SOFTWARE

KR C...

KUKA.SeamTech

Release 1.1
for KUKA System Software (KSS) Release 5.3, 5.4

Issued: 27 Jul 2005 Version: 01

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e Copyright 2005

KUKA Roboter GmbH

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

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Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Installation / uninstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Setup and configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Configuration tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.1 Enable Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.2 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.4 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.5 Control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2.6 Group no. output range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.1 State of the SeamTech package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.2 Display of corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1.1 Procedure for teaching the robot path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2 Description of the KUKA.SeamTech commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.1 Sensor Init . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2.2 Sensor On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.3 Sensor Swi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.4 Sensor Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2.5 Sensor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.2.6 Sensor Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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1 Introduction

1 Introduction
KUKA.SeamTech is a program for automatic seam tracking sensor systems, e.g. for laser
hybrid welding. The system is illustrated schematically in Fig. 1.

SCOUT PC PC --
SCOUT
user interface
Power Sensor Video Network with network
card
supply data card card

Adapter

Sensor Ethernet HUB

Video
Ethernet

Sensor

Monitor
KR C robot
controller
with network card
or VME BUS
coupling card

Fig. 1 Sensor system for seam tracking

Diagram of sensor PC (SCOUT) and KUKA robot controller

Such a sensor system consists primarily of the actual measuring head (sensor) with
associated processor (e.g. SCOUT sensor manufactured by Dr. Barthel Sensorsysteme) for
evaluating the sensor data and transferring the calculated path coordinates to the KUKA
robot controller.
The sensor processor communicates with the robot controller (KR C) by means of the CoRob
object embedded in the RSI environment. The actual seam tracking is carried out using the
three objects “SeamRgh”, “SeamCom” and “SeamCor”, which are part of the “rsiSeamLib.o”
driver installed with SeamTech.

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During communication, the Scout sensor assumes the role of the server, and the robot
controller assumes the role of the client. The connection is always initiated by the robot
controller. Data exchange between the robot and the sensor system is carried out cyclically
in each interpolation cycle (i.e. every 12 ms) and includes, as well as the setpoint and actual
positions of the robot, all the required operating parameters, such as the path file number
and system status information.
Since the communication is subjected to strict real--time requirements, the components
required for data exchange are implemented as an add--on driver that works in the real--time
kernel of the robot controller.
The Ethernet card present as standard in the (V)KR C must be deactivated under Windows
and assigned to the lower--level real--time operating system.
If the robot controller is to be integrated into a network, for the purpose of program archiving,
for example, another network card must be installed in the controller.
The robot is responsible for process control. The coupling enables the use of technology
packages, such as LaserWeld and LaserHybrid, offered by KUKA. Furthermore, the operator
works in the familiar environment (KCP) with the robot.
There is no need for an additional safety concept for the sensor. Operator control of the
sensor is limited to the calibration and setting of the seam parameters for the specific join
position.

1.1 System requirements

The system requirements for KUKA.SeamTech are:
Hardware:
G KR C2 controller
G SCOUT sensor system (Barthel)

Software:
G KSS Release 5.3, 5.4
G Robot Sensor Interface (RSI)
G CoRob

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1 Introduction (continued)

1.2 Restrictions
KUKA.SeamTech uses the following variables:
$TECHPAR[ , ]
$TECHPAR_C[ , ]
$SEN_PINT[ ] und
$SEN_PIN_C[ ]
$SEN_PREA[ ]

The variables are described in Section 2.3.

It must be ensured that these variables are not being used by anything else, e.g. if function
generators are being used.

It is assumed that only SeamTech itself is carrying out corrections to the robot path.
It is thus not possible to use additional RSI objects (outside “rsiseamlib.src”) that carry out
corrections (e.g. “ST_PATHCORR” or “ST_AXISCORR”).
All resources used are re--enabled by means of the command “SENSOR_CLEAR”.

It is assumed that only SeamTech itself is carrying out corrections to the robot path.

1.3 Installation / uninstallation

From KSS Release 5 onwards, technology packages are offered exclusively as add--on
software modules. These are available on CD--ROM.

The installation, uninstallation, reinstallation and update of technology packages are

described in detail in the documentation [Installation/Uninstallation/Update of Tech
Packages].

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2 Setup and configuration

2 Setup and configuration

2.1 Setup
Once the required hardware and software have been installed, setup can commence.
1. Move the sensor head to the desired position on the robot.
See the sensor system (SCOUT) documentation for more information.
2. Put the sensor processor into operation.
See the sensor system (SCOUT) documentation for more information.
3. Install the seam tracking system.
See also Section 1.3 of this documentation.

The IP adresses of the sensor processor and the KRC controller must be adapted
accordingly. Modification of the SCOUT IP address is described in the SCOUT sensor
system documentation.
The file “VXWIN.ini” (in the directory “C:\Windows”) must be adapted in the KR C controller.
The bootline reads as described below (with the exception of modifications to the IP
address after “e=”):
Bootline = esmc(0,1)pc:vxworks.st h=192.0.1.2 b=192.0.1.1 e=192.168.42.61
u=target pw=vxworks
Changes that have been made do not take effect until the system is rebooted.

4. Establish the Ethernet connections.

5. Carry out configuration (see the chapter “Configuration options”)
6. Reboot the (V)KR C.
7. If necessary, calibrate the sensor.
8. Develop application program.
See also Section 3 of this documentation.

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2.2 Configuration tool

The tracking conditions are configured centrally using the configuration tool.

The values in the configuration tool can only be edited in the user group “Expert”.

The configuration tool is started via the function “SeamTech configuration” (see Fig. 2).

Fig. 2 Starting the configuration tool

5 4

1 Configuration screen
2 Status keys
3 Selection list of the configuration screens
4 Softkey bar
5 Info line

Fig. 3 Main screen

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2 Setup and configuration (continued)

The following softkeys are displayed (see Fig. 3/4) when the configuration tool has been
started:
G Save Changes: The changes in the input boxes are saved. There follows a request for
confirmation – Yes/No/Cancel.
G Save Longtext: (only active if inputs or outputs are configured) saves the I/O
designations in the long text database.
G Save in file: saves the current configuration to disk.
G Load file: loads a saved configuration from disk.
G Edit Descr.: (only active if an input box in the configuration screen is followed by a
description) changes the description following the input box.
G Close: closes the configuration tool.
The following status keys are displayed (see Fig. 3/2) when the configuration tool has been
started:
G Screen: toggles between the configuration screens in the selection list.
G Tab: toggles between different tabs in the configuration screen.
G Item: toggles between the input boxes in the current configuration screen.
G Value: changes the value in the active input box of the configuration screen.
The individual functions of the configuration tool are described in the following sections.

2.2.1 Enable Sensor

If the check box “Enable sensor at KRC” (see Fig. 4) is not activated, the robot path is
executed without correction. With Sensor_Init, a message is generated, indicating that the
sensor is deactivated.
If the check box is activated, seam tracking is carried out.

Fig. 4 Enable Sensor

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2.2.2 Communication
The network configuration of the sensor is defined in the configuration screen
“Communication” (see Fig. 5).

Fig. 5 Communication
G Sensor IP--Address: IP address of the Scout system. This IP address can be viewed
and changed in the Scout user interface.
G Port number: The port is normally set to the value 5002, unless the port is modified
on the Scout side.
G Number of lost or delayed data packages: This integer value defines the maximum
number of data packets that can be delayed before the CoRob object indicates a
communications error. If more packets have been lost than the value that has been set,
a corresponding error message is generated. After this, the connection must be
re--established by means of the command “Sensor Ini”. After every “Sensor Ini”
command, the lost data packet counter is reset to 0.

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2 Setup and configuration (continued)

2.2.3 Outputs
The assignment of SeamTech signals to specific outputs is carried out on the configuration
screen “Outputs” (see Fig. 6).

Fig. 6 Outputs
G Enable of sensor option: This output defines whether the sensor is enabled or not
(see “Enable Sensor”).
G Sensor communication problem: This output signals whether the communication to
the sensor was correctly established or failed.
G Sensor not ready: This output signals that the communication to the sensor was
established correctly, but that no ready signal has been received from the sensor.
G Seam not found: This output signals that no seam has been detected within the
maximum seam search length.
G Loss of seam: This output signals that the sensor has lost the seam during the motion.
G Correction out of limit: This output signals that the correction window has been
violated during execution of the seam with the sensor.

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2.2.4 Inputs
The assignment of SeamTech signals to specific inputs is carried out on the configuration
screen “Inputs”.

Fig. 7 Inputs
G Enable sensor from external: This input enables the PLC to decide externally whether
to carry out motions with or without the sensor.
G Sensor PC enables sensor option: This input is assigned to the Scout PC (for future
developments).

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2 Setup and configuration (continued)

2.2.5 Control mode

The dynamic response of the system when correcting the path is defined in the configuration
screen “Control mode” (see Fig. 8).

Fig. 8 Control mode

G Gain Cartesian controller loop (XYZFAC): This parameter defines the dynamic
response of the system. The higher the value, the more dynamically the corrections are
controlled. The lower the value, the less responsive the system becomes.
G Gain rotatory controller loop (ABCFAC): This parameter defines the dynamic
response of the system. The higher the value, the more dynamically the corrections are
controlled. The lower the value, the less responsive the system becomes.

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2.2.6 Group no. output range

Fig. 9 Group no. output range

G Analog channel 1: An analog output of the robot must be entered here. The
sps_analogausgang[1] declared in the Scout path program is mapped to this output.
If the value 0 is entered, the Scout output is not mapped on the robot controller.
G Analog channel 2: An analog output of the robot must be entered here. The
sps_analogausgang[2] declared in the Scout path program is mapped to this output.
If the value 0 is entered, the Scout output is not mapped on the robot controller.
G Synchronized input byte: The robot can receive up to eight digital inputs from Scout.
The synchronized input byte defines which inputs are sent from the robot to the sensor.
Example: 1 means inputs 1--8, 2 means inputs 9--16, etc.
G Synchronized output byte: Scout can send up to eight digital outputs to the robot. The
synchronized output byte defines how the Scout outputs sps_ausgang[1] ....
sps_ausgang[8] are mapped to the outputs of the robot.
Example: 1 means outputs 1--8, 2 means outputs 9--16, etc.

2.3 Variables
2.3.1 State of the SeamTech package
The state of the kernel system driver in the SeamTech package is represented by the system
variables $SEN_PINT[]. The meaning of these variables is explained in the following points:
G $SEN_PINT[1]=1: Communication active
G $SEN_PINT[2]=1: Sensor active
G $SEN_PINT[3]=1: Seam detected
G $SEN_PINT[4]=1: Robot is moving on the seam
G $SEN_PINT[5]=1: Correction too great
G $SEN_PINT[6]: (no meaning)
G $SEN_PINT[7]=1: Robot moves with corrections
For all variables, the value “0” means the opposite.

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2 Setup and configuration (continued)

2.3.2 Display of corrections

The current Scout correction is indicated in the variables $SEN_PREA[1]...[3]. This makes
it easier for the user to check the corrections. The following applies here:
G $SEN_PREA[1]: X correction relative to the current #Base system
G $SEN_PREA[2]: Y correction relative to the current #Base system
G $SEN_PREA[3]: Z correction relative to the current #Base system

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3 Programming
3.1 Prerequisites
It is advisable to write a KRL program without sensor commands first and then to insert the
sensor commands.
1 2 3 4

A1
A2 A3 A4 A5 A6 A7
A8

9 8 7 6 5
1 Sensor advance run
2 Path of the seam
3 Path executed by the robot
4 Correction distance
5 Linear correction elimination
6 Taught path
7 Linear motion to the detected seam point
8 Optical markings of the sensor
9 Search length
A1 SENSOR_INIT (PTP HOME)
A2 SENSOR_ON (PTP P1 CONT)
A3 PROCESS_ON (LIN P2)
A4 SENSOR_SWI (LIN P6 CONT)
A5 PROCESS_OFF (LIN P3)
A6 SENSOR_OFF (LIN P4 CONT)
A7 LIN P5
A8 SENSOR_CLEAR (PTP HOME)

Fig. 10 Seam tracking example

The following points must be taken into consideration with regard to the sensor commands:
G The sensor can only carry out corrections for LIN and CIRC motions.
G If the robot remains stationary or executes a PTP motion, no corrections can be made.
G It is possible to limit the corrections. If, for example, corrections should not exceed
3 mm, precautions must be taken to ensure that the seam cannot deviate by more than
3 mm from the taught robot path.

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3 Programming (continued)

1 2 3 4

A1
A2 A3 A4 A5 A6
A7
1 Maximum correction, linear
2 Correction window
3 If the corrections exceed the maximum permissible value, the robot moves along the tolerance window.
4 Path of the seam
A1 SENSOR_INIT (PTP HOME)
A2 SENSOR_ON (PTP P1 CONT)
A3 PROCESS_ON (LIN P2)
A4 PROCESS_OFF (LIN P3)
A5 SENSOR_OFF (LIN P4 CONT)
A6 LIN P5
A7 SENSOR_CLEAR (PTP HOME)

Fig. 11 Path correction within the correction window

G Abrupt path direction changes in the robot motion are to be avoided. Path changes of
1 to 2 mm should not be taught explicitly (see Fig. 12 and Fig. 13).
1
1...2 mm

2
Fig. 12 Incorrect: Taught path for small path changes
(1 = Path of seam; 2 = Taught path)

1
1...2 mm

2
Fig. 13 Correct: Taught path for small path changes
(1 = Path of seam; 2 = Taught path)

G However, the taught path should follow the real seam as closely as possible, in order
to be able to keep the values for the tolerance window as small as possible.

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 KUKA.SeamTech

G A LIN or CIRC motion is required between the “Sensor On” command and the exact
positioning point at which, for example, the weld process is to be started, in order to
locate the seam.
The length of this motion depends on the “search length” specified in the parameter list
for the “Sensor On” command (see Section 3.2.2).
G Following a “Sensor Off” command, an additional LIN or CIRC motion is required in
order to be able to eliminate any outstanding corrections before a PTP motion is
executed.
The length of such a LIN or CIRC motion depends on the “correction distance” specified
in the parameter list for the “Sensor On” or “Sensor Swi” command (see Sections 3.2.2
and 3.2.3).

If the length of the LIN/CIRC motion is shorter than the correction distance, error messages
such as “Deviation at the start point” or “Approximation not possible” may be generated.

3.1.1 Procedure for teaching the robot path

In order to ensure that Scout sensor corrections are no longer active when teaching points,
carry out the steps described below:
G Disable the sensor in the configuration menu.
G Carry out Sensor_Clear.

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3 Programming (continued)

3.2 Description of the KUKA.SeamTech commands

KUKA.SeamTech commands are programmed, with the aid of menus, using inline forms,
some of the input boxes of which are also accompanied by parameter lists.
The available commands, the technology--specific inline forms and the corresponding
parameter lists are described in this section.

The “Technology” menu is only available in edit mode or when a program has been
selected. The mode selector switch on the KCP must not be set to “EXTERNAL”.

Pressing the “Technology” menu key opens the following menu:

If the menu item “KUKA Seam Tech” is selected, a submenu with a range of commands is
opened.

Sensor Init Initializes the KUKA.SeamTech technology package.

Sensor On Switches the sensor on.
A further submenu is opened:
SensorOnStat Switches the sensor on at the position reached by exact
positioning.
SensorOnDyn Activates the sensor on the path.
Sensor Swi Switches the sensor to new parameters (on the path before the
end point).
Sensor Off Switches the sensor off.
A further submenu is opened:
SensorOffStat Switches the sensor off at the position reached by exact
positioning.
SensorOffDyn Deactivates the sensor on the path.
Sensor Control Freezes and reactivates the sensor offset.
A further submenu is opened:
SensorFreezeStat Freezes the sensor offset at the position reached by exact
positioning.
SensorFreezeDyn Freezes the sensor offset and saves the values on the path.
SensorRestore Restores the frozen sensor function without taking the last
offset into consideration.
SensorRestore Positioning with the last sensor offset on the path.
WithOffset
Sensor Clear Terminates communication with the sensor computer and
enables all objects.

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For all commands, the sensor option “SSEN_SeamSensorStatuskey=TRUE” must be

activated. This can be checked, if required, using the menu function
Monitor ! Variable ! Single.
By disabling the sensor in the configuration screen “Enable Sensor” (see Section 2.2.1),
the execution of all sensor commands in a KRL program can be deactivated.
In the event of a block selection with the sensor activated, the system may lose the seam
if, for example, the robot moves in the opposite direction to the sensor.
Sensor commands selected by means of block selection may have no effect if, for example,
a “Sensor On” command is executed without first having been initialized by means of
“Sensor Init”.

3.2.1 Sensor Init

The command “Sensor Init” is used to initialize the KUKA.SeamTech technology package.
The system establishes communication with the sensor computer and waits for a response
from the sensor computer.

This command must be placed at the start of a sensor function with exact positioning. The
initialization command is required after every “SENSOR_CLEAR” command before the
sensor can be reactivated.
In the event of a failure to establish communication, a corresponding error message will
be generated.
The command is selected via the menu function
Technology ! KUKA Seam Tech ! Sensor Init
The following inline form is opened:

Test Sensor=[FALSE]
This defines whether the readiness of the sensor is tested.
Test Sensor = TRUE The readiness of the sensor is tested during initialization.

Under certain circumstances, testing the readiness of the sensor can take a long time.
It is thus not always useful to activate “Test Sensor”.

Test Sensor = FALSE The sensor is initialized without its readiness being tested.

Once the command “Sensor Init” has been selected, the softkey bar has the following
functions:

Cmd. Abort Cancels the command without saving it.

Cmd OK Ends the entry and saves the command.

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3 Programming (continued)

Initialization of the sensor has been successful if the message

Connected to <IP address>
is displayed.
Otherwise a corresponding error message is displayed. Robot motion cannot be resumed
until the Start key has been pressed again.
Once a connection has been terminated, another “Sensor Init” command is required in order
to be able to re--establish a connection. It is advisable to execute the “Sensor Init” command
before every seam/component.

3.2.2 Sensor On
Seam location is initiated by means of the “Sensor On” command.
Two options are available here as menu functions:
G Technology ! KUKA Seam Tech ! Sensor On ! SensorOnStat
G Technology ! KUKA Seam Tech ! Sensor On ! SensorOnDyn

Once the command “Sensor On ...” has been selected, the softkey bar has the following
functions:

Cmd. Abort Cancels the command without saving it.

SenOnToggle Toggles between the commands “SensorOnStat” and “SensorOnDyn”.
SenCmdToggle Toggles between the commands “Sensor On” and “Sensor Swi”.
Cmd OK Ends the entry and saves the command.

If the sensor cannot be activated following a start command, or if other errors have occurred,
a corresponding error message is generated.
Motion cannot be resumed until the Start key has been pressed again.

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SensorOnStat

This command activates the sensor at the position to which the robot has been moved
with exact positioning.

The command is selected via the menu function

Technology ! KUKA Seam Tech ! Sensor On ! SensorOnStat
The following inline form is opened:

Set=[S1]
A two--page parameter list is available for this data set.
See Parameter list “SSENSetParameter” in this section.

SensorOnDyn

This command activates the sensor on the path before the end point.

The command is selected via the menu function

Technology ! KUKA Seam Tech ! Sensor On ! SensorOnStat
The following inline form is opened:

Distance= [0] mm
Range of values: -- 100 ... 100 [mm]
The sensor activation point is shifted relative to the path.
[--] means before and [+] means after the end point of the CP block.

Set=[S1]
A two--page parameter list is available for this data set.

Parameter list “SSENSetParameter”, page 1

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3 Programming (continued)

SeamFileNr
This file from the sensor system contains tool
data and seam settings.

SearchLength
Range of values: 5 ... 150 [mm]
Distance after which the sensor
cancels the search.

ErrorReaction
Defines whether or not the sensor retains its
offset following a sensor error.

AbsPosCorrection
Range of values: 0 ... 50 [mm]
Maximum distance before the sensor signals
that the correction has been exceeded.

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 KUKA.SeamTech

Parameter list “SSENSetParameter”, page 2

AbsAngleCorrection
Range of values: 0 ... 180 [degrees]
Maximum permissible correction of the angle.

CorrectionDistance
Range of values: 0 ... 200 [mm]
Distance over which the sensor offset is
eliminated.

SensorHeadOrientation
Range of values: 0 ... 0.2
Control factor for the swivel motion of the
sensor head to the programmed path.

OrientationToTCPNormal
Range of values: 0 ... 0.1
Control factor for the speed at which the
TCP is adjusted.

The following is a detailed description of the parameters.

SeamFileNr
Before seam tracking can be carried out for the first time, a path file must be created on the
sensor computer. This contains information about the tool used (in accordance with the
calibration data) and the seam settings.

Search length
The search length determines the distance after which seam location is aborted. If the seam
is not detected within this distance, KUKA.SeamTech generates a message to this effect.
Motion cannot be resumed until the Start key has been pressed again. The robot then moves
without corrections. Parallel attempts nonetheless continue to be made to find the seam. If
a seam is detected during motion, the robot moves onto it.

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3 Programming (continued)

The process must not be started (PROCESS_ON) within the SearchLength (see
Fig. 14/Fig. 15), as there is a danger that the robot may otherwise come to a stand-
still, if it fails to detect a seam with the process activated, and that the workpiece
may be damaged.

2
1

3
A1 A2
A3

4
1 Laser
2 Sensor
3 Weld
4 Search length
A1 Start point of seam search
A2 End point of seam search
A3 Start point of process

Fig. 14 Correct: Search length and process start

A1 A2 A3

1 Weld
2 Search length
A1 Start point of seam search
A2 Start point of process
A3 End point of seam search

Fig. 15 Incorrect: Search length and process start

ErrorReaction
Defines the reaction in the event of an error (e.g. loss of seam); the available options are
“WithErrorOffset” and “WithoutErrorOffset”.
If “WithErrorOffset” is selected, the last valid corrections are frozen when the seam is lost.
This is only useful if it can be assumed that the offset along a seam remains constant to the
end of the seam.

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 KUKA.SeamTech

It is generally advisable to select the option “WithErrorOffset” so that the robot will always
return to the taught path in the event of an error. The offset following an error is eliminated
over a defined length (see also the parameter “CorrectionDistance”).

AbsPosCorrection, AbsAngleCorrection
The maximum linear correction (AbsPosCorrection) defines the maximum correction in x,
y and z (relative to the #BASE system). If the maximum correction is exceeded, a
corresponding message is generated. The robot continues its motion.
If the sensor sends a seam point that is outside the permissible tolerance window, the robot
only moves the maximum permissible correction distance towards the seam point. If a point
on the seam is found again within the tolerance window, corrections are immediately carried
out in full once again.
This also applies to correction of the angles.

CorrectionDistance
This parameter specifies the length over which corrections are eliminated or built up.

OrientationToTCPNormal, SensorHeadOrientation
If the values are set to 0.0, the sensor ignores the orientation specifications; in other words,
the orientations used along the seam are those for the taught path that runs parallel to the
seam.
If one or both values are greater than 0.0, the sensor takes over orientation control.
Appropriate values for these parameters can be found in the relevant sensor documentation.

If no “Sensor Off” command is executed, the program will repeatedly start seam location,
even after loss of the seam, and attempt to jump to a detected seam.

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3 Programming (continued)

3.2.3 Sensor Swi

The “Sensor Swi” command enables the path--related switching of some parameters. This
switching is carried out on the path before the end point.
The system establishes communication with the sensor computer and waits for a response
from the sensor computer.
The command is selected via the menu function
Technology ! KUKA Seam Tech ! Sensor Swi

Once the command “Sensor Swi” has been selected, the softkey bar has the following
functions:

Cmd. Abort Cancels the command without saving it.

SenCmdToggle Toggles between the commands “Sensor On” and “Sensor Swi”.
Cmd OK Ends the entry and saves the command.

The following inline form is opened:

Distance= [0] mm
Range of values: -- 100 ... 100 [mm]
The sensor activation point is shifted relative to the path.
[--] means before and [+] means after the end point of the CP block.

Set=[S2]
A two--page parameter list is available for this data set.

Parameter list “SSENSetParameter”, page 1

ErrorReaction
Defines whether or not the sensor retains its
offset following a sensor error.

AbsPosCorrection
Range of values: 0 ... 50 [mm]
Maximum distance before the sensor signals
that the correction has been exceeded.

AbsAngleCorrection
Range of values: 0 ... 180 [degrees]
Maximum permissible correction of the angle.

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 KUKA.SeamTech

Parameter list “SSENSetParameter”, page 2

CorrectionDistance
Range of values: 0 ... 200 [mm]
Distance over which the sensor offset is
eliminated.

SensorHeadOrientation
Range of values: 0 ... 0.2
Control factor for the swivel motion of the
sensor head to the programmed path.

OrientationToTCPNormal
Range of values: 0 ... 0.1
Control factor for the speed at which the
TCP is adjusted.

A detailed description of the parameters contained in the parameter list

“SSENSetParameter” can be found in Section 3.2.2.

3.2.4 Sensor Off

The “Sensor Off” command is used to switch the sensor off.
Two options are available here as menu functions:
G Technology ! KUKA Seam Tech ! Sensor Off ! SensorOffStat
G Technology ! KUKA Seam Tech ! Sensor Off ! SensorOffDyn

Once the command “Sensor Off” has been selected, the softkey bar has the following
functions:

Cmd. Abort Cancels the command without saving it.

SenOffToggle Toggles between the commands “SensorOffStat” and “SensorOffDyn”.
Cmd OK Ends the entry and saves the command.

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3 Programming (continued)

SensorOffStat

This command deactivates the sensor at the position to which the robot has been moved
with exact positioning.

The command is selected via the menu function

Technology ! KUKA Seam Tech ! Sensor Off ! SensorOffStat
The following inline form is opened:

Keep Offset=[TRUE]
This determines how the robot will continue its motion.
Keep Offset = TRUE Sensor offset is retained.
Keep Offset = FALSE Sensor offset is not retained.

SensorOffDyn

This command deactivates the sensor on the path before the end point.

The command is selected via the menu function

Technology ! KUKA Seam Tech ! Sensor Off ! SensorOffStat
The following inline form is opened:

Distance= [0] mm
Range of values: -- 100 ... 100 [mm]
The sensor deactivation point is shifted relative to the path.
[--] means before and [+] means after the end point of the CP block.

Keep Offset=[TRUE]
This determines how the robot will continue its motion.
Keep Offset = TRUE Sensor offset is retained.
Keep Offset = FALSE Sensor offset is not retained.

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 KUKA.SeamTech

3.2.5 Sensor Control

The menu item “Sensor Control” opens a further menu containing the following commands:

G Technology ! KUKA Seam Tech ! Sensor Control ! SensorFreezeStat

G Technology ! KUKA Seam Tech ! Sensor Control ! SensorFreezeDyn
G Technology ! KUKA Seam Tech ! Sensor Control ! SensorRestore
G Technology ! KUKA Seam Tech ! Sensor Control ! SensorRestoreWithOffset

Once the command “Sensor Control” has been selected, the softkey bar has the following
functions:

Cmd. Abort Cancels the command without saving it.

SenCtrlToggle Toggles between the commands
-- SensorFreezeStat
-- SensorFreezeDyn
-- SensorRestore
-- SensorRestoreWithOffset
Cmd OK Ends the entry and saves the command.

SensorFreezeStat

The sensor offset value is frozen at the position (following exact positioning) and saved.

The command is selected via the menu function

Technology ! KUKA Seam Tech ! Sensor Control ! SensorFreezeStat
The following inline form is opened:

Keep Offset=[TRUE]
This determines how the robot will continue its motion.
Keep Offset = TRUE Sensor offset is retained.
Keep Offset = FALSE Sensor offset is not retained.

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3 Programming (continued)

3
2 4
1 5

9 8 7 6
1 Path correction
2 SENSOR_FREEZE
3 Position of the weld seam
4 SENSOR_RESTORE
5 Path with offset
6 Correction build--up distance (same distance as correction elimination distance)
7 Path without offset
8 Correction elimination distance
9 Taught robot path

Fig. 16 Sensor Control

SensorFreezeDyn

The sensor offset value is frozen on the path and saved. This command is executed before
the end point is reached.

The command is selected via the menu function

Technology ! KUKA Seam Tech ! Sensor Control ! SensorFreezeDyn
The following inline form is opened:

Distance= [0] mm
Range of values: -- 100 ... 100 [mm]
The sensor deactivation point is shifted relative to the path.
[--] means before and [+] means after the end point of the CP block.

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 KUKA.SeamTech

Keep Offset=[TRUE]
This determines how the robot will continue its motion.
Keep Offset = TRUE Sensor offset is retained.
Keep Offset = FALSE Sensor offset is not retained.

SensorRestore

The current sensor offset value (depending on whether the offset has previously been
eliminated) is used and new correction values are activated. This command is executed
before the end point is reached.
The command is selected via the menu function
Technology ! KUKA Seam Tech ! Sensor Control ! SensorRestore
The following inline form is opened:

Distance= [0] mm
Range of values: -- 100 ... 100 [mm]
The sensor deactivation point is shifted relative to the path.
[--] means before and [+] means after the end point of the CP block.

SensorRestoreWithOffset

The sensor offset is reactivated on the path.

This command is executed before the end point is reached.

The command is selected via the menu function

Technology ! KUKA Seam Tech ! Sensor Control ! SensorRestore
The following inline form is opened:

Distance= [0] mm
Range of values: -- 100 ... 100 [mm]
The sensor deactivation point is shifted relative to the path.
[--] means before and [+] means after the end point of the CP block.

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3 Programming (continued)

A2

A1 A3 2
1

5
4
3
1 Path correction
2 Correction build--up distance (same value as correction elimination distance)
3 SENSOR_FREEZE
4 Programmed path
5 Correction elimination distance
A1 LIN P1
A2 PTP
A3 SENSOR_OFS_REACTIVATE (LIN P2)

Fig. 17 SensorFreeze/SensorRestoreWithOffset

3.2.6 Sensor Clear

This command deactivates communication with the sensor computer and re--enables all
objects.
The command is selected via the menu function
Technology ! KUKA Seam Tech ! Sensor Clear
The following inline form is opened:

This inline form does not have any input boxes.

Once the command “Sensor Clear” has been selected, the softkey bar has the following
functions:

Cmd. Abort Cancels the command without saving it.

Cmd OK Ends the entry and saves the command.
1

KUKA.SeamTech_1.1 11.04.01 en 35 of 35
 Index

A L
AbsAngleCorrection, 28 Load file, 11
AbsPosCorrection, 28 Loss of seam, 13
Analog channel, 16
O
C OrientationToTCPNormal, 28
Outputs, 13
Close, 11
Communication, 12
Configuration screen, 10 P
Configuration tool, 10 Parameter list “SSENSetParameter”, 24, 29
Control mode, 15 Port number, 12
Correction, 18 Programming, 18
Correction out of limit, 13
CorrectionDistance, 28 R
Restrictions, 7
D
Data packages, 12 S
Description of the KUKA.SeamTech com- Save Changes, 11
mands, 21
Save in file, 11
Direction change, 19
Save Longtext, 11
Screen, 11
E Seam not found, 13
Edit Descr., 11 SeamFileNr, 26
SearchLength, 26
Enable of sensor option, 13
Sensor Clear, 35
Enable Sensor, 11
Sensor communication problem, 13
Enable sensor from external, 14
Sensor Control, 32
ErrorReaction, 27
Sensor Init, 22
Sensor IP--Address, 12
G Sensor not ready, 13
Gain, 15 Sensor Off, 30
Group no. output range, 16 Sensor On, 23
Sensor PC enables sensor option, 14
Sensor Swi, 29
I SensorFreezeDyn, 33
Inline form, 21 SensorFreezeStat, 32
Inputs, 14 SensorHeadOrientation, 28
Installation, 7 SensorOffDyn, 31
IP address, 9 SensorOffStat, 31
Item, 11 SensorOnDyn, 24
SensorOnStat, 24
SensorRestore, 34
K SensorRestoreWithOffset, 34
KUKA.SeamTech commands, 21 Setup, 9

Index -- i
 Index

Synchronized input byte, 16

Synchronized output byte, 16
System requirements, 6

T
Tab, 11
Teaching the robot path, 20
Tracking conditions, 10

U
Uninstallation, 7

V
Value, 11

Index -- ii