
Staubli-Val // (two slashes)
Trallfa-Robtalk ;@ (semi-colon and “at” sign)
Universal-URScript # (pound sign)
Yaskawa-Inform // (two slashes)
Activities
In the Free text standard commands section, do the following activities:
• Entering basic OLP commands as free text

Lesson
OLP OLP commands
commands
Defining robot specific signals

Purpose
In this lesson, you learn the naming rules for creating robot signals for specific robot controllers. If the
signal is not named properly, Process Simulate ignores it.
Recall from the intermediate robotics training:

• A PLC output signal is connected to a robot input such as a digital input (DI).
• A PLC input signal is connected to a robot output such as a digital output (DO).
• In Process Simulate, you enter the signals from the perspective of the PLC, so the robot waits for
output signals (DI) and sends input signals (DO).
Objectives
After you complete this lesson, you should be able to:
• Creating robot signals for specific robot controllers.
Business process
ABB signal definition

Signal names for ABB must be strings. For example mysignal1 and do15 are valid, but DI[15] is not
valid.
Cloos signal definition

• Supported boolean input signals:

ESRC OLP commands
o IN<num> – for example IN1 is referenced in an OLP command as 1.
• Supported boolean output signals:

o OUT<num> – for example OUT2 is referenced in an OLP command as 2.
Comau signal definition

Signal names should be either $DOUT[n] or $DIN[n] for digital output or digital input.
For example: $DOUT[2] and $DIN[1]
As always:
Robotic output signals are represented as PLC input signals.
Robotic input signals are represented as PLC output signals.
Denso signal definition

There are no special naming conventions for signals on this controller. The signal name can be any
string. For example MySignal.
Duerr signal definition

This section is to be determined.
Epson signal definition

For Epson OLP commands, signals can be referenced by a signal number such as 5 or a signal
name such as Sig15R.
Epson signal commands use three types of numeric signals:
• Boolean
• Byte
• Word
Signal numbers are mapped to Process Simulate signal names.
If the signal name is used in the command (and not the signal number), it is used as
is without being mapped.
In Process Simulate, signal numbers are mapped to signal name names like this:
• Boolean input signals are mapped to INB[<SignalNumber>]. For example INB[1] for signal 1.
• Boolean output signals are mapped to OUTB[<SignalNumber>]. For example OUTB[1] for
signal 1.

Lesson
OLP OLP commands
commands
• Byte input signals are mapped to IN[<SignalNumber>]. For example IN[1] for signal 1.
• Byte output signals are mapped to OUT[<SignalNumber>]. For example OUT[1] for signal 1.
• Word input signals are mapped to INW[<SignalNumber>]. For example INW[1] for signal 1.
• Word output signals are mapped to OUTW[<SignalNumber>]. For example OUTW[1] for signal 1.
Fanuc signal definition

Signal Name Limitations:
• Supported numeric input signals:
o AI – for example AI[1]
o GI
• Supported numeric output signals:

o AO – for example AO[1]
o GO

o DI – for example DI[1]
o RDI
o SDI
o UI

o DO – for example DO[1]
o RDO
o SDO
o UO
IGM signal definition

This section is to be determined.
Kawasaki signal definition

Signals are mapped like this:
• WX (wait signal) 1 or –1 is modeled as robot input signal in1 (PLC output signal). A positive value
means to wait for ON, whereas a negative value means to wait for OFF

ESRC OLP commands
WX signals can only be negative if the robot setup Send type is set to Keeping
(default).
• OX (output signal) 2 or –2 is modeled as robot output signal out2 (PLC input signal)
Robot output signal behavior setup

In Robcad, this information used to be stored in a .sy file. In Process Simulate, it is stored on the
robot instance. In the Robot Setup dialog box, there are some simulation settings related to OX
(output signal) simulation:
Send type (robot output signals = PLC input signals)

• Keeping — only set OX signals mentioned in the step to ON if positive or OFF if negative
(default). Both positive and negative values are allowed.
• Each Step — set OX signals mentioned in the step to ON, and all other signals to OFF. Only
positive values are allowed.
Send timing
• At Motion Start — send OX signals before moving to the location (default) (PREOUT is set to ON)
• At Target Reached — send OX signals when the location is reached (PREOUT is set to OFF)
Synchronization is implemented in this order:

• If OX Send timing is set to At Motion Start:
o Send lo1 OX signals
o Start moving to lo1
o When lo1 is reached:

■ Wait for lo1 WX signals
■ Wait for lo1 timer
• If OX Send timing is set to At Location Reached:

o Start moving to lo1

Lesson
OLP OLP commands
commands
o When lo1 is reached:

■ Send lo1 OX signals
■ Wait for lo1 WX signals
■ Wait for lo1 timer
Kuka signal definition

In KRC fold, signal names are strings such as mysignal.
In Krl, signal names follow this format:$IN[1] and $OUT[1].
Nachi signal definition

Names used for signals are not allowed. Output signals start with a O and a number, while input
signals start with an I and number. For example
1. Output signal example: O54 (for Output 54)
2. Input signal example: I54 (for Input 54)
Panasonic signal definition
On the Panasonic controller, a signal can be referenced by its name, number, or both.
However, in Process Simulate, you must reference the signal by either its name, such as
o1#MySignal, or its number, such as o1#7. In the examples in this training, you reference
the signals by number.
• Supported input signals:

o i1#<num> – for Boolean input signals. For example i1#1
o i4#<num> – for 4-bit integer input signals. For example i4#1
o iH#<num> – for high-speed input signals. For example iH#1
• Supported output signals:

o o1#<num> – for Boolean input signals. . For example o1#1
o o4#<num> – for 4-bit integer input signals. . For example o4#1

ESRC OLP commands
Reis signal definition

For Reis OLP commands, signals can:
• Must be Boolean signals
• The signal corresponds to 1 bit of the byte
• Signal name must have a prefix:

o "i" for input signals
o "o" for output signals
o "m" for marker signals
• Signal name must follow this format:

o i5_<bit index in the byte>
Signal examples: i5_0, i5_1, i5_2, ... i5_7.

• Input signal name example: i5_0
• Output signal name example: o5_0
Trallfa signal definition

Input signals begin with the word INPUT and contain a number. Output signals begin with the word
OUTPUT and contain a number.
• Input signal name example: INPUT2
• Output signal name example: OUTPUT2
Universal signal definition

o DI[<num>] – standard digital input signal. For example DI[1]
o TI[<num>] – tool digital input signal. For example TI[1]
o AI[<num>] – tool analog input signal for example AI[1]

o DI[<num>] – standard digital input signal. For example DI[1]
o TI[<num>] – tool digital input signal. For example TI[1]
o AI[<num>] – tool analog input signal for example AI[1]
Yaskawa signal definition

Output signal names

Lesson
OLP OLP commands
commands
• OT#(<Output number>) — For example OT#(12)
• OG#(<Output group number>)
• OGH#(<Output group number>)
• SOUT#(<Specific output number>)
Input signal names

• IN#(<Input number>) — For example IN#(12)
• IG#(<Input group number>)
• IGH#(<Input group number>)
• SIN#(<Specific input number>)
In order to use Yaskawa-Inform signal names (that include parentheses) in default

controller commands, a special syntax should be used. The parentheses in the signal
names should be replaced with "&op;" and "&cl;". For example: IN#(12) should be entered
as IN&op;12&cl; Here is the result:
• # IF IN#&op;12&cl; THEN
• # SetVariable B000 IN#&op;12&cl;
Activities
In the Defining robot specific signals section, do the following activities:
• Defining robot specific signals

ESRC OLP commands
Sending and waiting for robot specific signals

Purpose
In this lesson, you learn to send/wait for signals using robot specific (downloadable) terms.
Objectives

• Send and wait for signals using robot specific (downloadable) terms.
Business process
ABB: Sending and waiting for signals
These commands must be entered as free text or using a custom XML (described later
in this course).
• SetDO (with optional delay) use like SendSignal on the default controller. Changes the value of a
digital output signal. For example SetDO do15, 1;
• Set use like SendSignal on the default controller. Set a digital output signal. For example Set
gripper;
• Reset use like SendSignal on the default controller. Resets a digital output signal to zero. For
example Reset do15;
• SetAO / SetGO use like SendSignal on the default controller. Changes the value of an analog
output signal or a group signal. For example SetAO ao2, 5.5;
• WaitDI (with optional \MaxTime and \TimeFlag options) use like WaitSignal on the default
controller. Waits until a digital input signal is set. For example WaitDI di4, 1;

Lesson
OLP OLP commands
commands
Cloos: Sending and waiting for signals
in this course).
• SET — Set a Boolean robot signal to true. For example

o SET(12), SET(8..12,16)
• RESET — Set a Boolean robot signal to false. For example

o RESET(12), RESET(8..12,16)
• WAITI — Wait for a Boolean robot signal expression. For example:

o WAITI (IN(4))
o WAITI (NOT IN(4))
o WAITI (IN(4) AND IN(6))
o WAITI (NOT IN(4)) OR (NOT IN(6))
Comau: Sending and waiting for signals
in this course).
• $DOUT[n] := <boolean expression> — digital output (as well as $SDOUT — system digital output
and $FDOUT — functional digital output), works like SendSignal
For example $DOUT[17] := TRUE
• $DIN — digital input.
• WAIT FOR <signal expression>, use like wait for signals

For example: WAIT FOR $DIN[1] = ON
Denso: Sending and waiting for signals
in this course).
• <signal name> = <expression> — Set a signal to a value. For example, to set MySignal to
true or false:
o MySignal = 1
o MySignal = 0

ESRC OLP commands
• SET <signal>, <time>, <mode> — Set a Boolean robot signal to true. For example:
o To set MySignal to true:
Set MySignal
o To set MySignal to true, wait 1000ms, then set MySignal to false:

Set MySignal, 1000
o To send a pulse signal with a delay of 1000 ms:

Set MySignal, 1000 <AnyAsyncMode>
• RESET <signal> — Set a Boolean robot signal to false. For example:

o To set MySignal to false:
Reset MySignal
• WAIT <signal expression> — Wait for an expression to become true. For example
o To wait until MySignal is true:
Wait MySignal = ON
o Wait MySignal = ON, 300
Duerr: Sending and waiting for signals
in this course).
• SET <Signal> <Low/High>, use like SendSignal on the default controller
• GET <Signal> <Low/High>
• RECEIVE <Signal> <Low/High>, use like WaitSignal on the default controller
Epson: Sending and waiting for signals
in this course).
• On
o On <BoolOutSignalNb> sets an output signal to 1. For example On 9
o On <SignalName> sets an output signal to 1. For example On Sig15R
o On {<BoolOutSignalNb>|<SignalName>}, <Time> sets an output signal to 1 during

indicated time in seconds and reset it back. For example On 5, 10
• Off

Lesson
OLP OLP commands
commands
o Off <BoolOutSignalNb> sets an output signal to 0. For example Off 14
o Off <SignalName> sets an output signal to 0. For example Off IRB240w.
o Off {<BoolOutSignalNb>|<SignalName>}, <Time> sets an output signal to 0 during

indicated time in seconds and reset it back. For example Off TotoSig, 5.
• Oport
o Oport(<BoolOutSignalNb>) returns output signal value. For example a = Oport(5)
• Sw
o Sw(<BoolInSignalNb>) returns input signal value. For example If Sw(5) Then Exit EndIf
• In
o In(<ByteInSignalNb>) returns input byte signal value. For example var1 = In(2)
• InW
o InW(<WordInSignalNb>) returns input word signal value. For example wordN = InW(8)
• Out
o Out(<ByteOutSignalNb>) returns output byte signal value. For example Print Out(0)
o Out <ByteOutSignalNb>, <SignalVal> sets output byte signal value. For example Out(3),
In(2)
• OutW
o OutW(<WordOutSignalNb>) returns output word signal value. For example If OutW(3) =
InW(5) Or InW(6) Then a=a+1 EndIf
o OutW <WordOutSignalNb >, <SignalVal> sets output word signal value. For example
OutW(3), InW(5)
• Wait
o Wait <Time> waits for the time in seconds. For example Wait 5
o Wait <Condition> wait for the condition to equal True. For example Wait Sw(5) = On
o Wait <Condition>, <Time> wait for the condition to equal True and the time in seconds.
For example Wait InW(4) > 8, 10
Fanuc: Sending and waiting for signals
in this course).
• <Boolean output signal>[<num> or <register>] = PULSE — pulse signals

ESRC OLP commands
• <Boolean output signal>[<num> or <register>] = PULSE, <duration> sec — Pulse signals with
explicit duration
• <Boolean output signal>[<num> or <register>] = <Boolean expression> — Send Boolean signals
• <analog output signal>[<num> or <register>] = <arithmetic expression> — Send analog signals
• WAIT <signals expression> — wait signals
IGM: Sending and waiting for signals
in this course).
• DOUT
• AOUT
• WAIT
• PULSE
Kawasaki: Sending and waiting for signals

These Kawasaki I/O commands are supported:
• BITS <sigNum>, <range> = <val> Sets signals to be equal to the specified value (up to 16
signals). For example:
o Set one signal value: BITS 23, 1 = 1 is mapped to SendSignal out23, 1 on the default
controller.
o Set three signal values: BITS 23, 3 = 0 is mapped to SendSignal out23,0 and SendSignal
out24, 0 and SendSignal out25,0 on the default controller.
• SWAIT <sig1>, <sig2>,… Suspends program execution until the specified condition is set. For
example:
o SWAIT 1 is mapped to Wait Signal in1 == TRUE on the default controller.
o SWAIT 2, 3 is mapped to Wait Signal (in2 == TRUE AND in3 == TRUE) on the default
controller.
o SWAIT 1,-4,-4is mapped to Wait Signal (in1 == TRUE AND in4 == FALSE AND in5 ==
FALSE) on the default controller.
• TWAIT <delay> Delays program execute the specified number of seconds
• SIGNAL <sig1>, <sig2> Turns on/off external output signals (OX). For example:
o SIGNAL 1,-2 is mapped to SendSignal out1,1 and SendSignal ou2,0 on the default controller.

Lesson
OLP OLP commands
commands
Kuka: Sending and waiting for signals
in this course).
• OUT <num> '<signal_name>' STATE=<TRUE|FALSE> (CONT)

example: OUT 1 'mysignal' STATE=TRUE CONT
• PULSE <num> '<signal_name>' STATE=<TRUE|FALSE> (CONT) TIME=<time> sec

o For example: PULSE 1 'mysignal' STATE=TRUE CONT TIME= 2.2 sec
• SYN OUT <num> '<signal_name>' STATE=<TRUE|FALSE> at <START|END|PATH=<distance>

mm> DELAY= <delay> ms
o For example: SYN OUT 2 'mysignal' STATE=FALSE at PATH=3 mm DELAY= 100 ms
• SYN PULSE <num> '<signal_name>' STATE=<TRUE|FALSE> at

<START|END|PATH=<distance> mm> TIME=<time> sec DELAY= <delay> ms
o For example: SYN OUT 2 'mysignal' STATE=FALSE TIME= 3 sec AT END DELAY= 100 ms
• WAIT FOR (NOT) ( <IN|OUT|CYCFLAG|TIMER|FLAG> <num> '<signal_name' ) (CONT)

o For example: WAIT FOR NOT ( IN 1 'mysignal' ) CONT
o Move to format 5.4.33
• WAIT FOR (NOT) ((expr) <AND|OR...> (Expr) ... ) (CONT), as WaitSignal $IN[<Num>] or
$OUT[<Num>]
o Expr in Krl = WAIT FOR (NOT) $<IN|OUT|CYCFLAG|TIMER|FLAG>[<Num>]
For example: WAIT FOR ( $IN[1] and $IN [2] )
o Move to format 5.4.33
KRC Fold commands:

• ($)OUT <Num> State = <TRUE|FALSE> (CONT) '<Signal Name>', use like SendSignal
OUT<Num>
o For example : OUT 3 State = TRUE 'signal 1'
o is simulated as SendSignal OUT3
• WAIT FOR (NOT) <IN|OUT|CYCFLAG|TIMER|FLAG> <Num> '<SignalName>'

o For example: WAIT FOR (IN 2 'signal 2') and (not OUT 3 '')
o is simulated as WaitSignal $IN[2] True and OUT 3 false
• PULSE <Num> State = <TRUE|FALSE> Time = <Duration> sec (CONT) '<SignalName>', as

pulse signal OUT<Num>

ESRC OLP commands
o For example : PULSE 3 State = TRUE Time = 0.1 sec 'signal 3'
o is simulated as Pulse Signal OUT 3 (set to value 1, then set to value 0 after 0.1 sec)
KRL commands
• WAIT FOR <Signal> == TRUE/FALSE, used like WaitSignal from the default controller
• (SET) <Signal> = <expression>, used like SendSignal from the default controller (only if <Signal>
is defined as a robot output signal)
• (SET) <Signal> = <expression>, used like SendSignal from the default controller (only if <Signal>
is defined as a robot output signal)
• PULSE(<signal>, TRUE/FALSE, <duration>)
Nachi: Sending and waiting for signals
in this course).
Sending Signals
• SET - Output signal ON (FN32)
o For example: SET[O12]
• SETO - Consecutive output signal ON/OFF (FN100)

o For example: SETO [O1, O512, 1]
• SETM - Output signal ON/OFF (FN105)

o For example: SETM [O17, 1]
• RESET - Output signal OFF (FN34)

o For example: RESET [O12]
Waiting Signals
• WAIT - Input signal wait with timer (FN552)
o For example: WAIT [I7, 3.0, 7]
• WAITI - Input signal wait (positive logic) (FN525)

o For example: WAITI [I7]
• WAITJ - Input signal wait (negative logic) (FN526)

o For example: WAITJ [I7]
• WAITA(D)

Lesson
OLP OLP commands
commands
o For example: WAITA[Group2, &B00000101, 60.0, 10] - Wait group input (AND) with timer
(FN553)
o For example: WAITAD[Group2, 63, 60.0, 10] - Wait group input BCD (AND) with timer
(FN558)
• WAITO(D)
o For example: WAITO[Group2, &B00000101, 60.0, 10] - Wait group input (OR) with timer
(FN554)
o For example: WAITOD[Group2, 63, 60.0, 10] - Wait group input BCD (OR) with timer (FN559)
• WAITE(D)
o For example: WAITE[Group2, &B00000101, 60.0, 10] - Wait group input with timer (FN555)
o For example: WAITED[Group2, 63, 60.0, 10] - Wait group input BCD with timer (FN558)
Example for class:

• SETM O54,1
o SETM is a constant string
o O54 is the output to control (for example Output 54)
o 1 or 0 for on or off
• WAITI I54
o WAITI is a constant string
o I54 is the input to wait for (for example Input 54)
Panasonic: Sending and waiting for signals
in this course).
• OUT or OUT2, <output signal>, <value> — Set a robot signal to a value. For example
o OUT, o1#4, 1
• PULSE <output Boolean signal>, <time>— Set a robot signal to a value for a specified amount
of time. For example
o PULSE, o1#4, 10
• IN or IN2 <variable>, <input signal>— Get signal value.
• WAIT_IP <input signal>, <value>, <time out> — Wait for a robot signal to acquire a value within
specified amount of time. For example
o wait for i1#5 to become true

ESRC OLP commands
WAIT_IP, i1#5, 1
o wait for i1#5 to become true with a 25 second timeout

WAIT_IP, i1#5, 1, 25
Reis: Sending and waiting for signals
in this course).
• WRITE_BIT (MARKER, OUTPUT)

o For example:WRITE_BIT #MARKER,Level:1,Byte:17043,Bit_No:7
o Simulated as SendSignal m17043_71
• WAIT_BIT
o For example: WAIT_BIT #MARKER,Level:1,Byte:17043,Bit_No:7,Max_Time[s]:2.00,Label:" "
o Simulated as WaitSignal m17043_7 1, with timeout 2 seconds
o Calls to a label at timeout are not simulated in the first step.
Trallfa: Sending and waiting for signals
in this course).
• WAIT INPUTnum ON/OFF - as WaitSignal INPUT[num]
• OUTPUTnum ON/OFF - as SendSignal OUTPUT[num]
Universal: Sending and waiting for signals
in this course).
• set_standard_digital_out(<num>, True/False) — Set a Boolean robot signal to true. For

example to set DO[4] to true:
o set_standard_digital_out(4, True)
• set_tool_digital_out(<num>, True/False) — Set a Boolean robot signal to true. For example

to set TO[4] to true:
o set_tool_digital_out(4, True)

Lesson
OLP OLP commands
commands
• set_standard_analog_out(<num>, <real>) — Set a Boolean robot signal to true. For example

to set AO[4] to 6.5:
o set_standard_analog_out(4, 6.5)
• get_standard_digital_in(<num>) — get the value of a Boolean robot signal. For example, for
DI[5]:
o get_standard_digital_in(5)
• get_standard_digital_out(<num>) — get the value of a Boolean robot signal. For example,

for DO[5]:
o get_standard_digital_out(5)
• get_tool_digital_in(<num>) — get the value of a Boolean robot signal. For example, for TI[5]:
o get_tool_digital_in(5)
• get_tool_digital_out(<num>) — get the value of a Boolean robot signal. For example, for TO[5]:
o get_tool_digital_out(5)
• get_standard_analog_in(<num>) — get the value of a Boolean robot signal. For example, for
AI[5]:
o get_standard_analog_in(5)
• get_standard_analog_out(<num>) — get the value of a Boolean robot signal. For example,

for AO[5]:
o get_standard_analog_out(5)
Waiting for a signal with a Universal robot

The "get" instructions read the value of the signal and do not "wait" for the signal to change its
value. There is no wait signal instruction in URScript, instead you must use a combination of a"get"
instruction and a while loop. For example, to want for DI[0] to become true:
while get_standard_digital_in(0) == False
sync()
end
Although the sync() instruction is not simulated in Process Simulate: you can add it to a location and
it is ignored. On the Universal controller, sync() uses up the remaining physical time a thread has
in the current frame.
Yaskawa: Sending and waiting for signals
in this course).
Supported I/O Instructions:

• DOUT

ESRC OLP commands
• AOUT
• WAIT
• PULSE
Activities
In the Sending and Waiting for Robotic Specific Signals section, do the following activities:
• Adding Digital Input and Digital Output OLP Commands to Locations

Lesson
OLP OLP commands
commands
More controller specific OLP commands

Purpose
In this topic, you learn about more robotic specific commands supported by the ESRC controllers
beyond signals and send/wait commands.
Objectives
• Convert something designed for the default controller for a robot specific controller.
• Describe more commands that are supported for the various controllers.
• Know some additional robot controller specific OLP commands for each controller
Business process
Controller specific OLP command basics

The support in this area of ESRC is continuing to improve. However, one strength of ESRC is that
it gives you the power to extend the robot controller’s support of a robot language using XML
customization. This is described later.
For the latest list of supported robot specific commands, see the GTAC support website
(support.industrysoftware.automation.siemens.com/gtac.shtml). The latest ESRC controllers and
related documentation can be downloaded from the updates area of the website.
Class discussion to put it all together

In the intermediate (CEE) robotics training, you created a main program for a robot with OLP
commands to follow one robotic path if part style 1 was detected in the fixture and a different robotic
path if part style 2 was detected. You created this logic and simulation using the default controller.
Which looked like this:
• # CycleStart

ESRC OLP commands
• # CallPath ROBOT R1 TO POUNCE
• # If selectStyle1 AND NOT selectStyle2 Then
• # CallPath ROBOT R1 WELD (STYLE 1)
• # EndIf
• # CallPath ROBOT R1 WELD (STYLE 2)
• # EndIf
• # CycleEnd
Although this logic works in Process Simulate simulations with any controller selected, all # OLP
commands are download as either comments or not placed in the downloaded file at all.
Making the logic downloadable
Use what you have learned about robot specific signal naming, change the robot signal so that it
is compatible with your selected robot controller. For example for some controllers, selectStyle1
is not a valid signal name.
If you are not sure of what is acceptable for the naming of a robot path, it should be 8 or less
characters and not contain spaces or special characters. So ROBOT R1 WELD (STYLE 1) is
probably not the best choice if you want to download it.
Use the descriptions in the following pages to replace the # default controller commands with robotic
specific commands for commands to be downloaded. For example #IF, #CalPath, and #EndIf.
In some cases the # default commands do not have a robot specific equivalent, since they Process
Simulate simulation specific. For example #CycleStart and #CycleEnd. (These commands are used to
create an Excel simulation report).
See the reworked examples later in this lesson for farther explanation.
ABB-Rapid — Beyond signals and send/wait commands

Additional OLP Commands:
On the Teach Pendant after clicking Add, the following menu is available beyond the basic OLP
commands:
• Free Text
• GridLoad
• Line Tracking – WaitWobj, and DropWobj
• Paint – SetBrush, SetColor, EnableEquip, DisableEquip, and UseBrushTab
AbbRapid Specifics:
• Baseware,Spotware, and Dispenseware are supported

Lesson
OLP OLP commands
commands
Free text commands only supported in simulation:

• Any basic OLP command described earlier, including the following ones which must be entered
as free text:
Relative motion simulation commands
o # MoveRelBase [<RefLoc>] <X> <Y> <Z> [<RX> <RY> <RZ>]
■ Move the robot with an offset expressed in location object frame coordinates system.
■ The offset is relative to: RefLoc if the optional <RefLoc> parameter is specified (RefLoc
should be the name of a location inside the current robotic operation), otherwise to the
current location, or (if defined at operation level), to the current robot TCPF
■ The optional rotational part of the offset are rotation angles in degrees expressed in
location object frame coordinate system (rotations are performed one after the other in
the rotating frame)
■ The current location motion type, speed, zone are used to move to the offset position
o # MoveJRelBase [<RefLoc>] <X> <Y> <Z> [<RX> <RY> <RZ>] — Same as # MoveRelBase,
except that motion type to the offset position is forced to Joint
o # MoveLRelBase [<RefLoc>] <X> <Y> <Z> [<RX> <RY> <RZ>] — Same as # MoveRelBase,
except that motion type to the offset position is forced to Linear
o # MoveRelTool [<RefLoc>] <X> <Y> <Z> [<RX> <RY> <RZ>]
■ Move the robot with an offset expressed in location self coordinates system.
should be the name of a location inside the current robotic operation), otherwise, to the
current location, or (if defined at operation level), to the current robot TCPF.
reference location self coordinate system (rotations are performed one after the other in
the rotating frame)
■ The current location motion type, speed, zone are used to move to the offset position.
o # MoveJRelTool [<RefLoc>] <X> <Y> <Z> [<RX> <RY> <RZ>] — Same as # MoveRelTool,
except that motion type to the offset position is forced toJoint
o # MoveLRelTool [<RefLoc>] <X> <Y> <Z> [<RX> <RY> <RZ>] — Same as # MoveRelTool,
except that motion type to the offset position is forced to linear.
Motion Parameters: By default, the current modal motion parameters (speed, zone, tool,
etc.) is used. It is also possible to define explicit motion parameters with following syntax:
# MoveRelBase <X> <Y> <Z> [Speed Data = v500] [Zone Data = z100]. These explicit
motion parameters is inherited on any subsequent relative motions
Robot specific fee text commands supported in simulation and download:

ESRC OLP commands
in this course).
• WaitUntil (with optional \MaxTime and \TimeFlag options) use like WaitSignal on the default
controller. Waits until a condition is met. For example WaitUntil di4 = 1;
• WaitTime use like Delay on the default controller. Waits a given amount of time. For example
WaitTime 0.3;
• WaitWobj (with optional RelDist), both on tracking and non-tracking locations. Wait for a work
object on a conveyor. For example WaitWObj wobj_on_conv1;
• UseBrushTab as storing the current active Brush Table for further use in Change Brush trigger
simulation
• SetBrush as opening or closing the paint gun depending on the brush number and the current
active Brush Table
• ConfJ (configuration joint) / ConfL (configuration linear) — Specify whether the robot’s
configuration is to be controlled during joint or linear motion. If not, the robot can sometimes use
a different configuration than programmed. For example ConfJ \Off; or ConfJ \ On;
• Singarea — Defines interpolation around singularities. For example Sing \Wrist; (avoid
singularity) or SingArea \Off; (stop at singularity)
• GripLoad — Defines the payload for a robot. For example GripLoad piece1;
• ActUnit / DeActUnit — Activates or deactivates a mechanical unit. For example: ActUnit

orbit_a;
• Assign a value (<var> := <constant or expression>;) For example: reg1 := 5; or regt := reg2 —
reg3;
• variable assignation from function call (<var> := <FunctionCall>).
• IF <condition> <action>; (compact if)
• IF <condition>THEN ... ELSEIF <condition> THEN ... ELSE ... ENDIF — If the condition is met
then perform some instructions. For example, IF reg1 > 5 THEN Set do1; ENDIF
• IF <FuntionCall> THEN ... ELSEIF <condition> THEN ... ELSE ... ENDIF
• WHILE <condition> DO ... ENDWHILE — Repeats the instructions as long as the condition is
true. For example WHILE reg1 < reg2 DO reg1 := reg1 + 1; ENDWHILE
• FOR <var> FROM <start> TO <end> [STEP <step>] DO ... ENDFOR — Repeats a given number
of times. For example FOR j FROM 1 TO 10 DO routine1; ENDFOR
• TEST <var> ... CASE <val1>,<val2>: ... DEFAULT: ... ENDTEST — depending on the value of
an expression, do something. For example TEST reg1 CASE 1,2,3: function1; ENDTEST

Lesson
OLP OLP commands
commands
• TEST <FunctionCall> ... CASE <val1>,<val2>: ... DEFAULT: ... ENDTEST
• RETURN — Finishes execution of a routine. For example Return;
• RETURN <expression> — If the routine is a function, then the function value is also returned.
For example Return value1;
• EXIT / STOP use to terminate or stop the program execution. For example EXIT; or Stop;
• GOTO <label> — Jump to someone in the program. For example GOTO sub1;
• SpeedData v_tcp assigment (<SpeedData>.v_tcp:=<expression>), use to temporarily modify

the tcp speed with the speed data
• Present(<ParamName>), automatically replaced by TRUE or FALSE depending on whether the

parameter <ParamName> was provided in the function call
• DInput(<sigName>), GInput(<sigName>), AInput(<sigName>), used to return the value of

input signal <sigName>
• <Name>; simulated as, in priority order:

o call to robot module procedure <Name>
o call to macro <Name>
o call to operation <Name>
o call to operation <Robot><Name>
o call to operation <Robot>_<Name>
o call to robotic program <Name>
o call to robotic program <Robot><Name>
o call to robotic program <Robot>_<Name>
MOP simulation (RCS disconnected/decouple mode):

• If the RCS in simulation is disconnected, a MOP simulation replaces the RRS based simulation.
• All commands supported in RRS simulation (see above) are also simulated in a MOP simulation,
except:
o ConfJ/ConfL
o SingArea
o GripLoad
o ActUnit/DeActUnit
• Motion parameters are mapped as follows:

ESRC OLP commands
o SpeedData→Cartesian Speed:
■ ...use SpeedData.VTcp
■ ...apply modal OverrideSpeed factor if any (from VelSet motion property)
■ ...apply modal MaxSpeed parameter if any (from VelSet motion property)
o ZoneData→ Zone:
■ ZoneData.FinePoint = true : fine
■ ...Otherwise use ZoneData.PathZoneTcp:
■ ...PathZoneTcp < 1 : fine
■ ...1 <= PathZoneTcp < 30 : medium
■ ...30 <= PathZoneTcp < 120 : coarse
■ ...PathZoneTcp >= 120 : nodecel
Class discussion continued for ABB

Here is one possible way to rework the default controller OLP commands for this robot controller:
• # CycleStart
• Call r1pounce;
• If selectStyle1 AND NOT selectStyle2 Then
• Call r1style1;
• EndIf
• If selectStyle2 AND NOT selectStyle1 Then
• Call r1style1;
• EndIf
• # CycleEnd
In this example, the robot paths and robot signals need to be renamed in the study to match what
is shown in these OLP commands.
Cloos-Carola - Beyond signals and send/wait commands

commands:
• Free Text

Lesson
OLP OLP commands
commands
in this course).
• JUMP/LABEL For example:

o L002:
RESET(1)
JUMP L002
• CALL For example:

o CALL SYNC
• IF THEN ELSE For example:

o IF IN(1) THEN JUMP L002 ELSE JUMP L003
o IF IN(1)
BEGIN
SET(12)
RESET(13)
END
ELSE
BEGIN
SET(13)
RESET(12)
END
• Variable assignment. For example

o PKT:=1
Comau-Pdl — Beyond signals and send/wait commands

commands:
• Free Text

ESRC OLP commands
in this course).
• DELAY <val>, use as a delay in ms

For example: DELAY 5
• $TIMER := <val>, use as a timer value memorization
• $<Var> := <val> or $ARM_DATA[<num>].<Var> := <val>, used for system variable assignment
$ARM_DATA — robot arm data
o Special case for following recognized variables (handled as modal motion parameters
modification)
■ $ARM_ACC_OVR — arm acceleration override
■ $ARM_DEC_OVR — arm deceleration override
■ $ARM_OVR — arm override
■ $ARM_SPD_OVR — arm speed override
■ $EMT_STRESS (with e-Motion option)
■ $FLY_TYPE — type of fly motion
■ $FLY_PER — percentage of fly motion
■ $FLY_DIST — distance in fly motion
■ $FLY_TRAJ — type of control on Cartesian fly
■ $GEN_OVR — general override
■ $LIN_SPD — linear speed
■ $ORNT_TYPE — type of orientation
■ $PROG_ACC_OVR — program acceleration override
■ $PROG_DEC_OVR — program deceleration override
■ $PROG_SPD_OVR — program speed override
■ $ROT_SPD — rotational speed
■ $SPD_EMT (with e-Motion option)

Lesson
OLP OLP commands
commands
■ $SPD_OPT — type of speed control
■ $TERM_TYPE — type of motion termination
• Other system variable assignments are sent as is to the RCS via RcsModifyRcsData
• <var> := <expression>, use it like an assigned variable

For example: count := count +1
• <var> := <FunctionCall>
• WAIT FOR <signal expression> OR ($TIMER[i] > <val>) (as well >= <val>), use it like a wait for
signal with a time out (time out equal to val - current timer memorized value)
$TIMER is the clock timer
• IF <condition>THEN ... ELSE ... ENDIF

For example:
IF $DI N[2] = OFF THEN
MOVE TO feeder
ELSE
MOVE TO discard
ENDIF
• IF <FunctionCall> THEN ... ELSE ... ENDIF
• WHILE <condition> DO ... ENDWHILE

For example:
WHILE counter < num_errors DO
couter := counter +1
ENDWHILE
• REPEAT ... UNTIL <condition>

For example:
REPEAT
UNTIL counter > 5
• FOR <var> :=<start> TO <end> [STEP <step>] DO ... ENDFOR

For example:
FOR test := 1 TO num_hoses DO

ESRC OLP commands
ENDFOR
• SELECT (<var>) OF ... CASE (<val1>, <val2>) : ... ELSE: ... ENDSELECT
For example:
SELECT tool_type OF
CASE (1):
$TOOL := utool_weld
style_weld
CASE (2):
$TOOL := utool_grip
style_grip
ELSE:
tool_error
ENDSELECT
• SELECT (<FunctionCall>) OF ... CASE (<val1>, <val2>): ... ELSE: ... ENDSELECT
• GOTO label / label ::

For example: GOTO ex1
• RETURN — return program control from the current routine to the place where it was called.
• RETURN <Expression> — return a value
• <Name>; simulated as, in priority order:


except:

Lesson
OLP OLP commands
commands
o System variables assignation

o Speed:
■ SpeedControl = SPD_NORM
◊ speed : joint speed in % and joint acceleration in %
■ SpeedControl = SPD_LIN
◊ speed : cartesian speed
o Zone
■ $FLY_TYPE = $FLY_OFF, : fine
■ 0 < fly param ($FLY_DIST or $FLY_PER) < 5 : fine
■ 5 < fly param ($FLY_DIST or $FLY_PER) < 30 : medium
■ 30 < fly param ($FLY_DIST or $FLY_PER) < 75 : coarse
■ 75 < fly param ($FLY_DIST or $FLY_PER) < 100 : nodecel
Class discussion continued for Comau

• # CycleStart
• Call r1pounce
• If $DOUT[10] AND NOT $DOUT[20] Then
• Call r1style1
• EndIf
• If $DOUT[20] AND NOT $DOUT[10]Then
• Call r1style1
• EndIf
• # CycleEnd
Denso-PacScript - Beyond signals and send/wait commands


ESRC OLP commands
commands:
• Free Text
in this course).
• GOTO <label> — For example:

o L002:
...
GOTO L002
• JUMP <label> — For example:

o L002:
SET ...
JUMP L002
• CALL <proc> or RUN <task> — For example:

o CALL SYNC
• IF < > THEN < > ELSEIF or ELSE END IF — For example:
o IF MySignal THEN JUMP L002 ELSE JUMP L003 END IF
o IF MySignal1 THEN JUMP L002 ELSEIF MySignal2 JUMP L003 END IF
• SELECT CASE
• DELAY <time> — Wait for a certain amount of time to pass.
• Arithmetic functions:+, -, /, *, and Mod
• Logic functions:And, Not, Or and Xor
Duerr-EcoTalk — Beyond signals and send/wait commands

commands:
• Free Text

Lesson
OLP OLP commands
commands
in this course).
• GET_VARIANT(<VarianteName>), interpreted as the current value of the VARIANT input signal

.<VariantName>. (GET_VARIANTE is also accepted)
• GET_REPAIRTYPE(<RepairTypeName>), interpreted as the current value of the

REPAIRTYPE.<RepairTypeName> input signal
• Signals:
o RECEIVE_HANDLERPOS(<Part> <Handler> <State>)
■ IF GetSignal (out_<Handler>_pos) != <Part>*10 + State) THEN ; Check if a signal
is already in LB
■ WaitSignal out_ <Handler>_pos == <Part>*10 + State ; Wait for a signal to set
■ ENDIF
o var = RECEIVE_HANDLERPOS(<Part> <Handler> <State>) — Simulated by:

■ IF GetSignal(out_<Handler>_pos) == -1) THEN Var = FALSE ; Handler inactive
■ ELSEIF GetSignal(out_<Handler>_pos) == <Part>*10 + State) THEN Var = TRUE ; Check

if a signal is already in a logic block
■ ELSE
■ WaitSignal out_<Handler>_pos == <Part>*10 + State ; Wait for a signal to set
■ Var = TRUE
■ ENDIF
■ IF Handler == All THEN
■ IF GetSignal(out_h1_pos) == -1 AND GetSignal(out_h2_pos) == -1) AND … THEN Var =

FALSE ; All handlers inactive
■ ELSEIF GetSignal(out_h1_pos) == <Part>*10 + State OR GetSignal(out_h2_pos) ==

<Part>*10 + State OR … THEN ; Check if a signal is already in LB
■ Var = TRUE ; A signal is set
■ ELSE
■ WaitSignal out_h1_pos == < Part >*10 + State OR out_h2_pos == < Part >*10 + State
OR… ; Wait for a signal to set
■ Var = TRUE

ESRC OLP commands
■ ENDIF
o IF RECEIVE_HANDLERPOS(<Part> <Handler> <State>) [THEN] — Simulated by:

■ tmpvar = RECEIVE_HANDLERPOS(<Part> <Handler> <State>)
■ IF tmpvar THEN ...
o SET_POSCODE(<Part> <State>) — Simulated by:

■ SendSignal(<Part>*10+<State>)
o SET_ORDER(<Part> <Handler> <State>) — Simulated by:

■ SendSignal(out_<Handler>_order, <Part>*10+<State>)
■ WaitTime(0.11)
■ SendSignal(out_<Handler>_order, 0)
o var = RECEIVE_ORDER(<Part>) — Simulated by:

■ SendSignal(out_<Handler>_order, <Part>*10+<State>)
■ WaitTime(0.11)
■ SendSignal(out_<Handler>_order, 0)
■ IF GetSignalValue(in_order) == 0 THEN ; Check if a signal is already in a logic

block
■ WaitSignal(in_order) != 0
■ GetSignalValue(in_order)
■ END_IF
• Conditional/Unconditional blocs:
In some cases there is different syntax for the EcoRC2 and EcoRPC controllers:
o IF <cond> ... ELSEIF <cond> ... ELSE ... ENDIF
o WHILE <cond> .... ENDWHILE

WHILE <cond> DO ... END_WHILE
o REPEAT <Num> ... ENDREPEAT

LOOP <Num> DO ... END_LOOP
o DELAY <duration>
DELAY(<duration>)
o LABEL <Lab>

Lesson
OLP OLP commands
commands
o GOTO <Lab>
o CALL "<name>"()
CALL <name>()
o RETURN
o <Var> = <Expression>
• CALL "<Name>"() or CALL <Name>(), simulated as (in priority order):

• Line tracking specific commands

o WAIT_CONVEYOR(<pos>)
o WAIT_PAINTPOSITION(<pos>)
o TRACKING(<On|Off>)
• Unknown instructions — The unknown instructions are sent through the RCS as an "instruction"
command.
Following Ecotalk constants can be used in the simulation:
• Ecotalk Constants
o Low: 0
o High: 1
o HalfOpen: 1
o FullOpen: 2
o HalfClosed: 3
o Wait: 4
o FullClose: 5
o Delete: 6

ESRC OLP commands
o Finish: 7

• All commands supported in RRS simulation (see above) are also simulated in a MOP simulation.
Class discussion continued for Duerr

• # CycleStart
• Call r1pounce;
• If selectStyle1 AND NOT selectStyle2
• Call r1style1;
• EndIf
• If selectStyle2 AND NOT selectStyle1
• Call r1style1;
• EndIf
• # CycleEnd
Epson — Beyond signals

commands:
• Free Text
in this course).
Program control simulation commands (syntax is not case sensitive). Variables assignment:
• Boolean <VarName>
<VarName> = {True|False}
• Integer <VarName>

Lesson
OLP OLP commands
commands
<VarName> = <value>
• String <VarName>
<VarName> = <value>
Fanuc-RJ — Beyond signals and send/wait commands

commands:
• Free Text
• Motion menu
o UFRAME_NUM
o UTOOL_NUM
o PAYLOAD
o JOINT_MAX_SPEED
o LINEAR_MAX_SPEED
o JOINT_MAX_SPEED_REG
o LINEAR_MAX_SPEED_REG
• Branch menu
o LABEL
o JUMP_LABEL
• I/O menu
o PULSE
o Wait Signals
o Digital Output
o Robot Digital Output
o User Digital Output
o System Digital Output
o Group Signal Output
o Analog Signal Output
• Conditions menu

ESRC OLP commands
o Skip Condition
• Control menu
o UALM
o PAUSE
o ABORT
o WAIT
o TIMER
• Arc menu
o Weave Start
o Weave End
o Track TAST
o Track End
• MESSAGE
• REMARK
• RSR ENABLE
• RSR DISABLE
• Register Assignment
in this course).
Commands interpreted at location:

• PAYLOAD [<num>] — payload
• PAUSE as simulation stop
• ABORT as simulation stop
• WAIT <delay> sec — wait time
Commands interpreted during pre-calculation (3 locations ahead [RCS 6.x] or 4 locations ahead
[RCS 7.x]) :
•

Lesson
OLP OLP commands
commands
• CALL <prog>, simulated in priority order as :

o call to macro <prog>
o call to operation <Robot><prog>
o call to operation <Robot>_<prog>
o call to robotic program <prog>
o call to robotic program <Robot><prog>
o call to robotic program <Robot>_<prog>
• CALL <prog>(<param1>, ..,<paramN>), simulated as a call to Robot Module <prog>.
• END as a return to calling program
• IF <Boolean expression>, CALL <prog> — conditional call
• LVC Olp commands

o LVC START — enable Learning Vibration Control
o LVC END — disable Learning Vibration Control
Commands that forces a No Advance / Full Arrival motion:

• JMP LBL [<num>:<comment>] — Jump
• IF <Boolean expression>, JMP LBL [<num>:<comment>] — Conditional Jump
Limitations:
• L P[2]
• LBL[1]
• WAIT 0.1(sec)
• IF RDI[1] = ON, JMP LBL[1]
• L P[3]
• L P[4]
• L P[5]

except:

ESRC OLP commands
o Payload

o Cartesian Speed / Joint speed : direct mapping
o TermType→Zone :
■ FINE : fine
■ CNT81-CNT100 : nodecel
■ CNT41-CNT80 : coarse
■ CNT11-CNT40 : medium
■ CNT0-CN10 : fine
■ CD : nodecel
Class discussion continued for Fanuc

• # CycleStart
• Call r1pounce;
• If DO[10] = ON AND NOT DO[20] = ON,
• Call r1style1;
• If DO[20] = ON AND NOT DO[10] = ON,
• Call r1style1;
• # CycleEnd
IGM-Ins — Beyond signals and send/wait commands

commands:
• Free Text

as free text:

Lesson
OLP OLP commands
commands
the rotating frame)
the rotating frame)
Motion Parameters: By default, the current modal motion parameters (speed, zone,
tool, etc.) is used. It is also possible to define explicit motion parameters with following
(controller specific) syntax: # MoveRelBase <X> <Y> <Z> [Speed Data = v500] [Zone Data
= z100]. These explicit motion parameters is inherited on any subsequent relative motions.
in this course).

ESRC OLP commands
• Supported operating Instructions

o SET
o CLEAR
o INC
o DEC
o ADD/SUB
o MUL/DIV
o AND/OR/NOT/XOR
Class discussion continued IGM

(A reworked version is not currently provided with this training)
• # CycleStart
• # Callpath r1pounce;
• # Callpath r1style1;
• #EndIf
• # EndIf
• # CycleEnd
Kawasaki-As — Beyond signals and send/wait commands

commands:
• Free Text
as free text:

Lesson
OLP OLP commands
commands
the rotating frame)
the rotating frame)
tool, etc..) is used. It is also possible to define explicit motion parameters with following
(controller specific) syntax: # MoveRelBase <X> <Y> <Z> [Speed = 2] [Accu = 4]. These
explicit motion parameters is inherited on any subsequent relative motions.

except:

ESRC OLP commands
o payload

o Speed value in % is converted to mm/s (via cart_max_lin_speed entry in
MotionParameters.e) for linear motions
• Accuracy:
o If ACCU<i> zone is defined in the MotionParameters.e file, this actual zone is used
o Otherwise conversion from accuracy value (in mm) to default zones is as follows:
o 0 < val < 5: fine
o 5 < val < 30: medium
o 30 < val < 75: coarse
o 75 < val: nodecel
Class discussion continued for Kawasaki

• # CycleStart
• #EndIf
• # EndIf
• # CycleEnd
Kuka-Krc — Beyond signals and send/wait commands

commands:
• Free Text

Lesson
OLP OLP commands
commands
• Gripper – Check Grp and Set Grp
• I/O – Wait Time, Out, Pulse, Syn Out, Syn Pulse, Wait For signal, and Wait For Expr.
• Misc – KRC (Fold) Comment and KRL Comment
Kuka Krc Specifics:

• Only Basis and Spot motions are supported.
in this course).
In addition to the KRC Fold commands supported in simulation (see below), the following additional
KRC Fold commands are also supported in download:
• data> <time> NAME:<name> CHANGES: <changes>
• ANOUT OFF CHANNEL_<channel>=<value>
• ANOUT OFF CHANNEL_<channel>
• ANOUT ON CHANNEL_<channel>=<factor> * TECHVAL[<no>] OFFSET = <offset>

DELAY=<delay> [sec]
• ANOUT ON CHANNEL_<channel>=<factor> * VEL_ACT OFFSET = <offset> DELAY=<delay>

[sec]
• CHECK GRP <num> STATE= <OPN|CLO> at <START|END> DELAY= <Delay> ms

For example: CHECK GRP 1 STATE =OPN at END DELAY = 5 ms
• <START|END> CONST_VEL PATH=<path> mm
• IBUS OFF
• INIT.GUN<gun_num>
For example: INIT.GUN1
• PROGRAM.GUN <gun_num> PRG = <prog> PART = <move> mm FORCE = <pressure> daN

o For example: PROGRAM.GUN 1 PRG=2 PART = 3mm FORCE = 10 daN
• STOP WHEN PATH=mm (ONSTART) CONDITION
• SET GRP <num> STATE= <OPN|CLO> (CONT) at <START|END> DELAY= <Delay> ms

o For example: SET GRP 1 STATE =OPN at START DELAY = 5 ms
• SET GRP <Number> STATE= <OPN|CLO>

o For example: SET GRP 2 STATE =CLO

ESRC OLP commands
• TRIGGER WHEN PATH=<path> mm (ONSTART) DELAY=<delay> ms DO PULSE <no>

'<signal_name>' STATE=<TRUE|FALSE> TIME=<time> sec
• TRIGGER WHEN PATH=<path> mm (ONSTART) DELAY=<delay> ms DO OUT <no>

'<signal_name>' STATE=<TRUE|FALSE>
KRC Fold commands:

• WAIT Time = <Time> sec, as delay
o For .example : WAIT Time = 3 sec
• ANOUT CHANNEL_<Num> = <Value>, used like SendSignal $ANOUT[<Num>]

o For example: ANOUT CHANNEL_1 = 0.1
o is simulated as SendSignal $ANOUT[1] 0.1
• SET GRP <num> STATE= <OPN|CLO> CONT

o For example: SET GRP 1 STATE =OPN CONT at START DELAY = 5 ms
o is simulated as call to H50(GRP_APO, <num>, <STATE>, GCONT)
• SET GRP <Number> STATE= <OPN|CLO>

o For example: SET GRP 2 STATE =CLO
o is simulated as call to H50(GRP, <num>, <STATE>, GCONT), with <STATE> = 1 for OPN and
2 for CLO
• CHECK GRP <num> STATE= <OPN|CLO> at <START|END> DELAY= <Delay> ms

o For example: CHECK GRP 1 STATE =OPN at END DELAY = 5 ms
o is simulated as a delay and then a call to H50(CHK_APO_UP, <num>, <STATE>, GCONT), with
<STATE> = 1 for OPN and 2 for CLO
KRL commands
• assignation of following special system variables (as RRS motion parameters change):
o $VEL.CP
o $VEL.ORI1
o $VEL.ORI2
o $ACC.CP
o $ACC.ORI1
o $ACC.ORI2
• $ECO_LEVEL = [#OFF, #LOW, #MEDIUM, #HIGH] (a special RRS Energy service and is only
active with the KUKA RCS versions 8.3 or higher)

Lesson
OLP OLP commands
commands
• $CYCFLAG[num] = <Any Signal Expression>, an alias variable assignment (storing the

expression instead of the expression value)
• <var> = <Any Signal Expression>, used like either SendSignal from the default controler (if <var>
is defined as a robot output signal) or as a variable assignment.
• IF <condition>THEN ... ELSE ... ENDIF
• IF <FunctionCall> THEN ... ELSE ... ENDIF
• WHILE <condition> ... ENDWHILE
• REPEAT ... UNTIL <condition>
• LOOP....ENDLOOP
• FOR <var> = <start> TO <end> [STEP <step>] ... ENDFOR
• SWTCH <var> ... CASE <val1>,<val2>: ... DEFAULT: ... ENDSWITCH
• SWITCH <FunctionCall> ... CASE <val1>,<val2> ... DEFAULT ... ENDSWITCH
• WAIT SEC <Time>, as a delay
• WAIT FOR <expression>

o For example: WAIT FOR $IN[1] OR NOT $IN[2], as WaitSignals
• HALT to exit program
• EXIT to exit from a loop
• GOTO <label> jump to label. ( jump from outside into a loop instruction bloc is forbidden )
• <label>: destination of a goto instruction
• RETURN
• RETURN <Expression>
• Varstate("<varName>")
Priority order:
• [Name](), simulated as:
o call to macro [Name]
o call to operation [Name]
o call to operation [Robot][Name]
o call to operation [Robot]_[Name]
o call to robotic program [Name]

ESRC OLP commands
o call to robotic program [Robot][Name]
o call to robotic program [Robot]_[Name]

except:
o System variables assignment (like $ACC.ORI1, etc.)

o Cartesian Speed / Joint speed : direct mapping
• Zone:
o FINE→fine
• C_PTP
o 0-10 : fine
o 10-40 : medium
o 40-80 : coarse
o 80-100 : nodecel
• C_DIS
o 0-2 : fine
o 2-7 : medium
o 7-15 : coarse
o > 15 : nodecel
• C_VEL→nodecel
• C_ORI→nodecel
Energy Simulation:
Starting from Kuka RCS 8.3, the RRS simulation of energy consumption is supported in Process
Simulate.
In order to get energy consumption information during simulation, it is necessary that the machine
data are created with KUKA.WorkVisual so that they contain the energy capacity values (see the
Kuka RCS documentation for more information).
It is possible to save energy at the expense of cycle time by using the Kuka system variable
$ECO_LEVEL, with possible values #OFF, #LOW, #MIDDLE and #HIGH. Changing the

Lesson
OLP OLP commands
commands
$ECO_LEVEL does not affect the trajectory but optimizes velocities and accelerations. $ECO_LEVEL
has no influence on LIN or CIRC motions, it only affects PTP and SPLINE motions.
Energy consumption during the motion execution is generally made of 2 parts:
1. Moving the payload against the inertia
2. Holding the payload against gravity
Reduction of acceleration and speed means less energy consumption for 1), but, as it creates larger
cycle-times, it means more energy consumption for 2). Therefore a higher $ECO_LEVEL does not
always imply a reduction of the overall consumed energy. It is therefore advised to increase the
$ECO_LEVEL step by step to get optimized results.
When simulation is reset, energy saving mode ($ECO_LEVEL) is automatically deactivated.
Class discussion continued

• # CycleStart
• Call r1pounce;
• If $OUT[10] AND NOT $OUT[20] Then
• Call r1style1;
• EndIf
• If $OUT[20] AND NOT $OUT[10] Then
• Call r1style1;
• EndIf
• # CycleEnd
Nachi-Slim — Beyond signals and send/wait commands

commands:
• Free Text

as free text:

ESRC OLP commands
the rotating frame)
the rotating frame)
in this course).

Lesson
OLP OLP commands
commands
• Constants
• Integer variables
o V1% = 10
o V%[1] = 10
o V2%=V1%+1
• Real variables
o V1!=2.5
o V![1]=2.5
o V2!=V1!*103.45
• String variables
o V1$="Execution state"
o V$[1]="Execution state"
• DELAY <time>
• Simple sentence IF
o IF <condition>THEN *<label name>
o IF <condition>THEN *<label name> ELSE *<label name>
• Compound sentence IF
o IF <condition> THEN
o [ELSEIF <condition> THEN]
o [ELSE]
o ENDIF
• SWITCH command
o SWITCH
o CASE
o BREAK
o CASE
o BREAK
o ENDS

ESRC OLP commands
• WHILE command
o WHILE <condition>
o ENDW
• FOR command
o FOR <VAR=init val.> TO <end value> STEP <incr>
o NEXT
o STOP
o END
Class discussion continued for Nachi

• # CycleStart
• Call r1pounce
• If O10 AND NOT O20 Then
• Call r1style1
• EndIf
• If O20 AND NOT O10 Then
• Call r1style1
• EndIf
• # CycleEnd
NC-Code — Beyond signals and send/wait commands

commands:
• Free Text
Class discussion continued for NC


Lesson
OLP OLP commands
commands
• # CycleStart
• #EndIf
• # EndIf
• # CycleEnd
Panasonic-Csr - Beyond signals and send/wait commands

commands:
• Free Text
in this course).
• SET, <variable>, <value>— Set a robot signal to a value. For example

o SET, o1#4, 1
• CLEAR, <variable> — Set a robot signal to 0. For example

o CLEAR, o1#4
o All LL variables are set to 0

CLEAR, LL#ALL
• DELAY, <time> — Wait for an amount of time to pass. The time can range between 0.01 and
99.99 seconds. For example:
o CALL SYNC
• JUMP, <Label> — For example:

ESRC OLP commands
o L002:
RESET(1)
JUMP, L002
• RET Simulated as return. For example:

o RET
• STOP For example:

o STOP
• IF <Value 1>, <Condition>, <Value 2>, <Execution statement 1>, <Execution statement 2>
— For example:
o If signal is true then jump to L002, else jump to L003
If i1#7, =, ON, JUMP, L001, JUMP, L002
• ADD or SUB or MUL or DIV or MOD, <variable>, <value> — Add, subtract, multiply, divide, and
remainder. For example:
o Add 5 to the integer signal
Add, i4#7, 5
o Subtract 5 from the integer signal

Sub, i4#7, 5
• INC or DEC, <variable> — Increment or decrement a variable. For example:

o INC, i4#7
o DEC, i4#7
• Logic functions:And Not or Or or Xor, <variable 1>, variable 2>

These are bitwise, not Boolean, operations.
Reis-Robstar — Beyond signals and send/wait commands

commands:
• Free Text
• I/O – WRITE_BIT, WAIT_BIT, and WAIT
• Control Flow – CALL, PROGRAM, LABEL, BRANCH, TEST_BIT, TEST #VARIABLE, TEST
#INPUT, and TEST #MARKER
• Arithmetics – COPY, ADD, SUB, MUL, DEIV, MODULO, NEG, and ABS_VALUE

Lesson
OLP OLP commands
commands

as free text:
the rotating frame)
the rotating frame)

ESRC OLP commands
in this course).
• Reis coordinates
o Translation: X,Y,Z
o Rotation:
A corresponds to Process Simulate RZ
B corresponds to Process Simulate RY
C corresponds to Process Simulate RX
• Comments with "C" and lines starting with "\" should be ignored during simulation.
• WAIT
o For example: WAIT [s]:1.50
o Simulated as a 1.5 second delay
• CALL
o Ex1: CALL Name:”SubProgName”
o Ex2: CALL Name:”S:/Prog/SubProgName”
o Simulated as (in priority order):

■ call to macro <SubProgName>
■ call to operation <SubProgName>
■ call to operation <Robot><SubProgName>
■ call to operation <Robot>_<SubProgName>
■ call to robotic program <SubProgName>
■ call to robotic program <Robot><SubProgName>
■ call to robotic program <Robot>_<SubProgName>
• PROGRAM
o For example: PROGRAM Name:"File1"
o Simulated similar to CALL command
• LABEL
o For example: Label "Text1"
o Simulated as storing a label name

Lesson
OLP OLP commands
commands
• BRANCH
o For example: BRANCH Label:"Text1"
o Simulated as an unconditional jump to label Text1
• TEST_BIT
o For example: TEST_BIT #INPUT,#=1,Byte:255,Bit_No:7,Label:"Text1"
o Simulated as: if input signal “i255_7” == 1, then Jump to label “Text1”.
• TEST #VARIABLE
o For example: TEST #VARIABLE,Op_1:Var1,#=,Byte:255,Label:"Text1"
o Simulated as: if (Var1 == 255), then jump to label “Text1”
• TEST #INPUT / #MARKER

o For example: TEST #MARKER,Op_1:5,#>=,Byte:100,Label:"Text1"
o Simulated by 8 signals m5_0, m5_2 ...value addition: if (m5_0 + 2*m5_1 + 4*m5_2 + …+

2^7*m5_7) >= 100, then jump to label “Text1”
• COPY
o For example: COPY Source:124,Dest_Var:Index
o Simulated as: Index = 124
• ADD
o For example: ADD Op_1:Var1,Dest_Var:Var2
o Simulated as: Var2 = Var2 + Var1
• SUB
o For example: SUB Op_1:Var1,Dest_Var:Var2
o Simulated as: Var2 = Var2 - Var1
• MUL
o For example: MUL Op_1:Var1,Dest_Var:Var2
o Simulated as: Var2 = Var2 * Var1
• DIV
o For example: DIV Op_1:Var1,Dest_Var:Var2
o Simulated as: Var2 = Var2 / Var1
• MODULO
o For example: MODULO Op_1:Var1,Dest_Var:Var2

ESRC OLP commands
o Simulated as: Var2 = Var2 % Var1
• NEG
o For example: NEG Variable:Var1
o Simulated as: Var1 = -Var1
• ABS_VALUE
o For example: ABS_VALUE Variable:Var1
o Simulated as: Var1 = |Var1|

• # CycleStart
• Call name: “r1pounce”
• If o10_0 AND NOT o20_0 Then
• Call name: “r1style1”
• EndIf
• If o20_0 AND NOT o10_0 Then
• Call name: “r1style1”
• EndIf
• # CycleEnd
Staubli-Val — Beyond signals and send/wait commands

commands:
• Free Text

Any basic OLP command described earlier, including the following ones which must be entered
as free text:
• # MoveRelBase [<RefLoc>] <X> <Y> <Z> [<RX> <RY> <RZ>]

Lesson
OLP OLP commands
commands
o Move the robot with an offset expressed in location object frame coordinates system.
o The offset is relative to: RefLoc if the optional <RefLoc> parameter is specified (RefLoc
o The optional rotational part of the offset are rotation angles in degrees expressed in location
object frame coordinate system (rotations are performed one after the other in the rotating
frame)
o The current location motion type, speed, zone are used to move to the offset position
• # MoveJRelBase [<RefLoc>] <X> <Y> <Z> [<RX> <RY> <RZ>] — Same as # MoveRelBase,
• # MoveLRelBase [<RefLoc>] <X> <Y> <Z> [<RX> <RY> <RZ>] — Same as # MoveRelBase,
• # MoveRelTool [<RefLoc>] <X> <Y> <Z> [<RX> <RY> <RZ>]
o Move the robot with an offset expressed in location self coordinates system.
o The offset is relative to: RefLoc if the optional <RefLoc> parameter is specified (RefLoc
o The optional rotational part of the offset are rotation angles in degrees expressed in reference
location self coordinate system (rotations are performed one after the other in the rotating
frame)
o The current location motion type, speed, zone are used to move to the offset position.
• # MoveJRelTool [<RefLoc>] <X> <Y> <Z> [<RX> <RY> <RZ>] — Same as # MoveRelTool, except
that motion type to the offset position is forced toJoint
• # MoveLRelTool [<RefLoc>] <X> <Y> <Z> [<RX> <RY> <RZ>] — Same as # MoveRelTool, except
that motion type to the offset position is forced to linear.
Motion Parameters: By default, the current modal motion parameters (speed, zone, tool,
etc.) is used. It is also possible to define explicit motion parameters with following syntax:
# MoveRelBase <X> <Y> <Z> [Speed Data = v500] [Zone Data = z100]. These explicit
motion parameters is inherited on any subsequent relative motions
in this course).
• Constants

ESRC OLP commands
• Boolean variables, for example:

bool test1
test1 = true
• Numeric variables, for example:

num test1
test1 = 10.12
• delay (num seconds) — Puts the current task on hold for seconds, for example:
delay(20)
• wait (<bool condition>) — Puts the current task on hold until condition is true.
• watch (<bool condition>, <num seconds>) — Puts the current task on hold until condition is true
or seconds have elapsed.
• call program([parameter1][,parameter2]) — Runs the specified program with the specified

parameters, for example:
call Op2(i,j)
• while <bool condition>

<instructions>
endWhile
for example:
i=0
while (k<10)
i=i+1
endWhile
• do
<instructions>
until <bool condition>
for example:
i=0
do
i=i+1
until (i==10)
• for <num counter> = <num beginning> to <num end> [step <num step>]
<instructions>
endFor

Lesson
OLP OLP commands
commands
for example:
for i= 0 to 10 step 1
test1 = test1 +I
endFor
• if <bool condition>
<instructions>
[else
<instructions>]
endIf
for example:
if i== 0
test1 = 10
else
test1=20
endIf
• switch <num selection>

case <num case1> [, <num case2>]
<instructions1-2>
break
[case <num case3> [, <num case4>]
<instructions3-4>
break ]
[default
<Default Instructions>
break ]
endSwitch
for example:
option = 273
switch option
case 271
a = 10
break
case 272

ESRC OLP commands
a = 20
break
case 273, 274, 275, 276, 277, 278
a = 120
break
default
a =0
break
endSwitch
Trallfa-Robtalk — Beyond signals and send/wait commands

commands:
• Free Text
• Robtalk menu
o Gun/Brush pick
o Move Offs
in this course).
• Block Instructions
o JUMP num
o LABEL num
o IF condition
instructions
o IF num condition THEN ... ELSE num ... ENDIF num

Conditions
■ INPUT num ON/OFF
■ REG num op expression
■ VAR num op expression

Lesson
OLP OLP commands
commands
or any combination of the above, such as: INPUT 1 ON AND INPUT 2 OFF OBJPOS [XYZ]
[<>] expression
when used in association with a JUMP action, this condition is simulated as tracking the
current location
Operators
■ <
■ >
■ =
■ #
o CALL SUB num - as call to operation <MainProgramName>_SUB<Num>
o CALL PATH num - as call to robotic operation <MainProgramName>_PATH<Num>
o CALL PROG Name - simulated as (in priority order):

■ call to robot module procedure <Name>
■ call to macro <Name>
■ call to operation <Name>
■ call to operation <Robot><Name>
■ call to operation <Robot>_<Name>
■ call to robotic program <Name>
■ call to robotic program <Robot><Name>
■ call to robotic program <Robot>_<Name>
INTERNAL_HALT
• Other instructions
o MOVE OFFS num — Cannot execute if a MOV OFFs num ;@@ [ x, y, z, a, b, c, r] was not
executed first.
o MOVE OFFS num ;@@ [ x, y, z, a, b, c, r] with r is an external axis (rail)
o LET VAR num = expression
o LET REG num = expression
o WAIT OBJPOS X|Y|Z >|< value - as a wait for specific conveyor position
o WAIT TIME duration - as a delay of duration ms

ESRC OLP commands
o PARAM VEL REG num — as setting modal linear speed to registry value
• Gun/ Brush instructions

o BRUSH num condition
o BRUSH num
o GUN ON|OFF condition
o GUN ON|OFF
Limitations:
• Following commands are not supported in simulation:
o #include filename
o REL
o MOVE NEGOFFS
o MOVE POSREG
o LET POSREG num = position expression
o INC POSREG num [XYZ] BY expression

except:
o Gun/Brush instructions with condition
o Wait conveyor while tracking (IF OBJPOS)
Universal-URScript - Beyond signals and send/wait commands

commands:
• Free Text
in this course).
• Sleep(t) —Wait for certain amount of seconds to pass. For example:

Lesson
OLP OLP commands
commands
o Sleep(10)
• Set_flag <num> — Output F[<num] signal or variable assignment. For example:

o Set_flag(2)
• Get_flag <num> — F[<num] is read. For example:

o Get_flag(2)
• While(condition) — For example:

o
sync()
end
• IF <Condition> Elif <condition> … Else … End, Execution statement 1>, <Execution statement
2>
o
If a > 3:
a = a + 1
elif b < 7:
b = b * a
else:
a = a + b
end
end
• Halt For example:

o Halt
• Return Simulated as return. For example:

o Return
• <function>(parameter1, paramter2) — Call a function with parameters. For example:

o result = add(1,4)
No switch/case instruction is supported
Yaskawa-Inform — Beyond signals and send/wait commands

commands:
• Free Text
Yaskawa Inform Specifics:

ESRC OLP commands
• Download is using Program Template mechanism
Free text commands:

Any basic OLP command described earlier, including the following ones which must be entered
as free text:
• Supported Operating Instructions
o SET
o CLEAR
o INC
o DEC
o ADD/SUB
o MUL/DIV
o AND/OR/NOT/XOR
• Supported Control Instructions

o JUMP *<LabelNum>, as
■ jump label *<LabelNum>
o JUMP LABEL:<LabelVar>, as
■ jump to *<LabelNum>, where <LabelNum> is the numerical value of <LabelVar>
o JUMP JOB:<Name>, as
■ call to <Name> (see CALL below for more information)
o JUMP *<LabelNum> IF <Condition>
o JUMP LABEL:<LabelVar> IF <Condition>
o JUMP JOB:<Name> IF <Condition>

■ same as above, only if condition is TRUE
o CALL Job:<Name>, simulated, in priority order, as:

■ call to macro <Name>
■ call to operation <Name>
■ call to operation <Robot><Name>
■ call to operation <Robot>_<Name>
■ call to robotic program <Name>

Lesson
OLP OLP commands
commands
■ call to robotic program <Robot><Name>
■ call to robotic program <Robot>_<Name>
o CALL Job:<Name> IF <Condition>

■ Same as above, only if condition is TRUE
o CALL <VariableName> (IF <Condition>) or CALL <SignalName> (IF <Condition>)

■ Same as above, where the called job name is the numerical value of <VariableName>
or <SignalName>
o TIMER T=<Expression>
■ Same as WaitTime
<Expression>
If <Expression> is a numerical value, the unit is second. If the <Expression> is

a variable, the unit is 1/100 of a second.
o RET <Expression>
■ Same as return with <Expression> value
CWAIT and NWAIT: These commands are understood but not simulated.
• Line Tracking specific commands

o SYSTART CV#(<conveyor number>) STP=<pos>
o SYEND CV#(<conveyor number>)
Limitations:
• In the case of JUMP JOB:<job name> UF#(<user frame no>) the UF# part is not simulated
• Spline motions are simulated as linear motions (both with RCS and MOP simulation).

If the RCS in simulation is disconnected, a MOP simulation replaces the RRS based simulation.
• Speed
o SpeedType = VJ
o speed : joint speed in %
o SpeedType = V

ESRC OLP commands
o speed : Cartesian position speed
o SpeedType = VR
o speed : Cartesian orientation speed
• Zone
o FlyLevel
o CONT : nodecel
o PL0: fine
o PL1: medium
o PL2–PL8: coarse
• # CycleStart
• Call r1pounce
• Call r1style1 If OUT#(10) AND NOT OUT#(20)
• Call r1style1 If OUT#(20) AND NOT OUT#(20)
• # CycleEnd

Lesson
OLP OLP commands
commands
Robot Program Viewer

Purpose
In this lesson, you learn how to use the Robot Program Viewer.
Objectives

• Use the Robot Program Viewer.
Robot Program Viewer basics

The Robot Program Viewer displays the commands sent to the robot controller when simulating
robotic operations.
You use it to view robotic programs or operations you have designed in Process Simulate after they
have been compiled and displayed in the syntax of their target robot controller. The viewer may
include collapsible blocks of code and colored keywords/regions for ease of debugging.
Support is provided for all available controllers.

If necessary, you can open multiple instances of the Robot Program Viewer to view multiple programs
of a single robot or of different robots simultaneously.

ESRC OLP commands
If there are errors that would cause the download to fail, the relevant command is marked in the
program panel (upper panel) with a vertical red line and details of the error are provided in the
notifications panel (lower panel). For example, if the robot speed has been omitted on a location, it is
likely that when downloading the program to the robot, a critical failure will occur and the download
will abort. After making the required changes in your program, you can reload it in the Robot
Program Viewer to confirm the improvement (and prevent download failures).
You can use this tool to:
• Follow highlighted motions/commands in the program panel as their execution is simulated.
• View notifications created by the (simulated) download process. There are three categories:
o Notes - General information.
o Warnings - Errors that will not cause the download to abort.
o Errors - Critical errors that will cause the download process to fail.
You cannot edit programs in the RobotProgramViewer.
Messages created by downloading a specific motion instruction or OLP command display the
serial number of the relevant instruction/command program line in the Line column. General
messages in the download process display a dash ("-") in the Line column.

Lesson
OLP OLP commands
commands
Use the viewer

To use the Robot Program Viewer:
1. From the ribbon, choose Home tab→Viewers group→Robot Program Viewer .

You can open multiple Robot Program Viewer dialog boxes.
This allows you to maintain a view of several paths from the same robot or from different robots to
be able to better debug complex scenarios that include several paths and robots.
2. If you had previously selected a program/operation, this is automatically loaded in the Robot
Program Viewer when you it launches. Otherwise, select a robotic program in the Robotic
Program Inventory or an operation in the Operation Tree.
3. Click Add .
The currently selected program/operation is added to the Robot Program Viewer. Process
Simulate converts the operation and displays it in the syntax of the controller of the robot to which
the program is assigned.
In the Program panel, motion instructions/commands with download errors are marked with
vertical red lines, warnings with yellow lines, and messages with blue lines.
4. You can do any of the following:

• Double-click a motion instruction or OLP command marked with a colored vertical line to view
only the notifications associated with that command in the lower panel.
• Double-click a notification in the lower panel to jump to the relevant line in the program panel.

ESRC OLP commands
• Click a notification tab to hide its contents. This enables you to concentrate on the other
notifications.
5. You can set breakpoints on locations, OLP commands (one per command) and end of operations.
Left-click in the margin of the viewer to insert breakpoints to pause the simulation at those points.
A red dot in the margin indicates the inserted breakpoint. Right-click the breakpoint to disable it
(white dot with red rim) or delete it. Right-click a disabled breakpoint to make it active again.
When you run the simulation with the Robot Program Viewer dialog box open, it stops at
each breakpoint to enable you to analyze the program for debugging purposes. Continue the
simulation the same way you would as after pressing the Pause button.
If you close the viewer, the simulation runs continuously without stopping at breakpoints, but they
remain in place for when you re-open the viewer, for the duration of the session. Once you close
the study or exit the application, the breakpoints are not persisted.
For complex OLP commands, it is not possible to set breakpoints on their nested
commands.

Lesson
OLP OLP commands
commands
If you add a breakpoint while displaying the same code in more than one viewer,
the breakpoint appears in all the viewers.
6. Optionally, set a robotic operation as the current operation.

When simulating the program in the Sequence Editor, the Robot Program Viewer dialog box
steps through the program, highlights the relevant line in the program, and displays a yellow
arrow to the left of the currently executing command.
Activities
In the Robot Program Viewer section, do the following activities:
• Use the Robot Program Viewer

ESRC OLP commands
Summary
• How use the standard OLP commands of emulated robot specific controllers (ESRC).
• Various commands supported in simulation on all controllers which must be entered as free text.
• The list of the supported OLP commands for several of the robot controllers.
• Compared the various methods available in Process Simulate.

Lesson 6: Calibration
Purpose
To describe how to use the Process Simulate calibration tools.
Objectives

• An overview of the concepts of calibration.
• How to create a calibration and use it to calibrate the position of a path relative to a robot.

Lesson
Lesson 6: 6: Calibration
Calibration
Calibration introduction
Purpose
In this topic, you get an overview of the concepts of calibration.
Objectives

• Use calibration within this system.
• Know what calibration is.
• Create and use calibration sets.
• View and use calibration results.
Calibration basics
In general, Process Simulate calibration attempts to:
• Eliminate and/or compensate for any differences that may exist between the Process Simulate
and actual studies, in order to ensure precise download of robot-program destinations from
Process Simulate to the actual robot.
• Enable downloading a robot program from an Process Simulate study to several robot studies on
the factory floor which are theoretically identical but in practice have differences in layout and
component performance.
• Enable transferring on-line teach programs from one robot study to another study that is
theoretically identical, without requiring manual corrections of robot destinations.
What is calibration?
Calibration is the process of bringing the modeled Process Simulate study into conformity with the
real-world study. This is done by creating a filter which describes how the real-world study differs
from the Process Simulate. This filter is called a "calibration set".
Calibration is needed by those users who require high accuracy in the downloaded program locations,
or in programs with a large number of locations, in order to avoid manual touch ups. Calibration
would not be required in a program with few locations needing high accuracy; manual touch ups
in this case would be more efficient.
The calibration process involves measuring the real study in some manner, and bringing that
information into Process Simulate. The robot itself is the primary method of study measurement.
However, external systems such as theodolites can be used to bring XYZ coordinate data into
Process Simulate.
The Process Simulate Calibration command, located on the Robot tab of the ribbon, is used to
build the calibration set to improve the accuracy of the downloaded program. In this class, you see
how to use these tools to achieve a good OLP result.

Calibration
Calibration sets
After creating objects in Process Simulate, it is possible to measure the equivalent real objects on the
shop floor. In this case, you may wish to calibrate (transform) the source points to be as close as
possible to the destination points, as measured and stored in Process Simulate. The Calibration
command accepts multiple pairs of points (each pair consists of a source point and an destination
point) and uses an algorithm to adjust the position and orientation of the source pairs so that the
average distance between the sources and destinations is as small as possible. The algorithm
calculates the optimum transformation for all the pairs - there is an improvement for most of the
pairs but one or two may not be improved. Siemens recommends using not more than ten pairs to
maintain system performance.
After adding all the desired pairs, the system calculates the transformation and you can apply it if
you are satisfied. You can Apply more transformations and Unapply them. At the end of your
session, you can store the calibration set.
There must be at least three calibration pairs to enable calibration calculation (because three pairs
define a plane).

Lesson
Calibration
The user can produce more than one calibration set for the same Process Simulate study, in order to
account for more than one actual study. Each set has a unique identity. Any set can be used when a
robot program is downloaded. In addition, a program can be uploaded from the actual robot study with
the use of one set, and then can be downloaded to another actual study with the use of another set.
The math behind calibration

Calibration uses the root mean square to calculate the adjustment factor to be applied on the
locations in the path.
In mathematics, root mean square (abbreviated RMS or rms) is a statistical measure of the magnitude
of a varying quantity. It can be calculated for a series of discrete values or for a continuously varying
function. The name comes from the fact that it is the square root of the mean of the squares of the
values. It is a power mean with the power t = 2.
The rms for a collection of N values is:
and the corresponding formula for a continuous function f(t) defined over the interval
is:
Calibration results
The calibration calculation runs in real time, updating the Calibration Results automatically when
new calibration pairs are added, removed, activated, or deactivated. The system displays the
following results.
• dX, dY, and dZ - Displays the transformation distance results on the X, Y, and Z axes.
• Rx, Ry, and Rz - Displays the transformation rotation results around the X, Y, and Z axes.
• Maximum distance - Displays the distance between a transformed object and the original object
for the calibration pair with the largest average distance.
• Average distance - Displays the average distance between all the transformed objects and
the original objects.

Calibration
• RMS - Displays the RMS (root mean square) distance between all the transformed objects
and the original ones.

Lesson
Calibration
Robot to part calibration

Purpose
In this topic, you learn how to create a calibration and use it to calibrate the position of a path relative
to a robot.
Objectives

• Perform a basic robot to part calibration.
Business process
Robot to part calibration basics

Study calibration is used to calculate the actual location of the robot relative to the workpiece.
What you need to do is independently create a path on the real robot and the Process Simulate robot
that includes the robot touching the same three points on the workpiece. Then you would upload the
path from the real robot and use the calibration window to reconcile them. In doing so, you create a
calibration set that can act as a filter to adjust the downloaded path from Process Simulate to better
fit to environment of the real robot.
Calibration Pairs are used to effect the RMS calculation by means of pairs of download and upload
locations: locations placed in the study are downloaded to the actual robot they are corrected
according to the actual, relative placement of the robot and workpiece, and the corrected locations
are uploaded back to the Process Simulate study.
The Calibration command is used to perform the RMS calculation based on user-supplied data,
and then display the results of the calculation and apply the results to a chosen component as a
transformation to the location of that component.

Calibration
Calibration steps overview

1. In Process Simulate, create (for example three) locations in a path to define the workpiece
calibration. These points are typically on known common “landmarks” such as point on the
fixture blocks.
2. Verify the locations in the path can be reached by the robot.
3. On the real robot, teach the same three locations into a new program.
4. Upload the program from the real robot into Process Simulate.
5. Using the Process Simulate Calibration dialog box, create a calibration set with these two
paths as input.
6. Apply the calibration set to the desired robotic path created in Process Simulate to properly
locate it relative to the robot.
7. Verify motion, cycle, and configuration location information through simulation.
8. Download the desired robotic path to the real robot.
Activities
In the Robot to part calibration section, do the following activities:
• Creating a calibration set
• Using a calibration set

Lesson
Calibration
Summary
• An overview of the concepts of calibration.
• How to create a calibration and use it to calibrate the position of a path relative to a robot.

Lesson 7: OLP command customization
Purpose
To describe how to do OLP command XML customization.
Objectives

• Got an overview of the capabilities in this area.
• How to create an enhanced OLP command.
• How to create a custom command and macro

Lesson
Lesson 7: 7: OLP OLP command
command customization
customization
Overview of customizing robot controllers

Purpose
In this topic, you get an overview of the basic areas of the robot controller interface customization
XML file.
Objectives

• Know the customizable user interface's layers and dialog standards.
• Create and use a OLP command customization file.
Business process
OLP command customization basics

Customized OLP Customized Motion
Controller Robot Path Template
Configuration Configuration
ABB Yes Yes Yes
ABB Volvo (Volvo only) Yes No Yes
Cloos Yes No Yes
Comau Yes Yes Yes
Comau Volvo (Volvo
Yes No Yes
only)
Default Yes Yes Yes
Denso
Duerr Yes No Yes
Epson Yes No Yes
Fanuc F100iA (CFLEX) Yes No Yes
Fanuc Yes Yes Yes
Fanuc Japan (Japan
Yes No Yes
customers only)

OLP command customization
Fanuc VW (VW only) Yes No Yes
IGM Yes Yes Yes

Kawasaki Yes No Yes
Kuka Yes Yes Yes
Kuka BMW (BMW only) Yes No Yes
Kuka Volvo (Volvo only) Yes No Yes
Kuka VKRC (VW only) Yes No Yes
Nachi Yes Yes Yes
NC Code Yes Yes Yes
NC Code BMW (BMW
Yes No Yes
only
NC Code Danobat
Yes No Yes
(Danobat only)
NC Code Riveting Yes Yes Yes
NC Code Riveting
Yes No Yes
Embraer (Embraer only)
Panasonic
Reis Yes Yes Yes
Staubli Yes No Yes
(ABB) Trallfa Yes No Yes
Universal Yes (TBD) Yes
Yaskawa (Motoman) Yes No Yes
Siemens PLM Software, together with its customers, has invested a lot of effort, based on broad
knowledge gained over many years, to offer advanced OLP programming capabilities. The availability
of the Teach Pendants, and in more recent versions, the greater use of the Path Editor, provides your
users a much greater scope of functionality than in the past. Nevertheless, there is always room for
user customization and the flexible application of customer "flavors".
Open System Complex User Requirements:
As the environment becomes ever more complex, the only solution that can serve users' needs is an
open solution. This is due to the following constraints:
• There are very few robotic program specialists.
• Multi-variant production requires complex synchronization.

Lesson
customization
• The system must be flexible enough to add commands which utilize correct syntax but are
still easy to use.
• No API or C/C++ programming.
Use of ESRC Enhances Verification Capabilities:

ESRC technology allows simulation and verification of many of the commands. The customizable
User Interface, based on ESRC, is designed to take advantage of these capabilities.
The customizable user interface's layers

In Process Simulate, you use XML files to support customization of OLP commands and motion
commands ... WYSIWYG. Here are the four primary sections of the OLP configuration file:
• The first layer, the User Interface Layer, defines the dialog that can be opened from within the
Teach Pendant during the session.
• The subsequent Simulation Layer includes the instructions as they have to be executed during
the simulation (CEE type). Define the behavior using the parameters and controls in the User
Interface dialog.
• The Download Layer is the last and probably most important of the three layers. Here users
define the actual controller specific commands from a form in the dialog from the User Interface
layer.
• Finally there are Upload Capabilities to reuse the definition and present the data in a form
to the user.
Automatic Generation of OLP Commands Dialogs – the User Interface Layer:

The entire customization is done by the user in a configuration file. The exact order of elements and
the obligatory and optional elements can be found in the example later in this course.
The system automatically generates an OLP command dialog with the appropriate information
from the configuration file.
Simulation and Download Layers:

Parameters used in the User Interface (UI) dialog are then used to generate the needed OLP strings
for the simulation needs as well as for the download to the real controller.
It is possible to define multi-line commands, meaning several lines of actual OLP code.
Changes Without Re-launching Process Simulate
When making changes in the configuration file, there is no need to close the Process Simulate
application. A simply opening the Customized Command XML Checker command loads
the latest configuration files. (Closing the Teach Pendant and re-opening it also loads the latest
configuration files).
Dialog standards
All OLP command dialogs are generated with the same layout.
Dialog Size:
The size of the dialog should be automatically calculated according to configuration file data.
Custom OLP Command Example:
This is not an exercise. A detailed exercise on this topic can be found later in this course.
• With the desired robot controller set for the assigned robot: Right-click a robotic operation and
• From the Teach Pendant, click Add.
• Slide across Customized and notice the two custom commands.
• Look at the Gripper Instructions command.
• Look at the Collision command.

Lesson
customization
Custom Motion Example:
This is not an exercise. A detailed exercise on this topic can be found later in this course.
• With the desired robot controller set for the assigned robot: Add the path to the Path Editor (and
the Customized Motion, Customized Debug, and Process type Columns).
• Open the Teach Pendant dialog box.
• Look at the custom user interface results in the bottom half of the Teach Pendant dialog box.


Lesson
customization
Custom OLP commands XML file

Purpose
In this topic, you get an introduction to the customized OLP commands .XML file.
Objectives

• Know the basic sections of an OLP command customization OLP file.
Customized XML basics
The rest of this section of the course deals with OLP command customization. Later in this
course you tackle motion command customization and path template customization.
For each controller there may be several OLP configuration, motion configuration, and
path template configuration files. By default, the OLP configuration files are located in the
OlpConfiguration subfolder (C:\Program Files\Tecnomatix\eMPower\Robotics\OLP\<Controller
name>\OlpConfiguration. However, this can be changed by specifying a CustomizedPath
in the rrs.xml file for the version of the controller used like the training course (for example
N:\sysroot\OLP_config_files\<Controller name>\OlpConfiguration).
Users can assign any names they want to the XML configuration files.
You can use the CustomizedPath in the rrs.xml file to change the location of the OlpConfiguration
folder, like was done for the training.
OLP configuration file basic elements

In this section you learn about the basic elements of the OLP configuration XML file.
The XML file must start and end with the RobotController element. This tab contains three other
elements which represent the three main parts of the file:
• RobotController - This element must occur only once and be the root. It contains these attributes:
o The Name must appear in the RobotController element. It should be the robot controller as
specified in the rrs.xml file. Example value: Fanuc-Rj
o Version (of the controller) can also be specified
• RoboticParams
• OlpCommands
• OlpDialogs
Here is the basic skeleton:


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customization
Robotic parameters section of the file

Purpose
In this topic, you learn how to setup the robotic parameters section of the file.
Objectives
• Understand the robotic params section of the file.
• Define a list of value.
• See several TxObject value type examples.
Robotic params dection basics

This element includes all the robotic parameters (Param elements) which are used by customized
OLP/Motion commands. Process Simulate reads this section from within all the relevant XML files
(per controller per version) into one cache which is used by all customized commands. Therefore it is
necessary for each robotic parameter name to be unique.
It is used to define the parameters (for example the parameter’s type, list of values, min, max
values, etc.)
Basic Description:
Each parameter (Param element) should have a name, a type and (optionally) a value. It contains
these attributes:
• Name - This element determines the name of the parameters
• ValueType - This element must occur only once. Values are either:
o Int – a number
o Double – a number
o String – text
o TxObject - Tecnomatix objects, such as robot gun, etc.
• MaxVal – for numbers only (double and int)
• MinVal – for numbers only (double and int)

• Default - Example value: “2”
• Multiline – for strings only
Defining a list of values

• ComboDef – Defines a list of values. Should contain at least one ElmDef.
• ElmDef – defines of the values of the list
More on TxObject ValueTypes

TxObjects must be only:
• compound,
• part_instance,
• part_physical_appearance,
• part_prototype_assignment,
• compound_resource,
• resource_instance,
• resource_prototype_assignment and any physical object in a component scope.
TxObject selection filtering options:

• Allow any object to be selected

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customization
• Allow only specific pick types using the PickTypes element
• Allow only filtered objects from a list using the ShowList attribute of the PickTypes tab
• Allow only objects based on the type using the TxValidatorType attribute of the Param tab.

OLP commands section of the file

Purpose
In this topic, you learn how to setup the OLP commands section of the file.
Objectives
• Understand the OLP commands section of the file.
• Understand the layers.
OLP commands section basics

This element includes all the OLP commands (Command elements) which are used by customized
OLP commands. The Process Simulate application reads this section from all relevant XML files (per
controller per version) into one cache which is used by all customized commands. Therefore, each
OLP command name must be unique.
• Command – This element represents one customized OLP command and it contains the
command name and parameters names. Contains the RoboticParamRef and Layers elements.
Attributes for this element:
o Name - Example value: “Do Something”
• RoboticParamRef – Contains the Param elements used in the command.
• Layers - This element is optional, but can occur only once. This element contains the primary
layers: UILayer, SimulationLayer, and DownloadLayer.
Layers
The Three Layers:
• UILayer – This element represents one customized OLP command in the Teach Pendant or
Path Editor. It is optional, but it can occur only once. It contains the Lines (and items) for the
user interface to be shown.
• SimulationLayer - This element is optional, but can occur only once. It defines how the
customized OLP command is simulated. During simulation, when the controller encounters a
customized OLP Command, replaces it with its simulation layer and interprets this simulation
layer instead. Inside the simulation layer, users can write any elementary command (one per
<line> ... </line> section) that is understood by the controller:
o "default controller" standard commands (ex : # SendSignal sig1, # WaitTime 2, # Blank
PaintFanEntity,....)
o native controller syntax supported by the controller simulation (ex : IF var1 = 3 THEN, call to
macros, call to robot module procedure,....)
o Inside the simulation layer, it is fully permissible to mix "default controller" commands with
commands in native controller syntax.

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customization
• DownloadLayer – It defines what is output when the program is downloaded. It has the same
capabilities as UILayer and supports several lines. This element is optional, but can occur only
once.
The content of a layer:

• Line - Defines a line break. It contains Item elements.
• Item - Only allowed below Line elements. Contains the Type attribute as well as either a
parameter name (when the type is parameter) or a constant. Attributes for this element:
o Type – Values are either const, optional, or parameter, or dynamicParameter

OLP dialogs section of the file
Purpose
In this topic, you learn how to use the OLP dialogs section of the file.
Objectives
• Use OLP command XML structure.
• Create a basic OLP command file.
OLP dialogs section basics

The OlpDialogs element contains a list of dialogs, each of which allows you to create one or more
OLP commands. It contains one or more Dialog elements.
• Dialog - Attributes for this element:
o Title - Shows the title of the dialog in the Teach Pendant. Each ‘|’ is a new subdirectory. For
example: Title="MyTest|Customized|ChooseLocation"
o Description - A short description inside the dialog for the user. For example:
Description=”Please select a location”
o Icon – The icon of the dialog. For example: Icon=”gripperOp.ico”

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customization
These icons should be placed in the .\eMPower\Robotics\Olp\CustomizedIcons

folder (or in a folder relative to this folder, such as a sub-folder). This folder is used
by all controllers and custom dialogs. You can use the CustomizedPath in the
rrs.xml file to change the location of the CustomizedIcons folder, like was done
for the training.
• OlpCommandRef – Contains the OlpCommand element.
• OlpCommand – References Command elements from the OlpCommands element.
OLP command XML structure example

<RobotController Name=””>
<RoboticParams>
<Param Name=”” ValueType=”” Default=””>
<ComboDef>
<ElmDef>xxx<ElmDef/>
</ComboDef>
</Param>
</RoboticParams>
<OlpCommands>
<Command Name=””>
<RoboticParamRef>
<Param>xxx</Param>

</RoboticParamRef>
<Layers>
<UILayer>
<Line>
<Item Type="">xxx</Item>
</Line>
</UILayer>
<SimulationLayer>
<Line>
</Line>
</SimulationLayer>
<DownloadLayer>
<Line>
</Line>
</DownloadLayer>
</Layers>
</Command>
</OLPCommands>
<OLPDialogs>
<Dialog Title="" Description="">
<OlpCommandRef>
<OlpCommand>xxx</Param>
</ OlpCommandRef >
</Dialog>
</OLPDialogs>
</RobotController>

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customization
Signal example
Purpose
In this topic, you learn how to create custom OLP commands, for various robot controllers, for send
signal and wait signal.
Recall from the intermediate robotics training:

• A PLC output signal is connected to a robot input such as a digital input (DI).
• A PLC input signal is connected to a robot output such as a digital output (DO).
• In Process Simulate, you enter the signals from the perspective of the PLC, so the robot waits for
output signals (DI) and sends input signals (DO).
Objectives
• Create custom OLP commands to send signals and wait for signals in the robot specific language.
Send signal and wait signal basics

In this lesson you create a custom command for send signal and wait signal in the robot controller’s
specific language (for example it is downloadable).
The below examples assume that you have a PLC input and robot signal defined (DO) and
a PLC output and robot signal defined (DI). In the activity, you use the signals created in an
earlier activity in this advanced robotics training.
For ABB-Rapid:
• Signals names: di1, do2
• Send Signal: SetDO do2, 1;
• Wait Signal: WaitDI di1, 1;
For Cloos-Carola:
• Signals names: IN1, OUT2
• Send Signal: SET(2)
• Wait Signal: WAITI(IN(1))

For Comau-Pdl:
• Signals names: $DIN[1], $DOUT[2]
• Send Signal: $DOUT[2] := TRUE
• Wait Signal: WAIT FOR $DIN[1] = ON
For Denso-PacScript:
• Signals names: MySignal1, MySignal2
• Send Signal: MySignal2 = 1
• Wait Signal: Wait MySignal1 = ON
For Duerr-Ecotalk:
• Send Signal: SET do2 1
• Wait Signal: RECEIVE di1 1
For Epson-Spel:
• Signals names: INB1, OUTB2
• Send Signal: On 2
• Wait Signal: Wait Sw(1) = On
For Fanuc-Rj:
• Signals names: DI[1], DO[2]
• Send Signal: DO[2] = ON
• Wait Signal: Wait DI[1] = ON;
For Igm-Ins:
• Send Signal: DOUT do2 1
• Wait Signal: WAIT di1 1
For Kawasaki-As:
• Signals names: in1, out2
• Send Signal: SIGNAL 2
• Wait Signal: SWAIT 1

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customization
For Kuka-Krc:
There are two options. However, you use the KRL syntax in the activity.
• Fold syntax
o Signals names: DI[1], DO[2]
o Send Signal: OUT 1 ‘DO[2]’ State= TRUE
o Wait Signal: Wait FOR (IN 1, ‘DI[1]’)
• KRL syntax
o Signals names: $IN[1], $OUT[2]
o Send Signal: $OUT[2] = TRUE
o Wait Signal: Wait FOR $IN[1]
For Nachi-Slim:
• Signals names: I1, O2
• Send Signal: SETM O2,1
• Wait Signal: WAITI I1
For Panasonic-Csr:
• Signals names: i1#1, i1#2
• Send Signal: OUT, o1#2, 1
• Wait Signal: WAIT_IP, i1#1, 1
For Reis-Robstar:
• Signals names: i1_0, o2_0
• Send Signal: WRITE_BIT o2_0 1
• Wait Signal: WAIT_BIT i1_0 1
For Staubli-Val:
• Send Signal: SetDO do2, 1
• Wait Signal: WaitDI di1, 1
For Trallfa-Robtalk:
• Signals names: INPUT1, OUTPUT2
• Send Signal: OUTPUT2 ON

• Wait Signal: WAIT INPUT1 ON
For Universal-URScript:
• Signals names: DI[1], DO[2]
• Send Signal: set_standard_digital_out(2, True)
• Wait Signal:
sync()
end
For Yaskawa-Inform:
• Signals names: IN#(1), OT#(2)
• Send Signal: DOUT OT#(2) ON
• Wait Signal: Wait IN#(1) ON
Activities
In the Signal example section, do the following activities:
• ABB — Creating a custom command to send and wait for signals
• Comau — Creating a custom command to send and wait for signals
• Denso — Creating a custom command to send and wait for signals
• Duerr — Creating a custom command to send and wait for signals
• Fanuc — Creating a custom command to send and wait for signals
• IGM — Creating a custom command to send and wait for signals
• Kawasaki — Creating a custom command to send and wait for signals
• Kuka — Creating a custom command to send and wait for signals
• Nachi — Creating a custom command to send and wait for signals
• NC — Creating a custom command to send and wait for signals
• Panasonic — Creating a custom command to send and wait for signals
• Reis — Creating a custom command to send and wait for signals
• Staubli — Creating a custom command to send and wait for signals
• Trallfa — Creating a custom command to send and wait for signals
• Universal — Creating a custom command to send and wait for signals

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• Yaskawa — Creating a custom command to send and wait for signals

Custom OLP command and macro example

Purpose
In this topic, you learn how to create a custom OLP command that calls a macro from the macro file.
Objectives
• Use a combination of a macro file and a custom OLP command.
Macro file example

A possible macro could look like this – although it should be mentioned that this macro is specific
(“hardcoded”) for a predefined equipment name:
Macro METHOD1_RIVET
# Destination xyz_riveter_rr_01
# Drive CLOSE
# Destination xyz_ riveter _rr_01
# WaitDevice CLOSE
# WaitTime 2
# Destination xyx_ riveter _rr_01
# Drive OPEN
# Destination xyz_ riveter _rr_01
# WaitDevice OPEN
Macro files must be stored in the defined macro folder under the system root (as defined in
File→Options ) and named with a .macro file extension.
The advantage of this solution is the fact that the original .cojt including only kinematics can be used.
The disadvantage of using this kind of macro is being it not flexible at all for any kind of equipment
change.
A much more and realistic way is turning the xyx_ riveter _rr_01 into a smart component (which
provides built in joint value sensors and the ability to move to a pose using a signal). The entries
and exists of this smart component could be connected to generic signal names which follow your
company standard.
Then you can reference these signals in your macro.
• Digital Output Signals:
o do9 used to move to open
o do10 used to move to close

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customization
o di7 used to verify moved to close OK
o di8 used to verify moved to open OK
Then a module or macro could be written in the following form:

Macro METHOD2_RIVET
# Send do10 1
# WaitSignal di7
# WaitTime 2
# Send do10 0
# Send do9 1
# WaitSignal di8
# Send do9 0
OLP command XML file requirement for example

The following would be added to the SimulationLayer of the OLP Command XML file:
<SimulationLayer>
<Line>
<Item Type=”const”>METHOD2_RIVET<Item>
</Line>
The .macro file must already exist, since this tool checks for the file before offering it as
a choice.

Summary
• Got an overview of the capabilities in this area.
• How to create an enhanced OLP command.
• How to create a custom command and macro

Lesson 8: Motion and robotic path template customization
Purpose
To provide a description on how to do motion and robotic path template customization.
Objectives

• How to create an enhanced motion XML
• How to create a robotic template XML
• Other selected custom XML topics

Lesson
Lesson 8: 8: Motion
Motion and robotic
and robotic path path template
template customization
customization
Motion command customization introduction

Purpose
In this topic, you learn to create and use motion command customization XML files.
Objectives

• Create and use motion customization files.
• Use custom motion type configurations.
• Use additional functionality concerning custom motion commands.
Business process
Motion customization basics

Recall from earlier in the advanced robotics training that motion customization is not supported on
all ESRC robot controllers:
Controller Customized Motion Configuration

ABB Yes
ABB Volvo (Volvo only) No
Cloos No
Comau Yes
Comau Volvo (Volvo only) No
Denso
Duerr No
Epson No
Fanuc F100iA (CFLEX) No
Fanuc Yes
Fanuc Japan (Japan customers only) No

Motion and robotic path template customization
Fanuc VW (VW only) No
IGM No
Kawasaki No
Kuka Yes
Kuka BMW (BMW only) No
Kuka Volvo (Volvo only) No
Kuka VKRC (VW only) No
Nachi No
NC Code Yes
NC Code BMW (BMW only No
NC Code Danobat (Danobat only) No
NC Code Riveting No
NC Code Riveting Embraer (Embraer only) No
Panasonic
Reis Yes
Staubli No
(ABB) Trallfa No
Universal (TBD)
Yaskawa (Motoman) No
A lot of companies have implemented their own standards to create a combination of existing
“official” robot motion commands with their own enhancements. Process Simulate supports these
requirements in the same way as for the Customized OLP user interface. This user customization
must be kept the flexible to allow customer "flavors" without the need to hard code them.
For each combination of location and process types (a column under the controller name section), a
different dialog can be used to edit the relevant robotic parameter.
• For weld locations, these options are shown:
• For via locations, these options are shown:

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Lesson 8: 8: Motion
Motion and robotic
customization
By choosing a value, users can customize the location.
Custom motion type configuration

As explained in the introduction, specific user defined process related commands can be defined in
all existing robot controllers. In order to support these commands, the customized User Interface
mechanism includes motion parameters. since they may influence several columns, a specific new
column in the Path Editor is used called “PROCESS TYPE”.
For each controller there may be several OLP and motion configuration files. By default, the
motion configuration files are located in the MotionConfiguration subfolder (C:\Program
Files\Tecnomatix\eMPower\Robotics\OLP\<Controller name>\OlpConfiguration. However,
this can be changed by specifying a CustomizedPath in the rrs.xml file for the version of the
controller used like the training course (for example N:\sysroot\OLP_config_files\<Controller
name>\MotionConfiguration).
Description
All the syntax of the OLPConfiguration elements can be used here as well.
Representation of Layers of motion commands:
Customized motion commands are stored in the Database only one time, but for each motion
command, there are three different representations. (User Interface, Simulation and Download)
The purpose of this service is to retrieve the right motion command representation according the
user needs.
In the XML file, for each location type and each process type, there is three layers:
1. UILayer – The user interface layer shows what is shown in Process Type column of Path Editor.
2. SimulationLayer - The simulation layer describes what needs to be simulated
3. DownloadLayer - The download layer describes what needs to be downloaded.
User Interface Layer:

1. When the user clicks in the ProcessType column in the Path Editor, the service read the XML
(only the first time and saves it in a cache for reusability) and an appropriate list of process types
(according to the suitable location type) is shown for the user to choose.

2. When the user chooses a value – a custom user interface is opened with the current values
displayed.
3. After setting the desired values and click OK, the values are set on all the referenced location
attributes.
The Customized Motion and Customized Debug columns can be added to the Path
Editor as well. If the location has not been customized, there won’t be a value in
these boxes.

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Lesson 8: 8: Motion
Motion and robotic
customization
Additional elements of motion command files

Purpose
In this topic, you learn about some additional elements of custom motion command XML files (as
apposed to custom OLP command XML files).
Objectives

• More motion command options.
Motion command basics

For motion command XML files the RobotController element contains the RoboticParams and
Location elements.
Location – This element represents the type of the location you select and contains a Type attribute
which can have these values: VIA, WELD, Seam Start, Seam End, Seam Middle
• Process – This element is one of the values of the list of values shown for the selected location
type. This is the value that is shown in the Process Type column. Several of these elements can
be placed within a Location element.
o Force - Once users select a process type for a location, the application forces new values for
specific robotic parameters.
o Dialog – Contains the Title and Description attribute and the RoboticParamRef element.
See the description provided earlier in this course.
o UILayer - See the description provided earlier in this course.
o SimulationLayer - See the description provided earlier in this course.
o Motion – The type of motion with the following Types: 1 Joint, 2 Linear, 3 Slew, 4 Circular
Via, 5 Circular2, 6 Circular Radius, 7 Circular Full, and 8 Spline.
This element contains the DownloadLayer

Motion command customization example

Purpose
In this topic, you learn how to create a custom motion command XML file.
Objectives
• Create and use a custom motion XML file
Motion example basics

Your custom motion XML shows a specific list of values for the Process Type based on location type.
For example for Weld locations, the user has the ability to select either Style1 or Style2 for the
Process Type (in the Path Editor).
Each Process type can have its own dialog which can be opened from the Customized Motion
column of the Path Editor.
One or all layers can be filtered based on the assigned motion type.
For example:
• Weld (location type)
o Style1 (process type) — Weld location dialog for Style1
■ PTP (motion type)
◊ User Interface layer
◊ Simulation layer
◊ Download layer
■ Lin (motion type)

◊ Download layer
■ Circ (motion type)

◊ Download layer
o Style2 (process type) — Weld location dialog for Style2

■ PTP

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Lesson 8: 8: Motion
Motion and robotic
customization
◊ Download layer
• Via (location type)

o Style 2 (process type) — Via location dialog for Style2
■ PTP (motion type)
◊ Download layer
■ Lin (motion type)

◊ Download layer
■ Circ (motion type)

◊ Download layer
o Style3 (process type) — Via location dialog for Style3

■ PTP
◊ Download layer
Simulation and Download layers:

When a location is marked as “customized”, the controller uses the XML simulation/download layer,
instead of performing the default simulation/download.
Each layer consists of hard coded strings, and robotic parameters (not necessarily the ones which
appear in the dialog). Process Simulate reads the related section in the XML file and converts it
with the following rules:
• The hard coded string - stays as is.
• The regular parameters – the service should find their value on the location,
• The controller parameters – the service gets their values by API from the controller.

• Finally, Process Simulate returns one string to the controller with everything it needs (or an
empty string if it required)
Activities
In the Motion command customization example section, do the following activities:
• ABB — Creating customized motion commands
• ABB — Using customized motion commands
• Comau — Creating customized motion commands
• Comau — Using customized motion commands
• Fanuc — Creating customized motion commands
• Fanuc — Using customized motion commands
• IGM — Creating customized motion commands
• IGM — Using customized motion commands
• Kuka — Creating customized motion commands
• Kuka — Using customized motion commands
• Nachi — Creating customized motion commands
• Nachi — Using customized motion commands
• NC — Creating customized motion commands
• NC — Using customized motion commands
• Reis — Creating customized motion commands
• Reis — Using customized motion commands

Lesson
Lesson 8: 8: Motion
Motion and robotic
customization
Robotic path template customization introduction

Purpose
In this topic, you learn how to create a custom robotic path template .XML file. This is supported by
all ESRC robot controllers.
Objectives
• Know the capabilities and syntax of the file.
• Create and use a path template file.
Business process
Path template basics

It is often necessary to configure location parameters (tool, speed, zone, etc.) to define a path for
a specific process. Additionally, approach and depart via locations with the same parameters are
added to the path. Each action can add locations to the selected path, and/or change location
orientation and robotic parameters, and OLP commands. For example, in a gluing operation, the
user configures the gluing start, stop, and robot speed. These are process specific parameters to be
applied to each gluing path.
Process Simulate enables you to define actions in an XML template and apply the actions to multiple
operations. You can set parameters and OLP commands for locations, add approach and depart via
locations, and set their coordinates. You can define many actions in the XML template and apply them
with a single click, saving repetitive manual configuration, increasing productivity, and reducing errors.
The robotic templates are stored as XML files in dedicated folders. Since each robot controller has its
own OLP commands (standard, specific, and customized) and motion parameters (regular, complex,
and customized), each controller requires its own path template configuration files.
For each controller there may be several OLP configuration, motion configuration,
and path template configuration files. By default, the path template configuration
files are located in the PathTemplateConfiguration subfolder (C:\Program
Files\Tecnomatix\eMPower\Robotics\OLP\<Controller name>\PathTemplateConfiguration.
However, this can be changed by specifying a CustomizedPath in the rrs.xml file for the version of

the controller used like the training course (for example N:\sysroot\OLP_config_files\<Controller
name>\PathTemplateConfiguration).
The following are examples of simple actions:
• Action A: For the first seam location with the Polishing process type:
o Set RRS_MOTION_TYPE to 2.
Recall that motion type 1 is joint motion and 2 is linear motion. Other internal
names for attributes, such as RRS_MOTION_TYPE can be found using the
Robotic Parameters Viewer tool. This tool is described in the Final Comments
lesson of the course.
o Add the OLP command OpenPaintGun
o Add the OLP command SetPaintBrush 3
o Change the location color to be Yellow
• Action B: For the last seam location with the Polishing process type:
o Set RRS_MOTION_TYPE to 2
o Add the OLP command ClosePaintGun
o Change the location color to be Red
The user can apply actions on chosen operations.

Basic Steps:
• Create custom path template XML file.
• Use the custom path template XML in Process Simulate by choosing Operation tab→Templates
group→Apply Path Template Action .

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Lesson 8: 8: Motion
Motion and robotic
customization
Capabilities
• Execute configurable templates of actions on list of operations
• Perform multiple actions to manipulate the paths at once
• Support different actions:
• Adding removing robotic parameters
• adding/removing of OLP commands
• Adding locations
• Set Paint gun off / on
• Support different templates for each controller, with and without parameters
Description
For robot path template XML files the RobotController element contains the ActionList and
ActionFilter elements.
• ActionList — This element contains a list of Action elements.

• ActionFilter
• Action — this element has several attributes such as:

o Name — The name of the action, this must be unique. The following example shows that
when the name includes ‘|‘, this is a sub menu, and when it includes ‘-‘ at the end, this
is a separator
o SeamRange — Defines the seam operations (under the selected continuous compound
operation) upon which this action should be performed. The possible values are: All
(including all via and seam locations, this is the default value), First, Last, n1, Last – n1,
”n1-n2”, ”n1,n2,n3”.
o LocRange —Defines the locations on which this action should be performed. The possible
values are: All (this is the default value), First, Last, n1, Last – n1, ”n1-n2”, ”n1,n2,n3”,
Operation. The Operation value does not work with any other filters; use it only for OLP
commands, color, and motion for the selected operation level.
o LocIndex (with values such as First, Last, All)
o LocationTypes — Filters the locations by their support for customized motion. The possible
values are: Via, Weld, Seam Start, Seam End, Seam Middle.
o Processtypes — Filters the locations by the process type defined in the customized motion
XML file (see also in Process Type column in the Path Editor). This attribute can take more
than one value.
o MotionTypes — Filters the locations by motion type. This attribute can take more than
one value.
o Description — The description of the action to be shown in the Apply Path Template Action
window in Process Simulate.
o etc.
Action content overview:

The Action element can contain several elements:
• Param — This is fully defined (min, max, list, type, etc.) in the customized motion XML file. This
attribute is mandatory unless you use the RemoveAll attribute.

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Lesson 8: 8: Motion
Motion and robotic
customization
• Olp — For a standard or controller specific controller, the system creates a free text command at
the location. For a standard customized controller, the system creates a composite command at
the location. If there is already an OLP command with the same name at the location, a new
OLP command is added.
• Color — The possible values are: Red, green, yellow, blue, magenta, cyan, orange, white, pink,
gray, brown, wood, dark green, dark red, dark brown, light blue, black.
• MoveLoc — This element describes the moving of locations in single or several coordinates. For
weld locations, only the Rx, Ry, Rz coordinates are set. If, however, these coordinates are bigger
or smaller than the range defined in the Option window, they are set to the minimum or maximum
value (unless IgnoreLimitations is set to True).
• Relocate — This element describes relocating locations according to the difference between two
TCP frames. For example, if you change a weld gun for another gun with a different x-axis.
o Add the following to the customized motion XML file:
o Also add the following to the customized motion XML file:

o To create this UI:
• AddLoc — This element describes the creation of a new via location and setting its coordinates
in degrees (double) value. In the AddLoc element, the user should define what to do with the new
via location. Outside the AddLoc element, the system checks again that the filter is on the fixed
operation. It then continues with the new output of the filter.
If several locations pass the action filter, each location entering the operation may
change the location pointed to by RefLoc.

Lesson
Lesson 8: 8: Motion
Motion and robotic
customization
• ActionRef — This element describes a reference to a single existing action and is for reusing of
the XML action definitions.
ActionFilter content example:

A filter determines what object types the action is shown.

Path template customization example

Purpose
In this topic, you learn how to create an example robot path template customization .XML file.
Objectives
• Learn more about how to create a Path Template file.
Path template example basics

In this lesson, you describe how to create an example robotic path template customization file and
use it in Process Simulate.
For example:
You want to define a path template XML to:
• Give the abilities to apply all defined path templates
• Give the abilities to apply specific path templates:

o Change the color of all via locations in the path to black
o Add a location before the first location in the path, offset -100 along the X-axis, and 100
along the Y-axis.
o Add a location before a location, offset -5 along the X, add an _01 suffix to the name, and set
its color to yellow. Also on these locations: set the zone to z30, the speed to v1000, and
the motion type to 1 (joint motion).
o Add a location after a location, offset -5 along the X, add an _02 suffix to the name, and
set its color to blue. Also on these locations: set the zone to z80, the speed to v600, and
the motion type to 1 (joint motion).
Example path template

In the basic robotics training, you used a default controller path template. Here are the contents of
that file named RobotSim.xml (which is part of the training data):
You do not need this XML file for this course. It is provided for reference.
<RobotController Name="Default" Version="All">

<ActionList>
<!– *************************************** –>
<!– Add spot approach and retract locations–>
<Action Name="Spot-weld Templates|Add Spot Approach Loc" LocRange="First"

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Description="For the selected weld operation: \n - Add a via before the first weld \n - Set the app/ret
locs to fine zone, joint motion type, \n with a speed of 100%">
<AddLoc Name="approachViaLoc" Placed="Before" RefLoc="FIRST" RelX="-100">
<Param Name="Zone" Dynamic="True" Value="fine"/>
<Param Name="Motion Type" Dynamic="True" Value="PTP"/>
<Param Name="Speed" Dynamic="True" Value="100"/>
</AddLoc>
</Action>
<Action Name="Spot-weld Templates|Add Spot Retract Loc" LocRange="Last"
Description="For the selected weld operation: \n - Add a via before the first weld \n - Set the app/ret
locs to fine zone, joint motion type, \n with a speed of 100%">
<AddLoc Name="retractViaLoc" Placed="After" RefLoc="LAST" RelX="-100">
</AddLoc>
</Action>
<!– Setup spot weld locations–>
<Action Name="Spot-weld Templates|Setup Spot-weld Locs" LocationTypes="Weld"
Description="For the selected weld operation: \n - Set the seam locs to nodecel zone, linear motion
type, \n with a speed of 150 mm/sec (350 IPM)">
<Param Name="Motion Type" Dynamic="True" Value="LIN"/>
</Action>
<!– Apply all spot templates–>
<Action Name="Spot-weld Templates|Apply All" LocRange="All"
Description="Add Spot Approach Loc, \n Add Spot Retract Loc, \n and Setup Spot-weld Locs">
<ActionRef>Spot-weld Templates|Add Spot Approach Loc</ActionRef>
<ActionRef>Spot-weld Templates|Add Spot Retract Loc</ActionRef>
<ActionRef>Spot-weld Templates|Setup Spot-weld Locs</ActionRef>
</Action>
<!– *************************************** –>
<!– Add arc approach and retract locations–>
<Action Name="Arc-weld Templates|Add Arc Approach Retract Locs" LocRange="First"

Description="For the selected continuous feature operation: \n - Add a via before and after the seam
\n - Set the app/ret locs to fine zone, joint motion type, \n with a speed of 100%">
<AddLoc Name="approachViaLoc" Placed="Before" RefLoc="FIRST" RelZ="100">
</AddLoc>
<AddLoc Name="retractViaLoc" Placed="After" RefLoc="LAST" RelZ="100">
</AddLoc>
</Action>
<!– Setup arc seam locations–>
<Action Name="Arc-weld Templates|Setup Arc-weld Seam Locs" LocationTypes="Seam Start,Seam
End,Seam Middle"
Description="For the selected continuous feature operation: \n - Set the seam locs to nodecel zone,
linear motion type, \n with a speed of 150 mm/sec (350 IPM)">
<Param Name="Zone" Dynamic="True" Value="nodecel"/>
</Action>
<!– Apply all arc templates–>
<Action Name="Arc-weld Templates|Apply All" LocRange="All"
Description="Add Arc Approach Retract Locs \n and Setup Arc-weld Seam Locs">
<ActionRef>Arc-weld Templates|Add Arc Approach Retract Locs</ActionRef>
<ActionRef>Arc-weld Templates|Setup Arc-weld Seam Locs</ActionRef>
</Action>
<!– *************************************** –>
<!– Add paint approach and retract locations–>
<Action Name="Paint Templates|Add Paint Approach Retract Locs" LocRange="First"
Description="For the selected continuous feature operation: \n - Add a via before and after the seam
\n - Set the app/ret locs to fine zone, joint motion type, \n with a speed of 100%">
<AddLoc Name="approachViaLoc" Placed="Before" RefLoc="FIRST" RelZ="100">

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</AddLoc>
<AddLoc Name="retractViaLoc" Placed="After" RefLoc="LAST" RelZ="100">
</AddLoc>
</Action>
<!– Setup paint seam locations–>
<Action Name="Paint Templates|Setup Paint Seam Locs" LocationTypes="Seam Start,Seam
End,Seam Middle"
Description="For the selected continuous feature operation: \n - Set the seam locs to nodecel zone,
linear motion type, \n with a speed of 150 mm/sec (350 IPM)">
<Param Name="Zone" Dynamic="True" Value="nodecel"/>
</Action>
<!– Apply all paint templates–>
<Action Name="Paint Templates|Apply All" LocRange="All"
Description="Add Paint Approach Retract Locs \n and Setup Paint Seam Locs">
<ActionRef>Paint Templates|Add Paint Approach Retract Locs</ActionRef>
<ActionRef>Paint Templates|Setup Paint Seam Locs</ActionRef>
</Action>
</ActionList>
<ActionFilter>
</ActionFilter>
</RobotController>
Activities
In the Robotic path template customization example section, do the following activities:
• ABB — Creating robotic path templates
• ABB — Using robotic path templates
• Comau — Creating robotic path templates

• Comau — Using robotic path templates
• Denso — Creating robotic path templates
• Denso — Using robotic path templates
• Duerr — Creating robotic path templates
• Duerr — Using robotic path templates
• Epson — Creating robotic path templates
• Epson — Using robotic path templates
• Fanuc — Creating robotic path templates
• Fanuc — Using robotic path templates
• IGM — Creating robotic path templates
• IGM — Using robotic path templates
• Kawasaki — Creating robotic path templates
• Kawasaki — Using robotic path templates
• Kuka — Creating robotic path templates
• Kuka — Using robotic path templates
• Nachi — Creating robotic path templates
• Nachi — Using robotic path templates
• NC — Creating robotic path templates
• NC — Using robotic path templates
• Panasonic — Creating robotic path templates
• Panasonic — Using robotic path templates
• Reis — Creating robotic path templates
• Reis — Using robotic path templates
• Staubli — Creating robotic path templates
• Staubli — Using robotic path templates
• Trallfa — Creating robotic path templates
• Trallfa — Using robotic path templates

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Lesson 8: 8: Motion
Motion and robotic
customization
• Universal — Creating robotic path templates
• Universal — Using robotic path templates
• Yaskawa — Creating robotic path templates
• Yaskawa — Using robotic path templates

Other XML customization topics

Purpose
In this topic, you learn about several other interesting features of the custom XML files.
Objectives

• Using custom debugging
• Use multi editing of customized motion.
• Use the picture attribute.
• Add your own online help for customized dialogs.
• Centralize all xml files under single shared folder.
• Encrypt your customized xml files.
Custom XML debugging

For Custom OLP commands:
From the Teach Pendant right-click the command in the OLP commands list and choose Show
Layers or Customized Upload Parameter Checker.
For Custom Motion:
Can be done in the Path Editor by picking in the Custom Debug column and choose Show Layers
or Custom Checker.
Multi editing of customized motion

In order to set values for customized motion only once for several locations:
In the Path Editor, select several locations and click Set Locations Properties . In the
Set Locations Properties dialog box, set the process type for all locations, and then select the
Customized motion row, and click in order to open the window.

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Picture attribute
The picture in the dialog changes dynamically according to the combo box selection. This aids you
in Selecting the correct gun.
Picture is an optional attribute. Its value is the relative path from the CustomizedPictures folder.
By default, the Picture path is relative to ..\eMPower\Robotics\Olp\CustomizedPictures, unless a

CustomizedPath is set in the rrs.xml file.
Under this folder, the user can manage pictures with nested sub folders as desired. For example:
…\eMPower\Robotics\Olp\ CustomizedPictures \Laser\appzc5299228.jpg for
<ElmDef Picture =" Laser\appzc5299228.jpg ">Weld 10Am</ElmDef>
This attribute is available in Custom OLP files only.

The ..\eMPower\Robotics\Olp\CustomizedIcon folder was discussed earlier. It is where

the custom icon that shows in the upper left corner of the dialog box is placed by default.

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Add online help to customized dialogs

You can add your own online help to your customized dialogs.
To do this, add the Help attribute to the Dialog element adds a help button to the user interface. This
attribute is available in Custom Motion and OLP files.
The Help path is relative to .\eMPower\Robotics\Olp\CustomizedHelp (unless you have set the
CustomizedPath in the rrs.xml file).
If you wish to launch a URL, add the shortcut to the folder and the XML (using the shortcut name
and ".url").
• You can now launch the desired item over the net (internet or intranet).
• You can store all items on a single server and use shortcuts to access them.
Centralize all XML files in a shared folder

You can centralize all XML files in a single shared folder.
Once you place all the .XML files under a shared folder in single location, you can point to this folder
by adding the CustomizedPath attribute to the Version element in the rrs.xml file. Typically, this
folder would be a shared drive such asN:\sysroot\OLP\Kuka-Krc or \\ilhzsomebody\Kuka-Krc.
This folder would contain all of the .XML customization folders that are found under the install folder
(for example C:\Program Files\Tecnomatix\eMPower\Robotics\OLP\Kuka-Krc (of course it would
not include the executables for the robot controller).
You do not learn aboutDataConfiguration, since it is beyond the scope of this course. It is
a way to create your own data types which can be used in your custom .XML files.
Encryption of customized XML files

To protect customized .XML files, it is possible to use encryption. To do so, select the Encrypt
button from the Customized Commands XML Checker dialog box (click Customized Command
XML Checker in Process Simulate) and select the .XML files to encrypt. The encrypted files
are created with the .XMLC suffix and can be safely shipped to contractors and suppliers. Process
Simulate handles both .XML and .XMLC files transparently.

Simulation keywords
Simulation keywords:
The following simulation keywords are supported and automatically substituted in macros, robot
modules, and XML simulation layers:
• ${Robot}
• ${ActiveGun}
• ${ActiveGunMainJoint}
• ${ActiveGripper}
• ${AutoTeach}: TRUE in AutoTeach simulation mode, FALSE otherwise
• ${MoveToSingleLocation}: TRUE if the Move To Location command has been issued, FALSE
otherwise
• ${Robot.Tcpf.X}, ${Robot.Tcpf.Y}, ${Robot.Tcpf.Z}: actual position of the robot TCPF with

respect to the active Object Frame in mm
• ${CurrentSimulationTime}: current simulation time in seconds
• ${UserName}: replaced with login name
• ${Date}: replaced with dd/mm/yyyy

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• ${Time}: replaced with hh:mm:ss

Summary
• How to create an enhanced motion XML
• How to create a robotic template XML
• Other selected custom XML topics

Lesson 9: Other customizations
Purpose
To learn other types of customizations related to robotics.
Objectives

• Attributes of mfg features and locations.
• Showing custom attributes in the Path Editor.

Lesson
Lesson 9: 9: OtherOther customizations
customizations
Attributes of mfg features and locations

Purpose
In this lesson, you learn about mapping and viewing attributes of mfg features and locations.
Objectives
• See an overview of the process.
• Create the file. to map attributes from mfg features to locations.
• View the attributes in the Mfg Viewer.
• View the attributes in the Robotic Parameters Viewer.
Basic data flow for locations and mfg features

There are topics in this training that describe how to perform each of these steps:
Configuration and setup of Process Simulate

1. Customize your environment and add additional object types and attributes. See the TR41213
Process Designer/Process Simulate Data Management, Variants, and Importing course.
2. Define additional tabs for the Properties dialog box to view custom attributes in a more friendly
way. See the TR41213 Process Designer/Process Simulate Data Management, Variants, and
Importing course.
3. Setup the RoboticParametersToMfgAttributes.xml file to map attributes from mfg features to

locations. Described in this training.
4. Setup the configuration file to show custom location attributes in the Path Editor. Described
in this training.
5. Define custom motion parameter or path template XML files that reference the custom location
attributes. Described in this training.
6. Setup custom download templates. Described in this training.
Data flow within Process Simulate

These steps are describes in the Process Simulate Basic Robotic Simulation and Process Simulate
Advanced Robotic Simulation courses.
1. Define new mfg features in Process Simulate, or in an external system and import via a Excel
spreadsheet in Process Simulate.
2. Associate mfg features to parts and operations.
3. View mfg feature attributes in the Mfg Viewer.

Other customizations
Custom mfg feature attributes are available in the Mfg Viewer Customize dialog box automatically.
4. Edit mfg feature custom attributes in the Excel spreadsheet or Properties dialog box
5. Project the mfg features to create locations.
6. Edit the location custom attributes in the Path Editor.
7. View Mfg feature attributes in the Robotic Parameters Viewer.
8. Use the custom motion parameter and path templates.
9. Apply a custom download template.
10. Teach the locations to create the downloadable configurations.
11. (Optional) Download the waypoints file.
12. Download the main program file. This file can contain custom location information.
Importing weld points or rivets
Defining custom attributes for weld points or rivets
In Process Simulate standalone, you cannot create custom object types or attributes. However,
you can create studies based on a template from Process Simulate on eMS that already contains
customized object types and attributes.
Rivets and weld points are represented in the eMS database as WeldPoints or an
object type derived from WeldPoints . Your administrator can use the eM-Planner
Customization tool to add custom attributes to the object type you use to represent rivets
and weld points.
For example, you could add attributes such as Diameter, Length, and Sealant.
Define additional tabs for the Properties dialog box to view custom attributes in a more
friendly way.
For more information see the TR41213 Process Designer and Process Simulate Data
Management, Variants, and Importing course.
Custom attributes on Mfgs can be mapped to the locations that result from projecting
the Mfgs.
Importing weld points or rivets
Although rivets and weld points could be created directly in Process Simulate one-by-one, they are
typically imported from an system where the Product Design group has authored them.

Lesson
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When running Process Simulate Standalone - eMS compatible, you can use the Import Mfgs
command to add Mfgs from external CAD programs to your study. If the imported Mfg already exists
in the study, it is updated from the CSV file. When you run Update eMServer after completing
your offline session, the new and updated Mfgs are uploaded to the eMServer database.
Prior to launching Import Mfgs , you must prepare a file in CSV format containing the Mfgs
to be imported.
The Name of the Mfg and its location fields X, Y, and Z are mandatory. If the file does not contain
exactly these fields, the import does not work.
You can also add the following optional columns:

• A Leading Part and any number of Connected Part fields. These are the parts with which the
Mfg is associated (when the leading part is moved, the Mfg moves together with the part, but
when connected parts are moved, the Mfg remains at its current location).
If a leading part is defined for the Mfg but it does not exist in the study, the system
ignores the leading part and connected parts.
• Attributes (other than relation attributes) — add an Attribute_<Attr_Name> column to the CSV
file. For example, Attribute_Diameter, Attribute_Length, and Attribute_Sealant
• Class — this is a sub class of weld points. If there is no value, then a PmWeldPoint is created.
Attributes of the sub class are supported.
• Rotation fields Rx, Ry, Rz in radians.

If the CSV file contains multiple Mfgs with the same name, none of them are imported.
If the study contains multiple Mfgs with the same name, the first Mfg in the study is updated
and the others are ignored.
If you have specified a leading part in the CSV file that occurs more than once in the study,
the first occurrence in the study is set and the others are ignored.
The system imports new Mfgs under the set "Current Operation". If no operation is set as
current, the system imports Mfgs under the Operations root.
1. From the ribbon, choose Process tab→Planning→Import Mfgs .

The Import Mfgs dialog box is displayed.
2. Find your CSV file or use the Browse button to navigate to it and click Open.
3. Set Use Working Frame if you wish to import the Mfgs with coordinates relative to the working
frame or clear it to import the Mfgs with absolute coordinates.
4. Click Import.
The system imports new Mfgs under the set "Current Operation". If no operation is set as current,
the system imports Mfgs under the Operations root.
5. Click View Log File if you wish to view detailed information on the import results.
6. Save your PSZ file if you are satisfied with the results of the import.
The imported Mfgs are now displayed in the Operation Tree and Mfg Viewer.
Configuring a mapping file

To map your own attributes, a RoboticParametersToMfgAttributes.xml file must be created in
the .\sysroot\General folder.

Lesson
customizations
Attributes referenced in this file are case sensitive.
It follows this structure:

• RoboticParametersToMfgAttributesMapping — This tag has all the mapping information within
it. It can contain any number of ParameterToAttributePair tags.
• ParameterToAttributePair — There is one of these tags for each attribute mapping. It contains
one RoboticParameterName tag and one MfgAttributeNameMfgTypeName tag.
• RoboticParameterName — It can either refer to an existing attribute on the location (shown in

the Robotic Parameters Viewer), or It defines a new attribute on the location.
• MfgAttributeName — The attribute name from the Mfg feature must be entered exactly as it
is shown in the Mfg Viewer (case sensitive).
o MfgTypeName — Specify the name of the mfg feature type to be used that contains the
mfg feature attributes.
Mapping attributes from mfg features to locations

There is no one file to specifically define location attributes (robotic parameters). However,
referencing a location attribute using one these techniques, defines the location attribute:
• In a motion customization XML file (described earlier)
• In the mfg feature to location attributes mapping file (RoboticParametersToMfgAttributes.xml)
You can map an attribute's initial value from an mfg feature to a location. This can be done after the
mfg feature is projected and the mapping file is setup.
• Unless overwritten, the value of the robotic parameter remains the same as its related Mfg (and
updates automatically when the Mfg value is changed).
• If you change the corresponding value on the location, it no longer corresponds to the value of
the Mfg attribute and the modified value on the mfg is indicated by italic font in the Path Editor.
Weld point mapping example using standard attributes

For example, define relations between these mfg attributes and location attributes on Process
Simulate on eMS:
Because these are standard location attributes, they are already setup in the Robotic
Parameters Viewer, Path Editor, and Teach Pendant. So you only need to setup the
connection from the Mfg Viewer.
• Weld Time
o Shown as actionTime on a WeldPoint mfg in the Mfg Viewer.
o Shown as SW_TIME_ON_PT on a location in the Robotic Parameters Viewer.

o Shown as Weld Time on a location in the Path Editor.
o Shown as Weld Time on a location in the Teach Pendant.
• Cool Down Time
o Shown as holdingTime on a WeldPoint mfg in the Mfg Viewer.
o Shown as SW_WAIT_TIME on a location in the Robotic Parameters Viewer.
o Shown as Cool Down on a location in the Path Editor.
o Shown as Cool Down on a location in the Teach Pendant.
Here is the RoboticParametersToMfgAttributes.xml required mapping file.

<?xml version="1.0"?>
<RoboticParametersToMfgAttributesMapping>
<ParameterToAttributePair>
<RoboticParameterName>SW_TIME_ON_PT</RoboticParameterName>
<MfgAttributeName MfgTypeName="PmWeldPoint">actionTime</MfgAttributeName>
</ParameterToAttributePair>
<RoboticParameterName>SW_WAIT_TIME</RoboticParameterName>
<MfgAttributeName MfgTypeName="PmWeldPoint">holdingTime</MfgAttributeName>
</RoboticParametersToMfgAttributesMapping>
Continuous mapping example using custom attributes
The following is an example of mapping a continuous Mfg attribute to a seam operation attribute
on Process Simulate on Teamcenter:
• Weld Time
o Shown as bl_sequence_no on a ArcWeld mfg in the Mfg Viewer.
o Shown as Test_ParamInt on a location in the Robotic Parameters Viewer.

<RoboticParameterName>Test_ParamInt</RoboticParameterName>
<MfgAttributeName MfgTypeName="ArcWeldRevision">bl_sequence_no</MfgAttributeNam

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Rivet mapping example using custom attributes
For example, define relations between these mfg attributes and location attributes on Process
Simulate on eMS:
• Type
o Shown as Type on a Rivet mfg in the Mfg Viewer.
o Shown as Type on a location in the Robotic Parameters Viewer.
o Shown as Type on a location in the Path Editor.
• Diameter
o Shown as Diameter on a Rivet mfg in the Mfg Viewer.
o Shown as Diameter on a location in the Robotic Parameters Viewer.
o Shown as Diameter on a location in the Path Editor.

<RoboticParameterName>Type</RoboticParameterName>
<MfgAttributeName MfgTypeName="Rivet">type</MfgAttributeName>
<RoboticParameterName>Diameter</RoboticParameterName>
<MfgAttributeName MfgTypeName="Rivet">diameter</MfgAttributeName>
Adding attributes to the Mfg Viewer

After you have configured your custom attributes for mfg features, you can now add them to the
Mfg Viewer just like the out of the box attributes:
1. In Process Simulate, load a study.
2. In the Mfg Viewer click Customize .
3. In the Customize dialog box, browse under a group of attributes such as MfgFeature,
ContinuousMfg, or WeldPoint.
4. Select some attributes.
5. Click Add and click OK.

Activities
In the Attributes of mfg features and locations section, do the following activities:
• Looking at the existing mapping file

Lesson
customizations
Showing custom attributes in the Path Editor

Purpose
In this lesson, you learn how to configure and show custom location attributes (mapped from mfg
features) in the Path Editor.
Objectives
• Look at the configuration file.
• Add the attributes to the Path Editor.
• See the attributes in the Set Location Properties dialog box.
Setting up the Path Editor for custom attributes

This XML file defines the attributes that are grouped by controller in the Customize dialog
box of the Path Editor. The name of the file is not important. These files are located in the
C:\ProgramData\Tecnomatix\Process Simulate\14.1\Robotics\PathEditor\AvailableColumns
folder.
When the software starts, all XML files are read from the folder and the content combined. If more
than one XML file is used and the same section name appears in more than one file or if the section
name is one of the already used groups such as General, Default, or Fanuc-Rj, then the attributes
are merged and appear under the same node in the Customize dialog box.
Structure of the XML file:
• The Root tag starts and ends the file and can have as many Section tags as needed.
• The Section tag represents a group of attributes. It can contain an unlimited number of Column
tags. It contains this attribute:
If Column tags (location attributes) are not defined in a Section, they are displayed
under the General node in Customize dialog box.
o The SectionName attribute is the name of the group of attributes such as General, Default,
or Fanuc-Rj.
• The Column tag describes a single column (attribute). It is a mandatory tag and contains these
attributes:
o Id — The ID is the attribute name as shown in the Robotic Parameters Viewer. For custom
attributes, this is the value shown in the mapping file. For example: RRS_MOTION_TYPE.
o Header — The displayed header of the column. For example: you may want the header for
RRS_MOTION_TYPE to be Motion Type.
o Units — (Optional) The supported units are: angular, linear, mass, time, and none. The
units define whether the attribute value represents a length, angle, etc. When units are

specified, the attribute value is converted according to the specified unit type and unit system
that is currently in use. For example: an attribute representing an angle is stored internally in
radians. To display it in degrees, you change the current angular units in the Options dialog
box to degrees (default).
o Alignment — (Optional) The attribute can be displayed: left, center or right justified. The
default is left justified. Alignment definitions are not case sensitive.
o ValueType — The ValueType declares how the attribute values are stored. The combination
of the ValueType and of the DisplayType should define the display format. The type
definition is not case sensitive. The available ValueTypes are:
■ Frame — The name of the selected frame is displayed.
■ String — Displayed as a string, or by the defined string per value if the DisplayType is
a Combobox.
■ Obj — The object ID is displayed.
■ Double — Displayed as a double (floating) number, or by the defined string per value, if
the DisplayType is a Combobox.
■ Bool — Displayed as a Boolean ("True" or "False"), as an integer ("0" or "1"), or by a

defined string per value. It depends on the DisplayType definition.
■ Int — Displayed as integer, or by a defined string per value. It depends on the

DisplayType definition.
o Access —The access to the attribute value can be "R" for read only, "RW" for read and
write, or "RX" for read and execute.
• Display — (Optional) A tag that contains both the value limitations (min and max values) and
the displayed text for attribute value. It is located under the Column tag and contains the
following optional attributes:
o MaxVal — The maximum displayed value. If the attribute value is bigger than this value, the
word "Illegal" is displayed instead of the attribute value. This attribute is relevant for the
integer, double float, and time ValueType only.
o MinVal — The minimum displayed value. If the attribute value is smaller than this value the
word "Illegal" is displayed instead of the attribute value. This attribute is relevant for the
integer, double, float, and time ValueType only.
o DisplayType — (Optional) Its main purpose is editing the attributes and defining the value's
representation. The display type can be one of these types:
■ Combobox — used to define arrays (multi value attributes). Using the combobox
DisplayType requires the definition of the ComboDef tag.
■ Int — used for Boolean and int ValueType.
■ Double — used for double (and floating) ValueType.

Lesson
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■ String — used for string, obj, and frame ValueType.
• The ComboDef tag contains the ElmDef tag. This is used for displaying meaningful string value
instead of the value of the attribute. The ComboDef is located under the Display tag. The
ElmDef tag contains two attributes:
o Name — The meaningful display value.
o Value — The attribute’s real value that causes the above name to be displayed. If for a given
attribute value no set of ElmDef is defined, the real value is displayed instead.
<Root>
<Section SectionName="Fanuc-Rj">
<Column Id="KRC_GUN_WAIT" Header="gun wait" >

<Display MaxVal="500" MinVal="0" DisplayType="combobox">
- <ComboDef>
<ElmDef Name="no wait" Value="0" />
<ElmDef Name="wait" Value="1" />
</ComboDef>
</Display>
</Column>
</Section>
</Root>
Training sample file

<Root>
<Section SectionName="Default">
<Column Id="Diameter" Header="Diameter" ValueType="double" Access="RW">

<Display DisplayType="double"/>
</Column>
<Column Id="Length" Header="Length" ValueType="double" Access="RW">

</Column>
<Column Id="Stack_Max" Header="Stack Max" ValueType="double" Access="RW">

</Column>
<Column Id="Stack_Min" Header="Stack Min" ValueType="double" Access="RW">

</Column>
<Column Id="Cycle" Header="Cycle" ValueType="string" Access="RW">

<Display DisplayType="string"/>
</Column>
<Column Id="Sealant" Header="Sealant" ValueType="string" Access="RW">

</Column>

<Column Id="Type" Header="Type" ValueType="string" Access="RW">

</Column>
</Section>
</Root>
Adding attributes to the Path Editor

After you have configured your custom attributes for locations, you can now add them to the Path
Editor just like the out of the box attributes:
1. In Process Simulate, load a study.
2. In the Path Editor click Customize .
3. In the Customize dialog box, browse under a group of attributes such as General, Default, or
Fanuc-Rj.
4. Select some attributes.
5. Click Add and click OK.
Activities
In the Showing custom attributes in the Path Editor section, do the following activities:
• Setting up and seeing custom attributes in the Path Editor

Lesson
customizations
Summary
• Attributes of mfg features and locations.
• Showing custom attributes in the Path Editor.

Lesson 10: Final comments
Purpose
To various other interesting topics related to robotics that have not been covered in the previous
courses.
Objectives

• An overview of creating an OLP procedure
• How to put it all together.

Lesson
Lesson 10:10:FinalFinal comments
comments
Creating an OLP procedure (putting it all together)

Purpose
In this topic, you get an review of the multi-step OLP procedure.
Objectives
• Review the multi-step OLP procedure.
A multi-step OLP procedure

An OLP/calibration procedure definition should be a goal of anyone attempting an OLP procedure
of any size. It enables the OLP provider to efficiently program and calibrate a line of robots without
wasting the time allowed for the task. An overview of a sample procedure is outlined below.
A Multi-Step OLP Procedure:
1. Prepare the OLP materials — This step is also accomplished by the Process Simulate user,
who create the program files, and prepare the OLP documentation, which is a reproduction of the
study layout, gun mounting, and locations of calibration points.
2. Verify robot and study installation — This step is done by the robot programmer, who uses
the OLP materials to verify that the robot, tool, and study infrastructure match the Process
Simulate layout.
3. Generate robot program and download — The final step is combined action by the process
designer and robot programmer. The user creates the robot program, which is input by the
robot programmer.

Final comments
Putting it all together

At the beginning of this class you had little or no knowledge of Process Simulate. Through class you
have been exposed to many Process Simulate features and had time to practice what you have
seen. You must continue to use this tool after class in conjunction with other users in your company,
additional training classes, and Siemens PLM Software services personnel in order to become
an expert.

Lesson
Lesson 10:10:FinalFinal comments
comments
Where do you go from here?

If you want to learn about Process Simulate Standalone (eMServer compatible), try these classes:
• TR45101 – Process Simulate Standalone (eMServer compatible) Flow Simulation
• TR45106 – Process Simulate Standalone (eMServer compatible) Human Simulation
• TR45115 – Process Simulate Standalone (eMServer compatible) Basic Robotic Simulation
• TR45215 – Process Simulate Standalone (eMServer compatible) Intermediate Robotics (CEE)
Final notes
Normally at some point you would begin developing simulative operations (paths) and organizing
them within a process. However since the steps to develop and analyze paths for different types
of operations are a little different (and are a little different for each type of simulative operation),
there are other courses to describe it.
• Device and robotic processes – Covered in more detail in these courses:MT45115, MT45215,
and MT45315.
• Human process – Covered in more detail in this course: MT45106.
• Assembly processes without the constraint of a human or a robot – Covered in more detail
in this course: MT45101.

Final comments
Summary
• An overview of creating an OLP procedure
• How to put it all together.

Appendix A: Appendix — Optional topics
Purpose
In this lesson, you learn about some optional advanced topics related to OLP.
Objectives

• How to group paths using the segmentizer (instead of a program).
• How to upload a process from Robcad.
• An overview of the robotic parameters viewer
• An overview of robot modules
MT45315-S-141 Process Simulate Standalone (eMS) Advanced Robotics A-1

Appendix
Appendix A: A: Appendix
Appendix — Optional
— Optional topics
topics
Segmentizer
Purpose
In this topic, you learn how to use the Segmentizer to create robot programs.
Objectives
• Segmentize a robotic operation
Segmentizer basics
This tool has own executable which must be installed first. It can be
downloaded from the GTAC FTP site separately from Process Simulate: from
https://download.industrysoftware.automation.siemens.com/tecnomatix, browse to
Planning Applications→Robot Controllers→v14.1→Tools→Segmentizer and
download it (either 32 or 64 bit).
The segmentizer can be used to divide one path into several for downloading.
• Use it to go from one early up-front single path to multiple paths by breaking it up by logic (also
known as a keyword).
• Use it to just create the scheduler for only one path if no key word is added to break up the path.
Need criteria to say how to split it (for example the wait signal).
Controlling logic is in the main program not in the path.
The paths that are created are GenericRoboticOperations.
Workflow:
• Select a compound operation (which contains at least one robotic operations) or a robotic
program to enable the Segmentizer button and click it.
• The Segmentizer uses the settings from the Segmentizer Setup to search segmentizing
commands and to name the segments.
• The Segmentizer segments all robotic operations inside the compound operation/robotic
program and create an additional robotic operation, called the Scheduler which contains the
calls to the segments and the segmenting commands. This scheduler is created inside the
selected compound operation (in case you segment a compound operation), or inside the parent
compound operation of the first robotic operation (in case you segment a robotic program).
• In case you segment a compound operation, the Segmentizer also creates a Robotic Program
from the Scheduler and segments operations.
A-2 Process Simulate Standalone (eMS) Advanced Robotics MT45315-S-141

Appendix — Optional topics
• Continuous operations:
• A seam operation cannot contain any segmenting command.
• Only the last seam location of a seam operation can contain segmentizing commands.
Weld Operation Example:

Start with:
• Compound operation
o WeldOperation1
■ via1
■ via2 (segmenting string)
■ weld3
■ via4 (segmenting string)
■ weld5
■ via6
Result is:
o WeldOperation1Seg1
■ via1
■ via2
■ weld3
■ via4
■ weld5
■ via 6
o Scheduler
The resulting compound operation contains a schedule and creates a robotic program automatically.
Continuous Operation Example:
Start with:
o ContinuousOperation1

Appendix
— Optional topics
topics
■ via1
■ via2
■ SeamOperation1
◊ SeamLoc3
◊ SeamLoc4 (segmenting string)
■ via5
■ SeamOperation2
◊ SeamLoc6
◊ SeamLoc7
◊ SeamLoc8
Result is:
o ContinuousOperation1Seg1
■ via1
■ via2
■ SeamOperation1
◊ SeamLoc3
◊ SeamLoc4 (segmenting string)
o ContinuousOperation1Seg2
■ via5
■ SeamOperation2
◊ SeamLoc6
◊ SeamLoc7
◊ SeamLoc8
o scheduler
The resulting compound operation contains a schedule and creates a robotic program automatically.
There is also an “unsegmentizer” tool (for example for uploaded data).
Unsegmentizer Workflow:

• To enable the UnSegmentizer button a selected compound operation, which have been
previously segmentized, must be selected (for example contains Scheduler and at least one
robotic operation).
• It may contain other kind of operations as well
• The UnSegmentizer uses the settings from the Segmentizer Setup to search segmentizing
commands and to name the segments.
• The UnSegmentizer unsegmentizes all robotic operations inside the compound operation in order
to recreate the compound operation as it was before segmentation was performed.
• It moves the segmentize instructions back to the location, join the segments and remove the
scheduler operation.
Activities
In the Segmentizer section, do the following activities:
• Segmentizing a robotic operation

Appendix
— Optional topics
topics
Comparison of various methods for handling robot macros

Purpose
In this topic, you compare various methods for handling robot macros.
Objectives

• Enter OLP commands.
• Compare methods of entering OLP commands.
• Learn a little bit about conditional statements.
Entering OLP commands

• Robot Macros - Entered in a robot macro file and referenced as OLP commands on a location
(for example grip which executes a series of commands). A macro is downloaded as just the
macro name (the contents of the macro are not downloaded.
• Robot Module - (for example tip dress/counter, sub program), setting up logic that can be
simulated.
o Can load modules from the program
o The robot’s database can be stored in an instance.
OLP Customization:
Later in this course, you learn how to create customized OLP and Motion commands and which
ESRC support it.
• User editable configuration XML file including:
o UI description - Parameter names, ranges, dependencies, default values, etc.
o Controller syntax - user level and advanced level
o Upload / Download Format

Entering OLP commands method comparison

Different levels of simulation requirements:
• Option 1: just a reach study (pick and place operation)
• Option 2: use programming standard macro “close gripper”
Can generate an appearance of IPA in using CEE simulation.
• Option 3: close gripper using logic (for example a logic block/smart component)
Details of Options:
• Option 1a: gripper device and gripper locations
• Option 1b: Robcad way: OLP commands:

o # drive device griper close
o # wait device gripper close
o # attach part to gripper
• Option 2: create macro, can take parameters for attach

o Add standard commands (blank, display, macro, grip) or free text.
• Option 3: gripper, kinematic with logic block (open/close) OLP

o request to open references at close signal
o request to close references at open signal
o For example: DO(1) = ON (digital output \ attached when closed)
Notes on conditional statements

• Conditional statements can’t be processed ahead of time because the “look ahead” for motion
smoothing
• So need to cancel existing motion and them start it again with another point
• Can avoid not knowing the start point between 2 paths by always stopping at the same point.

Appendix
— Optional topics
topics
Process upload from Robcad

Purpose
In this topic, you learn how to upload from Robcad.
Objectives
• Import a file downloaded from Robcad into this system.
Robcad upload basics
This is not the primary way to upload directly from the robot to Process Simulate. This
technique is for a special situation where you want to transfer paths, which were uploaded
to Robcad, to Process Simulate. For the more typical case of uploading directly from the
robot to Process Simulate, see the next lesson.
There are two ways to upload:

• Method 1: Upload a program from Robcad to Process Simulate (that was uploaded from a
real robot controller)
• Method 2: Upload directly to Process Simulate (typical method)
This method is discussed in the next lesson.
Uploading from Robcad

Programs can be uploaded into Robcad, output from Robcad, and then input into Process Simulate
by choosing Robot tab→Program group→Upload Robcad Robotic Program .
A special default.apg file must be copied to Robcad installation (for example

$Robcad\dat\olp\default\).
Here is how (NOT an activity):

1. Do these steps in Robcad:
• Setup Tool & Base data for the specific robot controller.
• Define all parameters for the locations of the path to be exchanged.

• Teach axis configuration (local locations).
• Simulate / test the path with the RCS.
• Change to the Default controller.
• Download path as localname.default file.

Appendix
— Optional topics
topics
2. Do these steps in Process Simulate:

• From the ribbon, choose Robot tab→Program group→Upload Robcad Robotic Program
.
• Select robot.
• For Robcad Attributes, define path to the Robcad attributes file. The default attributes
file is located under $Robcad\dat
• Select how the robot turns should be by default.

• For Standard Settings, there are pre settings for some robots such as ABB, Fanuc and Kuka.
• Click Add, select Robcad programs (*.default), and select program files to add to the list.

Appendix
— Optional topics
topics
• Click Upload.
• A message showing the upload process was successful.
• The path is added as Weld Operation to the Operation Viewer.
• All system frames and parameters is uploaded too.


Appendix
— Optional topics
topics
Overview of the Robotic Parameters Viewer

Purpose
In this topic, you learn about the Robotic Parameters Viewer.
Objectives

• Use the Robotic Parameters Viewer.
Robotic Parameters Viewer basics

Usage:
1. Select an operation or a location (or a robot when the API is available).
2. From the ribbon, choose Robot tab→Tools group→RoboticParametersViewer .
3. All the object parameters (with their value) are automatically displayed in the viewer.

4. You can select another object while the RoboticParametersViewer is open and it updates the
parameters list.

Appendix
— Optional topics
topics
Overview of Robot Modules

Purpose
In this topic, you learn how to describe robot modules.
Objectives
• Know more about robot modules.
Robot Modules basics

To open the Robot Modules dialog box, right-click a robot and then choose Robot Signals and
Modules→Robot Modules .
• Robot modules should be loaded / edited with the Robot Modules standard tool in Process
Simulate.
• Those modules can contain any number of procedures or functions defined in the controller
native language syntax (standard controller syntax [# commands] can also be used if needed in
the procedure body)
• In the teach pendant, the procedure/function calls should be entered manually, in free text, in the
controller native language syntax.
• In simulation, the procedure call is replaced by the procedure body (in which the procedure
parameters have been replaced with the call arguments).
• In download, the procedure call is downloaded as is.
Controller Modules Support

ABB Yes
ABB Volvo (Volvo only) Yes

Cloos No
Comau Yes
Comau Volvo (Volvo only) Yes
Denso
Duerr No
Epson No
Fanuc CFLEX (F100iA) No
Fanuc Yes
Fanuc Japan (Japan only) Yes
Fanuc VW (VW only) Yes
IGM No
Kawasaki No
Kuka Yes
Kuka Volvo (Volvo only) Yes
Kuka VW (VW only) Yes
Nachi No
NC (machining) No
NC (riveting) No
Panasonic
Reis No
Staubli No
Trallfa No
Universal
Yaskawa / Motoman No
Basic Usage:
1. Find a robot in the Graphic Viewer or Object Tree.
2. Right-click it and then choose Robot Signals and Modules→Robot Modules .

Appendix
— Optional topics
topics
3. Performed the desired action
4. Close the window.

Index
A Basic OLP commands . . . . . . . . . . . . . . 5-3

A multi-step OLP procedure . . . . . . . . . 10-2 Basic setup . . . . . . . . . . . . . . . . . . 3-8–3-9
ABB motion attributes . . . . . . . . . . . . . 3-80 Business process . . . . . . . . . . . . . 1-2, 1-8,
ABB Robot Setup dialog box — 1-29, 1-33, 1-37, 2-8, 2-15, 2-21, 3-8, 3-11,
continued . . . . . . . . . . . . . . . . . . . . 3-50 3-15, 3-44, 3-46, 3-98–3-99, 4-2, 4-16, 5-2,
ABB Robot Setup dialog box – first 5-7, 5-12, 5-19, 5-30, 6-6, 7-2, 8-2, 8-10
buttons . . . . . . . . . . . . . . . . . . . . . . 3-17
ABB signal definition . . . . . . . . . . . . . . 5-12 C
ABB supported configurations . . . . . . . . 3-3
Calibration . . . . . . . . . . . . . . . . . . . . . 6-1
ABB: Sending and waiting for signals . . 5-19
Calibration basics . . . . . . . . . . . . . . . . . 6-2
(ABB) Trallfa motion attributes . . . . . . . 3-93
Calibration introduction . . . . . . . . . . . . . 6-2
(ABB) Trallfa Robot Setup dialog box —
Calibration results . . . . . . . . . . . . . . . . 6-4
continued . . . . . . . . . . . . . . . . . . . . 3-73
Calibration sets . . . . . . . . . . . . . . . . . . 6-3
(ABB) Trallfa Robot Setup dialog box – first
Calibration steps overview . . . . . . . . . . . 6-7
buttons . . . . . . . . . . . . . . . . . . . . . . 3-34
Capabilities . . . . . . . . . . . . . . . . . . . . 8-12
ABB-Rapid — Beyond signals . . . . . . . 5-31
Centralize all XML files in a shared
Access to RCS/RRS . . . . . . . . . . . . . . 1-29
folder . . . . . . . . . . . . . . . . . . . . . . . 8-26
Accessing Robot Setup using method
Class discussion to put it all together . . . 5-30
1 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Cloos motion attributes . . . . . . . . . . . . 3-80
Accessing robot setup using method 2 . . 3-48
Cloos Sending and waiting for signals . . 5-20
Accessing Robot Setup using method
Cloos signal definition . . . . . . . . . . . . . 5-12
2 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Cloos specific MotionParameters.e for
Accessing robot setup using method 3 . . 3-48
zones . . . . . . . . . . . . . . . . . . . . . . . 1-17
Add online help to customized dialogs . . 8-26
Cloos Supported configurations . . . . . . . 3-3
Adding attributes to the Mfg Viewer . . . . . 9-8
Cloos-Carola - Beyond signals . . . . . . . 5-35
Adding attributes to the Path Editor . . . . 9-13
Comau motion attributes . . . . . . . . . . . 3-82
Additional elements of motion command
Comau Robot Setup dialog box —
files . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
continued . . . . . . . . . . . . . . . . . . . . 3-53
Advanced robotics (OLP) course
Comau Robot Setup dialog box – first
overview . . . . . . . . . . . . . . . . . . . . . . 13
buttons . . . . . . . . . . . . . . . . . . . . . . 3-18
Allocating a Worker . . . . . . . . . . . . . . . 1-4
Comau signal definition . . . . . . . . . . . . 5-13
Appendix Optional topics . . . . . . . . . . . . A-1
Comau: Sending and waiting for
Attributes of mfg features and locations . . 9-2
signals . . . . . . . . . . . . . . . . . . . . . . 5-20
Comau-Pdl — Beyond signals . . . . . . . 5-36
B Comparison of various methods for handling
Basic controller specific motion robot macros . . . . . . . . . . . . . . . . . . . A-6
attributes . . . . . . . . . . . . . . . . . . . . . 3-79 Configuring a mapping file . . . . . . . . . . . 9-5
Basic data flow for locations and mfg Contents of ESRC . . . . . . . . . . . . . . . 1-27
features . . . . . . . . . . . . . . . . . . . . . . . 9-2 Controller specific frames . . . . . . . . . . 3-75
Basic motion attributes (default Controller specific OLP command
controller) . . . . . . . . . . . . . . . . . . . . . 2-2 basics . . . . . . . . . . . . . . . . . . . . . . . 5-30
MT45315-S-141 Process Simulate Standalone (eMS) Advanced Robotics Index-1

Index
Index
Creating a robotic program from a compound E

operation . . . . . . . . . . . . . . . . . . . . . 2-22 Editing program templates . . . . . . . . . . . 4-2
Creating an OLP procedure (putting it all Entering OLP commands . . . . . . . . . . . . A-6
together) . . . . . . . . . . . . . . . . . . . . . 10-2 Entering OLP commands method
Creating robot programs (default comparison . . . . . . . . . . . . . . . . . . . . A-7
controller) . . . . . . . . . . . . . . . . . . . . 2-21 Entering robot specific comments . . . . . 5-10
Custom motion type configuration . . . . . . 8-4 Epson motion attributes . . . . . . . . . . . . 3-84
Custom OLP command and macro Epson Robot Setup dialog box —
example . . . . . . . . . . . . . . . . . . . . . 7-23 continued . . . . . . . . . . . . . . . . . . . . 3-59
Custom OLP commands XML file . . . . . . 7-8 Epson Robot Setup dialog box – first
Custom XML debugging . . . . . . . . . . . 8-23 buttons . . . . . . . . . . . . . . . . . . . . . . 3-23
Customized XML basics . . . . . . . . . . . . 7-8 Epson signal definition . . . . . . . . . . . . 5-13
customized XML files . . . . . . . . . . . . . 8-26 Epson specific MotionParameters.e for
zones . . . . . . . . . . . . . . . . . . . . . . . 1-17
D Epson Supported configurations . . . . . . . 3-4
Error sources . . . . . . . . . . . . . . . . . . . 1-49
Data model basics . . . . . . . . . . . . . . . . 1-4 ESRC history and content . . . . . . . . . . 1-25
Defining a List of Values . . . . . . . . . . . 7-11 ESRC OLP commands . . . . . . . . . . . . . 5-1
Defining robot specific signals . . . . . . . 5-12 ESRC setup and motion parameters . . . . 3-1
Defining zones in the MotionParameters.e Example download template use . . . . . 4-14
file . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Example path template . . . . . . . . . . . . 8-17
Denso motion attributes . . . . . . . . . . . 3-83 Example robot specific template
Denso Robot Setup dialog box — keywords . . . . . . . . . . . . . . . . . . . . . . 4-9
continued . . . . . . . . . . . . . . . . . . . . 3-57 External axis . . . . . . . . . . . . . . . . . . . 2-13
Denso Robot Setup dialog box – first
buttons . . . . . . . . . . . . . . . . . . . . . . 3-21 F
Denso Sending and waiting for signals . . 5-20 Fanuc motion attributes . . . . . . . . . . . . 3-85
Denso signal definition . . . . . . . . . . . . 5-13 Fanuc Robot Setup dialog box –
Denso Supported configurations . . . . . . . 3-4 continued . . . . . . . . . . . . . . . . . . . . 3-60
Denso-PacScript - Beyond signals . . . . 5-40 Fanuc Robot Setup dialog box – first
Description . . . . . . . . . . . . . . . . . 8-4, 8-12 buttons . . . . . . . . . . . . . . . . . . . . . . 3-24
Dialog standards . . . . . . . . . . . . . . . . . 7-5 Fanuc signal definition . . . . . . . . . . . . 5-14
Direct process upload . . . . . . . . . . . . . 4-26 Fanuc supported configurations . . . . . . . 3-4
Disconnecting from the RCS (RCS Fanuc: Sending and waiting for
decoupling) . . . . . . . . . . . . . . . . . . . 3-41 signals . . . . . . . . . . . . . . . . . . . . . . 5-22
Do I do this . . . . . . . . . . . . . . . . . 2-2, 3-79 Fanuc-RJ — Beyond signals . . . . . . . . 5-46
Do the up-front work required . . . . . . . . 1-45 Final comments . . . . . . . . . . . . . . . . . 10-1
Download basics . . . . . . . . . . . . . . . . 4-16 Final notes . . . . . . . . . . . . . . . . . . . . 10-4
Downloaded files for each controller . . . 4-18, Five major sources . . . . . . . . . . . . . . . 1-49
4-22 Free text basics . . . . . . . . . . . . . . . . . . 5-7
Duerr motion attributes . . . . . . . . . . . . 3-83 Free text standard commands . . . . . . . . 5-7
Duerr Robot Setup dialog box —
continued . . . . . . . . . . . . . . . . . . . . 3-58 G
Duerr Robot Setup dialog box – first
buttons . . . . . . . . . . . . . . . . . . . . . . 3-22 Getting robot models from GTAC . . . . . 1-11
Duerr signal definition . . . . . . . . . . . . . 5-13
Duerr supported configurations . . . . . . . . 3-4 H
Duerr: Sending and waiting for signals . . 5-21 How to figure out the manipulator type for an
Duerr-EcoTalk — Beyond signals . . . . . 5-41 RRS controller? . . . . . . . . . . . . . . . . 3-13
Index-2 Process Simulate Standalone (eMS) Advanced Robotics MT45315-S-141

Index
How to take OLP into consideration . . . . 1-45 M

Macro file example . . . . . . . . . . . . . . . 7-23
I Mapping attributes from mfg features to
locations . . . . . . . . . . . . . . . . . . . . . . 9-6
IGM motion attributes . . . . . . . . . . . . . 3-86 Methods to create and edit a program . . 2-22
IGM Robot Setup dialog box — Methods to define TCPF positions for a robot
continued . . . . . . . . . . . . . . . . . . . . 3-62 controller . . . . . . . . . . . . . . . . . . . . . 3-44
IGM Robot Setup dialog box — first MOP, RRS, and ESRC . . . . . . . . . . . . 1-25
buttons . . . . . . . . . . . . . . . . . . . . . . 3-25 More controller specific OLP
IGM signal definition . . . . . . . . . . . . . . 5-14 commands . . . . . . . . . . . . . . . . . . . . 5-30
IGM supported configurations . . . . . . . . 3-5 More on robot models . . . . . . . . . . . . . 1-10
IGM: Sending and waiting for signals . . . 5-23 More on TxObject ValueTypes . . . . . . . 7-11
IGM-Ins — Beyond signals . . . . . . . . . 5-49 Motion and robotic path template
Importing Mfg Features . . . . . . . . . . . . . 9-3 customization . . . . . . . . . . . . . . . . . . . 8-1
Include relevant information at each step of the Motion attributes basics (default
process . . . . . . . . . . . . . . . . . . . . . . 1-45 controller) . . . . . . . . . . . . . . . . . . . . . 2-3
Introduction to advanced robotics . . . . . . 1-1 Motion command basics . . . . . . . . . . . . 8-6
Introduction to OLP . . . . . . . . . . . . . . . . 1-2 Motion command customization
Introduction to the MotionParameters.e example . . . . . . . . . . . . . . . . . . . . . . 8-7
file . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Motion command customization
introduction . . . . . . . . . . . . . . . . . . . . 8-2
K Motion customization basics . . . . . . . . . 8-2
Motion example basics . . . . . . . . . . . . . 8-7
Kawasaki motion attributes . . . . . . . . . 3-86 Motion planning (Introduction to MOP, RCS,
Kawasaki Robot Setup dialog box — and RRS) . . . . . . . . . . . . . . . . . . . . 1-22
continued . . . . . . . . . . . . . . . . . . . . 3-63 Motion planning basics . . . . . . . . . . . . 1-22
Kawasaki Robot Setup dialog box – first Motion planning flowchart . . . . . . . . . . 1-23
buttons . . . . . . . . . . . . . . . . . . . . . . 3-26 Motion termination for the default
Kawasaki signal definition . . . . . . . . . . 5-14 controller . . . . . . . . . . . . . . . . . . . . . . 2-4
Kawasaki specific MotionParameters.e for Motion types (default controller) . . . . . . . 2-3
speed and accuracy . . . . . . . . . . . . . 1-17 MotionParameters.e configurations and
Kawasaki supported configurations . . . . . 3-5 turns . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Kawasaki: Sending and waiting for MotionParameters.e motion types . . . . . 1-14
signals . . . . . . . . . . . . . . . . . . . . . . 5-23 MotionParameters.e units . . . . . . . . . . 1-14
Kawasaki-As — Beyond signals . . . . . . 5-51 MotionParameters.e zones . . . . . . . . . 1-15
Kuka motion attributes . . . . . . . . . . . . 3-87 Multi editing of customized motion . . . . 8-23
Kuka Robot Setup dialog box —
continued . . . . . . . . . . . . . . . . . . . . 3-64
Kuka Robot Setup dialog box – first N
buttons . . . . . . . . . . . . . . . . . . . . . . 3-27 Nachi motion attributes . . . . . . . . . . . . 3-88
Kuka signal definition . . . . . . . . . . . . . 5-16 Nachi Robot Setup dialog box —
Kuka supported configurations . . . . . . . . 3-5 continued . . . . . . . . . . . . . . . . . . . . 3-67
Kuka: Sending and waiting for signals . . 5-24 Nachi Robot Setup dialog box — first
Kuka-Krc — Beyond signals . . . . . . . . . 5-53 buttons . . . . . . . . . . . . . . . . . . . . . . 3-29
Nachi signal definition . . . . . . . . . . . . . 5-16
L Nachi supported configurations . . . . . . . 3-5
Nachi: Sending and waiting for signals . . 5-25
Layers . . . . . . . . . . . . . . . . . . . . . . . 7-13 Nachi-Slim — Beyond signals . . . . . . . 5-58
Limitations of decouple mode . . . . . . . . 3-42 NC Code Robot Setup dialog box –
Location reference frames . . . . . . . . . . . 2-6 continued . . . . . . . . . . . . . . . . . . . . 3-69

Index
Index
NC Code Robot Setup dialog box – first Panasonic specific MotionParameters.e for
buttons . . . . . . . . . . . . . . . . . . . . . . 3-30 zones . . . . . . . . . . . . . . . . . . . . . . . 1-18
NC motion attributes . . . . . . . . . . . . . . 3-89 Panasonic Supported configurations . . . . 3-6
NC specific MotionParameters.e for Panasonic-Csr - Beyond signals . . . . . . 5-62
zones . . . . . . . . . . . . . . . . . . . . . . . 1-18 Path template basics . . . . . . . . . . . . . 8-10
NC supported configurations . . . . . . . . . 3-6 Path template example basic . . . . . . . . 8-17
NC-Code — Beyond signals . . . . . . . . 5-61 Picture attribute . . . . . . . . . . . . . . . . . 8-24
PProcess overview . . . . . . . . . . . . . . . 1-42
O Preparation . . . . . . . . . . . . . . . . . . . . 1-48
Problems that can occur without considering
OLP Basics . . . . . . . . . . . . . . . . . . . . . 1-2 OLP issues . . . . . . . . . . . . . . . . . . . 1-44
OLP command basics . . . . . . . . . . . . . . 5-2 Process download . . . . . . . . . . . . . . . 4-16
OLP command conditions . . . . . . . . . . . 5-8 Process generation . . . . . . . . . . . . . . . 1-42
OLP command customization . . . . . . . . . 7-1 Process simulation and robot
OLP command customization basics . . . . 7-2 configurations . . . . . . . . . . . . . . . . . 3-99
OLP command XML file requirement for Process to program . . . . . . . . . . . . . . 1-43
example . . . . . . . . . . . . . . . . . . . . . 7-24 Process upload from Robcad . . . . . . . . . A-8
OLP Command XML Structure Program creation . . . . . . . . . . . . . . . . 3-98
Example . . . . . . . . . . . . . . . . . . . . . 7-16 Program creation basics . . . . . . . . . . . 3-98
OLP commands section basics . . . . . . . 7-13 Program template basics . . . . . . . . . . . . 4-2
OLP Commands Section of the File . . . . 7-13 Program template selection . . . . . . . . . . 4-3
OLP configuration file basic elements . . . 7-8 Program templates for downloading . . . . 4-2
OLP dialogs section basics . . . . . . . . . 7-15 Putting it all together . . . . . . . . . . . . . . 10-3
OLP dialogs section of the file . . . . . . . 7-15
OLP in process design . . . . . . . . . . . . 1-44 R
OLP introduction . . . . . . . . . . . . . . . . . 3-2
OLP software packages . . . . . . . . . . . . 1-6 RCS connection testing basics . . . . . . . 3-38
Operation Tree . . . . . . . . . . . . . . . . . . . 1-4 RCS logs . . . . . . . . . . . . . . . . . . . . . 3-38
otes on conditional statements . . . . . . . . A-7 RCS management . . . . . . . . . . . . . . . 3-40
Other customizations . . . . . . . . . . . . . . 9-1 RCS management basics . . . . . . . . . . 3-40
Other default controller examples . . . . . . 2-7 RCS shell . . . . . . . . . . . . . . . . . . . . . 3-38
Other XML customization topics . . . . . . 8-23 Reis motion attributes . . . . . . . . . . . . . 3-91
Output file basics . . . . . . . . . . . . . . . . 4-22 Reis Robot Setup dialog box —
Overview of customizing robot controller continued . . . . . . . . . . . . . . . . . . . . 3-71
interfaces . . . . . . . . . . . . . . . . . . . . . 7-2 Reis Robot Setup dialog box – first
Overview of Robot Modules . . . . . . . . . A-16 buttons . . . . . . . . . . . . . . . . . . . . . . 3-32
Overview of Robotic Operation Merge . . 4-27 Reis signal definition . . . . . . . . . . . . . . 5-17
Overview of setting up MOP-based and Reis specific MotionParameters.e for
RCS-based robot controllers . . . . . . . . 3-2 zones . . . . . . . . . . . . . . . . . . . . . . . 1-19
Reis supported configurations . . . . . . . . 3-6
P Reis: Sending and waiting for signals . . 5-27
Reis-Robstar — Beyond signals . . . . . . 5-63
Panasonic motion attributes . . . . . . . . . 3-89 Reset RCS module . . . . . . . . . . . . . . . 3-40
Panasonic Robot Setup dialog box — Review of robot programs and robot
continued . . . . . . . . . . . . . . . . . . . . 3-70 signals . . . . . . . . . . . . . . . . . . . . . . 2-14
Panasonic Robot Setup dialog box – first Robcad upload basics . . . . . . . . . . . . . . A-8
buttons . . . . . . . . . . . . . . . . . . . . . . 3-31 Robot configuration basics . . . . . . . . . . 3-99
Panasonic Sending and waiting for Robot configuration selection basics . . . . 2-8
signals . . . . . . . . . . . . . . . . . . . . . . 5-26 Robot controller . . . . . . . . . . . . . . . . . . 2-3
Panasonic signal definition . . . . . . . . . 5-16 Robot controller application support . . . . 3-9

Index
Robot controller selection . . . . . . . . . . 3-11 Setting up MOP versus RRS robot

Robot controller selection basics . . . . . . 3-11 controllers . . . . . . . . . . . . . . . . 1-31, 1-35
Robot controller setup . . . . . . . . . . . . . 3-15 Setting up the Path Editor for custom
Robot controller setup basics . . . . 1-33, 3-15 attributes . . . . . . . . . . . . . . . . . . . . . 9-10
Robot controller specific frames and Setting up the RCS (part 1) . . . . . . . . . 1-29
setup . . . . . . . . . . . . . . . . . . . . . . . 3-46 Setting up the robot controller (part 2) . . 1-33
Robot model basics . . . . . . . . . . . . . . . 1-9 Setting up the RRS.XML file and more (part
Robot models . . . . . . . . . . . . . . . . . . . 1-8 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
Robot Modules Basics . . . . . . . . . . . . A-16 Showing custom attributes in the Path
Robot Path Reference Operation . . . . . 2-18 Editor . . . . . . . . . . . . . . . . . . . . . . . 9-10
Robot program . . . . . . . . . . . . . . . . . . 2-19 Signal example . . . . . . . . . . . . . . . . . 7-18
Robot program basics . . . . . . . . . . . . . 2-21 Simulate robot paths . . . . . . . . . . . . . 3-100
Robot Program Viewer . . . . . . . . . . . . 5-78 Simulation keywords . . . . . . . . . . . . . . 8-27
Robot Program Viewer basics . . . . . . . 5-78 Solution and turns . . . . . . . . . . . . . . . . 2-8
Robot programming background Standard OLP commands . . . . . . . . . . . 5-2
information . . . . . . . . . . . . . . . . . . . . 2-1 Status signals . . . . . . . . . . . . . . . . . . 2-17
Robot programs . . . . . . . . . . . . . . . . . 2-16 Staubli motion attributes . . . . . . . . . . . 3-92
Robot setup basics . . . . . . . . . . . . . . . 3-46 Staubli Robot Setup dialog box —
Robot signals . . . . . . . . . . . . . . . . . . 2-17 continued . . . . . . . . . . . . . . . . . . . . 3-72
Robot system frames . . . . . . . . . . . . . 3-49 Staubli Robot Setup dialog box – first
Robot to part calibration . . . . . . . . . . . . 6-6 buttons . . . . . . . . . . . . . . . . . . . . . . 3-33
Robot to part calibration basics . . . . . . . . 6-6 Staubli specific MotionParameters.e for
Robot Toolbox . . . . . . . . . . . . . . . . . . 3-45 zones . . . . . . . . . . . . . . . . . . . . . . . 1-20
Robotic configuration selection . . . . . . . . 2-8 Staubli supported configurations . . . . . . . 3-6
Robotic Operation Merge basics . . . . . . 4-27 Staubli-Val — Beyond signals . . . . . . . . 5-67
Robotic parameters section of the file . . 7-10 Supply information needed in later steps of the
Robotic Parameters Viewer basics . . . . A-14 process . . . . . . . . . . . . . . . . . . . . . . 1-45
Robotic params dection basics . . . . . . . 7-10
Robotic path template customization T
example . . . . . . . . . . . . . . . . . . . . . 8-17
TCPF definition basics . . . . . . . . . . . . 3-44
Robotic path template customization
Teaching and clearing robot
introduction . . . . . . . . . . . . . . . . . . . 8-10
configurations . . . . . . . . . . . . . . . . 3-100
Robotic simulative operations . . . . . . . . . 1-5
Template locations . . . . . . . . . . . . . . . . 4-4
Robotics: Information exchange between PLC
Testing the RCS connection and fixing setup
and robot . . . . . . . . . . . . . . . . . . . . . 1-28
problems . . . . . . . . . . . . . . . . . . . . . 3-38
Robots as integrated production
The customizable user interface's
resources . . . . . . . . . . . . . . . . . . . . 1-27
layers . . . . . . . . . . . . . . . . . . . . . . . . 7-4
RRS setup basics . . . . . . . . . . . . . . . . 1-37
The math behind calibration . . . . . . . . . . 6-4
Training sample file . . . . . . . . . . . . . . 9-12
S Trallfa signal definition . . . . . . . . . . . . 5-17
Trallfa supported configurations . . . . . . . 3-6
Segmentizer . . . . . . . . . . . . . . . . . . . . A-2
Trallfa: Sending and waiting for
Segmentizer basics . . . . . . . . . . . . . . . A-2
signals . . . . . . . . . . . . . . . . . . . . . . 5-27
Send signal and wait signal basics . . . . 7-18
Trallfa-Robtalk — Beyond signals . . . . . 5-71
Sending and waiting for robot specific
signals . . . . . . . . . . . . . . . . . . . . . . 5-19
Setting controller specific motion U
attributes . . . . . . . . . . . . . . . . . . . . . 3-79 Universal motion attributes . . . . . . . . . 3-94
Setting up MOP versus RCS robot Universal Robot Setup dialog box —
controllers . . . . . . . . . . . . . . . . . . . . 1-40 continued . . . . . . . . . . . . . . . . . . . . 3-74

Index
Index
Universal Robot Setup dialog box – first What is MOP . . . . . . . . . . . . . . . . . . . 1-22

buttons . . . . . . . . . . . . . . . . . . . . . . 3-35 What is RRS . . . . . . . . . . . . . . . . . . . 1-23
Universal Sending and waiting for What should be considered for OLP . . . 1-45
signals . . . . . . . . . . . . . . . . . . . . . . 5-27 Where do you go from here? . . . . . . . . 10-4
Universal signal definition . . . . . . . . . . 5-17
Universal specific MotionParameters.e for Y
zones . . . . . . . . . . . . . . . . . . . . . . . 1-20
Universal Supported configurations . . . . . 3-7 Yaskawa motion attributes . . . . . . . . . . 3-95
Universal-URScript - Beyond signals . . . 5-73 Yaskawa Robot Setup dialog box —
Upload basics . . . . . . . . . . . . . . . . . . 4-26 continued . . . . . . . . . . . . . . . . . . . . 3-75
Uploading and downloading . . . . . . . . . . 4-1 Yaskawa Robot Setup dialog box – first
Use the viewer . . . . . . . . . . . . . . . . . . 5-80 buttons . . . . . . . . . . . . . . . . . . . . . . 3-36
Using the Robot Viewer . . . . . . . . . . . . 2-11 Yaskawa signal definition . . . . . . . . . . . 5-17
Yaskawa supported configurations . . . . . 3-7
V Yaskawa: Sending and waiting for
signals . . . . . . . . . . . . . . . . . . . . . . 5-28
Viewing and editing location attributes . . . 2-7 Yaskawa-Inform — Beyond signals . . . . 5-74
W
What is calibration? . . . . . . . . . . . . . . . 6-2

Reference tear-out pages
These reference tear-out pages are provided for your convenience.
Course agenda
Day 1 Morning
Introduction
Course overview
Lesson 1 Introduction to Advanced Robotics
Afternoon
Lesson 2 Robot Programming Background Information
Day 2 Morning
Lesson 3 ESRC Setup and Motion Parameters
Lesson 4 Uploading and Downloading
Afternoon
Lesson 5 ESRC OLP Commands
Lesson 6 Calibration
Day 3 Morning
Lesson 7 OLP Command XML Customization
Lesson 8 Motion and Robotic Path Template XML Customization
Afternoon
Lesson 8 Motion and Robotic Path Template XML Customization (continued)
Lesson 9 Final Comments
Appendix (optional
Optionally, discuss topics from the appendix
topics)
Classroom data sheet
This table is provided so students can record their classroom setup, as described by the instructor.
Optionally, instructors may hand out a preprinted data sheet.
Data item Data value
OS user ID
OS password
User number
Process Simulate installation folder
System root folder
rrs_bin folder
ABB RCS server folder
Fanuc RCS server folder

Student user IDs and numbers
A user ID and the associated number is assigned to each student in class.
• Your user number is applied when you perform various activities in class.
User number User Id Password

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Instructor user ID and number
This user ID and number is reserved for use by instructors:
User number User Id Password

10
Course evaluation
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2 Process Simulate Standalone (eMS) Advanced Robotics MT45315-S-141

Tecnomatix copyright, proprietary, and restricted rights notice . . . . . . . . . . . . . . . . . . . . . 2

Advanced robotics (OLP) course overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Advanced robotics prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Introduction to OLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

MT45315-S-141 Process Simulate Standalone (eMS) Advanced Robotics 3

ESRC history and content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Robot programming background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Basic motion attributes (default controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

4 Process Simulate Standalone (eMS) Advanced Robotics MT45315-S-141

Using the Robot Viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

ESRC setup and motion parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Process Simulate OLP introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

MT45315-S-141 Process Simulate Standalone (eMS) Advanced Robotics 5

Robot controller setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

6 Process Simulate Standalone (eMS) Advanced Robotics MT45315-S-141

Epson Robot Setup dialog box — continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Upload and download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

MT45315-S-141 Process Simulate Standalone (eMS) Advanced Robotics 7

Program templates for downloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

ESRC OLP commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Standard OLP commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

8 Process Simulate Standalone (eMS) Advanced Robotics MT45315-S-141

Panasonic signal definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

MT45315-S-141 Process Simulate Standalone (eMS) Advanced Robotics 9

Use the viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80

Calibration introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

OLP command customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Overview of customizing robot controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Motion and robotic path template customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Motion command customization introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

10 Process Simulate Standalone (eMS) Advanced Robotics MT45315-S-141

Motion customization basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Other customizations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Final comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

MT45315-S-141 Process Simulate Standalone (eMS) Advanced Robotics 11

Appendix — Optional topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

12 Process Simulate Standalone (eMS) Advanced Robotics MT45315-S-141

• Creating Robot Programs

• Inverse Kinematics Solution Selections (Robot Configurations)

• Robot Controller Selection and Setup

• Testing the Teach Pendant and Fixing Setup Problems

• Templates, Uploading, and Downloading

• ESRC OLP Commands

• OLP Command XML Customization

MT45315-S-141 Process Simulate Standalone (eMS) Advanced Robotics 13

• Motion XML Customization

• Robotic Path Template XML Customization

• Other XML Customization Topics

• Other Related OLP Topics

Advanced robotics prerequisites

• TR45215 – Process Simulate Standalone Intermediate Robotics

Advanced robotics audience

• TR45101 – Process Simulate Standalone (eMServer Compatible) Part Flow Simulation

• TR45106 – Process Simulate Standalone (eMServer Compatible) Human Simulation

• TR45115 – Process Simulate Standalone (eMServer Compatible) Basic Robotic Simulation

• TR45215 – Process Simulate Standalone (eMServer Compatible) Intermediate Robotics

• TR45315 – Process Simulate Standalone (eMServer Compatible) Advanced Robotics

14 Process Simulate Standalone (eMS) Advanced Robotics MT45315-S-141

To discuss the basics of Off-Line Programming with Process Simulate.

After you complete this chapter, you should be familiar with: