Integrating ATI EtherCAT Force/Torque Sensors

with KUKA® FTCtrl

Manual

Document #: 9620-05-D-ATI KUKA FTCtrl

Engineered Products for Robotic Productivity

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

Foreword
Information contained in this document is the property of ATI Industrial Automation, Inc. and shall not be reproduced in
whole or in part without prior written approval of ATI Industrial Automation, Inc. The information herein is subject to
change without notice and should not be construed as a commitment on the part of ATI Industrial Automation, Inc. This
manual is periodically revised to reflect and incorporate changes made to the F/T system.
ATI Industrial Automation, Inc. assumes no responsibility for any errors or omissions in this document.
Copyright © (2024) by ATI Industrial Automation, Inc., Apex, North Carolina USA. All Rights Reserved.
Published in the USA.
ATI F/T Sensing Systems are considered components/ semi-finished goods intended for use in larger system/
device/ finished good.
In consideration that ATI Industrial Automation, Inc. (ATI) products are intended for use with robotic and/or automated
machines, ATI does not recommend the use of its products for applications wherein failure or malfunction of an ATI
component or system threatens life or makes injury probable. Anyone who uses or incorporates ATI components within
any potentially life threatening system must obtain ATI’s prior consent based upon assurance to ATI that a malfunction
of ATI’s component does not pose direct or indirect threat of injury or death, and (even if such consent is given) shall
indemnify ATI from any claim, loss, liability, and related expenses arising from any injury or death resulting from use of
ATI components.
For terms and conditions of sale, refer to the website or contact an ATI representative.

All trademarks belong to their respective owners.

Note:
Please read the manual before calling customer service, and have the following
information available:
1. Serial number (e.g., FT01234)
2. Sensor model (e.g., Axia90-M50)
3. Calibration (e.g., US-15-50, SI-65-6, etc.)
4. Accurate and complete description of the question or problem.
5. Robot model, controller model, controller software version, and installed KUKA
FTCtrl options.
Be near the F/T system when calling (if possible). For questions specific to KUKA-provided
software or hardware, please contact KUKA’s technical support.

Please contact an ATI representative for assistance, if needed:

Sale, Service and Information about ATI products:

ATI Industrial Automation (a Novanta Company)
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati-ia.com
Tel: +1 919-772-0115
Fax: +1 919-772-8259

Application Engineering
E-mail: [email protected]

24/7 Support
Tel: +1 855.ATI-IA.00 (+1 855-284-4200)

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-2
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

Table of Contents
Glossary.........................................................................................................................................D-4
1. Safety.......................................................................................................................................D-5
1.1 Explanation of Notifications...................................................................................................... D-5
1.2 General Safety Guidelines......................................................................................................... D-5
2. Product Overview...................................................................................................................D-6
2.1 System Components.................................................................................................................. D-6
2.1.1 ATI................................................................................................................................... D-6
2.1.2 KUKA............................................................................................................................... D-8
3. Hardware Set-Up....................................................................................................................D-8
4. Software Setup.......................................................................................................................D-9
4.1 Integrate the ATI Sensor’s Data into KRC Digital IO............................................................... D-9
4.1.1 Add the ATI Sensor to the DTM Catalog......................................................................... D-9
4.1.2 Add the Sensor to KUKA Extension Bus....................................................................... D-14
4.1.3 Map the Sensor’s Data into the Project’s I/O................................................................ D-17
4.1.3.1 Map the Sensor’s Digital Inputs (for V3.x)..................................................... D-17
4.1.3.2 Map the Sensor’s Digital Inputs (for V4.x and V5.x)...................................... D-20
4.1.3.3 Map the Sensor’s Digital Outputs (for V3.x, V4.x, and V5.x)......................... D-23
4.2 Confirm ATI Sensor EtherCAT Slave on Teach Pendant...................................................... D-24
4.3 Set Up FTCtrl to Use EtherCAT Axia/FT Data........................................................................ D-25
4.3.1 KUKA FTCtrl V3.x.......................................................................................................... D-25
4.3.2 KUKA FTCtrl V4.x and V5.x.......................................................................................... D-26
5. FTCtrl Programming............................................................................................................D-28
6. Monitoring F/T Data..............................................................................................................D-28
6.1 View Sensor Signals on Teach Pendant................................................................................ D-28
6.2 Convert ATI F/T Sensor’s Data From Counts to User Units................................................. D-28
6.3 Use F/T Data as REAL-type Variables.................................................................................... D-28
7. Troubleshooting Guidance..................................................................................................D-30
8. Specifications.......................................................................................................................D-30
8.1 F/T Sensor................................................................................................................................. D-30

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-3
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

Glossary
Term Definitions
An output command signal that corresponds to a feature of the ATI sensor, for
Control Code example: Bias, Filter selection, set Sample Rate, and select Calibration. Bit maps of
control codes are available in the ATI manual for the sensor.
Data type that the ATI sensor reports Force/Torque values. To convert to user units,
Counts the Counts must be divided by a scaling factor like Counts per Force (CpF) or Counts
per Torque (CpT).
Data Rate How fast data is output over the network.
DINT A (32) bit data type that represents a signed double integer.
EtherCAT Slave Information (ESI) is an ATI-provided EtherCAT (*.XML) file type that
ESI
defines the ATI EtherCAT sensor product in the installation of WorkVisual.
EtherCAT An industrial automation fieldbus.
Ethernet A family of computer networking technologies commonly used in local area networks.
A force is a push or pull action on an object caused by an interaction with another
Force
object. Force = mass x acceleration
KUKA’s Integrated ForceTorqueOption (FTCtrl) is an add-on package that allows the
FTCtrl robot to react in real-time to its surrounding and to deviate from its programed path or
speed, based on feedback from the force sensor.
FT or F/T Force and Torque.
IO or I/O Input and Output.
A separate plate that attaches the sensor to another surface. Interface plates are
often used if the bolt pattern on the sensor doesn’t match the bolt pattern on the
Interface Plate robot arm or customer tooling. The interface plate has two bolt patterns, one on either
side of the plate. One side is for the sensor. The other side is for the robot arm or
customer tooling.
N/A Not applicable.
P/N Part Number
Power Cycle When a user removes and then restores power to a device.
An advanced programming feature where the end user can convert binary IO to
Real-type Variable
REAL numbers (32 bit floating point number) that are stored in variables.
Sensor The component that converts a detected load into electrical signals.
Sensor System The entire assembly consisting of a sensor body and a system interface to translate
(or configuration) force and torque signals into a specific communication interface/protocol.
The application of a force through a lever or moment arm that causes something to
Torque want to turn. For example, a user applies torque to a screw to make it turn.
Torque = force x moment arm
UDINT A (32) bit type that represents an unsigned double integer.
User Units The end user’s units of measurement such as Newtons (N) and Newton meter (Nm).
A KUKA software package that is a development environment for configuring,
WorkVisual (or KUKA.
programming, and troubleshooting a KUKA industrial robot or customer-specific
WorkVisual)
kinematic system. The end user must install this software on a laptop or PC.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-4
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

1. Safety
The safety section describes general safety guidelines to be followed with this product, explanations of the
notifications found in this manual, and safety precautions that apply to the product. Product specific notifications
are imbedded within the sections of this manual (where they apply).

1.1 Explanation of Notifications

These notifications are used in all of ATI manuals and are not specific to this product. The user should heed
all notifications from the robot manufacturer and/or the manufacturers of other components used in the
installation.
DANGER: Notification of information or instructions that if not followed will result in
death or serious injury. The notification provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.

WARNING: Notification of information or instructions that if not followed could result

in death or serious injury. The notification provides information about the nature of the
hazardous situation, the consequences of not avoiding the hazard, and the method for
avoiding the situation.

CAUTION: Notification of information or instructions that if not followed could result

in moderate injury or will cause damage to equipment. The notification provides
information about the nature of the hazardous situation, the consequences of not
avoiding the hazard, and the method for avoiding the situation.

NOTICE: Notification of specific information or instructions about maintaining, operating,

installing, or setting up the product that if not followed could result in damage to equipment. The
notification can emphasize, but is not limited to: specific grease types, best operating practices,
and maintenance tips.

1.2 General Safety Guidelines

The customer should verify that the sensor is rated for the maximum load and torque expected during
operation. Because static forces are less than the dynamic forces from the acceleration or deceleration of the
robot, be aware of the dynamic loads caused by the robot.

WARNING: Performing maintenance or repair on the sensor when circuits (for

example: power, water, and air) are energized could result in death or serious injury.
Discharge and verify all energized circuits are de-energized in accordance with the
customer’s safety practices and policies.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-5
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

2. Product Overview
ATI 6-axis Force Torque (F/T) sensors are a high performance option for use with KUKA®’s ForceTorqueControl
software. KUKA’s Integrated ForceTorqueControl option (FTCtrl) allows the robot to react in real-time to its
surroundings and to deviate from its programmed path or speed, based on feedback from the force sensor.
While the ATI Ethernet (NET) F/T sensor with Net Box is the preferred product for use with KUKA.
ForceTorqueControl, ATI’s EtherCAT Axia and other EtherCAT F/T sensors are also compatible. Specifically for
ATI’s low-cost Axia line, only the EtherCAT version Axia is compatible. For more information about ATI sensor
models, refer to the ATI website.
For more information about KUKA products, refer to https://www.kuka.com/. To access KUKA manuals, log-in to
their customer portal or contact a representative at KUKA.
This manual includes these main how-to topics:
• Step-by-step instructions of how to integrate ATI F/T sensors into KUKA Digital IO and then into KUKA
FTCtrl software in Section 4—Software Setup.
• A brief overview of how to convert I/O signals into KRL variables in Section 6.3—Use F/T Data as
REAL-type Variables.

2.1 System Components

To use ATI EtherCAT F/T sensors within a KUKA system, verify the following hardware and software
requirements are met:

2.1.1 ATI
For a general image of Axia and standard F/T sensor configurations, refer to Figure 2.1, Figure 2.2,
and Figure 2.3.
Sensor
• Standard EtherCAT F/T: contact an ATI applications engineer for more information
• Axia EtherCAT F/T: refer to the Axia webpage

NOTICE: Examples in this manual use an ATI EtherCAT Axia80 sensor: ATI P/N
9105-ECAT-AXIA80.

NOTICE: ATI Ethernet (NET) F/T with Net Box (a different product from the EtherCAT
sensors described in this manual) is the preferred, easily integrated sensor interface for
use with KUKA FTCtrl. Instructions for the integration of NET F/T sensors with KUKA
FTCtrl is included in the KUKA FTCtrl documentation. For ATI’s low-cost Axia line, only
the EtherCAT Axia version is compatible.

Interface Plate
• Mounting Adapter Plate (MAP), customer or ATI supplied, from sensor to the robot
• Tool Adapter Plate (TAP), customer or ATI supplied, from sensor to the tool

NOTICE: If using a large, non-IP rated sensor with removable MAP, it may be possible
to machine the mounting patterns directly into the MAP. For mounting information, refer
to the ATI Transducer Section F/T manual.

Cable
• CAT5 or higher EtherCAT cable from sensor to KUKA’s RJ45 EtherCAT Extension Bus port
• For the ATI EtherCAT Axia, ATI provides two cables for power and EtherCAT connection (refer
to the ATI F/T EtherCAT Axia manual).
• For other ATI EtherCAT F/T sensors, contact ATI F/T applications support (ft.support@
novanta.com) for the correct cable.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-6
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02
Software
• EtherCAT ESI (*.XML) file, which is available to download from the ATI website
• For EtherCAT Axia, refer to https://www.ati-ia.com/Products/ft/software/axia_software.aspx.
• For other EtherCAT F/T, refer to https://www.ati-ia.com/Products/ft/software/
SysSoftwareTemplates.aspx?family=8.
Reference Materials
• ATI EtherCAT Axia Manual
• ATI EtherCAT F/T Manual

Figure 2.1—ATI F/T Axia Components (parts may vary)

Interface Plate
ATI F/T EtherCAT Axia Sensor
(P/N 9105-ECAT-Axia80 shown)

Power and EtherCAT Cable

(P/N 9105-C-ZC22-ZC28-X shown)

Power and EtherCAT Splitter Cable

with RJ45 Connector and Unterminated End
(P/N 9105-C-ZC28-U-RJ45S-X shown)
Figure 2.2—ATI F/T Standard Components with Power Supply (parts may vary)
ATI Standard F/T EtherCAT Sensor
(P/N 9105-ECAT-Gamma-IP65 shown)

Power Supply
Customer supplied
(Optional)

EtherCAT Cable
4-pin M12 to RJ45
(P/N 9105-C-ES-RJ45M-2 shown)
Ring Terminal
Ground Connection (Optional) Ground Cable (Optional)
Figure 2.3—ATI F/T Standard Components with PoE (parts may vary)
EtherCAT Cable 4-pin M12 to RJ45 ATI Standard F/T EtherCAT Sensor
EtherCAT cable (P/N 9105-C-ES-RJ45M-2 shown) with Mounting Adapter Plate (MAP)
(Customer supplied) (P/N 9105-ECAT-Gamma-IP65 shown)

Power supply
(Customer supplied)
Ground cable
Compatible PoE Injector (Optional)
(Customer supplied)

Ring Terminal Ground Connection

(Optional)

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-7
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

2.1.2 KUKA
Contact a KUKA sales or applications representative to ensure the correct components for the robot
and controller. Be sure to specify a preference for an ATI sensor system.
Hardware
• KRC4 or newer robot controller if using KUKA FTCtrl
• Access to KRC’s X44 EtherCAT Extension bus (or KEI Interface for KRC5 controllers)
• PC on Robot Controller’s network, with WorkVisual installed
Software
• WorkVisual
• FTCtrl option, if using KUKA.ForceTorqueControl

NOTICE: This manual includes instructions for FTCtrl V3.x, 4.x, and 5.x. Some steps
differ among these versions.

Reference Materials

NOTICE: To access KUKA manuals, log-in to their customer portal or contact a

representative at KUKA.

• KUKA KRL Programming Manual

• KUKA WorkVisual Manual
• KUKA FTCtrl Manual
• KUKA CREAD/CWRITE Manual

3. Hardware Set-Up
1. Mount the sensor to the robot using interface plate(s).
• For mounting guidelines, refer to the ATI’s Transducer Section F/T manual, or for Axia sensors,
refer to the ATI Axia sensor manual, such as: #9620-05-B-Axia80. Manuals are available on
the ATI webpage.
2. Install the rest of the tooling.
3. Connect the sensor’s power supply cable to an appropriate power supply.
• For details, refer to the appropriate ATI sensor manual.
• The sensor’s LEDs light up through the startup sequence.
4. Connect the Ethernet cable from the sensor to the KUKA X44 EtherCAT Extension Bus port (or KEI interface
on KRC5 controllers).

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-8
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

4. Software Setup
For the software setup, complete these three tasks:
Section 4.1—Integrate the ATI Sensor’s Data into KRC Digital IO
Section 4.2—Confirm ATI Sensor EtherCAT Slave on Teach Pendant
Section 4.3—Set Up FTCtrl to Use EtherCAT Axia/FT Data

4.1 Integrate the ATI Sensor’s Data into KRC Digital IO

Complete this task through KUKA’s WorkVisual Development Environment.
This task has three parts:
1. Add the ATI sensor to the DTM Catalog (refer to Section 4.1.1).
2. Add the ATI sensor to KUKA Extension Bus in the WorkVisual Project (refer to Section 4.1.2).
3. Map the ATI sensor’s data into the Project’s I/O (refer to Section 4.1.3).

4.1.1 Add the ATI Sensor to the DTM Catalog

The ATI EtherCAT Axia product is defined with an ATI-provided EtherCAT ESI (*.XML) file in
this installation of WorkVisual. This part should be completed once per EtherCAT Axia *.XML
version, per WorkVisual environment. If another EtherCAT Axia with newer firmware and ESI
*.XML file is used later, the new ESI *.XML file must be added to the DTM catalog.
1. Download the appropriate ATI ESI file to the laptop or PC.
• For EtherCAT Axia, refer to https://www.ati-ia.com/Products/ft/software/axia_software.aspx.
• For other EtherCAT F/T, refer to https://www.ati-ia.com/Products/ft/software/
SysSoftwareTemplates.aspx?family=8.
2. Close the current Project in WorkVisual.

NOTICE: The DTM Catalog cannot be changed if any Projects are open.

Figure 4.1—Close All Projects

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-9
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02
3. From the File dropdown menu, select Import/Export.
Figure 4.2—Import a New File

4. Select Import device description file and click Next>.

Figure 4.3—Import Device Description File

5. In the directory, navigate to the location of the ATI EtherCAT Axia *.XML ESI
file. Select Open.
Figure 4.4—Open the ATI EtherCAT Axia *.XML File

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-10
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02
6. Click Next>.
Figure 4.5—Import the ATI EtherCAT Axia *.XML File

NOTICE: Any existing ATI EtherCAT ESI file versions that are installed will show
up in the following window. To ensure the most current version is installed, remove
older versions.

7. Click Finish.
Figure 4.6—Finish Importing the File

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-11
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02
8. After WorkVisual finishes importing the file, click Close.
Figure 4.7—Close Window

9. From the Extras dropdown menu in WorkVisual, select DTM Catalog Management.
Figure 4.8—Extra Menu

10. At the bottom of the window, click Search for installed DTMs.
11. In the Known DTMs: pane, select the ATI EtherCAT sensor with the name of the ESI Device
Description file imported in Step 5.
Figure 4.9—Select the ATI File from Known DTMs

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-12
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

12. Click the > button to move the desired DTM into the Current DTM catalog.
13. Click OK.
Figure 4.10—Move the ATI Sensor to the DTM Catalog

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-13
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

4.1.2 Add the Sensor to KUKA Extension Bus

For this part, the ATI device is added to the DTM catalog of each WorkVisual Project that uses the
ATI sensor. If multiple sensors are used in a project, this part must be repeated for each sensor.
1. From the File dropdown menu, select Open Project.
Figure 4.11—Open Project

2. On the Project Structure, right-click the controller, and select Set as active controller.
Figure 4.12—Activate the Controller

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-14
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

NOTICE: If KUKA Extension Bus (SYS-X44) is not already in the controller’s bus
structure, then complete these steps:

1. Right-click Bus Structure and select Add.

2. Select KUKA Extension Bus.

3. Click OK.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-15
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02
3. Add the ATI sensor:
a. Right-click the KUKA Extension Bus, and select Add.

Figure 4.13—Add the ATI Sensor to the KUKA Extension Bus

b. In the DTM Selection window, select the appropriate ATI sensor, and click OK.

Figure 4.14—Select the ATI Sensor

4. Confirm that the ATI sensor is in the KUKA Extension Bus EtherCAT structure.
Figure 4.15—ATI Sensor Added to the Extension Bus

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-16
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

4.1.3 Map the Sensor’s Data into the Project’s I/O

Inputs of the WorkVisual Project are the signals from the ATI sensor to the robot controller. In
ATI documentation, these signals are referred to as outputs. Mapping the input signals varies for
different versions of the KUKA FTCtrl software. For V3.x, refer to Section 4.1.3.1. For V4.x and
V5.x, refer to Section 4.1.3.2.
Outputs of the WorkVisual Project are signals from the robot controller to the ATI sensor. In the
ATI documentation, these signals are referred to as inputs. Mapping the outputs is the same for all
software versions of KUKA FTCtrl: refer to Section 4.1.3.3. These Outputs are the Control Codes.
The Control Codes are used for commands to the sensor such as Bias, Filter selection, set Sample
Rate, and selecting which Calibration to use. For a bit map of these control codes, see the Control
Codes section in the ATI sensor’s manual.
For example, with ATI EtherCAT Axia, a Control Code 1, Bit 0, refers to Set Bias. The Set
Bias can have a value 1 or 0, where 1 = set bias and 0 = use last set bias. So, this Control
Code must be pulsed/flashed to 1 in order to bias the sensor, and then returned to 0 to continue
reading measurements.

4.1.3.1 Map the Sensor’s Digital Inputs (for V3.x)

1. In the WorkVisual IO Mapping editor tab, open KRC I/Os in the left pane and
Fieldbusses in the right pane.

Figure 4.16—IO Mapping Editor

2. In the Fieldbusses pane, select the ATI Axia (or other ATI ECAT F/T sensor).
• The Axia’s signals display in the lower pane (refer to Figure 4.17).
• Note that the sensor’s Force and Torque data are of type DINT (double integer).
A DINT is 32 bits. The inputs Status Code and Sample Counter, and the output
control codes are UDINT (unsigned double integer). A UDINT is also 32 bits. The
exact signals may appear different for different ATI sensors.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-17
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02
Figure 4.17—Select the ATI Sensor in the Fieldbusses

3. In the KRC I/Os pane, select Digital Inputs.

• The KRC Input signals display in the lower pane (refer to Figure 4.19).

Figure 4.18—KRC I/O’s Digital Inputs

4. Select the sensor’s Reading Data.Fx signal and move it to the desired KRC input.
• In this example, Fx is mapped to input bits starting at input bit 1 ($IN[1]).
Figure 4.19—Select and Move Signal Input

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-18
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

NOTICE: These KRC I/O input signals are being sent out of the ATI sensor
and into the robot controller. In ATI’s documentation for the sensor, these
inputs are referred to as outputs.

5. WorkVisual automatically groups the KRC input bits to fit the sensor
signal’s data size.
• In this example, the Fx DINT will use $IN[1] through $IN[32].
• If prompted to group and connect these signals, click Yes.

Figure 4.20—Confirm Automated Grouping and Connecting of Signal

6. Repeat for all inputs (NOT the Control Code Outputs).

• When inputs are mapped, the input icon next to the signal will show green, and the
mapped signals will appear in the upper pane.
• Note that all force and torque values are DINTs, while the status and sample
numbers are UDINT. The input data is a total of 256 bits.
• In this example (Figure 4.21), all sensor inputs are mapped to KRC IO groups,
which uses $IN[1] through $IN[256].
• Signals do not have to be mapped exactly as shown, but end users should take
note of the mapping in their controller for Section 4.3—Set Up FTCtrl to Use
EtherCAT Axia/FT Data.

Figure 4.21—Sensor Inputs Mapped to KRC IO Groups

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-19
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

4.1.3.2 Map the Sensor’s Digital Inputs (for V4.x and V5.x)
1. In the WorkVisual IO Mapping editor tab, open RSI in the left pane and
Fieldbusses in the right pane.
Figure 4.22—IO Mapping Editor

2. In the Fieldbusses pane, select the ATI sensor.

• The Axia’s signals display in the lower pane (refer to Figure 4.23).
• Note that the sensor’s force and torque data are of type DINT (double integer).
A DINT is 32 bits. The inputs Status Code and Sample Counter, and the output
Control Codes are UDINT (unsigned double integer). A UDINT is also 32 bits.
The exact signals may appear different for different ATI sensors.
Figure 4.23—Select the ATI Sensor in the Fieldbusses

3. In the RSI pane, select Digital inputs.

• The RSI input signals should display in the lower pane (refer to Figure 4.25).
Figure 4.24—RSI’s Digital Inputs

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-20
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02
4. Select the sensor’s Reading Data.Fx signal and move to the desired RSI input.
• In this example, Fx mapped to input bits starting at input bit 1 ($IN[1]).

NOTICE: These KRC I/O input signals are being sent out of the ATI sensor
and into the robot controller. In ATI’s documentation for the sensor, these
inputs are referred to as outputs.

Figure 4.25—Select and Move Signal Input

5. WorkVisual automatically groups the KRC input bits to fit the sensor
signal’s data size.
• In this example, the Fx DINT will use $IN[1] through $IN[32].
• If prompted to group and connect these signals, click Yes.

Figure 4.26—Confirm Automated Grouping and Connecting of Signal

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-21
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02
6. Repeat for all inputs (NOT the Control Code Outputs).
• When inputs are mapped, the input icon next to the signal will show green, and the
mapped signals will appear in the upper pane.
• Note that all force and torque values are DINTs, while the status and sample
numbers are UDINT. The input data is a total of 256 bits.
• In this example (Figure 4.27), all sensor inputs are mapped to RSI IO groups,
which uses $IN[1] through $IN[256].
• Signals do not have to be mapped exactly as shown, but end users should take
note of the mapping in their controller for Section 4.3—Set Up FTCtrl to Use
EtherCAT Axia/FT Data.

Figure 4.27—Sensor Inputs Mapped to RSI IO Groups

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-22
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

4.1.3.3 Map the Sensor’s Digital Outputs (for V3.x, V4.x, and V5.x)
1. In the KRC IOs pane (not in the RSI pane), select Digital Outputs.
• The KRC Output signals should display in the lower pane (refer to Figure 4.29).

Figure 4.28—KRC IO’s Digital Outputs

2. Repeat the mapping process for the two Control Code signals.

NOTICE: These KRC I/O output signals are being sent out of the robot controller
and into the sensor. In ATI’s documentation for the sensor, these outputs are
referred to as inputs.

Figure 4.29—Map the Control Code Signals

3. WorkVisual automatically groups the KRC output bits to fit the sensor
signal’s data size.
• In this example, the first Control Code UDINT will use $OUT[1]
through $OUT[32].
• If prompted to group and connect these signals, click Yes.

Figure 4.30—Confirm Automated Grouping and Connecting of Signal

4. Repeat for the second Control Code.

• When all input and output signals are mapped, all IO icons in the sensor signal
list should be green.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-23
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

4.2 Confirm ATI Sensor EtherCAT Slave on Teach Pendant

1. Deploy the WorkVisual Project to the controller.
2. Confirm that the ATI EtherCAT Axia or ATI EtherCAT F/T sensor is a slave on the
controller’s EtherCAT bus.
a. From the KUKA Main Menu (robot icon) select Diagnosis and then Diagnostic Monitor.
b. Change the selected Module: in the dropdown menu to KUKA Extension Bus (SYS-X44 –
Masterstack).
c. In the Name column, confirm that EtherCAT slave is listed with the Value as the appropriate ATI
sensor name, such as ATI Axia F/T Sensor.

Figure 4.31—Diagnostic Monitor for KUKA Extension Bus (SYS-X44 – Masterstack)

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-24
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

4.3 Set Up FTCtrl to Use EtherCAT Axia/FT Data

To complete the following steps, the end user should be familiar with using the KUKA FTCtrl option
software. For guidance on using this software, refer to the KUKA FTCtrl manual, or contact a KUKA
representative.
4.3.1 KUKA FTCtrl V3.x
1. In the Sensor Setup menu, select type Sensor on digital input.
Figure 4.32—Select Sensor System

2. Map the sensor values (Fx,Fy,Fz,Tx,Ty,Tz) in FTCtrl to the correct Digital IO. In this FTCtrl Sensor
Configuration, Index refers to the Digital IO byte.
• Because 1 byte contains 8 bits, the byte index increments 4 bytes for every 32 bits.
• Per the example in Section 4.1.3.1—Map the Sensor’s Digital Inputs (for V3.x), Fx data was mapped to
Bits 1 through 32. Thus, Fx starts at BYTE 1. Fy was mapped to Bits 33 through 64. Thus, Fy starts at
BYTE 5. And so the mapping continues for the other sensor values.
• Be sure these byte indices are correctly mapped to the Digital IO in the controller, because they may be
different from the example in Section 4.1.3.1.

Figure 4.33—FTCtrl Sensor Configuration

3. In the Offset field, enter 0 for all values.

4. Set the Data width to DWord.
5. Set the Scaling Factor (refer to Section 6.2—Convert ATI F/T Sensor’s Data From Counts
to User Units).
6. Press Save.
7. Continue with the FTCtrl task set up as described in the KUKA FTCtrl manual.
Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-25
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

4.3.2 KUKA FTCtrl V4.x and V5.x

1. Link the sensor system selection to each individual FTCtrl task independently:
• When creating a new task in the Task Management window, select type Field bus device, and
then the desired task type.

Figure 4.34—Link the Sensor System to the FTCtrl Task

2. Map the sensor values (Fx,Fy,Fz,Tx,Ty,Tz) in FTCtrl to the correct Digital IO. In this FTCtrl
Sensor Configuration, RSI input refers to the RSI Digital IO bit.
• Per the example in Section 4.1.3.2—Map the Sensor’s Digital Inputs (for V4.x and V5.x), Fx
data was mapped to Bits 1 through 32. Thus, Fx starts at BIT 1. Fy was mapped to Bits 33
through 64. Thus, Fy starts at BIT 33. And so the mapping continues for the other sensor values.
• Be sure these bit indices are correctly mapped to the Digital IO in the controller, because they
may be different from the example in Section 4.1.3.2.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-26
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02
Figure 4.35—FTCtrl Sensor Configuration

3. In the Offset field, enter 0 for all values.

4. Set the Data type to Int32.
5. Set the Scaling Factor (refer to Section 6.2—Convert ATI F/T Sensor’s Data From Counts
to User Units).
6. Press Save.
• Once saved, the scaling displays in scientific notation (refer to Figure 4.35).
7. Continue with the FTCtrl task set up as described in the KUKA FTCtrl manual.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-27
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

5. FTCtrl Programming
For information on how to program the application, refer to the KUKA.ForceTorqueManual and consult with a
KUKA applications engineer. FTCtrl training is available through KUKA College.

6. Monitoring F/T Data

6.1 View Sensor Signals on Teach Pendant
If the sensor inputs are mapped into KRC Digital IO (Section 4.3.1—KUKA FTCtrl V3.x), navigate to the
Digital Inputs. The individual bits should flash as the sensor reads values.
Remember, each 32 bits corresponds to an input reading from the sensor. In the example from
Section 4.3.1—KUKA FTCtrl V3.x, $IN[1] to $IN[32] were mapped to the Fx reading. $IN[1] through
$IN[32] are a 32-bit binary representation of the Fx reading, in Counts.
See the applicable ATI sensor manual for more information on Counts vs. user units.

6.2 Convert ATI F/T Sensor’s Data From Counts to User Units
Upon receipt of each real-time F/T sample in Counts, divide these values by the Counts per Force (CpF) and
Counts per Torque (CpT) scaling factor. These scaling factors are in the sensor’s Calibration Object.
• To determine the CpF or CpT of an ATI sensor, refer to the ATI manual. For an ATI EtherCAT Axia,
ATI provides a Calibration and Accuracy Report that lists the CpF and CpT values in the Output
Scaling section.
• For example, if the sensor’s CpF is 1,000,000 Counts per Newton (N), then
Force (N) = Counts ÷ 1,000,000.

NOTICE: KUKA FTCtrl Digital IO Sensor Type requires specifying a Scaling Factor. A
Scaling Factor is the same as 1 ÷ CpF or 1 ÷ CpT. So for a CpF of 1,000,000, enter a Scaling
Factor of 0.000001.

6.3 Use F/T Data as REAL-type Variables

In this section, these steps (namely converting from binary IO to REAL variables) require approximately
KUKA Programming 2 level of KUKA programming experience. ATI is not a robotic integrator and can only
provide limited support.
1. Programmatically, group each 32-bit binary number so that they can be converted into REAL numbers
and stored in variables:
• Group the 32 bits with the KUKA SIGNAL command.
• For values to update constantly, write the program in the KRC’s submit program.
• Note: If the sensor signals are mapped to the RSI IO (V4.x and V5.x), then they also must be
mapped to the KRC IO.
2. Determine the Scaling Factor for the sensor (refer to Section 6.2—Convert ATI F/T Sensor’s Data From
Counts to User Units).
NOTICE: The Scaling Factor is used to convert the sensor’s F/T data from Counts to user
units, such as N and Nm.

3. Create REAL variables for the scaling factor (1/CpF or 1/CpT) and the forces and torques in R1\
System\$config.dat. Refer to Figure 6.1.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-28
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02
Figure 6.1—Create User Defined Variables

4. Convert the sensor’s F/T data readings from Counts to user units, such as N and Nm. Refer to
Section 6.2—Convert ATI F/T Sensor’s Data From Counts to User Units.
• In order to constantly update the values, program the following calculation, as shown in Figure 6.2,
into the controllers R1\System\sps.sub program.

Figure 6.2—Calculation to Constantly Update Values

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-29
Manual, F/T Sensor, ATI KUKA FTCtrl
Document #9620-05-D-ATI KUKA FTCtrl-02

7. Troubleshooting Guidance
When troubleshooting the ATI sensor, refer to the appropriate ATI manual. Answers to frequently asked questions
are available from the ATI website: https://www.ati-ia.com/library/documents/FT_FAQ.pdf.

Note:
Please read the manual before calling customer service, and have the following information available:
1. Serial number (e.g., FT01234)
2. Sensor model (e.g., Axia90-M50)
3. Calibration (e.g., US-15-50, SI-65-6, etc.)
4. Accurate and complete description of the question or problem
5. Robot model, controller model, controller software version, and installed KUKA FTCtrl options.
Be near the F/T system when calling (if possible). For questions specific to KUKA-provided software or
hardware, please contact KUKA’s technical support.
For additional troubleshooting information or to speak with a customer service representative, please contact ATI at:
ATI Industrial Automation (a Novanta Company)
1031 Goodworth Drive
Apex, NC 27539 USA
www.ati-ia.com
Tel: +1 919-772-0115
Fax: +1 919-772-8259

Application Engineering
E-mail: [email protected]

24/7 Support
Tel: +1 855.ATI-IA.00 (+1 855-284-4200)

8. Specifications
8.1 F/T Sensor
For specifications of the ATI sensor, refer to the ATI website or appropriate ATI F/T sensor manual.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 • Tel:+1 919-772-0115 • Fax:+1 919-772-8259 • www.ati-ia.com
D-30