KUKA - ServoTech D 1.0 EN 17.2.2012 VORAB

KUKA.ServoTech D 1.
0
Proprietary information of KUKA Automatisering + Robots N.V | www.kuka.be
Software
KUKA.ServoTech_D 1.0
Option to KSS V8.2
Document history
Documentation version 1.0.1
Version 2012-02-07
Copyright
KUKA Automatisering + Robots N.V.
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the
publishers. Other functions not described in this documentation may be operable in the controller. The user has no claim to these
functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless,
discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this
documentation is checked on a regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.
300085 | 2012-02-07 | DC| KUKA.ServoTech_D_1.0_EN.doc Page 1/42

KUKA.ServoTech D 1.0
Software License Terms
By purchasing the Software product, or by installing or using it, Licensee agrees with the terms and conditions contained with the
license agreement terms and conditions contained herein.
1. The subject matter of this License is the Software product which has been pre-installed or recorded on a data medium, including
contents such as illustrations, diagrams, text and sample RoboSpin, and all associated documentation.
2. Licensor grants Licensee a nonexclusive, irrevocable, perpetual license to use the Software, subject to the confidentiality
provisions of this License. No right to grant sublicenses is granted hereunder, unless the prior written consent of Licensor is
obtained. All copyrights and other intellectual property rights are retained by the Licensor and the Licensor’s subcontractors.
3. The License includes:
· use of the Software product on a single computer;
· if multiple licenses are purchased, use of the Software product on as many computers as Licenses were purchased;
· creation of one backup copy. Licensee agrees to reproduce and include the copyright notice on any such copy.
The License does not include updates/upgrades, unless such were expressly specified as part of the scope of supply.
4. Neither the Licensee nor third parties may copy, modify, or separate components of the Software product, i.e. they may not
disassemble or decompile it or carry out reverse engineering. In addition, the Software product may not be transferred on to third
parties, leased, or sold.
5. The Licensee may not remove copyright notes or any other indications of legal ownership from the Software product.
6. Licensor warrants Licensor has the right to license the Software product and grant the rights granted herein. The Licensor further
warrants: that the data medium is free of material and manufacturing defects; that when used as agreed the Software product
substantially conforms to the associated documentation; and that it does not contain any defects which render it incapable of use or
substantially reduces its utility. The warranty period is 3 months, commencing on the date of delivery.
All other warranties and guarantees, whether statutory or implied in law, are excluded, and waived by Licensee, including, but not
limited to merchantability, fitness for a particular purpose, or assurance that intellectual property rights of third parties will not be
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special, incidental, or consequential damages, expenses or lost profits, lost savings, loss of data, business interruption or other
similar damages resulting from use of the Software product, or from the fact that the Software product could not be used. Licensor's
entire liability with respect to the Software shall be as set forth herein.
8. In addition, the Licensee and User is responsible for the selection of software and hardware, for installation and use, for the
expected results, and for data privacy and data protection.
9. Licensor may at any time, verify (audit) the use of the Software product and in such case, Licensee agrees to provide reasonable
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such information by using the same degree of care, but no less than a reasonable degree of care, to prevent the unauthorized use,
dissemination, or publication of the corporate and technical information of Licensor as Licensee uses to protect its own corporate
and technical information of a like nature. The Belgian Law Against Unfair Competition shall apply.
11. KUKA Automatisering + Robots” General Terms of Delivery and Performance shall apply to this License. In case of contrariness
of any clause this licence agreement is overriding applicable.
12. If individual provisions of this License are or become invalid, the validity of the remaining provisions shall remain unaffected.
Invalid provisions shall be replaced by valid provisions whose effect comes closest to the intended commercial purpose of the
invalid provisions.
13. This Agreement shall be construed according to, and the rights and obligations of the parties shall be governed under the laws
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14. This License and all documents specifically referenced herein constitute the entire agreement between Licensor and Licensee in
connection with this License and supersedes all prior and contemporaneous agreements, understandings, negotiations, and
discussions of the parties.
15. This License may be cancelled by Licensor if any material provisions hereof or of KUKA Automatisering + Robots’ General
Terms of Delivery and Performance are breached by Licensee.
16. Licensee warrants that, in the use of the Software, it shall comply with all applicable governmental laws, codes and regulations.
17. Any waiver of strict compliance with this License or KUKA Automatisering + Robots N.V.’s General Terms of Delivery and
Performance by Licensor must be in writing and signed by Licensor, and any such waiver shall not constitute a waiver of Licensor’s
rights under any other provision of this License or the General Terms of Delivery and Performance.

1 Introduction
1.1 Important notes
1.2 Safety instructions
2 Installation
2.1 Installation requirements
2.2 Installing the software
2.3 Updating the software
2.4 Uninstalling the software
2.5 Automatic software update
3 ServoGun_FC_D
3.1. Configuration ServoGun_FC_D
3.1.1 Gun specific options
3.1.2 Configure additional IO signals
3.1.3 Configure user specific sub programs
3.1.4 Special features
3.2 Programming ServoGun_FC_D
3.2.1 Initialize force control
3.2.2 Spot
3.2.3 Tip initialisation
3.2.4 Tipdress
3.2.5 Servo gun couple
3.2.6 Servo gun decouple
3.3 Plug-In Weld timer data overview
4 EqualizingTech_D
4.1 Configuration EqualizingTech_D
4.1.1 Configure gun compensation type

4.2 Programming EqualizingTech_D
4.2.1 Initialize equalizing tech
5 RoboSpin_D
5.1 Configuration RoboSpin_D
5.1.1 RoboSpin parameters
5.1.2 Diagnosis of RoboSpin technology
5.1.3 The diagnostics status keys
5.1.4 The diagnostics window
5.1.5 Diagnostic info messages
5.2 Programming RoboSpin_D
5.2.1 RoboSpin Spot
6 Functions overview
6.1 ServoGun_FC_D
6.2 EqualizingTech_D
6.3 RoboSpin_D
7 Release Notes

1 Introduction
KUKA.ServoTech_D is a software bundle that consists of following 3 technology packages:
• KUKA.ServoGun_FC_D
• KUKA.EqualizingTech_D
• KUKA.RoboSpin_D.
These technology packages are created with specifications from Daimler.

Because the KUKA.ServoTech_D packages are based upon KUKA.ServoGun_FC 2.0 package, these
technology packages can not be installed simultaneously on the robot controller.
KUKA.ServoGun_FC_D is based upon KUKA.ServoGun_FC V2.0 b15 and extends the technology with
following options:
- New way for program selection, definable pro gun
- Configurable number of digits for program selection in point name, definable pro gun
- New inline from for initializing force control behaviours.
- New option in inline from Initialize tooltip : SetTip
- Read data from weld timer at runtime: force, thickness, thickness tolerance and weld time.
- View data from weld timer in new parameter list
- Overview of data from weld timer in new plug-in window.
KUKA.EqualizingTech_D is based on KUKA.EqualizingTech V1.0 b6 and extends the technology with the
option to initialize different sets of Equalizing parameters.
KUKA.RoboSpin_D is a new technology with the option to execute a spinning motion around the tool
centre point during the welding process. The spinning motion results in a better welding quality and a
longer lifecycle for the tip-dress.
KUKA.ServoGun_FC_D <= KUKA.ServoGun_FC V2.0 b15

KUKA.ServoTech_D KUKA.EqualizingTech_D <= KUKA.EqualizingTech V1.0 b6
Bundle of Technology packages KUKA.RoboSpin_D
Fig. 1. KUKA ServoTech_D 1.0

1.1 Important notes
KUKA.ServoTech_D is an extension of other technology packages. This documentation only handles

the new features. Please read the documentation of KUKA.ServoGun_FC V2.0 and
KUKA.EqualizingTech V1.0 first.
KUKA.ServoTech_D is a software toolbox, which allows system integrators to build installations such
as the one shown above. However, the configuration of the software can be different for every
installation installed at the customer site. This integration step is not included in the delivery of KUKA.
RoboSpin. This integration step requires profound knowledge in following areas: cell design, KRL
expert level programming and robot machine data.
1.2 Safety instructions

The system may only be operated, maintained and repaired by personnel specially
trained to work on this system.
When operating or working on this system, the safety instructions in the chapter
[Safety] of the robot documentation and the safety instructions issued by the bending
press manufacturer must be observed!
Any injury to persons or damage to equipment resulting from the non-observance of
general safety instructions or instructions contained within this documentation
releases the manufacturer from his warranty obligations.

2 Installation
2.1 Installation requirements
The KUKA.ServoTech_D software bundle can be installed on KR C4 controllers with KSS version 8.2.
This software can not be installed simultaneous with following options:
• KUKA.ServoGun_FC 2.0
• KUKA.EqualizingTech 1.0
• KUKA.ServoTech TC 4.0
Note. The software has been tested and released with software 8.2 Other versions of the software,
are not supported.
2.2 Installing the software
The program Setup.exe is used to install the KUKA.ServoTech_D software.
The KUKA.ServoTech_D software consists of 3 technology packages that need to be installed in

following order:
1. KUKA.ServoGun_FC_D
2. KUKA.EqualizingTech_D
3. KUKA.RoboSpin_D
Install these 3 packages after each other with attention to the order.
A LOG file for each installed technology package is created under C:\KRC\ROBOTER\LOG.
Note. The installation of technology packages are described in detail in the documentation
“TechInstall_en.pdf”.
2.3 Updating the software
When the same or a minor version of the KUKA.ServoTech_D software is already installed, the setup is
able to automatically update the software from the installation CD. During an update the user settings will
be re-stored after the new installation. We advise to make a backup of the robot controller before starting
software updates.
2.4 Uninstalling the software
The program C:\KRC_OPTION\xxx\Uninst\Uninstall.exe is used to uninstall the KUKA.ServoTech_D

software.
The KUKA.ServoTech_D software consists of 3 technology packages that need to be uninstalled in

following order:

1. KUKA.RoboSpin_D
2. KUKA.EqualizingTech_D
3. KUKA.ServoGun_FC_D
Uninstall these 3 packages after each other with attention to the order.
A LOG file for each uninstalled technology package is created under C:\KRC\ROBOTER\LOG.
Note. The uninstallation of technology packages are described in detail in the documentation
“TechInstall_en.pdf”.
2.5 Automatic software update
After an update of the KUKA System Software without a change in the release (e.g. 8.2.95 to 8.2..
102), an automatic software update KUKA.ServoTech_D is possible.
After an automatic software update of the KUKA System Software with a change in the release (e.g. 8.2
to 8.3), KUKA.ServoTech_D does not provide automatic conversion tools.

3 ServoGun_FC_D
3.1. Configuration ServoGun_FC_D
The smooth and safe operation of KUKA.ServoTech_D depends on the correct setting of the technology
parameters. Following configuration steps should be performed:
• Set gun specific options

• Configure additional IO signals
• Special features
Note. These integration steps require a profound knowledge in KRL expert level programming.
Note. KUKA.ServoGun_FC_D 1.0 is an extension of KUKA.ServoGun_FC 2.0. This documentation

only handles the new configuration steps. Please handle the software commissioning of
KUKA.ServoGun_FC V2.0 first.
3.1.1 Gun specific options

In the file C:\KRC\ROBOTER\KRC\R1\TP\ServoGun_FC\eg_extern.dat following options can should
defined for each weld gun:
Option Values
ProgSelect FALSE (default) The end digits in the point name contain the program number
for the weld timer.
TRUE A separate field for weld timer program number is displayed in
the welding and tip dress inline forms
ProgDigits 1..10 (default = 7) Only significant if option ProgSelect==FALSE.
The number of digits at the end of the point name that contain
the weld timer program number.
Compensation #AIR (default) The gun position is corrected pneumatically. The “comp” field
is displayed in the inline form.
#EQUALIZING The gun position is corrected with KUKA.EqualizingTech_D.
Only available if this technology is installed.
ForceTimer FALSE (default) A separate field for weld force is displayed in the welding and
tip dress in the inline forms
TRUE The robot controller obtains the value for the closing force of
the gun from the weld timer during welding and tip dressing.
ThicknessTimer FALSE (default) A separate field for Part Thickness is displayed in the welding
and tip dress in the inline forms
TRUE The robot controller obtains the value for the part thickness
from the weld timer during welding and tip dressing.
ThicknessTolTimer FALSE (default) A default value is used for thickness tolerance
TRUE The robot controller obtains the value for thickness tolerance
from the weld timer during welding and tip dressing.
WeldTimeTimer FALSE (default) A separate field for spin time is displayed in the robospin
welding in the inline forms
TRUE The robot controller obtains the value for the weld time from
the weld timer during robospin welding. To this value an offset
is added to become the Spin Time. (see KUKA.RoboSpin_D)

Note. In a future version these configuration setting should be done in WorkVisual.
DEFDAT eg_extern PUBLIC
;FOLD gun typ
...
ServogunFC[1]={ProgSelect FALSE,ProgDigits 7,Compensation #AIR,ForceTimer
FALSE,ThicknessTimer FALSE,ThicknessTolTimer FALSE,WeldTimeTimer FALSE}
...
ENDDAT
3.1.2 Configure additional IO signals

Configure additional IO signals with weld controller for options:
• Robot receives weld force value from weld controller
• Robot receives part thickness value from weld controller
• Robot receives part thickness tolerance value from weld controller
• Robot receives weld time is set from weld controller
These settings are made in C:\KRC\ROBOTER\KRC\R1\TP\ServoGun_FC\eg_extern.dat.
Note. These additional IO should only be configured if the corresponding option is used.
...
;FOLD signals timer data
;Desired force from weld-timer program

GLOBAL INT EG_FORCE_TMR_START_IN[6] ; Force value start bit
EG_FORCE_TMR_START_IN[1]=999
GLOBAL INT EG_FORCE_TMR_END_IN[6] ; Force value end bit
EG_FORCE_TMR_END_IN[1]=999
GLOBAL REAL EG_FORCE_SCALE[6] ; Convert value to [kN]
EG_FORCE_SCALE[1]=0.001
GLOBAL REAL EG_FORCE_MIN[6] ; Lower limit [kN]

EG_FORCE_MIN[1]=0.8
EG_FORCE_MIN[2]=0.8
EG_FORCE_MIN[3]=0.8
EG_FORCE_MIN[4]=0.8
EG_FORCE_MIN[5]=0.8
EG_FORCE_MIN[6]=0.8
GLOBAL REAL EG_FORCE_MAX[6] ; Upper limit [kN]
EG_FORCE_MAX[1]=6.0
EG_FORCE_MAX[2]=6.0
EG_FORCE_MAX[3]=6.0
EG_FORCE_MAX[4]=6.0
EG_FORCE_MAX[5]=6.0
EG_FORCE_MAX[6]=6.0
;Part thickness from weld-timer program

GLOBAL INT EG_THICK_TMR_START_IN[6] ; Thickness value start bit
EG_THICK_TMR_START_IN[1]=999
GLOBAL INT EG_THICK_TMR_END_IN[6] ; Thickness value end bit
EG_THICK_TMR_END_IN[1]=999
GLOBAL REAL EG_THICK_SCALE[6] ; Convert value to [mm]
EG_THICK_SCALE[1]=1.0
GLOBAL REAL EG_THICK_MIN[6] ; Lower limit [mm]
EG_THICK_MIN[1]=0.1
EG_THICK_MIN[2]=0.1
EG_THICK_MIN[3]=0.1
EG_THICK_MIN[4]=0.1
EG_THICK_MIN[5]=0.1
EG_THICK_MIN[6]=0.1
GLOBAL REAL EG_THICK_MAX[6] ; Upper limit [mm]
EG_THICK_MAX[1]=25.0
; Allowed thickness tolerance from weld-timer program

GLOBAL INT EG_THICKTOL_TMR_START_IN[6] ; Thickness tollerance value start bit
EG_THICKTOL_TMR_START_IN[1]=999
GLOBAL INT EG_THICKTOL_TMR_END_IN[6] ; Thickness tolerance value end bit
EG_THICKTOL_TMR_END_IN[1]=999
GLOBAL REAL EG_THICKTOL_SCALE[6] ; Convert value to [mm]
EG_THICKTOL_SCALE[1]=1.0
GLOBAL REAL EG_THICKTOL_MIN[6] ; Lower limit [mm]
EG_THICKTOL_MIN[1]=0.1

GLOBAL REAL EG_THICKTOL_MAX[6] ; Upper limit [mm]
EG_THICKTOL_MAX[1]=25.0
; Weld time from weld-timer program

GLOBAL INT EG_WELDTIME_TMR_START_IN[6] ; Time value start bit
EG_WELDTIME_TMR_START_IN[1]=999
GLOBAL INT EG_WELDTIME_TMR_END_IN[6] ; Time tolerance value end bit
EG_WELDTIME_TMR_END_IN[1]=999
GLOBAL REAL EG_WELDTIME_SCALE[6] ; Convert value to [ms]
EG_WELDTIME_SCALE[1]=1.0
GLOBAL REAL EG_WELDTIME_MIN[6] ; Lower limit [ms]
EG_WELDTIME_MIN[1]=100.0
GLOBAL REAL EG_WELDTIME_MAX[6] ; Upper limit [ms]
EG_WELDTIME_MAX[1]=4600.0
GLOBAL REAL EG_WELDTIME_OFFSET[6] ; Offset [ms] added to weldtime to become the spin time
EG_WELDTIME_OFFSET[1]=-96.0
;ENDFOLD
...
ENDDAT

The technology contains subprograms that the user can adapt individually to his requirements.
The subprograms are located in the program EG_USER.SRC in the directory R1\TP\SERVOGUN_FC.

Special features of the inline forms can be configured over registry keys. These settings can be used to
fulfil customer specific wishes.
Change the prefix of the point names.

[HKEY_CURRENT_USER\Software\VB and VBA Program Settings\KUKATPSERVOTECH\
PROGRAM_SELECT] "PointPrefix" default “SG”
Deactivate the parameter list ”weld timer data”.

[HKEY_CURRENT_USER\Software\VB and VBA Program
Settings\KUKATPSERVOTECH\DATA_FROM_TIMER_IN_PL] "DATA_FROM_TIMER_IN_PL" default
"TRUE"
Other special features designed for KUKA.ServoGun_TC (not for KUKA.ServoGun_FC):
Activate TC style inline forms.

TC_GENERAL] "TC_GENERAL" default "FALSE"
Feature (bFPP) to use more than 6 external TC weld guns.

[HKEY_CURRENT_USER\Software\VB and VBA Program Settings\KUKATPSERVOTECH\FPP]
“FPP” default “FALSE
Feature (bJK) enables American units [kN à lbs] and declares Booleans for each point name.
FC_GENERAL] "FC_GENERAL" default "TRUE”, feature is activated when this value is set to
“FALSE”

3.2 Programming ServoGun_FC_D
Note. KUKA.ServoGun_FC_D is an extension of KUKA.ServoGun_FC V2.0. This documentation only

handles the new features in the programming commands. Please read the programming of
KUKA.ServoGun_FC V2.0 first.
The “ServoTech FC” menu is available under “Commands”.
“Commands” can only be selected if a program has been opened or selected. The key switch
must be in the manual position (operating mode is T1 or T2).
“Commands” can only be inserted if the robot and weld gun are mastered.
Figure 2. Menu KUKA.ServoGun_FC_D commands
Initialize force control (New!)

The command “Initialize force control” initializes options for the weld gun force control.
This command is new in KUKA.ServoGun_FC_D 1.0 and does not exist in KUKA.ServoGun_FC 2.0.
Spot (Extended!)
The command “SPOT” controls the robot motion to a weld spot, and the welding process. The closing and
opening of the welding gun during the welding process is programmed in this command.
The spot command can be executed in 3 different movement types:
• PTP
• LIN
• CIRC
This command is extended with options for program selection and additional communication parameters
with the weld controller.
Tip initialisation (Extended!)

The command “Tip initialisation” controls weld guns tip initialisation.
In this command the initialisation modes “new” and “same” are extended with “set tip”.
Tipdress (Extended!)

This command dresses the electrode tips at the end point.

The tipdress command can be executed in 3 different movement types:
• PTP
• LIN
• CIRC
This command is not modified.
Gun couple (Not modified)

This command couples – within the software – the gun currently in use.
Gun decouple (Not modified)

This command decouples – within the software – the gun currently in use.
3.2.1 Initialize force control
Figure 3. Initialize force control
Parameter Description Range of Values

ForceControl When the desired force is reached, should the force On during welding
control stay active during the welding or not? If the Off during welding
option is set to “Off”, the motor of the weld gun is in
position control during the welding
3.2.2 Spot
Figure 4. Spot PTP without parameters from weld timer

Figure 5. Spot PTP with parameters from weld timer
In the gun configuration can be selected if the parameters Force, Part, Tolerance and WeldTime are
programmed in the weld controller or in the robot. When selected the robot reads these parameters from
the weld controller at runtime. The inline form SPOT is adjusted according to these settings.
Note. This command can only use the parameters Force, Part and Tolerance from Weld timer.
(WeldTime is not used)
Note. If the Timer type “Test” is selected the robot will use the previously received values from weld
timer. In this mode the Weld timer data can be edited.
Note. The robot checks whether the received values from weld timer are within min- , max limits. If not
a corresponding error message is displayed.

Motion type Type of movement that is used. PTP
LIN
CIRC
Point Name Name of the end point. By default the last 7 1..23 chars may not
characters must be digits. These digits are used by start with a number
default as program number for the weld timer.
If this number is used as program number and the
number of relevant final digits can be configured.
Touch the arrow to edit the corresponding parameter
list.
Vel Velocity used for the motion
PTP 1..100 %
LIN, CIRC 0.001..2 m/s
PDAT Parameter list for motion parameter. Selecting this 1..23 chars may not
field opens a parameter list. start with a number
ProgNr Program number for the weld timer. This field is only 1..100000
available if in the gun configuration the option
ProgSelect is TRUE.
ServoGun Active weld gun number. 1..6
The guns must be configured before the number can
be selected. This is done by setting the KRL variable
EG_SERVOGUN_EXAXIS[1..6] and restart of the
robot controller.
Cont Approximate positioning for robot motions.
Approximation during gun closing and gun opening. CLS_OPN
Only Approximate during gun opening. OPN
Only Approximate during gun closing. CLS
Stop the robot during gun opening and gun closing. (nothing)
Part Total thickness of the work pieces to be welded. 0..100 mm
This field is only available if in the gun configuration
the option ThicknessTimer is FALSE.
Tolerance Acceptable tolerance in the part thickness. This is 0..100 mm
checked during the weld. If the Part parameter is set to
20 mm and the Tolerance is 5 mm, a thickness
between 15 and 25 mm is accepted. This field is only
available if the in the gun configuration the option
ThicknessTolTimer is FALSE.

Force Closing force of the gun. 0.8..10 kN

the option ForceTimer is FALSE.
Comp Without compensation 0
Compensator 1 1
Compensator 2 2
the option Compensation is #AIR.
Trigger Distance after which compensation is deactivated on -9999..0
opening the gun. The more negative this value, the
earlier the compensation is deactivated.
WeldTimer Parameter list with parameters that are received from 1..23 chars may not
the weld timer. These parameters are read only. start with a number
These parameters are only available if the
corresponding option in the gun configuration is set to
TRUE.
Figure 6. Parameter list for point name

Tool Tool number used for this motion point. Nullframe,
Tool_Data[1..16]
Base Base number used for this motion point. Nullframe,
Base_Data[1..32]
External TCP Robot guides the tool (false) or the work piece (true) FALSE, TRUE
This value should be “True” in case of a external floor
mounted weld gun. When the weld gun in mounted
directly on the robot this value should be false.
Collision detection Should the robot controller calculate for this motion FALSE (default)
the axis torques? These are required for collision TRUE
detection.

Figure 7. Parameter list for PTP motion

Acceleration Acceleration used for the motion 1..100 %
Approximation Size of approximate positioning range for the motion. 0..1000 mm
distance (default 100)
Figure 8. Parameter list for LIN / CIRC motion

CP acceleration Acceleration used for the motion 1..100 %
Orientation Type of orientation control Default
control Wrist PTP
Constant orientation

Figure 9. Parameter list for weld timer data

Weld force Weld force received during execution time from weld -1 .. 10 kN
timer. This field is “read only”, if the weld timer type is The range that is
set to “TEST” this value can be edited. checked at run time can
This field is only available if in the gun configuration be configured.
the option ForceTimer is TRUE.
Part thickness Total thickness of the work pieces received just before -1..100 mm
weld start from weld timer. This field is “read only”, if The range that is
the weld timer type is set to “TEST” this value can be checked at run time can
edited. be configured.
the option ThicknessTimer is TRUE.
Part thickness Thickness tolerance on the work piece received just -1..100 mm
tolerance before weld start from weld timer. This field is “read The range that is
only”, if the weld timer type is set to “TEST” this value checked at run time can
can be edited. be configured.
the option ThickTolTimer is TRUE.
Weld time Time of weld received just before weld start from weld -1..3000 ms
the option WeldTimeTimer is TRUE.
Figure 10. Spot softkey bar
Parameter Description
Cancel command Closes the inline fold without making any changes.
Touch Up Sets the current position coordinates as position for the point.
Cmd OK Changes made are stored and the inline fold is closed.

3.2.3 Tip initialisation
Figure 11. Tip initialisation

robot controller.
mode Cyclical initialization: Same
The gun closes twice with initialization force. The robot
controller saves the current tip wear in EG_WEAR[]. It
generates a message if the current wear is greater
than the maximum permissible wear
(EG_WEAR_MAX). The electrode tips must then be
exchanged.
First initialization:
The gun closes at a constant velocity until the first New
initialization force is reached. The electrode tips are
pressed firmly onto the electrodes. The gun opens.
The gun closes twice with initialization force. The robot
controller saves the current tip wear in EG_WEAR[].
The gun moves to the initialization position. The
moving gun arm performs a motion with initialization
force. The variable EG_WORN is set to FALSE. The
output “New electrodes” is set and reset.
Single gun motion: SetTip (New!)

The gun closes and opens once with initialization
force.
Note. The closing force for these commands is defined in the variable EG_FORCE_INIT[x] = 2.0

3.2.4 Tipdress
Figure 12. Tipdress PTP without parameters from weld timer
Figure 13. Tipdress PTP with parameters from weld timer
the weld controller at runtime. The inline form TIPDRESS is adjusted according to these settings.
Note. This command can only use the parameters Force and Part from Weld timer. (Tolerance and
WeldTime are not used)

LIN
list.
PTP 1..100 %
LIN 0.001..2 m/s
ProgSelect is TRUE.


robot controller.
Compensator 1 1
Compensator 2 2
TRUE.

Tool_Data[1..16]
Base_Data[1..32]

detection.


control Wrist PTP


Part thickness Not used in this command. Thickness tolerance on the -1..100 mm
tolerance work piece received just before weld start from weld The range that is
timer. This field is “read only”, if the weld timer type is checked at run time can
set to “TEST” this value can be edited. be configured.
Weld time Not used in this command. Time of weld received just -1..3000 ms
before weld start from weld timer. This field is “read The range that is
Figure 18. Tipdress softkey bar

3.2.5 Servo gun couple
Note. This command is not modified in regard to KUKA.ServoGun_FC 2.0.
Figure 19. Servo gun couple
This command couples – within the software – the gun currently in use. The inline form does not control
any hardware, inputs or outputs.

ServoGun Gun number to couple. 1..6
robot controller.
3.2.6 Servo gun decouple
Note. This command is not modified in regard to KUKA.ServoGun_FC 2.0.
Figure 20. Servo gun decouple
This command decouples – within the software – the gun currently in use. The inline form does not
control any hardware, inputs or outputs.

ServoGun Gun number to decouple. 1..6
robot controller.

3.3 Plug-In Weld timer data overview
This Plug-in contains an overview of the parameter values received from the weld timer pro robot
program. If a cell is empty this means that this parameter from weld timer is not used.
Figure 21. Plug-in Weld timer data overview
Export : When this button is pressed the contents of the table is exported into a CSV file located in folder
C:\KRC\Roboter\Log\WeldTimerData\.
#Robot Serial Number: 616036

#Robot Type: #210R2700 PRIME C4 FLR, Robot
#Number of external axes: 1
#Software version: KS V8.2.95 (krc1adm@deau1svr12pt-06) 3 Thu 27 Oct 2011 08:05:19
RELEASE
PointName;GunNumber;ProgramNumber;WeldForce;PartThickness;ThicknessTolerance;WeldTime
P0000001;1;1;3.2;1.5;1.1;150
P0000002;1;1;3.2;1.5;1.1;150
P0000003;1;1;3.2;1.5;1.1;150
P0000004;1;1;3.2;1.5;1.1;150
P0000005;1;1;3.2;1.5;1.1;150
...

4 EqualizingTech_D
4.1 Configuration EqualizingTech_D
Note. KUKA.EqualizingTech_D 1.0 is an extension of KUKA.EqualizingTech 1.0. This documentation

only handles the new configuration steps. Please handle the software commissioning of KUKA.
EqualizingTech V1.0 first.
4.1.1 Configure gun compensation type

In the file C:\KRC\ROBOTER\KRC\R1\TP\ServoGun_FC\eg_extern.dat options can be defined for each
weld gun:
Option Values
Compensation #AIR (default) The gun position is corrected pneumatically. The “comp” field
is displayed in the inline form.
#EQUALIZING The gun position is corrected with KUKA.EqualizingTech_D.
Only available if this technology is installed.
Note. In a future version these configuration setting should be done in WorkVisual.
;FOLD gun typ

...
GLOBAL ENUM COMPTYP_T AIR,EQUALIZING
...
ServogunFC[1]={ProgSelect FALSE,ProgDigits 7,Compensation #EQUALIZING,ForceTimer
...
ENDDAT

The technology contains subprograms that the user can adapt individually to his requirements.
The subprograms are located in the module EQ_USER.SRC in the directory R1\TP\ EqualizingTech.
4.2 Programming EqualizingTech_D
The “EqualizingTech FC” menu is available under “Commands”.

Figure 22. Menu KUKA.EqualizingTech_D commands
4.2.1 Initialize equalizing tech
Mainly due a variable stiffness of the part, the distance between gun and part, and a variable closing
speed, a number of parameter sets are implemented. With this command a suitable parameter set can be
selected.
Note. These parameter values need to be optimized with field experience.
Note. The Equalizing option is only active if following conditions are fulfilled:
Ø The gun is compensation type is set to equalizing

ServogunFC[EG_EXTAX_ACTIVE].Compensation == # EQUALIZING
Ø A equalizing parameter set, different from the OFF set, is initialized. EG_EQ_ACTIVE ==
TRUE

Figure 23. INIT Equalizing

Equalizing Changes the vector move parameter set according to Weak
the part stiffness. Medium
Strong
When set to “Off” vector move is not activated. Off
For User1, 2 and 3 the desired vector move parameter User1

must be programmed in the user specific sub program. User2
User3

5 RoboSpin_D
KUKA.RoboSpin_D extends the functionality of the KUKA.ServoGun_FC_D technology package with the
option to execute a spinning motion around the tool centre point during the welding process. The spinning
motion results in a better welding quality and a longer lifecycle for the tip-dress.
The robot will try to finish the spinning motion just after the welding process is finished. The speed of this
spinning motion is derived from the parameters spin angle and welding time. The welding time can either
be set manually, or can be derived from a self learning cycle. In this last case, changes to the welding
parameters, e.g. by changes in the welding controller, do not require for changes in the robot program.
The robot can also read the weld times directly from the weld controller and use this to calculate the spin
time.
5.1 Configuration RoboSpin_D
5.1.1 RoboSpin parameters

A KRL timer is used internally by the software, the timer number can be set in the RoboSpin.dat with KRL
variable RS_TIMER ([1..20] default = 20). Make sure this timer is not used for other functions.
A KRL cycle flag is used internally by the software, the cycle flag number can be set in the RoboSpin.dat
with KRL variable RS_CYCFLAG ([1..20] default = 20). Make sure this cycle flag is not used for other
functions.
A KRL interrupt is used internally by the software, the interrupt number can be set in the RoboSpin.dat
with KRL variable RS_INTERRUPT ([1..20] default = 20). Make sure this interrupt is not used for other
functions.
The weld timer type “TEST” disables the learning and update modus of the spin time.
RoboSpin contains a set of variables for diagnostics on the spinning process. These variables can be set
manually with Status keys
Example: RoboSpin.dat
;Variables for Settings

DECL GLOBAL INT RS_Timer=20 ;KRL TIMER used by Robospin
DECL GLOBAL INT RS_Cycflag=20 ;KRL CYCFLAG used by Robospin
DECL GLOBAL INT RS_Interrupt=20 ;KRL INTERRUPT used by Robospin
DECL GLOBAL BOOL RS_Update_SpinTime=TRUE ;Enable update modus
DECL GLOBAL INT RS_SpinTime_Offset=-168 ;Time added to measured spot time in update modus
[ms]
DECL GLOBAL REAL RS_ACC_ORI=200.0 ;Acceleration parameter used for spin motion
DECL GLOBAL REAL RS_APO_CDIS=0.100000001 ;Approximation parameter used for spin motion
;Variables for Diagnose

DECL GLOBAL BOOL RS_ShowInfoMessages=FALSE
DECL GLOBAL BOOL RS_Last_UpdateSpinTime=TRUE
DECL GLOBAL CHAR RS_Last_PointName[24]
DECL GLOBAL REAL RS_Last_SpinAngle=5.07000017
DECL GLOBAL REAL RS_Last_SpinVel=1.43804932
DECL GLOBAL INT RS_Last_OldSpinTime=3540
DECL GLOBAL INT RS_Last_MeasuredSpinTime=3744
DECL GLOBAL INT RS_Last_NewSpinTime=3840

5.1.2 Diagnosis of RoboSpin technology
For diagnosis of the spinning motion the robot controller should be set in expert mode. The information
displayed in the diagnosis window depends on the ConfigMon.ini file. After the installation of
KUKA.RoboSpin_D, the existing file C:\KRC\User\ConfigMon.ini should be extended or replaced with the
contents of the file ConfigMon_SevoTech_D_EN.ini for the English version or of the file
ConfigMon_SevoTech_D_DE.ini for the German version.
Fig. 24. Running the robot program in diagnostic modus
1. Programming window
2. Diagnosis window : Monitor / Variables / Overview / Display
3. RoboSpin spin status key list
4. Diagnostic info messages
5.1.3 The diagnostics status keys
To control the diagnostic functions during production of the installation, RoboSpin installs additional status
keys. After the menu function “Configuration” – “Status keys” – “Servo Tech” has been activated, the
control panel provides a number of status keys.

Figure 25. Menu item to activate status keys
Note. The RoboSpin status keys are only active if the dead man switch is pressed.
Next key list
Spin time parameter not updated
Update spin time parameter with info messages
Update spin time parameter
Figure 26. Key list RoboSpin
5.1.4 The diagnostics window

Fig. 27. The diagnostics window
RoboSpin info msg. This variable defines if the RoboSpin software will fire diagnostic info messages in
the message window. The variable can have to states: yes or no. (View + Edit)
Spin time offset [ms]. This variable defines the offset in ms which is added to the measured spot
welding time for each welding point. (View + Edit) This value is only used if the time value is not read
directly from weld timer. (ServogunFC[x].WeldTimeTimer == FALSE)
Update spin time. This variable defines if the learning mode to update the spot welding time for each
welding point is activated. The variable can have two states: yes or no. (View + Edit) Only used if the time
value is not read directly from weld timer. (ServogunFC[x].WeldTimeTimer == FALSE)
Point name. This variable defines the name of the point that last executed with RoboSpin motion with a
spinning angle <> 0 deg. (view only)
Spin Angle [deg]. This variable defines the angle in degrees of the spinning motion executed in this
point. (view only)
Spin vel [deg/s]. This variable defines the velocity of the spinning motion executed in this point. The
velocity is scaled with the override factor $OV_PRO. (view only)
Used spin time [ms] : Spot welding time used in the calculation of the velocity of the spinning motion
executed in this point.
Measured spin time [ms] : Spot welding time measured in this point. (view only)
Updated spin time [ms] : Spot welding time that will be used to calculate the velocity the next time that
the spinning motion will be executed. Normally this variable equals the measured spin time plus the spin
time offset (view only)
Note. The spin time is only automatically updated if following conditions are fulfilled:
Ø ServogunFC[x].WeldTimeTimer == FALSE
Ø RS_Update_SpinTime == TRUE
Ø WeldTimer typ <> TEST ( EG_TIMER_TYP <> 0)
Ø RS_Last_MeasuredSpinTime > 110 ms
Ø RS_Last_MeasuredSpinTime < 7000 ms
Ø SPIN Angle in the inline form < -0.0001 deg or > 0.0001 deg

5.1.5 Diagnostic info messages
When the status key “Update Spin time parameter with info messages” is pressed following messages
can appear in the message window:
TPRS 1 Spin velocity in point %1 is too high !

Cause : The robot can not execute the requested spin motion within the requested spin time with the
current override.
Effect : The spin motion will be executed with a slower velocity than the requested velocity.
($VEL_MA.ORI1)
Remedy : Rise the override, decrease the spin angle or increase the spin time.
TPRS 2 Spin velocity in point %1 is too low !

Cause : The robot is requested to execute a spin motion with a very slow velocity (< 0.01 deg/s).
Effect : The spin motion will be executed with a faster velocity than the requested velocity. (O.001 deg/s)
Remedy : Increase the spin angle or decrease the spin time.
TPRS 3 Measured Spin time in point %1 was too short (<110ms) !

Cause : The signal RS_READY came to early.
Effect : The robot assumes a false spin time measurement and will not update the spin time parameter.
Remedy : Check if the interface with the welding device.
TPRS 4 Measured Spin time in point %1 was too long (>7000ms) !

Cause : The signal RS_READY came to late.
Effect : The robot assumes a false spin time measurement and will not update the spin time parameter.
Remedy : Check if the interface with the welding device.
TPRS 5 Spin motion stopped too early in point %1 !

Cause : The signal RS_READY came before the spin motion was finished.
Effect : The robot did not turn during the complete welding.
Remedy : Increase the spin time. When the automatic update of the spin time is used, increase the value
“RS_SpinTime_Offset”. When the option read time value directly from weld timer is used, increase the
value “EG_WELDTIME_OFFSET[x]”.
Special features of the RoboSpin inline forms can be configured over registry keys. These settings can be
used to fulfil customer specific wishes.
Deactivate the RoboSpin Status key list.

[HKEY_CURRENT_USER\Software\VB and VBA Program Settings\KUKATPSERVOTECH\ ROBOSPIN]
"ROBOSPIN" default “TRUE”
5.2 Programming RoboSpin_D
The “RoboSpin_D” menu is available under “Commands”.

Figure 28. Menu KUKA.RoboSpin_D commands
5.2.1 RoboSpin Spot
Figure 29. RoboSpin Spot PTP without parameters from weld timer
Figure 30. RoboSpin Spot PTP with parameters from weld timer

the weld controller at runtime. The inline form SPOT is adjusted according to these settings.
Note. This command can use the parameters Force, Part, Tolerance and WeldTime from weld timer.

LIN
CIRC
list.
PTP 1..100 %
LIN, CIRC 0.001..2 m/s
ProgSelect is TRUE.
robot controller.
Cont Approximate positioning for robot motions.
Approximation during gun closing and gun opening. CLS_OPN
Only Approximate during gun opening. OPN
Only Approximate during gun closing. CLS
Stop the robot during gun opening and gun closing. (nothing)
Tolerance Acceptable tolerance in the part thickness. This is 0..100 mm
checked during the weld. If the Part parameter is set to
20 mm and the Tolerance is 5 mm, a thickness
between 15 and 25 mm is accepted. This field is only
available if the in the gun configuration the option
ThicknessTolTimer is FALSE.


Compensator 1 1
Compensator 2 2
TRUE.
Spin Parameter list for Spin motion. Selecting this field 1..23 chars may not
opens a parameter list. start with a number

Tool_Data[1..16]
Base_Data[1..32]
detection.



control Wrist PTP


Part thickness Not used in this command. Thickness tolerance on the -1..100 mm
tolerance work piece received just before weld start from weld The range that is
timer. This field is “read only”, if the weld timer type is checked at run time can
set to “TEST” this value can be edited. be configured.
Weld time Not used in this command. Time of weld received just -1..3000 ms
before weld start from weld timer. This field is “read The range that is

Figure 35. Parameter list for spin motion

Spin angle How many degrees should the robot spin around the -20 .. 20 deg
TCP during the spot weld. To deactivate the spin
motion set this value to 0.
Spin time How long may the spin motion take? This parameter is 0 .. 3000 ms
used to calculate the spin velocity. The RoboSpin
software can automatically update this value with the
duration of the weld process measured the previous
time this command was executed.
Force control The force control mode of the weld gun remains active On during welding
during the welding process and the spin motion.
The force control mode of the weld gun is deactivated Off during welding
during the welding process and the spin motion. The
weld gun is in position control.
Figure 36. Spot softkey bar
RSTouch Up Sets the current position coordinates as spin angle for the spin motion

6 Functions overview
6.1 ServoGun_FC_D
The force control during welding can be deactivated
Supports force controlled servo guns
Separate field for program selection
Configurable digit range for program selection with point name
Extended communication with weld timer
PTP, LIN, CIRC motions to welding points
Supports single gun closing command
6.2 EqualizingTech_D
Supports user specific parameterisation of vector move
6.3 RoboSpin_D
Supports force controlled servo guns
Supports robot mounted weld guns
Supports external floor mounted weld guns
Supports extended communication with weld timer
PTP, LIN, CIRC motions to welding points
Supports a rotation motion around the tip during welding
Learning mode
Diagnosis window

7 Release Notes
01/02/2012 - CD_1.0.0 prototype CD bundle released
06/02/2012 - KUKA.ServoGun_FC_D 1.0.1 Servo Control parameter in RoboSpin parameter list value names changed: ON --> On
during welding / OFF --> Off during welding)
06/02/2012 - KUKA.ServoGun_FC_D 1.0.1 Plugin Weld Timer Data: Added working functionality to first static prototype version.
06/02/2012 - KUKA.ServoGun_FC_D 1.0.1 + KUKA.RoboSpin_D 1.0.1 Structure of parameter list variables moved from
eg_extern.dat to Robospin.dat
07/02/2012 - KUKA.ServoGun_FC_D 1.0.1 afther error during part thickness measurement reload data from weld timer
07/02/2012 - CD 1.0.1 new prototype CD bundle released.

KUKA - ServoTech D 1.0 EN 17.2.2012 VORAB

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KUKA.ServoTech D 1.

Option to KSS V8.2

300085 | 2012-02-07 | DC| KUKA.ServoTech_D_1.0_EN.doc Page 1/42

Software License Terms

300085 | 2012-02-07 | DC| KUKA.ServoTech_D_1.0_EN.doc Page 2/42

1.1 Important notes

1.2 Safety instructions

2.1 Installation requirements

2.2 Installing the software

2.3 Updating the software

2.4 Uninstalling the software

2.5 Automatic software update

3.1. Configuration ServoGun_FC_D

3.1.1 Gun specific options

3.1.2 Configure additional IO signals

3.1.3 Configure user specific sub programs

3.1.4 Special features

3.2 Programming ServoGun_FC_D

3.2.1 Initialize force control

3.2.3 Tip initialisation

3.2.5 Servo gun couple

3.2.6 Servo gun decouple

3.3 Plug-In Weld timer data overview

4.1 Configuration EqualizingTech_D

4.1.1 Configure gun compensation type

300085 | 2012-02-07 | DC| KUKA.ServoTech_D_1.0_EN.doc Page 3/42

4.1.2 Configure user specific sub programs

4.2 Programming EqualizingTech_D

4.2.1 Initialize equalizing tech

5.1 Configuration RoboSpin_D

5.1.1 RoboSpin parameters

5.1.2 Diagnosis of RoboSpin technology

5.1.3 The diagnostics status keys

5.1.4 The diagnostics window

5.1.5 Diagnostic info messages

5.1.6 Special features

5.2 Programming RoboSpin_D

5.2.1 RoboSpin Spot

300085 | 2012-02-07 | DC| KUKA.ServoTech_D_1.0_EN.doc Page 4/42

These technology packages are created with specifications from Daimler.

KUKA.ServoGun_FC_D <= KUKA.ServoGun_FC V2.0 b15

Fig. 1. KUKA ServoTech_D 1.0

300085 | 2012-02-07 | DC| KUKA.ServoTech_D_1.0_EN.doc Page 5/42

1.1 Important notes

KUKA.ServoTech_D is an extension of other technology packages. This documentation only handles

1.2 Safety instructions

300085 | 2012-02-07 | DC| KUKA.ServoTech_D_1.0_EN.doc Page 6/42

2.1 Installation requirements

2.2 Installing the software

The program Setup.exe is used to install the KUKA.ServoTech_D software.

The KUKA.ServoTech_D software consists of 3 technology packages that need to be installed in

2.3 Updating the software

2.4 Uninstalling the software

The program C:\KRC_OPTION\xxx\Uninst\Uninstall.exe is used to uninstall the KUKA.ServoTech_D

The KUKA.ServoTech_D software consists of 3 technology packages that need to be uninstalled in

300085 | 2012-02-07 | DC| KUKA.ServoTech_D_1.0_EN.doc Page 7/42

2.5 Automatic software update

300085 | 2012-02-07 | DC| KUKA.ServoTech_D_1.0_EN.doc Page 8/42

3.1. Configuration ServoGun_FC_D

• Set gun specific options

Note. KUKA.ServoGun_FC_D 1.0 is an extension of KUKA.ServoGun_FC 2.0. This documentation

3.1.1 Gun specific options

300085 | 2012-02-07 | DC| KUKA.ServoTech_D_1.0_EN.doc Page 9/42