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KUKA - BendTechBasic KRC 6.0 EN

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KUKA - BendTechBasic KRC 6.0 EN

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ROBOTICA PRODISMO

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KUKA.BendTech Basic KRC V6.

0
Option to KSS 8.6
Minimal version KSS 8.6.4

Language : English
Version : 2020-10-21
KUKA Automatisering + Robots N.V. | Centrum-Zuid 1031 | B-3530 Houthalen-Helchteren | Belgium | [email protected] | www.kuka.be
Reference : KUKA Software Documentation
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Author: KUKA Automatisering + Robots N.V.
Copyright 2011 … 2020
KUKA Automatisering + Robots N.V.
Centrum-Zuid 1031
B-3530 Houthalen-Helchteren
Belgium

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the
express and written permission of the publishers.

Other functions not described in this documentation may be operable in the robot controller or on the
installation operation panel(s). The user has no claims to these functions, however, in the case of a
replacement or service work.

We have checked the content of the documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are notable to guarantee
total conformity. The information in this documentation is checked on a regular basis, however, and
necessary corrections will be incorporated in subsequent editions.

Subject to technical alterations without an effect on the function.

KUKA Automatisering + Robots N.V. accepts no liability for any errors in technical information
communicated orally or in writing in the training courses or contained in the documentation. Nor will
liability be accepted for any resultant damage or consequential damage.

In some cases, the documentation describes the functionality of non-KUKA material. These descriptions are
added to obtain a consequent documentation. The sole valid documentation of these non-KUKA materials
is the documentation of this equipment itself made by its manufacturer.

Translation of the original documentation

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Contents
1 Introduction ....................................................................................................................................................... 6
1.1 Target group ...................................................................................................................................... 6
1.2 Industrial robot documentation ........................................................................................................ 6

2 Introduction ....................................................................................................................................................... 7
2.1 Product description ........................................................................................................................... 7
2.2 Bending process................................................................................................................................. 8
2.3 The robot interface of a press brake controller ................................................................................ 9
2.4 Overview of components in a bending cell ..................................................................................... 11
2.5 Bending program ............................................................................................................................. 12
2.6 Robot bending process .................................................................................................................... 13
2.7 Press bending cycle and robot bending cycle.................................................................................. 13
2.8 Safety instructions ........................................................................................................................... 14

3 Installation ........................................................................................................................................................15
3.1 Installation requirements ................................................................................................................ 15
3.2 Installing the software ..................................................................................................................... 15
3.3 Updating the software..................................................................................................................... 15
3.4 Uninstalling the software ................................................................................................................ 15
3.5 KSS software update ........................................................................................................................ 16
3.6 Inline folds ....................................................................................................................................... 16

4 License ..............................................................................................................................................................17
4.1 Background ...................................................................................................................................... 17
4.2 Requesting a license ........................................................................................................................ 17
4.3 Entering a license............................................................................................................................. 18
4.4 Upgrading the software ................................................................................................................... 18
4.5 Exchanging the robot....................................................................................................................... 18

5 Configuration ....................................................................................................................................................19
5.1 Interface routines ............................................................................................................................ 19
5.1.1 Overview of routines ............................................................................................................... 20
5.2 Configure status keys on the Smartpad. ......................................................................................... 21
5.3 Calibration of the robot bases ......................................................................................................... 23
5.3.1 Advised use of bases................................................................................................................ 23
5.3.2 Base on input station (base 10..19) ......................................................................................... 24
5.3.3 Base on double sheet station (base1 and base2) .................................................................... 25

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5.3.4 Base on Center station (base 3)............................................................................................... 25
5.3.5 Base on Press brake (base 4) ................................................................................................... 27
5.3.6 Bases on Regrip station (base 5, base 6) ................................................................................. 31
5.3.7 Base on output station (base 20 .. 29)..................................................................................... 34
5.4 Synchronous robot - press motion .................................................................................................. 35

6 Programming ....................................................................................................................................................36
6.1 BT AUTHORIZE ................................................................................................................................. 37
6.2 BT CHECKCELL .................................................................................................................................. 38
6.3 BT CONFIG GRIPPER........................................................................................................................ 39
6.4 BT INIT GRIPPER ............................................................................................................................... 41
6.5 BT INIT BENDTECH ........................................................................................................................... 48
6.6 BT GET.............................................................................................................................................. 49
6.7 BT BGET ........................................................................................................................................... 53
6.8 BT MGET .......................................................................................................................................... 55
6.9 BT SENSOR ....................................................................................................................................... 61
6.10 BT IS CENTER EMPTY ....................................................................................................................... 63
6.11 BT CENTER ....................................................................................................................................... 64
6.12 BT SET SEQUENCE ............................................................................................................................ 69
6.13 BT SET BACKGAUGE ......................................................................................................................... 71
6.14 BT APPROACH .................................................................................................................................. 72
6.15 BT BEND ........................................................................................................................................... 76
6.16 BT PRESS .......................................................................................................................................... 80
6.17 BT PRESS MOVE ............................................................................................................................... 81
6.18 BT LIFT.............................................................................................................................................. 83
6.19 BT GRIPPER ...................................................................................................................................... 85
6.20 BT REGRIP GRIPPER ......................................................................................................................... 86
6.21 BT REGRIP MOVE ............................................................................................................................. 87
6.22 BT PUT3 ........................................................................................................................................... 89
6.23 BT MPUT2 ........................................................................................................................................ 93
6.24 BT LINE UP2 ..................................................................................................................................... 96
6.25 BT DROP ........................................................................................................................................... 98
6.26 BT RESET STATIONS ....................................................................................................................... 100

7 Example program ............................................................................................................................................102

8 Synchronization of robot with press brake motions ........................................................................................104

8.1 Factors that influence the synchronization ................................................................................... 104
8.2 Influence of the different factors .................................................................................................. 105

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8.3 Optimize the robot standard bend motion ................................................................................... 106
8.4 Optimize press brake parameters ................................................................................................. 107
8.5 Reducing the synchronization errors............................................................................................. 107

9 Reserved tools, cycle flags and timers .............................................................................................................108

9.1 Tools .............................................................................................................................................. 108
9.2 Bases .............................................................................................................................................. 108
9.3 Cycle flags ...................................................................................................................................... 108
9.4 Interrupts ....................................................................................................................................... 108
9.5 Timers ............................................................................................................................................ 109

10 Messages ........................................................................................................................................................109
10.1 Types of messages ......................................................................................................................... 109
10.2 Implementation ............................................................................................................................. 110
10.3 List of messages ............................................................................................................................. 110

11 Contact address...............................................................................................................................................117

12 Release notes ..................................................................................................................................................117

13 Software license terms ....................................................................................................................................118

14 Privacy policy ..................................................................................................................................................119

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1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and skills:

• Advanced knowledge of the robot controller system

• Basic knowledge of the bending process

For optimal use of our products, we recommend that our customers take part in a course of training at
KUKA College of KUKA Automatisering + Robots N.V. Look for the contact information at the end of the
document for the contact details to obtain information on the available training courses.

1.2 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 and is delivered with the robot. This document
belongs to the additional group of instructions for technology packages that completes the previous sets of
documentation.

The main functionalities of this add-on module are:

• Provide dedicated inline forms which simplify the programming of the robot at a press brake.

This software package offers following options:

• The external axis option provides the possibility to program a displacement with the robot on a
linear unit during a synchronized bend movement. The robot should be mounted on a linear unit
for this option.

Important notes

KUKA.BendTech Basic KRC is a software package and does not include any of the hardware listed in this
manual.

KUKA.BendTech Basic KRC is a software toolbox, which allows system integrators to build installations such
as the one listed above. However, the configuration of the software can be different for every installation
installed at the customer site. This integration step is not included in the delivery of KUKA.BendTech Basic
KRC. This integration step requires profound knowledge in following areas: cell design, KRL expert level
programming and robot machine data.

KUKA.BendTech Basic KRC does not provide any process knowledge on bending processes. The selection of
the appropriate components, of the process parameters to control these components is the responsibility of
the system integrator.

KUKA.BendTech Advanced KRC offers all the functionality of KUKA.BendTech Basic KRC and more. In
KUKA.BendTech Advanced KRC, the communication between the press brake and the robot is handled over
the KUKA Automatisering + Robots N.V. and LVD Group proprietary Interface. KUKA.BendTech Basic KRC and
KUKA.BendTech Advanced KRC cannot be installed on the same robot controller.

Figure 1. Bending process

The press brake consists of a lower part – the die – and the upper part – the punch – which clamps the
sheet down onto the die. The robot moves the sheet into the press until the end switches on the back
gauges detect the presence of the sheet. The upper dead point of the beam (UDP) represents the starting
position of the press motion. From here, the beam moves downwards to the mute point (MP) where the
robot can safely move the sheet in the press. The mute or safety point is therefore the wait position for the
beam while the robot moves the sheet on the die and searches for the sensors on the back gauges. Once
the robot has found the desired position with aid of the back gauges, the press brake moves downwards
towards the clamping point (CP). In the clamp point the back gauges will retract. The press can then bend
the sheet, the beam moves from the clamp point to the lower dead point (LDP). The robot follows the
motion of the sheet synchronously during the bend. After the bend, the beam moves slowly upwards to the
decompression point (DCP). The beam moves further upwards to the upper dead point UDP releasing the
sheet.

Note: the decompression point DCP is located slightly above the lower dead point LDP. In order to keep
the above picture simple, the indication of the decompression point DCP is omitted.

Note: some presses have a lower punch and an upper die. KUKA robots also can be programmed with
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KUKA.BendTech Basic KRC for these bending presses. All the figures in this manual have to be rotated
for 180 degrees.

Note: the mute point MP is sometimes called the safe point SP

2.3 The robot interface of a press brake controller

The communication between the press brake controller and the robot controller is made over digital IO.
The mapping of these press brake controller signals to the robot controller inputs and outputs is made in
KUKA.BendTech Basic KRC user routines. Robot interfaces are typically offered as an option to the press
brake controller. For more information on the robot interface on a press brake controller, contact your
press brake manufacturer.

Figure 2. Example of signals on robot interface : signals sequence of LVD EasyForm and LVD
DynaPress Series (image courtesy of company LVD )

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Figure 3. Example of signals on robot interface : signals sequence of Trumpf TruBend Series 5000
for motion without angle measurement system (image courtesy of company Trumpf)

12 11 5

4
7

6 1

2 10

Figure 4. Overview of the component in a robotic bending installation

1. Robot
2. Robot controller
3. Raw sheet (flat pattern)
4. Input station
5. Double sheet station
6. Center station
7. Press brake
8. Press brake controller
9. Regrip station (not shown)
10. Output station
11. Bended sheet
12. Fences

Note. KUKA.BendTech Basic KRC can also be used to program a robot on a linear axis, or to control a
re-grip station with a motorized axis or to control multiple input or output stations. The documentation
listed hereafter gives a generic overview of the software and does not limit itself on one or more fixed
bending cells.

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2.5 Bending program
The figure below shows a typical example of a bending program. The robot takes a raw sheet from a input
station (GET). When the sheet is grasped, the robot checks that the correct sheet is taken (SENSOR) and
aligns the sheet in a centring station (CENTER) before loading it into the press. The robot places the sheet
on the die of the press brake (SET SEQUENCE, APPROACH), follows the sheet during the bending motion
(BEND) and repositions the sheet for the next bend. For this the robot can make use of a re-grip station
(REGRIP). Once the forming process has been completed, the robot removes the sheet from the press and
palletizes it on an output station (PUT, LINE UP).

Figure 5. Sheet handling sequence

In a sequential order, the program is

1. Verify if authorizations for program are set (AUTHORIZE)

2. Initialize program settings (INIT BENDTECH / INIT GRIPPER / RESET STATIONS)
3. Take sheet from pallet (GET)
4. Measurement to check whether only one sheet is taken (SENSOR)
5. Synchronize with press in advance (SET SEQUENCE)
6. Align sheet in centring station (CENTER)
7. Synchronize programming step with press brake (SET SEQUENCE)
8. Load sheet into press (APPROACH)
9. Bend sheet (BEND) or press sheet (PRESS)
10. Move sheet out of press (LIFT) or move the press (PRESS MOVE)
11. Optional repositioning of sheet (REGRIP MOVE / REGRIP GRIPPER)
12. Repeat steps 6 to 9 for further bending sequences
13. Stacking of finished sheet on output station (PUT / LINE UP / MPUT / DROP / GRIPPER)

Note that it is also possible that certain steps are omitted or that alternative route is used. For example, it is
possible that for stacking the bended sheets, it might be required some part are first re-gripped before
stacking, and other parts are directly stacked.

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Note. KUKA.BendTech Basic KRC implicitly uses 1 tool. It is strongly advised not to use these tools as
the KUKA.BendTech Basic KRC overwrites the values of this tool.

• TOOLDATA[1] : used to set the tool in BT_BEND command

2.6 Robot bending process

The task of the robot in a robot bending cell is to handle the metal sheet in front of a press brake.
Therefore the robot is equipped with a gripper. This gripper can be a vacuum gripper or a clamping gripper
or a gripper with magnets.

2.7 Press bending cycle and robot bending cycle

The figure below shows the combination of the press brake bending cycle and the robot bending cycle

Figure 6. Bending process

The system may only be operated, maintained and repaired by personnel

specially trained to work on this system.

This documentation contains safety instructions which refer specifically to the

software described here. The fundamental safety information for the industrial
robot can be found in the "Safety" chapter of the Operating and Programming
Instructions for System Integrators or the Operating and Programming Instruc-
tions for End Users.
When operating or working on this system, the safety instructions in the chapter
[Safety] of the robot documentation and the safety instructions issued by the
bending press manufacturer must be observed. Death to persons, severe
physical injuries or considerable dam-age to property may otherwise result.
Any injury to persons or damage to equipment resulting from the non-
observance of general safety instructions or instructions contained within this
documentation or related documentation releases the manufacturer from his
warranty obligations.

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3 Installation
3.1 Installation requirements
The KUKA.BendTech Basic KRC software can be installed on KR C4 controllers with KSS version 8.6. It can
also be installed on KUKA.Office Lite version 8.6. Look for more information in the release notes. A license
key is required to use this software on the robot controller. Read Chapter 3 for more information.

Note. The software has been tested and released with Software 8.6. For lower or higher versions of the
software, contact KUKA.

Note : See the release notes for the latest compatibility issues.

3.2 Installing the software

The advised way to install the software is to use WorkVisual and to use the Option Package Management
system. By doing so, all the necessary steps for installing KUKA.BendTech KRC are carried out automatically.
You need to reboot the system to complete the installation. Look for the documentation of KUKA
WorkVisual for information on this mechanism.

An alternative way to install the software is to install the software manually

- Take a USB stick
- Put the software on the usb stick, but not the zip files, the unpacked files (take on folder per software)
- Make sure to be in T1 level
- Go to expert level on the robot controller <robot><configuration><user group>
- Install additional software <startup><additional software>
o <New software> button
o <Configure> button
o <Path Selection> button
o Select path on usb drive
o <Save button>
- Select software
o Select button <Install software>
o Reboot controller is started
- Repeat for every installation packages you want to install.

After restarting the controller, the license key of KUKA.BendTech KRC must be entered to activate all its
functionality. See Chapter 3, License.

3.3 Updating the software

Before updating make an archive.
Check if the user routines are correct. If this is not the case copy the incorrect user routines from the
archive to the robot controller.

3.4 Uninstalling the software

Use WorkVisual to uninstall the KUKA.BendTech KRC software.

After a software update of the KUKA System Software with a change in the release (e.g. 8.3 to 8.6), KUKA.
BendTech KRC will no longer be available. To perform a software update while keeping KUKA.BendTech KRC
the following steps have to be followed:

First step:
Make a backup of the robot controller

Second step:
Perform the software update

Third step:
If KUKA.BendTech KRC is no longer available on the controller, install KUKA.BendTech KRC

Fourth step:
If needed: copy back the user files from the backup

3.6 Inline folds

Once the software has been installed successfully, the menu item Technology contains the new menu item
BendTechKRC. This menu item contains the various commands of KUKA.BendTech KRC.

If no valid license is provided, the message “invalid license” is displayed in the output window. Read
Chapter 3 for more information.

Fig. 7. No valid license is available for this robot.

When the license key is valid, the full functionality of the software module can be used.
When no license key is available or when the license key is invalid for the software module, then the robot
has limited functionalities
• The robot can be moved in T1, but no program can be selected
• Inline folds cannot be edited

Temporary license keys (so called evaluation license keys) can be provided. The temporary license keys
have the full functionality and are valid for 1 month after shipping the license. No automatic method is
provided for obtaining the evaluation license keys. Every request is evaluated as a sales request. Temporary
license keys only can be extended by a purchase of the software.

4.2 Requesting a license

If the software is installed, but no license key is available, then all the information needed to order a license
can be filled in on the SmartPad. Select “Main menu” → “Configuration” → “Bendtech License state”. In
the bottom section of the screen there is a request license button. When you press this button you get the
license request screen in which all the necessary data can be entered in order to request a license.

The product name and Robot serial number are

already filled in and cannot be changed. For
license type you can choose between a full
license or a temporary license.

Under Customer information the Name,

company, address, email, order number and a
comment should be filled in. Then by pressing
the save button a file is written to
c:\KRC\Roboter\Log\LicRequest.txt. This file
contains all the data needed so that a license key
can be generated. Add this document to the
official order of the product.

Should this file not be attached, then the

product name, robot serial number and license
type should be clearly mentioned in the order.

Fig. 8. The License request screen.

4.3 Entering a license

After receiving a license it can be entered on the Smartpad. The license key can be entered in the text box.
Then press the “Validate” button. If the license key is correct then the textbox and validate button will
disappear and instead it will show a “Valid license” message. After validation, the license key can be found
in BT_Config.dat.

Fig. 9. The License key screen.

4.4 Upgrading the software

When the software is upgraded, the license key is kept and has not to be typed in. When the software is de-
installed, the license key is removed from the robot.

4.5 Exchanging the robot

The license key is only valid for the robot with the given serial-number. When there is a full license installed
and the robot has to be exchanged due to a hardware malfunction or crash. Then instead of shutting down
the license will switch to a 30 day grace period during which a new key can be requested for the new robot.

▪ Configuration of options for activating the rights fields inside the inline forms.
▪ Configuration of input- and output- routines to communicate with the components of the installation
▪ Configure the status keys on the robot controller for manual functions.
▪ Calibration of the robot bases: measuring the position of the components in the installation with
respect to robot

These configuration steps are typically performed by a system integrator.

5.1 Interface routines

To make the software generic for different bending installations, separate interface routines are provided
for the communication of the robot with the press brake and for the communication of the robot with
other components in the robot cell. These interface routines are installation specific routines which must
be customized to the hardware in the installation. The routines can be found in the folder
\\R1\TP\BendTechKRC\ on the robot controller. These input-, output-, and event routines are
programmed in KRL code. The robot controller has to be set in expert mode to do so.

Figure 10. Input routines, output routines and event routines

Inputs are the signals from a component to the robot. These inputs signals are checked by the
KUKA.BendTech KRC software through input routines. These input routines are functions that return a
value.

Events are occurrences of a certain condition. When this condition is true the corresponding event
procedure will be executed. These event routines contain the actions that the robot should perform.

Backup your controller data before (re)installing the technology package!

All variables and names of the KUKA.BendTech Basic KRC package start with the prefix BT_

5.1.1 Overview of routines

The figure below shows the available input routines, output routines and event routines. Upon installing
KUKA.BendTech Basic KRC, these routines are empty. Comments in the routines on the robot controller
allow defining how the routines should be implemented.

Input routines gripper Output routines gripper Events

BT_I_GripCode.src BT_O_AirOff.src BT_On_AppSearchEnd.src
BT_I_GripGetPart.src BT_O_AirOn.src BT_On_BendTechInit.src
BT_I_GripNoPart.src BT_O_GripRelease.src BT_On_GetStart.src
BT_I_GripPart.src BT_O_GripOff.src BT_On_GetSlowDown
BT_I_GripPutPart.src BT_O_GripGrab.src BT_On_GetSearchEnd.src
BT_On_GripperInit.src
BT_On_ILFExecuted.src
Input routines press brake Output routines press brake BT_On_LineSelect.src
BT_I_PressBackgauge1.src BT_O_Close.src BT_On_LineUpSetBase.src
BT_I_PressBackgauge2.src BT_O_Press.src BT_On_LineUpEnd.src
BT_I_Pressbg1_pos.src BT_O_ResetError.src BT_On_LineUpStart.src
BT_I_Pressbg2_pos.src BT_O_SetError.src BT_On_MemorizeOvPro.src
BT_I_PressClampPoint.src BT_O_SetSeq.src BT_On_OutputStationFull.src
BT_I_PressDECP.src BT_O_ToCP.src BT_On_PartDroppedCT.src
BT_I_PressEP.src BT_O_ToDECP.src BT_On_Partlost.src
BT_I_PressLDP.src BT_O_ToEP.src BT_On_PartNotFound.src
BT_I_PressMutePoint.src BT_O_ToLDP.src BT_On_PartPickedCT.src
BT_I_Pressopening.src BT_O_ToMaxOpen.src BT_On_PressInNewSeq.src
BT_I_Pressseq.src BT_O_ToSP.src BT_On_ProgCancel.src
BT_I_PressUDP.src BT_O_ToUDP.src BT_On_ProgReset.src
BT_On_ProgStart.src
Input routines regrip station Output routines regrip BT_On_ProgStop.src
station
BT_I_TableCupsBack.src BT_O_TableRelease.src BT_On_PutEnd.src
BT_I_TableCupsFront.src BT_O_TableCupsBack.src BT_On_PutSetBase.src
BT_I_TableOpening.src BT_O_TableCupsFront.src BT_On_PutStart.src
BT_O_TableOff.src BT_On_ResetError.src
Input routines Installation BT_O_TableOpening.src BT_On_SetTestRun.src

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BT_I_Cycle_Stop_Req.src BT_O_TableGrab.src BT_On_SetOvProOld.src
BT_O_TableJogClose.src BT_On_SPSInit.src
BT_O_TableJogOpen.src BT_On_SPSLoop.src
BT_On_SyncError.src
Input routines thickness Output routines thick.meas
meas.
BT_I_Sensor1Value.src BT_O_CalibSens1 + 2.src
BT_I_Sensor2Value.src BT_O_CloseSens1 + 2.src
BT_O_OpenSens1 + 2.src

Input routines center station Output routines input

station
BT_I_ PartOnCT.src BT_O_SeparateBlow.src
BT_O_SeparateOff.src
Figure 11. Overview of input routines, output routines and event routines

5.2 Configure status keys on the Smartpad.

To control the components in the installation, KUKA.BendTech KRC installs freely configurable status keys.
After the menu function Configuration > Status keys > BendTechKRC has been activated, the robot
controller provides a number of status keys especially defined for BendTechKRC.

Figure 12. Menu item to activate status keys

The system integrator can configure the KUKA.BendTech KRC status keys completely to his wishes. 10 key
lists with each up to 3 functions can be configured. The number of configured key lists must be set in the
file \\R1\TP\BendTechKRC\General\BT_Config.dat.

INT BT_SK_FUNC_NUM=8 ; 0..10

The icons that are displayed are defined in the folder C:\KRC\TP\BENDTECHKRC\StatkeybarImages.
The name of the icons must be the same as the predefined examples (BMP format with 32x32 pixels).

When a manual action button is pressed, the corresponding output routine will be executed. The buttons
only will be enabled when the robot is in operation mode $T1 or $T2, the drives are switched on and the
submit interpreter is running. When the lowest button of the four buttons is pressed, the next list of keys
will be displayed.

BT_O_GripRelease BT_O_TableRelease BT_O_TableCupsFront

BT_O_GripGrab BT_O_TableGrab BT_O_TableCupsBack

BT_O_GripOff BT_O_TableOff No action

Next key list Next key list Next key list

Figure 13. Key list 1..3/8 with manual action buttons

BT_O_TableJogOpen BT_O_ToMaxOpen BT_O_CloseSens1

BT_O_ TableJogClose BT_O_TOCP BT_O_OpenSens1

Or
BT_O_TOLDP

No action No action No action

Next key list Next key list Next key list

Figure 14. Key list 4..6/8 with manual action buttons

BT_O_CloseSens2 BT_O_AirOn

No action No action

Next key list Back to first key list

Figure 15. Key list 7..8/8 with manual action buttons

5.3 Calibration of the robot bases

Before the program is put into operation, the position of several components in the robot cell must be
measured with respect to the robot. The measurement results are stored in robot bases. There is a base for
each of the following components

1. Input Station (GET, MGET, BGET command)

2. Center station (CENTER command)
3. Press brake (BEND command, LIFT command)
4. Regrip station (REGRIP commands)
5. Output station (PUT command, LINEUP, DROP, MPUT command)

When there are two input stations, then there are two bases, one for each input station.

The reader is referred to the documentation of the KUKA KSS software on measuring
tools and bases.
A base normally only has to be measured once, during the commissioning of the robot
cell.
A base is unique and cannot be used for different components. This means that the base
for the centring table should not be used for the input station etc.
The base is measured by first measuring a tool. When the tool is not correctly
measured, the base is also not correctly measured.
The results for measuring a base are more accurate when the different points used in
the measuring method, are located at a long distance of each other. It is advised to
repeat the measurement of a base, when there is uncertainty that a base correctly
measured.

5.3.1 Advised use of bases

For every one of the following commands, a base ranging from BASE_DATA[1] to BASE_DATA[32] can be
used. Based on our experience, we recommend the use of following base numbers. The exact use depends
on the layout being used.

Bases 1..9 : for individual installation components

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Base 1 = Double Sheet Station 1
Base 2 = Double Sheet Station 2 (if available)
Base 3 = Center station
Base 4 = Press brake
Base 5 = Regrip station cups forwards (if available)
Base 6 = Regrip station cups backwards (if available)
Base 7..9 = not yet defined

Bases 10..19 : for input stations

Base 10 = Input station 1
Base 11 = Input station 2 (if available)
Base 12 = Input station 3 (if available)
Base 13..19 = not yet defined

Bases 20..29 : for output stations

Base 20 = Output station 1
Base 21 = Output station 2 (if available)
Base 22..29 = not yet defined

Bases 30..32 : not yet defined

5.3.2 Base on input station (base 10..19)

The base for the Input station can be measured using the 3-points method. The origin of the base is
situated in a corner, see the figure below. The positive Z direction of the base points upwards,
perpendicular to the sheet. The positive X direction has to follow a side of the sheet. The positive Y
direction has to follow the other side of the sheet.

Figure 16. Base on Input station

Figure 17. Base on double sheet station type 1 and type 2

Double sheet station type 1 : the sheet is placed horizontally in the station. The base on the double sheet
station is typically placed in the tip of the lower (and fixed) pin. The z-axis point upwards. It is
recommended to place the x-axis outwards of the station.

Double sheet station type 2 : the sheet is placed vertically in the station. The base on the double sheet
station is placed at the tip of the fixed side of the station. The z-axis points outwards of this fixed side. The
x-axis points downwards.

5.3.4 Base on Center station (base 3)

The base for the Center station can be measured using the 3-points method or with the aid of the
\\R1\TP\BendTechKRC\BT_Calib.src routine.
The origin of the base is situated in a corner. The positive Z direction of the base points perpendicular to
the sheet. The positive X direction has to follow a side of the sheet. The positive Y direction has to follow
the other side of the sheet.

Figure 18. Base on center station

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Calibrating the base is more accurate when using the \\R1\TP\BendTechKRC\Setup\BT_Calib.src routine.
In this routine 6 points have to be teached. With these 6 points, the robot calculates the base. It is best to
put a stiff sheet on the center station that can be used as reference plane during the calibration. The
thickness of this sheet must then be input in the PLATE_THICKNESS variable. During this calibration routine
extra user input is needed through the “Display” – “Variable” – “Single” menu item. The program will ask
the user to input the following values:

KRL Variable Description

BASE_DATA[x] CENTER_BASE Number [1..32] of the base that
will be assigned to the Center
station.
PLATE_THICKNESS Thickness of the plate that was
on the Center station.

First point on aligner plane near alignment corner Second point on aligner plane along short side

Third point on aligner plane along long side Fourth point on short side

Note that the results are more accurate if the points are measured at a large distance of each other.

5.3.5 Base on Press brake (base 4)

The base for the Press brake can be measured using the 3-points method or with the aid of the
\\R1\TP\BendTechKRC\Setup\BT_Calib.src routine.
The origin of the base is situated on the zero point of the press brake. The press zero point is on bending
line. The positive Z direction of the base points from left to right over the bending line. The positive X
direction faces into the press brake. The positive Y direction points upwards.

Figure 20. Base on press brake

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Calibrating the base is more accurate when using the \\R1\TP\BendTechKRC\BT_Calib.src routine. In this
BT_Calib routine 6 points have to be teached. With these 6 points, the robot calculates the base. During
this calibration routine extra input is needed through the “Display” – “Variable” – “Single” menu point. The
program will ask the user to input the following values:

Note: the results of the calibration routine are more accurate if the different measurement points are
located at a large distance of each other.

Note: in the above example, the origin of the press brake is located at the left side of the press brake.
This is the case for most of the press brakes on the market. There are however, press brakes with the
origin in the middle of the press brake.

KRL Variable Description

Number [1..32] of the base that will

BASE_DATA[x] PRESS_BASE
be assigned to the press brake.

Distance between die front (point

DIS_TO_BEND_LINE one) and bend line (middle of the
die)

DIE_HEIGHT Height of the DIE in the press brake

Distance along the bend line

DIS_TO_PRESS_ZERO between point six and press zero
point.

Teach second point on die front side, low in the middle

Teach fourth point on top of the die on the right

Teach sixth point to calibrate zero point: anywhere on the plane perpendicular to the bendline
and at the given dis_to_press_zero distance from the origin of the press.

Figure 21. BT_CALIB on press brake

Note : Make sure the dies are correctly mounted on the press brake !!! The text on the Die must face
forward.

When all the points are teached the KRL fold “Run this code” must be executed.

5.3.6 Bases on Regrip station (base 5, base 6)

The bases for the Regrip station can be measured using the 3-points method or with the aid of the
\\R1\TP\BendTechKRC\Setup\BT_Calib.src routine.

Figure 22. Bases on Regrip station

Calibrating the base is more accurate when using the \\R1\TP\BendTechKRC\BT_Calib.src routine. In this
BT_Calib routine 6 points have to be teached for each base. During this calibration routine extra input is
needed through the “Display” – “Variable” – “Single” menu point. The program will ask the user to input
the following values:

KRL Variable Description

Number [1..32] of the base that

will be assigned to the regrip
BASE_DATA[x] REGRIP_BASE1
station with cups towards the
robot.

The height (along the Y axis) from

HEIGHT_TO_REF_FRAME1
p4 and p5 to the origin of the base.

The distance (along the X axis)

DIS_TO_MIDDLE1
from P6 to the origin of the base.

Note that the results are more accurate if the points are measured at a large distance of each other.

First point, base plate of suction cup low on left arm Second point, base plate of suction cup
high on left arm

Fifth point, on top of base plate of left arm Sixth point, middle between the two beams

Figure 23. BT_CALIB on regrip station

Note : This measurement procedure have to be repeated with the regrip table turned. (cups away
from the robot)

5.3.7 Base on output station (base 20 .. 29)

The base for the Put station can be measured using the 3-points method. The origin of the base is situated
in a corner. The positive Z direction of the base points upwards, perpendicular to the sheet. The positive X
direction has to follow a side of the sheet. The positive Y direction has to follow the other side of the sheet.

5.4 Synchronous robot - press motion

This topic is described in the chapter Synchronisation of robot with press brake motions.

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6 Programming
The list of commands KUKA.BendTech Basic KRC are available under menu item Commands >
BendTechKRC. The menu items are listed in the same order as they occur in a bending program.

Figure 25. Menu BendTechKRC

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6.1 BT AUTHORIZE
With BT AUTHORIZE you can define which pieces of a bending program are executed by the robot. Allowing
pieces of a program to be executed is called authorization. Authorization can be made for the program
itself and for input stations and output stations. Up to 10 input and 10 output stations can be defined.
When an input station 1 is not authorized, then the robot will skip this input station 1.

Figure 26. BT Authorize

The result of this inline fold is reflected in bits of the return value (INT) of the routine BT_ON_Authorise. Bit
1 to 10 are for the input stations, bit 11 to 20 are for the output stations.

Parameter Description Range of values

Program Program: Allows the program to be started or True/False
Input/Output 1 not.
Input/Output 2
Input/Output 3 Input X/Output X: Allows the input/output of
Input/Output 4 that station to be used or not.
Input/Output 5
Input/Output 6 Can only be edited when User level is Expert
Input/Output 7 or higher
Input/Output 8
Input/Output 9
Input/Output 10

Note: If BT AUTHORIZE is not executed or Inputs/outputs/program are not authorized, then the BT INIT
BENDTECH or BT INIT GRIPPER routine will not be executed

Note: if you run the program in T1 or T2 you can run through BT authorize for testing purposes

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6.2 BT CHECKCELL
The BT CHECKCELL command is an instruction to check variables and signals usually at the start of
production .

Figure 27. BT CHECKCELL

Note: The command Checkcell can be executed for example in the beginning of the program before the
main loop starts.

Note: Following user routines are executed during this command

• \\UserEvents\ BT_On_CheckCell

Note : Following in- and output routines have to be configured to use this command
• \\UserEvents\ BT_On_CheckCell

Figure 28. BT Config Gripper

BT INIT GRIPPER initialises the parameters for the commands out the following tasks:

- Selection of gripper, configuration an

- Changing the robots actual TOOL and LOAD data

Parameter Description Range of Values

Config The desired configuration for the used gripper. This [0..255]
setting will be stored in KRL variable
BT_GRIPPER_CONFIG
TCP In this field the user can give the TCP a name. This 1..23 chars, may not
name is linked to the parameter lists with the Tool start with a number
Center Point data for the gripper.
XYZ: The TCP is situated in the centre of the sheet. X: [-2000..2000mm]
ABC: The positive X-axis is calibrated along one side of Y: [-2000..2000mm]
the gripper. The positive Y-axis is calibrated along the Z: [-2000..2000mm]
other side of the gripper. The positive Z-axis points A: [-180..180deg]
out the sheet handled by the gripper. B: [-180..180deg]
When the data field Measured Tool is used, the C: [-180..180deg]
measured tool data can be used to overrule the TCP
values of this data field.
Load In this field the user can give the LOAD a name. This 1..23 chars, may not
name is linked to the parameter lists with the Load start with a number
data for the gripper. The load data are M, CM and J.
• M=-1 … weight M: [-1..1000 kg]
The mass of the gripper with a sheet is to be entered
for M. If this value is set to -1, the default values for CM.X: [-2000..2000mm]
the mass, centre of gravity and inertia for the CM.Y: [-2000..2000mm]
corresponding robot type are used. CM.Z: [-2000..2000mm]
• CM{X 0, Y 0, Z 0, A 0, B 0, C 0} CM.A: [-180..180deg]
The centre of gravity of the gripper with a sheet is to CM.B: [-180..180deg]
be entered for CM. CM.C: [-180..180deg]
• J{X 0.0, Y 0.0, Z 0.0}
The moment of inertia with a sheet is to be entered J.X[0..50 kg*m²]
for J. The moments of inertia can be calculated J.Y[0..50 kg*m²]
mathematically or can be obtained dynamically using J.Z[0..50 kg*m²]
the load data determination functions.
Measured Tool In this field the user can select which TCP will be used
None
to overwrite the TCP that is entered in the INIT Tool[2]
gripper TCP data field. Tool[3]
Tool[4]
When None is selected, no measured tool is used, and Tool[5]

Note: All BendTech commands use TOOL_DATA[1]. During the Config_Gripper command the new tool
and load data are copied into the robots TOOL_DATA[1] and LOAD_DATA[1]. This way BendTech
extends the standard 16 toolsets of the KRC controller.

Note: the robot TCP is used implicitly by a number of other KUKA.BendTech KRC commands such as BT
GET, BT CENTER, BT PUT2. It is therefore useful to enter the correct values of the TCP.

Note : the option KUKA LoadDetermination can be used for the determination of the load. Look at the
documentation of this product on how to determine dynamically the load data of the gripper and
sheet.

Note: the command BT Bend places the tool centre point at the bending line. This replacement is
made dynamically and does not influence the parameters entered in the BT INIT GRIPPER command.

Note: in the case of a gripper with multiple configurations, a BT INIT GRIPPER or BT_GripperConfig
must be added to the robot program, for every situation where the configuration changes.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_GripperConfig
• \\UserEvents\BT_On_ILF_Executed

Figure 29. BT INIT GRIPPER4

BT INIT GRIPPER initialises the parameters for the commands out the following tasks:

- Selection of gripper, configuration an type

- Verification of gripper parameters
- Changing the robots actual TOOL and LOAD data

Parameter Description Range of Values

Gripper A number for the used gripper. This setting will be [0..255]
stored in the KRL variable. BT_GRIPPER
Config The desired configuration for the used gripper. This [0..255]
setting will be stored in KRL variable
BT_GRIPPER_CONFIG
Type Type of gripper that is used. This setting will be stored #VACUUM
in KRL variable BT_GRIPPER_TYPE #MAGNET
#CLAMPS
#CHANGER
#TYPE_X
#TYPE_Y
#TYPE_Z
CircuitA In this field the user can select the number of circuits #C0
that are connected on the gripper. Example C13 => #C1
circuit 1 and 3 will be used. This setting will be stored #C2
in KRL variable BT_GRIPPER_CIRCUITA and must be #C3
used in the interface routines. #C4
#C12
#C13
#C14
#C23
#C24
#C34
#C123
#C124
#C134
#C234
#C1234
CircuitB In this field the user can select the number of circuits #C0
that are connected on the gripper. Example C56 => #C5
circuit 5 and 6 will be used. This setting will be stored #C6
in KRL variable BT_GRIPPER_CIRCUITB and must be #C7

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used in the interface routines. #C8
#C56
#C57
#C58
#C67
#C68
#C78
#C567
#C568
#C578
#C678
#C5678
Code If the gripper reflects a code to the IO system of the [0..255]
robot, the code number can be programmed in this
field. The robot will check if the right gripper is
mounted on the robot. If the gripper is not equipped
with a hardware code, then the value must be set 0.
TCP In this field the user can give the TCP a name. This 1..23 chars, may not
name is linked to the parameter lists with the Tool start with a number
Center Point data for the gripper.
XYZ: The TCP is situated in the centre of the sheet. X: [-2000..2000mm]
ABC: The positive X-axis is calibrated along one side of Y: [-2000..2000mm]
the gripper. The positive Y-axis is calibrated along the Z: [-2000..2000mm]
other side of the gripper. The positive Z-axis points A: [-180..180deg]
out the sheet handled by the gripper. B: [-180..180deg]
When the data field Measured Tool is used, the C: [-180..180deg]
measured tool data can be used to overrule the TCP
values of this data field.
Load In this field the user can give the LOAD a name. This 1..23 chars, may not
name is linked to the parameter lists with the Load start with a number
data for the gripper. The load data are M, CM and J.
• M=-1 … weight M: [-1..1000 kg]
The mass of the gripper with a sheet is to be entered
for M. If this value is set to -1, the default values for CM.X: [-2000..2000mm]
the mass, centre of gravity and inertia for the CM.Y: [-2000..2000mm]
corresponding robot type are used. CM.Z: [-2000..2000mm]
• CM{X 0, Y 0, Z 0, A 0, B 0, C 0} CM.A: [-180..180deg]
The centre of gravity of the gripper with a sheet is to CM.B: [-180..180deg]
be entered for CM. CM.C: [-180..180deg]
• J{X 0.0, Y 0.0, Z 0.0}
The moment of inertia with a sheet is to be entered J.X[0..50 kg*m²]
for J. The moments of inertia can be calculated J.Y[0..50 kg*m²]
mathematically or can be obtained dynamically using J.Z[0..50 kg*m²]
the load data determination functions.
Measured Tool In this field the user can select which TCP will be used None
to overwrite the TCP that is entered in the INIT Tool[2]
gripper TCP data field. Tool[3]
Tool[4]
When None is selected, no measured tool is used, and Tool[5]
the data of the TCP data field is selected. Tool[6]

6.5 BT INIT GRIPPER5

Figure 30. BT INIT GRIPPER5

BT INIT GRIPPER5 is an improvement to BT INIT GRIPPER4 as it allows to control up to 16 vacuum cups. The
command initialises the parameters for the commands out the following tasks:

- Selection of gripper, configuration an type

- Verification of gripper parameters
- Changing the robots actual TOOL and LOAD data

Parameter Description Range of Values

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the i interface routines.
Code If the gripper reflects a code to the IO system of the [0..255]
robot, the code number can be programmed in this
field. The robot will check if the right gripper is
mounted on the robot. If the gripper is not equipped
with a hardware code, then the value must be set 0.
TCP In this field the user can give the TCP a name. This 1..23 chars, may not
name is linked to the parameter lists with the Tool start with a number
Center Point data for the gripper.
XYZ: The TCP is situated in the centre of the sheet. X: [-2000..2000mm]
ABC: The positive X-axis is calibrated along one side of Y: [-2000..2000mm]
the gripper. The positive Y-axis is calibrated along the Z: [-2000..2000mm]
other side of the gripper. The positive Z-axis points A: [-180..180deg]
out the sheet handled by the gripper. B: [-180..180deg]
When the data field Measured Tool is used, the C: [-180..180deg]
measured tool data can be used to overrule the TCP
values of this data field.
Load In this field the user can give the LOAD a name. This 1..23 chars, may not
name is linked to the parameter lists with the Load start with a number
data for the gripper. The load data are M, CM and J.
• M=-1 … weight M: [-1..1000 kg]
The mass of the gripper with a sheet is to be entered
for M. If this value is set to -1, the default values for CM.X: [-2000..2000mm]
the mass, centre of gravity and inertia for the CM.Y: [-2000..2000mm]
corresponding robot type are used. CM.Z: [-2000..2000mm]
• CM{X 0, Y 0, Z 0, A 0, B 0, C 0} CM.A: [-180..180deg]
The centre of gravity of the gripper with a sheet is to CM.B: [-180..180deg]
be entered for CM. CM.C: [-180..180deg]
• J{X 0.0, Y 0.0, Z 0.0}
The moment of inertia with a sheet is to be entered J.X[0..50 kg*m²]
for J. The moments of inertia can be calculated J.Y[0..50 kg*m²]
mathematically or can be obtained dynamically using J.Z[0..50 kg*m²]
the load data determination functions.
Measured Tool In this field the user can select which TCP will be used
None
to overwrite the TCP that is entered in the INIT Tool[2]
gripper TCP data field. Tool[3]
Tool[4]
When None is selected, no measured tool is used, and Tool[5]
the data of the TCP data field is selected. Tool[6]
Tool[1] cannot be selected, as this is a predefined Tool[7]
tool. Tool[8]
Tool[9]
Tool[10]
Tool[11]
Tool[12]
Tool[13]
Tool[14]
Tool[15]
Tool[16]

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Figure 31. BT INIT Gripper - The tool center point TCP is by definition laid in the middle of the
sheet to be handled.

Figure 32. BT INIT – Definition of the center of mass M with respect to the robot flange

Note: All BendTech commands use TOOL_DATA[1]. During the INIT_GRIPPER command the new tool
and load data are copied into the robots TOOL_DATA[1] and LOAD_DATA[1]. This way BendTech
extends the standard 16 toolsets of the KRC controller.

Note: the command BT INIT GRIPPER must be available at least one time in a bending program.

Note: the robot TCP is used implicitly by a number of other KUKA.BendTech KRC commands such as BT
GET, BT CENTER, BT PUT2. It is therefore useful to enter the correct values of the TCP.

Note: the command BT Bend places the tool centre point at the bending line. This replacement is
made dynamically and does not influence the parameters entered in the BT INIT GRIPPER command.

Note: in the case of a gripper with multiple configurations, a BT INIT GRIPPER config must be
added to the robot program, for every situation where the configuration changes.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_ON_GRIPPER_INIT
• \\UserEvents\BT_On_ILF_Executed

WARNING

Once a tool is set in the INIT GRIPPER command, use this tool for all next points

Init Gripper tool 11

PTP Pxx tool11
CFP

If this rule is not followed, the robot can come to stop due to out of reach.

Init Gripper tool 11

PTP Pxx tool11
CFP
PTP Pxx tool12
BT BEND <-- Robot comes to stop

Figure 34. BT INIT BENDTECH

BT INIT BENDTECH initializes the basic parameters for all BendTech commands and carries out the following
tasks:

- Selection of the simulation mode

- Check whether or not there is still a sheet in the gripper. A message appears in the message
window. If desired, suction to the sheet is released.

Parameter Description Range of Values

Test run Must be set to TRUE if program should run without TRUE or FALSE
sheet. Otherwise this value should be FALSE.
With press- If this value is set to NO the communication with the TRUE or FALSE
brake press brake is deactivated during the test run
execution. This option is only available if TEST RUN is
set to TRUE.
With regrip If this value is set to NO the communication with the TRUE or FALSE
station regrip station is deactivated during the test run
execution. This option is only available if TEST RUN is
set to TRUE.

Note: All BendTech programs must start with a BT INIT GRIPPER and BT INIT BENDTECH command.
These must be the first BendTech commands inside the robot program.

Note: Make sure the BT INIT GRIPPER command is properly initialized before calling the BT INIT
BENDTECH command.

Note : Folowing UserRoutines are executed during this command

• \\UserEvents\BT_On_SetTestRun
• \\UserEvents\BT_On_BendTechINIT
• \\UserEvents\BT_On_ILFExecuted

The parameter Test run offers the possibility to optimize the robot programs without bending a part.

- Grasping parts is omitted in all routines

- When using a vacuum gripper, no vacuum is generated
- When using a jaw gripper, the jaws are not controlled (and remain open)

The parameter Test run influences the different bending routines in following way

- BGET : go to approach point above pallet, do not make grasp motions

- MGET : go to point above stack, do not make search motion
- GET : identical to MGET
- CENTER : make all motions, but do not grasp part
- MEASURE : sensor is not controlled (and remains open)
- SET SEQ : is executed as variable BT_WITH_PRESS=TRUE
- BEND : use interpolation table or RSI when option is available
- APPROACH : go to taught position
- PUT : go to approach point above pallet, do not make release motions
- MPUT : go to approach point above pallet, do not make release motions
- LINEUP : go to approach point above pallet, do not make release motions

6.7 BT GET

Figure 35. BT GET

Figure 36. BT GET soft keys

BT GET combines different tasks to grasp a part at the input station

• Search motion to find the first sheet and rapid motion for the next sheets
• Grasp sheet
• Motions to separate the sheet
• Motion upwards
After the start-up of the installation, or after the opening of the doors of the installation, a search run is
carried out at reduced velocity. All subsequent sheets are grasped without this search run and at increased
velocity.

The position of the gripper to grasp the sheet is defined over inline parameters. When the soft key “Set Pick
XYA” is pressed, the coordinates of the actual robot position are set in the parameter list. The values of the
parameters Position X, Position Y and Rotation A in the parameter list are updated to the actual position of
the robot.

Parameter Description Range of Values

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PARAMETERS In this field the user can give the Get 1..23 chars may not start with a
parameter list a name. This name is number
linked to the parameter lists with
additional data for the Get command.

Get Parameters POS.X: [0..4000 mm]

Position X, Position Y: these POS.Y: [0..4000 mm]
parameters must be used to define the
position where to grab the sheet out
of the get stack.

Rotation A: this parameter can rotate ROT.A: [-180..180 deg]

the gripper. The orientation is used for
all motions inside the GET command
when rotation separation is switched
off.

Separation motion parameters

Sep Vel SEP.VEL [0..2 m/s]

Velocity for the separation motion

Sep Acc SEP.ACC [0..100 %]

Acceleration for the separation motion

Linear separation motion

Repetitions: Number of times to REPETITIONS [1..5]
repeat the linear scratch motion.

Distance Z, Offset X, Offset Y: these DISTANCE Z [0..200 mm]

parameters can be used to define the OFFSET.X: [-20..20 mm]
linear separation motion, the start of OFFSET.Y: [-20..20 mm]
the upwards movement.

Rotational separation motion

These parameters can be used to tilt the
sheet during the upwards movement.

Repetitions: Number of times to REPETITIONS [1..5]

repeat the rotative separation motion.

Blow side: On which side of the base Blow Side:

(x-side or y-side) are the air blowing 0 = X-Side
cups mounted. The rotation of the 1 = Y-Side
sheet is performed opposite to this air
blowing cups.
Spin angle: angle to which the sheet is Spin Angle: [0..45 deg]
tilted.
Spin Radius: The sheet length or width Spin radius: [0..4000 mm]
used to calculate the point around
which the sheet is tilted.
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Start height Maximum height of the parts on the [100..2000 mm]
input station. This value is used to
calculate the start point of the search
run. This value is also used for the return
motion after the sheet is grasped.
End height Minimum height of the parts on the [-100..2000 mm]
input station. This value is used to
calculate the end point of the search run.
Pal. Mode In the case of Pal. Mode=TRUE, axes 4 is TRUE of FALSE
moved to 0 deg and axes 6 is
perpendicular to the ground. In this
mode the robot will be able to move
through Alfa-5 situations.

Figure 38 BT GET with spin angle, Blow side = X-Side Spin angle (A), Spin Radius (R)

With the variable BT_GET_GRIP_GRAB the close gripper behavior on start of the search motion can be
activated.
BT_GET_GRIP_GRAB = TRUE (default): Robot will close gripper on start of the search motion. In case of a
vacuum gripper the sucking will start.
BT_GET_GRIP_GRAB = FALSE: Robot will not automatically close the gripper on start of the search
motion. User code for closing the gripper has to be provided in this situation.

With the variable BT_GET_NIO_HALT the robot behavior during a fail situation can be changed.
BT_GET_NIO_HALT = TRUE (default): Robot will stop with an error message when he was not able to
fetch a plate with the GET routine.
BT_GET_NIO_HALT = FALSE: Robot will continue with the program if he was not able to fetch a plate
with the GET routine. The The variable BT_GET_NIO will contain TRUE if the robot was not able to fetch
the plate. Also the event routine BT_On_PartNotFound will be executed. The robot program should
contain a proper error handling sequence.

With the variable BT_GET_FAST_REP the robot will execute the repetition motions faster.

Note: the velocity for the search motion is defined in the VEL parameter. The velocity used after the
sheet is grasped and when the robot is performing the motion to separate the sheet is defined in the
separate velocity parameter.

Note: the linear separation motion can be used for scratching the plate along a brush; the rotative
separation motion can be used for blowing air between the sheets.

Note: the rotative separation motion is executed first and then the linear separation motion is
executed.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_ON_GetStart
• \\UserEvents\ BT_On_PartNotFound
• \\UserEvents\ BT_OnILFExecuted

Note : Following in- and output routines have to be configured to use this command
• \\UserInput\ BT_I_GripPart
• \\UserInput\ BT_I_GripGetPart
• \\UserInput\ BT_I_GripNoPart
• \\UserOutputs\ BT_O_GripGrab
• \\UserOutputs\ BT_O_GripOff
• \\UserOutputs\ BT_O_GripRelease
• \\UserOutputs\ BT_O_SeparateBlow

6.8 BT BGET
BGET is the routine to pick parts on an input station using a clamp gripper (the German word is
Backengreifer, hence the abbreviation BGET).

Figure 39 BT BGET

Figure 40 BT BGET soft keys

The position of the gripper to grasp the sheet is defined over inline parameters. When the soft key “Set Pick
XYA” is pressed, the coordinates of the actual robot position are set in the parameter list. The values of the
parameters Position X, Position Y, Position Z, Rotation A, Rotation B and Rotation C in the parameter list
are updated to the actual position of the robot.

Parameter Description Range of Values

From BASE In this field the user must select the [1..32]
BASE [1..32] that is linked to the input
station.
VEL Velocity at which parts are grasped [0..2 m/s]
(range of values: 0...2 m/s)
Acc Acceleration for GET procedure (range of [0..100 %]
values: 0...100%)
OffsetParameters PartOffset [-250…250]
Distance between 2 parts on the same
layer
Offset between parts in different
layers needs to be the same
Position Parameters Get Parameters POS.X: [0..4000 mm]
Position X, Position Y, Position Z: POS.Y: [0..4000 mm]
these parameters must be used to POS.Z: [0..4000 mm]
define the position where to grab the
sheet out of the get stack.

Rotation A, Rotation B, Rotation C: ROT.A: [-360..360 deg]

this parameter can rotate the gripper. ROT.B: [-360..360 deg]
The orientation is used for all motions ROT.C: [-360..360 deg]
inside the GET command

Max Parts Max number of parts in one layer [0…150]

Active Layers Number of active layers [1…3]

Calculate Base If the input station needs to be [0…128] or the amount of bases
measured the base frame can be saved defined in Workvisual
in a different base data ( this is done so
the original base data is not
overwritten). Set this parameter to the
base where the re-measured base is
saved.

If the base is not re-measured set this

parameter to base(0)

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With the variable BT_GET_NIO_HALT the robot behaviour during a fail situation can be changed.
BT_GET_NIO_HALT = TRUE (default): Robot will stop with an error message when he was not able to fetch a
plate with the GET routine.
BT_GET_NIO_HALT = FALSE: Robot will continue with the program if he was not able to fetch a plate with
the GET routine. The variable BT_GET_NIO will contain TRUE if the robot was not able to fetch the plate.
Also the event routine BT_On_PartNotFound will be executed. The robot program should contain a proper
error handling sequence.

Note: the search run is repeated every time the command BT RESET INPUT STATION is executed, see
command BT RESET.

Note: the velocity for the search motion is defined in the VEL parameter. The velocity used after the sheet
is grasped and when the robot is performing the motion to separate the sheet is defined in the separate
velocity parameter.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_ON_GetStart
• \\UserEvents\ BT_On_PartNotFound
• \\UserEvents\ BT_OnILFExecuted
• \\UserEvents\ BT_ON_GetSearchEnd

6.9 BT MGET
The MGET command is similar to the GET command, but allows to define picking of parts from up to 8
stacks on a pallet. A number of rule apply :

- All the parts are the same type and lie in the same position and orientation in the stacking areas.
- The method for picking is defined over parameters
- The method for sheet separation is defined over parameters
- The parts can be grasped by the method StackByStack or by LayerByLayer

The routine MGET allows to pick parts that are stacked on multiple stacks on the same input station.
Typically, this is used when there are two or more stacks next to each other.

Figure 42. BT MGET

Figure 43. BT MGET soft keys

BT MGET combines different tasks to grasp a part at the input station

• Search motion to find the first sheet and rapid motion for the next sheets
• Grasp sheet
• Motion upwards

When sheet separation using rotation is used, following motions are made in addition

• Search motion to find the first sheet and rapid motion for the next sheets
• Grasp sheet
• Rotate around rotation point
• Rotate back
• Perform this action 3 times
• Make a small linear motion
• Motion upwards

Parameter Description Range of Values

Offset X, Offset Y: these parameters can [-100 .. 100]

be used to define the linear separation
motion, the start of the upwards
movement. This is shown as sepX in the
figure.

Position Parameters Position X, Position Y: these parameters

must be used to define the position POS.X: [0..4000 mm]
where to grab the sheet out of the get POS.Y: [0..4000 mm]
stack.

Rotation A: this parameter defines the ROT.A: [-180..180 deg]

orientation of the gripper used to grab
the sheet out of the stacks

EndHeight : Maximum height of the

parts on the input station. This value is
used to calculate the start point of the
search run. This value is also used for
the return motion after the sheet is
grasped.

Spin Angle : angle used in the sheet [-15deg … +15 deg]

separation motion

Spin Radius : distance perpendicular to [0 .. +4000 mm]

the blow side. See figure below.

Separation velocity : speed used during [0 … 2 m/s]

the separation motion

Separation acceleration : acceleration [0 … 100%]

used during the separation motion

Order StackByStack, LayerByLayer: order in StackByStack: stacks will be unloaded

which the stacks will be unloaded sequentially
LayerByLayer: layers will be unloaded
sequentially

The first motion is a motion downwards until the

sheet is grasped.

Small extra translation Final motion upwards

• Move SepX in base x-direction • Move in base +z direction
• Move SepY in base y-direction
• Move in base +z direction for value that is
maximum of SepX and Sep
This motion is performed if the parameters are set
Figure 44 BT MGET – Example of sheet separation methods

The sheet separation motion is a rotation motion around a rotation axis. The image below shows a pallet
with 4 local stack areas. The sheet can be rotated around the global axis (at edge of area 1), or around local
axes.

Figure 45 BT MGET – Example of sheet separation methods on input pallet with multiple areas

Note: the search run is repeated every time the command BT RESET INPUT STATION is executed, see
command BT RESET.

Note: if a part is not found the input will be set to empty, if you reset the input the input must be at
the initial state

Note: if the first or second part is not found in a layer the input will be set to invalid.

Note:if apart is not found then on the next layer parts will be taken until parts taken from previous
layer – 2

Note: The minimum height of a stack is determined by the Z position taught in that stack

Note : Following user routines are executed during this command

• \\UserEvents\ BT_ON_GetStart
• \\UserEvents\ BT_On_PartNotFound
• \\UserEvents\ BT_OnILFExecuted

6.10BT SENSOR

Figure 46. BT SENSOR

After the “GET” command, an external sensor is used to verify the sheet thickness. The verification is
performed using the BT SENSOR command. If the sheet thickness is greater than that of a single sheet, this
could indicate that a second sheet is still attached to the first sheet. If the measured sheet thickness differs
from the set thickness, this could indicate that a wrong type of sheet is loaded on the input station.

Parameter Description Range of values

Sensor Number of the sensor used to verify the [1..2]
sheet thickness
Action A KRL routine corresponding to the desired Open = 1
sensor action is executed: Close = 2
Measure = 3
Open → BT_O_OpenSens1.SRC Calibrate = 4

Close → BT_O_CloseSens1.SRC

Measure → BT_O_CloseSens1.SRC, evaluate

BT_I_Sens1Value.src, BT_O_OpenSens1.SRC

Calibrate → BT_O_CalibSens1.SRC

Thickness Only available with option MEASURE. The [0.5 ... 20 mm]
sheet thickness value which will be
compared with the measured value.

With the variable BT_SENSOR_NIO_HALT the robot behavior during an error situation can be changed.

BT_SENSOR_NIO_HALT = TRUE (default): the robot will stop with an error message when he measures a
wrong plate thickness with the SENSOR routine.

With the variable BT_SENSOR_ENABELD the SENSOR routine can be disabled.

BT_SENSOR_ENABELD = TRUE (default) : the sensor routine will be executed.

BT_SENSOR_ENABELD = FALSE : the sensor routine will not be executed.

With the variable BT_THICK_MEAS_TOL the tolerance on the measurements of the plate thickness can be
changed. The variable ranges from 0 (=0%) to 1 (=100%) of the defined plate thickness. When the tolerance
is set to zero, the tolerance is by default changed to 0.05 (= 5%). The default value of the tolerance is 0.1
(=10%).

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_ILFExecuted

Note : Following in- and output routines have to be configured to use this command
• \\UserInput\ BT_I_Sens1Value + 2
• \\UserOutputs\ BT_O_OpenSens1 + 2
• \\UserOutputs\ BT_O_CloseSens1 + 2
• \\UserOutputs\ BT_O_CalibSens1 + 2

Note : The station in which the thickness of the sheet is measured is often called the thickness
measurement station, even if the station is technically not able to measure the thickness of the
sheet accurately. A more correct name is the Double Sheet (measurement) Station.

6.11BT IS CENTER EMPTY

Figure 48. BT IS CENTER EMPTY

At the start of the program the BT IS CENTER EMPTY command can be added to check if there is a part on
the centre table. If there is a part on the centre table, an operator has to remove it. When the part is
removed the program can continue. The command also can be inserted after the BT CENTER command to
verify if the centred plate is removed by the robot.

Note : Following in- and output routines have to be configured to use this command
• \\UserInput\ BT_I_PartOnCT

6.12BT CENTER
Update for new parameters to continue from vacuum gripper to clamping gripper.

Figure 50. BT CENTER

Figure 51. BT CENTER soft keys

BT CENTER combines different tasks to center of sheet on the center station

• Move the sheet to a drop position on the center station

Offset values can be configured for both the release position as for the grasp position.

Figure 52.1. BT CENTER Z-direction

Figure 53.2. BT CENTER Y-direction

When the soft key “Set Out XYZA” is pressed the coordinates of the actual robot position are set in the
parameter list. The values of the parameters Out pos X, Out pos Y, Out pos Z and Out rot A in the
parameter list are updated to the actual position of the robot.

When the soft key “Set Drop XYZA” is pressed the coordinates of the actual robot position are set in the
parameter list. The values of the parameters Drop pos X, Drop pos Y, Drop pos Z and Drop rot A in the
parameter list are updated to the actual position of the robot.

Parameter Description Range of values

On Base In this field the user must select the BASE [1..32]
[1..32] that is linked to the Center station.
VEL Centering velocity. [0..2m/s]

ACC Centering acceleration. [1..100%]

Motion Parameters

Center type In which direction the points CenterType

between Drop and Pick are recalculated Type Y
according to base. Type Z
Pre-Drop position

Pre-Drop pos X Gripper position Before PreDrop.X [0..4000 mm]

moving to the drop position

Pre-Drop pos Y Gripper position Before PreDrop.Y [0..4000 mm]

moving to the drop position

Pre-Drop pos Z Gripper position Before PreDrop.Z [-10..50]

moving to the drop position

Pre-Drop rot A Gripper position Before PreDrop.A [-180..180]

moving to the drop position

Drop position

Drop pos X Gripper position on center Drop.X [0..4000 mm]

table before dropping the sheet.

Drop pos Y Gripper position on center Drop.Y [0..4000 mm]

table before dropping the sheet.

Drop pos Z Gripper position on center Drop.Z [-10..50]

table before dropping the sheet.

Drop rot A Gripper rotation on center Drop.A [-180..180]

table before dropping the sheet.

Drop-Out position

Drop-Out pos X Gripper position After DropOut.X [0..4000 mm]

dropping a part

Drop-Out pos Y Gripper position After DropOut.Y [0..4000 mm]

dropping a part

Drop-Out pos Z Gripper position After DropOut.Z [-10..50]

dropping a part

Drop-Out rot A Gripper position After DropOut.A [-180..180]

Pick pos X Gripper position on center table

after centering the sheet, to center the
Pre-Drop position

Pre-Pick pos X Gripper position Before Prepick.X [0..4000 mm]

moving to the Pick position

Pre- Pick pos Y Gripper position Before Prepick.Y [0..4000 mm]

moving to the Pick position

Pre- Pick pos Z Gripper position Before Prepick.Z [-10..50]

moving to the Pick position

Pre- Pick rot A Gripper position Before Prepick.A [-180..180]

moving to the Pick position

Drop position

Pick pos X Gripper position on center table pick.X [0..4000 mm]

before Picking the sheet.

Pick pos Y Gripper position on center table pick.Y [0..4000 mm]

before Picking the sheet.

Pick pos Z Gripper position on center table pick.Z [-10..50]

before Picking the sheet.

Pick rot A Gripper rotation on center table pick.A [-180..180]

before Picking the sheet.

Drop-Out position

Pick-Out pos X Gripper position After PickOut.X [0..4000 mm]

Picking a part

Pick-Out pos Y Gripper position After PickOut.Y [0..4000 mm]

Picking a part

Pick-Out pos Z Gripper position After PickOut.Z [-10..50]

Picking a part

Pick-Out rot A Gripper position After PickOut.A [-180..180]

Picking a part
.

Wait parameters
Wait for sensor
Wait for sensor Should robot check if the True
center station is empty before the False
command starts and wait for the part is
correctly positioned before repicking the
plate. WaitTime : [0..10 sec]
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Wait Time Wait time for the robot to allow
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the sheet to fall into position.

Sensor parameters
Figure 54. BT CENTER : the drop-off and pick-up position are defined w.r.t. the base

Note : if drop and pick are used independently it Is possible to program motions and gripper
configuration changes between drop and pick.

Note : If Complete is used it is not possible to change configuration of the gripper between drop and pick.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_ILFExecuted
• \\UserEvents\ BT_On_PartPickedOnCT
• \\UserEvents\ BT_OnPartDroppedOnCT

Note : Following in- and output routines have to be configured to use this command
• \\UserInput\ BT_I_PartOnCT
• \\UserInput\ BT_I_GripPart
• \\UserInput\ BT_I_GripNoPartn
• \\UserOutputs\ BT_O_GripReleas
• \\UserOutputs\ BT_O_GripGrab
• \\UserOutputs\ BT_O_GripOff

6.13BT SET SEQUENCE

The BT SET_SEQUENCE command is used to synchronize the program step of CNC controller of the press
brake with the program step in robot controller. When the BT SET_SEQUENCE instruction is executed, the
press brake jumps in the new CNC sequence and drives the back gauges to the new position.

Starting from KUKA.BendTechKRC 5.0.25 a completely new version of Set Sequence is implemented. As a
result, the previous version of KUKA.BendTechBasic must be deinstalled and after the installation, the code
to communicate with the press brake must be adapted to the new mechanism. The new mechanism allows
an integrator to be more flexible in the implementation of the Set Sequence mechanism. In the previous
version, a non-linear sequence such as 1, 5, 3, 4 was possible, under the condition that the press brake
reflected the actual bending sequence number. The drawback was that for a linear sequence 1,2,3,4 the
reflection needed to be mimicked or implemented. In the new method, it is much simpler to implement the
normal sequence 1,2,3,4 as the reflection is not required.

Parameter Description Range of values

Number In this field the user must select enter [1..1000]
the number of the current sequence.
This number is passed to the
BT_o_SetSeq () routine which controls
the interfacing with the press brake
controller.
CONT Without CONT the robot will send the TRUE or FALSE
sequence number to the press brake and
wait until the press brake CNC controller
has selected the corresponding
sequence.

With CONT the robot will send the

sequence number to the press brake
without waiting until the CNC controller
is finished with this command.

Note : Following in- and output routines have to be configured to use this command
• \\UserInput\ BT_I_PressSeq
• \\UserInput\ BT_I_CycleStopReq
• \\UserInput\ BT_I_GripNoPart
• \\UserOutputs\ BT_O_SetSeq

6.14BT SET BACKGAUGE

The search motion in BT APPROACH can be made so that it takes into account the position of the
backgauges. For those installations, the command BT APPROACH is preceded with the command BT
SETBACKGAUGE.

Figure 56. BT SET BACKGAUGE

Parameter Description Range of values

LeftBgPosX X position of the left back gauge in the press brake [0 … 1000mm]
coordinate system (typically in base 4).
LeftBgPosY Y position of the left back gauge in the press brake [-500 .. 1000mm]
coordinate system (typically in base 4).
LeftBgPosZ Z position of the left back gauge in the press brake [0 .. 6000mm]
coordinate system (typically in base 4).
RightBgPosX X position of the right back gauge in the press brake [0 … 1000mm]
coordinate system (typically in base 4).
RightBgPosY Y position of the right back gauge in the press brake [-500 .. 1000mm]
coordinate system (typically in base 4).
RightBgPosZ Z position of the right back gauge in the press brake [0 .. 6000mm]
coordinate system (typically in base 4).

Note : Following global variables are set using this command

• BT_LeftBgPos
• BT_RightBgPos

Note : Following in- and output routines have to be configured to use this command

6.15BT APPROACH

Figure 57. BT APPROACH

The BT APPROACH command is the step before the BT BEND or the BT PRESS command. The command
moves the sheet into the press. The end point of the approach motion is teached. The way how the robot
must move towards this end point is described with parameters. Just before the robot reaches the
endpoint, the press may lower down to the safety point. Once the end point is reached, the robot will start
searching the selected back gauges. In manual mode, the robot will display a dialog for the automatic re-
teaching of the approach end point. In automatic mode, this dialog is not shown.

Figure 59. BT Approach without retract motion

Parameter Description Range of values

Point name Name of the end point of the approach movement. 1..23 chars may not start
with a number
VEL Velocity at which the press is approached. [0..2 m/s]
ACC Acceleration when approaching the press. [1..100%]

Height in press (HP): this is the height of the sheet when Height in press
the sheet is inside the press brake defined with respect to [5..500 mm]
the teached Approach point.

Distance to backstop (DB): this defines the gap between Distance to backstop [0..200
sheet and back gauge when the sheet will be lowered to mm]
the teached height.

Die height (DH): the height of the die in mm. Die height:
[1..300 mm]

Maximum search distance: maximal distance used in the Search distance

search motion for the back gauges. [0 … 50mm]

Retract distance: the distance the robot retracts from the Retract distance
back gauges when the press has reached the clamping [0 ... 20mm]
point.

Retract velocity: the velocity used in the retract motion Retract velocity
[0 … 1 m/s]
Back gauge The back gauges that should be searched after the #None
approach movement. The left and the right back gauge (as #LowFlat
seen from the operator to the press brake) can be defined #LowCylindrical
separately. #HighFlat
#HighCylindric

When the robot is finished with searching the selected back gauges and the robot controller is in manual
mode (T1 or T2) the approach point can be teached. The robot controller will display a dialog. When an
approach point is successfully re-teached, an information message will appear on the robot control panel
and the robot will be stopped.

Figure 61. Automatic teaching of found approach points.

Yes The coordinates of this approach point will be re-teached with the current robot position.

Always The coordinates of this approach point will be re-teached with the current robot position.
For every next approach command the found position will be also re-teached, even if the
robot is not in manual mode, without showing this dialog. The dialog will reappear after
executing the INIT command again.

Never The coordinates of this approach point will not be changed. For every next approach
command the dialog will not be shown. The dialog will reappear after executing the INIT
command again.

There are two global variables that store the last (effective) search motion distance

BT_Glob_R_SEARCH_X1 For back gauge 1

BT_Glob_R_SEARCH_X2 For back gauge 2

The global KRL array BT_APP_SEARCH_RESULT[30] stores the last 30 positions of the when the back gauges
are found.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_ILFExecuted
• \\UserEvents\ BT_On_AppSearchEnd

Note : Following in- and output routines have to be configured to use this command
• \\UserInput\ BT_I_PressBackGauge1
• \\UserInput\ BT_I_PressBackGauge2
• \\UserInput\ BT_I_PressBG1_Pos
• \\UserInput\ BT_I_PressBG2_Pos
• \\UserInput\ BT_I_PressClampPoint
• \\UserInput\ BT_I_Cycle_Stop_Req
• \\UserOutputs\ BT_O_ToSP
• \\UserOutputs\ BT_O_ToCP

6.16BT BEND

Figure 62. BT BEND for robot with linear axis and with Inline Form configuration

When the robot is placed on a linear axis and the option linear axis is enabled, then an additional input field
is shown to the default inline form.

Figure 63. BT BEND

Parameter Description Range of values

Around BASE In this field the user must select the [1..32]
BASE [1..32] that is linked to the press
brake where the robot must bend.
Follow OFF: the robot does not follow the #OFF
sheet during the bend. The sequence to
pick up the sheet after the bend must
be added separately to the robot
program.

With vacuum: the robot follows the #VACUUM_ON

sheet during the bend with the vacuum
switched on.

Without vacuum: the robot follows the #VACUUM_OFF

sheet during the bend but will blow air
through the vacuum cups. On
completion of the bend motion the
vacuum will be switched back on. This
mode is recommended with thick parts.

Reversed When the gripper is attached to the SELECT or DESELECT

part of the sheet that is behind the
bend line, the robot must bend
downwards. In this case the option
reversed must be set to TRUE. The
default value is FALSE.

ETHERNET: for use with BendTech #ETHERNET

advanced.
Config INLINEFORM
Bend Angle The inner angle in degrees of the bend [20..180 deg]
that has to be made in the product.
Press Vel The velocity of the press brake in [0.001..10 mm/s]
mm/s.
Die Height The height of the die in mm. [1..300 mm]
Die Opening The width of the die opening in mm. [1..100 mm]
This parameter is sometimes called the
V-parameter .

Figure 64. BT BEND for robot with linear axis and with Ethernet configuration

By setting the variable GLOBAL BOOL BT_WITH_ETHERNET=TRUE (see file BT_Config.dat) additional options
become visible. These options allow the integrator to implement their own routines for synchronizing
motions between the robot and the press brake.

Config ETHERNET
Sync Out Defines when the synchronisation is #LDP (default)
stopped #DECP
#EP
#UDP
Sync With Defines how the synchronisation is #PUNCH
made #CAMERA

By setting the variable GLOBAL BOOL BT_WITH_SENSOR =TRUE (see file BT_Config.dat) additional options
become visible. These options allow the integrator to implement their own routines for synchronizing
motions between the robot and the press brake.

Config SENSOR

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Sync Out Defines when the synchronisation is #LDP (default)
stopped #DECP
#EP
#UDP
Sync With Defines how the synchronisation is #PUNCH
made #CAMERA

Figure 65. BT Bend - Bend reversed

Figure 66. BT Bend - Die Height (H) and Die Width (W)

Note : Sync out in DECP is useful when bending thick plates. (> springback)

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_ILFExecuted

Note : Following output routines have to be configured using this command

• \\UserOutputs\ BT_O_GripRelease
• \\UserOutputs\ BT_O_GripOff
• \\UserOutputs\ BT_O_ToLDP
• \\UserOutputs\ BT_O_ToDECP
• \\UserOutputs\ BT_O_ToEP
• \\UserOutputs\ BT_O_StartAMI

6.17BT PRESS

BT PRESS is used to program the sequence where a bended sheet is folded into a flat sheet. There is no
robot movement during the PRESS instruction.

Figure 67. BT PRESS

Figure 68. Folding a bended sheet.

Note: how the press brake is moving during this command, is set in the press brake controller. In the
figure above, the press brake is moving from the upper dead point UDP, over the clamping point CP to
the lower dead point LDP.

Note : Following in- and output routines have to be configured to use this command
• \\UserOutputs\ BT_O_Press

6.18BT PRESS MOVE

Using the BT PRESS MOVE command the press brake can be moved by the robot for
• UDP to MP
• UDP to CP
• MP to CP
• CP to LDP
• LDP to EP
• LDP to UDP

The robot can be set to follow the vertical motion.

Figure 69. BT PRESS MOVE for robot with InlineForm configuration

Figure 70. BT PRESS MOVE – Press moves from LDP to UPP and robot follows

With vacuum: the robot follows the #VACUUM_ON

Punch during the motion with the
vacuum switched on.

Without vacuum: the robot follows the #VACUUM_OFF

Punch during the motion but will blow
air through the vacuum cups.

Config INLINEFORM
Up The motion to follow the press brake [-300 .. 300mm]
Vel The velocity of the robot in mm/s. [0 .. 2 m/s]
Acc Acceleration during motion [0 … 100%]

Figure 71. BT PRESS MOVE for robot with Ethernet configuration

Config ETHERNET
No parameters

Note: the standard command to move the part out of the press, without moving the robot
synchronously, is the BT LIFT command.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_ILFExecuted

Note : Following in- and output routines have to be configured to use this command

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• \\UserInput\ BT_I_GripPart
• \\UserInput\ BT_I_GripNoPart
• \\UserInput\ BT_I_CycleStopReq
• \\UserInput\ BT_I_PressMutePoint
• \\UserInput\ BT_I_PressClampPoint
• \\UserInput\ BT_I_PressLDP
• \\UserInput\ BT_I_PressEP
• \\UserInput\ BT_I_PressUDP
• \\UserOutput\ BT_O_GripRelease
• \\UserOutputs\ BT_O_toSP
• \\UserOutputs\ BT_O_toCP
• \\UserOutputs\ BT_O_ToLDP
• \\UserOutputs\ BT_O_toEP
• \\UserOutputs\ BT_O_ToUDP

6.19BT LIFT

Figure 72. BT LIFT Inline form with wait for UDP

Figure 73. BT LIFT Inline form with wait for Time

Figure 74. BT LIFT Inline form with wait for Opening

BT LIFT is used to program the movement to lift the sheet out of the press brake after the bend. The punch
of the press brake will go up. The sheet is released by the press and the robot can lift the sheet out of the
die. All data for calculating the LIFT movement are programmed through this inline form.

Parameter Description Range of values

in BASE In this field the user must select the [1..32]
BASE [1..32] that is linked to the press
brake where the robot must lift the
sheet.
UP The distance in mm that the robot must [0..300 mm]
drive upwards to lift the sheet out of
the die.
Out The distance in mm that the robot must [-50..500 mm]
drive out of the press brake.
VEL Velocity at which the lift motion is [0..2 m/s]
executed.
ACC Acceleration for lift motion. [1..100%]
Wait for UDP: The robots wait to start the lift #UDP
motion after the punch has reached the
upped dead corner
TIME: The robots waits a certain delay #TIME
time before the robot starts the lift [0..10 sec]
motion.
OPENING: The robots waits until the #OPENING
punch has reached a certain opening [0..200 mm]

Note: the opening in the WAIT FOR fields is the distance between the punch and the die.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_ILFExecuted

Note : Following in- and output routines have to be configured to use this command
• \\UserInput\ BT_I_PressUDP
• \\UserInput\ BT_I_PressOpening
• \\UserOutputs\ BT_O_ToUDP

Figure 76. BT GRIPPER State Grab Guard part sensor No

Figure 77. BT GRIPPER State Off

Figure 78. BT GRIPPER State Release

This command is used to control the state of the gripper mounted on the robot.

Parameter Description Range of values

State Grab: The gripper circuits are set to grab #GRAB
the sheet.

Off: The gripper circuits are switched off. #OFF

Release: The gripper circuits are set to

release the sheet. #RELEASE

Guard part sensor This field is only available in combination SELECT or DESELECT
with state GRAB. The user can select if
the sheet in the robot gripper should be
guarded with the vacuum sensors during
the following robot movements. If option
is set to TRUE and the robot loses the
sheet, the robot will stop with a
corresponding error message.

Without CONT: the gripper circuits are

set and the robot waits until the
requested actions are completed.

Note: make sure the BT INIT GRIPPER command is properly initialized before calling the BT GRIPPER
command.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_ILFExecuted

Note : Following in- and output routines have to be configured to use this command
• \\UserInput\ BT_I_GripPart
• \\UserInput\ BT_I_GripNoPart
• \\UserOutputs\ BT_O_GripOff
• \\UserOutputs\ BT_O_GripGrab
• \\UserOutputs\ BT_O_GripRelease

6.21BT REGRIP GRIPPER

Figure 79. BT REGRIP GRIPPER

This command is used to control the state of gripper circuits on the regrip station.

Parameter Description Range of values

Gripper Grab: The gripper circuits are set to grab #GRAB
the sheet.

Off: The gripper circuits are switched off. #OFF

Release: The gripper circuits are set to

release the sheet. #RELEASE

Without CONT: the gripper circuits are

set and the robot waits until the
requested actions are completed.
Config The desired configuration for the used [0 .. 255]
gripper. This setting will be stored in KRL
variable BT_REGRIP_GRIP_CONFIG

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_ILFExecuted

Note : Following in- and output routines have to be configured to use this command
• \\UserOutputs\ BT_O_TableOff
• \\UserOutputs\ BT_O_TableGrab
• \\UserOutputs\ BT_O_TableRelease

6.22BT REGRIP MOVE

Figure 80. BT REGRIP MOVE

REGRIP STATION MOVE is used to regrip the sheet in the regrip station. The command can be
used to drive the regrip station to a certain position. In combination with the REGRIP STATION
VACUUM command, the GRIPPER command and LIN motions, the instruction can be used to
regrip the sheet on the other side of the regrip station.

Parameter Description Range of values

Move Desired turning position of the regrip Cups face forward = 1
station. Cups face forward: cups are Cups face backward = 2
pointing towards the robot. Cups face
backward: cups are pointing away from
the robot.
Stroke Distance between the two arms on the [0..1100 mm]
regrip station.
CONT With CONT: Set the regrip station TRUE or FALSE
settings without stopping the current
robot movements. The robot will not
wait until the requested actions are
completed.

Without CONT: Set the regrip station

settings and wait until the requested
actions are completed.

Note: make sure the BT INIT GRIPPER command is properly initialized before calling the BT GRIPPER
command.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_ILFExecuted

Note : Following in- and output routines have to be configured to use this command
• \\UserInput\ BT_I_TableCupsFront
• \\UserInput\ BT_I_TableCupsBack
• \\UserInput\ BT_I_TableOpening

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• \\UserOutputs\ BT_O_TableCupsFront
• \\UserOutputs\ BT_O_TableCupsBack
• \\UserOutputs\ BT_O_TableOpening

6.23BT PUT3

Figure 82. BT PUT

The BT PUT command is a palletizing instruction to make piles with the bended product. Starting from a
teached position, the robot will calculate the positions of the different parts in a stack. How the parts are
palletized upon each other can be configured with parameters. Up to 6 stacks can be made with one BT
PUT command.

Figure 83. BT PUT - Palletize bended sheets on a pallet

Parameter Description Range of values

On Base In this field the user must select the BASE [1..32]
[1..32] that is linked to the output
station. The base is typically placed on
the floor with the z-axis pointing
upwards.
Vel Velocity at which parts are palletized [0..2 m/s]
(range of values: 0...2 m/s)

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Acc Acceleration for procedure (range of [0..100 %]
values: 0...100%)
Using Pattern In this field the user can give the Put 1..23 chars may not start with a number
pattern parameter list a name. This
name is linked to the parameter lists
with additional data for the PUT
command. These parameters use the
teached palletizing points as reference.
[1..6]
Number of piles :this is the number of
piles that must be built on the output
station. For each pile a corresponding
point has to be teached.
#BetweenLayers
Offset: This parameter defines how the #SideBySide
offsets should be applied. [1..1000]
between layers: The offsets are applied
vertically, between the layers. This
method is used to pile up larger parts.
side by side: The offsets are applied
horizontally, between the parts. This way
a lot of small parts can be put next to
each other.
[-2000..2000 mm]
Offset reset counter: this is the number
of layers after which the sheet will be
dropped in the same offset position and
orientation as the first sheet. When the
layer counter has reached this value the [-2000..2000 mm]
calculation of the offset values is
restarted.

P1..6 Offset X: offset in X direction

relative to the BASE of the output [-180..180 deg]
station. The offset has to be configured
for the used piles (Count pro layer).

P1..6 Offset Y: offset in Y direction

relative to the BASE of the put stack
station. The offset has to be configured
for the used piles (Count pro layer).

P1..6 Offset A: rotation around Z relative

to the TCP of the gripper. The offset has
to be configured for the used piles
(Count pro layer).

Part height Height of the bended sheet. Necessary to [1..2000 mm]

calculate the distance between the
different layers and the drop height.

Figure 84. BT PUT Pattern Offset parameters.

Part height = 100 mm

Start height = 20 mm
End height = 270 mm
= 20 + (3x100)
= 220 < x < 320

Patern.NumberOfPiles = 1
Patern.Offset = BetweenLayers
Patern.OffsetResetCounter = 4

P1.OffsetX = 0 mm
P1.OffsetY = 0 mm
P1.DeltaA = 10°

Figure 85. BT PUT Example 1

Part height = 100 mm

Start height = 5 mm
End height = 320 mm
= 5 + (3x100)
= 205 < x < 305

Patern.NumberOfPiles = 2
Patern.Offset = BetweenLayers
Patern.OffsetResetCounter = 2

P1.Offset X = 50 mm
P1.Offset Y = 50 mm
P1.Delta A = 0°

P2.Offset X = 0 mm
P2.Offset Y = 0 mm
P2.Delta A = +10°
Figure 86. BT PUT Example 2

Patern.NumberOfPiles = 2
Patern.Offset = SideBySide
Patern.OffsetResetCounter = 19

P1.Offset X = 60 mm
P1.Offset Y = 0 mm
P1.Delta A = 0°

P2.Offset X = 60 mm
P2.Offset Y = 0 mm
P2.Delta A = 0°
Figure 87. BT PUT Example 3

Note: it is required to have a BT GRIPPER #release command directly after the BT PUT command in order
to release the sheet.

Note: It is advised to manually stack a pile of bended sheets and next to measure the dimensions of the
stack before programming the BT PUT command. This simplifies the testing.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_ILFExecuted
• \\UserEvents\ BT_On_PutSetBase
• \\UserEvents\ BT_On_PutStart
• \\UserEvents\ BT_On_OutputStationFull
• \\UserEvents\ BT_On_PutEnd

Note : Following in- and output routines have to be configured to use this command
• \\UserInputs\ BT_I_GripPutPart

6.24BT MPUT2

The MPUT command is a palletizing instruction to place the bended parts on a matrix pattern an output
station. This method will be used to palletize products. The robot calculates the positions where the parts
are placed. The position of the first part must be teached. The location of the other parts is calculated from
the position of the first sheet and from a number of MPUT2 parameters.

PTP P1
BT MPUT P8
BT GRIPPER2 #RELEASE
LIN P2

Figure 89. Palletize parts – First part (purple) is teached, others are calculated

Parameter Description Range of values

Point name Name of the first points on the put 1..23 chars may not start with a number
station. All the next line up motions will
be calculated starting from this point.
Base In this field the user must select the BASE [1..32]
[1..32] that is linked to the output station.
The base is typically placed on the floor
with the z-axis pointing upwards.
Vel Velocity at which parts are palletized [0..2 m/s]
(range of values: 0...2 m/s)
Acc Acceleration for procedure (range of [0..100 %]
values: 0...100%)
#Parts X Number of parts on row [1 .. 1000]
#Parts Y Number of parts on column [1 .. 1000]
#Parts Z Number of parts in height [1 .. 1000]]
Delta X Step in row direction [-1000..1000] mm
Delta Y Step in column direction [-1000..1000] mm
Delta Z Step in height direction [-1000..1000] mm

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LayerDeltaA All parts on the even layers (the lowest [-180 .. 180°]
later is an uneven layer) get an offset in
the Z-direction angle.
Pallet Height Height of the pallet where the parts are [0 .. 250 mm]
put upon. The height is measured from
the ground or the surface where the
pallet is placed on in the +z direction of
the base.

#Parts X = 3
#Parts Y = 5
#Parts Z = 2
Delta X = 260 mm
Delta Y = 250mm
Delta Z = 12mm
LayerDeltaA = -45°

Figure 90. Palletize parts – First part (purple) is teached, others are calculated

Note: the first point is not only used to define the position of the first sheet, but also for the orientation of
the first sheet on the output station. All other sheets have the same orientation.

Note: before the BT MPUT2 command, there is always a PTP command.

Note: it is required to have a BT GRIPPER #release command directly after the BT LINE UP command in
order to release the sheet.

Note: It is advised to manually stack a pile of bended sheets and next to measure the dimensions of the
stack before programming the BT MPUT2 command. This simplifies the testing.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_ILFExecuted
• \\UserEvents\ BT_On_MputSetBase
• \\UserEvents\ BT_On_MputStart
• \\UserEvents\ BT_On_MputStationFull
• \\UserEvents\ BT_On_MputEnd

Note : Following in- and output routines have to be configured to use this command
• None.

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6.25BT LINE UP2
LINEUP is not supported any more in the latest version. The documentation here is added for legacy
purposes. The routine is available as expert code, but no Inline fold is available.

Figure 91. BT Line Up2

The BT LINE UP command is a palletizing instruction to place the bended parts in a line on an output
station. This method will be used to palletize products. The robot calculates the positions where the parts
are placed. The position of the first part in the line must be teached. The location of the other parts is
calculated from the position of the first sheet and from a number of line up parameters.

PTP P1
BT LINE UP P8
BT GRIPPER2 #RELEASE
LIN P2

Figure 92. Palletize parts standing up – First part (purple) is teached, others are calculated

Parameter Description Range of values

Point name Name of the first points on the put 1..23 chars may not start with a number
station. All the next line up motions will
be calculated starting from this point.

Pallet Height = 144mm

Parts = 9
PartX = 75 mm
PartY = 0 mm
DropZ = 10mm

Layers = 1
Layer X = 0 mm
Layer Y = 0 mm
Layer Z (not applicable here)

Figure 93. Palletize parts standing up – First part (purple) is teached, others are calculated

Note: the first point is not only used to define the position of the first sheet, but also for the orientation of

Note: before the BT LINE UP command, there is always a PTP command.

Note: it is required to have a BT GRIPPER #release command directly after the BT LINE UP command in
order to release the sheet.

Note: It is advised to manually stack a pile of bended sheets and next to measure the dimensions of the
stack before programming the BT PUT command. This simplifies the testing.

Note : Following user routines are executed during this command

• \\UserEvents\ BT_On_ILFExecuted
• \\UserEvents\ BT_On_LineUpSetBase
• \\UserEvents\ BT_On_LineUpStart
• \\UserEvents\ BT_On_OutputStationFull
• \\UserEvents\ BT_On_LineUpEnd

Note : Following in- and output routines have to be configured to use this command
• None.

6.26BT DROP
The BT DROP command is an instruction to drop the bended parts. It is possible to define 8 drop positions.
these 8 positions will we used sequentially.

Figure 94. BT Drop

Parameter Description Range of values

On Base Number to specify the used base. [1…32]
Vel Programmed velocity [0…2] m/s
Acc Programmed acceleration [0…100]%
Position Count Number of positions where the robot [1…8]
will drop a part, sequentially
Points[1…8] The position where the robot will drop Frame {x y z a b c}
the part in reference to the selected
base

Note: The command Reset input stations can be executed for example in the beginning of the program
before the main loop starts.

Note: Following user routines are executed during this command

Note : Following in- and output routines have to be configured to use this command
• None.

Note : in contrast to PUT, MPUT, there is no implicit end for this routine. This means that the robot keeps
dropping parts. Estimating when the boxes are full must be done elsewhere in the robot program.

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6.27BT RESET STATIONS
With the BT RESET STATIONS command, the status information of a station can be reinitialized
When the command is executed on an input station, the robot will not remember the height of the pile.
Next time, when the GET command is executed, the robot will start a long search motion to redefine the
actual height of the input station.
When the command is executed on a PUT station, the robot will not remember how many pieces it already
palletized. The robot will restart the palletizing sequence from sheet 1.

Figure 95. BT RESET STATIONS

Parameter Description Range of values

Station ALL STATIONS: All input stations and all ALL STATIONS = 1
output stations are reinitialized. ALL GET STATIONS = 2
ALL GET STATIONS: The actual height of ALL PUT STATIONS = 3
all Input stations will be redefined GET STATION = 4
during next search motion. PUT STATION = 5
ALL PUT STATIONS: The robot will
restart the palletizing pattern from the
beginning on all output stations.
GET STATION: The actual height of the
specified input station will be redefined
during next search motion.
PUT STATION: The robot will restart the
palletizing pattern from the beginning
on the specified output station.

Station number Number to specify a station. Only [1..32]

[1..32] available when GET STATION or PUT
STATION is selected.

Note: The command Reset output stations can be executed for example in the SPS.SUB when the operator
confirmed with a button that he emptied the output station(s).

Note : Following in- and output routines have to be configured to use this command
• None.

1. INI
2. BT RESET ALL GET STATIONS
3.

4. BT INIT Gripper=2 Config=0 Type=Vacuum CircuitA= C34 CircuitB=C0 Code= 0 TCP= TCP_1
Load= LOAD_1
5. BT INIT BENDTECH Test run= TRUE With press-brake NO With regrip station NO
6.
7. HOMING ()
8. BT REGRIP Move = Cups face backward Stroke = 745 mm
9. BT SENSOR 1 Action = CALIBRATE

10. PTP HOME Vel= 100 % DEFAULT

11. LOOP

12. From Home to Input1

13. BT GET from BASE= [1] InputUnit1 Vel= 0.5 m/s, Acc= 90 %, GETDAT1 Start height= 300 mm,
End height= 10 mm, Pal. Mode= FALSE

14. LIN TickMeasure1 CONT Vel= 0.5 m/s CPDAT4 Tool[1]:BendTech Tool Base[0]
15. LIN TickMeasure2 CONT Vel= 0.2 m/s CPDAT5 Tool[1]:BendTech Tool Base[0]
16. BT SENSOR 1 Action = MEASURE Thickness= 1 mm
17. LIN TickMeasure4 CONT Vel= 0.2 m/s CPDAT8 Tool[1]:BendTech Tool Base[0]

18. From Input1 to Center-Table

19. BT CENTER on BASE= [3] Center Table Vel= 2 m/s, Acc= 100 % CTDAT4

20. From Center-Table to Press

21. PTP BEFORE_BEND1 CONT Vel= 100 % PDAT56 Tool[1]:BendTech Tool Base[4]:PressBrake
22. BT SET_SEQUENCE Number= 1
23. BT APPROACH Bend1 Vel= 0.1 m/s, Acc= 100 % APDAT01 Backgauge= BG12
24. BT BEND around BASE= [4] PressBrake Follow= With vacuum Reversed = FALSE
Sync Out=LDP
25. BT LIFT in BASE= [4] PressBrake Up= 10 mm, Out= 100 mm, Vel= 0.5 m/s, Acc= 100 %, Wait for
OPENING = 5 mm

26. BT SET_SEQUENCE Number= 2 CONT

27. PTP BEFORE_BEND2 CONT Vel= 100 % PDAT62 Tool[1]:BendTech Tool Base[4]:PressBrake
28. BT SET_SEQUENCE Number= 2
29. BT APPROACH BEND2 Vel= 0.1 m/s, Acc= 100 % APDAT02 Backgauge= BG12
30. BT BEND around BASE= [4] PressBrake Follow= With vacuum Reversed = FALSE
Sync Out = LDP
31. BT LIFT in BASE= [4] PressBrake Up= 10 mm, Out= 100 mm, Vel= 0.5 m/s, Acc= 100 %, Wait for

32. BT SET_SEQUENCE Number= 1 CONT

33. PTP TO_DROP_1 CONT Vel= 100 % PDAT145 Tool[1] Base[4]:PressBrake

34. PTP TO_DROP_2 CONT Vel= 100 % PDAT148 Tool[1] Base[6]:OutputUnit1

35. BT PUT on BASE= [6] OutputUnit1 Vel= 0.8 m/s, Acc= 100 % using PATTERN= PATTERN1DAT8
Part height= 52 mm, Start height= 50 mm, End height= 500 mm, Pal. Mode= FALSE DROP1 DROP2

36. BT GRIPPER Type = Vacuum Circuit = C34 State = Off

37. From Output1 to Input1

38. IF B_GO_HOME THEN

39. EXIT
40. ENDIF

41. ENDLOOP
42. B_GO_HOME=FALSE

43. PTP HOME Vel= 100 % DEFAULT

Figure 96. The press brake beam moves from the clamping point (CP) to the lower dead point (LDP).
During this motion, the robot moves from P1 to P2.

8.1 Factors that influence the synchronization

Factors of the press brake that influence the synchronization are
• Time for the hydraulics to be switched on
• Acceleration of the punch (at the clamping point CP)
• Attained speed of the press punch (between CP and LDP)
• Deceleration of the punch (at the Lower Dead Point LDP)
• Motion of the punch during angle measurement

Following parameters apply for the robot

• Pre-start time of the robot at P1
• Acceleration of the robot at P1
• Attained speed of the robot between P1 and P2
• Deceleration of the robot at P2
• Post-stop time of the robot at P2

Figure 97. Red graph : robot path over time, blue graph : path of the punch over time, green graph :
deviation between both paths over time.

Figure 98. Reducing the speed from 5mm/s to 2mm/s significantly reduces the synchronisation error
(but makes the bend to last for a longer time)

8.3 Optimize the robot standard bend motion

Warning : In the case of synchronous motions with thick sheets, large forces may occur which might
damage the robot or the robot equipment. It is common to program the robot to move more slowly than
the press with deactivated vacuum circuits and to re-grasp the sheet after the bending motion.

Warning : It is advisable to adapt the acceleration of the press brake to the maximal acceleration of the
robot. If the motion starts too quickly, the robot may stop because the permissible acceleration is
exceeded. If the motion stops too abruptly, the robot may leave the path.

The standard robot bend motion can be optimized with following KRL variables in the $config.dat.

BT_ROB_RAISE_TIME determines the time in seconds required by the robot to start the motion. The value
of BT_ROB _RAISE _TIME depends on the robot type and controller. Experience shows that this value is
close to the value of $DEF_FLT_PTP [ms] (R1/Mada/$machine.dat).

BT_WAIT_HYDRAULIC_ON determines the time in seconds after the start signal from the robot before the
press moves. This delay time is specific to the individual press and is caused by the hydraulic system. The
press is positioned, for example, at the clamp point and is started by the robot. The value of
BT_WAIT_HYDRAULIC_ON depends on the press type and controller.

BT_BEND_VEL_FACTOR The velocity at which the robot follows the sheet is calculated internally in the
system. This factor can be used to reduce or increase the actual velocity. If BT_BEND_VEL_FACTOR is
greater than 1, the robot follows the sheet at a higher velocity. If the factor is equal to 1, the motion is
carried out at the calculated velocity. If the factor is less than 1, the bending motion is carried out at a
lower velocity.

8.4 Optimize press brake parameters

In many cases adjusting the press brake controller acceleration parameters will help to achieve a good
synchronized motion between press-brake and robot. These parameters can be found in the manual of the
press-brake controller.

8.5 Reducing the synchronization errors

Reduce the high accelerations of the press brake
Start with a slow bending speed
Slowly speed up the bending speed
Tune the synchronization parameters
Put the vacuum cups on springs so that a deviation is compensated in the gripper.
If the error is too big, blow off before bending and put the vacuum cups back on after bending.

Figure 100. Example of a gripper with vacuum cups. The vacuum cups are placed on springs to
withstand the non-synchronous behaviour at the beginning and end of the bend.

9.1 Tools
TOOL_NAME[1,]="BendTech Tool "
TOOL_NAME[16,]="Measurement Pin "

It is advised not to use the above tools and to use Tool[2] up to Tool[15] for measured gripper tools.

9.2 Bases
BASE_NAME[1,]="MeasureUnit1"
BASE_NAME[2,]="CenterStation High"
BASE_NAME[3,]="CenterStation Low"
BASE_NAME[4,]="PressBrake"
BASE_NAME[5,]="RegripStationCupsForward"
BASE_NAME[6,]="RegripStatCupsBackward"
BASE_NAME[10..19]="InputStations"
BASE_NAME[20..29]="OutputStations"

Note: to set these base names, run program BT_SetBaseAndToolNames ()

Timers: 10,11, 18, 19, 20

9.3 Cycle flags

; CYCLE FLAG] USED TO DEFINE VACUUM SENSORS DURING SEARCH ABOVE GET_STACK
GLOBAL INT BT_CYCFLAG1=1 ; UserOpt
; CYCLE FLAG USED TO DEFINE SEARCH SENSORS ON GRIPPER DURING SEARCH ON GET_STACK
AND PUT_STACK
GLOBAL INT BT_CYCFLAG2=2 ; UserOpt
; CYCLE FLAG USED TO CHECK PART IN GRIPPER DURING MOVEMENT WITH PART
GLOBAL INT BT_CYCFLAG3=3 ; UserOpt
; CYCLE FLAG USED TO CHECK LEFT BACKGAUGE DURING APPROACH
GLOBAL INT BT_CYCFLAG4=4 ; UserOpt
; CYCLE FLAG USED TO CHECK RIGHT BACKGAUGE DURING APPROACH
GLOBAL INT BT_CYCFLAG5=5 ; UserOpt
; CYCLE FLAG USED TO CHECK LEFT AND RIGHT BACKGAUGE DURING APPROACH
GLOBAL INT BT_CYCFLAG6=6 ; UserOpt
; CYCLE FLAG USED FOR ON ERROR DURING SYNC IN SPS.SUB
GLOBAL INT BT_CYCFLAG7=7 ; UserOpt

9.4 Interrupts
; INTERRUPT 1: TO CHECK ROBOT DURING BEND PROCEDURE, WHEN FAILURE THE PRESS IS
STOPPED
GLOBAL INT BT_INTERRUPT_1=1 ; UserOpt
; INTERRUPT 2: CHECK PART ON GRIPPER DURING MOVEMENTS WITH PART (CYCLEFLAG[3])
GLOBAL INT BT_INTERRUPT_2=2 ; UserOpt
; INTERRUPT 3: IR_STOPM ( )

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GLOBAL INT BT_INTERRUPT_3=3 ; UserOpt
; INTERRUPT 4: STARTS STOP_SEARCH () WHEN ROBOT SEARCHES PLATE ON GET_STACK
(CYCLEFLAG[1]= VAKUUM SENSOR)
GLOBAL INT BT_INTERRUPT_4=4 ; UserOpt
; INTERRUPT 5: STARTS SLACKEN ( ) WHEN ROBOT SEARCHES PLATE ON GET_STACK ,
STARTS PUT_PLATE ( ) WHEN ROBOT SEARCHES FOR DROPOFF POINT ON PUT_STACK
(CYCLEFLAG[2]=SEARCH SENSOR)
GLOBAL INT BT_INTERRUPT_5=5 ; UserOpt
; INTERRUPT 6: CHECK ROBOT MOVEMENT WITH BEND_SENSOR, ROBOT MAY NOT FOLLOW
SENSOR MORE THAN 60 DEG
GLOBAL INT BT_INTERRUPT_6=6 ; UserOpt
; INTERRUPT 7: CHECK ROBOT MOVEMENT WITH SENSOR MOVEMENT, ROBOT MAY NOT FOLLOW
LONGER THAN 30 SEC
GLOBAL INT BT_INTERRUPT_7=7 ; UserOpt
; INTERRUPT 8: MEASURE WAIT TIME HYDRAULIC ON WITH SENSOR OPTION
GLOBAL INT BT_INTERRUPT_8=8 ; UserOpt

9.5 Timers
; $TIMER[1] - TO CHECK IF ROBOT MAX VELOCITY IS ACHIEVED DURING NORMAL BEND
MOVEMENT
; - TO CHECK IF ROBOT DOES NOT FOLLOW SENSOR LONGER THAN 30 SEC
GLOBAL INT BT_TIMER_1=1 ; UserOpt
; $TIMER[2] - TO Measure the reaction time of the press brake hydrolic system
GLOBAL INT BT_TIMER_2=2 ; UserOpt
; $TIMER[3] - For actions during PBI commands (Center / Get / Put / etc...)
GLOBAL INT BT_TIMER_3=3 ; UserOpt

10 Messages
10.1Types of messages
There are two types of messages that are displayed on the SmartPad of the robot.

• Default robot messages that are of the form KSSxxxxx. Look at Expert@Work for information.
• Application specific message are added on top of the default robot messages and are related to the
installation itself. These messages are described on the next pages.

Figure 101. Examples of output window on the smartpad of the robot.

There is one special message. BT_MESS(99) is used to display custom error messages and for which the
MsgTxt[] string is filled explicitly before calling the BT_MESS routine.

MsgTxt[] = "My Error Message"

BT_MESS(99) ; Custom Error

Messages from BT_MESS(99) are not translated.

10.3List of messages

Message 1 DE Teil abblasen (Greifer öffnen) ?

Warning EN Blow part (Open gripper) ?
Cause During the BT INIT command a sheet is detected by the sensor sensor
Effect Dialog message on Smartpad
Remedy Answer dialog on Smartpad with Yes or No. When Yes is pressed the robot will try to
remove the sheet from the gripper. When No is pressed the robot will continue the
program.

Message 2 DE Falsche Greifer Kodierung

Warning EN Wrong coding of gripper
Cause The result of the input routin BT_I_GripCode does not correspond with the Gripper code
filled in in the inline form INIT
Effect Robot will stop and will not continue with the program.
Remedy Check if the right gripper is mounted on the robot. If this gripper code should not be
checked fill in a 0 value in the inline form INIT

Message 3 DE Programmreset oder Satzanwahl erforderlich

Info EN Reset program or block select required
Cause A serious error occurred. The robot cannot automatically continue with the program
Effect Robot will stop with this message
Remedy Press on the buttons Program Cancel, Program Reset or Line select.

Message 4 DE BASE_DATA[ {0}] nicht vermessen

Warning EN BASE_DATA[ {0}] not measured
Cause The robot cannot automatically continue with the program
Effect Robot will stop with this message
Remedy Press on the buttons Program Cancel, Program Reset or Line select

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Message 5 DE Biegegeschwindigkeit zu hoch
Info EN Bend velocity too high
Cause The parameter for press velocity in the ILF BEND is too high. The robot will not be able to
follow the bend with this speed
Effect Robot program will be stopped
Remedy Lower the speed parameter in the BEND inline form.

Message 6 DE Wartezeit BT_WAIT_HYDRAULIC_ON zu kurz

Info EN Wait time BT_WAIT_HYDRAULIC_ON too short
Cause The value of the variable BT_WAIT_HYDRAULIC_ON is too low.
Effect Notification message
Remedy Increase the value of the variable BT_WATI_HYDRAULIC_ON using the variable modification
window

Message 7 DE Hinteranschlag {0} nicht gefunden

Warning EN Backgauge {0} not found
Cause At the end of the approach motion a search was made for the backgauge, but the backgauge
was not found
Effect The robot stops
Remedy Check the back gauges on the press brake and if necessary teach the approach point

Message 8 DE Betriebsart T2 erforderlich

Info EN Operation mode T2 required
Cause The robot can not reach synchronisation speed in mode T1
Effect Message on Smartpad that can be simulated
Remedy Set robot operation mode to T2 or simulate the notification message

Message 9 no longer used

Message 10 DE Teil (Blech) nicht gefunden

Info EN Part not found
Cause No plate was found during the GET Command
Effect Robot stops (depending on BT_GET_NIO_HALT)
Remedy Retry search run or put more raw parts on the input station

Message 11 DE Suchsensor auf Greifer defekt

Warning EN Search sensor on gripper is broken
Cause The sensor on the gripper used to search a sheet on the input station detects a sheet before
the search run starts.
Effect The robot stops

Message 12 DE Teilsensor auf Greifer defekt

Warning EN Part sensor on gripper is broken
Cause The sensor used to detect a sheet in the gripper detects a sheet before the search run starts
Effect Robot will stop
Remedy Check sheet sensors on Gripper. The input routine BT_I_GripPart must project a FALSE value
in $CYCFLAG [1] before the search run starts

Message 13 DE PUT_STATION[{0}] ist voll

Info EN PUT_STATION[{0}] is full
Cause The last plate has been set down on the Put station and the Put station is now full
Effect The robot will not palletize another plate on this Put station
Remedy Remove all parts from the Put station and reset the put station with the BT RESET command

Message 14 DE Teil verloren !

Error EN Part lost !
Cause The no sheet sensor is monitored during the robot motions with sheet. This sensor has
detected a TRUE signal. BT_I_GripNoPart
Effect The robot stops
Remedy Check if the sheet is in the gripper. Check the no sheet sensor in the gripper. If the user
wishes to deactivate this monitoring, program a BT GRIPPER command and set the “guard
sheet sensor” option to FALSE.

Message 15 DE Palettiermodus nicht möglich

Info EN Palletizing mode not possible
Cause A4 is not in range +10 to -10 deg
Effect Notification message. Robot will execute command without option Pal. Mode
Remedy A4 must be teached in a position between -10 and +10 degrees before the option pal mode
is activated

Message 16, 17, 18, 19 : no longer in use

Message 20 DE Geschwindigkeit der Presse < {0} mm/s

Info EN Press velocity < {0} mm/s
Cause The parameter for press velocity in the ILF BEND is too high. The robot will not be able to
follow the bend with this speed. This message displays the maximum speed.
Effect Robot program will be stopped.
Remedy Lower the speed parameter in the BEND inline form.

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Message 21 DE Wollen Sie den aktuellen Punkt nachbessern ?
Dialog EN Do you want to teach the current coordinates ?
Cause The approach motion is executed in T1 or T2. The point found after searching the back
gauges can be teached as new approach point.
Effect Dialog message
Remedy Answer the dialog with soft keys Yes or No. On Yes, the point will be teached with current
coordinates and X -1mm after restarting the program.

Message 22 DE Der aktuelle Punkt wurde übernommen

Info EN Point taught with current coordinates
Cause The coordinates of the approach motion are modified.
Effect Info message
Remedy None

Message 23 DE Ethernetverbindung mit Press defekt

Error EN Ethernet connection with press is broken
Cause The robot tried to make an Ethernet connection too the press controller but the connection
failed.
Effect Robot program stops.
Remedy Check the connection cables between robot and press brake. Press the start button and the
robot will try again to make the connection

Message 24 DE Blechdicke zu stark ! {0} mm

Warning EN Part thickness too thick! {0} mm
Cause The measured plate thickness is too tick.
Effect Robot program stops (depending on BT_SENSOR_NIO_HALT)
Remedy Check if there is only one sheet in the gripper.

Message 25 DE Blechdicke zu gering ! {0} mm

Warning EN Part thickness too thin ! {0} mm
Cause The measured plate thickness is too thin.
Effect Robot program stops (depending on BT_SENSOR_NIO_HALT)
Remedy Check if there is a correct sheet in the gripper.

Message 26 DE Inkompatible Blechdicke !

Error EN Incompatible part thickness !

Message 27 DE Bewegung wird ausgeführt min config Inlineform (TestRun ohne Presse)
Info EN Motion executed with config Inlineform (TestRun without press)
Cause The Sensor or Ethernet values are not used in this modus test run without press brake.
Effect Info message
Remedy None

Message 28 : no longer in use

Message 29 DE Testrun : keine Kameradaten vorhanden, Stempel Daten verwendet!

Info EN Testrun: no cameradata available, punch data used!
Cause Testrun with a synchronous motion between press and robot and option sync with camera.
Effect Info message
Remedy None

Message 30 DE Sequence {0}: such Fehler X {1}, B {2}.

Info EN Sequence {0}: search error X {1}, B {2}
Cause The robot searched long for the backgauges.
Effect Info message
Remedy Point of Approach instruction must be corrected.

Message 31 DE Sensor Option nicht implementiert

Error EN Sensor option not implemented
Cause Sensor option not implemented
Effect Command cannot be executed with config Sensor.
Remedy Set variable BT_WITH_SENSOR to FALSE and reprogramm the command.

Message 32 DE Ethernet Option nicht implementiert

Error EN Ethernet option not implemented
Cause Ethernet option not implemented
Effect Command cannot be executed with config Ethernet.
Remedy Set variable BT_WITH_ETHERNET to FALSE and reprogramm the command.

Message 33 DE Verifiziere Teil auf Zentriertisch

Message 34 DE Teil von Zentriertisch entfernen

Error EN Remove part from center table
Cause Part on center table
Effect Program execution stopped
Remedy Remove part from center table

Message 35 DE Input nicht autorisiert

Error EN Input not authorized
Cause Input that is not allowed by BT_authorize, is selected
Effect Program execution stopped
Remedy Select different Input or Allow this Input in BT_authorize

Message 36 DE Output nicht autorisier

Error EN Output not authorized
Cause Output that is not allowed by BT_authorize is selected
Effect Program execution stopped
Remedy Select different Output or Allow this Output in BT_authorize

Message 37 DE Programmablauf nicht autorisiert

Error EN Program Run authorized
Cause Program execution is not allowed by BT AUTHORIZE
Effect Program execution stopped
Remedy Check Program and allow program run in BT AUTHORIZE

Message 38 DE AUTHORIZE gelaufen in T1/T2

Error EN AUTHORIZE ran in T1/T2
Cause
Effect
Remedy

Message 39 DE AUTHORIZE Inline Form nicht ausgeführt

Message 40 DE BGET Parameter nicht korrekt

Error EN BGET Parameters Not Correct
Cause
Effect
Remedy

Message 41 DE Unterschied zwischen Offline TCP und Online TCP zu groß, greifer und TCP prüfen
Error EN Difference Between Offline TCP and Online TCP too big, Check Gripper and TCP
Cause Difference between offline generated TCP and Online Measured TCP is too big
Effect Program execution stopped
Remedy Check if gripper is bend and check TCP measurement

Message 42 DE TCP Data nicht korrekt

Error EN TCP Data not correct
Cause Difference between tcp used in motion point and bendtech tcp
Effect Program execution stopped
Remedy Check bendtech tcp and tcp used for motion point

Message 99 User defined message/ Custom error

In program use :
MsgTxt[] = "My Error Message "
BT_MESS(99) ; Custom Error

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11 Contact address
KUKA Automatisering + Robots N.V.
Centrum-Zuid 1031
B-3530 Houthalen
Tel +32 (0)11.51.61.60
Email. [email protected]
Web. www.kuka.be

Note When contacting KUKA, make sure to have following data available:

• Version of the KUKA.BendTech Basic KRC product.

• Serial number of your robot.
• KrcDiag file generated on your robot controller (File -> Archive -> USB (Controller) -> KrcDiag)
• Telephone number and e-mail address at which you can be reached
• Detailed description of your problem (screen shots, English, German).

12 Release notes
Look for the file ReleaseNotes\ReleaseNotes.txt on the product CD-Rom, USB-Stick or software downoload
of this product for the latest release notes..

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