KUKA System Technology KUKA Roboter GmbH

KUKA.VisionTech 2.1

For KUKA System Software 8.2

For VW System Software 8.2

Issued: 11.10.2013

Version: KST VisionTech 2.1 V1

 KUKA.VisionTech 2.1

© Copyright 2013
KUKA Roboter GmbH
Zugspitzstraße 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, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC

Publication: Pub KST VisionTech 2.1 (PDF) en

Book structure: KST VisionTech 2.1 V1.1
Version: KST VisionTech 2.1 V1

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 Contents

Contents
1 Introduction .................................................................................................. 7
1.1 Industrial robot documentation ................................................................................... 7
1.2 Representation of warnings and notes ...................................................................... 7
1.3 Trademarks ................................................................................................................ 7
1.4 Terms used ................................................................................................................ 8

2 Purpose ........................................................................................................ 9
2.1 Target group .............................................................................................................. 9
2.2 Intended use .............................................................................................................. 9

3 Product description ..................................................................................... 11

3.1 Overview of VisionTech ............................................................................................. 11
3.2 Hardware components ............................................................................................... 12
3.2.1 KUKA GigE switch ................................................................................................ 12
3.2.2 KUKA MXG20 camera .......................................................................................... 16
3.2.3 Connecting cables ................................................................................................ 17
3.2.4 Calibration plates .................................................................................................. 17

4 Technical data .............................................................................................. 19

4.1 KUKA MXG20 camera ............................................................................................... 19
4.2 KUKA GigE switch ..................................................................................................... 20
4.3 Connecting cables ..................................................................................................... 21
4.3.1 Connecting cables, KR C4 .................................................................................... 21
4.3.2 Connecting cables, KR C4 compact ..................................................................... 22
4.4 Dimensions of the camera ......................................................................................... 23
4.5 Dimensions of the extension ...................................................................................... 24
4.6 Plates and labels ........................................................................................................ 24

5 Safety ............................................................................................................ 27
5.1 General safety measures ........................................................................................... 27
5.2 Standards and regulations ......................................................................................... 27

6 Planning ....................................................................................................... 29
6.1 Connecting cables and interfaces .............................................................................. 29

7 Transportation ............................................................................................. 31
7.1 Transportation ............................................................................................................ 31

8 Installation and licensing ............................................................................ 33

8.1 System requirements ................................................................................................. 33
8.2 Installing or updating VisionTech ............................................................................... 33
8.3 Uninstalling VisionTech .............................................................................................. 34
8.4 Licensing VisionTech ................................................................................................. 34
8.4.1 Activating the license ............................................................................................ 34
8.4.2 Repairing the license ............................................................................................ 35
8.4.3 Activating an emergency license .......................................................................... 35

9 Start-up and recommissioning ................................................................... 37

9.1 Start-up for a stationary camera - overview ............................................................... 37

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9.2 Start-up for moving cameras - overview .................................................................... 37

9.3 Connecting cameras to the robot controller ............................................................... 38
9.3.1 Networking KR C4 with interface X64, stationary ................................................. 38
9.3.2 Networking KR C4 with cable inlet, stationary ...................................................... 38
9.3.3 Networking KR C4 compact, stationary ................................................................ 39
9.3.4 Networking KR C4 with interface X64, robot-guided ............................................ 39
9.3.5 Networking KR C4 with cable inlet, robot-guided ................................................. 40
9.3.6 Description of the connecting cables .................................................................... 40
9.4 Configuring the Ethernet KRL interface ..................................................................... 43
9.5 Configuring the camera network ................................................................................ 43
9.6 Configuring cameras ................................................................................................. 44
9.7 Aligning camera (stationary) ...................................................................................... 45
9.8 Aligning cameras (moving) ........................................................................................ 45
9.9 Calibrating camera (stationary) ................................................................................. 46
9.9.1 Deleting a calibration plane .................................................................................. 48
9.10 Calibrating cameras (moving) .................................................................................... 48

10 Configuration ............................................................................................... 51
10.1 Configuring a 2D measurement task - overview ........................................................ 51
10.2 Configuring a 3D measurement task - overview ........................................................ 51
10.3 Creating a task and taking images (stationary) ......................................................... 51
10.4 Creating a task and taking images (moving) ............................................................. 52
10.5 Setting up an image processing task in WorkVisual .................................................. 52
10.5.1 Installing the image processing environment ....................................................... 53
10.5.2 Licensing the image processing environment in WorkVisual ............................... 53
10.5.2.1 Activating the license ....................................................................................... 53
10.5.2.2 Repairing the license ....................................................................................... 53
10.5.2.3 Activating an emergency license ..................................................................... 54
10.5.3 Creating a tool block file in WorkVisual ............................................................... 54
10.5.3.1 Templates ........................................................................................................ 55
10.6 Configuring a 2D task ................................................................................................ 56
10.7 Generating a 2D model ............................................................................................. 59
10.7.1 2D model with a stationary camera ...................................................................... 59
10.7.2 2D model with a moving camera .......................................................................... 60
10.8 Testing a 2D task ....................................................................................................... 61
10.9 Configuring a 3D task ................................................................................................ 62
10.10 Generating a 3D model ............................................................................................. 64
10.11 Testing a 3D task ....................................................................................................... 65

11 Programming ............................................................................................... 67
11.1 Note on programming ................................................................................................ 67
11.2 Subprogram VT_INIT ................................................................................................ 67
11.3 Subprogram VT_OPENCONNECTION ..................................................................... 67
11.4 Subprogram VT_TASKTRIGGER ............................................................................. 67
11.5 Subprogram VT_TASKTRIGGER_REFBASE ........................................................... 68
11.6 Subprogram GET_VTRESULT .................................................................................. 68
11.7 Subprogram GET_VTCORRECTIONFRAME ........................................................... 68
11.7.1 Structure of VTRESULT ....................................................................................... 69
11.8 Subprogram VTRESULT_CHECK ............................................................................ 69

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11.9 Subprogram VT_RESULTCHECK2 ........................................................................... 70

11.10 Subprogram VT_WAIT ............................................................................................... 70
11.11 Subprogram VT_CLOSECONNECTION ................................................................... 71
11.12 Subprogram VT_CLEAR ............................................................................................ 71
11.13 Subprogram VT_CHECKPOSELIMIT ........................................................................ 71
11.14 Subprogram VT_CHECKPOSE ................................................................................. 72
11.14.1 Defining the points on the robot ............................................................................ 74
11.15 Subprogram GET_VTUSERDATA ............................................................................. 75
11.16 Subprogram DO_GETVTRESULT ............................................................................. 75
11.17 Subprogram DO_GETVTRESULTS .......................................................................... 76
11.18 Subprogram VT_DIRECT .......................................................................................... 77

12 Example programs ...................................................................................... 79

12.1 Example program ....................................................................................................... 79

13 Messages ..................................................................................................... 83
14 Maintenance ................................................................................................. 89
14.1 Maintenance symbols ................................................................................................ 89

15 Repair ........................................................................................................... 91
15.1 Exchanging the switch ............................................................................................... 91
15.2 Exchanging the camera ............................................................................................. 91
15.3 Exchanging the motherboard ..................................................................................... 91

16 Troubleshooting .......................................................................................... 93
17 Decommissioning, storage and disposal .................................................. 95
17.1 Decommissioning ....................................................................................................... 95
17.2 Storage ...................................................................................................................... 95
17.3 Disposal ..................................................................................................................... 95

18 Appendix ...................................................................................................... 97
18.1 Tightening torque ....................................................................................................... 97

19 KUKA Service .............................................................................................. 99

19.1 Requesting support .................................................................................................... 99
19.2 KUKA Customer Support ........................................................................................... 99

Index ............................................................................................................. 107

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 1 Introduction

1 Introduction

1.1 Industrial robot documentation

The industrial robot documentation consists of the following parts:

 Documentation for the manipulator
 Documentation for the robot controller
 Operating and programming instructions for the System Software
 Instructions for options and accessories
 Parts catalog on storage medium
Each of these sets of instructions is a separate document.

1.2 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable

that death or severe injuries will occur, if no precautions
are taken.

These warnings mean that death or severe injuries may

occur, if no precautions are taken.

These warnings mean that minor injuries may occur, if

no precautions are taken.

These warnings mean that damage to property may oc-

cur, if no precautions are taken.

These warnings contain references to safety-relevant information or

general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.

This warning draws attention to procedures which serve to prevent or remedy

emergencies or malfunctions:

Procedures marked with this warning must be followed

exactly.

Notes These hints serve to make your work easier or contain references to further
information.

Tip to make your work easier or reference to further information.

1.3 Trademarks

Windows is a trademark of Microsoft Corporation.

VisionPro is a trademark of Cognex Corporation.

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1.4 Terms used

Term Description
KUKA smartHMI User interface of the KUKA System Software
(KUKA smart Human-Machine Interface)
GigE Gigabit Ethernet
GenICam Generic Interface for Cameras: generic pro-
gramming interface for cameras used in
industrial image processing.
Reference pose Robot position for image acquisition
Tool block Image processing task created using WorkVi-
sual.
EKI Ethernet KRL interface
PoE Power over Ethernet
Power supply via network
KONI KUKA Option Network Interface
KLI KUKA Line Interface
Connection to Ethernet network

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 2 Purpose

2 Purpose

2.1 Target group

This documentation is aimed at users with the following knowledge and skills:
 Expert knowledge of KRL programming
 Advanced knowledge of the robot controller system
 Advanced knowledge of network connections
 Knowledge of the VisionPro software from Cognex (training)

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 ob-
tained directly from our subsidiaries.

2.2 Intended use

Use KUKA.VisionTech is used to determine and correct the position of a robot rel-
ative to the position of a component with the aid of one or more cameras. Up
to 3 cameras may be operated simultaneously with the system. Only hardware
components approved by KUKA Roboter GmbH may be used. The hardware
components must only be operated under the specified environmental condi-
tions.

Misuse Any use or application deviating from the intended use is deemed to be imper-
missible misuse. This includes e.g.:
 Operation outside the permissible operating parameters
 Use in potentially explosive environments
 Use in the vicinity of welding applications
 Networking the camera network with a company network

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 3 Product description

3 Product description

3.1 Overview of VisionTech

Functions VisionTech is an add-on technology package and consists of an image pro-

cessing package and a plug-in for the KUKA smartHMI. The acquisition and
processing of images is used to calculate a base correction. The base correc-
tion can be used to correct the position of the robot relative to the position of
a component.

Areas of appli-  Detecting the position of components

cation  Deracking
 Depalletizing

Communication The robot controller communicates with one or more GigE cameras via the im-
age processing system. The connection between the kernel system and the
image processing system is established via the Ethernet KRL interface.

Fig. 3-1: Communication, KR C4

1 Stationary camera 4 Robot

2 Connecting cable 5 Robot-guided cameras
3 KR C4 6 Service laptop

Fig. 3-2: Communication, KR C4 compact

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1 KR C4 compact 3 Switch
2 Connecting cable 4 Cameras

Image processing An image processing environment is installed on the controller during installa-
software tion of VisionTech. This software performs the image processing tasks. This
software must also be installed on the service laptop.

3.2 Hardware components

The following hardware components are available in the form of a hardware

package for KUKA.VisionTech:
 KUKA GigE switch
 KUKA MXG20 cameras
 Calibration plate
 Connecting cables
There are different variants of the hardware package. The variants differ with
regard to the interface, connecting cables and number of cameras:

Type Cameras Position Restriction

2D 1-3 Stationary None
1-3 Moving Only with KR C4
3D 2-3 Moving Only with KR C4

3.2.1 KUKA GigE switch

Overview There are 5 RJ45 connections on the KUKA GigE switch. Ports 1 to 4 are PoE-
capable. KUKA MXG20 cameras can be connected to ports 1 to 3.
Port 5 can be used to connect the KR C4 compact; this port is not PoE-capa-
ble. The switch must be integrated into a housing with a protection rating of
IP 54 and supplied with a direct voltage of 12-36 V. The switch can be mount-
ed on a TS 35 top-hat rail.
In the KR C4, the switch is installed and connected to the power supply of the
KR C4. Up to 3 cameras can be connected to interfaces X64.1 to X64.3. Alter-
natively, the cameras can be connected directly to the switch in the KR C4 via
a cable inlet.

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Fig. 3-3: KUKA GigE switch – overview

1 DIP switch for the function “Power Alarm Relay Output”

2 Changeover switch for port 6 (selection of SFP speed)
3 RJ45 PoE connection for the robot controller
4 3 RJ45 PoE connections for cameras

DIP switches Designation Description

DIP switch for “Power DIP switch 1: P1 error message
Alarm Relay Output”
DIP switch 2: P2 error message
On: Activated
Off: Deactivated
Changeover switch for DIP switches 1 and 2 on: 100 Mbps
port 6 (selection of
DIP switches 1 and 2 off: 1000 Mbps
SFP speed)

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LEDs

Fig. 3-4: KUKA GigE switch – LEDs

Item LED Description

1 P1 Green: Switch is on (if powered via V1)
2 P2 Green: Switch is on (if powered via V2)
3 Gigabit LAN port Green: GigE port is active, data being
transferred to the connected device
4 Gigabit LAN port Yellow: 100 Mbps
5 Gigabit PoE port Green: Port is active
6 Gigabit PoE port Green: PoE is active
7 Fault Yellow: Fault at P1 or P2

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Power supply

Fig. 3-5: KUKA GigE switch – power supply

1 Power supply connection 12-36 V DC

2 Power supply connection 24 V DC
3 Output, alarm relay
4 Power supply connection 12-36 V DC
5 Housing ground

Interfaces

Fig. 3-6: KUKA GigE switch – interfaces

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3.2.2 KUKA MXG20 camera

Overview The KUKA MXG20 camera conforms to the GigE standard and is PoE-capa-
ble. The image resolution is 2 megapixels. The camera can be powered via
PoE or from an external power supply. A protective lens hood is mounted on
the camera. C-Mount lenses can be used (lenses are not included in the scope
of supply).
The following must be ensured when selecting the lens:
 The lens fits on the camera
 The lens fits into the protective lens hood (depth: 45 mm, can be enlarged
using extension rings – 12 mm each)

It is recommended to use no more than 3 extension rings.

 The lens matches the sensor (size: 1 /1.8")

A protective cap is mounted on the connection for the process interface / pow-
er supply. This may only be removed if a cable is connected to the interface.

Fig. 3-7: KUKA MXG20 camera – overview

1 LEDs
2 Data/PoE interface
3 Process interface / power supply

The camera must not be powered simultaneously via

PoE and from an external source, otherwise the camera
may be damaged.

Connector pin
allocation

Fig. 3-8: Contact diagram, data/PoE interface (view from contact side)

1 MX3- 5 MX2+ (pos./neg. Vport)

2 MX4+ 6 MX1+ (neg./pos. Vport)
3 MX4- 7 MX3+
4 MX1- (neg./pos. Vport) 8 MX2- (pos./neg. Vport)

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Fig. 3-9: Contact diagram, process interface / power supply (view from
contact side)

1 OUT 3 5 Uext OUT

2 Power VCC+ 6 OUT 1
3 IN1 7 Power GND
4 IO GND 8 OUT 2

LEDs

Fig. 3-10: KUKA MXG20 camera – LEDs

Item LED Description

1 Status  Green: Connection is active.
 Flashing green: Data are being received
 Flashing red: Data are being sent
2 Power Green: Camera is switched on

3.2.3 Connecting cables

Different connecting cables are required for the operation of one or more cam-
eras. The connecting cables used conform to the CAT6 standard for network
cables. The network cables have different connectors depending on the inter-
face. The cables are available in various lengths.

3.2.4 Calibration plates

A calibration plate is required for the calibration of a camera. Calibration plates

are available in the following sizes:
 24 x 24 inch (60.9 x 60.9 cm), size of one square: 20 mm
 12 x 12 inch (30.5 x 30.5 cm), size of one square: 10 mm
 11.5 x 8 inch (29.2 x 20.3 cm), size of one square: 6.35 mm
 5.75 x 4 inch (14.6 x 10.2 cm), size of one square: 3.175 mm
 2.875 x 2 inch (7.3 x 5.1 cm), size of one square: 1.5875 mm

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 4 Technical data

4 Technical data

4.1 KUKA MXG20 camera

Basic data Power supply (exter- Control voltage: 12 … 24 V DC ± 10%

nal)
Rated current: 176 … 252 mA
Power supply (PoE) Control voltage: 36 … 57 V DC
Rated current: 88 mA (with 48 V DC)
Energy consumption approx. 4.2 W
Digital input Voltage (min.): 0 … 4.5 V DC
Voltage (max.): 11 … 30 V DC
Rated current: 6.0 … 10 mA
Pulse length: min. 2.0 µs
Trigger delay outside of treadout: 1 µs
Trigger delay during treadout: 14 µs
Digital output Voltage: 5 … 30 V DC
Rated current: max. 50 mA
MTBF 335774 h @ 45°C
Sensor size 1
/1.8"
Protection rating IP 67
Weight 185 g
Conformity CE

Ambient condi- Storage and transpor- -25 °C to +70 °C (248 K to 343 K)

tions tation
Operation +5 °C to +50 °C (278 K to 323 K)
Device temperature max. +50 °C (323 K) at the measurement point
Air humidity 5 … 95% (no condensation)

Connections Data/PoE interface Transmission speed:

 100 Mbit/s (Fast Ethernet)
 1000 Mbit/s (Gigabit Ethernet)
Connection: M12 male connector, 8-contact, A
standard
Process interface / Connection: M12 female connector, 8-contact, A
power supply standard

Standards and Name Definition

guidelines 2004/108/EC EMC Directive:
Directive 2004/108/EC of the European Parlia-
ment and of the Council of 15 December 2004
on the approximation of the laws of the Member
States relating to electromagnetic compatibility
and repealing Directive 89/336/EEC

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Name Definition
EN 61000-6-2 Electromagnetic compatibility (EMC) - Part 6-2:
Generic standards – Immunity for industrial envi-
ronments
EN 61000-6-4 Electromagnetic compatibility (EMC) - Part 6-4:
Generic standards – Emission standard for
industrial environments

4.2 KUKA GigE switch

Basic data Housing Metal

Protection classifica- IP 30
tion
Dimensions 41 x 99.9 x 144.3 mm
Weight 580 g
Control voltage 12 … 36 V DC
Energy consumption approx. 7.5 W
MTBF > 450000 h @ 45°
Conformity CE, FCC Part 15, RoHS

Ethernet interface Interface 1000base-T, 100base-TX, 10base-T

Standard IEEE 802.3 for 10base-T
IEEE 802.3u for 100base-TX and 100base-X
IEEE 802.3z for 1000base-X
IEEE 802.3ab for 1000base-T
IEEE 802.3x for flow control
IEEE 802.3at PoE specification (up to 30 watts
per port for PoE)
Ports 4x with PoE, 1x SFP, 1x without PoE
Packet size Up to 9 kB, supports jumbo frames
Auto-functions Auto-negotiation, auto-crossover
PoE Conforms to IEEE 802.3at
Protective function Against overload current
Power infeed Up to 30 watts per port

Ambient condi- Storage -40 °C to +85 °C (233 K to 358 K)

tions Operation -40 °C to +60 °C (233 K to 333 K)
Air humidity 5 … 95% (no condensation)

Standards and Name Definition

guidelines 2004/108/EC EMC Directive:
Directive 2004/108/EC of the European Parlia-
ment and of the Council of 15 December 2004
on the approximation of the laws of the Member
States relating to electromagnetic compatibility
and repealing Directive 89/336/EEC
EN 55022 Information technology equipment – Radio dis-
turbance characteristics – Limits and methods of
measurement

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Name Definition
EN 55024 Information technology equipment – Immunity
characteristics – Limits and methods of mea-
surement
EN 61000-3-2 Electromagnetic compatibility (EMC) - Part 3-2:
Limits – Limits for harmonic current emissions
EN 61000-3-3 Electromagnetic compatibility (EMC) - Part 3-3:
Limits – Limitation of voltage changes, voltage
fluctuations and flicker in public low-voltage sup-
ply systems, for equipment with rated current

4.3 Connecting cables

4.3.1 Connecting cables, KR C4

Basic data Type Suitable for use on robots

Configuration 4x CAT6 elements acc. to DIN EN 50288-5-2
Conductor Bare copper strand 4x2xAWG26
Outside diameter 8.3 ± 0.2 mm
Operating voltage ≤ 60 V
Transmission charac- in accordance with DIN EN 50288-5-2
teristics, CAT6 ele-
ment
Transmission range 50 m (nominal)
Bending radius (one- ≥ 3x cable diameter
time)
Bending radius (mov- ≥ 10x cable diameter
ing)
Certification UL AWM Style 20963 80 °C 30 V

Interfaces Connecting cable Connector des- Connections

ignation
KR C4 – linear unit X64.1 – X74.1.1 PushPull V4 connector at
both ends
X64.2 – X74.2.1
Linear unit – robot X74.1.1 – X74.1 PushPull V4 coupling –
PushPull V4 connector
X74.2.1 – X74.2
KR C4 – robot X64.1 – X74.1 PushPull V4 connector at
both ends
X64.2 – X74.2
KR C4 – camera X64.1 – B1 PushPull V4 connector –
M12 male connector, 8-
X64.2 – B2
contact
X64.3 – B3

Connecting cable Cable lengths

KR C4 – camera 5 m, 15 m, 25 m, 35 m
KR C4 – linear unit 7 m, 15 m, 25 m
Linear unit – robot 5m
KR C4 – robot 7 m, 15 m, 25 m

If a cable inlet on the KR C4 is used instead of interface X64, the following con-
nectors are available:

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Connecting cable Connector des- Connections

ignation
Switch – linear unit A13.1 – X74.1.1 RJ45 connector – Push-
Pull V4 connector
A13.2 – X74.2.1
Linear unit – robot X74.1.1 – X74.1 PushPull V4 coupling –
PushPull V4 connector
X74.2.1 – X74.2
Switch – robot A13.1 – X74.1 RJ45 connector – Push-
Pull V4 connector
A13.2 – X74.2
Switch – camera A13.1 – B1 RJ45 connector – M12
male connector, 8-contact
A13.2 – B2
A13.3 – B3

The RJ45 connectors that are connected to interfaces A13.1 to A13.3 have
protection rating IP 20.
For detailed specifications of the connecting cables, see (>>> 9.3.6 "De-
scription of the connecting cables" Page 40).

4.3.2 Connecting cables, KR C4 compact

Basic data Type Not suitable for use on robots

Configuration 4x CAT6 elements
Conductor Bare copper AWG 26
Outside diameter 6.2 ± 0.15 mm
Operating voltage 30 V
Bending radius 4x cable diameter
Certification UL 94 V0

Interfaces Connecting cable Connector des- Connections

ignation
KR C4 compact – switch KONI – No RJ45 connectors at both
PoE5 ends
Switch – camera PoE 1 – B1 RJ45 connector – M12
male connector, 8-contact
PoE 2 – B2
PoE 3 – B3

The RJ45 connectors that are connected to interfaces PoE 1 to PoE 3 have
protection rating IP 20.

Connecting cable Cable lengths

KR C4 compact – switch 1 m, 5 m
Switch – camera 5 m, 15 m, 25 m, 35 m

For detailed specifications of the connecting cables, see (>>> 9.3.6 "De-
scription of the connecting cables" Page 40).

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4.4 Dimensions of the camera

Fig. 4-1: Dimensions of the camera (dimensions in mm)

1 Rear view
2 Side view
3 View from below
4 Front view
5 Side view with protective lens hood

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4.5 Dimensions of the extension

Fig. 4-2: Dimensions of the extension (dimensions in mm)

1 Front view
2 Side view

4.6 Plates and labels

Camera The identification plate is already mounted on the camera. The camera label
must be selected and attached by the user; this depends on the interface to
which the camera is connected:
 Interface X64.1 / A13.1 / PoE 1: label B1
 Interface X64.2 / A13.2 / PoE 2: label B2
 Interface X64.3 / A13.3 / PoE 3: label B3 (for stationary cameras only)

Fig. 4-3: Plates and labels on the camera

Plate no. Designation

1 Camera identification plate
2 Camera label

Switch The following plates and labels are attached to the switch.

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Fig. 4-4: Plates and labels on the switch

Plate no. Designation

1 Switch identification plate

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 5 Safety

5 Safety
This documentation contains safety instructions which refer specifically to the
software and hardware 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 In-
tegrators or the Operating and Programming Instructions for End Users.

The “Safety” chapter in the operating and programming instructions

of the KUKA System Software (KSS) must be observed. Death to per-
sons, severe injuries or considerable damage to property may other-
wise result.

5.1 General safety measures

If the position of the component is not correctly detected,

this may result in a collision. Before operation, check the
result of the base correction using the subprogram VT_CHECKPOSE.

The Status and Turn of a target pose may be altered due

to the base correction, thereby causing a collision. To
avoid this, use the subprogram VT_DIRECT. (>>> 11.18 "Subprogram
VT_DIRECT" Page 77)

The protective lens hood must be mounted on the cam-

era during operation. Otherwise, the lens can become
loose and cause material damage.

The user must carry out a risk analysis and is responsible for ensuring
correctly adapted lighting.

When fastening the cameras, the tightening torques must be ob-

served; see (>>> 18.1 "Tightening torque" Page 97).

Personnel The operator must meet the following preconditions:

 The operator must be trained for the work to be carried out.
 Start-up work may only be carried out by qualified personnel. These are
people who, due to their specialist training, knowledge and experience,
and their familiarization with the relevant standards, are able to assess the
work to be carried out and detect any potential hazards.

5.2 Standards and regulations

Name Definition Edition

EN 60204-1 + A1 Safety of machinery: 2009

Electrical equipment of machines - Part 1: General require-
ments

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 6 Planning

6 Planning

6.1 Connecting cables and interfaces

Connecting The connecting cables comprise all the cables for transferring energy and sig-
cables nals between the robot controller, linear unit, robot and cameras. The following
connecting cables are available:
 For the KR C4 with interface X64:
 Connecting cable, KR C4 – linear unit
 Connecting cable, linear unit – robot
 Connecting cable, KR C4 – robot
 Connecting cable, KR C4 – camera
 For the KR C4 with cable inlet to interface A13 on the switch:
 Connecting cable, switch – linear unit
 Connecting cable, linear unit – robot
 Connecting cable, switch – robot
 Connecting cable, switch – camera
 For the KR C4 compact:
 Connecting cable, KR C4 compact – switch
 Connecting cable, switch – camera
All the connecting cables for the KR C4 are suitable for use on robots. The
connecting cables for the KR C4 compact are not suitable for use on robots.
Information about the energy supply system for axes 1 to 3 and axes 3 to 6
can be found in separate documentation.
Depending on the specific system configuration, connecting cables are re-
quired in different lengths. The following cable lengths are available:

Connecting cable Cable lengths

KR C4 – camera 5 m, 15 m, 25 m, 35 m
KR C4 – linear unit 7 m, 15 m, 25 m
Linear unit – robot 5m
KR C4 – robot 7 m, 15 m, 25 m
KR C4 compact – switch 1 m, 5 m
Switch – camera 5 m, 15 m, 25 m, 35 m

The maximum length of the connecting cables must not exceed 45 m with
moving (robot-guided) cameras and 35 m with stationary cameras. Thus if the
robot is operated on a linear unit which has its own energy supply chain these
cables must also be taken into account.
The following points must be observed when planning and routing the con-
necting cables:
 Protect cables against exposure to mechanical stress.
 Route the cables without mechanical stress – no tensile forces on the con-
nectors
 Cables are only to be installed indoors.
 Route cables in such a way that they cannot be damaged by sharp edges,
tools or other materials.
 Route cables in such a way that they are located outside of the camera’s
field of vision.
 Observe permissible temperature range (fixed installation) of 243 K (-
30 °C) to 363 K (+90 °C).

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For detailed specifications of the connecting cables, see (>>> 9.3.6 "De-
scription of the connecting cables" Page 40).

Interface X64 Interfaces X64.1 to X64.3 are situated on the connection panel of the KR C4.

Fig. 6-1: Interfaces X64.1 to X64.3

1 Connection X64.1 3 Connection X64.3

2 Connection X64.2

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 7 Transportation

7 Transportation

7.1 Transportation

Cameras Before transportation, the cameras must be removed. A protective cap must
be mounted on the connection for the process interface / power supply. The
cameras must be packaged for transportation in ESD protection foil. Care
must be taken to ensure that the cameras do not come into contact with hu-
midity.

Switch The switch must be packaged for transportation in ESD protection foil. Care
must be taken to ensure that the switch does not come into contact with hu-
midity.

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 8 Installation and licensing

8 Installation and licensing

8.1 System requirements

Robot controller Hardware:

 KR C4
 Or KR C4 compact
 Motherboard D3076-K
Software:
 KUKA System Software 8.2
 Or VW System Software 8.2
 KUKA.Ethernet KRL 2.2

Laptop/PC Software:
 WorkVisual 3.0
The requirements for installation of WorkVisual are contained in the
WorkVisual documentation.

8.2 Installing or updating VisionTech

It is advisable to archive all relevant data before updating a software

package.

Precondition  “Expert” user group

 Software on USB stick (unpacked)

Recommendation: Use a KUKA stick. Data may be lost if

any other stick is used.

At least 1.5 GB of free space must be available on the USB stick.

During the installation of the smartPAD, the installation may take up

to 1 hour due to the size of the technology package.

Procedure 1. Connect the USB stick to the robot controller or smartPAD.

2. In the main menu, select Start-up > Additional software.
3. Press New software. The entry VisionTech must be displayed in the
Name column and drive E:\ or K:\ in the Path column.
If not, press Refresh.
4. If the specified entries are now displayed, continue with step 5.
If not, the drive from which the software is being installed must be config-
ured first:
 Press the Configuration button. A new window opens.
 Select a line in the Installation paths for options area.
Note: If the line already contains a path, this path will be overwritten.
 Press Path selection. The available drives are displayed.
 Select E:\. (If stick connected to the robot controller.)
Or select K:\. (If stick connected to the smartPAD.)

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 Press Save. The window closes again.

The drive only needs to be configured once and then remains saved for
further installations.
5. Mark the entry VisionTech and click on Install. Answer the request for
confirmation with Yes.
6. Confirm the reboot prompt with OK.
7. Remove the stick.
8. Reboot the robot controller. The robot controller is then automatically re-
started once again.

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

8.3 Uninstalling VisionTech

It is advisable to archive all relevant data before uninstalling a soft-

ware package.

If VisionTech is uninstalled, the image processing environment is not

uninstalled automatically at the same time. If the image processing
environment is to be uninstalled, it must be uninstalled separately via
the Windows Control Panel.

Precondition  “Expert” user group

Procedure 1. In the main menu, select Start-up > Additional software.

2. Mark the entry VisionTech and click on Uninstall. Reply to the request for
confirmation with Yes. Uninstallation is prepared.
3. Reboot the robot controller. Uninstallation is resumed and completed.

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

8.4 Licensing VisionTech

8.4.1 Activating the license

Procedure 1. In the main menu, select VisionTech > Licensing.

2. Enter the license key in the License key box. The license key is either on
a sticker in the robot controller or is enclosed with the software.

Fig. 8-1: Adhesive label in the robot controller (example)

1 License key

3. Press Create footprint and select a directory. A file is generated in the se-
lected directory which links the control PC to the license. An encrypted sig-
nature for this control PC is saved in the file.
4. Send the generated file to [email protected]. KUKA Service
will use this to create a licensing file and send it to you.

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5. Press ..., select the received licensing file and confirm with OK.
6. Reboot the robot controller.

8.4.2 Repairing the license

Description If hardware components are modified, added or exchanged, this may invali-
date the license. A license becomes invalid if the current signature of the con-
trol PC differs too greatly from the saved signature. In this case, the license
can be repaired.

Procedure 1. In the main menu, select VisionTech > Licensing.

2. In the list of currently installed licenses, select the license to be repaired.
3. Press Create repair request and select a directory. A file is generated in
the selected directory.
4. Send the generated file to [email protected]. KUKA Service
will use this to create a new licensing file and send it to you.
5. Press ..., select the received licensing file and confirm with OK.
6. Reboot the robot controller.

8.4.3 Activating an emergency license

Description It is possible to activate an emergency license. A total of 5 emergency licenses

are available. An emergency license is valid for 3 days. On expiry, emergency
licenses cannot be reactivated. For this reason, they should only be used in
an actual emergency.

Procedure 1. In the main menu, select VisionTech > Licensing.

2. Select the Activate emergency license tab.
3. Press Activate next emergency license.
4. Reboot the robot controller.

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9 Start-up and recommissioning

9.1 Start-up for a stationary camera - overview

Step Description
1 Connect camera to the robot controller.
(>>> 9.3.1 "Networking KR C4 with interface X64, stationary"
Page 38)
(>>> 9.3.2 "Networking KR C4 with cable inlet, stationary"
Page 38)
(>>> 9.3.3 "Networking KR C4 compact, stationary"
Page 39)
2 Refresh the sensor overview.
1. In the main menu, select VisionTech > Sensor overview.
2. Press Refresh sensors.
3 Configure Ethernet KRL interface.
(>>> 9.4 "Configuring the Ethernet KRL interface" Page 43)
4 Configure the camera network.
(>>> 9.5 "Configuring the camera network" Page 43)
5 Configure the camera.
(>>> 9.6 "Configuring cameras" Page 44)
6 Align the camera.
(>>> 9.7 "Aligning camera (stationary)" Page 45)
7 Calibrate the camera.
(>>> 9.9 "Calibrating camera (stationary)" Page 46)

9.2 Start-up for moving cameras - overview

Step Description
1 Connect camera to the robot controller.
(>>> 9.3.4 "Networking KR C4 with interface X64, robot-
guided" Page 39)
(>>> 9.3.5 "Networking KR C4 with cable inlet, robot-guided"
Page 40)
2 Refresh the sensor overview.
1. In the main menu, select VisionTech > Sensor overview.
2. Press Refresh sensors.
3 Configure Ethernet KRL interface.
(>>> 9.4 "Configuring the Ethernet KRL interface" Page 43)
4 Configure the camera network.
(>>> 9.5 "Configuring the camera network" Page 43)
5 Configure the cameras.
(>>> 9.6 "Configuring cameras" Page 44)

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Step Description
6 Align the cameras.
(>>> 9.8 "Aligning cameras (moving)" Page 45)
7 Calibrate the cameras.
(>>> 9.10 "Calibrating cameras (moving)" Page 48)

9.3 Connecting cameras to the robot controller

Description The cameras are connected via Ethernet; the networking differs depending on
the robot controller used and the mounting type of the cameras.

Variant Description
KR C4 with interface X64, (>>> 9.3.4 "Networking KR C4 with inter-
robot-guided face X64, robot-guided" Page 39)
KR C4 with cable inlet, (>>> 9.3.5 "Networking KR C4 with cable
robot-guided inlet, robot-guided" Page 40)
KR C4 with interface X64, (>>> 9.3.1 "Networking KR C4 with inter-
stationary face X64, stationary" Page 38)
KR C4 with cable inlet, sta- (>>> 9.3.2 "Networking KR C4 with cable
tionary inlet, stationary" Page 38)
KR C4 compact, stationary (>>> 9.3.3 "Networking KR C4 compact,
stationary" Page 39)

9.3.1 Networking KR C4 with interface X64, stationary

Procedure  Carry out networking as illustrated below:

Fig. 9-1: Networking KR C4 with interface X64, stationary (maximum

number of cameras)

1 KR C4 2 KUKA MXG20 camera

9.3.2 Networking KR C4 with cable inlet, stationary

Procedure  Carry out networking as illustrated below:

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Fig. 9-2: Networking KR C4 with cable inlet, stationary (maximum num-

ber of cameras)

1 KR C4 2 KUKA MXG20 camera

9.3.3 Networking KR C4 compact, stationary

Procedure  Carry out networking as illustrated below:

Fig. 9-3: Networking KR C4 compact, stationary (maximum number of

cameras)

1 KR C4 compact 3 KUKA MXG20 camera

2 KUKA GigE switch

9.3.4 Networking KR C4 with interface X64, robot-guided

Procedure  Carry out networking as illustrated below:

Fig. 9-4: Networking KR C4 with interface X64, robot-guided

1 KUKA MXG20 camera 3 Linear unit (optional)

2 Robot 4 KR C4

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9.3.5 Networking KR C4 with cable inlet, robot-guided

Procedure  Carry out networking as illustrated below:

Fig. 9-5: Networking KR C4 with cable inlet, robot-guided

1 KUKA MXG20 camera 3 Linear unit (optional)

2 Robot 4 KR C4

9.3.6 Description of the connecting cables

Configuration The connecting cables are used to transfer power and signals between the ro-
bot controller, linear unit, robot and cameras.
The following connecting cables are available:
 For the KR C4 with interface X64:
 Connecting cable, KR C4 – linear unit
 Connecting cable, linear unit – robot
 Connecting cable, KR C4 – robot
 Connecting cable, KR C4 – camera
 For the KR C4 with cable inlet to interface A13 on the switch:
 Connecting cable, switch – linear unit
 Connecting cable, linear unit – robot
 Connecting cable, switch – robot
 Connecting cable, switch – camera
 For the KR C4 compact:
 Connecting cable, KR C4 compact – switch
 Connecting cable, switch – camera

Interfaces, KR C4 For connection of the connecting cables between the KR C4, linear unit, robot
and cameras, the following connectors are available at the interfaces:

Connecting cable Connector des- Connections

ignation
KR C4 – linear unit X64.1 – X74.1.1 PushPull V4 connector at
both ends
X64.2 – X74.2.1
Linear unit – robot X74.1.1 – X74.1 PushPull V4 coupling –
PushPull V4 connector
X74.2.1 – X74.2
KR C4 – robot X64.1 – X74.1 PushPull V4 connector at
both ends
X64.2 – X74.2
KR C4 – camera X64.1 – B1 PushPull V4 connector –
M12 male connector, 8-
X64.2 – B2
contact
X64.3 – B3

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If a cable inlet on the KR C4 is used instead of interface X64, the following con-
nectors are available:

Connecting cable Connector des- Connections

ignation
Switch – linear unit A13.1 – X74.1.1 RJ45 connector – Push-
Pull V4 connector
A13.2 – X74.2.1
Switch – robot A13.1 – X74.1 RJ45 connector – Push-
Pull V4 connector
A13.2 – X74.2
Switch – camera A13.1 – B1 RJ45 connector – M12
male connector, 8-contact
A13.2 – B2
A13.3 – B3

Connecting The following connecting cables are for a KR C4 with interface X64:
cables, KR C4

Fig. 9-6: Connecting cable, KR C4 – linear unit

Fig. 9-7: Connecting cable, linear unit – robot

Fig. 9-8: Connecting cable, KR C4 – robot

Fig. 9-9: Connecting cable, KR C4 – camera

The following connecting cables are for a KR C4 with a cable inlet:

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Fig. 9-10: Connecting cable, switch – linear unit

Fig. 9-11: Connecting cable, switch – robot

Fig. 9-12: Connecting cable, switch – camera

Interfaces, KR C4 For connection of the connecting cables between the KR C4 compact, switch
compact and cameras, the following connectors are available at the interfaces:

Connecting cable Connector des- Connections

ignation
KR C4 compact – switch KONI – No RJ45 connectors at both
PoE5 ends
Switch – camera PoE 1 – B1 RJ45 connector – M12
male connector, 8-contact
PoE 2 – B2
PoE 3 – B3

Connecting
cables, KR C4
compact

Fig. 9-13: Connecting cable, KR C4 compact – switch

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Fig. 9-14: Connecting cable, switch – camera

9.4 Configuring the Ethernet KRL interface

Description To establish a connection between the kernel system and the image process-
ing system, the number of the flag that is to trigger execution of the interrupt
program must be entered in the configuration file for the Ethernet KRL inter-
face. The interrupt program monitors the result of the image processing. It is
triggered once the calculation of the image processing is completed.

Precondition  User group "Expert".

 Operating mode T1 or T2.

Procedure 1. Open the configuration file VisionTechConfig.xml in the directory

C:\KRC\ROBOTER\Config\User\Common\EthernetKRL.
2. In the line:
<ELEMENT Tag="TaskResult/EndOfResult" Set_Flag="Choose Flag" />

replace the entry Choose Flag with the number of the flag that is to trig-
ger execution of the interrupt program.
3. Save and close the file.
4. In the main menu, select Configuration > Inputs/outputs > I/O drivers
and click on Reconfigure.
The I/O driver is reconfigured.

9.5 Configuring the camera network

The camera network must not be connected to another network.

During productive operation, the network configuration must not be
changed.

Following installation of VisionTech, the network card is configured as follows:

 IP address: 192.169.2.100
 Subnet mask: 255.255.0.0

Precondition  The cameras are connected to the GigE switch.

 A free address range is available for the camera network.

The address range of the camera network must not be in

the address range of the KLI or the Windows network.
This can cause severe errors in the robot controller.

Example Device IP address Subnet mask

address range 1st GigE camera 192.169.2.101 255.255.0.0
2nd GigE camera 192.169.2.102 255.255.0.0

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Device IP address Subnet mask

3rd GigE camera 192.169.2.103 255.255.0.0
GigE network card in the robot 192.169.2.100 255.255.0.0
controller

Procedure 1. In the main menu, select VisionTech > Sensor overview.

2. Select the camera that is to be configured.
3. On the Network tab, enter the IP address of the camera and the subnet
mask for the address range of the camera network.
4. Save the settings.
5. If necessary, repeat steps 2 to 4 for further cameras.

9.6 Configuring cameras

VisionTech can be used with both stationary and moving cameras. A station-
ary camera is fixed in its position, e.g. mounted on a stand or on the ceiling. A
moving camera is mounted on the robot flange.

Procedure 1. In the main menu, select VisionTech > Sensor overview.

2. Select the camera that is to be configured.
3. On the General tab, select the mounting type for the camera.
4. Optionally: Enter the name, e.g. “Camera on robot”, in the Description
box.
5. Press Save.
6. Repeat steps 2 and 3 for the other cameras.

Description

Fig. 9-15: Sensor overview

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Field Description
Serial number Serial number of the cameras
IP address IP address of the cameras
Description Description of the cameras
Status  Green: The camera is ready for operation.
 Red: The camera is not ready for operation
and can thus not be used.

9.7 Aligning camera (stationary)

Precondition  The object to be measured (e.g. component or calibration plate) is mount-

ed.
 The camera is networked.
 The network has been configured.

Procedure 1. In the main menu, select VisionTech > Live picture.

2. Press Start. A live image is generated for the camera.
3. Position the camera over the measurement object so that the measure-
ment object is visible in the live image of the camera.
4. Press on the live image of one camera. The live image is displayed in en-
larged form.
5. Enter the default exposure time or set it using the plus/minus keys or the
slider control.
6. Save the settings by selecting Set default exposure.
7. Use the arrow button to switch back to the overview and perform steps 4
to 6 for the other cameras.
8. Tighten and secure the camera fastening screws.
9. Focus the camera with the aid of the enlarged live image display until the
measurement object is clearly visible.
10. Secure the lens of the camera with the fastening screws.
11. Screw on the protective lens hood.
12. Remove the protection foil from the protective lens hood.

9.8 Aligning cameras (moving)

Precondition  The object to be measured (e.g. component or calibration plate) is mount-

ed.
 The cameras are networked.
 The network has been configured.
 The cameras are either mounted on the robot flange or on a tool that is
mounted on the robot flange.
 The cameras have the same orientation, i.e. the component is in the same
position in all the images.

Procedure 1. In the main menu, select VisionTech > Live picture.

2. Press Start. A live image is generated for each camera.
3. Position the robot over the measurement object so that the measurement
object is visible in the live image of the cameras. If necessary, align the
cameras again.
4. Press on the live image of one camera. The live image is displayed in en-
larged form.
5. Enter the default exposure time or set it using the plus/minus keys or the
slider control.

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6. Save the settings by selecting Set default exposure.

7. Use the arrow button to switch back to the overview and perform steps 4
to 6 for the other cameras.
8. Tighten and secure the camera fastening screws.
9. Focus the cameras with the aid of the enlarged live image display until the
measurement object is clearly visible.
10. Secure the lenses of the cameras with the fastening screws.
11. Screw on the protective lens hood.
12. Remove the protection foil from the protective lens hood.

9.9 Calibrating camera (stationary)

During calibration, the IP address of camera must not be changed.

Precondition  The camera is mounted in a fixed position and configured as stationary.

 The camera is networked.
 The network has been configured.
 The camera is aligned.
 A calibration plate is attached. This is in the workpiece plane and in the
field of vision of the camera.

Procedure 1. In the main menu, select VisionTech > Live picture.

2. Press on the live image of the camera. The live image is displayed in en-
larged form.
3. Enter the calibration exposure time or set it using the plus/minus keys or
the slider control.
4. Save the settings by selecting Set calibration exposure.
5. In the main menu, select VisionTech > Calibration.
A freeze-frame image from the camera is displayed on the fixed sensors
tab. If the camera is calibrated, the freeze-frame image has a green frame.
If the camera is not calibrated, the freeze-frame image has a red frame.
6. Select the calibration plate used as the calibration body.
All calibration plates from KUKA are available for selection. Each calibra-
tion plate has a different size which is marked on the plate. The calibration
plate used can be determined on the basis of size.
7. Select the camera by pressing on the freeze-frame image.
8. Press Calibration Wizard.
9. Press Take picture. The fiducial mark (cross at the center of the calibra-
tion plate) must be visible.

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Fig. 9-16: Calibration plate with fiducial mark

1 Fiducial mark 2 Origin

Recommendations
The camera should be directly above the calibration plate.
The calibration plate should fill as much of the image of the camera
as possible.

10. Press Calibrate.

11. Once the calibration process has been completed, the result is displayed.
For an adequate degree of accuracy, the result should be < 1 mm.
12. Select an existing calibration plane in the Calibration plane box or choose
Create new calibration plane... to create a new calibration plane:
a. Enter a name for the calibration plane in the Name box.
b. Optionally: Enter a description of the calibration plane in the Descrip-
tion box.

Recommendation: The description of the calibration plane should

contain the number of the base used.

c. Select an existing base in the Base ID box or choose Measure new

base... to measure a new base. The base can, for example, be cali-
brated using the 3-point method.

If an existing calibration plane is selected, the result is overwritten.

The base used must be calibrated to the calibration plate (>>> Fig. 9-
16 ).

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Fig. 9-17: Base for a stationary camera

1 Stationary camera 2 Calibration plate

13. Press Save. The settings are saved.

14. Press Exit. The window closes.

9.9.1 Deleting a calibration plane

Procedure 1. In the main menu, select VisionTech > Calibration management.

2. In the Serial number box, select the camera used to create the calibration
plane.
3. In the Calibration result box, select the plane that was deleted.
4. Press Delete. The calibration plane is deleted. If the calibration plane was
used in a task, the task can no longer be executed.

9.10 Calibrating cameras (moving)

If a palletizing robot is used, it is not possible to calibrate moving (ro-

bot-guided) cameras.

During calibration, the IP addresses of cameras must not be

changed.

Precondition  The cameras are mounted on the robot flange and configured as moving.
 The cameras are networked.
 The network has been configured.
 The cameras are aligned.
 A calibration plate is mounted and is located in the field of vision of the
cameras.
 The NULLFRAME tool is selected.

Procedure 1. In the main menu, select VisionTech > Calibration.

Freeze-frame images from the cameras are displayed on the moving sen-
sors tab. The freeze-frame images of the cameras that have already been
calibrated have a green frame. In the case of cameras that have not yet
been calibrated, the freeze-frame images have a red frame.
2. Select the cameras that are to be calibrated by pressing the freeze-frame
images.
3. Press Calibration Wizard.

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4. Move the robot to the first calibration pose and press Take picture. The
fiducial mark (cross at the center of the calibration plate) must be visible in
every pose. It is not possible to record the same pose twice.

Recommendation: For the first pose, the cameras should be directly

above the calibration plate. In every pose, the cameras should be at
a different angle relative to the calibration plate; for this, the robot
must be moved.

5. Repeat step 4 for every pose. Record at least 6 poses. A maximum of 9

poses are possible.
6. Select the calibration plate used as the calibration body.
All calibration plates from KUKA are available for selection. Each calibra-
tion plate has a different size which is marked on the plate. The calibration
plate used can be determined on the basis of size.
7. Press Calibrate. The calibration process takes approx. 5 to 10 minutes.
8. Once the calibration process has been completed, the result is displayed.
For an adequate degree of accuracy, the result should be < 1 mm.
9. Press Save. The result is saved.
10. Press Exit. The window closes.

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10 Configuration

10.1 Configuring a 2D measurement task - overview

Step Description
1 Teach reference position above the component.
2 Create task and take images.
(>>> 10.3 "Creating a task and taking images (stationary)"
Page 51)
(>>> 10.4 "Creating a task and taking images (moving)"
Page 52)
3 Set up an image processing task in WorkVisual.
(>>> 10.5 "Setting up an image processing task in WorkVi-
sual" Page 52)
4 Configure task.
(>>> 10.6 "Configuring a 2D task" Page 56)
5 Generate model.
(>>> 10.7 "Generating a 2D model" Page 59)
6 Test task.
(>>> 10.8 "Testing a 2D task" Page 61)
7 Create KRL program.

10.2 Configuring a 3D measurement task - overview

Step Description
1 Teach reference position above the component.
2 Create task and take images.
(>>> 10.4 "Creating a task and taking images (moving)"
Page 52)
3 Set up an image processing task in WorkVisual.
(>>> 10.5 "Setting up an image processing task in WorkVi-
sual" Page 52)
4 Configure task.
(>>> 10.9 "Configuring a 3D task" Page 62)
5 Generate model.
(>>> 10.10 "Generating a 3D model" Page 64)
6 Test task.
(>>> 10.11 "Testing a 3D task" Page 65)
7 Create KRL program.

10.3 Creating a task and taking images (stationary)

Precondition  The camera is networked and calibrated.

 The network has been configured.

Procedure 1. In the main menu, select VisionTech > Task configuration.

2. Press New and select the 2D fixed type. A new 2D task is created. The
name of the task can be changed.

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 KUKA.VisionTech 2.1

3. Select the created task and activate the desired camera by means of the
check box in the Configurations area.
4. Press the camera icon, select the calibration plane and press Save pic-
ture.
Or: In the Task area, press the Settings icon and select Save.
The image is saved in the directory C:\KRC\TP\VisionTech\Snap-
shots\Name of the task\Camera serial number\Name of the plane. The Snap-
shots folder is a shared network resource. A maximum of 20 images can
be saved per calibration plane; any further images overwrite the oldest ex-
isting image.

10.4 Creating a task and taking images (moving)

Precondition  The cameras are networked.

 The network has been configured.

Procedure 1. In the main menu, select VisionTech > Task configuration.

2. Press New and select the 2D moving or 3D moving type. A new task is
created. The name of the task can be changed.
3. Select the created task and activate the camera that is to be used for tak-
ing images by means of the check box in the Configurations area.
4. In the task, press the Settings icon and select Save.
The images are saved in the directory C:\KRC\TP\VisionTech\Snap-
shots\Name of the task\Camera serial number. The Snapshots folder is a
shared network resource. A maximum of 20 images can be saved per
camera; any further images overwrite the oldest existing image.

10.5 Setting up an image processing task in WorkVisual

Step Description
1 Install the image processing environment on the service lap-
top.
(>>> 10.5.1 "Installing the image processing environment"
Page 53)
Note: It is advisable to archive all the data on the service lap-
top before installation.
2 Install the VisionTech option package in WorkVisual.
3 License the image processing environment in WorkVisual.
(>>> 10.5.2 "Licensing the image processing environment in
WorkVisual" Page 53)
4 Save any perspective controlled images that were taken via
the controller to a USB stick or make them available via the
network.
5 Create a tool block file in WorkVisual.
(>>> 10.5.3 " Creating a tool block file in WorkVisual"
Page 54)
6 Transfer the tool block file to the controller on a USB stick or
via the network.

Information about installing and managing option packages can be

found in the WorkVisual documentation.

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10.5.1 Installing the image processing environment

Precondition  The VisionTech software has been copied to a USB stick, or is accessible
via the network.

Procedure 1. Copy the software to the service laptop.

2. Execute the file VisionTech.exe in the directory ..\INTERNAT\KRCSET-
UP\Vision. The image processing environment is installed.

10.5.2 Licensing the image processing environment in WorkVisual

10.5.2.1 Activating the license

Procedure 1. Select the menu sequence Editors > Option packages > VisionTech >
License configuration. The License configuration window is opened.
2. Click on Install license.
3. Enter the license key in the License key box. The license key is enclosed
with the software.

Fig. 10-1: Extract from the enclosed printout (example)

1 License key

It is not possible to take images with the license for the service laptop.

4. Click on Create footprint and select a directory. A file is generated in the

selected directory which links the image processing computer to the li-
cense. An encrypted signature for this computer is saved in the file.
5. Send the generated file to [email protected]. KUKA Service
will use this to create a licensing file and send it to you.
6. Click on ..., select the received licensing file and confirm with OK.
7. Restart WorkVisual.

10.5.2.2 Repairing the license

Description If hardware components are modified, added or exchanged, this may invali-
date the license. A license becomes invalid if the current signature of the im-
age processing computer differs too greatly from the saved signature. In this
case, the license can be repaired.

Procedure 1. Select the menu sequence Editors > Option packages > VisionTech >
License configuration. The License configuration window is opened.
2. Click on Repair license.
3. In the list of installed licenses, select the license to be repaired.
4. Click on Create repair request and select a directory. A file is generated
in the selected directory.

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 KUKA.VisionTech 2.1

5. Send the generated file to [email protected]. KUKA Service

will use this to create a new licensing file and send it to you.
6. Click ..., select the received licensing file and confirm with OK.
7. Restart WorkVisual.

10.5.2.3 Activating an emergency license

Description It is possible to activate an emergency license. A total of 5 emergency licenses

are available. An emergency license is valid for 3 days. On expiry, emergency
licenses cannot be reactivated. For this reason, they should only be used in
an actual emergency.

Procedure 1. Select the menu sequence Editors > Option packages > VisionTech >
License configuration. The License configuration window is opened.
2. Click on Install emergency license.
3. Click on Activate emergency license.
4. Restart WorkVisual.

10.5.3 Creating a tool block file in WorkVisual

Procedure 1. Open the VisionTech plug-in:

 Select the menu sequence Editors > Option packages > VisionTech
> Image processing task.

 Alternatively: Click on the button.

2. Select the menu sequence Toolblock > New > 2D or 3D.
3. Select the menu sequence Image source > File... or Directory... and se-
lect the image(s) that were taken using the controller.

4. Click on the button. The image(s) are inserted next to the inputs under
InputImage.

5. Click on the button. Tools and templates are displayed.

(>>> 10.5.3.1 "Templates" Page 55)
6. Select the desired template or tool and drag it between the inputs and out-
puts.
7. Link the inputs and outputs, e.g. InputImage under the inputs with InputIma-
ge in the template. To do so, click on the input or output and drag it onto
the other input or output. The link is displayed by an arrow.
8. Double-click on the template and configure the desired pattern.

9. Click on the button and choose whether the tool should be saved com-
pletely or without images or results.
10. Select a directory and click on Save.

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 10 Configuration

Description

Fig. 10-2: VisionTech plug-in: overview

1 Linking arrow

10.5.3.1 Templates

Template Description
LocatePartsOneStage Type: 2D
Suitable for parts which are defined by relatively coarse structures, e.g.
complete panels. The search area is the entire image. Further tools can
be added; only the result of “PatMax” is transferred, however.
LocatePartsKnown- Type: 2D
Position
With this template, a number of parts are searched for in the field of
view. The rough position of these parts must be known, however. The
search area is limited to the known rough position.

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Template Description
LocatePart3D Type: 3D
With this template, the search procedure is subdivided into 2 steps
(analogous to LocatePartTwoStages):
 Coarse search
The position of the parts in the picture is determined.
 Fine search
Individual features are located which are required for 3D position de-
termination of the part. The features are identified by a consecutive
index. The index is positioned at the start of the name of the feature
tool block. The numbering starts at zero and must be consecutive.
Numbering is largely automatic, however. The fine search is run once
for each instance found in the coarse search.
Templates for features:
 PointFeaturePM
Point feature which is located with a PatMax tool.
 LineSegFeature
Straight line feature; normally represents points on a straight edge of
the part that is to be located. Has a start point and end point, which
are defined by the search area of the FindLine tool.
 LineFeature
Line feature, without a start and end point.
 CircleFeature
Feature which describes a circle in 3D.
Note: The PatMax tool and the FindLine tool must not be renamed. The
features must be evenly distributed over the component.
CrspCollector Collects the data from the FeatureCrsp outputs of 3D feature tool blocks
and makes these available at the output as a list of Crsps. In addition,
the result images of the Crsps are collected and forwarded in the
Graphic output.
StringCollector Collects the values at its inputs and returns these values as a string,
separated by a vertical bar, at the UserData output. The inputs accept
the data types INT32, DOUBLE, BOOL and STRING. These inputs must
be created as required.
PoseCreator Can be used if a 2D pose is not to be generated by a PatMax tool. The
values from which the pose is to be created are provided by the inputs.
PoseCollector Collects the individual poses from various tools and generates a list
which is returned to the PartResults output. This list is expected at this
output by the KUKA interface for 2D tasks.

10.6 Configuring a 2D task

During configuration of a 2D task, a tool block is assigned to the camera. A tool

block contains image processing tasks and has the file extension VPP.
For 2D tasks, only 1 camera is needed; the calibration is carried out at the
workpiece level.

Precondition  A 2D task has been created.

 The following inputs and outputs are preconfigured in the tool block:

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Input Type Description

InputImage ICogImage Input image on which the image
processing task is carried out
NumberOf- INT Number of components to be
Parts detected by means of the image
processing

Output Type Description

PartResults List<CogTransform Positions of the found components
2DLinear> in image coordinates
Scores List<Double> Accuracy with which the compo-
nents were detected
Graphic CogGraphicCollec- Graphic showing the results of the
tion image processing task

 The following outputs can optionally be preconfigured:

Output Type Description
Error Exception Exceptions or errors that occur dur-
ing execution of the image process-
ing task
UserData Object User-specific data forwarded to
KRL by VisionTech. Any type can
be used that is derived from Object
and overwrites the ToString()
method.
Note: Do not make strings with a
semicolon since this is used as an
internal separator.

If the tool block is created with WorkVisual, the required inputs and
outputs already exist.

The directory INTERNAT\KRCSETUP\KRC\TP\VisionTech\Tem-

plate on the VisionTech CD contains sample tool blocks which meet
the following requirements:
 Tool block for 2D tasks with a stationary camera
 Tool block for 2D tasks with a moving camera
 Tool block for 3D tasks

Procedure 1. In the main menu, select VisionTech > Task configuration.

2. Select the desired 2D task.
3. Press the Settings icon and select the number of components to be found.

If the selected is too low, this may lead to inconsistencies, e.g. if each
camera detects different objects. It is advisable to enter the number
of components that one expects to find.

4. Press Import tool block.

5. Select the directory in which the tool block file is located.
6. Select the tool block file and confirm with OK. The file is imported into Vi-
sionTech and can then be used for all tasks.
7. In the line for the camera in the Toolblocks column, select the imported
tool block file.
8. Press the camera icon. A window for setting the exposure time is dis-
played and the selection of calibration planes is displayed.

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 KUKA.VisionTech 2.1

9. Select the calibration plane.

10. Optionally: Enter the exposure time or set it using the plus/minus keys or
the slider control.
11. Press Save. The settings are saved.
Configuration of the task has been successfully completed when the icon
in the Status column changes to green.

Description

Fig. 10-3: Configuring a 2D task

Item Description
1 Back to Overview
2 Name of the task
The name is freely selectable.
3 State of the task
 Green: Task has been successfully configured.
 Red: Task is not configured.
4 Generate model.
 Green frame: Model has been successfully generated.
 Red frame: No model has yet been generated.
5 Test task
 Activated: The task can be tested.
 Deactivated: The task cannot be tested. No model has yet
been generated, or the task is not configured.
6 Settings icon
 Select the number of parts
 Take images from all cameras

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 10 Configuration

Item Description
7 Camera icon
 Set exposure time
 0 … 200 ms
 Select calibration plane
 Take images from this camera
8 Exposure time that has been set
9 Select tool block file
10 Serial number of the camera
11  Activated: Camera is used.
 Deactivated: Camera is not used.

The following buttons are available:

Button Description
New Creates a new task.
Delete Deletes the selected task from the list and from
the file system.
Refresh tasks Reloads all tasks and tool blocks in the directory
C:\KRC\TP\VisionTech\Tasks.
Import tool block Copies the selected file into the directory
C:\KRC\TP\VisionTech\ToolBlocks. The file can
then be selected in every task via the selection
box in the Toolblocks column.

10.7 Generating a 2D model

10.7.1 2D model with a stationary camera

Precondition  The robot base is calibrated to the calibration base.

(>>> 9.9 "Calibrating camera (stationary)" Page 46)
 The task has been configured.
 The icon in the Status column is green.
 There is only 1 component in the field of vision of the camera.

Procedure 1. In the main menu, select VisionTech > Task configuration.

2. In the Task area, press Model.
A model is generated and a result window is displayed.
3. The images in the result window can be enlarged. To do so, press the de-
sired image once.
Generation of the model has been successfully completed when the Mod-
el button has a green frame.
The reference position of the component is now known; all deviations are
relative to this position.

Description Once the model has been generated, a result window with images and a table
is displayed. The result is the position of the component in the calibration base.
Areas detected by the cameras are indicated in green in the images. Areas
that have not been detected are marked in red.

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 KUKA.VisionTech 2.1

Fig. 10-4: Result of 2D model generation with a stationary camera (exam-

ple)

10.7.2 2D model with a moving camera

Precondition  The XY plane of the workpiece base is located on the surface of the com-
ponent.
 The Z axis of the workpiece base points in the same direction as the cali-
bration coordinate system.
 The task has been configured.
 The icon in the Status column is green.
 There is only 1 component in the field of vision of the cameras.
 The NULLFRAME tool is selected.

Procedure 1. In the main menu, select VisionTech > Task configuration.

2. Move the robot to the reference pose.
3. In the Task area, press Model. Confirm the request with Yes.
A model is generated and a result window is displayed.
4. The images in the result window can be enlarged. To do so, press the de-
sired image once.
Generation of the model has been successfully completed when the Mod-
el button has a green frame.
The reference position of the component is now known; all deviations are
relative to this position.

Description Once the model has been generated, a result window with images and a table
is displayed. The result is the position of the component in the workpiece base.
Areas detected by the cameras are indicated in green in the images. Areas
that have not been detected are marked in red.

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10.8 Testing a 2D task

Precondition  The task has been configured.

 The model has been generated.
 The base is the same as was used for model generation.
 Only with use of a moving camera: the NULLFRAME tool is selected.

Procedure 1. In the main menu, select VisionTech > Task configuration.

2. Only with use of a moving camera: move the robot to the reference pose.
3. In the Task area, press Test.
The test is carried out and a result window is displayed.
4. The images in the result window can be enlarged. To do so, press the de-
sired image once.
If user data from the tool block have been transferred, they are displayed
beneath the enlarged image.

Description Once the test has been performed, a result window with images and a table is
displayed.
Areas detected by the cameras are indicated in green in the images. Areas
that have not been detected are marked in red. The differences between the
reference position used for model generation and the calculated position are
displayed in the table. If multiple components have been detected, the tables
are displayed on tabs.
The value of Score is between 0.0 and 1.0. The better the match between the
trained pattern and the pattern in the current search image, the higher the val-
ue of Score.

Fig. 10-5: Result of a 2D task test (example)

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 KUKA.VisionTech 2.1

10.9 Configuring a 3D task

During configuration of a 3D task, a tool block is assigned to the cameras. A

tool block contains image processing tasks and has the file extension VPP.
For 3D tasks, at least 2 cameras are required.

Precondition  A 3D task has been created.

 The following inputs and outputs are preconfigured in the tool block:
Input Type Description
InputImage ICogImage Input image on which the image
processing task is carried out
NumberOf- INT Number of components to be
Parts detected by means of the image
processing

Output Type Description

Graphic CogGraphicCollec- Graphic showing the results of the
tion image processing task
Features List<Cog3DCrsp2D List of features found by means of
3D> the image processing

 The following outputs can optionally be preconfigured:

Output Type Description
Error Exception Exceptions or errors that occur dur-
ing execution of the image process-
ing task
UserData Object User-specific data forwarded to
KRL by VisionTech. Any type can
be used that is derived from Object
and overwrites the ToString()
method.
Note: Do not make strings with a
semicolon since this is used as an
internal separator.

If the tool block is created with WorkVisual, the required inputs and
outputs already exist.

The directory INTERNAT\KRCSETUP\KRC\TP\VisionTech\Tem-

plate on the VisionTech CD contains sample tool blocks which meet
the following requirements:
 Tool block for 2D tasks with a stationary camera
 Tool block for 2D tasks with a moving camera
 Tool block for 3D tasks

Procedure 1. In the main menu, select VisionTech > Task configuration.

2. Select the desired 3D task.
3. Press the Settings icon and select the number of components to be found.

If the selected is too low, this may lead to inconsistencies, e.g. if each
camera detects different objects. It is advisable to enter the number
of components that one expects to find.

4. Press Import tool block.

5. Select the directory in which the tool block file is located.

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6. Select the tool block file and confirm with OK. The file is imported into Vi-
sionTech and can then be used for all tasks.
7. Repeat steps 5 to 7 for further tool block files used.
8. In the line for the desired camera in the Toolblocks column, select the im-
ported tool block file.
9. Press the camera icon. A window for setting the exposure time is dis-
played and the taking of images is displayed.
10. Optionally: Enter the exposure time or set it using the plus/minus keys or
the slider control.
11. Press Save picture. An image is made.
12. Press Save. The setting is saved.
Configuration of the task has been successfully completed when the icon
in the Status column changes to green.

Description

Fig. 10-6: Configuring a 3D task

Item Description
1 Back to Overview
2 Name of the task
The name is freely selectable.
3 State of the task
 Green: Task has been successfully configured.
 Red: Task is not configured.
4 Generate model
 Green frame: Model has been successfully generated.
 Red frame: No model has yet been generated.

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 KUKA.VisionTech 2.1

Item Description
5 Test task
 Activated: The task can be tested.
 Deactivated: The task cannot be tested. No model has yet
been generated, or the task is not configured.
6 Settings icon
 Select the number of parts
 Take images from all cameras
7 Camera icon
 Set exposure time
 0 … 200 ms
 Take images from this camera
8 Exposure time that has been set
9 Select tool block file
10 Serial number of the camera
11  Activated: Camera is used.
 Deactivated: Camera is not used.

The following buttons are available:

Button Description
New Creates a new task.
Delete Deletes the selected task from the list and from
the file system.
Refresh tasks Reloads all tasks and tool blocks in the directory
C:\KRC\TP\VisionTech\Tasks.
Import tool block Copies the selected file into the directory
C:\KRC\TP\VisionTech\ToolBlocks. The file can
then be selected in every task via the selection
box in the Toolblocks column.

10.10 Generating a 3D model

Precondition  The task has been configured.

 The state of the task is green.
 There is only 1 component in the field of vision of the cameras.
 The NULLFRAME tool is selected.

Procedure 1. In the main menu, select VisionTech > Task configuration.

2. Move the robot to the reference pose.
3. In the Task area, press Model. Confirm the request with Yes.
A model is generated and a result window is displayed.
4. The images in the result window can be enlarged. To do so, press the de-
sired image once.
Generation of the model has been successfully completed when the Mod-
el button has a green frame.
The reference position of the component is now known; all deviations are
relative to this position.

Description Once the model has been generated, a result window with images and a table
is displayed. Areas detected by the cameras are indicated in green in the im-
ages. Areas that have not been detected are marked in red. All configured

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 10 Configuration

model points are listed in the table. For each model point, the model type is
specified and whether or not it has been found. The maximum and mean error
when finding the model point are also specified. For good results, the RMS er-
ror should be < 1 mm.

Fig. 10-7: Result of 3D model generation (example)

10.11 Testing a 3D task

Precondition  The task has been configured.

 The model has been generated.
 The base is the same as was used for model generation.
 The NULLFRAME tool is selected.

Procedure 1. In the main menu, select VisionTech > Task configuration.

2. Move the robot to the reference pose.
3. In the Task area, press Test.
The test is carried out and a result window is displayed.
4. The images in the result window can be enlarged. To do so, press the de-
sired image once.
If user data from the tool block have been transferred, they are displayed
beneath the enlarged image.

Description Once the test has been performed, a result window with images and a table is
displayed.
Areas detected by the cameras are indicated in green in the images. Areas
that have not been detected are marked in red. The differences between the
reference position and the calculated position are displayed in the table. If mul-
tiple components have been detected, the tables are displayed on tabs.

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 KUKA.VisionTech 2.1

The value of Score is the mean square residual error after calculation of the
object position relative to the nominal position. If the position of the object can-
not be calculated, Score has the value -1.

Fig. 10-8: Result of a 3D task test (example)

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 11 Programming

11 Programming

11.1 Note on programming

VisionTech is programmed using not KRL commands, but subpro-

grams.
The default configuration file has the name “VisionTechConfig”.

11.2 Subprogram VT_INIT

Description The subprogram VT_INIT initializes the EKI channel. The configuration file is
transferred. VT_INIT is executed in the advance run.

Syntax VT_INIT("Name of the configuration file")

Explanation of Element Description

the syntax Configuration file Name of the configuration file
Type: CHAR (IN)

Example VT_INIT("VisionTechConfig")

11.3 Subprogram VT_OPENCONNECTION

Description The subprogram VT_OPENCONNECTION opens an EKI connection to the

server. The configuration file is transferred. VT_OPENCONNECTION is exe-
cuted in the advance run.

Syntax VT_OPENCONNECTION("Configuration file")

Explanation of Element Description

the syntax Configuration file Name of the configuration file
Type: CHAR (IN)

Example VT_OPENCONNECTION("VisionTechConfig")

11.4 Subprogram VT_TASKTRIGGER

Description The subprogram VT_TASKTRIGGER requests acquisition and processing of

the images. The configuration file and the name of the image processing task
are transferred. VT_TASKTRIGGER triggers an advance run stop.

For this subprogram, the same base and the same tool files must be
used as for model generation. The result is calculated relative to the
base for model generation.

Syntax VT_TASKTRIGGER("Configuration file", "Image processing task")

Explanation of Element Description

the syntax Configuration file Name of the configuration file
Type: CHAR (IN)
Image processing Name of the image processing task to be executed
task
Type: CHAR (IN)

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Example VT_TASKTRIGGER("VisionTechConfig", "TestTask")

11.5 Subprogram VT_TASKTRIGGER_REFBASE

Description The subprogram VT_TASKTRIGGER_REFBASE requests acquisition and

processing of the images. The configuration file and the name of the image
processing task are transferred.
Any base can be used for the execution of the subprogram. However, the
same tool files must be used as for model generation. The result of the image
processing is calculated relative to the reference base.
VT_TASKTRIGGER_REFBASE triggers an advance run stop.

Syntax VT_TASKTRIGGER_REFBASE("Configuration file", "Image processing task", Refe-

rence base)

Explanation of Element Description

the syntax Configuration file Name of the configuration file
Type: CHAR (IN)
Image processing Name of the image processing task to be executed
task
Type: CHAR (IN)
Reference base Base frame relative to which the result (= deviation in
this base) is to be output
Type: FRAME (IN)

Example VT_TASKTRIGGER_REFBASE("VisionTechConfig", "TestTask",

referenceFrame)

11.6 Subprogram GET_VTRESULT

Description The return value of GET_VTRESULT is the result of the previously executed
image processing task in the form of a VTRESULT structure. The configura-
tion file is transferred. The subprogram is executed in the advance run.

Syntax RET = GET_VTRESULT("Configuration file")

Explanation of Element Description

the syntax RET Data structure containing the result of an image pro-
cessing task
Type: VTRESULT
Configuration file Name of the configuration file
Type: CHAR (IN)

Example DECL VTRESULT RESULT

RESULT = GET_VTRESULT("VisionTechConfig")

11.7 Subprogram GET_VTCORRECTIONFRAME

Description The return value of GET_VTCORRECTIONFRAME is the correction frame ex-

tracted from the image processing result. The image processing result is trans-
ferred. GET_VTCORRECTIONFRAME is executed in the advance run.

Syntax RET = GET_VTCORRECTIONFRAME(Image processing result)

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Explanation of Element Description

the syntax RET Correction frame that can be offset against the compo-
nent base
Type: FRAME
Image processing Image processing result from which the correction
result frame is extracted
Type: VTRESULT (IN)
(>>> 11.7.1 "Structure of VTRESULT" Page 69)

Example DECL VTRESULT RESULT

RESULT = GET_VTRESULT("VisionTechConfig")
CORRECTIONFRAME = GET_VTCORRECTIONFRAME(RESULT)
BASE_DATA[3] = BASE_DATA[2]:CORRECTIONFRAME

11.7.1 Structure of VTRESULT

Name Unit Data type Description

X mm REAL Translational deviation in the X direction
relative to the nominal position.
Y mm REAL Translational deviation in the Y direction
relative to the nominal position.
Z mm REAL Translational deviation in the Z direction
relative to the nominal position.
A degrees REAL Rotational deviation about the Z axis rela-
tive to the nominal position.
B degrees REAL Rotational deviation about the Y axis rela-
tive to the nominal position.
C degrees REAL Rotational deviation about the X axis rela-
tive to the nominal position.
SCORE REAL For a 2D task:
Match between the trained pattern and the
pattern on the current search image.
Note: The value is normally between 0.0
and 1.0. The closer the value is to 1.0, the
better the match.
For a 3D task:
Mean square residual error after calcula-
tion of the object position relative to the
nominal position.
Note: If the position of the object cannot be
calculated, the value -1 is displayed.
SUCCEEDED BOOL  TRUE: The image processing task has
been executed successfully.
 FALSE: An error occurred during exe-
cution of the image processing task.
ERRORMESSAGE CHAR[100] Indicates errors that have occurred during
execution of the image processing task.

11.8 Subprogram VTRESULT_CHECK

Description The subprogram VTRESULT_CHECK checks the result of an image process-

ing task. If the result is faulty, a message is displayed. The result of the image

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 KUKA.VisionTech 2.1

processing task is transferred. VTRESULT_CHECK is executed in the ad-

vance run.

Syntax VTRESULT_CHECK(Image processing result)

Explanation of Element Description

the syntax Image processing The image processing result that is to be checked
result
Type: VTRESULT (IN)

Example DECL VTRESULT RESULT

RESULT = GET_VTRESULT("VisionTechConfig")
VTRESULT_CHECK(RESULT,"VisionTechConfig")

11.9 Subprogram VT_RESULTCHECK2

Description The subprogram VT_RESULTCHECK2 checks the result of an image pro-

cessing task. If the result is faulty, a message is displayed. The result of the
image processing task is transferred. VT_RESULTCHECK2 is executed in the
advance run.

Syntax RET = VT_RESULTCHECK2(Image processing result)

Explanation of Element Description

the syntax RET Return value
Type: BOOL
 TRUE: The image processing task has been exe-
cuted successfully.
 FALSE: An error occurred during execution of the
image processing task.
Image processing The image processing result that is to be checked
result
Type: VTRESULT (IN)

Example DECL VTRESULT RESULT

RESULT = GET_VTRESULT("VisionTechConfig")
VT_RESULTCHECK2(RESULT,"VisionTechConfig")

11.10 Subprogram VT_WAIT

Description The subprogram VT_WAIT stops the program sequence until the flag is set to
the value TRUE. Program execution is then resumed. VT_WAIT triggers an
advance run stop.

The flag for which the program is to wait is the same flag that is set to
TRUE in the subprograms DO_GETVTRESULT and
DO_GETVTRESULTS.

Syntax VT_WAIT("Flag")

Explanation of Element Description

the syntax Flag Number of the flag for which the program is to wait
Type: INT (IN)

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11.11 Subprogram VT_CLOSECONNECTION

Description The subprogram VT_CLOSECONNECTION closes all existing connections to

the server. The configuration file is transferred. VT_CLOSECONNECTION is
executed in the advance run.

Syntax VT_CLOSECONNECTION("Configuration file")

Explanation of Element Description

the syntax Configuration file Name of the configuration file
Type: CHAR (IN)

Example VT_CLOSECONNECTION("VisionTechConfig")

11.12 Subprogram VT_CLEAR

Description The subprogram VT_CLEAR ends the EKI channel. The configuration file is
transferred. VT_CLEAR is executed in the advance run.

Ensure that no data are called by a connection that has already been
terminated by VT_CLEAR.

Syntax VT_CLEAR("Configuration file")

Explanation of Element Description

the syntax Configuration file Name of the configuration file
Type: CHAR (IN)

Example VT_CLEAR("VisionTechConfig")

11.13 Subprogram VT_CHECKPOSELIMIT

This subprogram only remains supported for reasons of compatibility.

It is recommended to use the subprogram VT_CHECKPOSE instead.

Description The subprogram VT_CHECKPOSELIMIT determines whether the target robot

pose (here: P1') lies within the defined limit range. The defined limit value
specifies a range about the original robot pose (here: P1). The range is repre-
sented here by a circle. The defined limit value specifies the radius of the circle
in which the target robot pose must lie.
If e.g. a limit value of 100 mm is specified, the target robot pose must lie within
a radius of 100 mm about the original robot pose.
VT_CHECKPOSELIMIT is executed in the advance run.

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Fig. 11-1: Base correction with VT_CHECKPOSELIMIT

1 Base correction
2 Offset of point P1 due to the base correction
3 Radius (limit value)

Syntax RET = VT_CHECKPOSELIMIT("Robot pose", "Frame", "Offset")

Explanation of Element Description

the syntax RET Return value
Type: BOOL
 TRUE: The target robot pose lies within the defined
limit range.
 FALSE: The limit value is exceeded.
Robot pose The robot pose to be checked
Type: FRAME (IN)
Frame Frame returned by the function
GET_VTCORRECTIONFRAME
Type: FRAME (IN)
Offset Maximum offset between the original robot pose and
the robot pose in the new workpiece base in mm
Type: REAL (IN)

11.14 Subprogram VT_CHECKPOSE

Description The subprogram VT_CHECKPOSE checks whether points on the robot de-
fined by the user lie within an area defined by the user. The points on the robot
defined by the user are defined relative to the robot flange. Up to 10 points can
be defined.
(>>> 11.14.1 "Defining the points on the robot" Page 74)
It must be possible for all defined points to be addressed by the robot in the
NULLFRAME base and with the NULLFRAME tool. If a point is located outside
of the robot’s workspace, the robot stops.

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VT_CHECKPOSE can only be used once the gripping point of the

component has been taught.

Fig. 11-2: Example: Defined points and defined area

1 Defined point on the robot

2 Defined area (green)

Fig. 11-3: Example: Defined points within and outside of the defined area

1 Defined point within the defined area

2 Defined point outside of the defined area

Syntax RET = VT_CHECKPOSE("Base of the area", "Limit value X", "Limit value Y", "Limit
value Z", "Base of the gripping point", "Gripping point", "Tool")

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Explanation of Element Description

the syntax RET Return value
Type: BOOL
 TRUE: All points defined by the user lie within the
defined limit values.
 FALSE: The limit value of at least one point has
been exceeded.
Base of the area Number of the base within which the point to be
checked must lie
Type: INT (IN)
Limit value X Maximum limit value of the base in X direction
Type: INT (IN)
Limit value Y Maximum limit value of the base in Y direction
Type: INT (IN)
Limit value Z Maximum limit value of the base in Z direction
Type: INT (IN)
Base of the grip- Number of the base in which the component must be
ping point gripped
Type: INT (IN)
Gripping point Point at which the component is gripped
Type: FRAME (IN)
Tool Number of the tool with which the component must be
gripped
Type: INT (IN)

Example RET = VT_CHECKPOSE(16,700,950,900,11,XGrippingPos,1)

All points (relative to the robot flange) in base 16 that lie within the following
values are valid:
 X value: max. 700 mm
 Y value: max. 950 mm
 Z value: max. 900 mm
The gripping point is in base 11 and taught with tool 1.

11.14.1 Defining the points on the robot

Preparation only needs to be carried out once after installation.

Preparation 1. Open the file ConfigMon.ini in the directory D:\KUKA_OPT\VisionTech\IN-

TERNAT\KRCSETUP\UTIL.
2. Copy sections [Group1] and [Group2].
3. Open the file ConfigMon.ini in the directory C:\KRC\USER.
4. Insert the copied sections under the existing group sections.
5. Adapt the index numbers. If, for example, the sections [Group1] to
[Group3] already exist, rename the new sections as [Group4] and
[Group5].
6. Save and close the file.

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Procedure 1. In the main menu, select Variable > Overview > Display.
2. Mark a variable in the UserCheckPoints tab and press Edit.
3. Enter the X, Y and Z values and save with OK.
4. Repeat steps 2 to 3 for the further points used. Enter the points in an un-
interrupted sequence from 1 to 10. If, for example, 5 points are desired,
enter the values into the variables UserCheckPoint[1] to UserCheck-
Point[5].

VT_CHECKPOSE ignores all variables in which all values are 0.

11.15 Subprogram GET_VTUSERDATA

Description The subprogram GET_VTUSERDATA calls up optional user data from all con-
figured tool blocks and makes them available to the KRL.
GET_VTUSERDATA is executed in the advance run.

For the execution of the subprogram, 1 entry with user data from the
tool block is created for each camera.

Syntax GET_VTUSERDATA("Configuration file", User data)

Explanation of Element Description

the syntax Configuration file Name of the configuration file
Type: CHAR (IN)
User data 2-dimensional array into which user data are written.
The first dimension corresponds to the camera index,
the second dimension contains the user data as a char-
acter string.
Type: CHAR (OUT)

Example DECL CHAR USERDATA[2, 100]

GET_VTUSERDATA("VisionTechConfig" USERDATA[ , ])

11.16 Subprogram DO_GETVTRESULT

Description The subprogram DO_GETVTRESULT is used for the detection of a compo-

nent.
DO_GETVTRESULT reads in the result of the image processing and creates
a result structure. The result is written to the transfer parameter RESULT. The
flags are then set to TRUE and FALSE. The subprogram is executed in the ad-
vance run.
DO_GETVTRESULT can also be used as an interrupt program. This is called
after the image processing task has been executed. In this case, the subpro-
gram is executed in the main run.

The flag that is to be set to TRUE is the same flag that is used in the
subprogram VT_WAIT. The flag that is to be set to FALSE is defined
in the configuration file.

Syntax DO_GETVTRESULT("Configuration file", RESULT, "Flag True", "Flag False")

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 KUKA.VisionTech 2.1

Explanation of Element Description

the syntax Configuration file Name of the configuration file
Type: CHAR (IN)
RESULT Result of image processing
Type: VTRESULT (OUT)
Flag True Number of the flag to be set to TRUE once the result
has been read
Type: INT (IN)
Flag False Number of the flag to be set to FALSE once the result
has been read
Type: INT (IN)

Example DECL VTRESULT RESULT

DO_GETVTRESULT("VisionTechConfig", RESULT, 1, 998)

11.17 Subprogram DO_GETVTRESULTS

Description The subprogram DO_GETVTRESULTS is used for the detection of multiple

components.
DO_GETVTRESULTS generates a result structure for all object instances
found. This is written to the transfer parameter RESULTS. Once the subpro-
gram has been executed, the parameter PARTCOUNTER contains the num-
ber of components that have been found by the image processing system. The
flags are then set to TRUE and FALSE. The subprogram is executed in the ad-
vance run.
DO_GETVTRESULT can also be used as an interrupt program. This is called
after the image processing task has been executed. In this case, the subpro-
gram is executed in the main run.

Syntax Syntax: DO_GETVTRESULTS("Configuration file", RESULTS[], PART-

COUNTER, "Flag True", "Flag False")

Explanation of Element Description

the syntax Configuration file Name of the configuration file
Type: CHAR (IN)
RESULTS Results of image processing
Type: VTRESULT (OUT)
PART- Contains the number of object instances found after
COUNTER execution of the subprogram
Type: INT (OUT)
Flag True Number of the flag to be set to TRUE once the result
has been read
Type: INT (IN)
Flag False Number of the flag to be set to FALSE once the result
has been read
Type: INT (IN)

Example DECL VTRESULT[100] RESULTS

DECL INT PARTCOUNTER = 0
DO_GETVTRESULTS("VisionTechConfig", RESULTS, PARTCOUNTER, 1, 998)

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 11 Programming

11.18 Subprogram VT_DIRECT

Description The subprogram VT_DIRECT calculates the status of axis 5 at the end point
in such a way that axes 4 and 6 are moved as little as possible. The program
requires the coordinates X, Y, Z, A, B and C of start and end points as well as
the status of the start point.
Start and end points can be taught with different tools and base coordinate
systems. In order for these to be calculated for the axis angles, the tool and
base must be transferred as a parameter for each start and end point.

If the status for the basic area or for axes 2 and 3 changes from the
start point to the end point, the program can no longer be used.

Syntax VT_DIRECT("Start point"), ("End point"), ("Base of the start point"), ("Base of the
end point"), ("Tool of the start point"), ("Tool of the end point")

Explanation of Element Description

the syntax Start point Type: E6POS (IN)
End point Type: E6POS (IN)
Base of the start Number of the base of the start point
point
Type: FRAME (IN)
Base of the end Number of the base of the end point
point
Type: FRAME (IN)
Tool of the start Number of the tool of the start point
point
Type: FRAME (IN)
Tool of the end Number of the tool of the end point
point
Type: FRAME (IN)

Example PTP VorPunkt Vel=100 % PDAT21 Tool[1]:Measuring Tip Base[1]:kalib

VT_DIRECT(XVorPunkt,XGreifpunkt,base_data[1],base_data[11],
tool_data[1],tool_data[10])
PTP Greifpunkt Vel=10 % PDAT12 Tool[10]:Measuring Tip Base[11]:greif

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 12 Example programs

12 Example programs

12.1 Example program

Program 1 DEF Example( )

2
3 DECL CHAR AppData[100,100]
4 DECL BOOL InGrippingZone, CheckPose_ok, Result_valid
5 DECL INT Part
6 DECL FRAME CorrFrame,GrippingPoint
7
8 INI
9
10 INTERRUPT DECL 98 WHEN $FLAG[998]==TRUE DO DO_GETVTRESULTS
("VisionTechConfig",RESULTS[],PARTCOUNTER,1,998)
11 INTERRUPT ON 98
12
13 PTP StartPos Vel=100 % PDAT1 Tool[0] Base[0]
14
15 BASE_DATA[11]=$NULLFRAME
16 $FLAG[1]=FALSE
17 InGrippingZone=False
18 Result_valid=False
19 PARTCOUNTER=0
20
21 VT_INIT("VisionTechConfig")
22 VT_OPENCONNECTION("VisionTechConfig")
23 VT_TASKTRIGGER_REFBASE("VisionTechConfig","Demo",BASE_DATA[16])
24 VT_WAIT(1)
25
26 Get_vtuserdata("VisionTechConfig",appdata[,])
27
28 FOR Part = 1 TO PARTCOUNTER STEP 1
29
30 Result_valid=VT_RESULTCHECK2(RESULTS[PART])
31
32 CorrFrame=Get_VTCORRECTIONFRAME(RESULTS[PART])
33 Base_Data[11]=BASE_DATA[16]:Corrframe
34 CheckPose_ok=VT_CHECKPOSE(12,700,950,950,11,xGrippingPos,1)
35
36 ;halt
37
38 IF(CheckPose_ok==True) then
39
40 IF(Part==1) then
41 VT_DIRECT(XStartPos,XProGrippingPos,$nullframe,base_data[11],
$nullframe,tool_data[1])
42 ELSE
43 VT_DIRECT(XPostGrippingPos,XProGrippingPos,base_data[11],
base_data[11],tool_data[1],tool_data[1])
44 ENDIF
45 PTP ProGrippingPos Vel=100 % PDAT2 Tool[1] Base[11]
46
47 VT_DIRECT(XProGrippingPos,XGrippingPos,base_data[11],
base_data[11],tool_data[1],tool_data[1])
48 PTP GrippingPos Vel=100 % PDAT3 Tool[1] Base[11]
49
50 VT_DIRECT(XGrippingPos,XPostGrippingPos,base_data[11],
base_data[11],tool_data[1],tool_data[1])
51 PTP PostGrippingPos Vel=100 % PDAT4 Tool[1] Base[11]
52 ENDIF
53 ENDFOR
54
55 VT_Closeconnection("VisionTechConfig")
56 VT_Clear("VisionTechConfig")
57
58 END

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 KUKA.VisionTech 2.1

Description Line Description

3…6 Declaration of the variables required for the example pro-
gram.
10 Defines the interrupt program that is to be executed when the
result of the image processing is received. On successful
execution, the program sets flag 1 to TRUE. This signals to
the main program that execution can be resumed. The num-
ber of workpiece instances found is saved in the PartCounter
variable.
Note: The variables PartCounter and RESULTS[] must be
declared in the DAT file.
13 Start position of the robot
 2D fixed: The robot is located outside of the camera’s field
of vision. The component is located in the camera’s field of
vision.
 2D and 3D moving: The robot is located above the compo-
nent. The component is located in the camera’s field of vi-
sion.
15 Initializes the base in which the gripping point of the robot
must be taught.
16 Flag 1 is set to FALSE.
17 … 19 Variables required for the further program sequence are ini-
tialized.
21 Initializes the EKI channel with the data from the configuration
file.
22 Opens an EKI connection to the server.
23 Requests execution of the task with the name “Demo”. The
result is output in base 16. As an alternative, the subprogram
VT_Tasktrigger() can be used.
 2D fixed: The result is output in the calibration base.
 2D and 3D moving: The result is output in the base of the
image acquisition point or the model generation (the base
of the image acquisition point and the base of the model
generation must be identical).
24 Waits for flag 1. This is set by the interrupt program when the
result of the image processing is received. Execution of the
main program is then resumed.
26 Calls the user data of the executed task and saves them in
the 2-dimensional array APPDATA[,].
Note: The program also functions without this call.
28 Executes the loop for each component instance found.
30 Checks the results of all components found. If a result is
faulty, a message is displayed.
Note: The program also functions without this call.
32 Takes the frame data required for the correction from the
result.
33 Calculates the base in which the component must be gripped.
34 Checks whether points defined by the user lie within the area
defined by the user. In this example, relative to base 12.
Note: The program also functions without this call.

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 12 Example programs

Line Description
36 Stops the program. During the initial execution of the pro-
gram, the points ProGrippingPos, GrippingPos and PostGrip-
pingPos in the newly calculated coordinate system (here:
base 11) must be taught here.
38 The query is TRUE if all defined points are located within the
defined area.
40 … 45 Calculates the motion between 2 points in such a way that
axis 4 and axis 6 are moved as little as possible. The query
determines whether only 1 component (start point -> ProGrip-
pingPos) or multiple components (PostGrippingPos -> Pro-
GrippingPos) have been detected.
Note: The program also functions without this call.
47 … 51 The point is addressed in the corrected component base.
Note: The program also functions without lines 43, 47 and 50.
55 Terminates all existing connections to the server.
56 Terminates the EKI channel.

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 13 Messages

13 Messages

Message Cause Remedy

An error occurred when creat- Insufficient access rights. Apply for the relevant access
ing the task {Task name}: rights.
{Error message} The directory Create the directory.
C:\KRC\TP\VisionTech\Tasks
does not exist.
An error occurred while The connection to the camera Check and restore the con-
acquiring an image from sen- has been interrupted. nection.
sor {Serial number}: {Error The camera is performing a Terminate the process and
message} different process. restart the controller.
Failed to save the calibration Insufficient access rights. Apply for the relevant access
result rights.
There is already a write-pro- Turn to person who created
tected calibration result avail- the existing calibration result.
able.
The directory Create the directory.
C:\KRC\TP\VisionTech\Sen-
sorCalibration does not exist.
Connection to sensor failed The camera is not connected. Connect the camera and
restart the controller.
The connecting cable is defec- Exchange the connecting
tive. cable and restart the control-
ler.
Cannot establish a connection The image processing module Wait until the image process-
to the image processing mod- is not yet completely loaded. ing module is completely
ule. VisionTech is not ready loaded.
for operation The image processing module Contact KUKA Service.
is not correctly installed.
An unknown exception The camera is not connected. Connect the camera and
occurred while acquiring a pic- restart the controller.
ture from the sensor {Serial The camera is performing a Terminate the process and
number}: {Error message} different process. restart the controller.
The connection to the camera Check and restore the con-
has been interrupted. nection.
The amount of captured pic- Too few images were taken for Take at least 6 images.
tures is not sufficient for per- performance of a calibration.
forming a calibration
The following error occurred The fiducial mark is not Move to the poses again and
during calibration: {Error mes- detected in all the images. ensure that the fiducial mark is
sage} visible in every pose.
The robot poses used are Move to the poses again and
unsuitable for calculating the ensure that the poses differ to
calibration. a greater extent.
No sensor selected for the cal- No camera is selected. Select a camera and restart
ibration calibration.
An error occurred while saving Insufficient access rights to Apply for the relevant access
the general sensor settings: the file system. rights.
{Error message} The existing camera settings Contact the person who saved
are write-protected. the existing camera settings.

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 KUKA.VisionTech 2.1

Message Cause Remedy

Model for task {Task name} It was not possible to detect Set the lighting lower or
could not be created: {Error features in the images higher.
message} because the lighting was too
strong or too weak.
Too few features were Align the cameras so that
detected in the images each camera can detect the
because each camera same features.
detected different features.
No object could be detected Align the cameras so that the
because the object was not in object is in the field of vision.
the field of vision of the cam-
eras.
The following error occurred It was not possible to detect Set the lighting lower or
while creating the reference features in the images higher.
model for task {Task name}: because the lighting was too
{Error message} strong or too weak.
Too few features were Align the cameras so that
detected in the images each camera can detect the
because each camera same features.
detected different features.
No object could be detected Align the cameras so that the
because the object was not in object is in the field of vision.
the field of vision of the cam-
eras.
The following error occurred The task is not compatible Only use compatible tasks.
while loading the task: {Error with this version of Vision-
message} Tech.
The task does not have the Only use files with the TASK
TASK file format. format.
The sensor {Serial number} The camera is not connected Establish the connection and
has no connection to the robot controller. restart the controller.
The camera is performing a Terminate the process and
different process. restart the controller.
The maximum number of cap- The maximum number of Start calibration or terminate
tured images has been images has already been the calibration process.
reached. It is not possible to taken.
add further images
Failed to calculate the position It was not possible to detect Set the lighting lower or
of the object features in the images higher.
because the lighting was too
strong or too weak.
Too few features were Align the cameras so that
detected in the images each camera can detect the
because each camera same features.
detected different features.
No object could be detected Align the cameras so that the
because the object was not in object is in the field of vision.
the field of vision of the cam-
eras.

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 13 Messages

Message Cause Remedy

Failed to calculate the position It was not possible to detect Set the lighting lower or
of the part features in the images higher.
because the lighting was too
strong or too weak.
Too few features were Align the cameras so that
detected in the images each camera can detect the
because each camera same features.
detected different features.
No component could be Align the cameras so that the
detected because the compo- component is in the field of
nent was not in the field of vision.
vision of the cameras.
Not enough features have It was not possible to detect Set the lighting lower or
been detected for calculating features in the images higher.
the object position because the lighting was too
strong or too weak.
Too few features were Align the cameras so that
detected in the images each camera can detect the
because each camera same features.
detected different features.
No object could be detected Align the cameras so that the
because the object was not in object is in the field of vision.
the field of vision of the cam-
eras.
Not enough features have It was not possible to detect Set the lighting lower or
been detected for calculating features in the images higher.
the position of the part because the lighting was too
strong or too weak.
Too few features were Align the cameras so that
detected in the images each camera can detect the
because each camera same features.
detected different features.
No component could be Align the cameras so that the
detected because the compo- component is in the field of
nent was not in the field of vision.
vision of the cameras.
The execution of a toolblock The tool block is faulty. Check the tool block in the
failed image processing environ-
ment or test the task in Vision-
Tech.
No toolblocks defined for the The task has not been config- Configure the task completely
specified task ured completely. and generate a model.
No toolblocks are set for the The task has not been config- Configure the task completely
specified task. ured completely. and generate a model.

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 KUKA.VisionTech 2.1

Message Cause Remedy

An unknown error occurred It was not possible to detect Set the lighting lower or
while testing the task features in the images higher.
because the lighting was too
strong or too weak.
Too few features were Align the cameras so that
detected in the images each camera can detect the
because each camera same features.
detected different features.
No object could be detected Align the cameras so that the
because the object was not in object is in the field of vision.
the field of vision of the cam-
eras.
The following error occurred Insufficient access rights. Apply for the relevant access
while saving the task: {Error rights.
message} There is already a write-pro- Contact the person who cre-
tected task available with the ated the existing task.
same name.
The directory Create the directory.
C:\KRC\TP\VisionTech\Tasks
does not exist.
The task has no model. It is No model has been generated Generate a model.
not possible to execute the for this task.
task
Failed to match the part The features are incorrectly Check the tool block in the
instances found in the tool- configured in the tool block: image processing environ-
blocks the order of the numbering of ment. The order of the num-
the features differs for 2 or bering of the features must be
more cameras. the same for all cameras.
Different objects can be seen Align the cameras so that the
in the camera images. same objects are in the field of
vision of all cameras.
The calibration contains Recalibrate the cameras.
errors.
Too few features have been At least 3 features must be
detected. detected.
Not enough features found for The tool block is faulty. Check the tool block in the
determining the part's position image processing environ-
ment. At least 3 features must
be detected.
The object is not fully in the Align the cameras so that the
field of vision of the camera. same objects are in their field
of vision.
The lighting is too weak. Increase the lighting setting.
The connection to one of the The camera is not connected. Connect the camera and
sensors could not be estab- restart the controller.
lished The connecting cable is defec- Exchange the connecting
tive. cable and restart the control-
ler.
Image acquisition with one of The connection to the camera Check and restore the con-
the sensors failed has been interrupted. nection.
The camera is performing a Terminate the process and
different process. restart the controller.

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 13 Messages

Message Cause Remedy

The specified task could not The task has not been loaded. Load the task with Refresh
be found tasks.
The task does not exist. Check the spelling.
Unknown error during the exe- It was not possible to detect Set the lighting lower or
cution of a task features in the images higher.
because the lighting was too
strong or too weak.
Too few features were Align the cameras so that
detected in the images each camera can detect the
because each camera same features.
detected different features.
No object could be detected Align the cameras so that the
because the object was not in object is in the field of vision.
the field of vision of the cam-
eras.
Invalid calibration pose The following causes can be Try a different calibration
ruled out: pose.
 TOOL or BASE data differ
from those of the previous
pose.
 Identical or similar coordi-
nates to those of the previ-
ous pose.
Unable to create image buffer Invalid image information. Only use valid image formats.
in memory: {Error message} Insufficient memory available. Contact KUKA Service.
No image buffer available: No image source has been ini- Contact KUKA Service.
{Error message} tialized.
Unable to write the data to the Insufficient memory reserved Only use valid image formats.
image buffer: {Error message} for the image source.
An error occurred when The camera cannot be Check the connection to the
changing the default exposure accessed. camera.
time
An error occurred when The camera cannot be Establish the connection to
changing the calibration expo- accessed. the camera.
sure time
An error occurred when sav- The camera is performing a Terminate the process and
ing the image from sensor different process. restart the controller.
{Serial number} The camera is in an invalid Check the connection to the
connection state. camera.
The entered name {Task The task name contains one Delete the invalid characters
name} contains invalid char- or more of the following char- from the name.
acters. Please choose a differ- acters: \ / : * ? " < > |
ent name
An error occurred while saving The network settings are Change the network settings.
the network settings of the faulty, see error description.
sensor: {Error message}
The task {Task name} cannot Another program or user is Exit the other programs.
be deleted: {Error message} accessing the task.
The task no longer exists. Update the task list.

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 KUKA.VisionTech 2.1

Message Cause Remedy

The calibration type of a sen- A camera with the wrong cali- Assign a different camera to
sor is not compatible with the bration type has been the task.
task type assigned to the task, e.g. a
stationary 2D camera has
been assigned a 3D task.
An incorrectly calibrated cam- Recalibrate the camera.
era has been assigned to a
task.
One of the configured sensors The camera is not connected. Connect the camera.
is not connected
Error in the subprogram The size of the transferred Declare an array of adequate
DO_GETVTRESULTS. The array is too small. size (at least the expected
transferred array is too small number of components).
Unable to create the footprint The license key entered is not Enter a valid license key.
valid.
No license key has been Enter a license key.
entered.
Unable to save the request file No write access is enabled for Request write access for the
to the selected path the selected directory. selected directory or select a
different path.
An error occurred while acti- The response file is not com- Check whether the correct
vating the license patible with the system that is response file has been
to be licensed. selected.
There is no emergency All the emergency licenses Contact KUKA Service.
license available have been used up.
The following error occurred See error description. Contact KUKA Service.
while activating the license:
{Error message}
The following error occurred The response file is invalid. Open a valid response file, or
while opening the selected contact KUKA Service.
response file: {Error message}
An error occurred while acti- The image processing module Contact KUKA Service.
vating an emergency license is not correctly installed.
The following error occurred The image processing module Contact KUKA Service.
while creating the repair is not correctly installed.
request file: {Error message}

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 14 Maintenance

14 Maintenance

14.1 Maintenance symbols

Maintenance
symbols
Oil change

Lubricate with grease gun

Lubricate with brush

Tighten screw/nut

Check component, visual inspection

Clean component

Exchange battery

Fig. 14-1: Maintenance points

Interval Item Activity

Depending 1 Depending on the degree of fouling, clean the lens
on the and the protective lens hood with a dry, dust-free
degree of microfiber cloth.
fouling
1 year at 1 Check the screw fastenings of the camera, the lens
the latest and the protective lens hood. Locking varnish can be
used to secure the screw fastenings.

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 15 Repair

15 Repair

15.1 Exchanging the switch

Precondition  The robot controller is switched off and secured to prevent unauthorized
persons from switching it on again.
 The power cable is de-energized.

Procedure 1. Disconnect the switch from the power supply.

2. Unplug the connecting cables.
3. Plug in the connecting cables on the new switch.
4. Connect the new switch to the power supply.

15.2 Exchanging the camera

Precondition  The robot controller is switched off and secured to prevent unauthorized
persons from switching it on again.
 The power cable is de-energized.

Procedure 1. Unplug the connecting cables.

2. Remove the camera.
3. Install the new camera.
4. Plug in the connecting cables on the new camera.
5. Switch on the new camera.
6. Calibrate the new camera.
7. Assign the new camera to the tasks.

15.3 Exchanging the motherboard

Information about exchanging the motherboard is contained in the ro-

bot controller documentation.

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 16 Troubleshooting

16 Troubleshooting

Fault Remedy
“Power” LED on the camera  Check that the plugged and screwed
does not light up connections along the connecting cable
are fitted securely.
 Check the connecting cable for dam-
age.
Neither LED “P1” nor LED Check whether voltage is present at the
“P2” lights up power connection (V1 or V2).
LED “P1” or LED “P2” lights Check that the DIP switches are set cor-
up red on the switch rectly. Both switches must be in the “ON”
position.
LED “Gigabit PoE Port” The connected device does not support
does not light up on the PoE.
switch

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 17 Decommissioning, storage and disposal

17 Decommissioning, storage and disposal

17.1 Decommissioning

Procedure 1. Disconnect the cameras and switch from the power supply.
2. Unplug the connecting cables.
3. Prepare the cameras and switch for storage or transportation.

17.2 Storage

Precondition If the cameras and switch are to be put into long-term storage, the following
points must be observed:
 The place of storage must be as dry and dust-free as possible.
 Avoid temperature fluctuations.
 Avoid condensation.
 Observe and comply with the permissible temperature ranges for storage.
 Select a storage location in which the packaging materials cannot be dam-
aged.
 Only store the cameras and switch indoors.

Procedure  Cover the cameras and switch with ESD protection foil and seal it against
dust.

17.3 Disposal

When the cameras and switch reach the end of their useful life, dispose of
them as electrical scrap without disassembling.

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 18 Appendix

18 Appendix

18.1 Tightening torque

Tightening torque The following tightening torques are valid for screws and nuts where no other
specifications are given.

Strength class
Screw size 8.8 10.9 12.9
M1.6 0.17 Nm 0.24 Nm 0.28 Nm
M2 0.35 Nm 0.48 Nm 0.56 Nm
M2.5 0.68 Nm 0.93 Nm 1.10 Nm
M3 1.2 Nm 1.6 Nm 2.0 Nm
M4 2.8 Nm 3.8 Nm 4.4 Nm
M5 5.6 Nm 7.5 Nm 9.0 Nm
M6 9.5 Nm 12.5 Nm 15.0 Nm
M8 23.0 Nm 31.0 Nm 36.0 Nm
M10 45.0 Nm 60.0 Nm 70.0 Nm
M12 78.0 Nm 104.0 Nm 125.0 Nm
M14 125.0 Nm 165.0 Nm 195.0 Nm
M16 195.0 Nm 250.0 Nm 305.0 Nm
M20 370.0 Nm 500.0 Nm 600.0 Nm
M24 640.0 Nm 860.0 Nm 1030.0 Nm
M30 1330.0 Nm 1700.0 Nm 2000.0 Nm

Tighten M5 domed cap nuts with a torque of 4.2 Nm.

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 19 KUKA Service

19 KUKA Service

19.1 Requesting support

Introduction This documentation provides information on operation and operator control,

and provides assistance with troubleshooting. For further assistance, please
contact your local KUKA subsidiary.

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

 Model and serial number of the manipulator
 Model and serial number of the controller
 Model and serial number of the linear unit (if present)
 Model and serial number of the energy supply system (if present)
 Version of the system software
 Optional software or modifications
 Diagnostic package KrcDiag:
Additionally for KUKA Sunrise: Existing projects including applications
For versions of KUKA System Software older than V8: Archive of the soft-
ware (KrcDiag is not yet available here.)
 Application used
 External axes used
 Description of the problem, duration and frequency of the fault

19.2 KUKA Customer Support

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

Argentina Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
[email protected]

Australia Headland Machinery Pty. Ltd.

Victoria (Head Office & Showroom)
95 Highbury Road
Burwood
Victoria 31 25
Australia
Tel. +61 3 9244-3500
Fax +61 3 9244-3501
[email protected]
www.headland.com.au

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 KUKA.VisionTech 2.1

Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
[email protected]
www.kuka.be

Brazil KUKA Roboter do Brasil Ltda.

Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
[email protected]
www.kuka-roboter.com.br

Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
[email protected]
www.robotec.cl

China KUKA Robotics China Co.,Ltd.

Songjiang Industrial Zone
No. 388 Minshen Road
201612 Shanghai
China
Tel. +86 21 6787-1888
Fax +86 21 6787-1803
www.kuka-robotics.cn

Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
[email protected]
www.kuka-roboter.de

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France KUKA Automatisme + Robotique SAS

Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
[email protected]
www.kuka.fr

India KUKA Robotics India Pvt. Ltd.

Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
[email protected]
www.kuka.in

Italy KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
[email protected]
www.kuka.it

Japan KUKA Robotics Japan K.K.

YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7691
Fax +81 45 744 7696
[email protected]

Canada KUKA Robotics Canada Ltd.

6710 Maritz Drive - Unit 4
Mississauga
L5W 0A1
Ontario
Canada
Tel. +1 905 670-8600
Fax +1 905 670-8604
[email protected]
www.kuka-robotics.com/canada

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Korea KUKA Robotics Korea Co. Ltd.

RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
[email protected]

Malaysia KUKA Robot Automation Sdn Bhd

South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
[email protected]

Mexico KUKA de México S. de R.L. de C.V.

Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de México
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
[email protected]
www.kuka-robotics.com/mexico

Norway KUKA Sveiseanlegg + Roboter

Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
[email protected]

Austria KUKA Roboter Austria GmbH

Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
[email protected]
www.kuka-roboter.at

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Poland KUKA Roboter Austria GmbH

Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
[email protected]

Portugal KUKA Sistemas de Automatización S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
[email protected]

Russia KUKA Robotics RUS

Werbnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
[email protected]
www.kuka-robotics.ru

Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
[email protected]

Switzerland KUKA Roboter Schweiz AG

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
[email protected]
www.kuka-roboter.ch

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Spain KUKA Robots IBÉRICA, S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
Fax +34 93 8142-950
[email protected]
www.kuka-e.com

South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

Taiwan KUKA Robot Automation Taiwan Co., Ltd.

No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
[email protected]
www.kuka.com.tw

Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
[email protected]
www.kuka-roboter.de

Czech Republic KUKA Roboter Austria GmbH

Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Počernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
[email protected]

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Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
[email protected]

USA KUKA Robotics Corporation

51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
[email protected]
www.kukarobotics.com

UK KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
[email protected]

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 Index

Index
Numbers I
2D model, generating 59 Image processing environment, installing 53
2D model, moving camera 60 Image processing environment, licensing 53
2D model, stationary camera 59 Image processing task, setting up 52
2D task, configuring 56 Images, taking (moving) 52
2D task, testing 61 Images, taking (stationary) 51
3D model, generating 64 Installation 33
3D task, configuring 62 Installation, VisionTech 33
3D task, testing 65 Intended use 9
89/336/EEC 19, 20 Interfaces 29
Interfaces, KR C4 compact, connecting cables
A 42
Appendix 97 Interfaces, KR C4, connecting cables 40
Introduction 7
C
Calibration plane, delete 48 K
Calibration plates 17 KLI 8
Camera network, configuring 43 Knowledge, required 9
Camera, aligning (stationary) 45 KONI 8
Camera, calibrating (stationary) 46 KUKA Customer Support 99
Camera, exchange 91 KUKA GigE switch 12
Cameras, aligning (moving) 45 KUKA GigE switch, technical data 20
Cameras, calibrating (moving) 48 KUKA MXG20 camera 16
Cameras, configuring 44 KUKA MXG20 camera, technical data 19
Configuration 51
Connecting cables 17, 21, 29 L
Connecting cables, KR C4 21, 41 License repair 35, 53
Connecting cables, KR C4 compact 22, 42 License, activation 34, 53
Licensing 33, 34
D
Decommissioning 95 M
Defining the points on the robot 74 Maintenance 89
Dimensions, camera 23 Maintenance symbols 89
Dimensions, extension 24 Messages 83
Disposal 95 Motherboard, exchange 91
DO_GETVTRESULT (subprogram) 75
DO_GETVTRESULTS (subprogram) 76 N
Documentation, industrial robot 7 Networking 38

E O
EKI 8 Overview, VisionTech 11
EMC Directive 19, 20
Emergency license, activation 35, 54 P
EN 60204-1 + A1 27 Plates and labels 24
Ethernet KRL interface, configuring 43 PoE 8
Example programs 79 Product description 11
Programming 67
F Purpose 9
Functions 11
R
G Recommissioning 37
General safety measures 27 Reference pose 8
GenICam 8 Regulations 27
GET_VTCORRECTIONFRAME (subprogram)
68 S
GET_VTRESULT (subprogram) 68 Safety 27
GET_VTUSERDATA (subprogram) 75 Safety instructions 7
GigE 8 Service, KUKA Roboter 99

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smartHMI 8
Standards 27
Start-up 37
Storage 95
Support request 99
Switch, exchange 91
System requirements 33

T
Target group 9
Task, creating (moving) 52
Task, creating (stationary) 51
Technical data 19
Templates 55
Terms used 8
Tightening torque 97
Tool block 8
Tool block file, creating 54
Trademarks 7
Training 9
Transportation 31
Troubleshooting 93

U
Uninstallation, VisionTech 34
Update, VisionTech 33

V
VT_CHECKPOSE (subprogram) 72
VT_CHECKPOSELIMIT (subprogram) 71
VT_CLEAR (subprogram) 71
VT_CLOSECONNECTION (subprogram) 71
VT_DIRECT (subprogram) 77
VT_INIT (subprogram) 67
VT_OPENCONNECTION (subprogram) 67
VT_RESULTCHECK2 (subprogram) 70
VT_TASKTRIGGER (subprogram) 67
VT_TASKTRIGGER_REFBASE (subprogram)
68
VT_WAIT (subprogram) 70
VTRESULT_CHECK (subprogram) 69
VTRESULT, structure 69

W
Warnings 7

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