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1. Fig 5 Integration of Force Torque Control 4 2 Robot Sensor Interface RSI Robot Sensor Interface is used to integrate any kind of sensor into the robot controller and provides an interface for various sensor applications Usually external interfaces are used to connect sensor systems with RSI it is possible to use KUKA Robot Language for integration Just as Force Torque Control Robot Sensor Interface extends the functions of the KUKA controller by adding more commands and options to KUKA Robot Language These commands are for example used for transformations comparison operations and controlling velocity and positioning Additionally RSI serves as a signal processing application By creating so called objects that consist of three elements inputs outputs and functions the programmer can decide how signals respectively outputs from the sensors should be processed A simple AND function could cause two inputs lead to one output for instance 2 unwanted forces acting on the work piece are received by the sensors and the robot automatically performs an appropriate compensation movement into the respective direction 4 3 KUKA Safe Robot To ensure safety while working with the robot via Safe Teaching KUKA Safe Robot functions as an axis range monitoring system that consists of hard and software components Hereby safe evaluation of the actual axis positions as well as cyclical monitoring of the reference positions is provided T
2. An SRC file and a DAT file are created containing a skeleton program Expert An SRC file and a DAT file are created containing merely the header DEF and END Cell Here only an SRC file containing a skeleton program is created This program is used for controlling the robot via a central PLC Function Here a function SRC file is created containing the header DEF and END Submit A SUB file with a skeleton program is created The Submit file contains instructions and can be used for example for cyclical monitoring grippers etc The Submit file works parallel to the robot and is processed by the controller interpreter Expert Submit As with the Submit template a SUB file is created this time containing merely the header DEF and END Tab 5 Templates for creating new programs 5 5 3 2 Editing compiling and linking a program After you have created a file or data list by means of New you can edit them using the editor The softkey Edit is used for this purpose On closing the editor the complete program code is compiled i e the textual KRL code is translated into a machine language that can be understood by the controller 33 In order to retain the clarity of the program branches for example must be indented at several levels In the editor this can be done using the space bar In this process the compiler checks that the code is syntactically and semantically correct If errors are detected a correspo
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4. and one for the reference run Parking position If a brake is defective the robot can be moved to the parking position The parking position must be selected in a position where the robot can sag safely The parking position should match with the transport position of the robot Reference run The reference run is used to check whether the mechanical position of the robot correspond to the resolver encoder values A reference run is required after e The robot controller has booted e Mastering Reference group The axes required for moving to the reference position are listed in the reference group Each configured axis must be assigned to the reference group Reference position During the reference run the reference position must be addressed in order to trigger the reference switch Safety zone The safety zone is the part of an axis range which is outside of the danger zone Safe operational stop The safe operational stop causes the robot to stop safely during operation The drives remain activated and the standstill monitoring is active STOP 0 In the case of a STOP O the drives are deactivated immediately and the brakes are applied The robot is stopped with path oriented braking STOP 1 In the case of a STOP 1 the robot brakes on the programmed path for 1 s The drives are then deactivated and the brakes are applied STOP 2 In the case of a STOP 2 the drives are not deactivated and the brakes are not applied The rob
5. robot Procedure 1 Prepare a mechanical mounting fixture for mounting the reference switch 2 Attach the reference switch to the mounting fixture 3 Fasten the actuating plate to the tool The mounting position of the actuating plate depends on the specific tool that is mounted 5 2 5 Safety 5 2 5 1 Robot system The robot system with KUKA Safe Robot must be operated in accordance with the applicable national laws regulations and standards The user must ensure that KUKA Safe Robot can be operated in complete safety The service life of the KUKA Safe Robot specific hardware components is 40 000 operating hours as counted by the operating hours meter Once this time has elapsed the KUKA Safe Robot specific hardware components must be exchanged 5 2 5 2 Workspaces The permanently monitored workspace 1 may only be used as a working range limitation if the braking distance is taken into consideration If this is not possible main axes A1 A3 must additionally be fitted with mechanical working range limitation 17 If the robot violates one of the axis limits of workspaces 8 10 the robot continues its motion without slowing down 5 2 5 3 Reference run When a reference run is carried out all axes must be switched to synchronous Otherwise they would be ignored in the reference run 5 2 5 4 Brake test If a brake is defective the parking position must be approached with a maximum velocity of 10 Robot axes A1 A6 a
6. the robot controller generates a message A brake test must be carried out in the following cases e After the robot controller has booted e Cyclically during operation every 46 h at the latest e The brake test can be called in the following ways e As a subprogram after the parameterized brake test cycle time 20 e Via an external signal e Manually The brake test cycle time can be freely selected in one hour increments between 1 h and 46 h Once this time has elapsed the robot controller generates the message Brake test required and the robot continues its motion without slowing down Once this message has been acknowledged the monitoring time starts and the robot can be moved for another 2 hours Once the monitoring time has elapsed the robot stops and the robot controller generates the following message No brake test carried out in the last two hours The programs required for the brake test are located in the folder KRC ROBOTER KRC R1 TP SAFEROBOT 5 2 9 1 2 Programming the brake test Assumptions User group is set to Safety maintenance Operating mode is set to T1 Procedure 1 Open the program BrakeTestStart SRC 2 Program the motion to the start position of the brake test and teach the required points 3 Close and save program 4 Open the program BrakeTestEnd SRC 5 Program the motion to the end position of the brake test and teach the required points Close and save program Open the program BrakeTestPark SRC
7. Configure menu Fig 17 of the KUKA Control Panel 1 Not available below Expert level to i s Def line omceGuroyor Monit working env Override 4 L Configuration echnology selection 1 Reinitialization USER Tech reinit e 1 BOF Reinitialization i Fig 17 Configure menu BR 5 5 8 2 I O Options for gripper and Automatic External interface settings are offered under the menu item I O Fig 18 5 8 2 1 Gripper D Gripper 11 0 Driver gt 1 Automatic External 2SUBMIT Interpreter gt 3 Statuskeys 4 Jogging gt 5 User group 6 Cur tool base Tool definition r 8 On Off options 9 Miscellaneous gt Fig 18 I O menu item Once the option Gripper has been selected the status window for gripper configuration is opened Fig 19 The default setting for the number of grippers available is 16 Gripper lt Name gt Name of the gripper Gripper type lt Number gt Functional type of gripper Outputs lt Number gt Assignment of robot controller outputs to gripper actuators Inputs lt Number gt Assignment of robot controller inputs to gripper sensors State lt Name gt Designation of the gripper states dependent on the gripper type i e open closed Fig 19 Status window for gripper configuration 46 5 8 3 1 O Driver Fig 20 Using the functions offered here you can configure and reset the peripheral interfaces of the
8. Program the motion to the parking position of the robot and teach the required points The parking position should correspond to the transport position 9 Close and save program 10 Set the brake test cycle time in the variable BRAKETEST CYCLETIME in the file KRC ROBOTERI INIT BrakeTestDrv INI 11 Integrate the program BrakeTestReq SRC in the application and run it every 2 hours at the latest a oa 5 2 9 2 Reference run 5 2 9 2 1 Overview of the reference run The reference run is used to check if the mechanical position of the robot and the external axes correspond to the resolver encoder values If the deviation is too great the robot can no longer move to the reference position The robot stops with a STOP1 and can now only be moved in T1 mode In this case the robot controller generates the message Mastering test failed If the reference run was successful the robot can be safely monitored using the Safe RDC The reference run must be carried out in the following cases After the robot controller has booted After mastering The reference run can be called in the following ways Via an external signal Manually If during operation the reference run is requested via the external signal the robot stops with a STOP2 In this case the following messages are generated e Mastering test required e Safety mode not possible 21 The robot can now only be moved in T1 mode and activation of the workspaces in the configuratio
9. a danger zone or a safety zone 14 Workspace A workspace is the space wherein the robot is allowed to move It is deviated from the different axis ranges KUKA Safe Robot has the following workspaces Workspace 1 Permanently monitored and always active It can be modified but not deactivated Workspaces 2 to 7 Activated using safe inputs Workspaces 8 to 10 These are always active and set safe outputs which can be wired externally These workspaces do not trigger a stop the robot continues its motion without slowing down Brake test In the brake test the robot controller checks the functionality and wear out of the brakes The brakes have to be tested in the following cases e After the robot controller has booted e Atleast every 46 hours during continuous operation Brake test cycle time The brake test cycle time is the time after which the robot controller initiates a brake test Braking distance The braking distance is the distance the robot needs to come to a standstill after the brakes have been applied It is part of the danger zone and should not exceed 30 Danger zone The danger zone consists of the workspace and the braking distances Monitoring time The monitoring time is 2 h If a brake test or a reference run is required a timer is started The robot can be moved during this time Once this time has elapsed the robot stops There are 2 timers which are independent of one another one for the brake test
10. all axes with shorter trajectories Phase synchronous motion control gives additionally a motion path which irrespective of the programmed velocity and acceleration always follows the same course 5 5 6 2 Linear motions In the case of a linear motion the KRC calculates a straight line from the current position the last point programmed in the program to the position specified in the motion command A linear motion is programmed using the keywords LIN or LIN_REL in connection with the specification of the end point i e analogous to PTP programming The end position for linear motions is entered with Cartesian coordinates Only the data tyoes FRAME or POS are thus permissible In the case of linear motions the angle status of the end point must always be the same as that of the start point Specification of Status and Turn for an end point of the data type POS will thus be ignored A PTP motion with complete coordinate specification e g HOME run must therefore be programmed before the first LIN instruction The assignment of velocity and acceleration variables necessary for continuous path motions as well as the setting of tool and base coordinate systems is again carried out in the following sample program using the initialization routine BAS SRC 5 5 7 Program branches 5 5 7 1 Conditional branch The structured IF statement allows instructions to be formulated conditionally with a choice of two alternatives The general form for
11. from within a subprogram or function The maximum permissible nesting depth is 20 If this is exceeded the error message PROGRAM STACK OVERFLOW is generated Recurrent calling of subprograms and functions is allowed In other words a subprogram or function can recall itself All subprograms are declared in exactly the same way as the main program with the DEF declaration plus name and concluded with END e g DEF SUBPROG END 38 PROG SRC DEF PROG Main program SUBPROG Subprogram cali SUBPROG Subprogram call End main program DEF SUBPROG Subprogram END End main program Fig 14 Subprogram call and return to main program 5 5 8 2 Local A fundamental distinction is made between local and global subprograms or functions In the case of local subprograms or functions the main program and the subprograms functions are found in the same SRC file The file bears the name of the main program The main program is always situated at the head of the source text and can be followed by any quantity of subprograms and functions in any order 5 5 8 3 Global Local subprograms functions can only be called from within the SRC file in which they were programmed If it is necessary to be able to call subprograms functions from other programs they must be global i e saved in a separate SRC file Fig 15 Global subprograms or functions are saved in a separate SRC file In this way every program becom
12. monitoring Safe RDC Resolver Digital Converter for KUKA Safe Robot RSI KUKA Robot Sensor Interface KGD software KRL KUKA Robot Language KUKA programming language Amatec Lib Additional software for RSI Tab 4 Safe handling terms 5 3 3 Hardware overview 5 3 3 1 KUKA Guiding Device KGD An optical sensor supplies the control signals to the robot controller Fig 10 These signals are used to move the robot 1 EMERGENCY STOP 2 Touch display 3 Joystick 4 Enabling switch Fig 10 Safe Handling controller 23 5 3 3 2 Connected components The individual hardware components are connected to the ESC safety logic via the interface on the control cabinet Fig 11 1 Interfaces on control cabinet X22 X23 2 ESC CIS 3 Safe RDC interfaces X22 X40 4 Connection if KGD mounted on robot 5 KGD connection 6 Terminating resistor 7 Safety PLC optional 8 Return signals from PLC to Safe RDC 9 External signal example roll door Fig 11 Component connection plan Terminating resistor The terminating resistor is required to complete the EMERGENCY STOP and enabling circuits The CAN bus terminator is also located in the terminating resistor 5 3 4 Safety instructions Do not connect and disconnect cables during operation The minimum bending radius of 150 mm must be observed when routing cables for fixed installation The encoder and data cables are coded and cannot b
13. options for bus devices 2x CAN bus 24 V DC and expanded bus connections different applications additional devices Fig 4 Multi power tap 4 Software Modules To use Safe Teaching some additional software modules need to be integrated into the conventional robot system These modules are Force Torque Control FTCtrl Robot Sensor Interface RSI and KUKA Safe Robot 4 1 Force Torque Control FTCtrl Force Torque Control extends the KUKA robot by the ability to control process forces contact forces and torques at programmable nominal values Thereby the force controlled robot can autonomously move to the position where the programmable forces are applied to a work piece or tool without programming an explicit move command The contact forces and torques are measured and processed every 12 ms The necessary software is implemented in the real time core of the robot control and accessible through KUKA Robot Language Fig 5 Further functions of Force Torque Control are the detection and reaction to a specific load condition and sensor load monitoring to protect the sensors from damage due to overload By adding a sense of touch to the robot applications such as polishing grinding and assembling which in the past had to be done by hand now become suitable for robot systems User Interface KRL Special FTC Commands Path Planning 9 1 de orce Torque Aq qe Sensor orce Torque Controller Fy F F M MM
14. the command override is reduced by WARMUP_MIN_FAC at most until the permissible motor current is no longer exceeded The status message Warm up active is displayed in the message window When the monitoring is no longer triggered the override is gradually increased by the value of WARMUP_SLEW_RATE up to the command value set for the override Once the warm up time has elapsed the velocity reduction is deactivated and the currents are no longer monitored 5 8 11 Cool down time The time in which the robot is not moved is calculated as the cooling time Cool down time can even include the time taken to shut the system down followed by a warm restart If the cool down time exceeds the value defined in the variable COOLDOWN_TIME the robot is deemed not to be warmed up and the motor currents are monitored again 5 8 12 Screensaver To increase the service life of the fluorescent lamp used to illuminate the KCP the background lighting can be reduced The normal service life of a fluorescent lamp is approximately 10 000 hours which corresponds to about 1 1 years of continuous operation By switching off the background lighting this service life can theoretically be almost doubled Therefore it is highly recommended to activate the KCP screensaver Fig 30 Display Properties E Backgcund Screen Savel Appearance a KUKA VGA Settings KUKA KCP Screen Saver Scieon Saver Kepsaver Seltings Preyer Fa
15. the origin is taught The second point is a point in positive x direction and the third one can be any point within the x y plane Programming of a simple program Initially the robot is moved to the so called home position which is equal for all robots but can be changed if required Then the robot is moved to several points of the designated program manually and each point is saved Points which will be accessed twice or more times within the trajectory can be copied Finally the last movement brings the robot back to the home position Advanced manual programming In this part we learned several different commands and elements of the expert programming course Loops can be used to repeat a certain movement or a whole program Running programs can be controlled or influenced by the use of different variables These need to be declared correctly before the execution of the 5 program and can be transferred between different programs To maintain the overview in complex programs the user can create folders and up to 32 subfolders However usually only two levels one folder one sub folder are used in order to avoid interlacing These folders can for example include commands To control the cycle time of a certain program a timer can be programmed We also learned how to teach movements not by moving the robot but by writing the specific coordinates manually It is possible to call so called background programs in the beginning of a main prog
16. the reference position The Cartesian coordinates refer to the centre point of the mounting flange Standstill monitoring If the safe input E HALT is set to LOW standstill monitoring is active The robot is in a safe operational stop but may move within the axis angle tolerance The axis angle tolerance is specified separately for each individual axis 5 2 8 3 2 Setting safety parameters Assumptions User group is set to Safety maintenance Operating mode is set to T1 Procedure 1 Select the menu sequence Setup Service Safe Robot Configuration The data are loaded 2 In the tree structure in the configuration program open the desired safety parameter and enter or select the values 3 Press the Enter key 4 For all further relevant parameters and sub entries repeat steps 2 and 3 5 Close the configuration program and save the changes 5 2 9 Programming 5 2 9 1 Break test 5 2 9 1 1 Overview of the brake test In the brake test the robot controller checks the functionality and wear out of the brakes The brakes of each configured axis are tested successively The brake test starts with axis A1 1 The robot moves at a defined velocity 2 The brakes are applied after the acceleration phase and the results of the brake test are displayed for each axis in the message window 3 Ifa brake is defective the brake test can be repeated or the robot can be moved to the parking position If a brake has reached the wear limit
17. used Fig 16 The tool number is transferred to the controller by pressing the Enter key The program is then loaded and displayed in the program window 42 5 7 System Variables This summary of the system variables is intended to serve as an aid for programmers with good knowledge of the functions of the KUKA robot system and the KRC and who are thoroughly familiar with programming Change the values of variables Tab 11 only if you have sufficient knowledge of the functions of the system variables and their effects Table entries Data type Real Integer Boolean Character Structure Signal declaration Enum Frame Array o ms mm m s s instructions 96 V A increments bits bit sequence motion KRC Roboter KRC R1 Mada Are Steu Mada Unit Original line Source text Comment Comments Functional description value Minimum and maximum values depending on the specific data type max Option Options depending on the data type TRUE FALSE 1 2 etc Tab 11 Properties of variables 43 5 7 2 Different system variables Name Data type Units Description ACC Structure D 7 Path swivel and rotational accelerations in the S S advance run ACC_AXIS n Integer Acceleration of the axes in the advance run n 1 6 ACC CAR ACT Frame A A The current values of the acceleration components
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19. 55 local subprograms and functions 32 5 5 2 1 DEF The object name without an extension is also the name of the file and is therefore prefixed by DEF in the declaration Fig 13 The name may consist of up to 24 characters and must not be a keyword Every file begins with the declaration DEF and ends with END DEF NAME x1 IN Declarations Instructions END Fig 13 File Structure 5 5 2 2 Declarations Declarations are already evaluated before program execution i e during compilation No instructions may therefore be located in the declaration section The first instruction is the beginning of the instruction section 5 5 2 3 Instructions Unlike declarations instructions are of a dynamic nature They are executed when the program is processed 5 5 2 4 Data List A robot program can consist of just a single program file or a program file with a related data list The data list and file are identified as belonging together by their common name The names differ in their extension only 5 5 3 Creating and editing programs 5 5 3 1 Creating a new program As a robot program can also be written without a data list the file and data list are not both automatically created at the same time at expert level When creating a new program you are prompted to select a template Tab 5 The available templates cannot be freely created in all directories The individual templates are Module
20. Escola Polit cnica Superior d Enginyeria de Vilanova i la Geltru UNIVERSITAT POLITECNICA DE CATALUNYA EPS PROJECT TITLE Robotic Cell Project progress report STUDENTS Ahsen Aras Industrial Engineering Alberto Salas Electronic Engineering Niels Diedrichsen Int Sales and Purchase Engineering Jona Rose Int Sales and Purchase Engineering SUPERVISORS Joaquin del Rio University Sharam Shahriat Panahi University Jesus Sanchez KUKA Company DATE 12 06 2009 TITLE Robotic Cell Project progress report FAMILY NAME Aras FIRST NAME Ahsen HOME UNIVERSITY Dumlupinar University Kutahya SPECIALITY Industrial Engineering FAMILY NAME Salas FIRST NAME Alberto HOME UNIVERSITY Universitat Politecnica de Catalunya SPECIALITY Electronic Engineering FAMILY NAME Diedrichsen FIRST NAME Niels HOME UNIVERSITY University of applied sciences Kiel SPECIALITY Int Sales and Purchase Engineering FAMILY NAME Rose FIRST NAME Jonas HOME UNIVERSITY University of applied sciences Kiel SPECIALITY Int Sales and Purchase Engineering Abstract The Robotic Cell Project Terms and conditions The Robotic Cell Project belongs to the field of robotics within the electrical engineering industry It is elaborated by four students from different engineering disciplines and different nationalities within the European Project Semester The task is developed in cooperation with the robo
21. an SRC file The lifetime is limited to the run time of the program The memory area is deal located again on completion of execution The value of the variable is thus lost 33 2 Variable declared in a data list see chapter Data lists The lifetime is independent of the run time of the program The variable exists only as long as the data list exists Such variables are therefore permanent until the system is next switched off 5 5 5 2 Data objects Data objects are nameable memory units of a particular data type The memory units may consist of a different number of memory units bytes words etc If such a data object is declared under a name by the programmer a variable is created The variable now occupies one or more memory locations in which data can be written and read by the program The symbolic naming of the memory locations with a freely selectable designation makes programming easier and more transparent and enhances the readability of the program 5 5 6 Motion programming One of the most important tasks of the robot controller is moving the robot The programmer controls the movements of the industrial robot by means of special motion commands These are also the main features which distinguish robot languages from conventional computer programming languages such as C or Pascal Depending on the type of control these motion instructions can be subdivided into commands for simple point to point motions and commands for co
22. anch with the corresponding identifier will ever be taken into consideration Permissible data types for the selection criterion are INT CHAR and ENUM The data types for the selection criterion and the block identifier must correspond The DEFAULT statement can be omitted and may only appear once within a SWITCH statement The SWITCH statement can be used for example to call up various subprograms by program number The program 37 number could for example be applied to the digital inputs of the KR C by the PLC In this way it is available as a selection criterion in the form of an integer value 5 5 7 3 Loops The next basic structure for program execution control is the loop these cause one or more instructions to be repeated until a certain condition is fulfilled Loops can be distinguished by the form the condition takes and by the position at which interrogation takes place to see if program execution can be resumed 5 5 7 4 Wait instructions Using the WAIT statement you can cause the program to stop until a certain situation arises A distinction is made between waiting for the occurrence of a certain event and the insertion of wait times 5 5 7 5 Input output instructions The KRC recognizes 1026 inputs and 1024 outputs In the standard KUKA control cabinet the following inputs and outputs are available to the user at the X11 connector MFCmodule Inputs 1_ 16 Outputs 1 16 with max capacity 100 mA 100 simultaneit
23. and the total acceleration ACC OV Structure Data for acceleration with changes of override CURR RED Real Current limitations of axes 1 12 in of maximum current Ist digit axis 2nd digit limit POS_ACT Structure mm Current robot position cartesian OV PRO Integer Program override value min 0 value max 100 NULLFRAME Structure All values for offset X Y Z and rotation A B C are set to zero SOFTN_END n Real mm Position of the software limit switches at the negative end of the axis axes 1 12 SOFTP_END n Real mm Position of the software limit switches at the positive end of the axis axes 1 12 TIMER n Integer ms Value of timer n increases by 1 each milli second if STIMER STOP FALSE S TORQUE AXIS Integer Axis in position when command value reached switch 1 to TORQUE_AXIS B000001 VEL Structure we 2 Velocities in the advance run SINTERRUPT Boolean Program is processing an interrupt WAIT_FOR 470 Character Interpreter waiting at a WAITFOR statement WORKSPACEI n Structure Definition of workspace monitoring n 1 8 WORKSPACE n MODE Enum Functional principle of the workspace monitoring function HOFF INSIDE OUTSIDE Tab 12 Types of system variables 44 5 8 Configuring the system The following sections display a selection of the numerous configuration options of a KUKA robot system 5 8 1 General Most of the configuration functions can be found in the
24. anically after a malfunction via the main axis drive motors and depending on the type of robot also via the wrist axis drive motors It is only designed for exceptional circumstances and emergencies e g for freeing people The emergency axis override device may only be used if the main switch on the control cabinet has been turned to OFF and secured with a padlock to prevent unauthorized persons from switching it on again If a robot axis has been moved using the emergency axis override device all robot axes must be remastered When using the override device it has to be pushed onto the axle of the motor remove protective cap which can then be turned It is necessary to overcome the resistance of the mechanical motor brake and any other loads acting on the axis The protective cap must be put back on after the operation 5 4 11 Start up It must be ensured that all safety devices limit switches and other protective measures are installed completely and functioning correctly before the robot system is started up The system elements of the robot and the control cabinet must be checked for foreign bodies No persons or objects may be in the danger zone work envelope of the robot during the start up procedure It must be ensured that the correct machine data has been loaded before the system is put into operation for the first time 3l 5 4 12 Software Special software has been developed for the control computer The software detec
25. cause damage to the robot system and to other material property The robot system may only be used in technically perfect condition in accordance with its designated use and only by safety conscious persons who are fully aware of the risks involved in its operation Any functional disorders affecting the safety of the robot system must be rectified immediately 5 4 2 Designated use The robot system is designed exclusively for the applications specified in the Technical Data Using the robot system for any other or additional purpose is considered contrary to its designated use KUKA cannot be held liable for any damage resulting from such use The risk lies entirely with the user Operating the robot system within the limits of its designated use also involves continuous observance of these operating instructions with particular reference to the maintenance specifications The software employed is matched to the applications specified by the customer user and has been thoroughly tested In the event that the functions contained in the software are not executed without interruption the chapter Error Messages Troubleshooting must be consulted to remedy this condition This also applies to malfunctions occurring during service set up programming and start up activities The robot system may not be put into operation until it is ensured that the functional machine or plant into which the robot system has been integrated conforms to the spec
26. cell to ensure that no persons are in the danger zone 5 2 The Safe Robot technology 5 2 1 Introduction KUKA Safe Robot is an axis range monitoring systems It consists of software and hardware components Its functions are the safe evaluation of the actual position the cyclical monitoring of the reference position and a cyclical brake test It can be connected to external safety logic 5 2 1 1 Features Monitoring of up to 10 user defined ranges Ranges can be combined Shorter reaction times and braking distances Safe inputs and outputs of a redundant design Safe reduced axis specific velocity and acceleration Safe reduced Cartesian velocity monitoring at the mounting flange Safe operational stop Safe stop via Electronic Safety Circuit with safe disconnection of the drives 5 2 1 2 Areas of application Human robot cooperation Use of robots in medical and laboratory technology Reduction of floor space requirements within a system Direct loading of workpieces without an intermediate support Replacement of conventional axis range monitoring systems 5 2 2 Definitions of terms Axis range The Axis range is the range in which an axis can be moved It is measured in degrees or millimetres It is required to define the axis range for every axis that is to be monitored Axis limit The upper limit and the lower limit of an axis define its axis range Inversion The inversion defines the nature of an axis range It can be defined as
27. cially trained for this purpose and acquainted with the risks involved The user is recommended to have personnel assigned for this work and complete an application specific training course The user and operating personnel must ensure that only authorized personnel are permitted to work on the robot system 5 4 5 User The responsibilities involved in operation of the robot system and in all other work performed on the robot system or in its immediate vicinity must be clearly defined and observed by the user in order to prevent any uncertainty regarding spheres of competence in matters of safety The user should check at specific intervals selected at his own discretion that the personnel attend to their work in a safety conscious manner are fully aware of the risks involved during operation and observe these operating instructions Work on the electrical system or equipment of the robot system may only be carried out by a professional electrician or by specially instructed personnel under the control and supervision of such an electrician and in accordance with the applicable electrical engineering rules Work on the hydro pneumatic counterbalancing system if present may only be carried out by persons having special knowledge and experience of hydraulic and pneumatic systems The user must ensure by means of appropriate instructions and checks that the work station and the environment of the robot system are kept in clean and orderly condition T
28. crease in productivity and reduced costs for loans and upkeep Regarding the possibility to easily teach the robot different applications and variations within these processes the owner of such a machine achieves a higher flexibility in his manufacturing activities Safe Teaching 100 Safe Teaching Conventional Teaching E Configuration of the tool E Configuration of the base El Changing Parameters Fig 31 Time savings achieved by Safe Teaching 32 References 01 02 03 04 05 06 07 08 09 10 11 12 13 KUKA Robot Group KUKA ForceTorqueControl FTCtrl 2 1 For KUKA System Software KSS 5 4 5 5 7 0 2007 KUKA Robot Group FTCtrl User Manual User Manual for the RSI Force Control Package for KUKA Robot Control KR C1 KR C2 and KR C3 Software Version V4 0 and higher 2005 KUKA Robot Group KUKA ForceTorqueControl FTCtrl 2 2 For KUKA System Software 5 4 5 5 7 0 2009 KUKA Robot Group Robot Sensor Interface RSI Release 2 0 2001 KUKA Robot Group KUKA RobotSensorlnterface RSI 2 1 For KUKA System Software KSS 5 4 5 5 7 0 2007 KUKA Robot Group KUKA SafeRobot V1 1 For KUKA System Software KSS V5 2006 KUKA Robot Group SAFE TEACHING TEACHEN DURCH HANDFUHRUNG EINES ROBOTERS 2008 http www springerlink com content c85871124272k063 http www kuka robotics com http www springerlink com content dh7 73201 14260
29. d with a safety Standstill monitoring under control category 3 DIN EN 954 1 Axis monitoring Safety function of KUKA Safe Robot to monitor the angle ranges of the individual robot axes 5 1 3 Safety aspects The Safe Teaching functionality is divided into two parts with separate tasks Sensor guided robot motion not safety oriented Safety oriented monitoring The velocity and acceleration of the robot motion are subjected to safety oriented monitoring to prevent danger to the human operator The safety oriented monitoring of the robot motion velocity acceleration makes it possible for a human to be present in the robot workspace 11 5 1 3 1 Using the Safe Teaching Option In teaching mode manual movements are recognised by the FTS If the enabling switch is pressed the robot executes the given movement If the operator releases the enabling switch the robot is stopped and comes to a monitored standstill after a delay of 200ms The robot is positioned manually by an operator and actuated points are recorded every 0 2 seconds After completion of the teaching process the operator leaves the workspace of the robot and the cell closes the door and acknowledges the end of the teaching process Afterwards the robot can be switched to automatic mode and execute the taught program If the door of the cell is opened while the robot is running in automatic mode the robot is stopped immediately 5 1 3 2 Possible hazards Automatic mode T
30. d by the KR C1 47 Here you can start stop or cancel the Submit interpreter oo gt 11 0 Driver gt 2 SUBMIT Interpreter gt elei 3 Statuskeys 4 Jogging gt 5 User group 6 Cur tool base 7 Tool definition gt 8 On Off options gt 9 Miscellaneous gt Fig 22 SUBMIT Interpreter menu item The status of the Submit Interpreter at any given time is displayed in the status line Fig 23 Green means that the Submit interpreter is running while a red display signifies that the Submit Interpreter is stopped If it is not highlighted in color the Submit Interpreter has been deselected NUM CAPs S JR R1 CELL Line 5 TI POV 100 Rob 1 13 09 Start select 1 Stop E Cancel Fig 23 Submit Interpreter status 5 8 5 User group For the purposes of increasing system security robot controller functions and or the programming thereof can be disabled for certain user groups This can be done by restricting access to these functions to specific user levels Access is then protected by a password By default the software for the KRC controller makes a distinction between users and experts Users do not require knowledge of programming syntax as they create programs by means of menus Whenever the system is booted the user level is automatically selected by default If the functions of the user level are not sufficient it is possible to switch to the expert level Experts can then use the ASCII k
31. e interchanged In the case of a defective brake no safety function may be executed e g E STOP opening the safety gate change of operating mode etc 24 5 3 4 1 Designated use The KUKA Safe Handling system makes it possible to move an industrial robot manually using a KGD The safety oriented monitoring of the robot motion must be implemented using the KUKA Safe Robot function Safe Handling can be used in various operating modes e Purely manual guidance mode e Semi automatic mode with a safeguard e g roll door e Semi automatic mode with non contact safeguards e g laser scanner photo electric barrier 5 3 4 2 Safety concept The safety oriented monitoring of the robot motion velocity acceleration makes it possible for a human to be present in the robot workspace The functionality is divided into two parts with separate tasks Safety oriented monitoring The velocity and acceleration of the robot motion are subjected to safety oriented monitoring to prevent danger to the human operator Sensor guided robot motion The processing of the KGD sensor signals is carried out on the PC based robot controller and is not safety oriented 5 3 5 Steering modes 5 3 5 1 KGD standalone mode In standalone mode the robot is guided using a single KGD The KGD is connected by means of a cable to the PC of the control cabinet A terminating resistor must be plugged into socket X2 5 3 5 2 KGD dual mode In d
32. e purpose 5 4 9 4 Enabling switches The KUKA Control Panel is equipped with three three position enabling switches which can be used to switch on the drives in the operating modes Test 1 and Test 2 Each of these enabling switches has three positions of which only the middle position allows the robot to move In either of the other positions hazardous motions are safely stopped and the drives are safely disconnected 5 4 9 5 External enabling switch The external enabling switch function allows the connection of an additional enabling device If it is necessary for a second person to be in the safeguarded space then this is only permitted if this person also uses an enabling device 5 4 9 6 Guard interlock operator safety The robot controller features a two channel safety input to which the guard interlock can be connected In the automatic modes the opening of the guard connected to this input causes a controlled stop with power to the drives being maintained in order to ensure this controlled stop The power is only disconnected once the robot has come to a standstill Motion in Automatic mode is prevented until the guard connected to this input is closed This input has no effect in Test mode The guard must be designed in such a way that it is only possible to acknowledge the stop from outside the safeguarded space 5 4 10 Emergency axis override device The emergency axis override device can be used to move the robot mech
33. er to program maximum axis specific velocities and e ACC AXIS axis number to program maximum axis specific acceleration rates All entries are given as percentages of the maximum value defined in the machine data If these two system variables have not been programmed for all axes execution of the program will cause a corresponding error message to be generated The movements of the axes are synchronized in such a way synchronous PTP that all of the axes start and stop moving at the same time This means that only the axis with the longest trajectory the so called leading axis is actually moved with the programmed limit value for acceleration and velocity All other axes move only with the velocity and acceleration rates necessary for them to reach the end point of the motion at the same moment irrespective of the values programmed in VEL_AXIS No and ACC_AXIS No If acceleration adaptation or the higher motion profile is activated SADAP_ACC STEP1 OPT_MOVE STEP1 axis traversing is additionally phase synchronous i e all axes enter the acceleration constant motion and deceleration phases together Since it is generally unknown in the case of PTP motions with Cartesian end coordinates which is the leading 36 axis it is usually sensible to set acceleration and velocity values which are identical for all axes Synchronous motion control diminishes mechanical stress on the robot since the motor and gear torques are reduced for
34. es a subprogram if it is called by another program main program subprogram or function PROG 1 SRC DEF PROG DEF PROG 1 EXT PROG 1 ee EXT PROG 3 END A A LOCALFUN LOCAL PROG 2FUN SRG PROG 3 PROG 1 DEFFCT INT PROG 2FUN END INT EXT PROG 1 PROG 1 PROG 1 DEF LOCAL EXTFCT PROG 2FUN da PROG_2FUN ENDFCT G PROG_2FUN H 5 LOCALFUN END PROG_3 SRC DEFFCT INT LOCALFUN INT INTVAR RETURN INTVAR ENDFCT DEF PROG 3 END Fig 15 Difference between local and global subprograms 39 5 5 9 Interrupt handling When using robots in complex manufacturing systems it is necessary for the robot to be able to react specifically and immediately to certain external or internal events and for the execution of other actions parallel to the robot process to be possible In other words a running robot program must be interrupted and an interrupt subprogram or function started After the subprogram has been executed and if nothing further is declared the interrupted robot program should be resumed This specific interruption or starting of a program is made possible by the interrupt statement In this way the user has the possibility of reacting by program to an event which does not occur synchronously with execution of the program Interrupts can be triggered by e equipment such as sensors peripheral units etc e error messages e the user or e safety circuits For exam
35. eypad to program in the programming language KRL KUKA Robot Language and to edit system or initialization files bus systems KRL is a high level PASCAL based programming language which is thus also suitable for programming complex tasks Access to the expert level is protected by a password For the purpose of changing to the expert level you can press the menu key Configure to open a menu containing the menu item User group 5 8 6 Force cold startup This menu item is available at both user and expert level When a cold start has been forced and the system has booted the controller displays the Navigator No program is selected the controller is completely reinitialized The menu command Force cold start is not 48 retained as a default setting i e it must be activated each time a cold start is required In the event of a warm restart on the other hand which the controller itself initiates following a power failure the robot program selected before can be resumed The state of the kernel system e g programs block pointer variable contents and outputs is completely restored The power failure could have been caused for example by failure of the power supply unit or by activation of the main switch while the program was running If the controller detects a system fault or altered data after the restart it automatically forces a cold start 5 8 7 DEF line If this function is activated the DEF line in the pro
36. facturers whose use is not explicitly permitted in the operating instructions or the parts catalog of the robot system 5 4 9 Safety functions The safety functions include Restricted envelope working space limitation EMERGENCY STOP External EMERGENCY STOP Enabling switches Technical guard interlock 5 4 9 1 Restricted envelope working space limitation The robot has a standard design to allow the attachment of adjustable mechanical stops in the three main axes for the limitation of the working space In addition the range of motion of all axes can be restricted using software limit switches 5 4 9 2 EMERGENCY STOP The EMERGENCY STOP button of the robot system is located on the KUKA Control Panel which is also used as the programming and operator control device When 30 triggered in the test modes the EMERGENCY STOP function causes a safety stop with immediate disconnection of power to the drives execution of dynamic braking and application of the holding brakes In the automatic modes an EMERGENCY STOP causes a controlled stop with power to the drives being maintained in order to ensure the controlled stop The power is disconnected once the robot has come to a standstill 5 4 9 3 External EMERGENCY STOP If due to the risk situation it is necessary to install additional EMERGENCY STOP devices or if several EMERGENCY STOP systems need to be linked together this can be done via a special interface provided for th
37. gram which is normally hidden is displayed Fig 24 amp 25 D Define 1 HI 2 PTP HOME Vel 188 DEFAULT Fig 24 Def line off w D DeHine 1 DEF T123 2 Eur 3 PTP HOME Vel 100 DEFAULT Fig 25 Def line on Declarations can only be made once the DEF line is visible This function is not available by default below the user group Expert It is automatically deactivated as soon as the operator carries out a restart or switches back to User mode 5 8 8 Detail view on off Limited Visibility This function is only available in Expert mode and is another aid to keeping the amount of information on the user interface as low as possible Detail view is deactivated by default If the function Detail view is deactivated all texts written after the sign in a FOLD line for example are suppressed Fig 26 amp 27 This information is needed however for displaying an inline form 1 Detail view on off PTP HOWE Uel 188 DEFAULT PTP HOME Uel 188 DEFAULT Fig 26 Detail view off v 1 Detail view on off 1 DEF Prog 81 2 FOLD INI 54 PE 2U3 2 6 HKUKATPBASIS CINIT ZUCOHHON SP 3 FOLD PTP HOME Uel 188 DEFAULT 4PE3 U3 2 6 HKUKATPBASIS l SCHOUE ZUPTP ZP 1 PTP 2 HOME 3 5 100 7 DEFRULT 4 5 6 5FOLD PTP HOME Vel 188 2 DEFAULT PE U3 2 6 2HKUKATPBASIS Ll CMOVE ZUPTP P 1 PTP 2 H HE 3 5 188 7 DEFAULT Y END Fig 27 Detail view o
38. he user must ensure that the robot system is only operated in faultless condition The operating personnel is obliged to inform the user immediately of any changes to the robot system which impair its safety or give reason to suspect that this might be the case 5 4 6 Danger zone The danger zones of the robot system i e areas in which the robot together with tools accessories and additional equipment moves must in all cases be safeguarded in compliance with safety standards of industrial robots The purpose of this safety measure is to prevent persons or objects from entering these zones or to ensure that the robot system is safely brought to a standstill and shut down by a stop or EMERGENCY STOP command in case a person or object should nevertheless enter a danger zone The maximum stopping distances of the robot must be taken into account when determining the size of the danger zones If it is essential for personnel to enter the working range of the robot system for conversion adjustment maintenance or repair work on the machine or plant in which the robot system is integrated the safety measures must always be designed in such a way e g enabling switches that the robot system is switched off immediately should an unintended situation arise When work is carried out in the danger zone of the robot the latter may only be moved and then only if absolutely essential in set up mode T1 with an enabling switch and jogmode at jog veloci
39. his is made possible by the SafeRDC box which is situated on the 10 base frame of the robot and includes the SafeRDC board and the I O Print expansion board Fig 6 How this device functions will be described in section 5 2 The possibility to connect the system to an external safety logic simplifies the coordination of several robots and machines working simultaneously Lastly the cyclical brake test makes sure that braking procedures e g an emergency stop can be performed safely at any time by the robot Fig 6 SafeRDC box 5 Research work 5 1 The Safe Teaching technology 5 1 1 Introduction The function Safe Teaching describes the possibility to move an industrial robot manually with the use of a FTS mounted to the robot s tool flange This allows faster and intuitive teaching of points and paths Due to the safety orientated monitoring of the movements with KUKA Safe Robot the safety of the system is increased 5 1 2 Definition of terms Safe Robot Safety orientated monitoring of the robot movement speed working areas and stop operations by evaluation of the angle encoder signals FTS Force Torque Sensor Teaching mode Movement of the robot by manually driving Speed acceleration and stop operation are monitored safety orientated through Safe Robot Automatic mode The robot runs a defined program without speed restriction Operational stop Stop of the robot with regards to category 2 DIN EN 60204 1 couple
40. his mode corresponds to a conventional robot application without human intervention Monitoring and safety devices in accordance with DIN EN ISO 10218 1 are necessary Especially the following aspects to be considered e Securing other access opportunities through fixed dividing regarding the safety margin against the achievement of dangerous areas according to DIN EN 294 e There is a danger that the gripper of the robot or work piece from grippers can get released e The gripper retainer and the gripper itself should be controlled and monitored specifically to reduce possible injuries by flying parts Protective fences need to have a sufficient retention e n case of a programming or technical failure it is possible that the robot crashes into dividing safety devices e g a fence If this could result in danger to the operator the safety monitoring of the axis ranges by KUKA Safe Robot need to be adjusted and activated accordingly Teaching mode Also in the teaching mode some risks have to be taken into account e For bodies or body parts of a person there is the danger to be clamped between the moving robot and the work piece or the work piece and surrounding devices This danger is present generally during the teaching process and can be reduces by the use of a two channel enabling switch e The risk of being clamped by the robot itself at the axis hinges can also be reduced by the use of a two channel enabling switch e The moveme
41. i ded 51 1 Introduction 1 1 Objectives Our project has three main targets The first one is to learn and understand conventional robot programming and to get to know all the soft and hardware involved The second step is to test and evaluate the new Safe Teaching technology We will find advantages possible applications and difficulties of this technology In the last section we will compare the conventional and the new teaching method and point out the significant differences and advantages in order to propose possible applications for Safe Teaching 1 2 State of the art One of the most important tasks when working with robots is the teaching of movements and trajectories The conventional way to teach a robot is by programming it with a control panel The programmer controls the movements of the industrial robot by means of special motion commands These motion instructions can be subdivided into commands for simple point to point motions and commands for continuous path movements Whereas with continuous path movements the end effector e g gripper or tool describes a precise geometrically defined path in space straight line or arc the motion path in point to point movements is dependent on the robot s kinematic system and therefore cannot be accurately predicted Complex movements are generated by saving several points in a sequence Safe Teaching is a method that simplifies the teaching of robotic movements The operator leads
42. iate stop The Beckhoff Device Net I O module contains a Device Net bus coupler with a 5 V power supply terminal and 4 dual channel analogue input terminals 10 V The Force Torque sensors can only read analogue signals therefore values of voltage are necessary 8 E gt e C Fig 2 1 ATI DAQ F T Sensor 2 Intermediate Flange 3 Beckhof DeviceNet I O Module 4 Power Supply Box 3 2 Operation Device This device Fig 3 is very important as it allows the user to switch to safe teaching once automatic mode has been selected and consequently start the process of saving points of the new trajectory Additionally it has an emergency button so that for example in case the robot program crashes the system can be stopped easily Teaching mode Automatic mode Key switch Emergency Acknowledge Operator buttons stop ment Fig 3 Operation device 3 3 Multi power tap MPT The multi power tap Fig 4 is an optional board for the KR C2 robot controller and has several functions It provides a central feed connection point for the 24 V DC of the Device Net The Star hub can for example be connected with a bus cable Device Net from MFC to multi power tap With this option the CAN bus available on the MFC card is extended to the distributor module allowing the connection of 2 external devices The module is supplied with power via the additional miniature circuit breaker F22 2 A Additionally the multi power tap offers simple connection
43. ifications of the EC directions No liability can be accepted if these directions are disregarded 5 4 3 Safety measures KUKA provides that the mechanical and electrical equipment of the respective robot system meets the standard requirements concerning the safety of industrial robots Improper use of the robot system or its employment for a purpose other than the intended one may cause e danger to life and limb e danger to the robot system and other assets of the user and 28 e danger to the efficient working of the robot system or its operator Therefore detailed operating instructions are necessary These are delivered with any robot system and contain numerous safety instructions which also apply to applications and to the use of supplied accessories and supplementary equipment The robot system must be switched off before exchange adjustment maintenance and repair procedures are executed i e the main switch on the robot control cabinet must be turned to OFF and secured with a padlock to prevent unauthorized persons from switching it on again Maintenance personnel should also take into consideration that voltages in excess of 50 V up to 600 V can be present in the KPS the KSDs and the intermediate circuit connecting cables up to 5 minutes after the control cabinet has been switched off 5 4 4 Personnel Installation exchange adjustment operation maintenance and repair must be performed only by qualified personnel spe
44. ive repeat the brake test by pressing the Repeat soft key or move the robot to the parking position by pressing the Park pos soft key 5 2 8 Configuration 5 2 8 1 Configuring robot axes for the brake test Robot axes A1 A6 are preconfigured for the brake test in the file KRCOWROBOTERWNITBrakeTestDrv INI 18 5 2 8 2 Defining ranges Assumptions e User group is set to Safety maintenance e Axis specific jogging e Operating mode is set to T1 Procedure 1 Select the menu sequence Setup Service Safe Robot Configuration The data is loaded Press the Areas soft key Select the range by pressing the soft keys Area and Area Select an axis in the configuration program Move the selected axis to the upper axis limit Press the Touch Up soft key and confirm the message Move the selected axis to the lower axis limit Press the Touch Up soft key and confirm the message Repeat steps 4 to 8 to define the ranges for further axes O Press the Inversion soft key to invert the workspace 1 Close the configuration program and save the changes The data is saved Ta Or Or ey 5 2 8 3 Safety parameters 5 2 8 3 1 Overview of safety parameters The safety parameters contain all the values and settings for the safe robot Tab 3 The safety parameters are displayed as a tree structure in the configuration program General information Display only Monitored axes Configurable Reduced axis velocity Configurable Cartesian vel
45. l packages are installed one after the other RSI KUKA Robot Sensor Interface AmatecLib additional objects for RSI KGD additional RSI object for the KGD functionality 5 A message appears telling you to switch the controller off and back on again 27 E ODS Once the system has rebooted the installation is complete During the installation process the following files are copied into the KUKA system directory KGD rsiKGD oto C KRC Roboter Drivers rsiKgd srcto C KRC Roboter KRC R1 TP KGD rsiKgd datto C KRC Roboter KRC R1 TP KGD AmatecLib rsiAmatecLib oto C KRC Roboter Drivers rsiAmatecLib srcto C KRC Roboter KRC R1 TP RSILIB rsiAmatecLib datto C KRC Roboter KRC R1 TP RSILIB RSI rsiLib o to C KRC Roboter Drivers rsiLib src to C KRC Roboter KRC R1 TP RSI rsiLib dat to C KRC Roboter KRC R1 TP RSI 5 4 Safety when working with an industrial robot This is a Summary of important safety issues that have to be taken into consideration when working with a KUKA industrial robot 5 4 1 Liability KUKA states that any industrial robot or robot system consisting of a robot connecting cables and a control cabinet delivered by the company has been built in accordance with state of the art standards and the recognized safety rules Nevertheless improper use of the robot system or its employment for a purpose other than the intended one may constitute a risk of life and limb of operating personnel or of third parties or
46. n The programmer only has access to all available lines when all the FOLDs are open and Detail view on off is switched off Fig 28 The display on the user interface then corresponds with the display in a normal text editor 49 KRC AI PROGRAMSPROG_O1 SAC En 1 Col 0 oe Fig 28 All FOLDs open 5 8 9 Velocity reduction during warm up At low ambient temperatures increased gear friction may cause the error message Regulator limit exceeded Ax to be generated when the robot is started up In this case the motor current of an axis reaches the maximum defined value To avoid this the velocity can be reduced during the warm up phase as soon as the motor current reaches a defined value The corresponding system variables Fig 29 can only be modified in the file SMACHINE DAT Variable Range of values Fig 29 Warm up related system variables If one of the values is outside the permissible range of values the velocity is not reduced 5 8 10 Warm up time When this function is activated by means of WARMUP RED VEL TRUE or following a cold start the robot is considered to be not yet warmed up For the duration of the warm up WARMUP TIME the motor currents are monitored in the case of PTP PTP and PTP CP motions in Automatic and Automatic External mode If the motor current of an axis 50 exceeds the value defined by the variable WARMUP_CURR_LIMIT max permissible motor current WARMUP CURR LIMIT
47. n esce ad tae ne uses teu E 32 A NON 32 5 5 3 Creating and editing programs essere 33 5 5 4 Program running fbedes uso etes edet T de o 35 5 5 5 Variables and name citan 35 5 5 6 Motion programmi s n s e a a a a ca e 36 5 5 o PrOgramDEIaricH BB s vc oe dito epi t e e oif E oe t at 37 5 5 8 Subprograms and functions ace e eet ets to ect e e ve ea a Rede 38 5 5 9 al A A ener eer eR eS eto ater eR eRe 40 Bib Standard Progr MS cuoc oce dece ae ee dete aeo eee eh eerta 40 56 A ete en rte ren es DE Et Mec 41 ES tasod suede Me canoe ease dee i dor E ceca E s 43 5 7 2 Different system Variables e ne itta veta ete 44 5 9 Configuring Me SVSTelT quos cere pt etse trate ete reete c ri tdt tui eed boe d 45 SEU General ren aie RR 45 DO e PORT aN 46 58 3 VO DIVET EE 47 5 8 4 Submit IBFeE DIOE GE acer t e apaa eh te alae A a N O 47 58 5 USer grope nirre eae estet aaa ac niat ntes o EE EA eas 48 5 9 6 Force Cold SIarIUp aceto esie od 48 5 8 7 DEIS suc enc Op aS spi tI edis nac o PD PRESE CERA 49 5 8 8 Detail view on off Limited Visibility sss 49 5 8 9 Velocity reduction during warm up cooooococonconconconcononncononononnonnonnon non non ncononncnnnnnos 50 5 9 TO Waim UD BINNS e oso ec ree ence Dee te Oe ae e ole enean eut 50 5 8 11 Cool down A rU 51 A A rics qs tet tavi ER aces ders qo tole bn EA Caec AU eae 51 CONCISO snot ise meei Vae eo to EE a OSEE gr R sons R waa sna ED UM SM IR ERR RN ME pos
48. n program triggers a STOP1 A reference run after the robot controller has booted or after mastering with workspaces already activated also triggers a STOP1 The programs required for the reference run are located in the folder KRC ROBOTER KRC R1 TP SAFEROBOT 5 2 9 2 2 Programming the reference run Assumptions Reference switches must be installed and connected User group is set to Safety maintenance Operating mode is set to T1 Procedure 1 Open the program MasRefStart SRC 2 Program a motion to a point approx 10 cm before the reference switch and teach the required points 3 Program a LIN motion to the reference switch so that it is actuated This position is the reference position 4 Teach reference position in the program MasRefStart SRC 5 Do not move the robot 6 Select the menu sequence Setup gt Service gt Safe Robot gt Configuration 7 Press the soft key Ref Pos 8 Press the Touch Up soft key and confirm the message The actual position is applied as the reference position 9 Close and save the program MasRefStart SRC 10 Open the program MasRefBack SRC 11 Program the motion to the end position of the reference run and teach the required points 12 Close and save the program MasRefBack SRC 13 Integrate the program MasRefReq SRC in the application and run it every 2 hours at the latest 5 2 10 During operation 5 2 10 1 Safe robot retraction If the robot has violated a workspace and been sto
49. nding message is generated and an error file created with the file extension ERR Only programs that contain no errors can be selected and executed On loading a program via the softkey Select all the files and data lists required are linked to create a program During linking it is checked whether all the modules are present compiled and free from errors When transferring parameters the linkage editor also checks the type compatibility of the transfer parameters If errors occur during linking an error file with the extension ERR is created as in compilation You can also write a KRL program using any normal text editor and then load it into the system memory by means of the softkey Load In this case however you must make sure yourself that all the necessary initializations e g axis velocities are carried out 5 5 3 3 Program correction Program correction is the standard method of altering a program The PROCOR mode is automatically active when a program is selected or a running program is stopped Here you can enter or edit commands that affect just one program line i e no check structures loops etc or variable declarations using the inline form or ASCII code at expert level If incorrect entries are selected these are immediately deleted when the program line is left and an error message appears in the message window 5 5 3 4 Editor If you want to edit or insert certain KRL commands or program structu
50. ng both With the tool still positioned at the final calibration point call the variable REF_PT x using the variable correction function As the new value enter SPOS ACT In this way the coordinates of the current position will be used as a reference point 3 Permissible deviation MAX_CRASH The maximum permissible deviation between the reference point and the tip of the tool in mm with which automatic correction is still carried out can be changed using the variable MAX CRASH The value can either be modified using the variable correction function or directly in the file SCONFIG DAT 5 6 1 1 Variables used In this table Tab 9 all necessary variables for using Cor T1 are displayed Variable Range of values Tab 9 Cor_T1 related variables 41 5 6 1 2 Error messages The following messages Tab 10 may be generated in connection with Cor_T1 Tab 10 Cor_T1 related messages 5 6 1 3 Tool correction Select program y Switch the operating mode to T1 and move the robot close to the reference point Load the program CorrTool by selecting the option Select gt With parameters This D D function can only be accessed using the menu bar Program 0 Mark all 1 Copy 2 Paste 3 Cut amp Delete 5 Duplicate D Without parameters nb Eze erra 1 With paramaters Reset pggream ee Fig 16 Tool correction As the parameter enter the number of the tool
51. nt of the robot can result in an impact to the operator This danger is reduced to a minimum by the limited velocity and the use of enabling switches 5 1 4 Components The safe teaching package consists of the following parts Hardware 1 Force Torque Sensor in combination with a two channel three step enabling switch and a safety orientated connection to the robot controller Fig 7 12 Fig 7 FT Sensor with handhold 2 Operation device with emergency stop acknowledgement key switch and operator button Fig 8 Teaching mode Automatic mode Key switch Emergency Acknowledge Operator buttons stop ment Fig 8 Operation device Software 1 KUKA Safe Robot option 2 Software for using the FT Sensor and safe the taught points and paths 5 1 5 Process of Safe Teaching While using the Safe Teaching Application two different Robot programs are exceeded 5 1 5 1 Program to record safe points or paths The key switch has to be set to Teaching mode safety orientated monitoring of velocity and stops The robot can be moved with the FTS With the two operator buttons either a point or a path path start and end can be saved When a path is taught the robot safes the actual coordinates automatically every 200 ms or after a defined distance i e 5mm When the user changes between automatic and teaching mode the acknowledgement button has to be pressed If this button is already pressed when the key switch is turned an error occurs The
52. ntinuous path movements Whereas with continuous path movements the end effector e g gripper or tool describes a precise geometrically defined path in space straight line or arc the motion path in point to point movements is dependent on the robot s kinematic system and cannot therefore be accurately predicted Common to both these types of motion is that programming takes place from the current position to a new position For this reason a motion instruction generally only requires the specification of the end position exception circular motions Position coordinates can be specified either as text by entering numeric values or by moving the robot to them and saving the actual values teaching The possibility exists in each case of relating the entries to various coordinate systems Further motion properties such as velocity and acceleration and orientation control can be set using system variables The approximation of auxiliary points is initiated with the aid of optional parameters in the motion instruction In order to carry out approximation a computer advance run must be set 5 5 6 1 Point to point motions PTP The point to point motion PTP is the quickest way of moving the tip of the tool Tool Center Point TCP from the current position to a programmed end position To do this the controller calculates the necessary angle differences for each axis The following system variables are used e VEL_AXIS axis numb
53. ntuitively reduces the need for expert knowledge and allows inexperienced users to work with an industrial robot On the other hand it is also possible for programmers who are used to conventional robot programming to combine both methods Additionally when the Force Torque Sensor system is used in the automatic mode it is possible to correct the executed movements in real time The robot controller then saves the response forces and calculates the new corrected path automatically and in the next execution the corrected movement can be repeated Compared to the conventional way of programming a robot with a standard controller Safe Teaching can save up to 80 of time needed for the teaching process As a result the productivity of the robot system is increased and costs for loans and upkeep are decreased Thus the implementation of this new technology is recommendable for robot users who are spending great amounts of time on teaching trajectories and work processes to their robots 2 5 Possible fields of application The Safe Teaching technology can be used in any kind of programming situation but is recommendable especially for very complex movements or movements that require a high number of points to be stored Examples would be processes as painting deburring the grinding of sharp edges of a work piece or polishing These applications need very fluent and complex motions with many slight changes in angle and orientation Teaching these mo
54. ocity Configurable Reduced axis acceleration Configurable Axis range monitoring Configurable Monitoring of mastering Configurable Standstill monitoring Configurable Interfaces Configurable Machine data Display only Machine data Display only Tab 3 Overview of safety parameters General Information Contains the software version of the configuration program and the time stamp indicating when the safety parameters were last saved Monitored axes This parameter activates the axes which are to be monitored An activated axis is monitored in all workspaces An axis that is not being monitored is crossed out in the display Reduced axis velocity Sets the axis velocity of an axis to a user defined maximum value for the following operating modes e T2and Automatic mode e T1 mode 19 Cartesian velocity Sets the Cartesian velocity at the center of the mounting flange to a user defined maximum value for the following operating modes e T2and Automatic mode e T1 mode Reduced axis acceleration Sets the axis acceleration of an axis to a user defined maximum value for the following operating modes e T2and Automatic mode e T1 mode Reduced axis acceleration can only be active if reduced velocity is active Axis range monitoring Contains the parameters and values of the workspaces so that these can be monitored Monitoring of mastering This parameter contains the Cartesian and axis specific coordinates of
55. oder cable X42 XS Ref and actuating plate Data cable X21 X31 Data cable X21 1 X41 KUKA robot with Safe Robot option 5 2 4 1 Safe RDC The Safe RDC box is situated on the base frame of the robot and includes the Safe RDC board and the I O Print expansion board The Safe RDC board evaluates the resolver signals and monitors the robot on the basis of the values supplied by the resolvers The values are transferred to the Safe RDC board and compared with the safety parameters that have been set The l O Print board is plugged onto the Safe RDC board and provides the 24 volt input and output signals Fig 9 16 Fig 9 1 Safe RDC box 2 Safe RDC board 3 Reference switch 4 Actuating plate Functions e Monitoring of the robot according to the safety parameters that have been set and the signals at the safe inputs Monitoring of the safe inputs and outputs for cross connections and cable breaks Evaluation of the actual position Safe disconnection of the drives Communication with the robot controller Motor temperature monitoring 5 2 4 2 Installing the reference switch Assumptions A tool must be mounted on the mounting flange For axes A1 A6 the axis specific coordinates of the reference position must be at minimum 5 different to the mastering position The reference position must be situated within the workspace of the robot The installation position of the reference switch must not constrain the work sequence of the
56. of KRL is based on the PASCAL programming language and optimized for robotic control In the following sections contents of expert programming which we learned and applied throughout our project will be described 5 5 1 File concept A KRL program can be made up of SRC and DAT files The SRC file contains the actual program code There are two variants DEF and DEFFCT with return value The DAT file on the other hand contains the specific program data This division is based on the KRL file concept apart from the processing sequence the program contains various actions which the industrial robot is to perform These can be special motion sequences the opening or closing of a gripper or complex sequences such as the control of a welding gun taking the related constraints into consideration For the purpose of testing programs it is helpful and or necessary to be able to execute tasks of this nature individually The KRL file concept is ideally suited to the special requirements of robot programming 5 5 2 File structure A file is the unit that is programmed by the programmer It thus corresponds to a file on the hard disk or in the memory RAM Any program in KRL may consist of one or more files Simple programs contain exactly one file More complex tasks can be solved better using a program that consists of several files The inner structure of a KRL file comprises the declaration section the instruction section and up to 2
57. omatic and manual guidance areas e Manual guidance area 26 5 3 7 1 Transitional areas Possible hazards Impact by the robot countermeasures reduced velocity The following states must be implemented in the transitional area e The robot may only move at reduced velocity generally 250 mm s e Safety oriented working range monitoring e f the manual guidance mode signal is sent to the controller the robot must stop and is monitored after approx 200 ms to ensure that it is at a standstill e Once manual guidance mode has been terminated signal for manual guidance mode is no longer active the robot can move independently without enabling switch 5 3 7 2 Manual guidance area Possible hazards Danger of being trapped by tool countermeasures two hand enabling motion enable Danger of being trapped by robot structure countermeasures two hand enabling motion enable additional covers Impact by the robot countermeasures reduced velocity The following states must be implemented in the manual guidance area e The robot may only move if it has a safety oriented motion enable signal e The robot may only move at reduced velocity generally 250 mm s e Once the motion enable has been withdrawn the robot is monitored after approx 200 ms to ensure that it is at a standstill e If there is a danger of the hands being trapped a two hand enabling system must be implemented the danger of other extremities being trapped when
58. on on the joystick an adds pressure towards a certain direction The Force Torque Sensor system measures the six parts of the motion forces in x y and z direction and torques around these three axes and generates a movement following this motion By this the operator can easily move the robot to a certain position and then by pressing the corresponding button on the control panel store a point or the starting point of a path In the second option after storing the starting point the robot is moved along the requested path and the robot saves its actual position automatically every 200 ms or after a defined distance i e 5 mm When the end point of the path is reached the operator acknowledges the arrival by again pressing the mentioned button Consequently the path is taught and can be repeated in the automatic mode Fig 1 Safe Teaching robot 7 2 3 Safety aspects If the operator releases the dead man button the robot is stopped and comes to a monitored standstill after a controlled delay of 200ms In teaching mode the velocity is generally limited to 250mm s and the acceleration is set to a maximum of 200 s These parameters can be changed if a danger analysis allows or affords higher or lower limits The limitations are necessary to give the operator enough time to move out of the way of hazardous robot movements or to stop the robot 2 4 Advantages On the one hand this possibility of moving and teaching a robot i
59. ot brakes with a normal braking run out 15 5 2 3 Functional principle The robot moves within the permanently monitored workspace and the activated workspaces workspaces 1 7 The actual position is continuously monitored and compared with the active workspaces The robot is monitored on the basis of the values supplied by the resolvers The values are compared with the safety parameters that have been set If the robot violates an axis limit or a safety parameter it stops with a STOP O Tab 2 The robot comes to a standstill at the end of the braking distance KUKA Safe Robot can be used for the setting and monitoring of the axis limits of each individual axis to define the range in which the robot may move The individual axis ranges together make up the overall workspace which may consist of up to 8 axes ranges The 6 robot axes in degrees and 2 external axes can be defined in a workspace Workspace Description Stop reaction if workspace violated 1 Permanently monitored and STOP 0 always active It can be modified but not deactivated These are always active They do not trigger a stop the and set safe outputs which robot continues its motion can be wired externally without slowing down Tab 2 Safe Teaching workspaces 5 2 4 Components Software components KUKA System Software KSS V5 4 KUKA Safe Robot V1 1 Hardware components KR C2 edition05 robot controller with Safe Robot option Reference switch with enc
60. ple an interrupt routine which resets certain output signals prepared program IR STOPM SRO can be called when an Emergency Stop button is pressed 5 6 Standard Programs A number of utility programs are delivered with the robot controller which may be of help to the user in certain situations Tab 8 Tab 8 Overview of standard programs 40 The following sections provide descriptions of some of these useful standard programs 5 6 1 COR_T1 This program can be used to check and if necessary correct the TCP following a crash The tool does not then need to be recalibrated A number of preconditions must however be met first The following steps must be taken before a tool correction may be carried out 1 Reference point First of all a fixed reference point in space is required This may be a wall mounted measuring tip for example This reference point must not be moved or removed a measuring tip placed on the table is thus insufficient 2 Calibration Then calibrate the tool e g welding torch using one of the calibration programs e g XYZ 4 Point method Make sure that the tool is situated as far as possible from the measuring tip and only touches it at a single easily observable point When the program is executed the tool will be moved to the reference point with precisely this orientation If the tool is positioned awkwardly in relation to the measuring tip the tool may collide with the measuring tip thus damagi
61. pped it can only be moved out of the violated workspace in T1 mode The workspaces remain active and messages are displayed in the message window In T1 mode the robot can be moved to any position irrespective of what workspaces are active 5 2 10 2 Displaying safety parameters To display the safety parameters no program may be selected Procedure 1 Select the menu sequence Setup Service Safe Robot Configuration The data are loaded 2 Open the desired safety parameters in the tree structure in order to display the sub entries parameters and values 3 Pressthe Areas soft key to display the ranges 4 Press the Ref Pos soft key to display the axis specific coordinates of the reference position 22 5 3 The Safe Handling technology 5 3 1 Introduction The KUKA Safe Handling function can be used to move an industrial robot manually In manual guidance mode the robot is moved using the sensor data of the KGD and the velocity and acceleration are subjected to safety oriented monitoring The robot can only be moved if an enabling switch is pressed It does not generally move independently but is steered by the operator 5 3 2 Definitions of terms Term Abbreviation Meaning KGD KUKA Guiding Device KCP KUKA Control Panel teach pendant KRC KUKA Robot Control control cabinet Safe Robot option KR KUKA robot type of robot used KSS KUKA System Software Safe Robot System for safe axis
62. pt programs have to be external global which means they cannot be written in the main program They can be switched on called by a certain output change i e from FALSE to TRUE To avoid rebounds of the sub program the interrupt has to be switched off in the beginning of the sub program AND after the subprogram is executed also has to be switched off again in the main program Within the main program disabling and enabling the interrupt functions is possible 1 3 2 Research work After we finished the course we started to research information about the different aspects of robot programming and about the Safe Teaching technology The results of our research can be found in section 5 We separated the documents as shown in Tab 1 Student Part Document Title chapter Jonas Safe Robot Safe Teaching 5 2 Safe Handling Ahsen Expert Programming s System variables us Tab 1 Research work 1 3 3 Writing of an example program with conventional teaching We simulated a painting program to analyze the procedure of conventional teaching for this specific application We will compare the programming process to the new teaching method later on In order to create the painting process we applied methods that are described in detail in the Programming course section e g Configuring the tool with 4 Point Method and Configuring the base with 3 Point Method Basically the process consists of a combination of linear movements with change
63. r is positioned All FOLDs opn opens all FOLDs of the program All FOLDs cls closes all FOLDs of the program Tab 6 FOLD options 34 5 5 4 Program running modes The program run modes Tab 7 define whether program execution is to take place e without a program stop e motion instruction by motion instruction or e step by step Run mode Tab 7 Program run modes The program run modes GO MSTEP and ISTEP can be selected on the KCP using a status key or via the variable PRO MODE PSTEP and CSTEP on the other hand can only be set via the variable 5PRO MODE 5 5 5 Variables and names Beside the use of constants in other words the direct specification of values in the form of numbers symbols etc it is also possible to use variables and other forms of data in a KRL program In the programming of industrial robots variables are required for the purpose of sensor processing for example They enable the value supplied by the sensor to be saved and evaluated at various points in the program Arithmetic operations can also be performed in order to calculate a new position A variable is represented by a name in the program this designation being freely selectable subject to certain restrictions 5 5 5 1 Variable life The lifetime of a variable is the time during which the variable is allocated memory It depends on whether the variable is declared in an SRC file or a data list 1 Variable declared in
64. ram These programs then run in the background while the main program is executed A typical background program would be a safety monitoring software Creation of virtual work areas Work areas are defined by four points and have the following five options Inside stop the robot stops when entering the area Outside stop the robot stops when leaving the area Inside output the robot gives a signal output when entering the area Outside output the robot gives a signal output when leaving the area Switch off the area is disabled The number of work areas is limited to eight at the same time In option 1 and 2 a so called bridge command is required to enter or leave a work area manual movement HEADS Axis space These spaces are similar to the work areas and are defined by angle limits Axis spaces have the following five options Inside stop the robot stops when entering the space Outside stop the robot stops when leaving the space Inside output the robot gives a signal output when entering the space Outside output the robot gives a signal output when leaving the space Switch off the space is deactivated EPI The number of axis spaces is equal to the number of axis In option 1 and 2 a so called bridge command is required to enter or leave an axis space manual movement Interrupts Different priorities can be assigned to interrupt functions The interrupt with the highest priority is always executed first Interru
65. re preconfigured for the brake test in the file BrakeTestDrv INI For the brake test any external axes used must be configured in the fileBrakeTestDrv INI When a brake test is carried out all axes must again be switched to synchronous 5 2 5 5 Cables The Cables must not be connect and disconnect during operation Only the data cables and encoder cables X42 XS Ref with the grey cladding may be used The minimum bending radii must be observed when routing cables 5 2 6 Performing a manual reference run Assumptions The reference switches must be installed and connected The reference position must be taught in the program MashRefStart SRC and in the configuration program All cables must be connected Operation mode has to be set to T1 or T2 Procedure 1 Select program MasRefReq SRC 2 Set program override to 100 and execute the program MasRefReq SRC to the end of the program 5 2 7 Performing a manual brake test Assumptions It must be ensured that no persons or objects are in the danger zone of the robot For the brake test every axis must have at least 10 freedom of motion starting from the start position of the brake test The parking position must be taught in the program BrakeTestPark SRC All cables must be connected Operation mode is set to T2 Procedure 1 Select program BrakeTestReq SRC 2 Set program override to 10096 and execute the program BrakeTestReq SRC to the end of the program 3 Ifa brake is defect
66. res the editor has to be used Since the complete code is compiled when the editor is closed errors can also be detected which only occur in the interaction of several lines e g incorrectly declared variables 5 5 3 5 Hiding program sections Unlike normal editors the KCP editor allows a requirement specific display of the program contents The user for example only sees the important contents of a program while at expert level the whole program is visible 5 5 3 5 1 FOLD The KUKA user interface uses a special technique to display a program clearly Instructions in the form of KRL comments make it possible to suppress the display of subsequent parts of the program In this way the program is subdivided into meaningful sections called FOLDS due to their folder like nature FOLDS are closed by default and can only be opened at expert level Tab 6 You then obtain information which is invisible to the user on the KUKA graphic user interface KUKA GUI At expert level you have the possibility of making a KRL block invisible at user level This is done by enclosing the relevant declarations or instructions within the designations FOLD and ENDFOLD Folds in a program can be displayed or hidden by pressing the menu key Program and then selecting FOLD and the desired command The following options are available Current FOLD opn cls opens or closes the FOLD of the line in which the edit curso
67. reword prtected Shende wait 20 mides Cancel Apply Fig 30 Setting the screensaver 51 6 Conclusion After receiving two weeks of KUKA Robot Language training we learned how to move robots and how to write programs We created programs for palletizing interrupting movements controlling the amount of current in single axes and several more In the following weeks we practiced independently and did research on expert programming and Safe Teaching When we received the Safe Teaching robot we first had to change some of the parameters to simplify the working process regarding the possible velocity of movements and the sensitivity of the sensor These changes where necessary to assure that the robot could be easily moved By this an operator for example can paint a work piece and at the same time teach the motion without being disturbed by the slow translation of the robot movement The Safe Teaching technology offers a revolutionary way of teaching an industrial robot Points and trajectories can be taught faster and more intuitively without the need for expert knowledge The technology is recommendable especially for very complex movements or processes that require a high number of points to be stored During our project KUKA s objective to realize time savings of up to 80 compared to a conventional robot proved to be realistic Fig 31 This reduction of teaching time was an immense improvement not to mention the resulting in
68. robot cannot be moved until the acknowledgement button is released This is method to prevent manipulation of the button 5 1 5 2 Production program automatic mode The key switch has to be set to automatic mode and the safety door has to be closed Then the robot can execute the taught program 13 5 1 6 Safety orientated parameters To move the robot in the teaching mode it is required that the key switch is set to automatic mode and that the enabling switch is pressed If the Safe teaching mode is not activated safety monitoring is deactivated as well and the robot moves as a conventional robot in automatic mode The option Safe Robot is parameterized as follows e maximum velocity is set to 250 mm s a danger analysis may allow other limitations e maximum acceleration is set to 200 s e standstill monitoring is set to 200 ms realised with a Safety SPS the signal of the KGD acknowledgement is transferred with a delay of 200 ms to the Safe RDW 5 1 7 Intended usage The intended usage of the robot in the safe teaching mode is moving the robot with a force torque sensor mounted on the tool flange Possible applications are i e the intuitive teaching of the robot by manual movement If the robotic sell provides special safety areas for the operator when the robot moves in automatic mode an acknowledgement button has to be installed within this area to start a programmed movement The operator has to have a good overview of the
69. robot system 01 0 11 0 Driver gt D Edit Config 2 SUBMIT Interpreter 1 Driver Reset 3 Statuskeys Ld 21 0 Reconfigure 4 Jogging 5 User group 6 Cur tool base 7 Tool definition F 8 On Off options r 39 Miscellaneous gt Fig 20 I O Driver menu item 5 8 3 1 Edit Config When the Edit Config menu item is selected the IOSYS INI file Fig 21 is loaded into the editor for editing This file is located in the directory C KRC Roboter Init CONFIG UERSIUN 2 68 OS O amp A oo M oL 11 DRIVERS 12 HFC B mFcEntry nFcdru o 13 INTERBUS d ibusInit ibusdru o 14 DEUNET 2 dnInit dndrv o 15 BOSCH 3 boschInit boschdru o 16 PERCEPTRON 4 percInit percdru o 17 SBIP 5 sbipInit sbipdru o 18 FIPIO 6 fipiolnit fipiodru o 19 PROFISL 7 pbs1Init pfbsldru o ICAKACAROBOTERNNITUOSYS INI Ln 1 Col E Fig 21 IOSYS INI file 5 8 4 Submit Interpreter The Submit interpreter Fig 22 is a program which runs in the background parallel to the robot program As this program runs entirely independently of the selected robot program it can be used to handle all types of different control tasks These might include for example the control and monitoring of a cooling circuit the monitoring of safety equipment or the integration of additional peripheral devices This makes the use of an additional PLC for smaller tasks unnecessary as these tasks can be accommodate
70. s in angle and orientation We encountered problems with the axes positioning due to the rather complex nature of the movement As a consequence the teaching of the motion was interrupted several times by system errors The next steps consisted of setting the velocity and acceleration of the movement and correcting the trajectory In the end we needed more time approximately 70 minutes for the whole task than we expected before starting the simulation After this experience our expectations towards Safe Teaching were high 2 Safe Teaching 2 1 What is Safe Teaching The Safe Teaching technology offers the possibility to move an industrial robot manually by hand This can be done with a Force Torque Sensor which is mounted on the tool flange of the robot and is connected to the robot controller Safe Teaching allows a much faster and more intuitive way of programming a robot meaning teaching several points or a whole path 2 2 Using Safe Teaching The Safe Teaching package has two user modes the automatic and the teaching mode The automatic mode is similar to the one of a conventionally programmed robot The robot simply runs a selected program The significant difference lies in the teaching mode Here the Safe Teaching robot Fig 1 is not moved by a conventional controller but with a special joystick mounted directly on the tool flange at the end of the sixth axe To initiate the process the operator presses the so called dead man butt
71. the KGD The robot is moved to a position behind the roll door in a defined area The roll door is closed by means of a manual command and the robot autonomously resumes its production program in Automatic mode Velocity and acceleration are no longer monitored 5 3 6 3 Semi automatic mode with non contact safeguards Example laser scanner photo electric barrier or similar In Automatic mode the robot picks a component from a defined position and stops at a transfer position When the human operator approaches first photo electric barrier or warning zone of a laser scanner the robot velocity is reduced and after a slight delay brakes safe monitoring of this reduced velocity is activated Fig 12 If the human operator approaches still further second photo electric barrier or alarm zone of the laser scanner the robot stops and switches to a safety oriented manual guidance mode Once the human operator has left the alarm and warning zones and manually acknowledged them the robot autonomously resumes its production program in Automatic mode Velocity and acceleration are no longer monitored 1 Automatic area red 2 Safety photo electric barrier 3 Safety photo electric barrier 4 Safety barrier 2 5 Safety barrier 1 Fig 12 Robotic cell with different safety area 5 3 7 Workspaces The workspace of a manually guided robot is divided into 3 areas e Automatic area e Transitional areas between aut
72. the motion enable is activated cannot be precluded entirely e Only one person is allowed in the workspace of the manually guided robot 5 3 8 Software installation The Robot Sensor Interface RSI is used to create sensor applications in the KRL programming language It contains a library of standard functions for sensor applications such as filters transformations control functions etc RSI is object oriented It is modularly structured and provides a special set of commands for standard applications RSI in conjunction with the KGD has been conceived for the following applications e Guiding a safe robot with one or two KGDs master slave operation for the implementation of handling devices in Automatic mode e Moving a robot with a KGD as a tabletop device in Automatic mode Procedure Before the software installation is carried out all the hardware installations required for connecting the KGD must have been completed The KGD software can be installed on a controller with software version V5 4 or higher This installation must be carried out in the user group Expert Place the setup CD in the CD ROM drive of the control PC Press CTRL ESC simultaneously gt The Windows Start menu is opened Select the menu item Run Enter CD ROM drive SetupAll in the input box press OK and follow the instructions on the screen Any previous RSI version present will be overwritten by the current RSI version The following individua
73. the robot manually with a handhold which is mounted on the tip of axis 6 While the robot is moved points are stored continuously and a motion program is automatically created As a result the robot can precisely and autonomously repeat the performed movement Hereby the procedure described in the previous paragraph becomes unnecessary and remarkable savings of effort and time can be achieved 1 3 Work developed 1 3 1 Programming course In the first two weeks of the project we took a course for conventional robot programming We learned both user and expert programming level In the following section we will present a short overview of what the course included Calculation of a tool The tool is calculated by teaching the robot the reference point of the mounted tool Calculation generally means calibration or teaching The calculation of a tool involves definition of the tool s contact point and its orientation The contact point is calculated via 4 point method A certain reference point is approached with the contact point of the tool from four different angles The tool orientation is calculated via movements in the necessary axes Calculation of a new reference base Reference bases are required to make the movement of robot or work piece possible without having to change the whole trajectory It is only necessary to update the reference base according to the new position of the moved object A base is calculated via 3 point method First
74. ther robots in a multi robot system 5 4 7 Safety equipment Any method of working that impairs the functional and operating safety of the robot system must be avoided No functional safety equipment may be dismantled or taken out of operation if this would directly or indirectly affect the robot system and if exchange adjustment maintenance or repair is carried out on the robot system This would cause danger to life and limb such as contusions eye injuries fractures serious internal and external injuries etc If nevertheless it is necessary for such safety equipment to be dismantled during the above mentioned work on the robot system the machine or plant in which the robot system is integrated must be shut down with particular attention being paid to the text passages of the operating instructions and measures must be taken to prevent unintentional or unauthorized start up Immediately after completion of the exchange adjustment maintenance or repair work the safety equipment must be reinstalled and checked to ensure that it is functioning correctly 5 4 8 Installed equipment attachments and conversion Any unauthorized conversion or modification of the robot system is prohibited No customer specific equipment may be installed without the approval of the sales representative of KUKA responsible for your system The robot system including accessories and additional equipment may not be equipped or operated with products of other manu
75. these instructions is IF Execution condition THEN Instructions ELSE Instructions ENDIF The execution condition is a boolean expression If the execution condition is fulfilled the THEN block is executed If it is not fulfilled the ELSE block can be either executed or dispensed with If it is dispensed with the branch is left immediately An unlimited number of instructions can be used In particular further IF statements can also be used Nesting of IF blocks is thus possible Each IF statement must however be concluded with its own ENDIF 5 5 7 2 Switch If more than 2 alternatives are available this can either be programmed using a nested IF construction or much more conveniently using the SWITCH multi way branch The SWITCH statement is a selection instruction for various program branches A selection criterion is assigned a certain value ahead of the SWITCH statement If this value agrees with a block identifier the corresponding branch is executed and the program jumps straight to the ENDSWITCH statement without taking subsequent block identifiers into consideration If no block identifier agrees with the selection criterion the DEFAULT statement block is executed if there is one Otherwise the program resumes at the instruction after the ENDSWITCH statement Several block identifiers can be assigned to one program branch On the other hand it is not sensible to use one block identifier several times as only the first br
76. tics company KUKA from Vilanova la Geltru and coordinated by the UPC The main goal of the project is to analyze and evaluate the advantages and disadvantages of the new Safe Teaching technology This technology can be used in manual teaching aid for robotic trajectories to simplify the programming of complex operations as painting or polishing movements The cell consists of a KUKA KR 16 robot with a force torque sensor and the software needed for safety monitoring It is already mounted and ready to be used Key words force torque sensor system robotic cell robot programming safe teaching Contents Me TIMROCUCTIONS met 5 Um Essi cmo a ED 5 Tee State ofthe BED cts emo eie ta e fe yas tur OR 5 1 3 Wo rkdevelope dii n E 5 1 3 1 Programming COUT Ste eal la le Sa A Me 2 13 2 Research WOEK ene ed optet Geen eyed er aca Sa Ate SAG sel pud OM eee edis 6 1 3 3 Writing of an example program with conventional teaching 7 AS c Soon S Sek epu weg NR A a a abd 7 2 1 What is Safe Teaching aec etia gover ed eei delen RN CHER sd teed east dais 7 2 2 Using Sale Teaching ceo ci o de pee trat N tein dae 7 2o A girs Lo 0 bc uolo e erotic eaae A S cn id 8 24 POV AINA CS oc s acd eibi bdo it di pou ive in Dod idee as 8 2 5 Possible fields of application ira e HI ERR ce consti Bate a eee eae 8 asHardware comporelils 3 oot deeidet t reete ete e oud talents de bud eet dey at iu ea ons 8 3 1 The Force Torque Con
77. trol System aet ce decere epe es 8 A eie sapie e ea e ida tetendit wate ck 9 3 9 Multi power tap MPT iiir ta Rd t re oie ee quidc m pat 9 4 Software OGG Sas vats cas sce Pul deor ah tc aco dic En dao os ap fox ein iba etit 10 4 1 Force Torque Control FTCtrl E seein 10 4 2 Robot Sensor Interface RSl eec cc oraci n cesis ber 10 4 3 KUKA Sale BODOE russore rt tee d qo RED esp Ne ied dain ese e ae duos 10 Be RES Sear chi WO A tp vase Mna N eves ean Um A MA us 11 5 1 The Safe Teaching technology eese 11 DTP ICHTOCIBIGITOEL A O 11 5 1 2 Definition OF Terris casco b oa tene a ae eho aidan lee 11 MEA lis Rene E E ett Devaar da e Ma 11 5 1 3 1 Using the Safe Teaching Option ii dies 12 MESZ POSSIDIO NAZIS Meet TS 12 51 4 GO pone ssi fasce tet atem eR A cuta s cat om Sese 12 5 1 5 Process of Sale Teaching oe e deca eoe a tone 13 5 1 6 Safety orientated parameters essere 14 5 1 7 Intended disage uso oo aee or oe Dae a se te o o Sec Dette uat 14 5 2 The Sate Ropot technology i 5 6 E o eo dl 14 5 2 T IMFOCUCHON s Cose nae anite redi cae Ere il 14 5 2 2 DEMONS OF SMS tas dba ced 14 52 3 FUNCION Principles e ne dd da ds o O 16 52 4 SOM PONES EN AA 16 AS A A Sa at aa cen cfe 17 5 2 6 Performing a manual reference run essent 18 5 2 7 Performing a manual brake test essere 18 5 28 COMMOTION oodd aet eats ned acea te dec gi aeie me et os 18
78. ts most incorrect entries and operator errors The hardware and software supplied have been checked for viruses It is the user s responsibility to make sure that the latest virus scanner is always used 5 4 13 Operation All safety regulations must be adhered to while the robot system is in operation No changes may be made to safety measures or equipment In the event of a malfunction the robot must be switched off immediately Until the fault has been eliminated measures must be taken to prevent unauthorized start up and to preclude any danger to persons or objects Appropriate records are to be kept of malfunctions their causes and the remedial action taken Check the robot system at least once per working shift for obvious damage and defects Report any changes including changes in the robot system s working behavior to the competent department or person immediately If necessary stop the robot immediately and lock it 5 4 14 Shut down Before any exchange adjustment maintenance or repair work is carried out the robot system must be shut down and precautions must be taken to prevent unauthorized start up e g padlock keyswitch It is important to be prepared for possible movements of the robot even after the controller has been switched off and locked 5 5 Expert programming When programming KUKA robots it is absolutely necessary to understand the structure and functions of KUKA Robot Language referred to as KRL The syntax
79. ty at the most to allow the personnel enough time either to avoid dangerous movements or to stop the robot All persons situated in the environment of the robot must be informed in time that the robot is about to move 29 Wherever possible only one person should work in the danger zone at any time If two or more persons are working in the danger zone at the same time they must all use an enabling switch They must also all remain in constant visual contact and have an unrestricted view of the robot system Responsibilities for each type of work and for each person must be clearly and comprehensibly defined In sensor assisted operation the robot is liable to perform unexpected movements and path corrections if the main switch on the control cabinet has not been turned to OFF If work is to be carried out within the working range of a switched off robot the robot must first be moved into a position in which it is unable to move on its own whether the payload is mounted or not If this is not possible the robot must be secured by appropriate means Components tools and other objects must not become jammed as a result of the robot motion nor must they lead to short circuits or be liable to fall off Any motion of the robot that would cause indirect danger to persons or objects must be avoided Appropriate attention must be paid to hazards posed near the peripheral system components of the robot such as grippers conveyors feed devices or o
80. ual mode the robot is guided using two KGDs The two KGDs work together via a connecting cable The processor in each individual KGD does not initially detect whether or not an additional KGD is connected The addresses are assigned subsequently by the control PC 5 3 6 Operating modes 5 3 6 1 Manual guidance mode In manual guidance mode the robot is moved using the sensor data of the KGD The velocity and acceleration are subjected to safety oriented monitoring safe reduction of velocity With enabling switch activated If the Safe Handling mode and the enabling switch are activated then the following parameters must be monitored e Maximum velocity can be configured e Maximum acceleration can be configured Without enabling switch activated robot at standstill If the Safe Handling mode is activated then the enabling switch must have the value 0 not activated If the enabling switch is not yet activated the following parameters must be monitored e Maximum velocity can be configured recommended 250 mm s e Maximum acceleration can be configured e Standstill monitoring after x ms time can be configured 25 5 3 6 2 Semi automatic mode with a safeguard Example roll door In Automatic mode the robot picks a component from a defined position and stops at a transfer position Opening a roll door switches the robot to a safety oriented manual guidance mode The operator can now move the robot manually using
81. vements with a conventional controller would require a very high level of programming knowledge and as our project team experienced when generating a sample painting application cost a lot of time With the Safe Teaching technology any operator can teach the path in the first execution correct it in a second execution if necessary and afterwards start working 3 Hardware components The main hardware components of the Safe Teaching package are a Force Torque Sensor system and an Operation Device Optionally a multi power tap can be added 3 1 The Force Torque Control System The sensor system consists of an ATI DAQ F T sensor an intermediate flange a device Net I O module from Beckhoff and a power supply box Fig 2 The sensor cannot be mounted directly on the mounting flange That is why an intermediate flange is required between the mounting flange of the robot and the sensor The Force Torque Sensor is able to read the forces in the direction of an axis of universal coordinates FX FY FZ and also the torque of these forces MX MY MZ The Force Torque Sensor is combined with a two channel three step enabling switch and a safety oriented connection to the robot controller This three position switch is responsible for the monitoring system It has the same function as the dead man button on the control panel of the KRC In a panic situation the operator would either release the button or tighten his grip both actions lead to an immed
82. y Outputs 17 _ 20 with max capacity 2 A 100 simultaneity Other inputs outputs can optionally be configured using field buses for example Inputs can be read outputs read and written They are addressed by means of the system variable IN No or OUT No Unused outputs can be used as flags The inputs outputs of the MFC module can be reassigned to other areas in the file IOSYS INI 5 5 8 Subprograms and functions In order to reduce the amount of typing and the program length when dealing with similar often repeated program sections subprograms and functions have been introduced as language constructs One effect of subprograms and functions that should not be underestimated with large programs is the possibility of re using in other programs algorithms that have already been written and in particular the use of subprograms for structuring the program This structuring process can bring about a hierarchical configuration so that individual subprograms called up by a higher level program can process tasks completely and pass on the results 5 5 8 1 Declaration A subprogram or function is a separate program section with its own program descriptor declaration section and instruction section which can be called for many position in the main program After execution of the subprogram or function the program jumps back to the next command after the subprogram call see Fig 14 Further subprograms and or functions can be called

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