TouchSense En

Issued: 26.06.2009

Version: KST TouchSense 1.3 V1 en

KUKA Roboter GmbHKUKA System Technology

KUKA.TouchSense 1.3

For KUKA System Software 5.2, 5.3, 5.4, 5.5 and 5.6

© Copyright 2009

KUKA Roboter GmbHZugspitzstraße 140D-86165 AugsburgGermany

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

Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work.

We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, how-ever, and necessary corrections will be incorporated in the subsequent edition.

Subject to technical alterations without an effect on the function.

Translation of the original operating instructions

KIM-PS5-DOC

KUKA.TouchSense 1.3

2 / 79 Issued: 26.06.2009 Version: KST TouchSense 1.3 V1 en

Publication: Pub KST TouchSense 1.3 enBook structure: KST TouchSense 1.3 V1.1Label: KST TouchSense 1.3 V1

Contents

Contents
1 Introduction .................................................................................................. 7
1.1 Target group .............................................................................................................. 71.2 Robot system documentation .................................................................................... 71.3 Terms used ................................................................................................................ 7

2 Product description ..................................................................................... 9

2.1 Overview of KUKA.TouchSense ................................................................................ 92.2 Communication .......................................................................................................... 92.3 Workpiece search ...................................................................................................... 102.3.1 Single Touch mode ............................................................................................... 102.3.2 Double Touch mode ............................................................................................. 11

3 Safety ............................................................................................................ 13

3.1 General ...................................................................................................................... 133.1.1 Liability .................................................................................................................. 133.1.2 Representation of warnings and notes ................................................................. 133.1.3 Designated use of the robot system ..................................................................... 143.1.4 EC declaration of conformity and declaration of incorporation ............................. 143.1.5 Description of the robot system ............................................................................ 153.1.6 Terms used ........................................................................................................... 153.2 Personnel ................................................................................................................... 163.3 Safety equipment and safeguards in the robot system .............................................. 183.3.1 Overview of the safety equipment and safeguards ............................................... 183.3.2 ESC safety logic ................................................................................................... 183.3.3 Category for safety-related controller components ............................................... 193.3.4 Mode selector switch ............................................................................................ 193.3.5 Stop reactions ....................................................................................................... 203.3.6 Workspace, safety zone and danger zone ........................................................... 213.3.7 Operator safety ..................................................................................................... 213.3.8 EMERGENCY STOP device ................................................................................ 223.3.9 Enabling device .................................................................................................... 233.3.10 Connection for external enabling device ............................................................... 233.3.11 Jog mode .............................................................................................................. 243.3.12 Mechanical end stops ........................................................................................... 243.3.13 Software limit switches ......................................................................................... 243.3.14 Overview of operating modes and safety measures ............................................. 243.3.15 Mechanical axis range limitation (option) .............................................................. 253.3.16 Axis range monitoring (option) .............................................................................. 253.3.17 Release device (option) ........................................................................................ 253.3.18 KCP coupler (optional) .......................................................................................... 263.3.19 External safety equipment and safeguards .......................................................... 263.3.20 Labeling on the robot system ................................................................................ 273.4 Safety measures ........................................................................................................ 273.4.1 General safety measures ...................................................................................... 273.4.2 Transportation ....................................................................................................... 283.4.3 Start-up and recommissioning .............................................................................. 283.4.4 Virus protection and network security ................................................................... 30

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3.4.5 Manual mode ........................................................................................................ 303.4.6 Simulation ............................................................................................................. 313.4.7 Automatic mode ................................................................................................... 313.4.8 Maintenance and repair ........................................................................................ 313.4.9 Decommissioning, storage and disposal .............................................................. 323.4.10 Safety measures for “single point of control” ........................................................ 333.5 Applied norms and regulations .................................................................................. 34

4 Installation ................................................................................................... 37

4.1 System requirements ................................................................................................. 374.2 Installation for KUKA System Software 5.4, 5.5, 5.6 ................................................. 374.2.1 Installing or updating KUKA.TouchSense ............................................................ 374.2.2 Uninstalling KUKA.TouchSense ........................................................................... 374.3 Installation for KUKA System Software 5.2, 5.3 ........................................................ 384.3.1 Installing KUKA.TouchSense ............................................................................... 384.3.2 Uninstalling KUKA.TouchSense ........................................................................... 384.3.3 Reinstalling KUKA.TouchSense ........................................................................... 38

5 Operation ...................................................................................................... 39

5.1 Menus ........................................................................................................................ 395.2 Starting a search with KUKA.TouchSense ................................................................ 39

6 Configuration ............................................................................................... 41

6.1 Configuration user interface ...................................................................................... 416.2 Configuring TouchSense ........................................................................................... 416.3 Loading a configuration ............................................................................................. 426.4 Saving a configuration ............................................................................................... 426.5 Configuration parameters .......................................................................................... 426.5.1 Configuration, general .......................................................................................... 426.5.2 Configuration, parameters .................................................................................... 436.5.3 Configuration, sensors .......................................................................................... 44

7 Programming ............................................................................................... 45

7.1 Programming a search instruction ............................................................................. 457.1.1 SEARCH LIN ........................................................................................................ 467.1.2 SEARCH PTP ....................................................................................................... 477.1.3 Option window “Frames” ...................................................................................... 487.1.4 Option window “Motion parameter” (CP motion) .................................................. 497.1.5 Option window “Motion parameter” (PTP motion) ................................................ 507.1.6 Option window “Calibrate adjustments” ................................................................ 507.1.7 Option window “Search Parameter” ..................................................................... 517.2 Programming a correction instruction ........................................................................ 527.2.1 CORR 1 dimensional ............................................................................................ 537.2.2 CORR 2 dimensional ............................................................................................ 547.2.3 CORR 3 dimensional ............................................................................................ 557.2.4 CORR Free programmable .................................................................................. 567.2.4.1 CORR Free programmable – detailed explanation .............................................. 577.2.5 CORR Turn off ...................................................................................................... 587.2.6 Linked search ....................................................................................................... 597.2.6.1 Example of a linked search: searching for the position of a fillet weld ................. 60

Issued: 26.06.2009 Version: KST TouchSense 1.3 V1 en

Contents

7.2.7 CHECK POINT ..................................................................................................... 617.2.8 Option window “Correction set” ............................................................................ 627.3 Reteaching a point ..................................................................................................... 637.4 Names in inline forms ................................................................................................ 64

8 Example programs ...................................................................................... 65

9 Messages ..................................................................................................... 67

10 KUKA Service .............................................................................................. 69

10.1 Requesting support .................................................................................................... 6910.2 KUKA Customer Support ........................................................................................... 69

Index ............................................................................................................. 75


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1. Introduction

1 Introduction

1.1 Target group

This documentation is aimed at users with the following knowledge and skills:

Advanced knowledge of the robot controller systemAdvanced KRL programming skills

1.2 Robot system documentation

The robot system documentation consists of the following parts:

Operating instructions for the robotOperating instructions for the robot controllerOperating and programming instructions for the KUKA System SoftwareDocumentation relating to options and accessories

Each of these sets of instructions is a separate document.

1.3 Terms used

For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training pro-gram can be found at www.kuka.com or can be obtained directly from our subsidiaries.

Term DescriptionSquare butt weld

A square butt weld is formed when 2 workpieces, e.g. 2 plates, lie parallel to each other. A square butt weld takes the form of a straight line.

Fillet weld A fillet weld is formed when 2 workpieces stand at right angles to each other. A fillet weld takes the form of a tri-angle with two sides of equal length and a slight fillet.

“Fast Measure-ment” option

The “Fast Measurement” option is used to program search commands in the KR C2 and KR C2 edition2005 robot controllers for measuring workpieces using digital sensors. The “Fast Measurement” option consists of a modified connection cover on the RDC housing on the robot base and the technology pack-ages KUKA.MeasureTech or KUKA.TouchSense.


www.kuka.com

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2. Product description

2 Product description

2.1 Overview of KUKA.TouchSense

KUKA.TouchSense is an add-on technology package e.g. for welding applica-tions that require a high degree of dimensional accuracy. Correction of the originally programmed path is often necessary in order to compensate for de-viations in the shape or position of workpieces. This is possible with KU-KA.TouchSense.

Functional principle

The original position of the workpiece is detected using the sensor, a live weld-ing wire. This is done by means of search instructions which are programmed via inline forms. When the welding wire touches the workpiece, the current flow is registered. At the same time, the search motion is interrupted by an in-terrupt signal and the position of the robot when the welding wire touches the workpiece is saved. Depending on the workpiece, one or more search instruc-tions must be programmed.

If the workpiece is then offset, the new position of the workpiece is determined using the same program. The robot controller calculates correction data sets from the difference between the original position and the new position.

When making the correction, the programmed path data are offset by the cor-rection data. This is done by means of one or more correction instructions, which are likewise programmed via inline forms.

Areas of appli-cation

If KUKA.TouchSense is used together with the KUKA.RoboTeam technology package, the following points must be observed:

Search motions may only be carried out sequentially. A robot cannot begin a search motion until the previous robot has completed its search motion.During the search motion, the robot controller sets the program override of every robot in the RoboTeam to 0%.The robots do not resume their motions with the programmed velocity until the search motion has been completed.

2.2 Communication

If KUKA.TouchSense is used e.g. for arc welding, a short-circuit between the welding wire and the workpiece causes a 24 volt signal from the robot to be

Fig. 2-1: Functional principle

1 Welding power source 4 Welding wire2 Relay 5 Workpiece3 “Fast Measurement” cable 6 Current flow on contact


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returned to the robot by the welding power source via a floating contact and a fast measuring input and to be evaluated by the robot controller.

2.3 Workpiece search

Overview There are two methods available for this:

Single Touch (>>> 2.3.1 "Single Touch mode" page 10)Double Touch (>>> 2.3.2 "Double Touch mode" page 11)

2.3.1 Single Touch mode

This method can be used to determine the positional offset of a workpiece.

The robot moves the sensor from the start point along a defined search path. The search direction is defined by the search point. The search motion is stopped when the sensor touches the workpiece.

The axis values determined during the search are saved as a correction data set. The robot then returns to the start point.

Fig. 2-2: Communication principle

1 Robot controller 5 Workpiece / clamping fixture2 RDC + “Fast Measurement”

option6 Welding power source

3 Robot 7 Relay / optocoupler4 Sensor / welding wire

KUKA Roboter GmbH does not supply universal touch hardware. When set-ting up the hardware, observe the specifications of the power source used.

Further information on connecting the Fast Measurement inputs can be found in the documentation “Option - KR C2 - Fast Measurement - Functions for Measuring Components”.


2. Product description

The search path must be programmed in such a way that both the original and new positions of the workpiece lie within the limits of the search motion and can thus be detected. The search path is dependent on the search distance X, which is set in the Search Parameter option window.

The number of search instructions needed depends on the possible changes in position of the workpiece. Up to 3 search instructions are generally neces-sary (for the offset and rotation of each axis) in order to adapt a path to the changed position. In the case of unfavorable geometries or poor accessibility, the number of search motions can be extended as required.

2.3.2 Double Touch mode

This method can be used to determine the center of a gap between 2 work-pieces, e.g. for a square butt weld.

The start point of the search lies within the gap. The search direction is defined by the search point. The search motion is stopped when the sensor touches the side of the gap. The search is then started automatically in the opposite direction. The search motion is stopped when the sensor touches the other side of the gap.

From the axis values determined during the search, the center of the gap is calculated and saved as a correction data set. The robot then returns to the start point.

The start point and the search path must be programmed in such a way that both the original and new positions of the gap lie within the limits of the search

Fig. 2-3: Example: search motion, original position of the workpiece

Fig. 2-4: Example: search motion, new position of the workpiece

1 Start point of the search2 Search point: determines the search direction3 Touch position: sensor touches workpiece4 Search distance5 Workpiece


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motion and can thus be detected. The search path is dependent on the search distance X, which is set in the Search Parameter option window.

Fig. 2-5: Example of a search motion: center of gap, touch 1

Fig. 2-6: Example of a search motion: center of gap, touch 2

1 Start point of the search2 Search point: determines the search direction3 Touch position 1: sensor touches the first side of the gap4 Center of gap5 Search distance6 Touch position 2: sensor touches the second side of the gap


3. Safety

3 Safety

3.1 General

3.1.1 Liability

The device described in these operating instructions is an industrial robot – called “robot system” in the following text – consisting of:

RobotRobot controllerTeach pendantConnecting cablesExternal axes, e.g. linear unit, two-axis positioner, positioner (optional)Top-mounted cabinet (optional)SoftwareOptions, accessories

The robot system is built using state-of-the-art technology and in accordance with the recognized safety rules. Nevertheless, impermissible misuse of the robot system may constitute a risk to life and limb or cause damage to the ro-bot system and to other material property.

The robot system may only be used in perfect technical condition in accord-ance with its designated use and only by safety-conscious persons who are fully aware of the risks involved in its operation. Use of the robot system is sub-ject to compliance with these operating instructions and with the declaration of incorporation supplied together with the robot system. Any functional disor-ders affecting the safety of the robot system must be rectified immediately.

Safety infor-mation

Safety information cannot be held against KUKA Roboter GmbH. Even if all safety instructions are followed, this is not a guarantee that the robot system will not cause personal injuries or material damage.

No modifications may be carried out to the robot system without the authori-zation of KUKA Roboter GmbH. Additional components (tools, software, etc.), not supplied by KUKA Roboter GmbH, may be integrated into the robot sys-tem. The user is liable for any damage these components may cause to the robot system or to other material property.

In addition to the Safety chapter, the operating instructions contain further safety instructions. These must be observed.

3.1.2 Representation of warnings and notes

Safety Warnings marked with this pictogram are relevant to safety and must be ob-served.

Danger!This warning means that death, severe physical injury or substantial material damage will occur, if no precautions are taken.

Warning!This warning means that death, severe physical injury or substantial material damage may occur, if no precautions are taken.


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Notes Notes marked with this pictogram contain tips to make your work easier or ref-erences to further information.

3.1.3 Designated use of the robot system

The robot system is designed exclusively for the specified applications.

Using the system for any other or additional purpose is considered impermis-sible misuse. The manufacturer cannot be held liable for any damage resulting from such use. The risk lies entirely with the user.

Operating the robot system and its options within the limits of its designated use also involves continuous observance of the operating instructions with particular reference to the maintenance specifications.

Impermissible misuse

Any use or application deviating from the designated use is deemed to be im-permissible misuse; examples of such misuse include:

Transportation of persons and animalsUse as a climbing aidOperation outside the permissible operating parametersUse in potentially explosive environments

3.1.4 EC declaration of conformity and declaration of incorporation

This robot system is a partial or incomplete machine as defined by the EC Ma-chinery Directive. The robot system may only be put into operation if the fol-lowing preconditions are met:

The robot system is integrated into an overall system.Or: The robot system, together with other machines, constitutes an overall system.Or: All safety equipment and safeguards required for operation in the over-all system as defined by the EC Machinery Directive have been added to the robot system.The overall system complies with the EC Machinery Directive. This has been confirmed by means of an assessment of conformity.

Declaration of conformity

The system integrator must issue a declaration of conformity for the overall system in accordance with the Machinery Directive. The declaration of con-formity forms the basis for the CE mark for the system. The robot system must be operated in accordance with the applicable national laws, regulations and standards.

The robot controller is CE certified under the EMC Directive and the Low Volt-age Directive.

Caution!This warning means that minor physical injuries or minor material damage may occur, if no precautions are taken.

Tips to make your work easier or references to further information.

Further information is contained in the technical data of the operating instruc-tions for the robot system and its options.


3. Safety

Declaration of incorporation

A declaration of incorporation is provided for the robot system. This declara-tion of incorporation contains the stipulation that the robot system must not be commissioned until it complies with the provisions of the Machinery Directive.

3.1.5 Description of the robot system

The robot system consists of the following components:

RobotRobot controllerGerman abbreviation for KCP teach pendantConnecting cablesExternal axes, e.g. linear unit, two-axis positioner, positioner (optional)Top-mounted cabinet (optional)SoftwareOptions, accessories

3.1.6 Terms used

Fig. 3-1: Example of a robot system

1 Linear unit 4 Connecting cables2 Robot 5 Robot controller3 Positioner 6 Teach pendant

Term DescriptionAxis range Range of each axis, in degrees, within which it may move. The axis

range must be defined for each axis that is to be monitored.Stopping distance Stopping distance = reaction distance + braking distance

The stopping distance is part of the danger zone.The braking distance is the distance covered by the robot and any optional external axes after the stop function has been triggered and before the robot comes to a standstill.


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3.2 Personnel

The following persons or groups of persons are defined for the robot system:

UserPersonnel

User The user must observe the labor laws and regulations. This includes e.g.:

The user must comply with his monitoring obligations.The user must carry out instruction at defined intervals.

Personnel Personnel must be instructed, before any work is commenced, in the type of work involved and what exactly it entails as well as any hazards which may ex-ist. Instruction must be repeated after particular incidents or technical modifi-cations.

Personnel includes:

System integratorOperators, subdivided into:

Start-up, maintenance and service personnelOperating personnelCleaning personnel

Workspace The robot is allowed to move within its workspace. The workspace is derived from the individual axis ranges.

Operator(User)

The user of the robot system can be the management, employer or del-egated person responsible for use of the robot system.

Danger zone The danger zone consists of the workspace and the stopping distances.KCP The KCP (KUKA Control Panel) teach pendant has all the operator con-

trol and display functions required for operating and programming the robot system.

Robot system The robot system consists of the robot controller and robot, together with any options (e.g. KUKA linear unit, two-axis positioner, other posi-tioner, top-mounted cabinet).

Safety zone The safety zone is situated outside the danger zone.Stop category 0 The drives are deactivated immediately and the brakes are applied. The

robot and any external axes (optional) perform path-oriented braking.

Note: This stop category is called STOP 0 in this document.Stop category 1 The robot and any external axes (optional) brake with path-maintaining

braking. The drives are deactivated after 1 s and the brakes are applied.

Note: This stop category is called STOP 1 in this document.Stop category 2 The drives are not deactivated and the brakes are not applied. The robot

and any external axes (optional) are braked with a normal braking ramp.

Note: This stop category is called STOP 2 in this document.System integrator(plant integrator)

System integrators are people who safely integrate the robot system into a plant and commission it.

T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)T2 Test mode, Manual High Velocity (> 250 mm/s permissible)External axis Motion axis which is not part of the robot but which is controlled using

the robot controller, e.g. KUKA linear unit, two-axis positioner, Posiflex

Term Description

All persons working with the robot system must have read and understood the robot system documentation, including the safety chapter.


3. Safety

System integrator The robot system is safely integrated into a plant by the system integrator.

The system integrator is responsible for the following tasks:

Installing the robot systemConnecting the robot systemPerforming risk assessmentOperating the required safety equipment and safeguardsIssuing the declaration of conformityAttaching the CE markCreating the operating instructions for the overall system

Operator The operator must meet the following preconditions:

The operator must be trained for the work to be carried out.Work on the robot system must only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and ex-perience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential dangers.

Example The tasks can be distributed as shown in the following table.

Installation, exchange, adjustment, operation, maintenance and repair must be performed only as specified in the operating instructions for the relevant component of the robot system and only by personnel specially trained for this purpose.

Tasks Operator ProgrammerSystem integrator

Switch robot controller on/off

x x x

Start program x x x

Select program x x x

Select operating mode x x x

Calibration (tool, base)

x x

Master robot x x

Configuration x x

Programming x x

Start-up x

Maintenance x

Repair x

Shutting down x

Transportation x

Work on the electrical and mechanical equipment of the robot system may only be carried out by specially trained personnel.


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3.3 Safety equipment and safeguards in the robot system

3.3.1 Overview of the safety equipment and safeguards

The following safety equipment and safeguards are present in the robot sys-tem:

Mode selector switch (>>> 3.3.4 "Mode selector switch" page 19)Operator safety (= connection for interlocking fixed guards) (>>> 3.3.7 "Operator safety" page 21)EMERGENCY STOP device (>>> 3.3.8 "EMERGENCY STOP device" page 22)Enabling device (>>> 3.3.9 "Enabling device" page 23) (>>> 3.3.10 "Connection for external enabling device" page 23)Jog mode in the test modes (>>> 3.3.11 "Jog mode" page 24)Mechanical limit stops (>>> 3.3.12 "Mechanical end stops" page 24)Mechanical axis range limitation (optional) (>>> 3.3.15 "Mechanical axis range limitation (option)" page 25)Axis range monitoring (optional) (>>> 3.3.16 "Axis range monitoring (option)" page 25)Release device (optional) (>>> 3.3.17 "Release device (option)" page 25)Labeling of danger areas in the robot system (>>> 3.3.20 "Labeling on the robot system" page 27)

The function and triggering of the electronic safety equipment are monitored by the ESC safety logic.

3.3.2 ESC safety logic

The ESC (Electronic Safety Circuit) safety logic is a dual-channel computer-aided safety system. It permanently monitors all connected safety-relevant components. In the event of a fault or interruption in the safety circuit, the pow-er supply to the drives is shut off, thus bringing the robot system to a standstill.

The ESC safety logic triggers different stop reactions, depending on the oper-ating mode of the robot system.

The ESC safety logic monitors the following inputs:

Operator safetyLocal EMERGENCY STOP (= EMERGENCY STOP button on the KCP)External EMERGENCY STOPEnabling deviceDrives OFF

Danger!In the absence of functional safety equipment and safeguards, the robot sys-tem can cause personal injury or material damage. If safety equipment or safeguards are dismantled or deactivated, the robot system may not be op-erated.


3. Safety

Drives ONOperating modesQualifying inputs

3.3.3 Category for safety-related controller components

Safety-related controller components include:

Local EMERGENCY STOP device (= EMERGENCY STOP button on the KCP)External EMERGENCY STOP deviceEnabling deviceExternal enabling deviceOperator safetyQualifying inputsAutomatic modeTest mode

These circuits conform to the requirements of category 3 according to EN 954-1.

3.3.4 Mode selector switch

The robot system can be operated in the following modes:

Manual Reduced Velocity (T1)Manual High Velocity (T2)Automatic (AUT)Automatic External (AUT EXT)

The operating mode is selected using the mode selector switch on the KCP. The switch is activated by means of a key which can be removed. If the key is removed, the switch is locked and the operating mode can no longer be changed.

If the operating mode is changed during operation, the drives are immediately switched off. The robot and any external axes (optional) are stopped with a STOP 0.

Fig. 3-2: Mode selector switch


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3.3.5 Stop reactions

Stop reactions of the robot system are triggered in response to operator ac-tions or as a reaction to monitoring functions and error messages. The follow-ing table shows the different stop reactions according to the operating mode that has been set.

STOP 0, STOP 1 and STOP 2 are the stop definitions according to DIN EN 60204-1:2006.

1 T2 (Manual High Velocity)2 AUT (Automatic)3 AUT EXT (Automatic External)4 T1 (Manual Reduced Velocity)

Operating mode

Use Velocities

T1For test operation, pro-gramming and teach-ing

Program verification:Programmed velocity, maxi-mum 250 mm/sJog mode:Jog velocity, maximum 250 mm/s

T2 For test operationProgram verification:Programmed velocity

AUT

For robot systems without higher-level controllers

Only possible with a connected safety cir-cuit

Program mode:Programmed velocityJog mode: not possible

AUT EXT

For robot systems with higher-level control-lers, e.g. PLC

Only possible with a connected safety cir-cuit

Program mode:Programmed velocityJog mode: not possible

Trigger T1, T2 AUT, AUT EXTSafety gate opened - STOP 1EMERGENCY STOP pressed

STOP 0 STOP 1

Enabling withdrawn STOP 0 -Start key released STOP 2 -“Drives OFF” key pressed

STOP 0

STOP key pressed STOP 2Operating mode changed

STOP 0

Encoder error (DSE-RDC connec-tion broken)

STOP 0


3. Safety

3.3.6 Workspace, safety zone and danger zone

Workspaces are to be restricted to the necessary minimum size. A workspace must be safeguarded using appropriate safeguards.

The safeguards (e.g. safety gate) must be situated inside the safety zone. If a safeguard is triggered, robot and external axes (optional) are braked and come to a stop within the danger zone.

The danger zone consists of the workspace and the stopping distances of the robot and external axes (optional). It must be safeguarded by means of phys-ical safeguards to prevent danger to persons or the risk of material damage.

3.3.7 Operator safety

The operator safety input is used for interlocking fixed guards. Safety equip-ment, such as safety gates, can be connected to the dual-channel input. If nothing is connected to this input, operation in Automatic mode is not possible. Operator safety is not active in the test modes T1 (Manual Reduced Velocity) and T2 (Manual High Velocity).

In the event of a loss of signal during Automatic operation (e.g. safety gate is opened), the drives are deactivated after 1 s and the robot and any external axes (optional) are stopped with a STOP 1. When the signal is applied again

Motion enable can-celed

STOP 2

Robot controller switched off

Power failure

STOP 0

Trigger T1, T2 AUT, AUT EXT

Fig. 3-3: Example of axis range A1

1 Workspace 3 Stopping distance2 Robot 4 Safety zone


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at the input (e.g. safety gate closed), Automatic operation can be resumed once the corresponding message has been acknowledged.

Operator safety can be connected via the peripheral interface on the robot controller.

3.3.8 EMERGENCY STOP device

The EMERGENCY STOP device for the robot system is the EMERGENCY STOP button on the KCP. The button must be pressed in the event of a haz-ardous situation or emergency.

Reactions of the robot system if the EMERGENCY STOP button is pressed:

Manual Reduced Velocity (T1) and Manual High Velocity (T2) modes:The drives are switched off immediately. The robot and any external axes (optional) are stopped with a STOP 0.Automatic modes (AUT and AUT EXT):The drives are switched off after 1 second. The robot and any external axes (optional) are stopped with a STOP 1.

Before operation can be resumed, the EMERGENCY STOP button must be turned to release it and the stop message must be acknowledged.

The operator safety must be designed in such a way that it is only possible to acknowledge the message from outside.

Fig. 3-4: EMERGENCY STOP button on the KCP

1 EMERGENCY STOP button

Warning!Tools and other equipment connected to the robot must be integrated into the EMERGENCY STOP circuit on the system side if they could constitute a po-tential hazard.Failure to observe this precaution may result in death, severe physical inju-ries or considerable damage to property.


3. Safety

3.3.9 Enabling device

The enabling devices of the robot system are the enabling switches on the KCP.

There are 3 enabling switches installed on the KCP. The enabling switches have 3 positions:

Not pressedCenter positionPanic position

In the test modes T1 (Manual Reduced Velocity) and T2 (Manual High Veloc-ity), the robot can only be moved if one of the enabling switches is held in the central position. If the enabling switch is released or pressed fully down (panic position), the drives are deactivated immediately and the robot stops with a STOP 0.

3.3.10 Connection for external enabling device

External enabling devices are required if there is more than one person in the danger zone of the robot system. They can be connected via the peripheral interface on the robot controller.

External enabling devices are not included in the scope of supply of the robot system.

Warning!The enabling switches must not be held down by adhesive tape or other means or manipulated in any other way.Death, serious physical injuries or major damage to property may result.

Fig. 3-5: Enabling switches on the KCP

1 - 3 Enabling switches


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3.3.11 Jog mode

In the operating modes T1 (Manual Reduced Velocity) and T2 (Manual High Velocity), the robot can only execute programs in jog mode. This means that it is necessary to hold down an enabling switch and the Start key in order to execute a program.

If the enabling switch is released or pressed fully down (panic position), the drives are deactivated immediately and the robot and any external axes (op-tional) stop with a STOP 0.

Releasing only the Start key causes the robot system to be stopped with a STOP 2.

3.3.12 Mechanical end stops

The axis ranges of main axes A 1 to A 3 and wrist axis A 5 of the robot are lim-ited by means of mechanical limit stops with a buffer.

Additional mechanical limit stops can be installed on the external axes.

3.3.13 Software limit switches

The axis ranges of all robot and positioner axes are limited by means of ad-justable software limit switches. These software limit switches only serve as machine protection and must be adjusted in such a way that the robot/posi-tioner cannot hit the mechanical limit stops.

The software limit switches are set during commissioning of a robot system.

3.3.14 Overview of operating modes and safety measures

The following table indicates the operating modes in which the safety meas-ures are active.

Danger!If the robot or an external axis hits an obstruction or a buffer on the mechan-ical end stop or axis range limitation, this can result in material damage to the robot system. KUKA Roboter GmbH must be consulted before the robot sys-tem is put back into operation (>>> 10 "KUKA Service" page 69). The affect-ed buffer must immediately be replaced with a new one. If a robot (or external axis) collides with a buffer at more than 250 mm/s, the robot (or external axis) must be exchanged or recommissioning must be carried out by the KUKA Roboter GmbH.

Further information is contained in the operating and programming instruc-tions.

Safety measures T1 T2 AUT AUT EXT

Operator safety - - active active

EMERGENCY STOP device

active (STOP

0)

active (STOP

0)

active (STOP

1)

active (STOP 1)

Enabling device active active - -

Reduced velocity during program verification

active - - -


3. Safety

3.3.15 Mechanical axis range limitation (option)

Most robots can be fitted with mechanical axis range limitation in axes A 1 to A 3. The adjustable axis range limitation systems restrict the working range to the required minimum. This increases personal safety and protection of the system.

In the case of robots that are not designed to be fitted with mechanical axis range limitation, the workspace must be laid out in such a way that there is no danger to persons or material property, even in the absence of mechanical axis range limitation.

If this is not possible, the workspace must be limited by means of photoelectric barriers, photoelectric curtains or obstacles on the system side. There must be no shearing or crushing hazards at the loading and transfer areas.

3.3.16 Axis range monitoring (option)

Most robots can be fitted with dual-channel axis range monitoring systems in main axes A 1 to A 3. The positioner axes may be fitted with additional axis range monitoring systems. The safety zone for an axis can be adjusted and monitored using an axis range monitoring system. This increases personal safety and protection of the system.

3.3.17 Release device (option)

Description The release device can be used to move the robot mechanically after an acci-dent or malfunction. The release device can be used for the main axis drive motors and, depending on the robot variant, also for the wrist axis drive mo-tors. It is only for use in exceptional circumstances and emergencies (e.g. for freeing people). After use of the release device, the affected motors must be exchanged.

Procedure 1. Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again.

2. Remove the protective cap from the motor.3. Push the release device onto the corresponding motor and move the axis

in the desired direction.The directions are indicated with arrows on the motors. It is necessary to overcome the resistance of the mechanical motor brake and any other loads acting on the axis.

Jog mode active active - -

Software limit switches active active active active

Safety measures T1 T2 AUT AUT EXT

This option can be retrofitted.

This option can be retrofitted.

Warning!The motors reach temperatures during operation which can cause burns to the skin. Contact should be avoided if at all possible. If necessary, appropri-ate protective equipment must be used.


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3.3.18 KCP coupler (optional)

The KCP coupler allows the KCP to be connected and disconnected with the robot controller running.

3.3.19 External safety equipment and safeguards

E-STOP There must be EMERGENCY STOP devices on every operator panel and an-ywhere else it may be necessary to trigger an EMERGENCY STOP. The sys-tem integrator is responsible for ensuring this. External EMERGENCY STOP devices are connected to the peripheral interface of the robot.

Safeguards The access of persons to the danger zone of the robot must be prevented by means of safeguards.

Physical safeguards must meet the following requirements:

They meet the requirements of EN 953.They prevent access of persons to the danger zone and cannot be easily circumvented.They are sufficiently fastened and can withstand all forces that are likely to occur in the course of operation, whether from inside or outside the en-closure.They do not, themselves, represent a hazard or potential hazard.The prescribed minimum clearance from the danger zone is maintained.

Safety gates (maintenance gates) must meet the following requirements:

They are reduced to an absolute minimum.The interlocks (e.g. safety gate switches) are linked to the operator safety input of the robot controller via safety gate switching devices or safety PLC.Switching devices, switches and the type of switching conform to category 3 according to EN 954-1.Depending on the risk situation: the safety gate is additionally safeguarded by means of a locking mechanism that only allows the gate to be opened if the robot is safely at a standstill.

Warning!Moving an axis with the release device can damage the motor brake. This can result in personal injury and material damage. After using the release de-vice, the affected motor must be exchanged.

Further information is contained in the robot operating instructions.

Warning!The operator must ensure that decoupled KCPs are immediately removed from the system and stored out of sight and reach of the robot system per-sonnel. This serves to prevent operational and non-operational EMERGEN-CY STOP facilities from becoming interchanged.Failure to observe this precaution may result in death, severe physical inju-ries or considerable damage to property.

Further information is contained in the robot controller operating instructions.


3. Safety

The button for acknowledging the safety gate is located outside the space limited by the safeguards.

Other safety equipment

Other safety equipment must be integrated into the system in accordance with the corresponding standards and regulations.

3.3.20 Labeling on the robot system

All plates, labels, symbols and marks constitute safety-relevant parts of the ro-bot system. They must not be modified or removed.

Labeling on the robot system consists of:

Rating platesWarning labelsSafety symbolsDesignation labelsCable markingsIdentification plates

3.4 Safety measures

3.4.1 General safety measures

The robot system may only be used in perfect technical condition in accord-ance with its designated use and only by safety-conscious persons. Operator errors can result in personal injury and damage to property.

It is important to be prepared for possible movements of the robot system even after the robot controller has been switched off and locked. Incorrect installa-tion (e.g. overload) or mechanical defects (e.g. brake defect) can cause the ro-bot or external axes to sag. If work is to be carried out on a switched-off robot system, the robot and external axes must first be moved into a position in which they are unable to move on their own, whether the payload is mounted or not. If this is not possible, the robot and external axes must be secured by appropriate means.

KCP If more than one KCP is used in the overall system, it must be ensured that each KCP is unambiguously assigned to the corresponding robot system. There must be no possibility of mixing them up in an emergency situation.

Further information is contained in the corresponding standards and regula-tions. These also include DIN EN 953.

Further information can be found in the operating instructions of the robot, lin-ear unit, positioner and robot controller.

Danger!In the absence of functional safety equipment and safeguards, the robot sys-tem can cause personal injury or material damage. If safety equipment or safeguards are dismantled or deactivated, the robot system may not be op-erated.

Warning!The motors reach temperatures during operation which can cause burns to the skin. Contact should be avoided if at all possible. If necessary, appropri-ate protective equipment must be used.


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External keyboard, external mouse

An external keyboard and/or external mouse may only be used if the following conditions are met:

Start-up or maintenance work is being carried out.The drives are switched off.There are no persons in the danger zone.

The KCP must not be used as long as an external keyboard and/or external mouse are connected.

The external keyboard and/or external mouse must be removed as soon as the start-up or maintenance work is completed.

Faults The following tasks must be carried out in the case of faults to the robot sys-tem:

Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. Indicate the fault by means of a label with a corresponding warning (tag-out).Keep a record of the faults.Eliminate the fault and carry out a function test.

Modifications After modifications to the robot system, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety circuits must also be tested.

3.4.2 Transportation

Robot The prescribed transport position of the robot must be observed. Transporta-tion must be carried out in accordance with the robot operating instructions.

Robot controller The robot controller must be transported and installed in an upright position. Avoid vibrations and impacts during transportation in order to prevent damage to the robot controller.

Transportation must be carried out in accordance with the operating instruc-tions for the robot controller.

External axis (optional)

The prescribed transport position of the external axis (e.g. KUKA linear unit, two-axis positioner, etc.) must be observed. Transportation must be carried out in accordance with the operating instructions for the external axis.

3.4.3 Start-up and recommissioning

Before starting up systems and devices for the first time, a check must be car-ried out to ensure that the systems and devices are complete and operational, that they can be operated safely and that any damage is detected.

The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety circuits must also be tested.

Warning!The operator must ensure that decoupled KCPs are immediately removed from the system and stored out of sight and reach of the robot system per-sonnel. This serves to prevent operational and non-operational EMERGEN-CY STOP facilities from becoming interchanged.Failure to observe this precaution may result in death, severe physical inju-ries or considerable damage to property.


3. Safety

Function test The following tests must be carried out before start-up and recommissioning:

General test

It must be ensured that:

The robot system is correctly installed and fastened in accordance with the specifications in the documentation.There are no foreign bodies or loose parts on the robot system.All required safety equipment is correctly installed and operational.The power supply ratings of the robot system correspond to the local sup-ply voltage and mains type.The ground conductor and the equipotential bonding cable are sufficiently rated and correctly connected.The connecting cables are correctly connected and the connectors are locked.

Test of safety-oriented circuits

A function test must be carried out for the following safety-oriented circuits to ensure that they are functioning correctly:

Local EMERGENCY STOP device (= EMERGENCY STOP button on the KCP)External EMERGENCY STOP device (input and output)Enabling device (in the test modes)Operator safety (in the automatic modes)Qualifying inputs (if connected)

Test of reduced velocity control

This test is to be carried out as follows:

1. Program a straight path with the maximum possible velocity.2. Calculate the length of the path.3. Execute the path in T1 mode with the override set to 100% and time the

motion with a stopwatch.4. Calculate the velocity from the length of the path and the time measured

for execution of the motion.The velocity thus calculated must not exceed 250 mm/s.

Machine data It must be ensured that the rating plate on the robot controller has the same machine data as those entered in the declaration of incorporation. The ma-

The passwords for logging onto the KUKA System Software as “Expert” and “Administrator” must be changed before start-up and must only be communi-cated to authorized personnel.

Danger!The robot controller is preconfigured for the specific robot system. If cables are interchanged, the robot and the external axes (optional) may receive in-correct data and can thus cause personal injury or material damage. If a sys-tem consists of more than one robot, always connect the connecting cables to the robots and their corresponding robot controllers.

Caution!If the internal cabinet temperature of the robot controller differs greatly from the ambient temperature, condensation can form, which may cause damage to the electrical components. Do not put the robot controller into operation un-til the internal temperature of the cabinet has adjusted to the ambient temper-ature.


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chine data on the rating plate of the robot and the external axes (optional) must be entered during start-up.

3.4.4 Virus protection and network security

The user of the robot system is responsible for ensuring that the software is always safeguarded with the latest virus protection. If the robot controller is in-tegrated into a network that is connected to the company network or to the In-ternet, it is advisable to protect this robot network against external risks by means of a firewall.

3.4.5 Manual mode

Manual mode is the mode for setup work. Setup work is all the tasks that have to be carried out on the robot system to enable automatic operation. Setup work includes:

Jog modeTeachingProgrammingProgram verification

The following must be taken into consideration in manual mode:

If the drives are not required, they must be switched off to prevent the robot or the external axes (optional) from being moved unintentionally.New or modified programs must always be tested first in Manual Reduced Velocity mode (T1).The robot, tooling or external axes (optional) must never touch or project beyond the safety fence. Components, tooling and other objects must not become jammed due to the motion of the robot system, nor must they lead to short-circuits or be liable to fall off.All setup work must be carried out, where possible, from outside the safe-guarded area.

If the setup work has to be carried out inside the safeguarded area, the follow-ing must be taken into consideration:

In Manual Reduced Velocity mode (T1):

If it can be avoided, there must be no other persons inside the safeguard-ed area.If it is necessary for there to be several persons inside the safeguarded ar-ea, the following must be observed:

Each person must have an enabling device.All persons must have an unimpeded view of the robot system.Eye-contact between all persons must be possible at all times.

The operator must be so positioned that he can see into the danger area and get out of harm’s way.

Warning!The robot must not be moved if incorrect machine data are loaded. Death, severe physical injuries or considerable damage to property may otherwise result. The correct machine data must be loaded.

For optimal use of our products, we recommend that our customers carry out a regular virus scan. Information about security updates can be found at www.kuka.com.


www.kuka.com

3. Safety

In Manual High Velocity mode (T2):

This mode may only be used if the application requires a test at a velocity higher than Manual Reduced Velocity.Teaching and programming are not permissible in this operating mode.Before commencing the test, the operator must ensure that the enabling devices are operational.The operator must be positioned outside the danger zone.There must be no other persons inside the safeguarded area. it is the re-sponsibility of the operator to ensure this.

3.4.6 Simulation

Simulation programs do not correspond exactly to reality. Robot programs cre-ated in simulation programs must be tested in the system in Manual Reduced Velocity mode (SSTEP T1). t may be necessary to modify the program.

3.4.7 Automatic mode

Automatic mode is only permissible in compliance with the following safety measures:

All safety equipment and safeguards are present and operational.There are no persons in the production line.The defined working procedures are adhered to.

If the robot or an external axis (optional) comes to a standstill for no apparent reason, the danger zone must not be entered until an EMERGENCY STOP has been triggered.

3.4.8 Maintenance and repair

After maintenance and repair work, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety circuits must also be tested.

The purpose of maintenance and repair work is to ensure that the system is kept operational or, in the event of a fault, to return the system to an operation-al state. Repair work includes troubleshooting in addition to the actual repair itself.

The following safety measures must be carried out when working on the robot system:

Carry out work outside the danger zone. If work inside the danger zone is necessary, the user must define additional safety measures to ensure the safe protection of personnel.Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. If it is necessary to carry out work with the robot controller switched on, the user must define addi-tional safety measures to ensure the safe protection of personnel.If it is necessary to carry out work with the robot controller switched on, this may only be done in operating mode T1.Label the system with a sign indicating that work is in progress. This sign must remain in place, even during temporary interruptions to the work.


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The EMERGENCY STOP systems must remain active. If safety equip-ment or safeguards are deactivated during maintenance or repair work, they must be reactivated immediately after the work is completed.

Faulty components must be replaced using new components with the same article numbers or equivalent components approved by KUKA Roboter GmbH for this purpose.

Cleaning and preventive maintenance work is to be carried out in accordance with the operating instructions.

Robot controller Even when the robot controller is switched off, parts connected to peripheral devices may still carry voltage. The external power sources must therefore be switched off if work is to be carried out on the robot controller.

The ESD regulations must be adhered to when working on components in the robot controller.

Voltages in excess of 50 V (up to 600 V) can be present in the KPS 600 (KUKA Power Supply), the KSDs (KUKA Servo Drives) and the intermediate-circuit connecting cables several minutes after the robot controller has been switched off. To prevent life-threatening injuries, no work may be carried out on the robot system in this time.

Water and dust must be prevented from entering the robot controller.

Counterbal-ancing system

Some robot variants are equipped with a hydropneumatic, spring or gas cylin-der counterbalancing system.

The hydropneumatic and gas cylinder counterbalancing systems are pressure equipment and, as such, are subject to obligatory equipment monitoring. De-pending on the robot variant, the counterbalancing systems correspond to cat-egory II or III, fluid group 2, of the Pressure Equipment Directive.

The user must comply with the applicable national laws, regulations and standards pertaining to pressure equipment.

Inspection intervals in Germany in accordance with Industrial Safety Order, Sections 14 and 15. Inspection by the user before commissioning at the instal-lation site.

The following safety measures must be carried out when working on the coun-terbalancing system:

The robot assemblies supported by the counterbalancing systems must be secured.Work on the counterbalancing systems must only be carried out by quali-fied personnel.

Hazardous substances

The following safety measures must be carried out when handling hazardous substances:

Avoid prolonged and repeated intensive contact with the skin.Avoid breathing in oil spray or vapors.Clean skin and apply skin cream.

3.4.9 Decommissioning, storage and disposal

The robot system must be decommissioned, stored and disposed of in accord-ance with the applicable national laws, regulations and standards.

To ensure safe use of our products, we recommend that our customers reg-ularly request up-to-date safety data sheets from the manufacturers of haz-ardous substances.


3. Safety

3.4.10 Safety measures for “single point of control”

Overview If certain components in the robot system are operated, safety measures must be taken to ensure complete implementation of the principle of “single point of control”.

Components:

Submit interpreterPLCOPC serverRemote control toolsExternal keyboard/mouse

Since only the system integrator knows the safe states of actuators in the pe-riphery of the robot controller, it is his task to set these actuators to a safe state, e.g. in the event of an EMERGENCY STOP.

Submit inter-preter, PLC

If motions, (e.g. drives or grippers) are controlled with the Submit interpreter or the PLC via the I/O system, and if they are not safeguarded by other means, then this control will take effect even in T1 and T2 modes or while an EMER-GENCY STOP is active.

If variables that affect the robot motion (e.g. override) are modified with the Submit interpreter or the PLC, this takes effect even in T1 and T2 modes or while an EMERGENCY STOP is active.

Safety measures:

Do not modify safety-relevant signals and variables (e.g. operating mode, EMERGENCY STOP, safety gate contact) via the Submit interpreter or PLC.If modifications are nonetheless required, all safety-relevant signals and variables must be linked in such a way that they cannot be set to a dan-gerous state by the Submit interpreter or PLC.

OPC server, remote control tools

These components can be used with write access to modify programs, outputs or other parameters of the robot controller, without this being noticed by any persons located inside the system.

Safety measures:

KUKA stipulates that these components are to be used exclusively for di-agnosis and visualization. Programs, outputs or other parameters of the robot controller must not be modified using these components.

External keyboard/mouse

These components can be used to modify programs, outputs or other param-eters of the robot controller, without this being noticed by any persons located inside the system.

Safety measures:

Only use one operator console at each robot controller.If the KCP is being used for work inside the system, remove any keyboard and mouse from the robot controller beforehand.

The implementation of additional safety measures may be required. This must be clarified for each specific application; this is the responsibility of the system integrator, programmer or user of the system.


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3.5 Applied norms and regulations

Name Definition Edition2006/95/EC Low Voltage Directive:

Directive of the European Parliament and the Council of 12 December 2006 on the harmonization of the laws of Member States relating to electrical equipment designed for use within cer-tain voltage limits

2006

89/336/EEC EMC Directive:

Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic com-patibility

1993

97/23/EC Pressure Equipment Directive:

Directive of the European Parliament and of the Council of 29 May 1997 on the approximation of the laws of the Member States concerning pressure equipment

1997

98/37/EC Machinery Directive:

Directive of the European Parliament and of the Council of 22 June 1998 on the approximation of the laws of the Member States relating to machinery

1998

EN ISO 13850 Safety of machinery:

E-STOP - Principles for design

2007

EN ISO 13732-1 Ergonomics of thermal environment:

Methods for the assessment of human responses to contact with surfaces - Part 1: Hot surfaces

2006

EN 614-1 Safety of machinery:

Ergonomic design principles – Part 1: Terms and general principles

2006


Safety-related parts of control systems - Part 1: General principles for design

1997


Electrical equipment of machines - Part 1: General requirements

2007

EN 61000-6-2 Electromagnetic compatibility (EMC):

Part 6-2: Generic standards; Immunity for industrial environments

2002

EN 61000-6-4 Electromagnetic compatibility (EMC):

Part 6-4: Generic standards; Emission standard for industrial environments

2002

EN ISO 10218-1 Industrial robots:

Safety

2006


3. Safety

EN ISO 12100-1 Safety of machinery:

Basic concepts, general principles for design - Part 1: Basic terminology, meth-odology

2004

EN ISO 12100-2 Safety of machinery:

Basic concepts, general principles for design - Part 2: Technical principles

2004

Name Definition Edition


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4. Installation

4 Installation

4.1 System requirements

Hardware Robot controller KR C2 or KR C2 edition2005Resolver Digital Converter RDC 2 with “Fast Measurement” option

Software KUKA System Software 5.2, 5.3, 5.4, 5.5 or 5.6

The procedure for installing and uninstalling the technology package depends on the software version:

KUKA System Software 5.4, 5.5, 5.6 (>>> 4.2 "Installation for KUKA System Software 5.4, 5.5, 5.6" page 37)KUKA System Software 5.2, 5.3 (>>> 4.3 "Installation for KUKA System Software 5.2, 5.3" page 38)

4.2 Installation for KUKA System Software 5.4, 5.5, 5.6

4.2.1 Installing or updating KUKA.TouchSense

Precondition CD-ROM with additional softwareOnly required if there is no CD-ROM drive on the control cabinet:Bootable USB CD-ROM/DVD driveUser group “Expert”

Procedure 1. Select the menu sequence Setup > Install Additional Software.2. Press New SW.

If the technology package is not yet displayed, press Refresh.3. Select TouchSense and press the Install softkey. Answer the request for

confirmation with Yes. The files are copied onto the hard drive.4. Reboot the robot controller. The installation is resumed and completed.

LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.

4.2.2 Uninstalling KUKA.TouchSense

Precondition Expert user group

Procedure 1. Select the menu sequence Setup > Install Additional Software. All in-stalled additional programs are displayed.

2. Select TouchSense and press the Uninstall softkey. Answer the request for confirmation with Yes.“De-installation prepared” is displayed in the State column.

3. Reboot the robot controller. Uninstallation is resumed and completed.

It is advisable to archive all relevant data before updating a software pack-age.

It is advisable to archive all relevant data before uninstalling a software pack-age.


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4.3 Installation for KUKA System Software 5.2, 5.3

4.3.1 Installing KUKA.TouchSense

Precondition User group “Expert”Windows interface (CTRL+ESC)

Procedure 1. Start the program Setup.exe from the CD-ROM. The files are copied onto the hard drive.

2. Confirm the reboot prompt with OK.3. Reboot the robot controller. The installation is resumed and completed.


4.3.2 Uninstalling KUKA.TouchSense


Procedure 1. Start the UnInstall.exe program in the directory C:\KRC_OPTION\TOUCHSENS\UNINST. Uninstallation is prepared.

2. Confirm the reboot prompt with OK.3. Reboot the robot controller.


4.3.3 Reinstalling KUKA.TouchSense


Procedure 1. Start the ReInstall.exe program in the directory C:\KRC_OPTION\TOUCHSENS\REINST. Setup is prepared.

2. Confirm the reboot prompt with OK.3. Reboot the robot controller.


It is advisable to archive all relevant data before uninstalling a software pack-age.


5. Operation

5 Operation

5.1 Menus

The following menus and commands are specific to this technology package:

Configure

TouchSense

Technology > TouchSense

SEARCHLINPTP

CORRTurn off1 dimensional2 dimensional3 dimensionalFree programmable

CHECK

5.2 Starting a search with KUKA.TouchSense

In order to start a search with KUKA.TouchSense, the robot controller switch-es the program override internally to 0% via the system variable $OV_PRO. This program override must not be changed during the search, whether with the status keys or in the KRL program. The search can otherwise not be start-ed or stopped.


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6. Configuration

6 Configuration

6.1 Configuration user interface

Overview

Status keys

6.2 Configuring TouchSense


Procedure 1. Select the menu sequence Configure > TouchSense.2. In the Select window, select the data to be configured.3. Set the configuration parameters as required.4. Press the Save Changes softkey. A request for confirmation is displayed,

asking if the changes should be saved.5. Press the Yes softkey. The configuration is saved.

Fig. 6-1: Configuration user interface

Item Description1 Configuration parameters2 Select area

The different screens are selected here. Also possible via the Screen status key.

3 The info line contains information about the selected parameter.

Status key DescriptionToggles between the different entries in the Select window.

Toggles between the items on a given screen.

Increases or decreases the value of the selected item.

With values of type BOOL: Toggles between TRUE and FALSE.


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6.3 Loading a configuration

Precondition User group “Expert”The configuration has been archived.

Procedure 1. Select the menu sequence Configure > TouchSense.2. Press the Load file softkey.3. Navigate to the archive file, select the archive file and confirm with Open.4. A request for confirmation is displayed, asking if the current configuration

should be overwritten. Press the Yes softkey.The configuration is loaded.

6.4 Saving a configuration


Procedure 1. Select the menu sequence Configure > TouchSense.2. Press the Save in file softkey.3. Specify a path and name for the archive file and confirm with Save.

6.5 Configuration parameters

6.5.1 Configuration, general

Fig. 6-2: Configuration: General

Parameter DescriptionTouchSense - option active

Activate or deactivate the TouchSense option.

Check box active: Option is activated. (Default)(H70_OPTION = TRUE)Check box not active: Option is deactivated.(H70_OPTION = FALSE)

Force referencing for piece

Check box active: At the next search routine, the position data of the workpiece will be saved as reference data.(NEW_REF = TRUE)Check box not active: At the next search routine, the position data of the workpiece will not be saved as reference data.(NEW_REF = FALSE)


6. Configuration

6.5.2 Configuration, parameters

Activated sensor Select the active sensor.

1 … 4

Up to 4 sensors can be connected and configured. Only one sensor may be active. (>>> 6.5.3 "Configuration, sensors" page 44)

Ignore search result Check box not active: If the sensor has not found the workpiece by the end of the search distance, the robot stops and an error message is displayed. (Default)(DECIDE_MODE = FALSE)Check box active: If the sensor has not found the workpiece by the end of the search distance, the robot does not stop and no error mes-sage is displayed.(DECIDE_MODE = TRUE)In this case, the search result is saved in the HIT_TARGET flag:

TRUE: The sensor has found the workpiece.FALSE: The sensor has not found the workpiece.

Parameter Description

Fig. 6-3: Configuration: Parameter

Parameter DescriptionInterrupt - part found This interrupt is activated via the Fast Measurement input when the sen-

sor makes contact with the workpiece. The search motion is ended, the interrupt position is evaluated and the return motion is started.

4 … 19

Default value: 15

Priority of the interrupt: 1

The lowest interrupt number must be entered here.Interrupt - start search movement

When the system is ready for the search motion, the search motion is started using this interrupt.

5 … 19

Default value: 16


The second highest interrupt number must be entered here.


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6.5.3 Configuration, sensors

Interrupt - search dis-tance reached

The interrupt is activated when the end of the search distance is reached. The search motion is terminated.

6 … 19

Default value: 17


The highest interrupt number must be entered here.Compensation time - capacity

Compensation time for the capacitive inertia of the system.

0.0 … 0.5 s

Default value: 0.1 sCompensation time - Relay

Compensation time for the time delay of the relay during signal trans-mission

0.0 … 0.7 s

Default value: 0.0 s

This value is dependent on the output capacitance of the welding power source and the settling time of the relay.

Parameter Description

Fig. 6-4: Configuration: Sensor - Example: Sensor 1

Parameter DescriptionOutput - touch voltage Number of the output for connecting the touch voltage

1 … 999: Positive logic (Touch = TRUE)0: No output configured-1 … -999: Negative logic (Touch = TRUE)

Fast measurement Input

Number of the Fast Measurement input

1 … 4: Positive logic (Touch = TRUE)0: No input configured-1 … -4: Negative logic (Touch = TRUE)

Input - system ready Number of the input used by the external system to communicate to the robot that it is ready

1 … 1,024: Positive logic (Sensor active = TRUE)0: No input configured-1 … -1,024: Negative logic (Sensor active = FALSE)


7. Programming

7 Programming

7.1 Programming a search instruction

Description The search is also suitable for robots with mathematically coupled external ax-es, or robots with a workpiece and a fixed tool (external TCP). The external axis must be in position before starting the search. It may be moved into new positions for the next search procedure. If teaching with external axes (math-ematically coupled or otherwise), these must remain stationary, i.e. only the 6 robot axes may be moved.

Programming a search instruction involves the following steps:

Saving the coordinates of the start point.Saving the coordinates of the search point.Setting various parameters, e.g. search velocity.

Precondition Program is selected.Operating mode T1 or T2.The welding wire must not be bent.

Preparation It is easier to program the search if the workpiece is positioned in the XY plane of a calibrated $BASE or parallel to $WORLD.If the welding wire is bent or pushed back on contact with the workpiece, this will falsify the correction data. To reduce the risk of this occurring, it is recommended that the maximum search velocity is determined before pro-gramming the search.

Procedure 1. Select the menu sequence TouchSense > SEARCH > LIN or PTP.The start point is addressed using LIN or PTP.

2. Set the parameters in the inline form. (>>> 7.1.1 "SEARCH LIN" page 46) (>>> 7.1.2 "SEARCH PTP" page 47)

3. If the search instruction is to detect the original position of the workpiece (instead of the deviation from the original position), set the calibration mode to ‘calibrate’. The data are saved as reference data. (>>> 7.1.6 "Option window “Calibrate adjustments”" page 50)

4. Move the TCP to the position that is to be taught as the start point.The start point must be approached in such a way that the welding wire is not perpendicular to the workpiece during the search, otherwise the result-ant correction data will be falsified. Ideally, the welding wire should be po-sitioned at an angle of approx. 45° to the search direction at the start position.

Caution!There is a risk of collisions if differently calibrated positions are used in search instructions. When programming search instructions, it must be en-sured that teaching is carried out using either a robot tool or an external tool or an external kinematic system.


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5. Press the StartPoint softkey and answer the request for confirmation with Yes.

6. Move the TCP to the position that is to be taught as the search point.7. Press the SearchPt. softkey and answer the request for confirmation with

Yes.8. Save the instruction by pressing the Cmd Ok softkey.

7.1.1 SEARCH LIN

Description

Fig. 7-1: Start position for search

Fig. 7-2: Inline form: SEARCH LIN

Item Description1 Name of the start point. The system automatically generates a

name. The name can be overwritten.

(>>> 7.4 "Names in inline forms" page 64)

Position the cursor in this box to edit the point data. The corre-sponding option window is opened.

(>>> 7.1.3 "Option window “Frames”" page 48)2 Velocity at which the motion to the start point is executed

0.01 … 2 m/s3 Name of the motion data set for moving to the start point. The sys-

tem automatically generates a name. The name can be overwrit-ten.


Position the cursor in this box to edit the motion data. The corre-sponding option window is opened.

(>>> 7.1.4 "Option window “Motion parameter” (CP motion)" page 49)

4 Name of the search point. The system automatically generates a name. The name can be overwritten.



7. Programming

7.1.2 SEARCH PTP

Description

5 Name of the correction data set. The system automatically gener-ates a name. The name can be overwritten.


Note: With freely programmable correction instructions, the name of the data set must be given in the form of CD1, CD2, etc. If no freely programmable correction instructions are being used, it is advisable to assign a logical name to the data set. This makes it easier to select a data set later when programming correction instructions.

A calibration mode must be selected. Place the cursor in the box and the relevant option window opens.

(>>> 7.1.6 "Option window “Calibrate adjustments”" page 50)6 Name of the motion data set for the search motion. The system

automatically generates a name. The name can be overwritten.



(>>> 7.1.7 "Option window “Search Parameter”" page 51)

Item Description

Fig. 7-3: Inline form: SEARCH PTP

Item Description1 Name of the start point. The system automatically generates a

name. The name can be overwritten.


Position the cursor in this box to edit the point data. The corre-sponding option window is opened.

(>>> 7.1.3 "Option window “Frames”" page 48)2 Velocity at which the motion to the start point is executed

1 … 100%3 Name of the motion data set for moving to the start point. The sys-

tem automatically generates a name. The name can be overwrit-ten.



(>>> 7.1.5 "Option window “Motion parameter” (PTP motion)" page 50)

4 Name of the search point. The system automatically generates a name. The name can be overwritten.



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7.1.3 Option window “Frames”

This option window is called from the following inline forms:

SEARCH LIN (>>> 7.1.1 "SEARCH LIN" page 46)SEARCH PTP (>>> 7.1.2 "SEARCH PTP" page 47)

5 Name of the correction data set. The system automatically gener-ates a name. The name can be overwritten.


Note: With freely programmable correction instructions, the name of the data set must be given in the form of CD1, CD2, etc. If no freely programmable correction instructions are being used, it is advisable to assign a logical name to the data set. This makes it easier to select a data set later when programming correction instructions.

A calibration mode must be selected. Place the cursor in the box and the relevant option window opens.

(>>> 7.1.6 "Option window “Calibrate adjustments”" page 50)6 Name of the motion data set for the search motion. The system

automatically generates a name. The name can be overwritten.



(>>> 7.1.7 "Option window “Search Parameter”" page 51)

Item Description

Fig. 7-4: Option window: Frames


7. Programming

7.1.4 Option window “Motion parameter” (CP motion)


SEARCH LIN (>>> 7.1.1 "SEARCH LIN" page 46)

Item Description1 Tool selection.

If True in the box External TCP: workpiece selection.

[1] … [16]2 Base selection.

If True in the box External TCP: fixed tool selection.

[1] … [32]3 Interpolation mode

False: The tool is mounted on the mounting flange.True: The tool is a fixed tool.

4 True: For this motion, the robot controller calculates the axis torques. These are required for collision detection.False: For this motion, the robot controller does not calculate the axis torques. Collision detection is thus not possible for this motion.

Fig. 7-5: Option window “Motion parameter” (CP motion)

Item Description1 Acceleration

Refers to the maximum value specified in the machine data. The maximum value depends on the robot type and the selected oper-ating mode.

2 This box has no function. Entered values will have no effect.3 Orientation control selection.

StandardWrist PTPConstant orientation


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7.1.5 Option window “Motion parameter” (PTP motion)


SEARCH PTP (>>> 7.1.2 "SEARCH PTP" page 47)

7.1.6 Option window “Calibrate adjustments”



Fig. 7-6: Option window "Motion parameter" (PTP motion)

Item Description1 Acceleration


2 This box has no function. Entered values will have no effect.


7. Programming

7.1.7 Option window “Search Parameter”



Fig. 7-7: Option window: Calibrate adjustments

Item Description1 Select the calibration mode.

calibrate: During the next search, the original position of the workpiece is detected. The data are saved as reference data. After the search, the calibration mode is automatically set to calibrated.calibrated: During the search, the deviation from the original position of the workpiece is detected.

2 Current offset, i.e. the difference in position between the original position of the workpiece and the position of the last workpiece to be searched

Display function: This value cannot be changed.3 Search direction in X, relative to the last search to be carried out

Display function: This value cannot be changed.4 Search direction in Y, relative to the last search to be carried out

Display function: This value cannot be changed.5 Search direction in Z, relative to the last search to be carried out

Display function: This value cannot be changed.


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7.2 Programming a correction instruction

Fig. 7-8: Option window: Search Parameter

Item Description1 Select the Touch mode.

single touch (>>> 2.3.1 "Single Touch mode" page 10)double touch (>>> 2.3.2 "Double Touch mode" page 11)

2 Enter the search distance.

3 … 1,000 mm

The search begins X mm before the search point and ends X mm after the search point.

3 Enter the search velocity.

Note: The search velocity must be set in such a way that the welding wire is not bent or pushed back on touching the work-piece, otherwise the resultant correction data will be falsified.

4 Enter the acceleration for returning to the start point.


5 Enter the velocity for returning to the start point.

Refers to the specified search velocity.

Caution!There is a risk of collisions if data sets of mixed origin are used in correction instructions. When programming correction instructions, it must be ensured that the data sets used originate from searches in which teaching was carried out using either a robot tool or an external tool or an external kinematic sys-tem.


7. Programming

7.2.1 CORR 1 dimensional

Description This correction instruction is used if the workpiece has a linear offset in one direction:

LengthWidthor height

A correction instruction overwrites the data of a previous correction instruction.

Precondition All SEARCH instructions have been programmed.

Procedure Select the menu sequence TouchSense > CORR > 1 dimensional.

Fig. 7-9: Example: 1-dimensional offset

1 Original position 2 Offset position

Fig. 7-10: Inline form: CORR 1 dimensional

Item Description1 Enter the correction data set.

All correction data sets created in the current program can be entered.

2 CONT: The robot controller executes this instruction without an advance run stop.[Empty box]: The robot controller executes this instruction with an advance run stop.

Note: We recommend selecting the CONT option in all cases.


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Description This correction instruction is used if the workpiece has a linear offset in two directions:

LengthWidthor height

A correction instruction overwrites the data of a previous correction instruction. The following example is valid for an unlinked search.






Item Description1, 2 Enter the correction data set.





7. Programming


Description This correction instruction is used if the workpiece has a linear offset in all di-rections:

LengthWidthand height

A correction instruction overwrites the data of a previous correction instruction. The following example is valid for an unlinked search.







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7.2.4 CORR Free programmable

Description This correction instruction is used if the workpiece has an angular (rotational) offset in one or more directions:

LengthWidthHeight

The workpiece may additionally have a linear offset in the other directions.

A correction instruction overwrites the data of a previous correction instruction.


Procedure Select the menu sequence TouchSense > CORR > Free programmable.

Item Description1 … 3 Enter the correction data set.




Fig. 7-15: Example: Angular offset


Fig. 7-16: Inline form: CORR Free programmable


7. Programming

7.2.4.1 CORR Free programmable – detailed explanation

Description

Boxes 1, 2 and 3 in the inline form define a plane between dimensions CD1, CD2 and CD3.The dimensions can be freely assigned to the boxes. (Dimension CD1 does not have to be entered in box 1. It could also be entered in box 2 or 3.)Boxes 4 and 5 in the inline form define a line between dimensions CD4 and CD5.The dimensions can be freely assigned to the boxes.Box 6 in the inline form defines the dimension CD6.

The amount of input required depends on the specific correction. If, for exam-ple, only a rotation of the surface needs to be corrected, it is only necessary to enter correction data sets in boxes 1 to 3. The default value -1 is entered in boxes 4 to 6.

Item Description1 … 6 Enter the number of the correction data set.

1 … n-1: This value must be entered if offset = 0 (default).



Fig. 7-17: CORR Freely programmable, dimensions


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KUKA.TouchSense 1.3

Example

7.2.5 CORR Turn off

Procedure Select the menu sequence TouchSense > CORR > Turn off.

Description Each of the correction instructions (CORR 1 dimensional, CORR 2 dimen-sional, CORR 3 dimensional or CORR Free programmable) switches the correction mode on. This instruction switches the correction mode off. This means that all following motion commands are executed without correction.

Point DescriptionCD1 Defines the surface.CD2 1st rotational dimension of the surfaceCD3 2nd rotational dimension of the surfaceCD4 Defines the line.CD5 1st rotational dimension of the lineCD6 Defines the offset.

Fig. 7-18: Example: CORR Free programmable, dimensions

Fig. 7-19: Example: CORR Free programmable, inline form

Fig. 7-20: Inline form CORR OFF


7. Programming

7.2.6 Linked search

Description With searches consisting of more than one search motion, there may be such a large deviation in one direction that a further SEARCH instruction no longer locates the workpiece. This can be avoided by linking searches as illustrated in the following diagrams.

Linking the searches leads to a higher hit rate and greater accuracy. The linked search is suitable for all linear offsets and slight rotations.

Example

The second search command no longer locates the workpiece:

Remedy: Program a linked search. The second search command then takes into account the first change in position.

Item Description1 CONT: The robot controller executes this instruction without an

advance run stop.[Empty box]: The robot controller executes this instruction with an advance run stop.


...LIN P1 SEARCH VIA P2 CD1LIN P3 SEARCH VIA P4 CD2CORR 2D CD1 CD2...

Fig. 7-21: Original position

Fig. 7-22: New position, without linked search

...LIN P1 SEARCH VIA P2 CD1CORR 1D CD1LIN P3 SEARCH VIA P4 CD2CORR 2D CD1 CD2...


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KUKA.TouchSense 1.3

7.2.6.1 Example of a linked search: searching for the position of a fillet weld

Description A fillet weld may be subject to a linear offset in 2 directions:

Horizontally to the right or leftVertically up or down

In order to determine the position of the fillet weld, a linked search is carried out, combining a search in Single Touch mode with a search in Double Touch mode.

1. Single Touch: Search for the corner point2. Double Touch: Search for the center of the weld

Fig. 7-23: New position and linked search

Fig. 7-24: Search for corner point, Single Touch

Item Description1 Start point P1 of the search2 Search point P2 of the search: determines the search direction3 Touch position = corner point4 Workpiece

Fig. 7-25: Search for center of weld, Double Touch


7. Programming

Example

7.2.7 CHECK POINT

Procedure Select the menu sequence TouchSense > CHECK.

Description This instruction checks whether a point is still within certain limits after the cor-rection. If the limits are exceeded, a message is displayed.

The instruction should be programmed directly after the CORR instruction. It may be inserted at any distance before the point to be checked.

The limits can be defined as a sphere about the original point, or as X, Y, Z and angle values.

Item Description1 Start point P3 of the search2 Search point P4 of the search: the search direction must be pro-

grammed so that it is perpendicular to the bisector of the weld angle.

3 Touch position 1: from this point, the search motion is started in the opposite direction.

4 Touch position 25 Workpiece

1 ...2 LIN P3 SEARCH VIA P4 CD13 CORR 1D CD14 LIN P1 SEARCH VIA P2 CD25 CORR 2D CD1 CD26 ...

Line Description2 Search instruction for determining the center of the weld

(Double Touch)3 Correction instruction 1 dimensional: Correction of the hori-

zontal offset of the weld4 Search instruction for determining the corner point (Single

Touch)5 Correction instruction 2 dimensional: Correction of the hori-

zontal offset of the weld, linked to correction of the vertical off-set of the weld

6 … Weld program

The CHECK POINT function is available in KUKA System Software 5.5 and higher.

Fig. 7-26: Inline form Check Point Radius

Fig. 7-27: Inline form Check Point Set


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KUKA.TouchSense 1.3

The softkey Radius/PL can be used to toggle between the Radius box and the Set box.

Example

CHECK POINT checks that point P17 is no more than 10 mm away from the original position following the correction. The direction of the deviation is not important.

7.2.8 Option window “Correction set”


CHECK POINT (>>> 7.2.7 "CHECK POINT" page 61)

Item Description1 Point whose position is to be checked.

All points created in the current program can be checked.2 The system checks whether the point is still within a sphere of this

radius.

1 … 200 mm3 Name of the data set containing the limit values. The system auto-

matically generates a name. The name can be overwritten.


The system checks whether the point lies within the defined limits.

To change the limit values, place the cursor in the box. The corre-sponding option window is opened.

(>>> 7.2.8 "Option window “Correction set”" page 62)

…CORR 1D CD2 CONTCHECK POINT P17 Radius=10 mm…PTP P17 Vel=100 % PDAT1 Tool[3] Base[3]


7. Programming

7.3 Reteaching a point

Description The coordinates of a taught point can be modified. This is done by moving to the new position and overwriting the old point with the new position.

Precondition Program is selected.Operating mode T1 or T2.

Procedure 1. If the motion to be changed is executed with corrected data, perform block selection to the associated correction instruction.

2. Execute the correction instruction.3. Move the TCP to the desired position.4. Position the cursor in the line containing the motion or search instruction

that is to be changed.5. Press the Change softkey. The inline form for this instruction is opened.6. For PTP and LIN motions: Press the Touch Up softkey to accept the cur-

rent position of the TCP as the new end point.For CIRC motions:

Fig. 7-28: Option window: Correction set

Item Description1 Permitted deviation in the X values2 Permitted deviation in the Y values3 Permitted deviation in the Z values4 Permitted deviation in the angle values

For motions that are executed with corrected data, the associated correction instruction must be executed before teaching the point.


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Press the Teach Aux softkey to accept the current position of the TCP as the new auxiliary point.Press the Teach End softkey to accept the current position of the TCP as the new end point.

For SEARCH motions:Press the StartPoint softkey to accept the current position of the TCP as the new start point.Press the SearchPt. softkey to accept the current position of the TCP as the new search point.

7. Confirm the request for confirmation with Yes.8. Save change by pressing the Cmd Ok softkey.

7.4 Names in inline forms

Names for data sets can be entered in inline forms. These include, for exam-ple, point names, names for motion data sets, etc.

The following restrictions apply to names:

Maximum length 23 charactersNo special characters are permissible, with the exception of $.The first character must not be a number.

The restrictions do not apply to output names.

Other restrictions may apply in the case of inline forms in technology pack-ages.


8. Example programs

8 Example programs

Program

Description

In order to start a search with KUKA.TouchSense, the robot controller switch-es the program override internally to 0% via the system variable $OV_PRO. This program override must not be changed during the search, whether with the status keys or in the KRL program. The search can otherwise not be start-ed or stopped.

1 DEF Example( )2 INI34 PTP HOME Vel=100 % DEFAULT56 PTP P1 CONT Vel=100 % PDAT1 Tool[1]:myTorch Base[0]7 PTP P2 CONT Vel=100 % PDAT2 Tool[1]:myTorch Base[1]8 PTP P3 Vel=100 % PDAT3 SEARCH VIA P4 CD1 PA0 Tool[1]:myTorch Base[1]9 PTP P5 Vel=100 % PDAT4 Tool[1]:myTorch Base[1]1011 CORR 1D CD1 CONT1213 CHECK POINT P8 Radius=3 mm1415 PTP P6 CONT Vel=100 % PDAT6 Tool[1]:myTorch Base[0]16 PTP P7 CONT Vel=100 % PDAT7 Tool[1]:myTorch Base[1]17 PTP P8 Vel=100 % PDAT8 SEARCH VIA P9 CD2 PA0 Tool[1]:myTorch Base[1]1819 CORR 2D CD1 CD2 CONT2021 CHECK POINT P13 Radius=3 mm2223 PTP P10 Vel=100 % PDAT10 Tool[1]:myTorch Base[0]24 PTP P11 Vel=100 % PDAT11 SEARCH VIA P12 CD3 PA0 Tool[1]:myTorch Base[1]25 PTP P13 Vel=100 % PDAT13 Tool[1]:myTorch Base[0]2627 CORR 3D CD1 CD2 CD3 CONT2829 CHECK POINT P18 Set=PF130 CHECK POINT P19 Radius=5 mm3132 PTP P15 CONT Vel=100 % PDAT15 Tool[1]:myTorch Base[0]33 LIN P16 CONT Vel=2 m/s CPDAT18 Tool[1]:myTorch Base[0]34 PTP P17 Vel=100 % PDAT17 Tool[1]:myTorch Base[0]35 LIN P18 Vel=0.2 m/s CPDAT18 Tool[1]:myTorch Base[1]36 LIN P19 Vel=0.2 m/s CPDAT19 Tool[1]:myTorch Base[1]37 PTP P20 CONT Vel= 100% PDAT20 Tool[1]:myTorch Base[0]3839 PTP HOME Vel= 100% DEFAULT4041 END

Line Description8 First search instruction with correction data set CD111 Correction instruction 1 dimensional13 CHECK POINT checks that point P8 is no more than 3 mm

away from the original position following the correction.15 … 17 These motions are executed with the data from the 1-dimen-

sional correction instruction.17 Second search instruction with correction data set CD219 Correction instruction 2 dimensional21 CHECK POINT checks that point P13 is no more than 3 mm

away from the original position following the correction.


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23 … 25 These motions are executed with the data from the 2-dimen-sional correction instruction.

24 Third search instruction with correction data set CD327 Correction instruction 3 dimensional29 CHECK POINT checks that point P18 is within the limits de-

fined in the Correction set option window.30 CHECK POINT checks that point P19 is no more than 5 mm

away from the original position following the correction.32 … 37 These motions are executed with the data from the 3-dimen-

sional correction instruction.39 The home position is not affected by the correction.

Line Description


9. Messages

9 Messages

Errors may occur in the application due to incorrect configuration or operation.

Error messages Message Cause RemedyBase coordi-nate system invalid. Correc-tion not possi-ble.

Invalid BASE in the SEARCH instruction

Reteach the start point and search point of the SEARCH instruction with a valid BASE.

Search not pos-sible, cancel or reset program.

Consequential error of a serious error, e.g. if no search point was taught. The corresponding error message was acknowl-edged and the Start key pressed again.

Reset the program and remedy the cause.

Invalid correc-tion data.

Invalid correction data set in the CORR instruction

Enter a valid correction data set in the CORR instruction.

Search error. Correction not possible.

The CORR instruction could not be executed because the search was unsuccessful.

Remedy the cause of the unsuccessful search, repeat the search and execute the CORR instruction.

T1 mode. Meas-urement invalid.

The search was executed in T1 mode.

Perform the search in the operating mode T2, Auto-matic, or Automatic Exter-nal.

Measurement out of tolerance.

Workpiece is too close. Extend the search dis-tance X or change the position of the workpiece.

End of search path – no part detected.

Workpiece is too far away. Extend the search dis-tance X or change the position of the workpiece.

Invalid search direction. Cor-rection not pos-sible.

The start point and search point are too close together.

Reteach the SEARCH instruction.

Distance between start-position and searchposition too small.

The start point and search point are too close together.

Reteach the SEARCH instruction.

Configuration error. Search or correction not possible.

Error when configuring the sensor.

Configure valid I/Os for the sensor.

Touch sensor option not avail-able => (H70_OPTION=FALSE)

KUKA.TouchSense has not been activated.

Activate KUKA.Touch-Sense.

Invalid com-mand. Correc-tion not executable.

KUKA.TouchSense was called with an invalid parameter.

KUKA Roboter GmbH must be consulted at all costs.


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Wire is still con-tacting work-piece. Jog robot away.

The Fast Measurement input signals before the search has been started that the workpiece has been found.

Check whether the welding wire is touch-ing the workpiece.Check whether the Fast Measurement in-put is defective.

Be careful ! Touch mode dis-abled (TOUCH_ON=FALSE).

The variable TOUCH_ON in $CONFIG.DAT is FALSE.

Set the variable TOUCH_ON in $CON-FIG.DAT to TRUE.

Message Cause Remedy


10. KUKA Service

10 KUKA Service

10.1 Requesting support

Introduction The KUKA Roboter GmbH documentation offers information on operation and provides assistance with troubleshooting. For further assistance, please con-tact your local KUKA subsidiary.

Information The following information is required for processing a support request:

Model and serial number of the robotModel and serial number of the controllerModel and serial number of the linear unit (if applicable)Version of the KUKA System SoftwareOptional software or modificationsArchive of the softwareApplication usedAny external axes usedDescription of the problem, duration and frequency of the fault

10.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)Luis Angel Huergo 13 20Parque Industrial2400 San Francisco (CBA)ArgentinaTel. +54 3564 421033Fax +54 3564 [email protected]

Australia Marand Precision Engineering Pty. Ltd. (Agency)153 Keys RoadMoorabbinVictoria 31 89AustraliaTel. +61 3 8552-0600Fax +61 3 [email protected]

Faults leading to production downtime should be reported to the local KUKA subsidiary within one hour of their occurrence.


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Austria KUKA Roboter Austria GmbHVertriebsbüro ÖsterreichRegensburger Strasse 9/14020 LinzAustriaTel. +43 732 784752Fax +43 732 [email protected]

Belgium KUKA Automatisering + Robots N.V.Centrum Zuid 10313530 HouthalenBelgiumTel. +32 11 516160Fax +32 11 [email protected]

Brazil KUKA Roboter do Brasil Ltda.Avenida Franz Liszt, 80Parque Novo MundoJd. GuançãCEP 02151 900 São PauloSP BrazilTel. +55 11 69844900Fax +55 11 [email protected]

Chile Robotec S.A. (Agency)Santiago de ChileChileTel. +56 2 331-5951Fax +56 2 [email protected]

China KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd.Shanghai Qingpu Industrial ZoneNo. 502 Tianying Rd.201712 ShanghaiP.R. ChinaTel. +86 21 5922-8652Fax +86 21 [email protected]


10. KUKA Service

France KUKA Automatisme + Robotique SASTechvallée6, Avenue du Parc91140 Villebon S/YvetteFranceTel. +33 1 6931660-0Fax +33 1 [email protected]

Germany KUKA Roboter GmbHZugspitzstr. 14086165 AugsburgGermanyTel. +49 821 797-4000Fax +49 821 [email protected]

Hungary KUKA Robotics Hungaria Kft.Fö út 1402335 TaksonyHungaryTel. +36 24 501609Fax +36 24 [email protected]

India KUKA Robotics, Private Limited621 Galleria TowersDLF Phase IV122 002 GurgaonHaryanaIndiaTel. +91 124 [email protected]

Italy KUKA Roboter Italia S.p.A.Via Pavia 9/a - int.610098 Rivoli (TO)ItalyTel. +39 011 959-5013Fax +39 011 [email protected]


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Japan KUKA Robotics Japan K.K.Daiba Garden City Building 1F2-3-5 Daiba, Minato-kuTokio135-0091JapanTel. +81 3 6380-7311Fax +81 3 [email protected]

Korea KUKA Robot Automation Korea Co. Ltd.4 Ba 806 Sihwa Ind. ComplexSung-Gok Dong, Ansan CityKyunggi Do425-110KoreaTel. +82 31 496-9937 or -9938Fax +82 31 [email protected]

Malaysia KUKA Robot Automation Sdn BhdSouth East Asia Regional OfficeNo. 24, Jalan TPP 1/10Taman Industri Puchong47100 PuchongSelangorMalaysiaTel. +60 3 8061-0613 or -0614Fax +60 3 [email protected]

Mexico KUKA de Mexico S. de R.L. de C.V.Rio San Joaquin #339, Local 5Colonia Pensil SurC.P. 11490 Mexico D.F.MexicoTel. +52 55 5203-8407Fax +52 55 [email protected]

Norway KUKA Sveiseanlegg + RoboterBryggeveien 92821 GjövikNorwayTel. +47 61 133422Fax +47 61 [email protected]


10. KUKA Service

Portugal KUKA Sistemas de Automatización S.A.Rua do Alto da Guerra n° 50Armazém 042910 011 SetúbalPortugalTel. +351 265 729780Fax +351 265 [email protected]

Russia OOO KUKA Robotics RusWebnaja ul. 8A107143 MoskauRussiaTel. +7 495 781-31-20Fax +7 495 781-31-19kuka-robotics.ru

South Africa Jendamark Automation LTD (Agency)76a York RoadNorth End6000 Port ElizabethSouth AfricaTel. +27 41 391 4700Fax +27 41 373 3869www.jendamark.co.za

Spain KUKA Sistemas de Automatización S.A.Pol. IndustrialTorrent de la PasteraCarrer del Bages s/n08800 Vilanova i la Geltrú (Barcelona)SpainTel. +34 93 814-2353Fax +34 93 [email protected]

Sweden KUKA Svetsanläggningar + Robotar ABA. Odhners gata 15421 30 Västra FrölundaSwedenTel. +46 31 7266-200Fax +46 31 [email protected]


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Switzerland KUKA Roboter Schweiz AGRiedstr. 78953 DietikonSwitzerlandTel. +41 44 74490-90Fax +41 44 [email protected]

Taiwan KUKA Robot Automation Taiwan Co. Ltd.136, Section 2, Huanjung E. RoadJungli City, TaoyuanTaiwan 320Tel. +886 3 4371902Fax +886 3 [email protected]

Thailand KUKA Robot Automation (M)SdnBhdThailand Officec/o Maccall System Co. Ltd.49/9-10 Soi Kingkaew 30 Kingkaew RoadTt. Rachatheva, A. BangpliSamutprakarn10540 ThailandTel. +66 2 7502737Fax +66 2 [email protected]

UK KUKA Automation + RoboticsHereward RiseHalesowenB62 8ANUKTel. +44 121 585-0800Fax +44 121 [email protected]

USA KUKA Robotics Corp.22500 Key DriveClinton Township48036 MichiganUSATel. +1 866 8735852Fax +1 586 [email protected]


Index

Index

Symbols$OV_PRO 39, 65

Numbers2006/95/EC 3489/336/EEC 3497/23/EC 3498/37/EC 34

AAccessories 13, 15Applied norms and regulations 34Areas of application 9AUT 20AUT EXT 20Automatic 20Automatic External 20Automatic mode 31Axis range 15Axis range limitation 25Axis range monitoring 25

BBrake defect 27Braking distance 15

CCalibration mode 45, 51CE mark 14CHECK POINT 61Cleaning work 32Communication 9Configuration 41Configuration, general 42Configuration, parameters 43Configuration, sensors 44Connecting cables 13, 15CORR 1 dimensional 53CORR 2 dimensional 54CORR 3 dimensional 55CORR Free programmable 56CORR Turn off 58Counterbalancing system 32

DDanger zone 16DECIDE_MODE 43Declaration of conformity 14Declaration of incorporation 13, 14, 15Decommissioning 32Designated use 14Disposal 32Documentation, robot system 7Double Touch 10Drives OFF 18Drives ON 19

EEC declaration of conformity 14EMC Directive 14, 34EMERGENCY STOP 20EMERGENCY STOP button 18, 19, 22, 29EMERGENCY STOP device 18, 22, 24, 26EMERGENCY STOP, external 18, 19, 26, 29EMERGENCY STOP, local 18, 19, 29EN 60204-1 34EN 61000-6-2 34EN 61000-6-4 34EN 614-1 34EN 954-1 34EN ISO 10218-1 34EN ISO 12100-1 35EN ISO 12100-2 35EN ISO 13732-1 34EN ISO 13850 34Enabling device 18, 23, 24Enabling device, external 23Enabling switches 23ESC 18Example programs 65External axes 13, 15, 16

FFast measurement Input 44Fast Measurement option 7Faults 28Fillet weld 7Firewall 30Function test 29Functional principle 9

GGeneral safety measures 27Guard interlock 21

HH70_OPTION 42Hazardous substances 32HIT_TARGET 43

IInstallation 37Installation, KSS 5.2, 5.3 38Installation, KSS 5.4, 5.5, 5.6 37Installation, KUKA.TouchSense 37, 38Interpolation mode 49Introduction 7

JJog mode 24, 25

KKCP 16, 27KCP coupler 26Keyboard, external 28


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Knowledge, required 7KUKA Customer Support 69KUKA.RoboTeam 9KUKA.TouchSense, activation 42

LLabeling 27Liability 13Linear unit 13, 15Low Voltage Directive 14, 34

MMachine data 29Machinery Directive 14, 34Maintenance 31Manual High Velocity 20Manual mode 30Manual Reduced Velocity 20Mechanical axis range limitation 25Mechanical end stops 24Messages 67Mode selector switch 19Mouse, external 28

NNetwork security 30NEW_REF 42

OOperating modes 19Operation 39Operator 16, 17Operator safety 18, 21, 24Options 13, 15Orientation control 49Overload 27Overview, KUKA.TouchSense 9

PPanic position 23Personnel 16Plant integrator 16Positioner 13, 15Pressure Equipment Directive 32, 34Preventive maintenance work 32Product description 9Programming 45Programming, correction 52Programming, search 45

QQualifying inputs 19, 29

RReaction distance 15Recommissioning 28Reinstallation, KUKA.TouchSense 38Release device 25Repair 31Robot 13, 15, 21Robot controller 13, 15, 30

Robot system 13, 15, 16

SSafeguards, external 26Safeguards, overview 18Safety 13Safety equipment, external 26Safety equipment, overview 18Safety instructions 13Safety logic 18Safety measures 24Safety zone 16, 21Safety, general 13SEARCH LIN 46SEARCH PTP 47Search, starting 39Service, KUKA Roboter 69Simulation 31Single point of control 33Single Touch 10Software 13, 15Software limit switches 24, 25Special characters 64Square butt weld 7Start-up 28Status keys 41STOP 0 16, 20STOP 1 16, 20STOP 2 16, 20Stop category 0 16Stop category 1 16Stop category 2 16Stop reactions 20Stopping distance 15, 21Storage 32Support request 69System integrator 14, 16, 17System requirements 37

TT1 16, 20T2 16, 20Target group 7Teach pendant 13, 15Teaching 63Technology packages 64Terms used 7Terms used, safety 15Top-mounted cabinet 13, 15Touch voltage 44Training program 7Transport position 28Transportation 28Two-axis positioner 13, 15

UUninstallation, KUKA.TouchSense 37, 38Updating, KUKA.TouchSense 37Use, contrary to designated use 13Use, improper 13User 16


Index

VVirus protection 30

WWarnings 13Working range limitation 25Workspace 16, 21


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KUKA.TouchSense 1.3

Documents

TouchSense En