kore: basic course kore: basic course - amtek …training kore: basic course target group: school...

Training

KORE: Basic Course

Target Group: School and College Students

KUKA Robotics USA

Issued: 30.05.2014 Version: KORE: Basic Course – V1.1

KUKA Official Robot Education

Training

KORE: Basic

Target Group: Scho

Issued: 30.05.2014

Version: KORE: Basic Course – V1.1

KUKA Official Robot Educatio

c Course

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KUKUKUKUUKAKAKAKAKA Robotics USAAAAA

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© Copyright 2013

KUKA Roboter GmbHZugspitzstraße 140D-86165 AugsburgGermany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Roboter GmbH.

Other functions not described in this documentation may be operable in the controller. The user hasno claims 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, how-ever, and necessary corrections will be incorporated in the subsequent edition.Subject to technical alterations without an effect on the function.

Translation of the original documentation

KIM-PS5-DOC

Publication: Pub College Einsatz und Programmierung von Industrierobotern (PDF-COL) enEduPack Einsatz und Programmierung von Industrierobotern V5.1 Edu Pack Einsatz und Programmierung von Industrierobotern V4 en(PDF-COL)

Bookstructure: Version:

2 Issued: 30.05.2014 Version: KORE: Basic Course – V1.1

© Copyright 2013

KUKA Roboter GmbHZugspitzstraße 140D-86165 AugsburgGermany

This documentation or excerpts therefrom may not be reproduced or disclosed to third partrr ies withoutthe express permission of KUKA Roboter GmbH.

Other functions not described in this documentation may be operable in the controller. The user hasno claims to these functions, however, in the case of a replacement or servrr ice work.

We have checked the content of this documentation for f conforf mity with the hardware and softwareffdescribed. Nevertrr heless, 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, how-ever, and necessary corrections will be incorporated in the subsequent edition.Subject to technical alterations without an effect on the function.

Translation of the original documentation

KIM-PS5-DOC

Publication: Pub College Einsatz und Programmierung von Industrierobotern (PDF-COL) enEduPack Einsatz und Programmierung von Industrierobotern V5.1 Edu Pack Einsatz und Programmierung von Industrierobotern V4 en(PDF-COL)

Bookstructure: VerVV sion:


Contents1 Introduction to robotics .............................................................................. 1.1 Overview ....................................................................................................................1.2 Introduction ................................................................................................................1.3 R.U.R. – Rossum’s Universal Robots ........................................................................1.4 Laws of Robotics ........................................................................................................1.5 The first robot .............................................................................................................1.6 KUKA company history ..............................................................................................1.6.1 Exercise: Introduction to the robot and group discussion .....................................

2 Fields of application for industrial robots ................................................. 2.1 Overview ....................................................................................................................2.2 Applications for industrial robots ................................................................................2.3 Examples of robotic applications ...............................................................................2.3.1 Exercise: Group discussion and video examples .................................................

3 Overview of the components of a robot system ....................................... 3.1 Overview ....................................................................................................................3.2 Components of a robotic cell .....................................................................................3.3 Robot selection ..........................................................................................................3.4 Controller configuration ..............................................................................................3.5 Selection of the end effector / tool .............................................................................3.6 Selection of the energy supply system ......................................................................3.7 Periphery connection (field bus) ................................................................................3.8 Use of sensors ...........................................................................................................3.9 Safety equipment .......................................................................................................3.9.1 Exercise: Identify the safety on the lab robot and group discussion ....................

4 Industrial robots .......................................................................................... 4.1 Overview ....................................................................................................................4.2 Introduction to robotics ...............................................................................................4.3 Definition and structure ..............................................................................................4.4 Robot arm of a KUKA robot .......................................................................................4.5 Arrangement of the main axes ...................................................................................4.6 Absolute accuracy and repeatability ..........................................................................4.6.1 Exercise: Robot component identification .............................................................

5 Robot controller ........................................................................................... 5.1 Overview ....................................................................................................................5.2 Description of a robot system ....................................................................................5.3 Overview of the KR C4 compact robot controller .......................................................5.4 Technical data for the KR C4 compact ......................................................................5.5 KR C4 compact interfaces ................................................................ .........................5.5.1 Exercise: Robot controller component identification .............................................

6 Moving the robot ......................................................................................... 6.1 Overview ....................................................................................................................6.2 KUKA smartPAD teach pendant ................................................................................6.2.1 Front view .............................................................................................................

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Contents1 Introduction to robotics .........

1.1 Overview ........................................1.2 Introduction ....................................1.3 R.U.R. – Rossum’s Universal Robo1.4 Laws of Robotics ............................1.5 The first robot .................................1.6 KUKAKK company historyr ..................1.6.1 Exercise: Introduction to the rob

2 Fields of application for indus

2.1 Overview ........................................2.2 Applications for industrial robots ....2.3 Examples of robotic applications ...2.3.1 Exercise: Group discussion and

3 Overview of the components o

3.1 Overview ........................................3.2 Components of a robotic cell .........3.3 Robot selection ..........................................................................................................3.4 Controller configuration ..............................................................................................3.5 Selection of the end effectoff r / tool .............................................................................3.6 Selection of the energy supply system ......................................................................3.7 Peripheryr connection (field bus) ................................................................................3.8 Use of sensors ...........................................................................................................3.9 Safety equipment .......................................................................................................3.9.1 Exercise: Identify the safety on the lab robot and group discussion ....................

4 Industrial robots ..........................................................................................

4.1 Overview ....................................................................................................................4.2 Introduction to robotics ...............................................................................................4.3 Definition and structure ..............................................................................................4.4 Robot arm of a KUKAKK robot .......................................................................................4.5 Arrangement of the main axes ...................................................................................4.6 Absolute accuracy and repeatability ..........................................................................4.6.1 Exercise: Robot component identification .............................................................

5 Robot controller ...........................................................................................

5.1 Overview ....................................................................................................................5.2 Description of a robot system ....................................................................................5.3 Overview of the KR C4 compact robot controller .......................................................5.4 Technical data for the KR C4 compact ......................................................................5.5 KR C4 compact interfaces ................................................................ .........................5.5.1 Exercise: Robot controller component identification .............................................

6 Moving the robot .........................................................................................

6.1 Overview ....................................................................................................................6.2 KUKAKK smartPAD teach pendant ................................................................................6.2.1 Front view .............................................................................................................

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......................................................................

............................................................................

............................................................................ots ............................................................................................................................................................................................................................................................................................................

bot and group discussion .....................................

strial robots .................................................

..................................................................................................................................................................................................................................... video examples .................................................

of a robot system .......................................

............................................................................

............................................................................

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6.2.2 Rear view .............................................................................................................6.3 Reading and interpreting robot controller messages .................................................6.4 Selecting and setting the operating mode .................................................................6.4.1 Exercise: Using the KUKA SmartPAD and interpreting messages .....................6.5 Moving individual robot axes .....................................................................................6.5.1 Exercise: Operator control and axis-specific jogging ...........................................6.6 Coordinate systems in conjunction with robots .........................................................6.7 Moving the robot in the world coordinate system ......................................................6.7.1 Exercise: Operator control and jogging in the world coordinate system ..............6.8 Moving the robot in the tool coordinate system .........................................................6.8.1 Exercise: Operator control and jogging in the tool coordinate system ................6.9 Moving the robot in the base coordinate system .......................................................6.9.1 Exercise: Operator control and jogging in the base coordinate system ..............

7 Start-Up ......................................................................................................... 7.1 Overview ....................................................................................................................7.2 Mastering principle ....................................................................................................7.3 Mastering with the MEMD and mark..........................................................................7.3.1 Moving A6 to the mastering position (with mark) ......................................................7.3.2 First mastering (with MEMD) ......................................................................................7.3.3 Teach offset (with MEMD) .........................................................................................7.3.4 Check load mastering with offset (with MEMD) .........................................................7.3.5 Exercise: Robot mastering ...................................................................................7.4 Loads on the robot .....................................................................................................7.5 Tool load data ............................................................................................................7.6 Supplementary loads on the robot .............................................................................7.6.1 Exercise: Tool load calibration – Gripper ............................................................7.7 Tool calibration ..........................................................................................................7.7.1 Exercise: Tool calibration – Gripper ....................................................................7.8 Base calibration .........................................................................................................7.8.1 Exercise: Base calibration – table, 3-point method ..............................................7.9 Displaying the current robot position .........................................................................7.9.1 Exercise: Displaying the current robot position ....................................................

8 Executing robot programs .......................................................................... 8.1 Overview ....................................................................................................................8.2 Performing an initialization run ..................................................................................8.3 Selecting and starting robot programs .......................................................................8.3.1 Exercise: Executing robot programs ...................................................................

9 Working with program files ........................................................................ 9.1 Overview ....................................................................................................................9.2 Creating program modules ........................................................................................9.3 Editing program modules ...........................................................................................9.3.1 Exercise: Program creation ...............................................................................

10 Creating and modifying programmed motions ......................................... 10.1 Overview ....................................................................................................................10.2 Creating new motion commands ...............................................................................

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137 137137138141

143 143143


6.2.2 Rear view .................6.3 Reading and interpreting 6.4 Selecting and setting the 6.4.1 Exercise: Using the K6.5 Moving individual robot ax6.5.1 Exercise: Operator co6.6 Coordinate systems in co6.7 Moving the robot in the wo6.7.1 Exercise: Operator co6.8 Moving the robot in the to6.8.1 Exercise: Operator co6.9 Moving the robot in the ba6.9.1 Exercise: Operator co

7 Start-Up .....................

7.1 Overview .........................7.2 Mastering principle .........7.3 Mastering with the MEMD7.3.1 Moving A6 to the masteri7.3.2 First mastering (with MEM7.3.3 Teach offset (with MEMD) .........................................................................................7.3.4 Check load mastering with offset (with MEMD) .........................................................7.3.5 Exercise: Robot mastering ...................................................................................7.4 Loads on the robot .....................................................................................................7.5 Tool load data ............................................................................................................7.6 Supplementary loads on the robot .............................................................................7.6.1 Exercise: Tool load calibration – Gripper ............................................................7.7 Tool calibration ..........................................................................................................7.7.1 Exercise: Tool calibration – Gripper ....................................................................7.8 Base calibration .........................................................................................................7.8.1 Exercise: Base calibration – table, 3-point method ..............................................7.9 Displaying the current robot position .........................................................................7.9.1 Exercise: Displaying the current robot position ....................................................

8 Executing robot programs ..........................................................................

8.1 Overview ....................................................................................................................8.2 Performing an initialization run ..................................................................................8.3 Selecting and starting robot programs .......................................................................8.3.1 Exercise: Executing robot programs ...................................................................

9 Working with program files ........................................................................

9.1 Overview ....................................................................................................................9.2 Creating program modules ........................................................................................9.3 Editing program modules ...........................................................................................9.3.1 Exercise: Program creation ...............................................................................

10 Creating and modifying programmed motions .........................................

10.1 Overview ....................................................................................................................10.2 Creating new motion commands ...............................................................................

9798

100102102103105107114116120122125

127

127127128135

137

137137138141

143

143143


............................................................................................robot controller messages .................................................operating mode .................................................................

KUKA SmartPAD and interpreting messages .....................xes .....................................................................................ontrol and axis-specific jogging ...........................................onjunction with robots .........................................................orld coordinate system ......................................................

ontrol and jogging in the world coordinate system ..............ool coordinate system .........................................................ontrol and jogging in the tool coordinate system ................ase coordinate system .......................................................ontrol and jogging in the base coordinate system ..............

....................................................................................

............................................................................................

............................................................................................D and mark..........................................................................ng position (with mark) ......................................................

MD) ......................................................................................)

59606264667072737879838589

90

909093949497

10.3 Creating cycle-time optimized motion (axis motion) ..................................................10.3.1 Exercise: PTP motions ..........................................................................................10.4 Creating CP motions .................................................................................................10.4.1 Exercise: CP motions ...........................................................................................10.5 Modifying motion commands .....................................................................................10.5.1 Exercise: Modifying motions parameters ..............................................................10.5.2 Exercise: CP motion and approximate positioning ...............................................

11 Using logic functions in the robot program ..............................................

11.1 Overview ....................................................................................................................11.2 Introduction to logic programming .............................................................................11.3 Programming wait functions ......................................................................................11.3.1 Exercise: Programming wait functions .................................................................11.4 Programming simple switching functions ..................................................................11.4.1 Exercise: Programming simple switching functions .............................................

12 Exercise: Final programming assignment .............................................................

13 Appendix ...................................................................................................... 13.1 Abbreviations ...............................................................................................................13.2 Terms used ................................................................................................................13.3 Excerpt from KR C4 safety ........................................................................................

Index ...........................................................................................................................

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10.3 Creating cycle-time optimized motio10.3.1 Exercise: PTP motions .............10.4 Creating CP motions ......................10.4.1 Exercise: CP motions ...............10.5 Modifying motion commands .........10.5.1 Exercise: Modifying motions pa10.5.2 Exercise: CP motion and approx

11 Using logic functions in the robo

11.1 Overview .........................................11.2 Introduction to logic programming .11.3 Programming wait functions ..........11.3.1 Exercise: Programming wait fu11.4 Programming simple switching func11.4.1 Exercise: Programming simple

12 Exercise: Final programming ass

13 Appendix .................................

13.1 Abbreviations ...................................13.2 Terms used ................................................................................................................13.3 Excerpt from KR C4 safety ........................................................................................

Index ...........................................................................................................................

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on (axis motion) .....................................................................................................................................................................................................................................................................................................................................................................rameters ..............................................................ximate positioning ...............................................

ot program ..............................................

...................................................................................................................................................................................................................................nctions .................................................................

ctions .................................................................. switching functions .............................................

signment .............................................................

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1 Introduction to robotics

1.1 Overview

The following contents are explained in this training module:

IntroductionR.U.R. – Rossum’s Universal RobotsLaws of roboticsThe first robotKUKA history

1.2 Introduction

Fig. 1-1 In view of the increasing diversity of products and variants, it is necessary to enhance manufacturing productivity and flexibility in order to maintain or in-crease competitiveness. The use of industrial robots (IR) is one suitable wayof achieving the flexible automation required.

The term “robot” originates in the Slavic word “robota”, in the sense of labori-ous work.

In the technical sense, however, industrial robots are defined as distinct fromother automation devices and working machines. Nevertheless, there is a cer-tain amount of international confusion over the term, as similar systems, suchas manipulators or loading devices, are often counted as robots and includedin the statistics.

The reason for this is that in all such systems, the mechanical structure con-sists of a kinematic chain with a fixed part and an arm (or several arms) onwhich a wrist with a gripper or tool (e.g. welding torch) is mounted.

1.3 R.U.R. – Rossum’s Universal Robots

R.U.R. (Czech: Rosumovi Umeli Roboti) is the title of a play by the Czech au-thor Karel Capek that appeared in 1921.

It is about a company that manufactures humanoid machines (robots) to re-lieve the workload on humans. These machines subsequently overthrow soci-ety and destroy humanity.


1 Introduction to roboti

1.1 Overvrr iew

The following con

IntroductionR.U.R. – RossuLaws of roboticThe first robotKUKA history

1.2 Introduction

Fig. 1-1

In view of the increasing diversity of products and variants, it is necessaryr to enhance manufacturing productivity and flexibility in order to maintain or in-crease competitiveness. The use of industrial robots (IR) is one suitable wayof achieving the flexible automation required.

The term “robot” originates in the Slavic word “robota”, in the sense of labori-ous work.

In the technical sense, however, industrial robots are defined as distinct fromother automation devices and working machines. Nevertrr heless, there is a cer-tain amount of international confusion over the term, as similar systems, suchas manipulatorsrr or loading devices, are often counted as robots and includedin the statistics.

The reason for this is that in all such systems, the mechanical structure con-sists of a kinematic chain with a fixed partrr and an arm (or several arms) onwhich a wrist with a gripper or tool (e.g. welding torch) is mounted.

1.3 R.U.R. – Rossum’s Universal Robots

R.U.R. (Czech: Rosumovi Umeli Roboti) is the title of a play by the Czech au-thor Karel Capek that appeared in 1921.

It is about a company that manufactures humanoid machines (robots) to re-lieve the workload on humans. These machines subsequently overtrr hrow soci-ety and destroy humanity.


ics

ntents are explained in this training module:

um’s Universal Robotscs

Fig. 1-2: R.U.R. – Rossum’s Universal Robots The name of the play, R.U.R., stands for Rossum’s Universal Robots, thecompany that produces these machines. The name Rossum is an ironic playon words by the author: the Czech word “rozum” (pronounced with a short firstsyllable) means reason, understanding. A correct translation of the original ti-tle would be “(Mr.) Reason’s Artificial (Slave-)Workers”; the name “Rossum”has been retained in translation, however, and “universal” has been used in order to be able to keep the Czech abbreviation R.U.R.

The term “Robot” coined in this play quickly found its way into many languagesas an everyday word. [8]

1.4 Laws of Robotics

The Laws of Robotics were first described by Isaac Asimov in his collection of science-fiction stories I, Robot (1950). Since then, they have influencedconcepts of what a robot should be and how it should act. These laws are bind-ing on the way the robots described by Asimov act and make decisions.

Initially, these laws only applied to “literary” robots, but they have since cometo influence the programming of modern robots and are used in modified formsin competitions, e.g. for cleaning robots. Modern industrial robots are also pro-grammed in accordance with these laws, even if most robot programmers areunaware of the fact.

Asimov’s laws state:

1. A robot may not injure a human being or, through inaction, allow a humanbeing to come to harm.

2. A robot must obey orders given to it by human beings except where suchorders would conflict with the First Law.

3. A robot must protect its own existence as long as such protection does not conflict with the First or Second Law.

It should be noted that the laws are hierarchical in nature. Although the laws appear to be clearly formulated, they are not “foolproof”, primarily becausethey are interpreted by humans, i.e. imperfectly and incompletely. [8]


Fig. 1-2:

The name of the play, R.U.R., stands for Rossum’s Universal Robots, thecompany that produces these machines. The name Rossum is an ironic playon words by the author: the Czech word “rozum” (pronounced with a short firstsyllable) means reason, understanding. A correct translation of the original ti-tle would be “(Mr.) Reason’s Artificial (Slave-)Workers”; the name “Rossum”has been retained in translation, however, and “universal” has been used in order to be able to keep the Czech abbreviation R.U.R.

The term “Robot” coined in this play quickly found its way into many languagesas an everyday word. [8]

1.4 Laws of Robotics

The Laws of Robotics were first described by Isaac AsAA imov in his collection of science-fiction stories I, Robot (1950). Since then, they have influencedconcepts of what a robot should be and how it should act. These laws are bind-ing on the way the robots described by Asimov act and make decisions.

Initially, these laws only applied to “literary” robots, but they have since cometo influence the programming of modern robots and are used in modified formsin competitions, e.g. for cleaning robots. Modern industrial robots are also pro-grammed in accordance with these laws, even if most robot programmers areunaware of the fact.

Asimov’s laws state:

1. A robot may not injure a human being or, through inaction, allow a humanbeing to come to harm.

2. A robot must obey orders given to it by human beings except where suchorders would conflict with the First Law.

3. A robot must protect its own existence as long as such protection does not conflict with the First or Second Law.

It should be noted that the laws are hierarchical in nature. Although the lawsappear to be clearly formulated, they are not “foolproof”, primarily becausethey are interpreted by humans, i.e. imperfectly and incompletely. [8]


R.U.R. – Rossum’s Universal Robots

1.5 The first robot

Fig. 1-3: The first industrial robot (type: Unimate; manufacturer: Unima-tion; entered service: 1961) The first industrial robot, later known as the Unimate, came about after its in-ventors, George Devol and Joseph Engelberger, discussed a science-fictionnovel at a meeting in 1956. On the basis of this novel, these two men decidedto develop a real robot.

The Unimate was integrated into a production line at General Motors (Trenton,USA) in 1962. This robot’s tasks consisted of taking hot workpieces out of ametal press and stacking them. The program for the robot consisted of a largenumber of individual instruction steps stored on a magnetic drum. This alreadyenabled it to perform a wide range of automation tasks.

1.6 KUKA company history

1898 The entrepreneurs Johann Josef Keller and Jakob Knappich founded theAugsburg Acetylene Factory in 1898.

Fig. 1-4: Johann Josef Keller (left) and Jakob Knappich (right)


1.5 The first robot

Fig. 1-3: The first indrr ustrial robot (type: Unimate; manufacturer: Unima-tion; entered service: rr 1961)

The first industrial robot, later known as the Unimate, came about after its in-ventors, George Devol and Joseph Engelberger, discussed a science-fictionnovel at a meeting in 1956. On the basis of this novel, these two men decidedto develop a real robot.

The Unimate was integrated into a production line at General Motors (Trenton,USA) in 1962. This robot’s tasks consisted of taking hot workpieces out of ametal press and stacking them. The program for the robot consisted of a largenumber of individual instruction steps stored on a magnetic drum. This alreadyenabled it to perform a wide range of automation tasks.

1.6 KUKA company history

1898 The entrepreneurs Johann Josef Keller and Jakob Knappich founded theAugsburg Acetylene Factory in r 1898.

Fig. 1-4: Johann Josef Keller (left)ff and Jakob Knappich (right)


3 Overview of the components of a robot system

3.1 Overview


Components of a robotic cellSelection criteria for a robotControl of robot and external axesTool selectionSelection of the energy supply systemPeriphery connectionUse of sensorsSafety equipment

3.2 Components of a robotic cell

A robot system / robotic cell consists of the following components:

Fig. 3-1: Arc welding cell

Item Description1 Robot2 Controllers3 Tool/tool changer4 Energy supply system5 Periphery connection6 Sensor system7 Safety fence8 Loading area with photoelectric curtain


3 Overview of the comp

3.1 Overvrr iew

The following con

Components ofSelection criterControl of roboTool selectionSelection of thePeripheryr connUse of sensorsSafety equipme

3.2 Components of a robotic ce

A robot system / ro

Fig. 3-1: Arc welding cell

Item Description1 Robot2 Controllers3 Tool/toolTT changer4 Energy supply system5 Periphery connection6 Sensor system7 Safety fence8 Loading area with photoelectric curtain


ponents of a robot system


f a robotic cellria for a robotot and external axes

e energy supply systemnectionsent

ell

obotic cell consists of the following components:

4 Industrial robots

4.1 Overview


What is a robot?Structure of a robotArrangement of the main axesAbsolute accuracy and repeatability

4.2 Introduction to robotics

What is a robot? The term robot comes from the Slavic word robota, meaning hard work.

According to the official definition of an industrial robot: “A robot is a freely pro-grammable, program-controlled handling device”.

The robot thus also includes the controller and the operator control device, to-gether with the connecting cables and software.

Fig. 4-1: Industrial robot

1 Controller ((V)KR C4 control cabinet)2 Manipulator (robot arm)3 Teach pendant (KUKA smartPAD)

Everything outside the system limits of the industrial robot is referred to as theperiphery:

Tooling (end effector/tool)Safety equipmentConveyor belts


4 Industrial robots

4.1 Overvrr iew

The following con

What is a robotStructure of a rArrangement oAbsolute accur

4.2 Introduction to robotics

What is a robot? The term robot com

According to the offgrammable, progra

The robot thus alsogether with the con

Fig. 4-1: Industrial robot

1 Controller ((V)KR C4 control cabinet)2 Manipulator (robot arm)3 Teach pendant (KUKA smartPAD)

Everything outside the system limits of the industrial robot is referred to as theperiphery:

Tooling (end effector/torr ol)Safety equipmentConveyor belts



t?robotof the main axesracy and repeatability

mes from the Slavic word robota, meaning hardrr workrr .

ficial definition of an industrial robot: “A robot is a freely pro-am-controlled handling device”.

o includes the controller and the operator control device, to-nnecting cables and software.

Overview

Fig. 6-1: KUKA smartPAD, front view

Item Description1 Button for disconnecting the smartPAD

2 Keyswitch for calling the connection manager. The switch can only be turned if the key is inserted.

The operating mode can be changed by using the connection man-ager.

3 EMERGENCY STOP button. Stops the robot in hazardous situa-tions. The EMERGENCY STOP button locks itself in place when itis pressed.

4 Space Mouse: For moving the robot manually.

5 Jog keys: For moving the robot manually.

6 Key for setting the program override7 Key for setting the jog override8 Main menu key: Shows the menu items on the smartHMI


Overview

Fig. 6-1: KUKA smartPAD, front view

Item Description1 Button for disconnecting the smartPAD

2 Keyswitch for calling the connection manager. The switch can only be turned if the key is inserted.

The operating mode can be changed by using the connection man-ager.

3 EMERGENCY STOP button. Stops the robot in hazardous situa-tions. The EMERGENCY STOP button locks itself in place when itis pressed.

4 Space Mouse: For moving the robot manually.

5 Jog keys: For moving the robot manually.

6 Key for setting the program override7 Key for setting the jog override8 Main menu key: Shows the menu items on the smartHMI


6.2.2 Rear view

Overview

Fig. 6-2: KUKA smartPAD, rear view

Item Description9 Status keys. The status keys are used primarily for setting param-

eters in technology packages. Their exact function depends on thetechnology packages installed.

10 Start key: The Start key is used to start a program.11 Start backwards key: The Start backwards key is used to start a

program backwards. The program is executed step by step.12 STOP key: The STOP key is used to stop a program that is run-

ning.13 Keyboard key

Displays the keyboard. It is generally not necessary to press thiskey to display the keyboard, as the smartHMI detects when key-board input is required and displays the keyboard automatically.

1 Enabling switch 4 USB connection

2 Start key (green) 5 Enabling switch3 Enabling switch 6 Identification plate


6.2.2 Rear view

Overview

Fig. 6-2: KUKA smartPAD, rear view

Item Descripti9 Status ke

eters in ttechnolo

10 Start key11 Start bac

program 12 STOP ke

ning.13 Keyboard

Displayskey to diboard inp

1 Enabling switch 4 USB connection

2 Start key (green) 5 Enabling switch3 Enabling switch 6 Identification plate


ioneys. The status keys are used primarily for setting param-technology packages. Their exact function depends on thegy packages installed.

y: The Start key is used to start a program.ckwards key: The Start backwards key is used to start abackwards. The program is executed step by step.

ey: The STOP key is used to stop a program that is run-

d key

the keyboard. It is generally not necessary to press thissplay the keyboard, as the smartHMI detects when key-put is required and displays the keyboard automatically.

Fig. 7-1: Mastering position for KR AGILUS Angle values of the mechanical zero position (= reference values)

When ismastering carriedout?

A robot must always be mastered. Mastering must be carried out in the follow-ing cases:

During commissioningFollowing maintenance work to components that are involved in the acqui-sition of position values (e.g. motor with resolver or RDC)If robot axes are moved without the controller (e.g. by means of a releasedevice)Following mechanical repairs/problems, the robot must first be unmas-tered before mastering can be carried out:

After exchanging a gear unitAfter an impact with an end stop at more than 250 mm/sAfter a collision

Before carrying out maintenance work, it is generally a good idea to check the current mastering.

Axis KR AGILUSA1 0°A2 -90°A3 +90°A4 0°A5 0°A6 0°


Fig. 7-1: Mastering position for KR AGILUS

Angle values of the mechanical zero position (= reference values)

When ismastering carriedout?

A robot must always be mastered. Mastering must be carried out in the follow-ing cases:

During commissioningFollowing maintenance work to components that are involved in the acqui-sition of position values (e.g. motor with resolver or RDC)If robot axes are moved without the controller (e.g. by means of a releasedevice)Following mechanical repairs/problems, the robot must first be unmas-tered before mastering can be carried out:

After exchanging a gear unitAfter an impact with an end stop at more than 250 mm/sAfter a collision

Before carrying r out maintenance work, it is generally a good idea to check the current mastering.

Axis KR AGILUSA1 0°A2 -90°A3 +90°A4 0°A5 0°A6 0°


A window opens. All axes to be mastered are displayed. The axis with the lowest number is highlighted.

2. Remove the cover from connection X32.

Fig. 7-6: X32 without cover 3. Connect the EtherCAT cable to X32 and to the MEMD box.

Fig. 7-7: EtherCAT cable at X32 and MEMD box 4. Remove the protective cap of the gauge cartridge on the axis highlighted

in the window.


A window openlowest number

2. Remove the co

Fig. 7-6: X32 without cover

3. Connect the EtherCAT cable to X32 and to the MEMD box.

Fig. 7-7: EtherCAT cable at X32 and MEMD box

4. Remove the protective cap of the gauge cartridge on the axis highlighted in the window.


ns. All axes to be mastered are displayed. The axis with the is highlighted.

over from connection X32.

out cover

Fig. 7-8: Removing protective cap from gauge cartridge 5. Screw the MEMD onto the gauge cartridge.

Fig. 7-9: Screwing MEMD onto gauge cartridge 6. Press Master.7. Press an enabling switch and the Start key.

When the MEMD has passed through the reference notch, the mastering position is calculated. The robot stops automatically. The values aresaved. The axis is no longer displayed in the window.

8. Remove the MEMD from the gauge cartridge and replace the protective cap.

9. Repeat steps 4 to 8 for all axes to be mastered, except A6.10. Close the window.11. In the main menu, select Start-up > Master > Reference.

The option window Reference mastering is opened. A6 is displayed andis selected.

12. Press Master. A6 is mastered and removed from the option window.13. Close the window.


Fig. 7-8:

5. Screw

Fig. 7-9: Screwing MEMD onto gauge cartr ridge

6. Press Master.7. Press an enabling switch and the Start key.

When the MEMD has passed through the reference notch, the masteringposition is calculated. The robot stops automatically. The values aresaved. The axis is no longer displayed in the window.

8. Remove the MEMD from the gauge cartridge and replace the protective cap.

9. Repeat steps 4 to 8 for all axes to be mastered, except A6.10. Close the window.11. In the main menu, select Startr -up > Master > Reference.

The option window Refeff rence mastering is opened. A6 is displayed andis selected.

12. Press Master. A6 is mastered and removed from the option window.13. Close the window.


Removing protective cap from gauge cartr ridge

w the MEMD onto the gauge cartridge.

7.7 Tool calibration

Description Tool calibration means the generation of a coordinate system which has its or-igin in a reference point of the tool. This reference point is called the TCP (ToolCenter Point); the coordinate system is the TOOL coordinate system.

Tool calibration thus consists of calibration...

of the TCP (origin of the coordinate system).of the alignment of the coordinate system.

Fig. 7-11: Examples of calibrated tools

A maximum of 16 TOOL coordinate systems can be saved. (Variable:TOOL_DATA[1…16]).

During calibration, the distance between the tool coordinate system (in X, Yand Z) and the flange coordinate system, and their rotation relative to one an-other (angles A, B and C), is saved.


7.7 Tool calibration

Description Tool calibii rarr titt oii n meaigin in a reference pCenter Point); the c

Tool calibration thu

of the TCP (origof the alignmen

Fig. 7-11: Examples of calibrated tools

A maximum of 16 TOOL coordinate systems can be saved. (Variable:TOOL_DATA[1…16]).

During calibration, the distance between the tool coordinate system (in X, Yand Z) and the flange coordinate system, and their rotation relative to one an-other (angles A, B and C), is saved.


ans the generation of a coordinate system which has its or-point of the tool. This reference point is called the TCP (Toolcoordinate system is the TOOL coordinate system.

s consists of calibration...

gin of the coordinate system).nt of the coordinate system.

Advantages If a tool has been calibrated precisely, this has the following practical advan-tages for the operating and programming personnel:

Improved joggingReorientation about the TCP (e.g. tool tip) is possible.

Fig. 7-13: Reorientation about the TCP

Moving the robot in the tool direction

Fig. 7-12: TCP calibration principle


AdAA vantages If a tool has been calibrated precisely, this has the following practical advan-tages for the operating and programming personnel:

Improved joggingReorientation about the TCP (e.g. tool tip) is possible.

Fig. 7-13: Reorientation about the TCP

Moving the robot in the tool direction

Fig. 7-12


2: TCP calibration principle

Fig. 7-14: Tool working direction

Use during motion programmingThe programmed velocity is maintained at the TCP along the path.

Fig. 7-15: Program mode with TCP

Furthermore, a defined orientation along the path is possible.

Tool calibrationoptions

Tool calibration consists of 2 steps:


Fig. 7-14: Tool wo

Use during moThe programmed e oc ty s a ta ed at t e C a o g t e pat

Fig. 7-15: Program mode with TCP

Furthermore, a defined orientation along the path is possible.

Tool calibrationoptions

Tool calibration consists of 2 steps:


orking direction

tion programmingammed velocity is maintained at the TCP along the path.

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