Manual: Mastering KUKA Control Systems

INDEX
PROJECT HISTORY ............................................................................................................... 1
GENERAL INFORMATION ..................................................................................................... 2
REASONS FOR MASTERING ................................................................................................ 2
MASTERING KUKA ROBOTS................................................................................................ 2
Moving the Robot to pre-position mastering ....................................................................................2
Driving to mechanical zero point......................................................................................................3
Transfer mastering value...................................................................................................................3
MASTERING KHS ROBOTS .................................................................................................. 4
Moving machine to mastering position.............................................................................................4
Transfer mastering value...................................................................................................................4
Project history
Data: Editor: Modified: Version:

14th. July 05 B. Miesel • Document created V1.0

28th. June 06 B. Miesel • Graphic “Detail dial gauge” modified V1.1

Editor (Name, Date) Version: Page:

Bernhard Miesel, 28th. June 2006 1.1 1 /4
E:\Standard_PC_S7_Steuerungen\PC_St_Anleitungen\Anleitung_Justage_KUKA_Steuerungssysteme_GB.doc
 Manual: Mastering KUKA Control Systems

General information
The precise approach is required for the exact positioning of the Robot axis. Improper handling might cause the damage of
machine components.
Reasons for mastering
Mastering is required... Reset mastering is carried out...

... after reparations (e.g. change of driving motors or RDW) ... automatically at Start-up ¹)
... when the Robot has been moved without control (e.g.
... automatically at Start-up ¹)
with the hand crank)
... after driving against a mechanical limit stop faster than
... manually from the operator
manual motion speed (25cm/s)
... after a collision of the Robot ... manually from the operator

¹) Are divergences at shut down of control between saved resolve data and actual position, all mastering data will be erased due to safety
reasons.

Reset of mastering when... Reset mastering is carried out...

... the mastering data of single axis have to be deleted ... manually from the operator

Mastering KUKA Robots

When mastering the Robot the axis are moved into a defined mechanical position, the so-called “Mechanical zero point”. Is
the Robot in this position the absolute sensor values are saved for each axis. For that purpose a device to apply a dial gauge
is provided at each axis of the Robot. At motion this dial gauge puts a check pin into a measuring notch. At the lowest point
of the notch is the mechanical zero point of the Robot axis.

Dial gauge Measuring cartridge, pre-position mastering (notch and bead sights)

Moving the Robot to pre-position mastering

Move the Robot axis to the pre-position for mastering with

specific axis motion. Notch and bead sights of each pre-position
have to be aligned.

Indication: Is the preposition of mastering reached and the dial

gauge mounted, move only in operation mode T1 with 1%
speed. Improper handling might cause damages of the dial
gauge or measuring cartridge.

The measuring order is always A1 -> A6.

Editor (Name, Date) Version: Page:

Bernhard Miesel, 28th. June 2006 1.1 2 /4
E:\Standard_PC_S7_Steuerungen\PC_St_Anleitungen\Anleitung_Justage_KUKA_Steuerungssysteme_GB.doc
 Manual: Mastering KUKA Control Systems

Driving to mechanical zero point

Mount the dial gauge onto the measuring cartridge. Move the axis to direction „Minus“ until the minimum value on the dial gauge is
adjusted. The lowest point is where the pointer of the dial gauge changes from the decreasing value to the increasing value. This point has
to be met exactly (1 scale line exactly!). If this point has been passed, move to positive direction first and than to direction „Minus“ again.
To follow this procedure is strictly necessary to eliminate a gear backlash.

Dial gauge
Motion direction

+ -

Measure-cartdrige

Notch and bead sight

Measure-jag
Measure-pin

Transfer mastering value

After the lowest point in „Minus-direction“ is reached, the mastering value has to be transferred into the KUKA Control System. Repeat
process for all available axis.
Indication: Please pay attention to the mastering order A1 -> A6.
To start the mastering select „Setup“ in the upper menu bar and select the entry „Master
Dial“ confirm with enter. „Setup“ is only
selectable at deselected program. To deselect the program select „Edit“ in the upper menu bar and select the entry „Cancel program“
confirm with enter. The window „Dial mastering“ opens. In „Dial mastering“ select the axis listed at first and select „Master“ in the lower
menu bar. This axis is now mastered. Repeat this process until all axis are mastered. The status message „No axis for mastering“ appears.
To close the window „Dial mastering“ select „Close“ in the lower menu bar.

Editor (Name, Date) Version: Page:

Bernhard Miesel, 28th. June 2006 1.1 3 /4
E:\Standard_PC_S7_Steuerungen\PC_St_Anleitungen\Anleitung_Justage_KUKA_Steuerungssysteme_GB.doc
 Manual: Mastering KUKA Control Systems

Mastering KHS Robots

When mastering the Robot the axis are moved into a defined mechanical position, the so-called “Mechanical zero point”. Is
the Robot in this position the absolute sensor values are saved for each axis.
Compared to the KUKA Robots, the according machine parts are marked with mastering marks. The mastering can be
carried out supported by this marks.

Mastering arrow and mastering mark at KHS Machine

Moving machine to mastering position

Move the Robot axis to the mastering position with specific axis
motion. Mastering arrow and mastering mark are aligned.

Transfer mastering value

After the lowest point in „Minus-direction“ is reached, the mastering value has to be transferred into the KUKA Control System. Repeat
process for all available axis.
Indication: Please pay attention to the mastering order A1 -> A6.
To start the mastering select „Setup“ in the upper menu bar and select the entry „Master
Dial“ confirm with enter. „Setup“ is only
selectable at deselected program. To deselect the program select „Edit“ in the upper menu bar and select the entry „Cancel program“
confirm with enter. The window „Dial mastering“ opens. In „Dial mastering“ select the axis listed at first and select „Master“ in the lower
menu bar. This axis is now mastered. Repeat this process until all axis are mastered. The status message „No axis for mastering“ appears.
To close the window „Dial mastering“ select „Close“ in the lower menu bar.

Editor (Name, Date) Version: Page:

Bernhard Miesel, 28th. June 2006 1.1 4 /4
E:\Standard_PC_S7_Steuerungen\PC_St_Anleitungen\Anleitung_Justage_KUKA_Steuerungssysteme_GB.doc