Kawasaki Programming Guide RIV0002 TC

Rivian Robot Programming Guide – Kawasaki Implementation
Tool Changer
July 22nd 2023

Table of Contents
1. INTRODUCTION ............................................................................................................................................. 3
PURPOSE .........................................................................................................................................................3
Document Description..............................................................................................................................3
Who should use the document ................................................................................................................3
What should be learned ...........................................................................................................................3
2. IMPLEMENTATION ........................................................................................................................................ 3
APP SET ROUTINE SETTINGS ................................................................................................................................4
TCP CONVENTION FOR ATI TOOL PIN ...................................................................................................................4
SETTING TOOL ID ON ATI ...................................................................................................................................5
3. INTERFACE PANEL.......................................................................................................................................... 5
ATC INTERFACE PANEL ......................................................................................................................................5
ATC INTERFACE PANEL ICON DESCRIPTION ............................................................................................................5
4. ROBOT SETTINGS ........................................................................................................................................... 8
I/O COMMUNICATION SETTING ...........................................................................................................................8
ATC I/O Communication Setting ..............................................................................................................8
I/O NAMING....................................................................................................................................................9
5. ATI TOOL CHANGER DETAILS ....................................................................................................................... 10
CUBIC S TOOL IDENTIFICATION ..........................................................................................................................10
Tool Identification System Switch Settings ............................................................................................10
CS CONFIGURATOR TOOL IDENTIFICATION SETTINGS ..............................................................................................11
Tool ID / NO. Table .................................................................................................................................11
Tool Points Of Area Monitoring .............................................................................................................12
MULTI TOOL MOV_HOME SUBROUTINE ..............................................................................................................13
STATUS IDENTIFIER FOR ATI MODULE .................................................................................................................13
RTL 1 & RTL 2 CONNECTION............................................................................................................................14
ATI ( LOCK/UNLOCK) SAFETY SENSORS ...............................................................................................................14
6. ROBOT PROGRAMS ..................................................................................................................................... 15
FLOW CHARTS ................................................................................................................................................15
pg01(); Multi Tool Maintenance ............................................................................................................15
pg240(); Tool Swap No Tool ...................................................................................................................17
pg214(); Pick Tool 1................................................................................................................................17
pg242(); Pick Tool 2................................................................................................................................18
pg243(); Pick Tool 3................................................................................................................................18
atc_xpick(), Pick Tool x ...........................................................................................................................19
atc_xdrop(); Drop Tool x ........................................................................................................................20
SERVICE ROUTINES ..........................................................................................................................................21
pg01() ;Multi Tool Maintenance ............................................................................................................21
notoolmnt() ;No Tool Maintenance .......................................................................................................22
Kawasaki Programming Guide RIV0002 TC.docxPage 2 of 58

tool1mnt() ; Tool 1 Maintenance (SSW Example) ..................................................................................23
tool2mnt() ;Tool 2 Maintenance ............................................................................................................24
pg240() ;No Tool Swap ...........................................................................................................................25
pg241() ; Tool 1 Swap ............................................................................................................................25
pg242() ;Tool 2 Swap .............................................................................................................................26
PRODUCTION SUBROUTINES ..............................................................................................................................26
mov_home() ;Multi Tool Home ..............................................................................................................26
atc_lock() ;Tool Changer Lock ................................................................................................................28
atc_unlock() ;Tool Changer Unlock ........................................................................................................28
atc_verify(.reqtoolnum) ;Tool Changer Verify .......................................................................................29
PROGRAM EXAMPLES ......................................................................................................................................33
atc_1pick() ;ATC Pick Tool 1 ...................................................................................................................33
atc_1drop() ;ATC Drop Tool 1 ................................................................................................................34
7. KLOGIC TOOL CHANGER .............................................................................................................................. 43
1. Introduction
Purpose
Document Description
This document defines the basic methodology and structure for programming Kawasaki robots for Rivian
Tool Change applications. It is designed to give the guideline for standard programming, with
expectations that integrators can customize where required.
Who should use the document

This document is intended to be used by the OEM and system integrator programmers and engineers, as
well as Rivian controls and process engineers.
What should be learned

This document explains the general programing strategy for a Kawasaki robot. It explains the standards
that are to be applied to all Tool Changer application programs. It also includes template production
programs that must be used as models for the final application programs to be written by the integrators
and end user.
2. Implementation
The Tool Changer application is not a standalone application, most often implemented with Material
Handling, Servo Spot Weld, Self Pierce Rivet, etc., application(s). Note that this programming guide

appendix is used as detailed reference to ATI tool changing application; there are additional special
considerations that need to be referenced in each application programming guide as well.
App Set Routine Settings

The app set routine settings are required for each application. These settings enable certain settings
specific to applications. App set routine only runs on the first cycle of autostart.pc. Therefore any time you
cycle power to the robot or pc program 1 is aborted and killed, will the app_set() routine actually run. By
simply removing the negative state of the application bit will enable the settings. If a robot is in auto and
cannot be stopped, it is possible to still enable the app set settings. First you want to edit the app_set()
routine in the background. Then proceed to the keyboard screen and type “sig” space and the specific
signal you want to the positive state. If running multiple applications, there may be more signals set to the
positive state then the ones show below.
ATC app_set() Example:
TCP Convention for ATI Tool Pin

TCP convention should be as followed. The ATI pin, closest to the connection module, should be tool 9.
Z+ direction should move towards tool to be coupled. X+ direction should move towards the ATI
connection module.

Setting Tool ID on ATI
When setting the tool ID, all five positions need to be set to the same number. Example below would be
for “Tool 2”.
3. Interface Panel
The Tool Changer Interface Panel is shown below, followed by explanations of each icon.
The Tool Change Covers can be operated manually through the software interface screen in Teach
mode. To operate the tool stand covers in manual you must first turn off the open/close signals (OX
518/519), then you must change the binary signal for which cover you want to open/ close (OX 531-534).
Then the interface panel push buttons will work.
ATC Interface Panel
ATC Interface Panel Icon Description

4. Robot Settings
I/O Communication Setting
The i/o communication settings can be found AUX: 6: Input/Output Signal 8: Signal Allocation 9: Software
EtherNet/IP setting 4: I/O Communication setting. ATC used Node Number 1. must be used
to proceed through the menus. I/P address will be specific to each system. Setup provided below.
ATC I/O Communication Setting

I/O Naming
.AUXDATA
N_OX513"TC ERR RESET"
N_OX514"TC IN ERR"
N_OX517"TC IN PROCESS"
N_OX518"OPN TOOL STND COVERS"
N_OX519"CLS TOOL STND COVERS"
N_OX523"DUST COVER NOT PRESENT"
N_OX525"RBT AT PICK/DROP POS"
N_OX529"TC COUPLE"
N_OX530"TC UNCOUPLE"
N_OX531"TOOL LID REQ ID 1"
N_OX543"DUST CVR USED"
N_OX544"OPDOCK ENABLE BIT"
N_WX1513"TOOL 1 ON STAND"
N_WX1521"TC STND CVRS OPND"
N_WX1522"TC STND CVRS CLSD"
N_WX1523"TC MAINT SELECTED"
N_WX1525"ANY TOOL ON ROBOT"
N_WX1526"NO TOOL ON ROBOT"

N_WX1527"UNLATCH ENABLED"
N_WX1528"TC COMM OK"
N_WX1529"TC COUPLED"
N_WX1530"TC UNCOUPLED"
N_WX1531"TC TOOL ID 1"
N_WX1535"TOOL PRESENT"
N_WX1536"ALL TOOLS ON STAND"
N_WX1537"TC RTL 1"
N_WX1538"TC RTL 2"
N_WX1539"TC RTL VERIFY"
N_WX1540"TC TSIV"
N_WX1541"TC TSRV"
N_WX1542"INPUT & LOGIC PWR OK"
N_WX1543"TC VALVE PWR OK"
N_WX1544"TC TOOL PWR ON"
.END
5. ATI Tool Changer Details

Cubic S Tool Identification
These settings are only applicable to Robots with intent to use different tool shapes for each associated
tool.
Before applying the following settings, a few hardware items need to be confirmed.
• There is a Tool ID Kit in the Kawasaki Controller.
• Allen Bradley Safety I/O Module is wired to the robot controller
• Allen Bradley Safety I/O Module is wired to each tool changer stand for each tool
• Two set’s of Euchner switches for each tool/tool stand. (One transmitter on robot tool and One
transmitter on tool changer stand)
PLC programming is required for this functionality. The Transmitter switches on the tool stand will go back
to the PLC and then relaying back to the robot, which tool the robot is holding.
Tool Identification System Switch Settings

The system switch settings can be found AUX: 5: Advance Setting 2: System Switch. must be
used to proceed through the page, continue until is seen. Below is a example of the proper
settings

CS Configurator Tool Identification Settings
There are Cubic S configurator settings, specific to tool identification function, that need to be applied for
this functionality to work properly. Some detail to the examples below will vary, depending on how many
tools are being used. One thing to note when using this functionality, EACH tool will need to have defined
values for Tool Points of Area Monitoring. Changes to Cubic S will result in a safety signature
change.
Tool ID / NO. Table

The following settings can be found at: PARAMETER TREE VIEW > MONITORING COMMON
SETTINGS > TOOL ID/NO. TABLE. The settings below should be matched.

Tool Points Of Area Monitoring
The following settings can be found at: PARAMETER TREE VIEW > MONITORING COMMON
SETTINGS > TOOL POINTS OF AREA MONITORING. Here is where you will assign tool points for
individual Tool No Numbers, 1 through 9, where 9(Tool ID zero) is for ATI only. Please note that tool
points should start at “Tool Point9”, the reason we do this is on the teach pendant tool points 1-8 can be
modified. It is required that an experienced robot programmer should only be making these changes, to
not allow for unwanted modification.
Examples for Tool No.1 and 2 are provided below:

Optimizing Tool area monitoring shapes is preferred. If it is required to use more than eight tool points to
optimize a tool shape, this is acceptable.
Multi Tool mov_home Subroutine

There is special mov_home subroutine, used specifically for robots that use the tool identification
function. Examples can be found in the Robot Programs Section.
Status Identifier for ATI Module

RTL 1 & RTL 2 Connection
ATI ( Lock/Unlock) Safety Sensors

6. Robot Programs
Table 1 lists each production program example, utilized for performing tool changing motion, provided by
Kawasaki in which the line builder must use as a reference for motion programs.
Table 2 lists each production subroutine, provided by Kawasaki and used directly by the line builder
without modification.
Flow Charts
pg01(); Multi Tool Maintenance

pg240(); Tool Swap No Tool
pg214(); Pick Tool 1


atc_xpick(), Pick Tool x

atc_xdrop(); Drop Tool x

Service Routines
pg01() ;Multi Tool Maintenance
;************************************************
; COMPANY : RIVIAN
; PROGRAM : pg01(), MULTI TOOL MAINTENANCE
; REVISED LAST: 1/22/2021
; Produced by : RIVIAN KAWASAKI ROBOTICS DEV
;************************************************
;
;VERIFY PROGRAM
CALL pgverify(1)
;
;MOVE TO HOME
CALL mov_home;MOVE TO HOME
;
;************************************************
1;MAINTENANCE BASED ON CURRENT TOOL HELD BY ROBOT
;COMMENT OUT UNUSED TOOLS
;
;SET TOOL ID BIT
current_tool = BITS(1531,4);Tool Number on Robot
;
IF BITS(1531,4)==15 THEN
CALL notoolmnt
END
CALL tool1mnt
END
CALL tool2mnt
END
CALL tool3mnt
END
;CALL tool4mnt
END
;CALL tool5mnt
END
;CALL tool6mnt
END
;
GOTO 20
;
;SOMETHING ELSE WENT WRONG
;STYLE SELECT BITS NOT IN RANGE
;OR SOMETHING ELSE WENT WRONG
;HALT PROGRAM
998
alarm[5] = 1
PAUSE

alarm[5] = 0
GOTO 1
;
20; CONTINUE HOME
;
;MOVE TO HOME
notoolmnt() ;No Tool Maintenance

;*******************************************************
; COMPANY : Rivian
; PROGRAM : notoolmnt, NO TOOL MAINTENANCE POSITION (EXAMPLE)
;*******************************************************
;
;SET INTERNAL VARIABLE
; WHAT TOOL IS ON EOAT
eoat_present = BITS(1531,4) ;TOOL ID BITS
;
;NO EOAT ON TOOL CHANGER
;IF TOOL ID BIT = 15 MEANS
;NO TOOL IS ON EOAT
IF BITS(1531,4)>8 GOTO 899 ;TOOL ID BITS
GOTO 900
;
;NO TOOL ON EOAT
899
;
;MOVE TO HOME
;
;APPROACH TO MAINT POS
JOINT SPEED5 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,0) 2 (OFF,0,0,O) 3 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-96.128,-46.5,-11.35,-82.669,-96.489,9.868,-2000,-
0.0099007] ;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-96.128,-31.693,-29.797,-82.669,-95.212,51.411,-2000,-
0.0099007] ;
LINEAR SPEED5 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,0) 2 (OFF,0,0,O) 3 (OFF,0,0,O)
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-96.128,-12.499,-52.496,-82.656,-95.194,51.557,-2000,-
0.0099007] ;
;
;MAINTENANCE POSITION
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-96.128,35.239,-88.216,-81.013,-89.953,86.94,-2000,-
0.0099007] ;
;
;MAINTENANCE POSITION ON
SIGNAL 5 ;ROBOT AT MAINTENANCE POSITION
;
;WAIT FOR MAINTENANCE CLEAR
;FROM PLC
WAIT SIG(1008) ;MAINTENANCE POSITION CLEAR

;
;MAINTENANCE POSITION OFF
SIGNAL -5 ;ROBOT AT MAINTENANCE POSITION
;
;DEPART POSITION
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-96.128,-12.499,-52.496,-82.656,-95.194,51.557,-2000,-
0.0099007] ;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-96.128,-31.693,-29.797,-82.669,-95.212,51.411,-2000,-
0.0099007] ;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-96.128,-46.5,-11.35,-82.669,-96.489,9.868,-2000,-
0.0099007] ;
;
;TOOL ON EOAT
900
;
;MOVE TO HOME
;
tool1mnt() ; Tool 1 Maintenance (SSW Example)

;*******************************************************
; COMPANY : Rivian
; PROGRAM : tool1mnt, TOOL 1 MAINTENANCE POSITION (EXAMPLE)
;*******************************************************
;
;MOVE TO HOME
;
JOINT SPEED5 ACCU0 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,1,1) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-73.201,67.21,-32.299,-106.31,97.212,98.875,-800,158] ;
;
10;MAINTENANCE POSITION
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-74.881,80.435,-36.349,-107.3,96.727,94.761,-800,158] ;MAINT
;
SIGNAL 5 ;ROBOT AT MAINTENANCE POSITION ON
;
; IF TIP CHANGE REQUIRED GROUP 1, WATER OFF
IF SIG(1258) THEN; TIP CHANGE REQUIRED GROUP 1
SIGNAL (722); VALVE CLOSED
WAIT SIG(1722) AND SIG(-1721); VALVE CLOSED/WATER OFF
END;
;
;WAIT MAINTENANCE CLEAR OR STEPPERS ARE RESEET GROUP 1
;OR I/F PB TIP ALIGNMENT CLOSE
WAIT SIG(1008) OR SIG(1257) OR SIG(1249) ;
;
IF SIG(1008) OR SIG(1257) GOTO 20; MAINT POS COMP

IF SIG(1249) THEN; IF I/F PB TIP ALIGNMENT
;
;****TIP ALIGNMENT POSITION GUN OPENING 4MM*****
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-74.881,80.435,-36.349,-107.3,96.727,94.761,-800,4] ;MAINT
;
;WAIT MAINTENANCE CLEAR OR I/F PB TIP ALIGNMENT OPEN
WAIT SIG(1008) OR SIG(1250) ;
;
END
;
GOTO 10; MAINTENANCE POSITION
;
;*******************************************************
20; MAINTENANCE POSITION COMPLETE
;*******************************************************
;
IF SIG(-1721) THEN; IF WATER OFF, RESET WATER
SIGNAL (-722); VALVE CLOSED OFF
PULSE 721,0.5; WATER SAVER RESET
TWAIT 1; WATER SAVER RESET DELAY
WAIT SIG(1721); WAIT WATER FLOW OK
END;
;
WAIT SIG(-1240); NOT PULLED TIP BYPASS
;
;IF TIP DRESS BYPASS ON AND STEPPERS ARE RESET GROUP 1
;THEN SEAT CAPS AND TIP MEASUREMENT
IF SIG(1245) AND SIG(1257) THEN;
CALL seat_cap; NEW TIPS SEAT CAPS
CALL tip_meas1; TIP MEASUREMENT
CALL tip_cal1; TIP MEASUREMENT
END
;
;MAINT POSITION OFF
SIGNAL -5 ;ROBOT AT MAINTENANCE POSITION
;
;DEPART FROM MAINT POS
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-73.942,67.21,-32.299,-106.31,97.212,98.875,-800,158] ;
;
;MOVE TO HOME
;
tool2mnt() ;Tool 2 Maintenance

;*******************************************************
; COMPANY : Rivian
; PROGRAM : tool2mnt, TOOL 2 MAINTENANCE POSITION (EXAMPLE)
;*******************************************************
;
;MOVE TO HOME

;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-110,-30,15,0,-82.016,-70,-2000,0] ;
;
10;MAINTENANCE POSITION
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-110,-27.728,-35.904,0,-31.112,-69.999,-2000,0.0001737]
;
;
SIGNAL 5 ;ROBOT AT MAINTENANCE POSITION ON
;
;WAIT MAINTENANCE POSITION CLEAR
WAIT SIG(1008);
;
; IF MAINT POS CLEAR NOT ON GOTO 10
IF SIG(-1008) GOTO 10;
;
SIGNAL -5 ;ROBOT AT MAINT POS OFF
;
;DEPART FROM MAINT POS
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-110,-30,15,0,-82.016,-70,-2000,0] ;
;
;MOVE TO HOME
;
pg240() ;No Tool Swap

;************************************************
; COMPANY : RIVIAN
; PROGRAM : pg240(), NO TOOL
;************************************************
;
;VERIFY PROGRAM
CALL pgverify(240)
;
;MOVE TO HOME
;
CALL atc_verify(0)
;
;MOVE TO HOME
;
pg241() ; Tool 1 Swap

;************************************************
; COMPANY : RIVIAN
; PROGRAM : pg241(), PICK TOOL 1

;************************************************
;
;VERIFY PROGRAM
CALL pgverify(241)
;
;MOVE TO HOME
;
CALL atc_verify(1)
;
;MOVE TO HOME
;
pg242() ;Tool 2 Swap

;************************************************
; COMPANY : RIVIAN
; PROGRAM : pg242(), PICK TOOL 2
;************************************************
;
;VERIFY PROGRAM
CALL pgverify(242)
;
;MOVE TO HOME
;
CALL atc_verify(2)
;
;MOVE TO HOME
;
Production Subroutines
mov_home() ;Multi Tool Home
;************************************************
; COMPANY : RIVIAN AUTOMOTIVE
; PROGRAM : mov_home(), MULTIPLE HOME (EXAMPLE)
;************************************************
eoat_present = BITS(1531,4) ;TOOL ON ROBOT
;
; ADVANCED CUBIC-S MULTIPLE HOME
;-------------------------
CASE eoat_present OF

VALUE 1:
;MOVE HOME TOOL#1
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-94.077,-19.028,12.57,0.12758,-66.684,159.98,-2000,-4299.3]
;HOME
;-------------------------
;
VALUE 2:
;MOVE HOME TOOL#2
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-94.077,-19.028,12.57,0.12758,-66.684,159.98,-2000,-4299.3]
;HOME
;------------------------------
;
VALUE 3:
;MOVE HOME TOOL#3
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-94.077,-19.028,12.57,0.12758,-66.684,159.98,-2000,-4299.3]
;HOME
;-------------------------
;
VALUE 4:
;MOVE HOME TOOL#4
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-94.077,-19.028,12.57,0.12758,-66.684,159.98,110,-4299.3] ;HOME
;-------------------------
;
VALUE 5:
;MOVE HOME TOOL#5
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-94.077,-19.028,12.57,0.12758,-66.684,-25,-2000,-4299.3] ;HOME
;-------------------------
;
VALUE 6:
;MOVE HOME TOOL#6
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-94.077,-19.028,12.57,0.12758,-66.684,159.98,-2000,-4299.3]
;HOME
;-------------------------
;
VALUE 7:
;MOVE HOME TOOL#7
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-94.077,-19.028,12.57,0.12758,-66.684,159.98,-2000,-4299.3]
;HOME
;-------------------------
;
VALUE 8:
;MOVE HOME TOOL#8
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-94.077,-19.028,12.57,0.12758,-66.684,159.98,-2000,-4299.3]
;HOME
;-------------------------
;
VALUE 15:
;MOVE HOME TOOL#9

CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-94.077,-19.028,12.57,0.12758,-66.684,159.98,-2000,-4299.3]
;HOME
;-------------------------
END;
;
;********************************
;END PROGRAM
999
;
atc_lock() ;Tool Changer Lock

;************************************************
; COMPANY : RIVIAN
; PROGRAM : atc_lock(), TOOL CHANGER LOCK
; REVISED LAST: 02/26/2023 REV 02 (ATC)
; Produced by RIVIAN KAWASAKI ROBOTICS DEV
;************************************************
;
IF SIG(-1542) THEN ; IF ATC INPUT POWER FAULT THEN
PULSE 513,1.5 ;PULSE ATC RESET
END; IF ATC INPUT POWER NOT OK
;
power_ok:;WAIT FOR TOOL CHANGER POWER AND AIR
WAIT SIG(1542) AND SIG(1543) ;ATC INPUT & LOGIC PWR OK, ATC VALVE PWR OK
IF SIG(-1542) OR SIG(-1543) GOTO power_ok; ANTI-WAIT OVERRIDE
;
rtl_inputs:;WAIT FOR READY 2 LOCK INPUTS
WAIT SIG(1537) AND SIG(1538) ;RTL1, RTL2
IF SIG(-1537) OR SIG(-1538) GOTO rtl_inputs; ANTI-WAIT OVERRIDE
;
; SET OUTPUTS FOR LOCK
SIGNAL -530 ;RESET TOOL CHANGER UNCOUPLE
SIGNAL 529 ;SET TOOL CHANGER COUPLE
;
locked_inputs:;WAIT FOR INPUTS ATC_LOCKED
WAIT SIG(1529) AND SIG(-1530) ;ATC COUPLED, ATC UNCOUPLED
IF SIG(-1529) OR SIG(1530) GOTO locked_inputs; ANTI-WAIT OVERRIDE
;
safe_inputs:;WAIT FOR INPUTS BEFORE MOVING
WAIT SIG(1528) AND SIG(1540) AND SIG(1541) ;COMMS ACTIVE, TSIV, TSRV
IF SIG(-1528) OR SIG(-1540) OR SIG(-1541) GOTO safe_inputs; ANTI-WAIT OVERRIDE
;
atc_unlock() ;Tool Changer Unlock

;************************************************
; COMPANY : RIVIAN
; PROGRAM : atc_unlock(), TOOL CHANGER UNLOCK
; REVISED LAST: 02/26/2023 REV 02 (ATC)
;************************************************
;
IF SIG(-1542) THEN ; IF ATC INPUT POWER FAULT THEN

PULSE 513,1.5 ;PULSE ATC RESET
END; IF ATC INPUT POWER NOT OK
;
power_ok:;WAIT FOR TOOL CHANGER POWER AND AIR
WAIT SIG(1542) AND SIG(1543) ;ATC INPUT & LOGIC PWR OK, ATC VALVE PWR OK
IF SIG(-1542) OR SIG(-1543) GOTO power_ok; ANTI-WAIT OVERRIDE
;
safe_inputs:;WAIT FOR INPUTS BEFORE UNLOCKING
WAIT SIG(1540) AND SIG(1541) ;TSIV, TSRV
IF SIG(-1540) OR SIG(-1541) GOTO safe_inputs; ANTI-WAIT OVERRIDE
;
; SET OUTPUTS FOR UNLOCK
SIGNAL -529 ;RESET TOOL CHANGER COUPLE
SIGNAL 530 ;SET TOOL CHANGER UNCOUPLE
;
unlocked_inputs:;WAIT FOR INPUTS ATC_UNLOCKED
WAIT SIG(-1529) AND SIG(1530) ;ATC COUPLED, ATC UNCOUPLED
IF SIG(1529) OR SIG(-1530) GOTO unlocked_inputs; ANTI-WAIT OVERRIDE
;
atc_verify(.reqtoolnum) ;Tool Changer Verify

;************************************************
; COMPANY : RIVIAN
; PROGRAM : atc_verify(.reqtoolnum), TOOL CHANGER VERIFY
; REVISED LAST: 03/08/2023 REV 02
;************************************************
1
;
WAIT SIG(1528) ; ATC COMMS OK
IF SIG(-1528) GOTO 1; ANTI WAIT OVERRIDE
;
eoat_present = BITS(1531,4) ;TOOL ON ROBOT
;
;
;********************************
;IF REQUESTED TOOL NUMBER NOT IN
; THE RANGE OF 1-8
; THEN ABORT THIS JOB
IF .reqtoolnum<1 OR .reqtoolnum>8 GOTO 998
;********************************
;
;
;NO EOAT ON TOOL CHANGER
; IF TOOL ID BIT = 15 MEANS
; NO TOOL IS ON EOAT
IF BITS(1531,4)>8 GOTO 899
;
;-------------------------
;VERIFY REQUESTED TOOL IS ON EOAT
; IF REQUESTED TOOL == TOOL ON EOAT
; THEN END PROGRAM

IF BITS(1531,4)==.reqtoolnum GOTO 999
;
;SET ATC INTERNAL VARIABLE
lst_eoat_doff = BITS(1531,4) ;TOOL NUMBER ON ROBOT
;
;VERIFY TOOL STAND EMPTY BEFORE
; GOING TO ATC_xDROP
;-------------------------
CASE eoat_present OF
VALUE 1:
;VERIFY TOOL STAND #1 IS EMPTY
WAIT SIG(-1513) ;TOOL ON STAND #1
IF SIG(1513) GOTO 610 ;TOOL ON STAND #1
CALL atc_1drop;TOOL 1 DROP TO STAND
;-------------------------
;
VALUE 2:
;-------------------------
;
VALUE 3:
;-------------------------
;
VALUE 4:
;-------------------------
;
VALUE 5:
;-------------------------
;
VALUE 6:
;-------------------------
;
VALUE 7:

;-------------------------
;
VALUE 8:
;-------------------------
;
ANY :
GOTO 610
END
;
;
;NO TOOL ON EOAT, SKIP DROPOFF
899
;
; VERIFY NO TOOL PRESENT AND UNLOCKED
WAIT SIG(-1537) AND SIG(-1538) AND SIG(1530); NO TOOL/UNLOCKED
IF SIG(1537) OR SIG(1538) OR SIG(-1530) GOTO 899; ANTI WAIT OVERRIDE
;VERIFY TOOLx PRESENT IN STAND
; BEFORE GOING TO ATC_xPICK
;-------------------------
CASE .reqtoolnum OF
VALUE 1:
;VERIFY TOOL #1 IS PRESENT
WAIT SIG(1513) ; TOOL 1 ON STAND
IF SIG(-1513) GOTO 610
CALL atc_1pick;PICK FROM STAND 1
;-------------------------
;
VALUE 2:
;-------------------------
;
VALUE 3:
;-------------------------
;
VALUE 4:
;-------------------------
;
VALUE 5:

;-------------------------
;
VALUE 6:
;-------------------------
;
VALUE 7:
;-------------------------
;
VALUE 8:
;-------------------------
;
ANY :
GOTO 610
END
;
;
;WE HAVE A GOOD TOOL
IF BITS(1531,4)>=1 AND BITS(1531,4)<=8 GOTO 1
;
;-------------------------
;INVALID NEST CHECK
;TOOL STAND NOT IN RANGE
; OR SOMETHING ELSE WENT WRONG
; HALT PROGRAM
610
alarm[11] = 1
PAUSE
GOTO 1; RECHECK
;
;-------------------------
;REQUESTED TOOL NUMBER NOT IN RANGE
; ABORT PROGRAM
998
alarm[5] = 1
PAUSE
GOTO 899; RECHECK
;
;********************************
;EVERYTHING IS GOOD, END PROGRAM
999
;
;TOOL CHANGE NOT IN PROGRESS

SIGNAL -517 ;ATC IN PROGRESS
;********************************
Program Examples
atc_1pick() ;ATC Pick Tool 1
;************************************************
; COMPANY : RIVIAN
; PROGRAM : atc_1pick(), ATC PICK 1(EXAMPLE)
;************************************************
;
1;VERIFY TOOL#1 IS EMPTY
;IF NOT = 15, ABORT PROGRAM
IF BITS(1531,4)<>15 GOTO 999
;
;TOOL CHANGE IN PROGRESS
SIGNAL 517 ;TOOL CHANGE IN PROGRESS
;
;REQUEST TOOL LID
BITS 531,4 = 1
;
SIGNAL -519 ;CLOSE TOOL STAND COVERS
SIGNAL 518 ;OPEN TOOL STAND COVERS
;
;MOVE ABOVE TOOL #1 POS
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-3.6973,-22.723,-32.013,12.928,21.519,128.13,-902.86,158] ;
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-40.232,-1.8259,-34.606,66.797,42.865,84.172,-902.86,158] ;
;
;VERIFY NEST OPEN INPUTS
WAIT SIG(-1522) AND SIG(1521) ;TOOL STAND COVERS CLOSED, TOOL STAND COVERS OPEN
;
LINEAR SPEED4 ACCU2 TIMER0 TOOL9 WORK0 CLAMP1 (OFF,0,1,1) OX= WX=
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-30.65,24.52,-35.327,56.08,36.408,90.978,-1382.3,158] ;ABOVE2
;
;MOVE 2" ABOVE TOOL
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-28.419,33.274,-33.605,55.6,33.909,89.961,-1382.3,157.99]
;ABOVE2
;
;MOVE TO ENGAGE POSITION
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-27.647,36.603,-32.739,55.709,32.886,89.324,-1382.3,157.99]
;ENGAGE
;
SIGNAL 525 ;RBT AT ATC PICK/DROP LOCATION
;
;CHECK IF ATC IS IN POS

; WAIT FOR READY 2 LOCK
; THE PRESENCE OF A TOOL
; IS DETERMINED IN KLOGIC
WAIT SIG(1537) OR SIG(1538) AND SIG(1539) ;RTL1, RTL2, RTLV
;
;LOCK EOAT
CALL atc_lock
;
SIGNAL -525 ;RBT AT ATC PICK/DROP LOCATION
SIGNAL 457; TOOL NUMBER 1
;
;ADJUST FOR SAG
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-27.72,36.369,-33.024,55.096,33.8,89.86,-1382.3,157.99] ;
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-27.499,34.857,-28.721,60.527,31.343,83.283,-1382.3,157.99] ;
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-61.17,-34.294,-18.08,91.964,59.409,59.049,-1382.3,157.99] ;
;
;MOVE ABOVE STAND POS
;
;MOVE ATC POUNCE POS
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-67.023,-37.581,-5.3538,18.122,41.246,26.664,-903.18,158] ;
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-52.848,-2.7955,12.246,-91.696,96.528,59.69,-800,158] ;
;
;MOVE HOME
CALL mov_home
;
;RESET TOOL CHANGE IN PROGRESS
SIGNAL -517 ;RESET TOOL CHANGE IN PROGRESS
;
;END PROGRAM
RETURN
;
;------------------------------
; ABORT PROGRAM
999
alarm[11] = 1
PAUSE
alarm[11] = 0
GOTO 1
;
atc_1drop() ;ATC Drop Tool 1

;************************************************
; COMPANY : Rivian

; PROGRAM : atc_1drop(), ATC DROP 1 (EXAMPLE)
;************************************************
;
1;VERIFY TOOL#1 IS ON EOAT
IF BITS(1531,4)<>1 GOTO 999;
;
;
;REQUEST TOOL LID 1 OPEN
BITS 531,4 = 1 ;TOOL COVER REQUEST
;
;OPEN TOOL STAND COVERS
;
;
;MOVE BEFORE STAND POSITION
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[87.807,-6.1848,-22.562,-0.024122,-67.511,-
107.8,80,0.0012159] ;
;
;MOVE 2" ABOVE TOOL
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[89.831,8.9459,-46.538,-0.21427,-43.186,-
110.19,80,0.0012159] ;
;
;MOVE TO RELEASE POSITION
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[89.831,10.89,-48.619,-0.22313,-41.105,-
110.18,80,0.0013896] ;
;
;
;UNLOCK EOAT
CALL atc_unlock;
;
; MOVE TO TC CHECK POSITION
; JUST ABOVE PINS AND HIGH
; ENOUGH FOR THE ROBOT TO
; MOVE AWAY AND FOR THE TC
; TOOL TO SLIDE BACK INTO
; THE NEST IN CASE OF
; STICKING
;
;MOVE 2" ABOVE TOOL
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[89.831,8.995,-46.592,-0.21427,-43.131,-110.19,-
2000,0.0013896] ;
;

; CLOSE TOOL STAND COVERS
SIGNAL -518 ;OPEN TOOL STAND COVERS
SIGNAL 519 ;CLOSE TOOL STAND COVERS
;
WAIT BITS(1531,4)==15 AND SIG(1514) ;TOOL ID BITS, TOOL 1 ON STAND
;
;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[89.831,-8.6317,-11.101,-0.14944,-78.623,-110.32,-
2000,0.0012159] ;
;
; CLOSE TOOL STAND COVERS
;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[158.54,-38.032,16.99,-4.9873,-71.838,-56.178,-
2000,0.0001737] ;Clr Tool Stand
;
;VERIFY NEST CLOSED INPUTS
WAIT SIG(1522) AND SIG(-1521) ;TOOL STAND COVERS CLOSED, TOOL STAND COVERS OPENED
;
;RESET TOOL LID REQUEST
BITS 531,4 = 0 ;Tool Cover Request
;
;END PROGRAM
RETURN;
;
;------------------------------
; ABORT PROGRAM
999;
alarm[11] = 1
PAUSE
alarm[11] = 0
GOTO 1
;

;************************************************
; COMPANY : RIVIAN
; PROGRAM : atc_2pick(), TOOL2 PICK
; Produced by KAWASAKI ROBOTICS (USA) Inc.
;************************************************
;
1; VERIFY TOOL#2 IS PRESENT
; IF NOT = 15, ABORT PROGRAM
; SOMETHING ELSE WENT WRONG
IF BITS(1531,4)<>15 GOTO 999

;
;
;REQ TOOL COVER
BITS 531,4 = 2
;
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-3.6243,-23.581,-31.42,10.663,19.931,-145.13,-902.86,158]
;ABOVE1
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[28.13,-15.122,-31.82,-58.52,32.68,-88.079,-902.68,158] ;ABOVE1
;
;
;MOVE 2" ABOVE TOOL
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[18.564,26.335,-35.31,-40.01,28.883,-103.43,-902.68,157.99]
;ABOVE2
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[18.088,29.316,-34.756,-39.84,28.208,-103.31,-902.68,157.99]
;ENGAGE
;
;
;
;LOCK EOAT
CALL atc_lock
;
SIGNAL 458 ; TOOL NUMBER 2 ACTIVE
;
;ADJUST FOR SAG
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[18.04,27.931,-32.095,-43.187,26.186,-99.517,-902.68,157.99] ;
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[33.273,-32.555,-21.745,-78.018,33.231,-67.685,-902.68,158] ;
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-46.816,-34.963,19.309,-121.52,62.966,9.5356,-464.15,158] ;

;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-74.725,-27.915,19.59,-95.986,77.826,14.129,-386.89,158] ;
;
CALL mov_home
;
;
;END PROGRAM
RETURN
;
;------------------------------
; ABORT PROGRAM
999
alarm[11] = 1
PAUSE
alarm[11] = 0
GOTO 1
;

;************************************************
; COMPANY : Rivian
;************************************************
;
IF BITS(1531,4)<>2 GOTO 999
;
;
;
;
;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[158.92,-27.28,20,14.391,-39.776,-36.666,-2000,179.99] ;
;
;MOVE 2" ABOVE TOOL

OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[140.24,19.666,-21.976,48.608,-46.131,7.7753,-2000,0] ;
;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[140.24,20.286,-23.622,49.829,-45.055,6.0306,-2000,0] ;
;
;
;UNLOCK EOAT
CALL atc_unlock
;
;MOVE TO TC CHECK POSITION
; STICKING
;
;MOVE 2" ABOVE TOOL
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[140.98,18.527,-22.637,49.238,-46.215,6.4565,-2000,0] ;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[142.17,15.48,-20.645,47.632,-48.212,7.68,-
2000,0.0012159] ;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[150.59,-12.011,-2.077,20.602,-24.362,-72.454,-2000,-
0.0067742] ;clr Stand
;
;REQUEST TOOL LID 2 CLOSE
;
;
;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[158.36,-37.373,16.374,-4.3326,-94.07,-146.38,-2000,180]
;clr Stand
;
;
;
;END PROGRAM
RETURN
;
;------------------------------
; ABORT PROGRAM

999
alarm[11] = 1
PAUSE
alarm[11] = 0
GOTO 1
;

;************************************************
; COMPANY : RIVIAN
; PROGRAM : atc_3pick(), ATC PICK 3 (EXAMPLE)
;************************************************
;
1; VERIFY TOOL#2 IS PRESENT
; IF NOT = 15, ABORT PROGRAM
; SOMETHING ELSE WENT WRONG
IF BITS(1531,4)<>15 GOTO 999
;
;
;REQ TOOL COVER
BITS 531,4 = 3
;
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-3.6243,-23.581,-31.42,10.663,19.931,-145.13,-902.86,158]
;ABOVE1
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[28.13,-15.122,-31.82,-58.52,32.68,-88.079,-902.68,158] ;ABOVE1
;
;
;MOVE 2" ABOVE TOOL
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[18.564,26.335,-35.31,-40.01,28.883,-103.43,-902.68,157.99]
;ABOVE2
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[18.088,29.316,-34.756,-39.84,28.208,-103.31,-902.68,157.99]
;ENGAGE
;
;

;
;LOCK EOAT
CALL atc_lock
;
SIGNAL 458 ; TOOL NUMBER 2 ACTIVE
;
;ADJUST FOR SAG
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[18.04,27.931,-32.095,-43.187,26.186,-99.517,-902.68,157.99] ;
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[33.273,-32.555,-21.745,-78.018,33.231,-67.685,-902.68,158] ;
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-46.816,-34.963,19.309,-121.52,62.966,9.5356,-464.15,158] ;
;
CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[-74.725,-27.915,19.59,-95.986,77.826,14.129,-386.89,158] ;
;
;
CALL mov_home
;
;END PROGRAM
RETURN
;
;------------------------------
; ABORT PROGRAM
999
alarm[11] = 1
PAUSE
alarm[11] = 0
GOTO 1
;

;************************************************
; COMPANY : Rivian
;************************************************
;

IF BITS(1531,4)<>3 GOTO 999
;
;
;
SIGNAL 518 ;OPEN TOOL STAND COVERSz
;
;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[163.01,-31.22,13.507,-2.4993,-110,-149.28,-2000,-
0.0076427] ;
;
;MOVE 2" ABOVE TOOL
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[145.22,50.5,-75.424,111.17,-38.385,-250.38,-2000,-
0.0099007] ;Above Ati Pic
;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[145.26,53.275,-76.717,112.63,-38.875,-252.3,-2000,-
0.0099007] ;PickPos.
;
;
;UNLOCK EOAT
CALL atc_unlock
;
;MOVE TO TC CHECK POSITION
; STICKING
;
;MOVE 2" ABOVE TOOL
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[146.14,51.196,-76.531,111.47,-38.993,-251.91,-2000,-
0.0076427] ;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[151.1,26.505,-70.594,104.99,-30.234,-245.31,-2000,-
0.0076427] ;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[155.38,-17.312,-45.311,61.682,-51.41,-193.7,-2000,180]
;clr Stand
;
;REQUEST TOOL LID 2 CLOSE

;
;
;
OX= WX= CL1=0.000,0.0,0.0,0.0,0.0,0.0,0.0 #[158.36,-37.373,16.374,-4.3326,-54.638,-146.38,-
2000,180] ;clr Stand
;
;
;
;END PROGRAM
RETURN
;
;------------------------------
; ABORT PROGRAM
999
alarm[11] = 1
PAUSE
alarm[11] = 0
GOTO 1
;
7. KLogic Tool Changer

The remainder of this document lists the Kawasaki KLogic that has been configured for the Tool Changer
application. In addition, the Common and Material Handling KLogic are included.


Kawasaki Programming Guide RIV0002 TC

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Rivian Robot Programming Guide – Kawasaki Implementation

July 22nd 2023

Kawasaki Programming Guide RIV0002 TC.docxPage 2 of 58

Who should use the document

What should be learned

Kawasaki Programming Guide RIV0002 TC.docxPage 3 of 58

App Set Routine Settings

ATC app_set() Example:

TCP Convention for ATI Tool Pin

Kawasaki Programming Guide RIV0002 TC.docxPage 4 of 58

ATC Interface Panel

ATC Interface Panel Icon Description

Kawasaki Programming Guide RIV0002 TC.docxPage 5 of 58

ATC I/O Communication Setting

Kawasaki Programming Guide RIV0002 TC.docxPage 8 of 58

Kawasaki Programming Guide RIV0002 TC.docxPage 9 of 58

5. ATI Tool Changer Details

Tool Identification System Switch Settings

Kawasaki Programming Guide RIV0002 TC.docxPage 10 of 58

Tool ID / NO. Table

Kawasaki Programming Guide RIV0002 TC.docxPage 11 of 58

Examples for Tool No.1 and 2 are provided below:

Kawasaki Programming Guide RIV0002 TC.docxPage 12 of 58

Multi Tool mov_home Subroutine

Status Identifier for ATI Module

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ATI ( Lock/Unlock) Safety Sensors

Kawasaki Programming Guide RIV0002 TC.docxPage 14 of 58

Kawasaki Programming Guide RIV0002 TC.docxPage 15 of 58

pg214(); Pick Tool 1

Kawasaki Programming Guide RIV0002 TC.docxPage 17 of 58

pg243(); Pick Tool 3

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notoolmnt() ;No Tool Maintenance

Kawasaki Programming Guide RIV0002 TC.docxPage 22 of 58

tool1mnt() ; Tool 1 Maintenance (SSW Example)

Kawasaki Programming Guide RIV0002 TC.docxPage 23 of 58

tool2mnt() ;Tool 2 Maintenance

Kawasaki Programming Guide RIV0002 TC.docxPage 24 of 58

pg240() ;No Tool Swap

pg241() ; Tool 1 Swap

Kawasaki Programming Guide RIV0002 TC.docxPage 25 of 58

pg242() ;Tool 2 Swap

Kawasaki Programming Guide RIV0002 TC.docxPage 26 of 58

Kawasaki Programming Guide RIV0002 TC.docxPage 27 of 58

atc_lock() ;Tool Changer Lock

atc_unlock() ;Tool Changer Unlock

Kawasaki Programming Guide RIV0002 TC.docxPage 28 of 58

atc_verify(.reqtoolnum) ;Tool Changer Verify

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atc_1drop() ;ATC Drop Tool 1

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atc_2pick() ;ATC Pick Tool 2

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