Training

Tra
aining KUKA
K Robotics
KA Robottics USA
US
SA

KORE: Basic Course

KUKA Official Robot Education

Target Group: School and College Students

Issued: 19.09.2014

Version: KORE: Basic Course – V1.1

Contents
1 Introduction to robotics .............................................................................. 7
1.1 Overview .................................................................................................................... 7
1.2 Introduction ................................................................................................................ 7
1.3 R.U.R. – Rossum’s Universal Robots ........................................................................ 7
1.4 Laws of Robotics ........................................................................................................ 8
1.5 The first robot ............................................................................................................. 9
1.6 KUKA
K company history
r .............................................................................................. 9
1.6.1 Exercise: Introduction to the robot and group discussion ..................................... 12

2 Fields of application for industrial robots ................................................. 13

2.1 Overview .................................................................................................................... 13
2.2 Applications for industrial robots ................................................................................ 13
2.3 Examples of robotic applications ............................................................................... 16
2.3.1 Exercise: Group discussion and video examples ................................................. 24

3 Overview of the components of a robot system ....................................... 25

3.1 Overview .................................................................................................................... 25
3.2 Components of a robotic cell ..................................................................................... 25
3.3 Robot selection .......................................................................................................... 26
3.4 Controller configuration .............................................................................................. 27
3.5 Selection of the end effector / tool ............................................................................. 28
3.6 Selection of the energy supply system ...................................................................... 28
3.7 Periphery connection (field bus) ................................................................................ 29
3.8 Use of sensors ........................................................................................................... 30
3.9 Safety equipment ....................................................................................................... 30
3.10 Excerpt from KR C4 safety ......................................................................................... 35
3.11 Terms used ................................................................................................................. 39
3.11.1 Exercise: Identify the safety on the lab robot and group discussion .................... 41

4 Industrial robots .......................................................................................... 43

4.1 Overview .................................................................................................................... 43
4.2 Introduction to robotics ............................................................................................... 43
4.3 Definition and structure .............................................................................................. 44
4.4 Robot arm of a KUKA robot ....................................................................................... 44
4.5 Arrangement of the main axes ................................................................................... 47
4.6 Absolute accuracy and repeatability .......................................................................... 49
4.6.1 Exercise: Robot component identification ............................................................. 51

5 Robot controller ........................................................................................... 53

5.1 Overview .................................................................................................................... 53
5.2 Description of a robot system .................................................................................... 53
5.3 Overview of the KR C4 compact robot controller ....................................................... 54
5.4 Technical data for the KR C4 compact ...................................................................... 55
5.5 KR C4 compact interfaces ................................................................ ......................... 57
5.5.1 Exercise: Robot controller component identification ............................................. 59

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 6 Moving the robot .........................................................................................
......................................................................................... 61
6.1 Overview ...........................................................................................................
....................................................................................................................
.......... 61
6.2 KUKA
K smartPAD teach pendant ................................................................................
................................................................................ 61
6.2.1 Front view ...................................................................................................
.............................................................................................................
.......... 61
6.2.2 .............................................................................................................
Rear view .............................................................................................................. 63
6.3 Reading and interpreting robot controller messages .................................................
................................................. 64
6.4 Selecting and setting the operating mode .................................................................
................................................................. 66
6.4.1 Exercise: Using the KUKA SmartPAD and interpreting messages .....................
..................... 68
6.5 Moving individual robot axes ............................................................................
..........
..................................................................................... 70
6.5.1 ...........................................
Exercise: Operator control and axis-specific jogging ........................................... 74
6.6 Coordinate systems in conjunction with robots .........................................................
......................................................... 76
6.7 Moving the robot in the world coordinate system ......................................................
...................................................... 77
6.7.1 Exercise: Operator control and jogging in the world coordinate system ..............
.............. 82
6.8 Moving the robot in the tool coordinate system .........................................................
......................................................... 83
6.8.1 Exercise: Operator control and jogging in the tool coordinate system ................
................ 87
6.9 .......................................................
Moving the robot in the base coordinate system ....................................................... 89
6 91
6.9.1 Exercise: Operator control and jogging in the base coordinate system .............. 93
7 Start-Up ......................................................................................................... 94
7.1 Overview .................................................................................................................... 94
7.2 Mastering principle .................................................................................................... 94
7.3 Mastering with the MEMD and mark.......................................................................... 97
7.3.1 Moving A6 to the mastering position (with mark) ...................................................... 98
7.3.2 First mastering (with MEMD) ...................................................................................... 98
7.3.3 Teach offset (with MEMD) ......................................................................................... 101
7.3.4 Check load mastering with offset (with MEMD) ......................................................... 102
7.3.5 Exercise: Robot mastering ................................................................................... 104
7.4 Loads on the robot ..................................................................................................... 106
7.5 Tool load data ............................................................................................................ 106
7.6 Supplementary loads on the robot ............................................................................. 108
7.6.1 Exercise: Tool load calibration ............................................................................. 110
7.7 Tool calibration .......................................................................................................... 113
7.7.1 Exercise: Tool calibration .................................................................................... 121
7.8 Base calibration ......................................................................................................... 124
7.8.1 Exercise: Base calibration – table, 3-point method .............................................. 128
7.9 Displaying the current robot position ......................................................................... 130
7.9.1 Exercise: Displaying the current robot position .................................................... 133

8 Executing robot programs .......................................................................... 135

8.1 Overview .................................................................................................................... 135
8.2 HOME position .......................................................................................................... 135
8.3 Performing an initialization run .................................................................................. 135
8.4 Selecting and starting robot programs ....................................................................... 136
8.4.1 Exercise: Executing robot programs ................................................................... 143

9 Working with program files ........................................................................ 145

9.1 Overview .................................................................................................................... 145
9.2 Creating program modules ........................................................................................ 145
9.3 Editing program modules ........................................................................................... 146
9.3.1 Exercise: Program creation ............................................................................... 147

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10 Creating and modifying programmed motions .................................................... 149
10.1 Overview .................................................................................................................... 149
10.2 Creating new motion commands ............................................................................... 149
10.3 Creating cycle-time optimized motion (axis motion) .................................................. 150
10.3.1 Exercise: PTP motions .......................................................................................... 157
10.4 Modifying motion commands ....................................................................................... 158
10.4.1 Exercise: Modifying motion parameters ................................................................ 161
10.5 Creating CP motions .................................................................................................. 162
10.5.1 Exercise: CP motion and approximate positioning ............................................... 170
10.5.2 Exercise: Fetch / return marker and ring tool ........................................................ 172

11 Using logic functions in the robot program .......................................................... 175

11.1 Overview .................................................................................................................... 175
11.2 Introduction to logic programming ............................................................................. 175
11.3 Programming wait functions ...................................................................................... 176
11.4 Input and output monitor ........................................................................................... 180
11.4.1 Exercise: Programming wait functions ................................................................. 181
11.5 Programming simple switching functions .................................................................. 182
11.5.1 Exercise: Programming simple switching functions ............................................. 185
12 Exercise: Final programming assignment ............................................................. 186

Index ........................................................................................................................... 188

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3 Overview of the components of a robot system

3.1 Overview
Overv
r iew

The following contents are explained in this training module:

„ Components of a robotic cell
„ Selection criteria for a robot
„ Control of robot and external axes
„ Tool selection
„ Selection of the energy supply system
„ Periphery
r connection
„ Use of sensors
„ Safety equipment

3.2 Components of a robotic cell

A robot system / robotic cell consists of the following components:

Fig. 3-1: Arc welding cell

Item Description
1 Robot
2 Controller
3 Tool / tool changer
4 Energy supply system
5 Periphery connection
6 Sensor system
7 Safety fence
8 Loading area with photoelectric curtain

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4 Industrial robots

4.1 Overview
Overv
r iew

The following contents are explained in this training module:

„ What is a robot?
„ Structure of a robot
„ Arrangement of the main axes
„ Absolute accuracy and repeatability

4.2 Introduction to robotics

What is a robot? The term robot comes from the Slavic word robota, meaning hard r .
r work
According to the official definition of an industrial robot: “A robot is a freely
free
ely pro-
grammable, program-controlled handling device”.
The robot thus also includes the controller and the operator control device,
devvice, to-
gether with the connecting cables and software.

Fig. 4-1: Industrial robot

1 Controller ((V)KR C4 control cabinet)

2 Manipulator (robot arm)
3 Teach pendant (KUKA smartPAD)

Everything outside the system limits of the industrial robot is referred to as the
periphery:

„ Tooling (end effector/tool)

„ Safety equipment
„ Conveyor belts
„ Sensors
„ Machines
„ Etc.

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5 Robot controller

5.1 Overview
Overv
r iew

The following contents are explained in this training module:

„ Description of the robot system
„ Overview of KR C4 compact
„ Technical data
„ Interfaces

5.2 Description of a robot system

The industrial robot consists of the following components:

„ Manipulator
„ Robot controller
„ smartPAD teach pendant
„ Connecting cables
„ Software
„ Options, accessories

Fig. 5-1: Example of an industrial robot

1 Manipulator
2 Teach pendant
3 Connecting cable, smartPAD
4 Robot controller
5 Connecting cable, data cable
6 Connecting cable, motor cable

For safe operator control of the robot system illustrated

here, additional safety measures are necessary, e.g.:
„ a safety fence
„ external Emergency Stop
„ possibly an external safety controller

Issued: 19.09.2014 Version: KORE: Basic Course – V1.1 53

 Overview

Fig. 6-1: KUKA smartPAD, front view

Item Description
1 Button for disconnecting the smartPAD

2 Keyswitch for calling the connection manager. The switch can only
be turned if the key is inserted.
The operating mode can be changed by using the connection man-
ager.

3 EMERGENCY STOP button. Stops the robot in hazardous situa-

tions. The EMERGENCY STOP button locks itself in place when it
is pressed.
4 Space Mouse: For moving the robot manually.

5 Jog keys: For moving the robot manually.

6 Key for setting the program override

7 Key for setting the jog override
8 Main menu key: Shows the menu items on the smartHMI

62 Issued: 19.09.2014 Version: KORE: Basic Course – V1.1

 Item Description
9 Status keys. The status keys are used primarily for setting param-
eters in technology packages. Their exact function depends s on the
technology packages installed.
10 Start key: The Start key is used to start a program.
11 Start backwards key: The Start backwards key is used to st
start
tart a
program backwards. The program is executed step by step.
stepp.
12 STOP key: The STOP key is used to stop a program that iss run-
ning.
13 Keyboard key
Displays the keyboard. It is generally not necessary to press
ss this
pres
key to display the keyboard, as the smartHMI detects when n key-
board input is required and displays the keyboard automatically.
automaticcally.

6.2.2 Rear view

Overview

Fig. 6-2: KUKA smartPAD, rear view

1 Enabling switch 4 USB connection

2 Start key (green) 5 Enabling switch
3 Enabling switch 6 Identification plate

Issued: 19.09.2014 Version: KORE: Basic Course – V1.1 63

6.8 Moving the robot in the tool coordinate system

Jogging in the
tool coordinate
system

Fig. 6-12: Robot tool coordinate system

Use and Programming of Industrial Robots

„ In the case of jogging in the tool coordinate system, the robot can be
moved relative to the coordinate axes of a previously calibrated tool.
The coordinate system is thus not fixed (cf. world/base coordinate sys-
tem), but guided by the robot.
In this case, all required robot axes move. Which axes these are is deter-
mined by the system and depends on the motion.
The origin of the tool coordinate system is called the TCP and corresponds
to the working point of the tool.
„ The jog keys or Space Mouse of the KUKA smartPAD are used for this.
„ There are 16 tool coordinate systems to choose from.
„ The velocity can be modified (jog override: HOV).
„ Jogging is only possible in T1 mode.
„ The enabling switch must be pressed.

In the case of jogging, uncalibrated tool coordinate systems always

correspond to the flange coordinate system.

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 Principle of
jogging – tool

Fig. 6-13: Cartesian coordinate system

A robot can be moved in a coordinate system in two different

diff
fferent ways:
„ Translational (in a straight line) along the orientation direc
directions
ctions of the co-
ordinate system: X, Y, Z
„ Rotational (turning/pivoting) about the orientation directions
directio
ons of the coordi-
nate
t system:
t angles
l A,A B and dC
Advantages of using the tool coordinate system:
„ The motion of the robot is always predictable as soon as the tool coordi-
nate system is known.
„ It is possible to move in the tool direction or to orient about the TCP.
The tool direction is the working or process direction of the tool: the direction
in which adhesive is dispensed from an adhesive nozzle, the direction of
gripping when gripping a workpiece, etc.

84 Issued: 19.09.2014 Version: KORE: Basic Course – V1.1

Procedure 1. Select Tool as the coordinate system to be used.

2. Select the tool number.

.
3. Set jog override.

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 4. Press the enabling switch into the center position and hold
old it down.
ho

5. Move the robot using the jog keys.

6. Alternatively: Move in the corresponding direction using the Space Mouse.

86 Issued: 19.09.2014 Version: KORE: Basic Course – V1.1

6.8.1 Exercise: Operator control and jogging in the tool coordinate system

Aim
m of th
Aim tthe
e On su
ssuccessful
successfu
u completion
ul comple
ul le
leti iss exercise,
et on of this cise, you
exerc yo will be able
ble to carry
ab carry out
out the fol--
exercise
ex
xercise lowing
lo
owing activities:
ng activiti
ies:
„ Jog
Jo
og the robot,
ro
obot,, in
n the
t e tool
th tool coordinate
to coorrdi
d nate
e system,
syste
em, by
by means
me
eans of
o the
th
he jog
g keys
key
y and
ys
Space
Spac
ace Mo
ac Mouse
ouse
e
„ Jog th
the ro
robot
obot in
in the
th
he working
wo
orkin
ng direction
dirrectio
on off the
the tool
tooll

Preconditions The following are preconditions for

f successful completion of this exercise:
exercise:
„ Completion of safety instruction
„ Theoretical knowledge of jogging in the tool coordinate system
„ Marker holder mounted on grid plate in holes A1 / A2
„ Pointer tool mounted on the grid plate in a location that will be easy
y to
reach from multiple different robot orientations.

Task description Carry out the following tasks:

1. Switch the control cabinet on and wait for the system to boot
2. Release and acknowledge the Emergency Stop.
3. Ensure that T1 mode is set.
4. Activate the tool coordinate system.
5. Select “Demo_Gripper_1” as your tool.
6. Jog the robot in the tool coordinate system with various different jog over-
ride (HOV) settings using the jog keys and space mouse. Test motion in
the working direction of the tool and re-orientation about the TCP.
7. Fetch the pen from the holder using the tool “Demo_Gripper_1”.
8. Return the pen to the holder using the tool “Demo_Gripper_1”.

What you should now know:

1. How many tools exist in the robot?
............................................................
............................................................

2. What steps are required for jogging relative to the desired tool coordinate
system?

............................................................
............................................................

3. Where is the location of an un-calibrated tool?

............................................................
............................................................

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 Fig. 7-1: Mastering position for KR AGILUS

Angle values of the mechanical zero position (= reference values)

Axis KR AGILUS
A1 0°
A2 -90°
A3 +90°
A4 0°
A5 0°
A6 0°

When is A robot must always be mastered. Mastering must be carried out in the follow-
mastering carried ing cases:
out? „ During commissioning
„ Following maintenance work to components that are involved in the acqui-
sition of position values (e.g. motor with resolver or RDC (Resolver digital
converter))
„ If robot axes are moved without the controller (e.g. by means of a release
device)
„ Following mechanical repairs/problems, the robot must first be unmas-
tered before mastering can be carried out:
„ After exchanging a gear unit
„ After an impact with an end stop at more than 250 mm/s
„ After a collision

Before carrying out maintenance work, it is generally a good idea to

check the current mastering.

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 Safe
f ty instruc-
Safety The functionality of the robot is severely restricted if robot ax
xes are not mas-
axes
tions for tered:
mastering „ Program mode is not possible: programmed points cannot
cann
not be executed.
„ No Cartesian jogging: motions in the coordinate systemss are not possible.
„ Software limit switches are deactivated.

The software limit switches of an unma stered robot are

unmastered
deactivated. The robot can hit the end stops buffers, thus
damaging the robot and making it necessary to exchange the the buffers. An un-
mastered robot should not be jogged, if at all avoidable. If it must be jogged,
the jog override must be reduced as far as possible.

Carrying out
mastering

Fig. 7-2: MEMD screwed in

Mastering is carried out by determining the mechanical zero point of the axis.
Every axis is thus equipped with a mastering cartridge and a mastering mark.

Fig. 7-3: EMD mastering sequence

1 MEMD (Micro Electronic Mas- 4 Reference notch

tering Device)
2 Gauge cartridge 5 Premastering mark
3 Gauge pin

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7.7.1 Exercise: Tool calibration

Aiim of the
Aim On su
On uccessful
successful u co
ul omp
mp etition
mple
completion o of th
this exercise,
exerc
cis
se, you
yo will
yo w ll be able
wi able to
to carry
carry
y out
outt the fol-
foll-
e
ex erc
cis
ise
exercisee lowing
lo g activities:
owing activitties:
„ Calibration
Callib
ibratioon off a tool
tool
o origin
orig
or ig
gin us
usin
using
ng the
e XYZZ 4-p
4-point
poi
o ntt and
and XYZ
XYZ reference
refere
re
encce
methods
m ethhods
„ Calibration
C
Ca libr
brratio
on off a too
tool
ol orient
orientation
nta
ntation
nuusing
sin
ng the
e AB
ABC
BC World and ABA
ABCC22-point
-po
po
oin
int
int
methods
meth
me thod
thods
od
„ Calibration of a tool using the numeric input method
„ Activation of a calibrated tool
„ Moving the robot in the tool coordinate system
„ Moving the robot in the tool direction
„ Reorientation of the tool about the Tool Center Point (TCP)

Preconditions The following are preconditions for successful completion of this exercise:
exerc
cise:
„ Theoretical
Th ti l knowledge
k l d off the
th various
i TCP calibration
lib ti methods
th d
„ Theoretical knowledge of the various tool orientation calibration methods
„ Theoretical knowledge of robot load data
„ Marker holder mounted on grid plate in holes A1 / A2
„ Ring tool holder mounted on the grid plate in hole A8
„ Pointer tool mounted on the grid plate in a location that will be easy to
reach from multiple different robot orientations.

Task description Carry out the following tasks:

1. Use the name “My_Gripper” and tool #3 for tool calibration of the gripper.
2. Calibrate the TCP of the gripper using the XYZ 4-point method as illustrated.
3. The tolerance should not exceed 0.95 mm. In practice, this value is not
sufficient. It is better to achieve tolerances of 0.5 mm or even 0.3 mm.
4. Calibrate the orientation of the gripper coordinate system using the ABC 2-point
method.
5. Save the TOOL data and test jogging with the gripper in the tool coordinate system.

Training gripper – TCP

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10 Creating and modifying programmed motions

10.1 Overview
Overv
r iew

The following contents are explained in this training module:

„ Creating cycle-time optimized motions
„ Creating CP motions
„ Modifying motion commands

10.2 Creating new motion commands

Programming
robot motions

Fig. 10-1: Robot motion

When robot motions have to be programmed, many questions are raised:

Question Solution Keyword

How does the robot remember The positions of the tool in space are saved POS
its positions? (robot position in accordance with the tool and
base that are set). E6POS
How does the robot know how From the specification of the motion type: PTP
to move? point-to-point, linear or circular.
LIN
CIRC
How fast does the robot The velocity between two points and the accel- Vel.
move? eration are specified during programming.
Acc.
Does the robot have to stop at To save cycle time, points can also be approxi- CONT
every point? mated; no exact positioning is carried out in
this case.
What orientation does the tool The orientation control can be set individually ORI_TYPE
adopt when a point is for each motion.
reached?
Does the robot recognize No, the robot “stubbornly” follows its pro- Collision de-
obstacles? grammed path. The programmer is responsible tection
for ensuring that there is no risk of collisions.
There is also a collision monitoring function,
however, for protecting the machine.

This information must be transferred when programming robot motions using

the teaching method. Inline forms, into which the information can easily be en-
tered, are used for this.

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11 Using logic functions in the robot program

11.1 Overview
Overv
r iew

The following contents are explained in this training module:

„ Programming wait functions
„ Programming switching functions
„ Viewing the current state of inputs and outputs in the I/O monitor

11.2 Introduction to logic programming

Use of inputs and

outputs in logic
programming

Fig. 11-1: Digital inputs and outputs

In order to implement communication with the periphery of the robot controller,

digital and analog inputs/outputs can be used.
Explanation of terms

Term Explanation Example

Communication Signal exchange via a Polling a state (grip-
serial interface per open/closed)
Periphery “Surroundings” Tool (e.g. gripper, weld
gun, etc.), sensors,
material conveyor sys-
tems, etc.
Digital Digital technology: Sensor signal: part
value- and time-dis- present: value 1
crete signals (TRUE), part not pres-
ent: value 0 (FALSE)
Analog Mapping of a physical Temperature measure-
variable ment
Inputs The signals arriving in Sensor signal: gripper
the controller via the is open / gripper is
field bus interface closed
Outputs The signals sent by the Command for switch-
controller to the ing a valve to close a
periphery via the field finger gripper.
bus interface

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