Kuka Krc2 Workbook

(1)

SOFTWARE

KR C2

Seminar workbook

of ………

Basic Robot

Programming

Release 4.1

(2)

© Copyright

KUKA Roboter GmbH

This documentation or excerpts therefrommay not be reproduced or disclosed to third parties without the express permission of the publishers.

1. Contents and goals of this course ... 5

2. Safety... 7

3. The robot system... 27

3.1. Basics at the robot system ... 27

3.2. System overview... 35

3.3. Energy supply ... 41

4. Operation of the KUKA control panel (KCP) ... 45

5. The coordinate systems at the robot ... 57

5.1. The axis coordinat system ... 59

5.2. The world coordinate system ... 61

5.3. The tool coordinate system ... 65

5.4. The base coordinate system ... 67

6. Stop reactions of the robot ... 69

7. Mastering... 73

8. Tool calibration ... 79

8.1. The calculation of the TCP's ... 79

8.1.1. The X Y Z - 4 Point method ... 83

8.1.2. The XYZ-reference method ... 85

8.2. Orientation calibration ... 87

8.2.1. The ABC-world 5D method... 87

8.2.2. The ABC-world 6D method... 89

8.2.3. The ABC-2 point method ... 91

8.3. Tool - payload ... 95

9. Base calibration ... 97

10. Motions programming at the robot ... 103

10.1. PTP – motion ... 105

10.2. LIN – motion... 109

10.3. CIRC – motion ... 113

10.4. Approximation of motion ... 117

11. The navigator (program production)... 121

12. Logic programming ... 129

13. Gripper Tech H50... 139

13.1. Gripper typ 1 ... 145

13.2. Gripper typ 2 ... 149

13.3. Gripper typ 3 ... 151

13.4. Gripper typ 4 ... 153

13.5. Gripper typ 5 ... 155

14. Fixed tool calibration... 157

15. Programming with subprograms ... 165

16. The expert level... 167

17. Loops and branches in programs ... 171

18. Automatik external ... 177

18.1. Programnumber typ 1 ... 189

18.2. Programnumber typ 2 ... 191

(4)

(5)

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KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-40 00, Fax: +49 (0) 8 21/7 97-16 16, http://www.kuka-roboter.de I 16.08.00 I College I ML I 1

Seminar goal

The Basic Robot Programming seminar is aimed at the

programming personnel for KUKA industrial robots. This

seminar provides training with regard to

• the proper and safety-conscious operation of a robot

in a production environment,

• the modification and maintenance of robot application

programs,

• and the creation of linear application programs.

Basic Robot Programming

Controller Type KR C2

Topics covered

Basic Robot Programming

Controller Type KR C2

• Safety requirements for programmers

• Components of the robot system

• Operation of the robot system (start-up, shut-down, manual

motion, program selection, automatic program execution)

• Commissioning the robot system (mastering, tool calibration)

• Creation of simple application programs (programming of

motion instructions and predefined application technology

instructions)

• Integration of application programs into the production process

(interface between equipment controller (PLC) and robot

controller)

(7)

(8)

I 14.03.02 I College I ML I 1

KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de (c) Copyright by KUKA Roboter GmbH College 1996-2002

Safety

Safety regulations for working with industrial robots

Liability

• The robot system is built using state-of-the-art technology and in accordance

with the recognized safety rules. Nevertheless, improper use of the robot

system or its employment for a purpose other than the intended one may

cause

danger to life and limb

or

damage to material property

.

• The robot system may only be used in

technically perfect condition

in

accordance with its designated use and only by safety-conscious persons

who are fully aware of the risks involved in its operation. Any functional

disorders affecting the safety of the linear unit must be rectified immediately.

• The robot system is designed to comply with the

EC Machinery Directive

and associated standards. These include, for example, EN 775, the

European norm for the safety of industrial robots.

(9)

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Designated use

• The robot system is designed exclusively for the specified

applications

.

Applications for the KR 125/2 include:

– Spot welding

– Handling

– Assembly

– Application of adhesives, sealants and preservatives

– Machining

– MIG/MAG welding

– YAG laser beam welding

Using the robot system for any other or additional purpose is

considered contrary to its designated use. The manufacturer cannot

be held liable for any damage resulting from such use. The risk lies

entirely with the user.

Safety symbols

This symbol is used where failure to fully and accurately observe

operating instructions, work instructions, prescribed sequences

and the like could result in

injury or a fatal accident

.

This symbol is used where failure to fully and accurately observe

operating instructions, work instructions, prescribed sequences

and the like could result in

damage to the robot system

.

This symbol is used to draw attention to a

particular feature

.

Observance of the note will generally result in facilitation of the

work concerned.

(10)

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General safety regulations

• Improper use

of the robot system or its employment for a

purpose other than the intended one may cause

– danger to life and limb

– danger to the robot system and other assets of the user

and

– danger to the efficient working of the robot system or its

operator.

General safety regulations

• Every person involved with the robot system must have read and

understood

these operating instructions, particularly the

“Safety” chapter

,

paying special attention to the passages marked with the warning symbol .

• Installation, exchange, adjustment, operation, maintenance and repair must

be performed only as specified in these operating instructions and only by

personnel specially trained

for this purpose.

(11)

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General safety regulations

• The

responsibilities

involved in operation of the robot system and in all other

work performed on the robot system or in its immediate vicinity must be

clearly

defined

and

observed

by the user in order to prevent any uncertainty

regarding spheres of competence in matters of safety.

• The user and operating personnel must ensure that only

authorized

personnel

are permitted to work on the robot system.

• The user must clearly set out what the responsibilities of operating personnel

actually entail and give them the authority to

refuse to carry out

instructions

from third parties which are

contrary to safety procedures

.

General safety regulations

• The

danger zones of the robot system

must be safeguarded to prevent

persons or objects from entering these zones. This safety facility is the

responsibility of the user.

• The

switching times of the EMERGENCY STOP system

must be taken

into account when determining the size of the danger zones.

(12)

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Particular safety regulations for the user and the operating personnel

• The robot system must be switched off before

maintenance

work

, i.e. the main switch on the control cabinet must be turned to

“OFF”.

• Secure it with a

padlock

to prevent unauthorized persons from switching it

on again.

• De-energize power supply lead

and disconnect X1.

• Before exchanging the

power unit

(power module), wait at least

5 minutes

.

• Work on the electrical equipment of the robot system

may only be carried out by a

skilled electrician

.

• Skin contact with grease is to be avoided.

Particular safety regulations for the user and the operating personnel

• The operating personnel are obliged to

inform

the user

immediately

of any

changes to the robot system which impair

its safety

.

• The user must ensure that the robot system is only ever operated in

faultless condition.

• No functional safety equipment may be dismantled

or taken out of

operation.

(13)

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Particular safety regulations for the user and the operating personnel

• When

work

is carried out

in the danger zone

of the robot, the

latter may only, if absolutely essential, be operated at

manual

traversing speed

at the most.

• All persons situated in the environment of the robot must be informed in

good time that the robot is about to move.

• Wherever possible,

only one person

should work in the danger zone of

the robot at any time.

Particular safety regulations for the user and the operating personnel

• In

sensor-assisted operation

, the robot is liable to perform

unexpected movements

and path corrections if the main

switch on the control cabinet has not been turned to “OFF”.

• Due regard must be paid to

hazards

posed by the

peripheral system

components of the robot such as grippers, conveyors, feed

devices or other robots in a multi-robot system.

• Any unauthorized

conversion

or

modification

of the robot system is

not

allowed

.

(14)

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Singularities of a 6-axis robot

• Singularities are points through which the robot cannot be moved

using

Cartesian traversing

. In the immediate vicinity of these

points, the affected axes are subjected to extreme acceleration.

This results in the robot motion being stopped by the controller

and the generation of an error message.

Alpha 5

Extended position

Safety features of the robot system: working space limitation

• The means of limiting the working space of the robot comprise:

– adjustable software limit switches

for all axes and

– for some axes

mechanical limit stops

with a buffer function,

– working range monitoring by means of

workspaces

($WORKSPACE),

– which as the

working range limitation accessory

are also adjustable.

(15)

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Safety features of the robot system: working space limitation

• Example: software limit switches for axis 1

$SOFT

N

_END[1] = -185°

$SOFT

P

_END[1] = 185°

Axis designation

Safety features of the robot system: working space limitation

• Examples: working range limitation on the KR 125

Axis 1

Axis 3

Axis 2

(16)

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Safety features of the robot system: counterbalancing system

• Some robot types are equipped with a hydropneumatic or mechanical

counterbalancing system

.

• Work on the hydropneumatic counterbalancing system may only be carried

out by persons having special knowledge and experience of hydraulic and

pneumatic systems.

• If work is to be carried out on

the counterbalancing systems,

the parts of the robot assisted

by these systems must be

secured so that they are

unable to move.

Safety features of the robot system: temperature monitoring

• The motors are protected against overload by means of temperature

sensors in the motor windings.

• The

motors

reach temperatures during operation which can

cause

burns to the skin

. Appropriate safety precautions must be

taken.

• The temperatures inside the control cabinet (internal

temperature) are monitored. The controller is switched

off if defined limits are exceeded.

(17)

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Safety features of the robot system: enabling switches

• The

enabling switches

on the KUKA Control Panel (KCP)

Enabling switches

Safety features of the robot system: jog mode

• Jog mode

(deadman function). All programs can be executed manually

in the test modes at reduced velocity. However, program execution is only

possible as long as the “Start” key is held down. If the “Start” key is

released, the robot stops. The program can only be continued by pressing

the “Start” key again.

(18)

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Release device for robot axes

• The robot can be moved after a malfunction via the main axis drive motors

and, depending on the type of robot, also via the wrist axis drive motors in

some instances. It is only intended for use in

emergencies

.

• The release device may only be used if the robot

control cabinet

has been

switched off

.

• If a robot axis has been moved by the release device,

all robot

axes

must be

remastered

. The motor concerned must be

exchanged.

Release device for robot axes

• The release device (reversible ratchet with size 12 socket wrench insert) is

pushed onto the axle of the motor (remove protective cap), which can then

be turned. It is necessary to overcome the resistance of the mechanical

motor brake and any other loads acting on the axis.

• The

motors

reach temperatures during operation which can

cause

burns to the skin

. Appropriate safety precautions must be

taken.

(19)

I 14.03.02 I College I ML I 23

Planning and construction: safety and working zones

• Working zones are to be restricted to the necessary minimum size.

On no

account may persons or equipment be exposed to any danger.

• The danger zones must be safeguarded by means of

protective barriers

and indicated by means of

paint markings

on the floor.

• The

safety fences

must be high enough to prevent anybody from reaching

over them. Design measures must be taken to prevent them from bending.

The number of entrances must be kept to a minimum. All entrances must be

connected to the overall EMERGENCY STOP system

operator safety

on the gate, Emergency Stop on the

safety fencing.

Planning and construction

• The

foundations

and

substructures

must meet the quality specifications

laid down by KUKA.

• The

loads

to be expected when operating the robot system must lie within

the permissible range.

• The operation of robots of normal design is not permitted in

potentially explosive areas

.

• The robot can be equipped with a

collision protection device

(additional

equipment).

(20)

I 14.03.02 I College I ML I 25

Planning and construction

• Removal and installation stations must be provided to allow

tools

to be

changed

. These stations must be accessible to the operator outside the

danger zone and the robot must be able to move to them by means of a

special program step.

• If the presence of operating personnel in the work envelope of the robot is

unavoidable (e.g. for loading components), the danger zone is to be isolated

by means of a

safety mat

or light curtain.

Planning and construction

• If the robot system is operated in conjunction with a

higher-level controller

,

the two EMERGENCY STOP circuits must be interconnected.

• Both these circuits must be of

failsafe design

(dual EMERGENCY STOP

contactors with reciprocal monitoring).

• It is particularly important that a regular check is made to ensure that that the

EMERGENCY STOP devices are

functioning correctly

.

• Outputs

are to be

preset

in accordance with the main project file, i.e. signals

for hold functions must not be reset when the robot controller is switched off if

personnel or equipment would be endangered as a result.

(21)

I 14.03.02 I College I ML I 27

I nstallation and operation

• All persons working within the danger zone of the robot system

must wear

protective clothing

. Of particular importance are safety

footwear and closely fitting clothing.

• The prescribed

transport positions

for the robot

must be observed. Only suitable and technically

faultless lifting gear and load-bearing equipment

with an adequate carrying capacity may be used.

• Never work or stand under

suspended

loads

!

I nstallation and operation

• No welding may be carried out in the immediate vicinity of the

open control cabinet due, among other factors, to the risk of

EPROMs being erased by

UV radiation

.

Foreign matter

(e.g.

swarf, water, dust) must be prevented from

entering the control

cabinet

.

• During

start-up

, check that all

protective devices

are complete and

functioning correctly. No persons or objects are allowed in the danger zone

during start-up. It must be ensured that the

correct machine data

have

been loaded before the system is put into operation for the first time.

(22)

I 14.03.02 I College I ML I 29

I nstallation and operation

• All

safety regulations

must be adhered to while the robot system is in

operation.

• Check the robot system at least once per working shift for

obvious damage

and defects

.

• Never use the robot or the control cabinet as a

climbing aid

.

• The software must be checked for

viruses

.

I nstallation and operation: safety instruction

• Personnel must be instructed before any work is commenced in the type of

work involved

and what exactly it entails as well as any

hazards

which

may exist.

• Records

are to be kept of the content and extent of the instruction.

• Personnel must be instructed

orally every six months

and

in writing

every two years

with regard to the observance of safety regulations and

precautions.

(23)

I 14.03.02 I College I ML I 31

Safety labeling

• All plates, labels, symbols and marks constitute

safety-relevant parts of the robot system.

They must remain attached to the robot or

control cabinet concerned for the whole of their

service lives in their specified, clearly visible

positions.

• It is forbidden

to remove, cover, obliterate, paint over or alter in any other way

detracting from their clear visibility

- identification plates,

- warning labels,

- safety symbols,

- designation labels and

- cable marks.

Safety instructions for KUKA training cells

• Entering the

motion range of the robot

is only permitted with the robot

operated in

“T1”

mode (at reduced velocity) using a

KCP

.

• All persons situated in the environment of the robot (at its own or adjacent

cells) must be

informed

in good time that the

robot is about to move

.

• On

leaving

the training cell, press the

EMERGENCY STOP button

on the

KCP, set

operating mode “T1”

and secure the KCP in its holder.

(24)

I 14.03.02 I College I ML I 33

Safety instructions for KUKA training cells

• When

testing programs

, always execute the program in “T1” mode first

and then in “T2” mode at reduced velocity.

• During program execution in

“T2” mode

, no persons are permitted in the

cell and the gate to the cell must remain closed.

• The robot and its tooling must

never touch or project beyond the safety

fence

.

• Warning:

memory dumps

from KUKA College must

not be loaded into

manufacturing systems

.

ESD directives

ESD = electrostatic sensitive devices

e.s.d. = electrostatic discharge

ESDs can be destroyed by voltages which are imperceptible to humans.

As well as causing complete failure of components, e.s.d. can also be responsible

for partial damage to an IC or component, which can reduce its service life or lead

to sporadic faults.

For these reasons, not only new modules, but also

defective modules, must be handled very carefully in a

way suitable for ESDs.

(25)

I 14.03.02 I College I ML I 35

ESD directives

16

14

12

10

8

6

4

2 20 40 60 80 100

synthetic

wool

antistatic

e.g. offices without air humidity

regulation (in winter)

U/kV

Rel. air humidity/%

15% 35%

Average values for electrical voltages to which a

person can be charged

Element

MOSFET

EPROM

JFET

OP amplifiers

CMOS

Schottky diodes

Thick/thin-film circuits

Bipolar transistors

Schottky TTL

Voltage (V)

100-200

100 140-7000

100-2500

250-3000

300-2500

300-3000

300-7000

1000-2500

e.s.d. vulnerability of semiconductor elements

ESD directives

Handling ESD modules:

• Components should only be unpacked if

a) you are wearing ESD shoes

or

b) you are wearing ESD shoe grounding strips

or

c) you are grounded by means of an ESD armband.

• Before touching an electronic module you should discharge the voltage

from your own body.

• Do not place electronic modules near monitors.

• Only measure with grounded measuring instruments or discharge the

measuring head before measuring.

(26)

(27)

3. The robot system

(28)

I 14.03.02 I College I ML I 1

KUKA Roboter GmbH, Blücherstr. 144, D-86165 Augsburg, Tel.: +49 (0) 8 21/7 97-1906, Fax: +49 (0) 8 21/7 97-2340, http://www.kuka-roboter.de © Copyright by KUKA Roboter GmbH College 1996-2002

KUKA Control Panel

(KCP)

Components of a complete KUKA robot system

KUKA robot

(e.g. KR 350/2 )

Robot controller

(e.g. KR C2)

KUKA Control Panel (KCP)

• Large color graphic

display

• Softkeys around the

display

• Hardkeys for program

and display control

6D mouse

Numeric keypad, alphabetic keypad, cursor block with Enter key

• Keyswitch for mode selection

• Drives on/off switch

• Emergency Stop button

(29)

I 14.03.02 I College I ML I 3

The model classification of KUKA industrial robots is based on the

rated payload.

The type designation is made up as follows:

KUKA

industrial

robot

Rated payload

of the robot

in kilograms

Generation of

the given

robot type

K

R

xxx / y

Robot type designations

KR 150 / 2

K

UKA industrial

r

obot

with a rated payload of

150 kg

of the

2 nd generation

(30)

I 14.03.02 I College I ML I 5

Mechanical construction of a KUKA robot

Wrist

Link arm

Base frame

Arm

Rotating

column

Axis designations of a KUKA robot

Axis 2

Axis 1

Axis 3

Axes

1 ,

2 and

3 are the

main axes

.

Axis 6

Axis 5

Axis 4

(31)

I 14.03.02 I College I ML I 7

The work envelope of a KUKA robot (side view)

Can be

expanded using

an arm extension

Side view:

work envelope

Overhead zone

The work envelope of a KUKA robot (top view)

Top view:

work envelope

Angle, axis 1:

>360°

(32)

I 14.03.02 I College I ML I 9

Load distribution on a KUKA robot

Total Load = Payload + Supplementary Load

From the KR 2000 series onwards, it is

also possible to attach supplementary

loads to the link arm and rotating column.

Supplementary load

Payload

Loads on a KUKA robot (standard series)

Load center distance

Load center of gravity, P

Mass, M, of the payload

(weight of tool)

Robot wrist

Robot flange

Axis 1

Axis 2

Axis 3

Payload

Supplementary

load

Mass, M, and center

of gravity of the

supplementary load

(33)

I 14.03.02 I College I ML I 11

Payload diagram for KR 125/2

L

_z

(mm)

L

_xy

(mm)

100

200

300

400

500

600

100

200

300

400

500

600

700

800 125 kg

115 kg

105 kg

95 kg

85 kg

75 kg

65 kg

55 kg

45 kg

Nominal distance KR 125/2:

L

_Z

=210 mm

L

_XY

=230 mm

230

210

(34)

(35)

(36)

I 14.03.02 I College I ML I 1

Control cabinet overview: KR C1, KR C1A and KR C2

Power supply connection 3x400 V

PC technology

Ambient temperature:

45 °C without cooling unit,

55 °C with cooling unit

Technical data - KR C2

• Cabinet type:

KR C2

– Control cabinet for max. 8 axes

• Permissible environmental conditions:

– without cooling unit:

max. 45 °C

– with cooling unit:

max. 55 °C

• Weight:

approx. 185 kg

• Power supply connection: 3x400 V

• Microprocessor:

Celeron 433 MHz

(37)

I 14.03.02 I College I ML I 3

Hard drive

PC chassis - KR C2

Floppy disk drive

CD-ROM drive

Top view of the PC - KR C2

Keyboard

LPT1

COM1

COM2

Ethernet

Mouse

External monitor

(38)

I 14.03.02 I College I ML I 5

Robot serial number

Serial number

Control cabinet serial number

(39)

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Software concept

Main memory

Windows 95

VxWorks

Operation / visualization

Kernel system

Drives

Robot programs

Control programs

C

R

O

S

Systems

communicate

with each other

KUKA GUI

R1 / STEU

User groups

User

• Start-up tasks (mastering,

tool calibration)

• Simple application programs

(programming using inline

forms, motion commands,

technology commands, limit

Administrator

• Configuration of the robot

controller (external axes,

technology packages)

• Configuration of the robot

system (field buses, vision

systems, etc.)

• User-defined technology

commands with UserTECH

Expert

• Advanced programming using

the KRL programming language

• Complex application programs

(subprograms, interrupt

programming, loops, program

branches)

(40)

(41)

(42)

I 03.02.03 I College I DON I 1

Energy supply - Overview KR 2000

Energy supply - Length attitude

Velcro fastener

Only as long as

necessary

(43)

Energy supply - Hose routing

adjusting trumpet

adjusting compression spring

If the protector is sanded off up to the red

interior, it is to be exchanged.

Energy supply - Attitude of the protectors

Protector cannot be

adjusted

(44)

(45)

(46)

KUKA Control Panel (KCP)

Hardwired operator control elements

EMERGENCY

STOP

Drives OFF

Drives ON

Mode selector

switch

(47)

T

_T

T1 (Test 1)

T2 (Test 2)

AUTOMATIC

AUTOMATIC EXTERNAL

Mode selector switch

Mode selector

switch

T1

T2

AUTOMATIC

EXTERNAL

Manual motion

using

keys

or

Space Mouse

250 mm/s

Manual motion

not active

Manual motion

not active

HOV

Enabling switch

(dead man

function)

Enabling switch

(dead man

function)

Program

execution

250 mm/s

POV

Prog.

velocity

Prog. velocity

Enabling switch

(dead man

function)

START key

Enabling switch

(dead man

function)

START key

Drives ON

START key

--> PULSE

Drives ON

External start

Mode table

(48)

CAN bus operator control elements

Escape key

Window selection key

Display window

Programming window

Status window

(49)

Window selection key

Softkeys

(50)

Status window

The status window is

displayed as required.

The status window can

be closed at any time.

Message window

The controller communicates with

the operator via the message window.

Softkeys for acknowledging

messages

(51)

Message types

Hint

-

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?"

CAN bus operator control elements

STOP key

Program start forwards

Program start backwards

(52)

CAN bus operator control elements

NUM key

Numeric keypad

HOME

Jumps to the

beginning of the line

in which the edit

cursor is positioned.

UNDO

Cancels the last entry.

END

Jumps to the end of

the line in which the

edit cursor is

positioned.

PGUP

Moves one screen

towards the

beginning of the file.

TAB

Tab jump

PGDN

Moves one screen

towards the end of

the file.

CTRL

Control key

Arrow

Backspace key;

deletes the

character to the left

of the edit cursor.

LDEL

Deletes the line in

which the edit

cursor is positioned.

DEL

Deletes the

character to the

right of the edit cursor.

INS

Switches between

insert and overwrite

modes.

(53)

CAN bus operator control elements

ASCII

alphabetic

keypad

ASCII alphabetic keypad

SYM key

SHIFT key

ALT key

(54)

CAN bus operator control elements

RETURN key

CURSOR block

Menu keys

(55)

Status keys

Status bar

Selected

program

Current line

number

Override

Time

Numeric keypad

Operating mode

Upper/lower-case letters

Robot name

(56)

Status bar

Submit interpreter deselected

Submit interpreter stopped

Submit interpreter running

Drives not ready

Drives ready

(600 ms)

(57)

(58)

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Coordinate systems

• Axis-specific motion

Each robot axis can be moved individually in a positive

or negative direction.

• WORLD coordinate system

Fixed, rectangular coordinate system whose origin is located

at the base of the robot.

• TOOL coordinate system

Rectangular coordinate system, whose origin is located in

the tool.

• BASE coordinate system

Rectangular coordinate system which has its origin on

the workpiece that is to be processed.

Selecting a coordinate system

• Select manual motion

Motion keys

Motion with mouse

• Select the coordinate system

Axis-specific manual motion

WORLD coordinate system

TOOL coordinate system

BASE coordinate system

(59)

(60)

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Axis-specific manual motion

Each robot axis can be moved individually in a positive

or negative direction.

(61)

(62)

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WORLD coordinate system

Fixed, rectangular coordinate system whose origin is

located at the base of the robot.

+X

+Y

+Z

Assignment of the angles of rotation in Cartesian coordinates

X

Y

Z

A

B

C

A

Angle

A

Rotation about the Z-axis

B

Angle

B

Rotation about the Y-axis

C

Angle

C

Rotation about the X-axis

(63)

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+Y

+Z

+X

Right hand rule (coordinate directions)

Right hand rule (direction of rotation)

+X, +Y or +Z

(64)

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(65)

(66)

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TOOL coordinate system

Rectangular coordinate system, whose origin is located

in the tool.

(67)

(68)

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BASE coordinate system

Rectangular coordinate system which has its origin on

the workpiece that is to be processed.

(69)

(70)

Braking reactions of the KR C2

Emergency Stop

Enabling sw. released

Safety gate opened

Drives OFF

Mode change

Encoder error

(DSE-RDC connection broken)

Move enable

Stop key

Path-oriented braking

Path-maintaining braking

Path-oriented braking

---

Path-maintaining braking

Path-oriented braking

Short-circuit braking

Ramp-down braking

TEST (T1 or T2)

AUTO or AUTOEXT

Braking reactions of the KR C2

Short-circuit

braking

Path-maintaining

braking

Path-oriented

braking

Ramp-down

braking

Technical

term

Reaction

of drives

Intermediate

circuit

Short-circuit

braking relays

Brakes

Software

Remain ON

High-speed

discharge

Applied

immediately

---Switched off

immediately

Only switched

off after 1 s

hardware

delay

Switched off

immediately

Remains

charged

Discharged;

high-speed

discharge if

U

IC

< 50 V

Remain

open

Applied if

U

IC

< 50 V

Remain open

for 1 s,

then applied

Applied

immediately

Remain

open

Applied

immediately

Applied

after 1 s

Normal ramp which is also

used for normal

acceleration and

deceleration at a point

The controller attempts to

brake the robot on the path

with the remaining

inter-mediate circuit voltage.

When the intermediate

circuit voltage is no longer

sufficient, short-circuit

braking is activated.

In this time the controller

brakes the robot on the path

using a steeper stop ramp.

Remains

charged for 1 s,

then high-speed

discharge

(71)

(72)

(73)

(74)

I 14.03.02 I College I ML I 1

Why is mastering carried out?

A1=0°

A2=-90°

A3=+90°

A4, A5, A6=0°

• When the robot is mastered, the axes

are moved into a defined mechanical

position, the so-called

mechanical zero

position

.

• Once the robot is in this mechanical

zero position, the absolute encoder

value for each axis is saved.

Mastering equipment

Electronic measuring tool (EMT)

Dial gauge

• In order to move the robot

exactly to the mechanical zero

position, a dial gauge or

electronic measuring tool

(EMT) is used.

In EMT mastering, the axis is

automatically moved by the

robot controller to the

mechanical zero position. If a

dial gauge is being used, this

must be carried out manually in

axis-specific mode.

(75)

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Cross-section of the gauge cartridge

EMT

or

dial gauge

"Frontsight/

rearsight" marker

Reference notch

Gauge pin

Gauge cartridge

Schematic representation of the mastering run

EMT

or

dial gauge

Motion direction

+

-EMT

or

dial gauge

Motion direction

+

-"Frontsight/

rearsight" marker

(76)

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Reasons for remastering

... manually by the operator

... if the mastering values for the individual axes

are to be specifically deleted

Mastering is canceled...

The robot can be unmastered...

1)

_{If discrepancies are detected between the resolver data saved when shutting down the controller and the}

current position, all mastering data are deleted for safety reasons.

... manually by the operator

...after a collision involving the tool or robot

... manually by the operator

...after an impact with a mechanical end stop at

more than manual velocity (25 cm/s)

... automatically on booting the

system

1)

...when the robot has been moved without the

controller (e.g. hand crank)

... manually by the operator

…replacement of a gear

... automatically on booting the

system

1)

...after repairs (e.g. replacement of a drive

motor or RDC)

Mastering is canceled...

The robot is to be mastered...

Mastering with the EMT

M

a

sterin

g

los

s

/

che

c

k

_Check

mastering

Master load

with offset

Master load

without offset

1)

Set mastering

Teach offset

First mastering

Mastering with the EMT

1)

_{Only possible if the first mastering is still valid (i.e. no change to the drive}

Kuka Krc2 Workbook

SOFTWARE

KR C2

Seminar workbook

of ………

Basic Robot

Programming

Release 4.1

© Copyright

KUKA Roboter GmbH

This documentation or excerpts therefrommay 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

1. Contents and goals of this course ... 5

2. Safety... 7

3. The robot system... 27

3.1.

Basics at the robot system ... 27

3.2.

System overview... 35

3.3.

Energy supply ... 41

4. Operation of the KUKA control panel (KCP) ... 45

5. The coordinate systems at the robot ... 57

5.1.

The axis coordinat system ... 59

5.2.

The world coordinate system ... 61

5.3.

The tool coordinate system ... 65

5.4.

The base coordinate system ... 67

6. Stop reactions of the robot ... 69

7. Mastering... 73

8. Tool calibration ... 79

8.1.

The calculation of the TCP's ... 79

8.1.1.

The X Y Z - 4 Point method ... 83

8.1.2.

The XYZ-reference method ... 85

8.2.

Orientation calibration ... 87

8.2.1.

The ABC-world 5D method... 87

8.2.2.

The ABC-world 6D method... 89

8.2.3.

The ABC-2 point method ... 91

8.3.

Tool - payload ... 95

9. Base calibration ... 97

10. Motions programming at the robot ... 103

10.1.

PTP – motion ... 105

10.2.

LIN – motion... 109

10.3.

CIRC – motion ... 113

10.4.

Approximation of motion ... 117

11. The navigator (program production)... 121

12. Logic programming ... 129

13. Gripper Tech H50... 139

13.1.

Gripper typ 1 ... 145

13.2.

Gripper typ 2 ... 149

13.3.

Gripper typ 3 ... 151

13.4.

Gripper typ 4 ... 153

13.5.

Gripper typ 5 ... 155

14. Fixed tool calibration... 157

15. Programming with subprograms ... 165

16. The expert level... 167

17. Loops and branches in programs ... 171

18. Automatik external ... 177

18.1.

Programnumber typ 1 ... 189