kuka manual

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_________________________

SEMINAR WORKBOOK OF

ROBOT BRIEFING

for KUKA System Software V5.x

OPERATOR

Workbook MO1 01.06.00



Copyright

2 / 58 Workbook MO1 01.06.00

Copyright

© Copyright 2006

KUKA Roboter GmbHZugspi tzstraße 140

D-86165 Augsburg

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 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 thisdocumentation 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.

KUKA Roboter GmbH accepts no liability whatsoever for any errors in technical information communicated orally or in writing in the

training courses or contained in the documentation. Nor will liability be accepted for any resultant damage or consequential damage.

Responsible for this training documentation: College Development (WSC-IC)



The robot system

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1. The robot system

1.1. Robot system basics



The robot system

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1.2. System overview



The robot system

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mo1_system_overview_en.ppt

© Copyright by KUKA Roboter GmbH College

KR C2 control cabinet for m ax. 8 axes

KR 6 to KR 500

Robots

KL 250 & KL 1500

Linear units

Two-axis positioner

DKP 200&

DKP 400

Control of the 6robot axes

Connection of up to 2 external axes

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PC chassis - KR C2

Floppy disk drive

CD-ROM drive



The robot system

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Robot serial number

Serial number

Typ Type Type: KR16

Wer k-Nr . Ser ial -No . No . Sér ie 858057

Baujahr Date Anneé de. Fab. 2003

Zeich.Nr. Draw No. Plan No. 394.029

Gewicht Weight Poids 235 kg

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Control cabinet serial number

Serial number



Operation and coordinate systems

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2. Operation and coordinate systems

2.1. Operation of the KUKA Control Panel (KCP)




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mo1_kcp_en.ppt


KUKA Control Panel (KCP)

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mo1_kcp_en.ppt


Operator control elements

E-STOP

Drives OFF

Drives ON

Mode selectorswitch




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mo1_kcp_en.ppt


T T

T1 (Test 1)T2 (Test 2)

AUTOMATIC AUTOMATIC EXTERNAL

Mode selector switch

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mo1_kcp_en.ppt


Mode selector switch

T1 T2 AUTOMATIC AUTOMATICEXTERNAL

Joggingusingkeys

or Space Mouse

250 mm/s 250 mm/s Joggingnot active

Joggingnot active

HOV

Enabling switch(dead manfunction)


Program execution 250 mm/s

POV

Prog.velocity

Prog. velocity Prog. velocity


START keypressed


START keypressed

Drives ONSTART key--> PULSE

Drives ON externalExternal start

Mode table




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mo1_kcp_en.ppt


CAN bus operator control elements

Escape key

Window selection key

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mo1_kcp_en.ppt


Display window

Programming window Status window

Message window




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mo1_kcp_en.ppt


Message types

Notify - e.g. “Start key required”

Status - e.g. “EMERGENCY STOP”

Acknowl. - e.g. “Ackn. EMERGENCY STOP”

Wait - e.g. “Wait for $IN[1]==True”

Dialog - e.g. “Do you want to teach point?”

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mo1_kcp_en.ppt


Online help

Select a message text using the arrow keys; the “Online help” function willprovide an explanation.




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mo1_kcp_en.ppt


Menu keys

Menu keys

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Status keys

Status keys




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mo1_kcp_en.ppt


Status bar

Selected

program

Current block

number

Override

Time

Numeric keypad

Operatingmode

Upper/lower-case letters

Robot name

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mo1_kcp_en.ppt


Status bar

Submit interpreter deselectedSubmit interpreter stoppedSubmit interpreter running

Drives not readyDrives ready (approx. 1 s)




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mo1_coordinate_systems_en.ppt


Coordinate systems

• Ax is-speci fic motionEach robot axis can be moved individually in a positiveor negative direction.

• WORLD coordinate system

Fixed, rectangular coordinate system whose origin is locatedat the base of the robot.

• TOOL coord inate system

Rectangular coordinate system, whose origin is located in

the tool.

• BASE coordinate system

Rectangular coordinate system which has its origin onthe workpiece that is to be processed.




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2.3. Jogging axis specific




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2.4. WORLD coordinate system




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mo1_coordinate_systems_world_en.ppt


Cartesian moti on with the 6D mouse

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Mouse configuration - Degrees of freedom of the mouse

The menu item “Mouse configuration” allows you to set the degrees offreedom and adapt the dominance of the mouse.

Degrees of freedomof the mouse

Unlimitedfunctionality

Only linear motions

Only rotationalmotions




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Mouse configuration - Dominant axis

When this function is switched on, only the coordinate axis withthe greatest deflection of the mouse is moved. In this exampleonly the Y axis is moved.

Dominant axis activated

Dominant axis not activated

X-

Z+

Y+

This function allows a superposed motion. Depending on thesetting of the degrees of freedom, either 3 or 6 axes can bemoved simultaneously. In this example, motion is possible in theX, Y and Z directions (the velocity depends on the deflection).

Current setting:




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2.5. Choice of a coordinate system




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mo1_coordinate_systems_en.ppt


Selecting a coordinate system

• Select the coordinate system

Axis-specific jogging

WORLD coordinate system

TOOL coordinate system

BASE coordinate system

• Select jog mode

Jog keys

Jogging with the mouse



Setup

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3. Setup

3.1. Mastering



Setup

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mo1_tool_en.ppt


Tool calibration

What happens during tool calibration?

The tool receives a user-definedCartesian coordinate system

with its origin at a referencepoint specified by the user.

XZ

Y

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mo1_tool_en.ppt


Activating t he tool

Tool nameis displayed

Enter the tool number

1 - 16



Setup

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3.3. Activate a base



Programming

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4. Programming

4.1. Motion programming



Programming

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4.2. PTP – Motion



Programming

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mo1_motion_ptp_en.ppt


Programming a PTP motion

Type of motion

Point name

Velocity

Motion parameters

Approximatepositioning ON

Exact positioning

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ToolTool selectionTool_Data[1]..[16], Nullframe

BaseWorkpiece coordinate systemselectionBase_Data[1]..[32], Nullframe

External TCPRobot guiding tool: FalseRobot guiding workpiece: True



Programming

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Accelerat ion Acceleration used for themotion.Range of values: 1..100%

Approximation d istance*)

Size of approximate positioningrange for the motion.Range of values: 0..100%

*) The parameter “Approximation distance” isdisplayed if approximate positioning hasbeen selected (CONT).

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BCO run - part 1

For the purpose of ensuring that the robot position corresponds to thecoordinates of the current program point, a so-called BCO run (blockcoincidence) is executed.

Block pointer(program pointer)

This is carried out at reduced velocity. The robot is moved to thecoordinates of the motion block in which the block pointer is situated.



Programming

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BCO run - part 2

This is done:

• after a program reset by means of a BCO run to the home position• after block selection to the coordinates of the point at which the block

pointer is situated

• after selection of the “CELL” program before the Automatic External modecan be started

• after a new program has been selected

• after modifying a command

• after jogging in programming mode

A HOME run is recommended for both the first andfinal motions as this represents an unambiguouslydefined uncritical position.

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BCO run - part 3

1. This is done by holding down the Start key after selecting theprogram

2. The robot moves automatically at reduced velocity3. Once the robot has reached the programmed path, the

program can be continued by pressing the Start key again

A BCO run always takes place by the direct route

from the current position to the destination position. Itis therefore important to make sure that there are noobstacles on this path in order to avoid damage tocomponents, tools or the robot!

No BCO run is carried out in Automatic External mode!



Navigator

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5. Navigator



Navigator

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mo1_navigator_user_en.ppt


Navigator (user)

Header

Directory structureDirectory

or file list

Status line

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Navigation using the keyboard

Focus

Select drive,directory or file

Toggle between

directory struc ture / file list Open drive,

directory or file



Navigator

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Program run modes

Motion Step (motion block)

The program is executed one motion instruction at a time, i.e. with a STOP

before each motion instruction.

The program is executed without advance processing.

MSTEP

GO mode

All instructions in the program are executed up to the end of the program

without a STOP.

GO

DescriptionRun mode

U S E R

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Archive

This function allows you to save important data to floppy disk. All files aresaved in compressed form as ZIP files.

If you try to insert a file in an existing archive, the robotname is checked. The robot name in the archive iscompared with the name that is set in the controller.

If the two names are different, a request for confirmationis generated asking if you really wish to overwrite theexisting archive.



Navigator

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Arch ive All

The menu item Archive “All” is used to save to floppy disk allthe data that are required to restore the robot system.These include

- machine data

- tool/base data- all applications- etc.

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Restore All

Once the system has been restored, it must be shut down andrebooted.

All files, with the exception of log files, are loaded backonto the hard disk.



Automatic external mode

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6. Automatic external mode



Automatic external mode

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System structure

Host computer

PLCs

Robots

Control systemcomponents

(robots and periphery)

Controls the entire

system and savesdata

Execute application programs

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mo1_automatic_external_en.ppt


The entire robot process, e.g.motion enable, faultacknowledgement, program start,is controlled by the PLC

Information about operating andfault states are transmitted to thePLC

System structure: KRC - SPS

CELL.SRC

P L C

Signal exchange

Organization program for selecting the motion programs

Automatic External:Operating mode in which ahost computer or PLCassumes control of the robotsystem.

T T



Exercise: Operator control, jogging101

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Tasks:

• Switch the control cabinet on and wait for the system to boot

• Check the robot type and software version

• Release and acknowledge the EMERGENCY STOP

• Make sure that the mode selector switch is set to T1

• Activate axis-specific jogging

• Move the robot in joint (axis-specific) mode with various different jog override settings (HOV) using

the jog keys and Space Mouse

• Explore the range of motion of the individual axes. Be careful to avoid any obstacles present, such

as a table or cube magazine with fixed tool (accessibility investigation)

• On reaching the software limit switches, observe the message window

• In joint (axis-specific) mode, move the gripper to the reference tool (black metal tip) from several

different directions

• Repeat this procedure in the World coordinate system



Exercise: “In-air” program (PTP motion) 105

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Exercise: “ In-air” program (PTP motion) 105

Aim of the exercise:

On successful completion of this exercise, you will be able to carry out the following activities:

• Create a new robot program (program folder / program)

• Select a robot program and execute, stop and reset it in the required operating modes

• Move between points in space by means of programmed PTP motion commands

• Change the program run mode and step-by-step movement to programmed points

• Carry out a BCO run (block selection)

Prerequisites:

• Theoretical knowledge of the PTP motion type

• Knowledge of the Navigator

Necessary equipment:

• Training robot cell

Shortest

distance Fastest path

TCP

P2

P1

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