SOFTWARE / HARDWARE
KR C
Seminar workbook
of …………………
Configuration & Programming of External Axes
for KUKA System Software V5.x
Issued: January 2010
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 1 of 240
Copyright
Copyright
© Copyright 2010
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express
permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claims to these
functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless,
discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this
documentation is checked on a regular basis, however, and necessary corrections will be incorporated in subsequent
editions.
Subject to technical alterations without an effect on the function.
KUKA Roboter GmbH accepts no liability whatsoever for any errors in technical information communicated orally or in
writing in the training courses or contained in the documentation. Nor will liability be accepted for any resultant damage or
consequential damage.
Responsible for this training documentation: College Development (WSC-IC)
Page 2 of 240
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Contents
Contents
1.
Introduction external axes ............................................................. 5
2.
Commissioning external axes and external kinematic systems .. 11
2.1. Jogging................................................................................. 11
2.2. Mastering ............................................................................. 17
2.3. Calibration ............................................................................ 21
3.
Programming of external axes..................................................... 29
3.1. Synchronal motion ............................................................... 29
3.2. Asynchronal motion.............................................................. 33
4.
System description ...................................................................... 47
4.1. Hardware.............................................................................. 47
4.1.1. Single Brake Modul ................................................... 63
4.2. Maschine data...................................................................... 71
4.2.1. Configurator............................................................. 119
5.
Examples for external axes ....................................................... 125
5.1. Two-axis positioner ............................................................ 125
5.2. Dual turnover positioner ..................................................... 149
5.3. Linear unit KL 1500 ............................................................ 155
5.4. 10-axis system ................................................................... 159
5.5. Special kinematics ............................................................. 167
6.
Optimization .............................................................................. 173
6.1. Determining optimal parameters ........................................ 173
6.2. Determininig the value for $CURR_MON[]......................... 199
7.
Multiple home positions ............................................................. 209
8.
Exercises................................................................................... 213
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 3 of 240
Introduction external axes
1. Introduction external axes
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Page 5 of 240
Introduction external axes
KR C2 - External axes
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Application range of external axes / kinematics
Improvement of accessibility
Enlargement of the working range
A
Tool drive
B
optimization of the cycle time
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Introduction external axes
Types of kinematics
BASE-kinematic
ROBROOT-kinematic
External axis as tool drive
external TOOL-Kinematic
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Is a kinematic needed ?
BASE-kinematic
A BASE-kinematic
is always needed, if the robot has to work
on a moving workpiece.
ROBROOT-kinematic
A ROBROOT-kinematic
is always needed,if the robot is moved
by a kinematic and has to execute
path-orientated motions on a workpiece.
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Page 7 of 240
Introduction external axes
Distinction between external axis and kinematic system
A kinematic system consists of 1 to 3 external axes
E1
E1
Turntable
(1 external axis)
E2
Two-axis turntable
(2 external axes)
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Under which conditions is it necessary to define a kinematic ?
A kinematic is to be defined,
if the robot has to execute motions on a moving workpiece.
Æ A kinematic must always be calibrated !
In all other cases the definition of external axes is sufficient !
( Æ definition of kinematics always means a big effort)
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Introduction external axes
Which data are located where?
• Variable data (installation site or “BASE” on the rotary table) are calculated by
means of calibration and entered in the $config.dat file.
• Fixed data (design) are stored in the machine data.
Z
X
Y
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Maximum values for external axis systems
¾ The KR C2 can control up to 6 kinematic systems.
¾ A kinematic system can consists of up to 3 external axes.
¾ Up to 8 amplifiers can be integrated into a KR C2 controller.
¾ All further external axis amplifiers must be integrated into a topmounted cabinet.
¾ Until now, the KR C1 could control max. 10 axes and the KR C2 could
control max. 10 axes.
¾ In principle, the KR C2 can control up to 12 axes.
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Page 9 of 240
Introduction external axes
Description of external kinematic systems
¾ Max. 6 kinematic systems
¾ Max. 3 axes per kinematic system
¾ Max. 6 external axes in the system
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Overview of motion types
Synchronous motion
Asynchronous motion
All the axes involved (robot axes and external
axes) execute a common motion, starting
simultaneously and stopping simultaneously.
The responding external axis executes an
asynchronous (not simultaneous) motion in
relation to the robot axes.
Math. coupling:
• Calibration of the ext.
kinematic system.
• The robot always
calculates its motion
path in relation to the
position of the external
kinematic system.
Without coupling:
• Axis calibration not
necessary.
• The position of the
external axis is not
calculated into the
motion path.
Coordinated:
• The asynchronous
external axes are
controlled via the KRL
program.
Uncoordinated:
• The asynchronous
external axes are
controlled from a
separate operator
control device.
Example:
• Two-axis positioner
Example:
• Turnover positioner
Example:
• Loading device
Example:
• Manual loading area
• Electric motor-driven
spot welding gun in
program mode
• Activation of the
electric motor-driven
spot welding gun via
status key
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Commissioning external axes and external kinematic systems
2. Commissioning external axes and external kinematic
systems
2.1.
Jogging
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Page 11 of 240
Commissioning external axes and external kinematic systems
Jogging external axes
Using the jog keys, you can move the robot or external axes in
accordance with the set coordinate system.
External axes cannot be moved using the
Space Mouse.
You can use the status key “Robot axes” to select whether the robot
axes or the configured external axes are to be jogged.
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Jogging external axes
When the status key “Robot axes” is pressed, the icon for external axes
appears (example with 4 external axes).
The main axes of the robot (A1...A3 or X,Y,Z) and the first 3 external
axes (E1...E3) can then be jogged. Another icon appears for the next 3
external axes (E4...E6) if these are present in the system.
This is followed by the icon for the ROBROOT kinematic system if one
has been configured.
Pressing the status key “Robot axes” again switches to mathematical
coupling (if this has been configured). This coupling has a number
corresponding to the configuration sequence in the file
“$MACHINE.DAT”.
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Commissioning external axes and external kinematic systems
Manual activation of a mathematical coupling
The kinematic system can
be selected directly in the
input window “Base No.”.
A mathematical coupling is only active in the Tool or Base
coordinate system! Exception: for ROBROOT kinematic
systems, also in the WORLD coordinate system!
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Programming mathematical couplings in the motion program
To activate a mathematical coupling in a motion program, the corresponding
transformation must be activated in the BASE coordinate system.
The transformation data for
the BASE kinematic system
used can be entered in the
input window “Base”.
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Page 13 of 240
Commissioning external axes and external kinematic systems
Programming mathematical couplings in the motion program
$Config.dat
entry
Open inline form
$Config.dat
entry
Closed inline form
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Automatic activation of a mathematical coupling
¾ Select program.
¾ Block selection to a motion instruction with transformation data for an
external kinematic system.
¾ Start the program in order to incorporate the data in the calculation.
¾ The mathematical coupling is now activated and can be used for
jogging the robot.
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Commissioning external axes and external kinematic systems
Jog options for external axes
The main axes of the robot (A1...A3 or X,Y,Z) and the first 3 external
axes (E1...E3) can be jogged.
Here the main axes (A1...A3 or X,Y,Z) and the external axes (E4...E6)
can be jogged.
The robot can be moved using the Space Mouse (axes A1...A6 or X, Y,
Z, A, B, C), while the external axes (E1...E6) can be moved using the
status keys.
• The type and number of options available depend on your system
configuration.
• From software V4.1 onwards it is possible to combine the mouse and
jog keys to jog the robot (mouse) and external axes (jog keys).
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Page 15 of 240
Commissioning external axes and external kinematic systems
2.2.
Mastering
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Page 17 of 240
Commissioning external axes and external kinematic systems
Why is mastering carried out?
A3=+90°
A4, A5, A6=0°
• When the robot is mastered, the axes
are moved into a defined mechanical
position, the so-called mechanical zero
position.
A2=-90°
• Once the robot is in this mechanical
zero position, the absolute encoder
value for each axis is saved.
A1=0°
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Mastering equipment
• In order to move the robot
exactly to the mechanical zero
position, a dial gauge or
electronic measuring tool
(EMT) is used.
Electronic measuring tool (EMT)
In EMT mastering, the axis is
automatically moved by the
robot controller to the
mechanical zero position. If a
dial gauge is being used, this
must be carried out manually in
axis-specific mode.
Dial gauge
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Commissioning external axes and external kinematic systems
Cross-section of the gauge cartridge
EMT
or
dial gauge
Gauge cartridge
"Frontsight/
rearsight" marker
Reference notch
Gauge pin
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Preparation for EMT mastering
• Move axes to pre-mastering position
(frontsight and rearsight aligned)
!
• Move axes manually in axisspecific mode
• Each axis is mastered individually
• Start with axis 1 and move upwards
• Always move axis from + to -
OK
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Commissioning external axes and external kinematic systems
Preparation for EMT mastering
• Remove protective cap from gauge
cartridge
Gauge
cartridge
• Attach EMT and connect signal cable
(connection X32 on the junction box on
the rotating column)
• Three LEDs on the EMT:
error
1 red
2 green
3 green
-
falling edge
-
rising edge
1
2
3
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Mastering external axes
Contents of: R1
Co
The external axes are
included in all EMT
mastering/unmastering
options.
External axis 1
External axis 2
External axis 3
External axis 4
11 Object(s)
HPU
Setup
If the system contains more than 8 axes, it may be necessary
to connect the signal cable to the 2nd RDC.
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Commissioning external axes and external kinematic systems
2.3.
Calibration
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Page 21 of 240
Commissioning external axes and external kinematic systems
External kinematics
Program
Calibration by...
Root point
moving the robot to the reference pin on the external
kinematic system (in 4 different positions)
Root point (numeric)
manual entry of the distance between the robot and the
external kinematic system
Offset
moving the robot to the calibration points of the tool mounted
on the external kinematic system
Offset (numeric)
manual entry of the distance between the external kinematic
system and the workpiece
Offset external kinematic
moving the robot to a fixed tool on an external kinematic
system
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Root point and offset
Offset = “Base” on the kinematic system
Root point = installation site
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Commissioning external axes and external kinematic systems
Root point calibration
Calibration of the installation site (root point) of the kinematic system:
1st step - Move the TCP to the reference mark
2nd step - Save the point
3rd step - Move the axis/axes of the external kinematic system
Carry out steps 1 to 3 four times in all.
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Calibrating the root point
Entry of the kinematic
system number
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Page 23 of 240
Commissioning external axes and external kinematic systems
Calibrating the root point
The reference pin data must be
stored in TOOL_DATA[x]
Tool on the robot
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Offset
Calibration of the offset (base) on an external kinematic system:
1st step - Move the TCP to the origin
2nd step - Move to a point on the positive X-axis
3rd step - Move to a point in the XY plane with a positive Y value
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Commissioning external axes and external kinematic systems
Calibrating the offset
Selection of the
kinematic system
Tool on the robot
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Save The „Root Point“-data
Entries in $CONFIG.DAT
Root point of kinematic 1
MACHINE_DEF[1] = {NAME[] "Robot",COOP_KRC_INDEX 1,PARENT[] "WORLD",
ROOT {x 0.0,y 0.0,z 0.0,a 0.0,b 0.0,c 0.0},
MECH_TYPE #ROBOT,
GEOMETRY[] " "}
MACHINE_DEF[2] = {NAME[] "DKP_400",COOP_KRC_INDEX 1,PARENT[] " ",
ROOT {x 1618.91589,y 292.508911,z 8.60157585,
a 179.682281,b 0.0912370011,c -0.269003987},
MECH_TYPE #EASYS,
GEOMETRY[] " "}
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Commissioning external axes and external kinematic systems
Save the „Offset“-data
Entries in $CONFIG.DAT
Offset of kinematic 1
BASE_DATA[17] =
{x -115.855698,y 151.380798, z 72.1764526,
a -90.7028885,b -0.149413005,c -0.112267002 }
Name of kinematic 1
BASE_NAME[17,]="DKP_400"
Type of kinematic 1
BASE_TYPE[17]=#BASE
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Special case: Offset external kinematic
Calibration is activated via
the menu item “Fixed tool”.
Example: external adhesive
nozzle for the application of
adhesive to glass
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Commissioning external axes and external kinematic systems
Offset external kinematic
With this calibration procedure, you can calibrate a tool on an external
kinematic system.
1st step - Calibrate tool direction
2nd step - Calibrate TCP of the tool
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Page 27 of 240
Programming of external axes
3. Programming of external axes
3.1.
Synchronal motion
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Page 29 of 240
Programming of external axes
Synchronous motions
Synchronous motion
All the axes involved (robot axes and external
axes) execute a common motion, starting
simultaneously and stopping simultaneously.
Math. coupling:
Without coupling:
•Calibration of the
•Axis calibration not
ext. kinematic
necessary.
system.
•The position of the
•The robot always
external axis is not
calculates its motion
calculated into the
path in relation to the motion path.
position of the
external kinematic
system.
Example:
Example:
•Turnover positioner
•Two-axis positioner
•Electric motor-driven
spot welding gun in
program mode
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Motion profile diagram for synchronous external axes
V
PTP (robot motion)
E1 (external axis motion)
t
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Programming of external axes
Motion profile diagram for synchronous external axes
without mathematical
coupling
with mathematical
coupling
V
PTP (robot motion)
(external axis motion)
t
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Programming of external axes
3.2.
Asynchronal motion
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Programming of external axes
Problems in practice
A
Machining
using synchronous
motions
B
Movement
to the loading or
unloading position
using asynchronous
motions
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Applications/Motivation
Problem/example:
An arc welding robot moves along a welding path, made up of many short
motions, on the first two-axis positioner, which is also moving.
Parallel to this, the axes of a second two-axis positioner in the same cell
are to be moved under program control into a position where the finished
workpieces can be removed.
The motions required for this are few, but time-consuming.
With synchronous motions (standard), the slow motions of the second
positioner would slow the motions of the robot at the first positioner, with the
result that the short motion blocks at the workpiece would take just as long
as the long motions of the second two-axis positioner.
Æ The resultant reduced weld velocity at the first two-axis positioner
causes major problems with the weldment!
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Programming of external axes
Solution
Remedy / General:
Using asynchronous motions, robot axes and synchronous external
axes can be moved independently of the motions of other external
axes.
This prevents the motion times of the asynchronous external axes
from slowing down the velocity of the robot and the synchronous
external axes.
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Asynchronous motions
Asynchronous motion
The responding external axis executes an
asynchronous (not simultaneous) motion in
relation to the robot axes.
Coordinated:
•The asynchronous
external axes are
controlled via the
KRL program.
Uncoordinated:
•The asynchronous
external axes are
controlled from a
separate operator
control device.
Example:
•Loading device
Example:
•Manual loading area
•Activation of the
electric motor-driven
spot welding gun via
status key
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Programming of external axes
Motion profile diagram for asynchronous external axes
V
PTP (robot motion)
(external axis motion)
t
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Enabling (STEU/$option.dat)
$ASYNC_OPT
Brief information
Enabling of the asynchronous motions.
Syntax
$ASYNC_OPT = Value
Example: $ASYNC_OPT = TRUE
Argument
Type
Explanation
Value
BOOL
FALSE: no asynchronous motions possible
TRUE: external axes can be defined as asynchronous
axes
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Programming of external axes
Activation and deactivation
$ASYNC_AXIS
Brief information
Activation and deactivation of asynchronous external axes
(not permissible in SPS.SUB!)
Syntax
$ASYNC_AXIS = Value
Example: $ASYNC_AXIS = 'B0100‘
Argument
Type
Explanation
Value
INT
This value switches bit-coded external axes to
asynchronous mode or back to synchronous mode. The
bits correspond to the external axes in ascending order:
bit 0 = external axis 1, bit 1 = external axis 2, etc.
1: external axis in asynchronous mode
0: external axis in synchronous mode
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Activation and deactivation
$ASYNC_AXIS
Activation and deactivation
Axes can only be switched to asynchronous mode if their mathematical coupling is
canceled first.
(The axes of a ROBROOT kinematic system cannot be switched to asynchronous
mode.)
Example:
PTP P10 VEL = 100% PDAT7 Tool[1]:Pin Base[17]:DKP_400
;Deactivation of the mathematical coupling
PTP P11 VEL = 100% PDAT8 Tool[1]:Pin Base[0]
$ASYNC_AXIS = 'B0100‘
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Programming of external axes
Coordinated asynchronous motions
ASYPTP
Brief information
Execution of coordinated asynchronous motions.
Æ Statement is executed in the advance run and is also permissible in SPS.SUB.
Æ If the asynchronous motion is not to be started until a specific point in
time/position has been reached, then the Trigger function is to be used.
Syntax
ASYPTP Target_Position
Argument
Type
Target_
Position
E6AXIS Target position of the motion in axis-specific coordinates.
E6POS
Explanation
Only the external axes specified in the Target_Position
are moved.
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Examples
Example 1:
ASYPTP {E1 10.0}
External axis 1 is moved to position 10.0°
ASYPTP {E1 10.0, E3 20.0}
External axis 1 is moved to position 10.0°,
external axis 3 is moved to position 20.0°
ASYPTP XP1
The axes are moved to the (external axis)
position saved in variable XP1.
Example 2:
PTP P10
TRIGGER WHEN DISTANCE = 1 DELAY= -50 DO SP1 ( ) PRIO = -1
PTP P11
...
DEF SP1 ( )
ASYPTP {E1 5.0}
External axis 1 is moved to position 5.0
END
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Programming of external axes
Override
$OV_ASYNC
Brief information
Override setting for the coordinated asynchronous motions.
Syntax
$OV_ASYNC = Value
Example: $OV_ASYNC = 20
Argument
Type
Explanation
Value
INT
This value is used to set the override for the coordinated
asynchronous motions.
Range of values:
0-100%
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Filter
$ASYNC_FLT
Brief information
Filter (smooth ramp) for the coordinated asynchronous motions.
Syntax
$ASYNC_FLT = Value
Example: $ASYNC_FLT = 10
Argument
Type
Explanation
Value
INT
This value specifies the filter length for the coordinated
asynchronous motions.
Range of values: 0 to 16 * interpolation cycle rate [ms]
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Programming of external axes
Stop motion
ASYSTOP
Brief information
Stops active coordinated asynchronous motions.
Syntax
ASYSTOP Axis
Argument
Type
Explanation
Axis
INT
Number of the asynchronous axis
Range of values: 0 ... $EX_AX_NUM
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Continue motion
ASYCONT
Brief information
Continues coordinated asynchronous motions stopped by means of ASYSTOP.
Syntax
ASYCONT Axis
Argument
Type
Explanation
Axis
INT
Number of the asynchronous axis
Range of values: 0 ... $EX_AX_NUM
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Programming of external axes
Cancel motion
ASYCANCEL
Brief information
Cancels and deletes coordinated asynchronous motions.
Syntax
ASYCANCEL Axis
Argument
Type
Explanation
Axis
INT
Number of the asynchronous axis - not currently used
Range of values: 0 ... $EX_AX_NUM
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Check state
$ASYNC_STATE
Brief information
Checks the state of the asynchronous motions (read only).
Syntax (example)
WHILE $ASYNC_STATE == #BUSY
...
ENDWHILE
Type
ENUM
Explanation
#IDLE:
No asynchronous motions active or stopped;
last motion terminated without an interrupt
#BUSY:
Asynchronous motions active.
#PEND:
Asynchronous motions stopped and temporarily stored.
#CANCELLED: No asynchronous motions active or stopped;
last motion was canceled.
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Programming of external axes
Permanent asynchronous axes (R1/$machine.dat)
$EX_AX_ASYNC
Brief information
Default setting for external axes in asynchronous mode.
Syntax
$EX_AX_ASYNC = Value
Example: $EX_AX_ASYNC = 'B0100'
Argument
Type
Explanation
Value
INT
This bit-coded value specifies which external axis is to be
moved asynchronously. The bits correspond to the
external axes in ascending order: bit 0 = external axis 1,
bit 1 = external axis 2, etc.
1: External axis always asynchronous
0: External axis can be moved as a synchronous axis and
as an asynchronous axis
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High velocity in T1 mode
$ASYNC_T1_FAST
Example: $ASYNC_T1_FAST=‘B0100’
External axis E3 is moved, in the case of coordinated asynchronous
motions in T1 mode, at maximum velocity.
Deactivation of the T1 velocity may only be used for special
applications which are not safety-sensitive, e.g. electric motor-driven
spot welding guns.
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Programming of external axes
Decoupling of (asynchronous) external axes
$ASYNC_EX_AX_DECOUPLE
Brief information
Decoupling of (asynchronous) external axes.
e.g. changing electric motor-driven spot welding guns during operation
Syntax
$ASYNC_EX_AX_DECOUPLE = Value
Argument
Type
Explanation
Value
INT
This value decouples/recouples external axes:
- The bits correspond to the external axes in ascending
order: bit 0 = external axis 1, bit 1 = external axis 2, etc.
- If the bit is set, the external axis is decoupled. If the bit is
reset, the external axis is recoupled.
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Uncoordinated asynchronous motions - Detach Jog
Door closed
Synchronous
motion
Door open
Uncoordinated
asynchronous
motion
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Programming of external axes
Assignment of digital inputs (STEU/$machine.dat)
Input 100 is used to
move external axis E1
asynchronously in the
positive direction.
Motion in the negative
direction
Input 103 is assigned
to the enabling switch.
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Assignment of digital inputs (STEU/$machine.dat)
$ZUST_ASYNC - enabling switch
For uncoordinated asynchronous motions, a separate enabling switch must be pressed.
This is assigned in the machine data (STEU/$machine.dat) to a digital input by means of
the instruction:
SIGNAL $ZUST_ASYNC $IN[no]
Options
Effect
TRUE
Asynchronous external axes enabled.
FALSE
Asynchronous external axes not enabled.
Releasing the enabling switch terminates the motion.
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Programming of external axes
Settings: $ASYNC_MODE (1)
$ASYNC_MODE
Brief information
Various asynchronous motion execution modes can be set, e.g. behavior of
ASYPTP motions in the Submit interpreter, response in the event of block selection,
etc. The setting of certain modes is particularly required for special applications
(electric motor-driven spot welding guns).
Syntax
$ASYNC_MODE = ‘B0000’
(Default-setting)
Argument
Type
Explanation
Value
INT
This value can be used to set different bit-coded modes
for the asynchronous motions.
- Bit 0 = 0:
- Bit 0 = 1:
Default mode in the Submit-Interpreter
Mode 1 in the Submit-Interpreter
- Bit 1 = 0:
- Bit 1 = 1:
Default mode for block selection
Mode 1 for block selection
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Settings: $ASYNC_MODE (2)
Default mode
Mode 1
$ASYNC_MODE: bit 0 = 0
$ASYNC_MODE: bit 0 = 1
The return position of the
asynchronous motions is saved.
Æ this means that repositioning is
not carried out as a result of
asynchronous motions
The return position of the
asynchronous motions is not saved.
Æ as in jog mode, repositioning is
carried out in the Submit
interpreter following
asynchronous motions
Irrespective of the state of the robot
interpreter, asynchronous motions
are always possible in the Submit
interpreter (c.f. interlocks in the
description of ASYPTP).
ASYPTP is only possible in the
Submit interpreter if the robot
interpreter is not active
($PRO_STATE <> #P_ACTIVE).
All external axes involved in an
ASYPTP motion must be switched to
asynchronous mode.
In the case of an ASYPTP motion in
the Submit interpreter, no axes need
to be switched to asynchronous
mode.
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Programming of external axes
Settings: $ASYNC_MODE (3)
Default-Mode
$ASYNC_MODE: Bit 1 = 0
With the default setting
the system variable $ASYNC_AXIS
will receive the value of
$EX_AX_ASYNC, if
• block selection or
• implicit block selection
is carried out.
Mode 2
$ASYNC_MODE: Bit 1 = 1
On
• block selection or
• implicit block selection
the value of $ASYNC_AXIS
remains unchanged.
Implicit block selection will be
triggered by
• Teaching a new point
• TouchUp
• Deletion of a point and
• Start backward
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System description
4. System description
4.1.
Hardware
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Page 47 of 240
System description
KUKA external axes
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Technical data of the KPS-600
Designation
Supply voltage
KPS-600/10
KPS-600/20
3x400 V/AC-10% to 480 V/AC +10% / 49-61 Hz
Rated supply current rms
12.5 A
25 A
Rated peak current rms
43 A for 0.5 s; cycle
95 A for 0.5 s; cycle
Rated peak current
60 A for 0.5 s; cycle
135 A for 0.5 s; cycle
Peak value fuse
16
25
Peak current I
71 A
156 A
Int. circuit voltage
(continuous operation)
510 – 765 V
Int. circuit voltage
(short-time operation)
60 – 800 V
Dimensions (WxHxD)
160 x 350 x 220 mm
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System description
Connectors for the external axes E1 and E2 on the KPS600
X17 provides the intercircuit voltage for the
motors A7 and A8 !
X17
X12
There are 2 independant braking channels on the
connector X12 !
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Technical data of the drive servos used - KSD
KSD1-08
KSD1-16
KSD1-32
KSD1-48
KSD1-64
[mm]
1 - 88
1 - 88
1 - 88
2 - 132
2 – 132
Int. circuit voltage
[V]
0 - 740
0 - 740
0 - 740
0 - 740
0 - 740
Max. accel. current
[A]
8
16
32
48
64
Rated current
[A rms]
4
8
16
17
20
Standstill current
[A rms]
5.1
8.5
17.0
22.6
26.9
Size/width
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System description
Nomenclature
At present there are 18 different motor types available.
The seminar books regards only a selection from this range.
The details for each motor type can be received from the Expert
documentation „KUKA Motordata“.
Mx_160_130_30_S0
“Motor”
x:
G:
E:
Placeholder
Smooth shaft
With involute
toothing
10 x standstill
torque
<Nm>
Flange height
<mm>
Speed/100
<rpm>
Free
type suffix,
S0: 1FK7
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List of servo-motors for KMC and external axes (1)
motor type (xy_S0)
Similar to the
following old
motor type
Articel-number
(00-xyz-abc)
Rated
power
[kW]
KSDtype
weight
[kg]
MG_ 8_44_45
F
131-269
0,3
8
2
MG/E_11_60_44
E
136-925/115-927
0,4
8
2,9
MG/E_16_60_42
E0
125-537/120-420
0,5
8
4
MG_40_80_45
-
136-895
1,4
16, 32
8,3
MG/E_60_110_30
D0
127-727/115-926
1,5
8
8,1
MG_64_110_45
-
136-896
1,6
32
11,2
MG/E_110_130_40
H
121-216/115-925
2,4
16
13,8
MG_120_110_25
-
136-897
2,1
32
16,8
MG/E_160_130_30
C0
138-891/131-493
3,1
32
16,5
MG/E_180_180_40
G1
129-492/117-606
3,0
32, 48
22,5
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
List of servo-motors for KMC and external axes (2)
motor-type (xy_S0)
Similar to the
following old
motor type
Articel-number
(00-xyz-abc)
Rated
power
[kW]
KSDtype
weight
[kg]
MG_220_130_25
-
136-898
1,7
64
25,7
ME_228_180_30
-
119-766
2,7
32, 48
26
ME_250_180_37
-
119-768
5,9
48
29
MG/E_260_180_30
I1
136-892/119-767
3,8
48, 32
28
MG/E_360_180_30
A0
136-893/131-492
6,9
64
31,6
MG/E_480_180_30
A01
136-894/131-491
8,6
64
43,5
MG/E_180_130_40_S6_cool
-
137-217/113-709
2,3
16
15,9
MG/E_180_180_40_S6_cool
-
137-220/113-707
3,0
48
22,5
Low temperature
motors:
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Fundamentals for external axes
Procedure:
•
•
•
Discuss project with KUKA Technical Support
Commissioning at customer's plant must only be carried out by qualified
personnel
Correct configuration has a positive effect on cycle time, and electrical and
mechanical components
Materials:
•
•
•
•
•
Use of KUKA motors
Use of KUKA mastering kit
The gear unit is dimensioned by the system builder
All single-axis external axis cables are suitable for installation in an energy
supply chain
Special connecting cable lengths are possible, but must be checked by
KUKA
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Drive package for external axes (with/without gear unit)
+
+ Single-axis motor cable
+
KSD
module
Single-axis control cable
+
+ Single-axis motor cable 15 m +
KSD
module
Single-axis control cable 7 m
Single-axis motor cables are available in a variety of different lengths
(7/15/25/35/50 m). The control cables are available in the lengths 7
and 15 m.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Names of motor/gearbox-combinations for external axes
Servo-motors and gearboxes match to each other and they
must be operated as a unit in accordance with the stated settings.
MGU 8800 – 250 – A01
“Motor-GearboxUnit”
Rated torque
of the gearbox
<Nm>
Gearbox-ratio
free additional
remark,
i.e. motor type
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
motor/gearbox-combinations for external axes
In order to drive external axes in different kinds of positioners
16 different motor-gearbox-combinations are available at present:
A selection from this range:
• motor-gearbox-unit MGU 8800-250-A01
• motor-gearbox-unit MGU 0850-125
• motor-gearbox-unit MGU 1200-125
• motor-gearbox-unit MGU 3100-118,5
• motor-gearbox-unit MGU 3100-185
• motor-gearbox-unit MGU 3900-219
• motor-gearbox-unit MGU 6800-234
(motor Typ A01)
(motor Typ H / 1FK7081)
(motor Typ H / 1FK7081)
(motor Typ G1 / 1FK7100)
(motor Typ G1 / 1FK7100)
(motor Typ G1 / 1FK7100)
(motor Typ I / 1FK7101)
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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motor/gearbox-combination MGU 8800-250-A01 (example)
motor
Motor type
Power
Max. motor speed
Rated torque
Acceleration torque
Static torque (brake)
gearbox
A01
10,7 KW
3000 rpm
26,5 Nm
85 Nm
48 Nm
Art.-Nr.
00-106-039
Ratio
250,33 (751 : 3)
Rated torque
8.800 Nm
Acceleration torque 12.000 Nm
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
motor/gearbox-combination MGU 0850-125 (example)
motor
Motor type
H/1FK7081
Power
7,5 KW
Max. speed
4.000 rpm
Rated torque
5,8 Nm
Max. acceleration torque
19 Nm
Static torque (brake)
11 Nm
gearbox
Art.-Nr.
ratio
Rated torque
Acceleration torque
00-114-485
125
850 Nm
1.150 Nm
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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External axes in the standard control cabinet
AND/
OR
The control cabinet is
designed for up to 8 axes!
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Wiring of an external axis in the basic cabinet
Robot motor/control cable
External axis control cable
External axis motor cable
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Wiring of two external axes in the basic cabinet
Robot motor/control cable
External axis control cable
External axis motor cable
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Comparison of control cabinets for 6 / 8 axes
6 axes
8 axes
KSD for E1 and E2
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Comparison of the control cabinet connector panels (1)
6 axes
8 axes
Motor cables
X7.1 and X7.2
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Fundamentals for the operation of more than 2 external axes
A top-mounted cabinet is required for three or more
external axes!
Æ In this case, all external axis KSDs are installed in the
top-mounted cabinet and supplied with power there by
the second KPS.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Comparison of control cabinets for 8 / 10 axes
8 axes
KSD for E1 and E2
10 axes
Additional KPS and
KSDs for E1 – E4 in
the top-mounted cabinet
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Comparison of the control cabinet connector panels (2)
8 axes
RDC cable X21
10 axes
2nd RDC cable XA21
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Comparison of the control cabinet connector panels (3)
8 axes
Motor cables
X7.1 and X7.2
10 axes
Motor cables
X9.1 – X9.4
I/O interface for
SBM2: XA16
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Top-mounted cabinet
The batteries ensure the supply of power to the second KPS and
the additional ESC board, even in the event of a power failure
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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ESC board in the top-mounted cabinet
X1: Power
supply
X3: Jumper
plug
X6: Connection to
ESC board in
the basic cabinet
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Wiring in top-mounted cabinet
X10
The external fans EA3 – EA7 are supplied with 24 V from
the basic cabinet via connector X10.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Wiring in basic cabinet (left-hand side)
3x400 V
Various
cables
Connecting cable from basic cabinet to top-mounted cabinet
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Second RDC
The second RDC transfers the position signals
of the external axes to the DSE-IBS-AUX.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
4.1.1. Single Brake Modul
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Page 63 of 240
System description
Example of use of single brake modules
Door closed
Robot welding
Door open
Operator changing
workpiece
(Æ protection of
personnel)
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Application and functional description of the single brake module
Application:
• asynchronous motions
(if no individual braking channel is available) and
• protection of personnel (safety functions)
The SBM brake module supports the safety functions
• “Safe stop” (safe disconnection) and
• “Protection against unexpected motion”
according to the requirements specified in EN 954, Parts 1 and 2.
For this purpose, the drive controllers (KSDs) are equipped with two
independent safety paths, which are connected in parallel.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Functional description of the single brake module (individual braking control)
In the case of asynchronous axes, a separate braking channel
(independent of the robot axes) is required for each axis that is
to be moved in asynchronous mode.
Possible alternatives:
• Second braking channel of the first KPS
(only in the case of one asynchronous axis)
• Single brake module with two or more asynchronous axes
(voltage supply from contactor K1 of the KPS in question)
1st braking channel
1st and 2nd braking channel
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Functional description of the SingleBrakeModules (individual braking control)
All external axes powered by the same KPS must
• either all be fitted with SBMs
• or all be operated without SBMs!
(Æ kernel system)
Basic cabinet
Top mounted cabinet
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Single brake module (individual braking control)
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Single brake module (individual braking control)
KSD
SBM
If single brake modules are used, a
DSE-IBS C33 and axis servos with
the following article numbers must
be used:
KUKA
Article no.
KSD1-08
00-117-341
KSD1-16
00-117-342
KSD1-32
00-117-343
KSD1-48
00-117-344
KSD1-64
00-117-345
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Reactors (only if SBMs are used)
The reactors suppress voltage peaks when the brakes
are used.
They protect the SBM against malfunction and destruction.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Single brake module (connector designation)
Connector X2 “I/O”
Connector X3 “brake”
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Single brake module (connector assignment)
Connector X3 “brake”
X3/1
X3/2
X3/3
X3/4
24 V brake power supply
GND of the brake power supply
GND terminal of the brake
Plus terminal of the brake
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Single brake module (connector assignment)
Connector X2 “I/O”
X2/1
X2/2
X2/3
X2/4
X2/5
X2/6
X2/7
X2/8
Reference potential for I/Os
Reference potential for internal signals
24 V external for both outputs
24 V internal
(power supply for SBM2)
“Servo enable” input
“Optocoupler power unit enable” input
Output 1 - feedback:
“Safe stop initiated”
Output 2 - Message:
“Axis ready for disconnection”
The input signals X2/5 and X2/6 are connected to the external voltage (24V).
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
SBM – operation without external voltage
If SBMs are used without external voltage,
then the following terminals on X2 „I/O“
have to be jumpered:
- jumper from pin 1 to pin 2 (0V, external to 0V, internal)
- jumper from pin 4 to pin 5 and pin 6
(24V, internal to Servo Enable and
Optocoupler power unit Enable)
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Functional description of the single brake module (individual braking control)
The function “Safe stop” is initiated if
• the signal “Servo enable” (SI1) or
• the signal “Optocoupler power unit enable” (SI2)
is deactivated.
As soon as this state is attained, a safety circuit prevents the motor from
starting again by means of two different, independent methods:
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Releasing the motor brake
The brake is connected to terminal module X3 (brake):
• X3/3 Ground terminal of the brake
• X3/4 Plus terminal of the brake
It receives its operating voltage from
• X3/1 (24 V) and
• X3/2 (GND)
The following conditions must be met in order to release it:
• the signal “Servo enable (SL_I1)” must be present at X2/5
• the signal “Optocoupler power unit enable (SL_I2)” must
be present at X2/6
• the brake must be under servo control
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Source of the input signals
The required input signals
“Servo enable” and “Optocoupler power unit enable”
can be wired, for example, via a door contact switch or a Safety-PLC.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
4.2.
Maschine data
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Page 71 of 240
System description
Enabling (STEU/$option.dat)
$EXT_AXIS
Brief information
Enabling of the external axes
Syntax
$EXT_AXIS = Value
Example: $EXT_AXIS = TRUE
Argument
Type
Explanation
Value
BOOL
FALSE: External axes cannot be defined
TRUE: External axes can be defined
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Axis identification
INT $NUM_AX=6
;ROBOT SYSTEM AXES (without external axes!)
INT $AXIS_TYPE[12]
;AXIS IDENTIFICATION
$AXIS_TYPE[1]=3
$AXIS_TYPE[2]=3
$AXIS_TYPE[3]=3
$AXIS_TYPE[4]=3
$AXIS_TYPE[5]=3
$AXIS_TYPE[6]=3
$AXIS_TYPE[7]=1
$AXIS_TYPE[8]=3
$AXIS_TYPE[9]=3
$AXIS_TYPE[10]=3
$AXIS_TYPE[11]=3
$AXIS_TYPE[12]=3
Axis identification:
1=
LINEAR (e.g. linear traversing units)
2=
3=
SPINDLE (special kinematics and spindle drive)
ROTATIONAL (standard case: rotational axes;
turning range from -358° to +358°)
FINITELY ROTATING AXES (no application
known)
INFINITE (infinitely rotating axes,
e.g. robot axis 4 or 6)
4=
5=
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Mechanical zero point
REAL $MAMES[12]
;OFFSET BETWEEN MECH. AND MATH. ZERO POINT
AXIS[I] (I=1:A1,I=7:E1) [MM,DEGREES]
$MAMES[1]=0.0
$MAMES[2]=-90.0
$MAMES[3]=90.0
$MAMES[4]=0.0
$MAMES[5]=0.0
$MAMES[6]=0.0
A3=+90°
$MAMES[7]=0.0
$MAMES[8]=0.0
$MAMES[9]=0.0
$MAMES[10]=0.0
$MAMES[11]=0.0
$MAMES[12]=0.0
A2=-90°
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Robot in the WORLD coordinate system
FRAME $ROBROOT={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
;ROBOT IN WORLD COORDINATE SYSTEM [MM,DEGREES]
$WORLD
$ROBROOT
$ROBROOT is important for Offline-programming.
It is also used for ceiling- and wall-mounted robots.
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System description
Robot root point kinematic system in the WORLD coordinate system
FRAME $ERSYSROOT={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
;ROBOT ROOT POINT KINEMATIC SYSTEM IN THE WORLD COORDINATE
SYSTEM [MM,DEGREES]
• $ERSYSROOT points to the
„zero mm“-position of the
ROBROOT-kinematic
$ROBROOT_C(t)
$WORLD
#ERSYS
($ROBROOT)
Lineareinheit
$ERSYSROOT *
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Resolution of the measuring system
INT $AXIS_RESO[12]
$AXIS_RESO[1]=4096
$AXIS_RESO[2]=4096
$AXIS_RESO[3]=4096
$AXIS_RESO[4]=4096
$AXIS_RESO[5]=4096
$AXIS_RESO[6]=4096
$AXIS_RESO[7]=4096
$AXIS_RESO[8]=4096
$AXIS_RESO[9]=4096
$AXIS_RESO[10]=4096
$AXIS_RESO[11]=4096
$AXIS_RESO[12]=4096
;RESOLUTION OF THE MEASURING SYSTEM AXIS[I]
(I=1:A1,I=7:E1) [INCR]
3 pairs of poles
Resolution 12 bits
(4096 incr.)
The resolution for the KR C1A is 16 bits. For this reason, the
value for $AXIS_RESO[n] must be set to 65536.
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System description
Ratio of motor to encoder (resolver)
DECL FRA $RAT_MOT_ENC[12]
$RAT_MOT_ENC[1]={N 1,D 4}
$RAT_MOT_ENC[2]={N 1,D 4}
$RAT_MOT_ENC[3]={N 1,D 4}
$RAT_MOT_ENC[4]={N 1,D 3}
$RAT_MOT_ENC[5]={N 1,D 3}
$RAT_MOT_ENC[6]={N 1,D 3}
$RAT_MOT_ENC[7]={N 1,D 4}
$RAT_MOT_ENC[8]={N 1,D 4}
$RAT_MOT_ENC[9]={N 1,D 3}
$RAT_MOT_ENC[10]={N 1,D 3}
$RAT_MOT_ENC[11]={N 1,D 3}
$RAT_MOT_ENC[12]={N 1,D 3}
;MOTOR:ENCODER RATIO
AXIS[I] (I=1:A1,I=7:E1)
N = NUMERATOR, D = DENOMINATOR
Motor type
Resolver
pole
pairs
MG_8_40_45_S0
D=3
Mx_40_80_45_S0
D=3
Mx_64_110_35_S0
D=3
MG_120_110_25_S0
D=4
Mx_160_130_30_S0
D=4
Mx_180_180_40_S0
D=4
Mx_220_130_25_S0
D=4
Mx_360_180_30_S0
D=4
Mx_480_180_30_S0
D=4
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Gear ratio (1)
DECL FRA $RAT_MOT_AX[12]
$RAT_MOT_AX[1]={N -125,D 1}
$RAT_MOT_AX[2]={N -125,D 1}
$RAT_MOT_AX[3]={N 125,D 1}
$RAT_MOT_AX[4]={N -690,D 9}
$RAT_MOT_AX[5]={N 33500,D 441}
$RAT_MOT_AX[6]={N -111,D 4}
$RAT_MOT_AX[7]={N -454874,D 10000}
$RAT_MOT_AX[8]={N 1904,D 10}
$RAT_MOT_AX[9]={N 107,D 1}
$RAT_MOT_AX[10]={N 0,D 1}
$RAT_MOT_AX[11]={N 0,D 1}
$RAT_MOT_AX[12]={N 0,D 1}
;MOTOR:AXIS RATIO
N = NUMERATOR,
D = DENOMINATOR
Motor A6: 111 revolutions
A6: 4 revolutions
Sign:
• With positive values, the axis (not the motor) must rotate clockwise (as seen from
behind the axis) when the PLUS key is pressed.
• If, when the PLUS key is pressed, the axis rotates in the negative direction
(according to the marking), the sign of the numerator must be changed!
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System description
Gear ratio (2)
DECL FRA $RAT_MOT_AX[12]
$RAT_MOT_AX[1]={N -125,D 1}
$RAT_MOT_AX[2]={N -125,D 1}
$RAT_MOT_AX[3]={N 125,D 1}
$RAT_MOT_AX[4]={N -690,D 9}
$RAT_MOT_AX[5]={N 33500,D 441}
$RAT_MOT_AX[6]={N -111,D 4}
;MOTOR:AXIS RATIO
N = NUMERATOR,
D = DENOMINATOR
Motor A6: 111 revolutions
$RAT_MOT_AX[7]={N -454874,D 10000}
$RAT_MOT_AX[8]={N 1904,D 10}
$RAT_MOT_AX[9]={N 107,D 1}
$RAT_MOT_AX[10]={N 0,D 1}
$RAT_MOT_AX[11]={N 0,D 1}
$RAT_MOT_AX[12]={N 0,D 1}
A6: 4 revolutions
Limit values:
• If the gear ratio is less than {N 15, D 1}, the motor can no longer be servo-controlled.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Approximation solution: Gear ratio with linear axes
In the case of linear axes, $RAT_MOT_AX[n] specifies
the number of motor revolutions per meter!
Travel difference:
1000 mm
Incremental difference on motor E1:
745,264 increments
The resolver resolution $RAT_MOT_ENC[n] must be known; here:
{N 1, D 4}.
Formula:
745,264 increments / (4*4096) = 45.4875 motor revolutions
Æ $RAT_MOT_AX[n] = {N 454875, D 10000}
Sign:
If, when the PLUS key is pressed, the axis rotates in the negative direction
(according to the marking), the sign must be changed!
Æ $RAT_MOT_AX[n] = {N - 454875, D 10000}
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Determination of number of resolver pole pairs on an unknown motor (1)
For KUKA motors, the following applies:
Æ No. of motor pole pairs = No. of resolver pole pairs
Possibilities:
1.
2.
3.
By means of increment display
DSE-RDW tool
Æ Number of zero passages per motor revolution
Oscilloscope
Æ Number of saw-tooth waves per motor revolution
By means of increment display:
• Remove the cover from the motor
• Move the colored marking on the motor shaft to the “12 o’clock” position
• Note the current increment value
• Move the motor through one revolution with 3% HOV
• Note the new increment value
• Divide the difference by 4096
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Determination of number of resolver pole pairs on an unknown motor (2)
For KUKA motors, the following applies:
Æ No. of motor pole pairs = No. of resolver pole pairs
2nd possibility:
DSE-RDW tool
Æ Number of zero passages per motor revolution
DSE-RDW tool:
• Setup
• Service
• DSE–RDW
• Select language
• [2] 2nd DSE-RDW
• [7] RDW check communication
• Received RDC data are displayed
• Move external axis for one revolution with override set to 1%
• Count no. of zero passages during one mech. revolution of the motor
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Determination of number of resolver pole pairs on an unknown motor (3)
3rd possibility:
Oscilloscope
Æ Number of saw-tooth waves per motor revolution
Oscilloscope:
• Monitor Æ Diagnosis Æ Oscilloscope Æ Configure
• Enter name of trace (max. 7 characters)
• Length of recording: 25 s
• “Trigger on motion start” or “Start by user, recording until buffer is full”
• Select DSE 2
• Softkey “DSE table”
• Select resolver of the corresponding axis
• Softkey “Main”
• Softkey “Save” Æ softkey “Start” Æ softkey “Show”: “Trace status: #T_WAIT”
• Move external axis for one revolution with override set to 1%
• After start of motion, the trace status changes to “#T_TRIGGERED”
• After end of motion, the trace status changes to “#T_END”
• Softkey “Show” Æ select trace name Æ softkey “Next”
• Count no. of saw-tooth waves during one mech. revolution of the motor
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Axis assignment on DSE and RDC
DSE channel corresponds to the Interbus
address (bus device sequence)
INT $DSECHANNEL[12]
;AXIS ASSIGNMENT ON DSE
KRC
$DSECHANNEL[1]=1
$DSECHANNEL[2]=2
$DSECHANNEL[3]=3
$DSECHANNEL[4]=4
$DSECHANNEL[5]=5
$DSECHANNEL[6]=6
$DSECHANNEL[7]=10
$DSECHANNEL[8]=11
$DSECHANNEL[9]=12
$DSECHANNEL[10]=13
$DSECHANNEL[11]=0
$DSECHANNEL[12]=0
1st DSE:
1st channel
2nd channel
3rd channel
4th channel
5th channel
6th channel
7th channel
8th channel
9th channel (spare)
2nd DSE:
10th channel
11th channel
12th channel
13th channel
14th channel
15th channel
16th channel
17th channel
18th channel (spare)
1st RDC:
1st channel
2nd channel
3rd channel
4th channel
5th channel
6th channel
7th channel
8th channel
2nd RDC:
1st channel
2nd channel
3rd channel
4th channel
5th channel
6th channel
7th channel
8th channel
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System description
Axis assignment on the power module - KR C2 (1)
The following applies for the KR C2:
Up to 8 axes:
The system has a standard DSE-IBS.
KR C2
1st
1stDSE-IBS
DSE-IBS(standard)
(standard)
9 axes or more:
The standard DSE-IBS now becomes the 2nd DSE and an
additional DSE-IBS-AUX (not the same as the standard card)
becomes the 1st DSE in the system.
KR C2
1st
1stDSE-IBS-AUX
DSE-IBS-AUX
2nd
2ndDSE-IBS
DSE-IBS(standard)
(standard)
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Braking channels on KPS600 - KR C2 (1)
1st braking channel
X12
2nd braking channel
There are two seperated braking channels on the connector X12.
$PMCHANNEL is also used to define the braking channel (2 per KPS)
assigned to the axis brake:
• Even numbers indicate the 1st braking channel of the KPS
• Odd numbers indicate the 2nd braking channel of the KPS
Example: $PMCHANNEL[7]=21 ;Axis 7 is assigned to the 2nd braking
channel of the 1st KPS of the 1st DSE.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Explanation of braking channel assignment (special kinematics)
DSE 1
No. of PMCHANNEL
4th KPS
3rd KPS
2nd KPS
1st KPS
M8
M7
M6
M5
M4
M3
M2
M1
27
26
25
24
23
22
21
20
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Explanation of braking channel assignment (special kinematics)
DSE 2
No. of PMCHANNEL
4th KPS
3rd KPS
2nd KPS
1st KPS
M8
M7
M6
M5
M4
M3
M2
M1
35
34
33
32
31
30
29
28
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System description
Axis assignment on the power module (standard case: 6 axes / 1 DSE)
INT $PMCHANNEL[12]
;DRIVE INTERFACE NO. ON THE POWER MODULE
1st PM of 1st DSE:
KRC
$PMCHANNEL[1]= 20
$PMCHANNEL[2]= 20
$PMCHANNEL[3]= 20
$PMCHANNEL[4]= 20
$PMCHANNEL[5]= 20
$PMCHANNEL[6]= 20
1st DSE:
1st PM channel
2nd PM channel
3rd PM channel
4th PM channel
5th PM channel
6th PM channel
2nd PM of 1st DSE:
7th PM channel
8th PM channel
9th PM channel
10th PM channel
11th PM channel
12th PM channel
$PMCHANNEL[7]= 0
$PMCHANNEL[8]= 0
$PMCHANNEL[9]= 0
$PMCHANNEL[10]= 0
$PMCHANNEL[11]= 0
$PMCHANNEL[12]= 0
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Axis assignment on the power module (8 axes / 1 DSE)
INT $PMCHANNEL[12]
;DRIVE INTERFACE NO. ON THE POWER MODULE
1st PM of 1st DSE:
KRC
$PMCHANNEL[1]= 20
$PMCHANNEL[2]= 20
$PMCHANNEL[3]= 20
$PMCHANNEL[4]= 20
$PMCHANNEL[5]= 20
$PMCHANNEL[6]= 20
$PMCHANNEL[7]= 21
$PMCHANNEL[8]= 21
$PMCHANNEL[9]= 0
$PMCHANNEL[10]= 0
$PMCHANNEL[11]= 0
$PMCHANNEL[12]= 0
1st DSE:
1st PM channel
2nd PM channel
3rd PM channel
4th PM channel
5th PM channel
6th PM channel
2nd PM of 1st DSE:
7th PM channel
8th PM channel
9th PM channel
10th PM channel
11th PM channel
12th PM channel
..
..
..
..
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System description
Axis assignment on the power module (9 axes / 2 DSE)
INT $PMCHANNEL[12]
;DRIVE INTERFACE NO. ON THE POWER MODULE
1st PM of 1st DSE:
KRC
$PMCHANNEL[1]= 20
$PMCHANNEL[2]= 20
$PMCHANNEL[3]= 20
$PMCHANNEL[4]= 20
$PMCHANNEL[5]= 20
$PMCHANNEL[6]= 20
$PMCHANNEL[7]= 28
$PMCHANNEL[8]= 28
$PMCHANNEL[9]= 28
$PMCHANNEL[10]= 0
$PMCHANNEL[11]= 0
$PMCHANNEL[12]= 0
1st PM channel
2nd PM channel
3rd PM channel
4th PM channel
5th PM channel
6th PM channel
1st DSE:
2nd PM of 1st DSE:
7th PM channel
8th PM channel
9th PM channel
10th PM channel
11th PM channel
12th PM channel
2nd DSE:
1st PM of 2nd DSE:
..
..
..
1st PM channel
2nd PM channel
3rd PM channel
4th PM channel
5th PM channel
6th PM channel
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Axis assignment on the power module (9 axes / 2 DSE + SBMs)
With SBMs (Single Brake Modules) Æ Channel no. + 100
INT $PMCHANNEL[12]
;DRIVE INTERFACE NO. ON THE POWER MODULE
1st PM of 1st DSE:
KRC
$PMCHANNEL[1]= 20
$PMCHANNEL[2]= 20
$PMCHANNEL[3]= 20
$PMCHANNEL[4]= 20
$PMCHANNEL[5]= 20
$PMCHANNEL[6]= 20
$PMCHANNEL[7]= 128
$PMCHANNEL[8]= 128
$PMCHANNEL[9]= 128
$PMCHANNEL[10]= 0 ..
$PMCHANNEL[11]= 0 ..
$PMCHANNEL[12]= 0 ..
1st DSE:
1st PM channel
2nd PM channel
3rd PM channel
4th PM channel
5th PM channel
6th PM channel
2nd PM of 1st DSE:
2nd DSE:
7th PM channel
8th PM channel
9th PM channel
10th PM channel
11th PM channel
12th PM channel
1st PM of 2nd DSE:
1st PM channel
2nd PM channel
3rd PM channel
4th PM channel
5th PM channel
6th PM channel
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System description
Servofiles – configuration file for servo motors KR C2
For each KSD-motor-combination
exists an individual Servo-File
in the directory R1/MADA .
CHAR $SERVOFILE1[16]
$SERVOFILE1[ ]=„KSD_16_MH_S7“
.
.
CHAR $SERVOFILE8[16]
$SERVOFILE8[ ]=„KSD_32_MB_S“
CHAR $SERVOFILE9[16]
$SERVOFILE9[ ]=„KSD_16_MC_A“
.
.
CHAR $SERVOFILE12[16]
$SERVOFILE12[ ]=„DEFAULT“
The Servo-files contain settings that are
needed to adopt a certain KSD type to a
certain motor type.
Servo-files also contain the settings for
the current control loop.
Æ These controller settings must not
be changed !!
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Example: Servo file for the KR C2
On booting, the data from the servo files are transferred to the
Lenze servos and overwrite the values stored there.
KSD_32_MB_S:
;****************************************
;*** KUKA
Parameter set
***
;*** Servo controller: KSD1-32
***
;*** Motor type: B
1FK6100 S39 ***
;*** Supplier: Siemens
***
;*** Version 1 date 18.09.00
***
;****************************************
;
;
PI
1069, 0 =
54
;VP_Isq-controller
PI
1070, 0 =
189
;KI_Isq-controller
PI
1071, 0 =
53
;VP_Isd-controller
PI
1072, 0 =
189
;KI_Isd-controller
PI
1073, 0 =
151
;Back_EMF
PI
1092, 0 =
18
;Servo precontrol
PI
1018, 0 =
0
;Switching rate 4 kHz
;
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System description
Maximum effective current of power module
REAL $CURR_MAX[12]
;MAXIMUM POWER MODULE CURRENT IN A rms
$CURR_MAX[1]=16.0
$CURR_MAX[2]=16.0
$CURR_MAX[3]=8.0
$CURR_MAX[4]=8.0
$CURR_MAX[5]=8.0
$CURR_MAX[6]=8.0
This entry is also relevant for the correct
display in the oscilloscope function.
KSD list: KR C2
• KSD1-08
• KSD1-16
• KSD1-32
• KSD1-48
• KSD1-64
$CURR_MAX[7]=16.0
$CURR_MAX[8]=32.0
$CURR_MAX[9]=16.0
$CURR_MAX[10]=32.0
$CURR_MAX[11]=0.0
$CURR_MAX[12]=0.0
=
=
=
=
=
8A
16 A
32 A
48 A
64 A
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Current calibration of the power module
REAL $CURR_CAL[12]
$CURR_CAL[1]=1.0
$CURR_CAL[2]=1.0
$CURR_CAL[3]=1.0
$CURR_CAL[4]=1.0
$CURR_CAL[5]=1.0
$CURR_CAL[6]=1.0
$CURR_CAL[7]=1.0
$CURR_CAL[8]=1.0
$CURR_CAL[9]=1.0
$CURR_CAL[10]=1.0
$CURR_CAL[11]=1.0
$CURR_CAL[12]=1.0
;CURRENT CALIBRATION OF POWER MODULE
(CURRENT TRANSFORMER)
KSD list: KR C2
• KSD1-08
• KSD1-16
• KSD1-32
• KSD1-48
• KSD1-64
Current factor
Current factor
Current factor
Current factor
Current factor
1
1
1
1
1
= 8A
= 16 A
= 32 A
= 48 A
= 64 A
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System description
Current command value limitation
INT $CURR_LIM[12]
$CURR_LIM[1]=100
$CURR_LIM[2]=100
$CURR_LIM[3]=86
$CURR_LIM[4]=90
$CURR_LIM[5]=90
$CURR_LIM[6]=90
$CURR_LIM[7]=100
$CURR_LIM[8]=100
$CURR_LIM[9]=100
$CURR_LIM[10]=100
$CURR_LIM[11]=100
$CURR_LIM[12]=100
;CURRENT COMMAND VALUE LIMIT AXIS [I] %
Motor type
IMAX (eff)
MG_8_40_45_S0
75 %
Mx_40_80_45_S0
100 % /
62 %
Mx_64_110_35_S0
78 %
MG_120_110_25_S0
96 %
Mx_160_130_30_S0
100 %
Mx_180_180_40_S0
100 %
Mx_220_130_25_S0
100%
Mx_360_180_30_S0
100 %
Mx_480_180_30_S0
100 %
If the motor current is set too high, this can result in damage to the gear unit or
demagnetization of the permanent magnets in the motors.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Current limit of the external axes for jogging
REAL $CURR_COM_EX[6]
$CURR_COM_EX[1]=100.0
$CURR_COM_EX[2]=100.0
$CURR_COM_EX[3]=100.0
$CURR_COM_EX[4]=100.0
$CURR_COM_EX[5]=100.0
$CURR_COM_EX[6]=100.0
;CURRENT LIMIT OF EXTERNAL AXES FOR
JOGGING
Unit [%]
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Holding current
REAL $CURR_MON[12]
;PERMISSIBLE HOLDING CURRENT DEFINES
THE LIMIT FOR THE I2t MONITORING
AT 55 °C (CABLE, AMPLIFIER AND MOTOR
WARMING!)
$CURR_MON[1]=7.3
$CURR_MON[2]=7.3
$CURR_MON[3]=2.7
$CURR_MON[4]=2.0
$CURR_MON[5]=2.0
$CURR_MON[6]=2.0
Motor type
$CURR_MON[7]=9.3
$CURR_MON[8]=12.8
$CURR_MON[9]=6.7
$CURR_MON[10]=0.0
$CURR_MON[11]=0.0
$CURR_MON[12]=0.0
Permissible limits:
Peak current:
2s
Holding current: 60 s
$CURR_
MON [A]
MG_8_40_45_S0
1,69
Mx_40_80_45_S0
6,30
Mx_64_110_35_S0
8,00
MG_120_110_25_S0
11,00
Mx_160_130_30_S0
14,00
Mx_180_180_40_S0
15,00
Mx_220_130_25_S0
22,50
Mx_360_180_30_S0
26,70
Mx_480_180_30_S0
25,50
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Peak current - Continuous current of the KPS for 1 s or 60 s
Each DSE module can operate up to 4 KPS.
REAL $KPS_CURR_MAX[8]
$KPS_CURR_MAX[1]=70.0
$KPS_CURR_MAX[2]=70.0
$KPS_CURR_MAX[3]=70.0
$KPS_CURR_MAX[4]=70.0
$KPS_CURR_MAX[5]=70.0
$KPS_CURR_MAX[6]=70.0
$KPS_CURR_MAX[7]=70.0
$KPS_CURR_MAX[8]=70.0
;MAXIMUM CURRENT OF A
;KPS FOR 1 s
REAL $KPS_CURR_RATED[8] ;RATED CURRENT OF A
$KPS_CURR_RATED[1]=20.0 ;KPS FOR 60 s
$KPS_CURR_RATED[2]=20.0
$KPS_CURR_RATED[3]=20.0
$KPS_CURR_RATED[4]=20.0
$KPS_CURR_RATED[5]=20.0
$KPS_CURR_RATED[6]=20.0
$KPS_CURR_RATED[7]=20.0
$KPS_CURR_RATED[8]=20.0
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Motor characteristic
REAL $KT_MOT[12]
$KT_MOT[1]=1.16
$KT_MOT[2]=1.16
$KT_MOT[3]=1.21
$KT_MOT[4]=0.82
$KT_MOT[5]=0.82
$KT_MOT[6]=0.82
$KT_MOT[7]=1.18
$KT_MOT[8]=1.25
$KT_MOT[9]=1.37
$KT_MOT[10]=1.0
$KT_MOT[11]=1.0
$KT_MOT[12]=1.0
;KT FACTOR OF THE MOTORS AT NOMINAL SPEED
Motor type
$KT_MOT
MG_8_40_45_S0
0,43
Mx_40_80_45_S0
0,66
Mx_64_110_35_S0
0,77
MG_120_110_25_S0
1,06
Mx_160_130_30_S0
1,17
Mx_180_180_40_S0
0,97
Mx_220_130_25_S0
0,98
Mx_360_180_30_S0
1,33
Mx_480_180_30_S0
1,72
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Motor characteristic
REAL $KT0_MOT[12]
;KT0 FACTOR OF MOTORS 1-12 AT STANDSTILL
Motortyp
$KT0_MOT[1]=1.20
$KT0_MOT[2]=1.20
$KT0_MOT[3]=1.33
$KT0_MOT[4]=0.80
$KT0_MOT[5]=0.80
$KT0_MOT[6]=0.80
$KT0_MOT[7]=1.18
$KT0_MOT[8]=1.41
$KT0_MOT[9]=1.57
$KT0_MOT[10]=1.0
$KT0_MOT[11]=1.0
$KT0_MOT[12]=1.0
$KT0_MOT
MG_8_40_45_S0
0,47
Mx_40_80_45_S0
0,64
Mx_64_110_35_S0
1,33
MG_120_110_25_S0
1,09
Mx_160_130_30_S0
1,14
Mx_180_180_40_S0
1,20
Mx_220_130_25_S0
0,98
Mx_360_180_30_S0
1,35
Mx_480_180_30_S0
1,88
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Axis acceleration time
REAL $RAISE_TIME[12]
$RAISE_TIME[1]=400.0
$RAISE_TIME[2]=800.0
$RAISE_TIME[3]=350.0
$RAISE_TIME[4]=250.0
$RAISE_TIME[5]=250.0
$RAISE_TIME[6]=260.0
;AXIS ACCELERATION TIME AXIS[I]
(I=1:A1,I=7:E1)[MS]
Normal values
= 300 to 1000 ms
Start value
= 500 ms
Blue Following Error_A3 Rad x 1.00
Magenta Actual Velocity_A3 RPM x 1000.0
$RAISE_TIME[7]=400.0
$RAISE_TIME[8]=250.0
$RAISE_TIME[9]=400.0
$RAISE_TIME[10]=0.0
$RAISE_TIME[11]=0.0
$RAISE_TIME[12]=0.0
$RAISE_TIME=500
The corresponding axis should not be allowed to go into
current limitation during measurement.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Motor acceleration time to rated speed without a load on the axis
REAL $RAISE_T_MOT[12]
$RAISE_T_MOT[1]=5.0
$RAISE_T_MOT[2]=5.0
$RAISE_T_MOT[3]=5.0
$RAISE_T_MOT[4]=1.4
$RAISE_T_MOT[5]=1.4
$RAISE_T_MOT[6]=1.4
;MOTOR ACCEL. TIME AXIS[I](I=1:A1,I=7:E1)[MS]
Unit [ms]
Default value = 5.0
$RAISE_T_MOT[7]=5.0
$RAISE_T_MOT[8]=5.0
$RAISE_T_MOT[9]=5.0
$RAISE_T_MOT[10]=5.0
$RAISE_T_MOT[11]=0.0
$RAISE_T_MOT[12]=0.0
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Motor speed at maximum setpoint value
REAL $VEL_AXIS_MA[12]
;RATED MOTOR SPEED AXIS[I]
(I=1:A1,I=7:E1) [R.P.M.]
$VEL_AXIS_MA[1]=2600.0
$VEL_AXIS_MA[2]=2600.0
$VEL_AXIS_MA[3]=2600.0
$VEL_AXIS_MA[4]=3360.0
$VEL_AXIS_MA[5]=3360.0
$VEL_AXIS_MA[6]=2280.0
$VEL_AXIS_MA[7]=4100.0
$VEL_AXIS_MA[8]=3000.0
$VEL_AXIS_MA[9]=2250.0
$VEL_AXIS_MA[10]=0.0
$VEL_AXIS_MA[11]=0.0
$VEL_AXIS_MA[12]=0.0
• The speed defined here is reached when the max. speed setpoint value is generated.
• This speed must be less than the rated motor speed.
• If the rated motor speed of the motor is exceeded, the motor is operated at
breakdown-torque speed.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Reduction factor for axial velocity (HOV)
INT $RED_VEL_AXC[12]
$RED_VEL_AXC[1]=6
$RED_VEL_AXC[2]=6
$RED_VEL_AXC[3]=6
$RED_VEL_AXC[4]=10
$RED_VEL_AXC[5]=10
$RED_VEL_AXC[6]=10
;REDUCTION FACTOR FOR AXIAL VELOCITY FOR
AXIS-SPECIFIC JOGGING AND COMMAND MODE
(PTP) AXIS[I](I=1:A1,I=7:E1)[%]
Unit [%]
Default value = 10
$RED_VEL_AXC[7]=10
$RED_VEL_AXC[8]=7
$RED_VEL_AXC[9]=7
$RED_VEL_AXC[10]=7
$RED_VEL_AXC[11]=0
$RED_VEL_AXC[12]=0
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System description
Reduction factor for axial acceleration (HOV)
INT $RED_ACC_AXC[12]
$RED_ACC_AXC[1]=5
$RED_ACC_AXC[2]=20
$RED_ACC_AXC[3]=20
$RED_ACC_AXC[4]=20
$RED_ACC_AXC[5]=20
$RED_ACC_AXC[6]=20
;REDUCTION FACTOR FOR AXIAL ACCELERATION
FOR AXIS-SPECIFIC JOGGING AND COMMAND MODE
(PTP) AXIS[I] (I=1:A1,I=7:E1) [%]
Unit [%]
Default value = 20
$RED_ACC_AXC[7]=10
$RED_ACC_AXC[8]=10
$RED_ACC_AXC[9]=10
$RED_ACC_AXC[10]=0
$RED_ACC_AXC[11]=0
$RED_ACC_AXC[12]=0
If the values are set too high, the axis will vibrate (jerky start
to motions).
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Axial reduction of acceleration for override changes in %
INT $RED_ACC_OV[12]
$RED_ACC_OV[1]=100
$RED_ACC_OV[2]=100
$RED_ACC_OV[3]=100
$RED_ACC_OV[4]=100
$RED_ACC_OV[5]=100
$RED_ACC_OV[6]=100
;AXIAL REDUCTION OF ACCELERATION
FOR OVERRIDE AXIS[I] (I=1:A1,I=7:E1) [%]
Unit [%]
Value is fixed!
Default value = 100
$RED_ACC_OV[7]=100
$RED_ACC_OV[8]=100
$RED_ACC_OV[9]=100
$RED_ACC_OV[10]=0
$RED_ACC_OV[11]=0
$RED_ACC_OV[12]=0
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Reduction factor for path-maintaining Emergency Stop ramp
The percentage value set here refers to the $RAISE_TIME[ ];
Æ 200% means: the gradient is twice as steep as the acceleration ramp.
INT $RED_ACC_EMX[12]
$RED_ACC_EMX[1]=190
$RED_ACC_EMX[2]=300
$RED_ACC_EMX[3]=300
$RED_ACC_EMX[4]=250
$RED_ACC_EMX[5]=250
$RED_ACC_EMX[6]=250
;REDUCTION FACTOR FOR PATH-MAINTAINING
E-STOP RAMP [%]
Start value = 100 [%]
Blue Following Error_A3 Rad x 1.00
Blue
Magenta Actual Velocity_A3 RPM x 1000.0
Green Command Velocity_A3 RPM x 1000.0
Green
Red
Red Actual Current_A3 Amp x 5.00
$RED_ACC_EMX=100
$RED_ACC_EMX[7]=300
$RED_ACC_EMX[8]=1000
$RED_ACC_EMX[9]=300
$RED_ACC_EMX[10]=150
$RED_ACC_EMX[11]=100
$RED_ACC_EMX[12]=100
E-STOP
The corresponding axis should not be allowed to go into
current limitation.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Deceleration time - Braking ramp for dynamic braking
REAL $DECEL_MB[12]
$DECEL_MB[1]=211.0
$DECEL_MB[2]=267.0
$DECEL_MB[3]=117.0
$DECEL_MB[4]=100.0
$DECEL_MB[5]=100.0
$DECEL_MB[6]=104.0
$DECEL_MB[7]=500.0
$DECEL_MB[8]=150.0
$DECEL_MB[9]=134.0
$DECEL_MB[10]=200.0
$DECEL_MB[11]=0.0
$DECEL_MB[12]=0.0
;BRAKING RAMP FOR DYNAMIC BRAKING [MS]
Unit [ms]
$RAISE_TIME * 100%
$DECEL_MB=
$RED_ACC_EMX
By this measure the extreme decrease of
the speed command value is avioded.
Otherwise it could happen that the current
controller exceeds its maximum value.
In such a case a path maintaining braking
would not longer be possible
Lowest value: 180
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Velocity tolerance for standstill detection
REAL $ST_TOL_VEL[12]
$ST_TOL_VEL[1]=15.0
...
$ST_TOL_VEL[12]=15.0
;VELOCITY TOLERANCE FOR STANDSTILL
DETECTION AXIS[I]
(I=1:A1,I=7:E1)
Unit [U_MOT /MIN]
Default value = 15.0 (fixed)
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Positioning time
INT $TIME_POS[12]
$TIME_POS[1]=512
$TIME_POS[2]=512
$TIME_POS[3]=512
$TIME_POS[4]=512
$TIME_POS[5]=512
$TIME_POS[6]=512
$TIME_POS[7]=512
$TIME_POS[8]=512
$TIME_POS[9]=512
$TIME_POS[10]=512
$TIME_POS[11]=512
$TIME_POS[12]=512
; During positioning, a check is made for each axis to
see whether the following error is inside the positioning
window for [axis velocity = 1] within the time specified
($TIME_POS)
Unit [ms]
Value is fixed
Default value = 512
...
…
…
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System description
Velocity for EMT mastering
REAL $VEL_AX_JUS[12]
$VEL_AX_JUS[1]=0.058
$VEL_AX_JUS[2]=0.095
$VEL_AX_JUS[3]=0.106
$VEL_AX_JUS[4]=0.349
$VEL_AX_JUS[5]=0.203
$VEL_AX_JUS[6]=0.623
;VELOCITY FOR EMT MASTERING AXIS[I]
(I=1:A1,I=7:E1) [DEGREES/S]
Unit [mm/s, °/s]
Default value = 0.1 (rotational axes)
Default value = 1.0 (translational axes)
$VEL_AX_JUS[7]=0.985
$VEL_AX_JUS[8]=0.123
$VEL_AX_JUS[9]=0.11
$VEL_AX_JUS[10]=0.0
$VEL_AX_JUS[11]=0.0
$VEL_AX_JUS[12]=0.0
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Distance traveled by EMT during signal propagation delay
INT $SEN_DEL[12]
;DISTANCE TRAVELED BY EMT DURING SIGNAL
PROPAGATION DELAY AXIS[I]
(I=1:A1,I=7:E1) [INCR]
$SEN_DEL[1]=17
...
…
…
$TIME_POS[12]=0
Unit [INCR]
Default value = 0
(fixed for external axes)
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Maximum length of EMT mastering travel
REAL $L_EMT_MAX[12]
$L_EMT_MAX[1]=1.6
$L_EMT_MAX[2]=4.2
$L_EMT_MAX[3]=4.0
$L_EMT_MAX[4]=8.0
$L_EMT_MAX[5]=8.0
$L_EMT_MAX[6]=8.0
;EMT MASTERING TRAVEL AXIS[I]
(I=1:A1,I=7:E1) [DEGREES]
Unit [mm, °]
Default values:
Rotational axes:
2.5 [°]
Translational axes: 10.0 [mm]
$L_EMT_MAX[7]=9.6
$L_EMT_MAX[8]=2.4
$L_EMT_MAX[9]=2.24
$L_EMT_MAX[10]=0.0
$L_EMT_MAX[11]=0.0
$L_EMT_MAX[12]=0.0
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Control principle of an axis
Speed
setpoint
Processor
with
position
controller
Current
setpoint
Speed
controller
PI
PWM
signals
Current
controller
Resolver /
tacho
Current
Amplifier
Motor
R
P
Current actual value
P
Speed actual value
Position actual value
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System description
Axis servo control fundamentals (1) (setting the servo parameters)
There are three (nested) control loops for motion control:
• Current control
(inner) Æ do not modify!
• Speed control
(middle)
• Position control
(outer)
• The values set for the speed controller influence adherence to the velocity.
• The values set for the position controller influence adherence to the path
(contour holding);
this is particularly relevant, for example, for laser welding.
• The current and position controllers are purely proportional controllers.
• The speed controllers are PI controllers.
Æ The values set for the controllers are axis-specific machine data.
Æ They can be modified via either
- the variable display (at Expert level), or
- KRL instructions in the program
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Axis servo control fundamentals (2)
(analogies)
Analogies with a cyclist:
• In all motion situations (uphill, downhill, straight, curves), the speed controller
ensures that the specified velocity is maintained.
• The position controller ensures that the cyclist remains on the specified path;
i.e. in all motion situations (narrow path or wide road), the position controller must
correct the position on the path.
On a wide road, the corrections can be made slowly;
on a narrow path, deviations must be corrected quickly.
• Rapid reactions can cause both the speed controller and the position controller to
overshoot.
In the case of the speed controller, the oscillation tendency can be reduced by
increasing the integral component.
• Increasing the P component shortens the reaction times.
Very short reaction times, however, increase the oscillation tendency!
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System description
Axis servo control fundamentals (3) (setting the servo parameters)
The position and speed controllers use different settings for
PTP and CP motions.
When adapting the machine data,
• the speed controller settings are made first and
• then the position controller settings.
The effect must then be tested by means of experimentation, as the speed controller
settings depend on the mass to be moved.
Test the speed controller settings in “jog” mode:
:
Immediate oscillation
Æ reduce P component
Oscillation gradually builds up
Æ increase the I component
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Speed controller gain - Factor for velocity precontrol
REAL $G_VEL_CAL[12]
$G_VEL_CAL[1]=0.0
$G_VEL_CAL[2]=0.0
$G_VEL_CAL[3]=0.0
$G_VEL_CAL[4]=0.0
$G_VEL_CAL[5]=0.0
$G_VEL_CAL[6]=0.0
;VELOCITY FACTOR FOR SPEED
CONTROLLER GAIN
Value is fixed!
Default value = 0.0
$G_VEL_CAL[7]=0.0
$G_VEL_CAL[8]=0.0
$G_VEL_CAL[9]=0.0
$G_VEL_CAL[10]=0.0
$G_VEL_CAL[11]=0.0
$G_VEL_CAL[12]=0.0
No values are to be entered here, as they are calculated by the “higher motion profile”.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Proportional gain of the position controller - KV factor for PTP
This setting influences how well the contours of the path are observed.
REAL $LG_PTP[12]
$LG_PTP[1]=0.6
$LG_PTP[2]=0.3
$LG_PTP[3]=0.3
$LG_PTP[4]=0.24
$LG_PTP[5]=0.24
$LG_PTP[6]=0.8
$LG_PTP[7]=0.3
$LG_PTP[8]=0.35
$LG_PTP[9]=0.3
$LG_PTP[10]=0.0
$LG_PTP[11]=0.0
$LG_PTP[12]=0.0
;KV FACTOR PTP AXIS[I] (I=1:A1,I=7:E1) [1/MS]
motor type
$LG_PTP
MG_8_40_45_S0
0,2…0,7
Mx_40_80_45_S0
0,2…0,7
Mx_64_110_35_S0
0,2…0,7
MG_120_110_25_S0
0,2…0,7
Mx_160_130_30_S0
0,2…0,7
Mx_180_180_40_S0
0,2…0,7
Mx_220_130_25_S0
0,2…0,7
Mx_360_180_30_S0
0,2…0,7
Mx_480_180_30_S0
0,2…0,7
If the control value is set too high, the command value is reached
quickly resulting in “hard control”. This causes the axis to “pulse”.
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Proportional gain of the position controller - KV factor for CP motion
This setting influences how well the contours of the path are observed.
REAL $LG_CP[12]
$LG_CP[1]=0.48
$LG_CP[2]=0.48
$LG_CP[3]=0.48
$LG_CP[4]=0.48
$LG_CP[5]=0.48
$LG_CP[6]=0.48
$LG_CP[7]=0.48
$LG_CP[8]=0.48
$LG_CP[9]=0.48
$LG_CP[10]=0.48
$LG_CP[11]=0.48
$LG_CP[12]=0.48
;KV FACTOR FOR CP MOTION [1/MS]
Unit [1/ms]
All axes have the same value.
The values of the robot axes are applied to
the external axes.
If the control value is set too high, the command value is reached
quickly resulting in “hard control”. This causes the axis to “pulse”.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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System description
Proportional gain of the current controller
INT $G_COE_CUR[12]
$G_COE_CUR[1]=15
$G_COE_CUR[2]=15
$G_COE_CUR[3]=15
$G_COE_CUR[4]=15
$G_COE_CUR[5]=15
$G_COE_CUR[6]=15
;PROPORTIONAL GAIN OF THE CURRENT
CONTROLLER AXIS[I] (I=1:A1,I=7:E1)
Unit [ ]
Default value = 15
(Only for KR C1!)
$G_COE_CUR[7]=15
$G_COE_CUR[8]=15
$G_COE_CUR[9]=15
$G_COE_CUR[10]=15
$G_COE_CUR[11]=15
$G_COE_CUR[12]=15
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Proportional gain of the speed controller - PTP
This setting influences the dynamics of the speed control.
If the control value is set too high, the command value is reached
quickly resulting in “hard control”. This causes the axis to “pulse”.
REAL $G_VEL_PTP[12]
;VN FACTOR OF THE SPEED CONTROLLER - PTP
motor type
$G_VEL_PTP[1]=60.0
$G_VEL_PTP[2]=54.0
$G_VEL_PTP[3]=46.0
$G_VEL_PTP[4]=25.0
$G_VEL_PTP[5]=23.0
$G_VEL_PTP[6]=19.0
$G_VEL_PTP[7]=25.0
$G_VEL_PTP[8]=31.0
$G_VEL_PTP[9]=29.0
$G_VEL_PTP[10]=50.0
$G_VEL_PTP[11]=50.0
$G_VEL_PTP[12]=50.0
$G_VEL_PTP
MG_8_40_45_S0
5…80
Mx_40_80_45_S0
5…80
Mx_64_110_35_S0
5…80
MG_120_110_25_S0
5…80
Mx_160_130_30_S0
5…80
Mx_180_180_40_S0
5…80
Mx_220_130_25_S0
5…80
Mx_360_180_30_S0
5…80
Mx_480_180_30_S0
5…80
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System description
Proportional gain of the speed controller - CP
This setting influences the dynamics of the speed control.
If the control value is set too high, the command value is reached
quickly resulting in “hard control”. This causes the axis to “pulse”.
REAL $G_VEL_CP[12]
;VN FACTOR OF THE SPEED CONTROLLER - CP
Motortyp
$G_VEL_CP[1]=80.0
$G_VEL_CP[2]=70.0
$G_VEL_CP[3]=38.0
$G_VEL_CP[4]=27.0
$G_VEL_CP[5]=25.0
$G_VEL_CP[6]=20.0
$G_VEL_CP[7]=25.0
$G_VEL_CP[8]=42.0
$G_VEL_CP[9]=21.0
$G_VEL_CP[10]=50.0
$G_VEL_CP[11]=50.0
$G_VEL_CP[12]=50.0
$G_VEL_CP
MG_8_40_45_S0
5…80
Mx_40_80_45_S0
5…80
Mx_64_110_35_S0
5…80
MG_120_110_25_S0
5…80
Mx_160_130_30_S0
5…80
Mx_180_180_40_S0
5…80
Mx_220_130_25_S0
5…80
Mx_360_180_30_S0
5…80
Mx_480_180_30_S0
5…80
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Integral-action factor of the speed controller - PTP
This setting influences the transient response of the axis
to the nominal speed and stabilizes the control loop.
REAL $I_VEL_PTP[12]
$I_VEL_PTP[1]=100.0
$I_VEL_PTP[2]=140.0
$I_VEL_PTP[3]=125.0
$I_VEL_PTP[4]=90.0
$I_VEL_PTP[5]=90.0
$I_VEL_PTP[6]=90.0
$I_VEL_PTP[7]=200.0
$I_VEL_PTP[8]=275.0
$I_VEL_PTP[9]=150.0
$I_VEL_PTP[10]=0.0
$I_VEL_PTP[11]=0.0
$I_VEL_PTP[12]=0.0
;INTEGRAL-ACTION FACTOR OF THE SPEED
CONTROLLER - PTP AXIS[I] (I=1:A1,I=7:E1)
Unit [ ]
Guide value:= 90 for small external
motors (types C, D, E)
= 200 ... 500 for large external
motors (types B, A, A0)
High value:
Low value:
Slow reaction
Fast reaction
Caution:
If the I factor of the controller is set too low, the
short reaction times cause vibrations.
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System description
Integral-action factor of the speed controller - CP motion
This setting influences the transient response of the axis
to the nominal speed and stabilizes the control loop.
REAL $I_VEL_CP[12]
$I_VEL_CP[1]=150.0
$I_VEL_CP[2]=150.0
$I_VEL_CP[3]=150.0
$I_VEL_CP[4]=75.0
$I_VEL_CP[5]=75.0
$I_VEL_CP[6]=75.0
$I_VEL_CP[7]=200.0
$I_VEL_CP[8]=200.0
$I_VEL_CP[9]=200.0
$I_VEL_CP[10]=0.0
$I_VEL_CP[11]=0.0
$I_VEL_CP[12]=0.0
;INTEGRAL-ACTION FACTOR OF THE SPEED
CONTROLLER - CP AXIS[I] (I=1:A1,I=7:E1)
Unit [ ]
Guide value:= 90 for small external
motors (types C, D, E)
= 200 ... 500 for large external
motors (types B, A, A0)
High value:
Low value:
Slow reaction
Fast reaction
Caution:
If the I factor of the controller is set too low, the
short reaction times cause vibrations.
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Software limit switches in the minus direction
REAL $SOFTN_END[12]
$SOFTN_END[1]=-185.0
$SOFTN_END[2]=-145.0
$SOFTN_END[3]=-120.0
$SOFTN_END[4]=-350.0
$SOFTN_END[5]=-135.0
$SOFTN_END[6]=-350.0
;SOFTWARE LIMIT SWITCHES NEGATIVE AXIS[I]
(I=1:A1,I=7:E1) [MM,DEGREES]
Unit [mm, °]
$SOFTN_END[1]
$SOFTN_END[7]=-1000.0
$SOFTN_END[8]=-90.0
$SOFTN_END[9]=-190.0
$SOFTN_END[10]=-0.0
$SOFTN_END[11]=0.0
$SOFTN_END[12]=0.0
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System description
Software limit switches in the plus direction
REAL $SOFTP_END[12];SOFTWARE LIMIT SWITCHES POSITIVE AXIS[I]
(I=1:A1,I=7:E1) [MM,DEGREES]
$SOFTP_END[1]=185.0
$SOFTP_END[2]=25.0
$SOFTP_END[3]=160.0
$SOFTP_END[4]=350.0
$SOFTP_END[5]=135.0
$SOFTP_END[6]=350.0
Unit [mm, °]
$SOFTP_END[7]=1000.0
$SOFTP_END[8]=90.0
$SOFTP_END[9]=190.0
$SOFTP_END[10]=0.0
$SOFTP_END[11]=0.0
$SOFTP_END[12]=0.0
$SOFTP_END[1]
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Machine data, that can be edited directly
The following machine data can be edited
without starting the machine data editor:
• controller settings
• software limit switches
• HOME positions
(exception: slave axes)
and the
Therefore exist the following possibilities:
• Monitor Æ variable Æ single,
• Monitor Æ variable Æ overview
• by program instruction
and
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System description
Tacho filter, time constant for the current speed filter
REAL $VEL_FILT[12]
$VEL_FILT[1]=2.5
$VEL_FILT[2]=2.5
$VEL_FILT[3]=2.5
$VEL_FILT[4]=2.5
$VEL_FILT[5]=2.5
$VEL_FILT[6]=2.5
;TACHO FILTER AXIS [I] [MS]
Unit [ms]
Value is fixed!
Default value = 2.5
$VEL_FILT[7]=2.5
$VEL_FILT[8]=2.5
$VEL_FILT[9]=2.5
$VEL_FILT[10]=2.5
$VEL_FILT[11]=2.5
$VEL_FILT[12]=2.5
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Maximum approximation distance PTP
REAL $APO_DIS_PTP[12]
$APO_DIS_PTP[1]=90.0
$APO_DIS_PTP[2]=90.0
$APO_DIS_PTP[3]=90.0
$APO_DIS_PTP[4]=90.0
$APO_DIS_PTP[5]=90.0
$APO_DIS_PTP[6]=90.0
;MAXIMUM APPROXIMATION DISTANCE PTP AXIS[I]
(I=1:A1,I=7:E1) [MM,DEGREES]
Unit [°, mm]
Default value = 90.0° or 500.0 mm
$APO_DIS_PTP[7]=500.0
$APO_DIS_PTP[8]=90.0
$APO_DIS_PTP[9]=90.0
$APO_DIS_PTP[10]=0.0
$APO_DIS_PTP[11]=0.0
$APO_DIS_PTP[12]=0.0
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System description
Referencing sequence of the axes
INT $SEQ_CAL[12]
;REFERENCING SEQUENCE OF THE AXES
INCREMENT[I]
$SEQ_CAL[1]=‘B0001’
$SEQ_CAL[2]=‘B0010’
$SEQ_CAL[3]=‘B0100’
$SEQ_CAL[4]=‘B1000’
$SEQ_CAL[5]=‘B0001 0000’
$SEQ_CAL[6]=‘B0010 0000’
Ascending order must be observed!
Exception:
Scara robot KR5 SC
Due to the mathematical coupling of
the axis the following mastering
sequence has to to be regarded:
$SEQ_CAL[7]=‘B0100 0000’
$SEQ_CAL[8]=‘B1000 0000’
$SEQ_CAL[9]=‘B0001 0000 0000’
$SEQ_CAL[10]=‘B0010 0000 0000’
$SEQ_CAL[11]=‘B0100 0000 0000’
$SEQ_CAL[12]=‘B1000 0000 0000’
1Æ2Æ4Æ3
$SEQ_CAL[3]=‘B1000‘
$SEQ_CAL[4]=‘B0100‘
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Braking
INT $BRK_MODE='B0101'
;BRAKE CONTROL MODE
'B
Bit no.:
Meaning:
Command mode:
Bit 0 = 0
Bit 0 = 1
Bit 1 = 0
Bit 1 = 1
Program mode:
Bit 2 = 0
Bit 2 = 1
External axes:
Bit 3 = 0
Bit 3 = 1
0
1
0
1'
3
Ext
2
Prog
1
Com
0
Com
Robot brakes do not close at end of command.
Robot brakes close at end of command in accordance with mode bit 1.
Robot brakes all open and close simultaneously.
Robot brakes open and close individually during axis-specific motion.
Robot brakes do not close during motion pauses within programs.
Robot brakes always close simultaneously during motion pauses within programs.
External axes respond in the same way as the robot brakes in accordance with mode
bits 0 - 2.
Mathematically coupled external axes respond in the same way as the robot axes.
External axes that are not mathematically coupled function independently of the robot
axes when they are controlled separately.
Æ asynchronous axis mode.
INT $BRK_DEL_EX=200
;BRAKE DELAY TIME FOR EXTERNAL AXES
in “DETACH JOG” mode
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System description
Servo inhibit time, inactive position control monitoring
INT $SERV_OFF_TM[12]
;SERVO INHIBIT TIME AXIS[I]
(I=1:A1,I=7:E1)
$SERV_OFF_TM[1]=84
...
$SERV_OFF_TM[12]=84
Unit [ms]
REAL $MS_DA[12]
;INACTIVE POSITION MONITORING
AXIS[I] (I=1:A1,I=7:E1)
$MS_DA[1]=‘B0000’
...
$MS_DA[12]=‘B0000’
Default value = 84 (fixed)
Unit [ ]
Default value = ‘B0000’ (fixed)
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Positioning window
REAL $IN_POS_MA[12]
$IN_POS_MA[1]=0.1
$IN_POS_MA[2]=0.1
$IN_POS_MA[3]=0.2
$IN_POS_MA[4]=0.2
$IN_POS_MA[5]=0.2
$IN_POS_MA[6]=0.2
;POSITIONING WINDOW AXIS[I] (I=1:A1,I=7:E1)
[MM,DEGREES]
Unit [mm, °]
Default value = 0.1
• for linear axes = 1.5 mm
• for motor type E = 0.2
$IN_POS_MA[7]=1.5
$IN_POS_MA[8]=0.1
$IN_POS_MA[9]=0.1
$IN_POS_MA[10]=0.1
$IN_POS_MA[11]=0.0
$IN_POS_MA[12]=0.0
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System description
Change in direction of rotation of the axes
INT $AXIS_DIR[12]
;DIRECTION OF ROTATION OF THE AXIS[I]
(I=1:A1,I=7:E1)
Unit [ ]
$AXIS_DIR[1]=-1
$AXIS_DIR[2]=1
$AXIS_DIR[3]=1
$AXIS_DIR[4]=-1
$AXIS_DIR[5]=-1
$AXIS_DIR[6]=-1
$AXIS_DIR[7]=1
$AXIS_DIR[8]=1
$AXIS_DIR[9]=1
$AXIS_DIR[10]=1
$AXIS_DIR[11]=1
$AXIS_DIR[12]=1
Mathematically positive = 1
Mathematically negative = -1
negative
positive
Definition of the direction is only meaningful once
the external kinematic system has been calibrated.
If there is an active mathematical coupling and you notice that the robot and the
corresponding axis of the kinematic travel in opposite directions, then the sign of
$AXIS_DIR has to be changed.
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Increment, axis-specific
REAL $INC_AXIS[6]
;INCREMENT, AXIS-SPECIFIC
$INC_AXIS[1]=0.005
$INC_AXIS[2]=0.0005
$INC_AXIS[3]=0.0005
$INC_AXIS[4]=0.002
$INC_AXIS[5]=0.002
$INC_AXIS[6]=0.002
REAL $INC_EXTAX[6]
$INC_EXTAX[1]=6.0
$INC_EXTAX[2]=6.0
$INC_EXTAX[3]=6.0
$INC_EXTAX[4]=6.0
$INC_EXTAX[5]=6.0
$INC_EXTAX[6]=6.0
;INCREMENT, AXIS-SPECIFIC, EXTERNAL AXES
Unit [incr]
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System description
Maximum energy of the axis
These values must be calculated each time for every individual case!
Emax = Epot + ( Ekin_transl. + Ekin_rot. )
Maximum energy of a linear unit:
Emax = ½ * m * (vmax)2
Maximum energy of a turntable:
Emax =
½ *JMotor*( Motor)2 +
½ * JGear_Unit*( Gear_Unit)2 +
¼*mTurntable*(rTurntable)2*( Turntable)2
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Maximum energy of the axis
INT AX_ENERGY_MAX[12]
$AX_ENERGY_MAX[1]=988
$AX_ENERGY_MAX[2]=647
$AX_ENERGY_MAX[3]=160
$AX_ENERGY_MAX[4]=85
$AX_ENERGY_MAX[5]=87
$AX_ENERGY_MAX[6]=93
;MAX. ENERGY OF THE AXIS [J]
Æ Note:
$AX_ENERGY_MAX[ ] < $BRK_ENERGY_MAX[ ]
$AX_ENERGY_MAX[7]=600
$AX_ENERGY_MAX[8]=700
$AX_ENERGY_MAX[9]=500
$AX_ENERGY_MAX[10]=1000
$AX_ENERGY_MAX[11]=1000
$AX_ENERGY_MAX[12]=1000
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System description
Maximum permissible braking en energy
INT BRK_ENERGY_MAX[12]
;MAX. PERMISSIBLE BRAKING ENERGY [J]
motor type
$BRK_ENERGY_MAX[1]=1908
$BRK_ENERGY_MAX[2]=1908
$BRK_ENERGY_MAX[3]=845
$BRK_ENERGY_MAX[4]=114
$BRK_ENERGY_MAX[5]=114
$BRK_ENERGY_MAX[6]=114
$BRK_ENERGY_MAX[7]=4600
$BRK_ENERGY_MAX[8]=4600
$BRK_ENERGY_MAX[9]=1650
$BRK_ENERGY_MAX[10]=4600
$BRK_ENERGY_MAX[11]=4600
$BRK_ENERGY_MAX[12]=4600
Energy [J]
MG_8_40_45_S0
Motortyp
Energie [J] 8
Mx_40_80_45_S0
A0
7650
74
A
5670
Mx_64_110_35_S0
B
6500
MG_120_110_25_S0
C0
2500
Mx_160_130_30_S0
C
1650
Mx_180_180_40_S0
D
2000
Mx_220_130_25_S0
E
400
Mx_360_180_30_S0
400
Mx_480_180_30_S0
400
2500
6736
1400
7650
10500
The values here can be read from a table and are dependent on the motor.
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Brake cooling factor
REAL $BRK_COOL_OFF_COEFF[12]
$BRK_COOL_OFF_COEFF[1]=30.8
$BRK_COOL_OFF_COEFF[2]=30.8
$BRK_COOL_OFF_COEFF[3]=4.7
$BRK_COOL_OFF_COEFF[4]=0.63
$BRK_COOL_OFF_COEFF[5]=0.63
$BRK_COOL_OFF_COEFF[6]=0.63
$BRK_COOL_OFF_COEFF[7]=25.5
$BRK_COOL_OFF_COEFF[8]=25.5
$BRK_COOL_OFF_COEFF[9]=9.16
$BRK_COOL_OFF_COEFF[10]=9.2
$BRK_COOL_OFF_COEFF[11]=9.2
$BRK_COOL_OFF_COEFF[12]=9.2
;BRAKE COOLING FACTOR in [J/s]
motor type
[J/sec]
MG_8_40_45_S0
0,044
Mx_40_80_45_S0
0,41
Mx_64_110_35_S0
2,2
MG_120_110_25_S0
2,2
Mx_160_130_30_S0
41
Mx_180_180_40_S0
37
Mx_220_130_25_S0
7,78
Mx_360_180_30_S0
127
Mx_480_180_30_S0
175
• The cooling time is only active if the motor brakes are applied mechanically.
• The brake cools down again when the system is at standstill.
• The energy dissipated depends on the cooling factor of the brake.
• A status message is generated during the cooling time.
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System description
Dynamic braking torque
REAL $BRK_TORQUE[12]
;DYNAMIC BRAKING TORQUE IN [NM]
$BRK_TORQUE[1]=22.0
$BRK_TORQUE[2]=22.0
$BRK_TORQUE[3]=11.0
$BRK_TORQUE[4]=2.4
$BRK_TORQUE[5]=2.4
$BRK_TORQUE[6]=2.4
$BRK_TORQUE[7]=22.0
$BRK_TORQUE[8]=20.0
$BRK_TORQUE[9]=12.0
$BRK_TORQUE[10]=20.0
$BRK_TORQUE[11]=20.0
$BRK_TORQUE[12]=20.0
motor type
[Nm]
MG_8_40_45_S0
1,5
Mx_40_80_45_S0
5,4
Mx_64_110_35_S0
17,5
MG_120_110_25_S0
17,5
Mx_160_130_30_S0
13
Mx_180_180_40_S0
23
Mx_220_130_25_S0
33
Mx_360_180_30_S0
32
Mx_480_180_30_S0
32
The energy taken up by the brake depends on the dynamic braking torque.
The values here can be read from a table and are dependent on the motor.
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Mathematical coupling of external axes
Frame chain without external axes:
$TOOL
Robot
$POS_ACT
Workpiece
$BASE
$ROBROOT
$WORLD
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System description
Mathematical coupling of external axes
External BASE kinematic system:
Z
$TOOL
Y
X OFFSET
$POS_ACT
Robot
$BASE_C(t)
Two-axis
positioner
#EASYS
$ROBROOT
$WORLD
ROOT
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Mathematical coupling of external axes
External ROBROOT kinematic system:
$POS_ACT
$BASE
Robot
$ROBROOT_C(t)
$TOOL
$WORLD
#ERSYS
($ROBROOT)
Linear traversing unit
$ERSYSROOT
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System description
External axes
INT $EX_AX_NUM=3
;NUMBER OF EXTERNAL AXES (0-6)
INT $EX_AX_ASYNC='B0000'
;ASYNCHRONOUS EXTERNAL AXES
'B
0
0
0
0'
E4
E3
E2
E1
0:
External axis can be moved as
synchronous or as asynchronous axis
1:
External axis always asynchronous
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External kinematic systems
DECL EX_KIN $EX_KIN=
{ET1 #EASYS,ET2 #EBSYS,ET3 #ERSYS,ET4 #NONE,ET5
#NONE,ET6 #NONE}
;EXTERNAL KINEMATIC SYSTEMS #NONE, #EASYS,
#EBSYS, #ECSYS, #EDSYS, #EESYS, #EFSYS, #ERSYS
Max. 6 external kinematic systems (ET1, ET2, ET3, ET4, ET5, ET6)
#EASYS
#EBSYS
#ECSYS
#EDSYS
#EESYS
#EFSYS
#ERSYS
External BASE kinematic system
External ROBROOT kinematic system
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System description
Axes and name of the 1st transformation
DECL ET_AX $ET1_AX={TR_A1 #E3,TR_A2 #E4,TR_A3 #NONE}
;EXTERNAL AXES #NONE, #E1, #E2, #E3, #E4, #E5, #E6
Max. 3 axes per external kinematic system (TR_A1, TR_A2, TR_A3)
#E1
#E2
#E3
#E4
#E5
#E6
External axis in the
1st external transformation
CHAR $ET1_NAME[20] ;NAME OF TRANSFORMATION ET1 MAXIMIMUM 20
CHARACTERS $ET1_NAME[ ]=“2axis_pos”
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Description of the transformation chain of a kinematic system
Description of the transformations:
$ETx_Tyyzz
$ET1_TPINFL*
$ET1_TFLA3
x:
FL
$ET1_TA3A2
PIN
A3
yy:
zz:
Transformation data set
number (1...6)
Destination of the
transformation
Start of the transformation
A2
$ET1_TA2A1
#EASYS
Joint
A1
ROOT: Installation site
A1...A3: External axes
FL:
Flange
PIN:
Reference pin
$ET1_TA1KR
ROOT (KR)
•Entry no longer taken
into consideration
from software release
5 onwards
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System description
Rules for the description of BASE kinematic systems (1)
Condition: all axes of the kinematic are in the 0°-position !
Joint
• The joints of the kinematic system are defined first.
• The description of a BASE kinematic system starts at
the selected ROOT point.
FL
• Starting at the ROOT point, the coordinate system is
PIN
shifted to the first joint (translation).
A3
• There, the coordinate system is turned so that the positive
Z axis corresponds to the rotational axis of the first
axis (rotation) and points to the next joint.
A2
#EASYS
• Translation and subsequent rotation take you from one
joint to the next.
A1
• This procedure is repeated until the surface of the flange
is reached.
• The last transformation specifies where on the surface
the calibration pin is located (up to software release 4).
ROOT
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Rules for the description of BASE kinematic systems (2)
• The first 3 lines contain the transformations
from the ROOT point to the third joint.
• In the case of kinematic systems with only one axis, only the first
of these three lines is completed!
• The 4th line describes the orientation of the coordinate
systems once it has been shifted to the flange center point;
this line is completed if required.
• The 5th line describes the position of the tip of the measuring
pin on the surface of the flange (up to software release 4).
• BASE kinematic systems should always be defined before the
ROBROOT kinematic system in the machine data!
Æ otherwise the ROBROOT kinematic system
will be displayed instead of the BASE kinematic
system in the motion commands
(with mathematical coupling)!
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System description
Transformation chain of 1st external kinematic system (two-axis positioner)
FRAME $ET1_TA1KR={X 0.0,Y 0.0,Z 510.0,A 0.0,B 90.0,C 0.0}
;FRAME BETWEEN A1 AND ROOT POINT OF KIN IN TRANSF. ET1
FRAME $ET1_TA2A1={X 0.0,Y 0.0,Z 324.0,A 0.0,B -90.0,C 0.0}
;BETWEEN A2 AND A1
FRAME $ET1_TA3A2={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
;BETWEEN A3 AND A2
FL
FRAME $ET1_TFLA3={X 0.0,Y 0.0,Z 340.0,A 90.0,B 0.0,C 0.0}
;BETWEEN FL AND A3
FRAME $ET1_TPINFL={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
;BETWEEN REFERENCE POINT AND FL
A3
PIN
A2
A1
ROOT (KR)
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Rules for the description of ROBROOT kinematic systems
• ROBROOT kinematic systems (e.g. linear axes) should
always be defined as the last kinematic system
in the machine data!
Æ otherwise the ROBROOT kinematic system
will be displayed instead of the BASE kinematic
system in the motion commands
(with mathematical coupling)!
• after the execution of the transformation the Z-axis points into the direction of translation
• In the case of ROBROOT kinematic systems, the robot stands on the flange
of the kinematic system.
• The transformation $ETx_FLA3 describes the offset and rotation of the robot
in the flange coordinate system of the kinematic system.
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System description
Data for the 2nd external kinematic system (linear unit)
DECL ET_AX $ET3_AX={TR_A1 #E1,TR_A2 #NONE,TR_A3 #NONE}
;EXTERNAL AXES #NONE, #E1, #E2, #E3, #E4, #E5, #E6
CHAR $ET3_NAME[20] ;NAME OF TRANSFORMATION ET3 MAX. 20 CHARACTERS
$ET3_NAME[ ]=“KL250”
FRAME $ET3_TA1KR={X 0.0,Y 0.0,Z 397.0,A 0.0,B 0.0,C 90.0}
;FRAME BETWEEN A1 AND ROOT POINT OF KIN IN TRANSF. ET3
FRAME $ET3_TA2A1={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
;BETWEEN A2 AND A1
FRAME $ET3_TA3A2={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
;BETWEEN A3 AND A2
FRAME $ET3_TFLA3={X 0.0,Y 0.0,Z 0.0,A 0.0,B 60.0,C -90.0}
;BETWEEN FL AND A3
FRAME $ET3_TPINFL={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
;BETWEEN REFERENCE POINT AND FL
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Simulating axes
$AX_SIM_ON
Axes that are not actually present can be simulated.
Syntax
$AX_SIM_ON = Value
Example:
Simulate axis 3 $AX_SIM_ON=‘B0100’
Argument
Type
Explanation
Value
INT
This bit-coded value specifies which axes are being
simulated.
1: Axis is simulated
0: Axis is moved
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System description
Simulating axes
$AX_SIM_ON
$AX_SIM_ON can be used to simulate axes.
No hardware actually needs to be connected.
If hardware is present, it must be borne in mind that the braking channel is
activated which can result in the simulated axis sagging.
Æ The brake cable should thus be disconnected first!
Once a simulated axis has been reset from bit 1 to bit 0 it must be mastered.
This machine datum may only be modified if it is absolutely certain
that the modification will not endanger persons.
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Simulating axes
$SIMULATED_AXIS
Axes that are present can be simulated.
In this case, the corresponding hardware must be connected.
Axes are included in the planning, but are not moved.
Modification of this machine datum does not necessitate mastering of the axis.
The brakes are activated, but the axis is regulated and does not sag.
Syntax
$SIMULATED_AXIS = Value
Example: Simulate axis 3
Æ
$SIMULATED_AXIS=‘B0100’
Argument
Type
Explanation
Value
INT
This bit-coded value specifies which axes are being
simulated.
1: Axis is simulated
0: Axis is moved
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System description
Modification of individual machine data in the GUI
• Open $MACHINE.DAT
• Select Configure Æ Miscellaneous Æ Editor Æ DEF line
• Enter the data line directly before the “ENDDAT” line
• Close
• The existing data are automatically overwritten by the new data when the file is closed.
No additional lines can be inserted into $MACHINE.DAT.
The machine data editor only permits modifications to existing lines!
Additional lines before the ENDDAT line cause the previous lines to be
overwritten!
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Loading user-created file fragments
• Enter data lines in a text document, with the file extension “.txt”, using NOTEPAD.
• Save text document on C:\ (not in the KRC directory!).
• Open the text document in the GUI (at Expert level) and select and copy its contents.
• Close the text document.
• Open $MACHINE.DAT.
• Select Configure Æ Miscellaneous Æ Editor Æ DEF line
• Create a blank line before the “ENDDAT” line.
• Position the cursor in the blank line.
• Program Æ Paste
• Close
• The existing data are automatically overwritten by the new data when the file is closed.
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System description
Loading file fragments from the external axis configurator
• Create data using the external axis configurator.
• The data are saved to floppy disk with the name “ExtAxisMach.dat”.
• There is a version identifier at the start of this file to prevent data from different
software versions from becoming mixed.
• Before the data are loaded, the external axis configurator must be started at Expert
level.
• File Æ Load from floppy
• Carry out any modification.
• When the program is closed, a request for confirmation is generated, asking whether
the changes are to be saved.
• Answer “Yes” and wait until the message “Download completed” appears.
The file with the standard name „ExtAxesData1.dat“ must contain
• the version identifier „KRCVERSION=(V)KR C2“ in the first line and
• „ENDDAT“ in the last line.
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System description
4.2.1. Configurator
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System description
General information
• The axis configurator is used for the parameterization of external axes
and main axes and for the creation and editing of servo files.
• The program can be started from Explorer “C:\KRC\UTIL\AxisConf.exe”
or, from software release V5.2 onwards, via the menu “Setup – Service
– Axisconfigurator”.
• When the program is started, the existing “$Machine.dat” used to boot
the machine is loaded into the program.
• It is only possible to start the program and save modifications in
“$Machine.dat” in Expert mode and only if no program is selected and
the mode selector switch is set to “T1” or “T2”.
• The user of the axisconfigurator has to take into consideration
that machine data of different software versions should not be mixed.
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Configurator for external axes
The configurator is accessed via the Setup menu:
The menu item “Axisconfigurator” is only available at
Expert level.
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System description
View: “General data”
Deactivated in the
case of a robot
kinematic system
Robot kinematic data
cannot be modified.
System information
from “$Machine.dat”
Number of external
axes connected. Value
can be changed.
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View: “External kinematic systems”
Display of the
transformation data
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System description
View: “External axes”
Display of the
variables for the
external axes
Selection of a KUKA or
user-specific motor
Selection of an existing
servo file
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View: “Servo file”
Editing a servo file
Modification of an existing KUKA standard servo file is not recommended, as
this file already contains optimized values for a motor/KSD combination.
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System description
Menu bar:
All relevant external axis
parameters are saved.
The external axis
parameters saved with this
program can be loaded.
The program is terminated
following a query dialog.
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Page 123 of 240
Examples for external axes
5. Examples for external axes
5.1.
Two-axis positioner
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 125 of 240
Examples for external axes
Description of the kinematic system for a DKP400.1 two-axis positioner
1) Description of a standard transformation
2) Description of a simplified transformation
3) Machine data for axes E1 and E2
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Two-axis positioner - KR C2
Axis E1
Axis E2
Gear ratio
190.4 : 1
107 : 1
Motor type
B
C
Motor current
max. ?
max. ?
340
340
510
X
210
210
PIN
Y
460
Axis E1
Axis E2
Rated speed
4100 min-1
2250 min-1
Mastering
position
0.0°
+ 90.0°
Working range
-90° to 90°
-100° to 280°
Mastering dist.
2.752°
2.752°
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Examples for external axes
Design drawing (1) from documentation
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510
Design drawing (2) from documentation
324
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Examples for external axes
Design drawing (3) from documentation
324
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Permissible load values from documentation
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Examples for external axes
Technical data (1) from documentation
Axis data:
Range of motion
(softwarelimited)
Rotational
velocity
(max.)
Permissible
acceleration
time
Tilting axis
(axis 7)
-90° to +90°
97.3°/s
0.6 s
Rotational axis
(axis 8)
+190° to -190°
126°/s
0.4 s
Axis
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Technical data (2) from documentation
Permissible load values:
Rated payload:
Permissible mass moment of inertia of rotational axis:
(in +90° position)
m1 = 400 kg
I = 120 kgm2
Rotational axis:
Permissible load torque
Permissible tilting torque
MLRot = 750 Nm
MTRot = 3550 Nm
Tilting axis:
Permissible load torque
Permissible tilting torque
MLTilt = 1900 Nm
MTTilt = 7000 Nm
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Examples for external axes
Description of the standard transformation
The transformation starts at the root point of the kinematic system
• The root point of the kinematic system is situated on the floor.
• The joints and the rotational axes are defined next.
• The position of the root point is to be selected such that all required dimensions
can be read directly from the drawing.
• Starting from the root point, transformations are now used to
follow the design of the kinematic system.
Æ all axes have to be in the 0°-position !
• Each individual line describes the transformation from one axis to the next!
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Two-axis positioner: Transformation sequence
340 mm
PIN (reference notch)
Transformation sequence:
1. Translation (X, Y, Z)
E2
E1
510 mm
2. Rotation (A, B, C),
sequence A, B, C
324 mm
236 mm
Dowel pin
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Examples for external axes
Two-axis positioner: Selection of the root point
340 mm
PIN (reference notch)
Transformation sequence:
1. Translation (X, Y, Z)
E2
E1
510 mm
2. Rotation (A, B, C),
sequence A, B, C
Root point
236 mm
324 mm
Dowel pin
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Two-axis positioner: Definition of the axes
340 mm
Flange center point
Transformation sequence:
1. Translation (X, Y, Z)
E2
E1
510 mm
2. Rotation (A, B, C),
sequence A, B, C
324 mm
236 mm
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Examples for external axes
Two-axis positioner: Definition of the rotational axes
340 mm
Flange center point
E2
510 mm
E1
236 mm
324 mm
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Execution of the first translation $ET1_TA1KR (1st line, Y direction)
$ET1_TA1KR={X 0, Y 280, Z 0,A 0, B 0, C 0}
First a transformation is executed
from the root point to the axis of
symmetry
324
Y
Centerline
X
280
Root point
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Examples for external axes
Execution of the first translation $ET1_TA1KR (1st line, Z direction)
$ET1_TA1KR={X 0, Y 280, Z 510,A 0, B 0, C 0}
340 mm
Z
Transformation sequence:
E2
E1
1. Translation (X, Y, Z)
X
2. Rotation (A, B, C),
sequence A, B, C
510 mm
Z
324 mm
X 236 mm
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Execution of the first rotation $ET1_TA1KR (1st line)
$ET1_TA1KR={X 0, Y 280, Z 510,A 0, B 90, C 0}
B
340 mm
Z
Rotational axis
E2 Z X
510 mm
E1
X
324 mm
236 mm
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Examples for external axes
Execution of the second translation $ET1_TA2A1 (2nd line)
340 mm
$ET1_TA2A1={X 0, Y 0, Z 324,A 0, B 0, C 0}
E1
Z
Z
510 mm
E2
X
X
236 mm
324 mm
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Execution of the second rotation $ET1_TA2A1 (2nd line)
$ET1_TA2A1={X 0, Y 0, Z 324,A 0, B -90, C 0}
Rotational axis
B
340 mm
Z
E2
Z
X
510 mm
E1
X
324 mm
236 mm
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Examples for external axes
Execution of the third translation $ET1_TA3A2 (3rd line)
$ET1_TA3A2={X 0, Y 0, Z 0, A 0, B 0, C 0}
Z
Sequence of 3rd transformation:
340 mm
There is no 3rd transformation,
as there is no 3rd motor in the
kinematic system.
E2
X
510 mm
E1
236 mm
324 mm
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Execution of the third rotation $ET1_TA3A2 (3rd line)
$ET1_TA3A2={X 0, Y 0, Z 0, A 0, B 0, C 0}
Z
Sequence of 3rd transformation:
340 mm
There is no 3rd transformation,
as there is no 3rd motor in the
kinematic system.
E2
X
510 mm
E1
324 mm
236 mm
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Examples for external axes
Translation to flange $ET1_TFLA3 (4th line)
Z
Z
340 mm
$ET1_TFLA3={X 0, Y 0, Z 340, A 0, B 0, C 0}
X
E2
E1
510 mm
X
236 mm
324 mm
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Rotation on flange $ET1_TFLA3 (4th line)
Z
Rotational
axis
Z
$ET1_TFLA3={X 0, Y 0, Z 340, A 90, B 0, C 0}
340 mm
Y
X
E2
510 mm
E1
324 mm
236 mm
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Examples for external axes
Determination of the position of the calibration pin on the flange
Execute the following steps in order to determine the position
of the calibration pin on the flange:
1.
Move all axes to the „0°-position“ !
( Æ this is not necessarily the mastering position !)
2.
Execute all transformations from the ROOT-point to the flange !
3.
Determine the position of the calibration pin in the
actual „flange“- coordination system !
4.
Define the position of the calibration pin as a TOOL in the $CONFIG.DAT.
X
210
210
PIN
Y
460
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Translation from flange to pin $ET1_TPINFL (5th line)
$ET1_TPINFL={X 0, Y -210, Z 0, A 0, B 0, C 0}
Z
Z
PIN (reference notch)
Y
340 mm
Y
E2
510 mm
E1
324 mm
210 mm
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Page 137 of 240
Examples for external axes
Transformation of two-axis positioner (standard)
$ET1_TA1KR = {X 0, Y 280 , Z 510, A
0, B
$ET1_TA2A1 = {X 0, Y
0, Z 324, A
0, B -90, C 0}
$ET1_TA3A2 = {X 0, Y
0, Z
0, B
0, C 0}
$ET1_TFLA3 = {X 0, Y
0, Z 340, A 90, B
0, C 0}
$ET1_TPINFL = {X 0, Y
0, Z
0, C 0}
0, A
0, A
0, B
90, C 0}
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Description of the kinematic system for a DKP400.1 two-axis positioner
1) Description of a standard transformation
2) Description of a simplified transformation
3) Machine data for axes E1 and E2
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Examples for external axes
Simplification of the transformation
The simplification is achieved by selecting a particularly suitable
root point
• The root point can be freely situated in any position.
• Visible symmetries can be used here, or the root point of the
kinematic system can be positioned in the very first axis.
• These measures make it possible to dispense with the need to read
the dimensions from the design drawing.
• The rotations, however, must be carried out in all cases.
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Two-axis positioner: Transformation sequence (simplification)
340 mm
PIN (reference notch)
Transformation sequence:
1. Translation (X, Y, Z)
E2
E1
510 mm
2. Rotation (A, B, C),
sequence A, B, C
324 mm
236 mm
Dowel pin
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Page 139 of 240
Examples for external axes
Two-axis positioner: Selection of the root point (simplification)
340 mm
PIN (reference notch)
Transformation sequence:
1. Translation (X, Y, Z)
E2
E1
510 mm
2. Rotation (A, B, C),
sequence A, B, C
Root point
236 mm
324 mm
Dowel pin
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Two-axis positioner: Definition of the axes (simplification)
340 mm
Flange center point
E2
510 mm
E1
2 Axis
324 mm
236 mm
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Examples for external axes
Execution of the first translation $ET1_TA1KR (1st line)
$ET1_TA1KR={X 0, Y 0, Z 510,A 0, B 0, C 0}
340 mm
Z
Transformation sequence:
E2
E1
1. Translation (X, Y, Z)
X
2. Rotation (A, B, C),
sequence A, B, C
510 mm
Z
X 236 mm
324 mm
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Execution of the first rotation $ET1_TA1KR (1st line)
$ET1_TA1KR={X 0, Y 0, Z 510,A 0, B 90, C 0}
B
340 mm
Z
Rotational axis
E2
X
Z
510 mm
E1
X
324 mm
236 mm
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Examples for external axes
Execution of the second translation $ET1_TA2A1 (2nd line)
340mm
$ET1_TA2A1={X 0, Y 0, Z 0, A 0, B 0, C 0}
E1
Z
510mm
E2
X
236mm
324mm
KUKA Roboter GmbH, Hery-Park 3000, D-86368 Gersthofen, Tel.: +49 (0) 8 21/45 33-1906, Fax: +49 (0) 8 21/45 33-2340, http://www.kuka-roboter.de
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Execution of the second rotation $ET1_TA2A1 (2nd line)
rotational axis
B
340mm
Z
X
E2
E1
510mm
$ET1_TA2A1={X 0, Y 0, Z 0,A 0, B -90, C 0}
324mm
236mm
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Examples for external axes
Execution of the third translation $ET1_TA3A2 (3rd line)
$ET1_TA3A2={X 0, Y 0, Z 0, A 0, B 0, C 0}
340mm
Z
Sequence of 3rd transformation:
E2
X
There is no 3rd transformation,
as there is no 3rd motor in the
kinematic system.
510mm
E1
236mm
324mm
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Execution of the third rotation $ET1_TA3A2 (3rd line)
Z
340mm
$ET1_TA3A2={X 0, Y 0, Z 0, A 0, B 0, C 0}
Sequence of 3rd transformation:
X
There is no 3rd transformation,
as there is no 3rd motor in the
kinematic system.
E2
510mm
E1
324mm
236mm
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Examples for external axes
Translation to the flange $ET1_TFLA3 (4th line)
Z X
Z
340mm
$ET1_TFLA3={X 0, Y 0, Z 340, A 0, B 0, C 0}
X
E2
510mm
E1
236mm
324mm
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Rotation on flange $ET1_TFLA3 (4th line)
Z
Rotational
axis
Z
$ET1_TFLA3={X 0, Y 0, Z 0, A 90, B 0, C 0}
340 mm
Y
X
E2
510 mm
E1
324 mm
236 mm
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Examples for external axes
Translation from flange to pin $ET1_TPINFL (5th line)
$ET1_TPINFL={X 0, Y -210, Z 0, A 0, B 0, C 0}
Z
Z
PIN (reference notch)
Y
340 mm
Y
E2
510 mm
E1
210 mm
324 mm
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Transformation of two-axis positioner (simplified)
$ET1_TA1KR = {X 0,
Y
0, Z 510, A
0, B
$ET1_TA2A1 = {X 0,
Y
0, Z
0, A
0, B -90, C 0}
$ET1_TA3A2 = {X 0,
Y
0, Z
0, A
0, B
0, C 0}
$ET1_TFLA3 = {X 0,
Y
0, Z
0, A 90, B
0, C 0}
$ET1_TPINFL = {X 0,
Y
0, Z
0, A
0, C 0}
0, B
90, C 0}
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Examples for external axes
Comparison of the transformations of the two-axis positioner
Standard:
$ET1_TA1KR = {X 0,
$ET1_TA2A1 = {X 0,
$ET1_TA3A2 = {X 0,
$ET1_TFLA3 = {X 0,
$ET1_TPINFL = {X 0,
Y 280, Z 510, A 0, B 90, C 0}
Y
0, Z 324, A 0, B -90, C 0}
Y
0, Z
0, A 0, B
0, C 0}
Y
0, Z 340, A 90, B
0, C 0}
Y
0, Z
0, A 0, B
0, C 0}
Simplified :
$ET1_TA1KR = {X 0,
$ET1_TA2A1 = {X 0,
$ET1_TA3A2 = {X 0,
$ET1_TFLA3 = {X 0,
$ET1_TPINFL = {X 0,
Y
Y
Y
Y
Y
0, Z 510, A 0, B 90, C 0}
0, Z
0, A 0, B -90, C 0}
0, Z
0, A 0, B
0, C 0}
0, Z 340, A 90, B
0, C 0}
0, Z
0, A 0, B
0, C 0}
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Description of the kinematic system for a DKP400.1 two-axis positioner
1) Description of a standard transformation
2) Description of a simplified transformation
3) Machine data for axes E1 and E2
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Examples for external axes
Machine data - Solution for KR C2
DEFDAT $MACHINE PUBLIC
$AXIS_TYPE[7]=3
$AXIS_TYPE[8]=3
$MAMES[7]=0.0
$MAMES[8]=90.0
$RAT_MOT_AX[7]={N 1904, D 10}
$RAT_MOT_AX[8]={N 107, D 1}
$RAT_MOT_ENC[7]={N 1, D 4}
$RAT_MOT_ENC[8]={N 1, D 3}
$AXIS_RESO[7]=4096
$AXIS_RESO[8]=4096
;Default
;Default
$DSECHANNEL[7]=7
$DSECHANNEL[8]=8
$PMCHANNEL[7]=21
$PMCHANNEL[8]=21
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Machine data - Solution for KR C2
$SERVOFILE7[ ]=“KSD_32_MB_S”
$SERVOFILE8[ ]=“KSD_16_MC_A”
$CURR_MAX[7]=32.0
$CURR_MAX[8]=16.0
$CURR_CAL[7]=1.0
$CURR_CAL[8]=1.0
$CURR_LIM[7]=100
$CURR_LIM[8]=100
$CURR_MON[7]=12.8
$CURR_MON[8]=6.7
$CURR_COM_EX[1]=100.0
$CURR_COM_EX[2]=100.0
$KT_MOT[7]=1.25
$KT_MOT[8]=1.37
$KT0_MOT[7]=1.41
$KT0_MOT[8]=1.57
$RAISE_TIME[7]=500.0
$RAISE_TIME[8]=500.0
$RAISE_T_MOT[7]=5.0
$RAISE_T_MOT[8]=5.0
;Default
;Default
;Start value for optimization
;Start value for optimization
;Default
;Default
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Examples for external axes
Machine data - Solution for KR C2
$VEL_AXIS_MA[7]=4100.0
$VEL_AXIS_MA[8]=2250.0
$RED_VEL_AXC[7]=10
$RED_VEL_AXC[8]=10
$RED_ACC_AXC[7]=20
$RED_ACC_AXC[8]=20
$RED_ACC_OV[7]=100
$RED_ACC_OV[8]=100
$RED_ACC_EMX[7]=100
$RED_ACC_EMX[8]=100
$ST_TOL_VEL[7]=15.0
$ST_TOL_VEL[8]=15.0
$VEL_AX_JUS[7]=0.1
$VEL_AX_JUS[8]=0.1
$SEN_DEL[7]=0
$SEN_DEL[8]=0
$L_EMT_MAX[7]=2.752
$L_EMT_MAX[8]=2.752
$DECEL_MB[7]=500.0
$DECEL_MB[8]=500.0
;Default
;Default
;Default
;Default
;Default
;Default
;Start value for optimization
;Start value for optimization
;Default
;Default
;Default
;Default
;Default
;Default
;Start value for optimization
;Start value for optimization
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Machine data - Solution for KR C2
$G_VEL_CAL[7]=0.0
$G_VEL_CAL[8]=0.0
$LG_PTP[7]=0.3
$LG_PTP[8]=0.3
$LG_CP[7]=0.48
$LG_CP[8]=0.48
$G_VEL_PTP[7]=30
$G_VEL_PTP[8]=30
$G_VEL_CP[7]=30
$G_VEL_CP[8]=30
$I_VEL_PTP[7]=200
$I_VEL_PTP[8]=200
$I_VEL_CP[7]=200
$I_VEL_CP[8]=200
;Default
;Default
;Start value for optimization
;Start value for optimization
;Start value for optimization
;Start value for optimization
;Start value for optimization
;Start value for optimization
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Examples for external axes
5.2.
Dual turnover positioner
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 149 of 240
Examples for external axes
Dual turnover positioner (vertical) DWPV - 500.1
200
WORLD
Z
X
Front view
Y
PIN
Y
X
E1
The origin of the kinematic ROOT coordinate system is
situated either in the center of the motor flange or
directly below this on the floor (Z = 0)
E3
+Z
Top view
E2
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Machine data for the DWPV - 500.1 dual turnover positioner
DEFDAT $MACHINE PUBLIC
$AXIS_TYPE[7]=
$AXIS_TYPE[8]=
$AXIS_TYPE[9]=
$MAMES[7]=
$MAMES[8]=
$MAMES[9]=
$RAT_MOT_AX[7]={N
,D
$RAT_MOT_AX[8]={N
,D
$RAT_MOT_AX[9]={N
,D
$RAT_MOT_ENC[7]={N
,D
$RAT_MOT_ENC[8]={N
,D
$RAT_MOT_ENC[9]={N
,D
$DSECHANNEL[7]=
$DSECHANNEL[8]=
$DSECHANNEL[9]=
$PMCHANNEL[7]=
$PMCHANNEL[8]=
$PMCHANNEL[9]=
$CURR_MAX[7]=
$CURR_MAX[8]=
$CURR_MAX[9]=
}
}
}
}
}
}
KR C2
3
3
3
0.0
0.0
0.0
{N -1637 ,D 10
}
{N 107 ,D 1
}
{N 107 ,D 1
}
{N 1
,D 4
}
{N 1
,D 3
}
{N 1
,D 3
}
10
11
12
21
21
21
32.0
16.0
16.0
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Examples for external axes
Machine data for the DWPV - 500.1 dual turnover positioner
$CURR_CAL[7]=
$CURR_CAL[8]=
$CURR_CAL[9]=
$CURR_LIM[7]=
$CURR_LIM[8]=
$CURR_LIM[9]=
$RAISE_TIME[7]=
$RAISE_TIME[8]=
$RAISE_TIME[9]=
$RAISE_T_MOT[7]=
$RAISE_T_MOT[8]=
$RAISE_T_MOT[9]=
$VEL_AXIS_MA[7]=
$VEL_AXIS_MA[8]=
$VEL_AXIS_MA[9]=
1.0
1.0
1.0
100
100
100
800.0
400.0
400.0
5.0
5.0
5.0
3000.0
2250.0
2250.0
KR C2
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Machine data for the DWPV - 500.1 dual turnover positioner
$AXIS_RESO[7]=
$AXIS_RESO[8]=
$AXIS_RESO[9]=
$RED_VEL_AXC[7]=
$RED_VEL_AXC[8]=
$RED_VEL_AXC[9]=
$RED_ACC_AXC[7]=
$RED_ACC_AXC[8]=
$RED_ACC_AXC[9]=
$RED_ACC_OV[7]=100
$RED_ACC_OV[8]=100
$RED_ACC_OV[9]=100
$RED_ACC_EMX[7]=
$RED_ACC_EMX[8]=
$RED_ACC_EMX[9]=
$ST_TOL_VEL[7]=15.0
$ST_TOL_VEL[8]=15.0
$ST_TOL_VEL[9]=15.0
$VEL_AX_JUS[7]=
$VEL_AX_JUS[8]=
$VEL_AX_JUS[9]=
4096
4096
4096
10
10
10
20
20
20
KR C2
Default
150
300
300
Default
0.06
0.11
0.11
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Examples for external axes
Machine data for the DWPV - 500.1 dual turnover positioner
$SEN_DEL[7]=0
$SEN_DEL[8]=0
$SEN_DEL[9]=0
$L_EMT_MAX[7]=
$L_EMT_MAX[8]=
$L_EMT_MAX[9]=
$G_VEL_CAL[7]=0.0
$G_VEL_CAL[8]=0.0
$G_VEL_CAL[9]=0.0
$LG_PTP[7]=
$LG_PTP[8]=
$LG_PTP[9]=
$LG_CP[7]=
$LG_CP[8]=
$LG_CP[9]=
$DECEL_MB[7]=
$DECEL_MB[8]=
$DECEL_MB[9]=
$G_COE_CUR[7]=15
$G_COE_CUR[8]=15
$G_COE_CUR[9]=15
KR C2
Default
1.6
2.24
2.24
Default
0.3
0.3
0.3
0.3
0.3
0.3
800.0
400.0
400.0
Default
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Machine data for the DWPV - 500.1 dual turnover positioner
$G_VEL_PTP[7]=
$G_VEL_PTP[8]=
$G_VEL_PTP[9]=
$G_VEL_CP[7]=
$G_VEL_CP[8]=
$G_VEL_CP[9]=
$I_VEL_PTP[7]=
$I_VEL_PTP[8]=
$I_VEL_PTP[9]=
$I_VEL_CP[7]=
$I_VEL_CP[8]=
$I_VEL_CP[9]=
$VEL_FILT[7]=2.5
$VEL_FILT[8]=2.5
$VEL_FILT[9]=2.5
$APO_DIS_PTP[7]=
$APO_DIS_PTP[8]=
$APO_DIS_PTP[9]=
54.0
33.0
33.0
54.0
33.0
33.0
300.0
100.0
100.0
300.0
100.0
100.0
2.5
2.5
2.5
90.0
90.0
90.0
KR C2
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Examples for external axes
Machine data for the DWPV - 500.1 dual turnover positioner
INT $BRK_ACTIVE=
INT $BRK_MODE=’B0101’
$IN_POS_MA[7]=0.1
$IN_POS_MA[8]=0.1
$IN_POS_MA[9]=0.1
$TIME_POS[7]=512
$TIME_POS[8]=512
$TIME_POS[9]=512
$FOL_ERR_MA[7]=20.0
$FOL_ERR_MA[8]=20.0
$FOL_ERR_MA[9]=20.0
$COM_VAL_MI[7]=150.0
$COM_VAL_MI[8]=150.0
$COM_VAL_MI[9]=150.0
$SOFTN_END[7]=
$SOFTN_END[8]=
$SOFTN_END[9]=
$SOFTP_END[7]=
$SOFTP_END[8]=
$SOFTP_END[9]=
$AXIS_DIR[7]=
$AXIS_DIR[8]=
$AXIS_DIR[9]=
B’111111111’
Default
-185.0
-185.0
-185.0
5.0
185.0
185.0
1
1
1
KR C2
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Machine data for the DWPV - 500.1 dual turnover positioner
INT $EX_AX_NUM = 3
DECL EX_KIN $EX_KIN =
DECL ET_AX $ET1_AX =
CHAR $ET1_NAME[20]
$ET1_NAME[] = ”DWPV_500.1
”
E2
FRAME $ET1_TA1KR =
FRAME $ET1_TA2A1 =
FRAME $ET1_TA3A2 =
FRAME $ET1_TFLA3 =
FRAME $ET1_TPINFL =
DECL ET_AX $ET2_AX =
CHAR $ET2_NAME[20]
$ET1_NAME[] = ”DWPV_500.1
”
E3
FRAME $ET2_TA1KR =
FRAME $ET2_TA2A1 =
FRAME $ET2_TA3A2 =
FRAME $ET2_TFLA3 =
FRAME $ET2_TPINFL =
{ET1 #EASYS
, ET2 #EBSYS
#NONE, ET5 #NONE, ET6 #NONE}
, ET3 #NONE, ET4
{TR_A1 #E2
, TR_A2 #NONE
, TR_A3 #NONE
} }
”
{X 0.0
{X 0.0
{X 0.0
{X 0.0
{X 0.0,
,Z 1000.0,
,A A 0.0,
,B B 0.0,
,CC - 90.0
,Z 0.0 ,A 0.0 ,B 0.0 ,C 0.0
,Z 0.0 ,A 0.0 ,B 0.0 ,C 0.0
,Z 0.0 ,A 0.0 ,B 0.0 ,C 0.0
,Z 0.0 ,A 0.0 ,B 0.0 ,C 0.0
,Y 0.0
,Y 0.0
,Y 0.0
,Y 0.0
,Y
Y 0.0
{TR_A1 #E3
, TR_A2 #NONE
”
{X 0.0
{X 0.0
{X 0.0
{X 0.0
{X 0.0
,Z 1000.0,
,A A 0.0,
,B B 0.0,
,CC - 90.0
,Z 0.0 ,A 0.0 ,B 0.0 ,C 0.0
,Z 0.0 ,A 0.0 ,B 0.0 ,C 0.0
,Z 0.0 ,A 0.0 ,B 0.0 ,C 0.0
,Z 0.0 ,A 0.0 ,B 0.0 ,C 0.0
,Y 0.0
,Y 0.0
,Y 0.0
,Y 0.0
,Y 0.0
}
}
}
}
}
, TR_A3 #NONE
} }
}
}
}
}
}
ENDDAT
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Examples for external axes
5.3.
Linear unit KL 1500
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Page 155 of 240
Examples for external axes
Linear unit KL 1500
+Y
WORLD
+X
+YFLA
+YERSYSROOT
Robot
+XFLA
+XERSYSROOT
+ZA1KR
Height H=450 mm
Direction of motion
XERSYSROOT
Carriage
Z direction of the
transformation
$ET3_TA1KR
X FL
The flange is the
baseplate on the KL
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Machine data for the KL 1500 linear unit
DEFDAT $MACHINE PUBLIC
$AXIS_TYPE[7] = 1
$MAMES[7] = 0.0
$RAT_MOT_AX[7] = {N 34 ,D 1}
$RAT_MOT_ENC[7] = {N 1,D 4}
$DSECHANNEL[7] = 7
$PMCHANNEL[7] = 21
$CURR_MAX[7] = 32.0
$CURR_CAL[7] = 1.0
$CURR_LIM[7] = 100
$RAISE_TIME[7] = 600.0
$RAISE_T_MOT[7] = 6.8
$VEL_AXIS_MA[7] = 3000.0
$AXIS_RESO[7] = 4096
$RED_VEL_AXC[7] = 10
$RED_ACC_AXC[7] = 7
$RED_ACC_OV[7] = 100
;Default
;Default
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Examples for external axes
Machine data for the KL 1500 linear unit
$RED_ACC_EMX[7] = 100
$ST_TOL_VEL[7] = 15.0
$VEL_AX_JUS[7] = 0.09648
$SEN_DEL[7] = 0
$L_EMT_MAX[7] = 9.6
$G_VEL_CAL[7] = 0.0
$LG_PTP[7] = 0.3
$LG_CP[7] = 0.15
$DECEL_MB[7] = 600.0
$G_COE_CUR[7] = 15
$G_VEL_PTP[7]= 67.0
$G_VEL_CP[7] = 67.0
$I_VEL_PTP[7] = 500.0
$I_VEL_CP[7] = 500.0
$VEL_FILT[7] = 2.5
$APO_DIS_PTP[7] = 500.0
;Default
;Default
;Default
;Default
;Default
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Machine data for the KL 1500 linear unit
INT $BRK_ACTIVE = ‘B1111111’
INT $BRK_MODE = ‘B0101’
;BRAKE CONTROL MODE
$IN_POS_MA[7] = 1.5
$TIME_POS[7] = 512
$FOL_ERR_MA[7] = 20.0
$COM_VAL_MI[7] = 150.0
;Default
;Default
;Default
;Default
$SOFTN_END[7] = -2500.0
$SOFTP_END[7] = 2500.0
$AXIS_DIR[7] = 1
INT $EX_AX_NUM = 1
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Examples for external axes
Machine data for the KL 1500 linear unit
DECL EX_KIN $EX_KIN =
{ET1 #ERSYS,ET2 #NONE ,ET3 #NONE,ET4
#NONE,ET5 #NONE,ET6 #NONE}
DECL ET_AX $ET1_AX =
{TR_A1 #E1,TR_A2 #NONE,TR_A3 #NONE}
CHAR $ET1_NAME[20]
$ET1_NAME[ ] = “KL1500”
FRAME $ET1_TA1KR = {X
FRAME $ET1_TA2A1 = {X
FRAME $ET1_TA3A2 = {X
FRAME $ET1_TFLA3 = {X
FRAME $ET1_TPINFL = {X
Y
Y
Y
Y
Y
Z
Z
Z
Z
Z
A
A
A
A
A
B
B
B
B
B
C
C
C
C
C
}
}
}
}
}
ENDDAT
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Machine data for the KL 1500 linear unit
DECL EX_KIN $EX_KIN =
{ET1 #ERSYS,ET2 #NONE ,ET3 #NONE,ET4
#NONE,ET5 #NONE,ET6 #NONE}
DECL ET_AX $ET1_AX =
{TR_A1 #E1,TR_A2 #NONE,TR_A3 #NONE}
CHAR $ET1_NAME[20]
$ET1_NAME[ ] = “KL1500”
”KL1500”
FRAME $ET1_TA1KR = {X 0.0,
FRAME $ET1_TA2A1 = {X 0.0,
FRAME $ET1_TA3A2 = {X 0.0,
FRAME $ET1_TFLA3 = {X 0.0,
FRAME $ET1_TPINFL = {X 0.0,
Y 0.0,
Y 0.0,
Y 0.0,
Y 0.0,
Y 0.0,
Z 450.0,A
A 0.0,
Z 0.0, A 0.0,
Z 0.0, A 0.0,
Z 0.0, A 0.0,
Z 0.0, A 0.0,
B 90.0, C 0.0
B 0.0, C 0.0
B 0.0, C 0.0
B -90.0, C 0.0
B 0.0, C 0.0
}
}
}
}
}
ENDDAT
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Examples for external axes
5.4.
10-axis system
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Examples for external axes
10-axis system
$ERSYSROOTÆ$WORLD
10-axis welding system (combination
of two-axis positioner, turntable and Z
linear unit)
Top view of the
welding cell with
linear unit
Front view of the
welding cell
Linear unit KL 250
Axis 7
Y
Axis 9
X
Axis 8
Axis 10
Axis 9
Axis 8
Axis 10
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Layout of the 10-axis system
2nd external
kinematic system
1st external kinematic system
180
Axis 9
559
1016
89
25
507
Axis 8
Axis 10
914
1143
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Examples for external axes
External kinematic system: #EASYS
DECL EX_KIN $EX_KIN={ET1 #EASYS, ET2 #EBSYS, ET3 #ERSYS, ET4 #NONE, ET5
#NONE, ET6 #NONE}
;EXTERNAL KINEMATICS
DECL ET_AX $ET1_AX={TR_A1 #E3, TR_A2 #E4, TR_A3 #NONE}
;EXTERNAL AXES
CHAR $ET1_NAME[20]
;NAME OF TRANSFORMATION ET1
$ET1_NAME[ ]=“two-axis positioner”
Axis 9 Î E3
Axis 10 Î E4
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Selection of the root point
Z
150 mm
Root point
X
Y
Top view: flange - reference pin distance
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Examples for external axes
1st transformation
FRAME $ET1_TA1KR = {X 0.0, Y 0.0, Z 1016.0, A 0.0, B 0.0, C -90.0}
X
Z
150 mm
Y
Top view: flange - reference pin distance
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2nd transformation
FRAME $ET1_TA1KR = {X 0.0, Y 0.0, Z 1016.0, A 0.0, B 0.0, C -90.0}
FRAME $ET1_TA2A1=
{X 0.0, Y 507.0, Z 739.0, A 0.0, B 0.0, C 90.0}
Z
X
Y
Z
Y
150 mm
X
Top view: flange - reference pin distance
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Examples for external axes
Transformation: flange - reference pin
FRAME $ET1_TA1KR = {X 0.0, Y 0.0, Z 1016.0, A 0.0, B 0.0, C -90.0}
FRAME $ET1_TA2A1=
{X 0.0, Y 507.0, Z 739.0, A 0.0, B 0.0, C 90.0}
FRAME $ET1_TA3A2=
{X 0.0, Y 0.0, Z 0.0, A 0.0, B 0.0, C 0.0}
FRAME $ET1_TFLA3=
{X 0.0, Y 0.0, Z 0.0, A 0.0, B 0.0, C 0.0}
Z
X
FRAME $ET1_TPINFL=
{X 0.0, Y 0.0, Z 0.0, A 0.0, B 0.0, C 0.0}
Y
Z
150 mm
Y
X
Top view: flange - reference pin distance
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External transformation: #EBSYS
DECL EX_KIN $EX_KIN={ET1 #EASYS, ET2 #EBSYS, ET3 #ERSYS, ET4 #NONE, ET5
#NONE, ET6 #NONE}
;EXTERNAL KINEMATICS
DECL ET_AX $ET2_AX={TR_A1 #E2, TR_A2 #NONE, TR_A3 #NONE}
;EXTERNAL AXES
CHAR $ET2_NAME[20]
;NAME OF TRANSFORMATION ET1
$ET2_NAME[ ]="Turntable"
Axis 8 Î E2
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Examples for external axes
Selection of the root point
200 mm
Z
Side view: flange - reference pin distance
Root point
Y
X
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1st transformation
FRAME $ET2_TA1KR= {X 0.0,Y 0.0,Z 1016.0,A 0.0,B 0.0,C 90.0}
Y
Y
200 mm
Z
X
Z
X
Side view: flange - reference pin distance
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Examples for external axes
Transformation: flange - reference pin
Y
FRAME $ET2_TA1KR= {X 0.0,Y 0.0,Z 1016.0,A 0.0,B 0.0,C 90.0}
FRAME $ET2_TA2A1= {X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
FRAME $ET2_TA3A2= {X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
FRAME $ET2_TFLA3= {X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
FRAME $ET2_TPINFL={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
Y
Z
X
200 mm
Z
X
Side view: flange - reference pin distance
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External transformation: #ERSYS
DECL EX_KIN $EX_KIN={ET1 #EASYS, ET2 #EBSYS, ET3 #ERSYS, ET4 #NONE, ET5
#NONE, ET6 #NONE}
;EXTERNAL KINEMATICS
DECL ET_AX $ET3_AX={TR_A1 #E1, TR_A2 #NONE, TR_A3 #NONE}
;EXTERNAL AXES
CHAR $ET3_NAME[20]
;NAME OF TRANSFORMATION ET1
$ET3_NAME[ ]="KL250"
Axis 7 Î E1
Æ Axis 1 of the robot is in the 0°-position !
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Examples for external axes
Selection of the root point
Z
Y
X
Z
347 mm
Y
X
Root point
Æ Axis 1 of the robot is in the -90°-position !
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Transformation
FRAME $ET3_TA1KR={X 0.0,Y 0.0,Z 347.0,A 0.0,B 0.0,C 90.0}
FRAME $ET3_TA2A1={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
FRAME $ET3_TA3A2={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
FRAME $ET3_TFLA3={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C -90.0}
FRAME $ET3_TPINFL={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
Z
X
Y
347 mm
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Examples for external axes
5.5.
Special kinematics
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Examples for external axes
Philosophy for creation of MADA for ROBROOT kinematic systems
1. In the case of kinematic systems with one motor, only transformation
TA1KR is taken into consideration.
In the case of kinematic systems with two motors, transformations TA1KR
and TA2A1 are taken into consideration.
In the case of kinematic systems with three motors, transformations TA1KR,
TA2A1 and TA3A2 are taken into consideration.
2. The robot stands on the flange plate of the ROBROOT kinematic system.
- The transformation $ETx_FLA3 describes the offset and rotation of the
robot in the flange coordinate system of the kinematic system
- Transformation TFLA3 is always taken into consideration.
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Special kinematics of type #ERSYS
200 mm
300 mm
Z
100 mm
Y
X
WORLD
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Examples for external axes
Solution: Robot on XY table
INT $AXIS_TYPE[12]
$AXIS_TYPE[7]=1
$AXIS_TYPE[8]=1
;AXIS IDENTIFIER
;1 = LINEAR, 2 = SPINDLE, 3 = ROTATIONAL,
;4 = FINITELY ROTATING, 5 = INFINITE
DECL EX_KIN $EX_KIN={ET1 #ERSYS,ET2 #NONE,ET3 #NONE,ET4 #NONE,ET5 #NONE,ET6
#NONE}
;EXTERNAL KINEMATICS #NONE,#EASYS,
#EBSYS,#ECSYS,#EDSYS, #EESYS,#EFSYS,#ERSYS
DECL ET_AX $ET1_AX={TR_A1 #E1,TR_A2 #E2,TR_A3 #NONE}
;EXTERNAL AXES #NONE, #E1, #E2, #E3, #E4, #E5,
#E6
CHAR $ET1_NAME[20]
;NAME OF TRANSFORMATION ET1 MAX. 20
$ET1_NAME[ ]="XY_TABLE"
;CHARACTERS
FRAME $ET1_TA1KR= {x 0.0,y 0.0,z 600.0,a 0.0, b 0.0, c -90.0} ;FRAME BETWEEN A1 AND KR
FRAME $ET1_TA2A1= {x 0.0,y 0.0,z 0.0, a 90.0,b 0.0, c 90.0} ;BETWEEN A2 AND A1
FRAME $ET1_TA3A2= {x 0.0,y 0.0,z 0.0, a 0.0, b 0.0,c 0.0}
;BETWEEN A3 AND A2
FRAME $ET1_TFLA3= {x 0.0,y 0.0,z 0.0, a 0.0, b -90.0, c 0.0} ;BETWEEN FL AND A3
FRAME $ET1_TPINFL={x 0.0,y 0.0,z 0.0, a 0.0, b 0.0, c 0.0}
;BETWEEN REF. PT. AND FL
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Special kinematics of type #ERSYS
Z
WORLD
Y
X
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Examples for external axes
Solution: Robot on Cartesian gantry
INT $AXIS_TYPE[12]
$AXIS_TYPE[7]=1
$AXIS_TYPE[8]=1
$AXIS_TYPE[9]=1
;AXIS IDENTIFIER
;1 = LINEAR, 2 = SPINDLE, 3 = ROTATIONAL,
;4 = FINITELY ROTATING, 5 = INFINITE
DECL EX_KIN $EX_KIN={ET1 #ERSYS,ET2 #NONE,ET3 #NONE,ET4 #NONE,ET5 #NONE,ET6 #NONE}
;EXTERNAL KINEMATICS #NONE,#EASYS,
#EBSYS,#ECSYS,#EDSYS,#EESYS,#EFSYS,#ERSYS
DECL ET_AX $ET1_AX={TR_A1 #E1,TR_A2 #E2,TR_A3 #E3}
;EXTERNAL AXES #NONE, #E1, #E2, #E3, #E4, #E5,
#E6
CHAR $ET1_NAME[20]
;NAME OF TRANSFORMATION ET1 MAX. 20
$ET1_NAME[]="CARTESIAN_GANTRY"
;CHARACTERS
FRAME $ET1_TA1KR= {x 0.0,y 0.0,z 0.0,a 0.0, b 90.0, c 0.0}
FRAME $ET1_TA2A1= {x 0.0,y 0.0,z 0.0, a 0.0,b 0.0, c -90.0}
FRAME $ET1_TA3A2= {x 0.0,y 0.0,z 0.0, a 0.0, b -90.0,c 0.0}
FRAME $ET1_TFLA3= {x 0.0,y 0.0,z 0.0, a -90.0, b 0.0, c 180.0}
FRAME $ET1_TPINFL={x 0.0,y 0.0,z 0.0, a 0.0, b 0.0, c 0.0}
;FRAME BETWEEN A1 AND KR
;BETWEEN A2 AND A1
;BETWEEN A3 AND A2
;BETWEEN FL AND A3
;BETWEEN REF. PT. AND FL
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Special kinematics of type #ERSYS
125
0
The surface of the rotary table is 230 mm above the floor
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Examples for external axes
Solution: Robot on rotary table
INT $AXIS_TYPE[12]
$AXIS_TYPE[7]=3
;AXIS IDENTIFIER
;1 = LINEAR, 2 = SPINDLE, 3 = ROTATIONAL,
4 = FINITELY ROTATING, 5 = INFINITE
DECL EX_KIN $EX_KIN={ET1 #ERSYS,ET2 #NONE,ET3 #NONE,ET4 #NONE,ET5 #NONE,ET6
#NONE}
;EXTERNAL KINEMATICS #NONE,#EASYS,
#EBSYS,#ECSYS,#EDSYS,#EESYS,#EFSYS,#ERSYS
DECL ET_AX $ET1_AX={TR_A1 #E1,TR_A2 #NONE,TR_A3 #NONE}
;EXTERNAL AXES #NONE, #E1, #E2, #E3, #E4, #E5,
#E6
CHAR $ET1_NAME[20]
;NAME OF TRANSFORMATION ET1 MAX. 20
$ET1_NAME[]="ROB_ON_ROTARY_TABLE" ;CHARACTERS
FRAME $ET1_TA1KR = {x 0.0,y 0.0,z 230.0,a 0.0, b 0.0, c 0.0}
FRAME $ET1_TA2A1 = {x 0.0,y 0.0,z 0.0, a 0.0,b 0.0, c 0.0}
FRAME $ET1_TA3A2 = {x 0.0,y 0.0,z 0.0, a 0.0, b 0.0,c 0.0}
FRAME $ET1_TFLA3 = {x 1250.0,y 0.0,z 0.0, a 0.0, b 0.0, c 0.0}
FRAME $ET1_TPINFL={x 0.0,y 0.0,z 0.0, a 0.0, b 0.0, c 0.0}
;FRAME BETWEEN A1 AND KR
;BETWEEN A2 AND A1
;BETWEEN A3 AND A2
;BETWEEN FL AND A3
;BETWEEN REF. PT. AND FL
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Special kinematics of type #ERSYS
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Optimization
6. Optimization
6.1.
Determining optimal parameters
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Optimization
Optimization goals for KMC axes
The optimization of external axes is intended to achieve the following
goals:
• Reduction of cycle time
through the use of high acceleration values
i.e. utilization of the maximum current
• Increase of path and velocity accuracy
through reduction of the following error
The optimization results that are achieved
must be checked with the aid of the oscilloscope function!
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Optimization procedure
Settings
Results
Speed servo, P component
Following error
Speed servo, I comp.
Current response
Oscilloscope
Position servo, P comp.
Axis acceleration time
function
Current magnitude
Acceleration
and
braking response
Filter time
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Optimization
Drive control
Proc.
Position
setpoint
/IPO
Servo bus
KSD
DSE-IBS 3
Speed
Speed
servo
servo
Pos.
Position
servo
servo
(-)
(-)
Current
Current
servo
servo
CommuCommutation
tation
(-)
PWM
PWM
Position
Position
calculation
calculation
Driver
Driver
Actual
Actual speed
speed
M Motor
RDC
R Resolver
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Sequence of operations when performing optimization
The following sequence must be observed:
•
Setting the speed servo (PI controller)
•
Setting the position servo (P controller)
•
Setting the axis acceleration time (acceleration)
•
Setting the E-Stop braking ramp
•
Setting the braking ramp for dynamic braking
The optimization results that are achieved
must be checked with the aid of the oscilloscope function!
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Optimization
Checking the optimization results (1)
The following tests are required for this purpose:
• Normal motion in Automatic mode
• Emergency Stop in Automatic mode
• Dynamic braking in T2
after releasing the enabling switch
The optimization results that are achieved
must be checked with the aid of the oscilloscope function!
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Checking the optimization results (2)
The following phenomena must not occur (check criteria):
• Heavy pulsing of the current
(i.e. axis hums during motion or vibrates)
• Current actual value is limited to the maximum value
• Permissible following error is exceeded
(i.e. motion is aborted with an error message)
Æ Orientation value for the following error:
approx. 1.0 rad
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Optimization
Unit of the following error on the oscillograms
The following error is specified in [rad] on the oscillogram.
1 rad = 360 / 2*3.14 = 57.296 [degrees]
This value is measured at the motor output.
It refers expressly to the motor and not to the axis.
To obtain the axis angle, the value must be divided by
$RAT_MOT_AX[ ] (transmission ratio between motor and gear).
Æ Orientation value for the following error:
approx. 1.0 rad
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Instructions for setting the speed servo (1)
When setting the speed servo the following sequence must be
observed:
1.
Setting the P component
(for this purpose the value of the I component must be set
to 9999, for example, in order to deactivate its function)
2.
Setting the I component
(while retaining the optimum P component previously determined)
The speed servo uses different settings in the machine data for PTP
and CP motions.
Its settings for "PTP" can also be adopted for "CP".
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Optimization
Instructions for setting the speed servo (2)
Increasing the P component shortens the reaction times,
because the setpoint is reached faster.
Setting the value too high results in hard control, which causes
the axis to pulse.
Remedy:
decrease the current setting by 20%!
The I component influences the transient response of the axis
in settling to the command velocity, and stabilizes the control loop.
Decreasing the I component shortens the reaction times,
because the setpoint is reached faster.
Setting the value too low causes the axis to vibrate.
Remedy:
increase the current setting by 20%!
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Instructions for setting the position servo
The procedure for setting the position servo is as follows:
1.
Set the P component
2.
Check the optimization result by "manual" motion
of the axis
3. If the axis starts to vibrate, decrease the current setting
by 10%
The position servo uses different settings for PTP and CP
motions.
Its settings for "PTP" can also be adopted for "CP".
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Optimization
Oscillogram - $G_VEL_PTP = 20
The setting $G_VEL_PTP = 20 is far too low!
Æ The motion was aborted!
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Oscillogram - $G_VEL_PTP = 30
The setting $G_VEL_PTP = 30 is low!
Æ Following error:
3.5 rad
Æ Current pulse height Ipp: 0.0 A
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Optimization
Oscillogram - $G_VEL_PTP = 40
Æ Following error:
3.0 rad
Æ Current pulse height Ipp: 2.0 A
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Oscillogram - $G_VEL_PTP = 60
Æ Following error:
2.0 rad
Æ Current pulse height Ipp: 3.0 A
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Optimization
Oscillogram - $G_VEL_PTP = 75
Æ Following error:
1.3 rad
Æ Current pulse height Ipp: 4.0 A
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Oscillogram - $G_VEL_PTP = 120
The setting $G_VEL_PTP = 120 is very high!
Æ Following error:
0.90 rad
Æ Current pulse height Ipp: 10.0 A
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Optimization
Oscillogram - $G_VEL_PTP = 150
The setting $G_VEL_PTP = 150 is far too high!
Æ The axis "hums"
Æ Following error:
0.56 rad
Æ Current pulse height Ipp: 20.0 A
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Conclusions with regard to setting the P-component of the speed servo
Evaluation of the oscillograms produces the following results:
1.
The higher the P component, the lower the following error
2.
The higher the P component, the greater the current pulse height
3.
If the P component is too low, the motion will be aborted with
error messages
4.
If the P component is too high, the axis will "hum"
5. Æ Favorable value:
approx. 75
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Optimization
Oscillogram - $I_VEL_PTP = 20
The setting $I_VEL_PTP = 20 is low!
Æ Fast servo control!
Æ Following error:
0.36 rad
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Oscillogram - $I_VEL_PTP = 50
Æ Following error:
0.52 rad
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Optimization
Oscillogram - $I_VEL_PTP = 100
Æ Following error:
0.80 rad
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Oscillogram - $I_VEL_PTP = 400
Æ Following error:
1.30 rad
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Optimization
Oscillogram - $I_VEL_PTP = 999
Æ Following error:
1.70 rad
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Conclusions with regard to setting the I component of the speed servo
Evaluation of the oscillograms produces the following results:
•
The higher the I component, the greater the following error
•
The I component has no effect on the current pulse height
•
If the I component is very low, the command velocity will be
reached quickly (Æ hard control)
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Optimization
Oscillogram - $LG_PTP = 0.10
The setting $LG_PTP = 0.10 is low!
Æ Large following error!
Æ Following error:
4.0 rad
Æ Current pulse height Ipp: 2.0 A
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Oscillogram - $LG_PTP = 0.20
Æ Following error:
2.4 rad
Æ Current pulse height Ipp: 2.0 A
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Optimization
Oscillogram - $LG_PTP = 0.40
Æ Following error:
1.2 rad
Æ Current pulse height Ipp: 2.0 A
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Oscillogram - $LG_PTP = 0.80
Following error:
0.56 rad
Æ Current pulse height Ipp: 4.00 A
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Optimization
Oscillogram - $LG_PTP = 1.00
The setting $LG_PTP = 1.00 is high!
Æ Current pulses heavily!
Æ Following error:
0.48 rad
Æ Current pulse height Ipp: 6.00 A
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Oscillogram - $LG_PTP = 1.40
The setting $LG_PTP = 1.40 is very high!
Æ Low following error, but heavy pulsing of the current!
Æ Following error:
0.36 rad
Æ Current pulse height Ipp: 10.00 A
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Optimization
Conclusions with regard to setting the P component of the position servo
Evaluation of the oscillograms produces the following results:
1. The higher the P component, the lower the following error
2. The higher the P component, the greater the current pulse height
3.
If the P component is too high, the axis will "hum"
(Æ hard control)
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Determining optimum acceleration parameters
Reasons for adjustment using the oscilloscope:
Exploitation of the available resources (current reserves) for
• Acceleration ramp
(Æ$RAISE_TIME [ ])
• Braking with path-maintaining E-Stop (Æ$RED_ACC_EMX [ ])
• Braking ramp
(Æ$DECEL_MB [ ])
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Optimization
Axis acceleration time (1)
REAL $RAISE_TIME[12]
AXIS[I](I=1:A1,I=7:E1)[MS]
$RAISE_TIME[1]=400.0
$RAISE_TIME[2]=800.0
$RAISE_TIME[3]=350.0
$RAISE_TIME[4]=250.0
$RAISE_TIME[5]=250.0
$RAISE_TIME[6]=260.0
$RAISE_TIME[7]=400.0
$RAISE_TIME[8]=250.0
$RAISE_TIME[9]=400.0
$RAISE_TIME[10]=0.0
$RAISE_TIME[11]=0.0
$RAISE_TIME[12]=0.0
;AXIS ACCELERATION TIME
Normal values
= 300 to 1000 ms
Start value
= 500 ms
$RAISE_TIME=500
$RAISE_TIME[ ] must be determined with the max. load!
The corresponding axis must not exceed the current
limitation during measurement.
$RAISE_TIME[ ] >= DEF_FLT_PTP (do not modify!)
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Axis acceleration time (2)
$DEF_FLT_PTP serves the purpose of smoothing the transitions
from the acceleration ramp to the constant travel phase and from
the constant travel phase to the braking ramp.
The starting and stopping characteristics can be influenced by this means.
The value is specified in [ms] and must be an integer multiple of the
interpolation cycle (12 ms).
This applies expressly only to non-KUKA kinematic systems,
since with these the acceleration adaptation is deactivated!
$RAISE_TIME[ ] + 0.5 * DEF_FLT_PTP is the time
in which the axis can be accelerated to its rated speed
($VEL_AXIS_MA)!
Guide values:
• The larger the kinematic system, the greater the filter value.
• Typical values: 96 ... 240 [ms]
• Times that are too short increase the oscillation tendency
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Optimization
Reduction factor for path-maintaining Emergency Stop ramp
The percentage value set here refers to the $RAISE_TIME[ ];
Æ 200% means: the gradient is twice as steep as the acceleration ramp.
INT $RED_ACC_EMX[12]
$RED_ACC_EMX[1]=190
$RED_ACC_EMX[2]=300
$RED_ACC_EMX[3]=300
$RED_ACC_EMX[4]=250
$RED_ACC_EMX[5]=250
$RED_ACC_EMX[6]=250
;REDUCTION FACTOR FOR PATH-MAINTAINING
E-STOP RAMP [ % ]
Start value = 100 [%]
$RED_ACC_EMX=100
$RED_ACC_EMX[7]=300
$RED_ACC_EMX[8]=1000
$RED_ACC_EMX[9]=300
$RED_ACC_EMX[10]=150
$RED_ACC_EMX[11]=100
$RED_ACC_EMX[12]=100
E-STOP
The corresponding axis should not be allowed to go into
current limitation.
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Deceleration time - Braking ramp for dynamic braking (path-oriented braking)
REAL $DECEL_MB[12]
$DECEL_MB[1]=211.0
$DECEL_MB[2]=267.0
$DECEL_MB[3]=180.0
$DECEL_MB[4]=200.0
$DECEL_MB[5]=200.0
$DECEL_MB[6]=200.0
$DECEL_MB[7]=500.0
$DECEL_MB[8]=200.0
$DECEL_MB[9]=200.0
$DECEL_MB[10]=0.0
$DECEL_MB[11]=0.0
$DECEL_MB[12]=0.0
;BRAKING RAMP FOR DYNAMIC BRAKING [MS]
Unit [ms]
$RAISE_TIME * 100%
$DECEL_MB=
$RED_ACC_EMX
Setting a ramp for dynamic braking (e.g. when the
enabling switch is released in T2).
This prevents the speed command value from falling
too quickly and causing the current controller to go
into limitation, which in turn would prevent the robot
from being braked in a controlled manner.
Minimum value: 180
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Optimization
KR C2 braking reactions
Test 1
Test 2
Automatic
Automatic External
Path-maintaining
braking
EMERGENCY STOP
Path-oriented braking
Enabling switch
released
Path-oriented braking
---
Safety gate opened
---
Path-maintaining
braking
Drives OFF
Path-oriented braking
Operating mode
change
Encoder error
(DSE-RDC connection
broken)
Path-oriented braking
Short-circuit braking
Motion enable
Ramp-down braking
Stop key
Ramp-down braking
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KR C2 braking reactions
Term
Shortcircuit
braking
Drives
Switched off
immediately
Switched off
Pathafter
maintainin
1 second
g braking
hardware delay
Pathoriented
braking
Switched off
immediately
Rampdown
braking
Remain on
Brakes
Applied --immediatel
y
Applied
after
1s
Applied
immediatel
y
Remain
open
Software
In this time the controller brakes the
robot on the path using a steeper stop
ramp.
V
The controller attempts to brake the
robot on the path with the remaining
energy.
If the voltage is no longer sufficient, the
robot leaves the programmed path.
Normal ramp which is used for
acceleration
and deceleration.
V
t
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Optimization
Adjustment using the oscilloscope: basic setting
Current limitation: 16 A
E-STOP
Parameters:
$RAISE_TIME[9] = 500
$RED_ACC_EMX[9] = 100
$DECEL_MB[9] = 500
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Adjustment using the oscilloscope: over-optimized setting
Current limitation: 16 A
E-STOP
Parameters:
$RAISE_TIME[9] = 100
$RED_ACC_EMX[9]=300
$DECEL_MB[9] = 180 (Min.)
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Optimization
Adjustment using the oscilloscope: optimized setting
Current limitation: 16 A
E-STOP
Parameters:
$RAISE_TIME[9] = 250
$RED_ACC_EMX[9] = 180
$DECEL_MB[9] = 180 (Min.)
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Machine data optimization form
$RAISE_TIME[n]
$RED_ACC_EMX[n]
(Acceleration time
to rated speed)
(Path-maintaining
braking in case of
E-Stop)
Value ↑ Æ Current ↓
Value ↑ Æ Current ↑
$DECEL_MB[n]
(Dynamic braking)
$RAISE_TIME[7] x100
= __________________
$RED_ACC_EMX[7]
Guide
values
2
3
4
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Optimization
Monitor – Diagnosis – Oscilloscope – Configure (1)
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Trace parameter selection (2)
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Optimization
Automatic start of the oscilloscope function by a program (1)
Start recording trace
Stop recording trace
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Automatic start of the oscilloscope function by a program (2)
Start recording trace
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Optimization
Automatic start of the oscilloscope function by a program (3)
Stop recording trace
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Automatic start of the oscilloscope function by a program (4)
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Optimization
Manual operation of the oscilloscope by means of the buttons
z = zoom
u = unzoom
q = close the Trace
k = change active graphic
s = save Trace sichern
d = Filter (on/off)
i = Info (select graphic)
w = return to configuration
m/n = change scale of active graphic
h/j = horizontal measurement
(cursor 1+2)
c/v = vertikal- or time measurement (cursor 1+2)
e = determining R.M.S. ON/OFF
(display cursor by means of the button „e“,
move cursor afterwards to the left border of the selected region –
Enter
move cursor afterwards to the right border of the selected region –
Enter
Æ display the R.M.S. value)
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Controller settings of slave drives
( Æ particularities )
The settings of the slave-axes cannot be modified by means of a
program.
Consequently an optimization of the slave-axes has to be executed
manually by means of the machine data editor.
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Optimization
6.2.
Determininig the value for $CURR_MON[]
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Optimization
Meaning of the setting $CURR_MON[ ] for external axes
Background:
In order to prevent a (thermal) overload of the motors
it is necessary to avoid permanent operation in the
range of the maximum current.
Due to this fact there exists an admissible limit-value (average
value over 60 s) for each motor-type, that must not be exceeded.
If the value of $CURR_MON[ ] is exceeded,
the acknowledgement message 1241 is generated:
“i*i-t – monitoring,
current limit of the motor cable E1 after 60 s exceeded 100%”
In such a case, the current r.m.s. value must be calculated from the overall
program cycle time (incl. wait times).
Æ The oscilloscope trace function is used for this.
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Holding current
REAL $CURR_MON[12]
;PERMISSIBLE HOLDING CURRENT
DEFINES THE LIMIT FOR THE I2t
MONITORING AT 55 °C (CABLE,
AMPLIFIER AND MOTOR WARMING!)
$CURR_MON[1]=7.3
$CURR_MON[2]=7.3
$CURR_MON[3]=2.7
$CURR_MON[4]=2.0
$CURR_MON[5]=2.0
$CURR_MON[6]=2.0
$CURR_MON[7]=9.3
$CURR_MON[8]=12.8
$CURR_MON[9]=6.7
$CURR_MON[10]=0.0
$CURR_MON[11]=0.0
$CURR_MON[12]=0.0
Permissible limits:
Peak current:
2s
Holding current: 60 s
Motortyp
$CURR_
MON
[A]
MG_8_40_45_S0
1,69
Mx_40_80_45_S0
6,30
Mx_64_110_35_S0
8,00
MG_120_110_25_S0
11,00
Mx_160_130_30_S0
14,00
Mx_180_180_40_S0
15,00
Mx_220_130_25_S0
22,50
Mx_360_180_30_S0
26,70
Mx_480_180_30_S0
25,50
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Optimization
Method
Method:
The system executes complete production cycles (incl. wait times) until a
minimum time of 60 seconds has elapsed.
During this time, the current of the axis in question is recorded in the trace.
The determined r.m.s. value value must not exceed the value of
$CURR_MON[ ] for the relevant axis.
The r.m.s. value value can be reduced by means of different measures.
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Remedy
Remedy:
• share the load to several axes
• program waiting times
• on A2: set the pressure value of the counter balancing system to the
correct value
• reduce acceleration / override in order to decrease the r.m.s. value.
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Optimization
Test program
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Data list for test program
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Optimization
Automatic start of the oscilloscope function by means of program commands
Automatic adaptation of the name
Start of the recording
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Automatic end of the recording
End of the trace recording
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Optimization
Settings for the oscilloscope trace function (1)
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Settings for the oscilloscope trace function (2)
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Optimization
Trace recording the current over 6 cycles in 90 s
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Selection of the area for calculation of the r.m.s. value
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Optimization
Display of the r.m.s. value
r.m.s. value: 4.78 from 11.70 to 89.99 s
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Trace settings for axis E1 (1)
• Monitor Æ Diagnosis Æ Oscilloscope Æ Configure
• Assign name to trace
• Enter
• Trace length min. 60 s
• Enter
• Enter
• Use the “UP” and “DOWN” arrow keys to select the trigger condition
“Trigger on motion start”
• Deactivate the “NUM” function
• Press “TAB” to access the DSE card
• Use the “UP” and “DOWN” arrow keys to select “DSE 2”
• Press “TAB” to access the I/O group
• Use the “UP” and “DOWN” arrow keys to select “No I/O data”
• Softkey “DSE Tab.”
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Optimization
Trace settings for axis E1 (2)
• Use the “UP” and “DOWN” arrow keys to position the cursor on the actual
current of axis E1
• Mark this by pressing the space bar
• Softkey “Main”
• Softkey “Save”
• Press softkey “Start” until the trace status “#T_WAIT” is displayed
• Run program
• Wait until trace status “#T_END” is displayed
• Softkey “Show”
• Softkey “Info”
• Curves that are not required can be removed from the display by pressing
the Enter key
• Softkey “Info” Æ only the current curve is visible
• Repeatedly press the softkey “Æ” until the softkey “RMS” appears
• Press the softkey “RMS”
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Trace settings for axis E1 (3)
• Use the left arrow key to mark the start of the area for which evaluation is
to be carried out
• Enter
• Use the right arrow key to mark the end of the area for which evaluation is
to be carried out
• Enter
• The r.m.s. value for the current is displayed above the zero line
Æ The displayed value must be lower than the motor specific limit
value $CURR_MON[n] in the machine data !!
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Optimization
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Multiple home positions
7. Multiple home positions
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Page 209 of 240
Multiple home positions
Multiple home positions
¾ From software version 2.3 onwards, in addition to the home position,
the user can define 5 more home positions.
¾ This makes it possible to program certain fault service functions which
take the progress of the program into consideration.
¾ When these HOME positions are reached, this is signaled to the PLC
by means of outputs.
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Multiple home positions (application)
Main program with complete program execution, e.g.: PROG_run01
HOME1
Pick up part
HOME2
Machine part
HOME3
Set down part
HOME1
Main program with reduced program execution, e.g.: PROG_run02
HOME2
Machine part
HOME3
Set down part
HOME1
Main program with reduced program execution, e.g.: PROG_run03
HOME3
Set down part
HOME1
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Multiple home positions
Multiple home positions (structure)
¾ The home positions must be saved in /R1/$CONFIG.DAT
as global positions.
The positions XHOME / XHOME1…XHOME5 stored here are used
for motion commands.
¾ These positions are stored in /R1/$MACHINE.DAT for the purpose of
cyclical monitoring of the HOME positions.
Æ $H_POS for XHOME
Æ $AXIS_HOME[1..5] for XHOME1…XHOME5
¾ When one of these HOME positions is reached, the corresponding
output defined in /STEU/$MACHINE.DAT is set.
This occurs as soon as all the axes are situated within the tolerance
window.
The outputs are defined in the signal declarations for
$IN_HOME / $IN_HOME1…$IN_HOME5.
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Multiple home positions (motion commands)
Creation of an additional
home position in the
application program
The position data are saved in
XHOME… in the $CONFIG.DAT
file
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Page 211 of 240
Multiple home positions
Multiple home positions (cyclical monitoring)
E6AXIS $H_POS={a1 0.0,………………………………….e6 0.0}
E6AXIS $AXIS_HOME[5]
$AXIS_HOME[1] ={a1 0.0,a2 -90.0,a3 90.0,a4 0.0,a5 0.0,a6 0.0,e1 0.0,e2 0.0,e3 0.0,e4
0.0,e5 0.0,e6 0.0}
………………
$AXIS_HOME[5]={a1 0.0,a2 -90.0,a3 90.0,a4 0.0,a5 0.0,a6 0.0,e1 0.0,e2 0.0,e3 0.0,e4
0.0,e5 0.0,e6 0.0}
______________________________________________________________________
E6AXIS $H_POS_TOL= {a1 0.0,………………………………….e6 0.0}
E6AXIS $H_AXIS_TOL[5]
$H_AXIS_TOL[1] ={a1 2.0,a2 2.0,a3 2.0,a4 2.0,a5 2.0,a6 2.0,e1 2.0,e2 2.0,e3 2.0,e4
2.0,e5 2.0,e6 2.0}
………………
$H_AXIS_TOL[5]={a1 2.0,a2 2.0,a3 2.0,a4 2.0,a5 2.0,a6 2.0,e1 2.0,e2 2.0,e3 2.0,e4
2.0,e5 2.0,e6 2.0}
The position data from $CONFIG.DAT can be loaded into the variable
$AXIS_HOME[x], e.g. by means of a program command. When the tolerance band
$H_AXIS_TOL[x] is reached, the corresponding output is set.
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Multiple home positions (definition of the outputs)
DEFDAT $MACHINE PUBLIC
CHAR $V_STEUMADA[32]
……………………………..
……………………………..
SIGNAL $IN_HOME $OUT[101] ;ROB IN HOMEPOSITION
SIGNAL $IN_HOME1 $OUT[977]
SIGNAL $IN_HOME2 $OUT[978]
SIGNAL $IN_HOME3 $OUT[979]
SIGNAL $IN_HOME4 $OUT[980]
SIGNAL $IN_HOME5 $OUT[981]
……………………………….
ENDDAT
The output that is to be set when a specific home position is
reached is defined in the machine data at the controller level.
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Exercises
8. Exercises
Exercise 1: Jogging external axes without mathematical coupling ... 214
Exercise 2: Mastering the robot and external axes........................... 216
Exercise 3: Calibration of the root point and offset ........................... 218
Exercise 4: Jogging with mathematical coupling .............................. 220
Exercise 5: Program creation with mathematical coupling ............... 222
Exercise 6: Programming asynchronous external axes.................... 224
Exercise 7: Hardware components in the control cabinet................. 227
Exercise 8: Definition and modification of machine data .................. 228
Exercise 9: Definition of transformation TFLA3Fehler! Textmarke nicht definiert.
Exercise 10: Optimization of machine data ...................................... 232
Exercise 11: Loading the MADA supplied for a DKP 400 and KL 250234
Exercise 12: Two different offsets on a DKP 400 ............................. 237
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 213 of 240
Exercise 1: Jogging external axes without mathematical coupling
9. Exercise 1: Jogging external axes without
mathematical coupling
Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the
following activities:
• Jog the robot and the external axes by means of the jog keys and Space
Mouse
•
Move the robot and external axes to various different positions
Requirements:
• Have received and understood KUKA College safety instructions
•
Theoretical knowledge of the general operator control of a KUKA industrial
robot
Equipment required:
• Robotic cell with external axes
Reading materials:
Standard documentation:
• External axes/linear units – chapter “Operator control”
Training documentation:
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Safety”
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Jogging external axes”
Page 214 of 240
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Exercise 1: Jogging external axes without mathematical coupling
Task:
• Move the robot using both the Space Mouse and the jog keys.
•
Make sure that the external axes are also moved.
What you should now know:
1. How many external axes does the training cell comprise?
………………………………………………………………………………………
………………………………………………………………………………………
2. Which key is used to activate the external axes?
………………………………………………………………………………………
………………………………………………………………………………………
3. Which key is used to rotate the turntable of the two-axis positioner?
………………………………………………………………………………………
………………………………………………………………………………………
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Page 215 of 240
Exercise 2: Mastering the robot and external axes
10. Exercise 2: Mastering the robot and external axes
Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the
following activities:
• Move the robot and external axes to the pre-mastering position
•
Master all axes using the EMT
Requirements:
• Theoretical knowledge of the general procedure for mastering
•
Mastering via the Setup menu
Equipment required:
• EMT
Reading materials:
Standard documentation:
• External axes/linear units – chapter “Start-up”
Training documentation:
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Mastering the robot and external axes”
Page 216 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en
Exercise 2: Mastering the robot and external axes
Task:
•
If required, unmaster all axes first.
•
Master both the robot and the external axes.
Observe the different ways of connecting the EMT to the RDC!
What you should now know:
1. Where is the mechanical zero position of the external axes located?
………………………………………………………………………………………
………………………………………………………………………………………
2. What values are indicated in the actual value display following mastering?
………………………………………………………………………………………
………………………………………………………………………………………
3. What must be taken into consideration regarding the EMT connection with
one or more external axes?
………………………………………………………………………………………
………………………………………………………………………………………
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 217 of 240
Exercise 3: Calibration of the root point and offset
11.
Exercise 3: Calibration of the root point and
offset
Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the
following activities:
• Calibrate the root point of a kinematic system
•
Define an offset on a kinematic system
Requirements:
• Theoretical knowledge of tool calibration
•
Theoretical knowledge of the calibration of the root point and offset
Equipment required:
• Black metal tip, pin
Reading materials:
Standard documentation:
• External axes/linear units – chapter “Start-up”
Training documentation:
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Calibrating external kinematic systems”
Page 218 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en
Exercise 3: Calibration of the root point and offset
Task:
•
First calibrate the pin and its orientation.
•
Calibrate the root point (installation site) of the two-axis positioner
•
Define an offset (blue base on the tabletop)
What you should now know:
1. What preconditions must be met in order to be able to determine the root
point?
………………………………………………………………………………………
………………………………………………………………………………………
2. What is meant by a “reference tool of the external machine”?
………………………………………………………………………………………
………………………………………………………………………………………
3. Where does the name assigned to the kinematic system reappear?
………………………………………………………………………………………
……………………………………………………………………………………....
4. What is meant by offset calibration of a fixed tool?
………………………………………………………………………………………
……………………………………………………………………………………....
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 219 of 240
Exercise 4: Jogging with mathematical coupling
12. Exercise 4: Jogging with mathematical coupling
Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the
following activities:
• Jog the robot and the external axes using all status keys
•
Execute motions with and without mathematical coupling
Requirements:
• Theoretical knowledge of the ways of activating the mathematical coupling
•
Knowledge of the meaning of the softkey icons
Equipment required:
• Robotic cell with external axes
Reading materials:
Standard documentation:
• External axes/linear units – chapter “Operator control”
Training documentation:
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Jogging external axes”
Page 220 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en
Exercise 4: Jogging with mathematical coupling
Task:
•
Activate the mathematical coupling for jogging…
− by means of the menu item “Cur. tool/base” in the Configure menu.
− by programming a point with the corresponding “BASE”
•
Move the two-axis positioner in the BASE or TOOL coordinate system.
•
Move the robot in the BASE coordinate system to different positions on the
two-axis positioner.
•
Move the robot on the linear axis…
− in the Joint (axis-specific) coordinate system.
− in the WORLD coordinate system.
What you should now know:
1. What different ways are there of activating the mathematical coupling?
………………………………………………………………………………………
………………………………………………………………………………………
2. Which setting moves only the linear axis?
………………………………………………………………………………………
………………………………………………………………………………………
3. Is a coupling still active when starting a motion to the home position?
………………………………………………………………………………………
………………………………………………………………………………………
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 221 of 240
Exercise 5: Program creation with mathematical coupling
13.
Exercise 5: Program creation with
mathematical coupling
Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the
following activities:
• Draft a robot program with activation of the mathematically coupled axes.
Requirements:
• Theoretical knowledge of the programming of mathematical couplings in
motion programs
Equipment required:
• Robotic cell with external axes
Reading materials:
Standard documentation:
• External axes/linear units – chapter “Operator control”
Training documentation:
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Jogging external axes”
Page 222 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en
Exercise 5: Program creation with mathematical coupling
Task:
•
Program the 3D contour
o
Path velocity: 0.15 m/s.
o
All motions between the start and end points are to be approximated.
o
The two-axis positioner is to support the motion by rotating towards
the robot.
o
Always try to tilt the two-axis positioner in such a way that the robot
performs an upward motion on it.
3D contour
START
Blue OFFSET
What you should now know:
1. Which setting for jogging is most suitable for programming this task?
………………………………………………………………………………………
………………………………………………………………………………………
2. What in the program indicates whether a point is approached with or
without mathematical coupling?
………………………………………………………………………………………
………………………………………………………………………………………
3. Where are the positions of the external axes saved?
………………………………………………………………………………………
………………………………………………………………………………………
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 223 of 240
Exercise 6: Programming asynchronous external axes
14. Exercise 6: Programming asynchronous external
axes
Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the
following activities:
• Optionally switch external axes to synchronous or asynchronous mode in
the program
•
Move uncoordinated external axes asynchronously by means of external
buttons
•
Use state polling of the axes switched to asynchronous mode
Requirements:
• Theoretical knowledge of the corresponding machine data and option data
Equipment required:
• Robotic cell with external axes
Reading materials:
Standard documentation:
• External axes/linear units – chapter “Asynchronous motion programming”
Training documentation:
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Asynchronous motions”
Page 224 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en
Exercise 6: Programming asynchronous external axes
Task 1:
• Write an “in-air” program with approx. 10 points.
o
All motions must be so programmed as to exclude the possibility of a
collision between the robot and the moving two-axis positioner.
•
Integration of asynchronous motions into the “in-air” program
o
Three asynchronous motions are to be inserted after the third point
in the “in-air” program.
o
Velocity of the asynchronous axes: 20%
The program is to wait at the eighth point until all asynchronous axes
have completed their motion. The asynchronous axes must then be
switched back to synchronous mode.
o
Repeat the experiment with various overrides for program execution
and execution of the asynchronous motions.
Use the function
“Monitor / Variable /
Overview”
to display the correction
and override values
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 225 of 240
Exercise 6: Programming asynchronous external axes
Task 2:
• Copy the “in-air” program and switch the axes E2 and E3 to the
asynchronous mode at the beginning of the program.
Configurate the following signals:
Input 12:
Move E2 to the PLUS direction
Input 13:
Input 14:
Input 15:
Input 16:
Move E2 to the MINUS direction
Move E3 to the PLUS direction
Move E3 to the MINUS direction
Deadman switch
o
Execute the “in-air” program in the AUTOMATIC-mode (POV 3%) !
Move the axes of the 2-axis-positioner manually by means of the
configurated signals while the “in-air” program is running.
o
Note the reaction of the asynchronous axes, if
- there is a reset of the program
- there is a bloc selection and
- there is a TouchUp of a motion bloc
o
How can you modify these reactions ?
What you should now know:
1. Under what circumstances is it useful to use asynchronous external axes?
………………………………………………………………………………………
………………………………………………………………………………………
2. What must be taken into consideration when switching axes to
asynchronous mode?
………………………………………………………………………………………
………………………………………………………………………………………
3. How can the velocity of asynchronous axes be influenced?
………………………………………………………………………………………
………………………………………………………………………………………
4. What is meant by Detach Jog?
………………………………………………………………………………………
Page 226 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en
Exercise 7: Hardware components in the control cabinet
15. Exercise 7: Hardware components in the control
cabinet
Aim of the exercise:
• Definition of the individual modules and connecting cables of the topmounted cabinet.
Requirements:
• Theoretical knowledge of the hardware structure of an external axis cabinet
Equipment required:
• Robotic cell with external axes
Reading materials:
Training documentation:
• Control cabinet/servicing handbooks
Training documentation:
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Hardware for external axis systems”
Task:
•
Explain the function of the individual modules in the top-mounted
cabinet.
•
Explain the various connections on the cabinet.
What you should now know:
1. Which hardware modules are additionally required for a robot with three
external axes?
………………………………………………………………………………………
………………………………………………………………………………………
2. How can the brakes of the external axes be activated?
………………………………………………………………………………………
………………………………………………………………………………………
3. What is the task of the reactors in the top-mounted cabinet?
………………………………………………………………………………………
………………………………………………………………………………………
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 227 of 240
Exercise 8: Definition and modification of machine data
16.
Exercise 8: Definition and modification of
machine data
Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the
following activities:
• Determination of number of resolver pole pairs
•
Determination of correct motor/gear ratio
•
Setting of jog parameters
•
Reduce the speed-setting at maximum command value
•
Modify the DSE channel
•
Modify the braking channel
•
Determination of the holding current ($CURR_MON)
•
Modification of the speed controller settings
Requirements:
• Theoretical knowledge of the corresponding machine data
Equipment required:
• Robotic cell with external axes
Reading materials:
Standard documentation:
• External axes/linear units – chapter “Configuration (Machine Data)”
Training documentation:
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Machine data”; chapter “Determining the value to be set for
$CURR_MON”
Page 228 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en
Exercise 8: Definition and modification of machine data
Task:
• Determine the number of resolver pole pairs on motor E2.
•
•
Modify the gear ratio ($RAT_MOT_AX[7..9]).
−
Change the sign
−
Exchange numerator and denominator
Modify the jog settings ($RED_VEL_AXC[7..9] and $RED_ACC_AXC[7..9]).
−
Increase the value
−
Decrease the value
−
•
Reduce the setting of $CURR_MON[ ] of an external axis to 10% of its old
value and move the axis manually with 100% HOV.
•
Trace the current over a complete production cycle and determine the
R.M.S. value of the selected external axis.
•
Reduce the setting of $VEL_AXIS_MA of an external axis to 10% of its old
value and move the axis manually with 100% HOV. Afterwards move the axis
under program control.
•
What happens if the DSE- or braking channel of an external axis is modified ?
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 229 of 240
Exercise 8: Definition and modification of machine data
•
Modify the speed controller gain ($G_VEL_PTP[ ], $I_VEL_PTP[ ]).
The dynamic performance of the speed controller increases as the
settings for the P component increase.
Increase these values by factors of 5 and 10 for all external axes!
Æ
Now move the external axes using the jog keys and make a note of
your observations (nominal speed / actual speed).
The value set for the I component influences the transient response
of the axis to the nominal speed.
Reduce these values to 5 and 10 for all external axes!
Æ
Now move the external axes using the jog keys and make a note of
your observations (nominal speed / actual speed).
Page 230 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en
Exercise 8: Definition and modification of machine data
What you should now know:
1. What is the simple way of determining the number of resolver pole pairs of
an unknown motor?
………………………………………………………………………………………
………………………………………………………………………………………
2. What is the effect of an incorrect sign for the gear ratio?
………………………………………………………………………………………
………………………………………………………………………………………
3. The linear axis jolts during motion in jog mode. Which value must be
modified?
………………………………………………………………………………………
………………………………………………………………………………………
4. How many control loops does the drive control comprise?
………………………………………………………………………………………
………………………………………………………………………………………
5. Name the most important controller parameters that are actually set?
………………………………………………………………………………………
………………………………………………………………………………………
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 231 of 240
Exercise 9: Definition of transformation TFLA3
17. Exercise 9: Definition of transformation TFLA3
Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the
following activity:
• Create the transformation data for a robot or BASE kinematic system
Requirements:
0) Theoretical knowledge of the definition of a transformation chain.
Equipment required:
1) Robotic cell with external axes
Reading materials:
Standard documentation:
• External axes/linear units – chapter “Configuration (Machine Data)”
Training documentation:
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Machine data”
Page 232 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en
Exercise 9: Definition of transformation TFLA3
Task:
•
Define transformation $ET2_TFLA3 for the linear unit in your cell of the
external axis system.
•
Define transformation $ET2_TFLA3 for the linear unit in your cell
if the positive Y-axis of the WORLD coordination system points to the
operators desk
Note 1:
Following transformation $ET2_TA1KR, the positive Z axis points away from the
window.
Note 2:
Transformation $ET2_TFLA3 defines the position and orientation of the robot
relative to the flange center point (of the linear unit).
Following transformation $ET2_TFLA3, the positive X axis of the coordinate
system points in the direction defined by:
• the connector panel and
• the center of the fastening ring.
What you should now know:
1. In which order is the transformation defined?
………………………………………………………………………………………
………………………………………………………………………………………
2. What direction does the positive Z axis point in the case of rotational or
translational external axes after the transformation has been carried out?
………………………………………………………………………………………
………………………………………………………………………………………
3. What is entered in $ET1_TFLA3?
………………………………………………………………………………………
………………………………………………………………………………………
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 233 of 240
Exercise 10: Optimization of machine data
18. Exercise 10: Optimization of machine data
Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the
following activities:
• Determine optimal values for existing machine data using the oscilloscope
function
Requirements:
• Theoretical knowledge of machine data and the oscilloscope function.
Equipment required:
0) Robotic cell with external axes
Reading materials:
Standard documentation:
• External axes/linear units – chapter “Configuration (Machine Data)”
Training documentation:
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Machine data”
Page 234 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en
Exercise 10: Optimization of machine data
Task 1:
• Use a test program (curr_e1_english) for axis E1.
o Make sure that only axis E1 moves with 100% PTP velocity.
•
Configure the oscilloscope function (as shown in the example) for the
optimization of the controller settings.
•
Select a start-value for the optimization.
Controller settings can be adopted directly in the following way:
Monitor Æ Variable Æ Overview
•
Execute the test program in #AUT mode.
•
Analyze the oscillogram and optimize the settings.
Task 2:
• Use a test program (curr_e1_english) for axis E1.
o Make sure that only axis E1 moves with 100% PTP velocity.
•
Configure the oscilloscope function (as shown in the example) for the
optimization of the acceleration values.
•
Define the settings (as shown in table).
o Write-protected MADA can only be modified by editing
$MACHINE.DAT.
•
Execute the program in #AUT mode.
•
Analyze the oscillogram and optimize the settings.
o Repeat the optimization process until the current pulses just below the
maximum value
- during acceleration and
- during path-maintaining E-Stop.
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 235 of 240
Exercise 10: Optimization of machine data
Machine data optimization form
Software
4.1.6
Guide
values
$RAISE_TIME[7]
$RED_ACC_EMX[7]
(Acceleration time to
rated speed)
(Path-maintaining braking
in case of E-Stop)
$DECEL_MB[7]
(Dynamic braking)
Value ↑ Æ Current ↓
Value ↑ Æ Current ↓
$RAISE_TIME[7] x100
= _________________
$RED_ACC_EMX[7
Line: 1105
500
Line: 1219
100
Line: 1326
500
2
3
4
What you should now know:
1. Which machine data can be optimized using the oscilloscope function?
………………………………………………………………………………………
………………………………………………………………………………………
2. How is the r.m.s. value determined using the oscilloscope function?
………………………………………………………………………………………
………………………………………………………………………………………
3. What does an optimal setting of the acceleration values look like?
………………………………………………………………………………………
………………………………………………………………………………………
4. What does an optimal setting of the controllers look like?
………………………………………………………………………………………
………………………………………………………………………………………
Page 236 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en
Exercise 11: Loading the MADA supplied for a DKP 400 and a KL250
19. Exercise 11: Loading the MADA supplied for a DKP
400 and a KL250
Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the
following activities:
• Handle and modify machine data
•
Work with the axis configurator
•
Adapt the data provided for a DKP 400 and load them into the controller
•
Adapt the data provided for a
KL 250 and load them into the controller
Requirements:
• Theoretical knowledge of machine data and rapid modification thereof.
Equipment required:
• Robotic cell with external axes
Reading materials:
Standard documentation:
• External axes/linear units – chapter “Configuration (Machine Data)”
Training documentation:
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Machine data – Loading user-created file fragments”
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 237 of 240
Exercise 11: Loading the MADA supplied for a DKP 400 and a KL250
Task:
Description
On delivery of a DKP 400 two-axis positioner, you receive a floppy disk with the
following contents:
− $MACHINE.DAT, which only contains the data for axes 7 and 8 and the
kinematic system
− two servo files for the corresponding motors on the DKP 400
On delivery of a linear unit KL250, you receive a floppy disk with the following
contents:
− $MACHINE.DAT, which only contains the data for axes 7 and the
kinematic system
− one servo file for the corresponding motor on the KL250
Task
• Load the data from the disks into the controller.
Note:
Your controller currently only contains the machine data for a KR 16.
What you should now know:
1. What should be taken into account when loading specified machine data?
………………………………………………………………………………………
………………………………………………………………………………………
2. What is the best way of extending existing robot machine data to cover
additional axes?
………………………………………………………………………………………
………………………………………………………………………………………
Page 238 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en
Exercise 12: Two different offsets on a DKP 400
20. Exercise 12: Two different offsets on a DKP 400
Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the
following activities:
• Handle and modify machine data
•
Work with the axis configurator
Requirements:
• Theoretical knowledge of machine data
Equipment required:
1) Robotic cell with external axes
Reading materials:
Standard documentation:
• External axes/linear units – chapter “Configuration (Machine Data)”
Training documentation:
• Workbook “Configuration & Programming of External Axes” Release 5.x –
chapter “Machine data”
© KUKA Roboter GmbH 2010 / EA KR C2 V5.x 01.10.03 en
Page 239 of 240
Exercise 12: Two different offsets on a DKP 400
Task:
• Define two different offsets on the DKP, which can be programmed with
different names.
Note 1:
Blue BASE = first offset
Red BASE = second offset
Note 2:
It must be clear in the program to which “Base” the motion blocks refers.
RED BASE
BLUE BASE
What you should now know:
1. How many offsets can be calibrated for a kinematic system?
………………………………………………………………………………………
………………………………………………………………………………………
2. What must be done if a second offset is required?
………………………………………………………………………………………
………………………………………………………………………………………
Page 240 of 240
© KUKA Roboter GmbH 2005 / EA KR C2 V5.x 11.05.02 en