Manual Kuka 68303

. To avoid this, the motor current can be monitored during the warm-up phase. If a defined value is reached, the robot controller reduces the motion velocity. This, in turn, reduces the motor current.

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Issued: 28.10.2010 Version: KSS 5.5 SI V2 en

6 Configuration

The monitoring refers to PTP motions and PTP- approximate positioning blocks. motions (including Spline) are not monitored and their velocity is not reduced.

6.12.1

Configuring warm-up

Precondition



Expert group

Procedure

1. Open the file R1\Mada\$machine.dat. 2. Set the corresponding system variables to the desired values. (>>> 6.12.3 "System variables for warm-up" Page 132) 3. Close the file. Respond to the request for confirmation asking whether the changes should be saved by pressing Yes.

6.12.2

Warm-up sequence

Precondition

Example



$WARMUP_RED_VEL =TRUE



Operating mode AUT or AUT EXT



The robot is considered to be cold. This applies in the following cases: 

Cold start



Or $COOLDOWN_TIME has expired.



Or $WARMUP_RED_VEL has been set from FALSE to TRUE.

Sequence on the basis of the following example values in $machine.dat: BOOL $WARMUP_RED_VEL = TRUE REAL $WARMUP_TIME = 30.0 REAL $COOLDOWN_TIME = 120.0 INT $WARMUP_CURR_LIMIT = 95 INT $WARMUP_MIN_FAC = 60 REAL $WARMUP_SLEW_RATE = 5.0

1. The cold robot starts. The motor currents are monitored for 30 minutes ($WARMUP_TIME). 2. If the motor current of an axis exceeds 95% ($WARMUP_CURR_LIMIT) of the maximum permissible motor current, the monitoring is triggered. The robot controller then generates the message Warm-up active and reduces the internal override. The robot slows down and the motor current drops. The program override on the K remains unchanged! The internal override is reduced to a maximum of 60% ($WARMUP_MIN_FAC) of the programmed override. There is no way of influencing how quickly the internal override is reduced. 3. Once the monitoring is no longer triggered, the robot controller increases the internal override again. This is generally the case before the minimum $WARMUP_MIN_FAC has been reached! The robot accelerates again. Once a second, the robot controller edges back up towards the programmed override. $WARMUP_SLEW_RATE determines the rate of increase. In the example, the internal override is increased by 5% per second. 4. It is possible that the robot is still not warm enough and that the motor current thus exceeds the maximum $WARMUP_CURR_LIMIT once again. The robot controller reacts (within $WARMUP_TIME) the same way as the first time. 5. If the robot is warm enough for the robot controller to increase the internal override all the way back up to the programmed override, the robot controller deactivates the message Warm-up active.


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KUKA System Software 5.5

6. After 30 minutes ($WARMUP_TIME), the robot is deemed to be warmed up and the motor currents are no longer monitored. LOG file

The following events are logged in the file “Warmup.LOG” (path “KRC:\Roboter\Log\”): Entry

Meaning

Monitoring active

The motor currents are monitored.

Monitoring inactive

The motor currents are not monitored.

Controlling active

The velocity is reduced.

Controlling inactive

The velocity corresponds to the programmed override once again.

Example: ... Date: Date: Date: Date: ...

6.12.3

21.08.08 21.08.08 21.08.08 21.08.08

Time: Time: Time: Time:

14:46:57 14:54:06 14:54:07 18:23:43

State: State: State: State:

Monitoring active Controlling active Controlling inactive Monitoring inactive

System variables for warm-up The system variables for the warm-up can only be modified in the file $Machine.dat (path KRC:\R1\MADA). If one of the values is outside the permissible range, the warm-up function is not active and the velocity is not reduced.

System variable

Description

$WARMUP_RED_VEL



TRUE: Warm-up functionality is activated.



FALSE: Warm-up functionality is deactivated (default).

If $WARMUP_RED_VEL is set from FALSE to TRUE, this sets the runtime of the robot to zero. The robot is deemed to be cold, irrespective of how long it was previously under servo control. $WARMUP_TIME

Time during which the motor currents are monitored by the warmup function. If the cold robot is started, a runtime value is incremented. If the robot is not under servo control, the value is decremented. If the runtime is greater than $WARMUP_TIME, the robot is deemed to be warmed up and the motor currents are no longer monitored. 

$COOLDOWN_TIME

> 0.0 min

If the warm robot is not under servo control, a standstill value is incremented. If the robot is under servo control, the value is decremented. If the standstill time is greater than $COOLDOWN_TIME, the robot is deemed to be cold and the motor currents are monitored. (Precondition: $WARMUP_RED_VEL = TRUE.) If the controller of a warm robot is shut down and restarted with a warm restart, the time the controller was switched off is counted as standstill time. 

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> 0.0 min


6 Configuration

System variable

Description

$WARMUP_CURR_LIMIT

Maximum permissible motor current during warm-up (relative to the regular maximum permissible motor current) Regular maximum permissible motor current = ($CURR_LIM * $CURR_MAX) / 100 

$WARMUP_MIN_FAC

0 … 100%

Minimum for the override reduction due to the warm-up function The internal override is reduced at most to the factor of the programmed override defined here. 

$WARMUP_SLEW_RATE

0 … 100%

Rate of increase for the increase in velocity Once the monitoring is no longer triggered, the robot controller increases the internal override again. The rate of increase is defined here. 

6.13

> 0.0%/s

Collision detection Collision detection is an extension and improvement of the torque monitoring function. The torque monitoring function remains available. Programs in which torque monitoring is already defined can still be executed as before. Alternatively, the lines with the torque monitoring in such programs can be deleted and collision detection can be used instead. Collision detection must not be used together with torque monitoring in a program.

Description

If the robot collides with an object, the robot controller increases the axis torques in order to overcome the resistance. This can result in damage to the robot, tool or other objects. Collision detection reduces the risk of such damage. It monitors the axis torques. If these deviate from a specified tolerance range, the following reactions are triggered: 

The robot stops with a STOP 1.



The robot controller calls the program tm_action. This is located in the Program folder and contains the HALT statement. Alternatively, the can program other reactions in the program tm_action.

The robot controller automatically calculates the tolerance range. (Exception: no values are calculated in T1 mode.) A program must generally be executed 2 or 3 times before the robot controller has calculated a practicable tolerance range. The can define an offset via the interface for the tolerance range calculated by the robot controller. If the robot is not operated for a longer period (e.g. over the weekend), the motors, gear units, etc., cool down. Different axis torques are required in the first few runs after such a break than in the case of a robot that is already at operating temperature. The robot controller automatically adapts the collision detection to the changed temperature. Precondition



In order to be able to use the collision detection function, acceleration adaptation must be activated. Acceleration adaptation is activated when system variable $ADAP_ACC is not equal to #NONE. (This is the default setting.) The system variable can be found in the file C:\KRC\Roboter\KRC\R1\MaDa\$ROBCOR.DAT.


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KUKA System Software 5.5 

The tolerance range is only calculated for motion blocks that have been executed completely.



To activate collision detection for a motion, the parameter Collision detection must be set to TRUE during programming. This can be seen from the addition CD in the program code: PTP P2

Vel= 100 % PDAT1 Tool[1] Base[1] CD

The parameter Collision detection is only available if the motion is programmed via an inline form. Information about collision detection for motions programmed without inline forms can be found in the documentation “KUKA.ExpertTech”. Restrictions



Collision detection is not possible for HOME positions and other global positions.



Collision detection is not possible for external axes.



Collision detection is not possible during backward motion.



Collision detection is not possible in T1 mode.



High axis torques arise when the stationary robot starts to move. For this reason, the axis torques are not monitored in the starting phase (approx. 700 ms).



The collision detection function reacts much less sensitively for the first 2 or 3 program executions after the program override value has been modified. Thereafter, the robot controller has adapted the tolerance range to the new program override.

System variables System variable

Description

$TORQ_DIFF

The values of $TORQ_DIFF (torque) and $TORQ_DIFF2 (impact) are automatically calculated during program execution. These values are compared with the values from the previous program execution or with the default values. The highest value is saved. The values are always calculated, even when collision detection is deactivated.

$TORQ_DIFF2

If collision detection is active, the system compares the values of $TORQ_DIFF and $TORQ_DIFF2 with the saved values during the motion. $TORQMON_DEF[1] … $TORQMON_DEF[6]

Values for the tolerance range in program mode (per axis)*

$TORQMON_COM_DEF[1] … $TORQMON_COM_DEF[6]

Values for the tolerance range in jog mode (per axis)*

$COLL_ENABLE

Signal declaration. This output is set if the value of one of the $TORQMON_DEF[…] variables is less than 200.

File C:\KRC\Roboter\KRC\MaDa\$CUSTOM.DAT File C:\KRC\Roboter\KRC\MaDa\$CUSTOM.DAT

File: KRC:\STEU\Mada\$machine.dat $COLL_ALARM

Signal declaration. This output is set if message 117 “Collision Detection axis ” is generated. The output remains set as long as $STOPMESS is active. File: KRC:\STEU\Mada\$machine.dat

$TORQMON_TIME

Response time for the collision detection. Unit: milliseconds. Default value: 0.0 File: C:\KRC\Roboter\KRC\Steu\MaDa\$CUSTOM.DAT.

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6 Configuration

*The width of the tolerance range is equal to the maximum torque [Nm] multiplied by the value in $TORQMON_... . The default value is 200. Unit: percent.

6.13.1

Calculating the tolerance range and activating collision detection

Precondition

Procedure



The acceleration adaptation is switched on.



The load data have been entered correctly.



In the program, the parameter Collision detection is set to TRUE for all motions that are to be monitored.



If required: the desired collision response has been programmed in the program tm_action.

1. Select the menu sequence Configure > Tools > Collision detection. (>>> 6.13.3 "Option window “Collision detection”" Page 136) 2. The box K must contain the entry MonOff. If this is not the case, press the Deactivate softkey. 3. Start the program and execute it several times. After 2 or 3 program executions, the robot controller has calculated a practicable tolerance range. 4. Press the Activate softkey. The box K in the Collision detection window now contains the entry MonOn. Save the configuration by pressing the Close softkey. If required, the can define an offset for the tolerance range. (>>> 6.13.2 "Defining an offset for the tolerance range" Page 135) The tolerance range must be recalculated in the following cases:

6.13.2



The velocity has been modified.



Points have been changed, added or removed.

Defining an offset for the tolerance range

Description

An offset for the torque and for the impact can be defined for the tolerance range. The lower the offset, the more sensitive the reaction of the collision detection. The higher the offset, the less sensitive the reaction of the collision detection. Torque: The torque is effective if the robot meets a continuous resistance. Examples: 

The robot collides with a wall and pushes against the wall.



The robot collides with a container. The robot pushes against the container and moves it.

Impact: The impact is effective if the robot meets a brief resistance. Example: 

The robot collides with a which is sent flying by the impact.

If the collision detection reacts too sensitively, do not immediately increase the offset. Instead, recalculate the tolerance range first and test whether the collision detection now reacts as desired. (>>> 6.13.1 "Calculating the tolerance range and activating collision detection" Page 135) Procedure

1. Select program. 2. Select the menu sequence Configure > Tools > Collision detection. (>>> 6.13.3 "Option window “Collision detection”" Page 136) 3. The offset for a motion can be modified while a program is running: if the desired motion is displayed in the Collision detection window, press the


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01 or 02 status key. The window remains focused on this motion. Modify the offset using the 01 and 02 status keys. Alternatively, a block selection to the desired motion can be carried out. 4. Save the change by pressing the Save softkey. 5. Save the configuration by pressing the Close softkey. 6. Set the original operating mode and program run mode.

6.13.3

Option window “Collision detection”

Fig. 6-11: Option window “Collision detection” The values in the option window Collision detection do not always refer to the current motion. Deviations are particularly possible in the case of points which are close together and approximated motions. Description

Item 1

2

The button indicates the status of a motion. 

Red: the current motion is not monitored.



Green: the current motion is monitored.



Orange: the 01 or 02 status key has been pressed. The window remains focused on the motion and the offset can be modified. The change can be applied by pressing the Save softkey.



Pixelated: a program must generally be executed 2 or 3 times before the robot controller has calculated a practicable tolerance range. All the while the robot controller is in the learning phase, the button remains pixelated.

Number of the TMx variable The robot controller creates a TMx variable for each motion block in which the parameter Collision detection is set to TRUE. TMx contains all the values for the tolerance range of this motion block. If 2 motion blocks refer to the same point Px, the robot controller creates 2 TMx variables.

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3

Point name

4

Path and name of the selected program


6 Configuration

Item

Description

5

Offset for the torque. The lower the offset, the more sensitive the reaction of the collision detection. Default value: 20. N.A.: the option Collision detection in the inline form is set to FALSE for this motion.

6

Offset for the impact. The lower the offset, the more sensitive the reaction of the collision detection. Default value: 30. N.A.: the option Collision detection in the inline form is set to FALSE for this motion.

7

This box is only active in “Automatic External” mode. It appears gray in all other modes. MonOn: collision detection has been activated by the PLC. If collision detection is activated by the PLC, the PLC sends the input signal sTQM_SPSACTIVE to the robot controller. The robot controller responds with the output signal sTQM_SPSSTATUS. The signals are defined in the file $config.dat. Note: Collision detection is only active in Automatic External mode if both the PLC box and the K box show the entry MonOn.

8

MonOn: collision detection has been activated from the K. Note: Collision detection is only active in Automatic External mode if both the PLC box and the K box show the entry MonOn.

The following status keys are available: Status key

Description Status key 01 modifies the offset for the torque.

Status key 02 modifies the offset for the impact.

The following softkeys are available: Softkey Activate

Description Activates collision detection. This softkey is not displayed if the torque or impact has been changed, but the changes have not yet been saved.

Deactivate

Deactivates collision detection. This softkey is not displayed if the torque or impact has been changed, but the changes have not yet been saved.

Save

Saves changes to the torque and/or impact.

Cancel

Rejects changes to the torque and/or impact.


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6.13.4

Torque monitoring Collision detection is an extension and improvement of the torque monitoring function. The torque monitoring function remains available. Programs in which torque monitoring is already defined can still be executed as before. Alternatively, the lines with the torque monitoring in such programs can be deleted and collision detection can be used instead. Collision detection must not be used together with torque monitoring in a program.

Description

Differences between torque monitoring and collision detection: 

The tolerance range is not automatically calculated by the robot controller, but must be defined by the .



The tolerance range only refers to the torque. No values can be defined for the impact.



The robot controller cannot automatically adapt the tolerance range to changed temperatures.



If a collision is detected, the robot stops with a STOP 1. It is not possible to call a -defined program.

Overview

Step 1

Description Determine suitable values for torque monitoring. (>>> 6.13.4.1 "Determining values for torque monitoring" Page 138)

2

Program torque monitoring. (>>> 6.13.4.2 "Programming torque monitoring" Page 138)

6.13.4.1 Determining values for torque monitoring Description

The maximum torque deviation that has occurred can be determined as a percentage by means of the system variable $TORQ_DIFF[...].

Procedure

1. Select the menu sequence Monitor > Variable > Single. 2. Set the value of the variable $TORQ_DIFF[…] to 0. 3. Execute the motion block and read the variable again. The value corresponds to the maximum torque deviation. 4. Set the variable for the monitoring of the axis to this value plus a safety margin of 5 - 10%. Only the value 0 can be assigned to the variables $TORQ_DIFF[...].

6.13.4.2 Programming torque monitoring Precondition

Procedure

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

In order to be able to use the collision detection function, acceleration adaptation must be activated. Acceleration adaptation is activated when system variable $ADAP_ACC is not equal to #NONE. (This is the default setting.) The system variable can be found in the file C:\KRC\Roboter\KRC\R1\MaDa\$ROBCOR.DAT.



A program is selected.

1. Position the cursor in the line before the motion for which the torque monitoring is to be programmed. Issued: 28.10.2010 Version: KSS 5.5 SI V2 en

6 Configuration

2. Select the menu sequence Commands > Moveparams > Torquemon.. An inline form is opened.

Fig. 6-12 3. In the TORQMON box, select the entry SetLimits.

Fig. 6-13 4. For each axis, enter the amount by which the command torque may deviate from the actual torque. 5. Press the Cmd OK softkey. 6. If a response time for the torque monitoring is to be defined: Set the variable $TORQMON_TIME to the desired value. Unit: milliseconds. Default value: 0. The values are automatically reset to the default value 200 in the following cases: 

Reset



Block selection



Program deselection

6.14

Configuring inline forms for motions

6.14.1

Indicating the approximation distance for motion commands

Description

Inline commands for approximated motions can be indicated in the program with or without the approximation distance. Example without approximation distance: LIN P8 CONT Vel= 100 % DAT9 Tool[1] Base[0]

Example with approximation distance: LIN P8 CONT = 50 mm Vel= 100 % DAT9 Tool[1] Base[0]

If the display is changed, this applies for all subsequently programmed commands. The change is not applied to existing commands unless these are also changed. Precondition



If the display is changed with the KSS running: group “Expert”

Procedure

1. Open the directory C:\KRC\UTIL\REGUTIL. 2. Double-click on the desired file. 3. Answer the request for confirmation with Yes. Then confirm the message indicating that the change has been made with OK. 4. If the change is made with the KSS running: Select the menu sequence Configure > Tools > Reinit > BOF Reinitialization.


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File

6.14.2

File

Description

ContStatingOn.reg

The approximation distance is displayed in inline commands for approximated motions.

ContStatingOff.reg

The approximation distance is not displayed in inline commands for approximated motions.

Changing the unit of the approximation distance for PTP The approximation distance in the option window Motion parameter (PTP) can be specified as a percentage or in mm. The default setting is percent. If the unit is changed, this applies for all subsequently programmed commands. The original unit is retained for existing commands. Exception: If an existing command is changed (e.g. the point name), the new unit is automatically applied for this command. The value remains the same, however! This causes the path to change. Example: 1. Existing command with approximation distance 88%. 2. The unit is changed from percent to mm. 3. The existing command is changed (e.g. the name of the point). The change to the unit thus takes effect. The approximation distance is now 88 mm. Caution! In this case, the system generates a message prompting the to check the new path. This message must be acknowledged. The new path must be tested in jog mode and adapted as required before returning to program mode. Physical injuries or damage to property may otherwise result.

Precondition



If the unit is changed with the KSS running: group “Expert”

Procedure

1. Open the directory C:\KRC\UTIL\REGUTIL. 2. Double-click on the desired file. 3. Answer the request for confirmation with Yes. Then confirm the message indicating that the change has been made with OK. 4. If the change is made with the KSS running: Select the menu sequence Configure > Tools > Reinit > BOF Reinitialization.

Description

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File

Description

DistCriterionPTPOn.reg

Unit of the approximation distance in the option window Motion parameter (PTP): mm

DistCriterionPTPOff.reg

Unit of the approximation distance in the option window Motion parameter (PTP): %


6 Configuration

6.15

Defining calibration tolerances Only modify the default values in exceptional cases. Otherwise, increased error messages and inaccuracy may result.

Precondition



Expert group

Procedure



Select the menu sequence Setup > Measure > Tolerances.

Description

Fig. 6-14: Error tolerances Item 1

Description The minimum distance for tool calibration. 

0 … 200 mm

2

The minimum distance for base calibration.

3

The minimum angle between the straight lines through the 3 calibration points in base calibration.





4

0 … 200 mm

0 … 360°

Maximum error in calculation. 

0 … 200 mm

The following softkeys are available:

6.16

Softkey

Description

Default

Restores the default settings. The data must then be saved by pressing the softkey OK.

Backward motion There are two methods for executing a program backwards: 

TRACE (>>> 6.16.1 "TRACE method" Page 142)



SCAN (>>> 6.16.2 "SCAN method" Page 143)

TRACE method and SCAN method can be activated simultaneously. During backward motion, in this case, the TRACE recordings are taken into consideration first. Once all TRACE recordings have been taken into consideration, program execution continues with SCAN. All interrupts are deactivated during backward motion. The updating of cyclical flags is also deactivated.


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6.16.1

TRACE method

Description

With the TRACE method, the forward motions of the robot are recorded. During backward motion, the recorded motions are executed in the reverse order. Unlike with the SCAN method, the program is not interpreted backwards. Advantages 

Outputs, flags and cyclical flags can be recorded at every point in forward motion. Their states can be restored for every point that is addressed backwards. All outputs, flags and cyclical flags that are set by TRIGGER are also correctly restored in this case. “Outputs” here refers to outputs. System outputs (e.g. $ALARM_STOP or $T2) are not affected by backward motion.



Branches and loops can also be executed backwards.

Disadvantages 

A program must first be executed forwards before backward motion is possible.



The recording is deleted if the program is modified or reset or in the case of block selection. Backward motion is no longer possible in this case.

Response in the case of subprograms 

If a subprogram has been completely executed during forward motion, it cannot be executed with backward motion. Depending on the configuration of Finished_Sub (>>> 6.16.4 "TRACE section" Page 144), the subprogram is either skipped during backward motion or the backward motion is stopped.



If the forward motion was stopped in a subprogram, the response depends on the position of the advance run pointer: Position of the advance run pointer

Response

Advance run pointer is in the subprogram.

Backward motion is possible.

Advance run pointer has already left the subprogram.

Backward motion is not possible. Prevention: Trigger an advance run stop before the END of the subprogram, e.g. with WAIT SEC 0. However, it is then no longer possible to carry out approximate positioning at this point. Or set $ADVANCE to "1". This does not always prevent the error message, but it reduces the probability. Approximate positioning is still possible.



Example

Hidden subprograms are skipped during backward motion.

Example of a TRACE recording. Backward motions of the robot are not recorded! 1. Forward motion: P1

->

P2

->

P3

->

P4

The position of the robot is now P4. Points P1 to P3 were recorded during the forward motion. (Only points that the robot has left are recorded; this is why P4 was not recorded.) 2. Backward motion:

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6 Configuration

P2

<-

P3

<-

P4

The position of the robot is now P2. Points P3 and P2 have been deleted from the recording. P1 is still present. 3. Forward motion: P2

->

P3

->

P4

->

P5

The position of the robot is now P5. Points P2 to P4 were recorded during the forward motion. All in all, points P1 to P4 are now recorded.

6.16.2

SCAN method In the SCAN method, the program is interpreted backwards from the current position of the program interpreter. Advantage 

Backward motion is still possible after a program modification or block selection.

Disadvantages 

Outputs, flags and cyclical flags cannot be restored.



Relative motions cannot be executed backwards.



If the program interpreter encounters a branch or loop, backward interpretation cannot be continued. This is because the system no longer knows which part of the branch to jump to or how often the loop is to be executed.

Response in the case of subprograms

6.16.3



If a subprogram has been completely executed during forward motion, it is skipped during backward motion.



If the forward motion was stopped in a subprogram, then backward motion can be executed as far as the start of the subprogram.

Configuring backward motion

Procedure

1. Double-click on the file BW_INI.EXE in the directory C:\KRC\UTIL. The Edit: Backward.ini window is opened. 2. Make the desired settings and save them by pressing Apply. Close the window. Apply saves the settings in the file "C:\KRC\ROBOTER\INIT\Backward.Ini". The settings are only saved, however, if the system is not currently in backward mode and no program is active.


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Description

Fig. 6-15: Edit: Backward.ini window

6.16.4



TRACE section (>>> 6.16.4 "TRACE section" Page 144)



OFC section (>>> 6.16.5 "OFC section" Page 144)



SCAN section (>>> 6.16.6 "SCAN section" Page 145)



GENERAL section (>>> 6.16.7 "GENERAL section" Page 146)

TRACE section Parameter

Description 

Enable

TRUE: TRACE method activated, i.e. the forward motions of the robot are recorded. 

FALSE: TRACE method deactivated, i.e. the forward motions are not recorded. Maximum number of motions to be recorded. Movements



0 … 60 

SKIP: If a subprogram is reached, a message is displayed which must be acknowledged. The subprogram is then skipped and the backward motion is continued.

Finished_Sub



STOP: If a subprogram is reached, further backward motion is not possible. Cycflags

Maximum number of cyclical flags to be recorded per motion. 

0 … 26

6.16.5

OFC section OFC stands for: outputs, flags, cyclical flags.

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6 Configuration

All parameters in the OFC section refer to the TRACE method. “Outputs” here refers to outputs. System outputs (e.g. $ALARM_STOP or $T2) are not affected by backward motion. Parameter

Description 

TRUE: When switching from forward to backward motion, all outputs, flags and cyclical flags are set to FALSE.

Set_To_False 

FALSE: When switching from forward to backward motion, all outputs, flags and cyclical flags retain their values. 

Trace

At_Leaving: The assignment of the outputs, flags and cyclical flags is recorded on leaving a programmed point. 

No_Trace: The assignment of the outputs, flags and cyclical flags is not recorded. 

Restore

At_Bwd: When a point is reached during backward motion, the outputs, flags and cyclical flags are restored according to the trace. 

At_Fwd: When switching from backward to forward motion, the outputs, flags and cyclical flags are restored according to the trace.

6.16.6

SCAN section Parameter

Description 

Enable

TRUE: SCAN method activated 

FALSE: SCAN method deactivated


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6.16.7

GENERAL section Parameter

Description

Backwardstart

Backwardstart is only relevant for the SCAN method. With the TRACE method, all parameters for tools, workpieces, etc., are automatically taken into consideration. 

TRUE: The parameters for tool, workpiece, etc., are taken into consideration during backward motion. There must be a Fold with a defined structure for every point that is to be interpreted backwards (see following example for a freely-selected point P6). 

FALSE: The parameters for tool, workpiece, etc., are not taken into consideration during backward motion. In other words, in the case of a tool change between two points, the backward motion may be different from what the forward motion would have been. 

TRUE: If the robot is not on the programmed path, the next motion is a BCO run, irrespective of whether START plus or START minus was pressed.

Implicit_BCO 

FALSE: If the robot is not on the programmed path, a BCO run with the START plus key is required. START minus generates an error message.

Quit_M_Trace_ scan

If both TRACE and SCAN methods are activated, the following message is displayed when ing from TRACE to SCAN during backward motion: “Trace buffer empty, start with backward scan”. Quit_M_Trace_Scan defines the message type. 

TRUE: Message is an acknowledgement message (message no. 1055). 

FALSE: Message is a notification message (message no. 1194). Example of the structure of the Fold for Backwardstart: ;FOLD PTP P6 CONT Vel= 30 % PDAT6 Tool[1]:tool_1 Base[0];%{PE}%R 5.2.17,%MKUKATPBASIS,%CMOVE,%VPTP,%P 1:PTP, 2:P6, 3:C_PTP, 5:30, 7:PDAT6 $BWDSTART = FALSE PDAT_ACT=PPDAT6 FDAT_ACT=FP6 BAS(#PTP_PARAMS,30) PTP XP6 C_PTP ;ENDFOLD

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6 Configuration

The first instruction after the start of the Fold must be $BWDSTART. It is irrelevant whether the $BWDSTART line is set to TRUE or FALSE. During backward interpretation, the interpreter finds the motion first (in the example: PTP XP6). It then searches further as far as the $BWDSTART line. When it finds it, it takes all the parameter modifications into consideration before planning the backward motion. In programs created in the group “”, all points automatically have the required Folds. In programs created in the group “Expert”, the Folds must be created manually as required. In a program that does not contain such Folds, the parameters for tool, workpiece, etc., cannot be taken into consideration. Tip: In this case, set Backwardstart to FALSE to prevent an error message from being displayed for every point.

6.17

Configuring the log-in

Procedure

1. Open the file C:\KRC\HMI\Config\Authentication.config. 2. Make the desired changes. 3. Save and close the file.

Description

Depending on the release, the file Authentication.config may vary slightly from the example given here.


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1 2 3 4 ModeOP2Aut ModeOP2Ext 5 false 6 <MethodList> 7 8 SelectionOnly 9 <ListName>secondaryList 10 300 11 12 13 nameOnly 14 300 15 16 17 18 AutoKrcOperator 19 <Level>5 20 KrcSecurity#Operator 21 true 22 <>kukaAuto 23 <UseAutomaticaly>true 24 25 300 26 27 28 <secondaryList> 29 <List xmlns:xsd="http://www.w3.org/2001/XMLSchema" xmlns:xsi="http://www.w3.org/2001/XMLSchema-instance"> 30 <Info> 31 AutoKrrogrammer 32 <Level>10 33 KrcSecurity#Programmer 34 true 35 <>kukaAuto 36 <UseAutomaticaly>true 37 38 <Info> 39 KrcExpertProgrammer 40 <Level>20 41 KrcSecurity#ExpertProgrammer 42 true 43 44 <Info> 45 Krc 46 <Level>30 47 KrcSecurity#Krc 48 true 49 50 51 52

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6 Configuration

Line 4

Description

Range of values

AutoLock

ModeOP2Aut = Automatic mode

If the mode is switched to that specified here, the robot controller switches to the default group. If both modes are specified, they must be separated by a space. 5

CanLockSystem

ModeOP2Ext = Automatic External mode TRUE, FALSE

TRUE: When the LeaseTime elapses, the robot controller is locked, i.e. it is disabled for all actions except a new log-in (the robot controller is not locked in the default group). FALSE: When the LeaseTime elapses, the robot controller switches to the default group. 6

MethodList

External

The MethodList contains all log-in methods. The robot controller always attempts to use the method that is at the top of the list. If this fails, the robot controller attempts to use the next method, etc.

SelectionOnly

The attempt could fail, for example, if the method at the top of the list is External, but the PLC signal required for this method is not received. 8, 13

nameOnly Other methods according to customer-specific settings

AuthenticationType

External

Name of the log-in method

SelectionOnly

See the table “Log-in methods”

nameOnly Other methods according to customer-specific settings

9

ListName

secondaryList

list that is used. The place where the list is situated and the type of encryption used are defined in the following file: C:\KRC\HMI\KUKA_HMI.exe.config

primaryList Other lists according to customer-specific settings

Note: When accessing a list, the system always refers to KUKA_HMI.exe.config. Even if the list is stored directly in Authentication.config, the system first checks the location in KUKA_HMI.exe.config and then accesses the location. 10, 14

LeaseTime

s (INT)

If no actions are carried out in the interface during this time, the robot controller reacts as configured in CanLockSystem. 17, 18

Default Name

See the table “ groups”

Default group.


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Line 17, 19

Description

Range of values

Default

See the table “ groups”

… Level Identification number of the group 25

0 … 300 s (INT)

AnnouncementTime Only relevant if an external log-in is used. Time available to the to confirm the external log-in, e.g. via Euchner key, so that it is actually carried out. If the value is set to 0, the external log-in is always active.

Log-in methods

Method

Description

External

Log-in method for log-in via a higher-level controller The robot controller must receive a “life signal” from the higher-level controller that toggles with a cycle rate of 500 ms. A digital input indicates to the robot controller which is logging in. The inputs are configured in the file $config.dat. 

Signal declaration for life signal:

SIGNAL ExtIDWatchDog $IN[1026] 

Signal declaration for log-in:

SIGNAL ExtID $IN[1026] TO $IN[1026]

A list that only contains automatic Windows names must be used for this log-in method, as no is to be requested when logging on via a higher-level controller. SelectionOnly

If this log-in method is used, the default group is automatically selected. When changing group, a list is displayed in the KUKA.HMI from which the new group can be selected. The list corresponds to the list assigned to this log-in method.

nameOnly

If this log-in method is used, the must enter the name, and domain.

groups

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The Windows names must be used, with unchangeable s, if the request to enter a is to be avoided when logging on.

group

Windows name

de/en (identification number)

(default : kuka)

Windows name (internal , unchangeable: kukaAuto)

Key

Bediener / Operator (5)

KrcOperator

AutoOperator

Operator

Anwender / Programmer () (10)

Krrogrammer

AutoKrrogrammer

Programmer

Inbetriebnehmer / Maintenance (19)

KrcMaintenance

AutoKrcMaintenance

Maintenance

Experte / Expert (20)

KrcExpertProgrammer

AutoKrcExpertProgrammer

ExpertProgrammer


6 Configuration

group

Windows name

de/en (identification number)

(default : kuka)

Sicherheitsinbetriebnehmer / SafetyMaintenance (29) / (30)

6.18

Windows name (internal , unchangeable: kukaAuto)

Key

KrcSafetyMaintenance

AutoKrcSafetyMaint

SafetyMaintenance

Krc

AutoKrc

Krc

Setting up a new group and

Description

In addition to the predefined groups, other groups can also be set up. Depending on the group, different menu items and softkeys are available in the interface. This is defined using identification numbers: Each group is assigned an identification number between 0 and 30. A menu item or softkey is available in a group if its identification number is less than or equal to the identification number of the group. Identification numbers of the predefined groups (>>> " groups" Page 150) The identification numbers of the menu items and softkeys are defined in the following files: 

Menu keys: C:\KRC\ROBOTER\INIT\MenueKeyKuka.ini



Softkeys: C:\KRC\ROBOTER\INIT\SoftKeyKuka.ini

If a menu item or softkey has no identification number, it is available in the group “Operator” or higher. Overview

Step 1

Description Set up new group. (>>> 6.18.1 "Example of setting up a new group" Page 151)

2

Set up for new group. (>>> 6.18.2 "Setting up a for a new group" Page 153)

3

Define new group as default group (optional). (>>> 6.19 "Defining the default group" Page 154)

6.18.1

Example of setting up a new group

Description

In this section, the group “MyGroup” will be set up by way of an example. The group “MyGroup” is to have the same functions as the group “” (“Programmer”) plus the function “Monitoring working envelope - Override”. This function is called as follows in the interface: menu sequence Configure > Tools > Monitoring working envelope > Override.


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Overview

Step 1

Description Define group. (>>> 6.18.1.1 "Defining a group" Page 152)

2

Define position of the softkey. (>>> 6.18.1.2 "Defining the position of the softkey" Page 152)

3

Enable function. (>>> 6.18.1.3 "Enabling the function" Page 153)

6.18.1.1 Defining a group Procedure

1. In the file SoftKeyKuka.ini, go to the section Mode-OCX. ;***** U s e r M o d e - O C X ***** _UMODE = Mode , 20, MODE, 10 EXPERT_UMODE = ModeExpert, 20, MODE, 20 _UMODE = Mode , 20, MODE, 30

2. Insert the new group after the line _UMODE. ;***** U s e r M o d e - O C X ***** _UMODE = Mode , 20, MODE, 10 EXPERT_UMODE = ModeExpert, 20, MODE, 20 _UMODE = Mode , 20, MODE, 30 MYGROUP_UMODE = MyGroup , 20, MODE, 11

The optional elements are indicated in bold type. All other elements must be entered unchanged. Element

Description

MYGROUP_UM ODE

Internal system designation.

MyGroup

Designation of the softkey in the interface.

This designation must end with _UMODE. Freely selectable

11

Identification number 

0 … 28, except 5, 10, 19, 20, 27! (These are the identification numbers of the predefined groups. (>>> " groups" Page 150))

6.18.1.2 Defining the position of the softkey Procedure

1. In the file SoftKeyKuka.ini, go to the section [#MODE]. [#MODE] Group = _UMODE, EXPERT_UMODE, _UMODE, , , , CANCEL_DISP

The entry contains the internal system designation of the softkeys. The order corresponds to the sequence in the softkey bar. 2. Enter the internal system designation in the desired position. [#MODE] Group = _UMODE, EXPERT_UMODE, _UMODE, MYGROUP_UMODE, , , CANCEL_DISP

Do not delete or overwrite any commas!

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6 Configuration

3. Save and close the file “SoftKeyKuka.ini”. 6.18.1.3 Enabling the function Procedure

1. In the file MenueKeyKuka.ini, go to the entry for the menu item Override. ; ************** Konfigurieren / Extras / Arbeitsraum-Menu ***** miDisableWBox = ConfigWBoxDisable, 165, KrcRobotLogic, $WBOXDISABLE;TRUE, , , 20

2. Change the identification number from 20 to 11. ; ************** Konfigurieren / Extras / Arbeitsraum-Menu ***** miDisableWBox = ConfigWBoxDisable, 165, KrcRobotLogic, $WBOXDISABLE;TRUE, , , 11

The menu item Override is now available in groups whose identification number ≥ 11. The identification number must always be the 7th element in the enumerated list to the right of the equals sign. The elements are separated by commas. Semicolons are not valid as separators. If a menu item does not yet have an identification number, it may be necessary to add not only an identification number, but also the corresponding commas. 3. Override is a sub-item of the menu item Monitoring working envelope. This must also be made available for the new group, as the menu item Override is not otherwise accessible. In the file MenueKeyKuka.ini, go to the entry for the menu item Monitoring working envelope. Change the identification number from 20 to 11. ; ************** Konfigurieren / Extras-Menu ***** … mpWorkspace = Workspace, 1035, HMI, ,POPUP, mWorkspace, 11

4. Save and close the file MenueKeyKuka.ini.

6.18.2

Setting up a for a new group

Precondition

Procedure



A new group has been set up.



Windows interface (CTRL+ESC)

1. Press the Windows Start button and select Run.... 2. In the Open box, enter “regedit” and press OK. The Registry editor window opens. 3. Select the following folder in the tree structure: HKEY_CURRENT_\Software\KUKA Roboter GmbH\KUKA BOF\OCX Controls\Mode\ 4. Select the menu sequence Edit > New > Binary value. 5. Change the designation of the new value to “xx”. Instead of “xx”, enter the identification number of the new group. 6. Close the Registry editor window. The now consists of a blank character string. It can be left like this or modified. 

If the blank character string is to be left: simply press the Enter key when the is requested.



If the is to be changed: (>>> 6.6 "Changing the " Page 119)


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By default, the values entered under HKEY_CURRENT_\… in the registry database are not overwritten when the KSS is installed.

6.19

Defining the default group

Description

When the system is booted, the group “Operator” is activated by default. An alternative group can be defined as the default group instead.

Procedure

1. Press the Windows Start button and select Run.... 2. In the Open box, enter “regedit” and press OK. The Registry editor window opens. 3. Select the following folder in the tree structure: HKEY_CURRENT_\Software\KUKA Roboter GmbH\KUKA BOF\OCX Controls\Mode 4. Select the menu sequence Edit > New > DWORD value. 5. Change the designation of the new value to “Mode”. 6. Right-click on the value and select the option Change. The Edit DWORD value window opens. 7. Enter the desired identification number as a decimal value or hexadecimal value and press OK. 8. Close the Registry editor window. When the system is next booted, the new default group will automatically be activated.

6.20

Configuring Automatic External

Description

If robot processes are to be controlled centrally by a higher-level controller (e.g. a PLC), this is carried out using the Automatic External interface. The higher-level controller transmits the signals for the robot processes (e.g. motion enable, fault acknowledgement, program start, etc.) to the robot controller via the Automatic External interface. The robot controller transmits information about operating states and fault states to the higher-level controller.

Overview

To enable use of the Automatic External interface, the following configurations must be carried out: Step 1

Description Configuration of the CELL.SRC program. (>>> 6.20.1 "Configuring CELL.SRC" Page 154)

2

Configuration of the inputs/outputs of the Automatic External interface. (>>> 6.20.2 "Configuring Automatic External inputs/outputs" Page 155)

3

Only if error numbers are to be transmitted to the higher-level controller: configuration of the P00.DAT file. (>>> 6.20.3 "Transmitting error numbers to the higher-level controller" Page 161)

6.20.1

Configuring CELL.SRC

Description

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In Automatic External mode, programs are called using the program CELL.SRC.


6 Configuration

Program

1

DEF CELL ( ) … INIT BASISTECH INI CHECK HOME PTP HOME Vel= 100 % DEFAULT AUTOEXT INI LOOP P00 (#EXT_PGNO,#PGNO_GET,DMY[],0 ) SWITCH PGNO ; Select with Programnumber

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Procedure

CASE 1 P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 ) ;EXAMPLE1 ( ) ; Call -Program CASE 2 P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 ) ;EXAMPLE2 ( ) ; Call -Program CASE 3 P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 ) ;EXAMPLE3 ( ) ; Call -Program DEFAULT P00 (#EXT_PGNO,#PGNO_FAULT,DMY[],0 ) ENDSWITCH ENDLOOP END

Line

Description

12

The robot controller calls the program number from the higher-level controller.

15

CASE branch for program number = 1

16

Receipt of program number 1 is communicated to the higherlevel controller.

17

The -defined program EXAMPLE1 is called.

27

DEFAULT = the program number is invalid.

28

Error treatment in the case of an invalid program number

1. Open the program CELL.SRC in the Navigator. (This program is located in the folder "R1".) 2. In the section CASE 1, replace the name EXAMPLE1 with the name of the program that is to be called via program number 1. Delete the semicolon in front of the name. … 15 16 17 …

CASE 1 P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 ) MY_PROGRAM ( ) ; Call -Program

3. For all further programs, proceed as described in step 2. If required, add additional CASE branches. To do so, select a CASE branch by means of SHIFT+CURSOR and copy and paste it using the Edit menu. 4. Press the Close softkey. Respond to the request for confirmation asking whether the changes should be saved with Yes.

6.20.2

Configuring Automatic External inputs/outputs

Procedure

1. Select the menu sequence Configure > I/O > Automatic External. 2. In the Value column, select the cell to be edited and press the Value softkey.


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3. Enter the desired value and save it by pressing the OK softkey. 4. Exit the configuration by pressing the Close softkey. Description of the inputs and outputs: 

(>>> 6.20.2.1 "Automatic External inputs" Page 157) 

(>>> 6.20.2.2 "Automatic External outputs" Page 159)

Description

Fig. 6-16: Configuring Automatic External inputs

Fig. 6-17: Configuring Automatic External outputs Item

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Description

1

Number

2

Long text name of the input/output


6 Configuration

Item

Description

3

Type 

Green: input/output 

Yellow: variable or system variable ($...) 4

Name of the signal or variable

5

Input/output number or channel number

6

The outputs are thematically assigned to the following tabs: 

Start conditions



Program status



Robot position



Operating mode

The following softkeys are available: Softkey

Description Monitor

Inputs/Outputs

Switches to the Automatic External display. (>>> 4.16.4 "Displaying inputs/outputs for Automatic External" Page 68) Toggles between the windows for inputs and outputs. The selected value is made available for editing.

Value Toggles between the tabs. Tab -/Tab +

This softkey is only available for outputs.

6.20.2.1 Automatic External inputs PGNO_TYPE

Type: Variable This variable defines the format in which the program number sent by the higher-level controller is read. Value 1

2

3

Description

Example

Read as binary number.

00100111

The program number is transmitted by the higher-level controller as a binary coded integer.

=> PGNO = 39

Read as BCD value.

00100111

The program number is transmitted by the higher-level controller as a binary coded decimal.

=> PGNO = 27

Read as “1 of n”*.

00000001

The program number is transmitted by the higher-level controller or the periphery as a "1 of n" coded value.

=> PGNO = 1 00001000 => PGNO = 4


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* When using this transmission format, the values of PGNO_REQ, PGNO_PARITY and PGNO_VALID are not evaluated and are thus of no significance. REFLECT_PROG _NR

Type: Variable This variable defines whether the program number is to be mirrored to an output range. The output of the signal starts with the output defined using PGNO_FBIT_REFL. (>>> 6.20.2.2 "Automatic External outputs" Page 159) Value

PGNO_LENGTH

Description

0

Function deactivated

1

Function activated

Type: Variable This variable determines the number of bits in the program number sent by the higher-level controller. Range of values: 1 … 16. Example: PGNO_LENGTH = 4 => the external program number is 4 bits long. If PGNO_TYPE has the value 2, only 4, 8, 12 and 16 are permissible values for the number of bits.

PGNO_FBIT

Input representing the first bit of the program number. Range of values: 1 … 4096. Example: PGNO_FBIT = 5 => the external program number begins with the input $IN[5].

PGNO_PARITY

Input to which the parity bit is transferred from the higher-level controller. Input

Function

Negative value

Odd parity

0

No evaluation

Positive value

Even parity

If PGNO_TYPE has the value 3, PGNO_PARITY is not evaluated. PGNO_VALID

Input to which the command to read the program number is transferred from the higher-level controller. Input

Function

Negative value

Number is transferred at the falling edge of the signal.

0

Number is transferred at the rising edge of the signal on the EXT_START line.

Positive value

Number is transferred at the rising edge of the signal.

If PGNO_TYPE has the value 3, PGNO_VALID is not evaluated. $EXT_START

If the I/O interface is active, this input can be set to start or continue a program. Only the rising edge of the signal is evaluated.

Warning! There is no BCO run in Automatic External mode. This means that the robot moves to the first programmed position after the start at the programmed (not reduced) velocity and does not stop there. $MOVE_ENABLE 158 / 403

This input is used by the higher-level controller to check the robot drives. Issued: 28.10.2010 Version: KSS 5.5 SI V2 en

6 Configuration

Signal

Function

TRUE

Jogging and program execution are possible.

FALSE

All drives are stopped and all active commands inhibited.

If the drives have been switched off by the higher-level controller, the message “GENERAL MOTION ENABLE” is displayed. It is only possible to move the robot again once this message has been reset and another external start signal has been given. During commissioning, the variable $MOVE_ENABLE is often configured with the value $IN[1025]. If a different input is not subsequently configured, no external start is possible. $CHCK_MOVENA

Type: Variable If the variable $CHCK_MOVENA has the value FALSE, $MOVE_ENABLE can be byed. The value of the variable can only be changed in the file C:\KRC\ROBOTER\KRC\STEU\Mada\$OPTION.DAT. Signal

Function

TRUE

MOVE_ENABLE monitoring is activated.

FALSE

MOVE_ENABLE monitoring is deactivated.

In order to be able to use MOVE_ENABLE monitoring, $MOVE_ENABLE must have been configured with the input $IN[1025]. Otherwise, $CHCK_MOVENA has no effect. $CONF_MESS

Setting this input enables the higher-level controller to acknowledge error messages automatically as soon as the cause of the error has been eliminated. Only the rising edge of the signal is evaluated.

$DRIVES_OFF

If there is a low-level pulse of at least 20 ms duration at this input, the higherlevel controller switches off the robot drives.

$DRIVES_ON

If there is a high-level pulse of at least 20 ms duration at this input, the higherlevel controller switches on the robot drives.

$I_O_ACT

If this input is TRUE, the Automatic External interface is active. Default setting: $IN[1025].

6.20.2.2 Automatic External outputs $RC_RDY1

Ready for program start.

$ALARM_STOP

This output is reset in the following EMERGENCY STOP situations: 

The EMERGENCY STOP button on the K is pressed.



External E-STOP


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In the case of an EMERGENCY STOP, the nature of the EMERGENCY STOP can be recognized from the states of the outputs $ALARM_STOP and IntEstop. 

Both outputs are FALSE: the EMERGENCY STOP was triggered on the K.



$ALARM_STOP is FALSE, IntEstop is TRUE: external EMERGENCY STOP. $_SAF

This output is reset if the safety fence monitoring switch is opened (AUTO mode) or an enabling switch is released (T1 or T2 mode).

$PERI_RDY

By setting this output, the robot controller communicates to the higher-level controller the fact that the robot drives are switched on.

$ROB_CAL

The signal is FALSE as soon as a robot axis has been unmastered

$I_O_ACTCONF

This output is TRUE if Automatic External mode is selected and the input $I_O_ACT is TRUE.

$STOPMESS

This output is set by the robot controller in order to communicate to the higherlevel controller any message occurring which requires the robot to be stopped. (Examples: EMERGENCY STOP, Driving condition, Operator safety or Command velocity)

PGNO_FBIT_REF L

Output representing the first bit of the program number. Precondition: The variable REFLECT_PROG_NR has the value 1. (>>> 6.20.2.1 "Automatic External inputs" Page 157) The size of the output area depends on the number of bits defining the program number (PGNO_LENGTH). If a program selected by the PLC is deselected by the , the output area starting with PGNO_FBIT_REFL is set to FALSE. In this way, the PLC can prevent a program from being restarted manually. PGNO_FBIT_REFL is also set to FALSE if the interpreter is situated in the CELL program.

IntEstop

This output is set to FALSE if the EMERGENCY STOP button on the K is pressed. In the case of an EMERGENCY STOP, the nature of the EMERGENCY STOP can be recognized from the states of the outputs $ALARM_STOP and IntEstop. 

Both outputs are FALSE: the EMERGENCY STOP was triggered on the K.



$ALARM_STOP is FALSE, IntEstop is TRUE: external EMERGENCY STOP. $PRO_ACT

This output is always set if a process is active at robot level. The process is therefore active as long as a program or an interrupt is being processed. Program processing is set to the inactive state at the end of the program only after all pulse outputs and all triggers have been processed. In the event of an error stop, a distinction must be made between the following possibilities: 

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If interrupts have been activated but not processed at the time of the error stop, the process is regarded as inactive ($PRO_ACT=FALSE). Issued: 28.10.2010 Version: KSS 5.5 SI V2 en

6 Configuration

PGNO_REQ



If interrupts have been activated and processed at the time of the error stop, the process is regarded as active ($PRO_ACT=TRUE) until the interrupt program is completed or a STOP occurs in it ($PRO_ACT=FALSE).



If interrupts have been activated and a STOP occurs in the program, the process is regarded as inactive ($PRO_ACT=FALSE). If, after this, an interrupt condition is met, the process is regarded as active ($PRO_ACT=TRUE) until the interrupt program is completed or a STOP occurs in it ($PRO_ACT=FALSE).

A change of signal at this output requests the higher-level controller to send a program number. If PGNO_TYPE has the value 3, PGNO_REQ is not evaluated.

APPL_RUN

By setting this output, the robot controller communicates to the higher-level controller the fact that a program is currently being executed.

$PRO_MOVE

Means that a synchronous axis is moving, including in jog mode. The signal is thus the inverse of $ROB_STOPPED.

$IN_HOME

This output communicates to the higher-level controller whether or not the robot is in its HOME position.

$ON_PATH

This output remains set as long as the robot stays on its programmed path. The output ON_PATH is set after the BCO run. This output remains set until the robot leaves the path, the program is reset or block selection is carried out. The ON_PATH signal has no tolerance window, however; as soon as the robot leaves the path the signal is reset.

$NEAR_POSRET

This signal allows the higher-level controller to determine whether or not the robot is situated within a sphere about the position saved in $POS_RET. The higher-level controller can use this information to decide whether or not the program may be restarted. The can define the radius of the sphere in the file $CUSTOM.DAT using the system variable $NEARPATHTOL.

$ROB_STOPPED

The signal is set when the robot is at a standstill. In the event of a WAIT statement, this output is set during the wait. The signal is thus the inverse of $PRO_MOVE.

$T1, $T2, $AUT, $EXT

6.20.3

These outputs are set when the corresponding operating mode is selected.

Transmitting error numbers to the higher-level controller Error numbers of the robot controller in the range 1 to 255 can be transmitted to the higher-level controller. To transmit the error numbers, the file P00.DAT, in the directory C:\KRC\ROBOTER\KRC\R1\TP, must be configured as follows:


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1 2 3 4 5 6 7 8 9 10 11 12 13 26 30 35 36 37 96 97

DEFDAT

P00

BOOL PLC_ENABLE=TRUE ; Enable error-code transmission to plc INT I INT F_NO=1 INT MAXERR_C=1 ; maximum messages for $STOPMESS INT MAXERR_A=1 ; maximum messages for APPLICATION DECL STOPMESS MLD SIGNAL ERR $OUT[25] TO $OUT[32] BOOL FOUND STRUC PRESET INT OUT,CHAR PKG[3],INT ERR DECL PRESET P[255] … P[1]={OUT 2,PKG[] "P00",ERR 10} … P[128]={OUT 128,PKG[] "CTL",ERR 1} … STRUC ERR_MESS CHAR P[3],INT E DECL ERR_MESS ERR_FILE[64] ERR_FILE[1]={P[] "XXX",E 0} … ERR_FILE[64]={P[] "XXX",E 0} ENDDAT

Line

Description

3

PLC_ENABLE must be TRUE.

6

Enter the number of controller errors for the transmission of which parameters are to be defined.

7

Enter the number of application errors for the transmission of which parameters are to be defined.

9

Specify which robot controller outputs the higher-level controller should use to read the error numbers. There must be 8 outputs.

13

In the following section, enter the parameters of the errors. P[1] … P[127]: range for application errors P[128] … P[255]: range for controller errors

26

30

37 … 96

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Example of parameters for application errors: 

OUT 2 = error number 2



PKG[] "P00" = technology package



ERR 10 = error number in the selected technology package

Example of parameters for controller errors: 

OUT 128 = error number 128



PKG[] "CTL" = technology package



ERR 1 = error number in the selected technology package

The last 64 errors that have occurred are stored in the ERR_FILE memory.


6 Configuration

6.20.4

Signal diagrams

Fig. 6-18: Automatic system start and normal operation with program number acknowledgement by means of PGNO_VALID


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Fig. 6-19: Automatic system start and normal operation with program number acknowledgement by means of $EXT_START

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6 Configuration

Fig. 6-20: Restart after dynamic braking (operator safety and restart)


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Fig. 6-21: Restart after path-maintaining EMERGENCY STOP

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6 Configuration

Fig. 6-22: Restart after motion enable


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Fig. 6-23: Restart after STOP

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6 Configuration

6.21

Torque mode

6.21.1

Overview of torque mode

Description

It is possible to switch either individual axes or several axes to torque mode. Torque mode means: The axis can push or pull with a defined torque against a resistance.



Example: application of a defined pressure on the workpiece by an electric motor-driven spot welding gun. The axis can be set to “soft”. It can then be moved by application of an external force. It can be pushed away, for example.



Example: the robot must grip a workpiece in a press that is then ejected by the press. In order for the robot to be able to yield and absorb the ejector stroke, the affected axis is set to “soft”. Restrictions

Axis

Torque mode allowed?

A1



Wall-mounted robots: torque mode must not be used.



Floor- and ceiling-mounted robots: torque mode may be used.

A2

Torque mode must not be used.

A3 … A6

KUKA Roboter GmbH must be consulted if torque mode is to be used for these axes.

External axes

KUKA Roboter GmbH must be consulted if torque mode is to be used for external axes.

Diagonal ejector motion: A diagonal ejector motion cannot be absorbed. If, however, the robot is positioned in such a way that the mounting plane is parallel to the ejector motion plane (e.g. inclined installation of the robot), torque mode is possible for A1. Inclined installation of the robot is only permissible up to a certain angle of inclination. Further information is contained in the robot operating or assembly instructions. 6.21.1.1 Using torque mode Description

Torque mode must be activated for the desired axis. The current for this axis is then limited, thereby reducing the torque. Warning! Current limitation can result in the axis no longer being able to achieve the necessary torque for holding, braking or moving the axis. Death to persons, severe physical injuries or considerable damage to property may result. 

The current for an axis may only be limited if torque mode has been activated for this axis.



Limit the current gradually to determine the required limit. Do not limit the current further than necessary.


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Warning! If an axis is in torque mode, no brakes are applied at the end of the motion. This also applies to the brakes of axes that are not in torque mode, including external axes. After the end of the motion, the robot remains under servo control in order to maintain its position. In this way, the surface can reach temperatures that can cause burns to the skin. must be avoided. Appropriate safety precautions must be taken, e.g. protective gloves must be worn. Procedure

1. Activate torque mode for the axis ($TORQUE_AXIS). 2. Reduce the current limit ($CURR_RED). 3. If the axis is to be set to “soft”: move any axis so that the brakes are released. At the end of the motion, the brakes of all axes remain open. Alternatively, a “motion” to the current position can be executed. The robot does not move, but the brakes are released. 4. Optionally: generate a signal indicating that the axis is stationary (e.g. signal to an injection molding machine). 5. Perform the desired action, e.g. move to workpiece and build up pressure or push the axis away. 6. Optionally: wait for a signal to end torque mode. 7. Deactivate torque mode again ($TORQUE_AXIS). The current limits are automatically set to 100%. Only in the case of deactivation in the robot program or Submit program: the command position is automatically adjusted to the actual position. 8. If this is not carried out automatically: adjust the command position to the actual position.

6.21.1.2 Robot program example: setting A1 to “soft” in both directions Description

This simple example illustrates the basic principle of torque mode. In this example, A1 is to be set to “soft” in both directions. For this purpose, both the positive and negative current limits are set to 0%. This allows the axis to be moved by application of an external force.

Program 1 2 3 4 5 6 7 8

... PTP {A1 10} $TORQUE_AXIS = $TORQ_VEL[1] = $CURR_RED[1,1] $CURR_RED[1,2] PTP {A1 11} ... $TORQUE_AXIS = PTP {A1 -20} ...

'B000001' 130 = 0 = 0

0

Line

Description

2

Activate torque mode for A1.

3

Set the desired limit for velocity monitoring.

4

Set the positive current limit of A1 to 0.

5

Set the negative current limit of A1 to 0.

6

Execute a “motion” to release the brakes. (Since both current limits are set to 0, the robot will not actually move.) A1 can now be moved by application of an external force.

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6 Configuration

Line

Description

7

Deactivate torque mode again. During deactivation, the following occurs automatically:

8



The command position is adjusted to the actual position.



The current limits are set to 100%.

Move to the next position. (The motion from line 6 is not belatedly executed now, as the command-actual adjustment has been carried out in line 7.)

6.21.2

System variables for torque mode

6.21.2.1 $TORQUE_AXIS Syntax

$TORQUE_AXIS = Bit array

Explanation of the syntax

Element

Description

Bit array

Bit array with which torque mode can be activated and deactivated for one or more axes. Examples:

Description



Activate for A1: $TORQUE_AXIS = 'B00001'



Activate for E1: $TORQUE_AXIS = 'B1000000'



Deactivate for all axes: $TORQUE_AXIS = 0

Bit n

12 …

5

4

3

2

1

0

Axis

E6 …

A6

A5

A4

A3

A2

A1

Monitoring: When torque mode is activated, the following monitoring functions are disabled for the affected axis: 

Command value



Stopped



Positioning time



Motor blocked

In order to be able still to detect hardware defects or sagging of the axis, the actual velocity continues to be monitored. 

T1: The monitoring limit set in the machine data applies.



T2 and Automatic: The monitoring limit can be set using $TORQ_VEL.

Validity: Assignment in the robot program: 

If $TORQUE_AXIS is set, it applies to all subsequent motions in the robot program (synchronous and asynchronous).



The value remains valid until a different value is set in a robot program, Submit program or subprogram.



When torque mode is activated, the monitoring functions of the affected axes are disabled, even if these axes are currently asynchronous and moved by a Submit program.


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Assignment in the Submit program: 

If $TORQUE_AXIS is set, it applies to all subsequent motions in the Submit program (only asynchronous). If, at the same time, a robot program is active or interrupted, the assignment also applies there.



When torque mode is deactivated, the following system variables are adapted to the current position: $AXIS_RET, $AXIS_BACK, $AXIS_FOR. If, at the same time, a robot program is active or interrupted, the adaptation also applies there.

Setting $TORQUE_AXIS in a Submit program is only recommended if no robot program is selected. This is the case of $PRO_STATE1==#P_FREE. Assignment in other cases: 

During deactivation, the monitoring functions are immediately re-enabled without waiting for the end of the motion.



During deactivation, the command position is not adapted to the actual position. The must perform the adaptation manually. (>>> 6.21.3.4 "Robot interrupt program example" Page 179)



In the case of assignment via a trigger subprogram or interrupt: The assignment is valid immediately, but only until the next exact positioning. Furthermore, the assignment is applied from the advance run onward, i.e. for all motions that are planned after the assignment. If there are already motions planned after the next exact positioning, the old value still applies to them! (>>> 6.21.3.6 "Negative example: robot program with trigger subprogram" Page 181)

Advance run stop: An assignment to $TORQUE_AXIS in a robot program triggers an advance run stop. Automatic modifications: When torque mode is deactivated: 

The current limits are set to 100%.



Only in the case of deactivation in the robot program or Submit program: the command position is adjusted to the actual position.

Torque mode is automatically deactivated in the following cases: 

Program is selected.



Program is reset.



Block selection



The KRL statement RESUME is executed.



If a running program is stopped and the robot is then jogged manually. If the program is then restarted, torque mode is automatically activated again. The robot moves back to the position at which it left the programmed path. Note: If the axis was set to “soft”, it does not move. The robot controller nonetheless internally executes a BCO run, i.e. the Start key must be held down until the programmed path is reached (BCO).

6.21.2.2 $CURR_RED Syntax

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$CURR_RED[Axis, y] = Limit


6 Configuration


Element

Description

Axis

Data type: INT 

1 … 6: axis A1 ... A6



7 … 12: external axis E1 … E6

Data type: INT

y

Limits



1: positive limit



2: negative limit

Data type: REAL Current limit of axes 1 - 12 in % of maximum current 

Description

1 … 100%

This system variable can be used to modify the limit of the speed controller output and thus of the current. Warning! Current limitation can result in the axis no longer being able to achieve the necessary torque for holding, braking or moving the axis. Death to persons, severe physical injuries or considerable damage to property may result. 

The current for an axis may only be limited if torque mode has been activated for this axis.



Limit the current gradually to determine the required limit. Do not limit the current further than necessary.

The direction of motion of the axis is not indicative of whether the current needs to be limited in the positive or negative direction, i.e. if an axis is to be set to “soft” in its positive direction of motion, this does not automatically mean that the current has to be limited in the positive direction. The direction in which the current has to be limited depends on the specific application. Validity: Assignment in the robot program: 

The value becomes valid when the next motion is executed.



Values set in the robot interpreter only apply there.

Assignment in the Submit program: 

The value becomes valid when the next asynchronous motion in the Submit interpreter is executed.



Values set in the Submit interpreter only apply there.



$CURR_RED is only valid for asynchronous axes. $CURR_RED can also be set for synchronous axes, but has no effect, as no synchronous axes can be moved in the Submit program. If a synchronous axis is subsequently switched to asynchronous mode, the previously set $CURR_RED value becomes valid.

Assignment in other cases: 

If $CURR_RED is set in the trigger, the value immediately becomes valid.

Automatic modifications: $CURR_RED is automatically reset to 100% in the following cases: 




Program is reset.



Block selection


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The KRL statement RESUME is executed.



If torque mode is deactivated with $TORQUE_AXIS, the current limits of the affected axes are reset to 100%. There is thus no need to reset $CURR_RED separately.

Advance run stop: An assignment to $CURR_RED does not trigger an advance run stop. Example 1

Robot program: ... $CURR_RED[7,1] = 20 PTP {...} PTP {...} $CURR_RED[7,1] = 60 PTP {...} PTP {...} ...

Submit program: ... $CURR_RED[7,1] = 40 ASYPTP {...} ... ASYPTP {...} ...

In the robot program, the positive current limit of external axis E1 is set to 20%. This value now applies from the next motion onwards until it is set to 60%. If, at any point, E1 is switched to asynchronous mode and then programmed in the Submit program as shown above, the current limit of 40% only applies to the subsequent ASYPTP motion(s) in the Submit program. If the axis is subsequently moved again in the robot interpreter, the last value set in the robot program applies. Example 2

Robot program: ... $CURR_RED[7,1] = 20 PTP {...} TRIGGER WHEN DISTANCE=0 DELAY=0 DO UP1() PRIO=4 PTP {...} $CURR_RED[7,1] = 60 PTP {...} ...

Trigger subprogram UP1: ... $CURR_RED[7,1] = 40 ...

In the robot program, the positive current limit of external axis E1 is set to 20%. This value is valid from the next motion onwards. If the current limit is set to 40% in the trigger, the value is valid immediately. It also remains valid for subsequent motions until a different value is programmed. This is the case in the example when $CURR_RED is set to 60. 6.21.2.3 $TORQ_VEL Syntax

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$TORQ_VEL[Axis] = Velocity limit


6 Configuration


Element

Description

Axis

Data type: INT

Velocity limit



1 … 6: axis A1 ... A6




Data type: REAL 

0 … 150 %

Limit for the actual velocity as a % of the maximum velocity. Description

When torque mode is activated, the following monitoring functions are disabled for the affected axis: 

Command value



Stopped



Positioning time



Motor blocked

In order to be able still to detect hardware defects or sagging of the axis, the actual velocity continues to be monitored. The maximum permissible velocity for the operating modes T2 and Automatic can be set in the program by means of $TORQ_VEL. If this velocity is exceeded, the drives are switched off and a message is generated. (For T1, the velocity set in the machine data applies. It cannot be influenced by means of $TORQ_VEL.) Advance run stop: An assignment to $TORQ_VEL does not trigger an advance run stop. 6.21.2.4 $CURR_ACT Syntax Explanation of the syntax

$CURR_ACT[Axis] = Current Element

Description

Axis number

Data type: INT

Current



1 … 6: axis A1 ... A6




Data type: REAL Current value of current of axes A1 to A12 as % of maximum amplifier current. 

Description

-100 … +100 %

This variable is write-protected. It can be used to limit $CURR_RED to the current value set for the current.


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6.21.2.5 Overview: writability of the system variables

Can be written to by... Robot program

No

Yes

Yes

Yes

Direct assignment in trigger

No

Yes

Yes

Yes

Subprogram called from in a robot program by a trigger or interrupt

No

Yes

Yes

Yes

Submit program

No

Yes

Yes

Yes

Subprogram called from in a Submit program by an interrupt

No

Yes

Yes

Yes

No

No

No

Yes *

(Triggers are not possible in Submit programs.) Command (e.g. variable correction)

* But not while a program is running or interrupted.

6.21.3

Other examples

6.21.3.1 Robot program example: setting A1 to “soft” in one direction Description

The robot must grip a workpiece in a press that is then ejected by the press. In order for the robot to be able to yield and absorb the ejector stroke, A1 is set to “soft” in the ejection direction.

Program 1 2 3 4 5 6 7 8

... $TORQUE_AXIS = 'B000001' $TORQ_VEL[1] = 130 $CURR_RED[1,1] = 0 PTP $AXIS_ACT $OUT[17] = TRUE WAIT FOR $IN[17] $TORQUE_AXIS = 0 PTP {A1 -20} ...

Line

Description

1

Activate torque mode for A1.

2


3

Set the positive current limit to 0.

4

Execute a “motion” to the current position to release the brakes. A1 can now be moved in the positive direction by the ejector of the press.

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5

Signal to the press controller that the axis is ready for the ejection.

6

Wait for signal from press controller that the workpiece has been ejected.

7

Deactivate torque mode again.

8

Move to the next position.


6 Configuration

6.21.3.2 Robot program example: E1 builds up pressure Description

The electric motor-driven spot welding gun (external axis E1) is to exert a defined pressure on the workpiece. A position behind the workpiece has been defined as the end point of the motion; in reality, this position cannot be reached. This causes the gun electrode to touch the workpiece and the desired pressure to be built up. As soon as the pressure has been built up, the command position changes, but the actual position remains virtually constant. Only the positive current limit is reduced. The negative current limit remains unchanged. This makes it possible to move away from the workpiece again at full velocity.

Program 1 2 3 4 5 6 7 8

... PTP {E1 -4} $TORQUE_AXIS = 'B1000000' $TORQ_VEL[1] = 130 $CURR_RED[7,1] = 20 PTP {E1 5} WAIT FOR END_OF_WELD $TORQUE_AXIS = 0 PTP {E1 -20} ...

Line

Description

1

Move the gun to a position just short of with the workpiece.

2

Activate torque mode for E1.

3


4

Set the required current limit for E1. (Positive torque -> push.)

5

Motion towards end point behind workpiece. The pressure on the workpiece builds up.

6

Wait for end of weld signal.

7

Deactivate torque mode again.

8

The weld gun moves away from the workpiece again.

6.21.3.3 Robot program example: E1 builds up pressure (with trigger subprogram) Description

The electric motor-driven spot welding gun (external axis E1) is to exert a defined pressure on the workpiece. A position behind the workpiece has been defined as the end point of the motion; in reality, this position cannot be reached (P5). This causes the gun electrode to touch the workpiece and the desired pressure to be built up. As soon as the pressure has been built up, the command position changes, but the actual position remains virtually constant. Only the positive current limit is reduced (in 2 steps here). The negative current limit remains unchanged. This makes it possible to move away from the workpiece again at full velocity.

Program

Main program:


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1 2 3 4 5 6 7 8 9

... PTP P1 C_PTP TRIGGER WHEN DISTANCE=0 DELAY=0 DO TORQUE_ON() PRIO=-1 PTP P2 C_PTP $CURR_RED[7,1]=CURR_VALUE_1 PTP P3 C_PTP TRIGGER WHEN DISTANCE=1 DELAY=0 DO $CURR_RED[7,1]=CURR_VALUE_2 PTP P4 C_PTP PTP P5 $TORQUE_AXIS=0 ...

Subprogram: 1 2 3

DEF TORQUE_ON() $TORQUE_AXIS = 64 END

Line

Main program description

1

The motion to P1 is still without torque mode. The current limit for E1 is 100%.

2

Torque mode is activated by means of a trigger subprogram. (The current limit initially remains set to 100%.)

3

Torque mode remains activated for this and subsequent motions, as all motions are approximated. Note: $TORQUE_AXIS set by a trigger subprogram or an interrupt only remains valid until the next exact positioning point. (The information from the motion block before $TORQUE_AXIS then becomes valid again.) $TORQUE_AXIS of this kind is also effective from the advance run onwards. (>>> 6.21.3.6 "Negative example: robot program with trigger subprogram" Page 181)

4

The positive current limit of E1 is set to the value of CURR_VALUE_1. This value remains valid until the trigger in line 6 is triggered. The assignment to $CURR_RED does not trigger an advance run stop.

6

The positive current limit of E1 is set to the value of CURR_VALUE_2. This value remains valid until torque mode is deactivated in line 9.

7

Move the gun to a position just short of with the workpiece.

8

Motion towards end point P5 behind the workpiece. The pressure on the workpiece builds up.

9

Deactivate torque mode when P5 has been reached. (Only the command position of the gun reaches P5.) On deactivation, the command position is automatically adjusted to the actual position, the current limit is set back to 100% and the monitoring functions are reactivated. The next motion in the program is planned from the actual position. The assignment to $TORQUE_AXIS triggers an advance run stop.

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6 Configuration

6.21.3.4 Robot interrupt program example Description

Torque mode can also be used in interrupt programs. In this example, E1 is to be switched to torque mode when a certain error occurs. For this purpose, an interrupt program is used that is executed when the error occurs.

Program

Main program: When the error ERROR_ON occurs, the interrupt program ERROR_PROG() is called. ... INTERRUPT DECL 30 WHEN ERROR_ON==TRUE DO ERROR_PROG() ...

Interrupt program: 1 2 3 4 5 6 7 8 9 10 11 12 13

DEF ERROR_PROG() BRAKE $TORQUE_AXIS=64 $CURR_RED[7,1]=10 $CURR_RED[7,2]=30 PTP $AXIS_INT HALT ACT_POS = GET_ACT_POS() PTP ACT_POS HALT $TORQUE_AXIS=0 PTP $POS_RET END

Line

Description

2

The current motion is stopped as soon as ERROR_PROG() is executed.

3


4

Set the positive current limit of E1 to the required value, here 10%.

5

Set the negative current limit of E1 to the required value, here 30%.

6

Under certain circumstances, the robot may have moved in the interval between activation of the interrupt and BRAKE. For this reason, it is moved back to the position at which the interrupt was triggered.

7

The program is stopped. The error can now be eliminated. (Instead of HALT, other statements can be programmed according to the specific situation, e.g. waiting for a signal.) Following HALT, the Start key must be held down to resume the program.

8, 9

Before torque mode is deactivated, the command position must be adjusted to the actual position. (The comparison is not carried out automatically in this case, because torque mode is not deactivated directly in the robot program, but in the interrupt program.) The positions are compared by performing a motion to the current actual position. This can be read from the system variable $AXIS_INC ($AXIS_ACT cannot be used because it contains the current command values.) The value in $AXIS_INC is specified in increments, however, and must be converted to millimeters and degrees. This is carried out with the function GET_ACT_POS(). (In the concrete application, the must write his own function for this.)


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Line

Description

10

Wait for the end of the motion PTP ACT_POS. Deactivation of torque mode and resetting of the current limit must not be carried out during a motion.

11

Deactivate torque mode. The current limits are automatically set to 100%.

12

In order to be able to resume execution of the main program, the robot must return to the point at which it left the programmed path. ($AXIS_RET could also be used for this.) The main program is resumed. The advance run that was planned before the interrupt was triggered is retained.

If it is not necessary for the advance run to be retained on returning to the main program, RESUME can be used in the interrupt program. This has the advantage that torque mode is deactivated automatically and the command position is adjusted to the actual position. The interrupt program then looks like this: 1 2 3 4 5 6 7 8

DEF ERROR_PROG() BRAKE $TORQUE_AXIS=64 $CURR_RED[7,1]=10 $CURR_RED[7,2]=30 PTP $AXIS_INT RESUME END

6.21.3.5 Submit program example: E1 builds up pressure Program

... 1 IF $PRO_STATE1==#P_FREE 2 $ASYNC_AXIS='B000001' 3 $TORQUE_AXIS=64 4 $CURR_RED[7,1]=10 5 ASYPTP {E1 -10} 6 WAIT FOR $ASYNC_STATE==#IDLE 7 $TORQUE_AXIS=0 8 $ASYNC_AXIS=0 9 ENDIF ...

Line

Description

1

Ensure that no robot program is selected. Otherwise, the assignment to $TORQUE_AXIS will also apply there.

2

Switch E1 to asynchronous motion.

3

Activate torque mode for E1. This assignment applies from the following asynchronous motion onwards, i.e. from ASYPTP {E1 -10}.

4

Set the positive current limit to 10%. This assignment applies from the following asynchronous motion onwards, i.e. from ASYPTP {E1 -10}.

5

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Motion towards end point {E1 -10} behind the workpiece. The pressure on the workpiece builds up.


6 Configuration

Line

Description

6

Wait for the end of the asynchronous motion. (Only the command position of the gun reaches the end point.) Note: There is no advance run in Submit programs. Without the WAIT statement, torque mode would thus already be deactivated again during the motion.

7

Deactivate torque mode. On deactivation, the command position is automatically adjusted to the actual position, the current limit is set back to 100% and the monitoring functions are reactivated.

8

Switch E1 back to synchronous motion.

6.21.3.6 Negative example: robot program with trigger subprogram Description

$TORQUE_AXIS set by a trigger subprogram or an interrupt has 2 effects: 

It is valid immediately, but only until the next exact positioning.



Furthermore, it is applied from the advance run onward, i.e. for all motions that are planned after the assignment.

If there are already motions planned after the next exact positioning, the old value still applies to them! This example shows how not to program. Program

Main program: 1 2 3 4 5 6 7 8 9 10

... $ADVANCE=3 $TORQUE_AXIS=64 PTP {E1 30} C_PTP PTP {E1 20} C_PTP TRIGGER WHEN DISTANCE=0 DELAY=0 DO TORQUE_OFF() PRIO=-1 PTP {E1 10} C_PTP PTP {E1 0} PTP {E1 -10} PTP {E1 -20} PTP {E1 -30} ...

Subprogram: 1 2 3

DEF TORQUE_OFF() $TORQUE_AXIS=0 END

Line


2


5

Deactivate torque mode by means of a trigger subprogram.

6

The trigger is activated in this line. $TORQUE_AXIS=0 is now valid until the next exact positioning point, i.e. until line 7. It also applies to all motions that are planned from now onwards. The advance run is now in line 9.

7, 8

Torque mode is activated in this motion block. (Not desired!) $TORQUE_AXIS=0 is no longer valid from line 7 onwards because of the exact positioning. Furthermore, this motion was already planned when the trigger was activated.


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Line


8, 9

Torque mode is activated in this motion block. (Not desired!) This motion was also already planned when the trigger was activated.

10

Torque mode is deactivated for E1. The advance run pointer was in line 9 when the trigger was activated. $TORQUE_AXIS=0 is thus valid again from line 10 onwards.

6.22

Event planner This function can be used for time-related or action-related control of the data comparison between the kernel system and the hard drive. During data comparison, the kernel system data are written to the hard drive.

6.22.1

Configuring a data comparison

Procedure

1. Select the menu sequence Configure > Tools > Event planner. 2. Open the tree structure in the left-hand part of the window. 3. Select the desired action: 

T1 and T2 Consistency: Compare data in operating modes T1 and T2 at regular intervals. 

AUT and EXT Consistency: Compare data in operating modes Automatic and Automatic External at regular intervals. 

Logic Consistency: Compare data after a change of operating mode or after online optimizing. Online optimizing is the modification of the parameters of a program during operation. 4. Make the desired settings in the right-hand part of the window. (>>> 6.22.2 "Configuring T1 and T2 Consistency, AUT and EXT Consistency" Page 182)

(>>> 6.22.3 "Configuring Logic Consistency" Page 183) 5. Save the configuration with the Apply softkey.

6.22.2

Configuring T1 and T2 Consistency, AUT and EXT Consistency The following settings are possible here:

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

Definition of the date and time that a comparison will first be made between the data in the kernel system and those on the hard drive.



Definition of the interval at which this operation is to be repeated.


6 Configuration

Description

Fig. 6-24: Configuring T1 and T2 Consistency Item 1

Description 

Check box active: data comparison is activated.



Check box not active: data comparison is deactivated.

2

Enter date and time in the format indicated.

3



Check box active: interval is activated.



Check box not active: interval is deactivated.

Caution! If the intervals selected are too small, this can result in damage to the hard drive. An interval of several minutes is recommended.

6.22.3

Configuring Logic Consistency

Description

The following settings are possible here:


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Fig. 6-25: Configuring Logic Consistency Item 1 2

3

4

5

6

6.23

Description 

Checkbox activated: data comparison is activated.






Checkbox activated: data are compared when operating mode is switched to T1.






Checkbox activated: data are compared when operating mode is switched to T2.






Checkbox activated: data are compared when operating mode is switched to Automatic.






Checkbox activated: data are compared when operating mode is switched to Automatic External.






Checkbox activated: data are compared after online optimizing.




KRC Configurator The KRC Configurator can be used to configure the Navigator and various other functions. Most functions can be specially configured for each group. The settings in the KRC Configurator are not checked for validity or plausibility.

Precondition



Procedure

1. Double-click on the file KrcConfigurator.exe in the directory C:\KRC\UTIL\KRCCONFIGURATOR. The KRC Configurator opens.

Windows interface (CTRL+ESC)

2. Edit the desired tab and save it by pressing Apply.

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6 Configuration

3. If necessary, repeat step 2 for other tabs. 4. Exit the KRC Configurator by pressing Exit.

6.23.1

Operating the KRC Configurator The following functions are available in each of the tabs: Select tab 1. Activate the menu bar by pressing the ALT key. 2. Using the arrow keys, select the Tabs menu and press the Enter key. The menu is opened. 3. Using the arrow keys, select the desired entry and press the Enter key. The desired tab is displayed. 4. Deactivate the menu bar by pressing the ALT key. Edit tab 1. Press the TAB key to jump to the desired element on the interface. Precondition: The NUM function must be deactivated. 2. List boxes: Select the desired entry by means of the arrow keys. Check boxes: Activate or deactivate by pressing the space bar. Buttons: Press the Enter key. The following buttons are available in each of the tabs:

Fig. 6-26

6.23.2

Item

Description

1

Saves the changes in the current tab.

2

Closes the KRC Configurator. Changes that have not been applied with Apply are not saved.

3

Restores the KRC Configurator to the state it had when the program was started or the last time changes were saved with Apply.

Display tab

Overview

The following Navigator properties can be configured here: 

Appearance of the directory structure



Number of columns in the file list



Number of columns in the file list

The Navigator can be specially configured for each group.


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Fig. 6-27: Navigator

Description: Display levels

1

Header

3

File list

2

Directory structure

4

Status bar

The group for which the Navigator is to be configured is selected here.

Fig. 6-28: Display tab, Display levels

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Element

Description

ed

Available groups (cannot be changed)

Defined

groups set up in the system. The group for which the Navigator is to be configured must be selected.


6 Configuration

Description: Properties for level

Element

Description

Add to defined

Adds the group selected in ed to Defined.

Remove from defined

Removes the group selected in Defined.

The Navigator is configured for a group here.

Fig. 6-29: Display tab, Properties for level

6.23.3

Element

Description

Properties for level:

The group selected in Display levels, Defined, is displayed.

ed

Columns that can be displayed in the file list (cannot be changed).

Defined

Columns that are displayed in the file list.

Add to defined

Adds the column selected in ed to the file list.

Remove from defined

Removes the column selected in Defined.

Up, Down

Changes the order of the columns displayed in the file list. (Exception: Label cannot be moved.)

Sort by column

Defines the column to be used for sorting the file list.

Sort descending

Check box active: inverted sorting order

Column width

Column width of the column selected in Defined.

Displayed volumes

Drives that are displayed in the directory structure.

Filter tab

Overview

The filters available in the Navigator are configured here. The filters can be specially configured for each group.

Description: Filter levels

The group for which the filters are to be configured is selected here.


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Fig. 6-30: Filter tab, Filter levels

Description: Available filters

Element

Description

ed filter levels

Available groups (cannot be changed)

Defined filter levels

groups set up in the system. The group for which the filters are to be configured must be selected.

Add to defined

Adds the group selected in ed filter levels to Defined filter levels.

Remove from defined

Removes the group selected in Defined filter levels.

Filters are assigned here to a group.

Fig. 6-31: Filter tab, Available filters

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6 Configuration

Element

Description

All available filters

Available filters

Remove from all available

Removes a filter from the list of available filters.

Filters for level:

Filters assigned to the group selected in Defined filter levels. Check box active: This filter is used by default with this group.

Description: Define new filter

Make available to level

Adds the filter selected in All available Filters to Filters for level.

Disable for level

Removes the filter selected in Filters for level.

New filters can be defined here.

Fig. 6-32: Filter tab, Define new filter

Description: Properties for filter

Element

Description

Name

Name of the new filter

Add to all available filters

Adds the filter to All available filters.

The properties for a filter are defined here.


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Fig. 6-33: Filter tab, Properties for filter Element

Description

Properties for filter:

The filter selected in All available filters is displayed.

Mask

Defines which files are displayed in the Navigator. Example: *.src = all SRC files are displayed.

Comment

Comment relating to the filter. When a filter is selected, the comment is displayed in the Navigator alongside the name of the filter. If the filter that is defined by default in the KSS is selected, this character string is not displayed; instead, the translation contained in the KUKA language database is displayed.

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Fast Delete Template

This function is not currently ed.

Show explode

Check box active: SRC and DAT files are displayed separately in the Navigator.

Attributes

Check box active: Files with the attribute System or Hidden are displayed in the Navigator.

Type

Objects that are displayed in the Navigator. The following objects are available: 

Dir: directories



Virtual: virtual directories (if available)



Archiv: archive files



Bin: binary files



Text: text files



Modul: modules



Raw: all other file types



Ibgn file: IBGN files



Protected files: encrypted and/or signed files


6 Configuration

6.23.4

Methods tab

Overview

Here the defines which commands are allowed in the Navigator, subject to certain system states and object states. Furthermore, the also defines which commands are available for which group.

Description: Available methods

The Navigator command whose properties are to be defined is selected here.

Fig. 6-34: Methods tab, Available methods Available methods

Navigator command

NewFileFolder

Create directory or file

DeleteFileFolder

Delete directory or file

RenameFileFolder

Rename directory or file

OpenFileFolder

Open directory or file

OpenDat

Open DAT file

OpenErr

Open ERR file

ArchiveFileFolder

Archive directory or file

RestoreFileFolder

Restore directory or file

ArchiveAll

Archive All

RestoreAll

Restore All

ModulProc39

Internal identifier

Select

Select

SelectWithParam

Not currently ed

Run

Start

Cut

Cut

Copy

Copy

Paste

Paste

Duplicate

Duplicate

SelectAll

Select all

Format

Format floppy

FileFilter

Filter

Attrib

Attribute

RefreshConfig

BOF Reinitialization

ModulProc82

Internal identifier


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Each Navigator command corresponds to an internal identifier (e.g. “ArchiveAll” corresponds to “ModulProc32”). When a module accesses the Navigator, only the internal identifier with the corresponding parameters is transferred. Description: Properties

The properties for the Navigator command are defined here.

Fig. 6-35: Methods tab, Properties Element

Description

Properties for:

The method/Navigator command selected in Available methods is displayed.

Ask before run

Check box active: Before the command is executed in this group, a request for confirmation is displayed.

Enable for

Check box active: This command is permissible for this group.

The settings in the KRC Configurator are not checked for validity or plausibility. It is possible, for example, to activate the object states SelSingle, SelMulti and SelNone for a Navigator command. In this case the Navigator command would be inactive, as at least one of these object states is active at any given time. System conditions Check box active: The Navigator command is not available if this system state is active. Example: 

Available method: NewFileFolder



System condition: check box DriveArch active This means: no directories or files can be created in the Navigator for the ARCHIVE drive.

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6 Configuration

System conditions

Description

ProState0Sel

Submit program with “SELECTED” state

ProState0Act

Submit program with “ACTIVE” state

ProState0Free

Submit program with “FREE” state

ProState1Sel

Robot program with “SELECTED” state

ProState1Act

Robot program with “ACTIVE” state

ProState1Free

Robot program with “FREE” state

DriveKRC

“KRC:\” drive

DriveArch

“ARCHIVE:\” drive

DriveCD

CD-ROM drive

DriveOther

Hard drive

ModeOpEXT

“Automatic External” mode

ModeOpAUT

“Automatic” mode

ModeOpT1

“T1” mode

ModeOpT2

“T2” mode

ModeOpUNK

“Unknown” mode

Disable

The Navigator is disabled as long as the selected command is active

SelTreeWindow

Focus in the directory structure

SelListWindow

Focus in the file list

Item conditions Check box active: The Navigator command is not available if this object state is active. Item conditions

Description

ItemState0Sel

Submit program in the file list with “SELECTED” state

ItemState0Act

Submit program in the file list with “ACTIVE” state

ItemState0Free

Submit program in the file list with “FREE” state

ItemState1Sel

Robot program in the file list with “SELECTED” state

ItemState1Act

Robot program in the file list with “ACTIVE” state

ItemState1Free

Robot program in the file list with “FREE” state

SelSingle

Only one object selected

SelMulti

Multiple objects selected

SelNone

No objects selected

EditModeFull

Edit mode “FULL”

EditModeProKor

Edit mode “PROKOR”

EditModeRO

Edit mode “READONLY”

EditModeUNK

Edit mode “UNKNOWN”

DAT / SRC

Object is a DAT or SRC file

DAT / SRC / ERR

Object is a DAT or SRC file containing errors


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6.23.5

Item conditions

Description

SRC

Object is an SRC file

SRC / ERR

Object is an SRC file containing errors

DAT / SUB

Object is a DAT or SUB file

DAT / SUB / ERR

Object is a DAT or SUB file containing errors

SUB

Object is a SUB file

SUB / ERR

Object is a SUB file containing errors

DAT / ERR

Object is a DAT file containing errors

DAT

Object is a DAT file

TXT

Object is a text file

BIN

Object is a binary file

Arch

Object is an archive

Virt

Object is a virtual directory

Folder

Object is a directory

IBGN File

Object is an IBGN file

Protected File

Object is an encrypted and/or signed file

Methods tab

Overview

The layout and function of this tab are largely identical to those of the Methods tab (>>> 6.23.4 "Methods tab" Page 191).

Description: Available methods

The -specific Navigator command whose properties are to be defined is selected here. Precondition: The Navigator command must have been defined in the file MenueKeyKuka.ini.

Fig. 6-36: Methods tab, Available methods

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6 Configuration

Description: Properties

Available methods

Description

PrintActSelection

Print the current selection.

ModulProc91

Internal identifier

ModulProc92

Internal identifier

ModulProc93

Internal identifier

ModulProc94

Internal identifier

ModulProc95

Internal identifier

ModulProc96

Internal identifier

ModulProc97

Internal identifier

ModulProc98

Internal identifier

ModulProc99

Internal identifier

The properties for the Navigator command are defined here. A name can be assigned to the command.

Fig. 6-37: Methods tab, Properties

6.23.6

Element

Description

Properties for:

The method/Navigator command selected in Available methods is displayed.

Name

Designation for the method/Navigator command

Templates/Templates list tab

Overview

The templates used for creating a new object (e.g. module, cell, …) can be configured here.

Description: Directories list

The paths for which specific templates are to be available are specified here.


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Fig. 6-38: Templates tab, Directories list Element

Description

Full path

Path for which templates are to be used. The path can be entered manually or selected via Browse for Path.

Add to defined

Adds the path from the Full path box to the path list.

Path list

The path to which templates are to be assigned must be selected in this list. DEFAULT: covers all paths that are not specifically included in the list.

Remove from defined Description: Available templates

Removes the selected path from the path list.

Templates are assigned here to a path.

Fig. 6-39: Templates tab, Available templates

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6 Configuration

Element

Description

All available

Available templates

Remove from all available

Removes the selected template from All available.

Templates for directory:

Templates assigned to the path selected in the path list. If there is no entry here, the New softkey is not available.

Description: Define new template

Enable for directory

Adds the template selected in All available to Templates for directory.

Disable for directory

Removes the template selected in Templates for directory.

New templates can be defined here.

Fig. 6-40: Templates tab, Define new template

Description: Properties for template

Element

Description

Name

Name of the new template

Add to all available templates

Adds the template to All available.

The properties for a template are defined here.


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Fig. 6-41: Templates tab, Properties for template Element

Description

Properties for template:

The template selected in All available is displayed.

Mask

Defines which character string is permissible as the name for the template. Examples: *: all characters are permissible. Temp99[1-99]: only the names Temp1 to Temp99 are permissible.

Comment

Database key for the template -specific templates: When a template is selected in the Navigator, the database key is displayed as a comment (alongside the name of the template). Templates that are defined by default in the KSS: When a template is selected in the Navigator, the translation of the database key is displayed as a comment.

6.23.7

Full path

File path of the template. The path can be entered manually or selected via Browse for it.

Define for s

group for which the template is to be available.

Attributes


Upgrade Manager tab

Overview

Here the can define monitoring functions that check, when files are added, whether it is permissible to add files to the path in question and the file version. The monitoring functions do not refer to a regular KSS upgrade. During this procedure they are not active. The monitoring functions are active during the system runtime and serve to monitor the manual addition of files.

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6 Configuration

Description: ed system types

Fig. 6-42: Upgrade Manager tab, ed system types

Description: Files and versions

Element

Description

ed system types

List of the file types that can be monitored. The following types are available: 

INI: INI files



MADA: machine data



Techpack: files belonging to technology packages

Adds a selected file to the current file type or removes it.

Fig. 6-43: Upgrade Manager tab, Files and versions Element

Description

Files and versions for:

The file type selected in ed system types is displayed.

Name

Name of the file to be monitored (without file extension)


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Description: Monitored paths

Element

Description

Version

Version identifier of the file

Add to defined

Adds the file with the corresponding version identifier to the list of files to be monitored.

Remove from defined

Removes the selected file from the list.

File list

List of the files to be monitored in the current file type.

The paths to be monitored by the Upgrade Manager are defined here.

Fig. 6-44: Upgrade Manager tab, Monitored paths Element

6.23.8

Description

Name

Symbolic name of the path to be monitored

Path

Path to be monitored. The path can be entered manually or selected via Browse for it.

Add to defined

Adds the path to the list of monitored paths

Path list

List of monitored paths

Remove from defined

Removes the selected path from the list

Archive Manager tab

Overview

The settings for archiving and restoring files are defined here. Additional configuration options for archiving and restoring files can be found in the History Info tab (>>> 6.23.9 "History Info tab" Page 203).

Description: Archive paths

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A symbolic name is defined here for the path to which files are to be archived. Symbolic names are displayed in the Navigator. Multiple paths can be grouped together under a single symbolic name.


6 Configuration

Fig. 6-45: Archive Manager tab, Archive paths Element

Description

Name

Defined a symbolic name (symbolic names can be used, for example, in the file MenueKey.ini). A symbolic name can stand for one or more paths.

Path

Path that is assigned to this symbolic name. The path can be entered manually or selected via Browse for path.

Remove path name

Removes the symbolic name selected in Available path names.

Available path names

List of symbolic names

Defined paths for:

Path that is assigned to this symbolic name. Multiple paths can be assigned to a single symbolic name. In this case, files are archived to each of these paths. Check box active: This path is the default path. The default path must be physically present when archiving is carried out. If not, archiving is not carried out, not even to the other paths. If a non-default path is not physically present, this has no effect on archiving to the other paths. When archived files are restored, the system accesses the default path. Recommendation: even if only one path is specified, define it as a default path.

Add path

Adds the symbolic name entered in Name to Available path names. Simultaneously adds the path entered in Path to Defined paths for. In this way, multiple paths can be assigned to a single symbolic name.

Remove path


Removes the path selected in Defined paths for.

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The file extension “.zip” in the path name (e.g. “Archive.zip”) generates a Zip file. Otherwise, the files are simply copied to the defined paths. Description: Archive configurations

Here the defines which data are to be archived for the individual archive configurations. The archive configurations correspond to the menu items under File > Archive.

Fig. 6-46: Archive Manager tab, Archive configurations Element

Description

Archive configurations

Existing archive configurations

New archive configuration

Name for a new archive configuration

Add to available

Adds a new archive configuration to the existing ones

Remove config

Deletes the configuration selected in item 1.

Registry sources for:

Registry database branches to be archived/ restored

Add reg source

Adds a branch to Registry sources for. A window opens in which a branch can be selected or entered manually. Only registry database branches that are relevant to the KUKA System Software can be added. This is checked by the KRC Configurator. For other branches, archiving and restoring would be too time-consuming.

Remove reg source

Removes the selected entry from Registry sources for.

File sources for:

Files and directories to be archived Check box active: The file or directory is restored

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6 Configuration

Element

Description

Add file source

Adds a directory to File sources for. A window opens in which a path can be selected or entered manually. In the case of manual entry: 

The following conventions apply: Example for individual files: “\Data\KUKA_CON.MDB” Example for complete directories, including subdirectories: “\ROBOTER\INIT\” Example for files with a filter: “Hugo*.*”



Remove file

6.23.9

The can define search filters, e.g. “myFiles*.bkp”.

Removes the directory selected in File sources for.

History Info tab

Overview

This tab is used to define whether, during archiving, the data should also be backed up on the hard drive (history trace). In this way, the data can still be restored if the archive is lost or damaged. Other archiving settings can also be defined.

Description: History

Fig. 6-47: History Info tab, History Element

Description

History path

Path on the hard drive to which the history data are archived. The path can be entered manually or selected via Browse for it.

Max no. of history traces

Maximum number of history traces on the hard drive. Each subsequent trace overwrites the oldest existing trace.


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Description: Comparison criteria

Fig. 6-48: History Info tab, Comparison criteria Element

Description

Comparison criteria

Comparison criteria to be checked when restoring data. Check box active: In the case of a deviation from this criterion when restoring data, a request for confirmation is displayed. The following criteria are available: 

IdCompare: archive version



RobCompare: robot name and serial number



VersionCompare: KSS version



TPCompare: technology packages

Description of further settings

Fig. 6-49: History Info tab, further settings

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6 Configuration

Element

Description

Enable

Check box active: The Archive Manager generates dialog messages. In the case of an unfulfilled comparison criterion, for example, the is asked whether the process should nonetheless be continued. Otherwise, the process is terminated without a message.

Generate info file when archiving

Check box active: The file AMI.INI is created during archiving. The file contains information about the robot name, archive ID, etc. This setting is also required if data are to be archived to multiple storage media.

Enable disk counting when archiving

Check box active: This setting is required if data are to be archived to multiple storage media.

Delete robot directory before restoring

Before the data are restored, the directory KRC:\R1 and all its subdirectories are deleted. Automatically activates the settings Save history before restoring and History.

Save history before restoring

Archives the current data before restoring archived data. Automatically activates the setting History.

History

During archiving, a copy is saved to the specified history path.

6.23.10 General/Folder Layout tab Overview

Here the defines the directories in the Navigator in which subdirectories may be created or deleted.

Description: Predefined tree

Fig. 6-50: General/Folder Layout tab, Predefined tree


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Element

Description

Full path

Directory to be displayed in Graphic view. The directory can be entered manually or selected via Browse for it. The path KRC:\ represents %INSTALLATIONDIR%\KRC\Roboter\KRC.

Graphic view

Directory structure as in the Navigator Check box active: Subdirectories may be created and deleted under this node

Add to tree

Displays the directory entered in Full Path in Graphic view.

Remove from tree

Removes the directory selected in Graphic view from the display. A directory that is not displayed is not monitored. The creation and deletion of subdirectories is thus possible. The directory is only removed from this display. It is not removed from the directory structure in the Navigator itself.

Description: General preferences


Fig. 6-51: General/Folder Layout tab, General preferences

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7 Program management

7

Program management

7.1

Navigator file manager

Overview

Fig. 7-1: Navigator

Description

1

Header

3

File list

2

Directory structure

4

Status bar

In the Navigator, the manages programs and system-specific files. Header 

Left-hand area: the selected filter is displayed.



Right-hand area: the directory or drive selected in the directory structure is displayed.

(>>> 7.1.1 "Selecting filters" Page 208)

Directory structure Overview of directories and drives. Exactly which directories and drives are displayed depends on the group and configuration. File list The contents of the directory or drive selected in the directory structure are displayed. The manner in which programs are displayed depends on the selected filter. The file list has the following columns: Column

Description

Name

Directory or file name

Extension

File extension This column is not displayed in the group “”.

Comment Issued: 28.10.2010 Version: KSS 5.5 SI V2 en

Comment 207 / 403


Column

Description

Attributes

Attributes of the operating system and kernel system This column is not displayed in the group “”.

Size

File size in kilobytes

#

Number of changes made to the file

Modified

Date and time of the last change

Created

Date and time of file creation

This column is not displayed in the group “”.

This column is not displayed in the group “”. The can scroll left and right in the file list using the keyboard shortcuts SHIFT+RIGHT ARROW or SHIFT+LEFT ARROW. Pop-up menus are available for the objects in the file list. Calling the pop-up menu: select object(s) and press the RIGHT ARROW key. Status bar The status bar can display the following information:

7.1.1



Selected objects



Action in progress



dialogs



entry prompts



Requests for confirmation

Selecting filters

Description

This function is not available in the group “”. The filter defines how programs are displayed in the file list. The following filters are available: 

Detail Programs are displayed as SRC and DAT files. (Default setting)



Modules Programs are displayed as modules.

Procedure

1. Select the menu sequence File > Filter. 2. Select the desired filter in the left-hand section of the Navigator. 3. Confirm with OK.

7.1.2

Displaying or modifying file properties

Precondition



To change properties: group “Expert”.

Procedure

1. Select the object in the directory structure or in the file list. 2. Select the menu sequence File > Attributes. 3. Change the properties and save the change by pressing the OK softkey.

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Description General

Fig. 7-2: File properties, “General” tab Description

Item 1

Name of the selected file

2

File type, path and file size. File types: 

Module: module



Dir: directory



Archiv: archive file



Bin: binary file



Text: text file



VirtualDir: virtual directory



Unknown: all other file types

3

Windows file properties

4

Windows file properties. The properties can be modified in the group “Expert”.

5

Free: the file is not selected in the KUKA.HMI and is not open. Full: the file is open in the KUKA.HMI. ProKor: the file is selected in the KUKA.HMI.


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Description Module info

Fig. 7-3: File properties, “Module info” tab Item

Description

1

Version: internal version number of the file. After creation, the file does not yet have a number. After the first change, the file receives the number 1. The number is incremented after every change. Size SRC: size of the SRC file Size DAT: size of the DAT file Source type: source type

2



SRC: SRC file



SubmitSub: SUB file



None: all other file types, e.g. DAT file

Status of the module in the Submit interpreter and in the robot interpreter Free: program is not selected. Selected: program is selected. Active: only relevant for the Submit box. This program is currently being used by the Submit interpreter.

3

Check box active: if this program is called as a subprogram, it is displayed in the Editor. Check box not active: if this program is called as a subprogram, it is not displayed in the Editor. This program cannot be selected manually.

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4

The can enter his name here (max. 30 characters).

5

The can enter a comment for the module here. It is possible to scroll up and down in the comment using the UP ARROW and DOWN ARROW keys. The comment is displayed in the Comment column in the Navigator.



Description Parameter

Fig. 7-4: File properties, “Parameter” tab Any desired information can be stored in KRL modules. Description

Item 1

The existing information is shown here. Information can be deleted by selecting the line, deleting the contents of the Parameter box and pressing the OK softkey.

Program in the editor

2

The can enter a name here for a new piece of information.

3

The can enter information here.

If a SRC or DAT file is opened in an editor (e.g. WordPad) in Windows, a number of the file properties are displayed above the DEF line. In KUKA.HMI, the file properties are not visible here. 1 2 3 4 5 6 7 8

&ACCESS RV &REL 2 &COMMENT test comment & kuka &PARAM test name = test param &PARAM TEMPLATE = C:\KRC\Roboter\Template\vorgabe &PARAM EDITMASK = * DEF test( )

…

7.1.3

Line

Description

1

Module info tab, check box Visible 

&ACCESS RV = check box active



&ACCESS R = check box inactive

2

Module info tab, Version box

3

Module info tab, Comment box

4

Module info tab, box

5

Parameter tab, Name and Parameter boxes

Icons in the Navigator Drives:


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Icon

Description

Default path

Robot

KRC:\

Floppy disk

A:\

Hard disk

e.g. "KUKADISK (C:\)" or "KUKADATA (D:\)"

CD-ROM

E:\

Network drive

F:\, G:\, …

Backup drive

Archive:\

Directories and files: Icon

Description Directory Open directory Archive in ZIP format The contents of a directory are being read. Module Module containing errors SRC file SRC file containing errors DAT file DAT file containing errors ASCII file. Can be read using any editor. Binary file. Cannot be read in the text editor.

7.1.4

Creating a new folder

Precondition



The Navigator is displayed.

Procedure

1. In the directory structure, use the UP and DOWN arrow keys to select the folder in which the new folder is to be created. Closed folders can be opened by pressing the Enter key. 2. Press the NEW softkey. 3. Enter a name for the folder and press OK.

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7.1.5

Creating a new program

Precondition




Procedure

1. In the directory structure, use the UP and DOWN arrow keys to select the folder in which the program is to be created. Closed folders can be opened by pressing the Enter key. 2. Move to the file list by pressing the RIGHT arrow button. 3. Press the New softkey. The Template selection window is opened. 4. Select the desired template and press OK. 5. Enter a name for the program and press the softkey OK. It is not possible to select a template in the group “”. By default, a program of type “Module” is created.

7.1.6

Renaming a file

Precondition




Procedure

1. In the directory structure, use the UP and DOWN arrow keys to select the folder in which the file is located. Closed folders can be opened by pressing the Enter key. 2. Move to the file list by pressing the RIGHT arrow button. Select the desired file. 3. Select the menu sequence File > Rename. 4. Overwrite the file name with a new name and press OK.

7.1.7

Encrypted files

Precondition

In order to display, select or execute signed or encrypted files on the robot controller: 

Description

group “Expert”

SRC, DAT and SUB files can be encrypted or signed using the KUKA.Encryption software. This prevents unauthorized persons from viewing or modifying programs. Encrypted and signed files are grouped together in so-called PFC files (Protected File Container). Further information about the KUKA.Encryption software is contained in the Expert documentation “KUKA.Encryption 1.0”.

Display of the files in the Navigator: When the robot controller is started, it recognizes all PFC files contained in the directory KRC:\ and loads the files contained in them.


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Fig. 7-5: Encrypted files in the Navigator PFC files are displayed in the directory structure with a key icon. The files contained in the PFC file are displayed in the file list in the customary manner as SRC, DAT and SUB files. The Attributes column indicates whether the file is encrypted or signed. 

E: File is encrypted. Encrypted files cannot be read by the , but can be edited (e.g. using the variable correction function).



S: File is signed. Signed files can be read by the , but cannot be edited.

An encrypted or signed program can be highlighted and selected using the Select softkey in the same way as other programs. The selected program can be executed, reset and deselected in the usual manner.

7.2

Selecting or opening a program

Overview



A program can be selected or opened. Instead of the Navigator, an editor is then displayed with the program. (>>> 7.2.1 "Selecting a program" Page 215) (>>> 7.2.2 "Opening a program" Page 216)



It is possible to toggle backwards and forwards between the program display and the Navigator. (>>> 7.2.3 "Toggling between the Navigator and the program" Page 216)



A program cannot be both opened and selected at the same time. It is possible, however, for one program to be opened while another one is selected. (>>> 7.2.4 "Selecting one program and opening another program" Page 217)

Differences

Program is selected: 

The block pointer is displayed.



The program can be started.



The program can be edited to a certain extent. Selected programs are particularly suitable for editing in the group “”. KRL instructions covering several lines (e.g. LOOP … ENDLOOP) are not permissible.



When the program is deselected, modifications are accepted without a request for confirmation. If impermissible modifications are programmed, an error message is displayed.

Program is opened: 

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The program cannot be started.



The program can be edited.



Opened programs are particularly suitable for editing in the group “Expert”. A request for confirmation is generated when the program is closed. Modifications can be accepted or rejected.



7.2.1

Selecting a program If a selected program is edited in the group “Expert”, the cursor must then be removed from the edited line and positioned in any other line! Only in this way is it certain that the editing will be applied when the program is deselected again.

Precondition



T1, T2 or AUT mode

Procedure

1. Select the program in the Navigator and press the Select softkey. Or: Double-click on the program in the Navigator. The program is displayed in the editor. It is irrelevant whether a module, an SRC file or a DAT file is selected. It is always the SRC file that is displayed in the editor. 2. Start or edit the program. 3. Deselect the program again by selecting the menu sequence Edit > Cancel program. When the program is deselected, modifications are accepted without a request for confirmation! If the program is running, it must be stopped before it can be deselected.

Description

Fig. 7-6: Program is selected 1

Block pointer

2

Cursor

3 (>>> 4.2.4 "Status bar" Page 50) 4

Program path and file name


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7.2.2

5

Position of the cursor

6

The icon indicates that the program is selected.

Opening a program

Precondition

T1, T2 or AUT mode



A program can be opened in AUT EXT mode, but not edited. Procedure

1. Select the program in the Navigator and press the Open softkey. The program is displayed in the editor. If a module has been selected, the SRC file is displayed in the editor. If an SRC file or DAT file has been selected, the corresponding file is displayed in the editor. 2. Edit the program. 3. Close the program: press the Close softkey. 4. To accept the changes, answer the request for confirmation with Yes.

Description

Fig. 7-7: Program is open

7.2.3

1

Cursor

2

(>>> 4.2.4 "Status bar" Page 50)

3

Program path and file name

4

Position of the cursor

Toggling between the Navigator and the program

Description

If a program is selected or open, it is possible to display the Navigator again without having to deselect or close the program. The can then return to the program.

Procedure

Program is selected: 

Toggling from the program to the Navigator: press the NAVIGATOR softkey.



Toggling from the Navigator to the program: press the PROGRAM softkey.

A program is open: 

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Toggling from the program to the Navigator: press the NAVIGATOR softkey. Issued: 28.10.2010 Version: KSS 5.5 SI V2 en


Toggling from the Navigator to the program: press the EDITOR softkey.



7.2.4

Selecting one program and opening another program

Description

A program cannot be both opened and selected at the same time. It is possible, however, for one program to be opened while another one is selected.

Procedure

1. Select a program. 2. Return to the Navigator by pressing the NAVIGATOR softkey. 3. Select another program then select the menu sequence File > Open > File/Folder. 4. You can return to the Navigator by pressing the NAVIGATOR softkey. Here you have the following options:

7.3



Display the selected program again by pressing the EDITOR softkey.



Display the opened program again by pressing the PROGRAM softkey.

Structure of a KRL program 1 2 3 4

DEF my_program( ) INI

PTP ... 8 LIN ... 14 PTP ... 20 PTP 21 22 END

HOME

Vel= 100 % DEFAULT

point_5 CONT Vel= 2 m/s DAT1 Tool[3] Base[4] point_1 CONT Vel= 100 % PDAT1 Tool[3] Base[4] HOME

Vel= 100 % DEFAULT

Line

Description

1

The DEF line indicates the name of the program. If the program is a function, the DEF line begins with "DEFFCT" and contains additional information. The DEF line can be displayed or hidden. Select the menu sequence Configure > Tools > Editor > Def-line. This function is not available in the group "".

2

The INI line contains initializations for internal variables and parameters.

4

HOME position

8

LIN motion

(>>> 7.3.1 "HOME position" Page 218) (>>> 9.2.3 "Programming a LIN motion" Page 258) 14

PTP motion (>>> 9.2.1 "Programming a PTP motion" Page 257)

20

HOME position

22

The END line is the last line in any program. If the program is a function, the wording of the END line is "ENDFCT". The END line must not be deleted!

The first motion instruction in a KRL program must define an unambiguous starting position. The HOME position, which is stored by default in the robot controller, ensures that this is the case.


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If the first motion instruction is not the default HOME position, or if this position has been changed, one of the following statements must be used: 

Complete PTP instruction of type POS or E6POS



Complete PTP instruction of type AXIS or E6AXIS

“Complete” means that all components of the end point must be specified. Warning! If the HOME position is modified, this affects all programs in which it is used. Physical injuries or damage to property may result. In programs that are used exclusively as subprograms, different statements can be used as the first motion instruction.

7.3.1

HOME position The HOME position is not program-specific. It is generally used as the first and last position in the program as it is uniquely defined and uncritical. The HOME position is stored by default with the following values in the robot controller: Axis

A1

A2

A3

A4

A5

A6

Position

0°

- 90°

+ 90°

0°

0°

0°

Additional HOME positions can be taught. A HOME position must meet the following conditions: 

Good starting position for program execution



Good standstill position. For example, the stationary robot must not be an obstacle.

Warning! If the HOME position is modified, this affects all programs in which it is used. Physical injuries or damage to property may result.

7.4

Displaying/hiding program sections

7.4.1

Displaying/hiding the DEF line

Description

By default, the DEF line is hidden. Declarations can only be made in a program if the DEF line is visible. The DEF line is displayed and hidden separately for opened and selected programs. If detail view (ASCII mode) is activated, the DEF line is visible and does not need to be activated separately.

Precondition

Procedure



group “Expert”



Program is selected or open.



Select the menu sequence Configure > Tools > Editor > Def-line. Check mark activated in menu: DEF line is displayed. Check mark not activated in menu: DEF line is hidden.

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7.4.2

Activating detail view (ASCII mode)

Description

Detail view (ASCII mode) is deactivated by default to keep the program transparent. If detail view is activated, hidden program lines, such as the FOLD and ENDFOLD lines and the DEF line, are displayed. Detail view is activated and deactivated separately for opened and selected programs.

Precondition

Procedure



group “Expert”






Select the menu sequence Configure > Tools > Editor > ASCII Mode. Check mark activated in menu: ASCII mode is activated. Check mark not activated in menu: ASCII mode is deactivated.

7.4.3

Activating/deactivating the line break function

Description

If a line is wider than the program window, the line is broken by default. The part of the line after the break has no line number and is marked with a black, L-shaped arrow. The line break function can be deactivated.

Fig. 7-8: Line break The line break function is activated and deactivated separately for opened and selected programs. Precondition

Procedure



group “Expert”






Select the menu sequence Configure > Tools > Editor > Linebreak. Check mark activated in menu: line break function is activated. Check mark not activated in menu: line break function is deactivated.

7.4.4

Displaying Folds

Description

Folds are used to hide sections of the program. In this way, Folds make programs more transparent. The hidden program sections are processed during program execution in exactly the same way as normal program sections. 

In the group “”, Folds are always closed. In other words, the contents of the Folds are not visible and cannot be edited.



In the group “Expert”, Folds are closed by default. They can be opened and edited. New Folds can be created. (>>> 7.6.3 "Creating Folds" Page 228)

If a program is deselected, all Folds are automatically closed.

Fig. 7-9: Example of a closed Fold


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Fig. 7-10: Example of an open Fold Color coding of Folds:

Precondition

Procedure

Color

Description

Dark red

Closed fold

Light red

Opened fold

Dark blue

Closed sub-Fold

Light blue

Opened sub-Fold

Green

Contents of the Fold



group “Expert”




1. Position the cursor in the line containing the Fold. 2. Select the menu sequence Program > FOLD > Current FOLD open/ close. The Fold then opens. 3. To close the Fold, select the same menu sequence as for opening it. Alternatively, select the menu sequence Program > FOLD > All FOLDs open or All FOLDs close to open or close all the Folds in a program at once.

7.5

Starting a program

7.5.1

Program run modes The program run mode is selected in the left-hand status key bar. Status key

Program run mode

Description

#GO

The program is executed through to the end without stopping.

#MSTEP

The program is executed with a stop after each motion block. The Start key must be pressed again for each motion block.

(Motion Step) #ISTEP (Incremental Step)

The program is executed with a stop after each program line. Program lines that cannot be seen and blank lines are also taken into consideration. The Start key must be pressed again for each line. ISTEP is only available to the group “Expert”.

#BSTEP (backward motion)

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This program run mode is automatically selected if the Start backwards key is pressed.



In #MSTEP and #ISTEP modes, the program is executed without an advance run. The following additional program run modes are available for systems integrators. These program run modes can only be selected via the variable correction function. System variable for the program run mode: $PRO_MODE. Status key

Program run mode #PSTEP (Program Step) #CSTEP (Continuous Step)

Description The program is executed step by step without an advance run. Subprograms are executed completely.

Approximate positioning points are executed with advance processing, i.e. they are approximated. Exact positioning points are executed without an advance run and with a stop after the motion instruction.

7.5.2

Advance run The advance run is the maximum number of motion blocks that the robot controller calculates and plans in advance during program execution. The actual number is dependent on the capacity of the computer. The advance run refers to the current position of the block pointer. It is set via the system variable $ADVANCE: 

Default value: 3



Maximum value: 5

The advance run is required, for example, in order to be able to calculate approximate positioning motions. If $ADVANCE = 0 is set, approximate positioning is not possible. Certain statements trigger an advance run stop. These include statements that influence the periphery, e.g. OUT statements.

7.5.3

Icons in the program Line break If a line is wider than the program window, the line is broken by default. The part of the line after the break has no line number and is marked with a black, L-shaped arrow. The line break function can be deactivated. (>>> 7.4.3 "Activating/deactivating the line break function" Page 219)

Fig. 7-11: Line break Block pointer During program execution, the block pointer indicates which motion block is currently being executed.


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Icon

Description L-shaped arrow (yellow): The motion block is being executed in the forwards direction. L-shaped arrow (yellow) with plus sign: The motion block is being executed in the forwards direction. This block pointer is not displayed in the group "". Normal arrow (yellow): The robot has completed the motion block in the forwards direction Normal arrow (yellow) with plus sign: The robot has completed the motion block in the forwards direction This block pointer is not displayed in the group "". L-shaped arrow (red): The motion block is being executed in the backwards direction. L-shaped arrow (red) with plus sign: The motion block is being executed in the backwards direction. This block pointer is not displayed in the group "". Normal arrow (red): The robot has completed the motion block in the backwards direction Normal arrow (red) with plus sign: The robot has completed the motion block in the backwards direction This block pointer is not displayed in the group "". Icon

Description The block pointer is located higher up in the program. The block pointer is located lower down in the program.

7.5.4

Setting the program override (POV)

Description

Program override is the velocity of the robot during program execution. The program override is specified as a percentage of the programmed velocity. In T1 mode, the maximum velocity is 250 mm/s, irrespective of the value that is set.

Preparation



Define the program override intervals: Select the menu sequence Configure > Jogging > Program OV Steps.

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Active

Procedure

7.5.5



Meaning

No

The override can be adjusted in 1% steps.

Yes

Intervals: 100%, 75%, 50%, 30%, 10%, 3%, 1%, 0%

Increase or reduce the override in the right-hand status key bar. The status key indicates the current override as a percentage.

Starting a program forwards (manual)

Precondition

Procedure






Operating mode T1 or T2.

1. Select the program run mode. 2. Hold the enabling switch down and wait until the status bar indicates (i.e. drives ready). 3. Carry out a BCO run: Press Start key and hold it down until the message “Programmed path reached (BCO)” is displayed in the message window. The robot stops. Warning! A BCO run is always executed as a PTP motion from the actual position to the target position. Observe the motion to avoid collisions. The velocity is automatically reduced during the BCO run. 4. Press Start key and hold it down. The program is executed with or without stops, depending on the program run mode. To stop a program that has been started manually, release the Start key.

7.5.6

Starting a program forwards (automatic)

Precondition

Procedure



A program is selected.



Operating mode Automatic (not Automatic External)

1. Select the program run mode GO in the left-hand status key bar:

2. Press Drives ON. 3. Carry out a BCO run: Press Start key and hold it down until the message “Programmed path reached (BCO)” is displayed in the message window. The robot stops. Warning! A BCO run is always executed as a PTP motion from the actual position to the target position. Observe the motion to avoid collisions. The velocity is automatically reduced during the BCO run. 4. Press the Start key. Program is executed.


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To stop a program that has been started in Automatic mode, press the STOP key.

7.5.7

Carrying out a block selection

Description

A program can be started at any point by means of a block selection.

Precondition







Procedure

1. Select the program run mode. 2. Position the cursor in the line containing the motion block at which the program is to be started. 3. Press the Line Sel. softkey. The yellow block pointer indicates the motion block. 4. Hold the enabling switch down and wait until the status bar indicates (i.e. drives ready). 5. Carry out a BCO run: Press Start key and hold it down until the message “Programmed path reached (BCO)” is displayed in the message window. The robot stops. Warning! A BCO run is always executed as a PTP motion from the actual position to the target position. Observe the motion to avoid collisions. The velocity is automatically reduced during the BCO run. 6. The program can now be started manually or automatically. It is not necessary to carry out a BCO run again.

7.5.8

Starting a program backwards

Description

In the case of backward motion, the robot stops at every point. Approximate positioning is not possible. Exactly how the controller responds during backward motion depends on the configuration. (>>> 6.16 "Backward motion" Page 141)

Precondition

Procedure







1. Hold the enabling switch down and wait until the status bar indicates (i.e. drives ready). 2. Carry out a BCO run: Press Start key and hold it down until the message “Programmed path reached (BCO)” is displayed in the message window. The robot stops. Warning! A BCO run is always executed as a PTP motion from the actual position to the target position. Observe the motion to avoid collisions. The velocity is automatically reduced during the BCO run. 3. Press Start backwards key. The program run mode "Backward motion" is automatically selected:

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4. Press Start backwards key again for each motion block.

7.5.9

Resetting a program

Description

In order to restart an interrupted program from the beginning, it must be reset. This returns the program to the initial state.

Precondition




Procedure



Select the menu sequence Program > Reset program.

7.5.10

Starting Automatic External mode

Precondition

Procedure



Operating mode T1 or T2



Inputs/outputs for Automatic External and the program CELL.SRC are configured.

1. Select the program CELL.SRC in the Navigator. (This program is located in the folder “R1”.) 2. Set program override to 100%. (This is the recommended setting. A different value can be set if required.) 3. Carry out a BCO run: Hold down the enabling switch. Then press the Start key and hold it down until the message “Programmed path reached (BCO)” is displayed in the message window. Warning! A BCO run is always executed as a PTP motion from the actual position to the target position. Observe the motion to avoid collisions. The velocity is automatically reduced during the BCO run. 4. Turn the mode selector switch to “Automatic External”. 5. Start the program from a higher-level controller (PLC). Warning! There is no BCO run in Automatic External mode. This means that the robot moves to the first programmed position after the start at the programmed (not reduced) velocity and does not stop there. To stop a program that has been started in Automatic mode, press the STOP key.

7.6

Editing a program

Overview



A running program cannot be edited.



Programs cannot be edited in AUT EXT mode.

If a selected program is edited in the group “Expert”, the cursor must then be removed from the edited line and positioned in any other line! Only in this way is it certain that the editing will be applied when the program is deselected again.


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Action Insert comment or stamp

Possible in group …? : Yes Expert: Yes

Delete lines : Yes Expert: Yes Create folds : No Expert: Yes Copy : No Expert: Yes Paste : No Expert: Yes Insert blank lines (press the Enter key)

: No Expert: Yes

Cut : No Expert: Yes Find : Yes Expert: Yes Possible for all groups in an open program, even in AUT EXT mode. Replace : No Expert: Yes (program is open, not selected) Programming with inline forms

: Yes Expert: Yes

KRL programming : Possible to a certain extent. KRL instructions covering several lines (e.g. LOOP … ENDLOOP) are not permissible. Expert: Yes

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7.6.1

Inserting a comment or stamp

Precondition

Procedure






T1, T2 or AUT mode

1. Position the cursor in the line after which the comment or stamp is to be inserted. 2. Select the menu sequence Commands > Comment > Normal or Stamp. 3. In the case of Stamp: update the system time by pressing the New time softkey. 4. Enter text. 5. Save by pressing the Cmd Ok softkey.

Description Comment

Fig. 7-12: Inline form "Comment" Item 1 Description Stamp

Description Any text

A stamp is a comment that is extended to include the system date and time and the ID.

Fig. 7-13: Inline form "Stamp" Item

7.6.2

Description

1

Current system date (cannot be edited)

2

Current system time

3

Name or ID of the

4

Any text

Deleting program lines

Precondition

Procedure






T1, T2 or AUT mode

1. Position the cursor in the line to be deleted. If several consecutive lines are to be deleted: Position the cursor in the first line. Then press SHIFT + DOWN ARROW until all the lines are selected. 2. Select the menu sequence Program > Delete. 3. Confirm the request for confirmation with Yes. If a program line containing a motion instruction is deleted, the point name and coordinates remain saved in the DAT file. The point can be used in other motion instructions and does not need to be taught again.

Lines cannot be restored once they have been deleted!


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7.6.3

Creating Folds

Syntax

;FOLD Name Statements

;ENDFOLD The ENDFOLD lines can be assigned more easily if the name of the Fold is entered here as well. Folds can be nested. Precondition

Procedure



group “Expert”




1. Enter Fold in program. A double semicolon prevents the Fold from closing when edited.

Fig. 7-14: Creating a sample Fold, step 1 2. Delete the second semicolon.

Fig. 7-15: Creating a sample Fold, step 2 3. Position the cursor in a line outside the Fold. The Fold closes.

Fig. 7-16: Creating a sample Fold, step 3

7.6.4

Additional editing functions The following additional program editing functions can be found in the Program menu: Function

Precondition

Copy






group “Expert”



T1, T2 or AUT mode






group “Expert”



T1, T2 or AUT mode






group “Expert”



T1, T2 or AUT mode

Paste

Cut

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7.7

Function

Precondition

Find




Replace



Program has been opened.



group “Expert”

Printing a program

Procedure

1. Select the program in the Navigator. Multiple program selection is also possible. 2. Select the menu sequence File > Print>Current selection.

7.8

Archiving

7.8.1

Archiving data

Description

Depending on the robot controller used, different paths can be selected. Which path the robot controller archives data to depends on the configuration in the KRC Configurator. (>>> 6.23.8 "Archive Manager tab" Page 200) Path

Robot controller

KUKA USB stick

Only KR C2 edition2005

Network path

All robot controllers

Floppy disk

Only robot controllers that have a floppy disk drive

Caution! The only USB stick that may be used is the KUKA USB stick. Data may be lost or modified if any other USB stick is used. Information about the KRC Configurator is contained in the “Operating and Programming Instructions for System Integrators”. Precondition

For all paths: 

The desired path is configured in the KRC Configurator.

For archiving to floppy: 

Disk has been formatted (if required).



Disk is in disk drive.

(>>> 7.8.3 "Formatting the floppy disk" Page 230) More than one floppy disk will be required if large quantities of data are involved! For archiving to a KUKA USB stick: 

Procedure

The stick is connected.

1. Select the menu sequence File > Archive and the desired menu item. (>>> 7.8.2 "Menu item “Archive”" Page 230) 2. Confirm the request for confirmation with Yes. 3. Only in the case of archiving to a floppy disk: a message indicates when another disk is required. Insert new disk.


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4. A message indicates completion of the archiving process. The file ARCHIVE.ZIP is generated by default. Caution! When archiving to the KUKA USB stick: the stick must not be removed until the LED on the stick is no longer lit. Otherwise, the stick could be damaged.

7.8.2

Menu item “Archive”

Description

The following menu items are available for archiving. Exactly which files are archived depends on the configuration in the KRC Configurator. Menu item

7.8.3

Description

All

The data that are required to restore an existing system are archived.

Applications

All -defined KRL modules and their corresponding system files are archived.

Machine data

The machine data are archived.

Configuration > Drivers

The I/O drivers are archived.

Configuration > I/O Longtexts

The long text names of the inputs/outputs are archived.

Configuration > KUKA TechPack

The configuration of the installed technology packages is archived.

Log Data

The log files are archived.

Current selection

The files selected in the Navigator are archived.

Not available in the group “”. Not available in the group “”.

Not available in the group “”.



If archiving is carried out using the menu item All, an existing archive will be overwritten.



If archiving is carried out using a menu item other than All and an archive is already available, the robot controller compares its robot name with that in the archive. If the names are different, a request for confirmation is generated.

Formatting the floppy disk

Description

This procedure can be used to format floppy disks in the case of robot controllers that have a floppy disk drive.

Procedure

1. Insert floppy disk into the drive. 2. Select the menu sequence File > Format floppy disk. 3. Confirm the request for confirmation with Yes. A message indicates completion of the formatting process. Caution! Do not remove the floppy disk from the drive until the LED on the drive is no longer lit. Otherwise the disk drive and/or the floppy disk could suffer damage.

7.8.4

Restoring data

Overview

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Caution! Only KSS 5.5 archives may be loaded into KSS 5.5. If other archives are loaded, the following may occur: 

Error messages



Robot controller is not operable.



Personal injury and damage to property.

The robot controller cannot detect whether multiple floppy disks were used for archiving. For this reason, the is not prompted, after the first floppy disk, to insert additional disks, but must do so without prompting. The order in which the disks are inserted is irrelevant. If the archive files are not the same version as the system files, an error message is generated. Similarly, if the version of the archived technology packages does not match the installed version, an error message is generated. 7.8.4.1

Restoring data via the menu

Description

With the exception of Log Data, the menu items available for restoring data are the same as those available for archiving. When restoring data, the robot controller accesses the path configured for archiving. For example, if data have been archived to floppy disk, they are also restored from the floppy disk.

Precondition

Procedure



If data were archived to floppy: Disk is in disk drive.



If data were archived to KUKA USB stick: The stick is connected.

1. Select the menu sequence File > Restore and the desired menu item. 2. Confirm the request for confirmation with Yes. A message indicates completion of the restoration process. 3. Only if restoring data from floppy: if data have been archived on more than one disk, insert the next floppy disk and repeat steps 1 and 2. 4. Only if restoring data from floppy: remove floppy from drive. Caution! When restoring data from the KUKA USB stick: the stick must not be removed until the LED on the stick is no longer lit. Otherwise, the stick could be damaged. 5. Reboot the robot controller.

7.8.4.2

Restoring data via softkey

Description

When restoring data using the softkey, a different path can be selected from that to which the data were archived.

Precondition



The path from which data are to be restored must be configured in the KRC Configurator.



If data are to be restored from floppy: Disk is in disk drive.



If data are to be restored from the USB stick: The stick is connected.

Procedure

1. Select the drive (ARCHIVE:\) in the Navigator. The directories belonging to (ARCHIVE:\) are displayed. 2. Select the desired object in a directory.


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3. Press the Restore softkey. 4. Confirm the request for confirmation with Yes. A message indicates completion of the restoration process. 5. Only if restoring data from floppy: if data have been archived on more than one disk, insert the next floppy disk and repeat steps 1 to 4. 6. Only if restoring data from floppy: remove floppy from floppy drive. Caution! When restoring data from the KUKA USB stick: the stick must not be removed until the LED on the stick is no longer lit. Otherwise, the stick could be damaged. 7. Reboot the robot controller. The Restr. All softkey ignores which objects are selected in the Navigator and accesses the path that is configured for archiving.

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8 Basic principles of motion programming

8

Basic principles of motion programming

8.1

Overview of motion types The following motion types can be programmed: 

Point-to-point motions (PTP) (>>> 8.2 "Motion type PTP" Page 233)



Linear motions (LIN) (>>> 8.3 "Motion type LIN" Page 233)



Circular motions (CIRC) (>>> 8.4 "Motion type CIRC" Page 234)



Spline motions (>>> 8.7 "Motion type “Spline”" Page 239)

LIN, CIRC and spline motions are also known as (“Continuous Path”) motions. The start point of a motion is always the end point of the previous motion.

8.2

Motion type PTP The robot guides the T along the fastest path to the end point. The fastest path is generally not the shortest path and is thus not a straight line. As the motions of the robot axes are rotational, curved paths can be executed faster than straight paths. The exact path of the motion cannot be predicted.

Fig. 8-1: PTP motion

8.3

Motion type LIN The robot guides the T at a defined velocity along a straight path to the end point.


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Fig. 8-2: LIN motion

8.4

Motion type CIRC The robot guides the T at a defined velocity along a circular path to the end point. The circular path is defined by a start point, auxiliary point and end point.

Fig. 8-3: CIRC motion

8.5

Approximate positioning Approximate positioning means that the motion does not stop exactly at the programmed point. Approximate positioning is an option that can be selected during motion programming.

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Approximate positioning is not possible if the motion instruction is followed by an instruction that triggers an advance run stop. PTP motion The T leaves the path that would lead directly to the end point and moves along a faster path. During programming of the motion, the maximum distance from the end point at which the T may deviate from its original path is defined. The path of an approximated PTP motion cannot be predicted. It is also not possible to predict which side of the approximated point the path will run.

Fig. 8-4: PTP motion, P2 is approximated LIN motion The T leaves the path that would lead directly to the end point and moves along a shorter path. During programming of the motion, the maximum distance from the end point at which the T may deviate from its original path is defined. The path in the approximate positioning range is not an arc.

Fig. 8-5: LIN motion, P2 is approximated CIRC motion The T leaves the path that would lead directly to the end point and moves along a shorter path. During programming of the motion, the maximum distance from the end point at which the T may deviate from its original path is defined. The motion always stops exactly at the auxiliary point. The path in the approximate positioning range is not an arc.


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Fig. 8-6: CIRC motion, PEND is approximated

8.6

Orientation control LIN, CIRC

Description

The orientation of the T can be different at the start point and end point of a motion. There are several different types of transition from the start orientation to the end orientation. A type must be selected when a motion is programmed. The orientation control for LIN and CIRC motions is defined as follows: 

In the option window Motion parameter



Or via the system variable $ORI_TYPE

(>>> 9.2.9 "Option window “Motion parameter” (LIN, CIRC)" Page 263)

LIN motion

Orientation control

Description



Option window: Constant orientation

The orientation of the T remains constant during the motion.



$ORI_TYPE = #CONSTANT

The programmed orientation is disregarded for the end point and that of the start point is retained.



Option window: Standard

The orientation of the T changes continuously during the motion.



$ORI_TYPE = #VAR

Note: If, with Standard, the robot es through a wrist axis singularity, use Wrist PTP instead.



Option window: Wrist PTP



$ORI_TYPE = #T

The orientation of the T changes continuously during the motion. This is done by linear transformation (axis-specific motion) of the wrist axis angles. Note: Use Wrist PTP if, with Standard, the robot es through a wrist axis singularity. The orientation of the T changes continuously during the motion, but not uniformly. Wrist PTP is thus not suitable if a specific orientation must be maintained exactly, e.g. in the case of laser welding.

If a wrist axis singularity occurs with Standard and the desired orientation cannot be maintained exactly enough with Wrist PTP, the following remedy is recommended: Re-teach start and/or end point. Select orientations that prevent a wrist axis singularity from occurring and allow the path to be executed with Standard.

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Fig. 8-7: Orientation control - Constant

Fig. 8-8: Standard or Wrist PTP CIRC motion

During CIRC motions, the robot controller only takes the programmed orientation of the end point into consideration. The programmed orientation of the auxiliary point is disregarded. The same orientation control options are available for selection for CIRC motions as for LIN motions. It is also possible to define for CIRC motions whether the orientation control is to be base-related or path-related. This is defined via the system variable $CIRC_TYPE. Orientation control

Description

$CIRC_TYPE = #BASE

Base-related orientation control during the circular motion

$CIRC_TYPE = #PATH

Path-related orientation control during the circular motion

$CIRC_TYPE is meaningless if $ORI_TYPE = #T. (>>> 8.6.1 "Combinations of $ORI_TYPE and $CIRC_TYPE" Page 237)

8.6.1

Combinations of $ORI_TYPE and $CIRC_TYPE $ORI_TYPE = #CONSTANT, $CIRC_TYPE = #PATH:


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Fig. 8-9: Constant orientation, path-related $ORI_TYPE = #VAR, $CIRC_TYPE = #PATH:

Fig. 8-10: Variable orientation, path-related $ORI_TYPE = #CONSTANT, $CIRC_TYPE = #BASE:

Fig. 8-11: Constant orientation, base-related

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$ORI_TYPE = #VAR, $CIRC_TYPE = #BASE:

Fig. 8-12: Variable orientation, base-related

8.7

Motion type “Spline” “Spline” is a Cartesian motion type that is suitable for particularly complex, curved paths. Such paths can generally also be generated using approximated LIN and CIRC motions, but Spline nonetheless has advantages. Disadvantages of approximated LIN and CIRC motions: 

The path is defined by means of approximated points that are not located on the path. The approximate positioning ranges are difficult to predict. Generating the desired path is complicated and time-consuming.



In many cases, the velocity may be reduced in a manner that is difficult to predict, e.g. in the approximate positioning ranges and near points that are situated close together.



The path changes if approximate positioning is not possible, e.g. for time reasons.



The path changes in accordance with the override setting, velocity or acceleration.


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Fig. 8-13: Curved path with LIN Advantages of Spline: 

The path is defined by means of points that are located on the path. The desired path can be generated easily.



The programmed velocity is maintained. There are few cases in which the velocity is reduced. (>>> 8.7.1 "Velocity profile for spline motions" Page 241)



The path always remains the same, irrespective of the override setting, velocity or acceleration.



Circles and tight radii are executed with great precision.

Fig. 8-14: Curved path with spline block A spline motion can consist of several individual motions: spline segments. These are taught separately. The segments are grouped together to form the overall motion in a so-called spline block. A spline block is planned and executed by the robot controller as a single motion block.

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Further characteristics of all spline motions:

8.7.1



If all points are situated on a plane, then the path is also situated in this plane.



If all points are situated on a straight line, then the path is also a straight line.

Velocity profile for spline motions The path always remains the same, irrespective of the override setting, velocity or acceleration. Only dynamic effects can cause deviations at different velocities. The programmed acceleration is valid not only for the direction along the path, but also perpendicular to the path. The same applies to the jerk limitation. Effects include the following: 

In the case of circles, the centrifugal acceleration is taken into consideration. The velocity that can be achieved thus also depends on the programmed acceleration and the radius of the circle.



In the case of curves, the maximum permissible velocity is derived from the radius of the curve, the acceleration and the jerk limitation.

Reduction of the velocity In the case of spline motions, the velocity may, under certain circumstances, fall below the programmed velocity. This occurs particularly in the case of: 

Tight corners



Major reorientation



Large motions of the external axes

If the points are close together, the velocity is not reduced. Reduction of the velocity to 0 This is the case for: 

Successive points with the same Cartesian coordinates.



Successive SLIN and/or SCIRC segments. Cause: inconstant velocity direction. In the case of SLIN-SCIRC transitions, the velocity is also reduced to 0 if the straight line is a tangent of the circle, as the circle, unlike the straight line, is curved.

Fig. 8-15: Exact positioning at P2


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Fig. 8-16: Exact positioning at P2 Exceptions: 

In the case of successive SLIN segments that result in a straight line and in which the orientations change uniformly, the velocity is not reduced.

Fig. 8-17: P2 is executed without exact positioning. 

8.7.2

In the case of a SCIRC-SCIRC transition, the velocity is not reduced if both circles have the same center point and the same radius and if the orientations change uniformly. (This is difficult to teach, so calculate and program points.)

Block selection with spline motions A spline block is planned and executed by the robot controller as a single motion block. Block selection to the spline segments is nonetheless possible. The BCO run is executed as a LIN motion. This is indicated by means of a message that must be acknowledged. If the second segment in the spline block is an SPL segment, a modified path is executed in the following cases: 

Block selection to the first segment in the spline block



Block selection to the spline block



Block selection to a line before the spline block if this does not contain a motion instruction and if there is no motion instruction before the spline block

If the Start key is pressed after the BCO run, the modified path is indicated by means of a message that must be acknowledged. Example: 1 PTP P0 2 SPLINE 3 SPL P1 4 SPL P2 5 SPL P3 6 SPL P4 7 SCIRC P5, P6 8 SPL P7 9 SLIN P8 10 ENDSPLINE

Line 2 3…9 10

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Description Start of the spline block Spline segments End of the spline block



Fig. 8-18: Example: modified path in the case of block selection to P1

8.7.3

Modifications to spline blocks

Description



Modification of the position of the point: If a point within a spline block is offset, the path is modified, at most, in the 2 segments before this point and the 2 segments after it. Small point offsets generally result in small modifications to the path. If, however, very long segments are followed by very short segments or vice versa, small modifications can have a very great effect, as the tangents and curves can change very greatly in such cases.



Modification of the segment type: If an SPL segment is changed into an SLIN segment or vice versa, the path changes in the previous segment and the next segment.

Example 1

PTP P0 SPLINE SPL P1 SPL P2 SPL P3 SPL P4 SCIRC P5, P6 SPL P7 SLIN P8 ENDSPLINE


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Fig. 8-19: Original path P3 is offset. This causes the path to change in segments P1 - P2, P2 - P3 and P3 - P4. Segment P4 - P5 is not changed in this case, as it belongs to an SCIRC and a circular path is thus defined.

Fig. 8-20: Point has been offset In the original path, the segment type of P2 - P3 is changed from SPL to SLIN. The path changes in segments P1 - P2, P2 - P3 and P3 - P4. PTP P0 SPLINE SPL P1 SPL P2 SLIN P3 SPL P4 SCIRC P5, P6 SPL P7 SLIN P8 ENDSPLINE

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Fig. 8-21: Segment type has been changed Example 2

... SPLINE SPL {X 100, SPL {X 102, SPL {X 104, SPL {X 204, ENDSPLINE

Y Y Y Y

0, ...} 0} 0} 0}

Fig. 8-22: Original path P3 is offset. This causes the path to change in all the segments illustrated. Since P2 - P3 and P3 - P4 are very short segments and P1 - P2 and P4 - P5 are long segments, the slight offset causes the path to change greatly. ... SPLINE SPL {X 100, SPL {X 102, SPL {X 104, SPL {X 204, ENDSPLINE

Y Y Y Y

0, ...} 1} 0} 0}

Fig. 8-23: Point has been offset Remedy:

8.7.4



Distribute the points more evenly



Program straight lines (except very short ones) as SLIN segments

Approximate positioning with spline motions Approximate positioning is not currently ed for spline motions.


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1 2 3 4 5 6 7 8 9 10

LIN P1 C_DIS CIRC P2, P3 C_DIS SPLINE SPL P4 SCIRC P5, P6 SPL P7 SLIN P8 ENDSPLINE LIN P9 C_DIS LIN P10 C_DIS

Line

8.7.5

Description

2

P3 is the start point for the spline motion. It is addressed with exact positioning.

8

Approximate positioning cannot be programmed for P8.

9

P9 is approximated.

Replacing an approximated motion with a spline block

Description

In order to replace conventional approximated motions with spline blocks, the program must be modified as follows: 

Replace LIN - LIN with SLIN - SPL - SLIN.



Replace LIN - CIRC with SLIN - SPL - SCIRC. Recommendation: Allow the SPL to project a certain way into the original circle. The SCIRC thus starts later than the original CIRC.

In approximated motions, the corner point is programmed. In the spline block, the points at the start and end of the approximation are programmed instead. The approximate positioning arc of the approximated motions varies according to the override. For this reason, when reproducing an approximated motion, it must be ensured that it is executed with the desired override. The following approximated motion is to be reproduced: LIN P1 C_DIS LIN P2

Spline motion: SPLINE SLIN P1A SPL P1B SLIN P2 ENDSPLINE

P1A = start of approximation, P1B = end of approximation

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Fig. 8-24: Approximated motion - spline motion Ways of determining P1A and P1B: 

Execute the approximated path and save the positions at the desired point by means of Trigger.



Calculate the points in the program with KRL.



The start of the approximation can be determined from the approximate positioning criterion. Example: If C_DIS is specified as the approximate positioning criterion, the distance from the start of the approximation to the corner point corresponds to the value of $APO.CDIS. The end of the approximation is dependent on the programmed velocity.

The SPL path does not correspond exactly to the approximate positioning arc, even if P1A and P1B are exactly at the start/end of the approximation. In order to recreate the exact approximate positioning arc, additional points must be inserted into the spline. Generally, one point is sufficient. Example

The following approximated motion is to be reproduced: $APO.CDIS=20 $VEL.=0.5 LIN {Z 10} C_DIS LIN {Y 60}

Spline motion: SPLINE WITH $VEL.=0.5 SLIN {Z 30} SPL {Y 30, Z 10} SLIN {Y 60} ENDSPLINE

The start of the approximate positioning arc has been calculated from the approximate positioning criterion.


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Fig. 8-25: Example: Approximated motion - spline motion 1 The SPL path does not yet correspond exactly to the approximate positioning arc. For this reason, an additional SPL segment is inserted into the spline. SPLINE WITH $VEL.=0.5 SLIN {Z 30} SPL {Y 15, Z 15} SPL {Y 30, Z 10} SLIN {Y 60} ENDSPLINE

Fig. 8-26: Example: Approximated motion - spline motion 2 With the additional point, the path now corresponds to the approximate positioning arc.

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8.8

Orientation control SPLINE

Description

The orientation of the T can be different at the start point and end point of a motion. When a motion is programmed, it is necessary to select how to deal with the different orientations. The orientation control for SLIN and SCIRC motions is defined as follows: 

If programming with KRL syntax: by means of the system variable $ORI_TYPE



If programming with inline forms: in the option window Motion parameter

(>>> 9.3.4 "Option window “Motion parameter” (spline motion)" Page 266) The orientation control can be defined in the spline block or in the individual segment. Settings in the segment overwrite the setting in the spline block. SLIN segment

Orientation control

Description



Option window: Constant orientation

The orientation of the T remains constant during the motion.



$ORI_TYPE = #CONSTANT

The orientation of the start point is retained. The programmed orientation of the end point is not taken into consideration.



Option window: Standard



$ORI_TYPE = #VAR

The orientation of the T changes continuously during the motion. At the end point, the T has the programmed orientation.



Option window: Ignore Orientation

This option is only available for individual spline segments, not for the spline block.



$ORI_TYPE = #IGNORE

It is used if no specific orientation is required at a point. (>>> "#IGNORE" Page 250)

Fig. 8-27: Orientation control - Constant


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Fig. 8-28: Standard #IGNORE

$ORI_TYPE = #IGNORE is used if no specific orientation is required at a point. If this option is selected, the taught or programmed orientation of the point is ignored. Instead, the robot controller calculates the optimal orientation for this point on the basis of the orientations of the surrounding points. Example: SPLINE SPL XP1 SPL XP2 SPL XP3 WITH $ORI_TYPE=#IGNORE SPL XP4 WITH $ORI_TYPE=#IGNORE SPL XP5 SPL XP6 ENDSPLINE

The taught or programmed orientation of XP3 and XP4 is ignored. Characteristics of $ORI_TYPE = #IGNORE: 

In the program run modes MSTEP and ISTEP, the robot stops with the orientations calculated by the robot controller.



In the case of a block selection to a point with #IGNORE, the robot adopts the orientation calculated by the robot controller.

$ORI_TYPE = #IGNORE is not allowed for the following segments:

SCIRC segment



The first segment in a spline block



The last segment in a spline block



SCIRC segments with $CIRC_TYPE=#PATH



Segments followed by a SCIRC segment with $CIRC_TYPE=#PATH



Segments followed by a segment with $ORI_TYPE=#CONSTANT



In the case of successive segments with identical Cartesian end points, #IGNORE is not allowed for the first and last segments.

During SCIRC motions, the robot controller takes the programmed orientation of the auxiliary point into consideration. The same orientation control options are available for selection for SCIRC motions as for SLIN motions. It is also possible to define for SCIRC motions whether the orientation control is to be space-related or path-related. (>>> 8.8.1 "SCIRC: reference system for the orientation control" Page 250)

8.8.1

SCIRC: reference system for the orientation control It is possible to define for SCIRC motions whether the orientation control is to be space-related or path-related. This can be defined as follows:

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8 Basic principles of motion programming 

If programming with inline forms: in the option window Motion parameter



If programming with KRL syntax: by means of the system variable $CIRC_TYPE Orientation control 

Option window: Base-related



$CIRC_TYPE = #BASE



Option window: Path-related



$CIRC_TYPE = #PATH

Description Base-related orientation control during the circular motion Path-related orientation control during the circular motion

$CIRC_TYPE = #PATH is not allowed for the following motions: 

SCIRC segments for which $ORI_TYPE = #IGNORE



SCIRC motions preceded by a spline segment for which $ORI_TYPE = #IGNORE

(>>> 8.6.1 "Combinations of $ORI_TYPE and $CIRC_TYPE" Page 237)

8.9

Status and Turn

Overview

The position (X, Y, Z) and orientation (A, B, C) values of the T are not sufficient to define the robot position unambiguously, as different axis positions are possible for the same T. Status and Turn serve to define an unambiguous position that can be achieved with different axis positions.

Fig. 8-29: Example: Same T position, different axis position Status (S) and Turn (T) are integral parts of the data types POS and E6POS: STRUC POS REAL X, Y, Z, A, B, C, INT S, T STRUC E6POS REAL X, Y, Z, A, B, C, E1, E2, E3, E4, E5, E6, INT S, T

KRL program

The robot controller only takes the programmed Status and Turn values into consideration for PTP motions. They are ignored for motions. The first motion instruction in a KRL program must therefore be one of the following instructions so that an unambiguous starting position is defined for the robot: 

A complete PTP instruction of type POS or E6POS



Or a complete PTP instruction of type AXIS or E6AXIS


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“Complete” means that all components of the end point must be specified. The default HOME position is always a complete PTP instruction. Status and Turn can be omitted in the subsequent instructions:

8.9.1



The robot controller retains the previous Status value.



The Turn value is determined by the path in motions. In the case of PTP motions, the robot controller selects the Turn value that results in the shortest possible path.

Status The Status specification prevents ambiguous axis positions.

Bit 0

Bit 0 specifies the position of the intersection of the wrist axes (A4, A5, A6). Position

Value

Overhead area

Bit 0 = 1

If the x-value of the intersection of the wrist axes, relative to the A1 coordinate system, is negative, the robot is in the overhead area. Bit 0 = 0

Basic area If the x-value of the intersection of the wrist axes, relative to the A1 coordinate system, is positive, the robot is in the basic area.

The A1 coordinate system is identical to the $ROBROOT coordinate system if axis 1 is at 0°. For values not equal to 0°, it moves with axis 1.

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Fig. 8-30: Example: The intersection of the wrist axes (red dot) is in the basic area. Bit 1

Bit 1 specifies the position of axis 3. The angle at which the value of bit 1 changes depends on the robot type. For robots whose axes 3 and 4 intersect, the following applies: Position

Value

A3 ≥ 0°

Bit 1 = 1

A3 < 0°

Bit 1 = 0

For robots with an offset between axis 3 and axis 4, the angle at which the value of bit 1 changes depends on the size of this offset.


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Fig. 8-31: Offset between A3 and A4 – example: KR 30 Bit 2

Bit 2 specifies the position of axis 5. Position

Value

A5 > 0

Bit 2 = 1

A5 ≤ 0

Bit 2 = 0

Bit 3

Bit 3 is not used and is always 0.

Bit 4

Bit 4 specifies whether or not the point was taught using an absolutely accurate robot. Depending on the value of the bit, the point can be executed by both absolutely accurate robots and non-absolutely-accurate robots. Bit 4 is for information purposes only and has no influence on how the robot calculates the point. This means, therefore, that when a robot is programmed offline, bit 4 can be ignored.

8.9.2

Description

Value

The point was not taught with an absolutely accurate robot.

Bit 4 = 0

The point was taught with an absolutely accurate robot.

Bit 4 = 1

Turn

Description

The Turn specification makes it possible to move axes through angles greater than +180° or less than -180° without the need for special motion strategies (e.g. auxiliary points). With rotational axes, the individual bits determine the sign before the axis value in the following way: Bit x = 0: angle of axis x+1 ≥ 0° Bit x = 1: angle of axis x+1 < 0° Value

Example

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Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

0

A6 ≥ 0°

1

A6 < 0°

A5 ≥ 0°

A4 ≥ 0°

A3 ≥ 0°

A2 ≥ 0°

A1 ≥ 0°

A5 < 0°

A4 < 0°

A3 < 0°

A2 < 0°

A1 < 0°

DECL POS XP1 = {X 900, Y 0, Z 800, A 0, B 0, C 0, S 6, T 19}



T 19 corresponds to T 'B010011'. This means:

8.10

Axis

Angle

A1

negative

A2

negative

A3

positive

A4

positive

A5

negative

A6

positive

Singularities KUKA robots with 6 degrees of freedom have 3 different singularity positions. 

Overhead singularity



Extended position singularity



Wrist axis singularity

A singularity position is characterized by the fact that unambiguous reverse transformation (conversion of Cartesian coordinates to axis-specific values) is not possible, even though Status and Turn are specified. In this case, or if very slight Cartesian changes cause very large changes to the axis angles, one speaks of singularity positions. Overhead

In the overhead singularity, the wrist root point (intersection of axes A4, A5 and A6) is located vertically above axis 1. The position of axis A1 cannot be determined unambiguously by means of reverse transformation and can thus take any value. If the end point of a PTP motion is situated in this overhead singularity position, the robot controller may react as follows by means of the system variable $SINGUL_POS[1]:

Extended position



0: The angle for axis A1 is defined as 0 degrees (default setting).



1: The angle for axis A1 remains the same from the start point to the end point.

In the extended position singularity, the wrist root point (intersection of axes A4, A5 and A6) is located in the extension of axes A2 and A3 of the robot. The robot is at the limit of its work envelope. Although reverse transformation does provide unambiguous axis angles, low Cartesian velocities result in high axis velocities for axes A2 and A3. If the end point of a PTP motion is situated in this extended position singularity, the robot controller may react as follows by means of the system variable $SINGUL_POS[2]:

Wrist axes



0: The angle for axis A2 is defined as 0 degrees (default setting).



1: The angle for axis A2 remains the same from the start point to the end point.

In the wrist axis singularity position, the axes A4 and A6 are parallel to one another and axis A5 is within the range ±0.01812°. The position of the two axes cannot be determined unambiguously by reverse transformation. There is an infinite number of possible axis positions for axes A4 and A6 with identical axis angle sums.


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If the end point of a PTP motion is situated in this wrist axis singularity, the robot controller may react as follows by means of the system variable $SINGUL_POS[3]: 

0: The angle for axis A4 is defined as 0 degrees (default setting). 

1: The angle for axis A4 remains the same from the start point to the end point. In the case of SCARA robots, only the extended position singularity can arise. In this case, the robot starts to move extremely fast.

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9 Programming for group “” (inline forms)

9

Programming for group “” (inline forms) Inline forms are available in the KSS for frequently used instructions. They simplify programming. Instructions can also be programmed without inline forms. Information is contained in the description of the KRL syntax. (>>> 10 "Programming for group “Expert” (KRL syntax)" Page 285)

9.1

Names in inline forms Names for data sets can be entered in inline forms. These include, for example, point names, names for motion data sets, etc. The following restrictions apply to names: 

Maximum length 23 characters



No special characters are permissible, with the exception of $.



The first character must not be a number.

The restrictions do not apply to output names. Other restrictions may apply in the case of inline forms in technology packages.

9.2

Programming PTP, LIN and CIRC motions

9.2.1

Programming a PTP motion Caution! When programming motions, it must be ensured that the energy supply system is not wound up or damaged during program execution.

Precondition

Procedure







1. Move the T to the position that is to be taught as the end point. 2. Position the cursor in the line after which the motion instruction is to be inserted. 3. Select the menu sequence Commands > Motion > PTP. 4. Set the parameters in the inline form. (>>> 9.2.2 "Inline form for PTP motions" Page 257) 5. Save the instruction by pressing the Cmd Ok softkey.

9.2.2

Inline form for PTP motions

Fig. 9-1: Inline form for PTP motions


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Item

Description

1

Motion type

2



PTP



LIN



CIRC

Name of the end point The system automatically generates a name. The name can be overwritten. (>>> 9.1 "Names in inline forms" Page 257) Position the cursor in this box to edit the point data. The corresponding option window is opened. (>>> 9.2.7 "Option window “Frames”" Page 261)

3 4



CONT: end point is approximated.



[Empty box]: the motion stops exactly at the end point.

Velocity 

5

1 … 100%

Name for the motion data set The system automatically generates a name. The name can be overwritten. (>>> 9.1 "Names in inline forms" Page 257) Position the cursor in this box to edit the motion data. The corresponding option window is opened. (>>> 9.2.8 "Option window “Motion parameter” (PTP)" Page 262)

9.2.3

Programming a LIN motion Caution! When programming motions, it must be ensured that the energy supply system is not wound up or damaged during program execution.

Precondition

Procedure







1. Move the T to the position that is to be taught as the end point. 2. Position the cursor in the line after which the motion instruction is to be inserted. 3. Select the menu sequence Commands > Motion > LIN. 4. Set the parameters in the inline form. (>>> 9.2.4 "Inline form for LIN motions" Page 258) 5. Save the instruction by pressing the Cmd Ok softkey.

9.2.4

Inline form for LIN motions

Fig. 9-2: Inline form for LIN motions

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Item

Description

1

Motion type

2



PTP



LIN



CIRC


3 4







Velocity 

5

0.001 … 2 m/s

Name for the motion data set The system automatically generates a name. The name can be overwritten. (>>> 9.1 "Names in inline forms" Page 257) Position the cursor in this box to edit the motion data. The corresponding option window is opened. (>>> 9.2.9 "Option window “Motion parameter” (LIN, CIRC)" Page 263)

9.2.5

Programming a CIRC motion Caution! When programming motions, it must be ensured that the energy supply system is not wound up or damaged during program execution.

Precondition

Procedure







1. Move the T to the position that is to be taught as the auxiliary point. 2. Position the cursor in the line after which the motion instruction is to be inserted. 3. Select the menu sequence Commands > Motion > CIRC. 4. Set the parameters in the inline form. (>>> 9.2.6 "Inline form for CIRC motions" Page 260) 5. Press the Teach Aux softkey. 6. Move the T to the position that is to be taught as the end point. 7. Save the instruction by pressing the Cmd Ok softkey.


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9.2.6

Inline form for CIRC motions

Fig. 9-3: Inline form for CIRC motions Item

Description

1

Motion type

2



PTP



LIN



CIRC

Name of the auxiliary point The system automatically generates a name. The name can be overwritten. (>>> 9.1 "Names in inline forms" Page 257)

3


4







5

Velocity 

6

0.001 … 2 m/s

Name for the motion data set The system automatically generates a name. The name can be overwritten. (>>> 9.1 "Names in inline forms" Page 257) Position the cursor in this box to edit the motion data. The corresponding option window is opened. (>>> 9.2.9 "Option window “Motion parameter” (LIN, CIRC)" Page 263)

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9.2.7

Option window “Frames”

Fig. 9-4: Option window: Frames Item 1

Description Tool selection. If True in the box External T: workpiece selection. Range of values: [1] … [16]

2

Base selection. If True in the box External T: fixed tool selection. Range of values: [1] … [32]

3

4

Interpolation mode 

False: The tool is mounted on the mounting flange.



True: The tool is a fixed tool.



True: For this motion, the robot controller calculates the axis torques. These are required for collision detection.



False: For this motion, the robot controller does not calculate the axis torques. Collision detection is thus not possible for this motion.


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9.2.8

Option window “Motion parameter” (PTP)

Fig. 9-5: Option window “Motion parameter” (PTP) Item

Description

1

Acceleration Refers to the maximum value specified in the machine data. The maximum value depends on the robot type and the selected operating mode. 

2

1 … 100 %

This box is only displayed if CONT was selected in the inline form. Furthest distance before the end point at which approximate positioning can begin. Maximum distance 100%: half the distance between the start point and the end point relative to the contour of the PTP motion without approximate positioning The unit for this box can also be mm. This depends on the configuration. (>>> 6.14.2 "Changing the unit of the approximation distance for PTP" Page 140) Distance in mm: The maximum permissible value is half the distance between the start point and the end point. If a higher value is entered, this is ignored and the maximum value is used.

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

1 … 100 %



Or 0 … 300 mm



9.2.9

Option window “Motion parameter” (LIN, CIRC)

Fig. 9-6: Option window “Motion parameter” (LIN, CIRC) Item

Description

1

Acceleration Refers to the maximum value specified in the machine data. The maximum value depends on the robot type and the selected operating mode.

2

Furthest distance before the end point at which approximate positioning can begin The maximum permissible value is half the distance between the start point and the end point. If a higher value is entered, this is ignored and the maximum value is used. This box is only displayed if CONT was selected in the inline form.

3

9.3

Orientation control selection.

Programming spline motions

Overview

Step 1

Description Program the spline block. (>>> 9.3.2 "Programming a spline block" Page 265)

2

Program the spline segments. (>>> 9.3.5 "Programming an SPL segment" Page 267) (>>> 9.3.6 "Programming an SLIN segment" Page 267) (>>> 9.3.7 "Programming an SCIRC segment" Page 268)

3

If required, and only in the group “Expert”: Program PATH trigger. (>>> 10.11.3 "TRIGGER WHEN PATH (for SPLINE)" Page 331)

As for all motion instructions, the start point of a spline motion is the end point of the previous motion.


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9.3.1

Programming tips for spline motions 

A spline block should cover one process (e.g. an adhesive seam). More than one process in a spline block leads to a loss of structural clarity within the program and makes changes more difficult.



Use SLIN and SCIRC segments in cases where the workpiece necessitates straight lines and arcs. (Exception: use SPL segments for very short straight lines.) Otherwise, use SPL segments, particularly if the points are close together.



Procedure for defining the path: a. First teach or calculate a few characteristic points. Example: points at which the curve changes direction. b. Test the path. At points where the accuracy is still insufficient, add more SPL points.



Avoid successive SLIN and/or SCIRC segments, as these trigger exact positioning. Exact positioning can be avoided as follows: 

Program SPL segments between SLIN and SCIRC segments. The length of the SPL segments must be greater than 0.5 mm.



Replace an SLIN segment with several SPL segments. If SPL points are situated on a straight line, then the path will also be a straight line.



Avoid successive points with identical Cartesian coordinates, as these trigger exact positioning.



The parameters (tool, base, velocity, etc.) assigned to the spline block have the same effect as assignments before the spline block. The assignment to the spline block has the advantage, however, that the correct parameters are read in the case of a block selection.



Use the option Ignore Orientation if no specific orientation is required at a point. The robot controller calculates the optimal orientation for this point on the basis of the orientations of the surrounding points. This way, even large changes in orientation between two points are optimally distributed over the points in between.



Jerk limitation can be programmed. The jerk is the change in acceleration. Procedure: a. Use the default values initially. b. If vibrations occur at tight corners: reduce values. If the velocity drops or the desired velocity cannot be reached: increase values or increase acceleration.



If the robot executes points on a work surface, a collision with the work surface is possible when the first point is addressed.

Fig. 9-7: Collision with work surface A collision can be avoided as follows:

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

Program the first segment on the work surface as SLIN.



Additionally, if required: Insert an SLIN segment before the first point. The following precondition must be met: 2/3 ≤ a/b ≤ 3/2



a = distance from start point of the SPL segment to intersection of the SLIN segments b = distance from intersection of the SLIN segments to end point of the SPL segment

Fig. 9-8: Avoiding a collision with the work surface

9.3.2

Programming a spline block

Precondition

Procedure







1. Position the cursor in the line after which the spline motion is to be inserted. 2. Select the menu sequence Commands > Motion > SPLINE Block. 3. Set the parameters in the inline form. (>>> 9.3.3 "Inline form for spline block" Page 265) 4. Press the Cmd OK softkey. 5. Press the Fold open/cls softkey. Lines can now be inserted into the spline block.

Description

A spline block may contain the following: 

Spline segments (only limited by the memory capacity. As a rule, at least 1,000 segments are possible.)



PATH trigger



Comments



Blank lines



Inline commands from technology packages that the spline function

A spline block must not include any other instructions, e.g. variable assignments or logic statements. A spline block does not trigger an advance run stop.

9.3.3

Inline form for spline block

Fig. 9-9: Inline form for spline block


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Item

Description

1

Name of the spline motion. The system automatically generates a name. The name can be overwritten. Position the cursor in this box to edit the motion data. The corresponding option window is opened. (>>> 9.2.7 "Option window “Frames”" Page 261)

2

The velocity is valid by default for the entire spline motion. It can also be defined separately for individual segments. 

0.001 … 2 m/s 3

Name for the motion data set. The system automatically generates a name. The name can be overwritten. Position the cursor in this box to edit the motion data. The corresponding option window is opened. (>>> 9.3.4 "Option window “Motion parameter” (spline motion)" Page 266) The motion data are valid by default for the entire spline motion. They can also be defined separately for individual segments.

9.3.4

Option window “Motion parameter” (spline motion)

Fig. 9-10: Option window “Motion parameter” (spline motion)

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Item

Description

1

Acceleration. The value refers to the maximum value specified in the machine data. 

2

1 … 100 %

Jerk limitation. The jerk is the change in acceleration. The value refers to the maximum value specified in the machine data. 

3

1 … 100 %

Orientation control selection (>>> 8.8 "Orientation control SPLINE" Page 249)

4

9.3.5

Only for spline block and SCIRC segments: Circle orientation control selection 

Base-related



Path-related

Programming an SPL segment Caution! When programming motions, it must be ensured that the energy supply system is not wound up or damaged during program execution.

Description

The robot guides the T to the end point. The robot controller selects a suitable path.

Precondition









The spline block fold is open.

Procedure

1. Move the T to the end point. 2. Position the cursor in the line after which the segment is to be inserted in the spline block. 3. Select the menu sequence Commands > Motion > SPL. 4. Set the parameters in the inline form. (>>> 9.3.8 "Inline form “Spline Segment”" Page 268) 5. Press the Cmd OK softkey.

9.3.6

Programming an SLIN segment Caution! When programming motions, it must be ensured that the energy supply system is not wound up or damaged during program execution.

Description

The robot guides the T along the shortest path to the end point. The shortest path is always a straight line.

Precondition










Procedure

1. Move the T to the end point.


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2. Position the cursor in the line after which the segment is to be inserted in the spline block. 3. Select the menu sequence Commands > Motion > SLIN. 4. Set the parameters in the inline form. (>>> 9.3.8 "Inline form “Spline Segment”" Page 268) 5. Press the Cmd OK softkey.

9.3.7

Programming an SCIRC segment Caution! When programming motions, it must be ensured that the energy supply system is not wound up or damaged during program execution.

Description

The robot guides the T along a circular path to the end point. The circular path is defined by a start point, auxiliary point and end point.

Precondition










Procedure

1. Move the T to the auxiliary point. 2. Position the cursor in the line after which the segment is to be inserted in the spline block. 3. Select the menu sequence Commands > Motion > SCIRC. 4. Set the parameters in the inline form. (>>> 9.3.8 "Inline form “Spline Segment”" Page 268) 5. Press the Teach Aux softkey. 6. Move the T to the end point. 7. Press the Cmd OK softkey.

9.3.8

Inline form “Spline Segment”

Fig. 9-11: Inline form “Spline Segment” The boxes in the inline form can be displayed or hidden one by one using the Toggle Param softkey.

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Item

Description

1

Select the motion type for the spline segment using the Toggle Cmd softkey. 

SPL 

SLIN 

SCIRC 2

Point name for end point. Only for SCIRC: point names for auxiliary point and end point. The system automatically generates a name. The name can be overwritten. Position the cursor in the box of the end point to edit the point data. The corresponding option window is opened. (>>> 9.3.9 "Option window “Frames” (spline segment)" Page 269)

3

Velocity This only refers to the segment to which it belongs. It has no effect on subsequent segments. 

0.001 … 2 m/s 4

Name for the motion data set. The system automatically generates a name. The name can be overwritten. Position the cursor in this box to edit the motion data. The corresponding option window is opened. (>>> 9.3.4 "Option window “Motion parameter” (spline motion)" Page 266) The motion data only refer to the segment to which they belong. They have no effect on subsequent segments.

9.3.9

Option window “Frames” (spline segment)

Fig. 9-12: Inline form “Frames” (spline segment)


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9.4

Item

Description

1



True: For this motion, the robot controller calculates the axis torques. These are required for collision detection.



False: For this motion, the robot controller does not calculate the axis torques. Collision detection is thus not possible for this motion.

Modifying motion parameters

Precondition

Procedure







1. Position the cursor in the line containing the instruction that is to be changed. 2. Press the Change softkey. The inline form for this instruction is opened. 3. Modify parameters. 4. Save changes by pressing the Cmd Ok softkey.

9.5

Modifying the coordinates of a taught point

Description

The coordinates of a taught point can be modified. This is done by moving to the new position and overwriting the old point with the new position.

Precondition







Procedure

1. Move the T to the desired position. 2. Position the cursor in the line containing the motion instruction that is to be changed. 3. Press the Change softkey. The inline form for this instruction is opened. 4. For PTP and LIN motions: Press the Touch Up softkey to accept the current position of the T as the new end point. For CIRC motions: 

Press the Teach Aux softkey to accept the current position of the T as the new auxiliary point.



Press the Teach End softkey to accept the current position of the T as the new end point.

5. Confirm the request for confirmation with Yes. 6. Save change by pressing the Cmd Ok softkey.

9.6

Programming logic instructions

9.6.1

Inputs/outputs Digital inputs/outputs The robot controller can manage up to 4096 digital inputs and 4096 digital outputs. The configuration is customer-specific. Anaputs/outputs The robot controller can manage 32 anaputs and 32 analog outputs. The configuration is customer-specific. Permissible range of values for inputs/outputs: -1.0 to +1.0. This corresponds to a voltage range from -10 V to +10 V. If the value is exceeded, the input/out-

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put takes the maximum value and a message is displayed until the value is back in the permissible range. The inputs/outputs are managed via the following system variables: Inputs

9.6.2

Outputs

Digital

$IN[1] … $IN[4096]

$OUT[1] … $OUT[4096]

Analog

$ANIN[1] … $ANIN[32]

$ANOUT[1] … $ANOUT[32]

Setting a digital output - OUT

Precondition

Procedure







1. Position the cursor in the line after which the logic instruction is to be inserted. 2. Select the menu sequence Commands > Logic > OUT > OUT. 3. Set the parameters in the inline form. (>>> 9.6.3 "Inline form “OUT”" Page 271) 4. Save the instruction by pressing the Cmd Ok softkey.

9.6.3

Inline form “OUT” The instruction sets a digital output.

Fig. 9-13: Inline form "OUT" Item 1

Description Output number 

1 … 4096 2

If a name exists for the output, this name is displayed. Only for the group “Expert”: A name can be entered by pressing the Longtext softkey. The name is freely selectable.

3

State to which the output is switched 

TRUE 

FALSE 4



CONT: Execution in the advance run 

[Empty box]: Execution with advance run stop


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9.6.4

Setting a pulse output - PULSE

Precondition

Procedure







1. Position the cursor in the line after which the logic instruction is to be inserted. 2. Select the menu sequence Commands > Logic > OUT > PULSE. 3. Set the parameters in the inline form. (>>> 9.6.5 "Inline form “PULSE”" Page 272) 4. Save the instruction by pressing the Cmd Ok softkey.

9.6.5

Inline form “PULSE” The instruction sets a pulse of a defined length.

Fig. 9-14: Inline form "PULSE" Item 1


1 … 4096 2


3


TRUE: “High” level 

FALSE: “Low” level 4




[Empty box]: Execution with advance run stop 5

Length of the pulse 

0.1 … 3 s

9.6.6

Setting an analog output - ANOUT

Precondition

Procedure







1. Position the cursor in the line after which the instruction is to be inserted. 2. Select the menu sequence Commands > Analog output > Static or Dynamic.

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3. Set the parameters in the inline form. (>>> 9.6.7 "Inline form “ANOUT” (static)" Page 273) (>>> 9.6.8 "Inline form “ANOUT” (dynamic)" Page 273) 4. Save the instruction by pressing the Cmd Ok softkey.

9.6.7

Inline form “ANOUT” (static) This instruction sets a static analog output. A maximum of 8 analog outputs (static and dynamic together) can be used at any one time. ANOUT triggers an advance run stop. The voltage is set to a fixed level by means of a factor. The actual voltage level depends on the analog module used. For example, a 10 V module with a factor of 0.5 provides a voltage of 5 V.

Fig. 9-15: Inline form "ANOUT" (static) Item 1

Description Analog output number 

2

Factor for the voltage 

9.6.8

CHANNEL_1 … CHANNEL_32 0 … 1 (intervals: 0.01)

Inline form “ANOUT” (dynamic) This instruction activates or deactivates a dynamic analog output. A maximum of 4 dynamic analog outputs can be activated at any one time. ANOUT triggers an advance run stop. The voltage is determined by a factor. The actual voltage level depends on the following values: 

Velocity or function generator For example, a velocity of 1 m/s with a factor of 0.5 results in a voltage of 5 V.



Offset For example, an offset of +0.15 for a voltage of 0.5 V results in a voltage of 6.5 V.

Fig. 9-16: Inline form "ANOUT" (dynamic)


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Item 1

Description Activation or deactivation of the analog output 

ON 

OFF 2

Analog output number 

CHANNEL_1 … CHANNEL_32 3

Factor for the voltage 

0 … 10 (intervals: 0.01) 4



VEL_ACT: The voltage is dependent on the velocity. 

TECHVAL[1] … TECHVAL[6]: The voltage is controlled by a function generator. 5

Value by which the voltage is increased or decreased 

-1 … +1 (intervals: 0.01) 6

Time by which the output signal is delayed (+) or brought forward (-) 

-0.2 … +0.5 s

9.6.9

Programming a wait time - WAIT

Precondition

Procedure







1. Position the cursor in the line after which the logic instruction is to be inserted. 2. Select the menu sequence Commands > Logic > WAIT. 3. Set the parameters in the inline form. (>>> 9.6.10 "Inline form “WAIT”" Page 274) 4. Save the instruction by pressing the Cmd Ok softkey.

9.6.10

Inline form “WAIT” WAIT can be used to program a wait time. The robot motion is stopped for a programmed time. WAIT always triggers an advance run stop.

Fig. 9-17: Inline form "WAIT"

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Item 1

Description Wait time 

≥0s

9.6.11

Programming a signal-dependent wait function - WAITFOR

Precondition

Procedure







1. Position the cursor in the line after which the logic instruction is to be inserted. 2. Select the menu sequence Commands > Logic > WAITFOR. 3. Set the parameters in the inline form. (>>> 9.6.12 "Inline form “WAITFOR”" Page 275) 4. Save the instruction by pressing the Cmd Ok softkey.

9.6.12

Inline form “WAITFOR” The instruction sets a signal-dependent wait function. If required, several signals (maximum 12) can be linked. If a logic operation is added, boxes are displayed in the inline form for the additional signals and links.

Fig. 9-18: Inline form "WAITFOR"


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Item 1

Description Add external logic operation. The operator is situated between the bracketed expressions. 

AND 

OR 

EXOR Add NOT. 

NOT 

[Empty box] Enter the desired operator by means of the softkey. 2

Add internal logic operation. The operator is situated inside a bracketed expression. 

AND 

OR 

EXOR Add NOT. 

NOT 

[Empty box] Enter the desired operator by means of the softkey.

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Item 3

Description Signal for which the system is waiting 

IN 

OUT 

CYCFLAG 

TIMER 

FLAG 4

Signal number 

1 … 4096 5

If a name exists for the signal, this name is displayed. Only for the group “Expert”: A name can be entered by pressing the Longtext softkey. The name is freely selectable.

6




[Empty box]: Execution with advance run stop

9.6.13

Switching on the path - SYN OUT

Precondition

Procedure







1. Position the cursor in the line after which the logic instruction is to be inserted. 2. Select the menu sequence Commands > Logic > OUT > SYN OUT. 3. Set the parameters in the inline form. (>>> 9.6.14 "Inline form “SYN OUT”, option “START/END”" Page 277) (>>> 9.6.15 "Inline form “SYN OUT”, option “PATH”" Page 280) 4. Save the instruction by pressing the Cmd Ok softkey.

9.6.14

Inline form “SYN OUT”, option “START/END” A switching action can be triggered relative to the start or end point of a motion block. The switching action can be delayed or brought forward. The motion block can be a LIN, CIRC or PTP motion. Possible applications include: 

Closing or opening the weld gun during spot welding



Switching the welding current on/off during arc welding


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Starting or stopping the flow of adhesive in bonding or sealing applications.

Fig. 9-19: Inline form SYN OUT, option START/END Item 1


1 … 4096 2


3


TRUE 

FALSE 4

Point at which switching is carried out 

START: Switching is carried out at the start point of the motion block. 

END: Switching is carried out at the end point of the motion block. 

PATH: (>>> 9.6.15 "Inline form “SYN OUT”, option “PATH”" Page 280) 5

Switching action delay 

-1000 … +1000 ms

Note: The time specification is absolute. The switching point varies according to the velocity of the robot. Example 1

Start point and end point are exact positioning points. LIN LIN SYN SYN LIN LIN

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P1 VEL=0.3m/s DAT1 P2 VEL=0.3m/s DAT2 OUT 1 '' State= TRUE at START Delay=20ms OUT 2 '' State= TRUE at END Delay=-20ms P3 VEL=0.3m/s DAT3 P4 VEL=0.3m/s DAT4



Fig. 9-20 OUT 1 and OUT 2 specify approximate positions at which switching is to occur. The dotted lines indicate the switching limits. Switching limits: 

START: The switching point can be delayed, at most, as far as exact positioning point P3 (+ ms).



END: The switching point can be brought forward, at most, as far as exact positioning point P2 (- ms).

If greater values are specified for the delay, the controller automatically switches at the switching limit. Example 2

Start point is exact positioning point, end point is approximated. LIN LIN SYN SYN LIN LIN

P1 VEL=0.3m/s DAT1 P2 VEL=0.3m/s DAT2 OUT 1 '' State= TRUE at START Delay=20ms OUT 2 '' State= TRUE at END Delay=-20ms P3 CONT VEL=0.3m/s DAT3 P4 VEL=0.3m/s DAT4

Fig. 9-21 OUT 1 and OUT 2 specify approximate positions at which switching is to occur. The dotted lines indicate the switching limits. M = middle of the approximate positioning range. Switching limits: 

START: The switching point can be delayed, at most, as far as the start of the approximate positioning range of P3 (+ ms).


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END: The switching point can be brought forward, at most, as far as the start of the approximate positioning range of P3 (-). The switching point can be delayed, at most, as far as the end of the approximate positioning range of P3 (+).

If greater values are specified for the delay, the controller automatically switches at the switching limit. Example 3

Start point and end point are approximated LIN LIN SYN SYN LIN LIN

P1 VEL=0.3m/s DAT1 P2 CONT VEL=0.3m/s DAT2 OUT 1 '' State= TRUE at START Delay=20ms OUT 2 '' State= TRUE at END Delay=-20ms P3 CONT VEL=0.3m/s DAT3 P4 VEL=0.3m/s DAT4

Fig. 9-22 OUT 1 and OUT 2 specify approximate positions at which switching is to occur. The dotted lines indicate the switching limits. M = middle of the approximate positioning range. Switching limits: 

START: The switching point can be situated, at the earliest, at the end of the approximate positioning range of P2. The switching point can be delayed, at most, as far as the start of the approximate positioning range of P3 (+ ms).



END: The switching point can be brought forward, at most, as far as the start of the approximate positioning range of P3 (-). The switching point can be delayed, at most, as far as the end of the approximate positioning range of P3 (+).

If greater values are specified for the delay, the controller automatically switches at the switching limit.

9.6.15

Inline form “SYN OUT”, option “PATH” A switching action can be triggered relative to the end point of a motion block. The switching action can be shifted in space and delayed or brought forward. The motion block can be a LIN or CIRC motion. It must not be a PTP motion.

Fig. 9-23: Inline form SYN OUT, option PATH

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Item 1


1 … 4096 2


3


TRUE 

FALSE 4

Point at which switching is carried out 

PATH: Switching is carried out at the end point of the motion block. 

START: (>>> 9.6.14 "Inline form “SYN OUT”, option “START/END”" Page 277) 

END: (>>> 9.6.14 "Inline form “SYN OUT”, option “START/END”" Page 277) 5

Distance from the switching point to the end point 

-2000 … +2000 mm This box is only displayed if PATH has been selected. 6


-1000 … +1000 ms

Note: The time specification is absolute. The switching point varies according to the velocity of the robot. Example 1

Start point is exact positioning point, end point is approximated. LIN SYN LIN LIN LIN

P1 VEL=0.3m/s DAT1 OUT 1 '' State= TRUE at START PATH=20mm Delay=-5ms P2 CONT VEL=0.3m/s DAT2 P3 CONT VEL=0.3m/s DAT3 P4 VEL=0.3m/s DAT4


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Fig. 9-24 OUT 1 specifies the approximate position at which switching is to occur. The dotted lines indicate the switching limits. M = middle of the approximate positioning range. Switching limits: 

The switching point can be brought forward, at most, as far as exact positioning point P1.



The switching point can be delayed, at most, as far as the next exact positioning point P4. If P3 was an exact positioning point, the switching point could be delayed, at most, as far as P3.

If greater values are specified for the shift in space or time, the controller automatically switches at the switching limit. Example 2

Start point and end point are approximated LIN SYN LIN LIN LIN

P1 CONT VEL=0.3m/s DAT1 OUT 1 '' State= TRUE at START PATH=20mm Delay=-5ms P2 CONT VEL=0.3m/s DAT2 P3 CONT VEL=0.3m/s DAT3 P4 VEL=0.3m/s DAT4

Fig. 9-25 OUT 1 specifies the approximate position at which switching is to occur. The dotted lines indicate the switching limits. M = middle of the approximate positioning range.

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Switching limits: 

The switching point can be brought forward, at most, as far as the start of the approximate positioning range of P1.



The switching point can be delayed, at most, as far as the next exact positioning point P4. If P3 was an exact positioning point, the switching point could be delayed, at most, as far as P3.

If greater values are specified for the shift in space or time, the controller automatically switches at the switching limit.

9.6.16

Setting a pulse on the path - SYN PULSE

Precondition

Procedure







1. Position the cursor in the line after which the logic instruction is to be inserted. 2. Select the menu sequence Commands > Logic > OUT > SYN PULSE. 3. Set the parameters in the inline form. (>>> 9.6.17 "Inline form “SYN PULSE”" Page 283) 4. Save the instruction by pressing the Cmd Ok softkey.

9.6.17

Inline form “SYN PULSE” A pulse can be triggered relative to the start or end point of a motion block. The pulse can be delayed or brought forward and shifted in space.

Fig. 9-26: Inline form "SYN PULSE" Item 1


1 … 4096 2


3


TRUE 

FALSE 4

Duration of the pulse 

0.1 … 3 s


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Item 5

Description 

START: The pulse is triggered at the start point of the motion block. 

END: The pulse is triggered at the end point of the motion block. See SYN OUT for examples and switching limits. (>>> 9.6.14 "Inline form “SYN OUT”, option “START/END”" Page 277) 

PATH: The pulse is triggered at the end point of the motion block. See SYN OUT for examples and switching limits. (>>> 9.6.15 "Inline form “SYN OUT”, option “PATH”" Page 280) 6

Distance from the switching point to the end point 

-2000 … +2000 mm This box is only displayed if PATH has been selected. 7


-1000 … +1000 ms

Note: The time specification is absolute. The switching point varies according to the velocity of the robot.

9.6.18

Modifying a logic instruction

Precondition

Procedure







1. Position the cursor in the line containing the instruction that is to be changed. 2. Press the Change softkey. The inline form for this instruction is opened. 3. Modify parameters. 4. Save changes by pressing the Cmd Ok softkey.

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10 Programming for group “Expert” (KRL syntax)

10

Programming for group “Expert” (KRL syntax) If a selected program is edited in the group “Expert”, the cursor must then be removed from the edited line and positioned in any other line! Only in this way is it certain that the editing will be applied when the program is deselected again.

10.1

Overview of KRL syntax

Variables and declarations DECL

(>>> 10.4.1 "DECL" Page 291)

ENUM

(>>> 10.4.2 "ENUM" Page 292)

IMPORT … IS

(>>> 10.4.3 "IMPORT ... IS" Page 293)

STRUC

(>>> 10.4.4 "STRUC" Page 294)

Motion programming CIRC

(>>> 10.5.5 "CIRC" Page 300)

CIRC_REL

(>>> 10.5.6 "CIRC_REL" Page 301)

LIN

(>>> 10.5.3 "LIN" Page 297)

LIN_REL

(>>> 10.5.4 "LIN_REL" Page 298)

PTP

(>>> 10.5.1 "PTP" Page 295)

PTP_REL

(>>> 10.5.2 "PTP_REL" Page 296)

SPLINE … ENDSPLINE

(>>> 10.6.1 "SPLINE ... ENDSPLINE" Page 303)

SCIRC

(>>> 10.6.4 "SCIRC" Page 304)

SLIN

(>>> 10.6.3 "SLIN" Page 304)

SPL

(>>> 10.6.2 "SPL" Page 304)

Program execution control CONTINUE

(>>> 10.7.1 "CONTINUE" Page 305)

EXIT

(>>> 10.7.2 "EXIT" Page 305)

FOR … TO … ENDFOR

(>>> 10.7.3 "FOR ... TO ... ENDFOR" Page 306)

GOTO

(>>> 10.7.4 "GOTO" Page 307)

HALT

(>>> 10.7.5 "HALT" Page 307)

IF … THEN … ENDIF

(>>> 10.7.6 "IF ... THEN ... ENDIF" Page 308)

LOOP … ENDLOOP

(>>> 10.7.7 "LOOP ... ENDLOOP" Page 308)

REPEAT … UNTIL

(>>> 10.7.8 "REPEAT ... UNTIL" Page 309)

SWITCH … CASE … ENDSWITCH

(>>> 10.7.9 "SWITCH ... CASE ... ENDSWITCH" Page 309)

WAIT … FOR

(>>> 10.7.10 "WAIT FOR" Page 311)

WAIT … SEC

(>>> 10.7.11 "WAIT SEC" Page 311)

WHILE … ENDWHILE

(>>> 10.7.12 "WHILE ... ENDWHILE" Page 311)

Inputs/outputs ANIN

(>>> 10.8.1 "ANIN" Page 312)

ANOUT

(>>> 10.8.2 "ANOUT" Page 313)

PULSE

(>>> 10.8.3 "PULSE" Page 314)

SIGNAL

(>>> 10.8.4 "SIGNAL" Page 318)


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Subprograms and functions RETURN

(>>> 10.9.1 "RETURN" Page 319)

Interrupt programming BRAKE

(>>> 10.10.1 "BRAKE" Page 320)

INTERRUPT

(>>> 10.10.3 "INTERRUPT" Page 322)

INTERRUPT … DECL … WHEN … DO

(>>> 10.10.2 "INTERRUPT ... DECL ... WHEN ... DO" Page 320)

RESUME

(>>> 10.10.4 "RESUME" Page 324)

Path-related switching actions (=Trigger) TRIGGER WHEN DISTANCE

(>>> 10.11.1 "TRIGGER WHEN DISTANCE" Page 325)

TRIGGER WHEN PATH

(>>> 10.11.2 "TRIGGER WHEN PATH" Page 328)

TRIGGER WHEN PATH (for spline)

(>>> 10.11.3 "TRIGGER WHEN PATH (for SPLINE)" Page 331)

Communication (>>> 10.12 "Communication" Page 333) System functions VARSTATE()

(>>> 10.13.1 "VARSTATE()" Page 333)

Manipulating string variables (>>> 10.14 "Editing string variables" Page 335)

10.2

Symbols and fonts The following symbols and fonts are used in the syntax descriptions: Syntax element

Representation

KRL code



Courier font



Upper-case letters

Examples: GLOBAL; ANIN ON; OFFSET Elements that must be replaced by program-specific entries



Italics



Upper/lower-case letters

Optional elements



Examples: Distance; Time; Format In angle brackets

Example: <STEP Increment> Elements that are mutually exclusive

10.3

Important KRL

10.3.1

SRC files and DAT files



Separated by the "|" symbol

Example: IN |OUT

A KRL program generally consists of an SRC file and a DAT file of the same name.

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

SRC file: contains the program code.



DAT file: contains permanent data and point coordinates. The DAT file is also called a data list. Issued: 28.10.2010 Version: KSS 5.5 SI V2 en


The SRC file and associated DAT file together are called a module. Depending on the group, programs in the Navigator are displayed as modules or individual files: 

group "" A program is displayed as a module. The SRC file and the DAT file exist in the background. They are not visible for the and cannot be edited individually.



group "Expert" By default, the SRC file and the DAT file are displayed individually. They can be edited individually.

10.3.2

Subprograms and functions Subprograms Subprograms are programs which are accessed by means of branches from the main program. Once the subprogram has been executed, the main program is resumed from the line directly after the subprogram call. 

Local subprograms are contained in the same SRC file as the main program. They can be made to be recognized globally using the keyword GLOBAL (>>> 10.3.5 "Areas of validity" Page 289).



Global subprograms are programs with a separate SRC file of their own, which is accessed from another program by means of a branch.

Functions Functions, like subprograms, are programs which are accessed by means of branches from the main program. In addition, however, they also have a data type and always return a value to the main program.

10.3.3

Naming conventions and keywords

Names

Examples of names in KRL: variable names, program names, point names 

Names in KRL can have a maximum length of 24 characters.



Names in KRL can consist of letters (A-Z), numbers (0-9) and the signs "_" and "$".



Names in KRL must not begin with a number.



Names in KRL must not be keywords.

The names of all system variables begin with the "$" sign. To avoid confusion, do not begin the names of -defined variables with this sign. Keywords

Keywords are sequences of letters having a fixed meaning. They must not be used in programs in any way other than with this meaning. No distinction is made between uppercase and lowercase letters. A keyword remains valid irrespective of the way in which it is written. Example: The sequence of letters CASE is an integral part of the KRL syntax SWITCH … CASE … ENDSWITCH. For this reason, CASE must not be used in any other way, e.g. as a variable name. The system distinguishes between reserved and non-reserved keywords: 

Reserved keywords These may only be used with their defined meaning.


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Non-reserved keywords With non-reserved keywords, the meaning is restricted to a particular context. Outside of this context, a non-reserved keyword is interpreted by the compiler as a name.

In practice, it is not helpful to distinguish between reserved and non-reserved keywords. To avoid error messages or compiler problems, keywords are thus never used other than with their defined meaning. Overview of important keywords: All elements of the KRL syntax described in this documentation that are not program-specific are keywords. The following important keywords are worth a particular mention:

10.3.4

AXIS

ENDFCT

BOOL

ENDFOR

CHAR

ENDIF

CAST_FROM

ENDLOOP

CAST_TO

ENDSWITCH

CCLOSE

ENDWHILE

CHANNEL

EXT

CIOCTL

EXTFCT

CONFIRM

FALSE

CONST

FRAME

COPEN

GLOBAL

CREAD

INT

CWRITE

MAXIMUM

DEF

MINIMUM

DEFAULT

POS

DEFDAT

PRIO

DEFFCT

PUBLIC

E6AXIS

SREAD

E6POS

SWRITE

END

REAL

ENDDAT

TRUE

Data types

Overview

There are 2 kinds of data types: 

-defined data types -defined data types are always derived from the data types ENUM or STRUC.



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Predefined data types, e.g.: 

Simple data types



Data types for motion programming



The following simple data types are predefined: Data type

Keyword

Description

Integer

INT

Integer 

-2³¹-1 … 2³¹-1

Examples: 1; 32; 345 Real

Floating-point number

REAL



+1.1E-38 … +3.4E+38

Examples: 1.43; 38.50; 300.25 Boolean

Character

Logic state

BOOL



TRUE



FALSE

1 characters

CHAR



ASCII character

Examples: "A"; "1"; "q" The following data types for motion programming are predefined: Structure type AXIS A1 to A6 are angle values (rotational axes) or translation values (translational axes) for the axis-specific movement of robot axes 1 to 6. STRUC AXIS REAL A1, A2, A3, A4, A5, A6

Structure type E6AXIS E1 to E6 are angle values or translation values of the external axes 7 to 12. STRUC E6AXIS REAL A1, A2, A3, A4, A5, A6, E1, E2, E3, E4, E5, E6

Structure type FRAME X, Y and Z are space coordinates, while A, B and C are the orientation of the coordinate system. STRUC FRAME REAL X, Y, Z, A, B, C

Structure types POS and E6POS S (Status) and T (Turn) define axis positions unambiguously. STRUC POS REAL X, Y, Z, A, B, C, INT S, T STRUC E6POS REAL X, Y, Z, A, B, C, E1, E2, E3, E4, E5, E6, INT S, T

10.3.5 Local

Areas of validity Data object

Area of validity

Variable

Valid in the program code between DEF and END containing the declaration of the variables.

Constant

Valid in the module to which the data list in which the constant was declared belongs.


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Data object -defined data type

Area of validity If the data type has been defined in an SRC file: valid at, or below, the program level in which it was declared. If the data type has been defined in a DAT file: valid in the SRC file that belongs to the DAT file.

Global

Subprogram

Valid in the main program of the shared SRC file.

Function

Valid in the main program of the shared SRC file.

Interrupt

Valid at, or below, the programming level in which it was declared.

The data objects referred to under “Local” are globally valid if they are declared using the keyword GLOBAL. 

GLOBAL can only be used for variables and -defined data types if they have been declared in a data list.



To use GLOBAL, the entry GLOBAL_KEY in the file PROGRESS.INI, in the INIT directory, must be set to TRUE: GLOBAL_KEY=TRUE

Variables and -defined data types are also globally valid if they were declared in the section GLOBALS in $CONFIG.DAT. If there are local and global variables with the same name, the compiler uses the local variable within its area of validity. Always globally valid:

Examples



The first program in an SRC file. By default, it bears the name of the SRC file.



Predefined data types



KRL system variables



Variables declared in $CONFIG.DAT

The examples show where the keyword GLOBAL must be positioned. Declaration of a global variable: GLOBAL Data type Variable name Declaration of a global subprogram: Main program

GLOBAL DEF Subprogram name ()

10.3.6

Constants The value of a constant can no longer be modified during program execution after initialization. Constants can be used to prevent a value from being changed accidentally during program execution. Constants must be declared and, at the same time, initialized in a data list. The data type must be preceded by the keyword CONST. DECL CONST Data_Type Variable_Name = Value The keyword CONST must only be used in data lists. Precondition: To use CONST, the entry CONST_KEY in the file PROGRESS.INI, in the INIT directory, must be set to TRUE: CONST_KEY=TRUE

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10.4

Variables and declarations

10.4.1

DECL

Description

Declaration of variables, arrays and constants

Syntax

Declaration of variables Declaration of variables in programs: Data_Type Name1 <, ..., NameN> Declaration of variables in data lists: Data_Type Name1 <, ..., NameN> Declaration of variables in data lists with simultaneous initialization: Data_Type Name = Value In the case of declaration with simultaneous initialization, a separate DECL declaration is required for each variable. It is not possible to declare and initialize several variables with a single DECL declaration. If a non-declared variable is used in the program, this variable is automatically assigned the default data type POS. Declaration of arrays Declaration of arrays in programs: Data_Type Name1 [Dimension1 <, ..., Dimension3> ] <, ..., NameN [DimensionN1 <,..., DimensionN3>] >

Declaration of arrays in data lists: Data_Type Name1 [Dimension1 <, ..., Dimension3> ] <, ..., NameN [DimensionN1 <,..., DimensionN3>] >

For the declaration of arrays or constant arrays in data lists with simultaneous initialization: 

It is not permissible to declare and initialize in a single line. The initialization must, however, follow directly after the line containing the declaration. There must be no lines, including blank lines, in between.



If several elements of an array are initialized, the elements must be specified in ascending sequence of the array index (starting from the right-hand array index).



If the same character string is to be assigned to all of the elements of an array of type CHAR as a default setting, it is not necessary to initialize each array element individually. The right-hand array index is omitted. (No index is written for a one-dimensional array index.)

Declaration of arrays in data lists with simultaneous initialization: Data_Type Name [Dimension1 <,..., Dimension3> ] Name [1 <, 1, 1> ] = Value1 ] = Value2> ... Name [Dimension1 <, Dimension2, Dimension3> ] = ValueN

Declaration of constant arrays in data lists with simultaneous initialization: DECL CONST Data_Type Name [Dimension1 <,..., Dimension3> ] Name [1 <, 1, 1> ] = Value1 ] = Value2>

... Name [Dimension1 <, Dimension2, Dimension3> ] = ValueN


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Element DECL

Description DECL can be omitted if Data_Type is a predefined data type. If Data_Type is a -defined data type, then DECL is obligatory.

GLOBAL

(>>> 10.3.5 "Areas of validity" Page 289)

CONST

The keyword CONST must only be used in data lists. Precondition: To use CONST, the entry CONST_KEY in the file PROGRESS.INI, in the INIT directory, must be set to TRUE: CONST_KEY=TRUE

Data type

Specification of the desired data type

Name

Name of the object (variable, array or constant) that is being declared.

Dimension

Type: INT Dimension defines the number of array elements for the dimension in question. Arrays have a minimum of 1 and a maximum of 3 dimensions.

Value

Example 1

The data type of Value must be compatible with Data_Type, but not necessarily identical. If the data types are compatible, the system automatically matches them.

Declarations with predefined data types. The keyword DECL can also be omitted. DECL INT X DECL INT X1, X2 DECL REAL ARRAY_A[7], ARRAY_B[5], A

Example 2

Declarations of arrays with simultaneous initialization (only possible in data lists). INT A[7] A[1]=27 A[2]=313 A[6]=11 CHAR TEXT1[80] TEXT1[]="message" CHAR TEXT2[2,80] TEXT2[1,]="first message" TEXT2[2,]="second message"

10.4.2

ENUM

Description

Definition of an enumeration type (= ENUM data type)

Syntax

ENUM NameEnumType Constant1<, ..., ConstantN>


Example 1

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Element GLOBAL

Description (>>> 10.3.5 "Areas of validity" Page 289)

NameEnumType

Name of the new enumeration type.

Constant

The constants are the values that a variable of the enumeration type can take. Each constant may only occur once in the definition of the enumeration type.

Recommendation: For -defined data types, assign names ending in _TYPE, to distinguish them from variable names.

Definition of an enumeration type with the name COUNTRY_TYPE.



ENUM COUNTRY_TYP SWITZERLAND, AUSTRIA, ITALY,

Declaration of a variable of type COUNTRY_TYPE: DECL COUNTRY_TYP MYCOUNTRY

Initialization of the variable of type COUNTRY_TYPE: MYCOUNTRY = #AUSTRIA

Example 2

An enumeration type with the name SWITCH_TYPE and the constants ON and OFF is defined. DEF PROG() ENUM SWITCH_TYP ON, OFF DECL SWITCH_TYP GLUE IF A>10 THEN GLUE=#ON ELSE GLUE=#OFF ENDIF END

10.4.3

IMPORT ... IS

Description

Imports a variable or a complete array from an external data list. The data object can be imported into an SRC or DAT file. Each data object that is to be imported requires its own IMPORT declaration. If an imported data object is accessed in a program, this triggers an advance run stop. Precondition for importing: The name in the DEF line in the external data list must be followed by the keyword PUBLIC. DEFDAT DataListName PUBLIC

Syntax

IMPORT DataType Name IS /R1/DataSource..NameOld The IMPORT line is a declaration and must be situated in the declaration section.


Element

Description

Data type

Data type of the data object as declared in the external data list. It is not possible to assign a different data type to the data object during importing.

Name

A different name can be assigned to the data object during importing. The original name is retained in the data source. If an array is imported, Name must be followed by square brackets. The brackets must be empty, with the exception of commas in the case of multi-dimensional arrays: 

One-dimensional array: Name[]



Two-dimensional array: Name[,]



Three-dimensional array: Name[,,]

Data source

Name of the external data list without the dot and file extension. The data objects must be imported from the data lists in which they were originally created.

NameOld

Name in the external data list of the data object to be imported. Unlike with Name, no brackets are specified for arrays.


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DataSource and NameOld are connected to one another by two periods. No

blanks may appear between the two periods. Example 1

Import of the value of the integer variable VAR from the data list DATA1. The name VAR is retained. IMPORT INT VAR IS /R1/DATA1..VAR

Example 2

Import of the two-dimensional POS array POS_EX from the data list POSITION. The name of the array must be POS1 in the new program. IMPORT POS POS1[,] IS /R1/POSITION..POS_EX

10.4.4

STRUC

Description

Definition of a structure type (= STRUC data type). Several data types are combined to form a new data type.

Syntax

STRUC NameStructureType DataType1 Component1A<, Component1B, ...> < , DataType2 Component2A<, Component2B, ...>>


Element GLOBAL

Description (>>> 10.3.5 "Areas of validity" Page 289)

NameStructureType

Name of the new structure type. The names of defined data types should end in _TYPE, to distinguish them from variable names.

Data type

TYPE: Any data type Structure types are also permissible as data types.

Component

Name of the component. It may only be used once in the structure type. Arrays can only be used as components of a structure type if they have the type CHAR and are one-dimensional. In this case, the array limit follows the name of the array in square brackets in the definition of the structure type.

Value assignment

There are 2 ways of asg values to variables based on a STRUC data type: 

Assignment of values to several components of a variable: with an aggregate



Assignment of a value to a single component of a variable: with the point separator

Information regarding the aggregate:

Example 1



The values of an aggregate can be simple constants or themselves aggregates; they may not, however, be variables (see also Example 3).



Not all components of the structure have to be specified in an aggregate.



The components do not need to be specified in the order in which they have been defined.



Each component may only be contained once in an aggregate.



The name of the structure type can be specified at the beginning of an aggregate, separated by a colon.

Definition of a structure type CAR_TYPE with the components AIR_COND, YEAR and PRICE. STRUC CAR_TYP BOOL AIR_COND, INT YEAR, REAL PRICE

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Declaration of a variable of type CAR_TYPE: DECL CAR_TYP MYCAR

Initialization of the variable MYCAR of type CAR_TYPE with an aggregate: A variable based on a structure type does not have to be initialized with an aggregate. It is also possible to initialize the components individually with the point separator. MYCAR = {CAR_TYP: PRICE 15000, AIR_COND TRUE, YEAR 2003}

Modification of an individual component using the point separator: MYCAR.AIR_COND = FALSE

Example 2

Definition of a structure type S_TYPE with the component NUMBER of data type REAL and of the array component TEXT[80] of data type CHAR. STRUC S_TYP REAL NUMBER, CHAR TEXT[80]

Example 3

Example of aggregates as values of an aggregate: STRUC INNER_TYP INT A, B, C STRUC OUTER_TYP INNER_TYP Q, R DECL OUTER_TYP MYVAR ... MYVAR = {Q {A 1, B 4}, R {A 3, C 2}}

10.5

Motion programming: PTP, LIN, CIRC

10.5.1

PTP

Description

Executes a point-to-point motion to the end point. The coordinates of the end point are absolute.

Syntax

PTP End_Point >


Element End_Point

Description Type: POS, E6POS, AXIS, E6AXIS, FRAME The end point can be specified in Cartesian or axis-specific coordinates. Cartesian coordinates refer to the BASE coordinate system. If not all components of the end point are specified, the controller takes the values of the previous position for the missing components.


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Element C_PTP

Description Causes the end point to be approximated. The specification C_PTP is sufficient for PTP-PTP approximate positioning. In the case of PTP- approximation, i.e. if the approximated PTP block is followed by a LIN or CIRC block, Approximate_Positioning must also be specified.

Approximate_ Positioning

Only for PTP- approximate positioning. This parameter defines the earliest point at which the approximate positioning can begin. The possible specifications are: 

C_DIS Distance parameter (default): Approximation starts, at the earliest, when the distance to the end point falls below the value of $APO.CDIS.



C_ORI Orientation parameter: Approximation starts, at the earliest, when the dominant orientation angle falls below the value of $APO.CORI.



C_VEL Velocity parameter: Approximation starts, at the earliest, when the velocity in the deceleration phase to the end point falls below the value of $APO.CVEL.

Example 1

End point specified in Cartesian coordinates. PTP {X 12.3,Y 100.0,Z 50,A 9.2,B 50,C 0,S ’B010’,T ’B1010’}

Example 2

End point specified in axis-specific coordinates. The end point is approximated. PTP {A1 10,A2 -80.6,A3 -50,A4 0,A5 14.2, A6 0} C_PTP

Example 3

End point specified with only 2 components. For the rest of the components, the controller takes the values of the previous position. PTP {Z 500,X 123.6}

10.5.2

PTP_REL

Description

Executes a point-to-point motion to the end point. The coordinates of the end point are relative to the current position. A REL statement always refers to the current position of the robot. For this reason, if a REL motion is interrupted, the robot executes the entire REL motion again, starting from the position at which it was interrupted.

Syntax

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PTP_REL End_Point >




Element End_Point

Description Type: POS, E6POS, AXIS, E6AXIS The end point can be specified in Cartesian or axis-specific coordinates. The controller interprets the coordinates as relative to the current position. Cartesian coordinates refer to the BASE coordinate system. If not all components of the end point are specified, the controller sets the value of the missing components to 0. In other words, the absolute values of these components remain unchanged.

C_PTP

Causes the end point to be approximated. The specification C_PTP is sufficient for PTP-PTP approximate positioning. In the case of PTP- approximation, i.e. if the approximated PTP block is followed by a LIN or CIRC block, Approximate_Positioning must also be specified.


Only for PTP- approximate positioning. This parameter defines the earliest point at which the approximate positioning can begin. The possible specifications are: 

C_DIS Distance parameter (default): Approximation starts, at the earliest, when the distance to the end point falls below the value of $APO.CDIS.







Example 1

Axis 2 is moved 30 degrees in a negative direction. None of the other axes moves. PTP_REL {A2 -30}

Example 2

The robot moves 100 mm in the X direction and 200 mm in the negative Z direction from the current position. Y, A, B, C and S remain constant. T is calculated in relation to the shortest path. PTP_REL {X 100,Z -200}

10.5.3

LIN

Description

Executes a linear motion to the end point. The coordinates of the end point are absolute.

Syntax

LIN End_Point <Approximate_Positioning>


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Element End_Point

Description Type: POS, E6POS, FRAME If not all components of the end point are specified, the controller takes the values of the previous position for the missing components. The Status and Turn specifications for an end point of type POS or E6POS are ignored in the case of LIN (and CIRC) motions. The coordinates refer to the BASE coordinate system.


This parameter causes the end point to be approximated. It also defines the earliest point at which the approximate positioning can begin. The possible specifications are: 

C_DIS Distance parameter: Approximation starts, at the earliest, when the distance to the end point falls below the value of $APO.CDIS.







Example

End point with two components. For the rest of the components, the controller takes the values of the previous position. LIN {Z 500,X 123.6}

10.5.4

LIN_REL

Description

Executes a linear motion to the end point. The coordinates of the end point are relative to the current position. A REL statement always refers to the current position of the robot. For this reason, if a REL motion is interrupted, the robot executes the entire REL motion again, starting from the position at which it was interrupted.

Syntax

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LIN_REL End_Point <Approximate_Positioning> <#BASE|#TOOL>




Element End_Point

Description Type: POS, E6POS, FRAME The end point must be specified in Cartesian coordinates. The controller interprets the coordinates as relative to the current position. The coordinates can refer to the BASE or TOOL coordinate system. If not all components of the end point are specified, the controller automatically sets the value of the missing components to 0. In other words, the absolute values of these components remain unchanged. The Status and Turn specifications for an end point of type POS or E6POS are disregarded in the case of LIN motions.










#BASE, #TOOL



#BASE Default setting. The coordinates of the end point refer to the BASE coordinate system.



#TOOL The coordinates of the end point refer to the TOOL coordinate system.

The specification of #BASE or #TOOL refers only to the corresponding LIN_REL statement. It has no effect on subsequent statements. Example 1

The T moves 100 mm in the X direction and 200 mm in the negative Z direction from the current position in the BASE coordinate system. Y, A, B, C and S remain constant. T is determined by the motion. LIN_REL {X 100,Z -200}

Example 2

The T moves 100 mm from the current position in the negative X direction in the TOOL coordinate system. Y, Z, A, B, C and S remain constant. T is determined by the motion. This example is suitable for moving the tool backwards against the tool direction. The precondition is that the tool direction has been calibrated along the X axis. LIN_REL {X -100} #TOOL


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10.5.5

CIRC

Description

Executes a circular motion. An auxiliary point and an end point must be specified in order for the controller to be able to calculate the circular motion. The coordinates of the auxiliary point and end point are absolute.

Syntax Explanation of the syntax

CIRC Auxiliary point, End point<, CA Circular angle> <Approximate positioning> Element Auxiliary point

Description Type: POS, E6POS, FRAME If not all components of the auxiliary point are specified, the controller takes the values of the previous position for the missing components. The orientation angles and the Status and Turn specifications for an auxiliary point are always disregarded. The auxiliary point cannot be approximated. The motion always stops exactly at this point. The coordinates refer to the BASE coordinate system.

End point

Type: POS, E6POS, FRAME If not all components of the end point are specified, the controller takes the values of the previous position for the missing components. The Status and Turn specifications for an end point of type POS or E6POS are ignored in the case of CIRC (and LIN) motions. The coordinates refer to the BASE coordinate system.

Circular_Angl e

Specifies the overall angle of the circular motion. This makes it possible to extend the motion beyond the programmed end point or to shorten it. The actual end point thus no longer corresponds to the programmed end point. Unit: degrees. There is no limit; in particular, a circular angle greater than 360° can be programmed.

Approximate positioning



Positive circular angle: the circular path is executed in the direction Start point › Auxiliary point › End point.



Negative circular angle: the circular path is executed in the direction Start point › End point › Auxiliary point.









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Example

The end point of the circular motion is defined by a circular angle of 260°. The end point is approximated. CIRC {X 5,Y 0, Z 9.2},{X 12.3,Y 0,Z -5.3,A 9.2,B -5,C 20}, CA 260 C_ORI

10.5.6

CIRC_REL

Description

Executes a circular motion. An auxiliary point and an end point must be specified in order for the controller to be able to calculate the circular motion. The coordinates of the auxiliary point and end point are relative to the current position. A REL statement always refers to the current position of the robot. For this reason, if a REL motion is interrupted, the robot executes the entire REL motion again, starting from the position at which it was interrupted.

Syntax

CIRC_REL Auxiliary point, End point<, CA Circular angle> <Approximate positioning>


Element Auxiliary point

Description Type: POS, E6POS, FRAME The auxiliary point must be specified in Cartesian coordinates. The controller interprets the coordinates as relative to the current position. The coordinates refer to the BASE coordinate system. If $ORI_TYPE, Status and/or Turn are specified, these specifications are ignored. If not all components of the auxiliary point are specified, the controller sets the value of the missing components to 0. In other words, the absolute values of these components remain unchanged. The orientation angles and the Status and Turn specifications for an auxiliary point are disregarded. The auxiliary point cannot be approximated. The motion always stops exactly at this point.

End point

Type: POS, E6POS, FRAME The end point must be specified in Cartesian coordinates. The controller interprets the coordinates as relative to the current position. The coordinates refer to the BASE coordinate system. If not all components of the end point are specified, the controller sets the value of the missing components to 0. In other words, the absolute values of these components remain unchanged. The Status and Turn specifications for an end point of type POS or E6POS are disregarded.


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Element

Description

Circular_Angl e

Specifies the overall angle of the circular motion. This makes it possible to extend the motion beyond the programmed end point or to shorten it. The actual end point thus no longer corresponds to the programmed end point. Unit: degrees. There is no limit; in particular, a circular angle > 360° can be programmed.

Approximate positioning



Positive circular angle: the circular path is executed in the direction Start point › Auxiliary point › End point.



Negative circular angle: the circular path is executed in the direction Start point › End point › Auxiliary point.









Example

The end point of the circular motion is defined by a circular angle of 500°. The end point is approximated. CIRC_REL {X 100,Y 3.2,Z -20},{Y 50},CA 500 C_VEL

10.6

Motion programming: spline

Overview

Step 1

Description Program the spline block. (>>> 10.6.1 "SPLINE ... ENDSPLINE" Page 303)

2

Program the spline segments. (>>> 10.6.2 "SPL" Page 304) (>>> 10.6.3 "SLIN" Page 304) (>>> 10.6.4 "SCIRC" Page 304)

3

If required, and only in the group “Expert”: Program PATH trigger. (>>> 10.11.3 "TRIGGER WHEN PATH (for SPLINE)" Page 331)

As for all motion instructions, the start point of a spline motion is the end point of the previous motion. The following components must be specified for the first point in a spline block:

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

X, Y, Z



A, B, C



E1 to E6 (if present)



Explanations of the motion type SPLINE can be found in the following section of this documentation: Programming tips relating to the motion type SPLINE can be found in the following section of this documentation: (>>> 9.3.1 "Programming tips for spline motions" Page 264)

10.6.1

SPLINE ... ENDSPLINE

Syntax

SPLINE <WITH SysVarSpline = Value> Spline-Segment

<Spline-Segment2 > … <Spline-SegmentN > ENDSPLINE Explanation of the syntax

Element

Description

SysVarSpline

The following system variables may be used:

Value

Value of the system variable. The unit and the range of values depend on the specific system variable.

$BASE, $TOOL, $IPO_MODE, $LOAD, $VEL, $VEL_EXTAX[], $ACC, $ACC_EXTAX[], $JERK (=Jerk limitation), $ORI_TYPE, $CIRC_TYPE

The values are valid for every segment in the spline block unless values are assigned separately to a segment. Description

A spline block may contain the following: 

Spline segments (only limited by the memory capacity. As a rule, at least 1,000 segments are possible.)



PATH trigger



Comments



Blank lines



Inline commands from technology packages that the spline function

A spline block must not include any other instructions, e.g. variable assignments or logic statements. A spline block does not trigger an advance run stop. Example

SPLINE SPL P1 TRIGGER WHEN PATH=GET_PATH() ONSTART DELAY=0 DO <subprog> PRIO=-1 SPL P2 SLIN P3 SPL P4 SCIRC P5, P6 WITH $VEL.=0.2 SPL P7 WITH $ACC={ 2.0, ORI1 200, ORI2 200} SCIRC P8, P9 SPL P10 ENDSPLINE


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10.6.2

SPL

Description

The robot guides the T to the end point. The robot controller selects a suitable path. This statement can only be used within a spline block.

Syntax

SPL End_Point <WITH SysVarSpl = Value>


Element End_Point

Description Type: POS, E6POS, FRAME If not all components of the end point are specified, the controller takes the values of the previous position for the missing components. The coordinates refer to the BASE coordinate system.

SysVarSpl

The following system variables may be used: $VEL, $VEL_EXTAX[], $ACC, $ACC_EXTAX[], $JERK (=Jerk limitation), $ORI_TYPE

Value

Value of the system variable. The unit and the range of values depend on the specific system variable. The assignment applies only for this spline segment. It has no effect on subsequent segments.

Example

10.6.3

SPL P4 WITH $ACC={ 2.0, ORI1 200, ORI2 200}

SLIN

Description

The robot guides the T along the shortest path to the end point. The shortest path is always a straight line. This statement can only be used within a spline block.

Syntax

SLIN End_Point <WITH SysVarSlin = Value>


Element End_Point

Description Type: POS, E6POS, FRAME If not all components of the end point are specified, the controller takes the values of the previous position for the missing components. The coordinates refer to the BASE coordinate system.

SysVarSlin

The following system variables may be used: $VEL, $VEL_EXTAX[], $ACC, $ACC_EXTAX[], $JERK (=Jerk limitation), $ORI_TYPE

Value


Example

10.6.4

SLIN P8 WITH ORI_TYPE = #IGNORE, $JERK = 30

SCIRC

Description

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The robot guides the T along a circular path to the end point. The circular path is defined by a start point, auxiliary point and end point. Issued: 28.10.2010 Version: KSS 5.5 SI V2 en


This statement can only be used within a spline block. Syntax

SCIRC Auxiliary_Point, End_Point <WITH SysVarScirc = Value>


Element

Description

Auxiliary_Po int

Type: POS, E6POS, FRAME

End_Point

Type: POS, E6POS, FRAME

The coordinates refer to the BASE coordinate system. If not all components of the end point are specified, the controller takes the values of the previous position for the missing components. The coordinates refer to the BASE coordinate system.

SysVarScirc

The following system variables may be used: $VEL, $VEL_EXTAX[], $ACC, $ACC_EXTAX[], $JERK (=Jerk limitation), $ORI_TYPE, $CIRC_TYPE

Value


Example

SCIRC P2, P3 WITH $CIRC_TYPE = #PATH

10.7

Program execution control

10.7.1

CONTINUE

Description

Prevents an advance run stop that would otherwise occur in the following program line. CONTINUE always applies to the following program line, even if this is a blank line!

Syntax

CONTINUE

Example

Preventing both advance run stops: CONTINUE $OUT[1]=TRUE CONTINUE $OUT[2]=FALSE

Caution! In this case, the outputs are set in the advance run. The exact point at which they are set cannot be foreseen.

10.7.2

EXIT

Description

Exit from a loop. The program is then continued after the loop. EXIT may be used in any loop.

Syntax

EXIT

Example

The loop is exited when $IN[1] is set to TRUE. The program is then continued after ENDLOOP.


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DEF EXIT_PROG() PTP HOME LOOP PTP POS_1 PTP POS_2 IF $IN[1] == TRUE THEN EXIT ENDIF CIRC HELP_1, POS_3 PTP POS_4 ENDLOOP PTP HOME END

10.7.3

FOR ... TO ... ENDFOR

Description

A statement block is repeated until a counter exceeds or falls below a defined value. After the last execution of the statement block, the program is resumed with the first statement after ENDFOR. The loop execution can be exited prematurely with EXIT. Loops can be nested. In the case of nested loops, the outer loop is executed completely first. The inner loop is then executed completely.

Syntax

FOR Counter = Start TO End <STEP Increment> <Statements> ENDFOR


Element Counter

Description Type: INT Variable that counts the number of times the loop has been executed. The preset value is Start. The variable must first be declared. The value of Counter can be used in statements inside and outside of the loop. Once the loop has been exited, Counter retains its most recent value.

Start; End

Type: INT Counter must be preset to the value Start. Each time the loop is executed, the value of Counter is automatically

increased by the increment. If the value exceeds or falls below the End value, the loop is terminated. Increment

Type: INT Value by which Counter is changed every time the loop is executed The value may be negative. Default value: 1. 

Positive value: the loop is ended if Counter is greater than End.



Negative value: the loop is ended if Counter is less than End.

The value may not be either zero or a variable. Example

The variable B is incremented by 1 after each of 5 times the loop is executed. INT A ... FOR A=1 TO 10 STEP 2 B=B+1 ENDFOR

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10.7.4

GOTO

Description

Unconditional jump to a specified position in the program. Program execution is resumed at this position. The destination must be in the same subprogram or function as the GOTO statement. The following jumps are not possible: 

Into an IF statement from outside.



Into a loop from outside.



From one CASE statement to another CASE statement.

GOTO statements lead to a loss of structural clarity within a program. It is better to work with IF, SWITCH or a loop instead. Syntax

GOTO Marker ... Marker:


Example 1

Element Marker

Description Position to which a jump is made. At the destination position, Marker must be followed by a colon.

Unconditional jump to the program position GLUESTOP. GOTO GLUESTOP ... GLUESTOP:

Example 2

Unconditional jump from an IF statement to the program position END. IF X>100 THEN GOTO ENDE ELSE X=X+1 ENDIF A=A*X ... ENDE: END

10.7.5

HALT

Description

Stops the program. The last motion instruction to be executed will, however, be completed. Execution of the program can only be resumed using the Start key. The next instruction after HALT is then executed. In an interrupt program, program execution is only stopped after the advance run has been completely executed.

Syntax

HALT


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10.7.6

IF ... THEN ... ENDIF

Description

Conditional branch. Depending on a condition, either the first statement block (THEN block) or the second statement block (ELSE block) is executed. The program is then continued after ENDIF. The ELSE block may be omitted. If the condition is not satisfied, the program is then continued at the position immediately after ENDIF. There is no limit on the number of statements contained in the statement blocks. Several IF statements can be nested in each other.

Syntax

IF Condition THEN Statements

<ELSE Statements>

ENDIF Explanation of the syntax

Element Condition

Description Type: BOOL Possible:

Example 1



Variable of type BOOL



Function of type BOOL



Logic operation, e.g. a comparison, with a result of type BOOL

IF statement without ELSE IF A==17 THEN B=1 ENDIF

Example 2

IF statement with ELSE IF $IN[1]==TRUE THEN $OUT[17]=TRUE ELSE $OUT[17]=FALSE ENDIF

10.7.7

LOOP ... ENDLOOP

Description

Loop that endlessly repeats a statement block. The loop execution can be exited with EXIT. Loops can be nested. In the case of nested loops, the outer loop is executed completely first. The inner loop is then executed completely.

Syntax

LOOP Statements

ENDLOOP Example

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The loop is executed until input $IN[30] is set to true.



LOOP LIN P_1 LIN P_2 IF $IN[30]==TRUE THEN EXIT ENDIF ENDLOOP

10.7.8

REPEAT ... UNTIL

Description

Non-rejecting loop. Loop that is repeated until a certain condition is fulfilled. The statement block is executed at least once. The condition is checked after each loop execution. If the condition is met, program execution is resumed at the first statement after the UNTIL line. Loops can be nested. In the case of nested loops, the outer loop is executed completely first. The inner loop is then executed completely.

Syntax

REPEAT Statements

UNTIL Termination condition Explanation of the syntax

Element Termination condition

Description Type: BOOL Possible: 







Example 1


The loop is to be executed until $IN[1] is true. R=1 REPEAT R=R+1 UNTIL $IN[1]==TRUE

Example 2

The loop is executed once, even though the termination condition is already fulfilled before the loop execution, because the termination condition is not checked until the end of the loop. After execution of the loop, R has the value 102. R=101 REPEAT R=R+1 UNTIL R>100

10.7.9

SWITCH ... CASE ... ENDSWITCH

Description

Selects one of several possible statement blocks, according to a selection criterion. Every statement block has at least one identifier. The block whose identifier matches the selection criterion is selected. Once the block has been executed, the program is resumed after ENDSWITCH. If no identifier agrees with the selection criterion, the DEFAULT block is executed. If there is no DEFAULT block, no block is executed and the program is resumed after ENDSWITCH.


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The SWITCH statement cannot be prematurely exited using EXIT. Syntax

SWITCH Selection_Criterion CASE Identifier1 <,Identifier2,...> Statement block

Statement block >

ENDSWITCH There must be no blank line or comment between the SWITCH line and the first CASE line. DEFAULT may only occur once in a SWITCH statement. Explanation of the syntax

Element

Description

Selection_Crit erion

Type: INT, CHAR, ENUM

Identifier

Type: INT, CHAR, ENUM

This can be a variable, a function call or an expression of the specified data type. The data type of the identifier must match the data type of the selection criterion. A statement block can have any number of identifiers. Multiple block identifiers must be separated from each other by a comma.

Example 1

Selection criterion and identifier are of type INT. INT VERSION ... SWITCH VERSION CASE 1 UP_1() CASE 2,3 UP_2() UP_3() UP_3A() DEFAULT ERROR_UP() ENDSWITCH

Example 2

Selection criterion and identifier are of type CHAR. The statement SP_5() is never executed here because the identifier C has already been used. SWITCH NAME CASE "A" UP_1() CASE "B","C" UP_2() UP_3() CASE "C" UP_5() ENDSWITCH

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10.7.10 WAIT FOR Description

Stops the program until a specified condition is fulfilled. Program execution is then resumed. If, due to incorrect formulation, the expression can never take the value TRUE, the compiler does not recognize this. In this case, execution of the program will be permanently halted because the program is waiting for a condition that cannot be fulfilled.


WAIT FOR Condition Element Condition

Description Type: BOOL Condition, the fulfillment of which allows program execution to be resumed.

Example



If the condition is already TRUE when WAIT is called, program execution is not halted.



If the condition is FALSE, program execution is stopped until the condition is TRUE.

Interruption of program execution until $IN[17] is TRUE: WAIT FOR $IN[17]

Interruption of program execution until BIT1 is FALSE: WAIT FOR BIT1==FALSE

10.7.11 WAIT SEC Description

Halts execution of the program and continues it after a wait time. The wait time is specified in seconds.

Syntax

WAIT SEC Wait_Time


Element Wait_Time

Description Type: INT, REAL Number of seconds for which program execution is to be interrupted. If the value is negative, the program does not wait. With small wait times, the accuracy is determined by a multiple of 12 ms.

Example

Interruption of program execution for 17.156 seconds: WAIT SEC 17.156

Interruption of program execution in accordance with the variable value of V_WAIT in seconds: WAIT SEC V_ZEIT

10.7.12 WHILE ... ENDWHILE Description

Rejecting loop. Loop that is repeated as long as a certain condition is fulfilled. If the condition is not met, program execution is resumed at the first statement after the ENDWHILE line. The condition is checked before each loop execu-


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tion. If the condition is not already fulfilled beforehand, the statement block is not executed. Loops can be nested. In the case of nested loops, the outer loop is executed completely first. The inner loop is then executed completely. Syntax

WHILE Repetition_Condition Statement block

ENDWHILE Explanation of the syntax

Example 1

Element Repetition_C ondition

Description Type: BOOL Possible: 








The loop is executed 99 times. After execution of the loop, W has the value 100. W=1 WHILE W<100 W=W+1 ENDWHILE

Example 2

The loop is executed as long as $IN[1] is true. WHILE $IN[1]==TRUE W=W+1 ENDWHILE

10.8

Inputs/outputs

10.8.1

ANIN

Description

Cyclical reading (every 12 ms) of an anaput. ANIN triggers an advance run stop.

Syntax

Starting cyclical reading: ANIN ON Value = Factor * Signal_Name * < ±Offset > Ending cyclical reading: ANIN OFF Signal_Name

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

A maximum of three ANIN ON statements can be used at the same time.



A maximum of two ANIN ON statements can use the same variable Value or access the same anaput.



All of the variables used in an ANIN statement must be declared in data lists (locally or in $CONFIG.DAT).



The robot controller has 32 anaputs ($ANIN[1] … $ANIN[32]).




Element

Description Type: REAL The result of the cyclical reading is stored in Value. Value can be a variable or a signal name for an output.

Value

Type: REAL Factor

Any factor. It can be a constant, variable or signal name. Type: REAL

Signal_Name

Specifies the anaput. Signal_Name must first have been declared with SIGNAL . It is not possible to specify the anaput $ANIN[x] directly instead of the signal name. The values of an anaput $ANIN[x] range between +1.0 and -1.0 and represent a voltage of +10 V to -10 V. Type: REAL

Offset

Example

It can be a constant, variable or signal name.

In this example, the program override (= system variable $OV_PRO) is defined by means of the anaput $ANIN[1]. $ANIN[1] must first be linked to a freely selected signal name, in this case SIGNAL_1, in the declaration section. SIGNAL SIGNAL_1 $ANIN[1] ... ANIN ON $OV_PRO = 1.0 * SIGNAL_1

The cyclical scanning of SIGNAL_1 is ended using the ANIN OFF statement. ANIN OFF SIGNAL_1

10.8.2

ANOUT

Description

Cyclical writing (every 12 ms) to an analog output. ANOUT triggers an advance run stop.

Syntax

Starting cyclical writing: ANOUT ON Signal_Name = Factor * Control_Element <±Offset> <MINIMUM = Minimum_Value> <MAXIMUM = Maximum_Value> Ending cyclical writing: ANOUT OFF Signal_Name 

A maximum of four ANOUT ON statements can be used at the same time.



All of the variables used in an ANOUT statement must be declared in data lists (locally or in $CONFIG.DAT).



The robot controller has 32 analog outputs ($ANOUT[1] … $ANOUT[32]).


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Element Signal_Name

Description Type: REAL Specifies the analog output. Signal_Name must first have been declared with SIGNAL . It is not possible to specify the analog output $ANOUT[x] directly instead of the signal name. The values of an analog output $ANOUT[x] range between +1.0 and -1.0 and represent a voltage of +10 V to -10 V.

Factor

Type: REAL Any factor. It can be a constant, variable or signal name.

Control_Element

Type: REAL

Offset

Type: REAL

It can be a constant, variable or signal name. It can be a constant, variable or signal name.

Time

Type: REAL Unit: seconds. By using the keyword DELAY and entering a positive or negative amount of time, the output signal can be delayed (+) or set early (-).

Minimum_Val ue, Maximum_Value

Type: REAL Minimum and/or maximum voltage to be present at the output. The actual value does not fall below/exceed these values, even if the calculated values fall outside this range. Permissible values: -1.0 to +1.0 (corresponds to -10 V to +10 V). It can be a constant, variable, structure component or array element. The minimum value must always be less than the maximum value. The sequence of the keywords MINIMUM and MAXIMUM must be observed.

Example

In this example, the output $ANOUT[5] controls the adhesive output. A freely selected name, in this case GLUE, is assigned to the analog output in the declaration section. The amount of adhesive is to be dependent on the current path velocity (= system variable $VEL_ACT). Furthermore, the output signal is to be generated 0.5 seconds early. The minimum voltage is to be 3 V. SIGNAL GLUE $ANOUT[5] ... ANOUT ON GLUE = 0.5 * $VEL_ACT DELAY=-0.5 MINIMUM=0.30

The cyclical analog output is ended by using ANOUT OFF: ANOUT OFF GLUE

10.8.3

PULSE

Description Sets a pulse. The output is set to a defined level for a specified duration. The output is then reset automatically by the system. The output is set and reset irrespective of the previous level of the output. At any one time, pulses may be set at a maximum of 16 outputs. If PULSE is programmed before the first motion block, the pulse duration also elapses if the Start key is released again and the robot has not yet reached the BCO position.

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The PULSE statement triggers an advance run stop. It is only executed concurrently with robot motion if it is used in a TRIGGER statement. The pulse is not terminated in the event of an EMERGENCY STOP, an operator stop or an error stop! Syntax PULSE ( Signal, Level, Pulse_Duration ) Explanation of the syntax

Element

Description Type: BOOL

Signal

Output to which the pulse is to be fed. The following are permitted: 

OUT[No]



Signal variable

Type: BOOL Level

Logical expression: 

TRUE represents a positive pulse (high).



FALSE represents a negative pulse (low).

Type: REAL Pulse duration

Range of values: 0.1 to 3.0 seconds. Pulse durations outside this range trigger a program stop. Pulse interval: 0.1 seconds, i.e. the pulse duration is rounded up or down. The PULSE statement is executed in the controller at the low-priority clock rate. This results in a tolerance in the order of the pulse interval (0.1 seconds). The time deviation is about 1% - 2% on average. The deviation is about 13% for very short pulses.

$OUT+PULSE

If an output is already set before the pulse, it will be reset by the falling edge of the pulse. $OUT[50] = TRUE PULSE($OUT[50],TRUE,0.5) Actual pulse characteristic at output 50

Fig. 10-1: $OUT+PULSE, example 1 If a negative pulse is applied to an output that is set to Low, the output remains Low until the end of the pulse and is then set to High: $OUT[50] = FALSE PULSE($OUT[50],FALSE,0.5) Actual pulse characteristic at output 50


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Fig. 10-2: $OUT+PULSE, example 2 PULSE+$OUT

If the same output is set during the pulse duration, it will be reset by the falling edge of the pulse. PULSE($OUT[50],TRUE,0.5) $OUT[50] = TRUE Actual pulse characteristic at output 50

Fig. 10-3: PULSE+$OUT, example 1 If the output is reset during the pulse duration, the pulse duration is reduced accordingly: PULSE($OUT[50],TRUE,0.5) $OUT[50] = FALSE Actual pulse characteristic at output 50

Fig. 10-4: PULSE+$OUT, example 2 If an output is set to FALSE during a pulse and then back to TRUE, the pulse is interrupted and then resumed when the output is set to TRUE. The overall duration from the first rising edge to the last falling edge (i.e. including the duration of the interruption) corresponds to the duration specified in the PULSE statement. PULSE($OUT[50],TRUE,0.8) $OUT[50]=FALSE $OUT[50]=TRUE Actual pulse characteristic at output 50

Fig. 10-5: PULSE+$OUT, example 3

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The actual pulse characteristic is only specified as above if $OUT[x]=TRUE is set during the pulse. If $OUT[x]=TRUE is not set until after the pulse (see line 3), then the actual pulse characteristic is as follows (line 4):

Fig. 10-6: PULSE+$OUT, example 4 PULSE+PULSE

If several PULSE statements overlap, it is always the last PULSE statement that determines the end of the overall pulse duration. If a pulse is activated again before the falling edge, the duration of the second pulse starts at this moment. The overall pulse duration is thus shorter than the sum of the values of the first and second pulses: PULSE($OUT[50],TRUE,0.5) PULSE($OUT[50],TRUE,0.5) Actual pulse characteristic at output 50

Fig. 10-7: PULSE+PULSE, example 1 If, during the pulse duration of a positive pulse, a negative pulse is sent to the same output, only the second pulse is taken into consideration from this moment onwards: PULSE($OUT[50],TRUE,0.5) PULSE($OUT[50],FALSE,0.5) Actual pulse characteristic at output 50

Fig. 10-8: PULSE+PULSE, example 2 PULSE($OUT[50],TRUE,3) PULSE($OUT[50],FALSE,1) Actual pulse characteristic at output 50

Fig. 10-9: PULSE+PULSE, example 3


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PULSE+END

If a pulse is programmed before the END statement, the duration of program execution is increased accordingly. PULSE($OUT[50],TRUE,0.8) END Program active Actual pulse characteristic at output 50

Fig. 10-10: PULSE+END, example PULSE+RESET/ CANCEL

If program execution is reset (RESET) or aborted (CANCEL) while a pulse is active, the pulse is immediately reset: PULSE($OUT[50],TRUE,0.8) RESET or CANCEL Actual pulse characteristic at output 50

Fig. 10-11: PULSE+RESET, example

10.8.4

SIGNAL

Description

SIGNAL declarations must appear in the declaration section. 

SIGNAL links predefined signal variables for inputs or outputs with a name. A SIGNAL declaration is required in order to be able to address an anaput or output. An input or output may appear in several SIGNAL declarations.



SIGNAL declarations that are predefined in the system can be deactivated by means of SIGNAL in conjunction with the keyword FALSE. Can only be used in KRC:\STEU:\MADA:\$machine.dat.

Syntax

Declaration of signal names for inputs and outputs: SIGNAL Signal name Signal variable Deactivation of a SIGNAL declaration predefined in the system: SIGNAL System signal name FALSE

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Element

Description

Signal name

Any name

Signal variable

Predefined signal variable. The following types are available: 

$IN[x]



$OUT[x]



$ANIN[x]



$ANOUT[x]

TO

Groups together several consecutive binary inputs or outputs (max. 32) to form a digital input or output. The combined signals can be addressed with a decimal name, a hexadecimal name (prefix H) or with a bit pattern name (prefix B). They can also be processed with Boolean operators.

System signal name

Signal name predefined in the system, e.g. $T1.

FALSE

Deactivates a SIGNAL declaration predefined in the system. The inputs or outputs to which the SIGNAL declaration refers are thus available again for other purposes. FALSE is not a Boolean value here, but a keyword. The option TRUE is not available. If the SIGNAL declaration that has been deactivated by means of FALSE is to be reactivated, the program line containing the entry FALSE must be deleted.

Example 1

The output $OUT[7] is assigned the name START_PROCESS. The output $OUT[7] is set. SIGNAL START_PROCESS $OUT[7] START_PROCESS = TRUE

Example 2

The outputs $OUT[1] to $OUT[8] are combined to form one digital output under the name OUTWORT. The outputs $OUT[3], $OUT[4], $OUT[5] and $OUT[7] are set. SIGNAL OUTWORT $OUT[1] TO $OUT[8] OUTWORT = 'B01011100'

10.9

Subprograms and functions

10.9.1

RETURN

Description

Jump from a subprogram or function back to the program from which the subprogram or function was called. Subprograms RETURN can be used to return to the main program if a certain condition is met in the subprogram. No values from the subprogram can be transferred to the main program. Functions Functions must be ended by a RETURN statement containing the value that has been determined. The determined value is hereby transferred to the program from which the function was called.

Syntax

For subprograms: RETURN


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For functions: RETURN Function_Value Explanation of the syntax

Element

Description

Function_Val ue

Type: The data type of Function_Value must match the data type of the function. Function_Value is the value determined by the function. The value can be specified as a constant, a variable or an expression.

Example 1

Return from a subprogram to the program from which it was called, dependent on a condition. DEF PROG_2() ... IF $IN[5]==TRUE THEN RETURN ... END

Example 2

Return from a function to the program from which it was called. The value X is transferred. DEFFCT INT CALCULATE(X:IN) INT X X=X*X RETURN X ENDFCT

10.10

Interrupt programming

10.10.1 BRAKE Description

Brakes the robot motion. BRAKE may only be used in an interrupt program. The interrupt program is not continued until the robot has come to a stop. The robot motion is resumed as soon as the interrupt program has been completed.


BRAKE Element F

Description F triggers a STOP 1. In the case of a BRAKE statement without F, the robot brakes with a STOP 2.

Example

(>>> 10.10.3 "INTERRUPT" Page 322)

10.10.2 INTERRUPT ... DECL ... WHEN ... DO Description

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In the case of a defined event, e.g. an input, the controller interrupts the current program and executes a defined subprogram. The event and the subprogram are defined by INTERRUPT ... DECL ... WHEN ... DO.



Once the subprogram has been executed, the interrupted program is resumed at the point at which it was interrupted. Exception: RESUME (>>> 10.10.4 "RESUME" Page 324). A subprogram called by an interrupt is called an interrupt program. A maximum of 32 interrupts may be declared simultaneously. An interrupt declaration may be overwritten by another at any time. The interrupt declaration is a statement. It must be situated in the statements section of the program and not in the declaration section! When first declared, an interrupt is deactivated. The interrupt must be activated before the system can react to the defined event! (>>> 10.10.3 "INTERRUPT" Page 322) Syntax INTERRUPT DECL Prio WHEN Event DO Subprogram Explanation of the syntax

Element

Description An interrupt is only recognized at, or below, the level in which it is declared. In other words, an interrupt declared in a subprogram is not recognized in the main program (and cannot be activated there). If an interrupt is also to be recognized at higher levels, the declaration must be preceded by the keyword GLOBAL.

GLOBAL

Type: INT Prio

If several interrupts occur at the same time, the interrupt with the highest priority is processed first, then those of lower priority. 1 = highest priority. Priorities 1, 2, 4 to 39 and 81 to 128 are available. Note: Priorities 3 and 40 to 80 are reserved for use by the system. They must not be used by the because this would cause system-internal interrupts to be overwritten and result in errors. Type: BOOL

Event

Subprogram

Event that is to trigger the interrupt. Structure components are impermissible. The following are permitted: 

a Boolean constant



a Boolean variable



a signal name



a comparison



a simple logic operation: NOT, OR, AND or EXOR

The name of the interrupt program to be executed. Runtime variables may not be transferred to the interrupt program as parameters, with the exception of variables declared in a data list.



GLOBAL can only be used for variables and -defined data types if they have been declared in a data list.



To use GLOBAL, the entry GLOBAL_KEY in the file PROGRESS.INI, in the INIT directory, must be set to TRUE: GLOBAL_KEY=TRUE


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Example 1

Declaration of an interrupt with priority 23 that calls the subprogram SP1 if $IN[12] is true. The parameters 20 and VALUE are transferred to the subprogram. INTERRUPT DECL 23 WHEN $IN[12]==TRUE DO UP1(20,WERT)

Example 2

Two objects, the positions of which are detected by two sensors connected to inputs 6 and 7, are located on a programmed path. The robot is to be moved subsequently to these two positions. For this purpose, the two detected positions are saved as points P_1 and P_2. These points are then addressed in the second section of the main program. If the robot controller detects an event defined by means of INTERRUPT ... DECL ... WHEN ... DO, it always saves the current robot position in the system variables $AXIS_INT (axis-specific) and $POS_INT (Cartesian). Main program: DEF PROG() ... INTERRUPT DECL 10 WHEN $IN[6]==TRUE DO UP1() INTERRUPT DECL 20 WHEN $IN[7]==TRUE DO UP2() ... INTERRUPT ON LIN START LIN END INTERRUPT OFF LIN P_1 LIN P_2 ... END

Local interrupt program 1: DEF UP1() P_1=$POS_INT END

Local interrupt program 2: DEF UP2() P_2=$POS_INT END

10.10.3 INTERRUPT Description

Executes one of the following actions: 

Activates an interrupt.



Deactivates an interrupt.



Disables an interrupt.



Enables an interrupt.

The interrupt must previously have been declared. (>>> 10.10.2 "INTERRUPT ... DECL ... WHEN ... DO" Page 320) Syntax

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INTERRUPT Action




Element Action

Number

Description 

ON: Activates an interrupt.



OFF: Deactivates an interrupt.



DISABLE: Disables an activated interrupt.



ENABLE: Enables a disabled interrupt.

Type: INT Number (= priority) of the interrupt to which the Action is to refer. Number can be omitted. In this case, ON or OFF refers to all

declared interrupts, while DISABLE or ENABLE refers to all active interrupts. Up to 16 interrupts may be active at any one time. In this regard, particular attention must be paid to the following: 

If, in the case of INTERRUPT ON, the Number is omitted, all declared interrupts are activated. The maximum permissible total of 16 may not be exceeded, however.



If a trigger calls a subprogram, it counts as an active interrupt until the subprogram has been executed.

If, in the interrupt declaration, a Boolean variable, e.g. an input, has been defined as the Event: 

In this case, the interrupt is triggered by a change of state, e.g. in the case of $IN[x]==TRUE by the change from FALSE to TRUE. The state must therefore not already be present at INTERRUPT ON, as the interrupt is not then triggered!



Furthermore, the following must also be considered in this case: the change of state must not occur until at least one interpolation cycle after INTERRUPT ON. (This can be achieved by programming a WAIT SEC 0.012 after INTERRUPT ON. If no advance run stop is desired, a CONTINUE command can also be programmed before the WAIT SEC.) The reason for this is that INTERRUPT ON requires one interpolation cycle (= 12 ms) before the interrupt is actually activated. If the state changes before this, the interrupt cannot detect the change.

Example 1

The interrupt with priority 2 is activated. (The interrupt must already be declared.) INTERRUPT ON 2

Example 2

A non-path-maintaining EMERGENCY STOP is executed via the hardware during application of adhesive. The application of adhesive is stopped by the program and the adhesive gun is repositioned onto the path after enabling (by input 10). DEF PROG() ... INTERRUPT DECL 1 WHEN $STOPMESS DO STOP_PROG() LIN P_1 INTERRUPT ON LIN P_2 INTERRUPT OFF ... END


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DEF STOP_PROG() BRAKE F GLUE=FALSE WAIT FOR $IN[10] LIN $POS_RET GLUE=TRUE END

10.10.4 RESUME Description

RESUME may only occur in an interrupt program. RESUME cancels all running interrupt programs and subprograms up to the level at which the current interrupt was declared. When the RESUME statement is activated, the advance run pointer must not be at the level where the interrupt was declared, but at least one level lower. Changing the variable $BASE in the interrupt program only has an effect there. The computer advance run, i.e. the variable $ADVANCE, must not be modified in the interrupt program. The behavior of the robot controller after RESUME depends on the following motion instruction: 

PTP instruction: is executed as a PTP motion.



LIN instruction: is executed as a LIN motion.



CIRC instruction: is always executed as a LIN motion! Following a RESUME statement, the robot is not situated at the original start point of the CIRC motion. The motion will thus differ from how it was originally planned; this can potentially be very dangerous, particularly in the case of CIRC motions.

Warning! If the first motion instruction after RESUME is a CIRC motion, this is always executed as LIN! This must be taken into consideration when programming RESUME statements. The robot must be able to reach the end point of the CIRC motion safely, by means of a LIN motion, from any position in which it could find itself when the RESUME statement is executed. Failure to observe this may result in death to persons, physical injuries or damage to property. Syntax

RESUME

Example

The robot is to search for a part on a path. The part is detected by means of a sensor at input 15. Once the part has been found, the robot is not to continue to the end point of the path, but to return to the interrupt position and pick up the part. The main program is then to be resumed. Motions that are to be canceled by means of BRAKE and RESUME must be programmed in a subprogram. (Here SEARCH().) Main program: DEF PROG() INI ... INTERRUPT DECL 21 WHEN $IN[15] DO FOUND() PTP HOME ... SEARCH() $ADVANCE=3 ... END

Subprogram with search path: 324 / 403



When the RESUME statement is activated, the advance run pointer must not be at the level where the current interrupt was declared. To prevent this, the advance run is set to 0 here in the subprogram. DEF SEARCH() INTERRUPT ON 21 LIN START_SEARCH LIN END_SEARCH $ADVANCE=0 ... END

Interrupt program: LIN $POS_INT is the return motion to the position at which the interrupt was triggered. After LIN $POS_INT (in the example: …), the robot grips the part. RESUME causes the main program to be resumed after the part has been gripped. Without the RESUME statement, the subprogram SEARCH would be resumed after END. DEF FOUND() INTERRUPT OFF BRAKE LIN $POS_INT ... RESUME END

10.11

Path-related switching actions (=Trigger)

10.11.1 TRIGGER WHEN DISTANCE Description

The Trigger triggers a defined statement. The statement refers to the start point or end point of the motion block in which the Trigger is situated in the program. The statement is executed parallel to the robot motion. The statement can be shifted in time. It is then not triggered exactly at the start or end point, but brought forward or delayed.

Syntax

TRIGGER WHEN DISTANCE=Position DELAY=Time DO Statement


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Element Position

Description Type: INT; variable or constant Defines the point at which the statement is triggered. Possible values: 0 or 1.

Time



0: The statement is triggered at the start point of the motion block. If the start point is approximated, the statement is triggered at the end of the approximate positioning arc.



1: The statement is triggered at the end point. If the end point is approximated, the statement is triggered in the middle of the approximate positioning arc.

Type: REAL; variable or constant; unit: ms Shifts the statement in time. Obligatory specification: if no time shift is desired, set Time = 0. The statement cannot be shifted freely in time. The shifts that are available depend on the value selected for Position: 

Position = 0 (start point) In this case, the statement can only be triggered with a delay, i.e. it is only possible to select a positive value for Time. The statement can be delayed, at most, as far as the end point. If the end point is approximated, the statement can be delayed, at most, as far as the start of the approximate positioning arc.



Position = 1 (end point) In this case, a distinction must be made as to whether the end point is an exact positioning point or an approximate positioning point.

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

Exact positioning point: In this case, the statement can only be triggered earlier, i.e. it is only possible to select a negative value for Time. The statement can be brought forward, at most, as far as the start point. If the start point is approximated, the statement can be brought forward, at most, as far as the end of the approximate positioning arc.



Approximate positioning point: In this case, the statement can be triggered earlier or with a delay, i.e. it is possible to select a negative or positive value for Time. The statement can be shifted, at most, as far as the start or end of the approximate positioning arc of the end point.



Element Statement

Priority

Description Possible: 

Assignment of a value to a variable



OUT statement



PULSE statement



subprogram call. In this case, Priority must be specified.

Type: INT; variable or constant Priority of the trigger. Only relevant if Statement calls a subprogram, and then obligatory. Priorities 1, 2, 4 to 39 and 81 to 128 are available. Priorities 3 and 40 to 80 are reserved for cases in which the priority is automatically assigned by the system. If the priority is to be assigned automatically by the system, the following is programmed: PRIO = -1. If several triggers call subprograms at the same time, the trigger with the highest priority is processed first, then the triggers of lower priority. 1 = highest priority.

If a trigger calls a subprogram, it counts as an active interrupt until the subprogram has been executed. Up to 16 interrupts may be active at any one time. System variables

Example 1

Useful system variables for working with triggers: System variable

Data type

Description

$DIST_NEXT

REAL

Distance to next point. Value is negative or 0. This system variable can be used for teaching triggers.

$DISTANCE

REAL

Overall length of current motion

130 milliseconds after P_2, $OUT[8] is set to TRUE. LIN P_2 TRIGGER WHEN DISTANCE=0 DELAY=130 DO $OUT[8]=TRUE LIN P_3

Example 2

In the middle of the approximate positioning arc of P_5, the subprogram MY_SUBPROG with priority 5 is called. PTP P_4 TRIGGER WHEN DISTANCE=1 DELAY=0 DO MY_SUBPROG() PRIO=5 PTP P_5 C_DIS

Example 3

Explanation of the diagram: In the diagram, the approximate positions in which the Triggers would be triggered are indicated by arrows. In addition to these points, the start, middle and end of each approximate positioning arc are indicated.


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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

DEF PROG() ... PTP P_0 TRIGGER WHEN DISTANCE=0 ... TRIGGER WHEN DISTANCE=1 ... LIN P_1 TRIGGER WHEN DISTANCE=0 ... TRIGGER WHEN DISTANCE=1 ... LIN P_2 C_DIS TRIGGER WHEN DISTANCE=0 ... TRIGGER WHEN DISTANCE=1 ... LIN P_3 C_DIS TRIGGER WHEN DISTANCE=0 ... TRIGGER WHEN DISTANCE=1 ... LIN P_4 ... END

DELAY=40 DO A=12 DELAY=-20 DO UP1() PRIO=10

DELAY=10 DO UP2(A) PRIO=5 DELAY=15 DO B=1

DELAY=10 DO UP2(B) PRIO=12 DELAY=0 DO UP(A,B,C) PRIO=6

DELAY=50 DO UP2(A) PRIO=4 DELAY=-80 DO A=0

Line

Description

4

Switching range: 0 - 1

6

Switching range: 0 - 1

9

Switching range: 1 - 2*start

11

Switching range: 2*start - 2*end

14

Switching range: 2*end - 3*start

16

Switching range: 3*start - 3*end

19

Switching range: 3*end - 4

21

Switching range: 3*end - 4

Fig. 10-12: Example of TRIGGER WHEN DISTANCE

10.11.2 TRIGGER WHEN PATH Description

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The Trigger triggers a defined statement. The statement refers to the end point of the motion block in which the Trigger is situated in the program. It is possible Issued: 28.10.2010 Version: KSS 5.5 SI V2 en


to shift the statement in time and/or space so that it is not triggered exactly at the end point, but before or after it. The end point must be LIN or CIRC. It must not be PTP. The statement is executed parallel to the robot motion. Syntax

TRIGGER WHEN PATH =Distance DELAY=Time DO Statement


Element Distance

Description Type: REAL; variable or constant; unit: mm Obligatory specification. If no shift in space is desired, set Distance = 0. If the statement is to be shifted in space, the desired distance from the end point must be specified here. If this end point is approximated, Distance is the distance to the position on the approximate positioning arc closest to the end point. 

Positive value: shifts the statement towards the end of the motion.



Negative value: shifts the statement towards the start of the motion.

The statement cannot be shifted freely. Maximum possible shift: see below, section “Switching range”. Time

Type: REAL; variable or constant; unit: ms Obligatory specification. If no shift in time is desired, set Time = 0. If the statement is to be shifted in time (relative to PATH), the desired duration must be specified here. 





The statement cannot be shifted freely. Maximum possible shift: see below, section “Switching range”.


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Element Statement

Description Possible: 




OUT statement



PULSE statement



subprogram call. In this case, Priority must be specified.

Type: INT; variable or constant

Priority

Priority of the trigger. Only relevant if Statement calls a subprogram, and then obligatory. Priorities 1, 2, 4 to 39 and 81 to 128 are available. Priorities 3 and 40 to 80 are reserved for cases in which the priority is automatically assigned by the system. If the priority is to be assigned automatically by the system, the following is programmed: PRIO = -1. If several triggers call subprograms at the same time, the trigger with the highest priority is processed first, then the triggers of lower priority. 1 = highest priority. If a trigger calls a subprogram, it counts as an active interrupt until the subprogram has been executed. Up to 16 interrupts may be active at any one time. System variables

Switching range

Useful system variables for working with triggers:



System variable

Data type

Description

$DIST_NEXT

REAL


$DISTANCE

REAL

Overall length of current motion

Shift towards the end of the motion: A statement can be shifted, at most, as far as the next exact positioning point after TRIGGER WHEN PATH (skipping all approximate positioning points).

In other words, if the end point is an exact positioning point, the statement cannot be shifted beyond the end point. 

Shift towards the start of the motion: A statement can be shifted, at most, as far as the start point of the motion block (i.e. as far as the last point before TRIGGER WHEN PATH). If the start point is an approximated LIN or CIRC point, the statement can be brought forward, at most, as far as the start of its approximate positioning arc. If the start point is an approximated PTP point, the statement can be brought forward, at most, as far as the end of its approximate positioning arc.

Example

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LIN P_2 TRIGGER LIN P_3 LIN P_4 LIN P_5

C_DIS WHEN PATH = -20.0 DELAY= -10 DO $OUT[2]=TRUE C_DIS C_DIS



In the diagram, the approximate position in which the $OUT[2]=TRUE statement would be triggered is indicated by an arrow.

Fig. 10-13: Example of TRIGGER WHEN PATH Switching range: P_2*start to P_5. If P_2 were not approximated, the switching range would be P_2 to P_5. The switching range goes to P_5 because P_5 is the next exact positioning point after the TRIGGER statement. If P_3 were not approximated, the switching range would be P_2 to P_3, as P_3 is the next exact positioning point in the program after the Trigger statement.

10.11.3 TRIGGER WHEN PATH (for SPLINE) Description

This trigger can only be used in spline blocks. The Trigger triggers a defined statement. The statement refers to the start point or end point of the motion block in which the Trigger is situated in the program. The statement is executed parallel to the robot motion. The statement can be shifted in time and/or space. It is then not triggered exactly at the start or end point, but beforehand or afterwards. The statement can be shifted, at most, as far as the first point before the spline block or the last point of the spline block.

Syntax

TRIGGER WHEN PATH = Distance DELAY = Time DO Statement

Functions

PATH and DELAY can call functions. The following restrictions apply here: 

The KRL program with the function must have the attribute Hidden. (>>> 7.1.2 "Displaying or modifying file properties" Page 208)



The function must be globally valid.



The functions may only contain the following statements: 

Write to -defined variable



IF statement



Assignment



Read system variable


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Element Distance

Description Type: REAL; variable, constant or function; unit: mm Obligatory specification. If no shift in space is desired, set Distance = 0. If the statement is to be shifted in space, the desired distance from the start or end point must be specified here.

ONSTART







The statement refers to the start point. Without ONSTART: the statement refers to the end point.

Time

Type: REAL; variable, constant or function; unit: ms Obligatory specification. If no shift in time is desired, set Time = 0. If the statement is to be shifted in time (relative to PATH), the desired duration must be specified here.

Statement

Priority



Positive value: shifts the statement towards the end of the motion. Maximum: 1,000 ms




Possible: 




OUT statement



PULSE statement



Subprogram call. In this case, Priority must be specified.

Type: INT; variable or constant Priority of the trigger. Only relevant if Statement calls a subprogram, and then obligatory. Priorities 1, 2, 4 to 39 and 81 to 128 are available. Priorities 3 and 40 to 80 are reserved for cases in which the priority is automatically assigned by the system. If the priority is to be assigned automatically by the system, the following is programmed: PRIO = -1. If several triggers call subprograms at the same time, the trigger with the highest priority is processed first, then the triggers of lower priority. 1 = highest priority.

If a trigger calls a subprogram, it counts as an active interrupt until the subprogram has been executed. Up to 16 interrupts may be active at any one time. System variables

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Useful system variables for working with triggers: System variable

Data type

Description

$DIST_NEXT

REAL


$DISTANCE

REAL

Overall length of current motion Issued: 28.10.2010 Version: KSS 5.5 SI V2 en


Example

1 PTP P0 2 SPLINE 3 SPL P1 4 SPL P2 5 SPL P3 6 SPL P4 7 TRIGGER WHEN PATH=0 ONSTART DELAY=10 DO $OUT[5]=TRUE 8 SCIRC P5, P6 9 SPL P7 10 TRIGGER WHEN PATH=-20.0 DELAY=0 DO SUBPR_2() PRIO=-1 11 SLIN P8 12 ENDSPLINE

The Trigger in line 10 would have the same result if it was positioned directly before the spline block (i.e. between line 1 and line 2). In both cases, it refers to the last point of the spline motion: P8.

Fig. 10-14: Example of TRIGGER WHEN PATH (for spline)

10.12

Communication Information about the following statements is contained in the Expert documentation CREAD/CWRITE.

10.13



CAST_FROM



CAST_TO



CCLOSE



CHANNEL



CIOCTL



COPEN



CREAD



CWRITE



SREAD



SWRITE

System functions

10.13.1 VARSTATE() Description

VARSTATE() can be used to monitor the state of a variable. VARSTATE() is a function with a return value of type VAR_STATE. VAR_STATE is an enumeration type that is defined as follows in the system:


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ENUM VAR_STATE DECLARED, INITIALIZED, UNKNOWN

VARSTATE is defined as follows in the system: VAR_STATE VARSTATE(CHAR VAR_STR[80]:IN)

Example 1

DEF PROG1() INT MYVAR ... IF VARSTATE("MYVAR")==#UNKNOWN THEN $OUT[11]=TRUE ENDIF ... IF VARSTATE("MYVAR")==#DECLARED THEN $OUT[12]=TRUE ENDIF ... IF VARSTATE("ANYVAR")==#UNKNOWN THEN $OUT[13]=TRUE ENDIF ... MYVAR=9 ... IF VARSTATE("MYVAR")==#DECLARED THEN $OUT[14]=TRUE ENDIF ... IF VARSTATE("MYVAR")==#INITIALIZED THEN $OUT[15]=TRUE ENDIF ... END

Explanation of the state monitoring:

Example 2



The first IF condition is false, as MYVAR has already been declared. Output 11 is not set.



The second IF condition is true, as MYVAR has been declared. Output 12 is set.



The third IF condition is true, on the condition that there is also no variable with the name ANYVAR in $CONFIG.DAT. Output 13 is set.



The fourth IF condition is false, as MYVAR has not only been declared, but has also already been initialized here. Output 14 is not set.



The fifth IF condition is true, as MYVAR has been initialized. Output 15 is set. DEF PROG2() INT MYVAR INT YOURVAR DECL VAR_STATE STATUS ... STATUS=VARSTATE("MYVAR") UP() ... STATUS=VARSTATE("YOURVAR") UP() ... END DEF UP() ... IF VARSTATE("STATUS")==#DECLARED THEN $OUT[100]=TRUE ENDIF ... END

Explanation of the state monitoring:

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In this example, the state is monitored indirectly, i.e. via an additional variable. The additional variable must be of type VAR_STATE. The keyword DECL must not be omitted in the declaration. The name of the additional variable may be freely selected. In this example it is STATUS.

10.14

Editing string variables

Overview

Various functions are available for editing string variables. The functions can be used in SRC files, in SUB files and in the variable display. 

String variable length in the declaration (>>> 10.14.1 "String variable length in the declaration" Page 335)



String variable length after initialization (>>> 10.14.2 "String variable length after initialization" Page 336)



Deleting the contents of a string variable (>>> 10.14.3 "Deleting the contents of a string variable" Page 336)



Extending a string variable (>>> 10.14.4 "Extending a string variable" Page 337)



Searching a string variable (>>> 10.14.5 "Searching a string variable" Page 338)



Comparing the contents of string variables (>>> 10.14.6 "Comparing the contents of string variables" Page 338)



Copying a string variable (>>> 10.14.7 "Copying a string variable" Page 339)

10.14.1 String variable length in the declaration Description

The function StrDeclLen() determines the length of a string variable according to its declaration in the declaration section of a program.

Syntax

Length = StrDeclLen(StrVar[])


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Element Length

Description Type: INT Variable for the return value. Return value: Length of the string variable as declared in the declaration section

StrVar[]

Type: CHAR array String variable whose length is to be determined Since the string variable StrVar[ ] is an array of type CHAR, individual characters and constants are not permissible for length determination.

Example

1 2 3 4

CHAR ProName[24] INT StrLength … StrLength = StrDeclLen(ProName) StrLength = StrDeclLen($Trace.Name[ ])

Line

Description

3

StrLength = 24

4

StrLength = 7

10.14.2 String variable length after initialization Description

The function StrLen() determines the length of the character string of a string variable as defined in the initialization section of the program.

Syntax

Length = StrLen(StrVar)


Element Length

Description Type: INT Variable for the return value. Return value: Number of characters currently assigned to the string variable

StrVar

Type: CHAR Character string or variable whose length is to be determined

Example

1 2 3 4

CHAR PartA[50] INT AB … PartA[] = "This is an example" AB = StrLen(PartA[])

Line 4

Description AB = 18

10.14.3 Deleting the contents of a string variable

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Description

The function StrClear() deletes the contents of a string variable.

Syntax

Result = StrClear(StrVar[])




Element

Description

Result

Type: BOOL Variable for the return value. Return value:

StrVar[]



The contents of the string variable have been deleted: TRUE



The contents of the string variable have not been deleted: FALSE

Type: CHAR array Variable whose character string is to be deleted

Example

IF (NOT StrClear($Loop_Msg[])) THEN HALT ENDIF

The function can be used within IF branches without the return value being explicitly assigned to a variable. This applies to all functions for editing string variables.

10.14.4 Extending a string variable Description

The function StrAdd() can be used to expand a string variable with the contents of another string variable.

Syntax

Sum = StrAdd(StrDest[], StrToAdd[])


Element

Description

Sum

Type: INT Variable for the return value. Return value: Sum of StrDest[ ] and StrToAdd[ ] If the sum is longer than the previously defined length of StrDest[ ], the return value is 0. This is also the case if the

sum is greater than 470 characters. StrDest[]

Type: CHAR array The string variable to be extended Since the string variable StrDest[ ] is an array of type CHAR, individual characters and constants are not permissible.

StrToAdd[]

Type: CHAR array The character string by which the variable is to be extended

Example

1 2 3 4 5

DECL CHAR A[50], B[50] INT AB, AC … A[] = "This is an " B[] = "example" AB = StrAdd(A[],B[])

Line 5

Description A[ ] = “This is an example” AB = 18


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10.14.5 Searching a string variable Description

The function StrFind() can be used to search a string variable for a character string.

Syntax

Result = StrFind(StartAt, StrVar[], StrFind[], CaseSens)


Element

Description

Result

Type: INT Variable for the return value. Return value: Position of the first character found. If no character is found, the return value is 0.

StartAt

Type: INT The search is started from this position.

StrVar[]

Type: CHAR array The string variable to be searched

StrFind[]

Type: CHAR array

CaseSens



#CASE_SENS: Upper and lower case are taken into consideration.



#NOT_CASE_SENS: Upper and lower case are ignored.

The character string that is being looked for.

Example

1 2 3 4 5 6 7

DECL CHAR A[5] INT B A[]="ABCDE" B = StrFind(1, B = StrFind(1, B = StrFind(1, B = StrFind(1,

A[], A[], A[], A[],

"AC", #CASE_SENS) "a", #NOT_CASE_SENS) "BC", #Case_Sens) "bc", #NOT_CASE_SENS)

Line

Description

4

B=0

5

B=1

6

B=2

7

B=2

10.14.6 Comparing the contents of string variables Description

The function StrComp() can be used to compare two string variables.

Syntax

Comp = StrComp(StrComp1[], StrComp2[], CaseSens)


Element Comp

Description Type: BOOL Variable for the return value. Return value:

StrComp1[]



The character strings match: TRUE



The character strings do not match: FALSE

Type: CHAR array String variable that is compared with StrComp2[].

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Element

Description

StrComp2[]

Type: CHAR array String variable that is compared with StrComp1[].

CaseSens

Example

1 2 3 4 5 6 7



#CASE_SENS: Upper and lower case are taken into consideration.



#NOT_CASE_SENS: Upper and lower case are ignored.

DECL CHAR A[5] BOOL B A[]="ABCDE" B = StrComp(A[], B = StrComp(A[], B = StrComp(A[], B = StrComp(A[],

"ABCDE", #CASE_SENS) "abcde", #NOT_CASE_SENS) "abcd", #NOT_CASE_SENS) "acbde", #NOT_CASE_SENS)

Line

Description

4

B = TRUE

5

B = TRUE

6

B = FALSE

7

B = FALSE

10.14.7 Copying a string variable Description

The function StrCopy() can be used to copy the contents of a string variable to another string variable.

Syntax

Copy = StrCopy(StrDest[], StrSource[])


Element

Description

Copy

Type: BOOL Variable for the return value. Return value:

StrDest[]



The string variable was copied successfully: TRUE



The string variable was not copied: FALSE

Type: CHAR array The character string is copied to this string variable. Since StrDest[ ] is an array of type CHAR, individual characters and constants are not permissible.

StrSource[]

Type: CHAR array The contents of this string variable are copied.

Example

1 2 3 4 5

DECL CHAR A[25], B[25] DECL BOOL C A[] = "" B[] = "Example" C = StrCopy(A[], B[])

Line 5

Description A[ ] = “Example” C = TRUE


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11 Submit interpreter

11

Submit interpreter

11.1

Function of the Submit interpreter

Function

2 tasks run in parallel on the robot controller: Robot interpreter



The motion program runs in the robot interpreter. Submit interpreter



A SUB program runs in the Submit interpreter. A SUB program can perform operator control or monitoring tasks. Examples: monitoring of safety equipment; monitoring of a cooling circuit. This means that no PLC is required for smaller applications, as the robot controller can perform such tasks by itself. The Submit interpreter starts automatically when the robot controller is switched on. The program defined in the file KRC/STEU/MADA/$custom.dat is started. By default, this is SPS.SUB. $PRO_I_O[]="/R1/SPS()"

The Submit interpreter can be stopped or deselected manually and can also be restarted. It is also possible to start a SUB program other than the one entered in $custom.dat. (>>> 11.2 "Manually stopping or deselecting the Submit interpreter" Page 342) (>>> 11.3 "Manually starting the Submit interpreter" Page 342) SUB programs are always files with the extension *.SUB. The program SPS.SUB can be modified and new SUB programs can be created. (>>> 11.4 "Modifying the program SPS.SUB" Page 342) (>>> 11.5 "Creating a new SUB program" Page 343) Caution! The Submit interpreter must not be used for time-critical applications! A PLC must be used in such cases. Reasons: 

The Submit interpreter shares system resources with the robot interpreter, which has the higher priority. The Submit interpreter is thus not executed at the robot controller’s interpolation cycle rate of 12 ms. Furthermore, the runtime of the Submit interpreter is irregular.



The runtime of the Submit interpreter is influenced by the number of lines in the SUB program. Even comment lines and blank lines have an effect.

If a system file, e.g. $config.dat or $custom.dat, is modified in such a way that errors are introduced, the Submit interpreter is automatically deselected. Once the error in the system file has been rectified, the Submit interpreter must be reselected manually. Display

The program SPS.SUB can be found in the “System” folder in the Navigator. SUB files are only visible in the Navigator in the group “Expert”. By default, the execution of a selected SUB program is not displayed. This can be changed using the system variable $INTERPRETER. The SUB program


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can only be displayed, however, if a motion program is selected at the same time. Value of $INTERPRETER

11.2

Description

1

The selected motion program is displayed in the editor (default).

0

The selected SUB program is displayed in the editor.

Manually stopping or deselecting the Submit interpreter

Procedure



Description

Select the menu sequence Configure > SUBMIT Interpreter > Stop or Cancel. Command

Description

Stop

The Submit interpreter is stopped. When it is restarted, the SUB program is resumed at the point at which it was stopped.

Deselect

The Submit interpreter is deselected. A different SUB program can now be selected.

Once the Submit interpreter has been stopped or deselected, the corresponding icon in the status bar is red or gray. Icon

11.3

Color

Description

Red

Submit interpreter has been stopped.

Gray

Submit interpreter is deselected.

Manually starting the Submit interpreter

Procedure



Select the menu sequence Configure > SUBMIT interpreter > Start/Select.

If the Submit interpreter is deselected, the command Start/Select selects the SUB program defined in the file $custom.dat. If the Submit interpreter has been stopped, the command Start/Select resumes the selected SUB program at the point at which it was stopped. Alternative procedure

A SUB program can also be selected directly. Precondition: the Submit interpreter is deselected. 1. Select the program in the Navigator. 2. Press the Select softkey. The program starts automatically.

Description

Once the Submit interpreter has been started, the corresponding icon in the status bar is green. Icon

Color Green

11.4

Submit interpreter is running.

Modifying the program SPS.SUB

Precondition

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Description



The program SPS.SUB is not selected or has been stopped.



group “Expert”



Procedure

1. Select the program SPS.SUB in the Navigator and press the Open softkey. 2. Enter changes. Enter initializations in the INIT Fold. This Fold is located in the INIT Fold.



INIT ; Please insert defined initialization commands

Enter all other changes in the PLC Fold.



PLC ; Make your modifications here

3. Press the Close softkey. Respond to the request for confirmation asking whether the changes should be saved by pressing the Yes softkey. 4. The program SPS.SUB can now be started via the menu sequence Configure > SUBMIT interpreter > Start. Description

Structure of the program SPS.SUB: 1 2 3 4 5 6 7 8 9 11 12 13 14

DEF SPS() DECLARATIONS INI LOOP ... GRIPPERTECH PLC PLC ENDLOOP

Line

11.5

Description

3

Declaration section

5

Initialization section. For statements that are only to be executed once after the system has booted.

7, 14

LOOP statement. For programs that are to run continuously in the background.

9

Fold with statements for a technology package (example). The Folds that are present depend on what technologies are installed.

12

Fold for -specific adaptations

Creating a new SUB program

Precondition



Expert group

Procedure

1. In the Navigator, use the UP and DOWN arrow keys to select the folder in which the program is to be created. Closed folders can be opened by pressing the Enter key. 2. Move to the file list by pressing the RIGHT arrow button. 3. Press the New softkey. The Template selection window is opened. 4. Select the template Submit or Expert Submit and press the softkey OK. 5. Enter a name for the program and press the softkey OK.

Description


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Newly created SUB programs contain no Folds for the installed technology packages. These Folds are present by default in the program SPS.SUB. If the program SPS.SUB is to be replaced with a new SUB program, these Folds must be copied into the new program. The technology packages are otherwise no longer fully operational. The template Submit generates a SUB file with the following structure:

 1 2 3 4 5 6 7

DECLARATIONS INI LOOP PLC ENDLOOP SUBROUTINE

Line Declaration section

2

Initialization section. For statements that are only to be executed once after the system has booted.

4, 5, 6

LOOP statement containing the Fold PLC. The Fold is for programs that are to run continuously in the background.

7 

Description

1

For -specific subroutines

The template Expert Submit generates an empty SUB file. With this template, everything has to be programmed by the .

Use a LOOP statement when programming. SUB programs without a LOOP statement are only executed once by the Submit interpreter. It is then automatically deselected.

11.6

Programming

KRL code

Almost all KRL instructions can be used in a SUB program. The following statements are not possible, however: 

Statements for robot motions Robot motions can only be interpreted by the robot interpreter. For this reason, SRC programs containing motion commands cannot be called as subprograms from a SUB program.



Statements referring to robot motions These include BRAKE and all TRIGGER statements.

Motion commands for external axes can be used in a SUB program. Example: IF (($IN[12] == TRUE) AND ( NOT $IN[13] == TRUE)) THEN ASYPTP {E2 45} ASYPTP {E3 200} ... IF ((NOT $IN[12] == TRUE) AND ($IN[13] == TRUE)) THEN ASYPTP {E2 0} ASYPTP {E3 90}

External axes E2 and E3 are moved in accordance with specific inputs. WAIT statements or wait loops stop the cycle. System variables

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The Submit interpreter has read-access to all system variables and write-access to many of them. Access works even if the system variables are being used in parallel by a motion program.



If a system variable to which the Submit interpreter does not have write-access is modified in a SUB program, an error message is generated when the program is started and the Submit interpreter stops. System variables that are frequently required in SUB programs: $MODE_OP = Value Value

Description

#T1

Robot controller is in T1 mode.

#T2

Robot controller is in T2 mode.

#AUT

Robot controller is in Automatic mode.

#EX

Robot controller is in Automatic External mode.

#INVALID

Robot controller has no defined state.

$OV_PRO = Value Element

Data type

Description

Value (%)

INT

Program override value

Example: If the programmed velocity is not reached, output 2 is set to FALSE. … IF (($MODE_OP == #T1) OR ($OV_PRO < 100)) THEN $OUT[2] = FALSE ENDIF …

Inputs/outputs

The Submit interpreter can access the inputs and outputs of the robot controller. Warning! No check is made to see if the robot interpreter and Submit interpreter are accessing the same output simultaneously, as this may even be desired in certain cases. The must therefore carefully check the assignment of the outputs. Otherwise, unexpected output signals may be generated, e.g. in safety equipment. Death, serious physical injuries or major damage to property may result.

Subprograms

Other programs can be called as subprograms in a SUB program. The following are possible: 

Other SUB programs



SRC programs without statements for robot motions

Example: CELL.SRC can be called from the program SPS.SUB with a CWRITE statement and RUN. The call only takes effect in the case of a cold start.


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Fig. 11-1: SPS.SUB calls CELL.SRC Further information about the program CELL.SRC can be found in this documentation. (>>> 6.20.1 "Configuring CELL.SRC" Page 154) Further information about CWRITE statements can be found in the Expert documentation CREAD/CWRITE. Communication

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The flags of the robot controller can be used to enable the exchange of binary information between a running motion program and a SUB program. A flag is set by the Submit interpreter and read by the robot interpreter.


12 Diagnosis

12

Diagnosis

12.1

Logbook

12.1.1

Displaying the logbook The operator actions on the K are automatically logged. The command Logbook displays the logbook.

Procedure



Select the menu sequence Monitor > Diagnosis > Logbook and select the desired log.

The following tabs are available:

12.1.2



Log (>>> 12.1.2 "“Log” tab" Page 347)



Filter (>>> 12.1.3 "“Filter” tab" Page 348)

“Log” tab

Fig. 12-1: Logbook, Log tab Item 1

Description Type of log event Example : Filter type "Note" + filter class "System" = note originated by the kernel system of the robot. The individual filter types and filter classes are listed on the Filter tab.

2

Log event number

3

Brief description of the log event

4

Detailed description of the selected log event

5

Indication of the active filter


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The following softkeys are available: Softkey

Description Toggles between the Log and Filter tabs.

Tab +

Export

Exports the log data as a text file. Default path: C:\KRC\ROBOTER LOG\LOGBUCH.TXT Refreshes the log display.

Refresh Scrolls up/down in the list of log events. Page +/ Page -

12.1.3

“Filter” tab

Fig. 12-2: Logbook, Filter tab The following softkeys are available:

12.2

Softkey

Description

Tab +

Toggles between the Log and Filter tabs.

Mark

Activates or deactivates the selected filter.

Displaying the caller stack This function displays the data for the process pointer ($PRO_IP).

Precondition

Procedure

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

group "Expert"






Select the menu sequence Monitor > Diagnosis > Caller Stack.


12 Diagnosis

Description

Fig. 12-3: Caller Stack window Item 1

Description 

None: Call not initiated by interrupt 

[No.]: Call initiated by interrupt with the number [No.] 2

This file contains the call.

3

The program line with this number contains the call. Preconditions in the program for the correct line to be determined using the number:

12.3



DEF line is displayed.



Detail view (ASCII mode) is activated.



All Folds are open.

4

Source line

5

Detailed information about the entry selected in the list

Displaying interrupts

Precondition



group “Expert”

Procedure



Select the menu sequence Monitor > Diagnosis > Interrupts.


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Description

Fig. 12-4: Interrupts Item 1

Description Status of the interrupt 

Interrupt ON or ENABLE



Interrupt DISABLE



Interrupt OFF or not activated

2

Number/priority of the interrupt

3

Validity range of the interrupt: global or local

4

Type of interrupt, dependent on the defined event in the interrupt declaration

5



Standard: e.g. $IN[1…4096]



Error stop: $STOPMESS



EMERGENCY STOP: $ALARM_STOP



Measurement (Fast Measurement): $MEAS_PULSE[1…5]



Trigger: Trigger subprogram

Module and program line of the interrupt declaration

The following softkeys are available:

12.4

Softkey

Description

Submit/Robot

Toggles between the displays for robot interrupts and Submit interrupts.

Refresh

Refreshes the display.

Oscilloscope

Overview

The oscilloscope is an important diagnostic tool during start-up of the industrial robot and during troubleshooting. It is also used for optimization of the machine data. The oscilloscope can be used to record different variables with the program running, e.g. actual current, setpoint current, states of inputs and outputs, etc. The recording (trace) can then be displayed. The variables are displayed as colored curves. 8 colors are available for this. If more than 8 variables have

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12 Diagnosis

been recorded, individual variables can be removed from the display and others displayed.

Fig. 12-5: Oscilloscope

12.4.1

Configuring and starting the oscilloscope

Description

During configuration, the data to be recorded by the oscilloscope are specified. The robot controller saves the trace recording as a TRC file in the directory C:\KRC\ROBOTER\TRACE.

Procedure

1. Select the menu sequence Monitor > Diagnosis > Oscilloscope > Configure. 2. Specify the basic data to be recorded. (>>> 12.4.1.1 "Main window" Page 352) 3. If DSE data are to be recorded: Press the DSE Table softkey and configure the DSE recording. (>>> 12.4.1.2 "DSE table" Page 354) 4. If I/O data are to be recorded: Press the I/O Table softkey and configure the I/O recording. (>>> 12.4.1.3 "I/O table" Page 356) 5. Press the Main menu softkey. 6. Optionally: Press the Save softkey to save the current configuration. 7. Start the KRL program. 8. Either: Press the Start softkey. The recording is started in accordance with the defined trigger. Or: Press the Trigger softkey. The recording starts immediately. The Trace Status box jumps from #T_END to either #T_WAIT or #TRIGGERED.


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The recording is ended when the Trace Status box displays the value #T_END again. 12.4.1.1 Main window Description

Fig. 12-6: Oscilloscope configuration – main window Item 1

Description Name of the TRC file (max. 7 characters). The robot controller appends a number to the end of the name, indicating what data have been recorded. 

1: DSE data



3: I/O data



4: Interpolator data



5: Test data

If, for example, DSE data and interpolator data have been recorded, the robot controller creates 2 TRC files: one with the number 1 and one with the number 4. Note: If a file of the same name already exists, it is overwritten by the new file without a request for confirmation! 2

Duration of the recording. Only whole numbers can be entered. Maximum value: 999 s.

3

The trigger controls the point in time at which the recording of data is started. (>>> "Trigger" Page 353) The oscilloscope actually starts recording data as soon as the Start or Trigger softkey is pressed. The trigger merely controls which time phase of the recording is then displayed in the TRC file.

4

The position of the time phase displayed in the TRC file relative to the trigger. The % value refers to the duration of the recording. Examples:

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

0%: The displayed time phase starts at the trigger.



30%: 30% of the displayed time phase comes before the trigger, 70% after the trigger.



100%: The displayed time phase ends at the trigger. Issued: 28.10.2010 Version: KSS 5.5 SI V2 en

12 Diagnosis

Item 5

Description This box is only available in the group “Expert”. The interpolator data include the Cartesian position of the robot (X, Y, Z, A, B, C), the path velocity and the geometric angles of axes A1 to A12. 

None: No interpolator data are recorded.



Command: The setpoint interpolator data are recorded.



Actual: The actual interpolator data are recorded.

6

This function is intended for KUKA service personnel only. This box is only available in the group “Expert”.

7



No DSE data: No DSE data are recorded.



DSE 1: The DSE data of axes A1 to A8 are recorded.



DSE 2: The DSE data of axes A7 to A12 are recorded.

DSE data are recorded every 2 ms. 500 data sets are generated per second. 8



No I/O data: No I/O data are recorded.



I/O: Inputs and/or outputs are recorded, depending on the configuration in the I/O table.



CYCFLAG: All cyclical flags [1] … [32] which have been assigned a value are recorded. Specific cyclical flags cannot be selected.

Note: Data are recorded every 12 ms. Approx. 85 data sets are generated per second.

Trigger

9

A comment can be entered here.

10

Status of the oscilloscope 

#T_WAIT: The oscilloscope is waiting for the trigger.



#TRIGGERED: The recording shall continue for the time defined by the trace length and trigger.



#T_END: The oscilloscope does not record any data.

Trigger

Description

Trigger on I/O state

Additional boxes are displayed if this trigger is selected. An input, output or cyclical flag must be selected here, together with a state.

Start by , recording until buffer is full

The recording must be started with the Start softkey. The recording stops after a defined duration. This trigger must be selected if the recording is to be started from a KRL program.

Cyclical recording until stop

The recording starts when the Start softkey is pressed. The recording stops when the Stop softkey is pressed. The defined duration before Stop is pressed is then displayed in the TRC file. Example: A recording duration of 12 s is defined. The presses Start and 30 s later Stop. The last 12 s before Stop was pressed are then displayed in the TRC file.


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Trigger

Description

Trigger on error

Trigger = occurrence of a fault that causes the robot to stop. With this trigger, it is useful for the TRC file also to display data from before the trigger. Define in the main window, in the Pre-Trigger (%) box.

Trigger on motion start

The trace is started as soon as one or more axes move. The recording stops after a defined duration.

Trigger on clearing filter

This function is intended for KUKA service personnel only.

Trigger on DSE error

Trigger = fault in the drive circuit. With this trigger, it is useful for the TRC file also to display data from before the trigger. Define in the main window, in the Pre-Trigger (%) box.

Softkeys

Softkey

Description

Display

Jumps to the oscilloscope display.

DSE Table

Displays the DSE table.

I/O Table

Displays the I/O table.

Trigger

Starts the recording immediately, irrespective of the trigger.

Start

This softkey is only displayed if no recording is in progress. Starts the recording in accordance with the trigger.

Stop

This softkey is only displayed if the recording is in progress. Stops the recording.

Save

Saves the current configuration. It is available again next time the oscilloscope function is opened.

Close

Closes the configuration window. The values are not saved.

12.4.1.2 DSE table Description

Here you can select which DSE data are to be recorded. A maximum of 21 variables can be selected. Reason: 21 DSE channels are available.

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12 Diagnosis

Fig. 12-7: Oscilloscope configuration – DSE table Item

Description

1

Select which intermediate circuit voltage is to be recorded.

2

Select which data are to be recorded.

DSE data

Key commands

Softkeys

Description

Bus Voltage PM1

KPS600

Bus Voltage PM1

KPS600 in the top-mounted cabinet (only relevant if top-mounted cabinet present)

Command Value

Command value from the interpolator per position control cycle

Actual Value

Actual value per position control cycle

Following Error

Difference between command position and actual position

Command Velocity

At the position controller output

Actual Velocity

Motor speed

Actual Current

Current sensors

Motor Temperature

In increments

Resolver

Encoder position

Command Current

At the speed controller output

Torque Differential

Value calculated from the command/actual current

Key command

Action

Arrow keys

Switch from cell to cell.

Space bar

Select cell or cancel selection.

Softkey

Description

Main menu

Displays the main window.

I/O Table

Displays the I/O table.

Select Line

Selects the whole of the current line.

Clear Line

Removes all selections in the current line.

Clear All

Removes all selections in the lower table.


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12.4.1.3 I/O table Description

Here you can select which inputs or outputs are to be recorded. There are 4 channels available for the recording. A maximum of 8 inputs or outputs can be assigned to each channel. Each channel is subsequently displayed in a different color in the trace recording.

Fig. 12-8: Example: 2 outputs are recorded, 1 channel = 1 color

Fig. 12-9: Example: 2 outputs are recorded, 2 channels = 2 colors Item 1

2

Description Display the channels in the I/O table: 

Channels 1/2



or Channels 3/4

Channel 1 Select whether an input or output is to be recorded:

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

None



$IN



$OUT


12 Diagnosis

Item

Softkeys

Description

3

Enter the number of the input/output to be recorded.

4

Channel 2

Softkey

Description

Main menu

Displays the main window.

DSE Table

Displays the DSE table.

12.4.1.4 Starting the recording via a program Description

It is also possible to start a recording via a program (instead of via the softkeys Trigger or Start in the configuration). In this case, the trigger start, record until buffer is full must be selected in the main window.

Example

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

DEF myprogramm ( ) INI $TRACE.NAME[]="CUR_" PTP HOME Vel= 100 % DEFAULT LOOP $TRACE.MODE=#T_START WAIT SEC 0.1 REPEAT WAIT SEC 0.2 UNTIL $TRACE.STATE==#T_WAIT WAIT SEC 0.5 PTP ... ... WAIT SEC 0.5 $TRACE.MODE=#T_STOP WAIT SEC 0.1 REPEAT WAIT SEC 0.2 UNTIL $TRACE.STATE==#T_END WAIT SEC 0.1 ... PTP HOME Vel= 100 % DEFAULT ENDLOOP END

Line

Description

3

Name of the TRC file A name must always be defined in the main window of the configuration. However, the name in the program overwrites the one from the main window. This makes it possible to start several different recordings (with different names) via several different programs, without constantly overwriting the TRC files.

8

Starts the recording in accordance with the trigger. (Corresponds to the Start softkey.)

9 … 13

Here it is assured that the oscilloscope reaches the state #T_WAIT before the robot motions begin.

15

The robot motions start.


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Line

Description

19

Stops the recording (corresponds to the Stop softkey).

20 … 24

Here it is assured that the oscilloscope reaches the state #T_END before the robot moves to the HOME position and the loop starts again.

12.4.1.5 Configuring the oscilloscope – example 1 Description

The following variables are to be recorded: 

Command velocity of the drive of axis 1



Actual velocity of the drive of axis 1



Outputs 9 to 16 and 20 to 23

The recording should be called TRACE and have a duration of 12 s. Procedure

1. Configure the Main window, DSE table and I/O table. 2. Start a KRL program. 3. Press the Start softkey. 2 files are generated: 

TRACE1.trc (contains the DSE data)



TRACE3.trc (contains the I/O data)

The files represent the time from the first robot motion to 12 s afterwards. Main window

Make the following settings in the main window:

Fig. 12-10: Example 1, main window DSE table

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Make the following settings in the DSE table:


12 Diagnosis

Fig. 12-11: Example 1, DSE table I/O table

Make the following settings in the I/O table: The outputs need not be specified in numerical order.

Fig. 12-12: Example 1, I/O table 12.4.1.6 Configuring the oscilloscope – example 2 Description

Background: A KRL program calls subprograms in accordance with signals from the PLC. For unknown reasons, it also calls subprogram SP55.src; this is not desired. Remedy: A free output, e.g. output 32, is set in subprogram SP55.src and reset when the subprogram is left. The recording is started in accordance with this output. The I/O communication of the KRL program with the PLC can then be analyzed using this recording. The affected robot controller inputs/outputs are inputs 1 to 16 and outputs 1 to 16. The recording should be called TRACE2 and have a duration of 12 s.

Procedure

1. Configure the Main window and I/O table. 2. Start a KRL program. 3. Press the Start softkey. 1 file is generated: 

TRACE23.trc (contains the I/O data)


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Main window


Fig. 12-13: Example 2, main window The value in the Pre-Trigger box is set to 90 or a similarly high value, as the important thing for fault analysis is what happens before output 32 is set. The inputs and outputs are then recorded for 10.8 s before this event and for 1.2 s after it. I/O table

Make the following settings in the I/O table:

Fig. 12-14: Example 2, I/O table (outputs)

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12 Diagnosis

Fig. 12-15: Example 2, I/O table (inputs) 12.4.1.7 Configuring the oscilloscope – example 3 Description

Background: A KRL program always stops at night because an error occurs in the I/O communication with the PLC. It is unclear whether the PLC program or the KRL program is causing the error. Remedy: Start the oscilloscope from the KRL program, before the affected section of the program. The old TRC file is overwritten by the new one every time the program is correctly executed. If the program is interrupted by the error, however, the last TRC file is retained and the I/O communication can be analyzed with the aid of the recorded data. The recording should be called TRACE3.

Precondition



Procedure

1. Configure the Main window and I/O table.

Expert group

2. Insert instructions into the KRL program for starting and ending the oscilloscope. (>>> 12.4.1.4 "Starting the recording via a program" Page 357) 3. Restart the KRL program. Once the error has been located, remove the instructions from the KRL program again! Main window



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Fig. 12-16: Example 3, main window The length of the trace must be selected in such a way that the relevant I/O communication between the robot controller and the PLC is recorded. I/O table

12.4.2

Set all affected inputs/outputs in the I/O table.

Displaying recorded data

Description

This procedure can be used to select and display a recording (=TRC file) located in the directory C:\KRC\ROBOTER\TRACE. The robot controller appends a number to the end of the name of every TRC file, indicating what data have been recorded. 

1: DSE data 

3: I/O data 

4: Interpolator data 

5: Test data Procedure

1. Select the menu sequence Monitor > Diagnosis > Oscilloscope > Display. 2. The TRC files are displayed. Select the desired file and press OK. The trace is displayed. 3. The LEFT and RIGHT ARROW keys can be used to scroll along the X axis. The UP and DOWN ARROW keys can be used to scroll along the Y axis. 4. The ESC key can be used to close the oscilloscope.

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12 Diagnosis

12.4.2.1 interface Recording

Fig. 12-17: Example of a trace recording

Fig. 12-18: Example of a trace recording of outputs 1

Characteristics of the curves

5

X axis

2

Y axis

6

Output

3

Curves

7

Curves for inputs/outputs

4

Active color/curve


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Element

Description

Characteristics of the curves

From left to right: color, designation, unit, scale

Y axis

The value of the curve on the Y axis multiplied by the scale gives the value of the curve at a specific point in time. If inputs and outputs have been recorded, the inputs and outputs are labeled on the Y axis with numbers.

Curves for inputs/outputs



I[x]: input no. x



O[x]: output no. x

Inputs and outputs are only displayed if they were TRUE. If an input or output was FALSE, a dotted gray line is displayed. The color of inputs/outputs depends on which channels they were assigned to in the configuration. If they were all assigned to the same channel, they will all have the same color.

Info window

Active color/curve

Active color/curve

X axis

Time; unit: seconds

The Info window displays information about the curves. The Info window can be opened and closed by means of the I key.

Fig. 12-19: Info window Column

Description

No.

Number and color of the curve

File

File from which the curve data have been read

Channel

Channel to which the curve is assigned

Description

Variable represented by the curve

Color

Name of color

Visible

Yes: curve is visible. No: curve is invisible.

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12 Diagnosis

Operator control

The interface can be operated by means of key commands and with softkeys. For most actions, both a key command and a softkey are available. Key commands: Key

Description

Corresponds to softkey

ESC

Closes the oscilloscope.

Cancel; Close

UP ARROW/ DOWN ARROW

Scrolling along the X axis.

----

LEFT ARROW/ RIGHT ARROW

Scrolling along the Y axis.

----

D

Switches the filter on or off.

Filt.OnOff

(>>> 12.4.2.7 "Filtering the display" Page 370) E

Activates or deactivates the RMS function.

RMS

(>>> 12.4.2.8 "Determining the r.m.s. value" Page 371) I

Displays or hides the Info window.

Info

K

Activates a different curve. (Curves/channels which have not been assigned a color cannot be activated.)

Channel

Note: After pressing K, always press the Unzoom softkey. This reinitializes the display so that the correct information is shown. M

Enlarges the active curve.

----

N

Shrinks the active curve.

----

Q

Switches to the window where a TRC file can be selected.

----

S

Saves the trace as a BMP file in the directory C:\KRC\ROBOTER\TRACE.

Save

(>>> 12.4.2.10 "Saving the display as a BMP file" Page 375) Z

Activates the Zoom function.

Zoom

(>>> 12.4.2.6 "Enlarging the display" Page 368) U

Deactivates the Zoom function.

Unzoom

C

Keys for the cursor functions

VCursor 1

V

(>>> 12.4.2.9 "Cursor functions" Page 373)

VCursor 2

H J W

HCursor 1 HCursor 2

Switches to the oscilloscope configuration.


Config

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V key or VCursor 2 softkey only works if C or VCursor 1 has already been pressed. J key or HCursor 2 softkey only works if H or HCursor 1 has already been pressed. Softkeys in the window with the TRC files: Softkey

Description

Config

Switches to the oscilloscope configuration.

TraceFile2

This softkey is used to select a TRC file that is to be compared with another one. (>>> 12.4.2.2 "Superimposing traces" Page 367)

OK

Confirms the selection of a TRC file.

Cancel


If a trace is opened, 4 softkey bars are available. Softkey bar 1: Softkey

Description

Info

Displays or hides the Info window.

Blue; Green; White; Red

Displays or hides the curve with this color.

-->

Displays softkey bar 2.

Close


If the Info window is open: assigns this color to the selected curve. If the selected curve already has this color, the curve is hidden.

Softkey bar 2: Softkey

Description

Magenta; Brown; Yellow; Cyan

Displays or hides the curve with this color.

Channel

Activates a different curve. (Curves/channels which have not been assigned a color cannot be activated.)

If the Info window is open: assigns this color to the selected curve. If the selected curve already has this color, the curve is hidden.

Note: After pressing Channel, always press the Unzoom softkey. This reinitializes the display so that the correct information is shown. -->


Close



Description

Zoom

Activates the Zoom function. (>>> 12.4.2.6 "Enlarging the display" Page 368)

Unzoom

Deactivates the Zoom function.

Save

Saves the current oscilloscope display as a BMP file in the directory C:\KRC\ROBOTER\TRACE. (>>> 12.4.2.10 "Saving the display as a BMP file" Page 375)

RMS

Activates or deactivates the RMS function. (>>> 12.4.2.8 "Determining the r.m.s. value" Page 371)

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12 Diagnosis

Softkey

Description

Print

Prints the display. (>>> 12.4.2.11 "Printing the display" Page 375)

-->


Close



Description

VCursor 1

Softkeys for the cursor functions

VCursor 2

(>>> 12.4.2.9 "Cursor functions" Page 373)

HCursor 1 HCursor 2 Filt.OnOff

Switches the filter on or off. (>>> 12.4.2.7 "Filtering the display" Page 370)

-->


Close


12.4.2.2 Superimposing traces Description

This function can be used to superimpose 2 traces. This makes it possible to compare them with one another. The traces are displayed superimposed. The information in the upper area of the window always refers to the second file that was selected.

Procedure

1. Select the menu sequence Monitor > Diagnosis > Oscilloscope > Display. 2. The TRC files are displayed. Select a file and press the TraceFile2 softkey. The trace is displayed. 3. Select the file that is to be compared with the first file and press the OK softkey.

12.4.2.3 Activating and deactivating curves Procedure

1. Press the softkey with the color of the curve. The curve is removed from the display. 2. To reactivate the curve, press the softkey again.

Alternative procedure

1. Press I. The Info window is opened. 2. Select the curve that is to be deactivated (e.g. Blue).

Fig. 12-20: Curve is selected 3. Press Enter. The curve is removed from the display.


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Fig. 12-21: Curve is deactivated 4. Press I again. The Info window is closed. 5. To reactivate the curve, repeat steps 1 to 4. 12.4.2.4 Changing colors Description

The colors of the curves can be changed. This is necessary, for example, if more than 8 channels are assigned. In this case, not all channels can be displayed at the same time, as only 8 colors are available.

Procedure Assign a different color to one curve (e.g. Blue). 1. Press I. The Info window is opened. 2. Select the curve that is to be displayed in blue and press the Blue softkey. The curve is now blue. The curve that was previously blue now has no color and is no longer visible. 3. Press I again. The Info window is closed. Switching colors (e.g. Green and Red): 1. Press I. The Info window is opened. 2. Select the green curve and press the Green softkey. The curve now has no color. 3. Select the red curve and press the Green softkey. The curve that was red is now green. 4. Select the curve that was previously green (now colorless) and press the Red softkey. The curve is now red. 5. Press I again. The Info window is closed. 12.4.2.5 Scaling curves Description

Using this function, it is also possible to make curves more visible which only have a low amplitude or which are hidden by other curves. The current scale of the current curve is indicated in the upper area of the screen.

Procedure

1. Press K until the desired curve is active. The active curve is always indicated in the bottom left-hand corner. 2. Press N repeatedly to increase the amplitude gradually. Press M repeatedly to reduce the amplitude gradually.

12.4.2.6 Enlarging the display

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Description

This function can be used to select and enlarge any area of the trace.

Procedure

1. Press Z. A white cross appears in the center of the trace. The cross represents the corner of a window. Issued: 28.10.2010 Version: KSS 5.5 SI V2 en

12 Diagnosis

2. Shift the cross as required using the arrow keys. 3. Press Enter. Drag with the arrow keys to form a window. Example: Use the UP ARROW to drag the window upwards from the cross. Then use the LEFT ARROW to extend the window across to the left from the cross. 4. Press Enter. The contents of the window are enlarged. 5. The enlargement can be undone by pressing U.

Fig. 12-22: Cross is displayed

Fig. 12-23: Window has been stretched


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Fig. 12-24: Contents of the window are enlarged 12.4.2.7 Filtering the display Description

The display is filtered by default. This ensures clear presentation of the curves. In order to obtain an exact display of the recorded data for the purpose of analysis, the filter is switched off.

Procedure

1. Press D. The filter is deactivated. 2. The filter can be reactivated by pressing D again.

Fig. 12-25: Filter on

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12 Diagnosis

Fig. 12-26: Filter off 12.4.2.8 Determining the r.m.s. value Description

This function can be used to determine the r.m.s. value for a particular interval. In electrical engineering, the r.m.s. value is the root-mean-square value of a signal that changes over time.

Procedure

1. Press K repeatedly until the desired curve is active. The active curve is always indicated in the bottom left-hand corner. 2. Press E. A vertical white line is displayed. The line marks the start of the interval on the X axis. The LEFT and RIGHT ARROW keys can be used to shift the line. 3. Press Enter. The LEFT and RIGHT ARROW keys can then be used to stretch the line to form a window. The right-hand edge of the window marks the end of the interval on the X axis. 4. Press the Enter key again. The result of the calculation is displayed in the window. (If the text is concealed by other curves, hide these curves.) 5. To end the function, press E again.


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Fig. 12-27: Vertical line is displayed

Fig. 12-28: Line has been stretched to form a window

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12 Diagnosis

Fig. 12-29: Result is displayed Item

Description

1

Vertical line

2

Window

3

Result

12.4.2.9 Cursor functions Description

This function can be used to determine the value that a curve represented at a specific time. For this purpose, a vertical line is displayed, intersecting the desired time value on the X axis. The differential value between two points in time can also be determined. If the trace represents inputs and outputs, the bit pattern of the input or output group is displayed as the value. Additionally, a horizontal line can be used to mark a specific value on the Y axis. The difference between two values can also be determined. If the trace represents inputs and outputs, the horizontal lines are not suitable.

Procedure

1. Press K repeatedly until the desired curve is active. The active curve is always indicated in the bottom left-hand corner. 2. Press C. A vertical line is displayed. It marks a point in time on the X axis. The time and the corresponding measured value are indicated in the top left-hand corner. The LEFT and RIGHT ARROW keys can be used to shift the line. 3. Press V. A second vertical line is displayed. In addition to the value of the first line, the value of the second line is also displayed, together with the difference. 4. Press H. A horizontal line is displayed. It marks a value on the Y axis. The value is displayed in the top left-hand corner. The UP and DOWN ARROW keys can be used to shift the line. 5. Press J. A second horizontal line is displayed. In addition to the value of the first line, the value of the second line is also displayed, together with the difference. 6. The lines can be deactivated by pressing the keys again.


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Fig. 12-30: First vertical line

Fig. 12-31: First and second vertical lines

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12 Diagnosis

Fig. 12-32: First and second horizontal lines Item

Description

1

Position and measured value of the first vertical line

2

First vertical line

3

Position and measured value of the first and second vertical lines and the difference

4

First and second vertical lines

5

Position and measured value of the first and second horizontal lines and the difference

6

First horizontal line

7

Second horizontal line

12.4.2.10Saving the display as a BMP file Description

This function saves the trace as a BMP file in the directory C:\KRC\ROBOTER\TRACE. All current settings, e.g. enlarged curves, are saved. The BMP file has the same name as the TRC file. If 2 superimposed traces are saved, the name is composed of the names of both TRC files. If a file of the same name already exists, it is overwritten by the new file without a request for confirmation!

Procedure



Press S.

12.4.2.11Printing the display Procedure

1. Set the printer to landscape format. 2. Press the --> softkey repeatedly until the Print softkey is displayed. 3. Press the Print softkey. The display is printed.


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13 Installation

13

Installation The robot controller is supplied with a Windows operating system and an operational version of the KUKA System Software (KSS). Therefore, no installation is required during initial start-up. Installation becomes necessary, for example, in the event of the hard drive being damaged and exchanged. The robot controller may only be operated using the software provided with the controller by KUKA. KUKA Roboter GmbH must be consulted if different software is to be used. (>>> 15 "KUKA Service" Page 387)

13.1

Overview of the software components

Overview

The following software components are used: 




Windows XP embedded 2.x incl. Service Pack 2

It is not possible to upgrade from Windows Service Pack 1 to Windows Service Pack 2.

13.2

Installation overview Step 1

Description Install Windows: 1. Only required if there is no CD-ROM drive on the control cabinet: Adapt BIOS settings for USB CD/DVD drive. (>>> 13.2.1 "Adapting BIOS settings for USB CD/DVD drive" Page 377) 2. Install Windows. (>>> 13.2.2 "Installing Windows" Page 378) 3. If required, change the Windows language. (>>> 13.2.3 "Changing the Windows language" Page 378)

2

Install the KUKA System Software. (>>> 13.2.4 "Installing the KUKA System Software" Page 379)

3

Install technology packages. (>>> 13.3 "Installing additional software (via KUKA.HMI)" Page 379)

4

If applicable: load archive. (>>> 7.8.4 "Restoring data" Page 230)

13.2.1

Adapting BIOS settings for USB CD/DVD drive This procedure is only required if there is no CD-ROM drive on the control cabinet.

Precondition



Bootable USB CD-ROM/DVD drive



External keyboard


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Procedure

1. Connect USB CD/DVD drive. 2. After switching on the controller, press the F12 key while it is booting. The BIOS Boot Menu is displayed. 3. Select CD-ROM Drive as Boot Device. 4. Press the Enter key.

13.2.2

Installing Windows Warning! When Windows is installed, the hard drive is formatted. Data on the hard drive are deleted.

Preconditions

Procedure



KUKA Windows CD-ROM



External keyboard



Only required if there is no CD-ROM drive on the control cabinet: 

Bootable USB CD-ROM/DVD drive



BIOS settings have been adapted.

1. Insert KUKA Windows CD-ROM 2. Boot the robot controller. 

If no operating system has yet been installed, the installation starts automatically.



If an operating system has already been installed, the prompt Press any key to boot from ... appears following the BIOS sequence. Press any key. The installation starts and the existing operating system is overwritten.

2 partitions are set up. The first partition (drive C:\) has a defined size of 5 GB. The remaining capacity is allocated to the second partition (drive D:\). Both partitions are formatted. The operating system is loaded. The system is rebooted. 3. The KUKA drivers are installed. Depending on the system, entries may be required, e.g. language selection or entry of a computer name. The system is then restarted. 4. Remove CD-ROM from drive.

13.2.3

Changing the Windows language

Description

By default, the Windows interface can be displayed in German or English. Additional languages can be installed.

Precondition



Procedure

1. Start the CD-ROM.

Windows XP embedded Languages CD

2. Open the folder with the desired language. Start the program SETUP.EXE. Follow the instructions in the installation wizard. 3. Open the Windows Start menu (CTRL+ESC) 4. Select Settings > Control > Regional and Language Options. The Regional and Language Options window is opened. 5. Select the Languages tab. In the Language used in menus and dialogs box, select the previously installed language. Press OK. 6. Reboot the robot controller.

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13 Installation

13.2.4

Installing the KUKA System Software

Precondition



Windows XP embedded 2.0 incl. Service Pack 2 is installed. Or Windows XP embedded 2.2 incl. Service Pack 3 is installed.

Caution! Windows Service Packs must not be installed subsequently, as the system will not be operable. 

256 MB RAM



KSS CD-ROM



Only required if there is no CD-ROM drive on the control cabinet: Bootable USB CD-ROM/DVD drive

Procedure

1. If a KSS version is already installed: Reboot the robot controller. As soon as the Windows screen is displayed, press the CTRL key and hold it down. During the loading procedure, a message referring to the Ikarus virus scanner will appear briefly. After this, keep the CTRL key held down for approximately another 15 seconds, then release it. This prevents the KSS from being started automatically. 2. Press the Windows Start button and select Run.... Navigate to the KSS CD-ROM with Browse… and start the program SETUP.EXE. 3. Select the desired language. Press the Enter key. 4. Information about the setup and copyright are displayed. Press the Enter key. 5. Select Copy CD-ROM. This window is not displayed if installing from the hard drive or server. Press the Enter key. 6. Select Install Ikarus virus scanner. Press the Enter key. 7. Select the desired customer version. Press the Enter key. 8. Only if a KSS version is already installed: It is possible to select which data are to be retained from the existing installation. Select data. Press the Enter key. 9. Select which bus drivers are to be installed. Press the Enter key. 10. The system suggests a robot type. If the type suggested does not correspond to the type used, select Browse with the TAB key and press Enter. In the MaDa directory, select the control cabinet used and the corresponding type. Press the Enter key. If, under point 8, the data from an existing KSS installation have been retained, the system does not suggest a robot type, but retains the previous one. 11. A summary of the setup settings is displayed. Press the Enter key. The installation starts. 12. A message indicates completion of the installation. Remove CD-ROM from drive. 13. Select Yes, restart computer. Press the Enter key.

13.3

Installing additional software (via KUKA.HMI) This function can be used to install additional software, e.g. technology packages. New programs and updates can be installed. The software can be installed from CD or from another path. The system checks whether the additional software is relevant for the KSS. If not, the system rejects the instal-


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lation. If a software package that the system has rejected is nonetheless to be installed, KUKA Roboter GmbH must be ed. (>>> 15.2 "KUKA Customer " Page 387) This function can also be used to uninstall additional software. Multiple additional programs can be installed or uninstalled one after the other. This function is also used to select the path for a KSS update from the network. This function cannot be used, however, to install the KSS update. (>>> 13.4 "KSS update (via KUKA.HMI)" Page 381) Precondition



CD-ROM with additional software



Only required if there is no CD-ROM drive on the control cabinet: Bootable USB CD-ROM/DVD drive



Procedure

group “Expert”

1. Select the menu sequence Setup > Install Additional Software. 2. Press the New SW softkey. If a software package on the CD-ROM in the drive is not yet displayed, press the Refresh softkey. 3. Select the software to be installed and press the softkey Install. Answer the request for confirmation with Yes. The files are copied onto the hard drive. 4. If another additional software package is to be installed, repeat step 3. 5. Depending on the specific additional software, it may be necessary to reboot the controller. In this case, a corresponding prompt will be displayed. Confirm with OK and restart the robot controller. The installation is resumed and completed.

Description The following softkeys are available: Softkey New SW

Description All programs available for installation are displayed. Programs on the CD-ROM in the drive are also displayed. Additional software already installed is displayed.

Back

Refresh

Refreshes the display, e.g. after a CD-ROM has been inserted. Shows additional softkeys:

Install



Yes: The selected software is installed. If it is necessary to reboot the controller, this is indicated by a message. 

No: The software is not installed.

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13 Installation

Softkey

Description

Config.

This softkey is only displayed if the New SW softkey has been pressed. Paths for the installation of additional software or KSS updates can be selected and saved here. Shows additional softkeys: 

Browse: A new path can be selected. 

Apply: Saves the displayed paths. Shows additional softkeys: De-install



Yes: The selected software is uninstalled. 

No: The software is not uninstalled.

13.4

KSS update (via KUKA.HMI)

Description

This function can be used to install KSS updates, e.g. from KSS 5.5.3 to KSS 5.5.4. It is advisable to archive all relevant data before updating a software package. If necessary, the old version can be restored in this way. It is also advisable to archive the new version after carrying out the update. This function cannot be used to install new versions, e.g. from KSS 5.4 to KSS 5.5. KUKA Roboter GmbH must be consulted before a new version is installed. (>>> 15 "KUKA Service" Page 387) This function cannot be used to install updates of additional software, such as technology packages. (>>> 13.3 "Installing additional software (via KUKA.HMI)" Page 379)

Warning! If machine data are reloaded after an update, the version of the machine data must correspond exactly to the KSS version. This is ensured if the machine data from the CD with the KSS update are used. The robot must not be moved if incorrect machine data are loaded. Personal injuries or damage to property may result in this case. Overview

There are 2 ways of installing a KSS update: 

From CD-ROM (>>> 13.4.2 "KSS update from CD-ROM" Page 383)



From the network (>>> 13.4.3 "KSS update from the network" Page 383)


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13.4.1

Accepting data during a KSS update -defined variables, initializations, etc., are only retained in a KSS update if they are defined in the following program sections. Programs created by the : In the Fold EXT (a sub-Fold of EXTERNAL DECLARATIONS): EXTERNAL DECLARATIONS ... EXT ;Make here your modifications

System\$config.dat: In the Fold GLOBALS: GLOBALS ;******************************************* ;Make your modifications -ONLY- here ;******************************************* ;================================== ; defined Types ;================================== ;================================== ; defined Externals ;================================== ;================================== ; defined Variables ;==================================

System\ir_stopm.src: For declarations: in the Fold DECL (a sub-Fold of DECLARATIONS) FOLD DECLARATIONS FOLD DECL ; Please insert defined declarations ;ENDFOLD ( DECL)

In the case of a stop: in the Fold STOP ;FOLD STOP ;Make your modifications here ;ENDFOLD ( STOP)

For restart: in the Fold RESTART ;FOLD RESTART ;Make your modifications here ;ENDFOLD ( RESTART)

sps.sub: For declarations: in the Fold DECL (a sub-Fold of DECLARATIONS) ;FOLD DECLARATIONS ... ;FOLD DECL ; Please insert defined declarations ;ENDFOLD ( DECL)

For initialization: in the Fold INIT (a sub-Fold of INI)

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13 Installation

;FOLD INI ... ;FOLD INIT ; Please insert defined initialization commands ;ENDFOLD ( INIT)

For a cyclical call: in the Fold PLC ;FOLD PLC ;Make your modifications here ;ENDFOLD ( PLC)

For subprograms: in the Fold SUBROUTINE (a sub-Fold of the Fold ;%{H}) ;FOLD ;%{H}) ... ;FOLD SUBROUTINE ; Integrate your defined subroutines ;ENDFOLD ( SUBROUTINE)

13.4.2

KSS update from CD-ROM

Precondition



Only required if there is no CD-ROM drive on the control cabinet: A USB CD/DVD drive is connected.

Procedure

1. Select the menu sequence Setup > Software Update > Automatic. 2. A request for confirmation is displayed, asking if the update should be carried out. Confirm by pressing the Yes softkey. 3. A message is displayed, indicating that a cold start will be forced next time the system is booted. Switch the controller off. 4. Wait until the computer has shut down completely. Then switch the controller back on. 5. Once the update has been completed, the computer is automatically shut down and rebooted. Only now may the remove the installation CD-ROM from the drive or remove the USB CD/DVD drive.

13.4.3

KSS update from the network

Description

With this kind of update, the installation data are copied from the network to the local drive D:\. If there is a copy of a KSS CD-ROM on D:\, it will be overwritten, but not until the installation data have been completely transferred. Installation is started on completion of the copying operation.

Precondition



Preparation

The network path from which the installation is to be carried out is configured as follows:

Expert group

It is only necessary to configure the network path once. It remains saved for subsequent updates. 1. Select the menu sequence Setup > Install Additional Software. 2. Press the New SW softkey. 3. Press the Config. softkey.


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4. Select the Installationpath for KRC Update from network box. Press the Browse softkey. 5. Select the desired network path. Press the Apply softkey. 6. The selected path is displayed in the Installationpath for KRC Update from network box. Press the Apply softkey. 7. Press the Close softkey. Procedure

1. Select the menu sequence Setup > Software Update > Net. 2. A request for confirmation is displayed, asking if the update should be carried out. Confirm by pressing the Yes softkey. Depending on the network utilization, the procedure may take up to 15 min. 3. A message is displayed, indicating that a cold start will be forced next time the system is booted. Switch the controller off. 4. Wait until the computer has shut down completely. Then switch the controller back on. 5. Once the update has been completed, the computer is automatically shut down and rebooted.

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14 Messages

14

Messages

14.1

System messages Details about the system messages can be found in the online help. (>>> 4.2.5 "Calling online help" Page 51)

14.2

Automatic External error messages No.

Message text

Cause

P00:1

PGNO_TYPE incorrect value permissible values (1,2,3)

The data type for the program number was entered incorrectly.

P00:2

PGNO_LENGTH incorrect value Range of values 1 ≤ PGNO_LENGTH ≤ 16

The selected program number length in bits was too high.

P00:3

PGNO_LENGTH incorrect value permissible values (4,8,12,16)

If BCD format was selected for reading the program number, a corresponding number of bits must also be set.

P00:4

PGNO_FBIT incorrect value not in the $IN range

The value “0” or a non-existent input was specified for the first bit of the program number.

P00:7

PGNO_REQ incorrect value not in the $OUT range

The value “0” or a non-existent output was specified for the output via which the program number is to be requested.

P00:10

Transmission error incorrect parity

Discrepancy detected when checking parity. A transmission error must have occurred.

P00:11

Transmission error incorrect program number

The higher-level controller has transferred a program number for which there is no CASE branch in the file CELL.SRC.

P00:12

Transmission error incorrect BCD encoding

The attempt to read the program number in BCD format led to an invalid result.

P00:13

Incorrect operating mode

The I/O interface output has not been activated, i.e. the system variable $I_O_ACTCONF currently has the value FALSE. This can have the following causes: 

The mode selector switch is not in the “Automatic External” position.



The signal $I_O_ACT currently has the value FALSE.

P00:14

Move to Home position in operating mode T1

The robot has not reached the HOME position.

P00:15

Incorrect program number

More than one input set with “1 of n”.


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15 KUKA Service

15

KUKA Service

15.1

Requesting

Introduction

The KUKA Roboter GmbH documentation offers information on operation and provides assistance with troubleshooting. For further assistance, please your local KUKA subsidiary. Faults leading to production downtime should be reported to the local KUKA subsidiary within one hour of their occurrence.

Information

15.2

The following information is required for processing a request: 

Model and serial number of the robot



Model and serial number of the controller



Model and serial number of the linear unit (if applicable)



Version of the KUKA System Software



Optional software or modifications



Archive of the software



Application used



Any external axes used



Description of the problem, duration and frequency of the fault

KUKA Customer

Availability

KUKA Customer is available in many countries. Please do not hesitate to us if you have any questions.

Argentina

Ruben Costantini S.A. (Agency) Luis Angel Huergo 13 20 Parque Industrial 2400 San Francisco (CBA) Argentina Tel. +54 3564 421033 Fax +54 3564 428877 [email protected]

Australia

Marand Precision Engineering Pty. Ltd. (Agency) 153 Keys Road Moorabbin Victoria 31 89 Australia Tel. +61 3 8552-0600 Fax +61 3 8552-0605 [email protected]


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Belgium

KUKA Automatisering + Robots N.V. Centrum Zuid 1031 3530 Houthalen Belgium Tel. +32 11 516160 Fax +32 11 526794 [email protected] www.kuka.be

Brazil

KUKA Roboter do Brasil Ltda. Avenida Franz Liszt, 80 Parque Novo Mundo Jd. Guançã CEP 02151 900 São Paulo SP Brazil Tel. +55 11 69844900 Fax +55 11 62017883 [email protected]

Chile

Robotec S.A. (Agency) Santiago de Chile Chile Tel. +56 2 331-5951 Fax +56 2 331-5952 [email protected] www.robotec.cl

China

KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd. Shanghai Qingpu Industrial Zone No. 502 Tianying Rd. 201712 Shanghai P.R. China Tel. +86 21 5922-8652 Fax +86 21 5922-8538 [email protected] www.kuka.cn

KUKA Roboter GmbH Zugspitzstr. 140 86165 Augsburg Tel. +49 821 797-4000 Fax +49 821 797-1616 [email protected] www.kuka-roboter.de


15 KUKA Service

KUKA Automatisme + Robotique SAS Techvallée 6, Avenue du Parc 91140 Villebon S/Yvette Tel. +33 1 6931660-0 Fax +33 1 6931660-1 [email protected] www.kuka.fr

India

KUKA Robotics, Private Limited 621 Galleria Towers DLF Phase IV 122 002 Gurgaon Haryana India Tel. +91 124 4148574 [email protected] www.kuka.in

Italy

KUKA Roboter Italia S.p.A. Via Pavia 9/a - int.6 10098 Rivoli (TO) Italy Tel. +39 011 959-5013 Fax +39 011 959-5141 [email protected] www.kuka.it

Japan

KUKA Robotics Japan K.K. Daiba Garden City Building 1F 2-3-5 Daiba, Minato-ku Tokyo 135-0091 Japan Tel. +81 3 6380-7311 Fax +81 3 6380-7312 [email protected]

Korea

KUKA Robot Automation Korea Co. Ltd. 4 Ba 806 Sihwa Ind. Complex Sung-Gok Dong, Ansan City Kyunggi Do 425-110 Korea Tel. +82 31 496-9937 or -9938 Fax +82 31 496-9939 [email protected]


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Malaysia

KUKA Robot Automation Sdn Bhd South East Asia Regional Office No. 24, Jalan TPP 1/10 Taman Industri Puchong 47100 Puchong Selangor Malaysia Tel. +60 3 8061-0613 or -0614 Fax +60 3 8061-7386 [email protected]

Mexico

KUKA de Mexico S. de R.L. de C.V. Rio San Joaquin #339, Local 5 Colonia Pensil Sur C.P. 11490 Mexico D.F. Mexico Tel. +52 55 5203-8407 Fax +52 55 5203-8148 [email protected]

Norway

KUKA Sveiseanlegg + Roboter Bryggeveien 9 2821 Gjövik Norway Tel. +47 61 133422 Fax +47 61 186200 [email protected]

Austria

KUKA Roboter Austria GmbH Vertriebsbüro Österreich Regensburger Strasse 9/1 4020 Linz Austria Tel. +43 732 784752 Fax +43 732 793880 [email protected] www.kuka-roboter.at

Poland

KUKA Roboter Austria GmbH Spółka z ograniczoną odpowiedzialnością Oddział w Polsce Ul. Porcelanowa 10 40-246 Katowice Poland Tel. +48 327 30 32 13 or -14 Fax +48 327 30 32 26 [email protected]


15 KUKA Service

Portugal

KUKA Sistemas de Automatización S.A. Rua do Alto da Guerra n° 50 Armazém 04 2910 011 Setúbal Portugal Tel. +351 265 729780 Fax +351 265 729782 [email protected]

Russia

OOO KUKA Robotics Rus Webnaja ul. 8A 107143 Moskau Russia Tel. +7 495 781-31-20 Fax +7 495 781-31-19 kuka-robotics.ru

Sweden

KUKA Svetsanläggningar + Robotar AB A. Odhners gata 15 421 30 Västra Frölunda Sweden Tel. +46 31 7266-200 Fax +46 31 7266-201 [email protected]

Switzerland

KUKA Roboter Schweiz AG Riedstr. 7 8953 Dietikon Switzerland Tel. +41 44 74490-90 Fax +41 44 74490-91 [email protected] www.kuka-roboter.ch

Spain

KUKA Robots IBÉRICA, S.A. Pol. Industrial Torrent de la Pastera Carrer del Bages s/n 08800 Vilanova i la Geltrú (Barcelona) Spain Tel. +34 93 8142-353 Fax +34 93 8142-950 [email protected] www.kuka-e.com


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South Africa

Jendamark Automation LTD (Agency) 76a York Road North End 6000 Port Elizabeth South Africa Tel. +27 41 391 4700 Fax +27 41 373 3869 www.jendamark.co.za

Taiwan

KUKA Robot Automation Taiwan Co. Ltd. 136, Section 2, Huanjung E. Road Jungli City, Taoyuan Taiwan 320 Tel. +886 3 4371902 Fax +886 3 2830023 [email protected] www.kuka.com.tw

Thailand

KUKA Robot Automation (M)SdnBhd Thailand Office c/o Maccall System Co. Ltd. 49/9-10 Soi Kingkaew 30 Kingkaew Road Tt. Rachatheva, A. Bangpli Samutprakarn 10540 Thailand Tel. +66 2 7502737 Fax +66 2 6612355 [email protected] www.kuka-roboter.de

Czech Republic

KUKA Roboter Austria GmbH Organisation Tschechien und Slowakei Sezemická 2757/2 193 00 Praha Horní Počernice Czech Republic Tel. +420 22 62 12 27 2 Fax +420 22 62 12 27 0 [email protected]

Hungary

KUKA Robotics Hungaria Kft. Fö út 140 2335 Taksony Hungary Tel. +36 24 501609 Fax +36 24 477031 [email protected]


15 KUKA Service

USA

KUKA Robotics Corp. 22500 Key Drive Clinton Township 48036 Michigan USA Tel. +1 866 8735852 Fax +1 586 5692087 [email protected] www.kukarobotics.com

UK

KUKA Automation + Robotics Hereward Rise Halesowen B62 8AN UK Tel. +44 121 585-0800 Fax +44 121 585-0900 [email protected]


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Index

Index Symbols _TYP 292 _TYPE 294 #BSTEP 220 #CSTEP 221 #GO 220 #IGNORE 249, 250 #ISTEP 220 #MSTEP 220 #PSTEP 221 $ 287 $ADAP_ACC 133, 138 $ADVANCE 221 $ANIN 271 $ANOUT 271 $CIRC_TYPE 251 $COLL_ALARM 134 $COLL_ENABLE 134 $COOLDOWN_TIME 132 $CURR_ACT 175 $CURR_RED 172 $IN 271 $INSIM_TBL 121 $IOSIM_OPT 121 $JERK 303 $ORI_TYPE 236, 249 $OUT 271 $OUTSIM_TBL 121 $PAL_MODE 80 $PRO_IP 348 $PRO_MODE 221 $RDC_FLASH_DEFECT 82 $ROBRUNTIME 74, 75 $TORQ_DIFF 134, 138 $TORQ_DIFF2 134 $TORQ_VEL 174 $TORQMON_COM_DEF 134 $TORQMON_DEF 134 $TORQMON_TIME 134, 139 $TORQUE_AXIS 171 $TRACE.MODE 357 $TRACE.NAME 357 $TRACE.STATE 357 $WARMUP_CURR_LIMIT 133 $WARMUP_MIN_FAC 133 $WARMUP_RED_VEL 132 $WARMUP_SLEW_RATE 133 $WARMUP_TIME 132 Numbers 2004/108/EC 39 2006/42/EC 39 3-point method 103 89/336/EEC 39 95/16/EC 39 97/23/EC 39


A ABC 2-Point method 95 ABC World method 96 Acceleration, maximum for technologies 128 Accessories 15, 17 Actual position 66 55 Advance run 221 Advance run stop 305 All FOLDs close (menu item) 220 All FOLDs open (menu item) 220 ALT 42 Anaputs 312 Analog outputs 313 ANIN 312 ANOUT 272, 313 Applied norms and regulations 39 Approximate positioning 234, 262, 263 Archive (menu item) 230 ARCHIVE.ZIP 230 Archiving 200, 203, 229 Areas of validity 289 Arrow keys 41 ASCII Mode (menu item) 219 Attributes (menu item) 208 AUT 24, 57 AUT and EXT Consistency 182 AUT EXT 24, 57 Automatic 24, 57 Automatic External 24, 57 Automatic External error messages 385 Automatic mode 36 Auxiliary point 234, 300, 301 Axis range 19 Axis range limitation 28 Axis range monitoring 28 Axis selection 61 B Backward motion 141, 220, 224 Base (external kinematic system), calibration 108 Base calibration 102 BASE coordinate system 58, 102 Base type (menu item) 117 BIOS 74 Block pointer 215, 221 Block selection 224, 242 BOF Reinitialization (menu item) 128 BRAKE 320 Brake defect 31 Braking distance 19 Braking the robot motion 320 Branch, conditional 308 Brightness 51 BW_INI.EXE 143

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C Calibrating an external kinematic system 105 Calibration 91 Calibration, base 102 Calibration, base (external kinematic system) 108 Calibration, external T 98 Calibration, fixed tool 98 Calibration, root point, kinematic system 106 Calibration, tool 91 Calibration, TOOL kinematic system 110 Calibration, workpiece 98 Caller stack 348 Caller Stack (menu item) 348 CASE 309 CAST_FROM 333 CAST_TO 333 CCLOSE 333 CE mark 18 CELL.SRC 225 CHANNEL 333 Check box 49 CIOCTL 333 CIRC 300 CIRC motion 259 CIRC_REL 301 CIRC, motion type 234 Circular motion 300, 301 Circular_Angle 300, 302 Cleaning work 37 Cold start 54 Collision detection 133, 135 Collision detection (menu item) 135 Collision detection, Automatic External 137 Collision detection, offset 135 Collision detection, system variables 134 Collision detection, variable 136 Comment 227 Comparison, data from kernel system and hard drive 182 Conditional branch 308 Configuration 117 Configure (menu item) 117 Configuring CELL.SRC 154 Connecting cables 15, 17 CONST_KEY 290, 292 Constants 290 CONTINUE 305 Continuous Path 233 Contrast 51 Coordinate systems 57 Coordinate systems, angles 59 Coordinate systems, orientation 59 COPEN 333 Copy 228 Counterbalancing system 37 motions 233 CREAD 333 Creating a new folder 212 Creating a new program 213 Cross-connections 33 396 / 403

Current FOLD open/close (menu item) 220 Current, limiting 173 Cut 228 CWRITE 333 Cycle time, optimizing 128 D Danger zone 19 DAT 286 Data list 286 Data lists, external 293 Data types 288 Data, restoring 230 DECL 291 Declaration of conformity 18 Declaration of incorporation 17, 18 Decommissioning 38 DEF line, displaying/hiding 218 DEF_ACC_ 129 Def-line (menu item) 218 DEFAULT 309 Default data type 291 Defining calibration tolerances 141 Deleting mastering 90 Detail view (ASCII mode), activating 219 Diagnosis 347 Dial gauge 87 Directory structure 186, 207 Disable PowerOff Delay (menu item) 119 Disabling the robot controller 55 Display (menu item) 72 Displaying a variable, single 70, 71 Displaying the logbook 347 Displaying variables, in overview 72 Displaying, robot controller information 73 Displaying, robot information 73 Disposal 38 DISTANCE 325 Documentation, industrial robot 13 Dominant mode 62 Drives OFF 23, 41 Drives ON 23, 41 E EC declaration of conformity 18 Editing a program 225 Editor 214 Electronic measuring tool 84 ELSE 308 EMC Directive 18, 39 EMERGENCY STOP 22, 41 EMERGENCY STOP button 22, 23, 25, 34 EMERGENCY STOP device 25, 26, 30 EMERGENCY STOP, external 22, 23, 26, 34 EMERGENCY STOP, local 22, 23, 34 EMT 84 EN 60204-1 40 EN 61000-6-2 40 EN 61000-6-4 40 EN 614-1 39 EN ISO 10218-1 39 Issued: 28.10.2010 Version: KSS 5.5 SI V2 en

Index

EN ISO 12100-1 39 EN ISO 12100-2 39 EN ISO 13849-1 39 EN ISO 13849-2 39 EN ISO 13850 39 Enabling device 23, 26, 30 Enabling device, external 27 Enabling switch 44 Enabling switches 26, 27 Encrypted files 213 Encryption 213 ENDFOR 306 ENDIF 308 Endless loop 308 ENDLOOP 308 ENDSPLINE 303 ENDSWITCH 309 ENDWHILE 311 Enter key 41 ENUM 292 Enumeration type 292 error messages, Automatic External 385 ESC 23 ESC key 41 Event planner (menu item) 182 EXIT 305, 308 External axes 17, 19, 66, 74 External kinematic system, calibration 105 F F 320 FALSE 319 Faults 32 File list 186, 207 File, renaming 213 Filter 187, 208 Find 229 Firewall 35 First mastering 85 Fixed tool, calibration 98 FLANGE coordinate system 58, 91 Floppy disk, formatting 230 Folder, creating 212 Folds 219 Folds, creating 228 Folds, displaying 219 Fonts 286 FOR 311 FOR ... TO ... ENDFOR 306 Function test 34 Function, enabling 153 Functions 287 G General safety measures 31 Global 290 GLOBAL (interrupt declaration) 321 GLOBAL_KEY 290, 321 GOTO 307 Group 49 Guard interlock 24 Issued: 28.10.2010 Version: KSS 5.5 SI V2 en

H HALT 307 Hard drive, exchange 79 Hardware, information about 76 Hazardous substances 38 Header 186, 207 Help 51 Hibernate 54 HOME position 218 HOV 60 I I/O driver, reconfiguring 117 I/Os, reconfiguring 117 IF ... THEN ... ENDIF 308 Impact 134, 135 IMPORT ... IS 293 Increment 65 Incremental jogging 64 Incremental Step 220 Indirect method 104 Industrial robot 15, 17 Info (menu item) 73 Inline forms 257 Input box 48 Inputs, qualifying 22 Inputs/outputs, analog 67, 270 Inputs/outputs, Automatic External 68, 155 Inputs/outputs, digital 66, 270 Installation 377 Intended use 17 Interpolation mode 261 INTERRUPT 320, 322 Interrupt 320 Interrupt program 321 Interrupts 349 Introduction 13 J Jerk 267 Jerk limitation 267, 303 Jog keys 59, 60, 61 Jog mode 27, 30 Jog override 60 Jogging, axis-specific 59, 60 Jogging, Cartesian 59, 61, 64 Jogging, robot 59 Jump 307 K K 19, 31, 41 K coupler 29, 44 K coupler, display 45 K coupler, operator control elements 45 K coupler, visualization 45 K, coupling 46 K, uncoupling 45 Keyboard, external 31 Keypad 41, 42 Keywords 287 KRC Configurator 184 397 / 403


KrcConfigurator.exe 184 KRL syntax 285 KSS 15 KUKA Control 41 KUKA Customer 73, 387 KUKA.HMI 16, 47 KUKA.Load 112 KUKA.Load Detect 112 L Labeling 29 Language 54 Liability 17 Limit point correction (menu item) 129 LIN 297 LIN motion 258 LIN_REL 298 LIN, motion type 233 Line break 221 Linear motion 297, 298 Linear unit 17, 105 Linebreak (menu item) 219 List box 49 Load data 111 Log On... (softkey) 55 Log-in, configuring 147 Logbook 347 Logic Consistency 182, 183 Long text (menu item) 114 Long text names 113 LOOP ... ENDLOOP 308 Loss of mastering 84, 86 Low Voltage Directive 18 M Machine data 35, 74, 75, 78, 381 Machinery Directive 18, 39 Main window 48 Maintenance 36 Manipulator 15, 17, 19, 21 Manual High Velocity 24, 57 Manual mode 35 Manual Reduced Velocity 24, 57 Mastering 81 Mastering after maintenance work 89 Mastering marks 82, 83 Mastering methods 82 Mastering, automatic saving 82 Mastering, saving 90 Measurement Points (menu item) 73 Mechanical axis range limitation 28 Mechanical end stops 28 Menu items, identification numbers 151 Menu keys 41, 47 Message window 48 Messages 48, 385 Mode selector switch 23, 41, 56 Modifying a logic instruction 284 Modifying a variable 70 Modifying coordinates 270 Modifying motion parameters 270 398 / 403

Modifying variables 72 Modifying, file properties 208 Module 287 Monitoring, adding files 198 Motion programming, basic principles 233 Motion Step 220 Motion types 233 Motor, exchange 89 Mouse configuration (menu item) 61 Mouse position (menu item) 63 Mouse, external 31 N Name, control PC 74 Name, robot 74, 75 Name, virus scanner 74 Names 287 Navigator 184, 207 Network security 35 Non-rejecting loop 309 NUM 42 Numeric entry, base 105 Numeric entry, external T 100 Numeric entry, external tool 111 Numeric entry, offset base 110 Numeric entry, root point, kinematic system 107 Numeric entry, tool 97 Numeric keypad 41, 43 O Offset 84, 85, 273 Online help 51 Online help - Contents/Index (menu item) 51 Online help (menu item) 51 Online optimizing 182, 184 Opening a program 214 Operating hours 75 Operating hours meter 75 Operating modes 23 Operating system 56 Operation 41 Operator 19, 20, 55 Operator safety 23, 24, 30 Optimizing the cycle time 128 Option box 49 Option window 48 Options 15, 17 Orientation control 267 Orientation control (spline) 267 Orientation control, LIN, CIRC 236 Oscilloscope, activating/deactivating curves 367 Oscilloscope, changing colors 368 Oscilloscope, configuring 351 Oscilloscope, cursor functions 373 Oscilloscope, determining the r.m.s. value 371 Oscilloscope, displaying data 362 Oscilloscope, enlarging the display 368 Oscilloscope, filtering the display 370 Oscilloscope, overview 350 Oscilloscope, printing the display 375 Oscilloscope, saving display as BMP file 375 Issued: 28.10.2010 Version: KSS 5.5 SI V2 en

Index

Oscilloscope, scaling curves 368 Oscilloscope, starting 351 Oscilloscope, starting via a program 357 Oscilloscope, status 353 Oscilloscope, superimposing traces 367 OUT 271 Output, analog 272 Output, digital 271 Overload 31 Override 60, 222 Override (menu item) 66 Overview of the industrial robot 15 P Palletizing robots 78, 80, 92, 97 Panic position 26 , changing 119 Paste 228 PATH 328, 331 Payload data 112 Payload data (menu item) 112 Performance Level 22 Personnel 19 Plant integrator 19 Point correction, defining limits 129 Point-to-point 233 Point-to-point motion 295, 296 Pop-up menu 208 Positioner 17, 105 POV 222 Pre-mastering position 82 Pressure Equipment Directive 37, 39 Preventive maintenance work 37 Printing a program 229 Priority 321, 327, 330, 332 Product description 15 Program lines, deleting 227 Program management 207 Program override 222 Program run modes 220 Program, closing 216 Program, creating 213 Program, deselecting 215 Program, opening 214 Program, selecting 214 Program, starting 223 Programmer 55 Programming, Expert 285 Programming, inline forms 257 Programming, KRL syntax 285 Programming, 257 Protective equipment 27 PTP 295 PTP motion 257 PTP_REL 296 PTP, motion type 233 PUBLIC 293 PULSE 272, 314 Pulse 272, 314 Pulse, path-related 283


Q Qualifying inputs 23, 34 R Rating plate 44, 79 RDC, exchange 80, 89 Reaction distance 19 Recommissioning 33, 77 Reference mastering 89 Rejecting loop 311 Release device 29 Renaming a file 213 Renaming the base 117 Renaming the tool 117 Repair 36 REPEAT ... UNTIL 309 Replace 229 Request button 45 Request LED 45 Resetting a program 225 Restart Windows 54 Restart, Windows 53 Restarting, KSS 52 RESUME 172, 174, 180, 324 RETURN 319 Robot controller 15, 17, 35 Robot data (menu item) 74, 79, 80 ROBROOT coordinate system 57 S Safeguards, external 30 Safety 17 Safety functions 30 Safety instructions 13 Safety logic 23 Safety zone 19, 21 Safety, general 17 SCAN 143 SCIRC 304 SCIRC segment, programming 268 SEC 311 Selecting a program 214 Selecting the base 60 Selecting the tool 60 Serial number 75 Service life 74 Service life, safety 32 Service life, safety bus terminals 32 Service, KUKA Roboter 387 Set tool/base (menu item) 60 SHIFT 43 Shut down KRC (menu item) 52 SIGNAL 318 Signal diagrams 163 Simulating inputs/outputs 120 Simulation 36 Single (menu item) 70, 71, 138 Single point of control 38 Singularities 255 Slider 49 SLIN 304 399 / 403


SLIN segment, programming 267 Soft axes 169 Softkey position, defining 152 Softkeys 41, 47 Softkeys, identification numbers 151 Software 15, 17 Software components 15, 377 Software limit switch 90 Software limit switches 27, 30 Space Mouse 41, 59, 61, 63, 64 Special characters 257 SPL 304 SPL segment, programming 267 SPLINE 331 SPLINE ... ENDSPLINE 303 Spline block, programming 265 Spline motion, orientation control 267 Spline motions 263 Spline, motion type 239 SPS.SUB, modifying 342 SRC 286 SREAD 333 SSB GUI 41 Stamp 227 Start backwards key 41 Start key 41, 44 Start type, KSS 53 Start Types (menu item) 53 Start-up 33, 77 Starting a program, automatic 223 Starting a program, backwards 224 Starting a program, manual 223 Starting Automatic External mode 225 Starting the KSS 52 Status 251 Status bar 50, 186, 207 Status keys 41, 47 Status keys (menu item) 117 Status keys, technology package 117 STEP 306 STOP 0 19, 22 STOP 1 19, 22 STOP 2 19, 22 Stop category 0 19 Stop category 1 19 Stop category 2 19 STOP key 41 Stop reactions 21 Stopping a program 223, 224, 225 Stopping distance 19, 21 Storage 38 Storage capacities 74 String variable length after initialization 336 String variable length in the declaration 335 String variable, deleting contents 336 String variables 335 String variables, comparing contents 338 String variables, copying 339 String variables, extending 337 String variables, searching 338 STRUC 294 400 / 403

Structure type 294 Submit interpreter 50, 341 Submit interpreter, modifying SPS.SUB 342 Submit interpreter, starting 342 Submit interpreter, stopping 342 Subprograms 287 Supplementary load data (menu item) 113 request 387 SWITCH ... CASE ... ENDSWITCH 309 Switching action, path-related 277 Switching on the robot controller 52 SWRITE 333 SYM 43 Symbols 286 SYN OUT 277 SYN PULSE 283 System integrator 18, 19, 20 T T1 19, 24, 57 T1 and T2 Consistency 182 T2 19, 24, 57 TAB 43 T 91 T, external 98 Teach pendant 15, 17, 41 Teaching 270 Technology package, status keys 117 Technology packages 16, 74, 257 Templates 195 used, safety 19 tm_action 133 TMx 136 Tolerances, calibration 141 Tool calibration 91 Tool Center Point 91 TOOL coordinate system 58, 91 Tool type (menu item) 117 Tool, external 110 Torque 134, 135 Torque mode, activation/deactivation 171 Torque mode, examples 170, 176 Torque mode, overview 169 Torque mode, system variables 171 Torque monitoring 138 Torque monitoring (menu item) 139 TRACE 142 Trademarks 13 Training 13 Transport position 32, 33 Transportation 32 TRC file 351, 352 TRIGGER 325, 328, 331 Turn 251 Turn-tilt table 17, 105 Type, robot 74 Type, robot controller 74 U Unmastering 90 UNTIL 309 Issued: 28.10.2010 Version: KSS 5.5 SI V2 en

Index

Update 381 Upper-case/lower-case 43, 50 Use, contrary to intended use 17 Use, improper 17 19 group, changing 55 group, default 55, 149 group, defining the default group 154 group, setting up 151 groups, identification numbers 151 interface 47 interface, refreshing 128 V Variable correction 70 Variable overview, configuring 117 VARSTATE() 333 Velocity 60, 222 Version, BIOS 74 Version, kernel system 74 Version, operating system 74 Version, robot controller 74 Version, interface 74 Version, virus scanner 74 Virus protection 35 Virus scanner 74 Voltage 68, 271, 273, 274 W WAIT 274, 311 WAIT FOR 311 Wait function, signal-dependent 275 WAIT SEC 311 Wait time 274, 311 WAITFOR 275 Warm start 54 Warm-up 130 Warnings 13 WHILE ... ENDWHILE 311 Window selection key 41 Windows Service Pack 379 Windows, changing the language 378 Windows, installing 378 Windows, restart 53, 54 Working range limitation 28 Workspace 19, 21 Workspace monitoring, bying 65 Workspaces, axis-specific 122 Workspaces, Cartesian 122 Workspaces, cubic 122 WORLD coordinate system 57 X XYZ 4-Point method 92 XYZ Reference method 94


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