Kawasaki Robot Controller

D/E Series

Manual for Signal

Output within Path
Function
(Option)

Kawasaki Heavy Industries, Ltd.

90210－1222DEC
D/E Series Controller
Kawasaki Robot Signal Output within Path Function (Option)

PREFACE

This manual describes operating instructions for the “Signal Output within Path” function
(Option) of the Kawasaki Robot Controller D/E series. This function is available in AS
language programming. For details about AS language, see AS Language Reference Manual,
and for general operation methods, other functions, etc., see Operation Manual.

This manual provides as much detailed information as possible on the standard operating methods
for signal output within path function. However, not every possible operation, condition or
situation that should be avoided can be described in full. Therefore, should any unexplained
questions or problems arise during robot operation, please contact Kawasaki. Also, Kawasaki
does not guarantee the results of operations not specifically described here. For questions on
operations not covered here, consult the appropriate manual or Kawasaki as necessary. Refer
to the contact information listed on the rear cover of this manual for the nearest Kawasaki office.

1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems
relating to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching,
maintenance or inspection of the robot attend the necessary education/training course(s)
prepared by Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is
reinstalled or moved to a different site or sold off to a different user, attach this manual to the
robot without fail. In the event the manual is lost or damaged severely, contact Kawasaki.
Copyright © 2009 Kawasaki Heavy Industries Ltd. All rights reserved.
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D/E Series Controller
Kawasaki Robot Signal Output within Path Function (Option)

SYMBOLS

The items that require special attention in this manual are designated with the following symbols.

Ensure proper and safe operation of the robot and prevent physical injury or property damage by
complying with the safety matters given in the boxes with these symbols.

！ DANGER

Failure to comply with indicated matters can result in

imminent injury or death.

！ WARNING

Failure to comply with indicated matters may possibly lead

to injury or death.

！ CAUTION
Failure to comply with indicated matters may lead to physical
injury and/or mechanical damage.

[ NOTE ]

Denotes precautions regarding robot specification,

handling, teaching, operation and maintenance.

！ WARNING

1. The accuracy and effectiveness of the diagrams, procedures, and detail

explanations given in this manual cannot be confirmed with absolute
certainty. Accordingly, it is necessary to give one’s fullest attention when
using this manual to perform any work. Should any unexplained
questions or problems arise, please contact Kawasaki.
2. Safety related contents described in this manual apply to each individual
work and not to all robot work. In order to perform every work in safety,
read and fully understand the safety manual, all pertinent laws, regulations
and related materials as well as all the safety explanation described in each
chapter, and prepare safety measures suitable for actual work.

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D/E Series Controller
Kawasaki Robot Signal Output within Path Function (Option)

INTRODUCTORY NOTES

1. HARDWARE KEYS AND SWITCHES (BUTTONS)

D/E series controller provides hardware keys and switches on the operation panel and the teach
pendant for various kinds of operations. In this manual the names of the hardware keys and
switches are enclosed with a square as follows. The terms “key” or “switch” which should
follow the relevant names are sometimes omitted for simpler expression. When pressing two or
more keys at the same time, the keys are indicated by “+” as shown in the example below.

EXAMPLES
SELECT : expresses the hardware key “SELECT”.
A + MENU : indicates pressing and holding down A then pressing MENU.

2. SOFTWARE KEYS AND SWITCHES

D/E series controller provides software keys and switches which appear on the screen of the teach
pendant for various kinds of operations depending on specifications and situations. In this
manual, the names of software keys and switches are enclosed by “< >” parentheses. The terms
“key” or “switch” which should follow the relevant names are sometimes omitted for simpler
expression.

EXAMPLES
<ENTER> : expresses an “ENTER” key that appears on the teach pendant screen.
<NEXT PAGE> : expresses a “NEXT PAGE” key on the teach pendant screen.

3. SELECTION ITEMS

Quite often an item must be selected from a menu or pull-down menu on the teach pendant screen.
In this manual the names of these menu items will be enclosed [XXX] in brackets.

EXAMPLES
[BASIC SETTING] : expresses the item “BASIC SETTING” in a menu. To select it, press
the “SELECT” key after moving the cursor to the relevant item by the
arrow keys. For detailed description, this procedure should be
described every time, but “select [XXX] item” will be used instead for
simpler expression.

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D/E Series Controller
Kawasaki Robot Signal Output within Path Function (Option)

CONTENTS
1.0 Overview of Signal Output within Path Function ······························································5

2.0 Basic Program Construction ·······························································································6

3.0 Precautions when Programming ·························································································7

3.1 Teaching and Motion ··········································································································7
3.2 Signal Output ····················································································································11

4.0 Programming·····················································································································13
4.1 AS Program Instruction ····································································································13

5.0 Error Messages for Signal Output within Path Function··················································18

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D/E Series Controller 1.Overview of Signal Output within Path Function
Kawasaki Robot Signal Output within Path Function (Option)

1.0 OVERVIEW OF SIGNAL OUTPUT WITHIN PATH FUNCTION

In standard output function, to output a signal at a specific point in space, a point must be taught
in the robot program for the purpose of outputting the signal. The signal is output when the
robot completes motion and reaches axis coincidence at the taught point, or said differently, after
the memory change when the processor switches from the current point to the next point. This
is also true when teaching an output signal at a specified point on a robot motion path. However,
this operation actually splits one continuous robot motion thus reducing the max. speed possible
for the path or causing deceleration near the taught signal output point.

To avoid these cases, this optional function calculates the signal output point on the robot motion
path from the specified parameters (pose, distance) without splitting the motion and reducing
robot motion speed.

“Signal Output within Path” (between taught points) function consists of the following three AS
program instructions. (For details, see 4.1 AS Program Instruction.)

1. AS program instruction
SIGPOINT instruction : Outputs the specified signal at a point within the path that is nearest
to the taught pose.
SIGAPPRO instruction : Outputs the specified signal at a point within the path separated from
the end point by the specified distance.
SIGDEPART instruction: Outputs the specified signal at a point within the path separated from
the start point by the specified distance.

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D/E Series Controller 2. Basic Program Construction
Kawasaki Robot Signal Output within Path Function (Option)

2.0 BASIC PROGRAM CONSTRUCTION

This section describes how signals are output when using the signal output within path
function and compares it with programs using conventional SIGNAL instructions to clarify the
difference between the two methods.

Example:
Output signal1 at point #B1 during motion from point #A to #B by linear interpolation. Two
AS programs using the signal output within path function and the SIGNAL instruction are
shown below.

Signal output within path function Conventional SIGNAL instruction

JMOVE #A JMOVE #A
LMOVE #B1
SIGPOINT #B1, 1 SIGNAL 1
LMOVE #B LMOVE #B

Signal1 Signal1

#B1 #B #B1 #B
#A #A

Reduction of max. speed

V V

t t
t0 t0 t1

Deceleration near the taught signal output point

As shown above, program using the signal output within path function avoids the reduction of
robot motion speed at signal output point and in acceleration area. As a result, cycle time
shortens.

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D/E Series Controller 3. Precautions when Programming
Kawasaki Robot Signal Output within Path Function (Option)

3.0 PRECAUTIONS WHEN PROGRAMMING

3.1 TEACHING AND MOTION

1. Program cannot be started or ended by an instruction for signal output within path function.
Teach motion instructions before and after the instruction for this function. If not, error
“E1222 Motion instruction to start/end point of path not set.” occurs.

Example 1:
SIGPOINT #A , 1 E1222 Motion instruction to start/end point of path not set.
JMOVE #B
…

Example 2:
…
JMOVE #C
SIGPOINT #D , 2 E1222 Motion instruction to start/end point of path not set.

2. Before and after the instruction for this function, do not use motion instructions which do not
include pose information. If used, error “E1223 No pose data in last/next motion instruction.”
occurs. Instructions that do not include pose information are JAPPRO/LAPPRO,
JDEPART/LDEPART, HOME, DELAY, STABLE, etc.

Example 1:
JMOVE #A
LDEPART 100
SIGPOINT #B , 1 E1223 No pose data in last/next motion instruction.
LMOVE #C

Example 2:
JMOVE #A
SIGPOINT #B , 1 E1223 No pose data in last/next motion instruction.
LAPPRO #C , 100
LMOVE #C

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D/E Series Controller 3. Precautions when Programming
Kawasaki Robot Signal Output within Path Function (Option)

3. In this function, a max. of three signal output points can be specified within one path.
Specifying four or more signal output points results in error “E1219 Exceeds allowable No. of
output instructions for the path.” However, this error does not occur in single step check
mode.

Example:
JMOVE #A
SIGDEPART 100, 1
SIGPOINT #B1, 2
SIGAPPRO 100, 3
SIGAPPRO 50, 4 E1219 Exceeds allowable No. of output instructions for the path.
LMOVE #B

4. A max. of five output signals can be specified in each signal output point. Specifying six or
more output signals results in error “E1221 Too many signal numbers are specified.”

Example:
JMOVE #A
SIGPOINT #B2, 1, 2, 3, 4, 5, 6 E1221 Too many signal numbers are specified.
LMOVE #B

To output six or more signals at one signal output point, set another instruction as follows.

Example:
JMOVE #A
SIGPOINT #B2, 1, 2, 3, 4, 5
SIGPOINT #B2, 6
LMOVE #B

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D/E Series Controller 3. Precautions when Programming
Kawasaki Robot Signal Output within Path Function (Option)

5. When using the signal output within path function, the actual signal output point may deviate
from the taught signal output point.

Example:
When pose #B1 is taught for signal output point, actual signal output is at point #B1’ on the robot
motion line that is nearest to point #B1 if this function is used.

Signal output within path function Conventional SIGNAL instruction

JMOVE #A JMOVE #A
LMOVE #B1
SIGPOINT #B1, 1 SIGNAL 1
LMOVE #B LMOVE #B

Signal1

Signal1
#B1 #B1
#B #B

#A #A
#B1’

6. To check the actual signal output point (#B1’), move the robot in single step check mode. In
single step check mode, the instruction for this function outputs the signal after axes coincide
with the calculated signal output point and robot stops so that signal output point can be
confirmed.

Signal1
#B1 #B

#A
#B1’

7. In check back mode, robot does not stop at the signal output point.

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D/E Series Controller 3. Precautions when Programming
Kawasaki Robot Signal Output within Path Function (Option)

8. When signal output point calculated from the specified parameters (pose, distance) is not
within the robot motion path, signal cannot be output and error “E1220 Signal output point is
out of the path.” occurs.
Signal1
#B1
Example:
JMOVE #A #A #B
SIGPOINT #B1 , 1
LMOVE #B #B1’

E1220 Signal output point is out of the path.

9. If large accuracy is set, beware that signals in steps undergoing superposing motion may output
in reverse order, as shown below. For motion type 1, superposing is executed between all
motion steps/paths, for motion type 2, only between paths taught joint interpolation motion.

Example:
ACCURACY 200 ALWAYS
Superposing portion
JMOVE #A
SIGAPPRO 50 , 1 (Point S1) S1 #B
JMOVE #B Joint interp. S2
SIGDEPART 50 , 2 (Point S2) S2’
LMOVE #C S1’
#A
Linear interp.
#C

10. When SIGAPPRO/SIGDEPART instructions are used with JMOVE instruction, the distance
specified to calculate the signal output point is the distance on the straight line between the
start and end points. (“x” stands for distance here.)

Example:
JMOVE #A #A #B
SIGDEPART x , 1
x #B1
JMOVE #B

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D/E Series Controller 3. Precautions when Programming
Kawasaki Robot Signal Output within Path Function (Option)

3.2 SIGNAL OUTPUT

1. AS instructions for signal output within path function are not affected by ON/OFF of
PREFETCH.SIGINS. Signal is output at signal output point regardless of the switch
condition.

Example: #B
JMOVE #A #B1 #B2’
SIGPOINT #B1 , 1 , 2
SIGPOINT #B1 , 3
SIGPOINT #B2 , 4 #A #B1’ #B2
LMOVE #B
#A #B1’ #B2’ #B

SIG=1

SIG=2

SIG=3

SIG=4

2. In single step check mode, the instruction for this function outputs the signal after axes
coincide with the calculated signal output point and robot stops so that signal output point can
be confirmed.

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D/E Series Controller 3. Precautions when Programming
Kawasaki Robot Signal Output within Path Function (Option)

3. Be aware that the order of signal output may differ between single step check mode and
continuous check forward/repeat modes.
#B
Example: #B1 #B2’
JMOVE #A
SIGPOINT #B2 , 2
SIGPOINT #B1 , 1
#A #B1’ #B2
LMOVE #B

When the program above is executed in forward motion by single step check mode, robot moves
in order of #A → #B2’ → #B1’ → #B. Time charts for signal output for single step check mode
and continuous check forward mode/repeat mode are as follows.

Single step check mode Cont. check forward mode/repeat mode

#A #B2’ #B1’ #B #A #B1’ #B2’ #B

SIG=1 SIG=1

SIG=2 SIG=2

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D/E Series Controller 4. Programming
Kawasaki Robot Signal Output within Path Function (Option)

4.0 PROGRAMMING

4.1 AS PROGRAM INSTRUCTION

This section describes AS language specific to the signal output within path function. (For
details on AS language, see AS Language Reference Manual, a separate volume.)

1. SIGPOINT instruction
2. SIGAPPRO instruction
3. SIGDEPART instruction

[ NOTE ]
Syntax for the instructions is as follows.

Keyword Parameter

SIGPOINT Pose variable name, Signal number 1, Signal number 2, …

1. Parameters marked with can be omitted.

2. Always enter a space between the keyword and the parameter.
3. ↵ represents the ENTER key in the examples.

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D/E Series Controller 4. Programming
Kawasaki Robot Signal Output within Path Function (Option)

Program instruction
SIGPOINT Pose variable name, Signal number 1, Signal number 2, …

Function
Outputs the specified signal at a point within the path that is nearest to the taught pose.

Parameter
1. Pose variable name
Specifies the pose variable name where the signal will be output. (transformation values, joint
displacement values)

2. Signal number
Sets the number of an external output signal or an internal output signal. Error occurs when
selecting a signal number already set as a dedicated signal. Max. five signals can be specified.
Acceptable signal numbers are as follows:
External output signal : 1 ∼ max. available number of signals
Internal output signal : 2001 ∼ 2256
Plus signal number turns ON the signal and minus turns OFF the signal.

Detail description
When teaching a pose for outputting the signal, the actual output point is calculated from the
specified Pose variable name as a point on the motion path between the start and end points.
The output point is determined by the calculations below.

Example
1. In linear interpolation:
Outputs signals at points #B1’ and #B2’ on the straight line from start point (#A) to end point
(#B) that are nearest to the taught points (#B1 and #B2).

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D/E Series Controller 4. Programming
Kawasaki Robot Signal Output within Path Function (Option)

2. In joint interpolation:
Determines the signal output point based on the axis calculated to move the most among all
axes during motion from #A to #B. For example, if JT1 moves the most among the axes,
signals #B1 and #B2 output at #B1” and #B2” where JT1 values at those points become equal
to the values of JT1 in #B1 and #B2, respectively.

#B1 #B2’’ Signal2

JMOVE #A #B1’’
SIGPOINT #B1, 1 Signal1 #B2’
SIGPOINT #B2, 2 #B
#B1’
LMOVE #B #A
#B2
For linear/joint interpolations

3. In circular interpolation:
Outputs a signal at point #B1’ on the circular arc from points #A to #B when ∠#AO#B1 and
∠#AO#B1’ become equal. #C1’ is calculated in the same way as in the figure below.

JMOVE #A #C1’
SIGPOINT #B1, 1 Signal2
C1MOVE #B #C #C1
O
SIGPOINT #C1, 2
C2MOVE #C #B

#B1’
#A
Signal1
#B1
For circular interpolation

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D/E Series Controller 4. Programming
Kawasaki Robot Signal Output within Path Function (Option)

Program instruction
SIGAPPRO Distance, Signal number 1, Signal number 2, …

Function
Outputs the specified signal at a point within the path separated from the end point by the
specified distance.

Parameter
1. Distance
Specifies the distance between the signal output point and the path end point.

2. Signal number
Sets the number of an external output signal or an internal output signal. Error occurs when
selecting a signal number already set as a dedicated signal. Max. five signals can be specified.
Acceptable signal numbers are as follows:
External output signal : 1 ∼ max. available number of signals
Internal output signal : 2001 ∼ 2256
Plus signal number turns ON the signal and minus turns OFF the signal.

Detail description
1. In linear/circular interpolations:
Calculates the point that is separated from the end point by the specified distance as measured
along the robot motion path and outputs the signal at the point.

2. In joint interpolation:
First, obtains the linear distance between the start point and the end point and then the ratio of
the specified distance to the total linear distance. Then, finds the axis which moves the most
among the axes and then calculates the signal output point. For example, if JT1 moves the
most among the axes, signal is output at the point where the ratio of displacement to be traveled
to the total displacement in JT1 for the motion path becomes equal to the ratio of the specified
distance to the total distance obtained above.

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D/E Series Controller 4. Programming
Kawasaki Robot Signal Output within Path Function (Option)

Program instruction
SIGDEPART Distance, Signal number 1, Signal number 2, …

Function
Outputs the specified signal at a point within the path separated from the start point by the
specified distance.

Parameter
1. Distance
Specifies the distance between the path start point and the signal output point.

2. Signal number
Sets the number of an external output signal or an internal output signal. Error occurs when
selecting a signal number already set as a dedicated signal. Max. five signals can be specified.
Acceptable signal numbers are as follows:
External output signal : 1 ∼ max. available number of signals
Internal output signal : 2001 ∼ 2256
Plus signal number turns ON the signal and minus turns OFF the signal.

Detail description
1. In linear/circular interpolations:
Calculates the point that is separated from the start point by the specified distance as measured
along the robot motion path and outputs the signal at the point.

2. In joint interpolation:
First, obtains the linear distance between the start point and the end point and then the ratio of
the specified distance to the total linear distance. Then, finds the axis which moves the most
among the axes and then calculates the signal output point. For example, if JT1 moves the
most among the axes, signal is output at the point where the ratio of displacement to be traveled
to the total displacement in JT1 for the motion path becomes equal to the ratio of the specified
distance to the total distance obtained above.

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D/E Series Controller 5. Error Messages for Signal Output within Path Function
Kawasaki Robot Signal Output within Path Function (Option)

5.0 ERROR MESSAGES FOR SIGNAL OUTPUT WITHIN PATH FUNCTION

This section describes troubleshooting for errors specific to the signal output within path function.
(For other errors, see Troubleshooting Manual, a separate volume.)

1. E1219 Exceeds allowable No. of output instructions for the path.

This error does not occur in single step check mode.

Main cause:
No. of signal output points set for one robot motion path exceeds the allowable range.

Countermeasure:
Change the program by increasing the number of taught points, etc. so that No. of signal output
points for each robot motion does not exceed the allowable range.

2. E1220 Signal output point is out of the path.

Main cause:
Incorrect parameters (pose, distance) are set for the signal output point. Thus, the signal output
point was calculated to be outside the motion path and the signal was not output.

Countermeasure:
Set the correct parameters (pose, distance) so that the signal output point is calculated to be within
the motion path.

3. E1221 Too many signal numbers are specified.

This error occurs only when using the AS program instructions that are specific to the signal
output within path function.

Main cause:
The set number of output signals exceeds the range allowed to be used in AS program
instructions of the signal output within path function.

Countermeasure:
Reduce the specified number of signals.

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D/E Series Controller 5. Error Messages for Signal Output within Path Function
Kawasaki Robot Signal Output within Path Function (Option)

4. E1222 Motion instruction to start/end point of path not set.

Main cause:
In signal output within path function, motion points must be taught before and after the signal
output instruction to calculate signal output point. This error indicates that signal output point
cannot be calculated as there is no motion instruction to start/end point of path.

Countermeasure:
Specify the motion start point and/or motion end point with motion instructions.

5. E1223 No pose data in last/next motion instruction.

Main cause:
In signal output within path function, motion instruction with pose data must be taught before and
after the signal output instruction to calculate signal output point. This error indicates that a
motion instruction before and/or after the instruction for this function does not include pose
information.

Countermeasure:
Change the data set in the motion instruction, such as JMOVE, LMOVE, etc., to include pose
information.

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D/E Series Controller
Kawasaki Robot Signal Output within Path Function (Option)

MEMO

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 Kawasaki Robot Controller D/E Series
MANUAL FOR SIGNAL OUTPUT
WITHIN PATH FUNCTION (OPTION)

April 2005 : 1st Edition

July 2009 : 3rd Edition

Published by KAWASAKI HEAVY INDUSTRIES, LTD.

90210-1222DEC

Copyright © 2009 KAWASAKI HEAVY INDUSTRIES, LTD. All rights reserved.