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MANIPAL UNIVERSITY
For partial fulfillment of the requirement for the
Award of the Degree
of
BACHELOR OF ENGINEERING
in
CERTIFICATE
This is to certify that project work titled WORKING AND PROGRAMMING OF
KUKA ROBOT is a bonafied work of
SHAHID FAIZEE
080929282
SAMRAT SUR
080929014
carried out in partial fulfillment of the requirements for awarding the degree of Bachelor
of Engineering in Mechanical discipline in Manipal Institute of Technology under
MANIPAL University, Manipal during the academic year 2008-2009.
Manager
External Guide
ii
ACKNOWLEDGEMENT
Written words have an unfortunate tendency to degenerate genuine gratitude into a
formality. However it is the only way to record one's feelings permanently.
I was bestowed with the golden opportunity to undergo my summer training at Larsen &
Toubro Limited, Powai, and hence take this opportunity to express my heartfelt thanks to
all those who have been associated with my training.
I express my special thanks to Mr. Pravin Koli, HED- Electronics Cell, I gained
experience and knowledge about the importance of work culture and planning, which is
one of the best of the establishment; I had the privilege of working in the Electronic Cell,
HED during my summer training. I had exposure to:
Knowledge about computer & various packages, which are used in an
organization for its efficient function.
Achieving goals and targets by proper planning & time management.
The importance of communication skill especially when having a group
discussion.
I express my heartfelt gratitude to Mr. Rishi Shahani. For providing me with endless
support and encouragement in all my endeavors at every moment during my training.
This acknowledgement is really incomplete if I would fail to express my sincere thanks to
Ms. Kirti Uchil, placement department, L&T for giving the opportunity of working in the
Production Engineering. Last but not the least I thank all my fellow Trainees for their Cooperation and support.
SHAHID FAIZEE
SAMRAT SUR
Mentor
iii
TABLE OF CONTENT
CHAPTER
1.0
2.0
3.0
PARTICULARS
PAGE. NOS.
CERTIFICATE
ACKNOLWEDGEMENT
TABLE OF CONTENT
INTRODUCTION
THE ROBOT SYSTEM
ROBOT SYSTEM BASICS
1.1
1.1.1 Components of a complete KUKA robot system
1.1.2 KUKA Control Panel (KCP)
1.1.3 Mechanical construction of a KUKA robot
1.1.4 Axis designation of a KUKA robot
SYSTEM OVERVIEW
1.2
1.2.1 KR C2 control for max. 7 axes
1.2.2 USER GROUPS
ENERGY SUPPLY
1.3
1.3.1 KUKA energy supply systems series 2000 robot
1.3.2 Energy supply systems Adjusting the protectors
1.3.3 KUKA robot controller (KRC)
1.3.4 Performance features of KUKA Robot Controller
(KRC)
COORDINATE SYSTMES
OPERATION OF KUKA ROBOT PANEL (KCP)
2.1
2.1.1 Operator control elements
2.1.2 Mode table
2.1.3 Types of Keys
COORDINATE SYSTEM OF ROBOTS
2.2
JOGGING AXIS SPECIFIC
2.3
WORLD COORDINATE SYSTEM
2.4
2.4.1 Assignment of the angles of rotation in Cartesian
coordinate
2.4.2 Dominant axis activated
2.4.3 Dominant axis not activated
2.4.4 TOOL Coordinate system
2.4.5 BASE Coordinate system
SETUP
MASTERING
3.1
3.1.1 Why is Mastering carried out
3.1.2 Mastering Equipments
3.1.3 Reasons for Re mastering
3.1.4 Mastering with the EMT
3.1.5 Preparation for EMT Mastering
3.1.6 What Happen in during tool calibration
METHODS OF TOOL CALIBRATION
3.2
3.2.1 Methods of measurement of the TCP
3.2.2 Methods of the measurement of the orientation
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v-vi
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1
1
1
1
2
3
3
4
5
5
5
5
6
7
7
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7
8
9
9
9
9
10
10
10
10
12
12
12
12
12
13
13
14
14
14
15
3.3
4.0
5.0
6.0
7.0
TOOL PAYLOAD
16
16
16
16
17
17
17
18
18
18
19
19
19
20
20
21
23
23
24
24
25
25
25
25
26
26
26
26
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27
27
27
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INTRODUCTION
KUKA Robots come with a control panel that has a display resolution of 640 x 480
pixels and an integrated mouse, with which the manipulator is moved, positions are saved
(TouchUp), or where modules, functions, data lists, etc. are created and modified. To
manually control the axles the enabling switch on the back of the control panel (the KCP,
or KUKAControlPanel) must be activated (today only with a panic function). The
connection to the controller is a VGA interface and a CAN-bus.
A rugged computer located in the control cabinet communicates with the robot system
via an MFC card. Control signals between the manipulator and the controls are
transferred using the so-called DSE-RDW connection. The DSE card is in the control
cabinet, the RDW card in the robot socket.
Controls for the old KRC1 types used Windows 95 to run VxWorks-based software.
Peripheral equipment includes a CD-ROM and a disk drive; Ethernet, Profibus, Interbus,
Devicenet and ASI sockets are also available.
Controls for the newer KRC2 type use the Windows XP operating system. Systems
contain a CD-ROM drive and USB ports, Ethernet connection and feature optional
connections for Profibus, Interbus, DeviceNet and Profinet.
Most robots come in the orange or black, the former featuring prominently as a corporate
color.
KUKA's industrial robots product range:[3]
Number
of Axis
6 axis
6 axis
6 axis
6 axis
Significance
handling robots
arc welding robots
spot welding robots
shelf-mounted robots, top loader robots
for machine loading and unloading
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Payload Range
5 to 1000 kg
5 to 16 kg
100 to 240 kg
6 to 210 kg
articulated robot
6 axis
articulated robot
articulated robot
articulated robot
6 axis
6 axis
6 axis
articulated robot
articulated robot
6 axis
4 axis
SCARA robot
4 axis
gantry robot
6 axis
15 kg
16 to 500 kg
16 to 500 kg
16 kg
16 to 500 kg
40 to 1300 kg[4]
5 to 10 kg
30 to 60 kg
CHAPTER 1
THE ROBOT SYSTEM
1.1
Link arm
Rotating column
Base frame
NOTE: The modular design means that the number of robot assemblies,
and thus the overall number of components, can be restricted.
1.1.4. Axis designation of a KUKA robot :
It consists of following axis:
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
NOTE: Axis 1, 2 and 3 are the main axis
Axis 4, 5 and 6 are the wrist axis
Control of the 6
robot axis
1.3
ENERGY SUPPLY
1.3.1 KUKA energy supply systems series 2000 robot
Interface A1
6
Outlet on A2
External section
rotating column
dress package A1-A3
3
1
Interface A3
CHAPTER 2
COORDINATE SYSTEMS
2.1 OPERATION OF KUKA ROBOT PANEL (KCP)
2.1.1 Operator control elements
Mode selector
Drives ON
Drives OFF
E-STOP
Mode selector
switch
Jogging
using
keys
or
Space Mouse
T1
T2
250 mm/s
250 mm/s
Enabling switch
(dead man
function)
Enabling switch
(dead man
function)
250 mm/s
Prog.
Velocity
AUTOMATIC AUTOMATIC
EXTERNAL
Jogging
not active
Jogging
not active
Prog. Velocity
Prog. Velocity
Drives ON START
key
pulse
Drives ON
External start
HOV
Program
execution
POV
Enabling switch
(dead man
function) START
key pressed
Enabling switch
(dead man
function)
START key
pressed
STOP key
Program start forward key
Program start backward
Escape key
Window selection key
Softkeys
ASCII alphabetic keypad
NUM key
SYM key
SHIFT key
ALT key
RETURN key
CURSOR key
Menu keys
Status keys
Angle B
Angle C
+Z
A
B
C
+Y
+X
2.4.2
2.4.3
2.4.4
2.4.5
10
+Z
+X
+Y
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CHAPTER 3
SETUP
3.1
MASTERING
3.1.1
When the robot is measured, the axes are moved into a defined mechanical
position, the so called mechanical zero position.
Once the robot in this mechanical zero position, the absolute encoder value
for each axis is saved.
NOTE : Only a mastered robot can move to programmed position and be moved
using Cartesian coordinates; a mastered robot also knows the position of
the software limit switches.
3.1.2 Mastering Equipments
In order to move the robot to the mechanical zero position, a dial gauge or
electronics or electronic measuring tool (EMT) is used. In EMT mastering, the
axis is automatically moved by the robot controller to the mechanical zero
position. If a dial gauge is being used, this must be carried out manually in axisspecific mode.
3.1.3 Reasons for Remastering
The robot is to be mastered...
...after repairs (e.g. replacement of a drive
motor or RDC)
...after exchanging a gear unit
Mastering is cancelled...
...automatically on booting the system 1
1) If dispensaries are detected between the resolver data saved when shutting down the
controller and the current position, all mastering data are deleted for safety reasons.
12
SET - UP
Set mastering
First mastering
Teach offset
Mastering Loss
Check
mastering
Master load
with offset
1) Only possible if the mastering is still valid (i.e. no change to the drive train e.g.
replacement of a motor or parts, or following a collision, etc.)
3.1.5
13
Attach EMT and connect signal cable (connection X32 on the junction
box on the rotating column )
Three LEDs on the EMT
- Error
-
Falling edge
- Rising edge
14
2.
First of all, the TCP (which has been calibrated beforehand) is moved
to a known reference point
The TCP is now moved to a point on the negative X axis of the tool to
be calibrated. The working direction of the tool is defined in this way.
The tool is now moved so that the reference point is located with a
positive Y value on the future XY plane of the tool.
15
3.3.
Tool Payload
3.3.1
Roboter GmbH.
3.3.2
Payload Data
In order to optimize use of the available maximum moments of
acceleration of the robot axes, it is necessary to enter the load data of the
tool that is being used.
CAUTION: The load data must be entered for every geometrically
calibrated tool.
3.3.3
3.4
Base Calibration
The work surface (pallet, clamping table, workpiece...) receives a user-defined
Cartesian coordinate system with its origin at a reference point specified by the
user.
3.4.1
3.4.2
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CHAPTER 4
APPLICATIONS OF KUKA ROBOT
4.1
KUKA.LaserCut
Technologies for laser cutting: once KUKA.Laser Cut has been set up, additional
commands are available. These commands support the programmer in the
creation of robot programs which use
laser functions. Commands for switching the laser on and off, control of a
distance sensor system, the setting of the gas pressure and the programming of
simple geometric figures are
4.2
KUKA.LaserWeld
KUKA.LaserWeld is a time-saving and easy-to-operate programming support
package with a modular structure for laser welding with KUKA robots. Userfriendly inline forms and parameter lists make for easy inputting, setting and
modification of parameters. In addition to the functions for laser welding
applications, KUKA.LaserWeld also contains an independent configuration
program and various modules help you create applications. The integration of
laser welding systems into the KUKA KR C2 robot controllers allows the
programming of all important functions.
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4.3
KUKA.GlueTech
KUKA.GlueTech packages are used for controlling a range of different
dispensing controllers. Depending on the capabilities of the dispensing controller
used, a range of ready-made functions is available, from simple opening and
closing of the adhesive gun to checking the quantity of adhesive dispensed. To
simplify operator control, these functions are offered to the programmer in dialog
form. A configuration tool is provided for fast commissioning. This tool provides
input masks, for example, for the configuration of any input/outputs or seamspecific parameters that may be required.
4.4
KUKA.ArcTech
KUKA.ArcTech is a welding technology package for controlling power sources
with program number control. This package has been specially developed for use
with cooperating robots and enables the simultaneous operation of up to three
robots that are in communication with one another. The package is further
characterized by its high degree of operating convenience. The setup procedures
are simplified by means of a configuration tool. Safe operation with the Shared
Pendant is supported by the wide range of available operating and simulation
modes for convenient teaching, and detailed, cause-specific messages including
indication of the originator.
The technology package is also available, with all its user-friendly features, to
users of single applications.
4.5
KUKA.PalletTech
Shortening the distance from application to program. The KUKA.PalletTech
intelligent palletizing software and the KUKA robot controller KR C2 ensure easy
and efficient implementation of your application. As the second generation of the
PC-based robot controller, the KR C2 offers you even more flexibility and power.
It can be used to control an entire line, and can be integrated into higher-level
structures via a field bus. Moreover, all of the standard interfaces for gripper,
vision, and sensor systems are also provided. Programming is easy with the
Windows user interface and with the new "Icon Editor" program, which allows
programming and operator control using an intuitive set of symbols.
19
4.6
KUKA Milling 8 kW
With the milling 8 kW application module, KUKA offers application-specific
components and tools for deployment of a robot as a machine tool for milling
tasks. Milling 8 kW is specially designed for machining tasks using an
electrically-driven spindle with a rated power of 8 kW. It
20
CHAPTER 5
CAN A CAR SEAT WITHSTAND CONDITIONS AT THE
NORTH POLE?
Starting point / Task definition
Implementation / Solution
The manufacturers high quality standards led to the company investing in a state-of-theart system that allowed it not only to subject the seats to extreme climatic conditions, but
also to provide authentic simulation of the motions of a wide range of different vehicle
occupants.
A KUKA robot fitted with a special protective suit and located in a climatic chamber
imitates the motions of a human driver, thereby testing the durability of the seats. The KR
210-2 works day and night at varying temperatures. Five seats are set up around the
robot in the climatic chamber. The robot executes the preprogrammed motions in
sequence, holding a padded dummy shaped to mimic the human from.
21
Results / Success
The robot treats all seats equally. It is also flexibly programmable. It is therefore possible
to subject all test objects to the same loading. A standard program is generally executed.
If, however, a new seat is introduced part way through a test series, the robot notes the
arrival of this newcomer and knows exactly which test cycles are still required for this
seat.
A test phase can last up to ten weeks. This yields results for five seat types. With the old
test system, it took four weeks to test just a single seat.
22
CHAPTER 6
A.C. SERVO MOTOR
6.1
WHAT IS A SERVO?
This is not easily defined nor self-explanatory since a servomechanism, or servo
drive, does not apply to any particular device. It is a term which applies to a
function or a task.
The function, or task, of a servo can be described as follows. A command signal
which is issued from the user's interface panel comes into the servo's "positioning
controller". The positioning controllers the device which stores information about
various jobs or tasks. It has been programmed to activate the motor/load, i.e.
change speed/position.
The signal then passes into the servo control or "amplifier" section. The servo
control takes this low power level signal and increases, or amplifies the power up
to appropriate levels to actually result in movement of the servo motor/load.
These low power level signals must be amplified: Higher voltage levels are
needed to rotate the servo motor at appropriate higher speeds and higher current
levels are required to provide torque to move heavier loads.
This power is supplied to the servo control (amplifier) from the "power supply"
which simply converts sac power into the required DC level. It also supplies any
low level voltage required for operation of integrated circuits.
As power is applied onto the servo motor, the load begins to move . . . speed and
position changes. As the load moves, so does some other "device" move. This
other "device" is a tachometer, resolver or encoder (providing a signal which is
"sent back" to the controller). This "feedback" signal is informing the positioning
controller whether the motor is doing the proper job.
The positioning controller looks at this feedback signal and determines if the load
is being moved properly by the servo motor; and, if not, then the controller makes
appropriate corrections. For example, assume the command signal was to drive
the load at 1000 rpm. For some reason it is actually rotating at 900 rpm. The
feedback signal will inform the controller that the speed is 900rpm. The controller
then compares the command signal (desired speed) of 1000 rpm and the feedback
signal (actual speed) of 900 rpm and notes an error. The controller then outputs a
signal to apply more voltage onto the servo motor to increase speed until the
feedback signal equals the command signal, i.e. there is no error.
Therefore, a servo involves several devices. It is a system of devices for
controlling some item (load). The item (load) which is controlled (regulated) can
23
be controlled in any manner, i.e. position, direction, speed. The speed or position
is controlled in relation to reference (command signal), as long as the proper
feedback device (error detection device) is used. The feedback and command
signals are compared, and the corrections made. Thus, the definition of a servo
system is, that it consists of several devices which control or regulate
speed/position of a load.
6.2
6.3
The stator is made of laminated steel with properly designed slots. In the slots a
well designed number of windings is located which is connected to the power
supply. The power supply generates a rotating magnetic field. When the motor is
connected to the power supply, a voltage is induced in the bars located in the rotor
which causes a current flow through them. As a result of the current, an
electromotive torque is developed which accelerates the motor. As the speed
increases the induced voltage reduces because the rotor approaches the
synchronous speed. At the synchronous speed, the torque becomes zero.
Therefore, AC motors always rotate at a speed lower than the synchronous speed.
The synchronous speed is determined by the frequency of the power supply and
number of poles in the stator.
24
6.4
6.5
A.C. Servo motors can be found in radio-controlled toy cars. Servos are
used in radio-controlled airplanes to position the rudders, in radiocontrolled cars to move the wheels and in other remote-controlled toys
like puppets.
6.5.2
Industrial Application
In food services and pharmaceuticals, the tools are designed to be used in
harsher environments, where the potential for corrosion is high due to
being washed at high pressures and temperatures repeatedly to maintain
strict hygiene standards.
25
CHAPTER 7
PROGRAMMING OF KUKA ROBOT
7.1
Motion Programming
1) Axis-specific motions
* PTP (point-to-point): The tool is moved along the quickest path to an end
point.
2) Path-related motions
*
*
LIN (Linear): The tool is guided at a defined velocity along a straight line.
CIRC (Circular): The tool is guided at a defined velocity along a circular
path.
PTP
7.2
CONT
Vel =
100
PDAT2
BCO Run
7.2.1
Part 1
For the purpose of ensuring that the robot position corresponds to the
coordinates of the current program point, a so called BCO run (Block
Coincidence) is executed.
This is carried out at reduced velocity. The robot is moved to the
coordinates of the motion block in which the block pointer is situated.
7.2.2
Part 2
This is done :
After a program reset by means of a BCO run to the home position
After block selection to the coordinates of the point at which the block
pointer is situated
26
Part 3
1. This is done by holding down the Start key after selecting the program.
2. The robot moves automatically at reduced velocity
3. Once the robot has reached the programmed path, the program can be
continued by pressing the Start key again.
NOTE: A BCO run always take place by the direct route from the
current position to the destination position. It is therefore important to
make sure that there are no obstacles on this path in order to avoid
damage to components, tools or the robot!
CAUTION: No BCO run is carried out in Automatic External Mode!
7.3
LIN
P1
CONT
Vel =
27
m/s
PDAT2
7.3.2
Orientation Control
Standard During the path motion, the orientation of the tool
changes continuously from the start position to the end position. This
is achieved by rotating and pivoting the tool direction.
Wrist PTP During the path motion, the orientation of the tool
changes continuously from the start position to the end position. This
is done by linear transformation (axis- specific motion) of the wrist
angles. The problem of the wrist singularities can be avoided using
thisoption as there is no orientation control by rotating and pivoting he
tool direction.
Constant The orientation remains constant during the CP motion. he
programmed orientation is disregarded for the end point and that of the
start point is used.
7.4
CIRC
P1
CONT
Vel. =
28
m/s
CPDAT1
7.4.2
Orientation Control
Standard During the path motion, the orientation of the tool changes
continuously from the start position to the end position. This is
achieved by rotating and pivoting the tool direction.
Wrist PTP During the path motion, the orientation of the tool
changes continuously from the start position to the end position. This is
done by linear transformation (axis- specific motion) of the wrist
angles. The problem of the wrist singularities can be avoided using this
option as there is no orientation control by rotating and pivoting the
tool direction.
Constant The orientation remains constant during the CP motion.
The programmed orientation is disregarded for the end point and that of
the start point is used.
7.4.3
INI
PTP HOME
....
LINE P1
LINE P2
CIRC P3 P4;
P3 is AUX; P4 is END
CIRC P3 P2;
P5 is AUX; P2 is END
LIN P1
....
PTP HOME
END
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7.5
Approximation of a motion
During approximate positioning, the robot does not move exactly to each
programmed position, nor is it broken completely.
ADVANTAGE:
Reduce wear
Improved cycle times
7.5.1
7.5.2
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REFERENCES
1. SEMINAR WORKBOOK OF BASIC ROBOT PROGRAMMING for
KUKA System Software V5.x PROGRAMMER
2. SEMINAR WORKBOOK OF ADVANCED ROBOT
PROGRAMMING for KUKA System Software V5.x
PROGRAMMER
3. www.wikipedia.com
4. www.kuka.com
5. www.kuka-robotics.com
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