Documente Academic
Documente Profesional
Documente Cultură
Issued: 30.09.2010
Copyright 2010
KUKA Roboter GmbH
Zugspitzstrae 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
2 / 65
Publication:
Bookstructure:
Label:
Contents
Contents
1
Introduction ..................................................................................................
1.1
1.2
1.3
1.4
Trademarks ................................................................................................................
1.5
2.1
2.2
10
Safety ............................................................................................................
13
Installation ...................................................................................................
15
4.1
15
4.2
15
4.3
16
4.4
16
4.5
17
4.6
17
Operation ......................................................................................................
19
5.1
Menus ........................................................................................................................
19
5.2
19
Configuration ...............................................................................................
23
6.1
23
6.1.1
23
6.1.2
24
6.1.3
24
6.1.4
24
6.1.5
24
25
6.2.1
25
6.2.2
26
6.2.3
26
6.2.3.1
26
6.2.3.2
28
6.2.3.3
29
6.2.3.4
30
6.2.3.5
31
33
33
6.2
6.3
6.3.1
6.3.2
33
6.4
34
Programming ...............................................................................................
37
7.1
37
7.2
38
3 / 65
7.3
39
7.4
39
39
7.4.1
7.4.2
40
7.4.3
41
7.4.4
42
43
7.5.1
43
7.5.2
44
7.5.3
44
7.5.4
44
7.5.5
44
7.5.6
45
7.5.7
45
7.5.8
45
7.5
4 / 65
7.5.8.1
46
7.5.8.2
46
7.5.9
Actions ..................................................................................................................
47
7.5.9.1
47
7.5.9.2
48
7.6
48
7.7
48
49
8.1
49
8.1.1
49
8.1.2
50
8.1.3
51
8.1.4
52
8.1.5
53
8.1.6
53
55
9.1
55
9.2
55
Index .............................................................................................................
63
1 Introduction
Introduction
1.1
Target group
This documentation is aimed at users with the following knowledge and skills:
Advanced knowledge of other peripheral controller systems (e.g. weld current controller)
For optimal use of our products, we recommend that our customers take part
in a course of training at KUKA College. Information about the training program can be found at www.kuka.com or can be obtained directly from our
subsidiaries.
1.2
1.3
Safety
Notes
Notes marked with this pictogram contain tips to make your work easier or references to further information.
Tips to make your work easier or references to further information.
5 / 65
1.4
Trademarks
Windows is a trademark of Microsoft Corporation.
WordPad is a trademark of Microsoft Corporation.
1.5
Terms used
Term
Description
Action
Asynchronous weld
seam
Component program
Seam program
Remote device
On-the-fly activation
and deactivation of the
gas
Local device
Weld error
Service routine
Synchronous weld
seam
Without welding
6 / 65
1 Introduction
Term
Description
Dry run
Ignition error
7 / 65
8 / 65
2 Product description
Product description
2.1
Functions
Program Generator
The welding programs can be created using the standard procedure for
general robot programs, or alternatively using the Program Generator.
The Program Generator automatically generates a logical folder structure.
The programs contain, by default, the most important instructions and predefined subprograms for service routines and actions.
Areas of application
Arc welding
9 / 65
Communication
The robot controller communicates with the weld controller via a field bus. The
robot controllers communicate with one another via a real-time capable network connection.
Further information about the field buses can be found in the corresponding
KUKA documentation.
Additional
software
KUKA.ToolCorrManual
This software enables the TCP to be checked after a collision. If necessary, the TCP can be corrected. This means that the tool does not need to
be recalibrated.
Installation: KUKA.ToolCorrManual is automatically installed together with
CR.ArcTech Digital. It does not need to be installed separately.
KUKA.WeaveTech
This software enables mechanical weaving to be carried out.
Installation: To enable mechanical weaving, KUKA.WeaveTech must be
installed.
2.2
10 / 65
2 Product description
A component program contains the motions to the weld seams and between
the weld seams. It contains the calls for the individual seam programs. A seam
program contains the weld instructions for 1 seam.
Fig. 2-3: Program folder with component program and seam programs
The component program and the seam programs are created by the user in a
single operation. During this procedure, the user defines how many seam programs are to be created.
In the component and seam programs, service routines and user-defined actions can be taught for use in the event of an error.
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3 Safety
Safety
This documentation contains safety instructions which refer specifically to the
software described here. The fundamental safety information for the industrial
robot can be found in the Safety chapter of the Operating and Programming
Instructions for System Integrators or the Operating and Programming Instructions for End Users.
Warning!
The Safety chapter in the operating and programming instructions must be
observed. Death to persons, severe physical injuries or considerable damage to property may otherwise result.
13 / 65
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4 Installation
Installation
It is advisable to archive all relevant data before updating or uninstalling a
software package.
4.1
System requirements
Hardware
Software
KR C2 edition2005
For welding in job mode: Welding controllers with job number control and
relevant welding accessories
Number
Interrupts
8 10
Timers
14 17
Cycflags
240 243
Recommended
robots
Compatibility
KUKA.ArcTech Analog
KUKA.ArcTech Digital
If KUKA.WeaveTech and KUKA.SeamTech are installed on the same robot controller, there may be conflicts in the assignment of the function generators. If this occurs, please contact KUKA Roboter GmbH.
(>>> 9 "KUKA Service" Page 55)
4.2
Precondition
Procedure
1. Select the menu sequence Setup > Install Additional Software and
press the softkey New SW.
2. If the entry CR.ArcTechDigital is not displayed, press the Refresh softkey.
3. Select CR.ArcTechDigital and press the Install softkey. Answer the request for confirmation with Yes.
4. Confirm the reboot prompt with OK and reboot the robot controller.
5. Select a power source and confirm with Next. (Or abort with Cancel. In
this case, CR.ArcTech Digital Power Sources is not installed.)
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6. The following selection is only displayed if various models exist for the selected power source:
Select a power source model and confirm with Next. (Or abort with Cancel. In this case, CR.ArcTech Digital Power Sources is not installed.)
If CR.ArcTech Digital Power Sources has not been installed, it can be installed separately later.
KUKA.ToolCorrManual is automatically installed together with
CR.ArcTech Digital.
LOG file
4.3
Description
Precondition
To install or update CR.ArcTech Digital Power Sources separately, the directory AddOn\CrArcTechPowersources on the CD must be accessed.
Preparation
To do so, select the menu sequence Setup > Install Additional Software. Configure the installation directory.
Information about configuring the installation directory is contained in the operating and programming instructions for the KUKA System Software (KSS).
Procedure
1. Select the menu sequence Setup > Install Additional Software and
press the softkey New SW.
2. If the entry CR.ArcTechPowersources is not displayed, press the Refresh softkey.
3. Select CR.ArcTechPowersources and press the Install softkey. Answer
the request for confirmation with Yes.
4. Select a power source and confirm with Next.
5. The following selection is only displayed if various models exist for the selected power source:
Select a power source model and confirm with Next.
6. Confirm the reboot prompt with OK and reboot the robot controller.
LOG file
4.4
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4 Installation
If CR.ArcTech Power Sources is uninstalled, the I/O ranges created in IOSYS.INI during installation are automatically deleted.
Example: If Profibus is used, the I/O ranges under [PBMASL] are deleted. If
DeviceNet is used, the I/O ranges under [DEVNET] are deleted.
(I/O ranges under [PBMASL], [DEVNET] etc., that are not from CR.ArcTech
Power Sources are not deleted.)
Expert user group
Precondition
Procedure
1. Select the menu sequence Setup > Install Additional Software. All installed additional programs are displayed.
2. Select the entry CRArcTechPowersources and press the Uninstall softkey.
3. Answer the request for confirmation with Yes. De-installation prepared is
displayed in the State column.
4. Reboot the robot controller. The uninstallation is completed.
A LOG file is created under C:\KRC\ROBOTER\LOG.
LOG file
4.5
Description
To uninstall the CR.ArcTech Digital technology package completely, the following components must be uninstalled:
App-Library
CRArcTechDigital
TechConfigPlugIn
ToolCorrManual
Only uninstall components if it has been ascertained that they are not being
used by another technology package!
Precondition
Procedure
CR.ArcTech Digital Power Sources has been uninstalled/has not been installed.
1. Select the menu sequence Setup > Install Additional Software. All installed additional programs are displayed.
2. Select the software component to be uninstalled and press the softkey Uninstall. Answer the request for confirmation with Yes.
De-installation prepared is displayed in the State column.
3. Repeat step 2 to prepare further software components for uninstallation.
4. Reboot the robot controller. The uninstallation is completed.
A LOG file is created under C:\KRC\ROBOTER\LOG.
LOG file
4.6
Description
The user can check which power source was most recently installed or uninstalled.
Procedure
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Entry
Meaning
KUKA.CR.ArcTech Powersources
[No., Build] installed
KUKA.CR.ArcTech Powersources
[No., Build] removed
No.
Power source
010101
010201
010301
020102
020202
5 Operation
Operation
5.1
Menus
The following menus and commands are specific to this technology package:
File
Standard programs
CR.ArcTech programs
Configuration
Statuskeys
CR.ArcTech
CR.ArcTech
Configuration
Technology
CR.ArcTech
Strike parameters
Welding
5.2
PTP
LIN
CIRC
Welding off
LIN
CIRC
Initializing
Special commands
Status keys
Procedure
Select the menu sequence Configure > Status keys > CR.ArcTech.
Description
The status keys only refer to the local device, not to the other devices in
the RoboTeam.
Description
Wire feed
Wire retract
No program is selected.
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State
Description
The power source is coupled to the robot. The control elements on the power source are disabled.
Pressing the status key decouples the power source.
The power source is decoupled from the robot. The control
elements on the power source can be operated.
Pressing the status key couples the power source.
A program is selected.
Welding has taken place, after which welding was deactivated using the
Welding status key.
State
Description
Dry run is deactivated: the robot moves at welding velocity.
Pressing the status key activates the dry run: the velocity is
increased to 0.15 m/s if it was previously lower than this.
Dry run is activated: the robot moves at 0.15 m/s (or welding velocity if this is higher).
Pressing the status key deactivates the dry run.
Only relevant if KUKA.WeaveTech is installed:
Dry run is deactivated: the robot moves at welding velocity.
Pressing the status key activates the dry run: the velocity is
increased to 0.15 m/s if it was previously lower than this.
Only relevant if KUKA.WeaveTech is installed:
Dry run is activated: the robot moves at 0.15 m/s (or welding velocity if this is higher). Weaving is deactivated.
Pressing the status key deactivates the dry run.
The dry run is executed from the advance run onward, i.e. for motions that
have not yet been planned.
Example: The advance run has a default value of 3 ($ADVANCE = 3). If a
seam consists of only 2 motions, the dry run will not be executed as the motions are already planned.
Status key:
Welding
Description
All conditions for welding are met (internal and external).
Pressing the status key deactivates welding.
The robot is on the weld path. Ignition was simulated with
ARC STRIKE OnFly and ARC.
The effect depends on the next weld command:
5 Operation
Description
The configuration parameter Allow process in T1 is not
active and operating mode T1 is selected.
One or more simulation events are active. Examples:
An axis is simulated.
Set_To_False = TRUE
Restore = At_Fwd
Welding has been deactivated via the status key. All other
conditions for welding are met.
Pressing the status key activates welding.
Welding has been deactivated via the status key.
The external enabling signal for the weld operation is not
set. (= Input weld enable - Extern is LOW.)
The external enabling signal for the weld operation is not
set. (= Input weld enable - Extern is LOW.)
By default, welding is disabled in every operating mode if
Input weld enable - Extern is LOW. Remedy:
Set the configuration parameter Input reaction to Automatic extern. Input weld enable - Extern then only
has an effect in AUT EXT mode.
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Description
The torch has had a collision. T1 mode must first be set
before the torch can be moved out of the collision zone.
The torch has had a collision.
Press the status key to move the torch a short distance.
If necessary, press the status key several times until the
torch is out of the collision zone.
The torch has had a collision. The robot can now be
moved.
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6 Configuration
Configuration
6.1
Configuration: General
6.1.1
Overview
Description
Select
The various screens are selected here. Also possible via the
Screen status key.
Configuration parameters
The configuration parameters vary according to the power source
used. Descriptions of the individual screens and parameters can
be found in the CR.ArcTech Digital Power Sources documentation (separate documentation for each power source).
Info bar
The info bar displays a description of the selected parameter. In
the user group Expert it additionally displays the variable name of
the parameter.
Status keys
Status key
Description
Toggles between the different screens in the Select window.
Toggles between the items on a given screen.
If an input or output is set, the LED icon next to the box is red (otherwise gray).
If an input or output is used more than once in the technology package, this is
indicated by an exclamation mark next to the box. All affected outputs or inputs
are displayed in the info line.
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6.1.2
Precondition
Procedure
Deselect the Submit interpreter and reselect it. (It is not enough to stop
and restart the Submit interpreter.)
The configuration parameters vary according to the power source used. Descriptions of the individual screens and parameters can be found in the
CR.ArcTech Digital Power Sources documentation (separate documentation for each power source).
6.1.3
Archiving a configuration
Expert user group
Precondition
Procedure
6.1.4
Loading a configuration
Precondition
Procedure
6.1.5
Description
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The names of the inputs and outputs in the configuration can be transferred to
the Digital I/O window. If the names are displayed here, this aids orientation
in the window.
6 Configuration
If the names are changed in the Digital I/O window, these changes cannot
be transferred back to the configuration.
Expert user group
Precondition
Procedure
General
Weld control
Other inputs
Other outputs
PLC Interface
Roboteam
6.2
6.2.1
Description
The parameters for ignition errors and weld errors are configured here.
It is possible to define whether a parameter is visible or not in the option windows for error strategies.
If a parameter is not visible in the option windows, the value defined here
in the configuration applies.
Overview
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Item
Description
List boxes: Click on the arrow. A list opens from which a value
can be selected.
Boxes with numeric values: Click in the box. The value can be
changed.
Note: Changes must be confirmed using the Enter key.
5
Softkeys
6.2.2
Softkey
Description
Expand All
Collapse All
Expand
Collapse
Save
Close
Precondition
Procedure
1. Select the menu sequence Configure > CR.ArcTech > Error handling
strategy.
The Error strategy settings window is opened.
2. Select the entry Strike error strategies or Weld error strategies and
press the Expand softkey.
The tree structure is opened.
3. Open the desired elements and change the values as required. Confirm
the changes by pressing the Enter key.
4. Press the Save softkey.
5. Press the Close softkey. The Error strategy settings window is closed.
Description
6.2.3
6.2.3.1
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6 Configuration
The tool direction must correspond to the direction in which the wire comes
out of the torch.
Parameter
Description
Error detection
Timeout
During this time, the robot controller waits for the input Arc established
from the weld controller. If this information is not available within this
time, the ignition process of the robot is deemed to have failed.
Roboteam
Ignore: If an ignition error occurs in another robot, the robot continues its own seam.
Strategy
(= Action)
Retracting torch: The TCP is moved 20 mm in the negative X direction of the TOOL coordinate system and then back to the path. The
robot does not stop during this motion.
The default value 20 mm can be changed in the file
CADA_ActionsAndServices.dat.
This parameter defines where the service routine should be started from
in the event of an ignition error.
Error position: The service routine is executed from the error position. The robot then returns to the error position.
Seam end position: The robot moves from the error position to the
end of the seam without welding (ARC OFF). The service routine is
executed from here. The robot then moves to the start of the seam
(first ARC instruction in the program).
Ackn: An acknowledgement message is generated. Acknowledgement possible via KCP and PLC.
Ackn KCP: An acknowledgement message is generated. Acknowledgement only possible via KCP.
27 / 65
Parameter
Description
Service routine
None: No service routine, the robot carries out ignition again immediately.
Next seam: No service routine. The current seam is ignored. The robot moves to the next seam and resumes the program.
Waiting endless: Endless loop. The user must deselect and reselect
the program.
Retracting torch: The TCP is moved 20 mm in the negative X direction of the TOOL coordinate system. The robot stops and then moves
back to the path.
The default value 20 mm can be changed in the file
CADA_ActionsAndServices.dat.
Part service routine 1: Service routine 01, programmed in the component program
Part service routine 2: Service routine 02, programmed in the component program
Number
6.2.3.2
Parameter
Description
Overlap distance
Ignore: If a weld error occurs in another robot, the robot continues its
own seam.
Consider: If a weld error occurs in another robot, the robot aborts its
own seam.
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6 Configuration
Parameter
Description
Movement
This parameter defines where the service routine should be started from
in the event of a weld error.
Error position: The service routine is executed from the error position. The robot then returns to the error position.
Seam end position: The robot moves from the error position to the
end of the seam without welding (ARC OFF). The service routine is
executed from here. The robot then moves to the start of the seam
(first ARC instruction in the program). From the start of the seam, the
robot moves without welding as far as the position defined by the parameter Overlap distance.
Message
Service routine
Ackn: An acknowledgement message is generated. Acknowledgement possible via KCP and PLC.
Ackn KCP: An acknowledgement message is generated. Acknowledgement only possible via KCP.
None: No service routine, the robot carries out ignition again immediately.
Next seam: No service routine. The current seam is ignored. The robot moves to the next seam and resumes the program.
Waiting endless: Endless loop. The user must deselect and reselect
the program.
Retracting torch: The TCP is moved 20 mm in the negative X direction of the TOOL coordinate system. The robot stops and then moves
back to the path.
The default value 20 mm can be changed in the file
CADA_ActionsAndServices.dat.
Part service routine 1: Service routine 01, programmed in the component program
Part service routine 2: Service routine 02, programmed in the component program
Number
6.2.3.3
For all robots in the RoboTeam, the parameter Movement under Strike
error strategy 2 must have the same configuration.
(Either all on Error position or all on Seam end position.)
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For all robots in the RoboTeam, the parameter Movement under Weld error strategy must have the same configuration.
(Either all on Error position or all on Seam end position.)
6.2.3.4
If the parameter Movement is set to Seam end position, then the parameter RoboTeam may be set to different values for the individual robots.
Some actions and service routines can only be used in programs generated with the Program Generator. These are specified in the description of
the configuration parameters.
(>>> 6.2.3.1 "Configuration parameters: Arc-strike error strategies"
Page 26)
(>>> 6.2.3.2 "Configuration parameters: Weld error handling strategy"
Page 28)
Movement
Error position
None
Next seam
Waiting endless
Only possible in the following cases:
Retracting torch
Only possible if the configuration parameter
Number of connected robots within robo
team = 1
All
With ignition errors, the actions / service routines the robot controller can execute depends additionally on where the ignition error occurs. (Actions are configured via the parameter Strategy.)
Ignition error at the start of the seam:
Possible values for
Strategy
Error position
All
All
None
Wire
Movement
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All
6 Configuration
Error position
None
Wire
Retracting torch
Only possible if
the configuration
parameter Number of connected
robots within robo
team = 1
Seam end
position
None
Wire
If you wish to configure different actions / service routines for ignition errors
on the path from those configured for the start of the seam, insert a further
ARC STRIKE instruction in the program after the first ARC instruction and set
the parameters there as desired.
6.2.3.5
Overlap distance
Description
If a weld error occurs, the robot executes the defined service routine. When it
reaches the path again via the service routine, the robot moves to the position
defined by the parameter Overlap distance. There the robot stops and carries
out ignition again.
The parameter is defined in the configuration of the weld error strategy.
The parameter Overlap distance can only be used in programs generated
with the Program Generator.
Overlap distance
0 mm
< 0 mm
A negative value defines a position after the error position. This is where
the robot carries out ignition.
(negative value)
The distance from the error position to the defined position remains
unwelded, i.e. a gap is left.
> 0 mm
(positive value)
Movement =
Seam end
position
Robots behavior when the parameter Movement is set to Seam end position:
31 / 65
The robot moves from the error position to the end of the seam without
welding (ARC OFF).
The robot executes the service routine and moves back to the start of
the seam (first ARC instruction in the program).
From the start of the seam, the robot moves without welding as far as
the defined position.
Here the robot carries out ignition again and welds to the end of the
path.
Not every service routine allows both negative and positive values to be executed. If Movement = Seam end position:
Overlap distance
< 0 mm
All except:
(negative value)
Next seam
Waiting endless
> 0 mm
All except:
(positive value)
None
Next seam
Waiting endless
Retracting torch
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6 Configuration
Movement = Error
position
The robot executes the service routine and moves back to the error
position.
From the error position, the robot moves without welding as far as the
defined position.
Here the robot carries out ignition again and welds to the end of the
path.
< 0 mm
None
(negative value)
Retracting torch
6.3
6.3.1
Description
The velocity applies to both automatic and manual dry runs. The default is
0.15 m/s. This is also the maximum value. If a higher value is defined, it is limited internally to 0.15 m/s.
The currently configured velocity is displayed in the configuration.
Procedure
The dry run velocity can be changed using one of the following functions. The
function must be inserted into the program. In place of Velocity, the desired velocity is set in m/s.
ROP_Init(,Velocity,)
ROP_Set_DryRun_Velocity(Velocity)
In both of the following examples, the dry run velocity is set to 0.1 m/s:
ROP_init(,0.1,)
ROP_Set_DryRun_Velocity(0.1)
6.3.2
Description
The automatic dry run function is deactivated by default. When activated, a dry
run is automatically executed after weld errors at the dry run velocity (if this is
higher than the weld velocity). This comprises the following motions:
1. From the error position to the end of the seam
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2. From the start of the seam to the beginning of the section where the arc is
struck again.
Precondition
Procedure
A service routine and Seam end position are selected as the weld error
strategy.
It is possible to prevent the increased velocity for the motion from the error position to the end of the seam. The automatic dry run then applies only to the
following motion:
From the start of the seam to the beginning of the section where the arc is
struck again.
For this, the call in the program BAS.SRC (in the folder R1\System) must be
modified as follows:
VEL_VALUE=ROP_Give_DryRun_Velocity(VEL_VALUE,FALSE)
6.4
Configuration of VelUnitsConfig.xml
Description
In the file VelUnitsConfig.xml, the units are selected which are to be available
for selection for the velocity in the inline forms ARC und ARC OFF. It is also
possible to create new units.
Precondition
Procedure
2. For each unit, define whether it is to be displayed in the inline form using
the parameter IlfMode.
3. To create a new unit: Copy an existing line, insert it after the last line and
set the parameters as required.
4. Save and close the file.
5. On the KUKA.HMI, select the menu sequence Configure > Tools > Reinit
> BOF Reinitialization.
VelUnitsConfig.x
ml
34 / 65
6 Configuration
Parameter
Description
Unit
FactorSI
IlfMode
35 / 65
36 / 65
7 Programming
Programming
7.1
Description
The weld operation will be explained using the example of a workpiece with 2
weld seams.
Ignition position
Further points are possible before the ignition position, after the end crater position and between these two points.
The following weld instructions are required for a weld seam:
ARC INIT
ARC STRIKE
ARC
ARC OFF
Description
Instruction
Seam 1 (1 motion)
LIN
ARC (LIN)
ARC (LIN)
ARC (CIRC)
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Item
Description
Instruction
LIN
Description
Allocation
P1,
P2
Component program
P3
Seam program 1
P4
Seam program 1
P5
Seam program 1
P6
Seam program 1
P7,
P8
Component program
P9
Seam program 2
P10
Seam program 2
P11
Seam program 2
P12
Seam program 2
P13
Seam program 2
P14
Seam program 2
P15,
P16
Component program
7.2
Always teach a point above the ignition position. This point makes it easier to move correctly to the ignition position.
Always teach a point above the end crater position. This point makes it
easier to lift off the torch correctly from the end crater position.
Standard
program
Advantage:
Disadvantages:
Generator
program
38 / 65
Advantages:
7 Programming
The programs contain, by default, the most important instructions and predefined subprograms for service routines and actions.
Disadvantages:
Procedure
Select the menu sequence File > New > Standard programs.
7.3
(>>> 7.5 "Creating programs with the Program Generator" Page 43)
Line
Description
3 10
Seam 1
13 16
Seam 2
7.4
7.4.1
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1 DEF MyProgram1( )
2 INI
3 PTP HOME Vel= 100 % DEFAULT
4 PTP P1 Vel= 100 % PDAT1 Tool[1] Base[0]
5
6 MyProgram1_Seam01()
7 MyProgram1_Seam02()
8
9
10 PTP P1000 Vel= 100 % PDAT1 Tool[1] Base[0]
11 PTP HOME Vel= 100 % DEFAULT
12 END
-----------------------------------------------------------------13 ...
Line
Description
Here the motions from the HOME position to the first seam are
inserted.
P1 is an example point and can be retaught or deleted.
6, 7
10
Here the motions from the last seam to the HOME position are
inserted.
P1000 is an example point and can be retaught or deleted.
13
7.4.2
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7 Programming
Recommendation:
Always teach a point above the ignition position. This point makes it easier to move correctly to the ignition position.
Always teach a point above the end crater position. This point makes it
easier to lift off the torch correctly from the end crater position.
Line
Description
By default, the INI line contains the instruction ARC INIT. ARC
INIT does not need to be programmed.
From this line, it is possible to jump to subprograms for the service routines and actions. Only possible if set in the configuration.
(>>> 7.5.8.1 "Teaching a service routine" Page 46)
(>>> 7.5.9.1 "Teaching an action" Page 47)
Ignition.
ARC is present by default in every seam program. The parameters must be adapted to the current seam program.
9 11
13
End of seam.
ARC OFF is present by default in every seam program. The
parameters must be adapted to the current seam program.
7.4.3
15
From this line, it is possible to jump to subprograms for the service routines and actions. Only possible if set in the configuration.
16
Here motions can be inserted after the end crater position, e.g.
a point above the end crater position.
18
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17
...
-----------------------------------------------------------------18 Service strategy on seam - to teach open fold
19 DEF
ServiceStrategy(ConsiderCRErr:IN,Motion:IN,Service:IN,MsgType:IN,Tea
chModeSender:IN)
20 {H}
21 HALT for TeachMode on seam
22 {H}
23
CASE #SeamServiceRoutine01
24
-- insert motion from pos. on seam to maintenance pos. -25
26 KL_MsgSendNotify("SeamServiceRoutine01NotTeached","CAD")
27 LIN P1001 Vel=0.2 m/s CPDAT Tool[1] Base[0]
28
29
HALT ;** maintenance position reached
30
-- insert motion from maintenance pos. back to seam -31
32
33
CASE #SeamServiceRoutine02
34
35
-- insert motion from pos. on seam to maintenance pos. -36
37 KL_MsgSendNotify("SeamServiceRoutine02NotTeached","CAD")
38 LIN P1002 Vel=0.2 m/s CPDAT Tool[1] Base[0]
39
40
HALT ;** maintenance position reached
41
-- insert motion from maintenance pos. back to seam -42
43
44
{H}
45 {H}
46 END
-----------------------------------------------------------------47 ...
Line
Description
23 32
25
26
27
29
31
Teach the motions from the service position back to the path
here.
33 42
7.4.4
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7 Programming
20 DEF ActionStrategy(StrikeErrorSet:IN,TeachModeSender:IN)
21 {H}
22 HALT for TeachMode on seam
23 {H}
24
CASE #SeamActionRoutine
25
KL_MsgSendNotify("SeamActionRoutineNotDefined","CAD")
26
-- insert user defined actions -27 {H}
28 END
7.5
Line
Description
26
7.5.1
Precondition
Procedure
Operating mode T1 or T2
CR.ArcTech Digital has been configured (general configuration and configuration of error strategies).
1. Select the menu sequence File > CR.ArcTech programs. One of the following windows then opens:
2. Press the New softkey. The New set of weld programs window is
opened.
3. Enter the data for the new program.
4. Press the Create softkey. The program is created. The Seam program
overview window is displayed.
5. If required, assign IDs for the seam programs and confirm with the Enter
key.
(>>> 7.5.2 "Program IDs" Page 44)
6. Press the Back softkey. The Part program overview window is displayed.
7. If required, assign an ID for the component program and confirm with the
Enter key.
8. Press the Close softkey.
If the new folder is not displayed in the Arc folder in the Navigator, select
a higher-level folder and then return to the Arc folder. This refreshes the
display.
Description
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Item
7.5.2
Description
Name for the component program and all seam programs. (The
seam programs are also assigned an additional name and number.)
Comment (optional)
Number of seam programs. The seam programs are generated automatically and are assigned consecutive numbers as the last element in the name.
Program IDs
Program IDs enable called programs, for example, to be checked and released by a PLC before they are actually executed. Furthermore, they can also
be used for static evaluations, etc.
In the Part program overview window, IDs can be assigned to the component programs if required.
The ID is saved in the DAT file of the component program in the variable
PartNumber (data type: INT).
In the Seam program overview window, IDs can be assigned to the seam
programs if required.
The ID is saved in the DAT file of the seam program in the variable SeamNumber (data type: INT).
7.5.3
Precondition
Procedure
1. Select the menu sequence File > CR.ArcTech programs. The Part program overview window is opened.
2. Select the component program and press the Details softkey. The seam
programs belonging to this component program are displayed.
3. Select a seam program and press the Move softkey.
4. Move the seam program to the desired position using the arrow keys and
confirm with the OK softkey.
7.5.4
Precondition
Procedure
1. Select the menu sequence File > CR.ArcTech programs. The Part program overview window is opened.
2. Select a component program and press the Modify softkey.
3. Change the name and confirm with the Enter key.
If the new name is not displayed in the Arc folder in the Navigator, select
a higher-level folder and then return to the Arc folder. This refreshes the
display.
7.5.5
Precondition
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7 Programming
Procedure
1. Select the menu sequence File > CR.ArcTech programs. The Part program overview window is opened.
2. Select the component program and press the Details softkey. The seam
programs belonging to this component program are displayed.
3. Select the seam program and press the Modify softkey.
4. Change the name and confirm with the Enter key.
If the new name is not displayed in the Arc folder in the Navigator, select
a higher-level folder and then return to the Arc folder. This refreshes the
display.
7.5.6
Precondition
Procedure
1. Select the menu sequence File > CR.ArcTech programs. The Part program overview window is opened.
2. Select a component program and press the Duplicate softkey. The component program is duplicated.
3. Enter a program name and ID (optional).
4. Confirm by pressing the OK softkey.
7.5.7
Precondition
Procedure
1. Select the menu sequence File > CR.ArcTech programs. The Part program overview window is opened.
2. Select the component program and press the Details softkey. The seam
programs belonging to this component program are displayed.
3. Select the seam program and press the Duplicate softkey. The seam program is duplicated.
4. Enter a program name and ID (optional).
5. Confirm by pressing the OK softkey.
7.5.8
Service routines
The robot controller can execute a service routine in the event of an ignition or
weld error. A service routine is a motion to a service position (e.g. to clean the
torch) and back to the path. There are a number of service routines available
for selection. Which service routine is to be executed is selected during configuration of the error strategies or in the inline forms.
The service routines are already prepared as subprograms. They still need to
be taught, however.
Subprograms for service routines:
The subprograms are located at the end of each program in the form of folds.
Each subprogram contains 2 service routines:
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Service routine 1 is used for ignition errors. Here the motions are taught
from the ignition position to the service position and back.
Service routine 2 is used for weld errors. Here the motions are taught from
the end of seam to the service position and back to the ignition position.
Warning!
Teach service routines so that they can be executed by the robot without any
collisions. Severe physical injuries or considerable damage to property may
otherwise result.
Precondition
Procedure
Operating mode T1 or T2
1. Open a program.
2. At the end of the program, select the following line: Service strategy
on seam - to teach open fold. This line is a fold.
3. Open the fold with the Fold open/cls softkey.
4. Place the cursor in the blank line after CASE #SeamServiceRoutine01.
5. Teach the motions to the service position here.
6. Delete the line
KL_MsgSendNotify("SeamServiceRoutine01NotTeached"
...). This line triggers a message during program execution, stating that
this service routing has not been taught.
7. The line after this contains an example point. Either change or delete this
point.
8. Place the cursor in the blank line after HALT ;** maintenance position reached.
9. Teach the motions from the service position back to the path.
10. If required, teach service routine 2:
Place the cursor in the blank line after CASE #SeamServiceRoutine02.
Carry out the remaining steps as for service routine 1.
11. Close the program.
7.5.8.2
Warning!
Teach service routines so that they can be executed by the robot without any
collisions. Severe physical injuries or considerable damage to property may
otherwise result.
Precondition
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Operating mode T1 or T2
Issued: 30.09.2010 Version: KST CR.ArcTech Digital 3.2 V3 en
7 Programming
Procedure
The configuration parameter Teach mode for startup is set to one of the
following values:
Services
Or ActionsAndServices
3. Continue executing the seam program. The block pointer stops in this line:
Service strategy on seam - to teach open fold. This line is
a fold.
4. Open the fold with the Fold open/cls softkey.
5. Carry out block selection to the desired point.
7.5.9
Actions
The robot controller can execute a user-defined action in the event of an ignition error. There are a number of actions available for selection. Which action
is to be executed is selected during configuration of the error strategies or in
the inline forms.
Subprograms are already prepared for the actions. They still need to be programmed, however.
Subprograms for actions:
The subprograms are located at the end of each program in the form of folds.
(>>> 7.4.4 "Structure of a subprogram for actions" Page 42)
In order to teach points in the subprogram, the fold in the relevant program can
be opened and edited. Block selection is not possible here.
(>>> 7.5.9.1 "Teaching an action" Page 47)
In order to move to points in the subprogram by means of block selection, it is
necessary to jump to the subprogram from the seam program. This is often
necessary for later adaptation of points.
(>>> 7.5.9.2 "Action: moving to points by means of block selection" Page 48)
7.5.9.1
Teaching an action
Precondition
Procedure
Operating mode T1 or T2
1. Open a program.
2. At the end of the program, select the following line: Action strategy
on seam - to teach open fold. This line is a fold.
3. Open the fold with the Fold open/cls softkey.
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4. Program the desired action after the line insert user defined actions.
5. Close the program.
7.5.9.2
Precondition
Procedure
Operating mode T1 or T2
The configuration parameter Teach mode for startup is set to one of the
following values:
Actions
Or ActionsAndServices
1. Select and execute the seam program. (Subprograms for actions can only
be accessed from seam programs.)
The block pointer stops in the line Seam start. A message prompts the
user to select a subprogram.
2. Use the relevant softkey to select the desired subprogram:
3. Continue executing the seam program. The block pointer stops in this line:
Action strategy on seam - to teach open fold. This line is a
fold.
4. Open the fold with the Fold open/cls softkey.
5. Carry out block selection to the desired point.
7.6
RoboTeam
7.7
Synchronous weld seams must have the same motion points for all robots.
The number of ARC instructions for a weld seam does not need to be the
same for all robots. It is possible to change weld parameters for one robot
without changing these for the other robots.
The defined weld parameters may, in principle, differ from robot to robot.
In practice, however, it must always be ensured that the different weld parameters are compatible.
Weld instructions
The weld instructions vary according to the power source used. The descriptions can be found in the CR.ArcTech Digital Power Sources documentation (separate documentation for each power source).
48 / 65
8 Example programs
Example programs
8.1
Instructions from KUKA.CR.MotionCooperation are used in the programs. Information about these can be found in the documentation for KUKA.CR.MotionCooperation.
8.1.1
Description
In the event of an ignition error, the robot attempts to carry out ignition as many
times as are configured in the error strategy. If the ignition attempts fail, the
robot executes the service routine. A new ignition attempt is then carried out.
Description
Seam 1
Seam 2
Service routine 01
P1 P3
S1P1
S1P2
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8.1.2
Element
Description
P101 P105
S1P3 S1P1000
Motions on seam 1.
S1P1000
S1P6
P4
S2P1
S2P2
S2P3 S2P1000
Motions on seam 2.
S2P1000
S2P6
P5, P1000
Description
If a weld error occurs, the robot completes the seam as a dry run and then executes the defined service routine. When it reaches the path again via the service routine, the robot moves to the position defined by the overlap distance.
There the robot stops and carries out ignition again. The weld operation is resumed.
Description
Weld error
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8 Example programs
Element
Description
P201...P204
A description of the remaining positions can be found here: (>>> 8.1.1 "Path
with service routine for ignition errors example" Page 49)
8.1.3
Program
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DEF MyProgram_1( )
INI
PTP HOME Vel= 100 % DEFAULT
PTP P1 Vel=100 % PDAT1 Tool[1] Base[0]
PROGSYNC a1 -> R1_R2_R3 WAIT
PTP P2 Vel=50 % PDAT2 Tool[1] Base[0]
LIN P3 Vel=1 m/s CPDAT3 Sync=a2 -> R1_R2_R3 Tool[1] Base[0]
MyProgram_Seam01()
LIN P4 Vel=1 m/s CPDAT4 Sync=a11 -> R1_R2_R3 Tool[1] Base[0]
MyProgram_Seam02()
LIN P5 Vel=1 m/s CPDAT5 Sync=a20 -> R1_R2_R3 Tool[1] Base[0]
PTP P1000 Vel=100 % PDAT1000 Tool[1] Base[0]
PTP HOME Vel= 100 % DEFAULT
END
Line
Description
6, 7
10
11 13
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8.1.4
Program
1 DEF MyProgram_Seam01( )
2 INI
3
4 -> if needed add movements before first seam position
5
6 LIN S1P1 Vel=1 m/s CPDAT1 Sync=a3 -> R1_R2_R3 Tool[1] Base[0]
7 CALL strategys on Teachmode
8 == seam start ==>
9 = strike start =>
10 ARC_Strike_Param Job=10 Set=S1 ESet=ES Sync=s1 -> R1_R2_R3
11 -> this point must be the same as the ARC start point
12 LIN S1P2 Vel=0.6 m/min CPDAT2 Tool[1] Base[0]
13 -> this is the ARC start point
14 LIN S1P2 Vel=0.6 m/min CPDAT2 ARC Job=10 Set=W1 ESet=EW1
Sync=a4 -> R1_R2_R3 Tool[1] Base[0]
15 <= strike end =
16 = start insert movements =>
17 ;insert movements on seam with or without ARC only here
18
19 LIN S1P3 CONT Vel=0.6 m/min CPDAT3 Sync=a5 -> R1_R2_R3 Tool[1]
Base[0]
20 LIN S1P4 CONT Vel=0.6 m/min CPDAT4 Sync=a6 -> R1_R2_R3 Tool[1]
Base[0]
21 LIN S1P5 CONT Vel=0.6 m/min CPDAT5 Sync=a8 -> R1_R2_R3 Tool[1]
Base[0]
22
23 <= end insert movements =
24 this is the ARC_OFF point
25
26 LIN S1P1000 Vel=0.6 m/min CPDAT1000 ARC_OFF Job=10 Set=C
Sync=a9 -> R1_R2_R3 Tool[1] Base[0]
27 <== Seam End ==
28 CALL strategys on Teachmode
29 -> if needed add additional movements after ARC_OFF below
30
31 LIN S1P6 CONT Vel=1 m/s CPDAT6 Sync=a10 -> R1_R2_R3 Tool[1]
Base[0]
32 END
-----------------------------------------------------------------33 ...
Description
Line
Description
By default, the INI line contains the instruction ARC INIT. ARC
INIT does not need to be programmed.
10
12
14
Ignition.
19 21
26
31
Point in the seam program after the end of the seam. (A point
is generally taught above the end crater position for this.)
33
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8 Example programs
8.1.5
Program
1 DEF MyProgram_Seam02( )
2 INI
3
4 -> if needed add movements before first seam position
5
6 LIN S2P1 Vel=1 m/s CPDAT1 Sync=a12 -> R1_R2_R3 Tool[1] Base[0]
7 CALL strategys on Teachmode
8 == seam start ==>
9 = strike start =>
10 ARC_Strike_Param Job=10 Set=S ESet=ES Sync=s2 -> R1_R2_R3
11 -> this point must be the same as the ARC start point
12 LIN S2P2 Vel=0.6 m/min CPDAT2 Tool[1] Base[0]
13 -> this is the ARC start point
14 LIN S2P2 Vel=0.6 m/min CPDAT2 ARC Job=10 Set=W1 ESet=EW1
Sync=a13 -> R1_R2_R3 Tool[1] Base[0]
15 <= strike end =
16 = start insert movements =>
17 ;insert movements on seam with or without ARC only here
18
19 LIN S2P3 CONT Vel=0.6 m/min CPDAT3 Sync=a14 -> R1_R2_R3
Tool[1] Base[0]
20 LIN S2P4 CONT Vel=0.6 m/min CPDAT4 Sync=a15 -> R1_R2_R3
Tool[1] Base[0]
21 LIN S2P5 Vel=0.6 m/min CPDAT5 ARC Job=3 Set=W2 ESet=EW2
Sync=a17 -> R1_R2_R3 Tool[1] Base[0]
23
24 <= end insert movements =
25 this is the ARC_OFF point
26 LIN S2P1000 Vel=0.6 m/min CPDAT1000 ARC_OFF Job=3 Set=C
Sync=a18 -> R1_R2_R3 Tool[1] Base[0]
27 <== Seam End ==
28 CALL strategys on Teachmode
29 -> if needed add additional movements after ARC_OFF below
30
31 LIN S2P6 Vel=1 m/s CPDAT6 Sync=a19 -> R1_R2_R3 Tool[1] Base[0]
32 END
Description
Line
Description
By default, the INI line contains the instruction ARC INIT. ARC
INIT does not need to be programmed.
10
12
14
Ignition.
19, 20
21
8.1.6
26
31
Point in the seam program after the end of the seam. (A point
is generally taught above the end crater position for this.)
53 / 65
Program
Description
54 / 65
33 DEF
ServiceStrategy(ConsiderCRErr:IN,Motion:IN,Service:IN,MsgType:IN,Cal
lFrom[]:OUT,TeachModeSender:IN)
34 HALT for TeachMode
35
CASE #SeamServiceRoutine01
36
-- insert motion from pos. on seam to maintenance pos. -37
38 LIN P101 CONT Vel=1 m/s CPDAT101 Sync=b1 -> R1_R2_R3 Tool[1]
Base[0]
39 LIN P102 CONT Vel=1 m/s CPDAT102 Sync=b2 -> R1_R2_R3 Tool[1]
Base[0]
40 LIN P103 Vel=1 m/s CPDAT103 Sync=b3 -> R1_R2_R3 Tool[1]
Base[0]
41
HALT ;** maintenance position reached
42
-- insert motion from maintenance pos. back to seam -43
44 LIN P104 CONT Vel=1 m/s CPDAT104 Sync=b4 -> R1_R2_R3 Tool[1]
Base[0]
45 LIN P105 CONT Vel=1 m/s CPDAT105 Sync=b5 -> R1_R2_R3 Tool[1]
Base[0]
46
47
CASE #SeamServiceRoutine02
48
49
-- insert motion from pos. on seam to maintenance pos. -50
51 LIN P201 CONT Vel=1 m/s CPDAT201 Sync=b6 -> R1_R2_R3 Tool[1]
Base[0]
52 LIN P202 Vel=1 m/s CPDAT202 Sync=b7 -> R1_R2_R3 Tool[1]
Base[0]
53
HALT ;** maintenance position reached
54
-- insert motion from maintenance pos. back to seam -55 LIN P203 CONT Vel=1 m/s CPDAT203 Sync=b9 -> R1_R2_R3 Tool[1]
Base[0]
56 LIN P204 Vel=1 m/s CPDAT204 Sync=b8 -> R1_R2_R3 Tool[1]
Base[0]
57
58 END
Line
Description
36 46
Service routine 01
38 40
41
44, 45
48 57
Service routine 02
51, 52
53
55, 56
9 KUKA Service
KUKA Service
9.1
Requesting support
Introduction
Information
9.2
Application used
Availability
KUKA Customer Support is available in many countries. Please do not hesitate to contact us if you have any questions.
Argentina
Australia
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Belgium
Brazil
Chile
China
Germany
9 KUKA Service
France
India
Italy
Japan
Korea
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Malaysia
Mexico
Norway
Austria
Poland
9 KUKA Service
Portugal
Russia
Sweden
Switzerland
Spain
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South Africa
Taiwan
Thailand
Czech Republic
Hungary
9 KUKA Service
USA
UK
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Index
Index
A
Action 6
Actions 47
Areas of application 9
C
CADU_UserGlobal 10
Checking, TCP 10
Collision 10
Communication 10
Component program 6
Component program, changing the name 44
Component program, creating 43
Component program, duplicating 45
Configuration 23
CR.ArcTech Digital Power Sources 10
Cycflags 15
D
Documentation, industrial robot 5
Dry run 7
Dry run velocity 33
Dry run, automatic 33
Dry run, configuration 33
Dry run, manual 20
Duplicating a component program 45
Duplicating a seam program 45
E
End crater position 6
Error strategies, configuration 26
Example programs 49
F
Function generators 15
Functions, CR.ArcTech Digital 9
I
Ignition error 7
Ignition errors 49
Installation 15
Interrupts 15
Introduction 5
K
Knowledge, required 5
KUKA Customer Support 55
KUKA.CR.MotionCooperation 49
KUKA.ToolCorrManual 10
KUKA.WeaveTech 10
L
Local device 6
M
Menus 19
O
On-the-fly, activation 6
On-the-fly, deactivation 6
On-the-fly, ignition 6
Operation 19
Overlap distance 28, 31
Overview of CR.ArcTech Digital 9
P
Product description 9
Program Generator 9, 10, 26, 28
Programming 37
Programs, creating 38, 43
R
Remote device 6
S
Safety 13
Safety instructions 5
Seam program 6
Seam program, changing the name 44
Seam program, creating 43
Seam program, duplicating 45
Seam programs, changing the order 44
Service routine 6
Service routines 45
Service, KUKA Roboter 55
Status keys 19, 23
Support request 55
System requirements 15
T
Target group 5
Terms 6
Terms used 6
Timers 15
Trademarks 6
Training 5
U
Uninstallation, CR.ArcTech Digital Power Sources 16
Uninstalling CR.ArcTech Digital 17
V
VelUnitsConfig.xml 34
W
Warnings 5
Weaving, mechanical 10
Weld error 6
Weld errors 50
Weld instructions 48
Weld operation, structure 37
Weld seam, asynchronous 6
Weld seam, synchronous 6
Without welding 6
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