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KUKA OPERATION MANUAL
WITH INTELLIGENTLASER SEAM TRACKING SYSTEM V1.0
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PREFACE
Copyright Notice
The information contained within this document is the proprietary property of Intelligentlaser
Co., Ltd. and may not be copied, reproduced or transmitted to other parties without the
expressed written authorization of Intelligentlaser Co., Ltd.
Reading Notice

Please read this manual carefully and use it properly.

Please keep it in the right place so that the operators can read it in time.

Please pass this manual to the new operators and instruct them to read this instruction
before moving, transferring or selling this system.

Please ask the trained personnel or appointed operators by the customers to operate,
install, maintain and repair this equipment once needed.

Please contact with our engineers at once there is any confusion.
Safety Notice for Laser

The debugging and maintenance must be operated by qualified personnel.

Laser safety class: Class 3B.

Caution: Avoid direct laser radiation.
Safety Suggestion

To avoid the eye damage, please observe the following suggestion strictly once the alarm
light of the sensor is on:

Do not look directly into the laser aperture while the laser system is working.

Do not look into the laser beam for a long time without protective measures.
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Sensor Installation Instruction

Please fix the sensor tightly. Improper installation would cause malfunction or offset
during operation. Please contact with the professionals when deviations about accuracy
occur due to sensor collision or there is damage possibility.

Users have no right to disassemble the relevant components of the sensor or host control
unit. Please contact with the us if there is any problem.

Please use the goggles if operators have to work in the condition with the laser on.
Safety Instruction for Robots
General Notice

In case the bad effects on robots or the other equipment, also in order not to injure the
operators, please Do Not operate the robot in the following conditions:

Environment of flammable or explosive.

Environment with a lot of radiation.

Environment of high humidity or in the water.

Use robot as step stone to deliver people or animals or to jump on robots.

Operators should wear the following safety tools when operating:

Clothes that suitable for operation

Safety shoes

Helmet
Operating Notice

Make sure there is no one in the safety fence when operating the robot. Meantime, please
check the potential hazards. You can ONLY operate when all the potential hazards are
cleared.

Please touch the display and teaching pendant without gloves in case of the deviations.

Please save the data at times in case of the loss of data accidentally. The information of
the programme and system variable number can be saved in the memory cards or floppy
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drives.
Programming Notice

Please keep the following things in mind if have to working inside the fences:

Check and make sure there is no danger before go inside the fences.

Make sure that E. STOP Button is at hand.

Use the robot in low speed.

Operate the robot in a clear mind in case not put the other operators in a danger condition
when there’s some commands or motions relate to peripheral equipment.

The programming operator should be trained in related company properly.
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Content
1. Preparation ................................................................................................................. 1
1.1 Connection ....................................................................................................... 1
1.2 Laser Sensor Installation ..................................................................................3
1.3 Sensor Position Adjustment ............................................................................. 4
1.4 Import the Configuration Files to Robot ..........................................................5
1.4.1 Enter Expert Mode ................................................................................5
1.4.2 Check Robot System .............................................................................6
1.4.3 Check the Software package .................................................................7
1.4.4 Backup Robot System ...........................................................................9
1.4.5 Import Finding Configuration Files ....................................................10
1.4.6 Load Configure File: IL_FINDING ................................................... 15
1.4.7 Modify IP address for Robot ...............................................................17
1.4.8 Configure Tracking Function ..............................................................19
2. Tool Calibration ....................................................................................................... 29
2.1 Calibrate tool data ..........................................................................................29
3. Sensor Calibration ....................................................................................................34
3.1 Calibration Program .......................................................................................34
3.2 Calibrate .........................................................................................................36
4. Finding Function ......................................................................................................40
4.1 Principle of Finding ....................................................................................... 40
4.1.1 Introduction for Sensor Correction. Shown as picture 4-1. ................ 40
4.1.2 Introduction for Sensor Finding Method. Shown as picture 4-2. ....... 40
4.2 Sample Program .............................................................................................41
4.3 Explanation for the Code ............................................................................... 43
5. Tracking Function .................................................................................................... 45
Appendix 1 ...................................................................................................................46
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1. Preparation
1.1 Connection
Picture 1-1 refers to the samples of IL-HOST03 for host control unit;
IL-HSP-150SD02 for sensor:
A. Using the FUNCTION & LAN cable to connect the host control unit with the
sensor.
B. Using the cable to connect the robot control cabinet with the host control unit.
C. Connect the host control unit with power adapter to a stable power supply
( available voltage range: 100V~240V, Hertz: 50-60 Hz).
D. Connect the mouse and keyboard to USB.
E. Connect the air-cooling system of the sensor. Connect the FRL with the air
compressor; connect the vent tube with FRL and the sensor. Adjust the air
pressure to 100kPa. (Note: keep the air dry and clean).
F.
The cabinet requires separate grounding.
G. The temperature of the sensor should be controlled within 5--40 degree.
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Picture 1-1
Note: a. host control unit b.laser sensor c. FUNCTION cable d. LAN cable e. cable f. power adapter g.
mouse&keyboard h.monitor* i. robot control cabinet j. vent tube* k. FRL* l. air compressor*
*optional
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1.2 Laser Sensor Installation
First, adjust the torch posture to the welding position according to its welding
requirements. Second, adjust the angle of the sensor (5~15 degree with the workpiece).
The distance between the beam and the TCP is around 35--60 mm. Refer to the
Picture 1-2.
Picture 1-2
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1.3 Sensor Position Adjustment
A. Adjust the torch, make sure the torch is in the right position and posture.
B. Turn the beam ON by clicking the button from CUTEWELDER.
C. Adjust the sensor position. The TP (Target point) in the field of view image should
be in the center when the robot is in the right posture. Picture 1-3 shows the correct
profile image in the graphic display.
Picture 1-3
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1.4 Import the Configuration Files to Robot
1.4.1 Enter Expert Mode
A. Menu\configuration\user group\expert (password:kuka)\log on. Refer to the
Pictures 1-4, 1-5.
Picture 1-4
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Picture 1-5
1.4.2 Check Robot System
A. Use system 8.6 for example, click Setting\Help\Info, the kernel system version
should above 8.6. Refer to pictures 1-6, 1-7.
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Picture 1-6
Picture 1-7
1.4.3 Check the Software package
A. Setting\Start-up\Additional software, check if installed EthernetKRL, Usertech,
SeamTechTracking, RobotSensorinterface package. Refer to pictures 1-8, 1-9.
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Picture 1-8
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Picture 1-9
1.4.4 Backup Robot System
A. Insert the USB to the cabinet.
B. Click File\Restore\USB (Cabinet)\All, select “Yes”. Refer to Pictures 1-10, 1-11.
C. Wait for the remind “ Archiving to USB cabinet successful”.
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Picture 1-10
Picture 1-11
1.4.5 Import Finding Configuration Files
A. Copy xmltransmit from USB file to
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C:\KRC\ROBOTER\config\User\Common\EthernetKRL. Refer to pictures 1-12, 1-13.
Picture 1-12
Picture 1-13
B. Copy IL_Base.kfdx, IL_Center.kfdx, IL_Seamfinding.kfdx from USB file to
C:\KRC\TP\config\USERTECH\TEMPLATE. Refer to picture 1-14.
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Picture 1-14
C. Copy and open ILFIND.TXT from USB file to KRC\R1\SYSTEM. Then copy
il_find command to R1\System\$config\USER GLOBALS. Refer to pictures 1-15, 1-16,
1-17.
Picture 1-15
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Picture 1-16
Picture 1-17
Copy
file
to
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SmartHMI.exe.Usertech.InlineForms
from
USB
C:\KRC\TP\UserTech\SmartHMI. Refer to pictures 1-18, 1-19.
Picture 1-18
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Picture 1-19
1.4.6 Load Configure File: IL_FINDING
A. Create a new file, name it ILConfig from R1\System. Refer to picture 1-20.
B. Copy programs calcrosspointdr commdr and mathlib from USB file to ILConfig
file. Refer to pictures 1-21, 1-22.
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Picture 1-20
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Picture 1-21
Picture 1-22
1.4.7 Modify IP address for Robot
A. Click Setting\Start-up\NetworkConfiguration, Modify IP address: 192.168.2.100,
subnet mask: 255.255.255.0. Save and Confirm. Refer to pictures 1-23, 1-24. (If the
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robot has already configured other communication IP and cannot be changed, please
contact with us.)
Picture 1-23
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Picture 1-24
1.4.8 Configure Tracking Function
A. Set the laptop IP (loaded with WorkVisual) and robot IP in the same network
segment. Refer to picture 1-25.
Picture 1-25
B. De-zip file kop from SeamTechTracking package. Refer to picture 1-26.
Picture 1-26
C. Open WorkVisual software, go to Menu\Extra\Option Package Management.
Create a new profile, and activate it. Then add the software robot needed to the new
profile. Refer to pictures 1-27, 1-28, 1-29.
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Picture 1-27
Picture 1-28
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Picture 1-29
D. Open Working Project in WorkVisual software, click Browse and open the needed
project, double click the WorkingProject. Refer to pictures 1-30, 1-31.
Picture 1-30
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Picture 1-31
E. Find file Intelligent Laser.afc, the steps are shown below:
 De-zip
 Click File
 Cataloghandling (picture 1-32)
 Click
from the left bottom
 Click SeamTechTracking \SmartHMI\ILT\Intelligent Laser.afc (picture 1-33)
 Add Intelligent Laser.afc to Projectcatalogs (picture 1-34)
 Close
Picture 1-32
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Picture 1-33
Picture 1-34
F. Right click
, Add\Intelligent laser. Refer to pictures 1-35,
1-36.
Picture 1-35
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Picture 1-36
G. Double click Intelligent Laser, then click General, Modify the IP address:
192.168.2.50, Port Number: 5020. Click Extras\Deploy, set the Permission of Robot
to Expert or above, click YES and Save. Refer to pictures 1-37, 1-38, 1-39, 1-40.
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Picture 1-37
Picture 1-38
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Picture 1-37
Picture 1-38
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Picture 1-39
Picture 1-40
H. Re-start the robot system. Click Settings\Shut down\Reload files\Reboot control
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PC. Refer to picture 1-41.
Picture 1-41
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2. Tool Calibration
2.1 Calibrate tool data
A. Click Settings\Start-up\Tool/Base management. Shown as picture 2-1.
Picture 2-1
B. Choose the Tool number needed to be calibrated. Click Edit. Shown as picture 2-2.
Picture 2-2
C. Set a name for the tool. Shown as picture 2-3.
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Picture 2-3
D. Click the Calibrate from Transformation. (Choose XYZ 4-point for example.)
Shown as picture 2-4.
Picture 2-4
E. Keep the torch in the same position and then change its postures as pictures 1--4.
Click Touch-up to record data, then save. The mistakes should be within 0.5mm.
Refer to pictures 2-5, 2-6, 2-7.
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Picture 2-5
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Picture 2-6
Picture 2-7
F. Input Actual Mass data to Load Data. Then Save. Shown as picture 2-8.
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Picture 2-8
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3. Sensor Calibration
3.1 Calibration Program
A. Select R1\Program file\STT file\stt_calibration program.
B. Program explanation, refer to picture 3-1.

31st line, P0--Safe Point, can be any point.

38th line, P1--Robot position, where TCP can touch the mark point on the
workpiece.

(*Mark point is a point you should mark it before calibration)
44th line, P2--beam on the mark point. Meanwhile, the red cross on the screen
should be on the top of the center.

50th line, P3--beam on the mark point. Meanwhile, the red cross on the screen
should be in the center.

56th line, P4--beam on the mark point. Meanwhile, the red cross on the screen
should be on the left bottom of the center.

62th line, P5--beam on the mark point. Meanwhile, the red cross on the screen
should be on the right bottom of the center.

68th line, P6 is the point for testing accuracy for sensor calibration. (Control the
torch accuracy with 0.5mm). Beam should be on the mark point. Meanwhile, red
cross should be within the screen.
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3.2 Calibrate
A. Prepare a workpiece. (Recommend to use a workpiece with a Lap Joint while
calibrating)
B. Select a mark point on the workpiece.
C. Double click
, run the program to the line 31st (Make sure to keep the robot
still). Then teach the point from P0 to P6. Shown in the pictures 3-2--3-6.
D. Run the program till it ends. The torch will move to the mark point if calibrated
correctly. TCP needs to stop at the mark point within 0.5mm. Shown in the picture
3-7.
Picture 3-2
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Picture 3-3 UP
Picture 3-4 CENTER
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Picture 3-5 LEFT
Picture 3-6 RIGHT
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Picture 3-7 TEST POSITION
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4. Finding Function
4.1 Principle of Finding
4.1.1 Introduction for Sensor Correction. Shown as picture 4-1.
Picture 4-1
YS and ZS is Y and Z direction of the sensor coordinates. The sensor can test the
deviation of the TP on YS and ZS direction.
4.1.2 Introduction for Sensor Finding Method. Shown as picture 4-2.
Picture 4-1
Prb1 and Prb2 are two points (Arc on & Arc off) used for teaching. SeamID1 and
SeamID2 are positions for testing beam. Prb1 and Prb2 can be corrected by SeamID1
and SeamID2, which are P’rb1 and P’rb2.
T
Y
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4.2 Sample Program
Explanation for the program

3rd line: P0 start point.

4th line: robot arriving at P1 position.

5th line: turn on the beam, record current position as CD1.

6th line: robot arriving at P2 position.

7th line: turn on the beam, record current position as CD2.

8th line: robot arriving at P3 position.

9th line: turn on the beam, record current position as CD3.

10th line: base correction, CD2 is used to correct the X and Z directions of the
starting point of welding, and CD1 is used to correct the Y direction of the
starting point of welding

11th line: arc on point.

12th line: clear base deviation.

13th line: base correction, CD3 is used to correct the X and Z directions of the
starting point of welding, and CD1 is used to correct the Y direction of the
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starting point of welding

14th line: arc off position.

15th line: clear deviation.

16th line: safe point.
.
Shown as picture 4-3.
Picture 4-3
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4.3 Explanation for the Code
A. The code above is used for turning on the beam, and name the seam/joint info. that
identified by current sensor with CD number, which is convenient to use the deviation
value for base correction.
The two parameters (shown in the picture below) from the code can be modified:
Shown as picture 4-4.
Picture 4-4
Seam Type: JOB number in CUTEWELDER.
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Cal Mode: during Finding mode: calibrating means recording mode, calibrated
means correction mode. Shown as picture 4-5.
Picture 4-5
B. This code is for base correction. The three parameters of
“XDirectCorr/YDirectCorr/ZDirectCorr/” are for the deviations of X/Y/Z direction
of each CD. The picture above shows the deviation of X direction of CD3,
deviation of Y direction of CD1 and deviation of Z direction of CD3 to correct
base.
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5. Tracking Function
Please check KUKA KST_SeamTech_Tracking for more information.
Explanation for the Code:

3rd line: any point.

4th line: initialization for tracking.

5th line: a transitional position. (* This code must be in LINE action).

6th line: seam tracking on.

7th line: start point when beam arrives on the seam/joint.

8th line: start point for welding.

9th line: seam tracking off.

10th line: end point for welding.

12th line: cancel seam tracking.
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Appendix 1
Error Instruction
Error
Instruction
1. Re-start the program
Recieve Sensor data failure!
2. Check if communication overtime
3. Contact us
1. Check if turn on the software
2. Check if communication right
Laser on failure
3. Check communication IP address of host control
unit and robot
1. Check if communication connected
Laser off failure
2. Contact us
Recieve data failure and Switch
1. Check if communication connected
JOB. NO failure
2. Contact us
Recieve data failure and Sensor
1. Check if communication connected
test failure
2. Contact us
1. Check if the deviation of workpiece over 15mm
Sensor data test failure
2. Set the maximum deviation value larger
3. Check if the profile image correct
Correction
data
of
some
1. Check if the deviation of workpiece over 15mm
direction is not accurate OR
1. Set the maximum deviation value larger
TOO MUCH
2. Check if the profile image correct
Robot data is not accurate,
please teach and record again
Re-teach program and record
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