MTXW315S S 101 - 272pages PDF

Process Simulate on eMS
Advanced Robotics (OLP)
Publication Number
MTXW315S-S-101
Contents
Advanced Robotics (OLP) Course Overview. . . . . . . . . . . . . . . . . . . . . . . 11

Advanced Robotics Prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Advanced Robotics Audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Learning tracks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
How to Use the Activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Introduction to Advanced Robotics. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Introduction to OLP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
OLP Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Review of the Data Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Data Model Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Operations Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Robotic Simulative Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
OLP Software Packages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Robot Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Robot Model Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Motion Planning (Introduction to RCS and RRS). . . . . . . . . . . . . . . . . . . . 1-10
Motion Planning Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
What is MOP?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Process Simulate Motion Planning Flowchart. . . . . . . . . . . . . . . . . . . . 1-10
What is RRS?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
RRS and ESRC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
RRS and ESRC Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Contents of ESRC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Robots as Integrated Production Resources. . . . . . . . . . . . . . . . . . . . . 1-16
Robotics: Information Exchange PLC <# Robot. . . . . . . . . . . . . . . . . . 1-16
Setting up the RCS and RRS (Part 1). . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Process Simulate Access to RCS/RRS. . . . . . . . . . . . . . . . . . . . . . . . 1-18
Robot Controller Setup Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
RRS Setup Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Process Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Process Generation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Process to Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
OLP in Process Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
MTXW315S-S-101 Process Simulate on eMS Advanced Robotics (OLP) 3

Problems that Can Occur without Considering OLP Issues. . . . . . . . . . . . 1-27
How to take OLP into Consideration…. . . . . . . . . . . . . . . . . . . . . . . . 1-28
Do the Up-front Work Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Include Relevant Information at each Step of the Process. . . . . . . . . . . . . 1-28
Supply Information Needed in Later steps of the Process. . . . . . . . . . . . . 1-28
What Should be Considered for OLP?. . . . . . . . . . . . . . . . . . . . . . . . 1-28
Study Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Error Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Five Major Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Robot Programming Background Information. . . . . . . . . . . . . . . . . . . . . 2-1
Basic Motion Attributes (Default Controller). . . . . . . . . . . . . . . . . . . . . . . . 2-2
Motion Attributes Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Robot Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Motion Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Motion Termination (Accuracy/Zones). . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Location Reference Frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Other Default Controller Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Viewing and Editing Location Attributes. . . . . . . . . . . . . . . . . . . . . . . 2-7
Inverse Kinematics Solution Selections (Configurations). . . . . . . . . . . . . . . . . 2-8
Solution (Configuration) Selection Basics. . . . . . . . . . . . . . . . . . . . . . . 2-8
Solution and Turns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Using the Robot Viewer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
External Axis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Review of Robot Programs and Robot Signals. . . . . . . . . . . . . . . . . . . . . . 2-13
Robot Programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Robot Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Status Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Robot Path Reference Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Robot Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Creating Robot Programs (Default Controller). . . . . . . . . . . . . . . . . . . . . . 2-20
Robot Program Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Methods to Create and Edit a Program. . . . . . . . . . . . . . . . . . . . . . . . 2-20
Creating a Robotic Program from a Compound Operation. . . . . . . . . . . . . 2-21
Segmentizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Segmentizer Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
ESRC Setup and Motion Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Process Simulate OLP Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
How to Setup a RRS Simulation Overview. . . . . . . . . . . . . . . . . . . . . . 3-3
Basic Study Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Study Study Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Robot Controller Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Robot Controller Selection Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
4 Process Simulate on eMS Advanced Robotics (OLP) MTXW315S-S-101

How to Figure Out the Manipulator Type?. . . . . . . . . . . . . . . . . . . . . . 3-8
Robot Controller Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Robot Controller Setup Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Accessing Robot Setup Using Method 1. . . . . . . . . . . . . . . . . . . . . . . 3-11
ABB Robot Setup window – First Buttons. . . . . . . . . . . . . . . . . . . . . . 3-12
Comau Robot Setup window – First Buttons. . . . . . . . . . . . . . . . . . . . 3-13
Duerr Robot Setup window – First Buttons. . . . . . . . . . . . . . . . . . . . . 3-14
Fanuc Robot Setup window – First Buttons. . . . . . . . . . . . . . . . . . . . . 3-14
Kawasaki Robot Setup window – First Buttons. . . . . . . . . . . . . . . . . . . 3-15
Kuka Robot Setup window – First Buttons. . . . . . . . . . . . . . . . . . . . . 3-16
NC Code Robot Setup window – First Buttons. . . . . . . . . . . . . . . . . . . 3-18
Reis Robot Setup window – First Buttons. . . . . . . . . . . . . . . . . . . . . . 3-18
(ABB) Trallfa Robot Setup window – First Buttons. . . . . . . . . . . . . . . . 3-19
Yaskawa Robot Setup window – First Buttons. . . . . . . . . . . . . . . . . . . 3-20
Testing the Teach Pendant and Fixing Setup Problems. . . . . . . . . . . . . . . . . 3-22
Teach Pendant Testing Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
RCS Shell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
RCS Logs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
RCS Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
RCS Management Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Reset RCS Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
RCS Decoupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Limitations on Decouple Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Methods to Define TCPF Positions for the RCS. . . . . . . . . . . . . . . . . . . . . 3-27
TCPF Definition Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Robot Toolbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Robot Controller Specific Frames and Setup. . . . . . . . . . . . . . . . . . . . . . . 3-29
Robot Setup Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
ABB Robot Setup window - Continued. . . . . . . . . . . . . . . . . . . . . . . 3-32
Comau Robot Setup window - Continued. . . . . . . . . . . . . . . . . . . . . . 3-36
Duerr Robot Setup window - Continued. . . . . . . . . . . . . . . . . . . . . . . 3-37
Fanuc Robot Setup window – Continued. . . . . . . . . . . . . . . . . . . . . . . 3-38
Kawasaki Robot Setup window – Continued. . . . . . . . . . . . . . . . . . . . 3-40
Kuka Robot Setup window - Continued. . . . . . . . . . . . . . . . . . . . . . . 3-41
NC Code Robot Setup window – Continued. . . . . . . . . . . . . . . . . . . . . 3-44
Reis Robot Setup window – Continued. . . . . . . . . . . . . . . . . . . . . . . . 3-45
(ABB) Trallfa Robot Setup window – Continued. . . . . . . . . . . . . . . . . . 3-46
Yaskawa Robot Setup window - Continued. . . . . . . . . . . . . . . . . . . . . 3-46
Controller Specific Frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Setting Controller Specific Motion Attributes. . . . . . . . . . . . . . . . . . . . . . 3-50
Controller Specific Motion Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
ABB Motion Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Comau Motion Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Duerr Motion Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Fanuc Motion Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Kawasaki Motion Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Kuka Motion Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
NC Motion Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Reis Motion Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
(ABB) Trallfa Motion Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Yaskawa Motion Attributes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Program Creation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Program Creation Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Process Simulation and Robot Configurations. . . . . . . . . . . . . . . . . . . . . . 3-59
Robot Configuration Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Teaching and Clearing Robot Configurations. . . . . . . . . . . . . . . . . . . . 3-59
Simulate Robot Paths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Uploading and Downloading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Program Templates for Downloading. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Program Template Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Editing Program Templates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Program Template Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Template Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Example Robot Specific Template Keywords. . . . . . . . . . . . . . . . . . . . . 4-5
Example Template Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Process Download. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Download Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Examining Output Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Output File Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Process Upload from Robcad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Robcad Upload Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Direct Process Upload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Upload Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Overview of Robot Operation Merge. . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Robot Operation Merge Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
ESRC OLP Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Standard OLP Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
OLP Command Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Basic OLP Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Free Text Standard Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Free Text Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Supported Controller Specific OLP Commands. . . . . . . . . . . . . . . . . . . . . . 5-7
Controller Specific OLP Command Basics. . . . . . . . . . . . . . . . . . . . . . 5-7
ABB-Rapid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Comau-Pdl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Duerr-EcoTalk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Fanuc-RJ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Kawasaki-As. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Kuka-Krc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Reis-Robstar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
(ABB) Trallfa-Robtalk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Yaskawa-Inform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Comparison of Various Methods for Handling Robot Macros. . . . . . . . . . . . . 5-34
Entering OLP Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Entering OLP Commands Method Comparison. . . . . . . . . . . . . . . . . . . 5-35
Conditional Statement Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Calibration Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Calibration Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
What is Calibration?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Calibration Sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
The Math Behind Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Calibration Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Robot to Part Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Robot to Part Calibration Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Calibration Steps Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
OLP Command XML Customization. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Overview of Customizing Robot Controller Interfaces. . . . . . . . . . . . . . . . . . 7-2
OLP Command Customization Basics. . . . . . . . . . . . . . . . . . . . . . . . . 7-2
The Customizable User Interface's Layers. . . . . . . . . . . . . . . . . . . . . . . 7-3
Dialog Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Introduction to the Customized OLP Commands XML File. . . . . . . . . . . . . . . 7-8
Customized XML Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
The Basic Sections of the File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Robotic Parameters Section of the File. . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Robotic Params Section Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Defining a List of Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
More on TxObject ValueTypes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
OLP Commands Section of the File. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
OLP Commands Section Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Layers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
OLP Dialogs Section of the File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
OLP Dialogs Section Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
OLP Command XML Structure Example. . . . . . . . . . . . . . . . . . . . . . 7-16
Send Signal and Wait Signal Example. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Send Signal and Wait Signal Basics. . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Custom OLP Command and Macro Example. . . . . . . . . . . . . . . . . . . . . . . 7-19

Macro File Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
OLP Command XML File Requirement for Example. . . . . . . . . . . . . . . 7-20
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Motion and Robotic Path Template XML Customization. . . . . . . . . . . . . . 8-1
Motion Command Customization Introduction. . . . . . . . . . . . . . . . . . . . . . . 8-2
Motion Customization Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Custom Motion Type Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Additional Elements of Motion Command XML Files. . . . . . . . . . . . . . . . . . 8-5
Motion Command Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Motion Command Customization Example. . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Motion Example Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Robotic Path Template Customization Introduction. . . . . . . . . . . . . . . . . . . . 8-9
Path Template Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Capabilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Robotic Path Template Customization Example. . . . . . . . . . . . . . . . . . . . . 8-16
Path Template Example Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Other XML Customization Topics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Custom Debugging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Multi Editing of Customized Motion. . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Picture Attribute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Adding your Own Online Help for Customized Dialogs. . . . . . . . . . . . . . 8-20
Centralize all XML files under single shared folder. . . . . . . . . . . . . . . . 8-20
Encryption of Customized XML Files. . . . . . . . . . . . . . . . . . . . . . . . 8-21
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Final Comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Overview of the Robotic Parameters Viewer. . . . . . . . . . . . . . . . . . . . . . . . 9-2
Robotic Parameters Viewer Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Overview of Robot Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Robot Modules Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Overview of the Roller Hemming Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Roller Hemming Tool Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Overview of the OLP Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
OLP Tools Basics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Convert to Via Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Convert to Weld Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Create Seam Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Define Gun Main Joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Mark Current Rail Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Rail Jog with Locked TCPF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Shift Rail Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Smooth External. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Smooth Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

Creating an OLP Procedure (Putting It All Together). . . . . . . . . . . . . . . . . . 9-17
A Multi-Step OLP Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Putting It All Together. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

Advanced Robotics (OLP) Course
Overview
Course description
The RobotExpertProcess Simulate on eMS Advanced Robotics course provides step-

by-step instruction on how to use RobotExpertProcess Simulate to configure, simulate,
and upload/download (i.e. OLP) using realistic robot simulation (RRS), RCS (Robot
Controller Software), and ESRC (Emulated Robot Specific Controllers).
Course objectives
Learn about:
• Introduction to Robotic Off-Line Programming (OLP)
• Introduction to RCS, RRS, and ESRC
• Setting up the RCS, RRS, and ESRC
• Creating Robot Programs
• Inverse Kinematics Solution Selections (Robot Configurations)
• Robot Controller Selection and Setup
• Testing the Teach Pendant and Fixing Setup Problems
• RCS Management
• Robot Controller Specific Frames, Setup, and Motion Attributes

• Templates, Uploading, and Downloading
• ESRC OLP Commands
• OLP Command XML Customization
• Motion XML Customization
• Robotic Path Template XML Customization
• Other XML Customization Topics
• OLP Add-ons and OLP Tools
Advanced Robotics Prerequisites

Knowledge of a robot language: such as those from ABB, Comau, Duerr, Fanuc,
Kawasaki, Kuka, Reis, (ABB) Trallfa, or Yaskawa/Motoman. Please specify two
desired robot languages when signing up for this course.
Required courses:
• WKP115S – Process Simulate on eMS Basic Robotic Simulation
• WKP215S – Process Simulate on eMS Intermediate Robotics
Advanced Robotics Audience

Individuals who would like to use RobotExpertProcess Simulate to configure, simulate,
and upload/download (i.e. OLP) using realistic robot simulation (RRS), RCS (Robot
Controller Software), and ESRC (Emulated Robot Specific Controllers).
Learning tracks
Learning tracks for the Tecnomatix application are found on the Siemens PLM Software
training website: training.industrysoftware.automation.siemens.com/index.cfm
Related Courses
• WKP101S – Process Simulate on eMS Part Flow Simulation
• WKP106S – Process Simulate on eMS Human Simulation
• WKP115S – Process Simulate on eMS Basic Robotic Simulation
• WKP215S – Process Simulate on eMS Intermediate Robotics
• WKP315S – Process Simulate on eMS Advanced Robotics

How to Use the Activities
The steps for each activity are displayed in a window on your computer.
The following steps show you how to launch an activity.
1. Expand the appropriate lesson (1) and click the assigned activity (2).
2. Click Launch the activity to open the activity window.

3. To keep them both in view, position the activities and windows similar to
following.

4. If you see a scroll bar, be sure to scroll down to see additional activity steps.

Lesson
1 Introduction to Advanced Robotics
Purpose
To discuss the basics of Off-Line Programming with Process Simulate Robotics.
Objectives
After you complete this chapter, you should be familiar with:
• An overview of OLP.
• An overview of theProcess Simulate data model.
• The basics of robot models.
• The basics of RRS, RCS, and ESRC.
• How to setup the RCS and RRS.
• The steps for process generation and process to program.
• The problems that can occur if OLP is not considered.
• How to prepare the study for OLP.
• Some sources of error in OLP.
Process Simulate on eMS Advanced Robotics (OLP) 1-1

Introduction to Advanced Robotics
Introduction to OLP
This topic provides an introduction to OLP.
It contains the following subtopics:
• OLP Basics
OLP Basics
This course focuses on portion of Process Simulate known as Process Simulate

Robotics. Process Simulate Robotics contains a set of tools for performing OLP.
• OLP (ak.a. Off-line programming) – the process of designing, modifying, and
testing a robot program in an external system without the need of the actual robot.
Once the program is created it can be downloaded from the external system and
uploaded into the actual robot controller.
• Downloading – the process of exporting a text file of the program from an external
system or robot controller.
• Uploading – the process of importing a text file of the program from an external
system or robot controller.
Here is the basic process. A program can be originated in Process Simulate or directly
on the real robot (controller). After that, it can be cycled through this continuous loop:
1-2 Process Simulate on eMS Advanced Robotics (OLP) MTXW315S-S-101

• Path – A path (a.k.a. robotic operation) is a representation of the robot work plan
in the Process Simulate world. It consists of locations, sequence of locations, and
location attributes.
• Program – A collection of paths (and or locations) used for downloading.
• Program File – A task is a textual format of the robot work plan which includes
motion commands and parameters.

Review of the Data Model

This topic provides an overview of the data model.
• Data Model Basics
• Operations Tree
• Robotic Simulative Operations
• OLP Software Packages
Data Model Basics
The center of the Process Simulate universe is the operation tree of the loaded study.
Studies can contain four types of data. The actual content depends on the shortcuts
that have been added to the study and the relationships of the data to objects in the
operations tree:
• Product
• Operation
• Resources
• Manufacturing Features
• “Engineering Data”
In general, the data can be initially found in these viewers:

• Product, Resources, and Engineering Data can be found in the Objects Tree
viewer.
• Operations are found in the Operations Tree viewer.
• Manufacturing Features can be found in the Mfg Viewer.
Operations Tree
The operations tree contains a structure that typically starts with a station (i.e.
PrStationProcess ). This station contains several compound operations sequenced
together. This initial structure could have been setup in Process Designer and will now
be farther detailed and validated in Process Simulate. This is done by adding simulative

operations to the desired compound operations. There are several types of simulative
operations:
• Object flow operation - a simulative operation consisting of the movement of
a part along its assembly path. It is represented using the icon. (Covered in the
WKP101S, WKP106S, WKP115S, and WKP215S courses).
• Device operation - a simulative operation consisting of any mechanical device

(i.e. a robot, human, clamps, cart, etc…) moving from one pose to another. It is
represented using the icon. (Covered in the WKP115S and WKP215S courses).
• Robotic operation - a simulative operation consisting of a sequence of locations

(positions) for the Robot TCPF. This type can be used for material handling or
welding. It is represented using these , , icons.
• Human operation - a simulative operation consisting of a single human motion

or a series of motions. It is represented using these , , , , icons.
(Covered in the WKP106S course).
• Non-sim operation - a simulative operation detailing an activity requiring time

(but will not be simulated) that you want to include. It is represented using the
icon.
Robotic Simulative Operations
A robotic operation can be made up of:

• Weld locations – each is linked to a weldpoint (manufacturing feature). The weld
gun will be actuated at each weld location.
• Pick and Place Locations
• Seam Locations – locations that move the robot along the contour of the part
• Via Locations – general movement or clearance moves
Robotic operations can be visualized as a path (a.k.a. a sequence of locations) in the

Graphic Viewer.
Robotic properties of locations and robotic operation:
There are several types of properties that can be stored on a location or robotic
operation.
• Motion Type (interpolation)
• Speed

• Zone
• Tool
• Process parameters
• OLP commands
• Configuration and turns
Some of this information can be mapped from a generic (default) controller (i.e.
for something simple like motion type). Much of the information that is robot
manufacturer (or sometimes robot) specific is done differently (i.e. how configurations
are represented).
Instead it is typically better to work directly in the language of the robot, within Process
Simulate, rather than to work in a generic language and then translate it later. However,
you could work with the default controller if needed (no RRS), and get about 80%
motion accuracy.
The motion planning, how the joint motions of the robot are synchronized, cannot have
the accuracy of the real robot because of the real robot’s smoothing algorithms may be
different than the default controller’s (i.e. motion from down to up may use a different
motion than from up to down).
OLP Software Packages
An OLP software package contains the following:

• A user interface to set parameters
• RRS Simulation access to the RCS

We will discuss this topics in detail starting in lesson 4, however these are
two core technologies of robotic offline programming:
o RRS – Realistic Robot Simulation
o RCS – Robot Controller Software
• Downloads – create a program file to run on the real robot
• Uploads – the most complex since some things needed to run a simulation are only
defined (exist) in Process Simulate and cannot be exacted from the program file.
Standard OLP software packages are released with the Process Simulate software.
Currently there are packages for robot manufacturers.
Each controller has its own OLP package executable. Files will be installed
under the .\Tecnomatix\eMPower and .\Tecnomatix\eMPower\Robotics\OLP
folders.

A specific license is required from Siemens PLM Software and the robot vendor
to activate each controller (and underlying robot specific abilities).

Robot Models
This topic describes a little bit about robot models.

• Robot Model Basics
Robot Model Basics
One of the first factors that must be considered when doing OLP is the robot model.
There are several questions that can be asked. For example: Does a robot model for my
real robot already exist in Process Simulate
Answer: There are two places to go to find robot models
• Software install DVD (currently Robcad only)
• GTAC (Many robot models are available for download from

the Siemens PLM Software Global Technical Access Center at
support.industrysoftware.automation.siemens.com or 1–800-955-000. However,
some new robot models must be gotten directly from the robot manufacturer, for
intelectual property reasons)


Motion Planning (Introduction to RCS and RRS)

This topic provides an introduction to the concepts of RCS and RRS.

• Motion Planning Basics
• What is MOP
• Process Simulate Motion Planning Flowchart
• What is RRS
Motion Planning Basics
Process Simulate’s motion planner controls the trajectory and cycle-time of all motions.
It also determines if a motion is possible, and also can give error messages if a motion
request exceeds the capability of the modeled mechanism.
There are several different types of robot controllers available:
• DCM - the default controller. No RCS license is required.
DCM – Dynamic Controller Model
• DCM with RRS – the most accurate robot motion
RRS – Realistic Robot Simulation
What is MOP?
MOP stands for MOtion Planner. Process Simulate uses it to processes motion requests
from the user, and passes the results back to the Graphic Viewer.
Process Simulate Motion Planning Flowchart

Description:
• Path based simulation based on a selected Process Simulate robot controller
Advantages:
• User designs, simulates, and optimizes a path using the related Process Simulate
teach pendant.
• Automatic creation of a robot program file from Process Simulate path
• The created program is an accurate translation of the designed path
• Only a few modifications may be required
What is RRS?
RRS – In a combined effort, initiated by the European Car Manufacturers Association,

robot manufacturers, and software simulation vendors worked together to form an
accurate representation of robot algorithms for each robot in production engineering
simulation packages (i.e. Process Simulate).
Basically RRS is the interface used by Process Simulate to access a virtual robot
controller (RCS).

• Realistic Robot Simulation (RRS) - An international standard developed by

robot manufacturers and robotic CAD/CAM companies. The standard specifies
communication algorithms and protocols, used by Process Simulate, or any other
system, to communicate with a software model of a robot controller. The standard
defines a software model of a robot controller as a "Black Box" with a specific
input and output scheme. Siemens PLM Software develops an RRS interfaces for
Process Simulate to access the RCS.
• RCS Module - A software model of a robot controller (i.e. virtual robot controller),
which knows how to deal with RRS inputs and outputs. It is developed by the robot
manufacturer to behave just like the real robot controller.

RRS and ESRC

This topic provides an introduction to RRS and ESRC.
• RRS and ESRC Basics
• Contents of ESRC
• Robots as Integrated Production Resources
• Robotics: Information Exchange PLC <→ Robot
RRS and ESRC Basics
RRS1:
• Developed a long time ago (around 1990).
• Motion planning of robot to communicate to simulation software

o Interpolation
o Transformation
o Kinematics modeling
o Machine data
o External axes
o Conveyor synchronization
o Internal event generation
o Error messages
o RCS Validated (accurate) robot path
o RCS Verified (accurate) motion time
• About 97% motion accuracy including (payload) dynamics
• All process parameters are included / can be downloaded
• Need a configuration file
• Good for standard, noncomplex, configurations (i.e. no servo gun, non-rail robot,
etc…)

• But cannot provide accurate cell cycle time because of the following reasons:
o Waiting for devices
o Robot interlocks
o Path optimization cannot take into account any synchronization of devices
RRS2:
• Good for local changes after robot commissioning
• Too complex
• Gives full controller
• Motion and logic
• Need real controller available
• Need to know all sorts of information to set it up that is not known when the paths
are developed in Process Simulate or it won’t run (i.e. temperatures, sensor signal
registers, how many I/O boards, how may servo motors, etc…)
• Not the best for project lifecycle (i.e. want to do robot simulations two years before
commissioning)
• Performance problems (controller needs to “boot” and start everything)
ESRC:
• Emulated Specific Robot Controller
• Easier to use and configure than RRS2
• ESRC = RRS1 + desired logic + robot specific commands
• It is used in the Process Simulate Cyclic Event Evaluator environment (CEE is

covered in the WKP215S Process Simulate on eMS Intermediate Robotics (CEE)
course)
• Subset of robot language used to get accurate cycle time
• Don’t need all the overhead of RRS2 during the program design phase.
• Who cares about logic 20% of station time is logic. If you have multiple robots,
each have a factor effect on the logic percentage of cycle time. Logic is used more
to:
o Prove out feasibility
o Get more accurate cycle time

Contents of ESRC
• Command Recognition (Send/Wait Signals, etc…)
• Edit Robotic Commands
• Non Boolean Signals
• Comment Robotic Command
• Free Text Command
• Boolean/Analog Evaluation
• Under Program/Call Path (conditional)
• Macro
• Simulates Robot commands without the need of RRS2
• Enhances the usage of RRS1 with internal robot logic
• Enables a better design

• Enables checking alternatives at an early stage
Robots as Integrated Production Resources
All RRS papers identify clearly 2 very important points:

• Robots never are standalones in a production station – they need all the relevant
production and control devices (conveyors, tools, sensors etc.)
• An external Controller (PLC or similar) is a must in order to make the VRC (virtual
robot controller) work.
Robotics: Information Exchange PLC <→ Robot
There are 3 categories of information to be exchanged:

• Synchronization signals (Wait, Continue) on locations
• Program (path) number and GO/End
• Status Information even on “in between location” positions (e.g. on each simulation
cycle)

Setting up the Process Simulate OPC connection to a PLC was described

in the WKP215S Process Simulate on eMS Intermediate Robotics (CEE)
course.

Setting up the RCS and RRS (Part 1)

This topic describes how to setup the RCS.
• Process Simulate Access to RCS/RRS
• ABB Activity: Setting up the RCS (Discussion Only)
• Comau Activity: Setting up the RCS (Discussion Only)
• Duerr Activity: Setting up the RCS (Discussion Only)
• Fanuc Activity: Setting up the RCS (Discussion Only)
• Kawasaki Activity: Setting up the RCS (Discussion Only)
• Kuka Activity: Setting up the RCS (Discussion Only)
• Reis Activity: Setting up the RCS (Discussion Only)
• Yaskawa Activity: Setting up the RCS (Discussion Only)
Process Simulate Access to RCS/RRS
Process Simulate Robotics interfaces with robot manufacturer supplied RCS modules.
Each robot interface is customized to use the functionality of the RCS module as
defined by the robot manufacturer.
In order to use RRS to perform a simulation in Process Simulate:
• You must have the RCS module from the robot manufacturer installed and licensed
in the computer. This is setup before starting Process Simulate in the rrs.xml file.
• You must use a RCS robot and compatible RRS controller (its motion can be
controlled in Process Simulate using an installed RCS module). This is setup in a
specific study in the Robot Properties window.
For example:
Robot
Language Controller RCS or MOP
Manufacturer
S4, S4C, S4C+,
ABB Rapid RCS
IRC5
S4, S4C, S4C+,
ABB Volvo Rapid RCS
IRC5
S4, S4C, S4C+,
Comau PDL RCS
IRC5

Comau Volvo S4, S4C, S4C+,

PDL RCS
(Volvo only) IRC5
Duerr EcoTalk EcoRC2, EcoRPC RCS
F100iA a.k.a.
Fanuc F100iA F100iA RCS
CFLEX
RJ3, RJ3iB, R30iA TPE (teach pendant
Fanuc RCS
(RJ13ic) editor)
Fanuc Japan (Japan RJ3, RJ3iB, R30iA TPE (teach pendant
RCS
only) (RJ13ic) editor)
Fanuc VW (VW RJ3, RJ3iB, R30iA TPE (teach pendant
RCS
only) (RJ13ic) editor)
C, D, E (block step
Kawasaki AS RCS (soon)
motion format)
KRC1, KRC2,
Kuka KRC RCS
KRC3, KRC4
Kuka Volvo (Volvo
KRC KRC1, KRC2 RCS
only)
Kuka VKRC (VW VKRC1, VKRC2,
VKRC RCS
only) VKRC3, VKRC4
NC Code G Code G Code MOP
Reis Robstar Robstar5 MOP
(ABB) Trallfa Robtalk Robtalk3 MOP
Yaskawa/ Motoman INFORM NX, DX RCS (soon)


This topic describes how to setup the ESRC robot controllers.
• Robot Controller Setup Basics
• ABB Activity: Setting up the Latest Process Simulate Robot Controller (Discussion
Only)
• Comau Activity: Setting up the Latest Process Simulate Robot Controller

(Discussion Only)
• Duerr Activity: Setting up the Latest Process Simulate Robot Controller

(Discussion Only)
• Fanuc Activity: Setting up the Latest Process Simulate Robot Controller

(Discussion Only)
• Kawasaki Activity: Setting up the Latest Process Simulate Robot Controller

(Discussion Only)
• Kuka Activity: Setting up the Latest Process Simulate Robot Controller (Discussion
Only)
• Reis Activity: Setting up the Latest Process Simulate Robot Controller (Discussion
Only)
• Yaskawa Activity: Setting up the Latest Process Simulate Robot Controller

(Discussion Only)
Robot Controller Setup Basics
In this lesson, we will discuss downloading and installing the latest Process Simulate
robot controller from the GTAC site.
For example:
Robot Manufacturer Language

ABB Rapid
ABB Volvo Rapid
Comau PDL
Comau Volvo (Volvo only) PDL
Duerr EcoTalk
Fanuc F100iA F100iA

Fanuc RJ3, RJ3iB, R30iA (RJ13ic)

Fanuc Japan (Japan only) RJ3, RJ3iB, R30iA (RJ13ic)
Fanuc VW (VW only) RJ3, RJ3iB, R30iA (RJ13ic)
Kawasaki AS
Kuka KRC
Kuka Volvo (Volvo only) KRC
Kuka VKRC (VW only) VKRC
NC Code G Code
Reis Robstar
(ABB) Trallfa Robtalk
Yaskawa/ Motoman INFORM
** The Duerr, Fanuc F100iA, NC Code, Reis, Template RRS, and Trallfa robot
controllers are currently license free.
In order that all parameters set on the robot (like local data definitions) are stored
in the eMS, it is mandatory to import following customization file: .\Tecnomatix
\eMPower\InitData\RoboticsCust\RoboticsCust.ppc.
It is also mandatory to import it again after migrating from v8.2.1 to v9.0 and
up (starting in v9.0, robot parameters are no longer stored in the study but in the
eMS).
Terminology note:
We can install various Process Simulate robot controllers, which include a teach
pendant and an interface to the related RCS. The RCS is the virtual robot controller
(software and license) from the robot manufacturer. A Process Simulate robot controller
and teach pendant together are our interface to various features of the real robot
controller. It is not required to have a real robot controller or teach pendant from the
robot manufacturer to use the Process Simulate robot controller and teach pendant.

Pictured: A real robot controller and teach pendant from Kawasaki Robotics, Inc.


This topic describes how to setup the RRS.
• RRS Setup Basics
• ABB Activity: Preparing to Setup the RRS (Discussion Only)
• Comau Activity: Preparing to Setup the RRS (Discussion Only)
• Duerr Activity: Preparing to Setup the RRS (Discussion Only)
• Fanuc Activity: Preparing to Setup the RRS (Discussion Only)
• Kawasaki Activity: Preparing to Setup the RRS (Discussion Only)
• Kuka Activity: Preparing to Setup the RRS (Discussion Only)
• Reis Activity: Preparing to Setup the RRS (Discussion Only)
• Yaskawa Activity: Preparing to Setup the RRS (Discussion Only)
RRS Setup Basics
The rrs.xml file can have several lines. Typical parameters are:
• ControllerName – the RRS name used to reference the RCS from within
Process Simulate.
• VersionName – the version of the RCS module.
• ModuleName – the absolute path and name of the executable that is the
RCS.
• ModulePathName – the absolute path where the RCS module is located.

• The controller and machine data for the robot must be set as specified in the RCS
module.
• The RRS controller to RCS module mapping must be setup in the rrs.xml file.
This file is located in the .\Tecnomatx\eMPower\Robotics\OLP folder.
For example:
Example RCS Example Version
Robot Mfgr Controller Name
Module Name Names
.\rrs_bin\rcs_abb 5.0 IRC5
ABB ABB-Rapid
\rcsabb_rw5.07.01.irc5\rcsabb_tune.exe
(rw5.11.01)

.\rrs_bin\rcs_abb 5.0 IRC5

ABB ABB-Rapid-Volvo
\rcsabb_rw5.07.01.irc5\rcsabb_tune.exe
(rw5.11.01)
.\rrs_bin\rcs_comau
Comau C3G+ (5.63) Comau-Pdl
\rcs_cm_c3gplus_5.63\cm_c3gplus_5.63_tune.exe
Comau Volvo .\rrs_bin\rcs_comau
C3G+ (5.63) Comau-Pdl-Volvo
(Volvo only) \rcs_cm_c3gplus_5.63\cm_c3gplus_5.63_tune.exe
.\rrs_bin\rcs_ecopc
Duerr RPC (v5.1.7) Duerr-Ecotalk
\v5\rcsdb01_tune.exe
.\rrs_bin
V7.7b (fr13.v5.0),
Fanuc F100iA \rcsfr13\robcad.bin Fanuc-F100iA
debug
\rj3_rcs_tune.exe
.\rrs_bin
V7.7b (fr13.v5.0),
Fanuc \rcsfr13\robcad.bin Fanuc-RJ
debug
\rj3_rcs_tune.exe
.\rrs_bin
Fanuc Japan (Japan V7.7b (fr13.v5.0),
\rcsfr13\robcad.bin Fanuc-Rj-Japan
only) debug
\rj3_rcs_tune.exe
.\rrs_bin
Fanuc VW (VW V7.7b (fr13.v5.0),
\rcsfr13\robcad.bin Fanuc-Rj-Vw
only) debug
\rj3_rcs_tune.exe
.\rrs_bin\rcskw C (KW07), D
Kawasaki Kawasaki_As
\rcsKW09_tune.exe (KW08), E (KW09)
.\rrs_bin
Kuka \rcs_krc1\krc5.2_r02\bin
V52 (r02) Kuka-Krc
\rcskrc1_tune.exe
.\rrs_bin
Kuka Volvo (Volvo
\rcs_krc1\krc5.2_r02\bin
V52 (r02) Kuka-Krc-Volvo
only)
\rcskrc1_tune.exe
.\rrs_bin
Kuka VKRC (VW
\rcs_krc1\krc5.2_r02\bin
V52 (r02) Kuka-vKrc
only)
\rcskrc1_tune.exe
NC Code N/A N/A NC-Code
Reis N/A N/A Reis-Robstar
(ABB) Trallfa N/A N/A Trallfa-Robtalk
.\rrs_bin\rcsyma
Yaskawa/ Motoman NX (v2007) Yaskawa-Inform
\rcsmainNX_tune.exe
The rrs.xml file is a mapping file. It must be edited to reflect your environment (i.e. the
version of the RCS used, the folder it is installed in, the robot’s name, etc…).

A section must exist in this file for every RCS and RCS module version that will be
used, but not for every RCS supported by Process Simulate.
An example of the rrs.xml which matches the exercises in this course is included
with the training data. Some modifications may need to be done to the file in
order to use it in your training environment.

Process Overview
This topic provides an overview of the process.
• Process Generation
• Process to Program
Process Generation
1. Basic Process Roughed Out. (Topic covered in EMS127 Process Designer Basics
and EMS228 Process Designer Body-In-White Processing)
• Setup of basic structure of data
2. Detailed process motion completed and verified. (Topic covered in

• Create Process Locations
• Select Robot Tool
• Place Robot
• Create Via Locations
• Optimize the Process
• Simulate the Process
3. Fully verified robot programs are completed and ready for downloading. (Topic
covered in
• Sending a Process to a Robot using OLP
• etc ...
Process to Program
1. Verify Collision Free Simulation
2. Add Process Logic Attributes
3. Teach Local Locations For Process Using Correct Motion Type At Each Location
4. Download The Program

OLP in Process Design

This topic describes how to .

• Problems that Can Occur without Considering OLP Issues
• How to take OLP into Consideration…
• Do the Up-front Work Required
• Include Relevant Information at each Step of the Process
• Supply Information Needed in Later steps of the Process
• What Should be Considered for OLP
Problems that Can Occur without Considering OLP Issues
If no Off-Line Programming considerations are made by the process designer, it

will be assured that the shop floor engineer will have major problems with the
Process Simulate generated programs. In many cases these problems may justify
discarding the OLP deliverables.
Some of the types of problems are:
1. 1 Robot pose configurations (impossible, senseless, etc.).
• Example: The robot moves from a FLIP to NO-FLIP.
2. 2 Dangerous (to man and machine) singularity problems.
• Example: Joint 4 & 6 move in an unpredictable, high-speed rotation.
3. 3 Elements of the program are missing.
• Example: The robot controller doesn’t have good editing capabilities.
4. 4 The shop floor engineer does not understand the total control scheme.
5. 5 Need to calibrateNeed to maintain?
6. 6 No flexibility in the design to compensate for mechanical and build inaccuracies.
• Example: A change is required, but the robot is already working on a joint

limit!
7. 7 No obvious way to "dress" the robot with this program.

How to take OLP into Consideration…
At each processing stage, a good designer can make many of the OLP shopfloor
decisions without venturing out of their office. Also, a good designer will be
responsible for ensuring successful OLP by making their design intent clear
NOTES:
Do the Up-front Work Required
Example:
• Using the required Robot Controller Model, test a sample of the programs you
generate. Identify a program certification process/authority. What is the required
program structure?
Include Relevant Information at each Step of the Process
Example:
• What robot will be used?
• What is the maximum cycle time allowed?
• How many robots does the cell include?
• What about zones clearance?
• What about joint limits?
Supply Information Needed in Later steps of the Process
Example:
• Enter gun poses (spot-weld).
• Enter signals information.
• Create the sequencing.
• Add notes for shop floor engineers.
Always be alert, and check the design against common robotic constraints.
What Should be Considered for OLP?

At the concept design stage:
1. Robotic welding? Human operations? Fixed automation?
2. Do not position robots close to each other.
3. Make the part accessible - Shop floor personnel will need to work there safely.
4. Is the robot required to pick & place as well as weld? Remember: The tooling on
this robot will make it harder to manipulate and less flexible.
5. What robot has been designated for use? Can it do the job (weight, speed, etc.)?
6. Go and see the actual robot you will be working with. Request a presentation of the
unique capabilities of this robot.
7. Where will calibration be performed? Maintenance?
Activity: Any other issues to be considered in your case...
At the initial (rough) processing stage:
1. Assign a robot only those locations it can actually reach. Check extreme cases with
the ACTUAL robot.
2. Make sure location orientation makes sense.
3. Color-map the location assignment. This will make it easier to see what is
happening.
4. Use naming conventions from the very beginning (weld locations, via points,
pounce, home, maintenance, safe, tip dress, etc.).
5. Sequence the locations assigned to a robot in a consistent fashion, according to

plant specifications as well as the concept sequence (e.g. a robot that is assigned a
pick & place and weld combination).
6. When sequencing welds, consider orientation changes as well as geometric

properties. It may be easier and faster for a robot to work on a further out
(geometrically) weld than to twist it’s configuration.
7. Make realistic gun size assumptions.
8. Process for a smooth gun motion. This will in turn lead to a smooth robot motion
and an easy program.
9. Immediately (by default) assign a linear motion type to all segments where the gun
tip is close to the part.
10. Immediately (by default) assign zone type fine to all segments where the gun tip is
close to the part.

Activity: Any other issues you may think about ...
At the layout and integration stage:
1. Position the robot such that not only can it reach all the locations, but also comply
with the shop floor soft limit set up.
2. Position the robot such that not only can it reach all locations, but also have a +/- 10
degrees of freedom for future changes.
3. Position the robot such that not only 1& 2 are covered, but also all segments of
motion in between welds are considered for 1 & 2, and all possible configurations.
4. Optimize for bottlenecks.
5. Optimize for cycle time, but indicate possible changes.
6. Include all robot specific commands you find relevant to maintain the design intent,
such as : speed instructions, signal and control instructions, etc.
7. Duplicate locations if it will make program structure easier for the shop floor
engineers to manipulate.
8. 8 Approve and certify the program/database (by a shop floor representative).
Activity: Any thing else you can think of ...
At the detail process design stage:
1. Keep the gun motion smooth. Don’t force big gun orientation changes.
2. Avoid using large envelope stretches. This will cause difficulty in positioning the
robot.
3. Avoid complicated control schemes if possible (e.g. opening and closing clamps
to make welds). Request a change as early as possible for such conditions. If you
don’t, the shop floor engineers will need to do it later.
4. Mirror situations, where the left robot and right robot are performing a mirror
image of the same path, are preferable.
5. Mark optional calibration data (use naming and color conventions).
6. Add via locations the way the robot would naturally move - not how you think it
should.
7. Immediately, (by default) assign jointed motion type to all segments where the gun
is moving between via locations.
8. Immediately, (by default) assign zone type coarse to all segments where the gun is
moving between via locations.

9. Add your comments of design intent for the shop floor engineer.
Activity: Any other issues you may think of ...

At the documentation stage:
1. Create OLP outputs. Set up as follows:
• Create a Snapshot, displaying only relevant data. Blank data used for
presentation needs. Blank all irrelevant details. Include Notes and Labels in the
image to document the location names or other relevant information.
• Include screenshots of problematic areas.
• Create AVI of the simulation, so shop floor can understand the complete
design.
• Create robot program files (OLP downloads).
2. Prepare the media for the program (diskette, files, etc…).
3. Test problematic programs locally before they are shipped to the plant.
Activity: Any other issues that come to mind ...

Study Preparation
1. CAD geometry is latest revision of workpiece.
2. Study components are modeled to a sufficient level of detail to verify collision

avoidance.
3. Robot model selected according to job requirements.
4. Robot is positioned to reach all target locations.
5. Study layout of components is matched to real-world conditions.
Activity: Verify and adjust your study as required per previous instruction.

Error Sources
This topic describes several major sources of error in OLP.
• Five Major Sources
Five Major Sources
Robot inaccuracies:
• Geometric model (link lengths, joint limits, joint direction)
• Elasticity (gravity effects)
• Zero positions
• Conversion coefficients
• Motor and gear performance
• Every robot on the factory floor will be slightly different from each other and from
the Process Simulate "ideal" model.
Tool inaccuracies:
• Manufacturing tolerances
• Geometric model
• Mounting frame
Workpiece:
• CAD model variances
• Manufacturing tolerances
• Deformations during the process
Layout:
• Installation errors
• Tolerances
External devices:
(positioner, gantry, rotary tables, 7th axis, etc...)

Summary
Subjects learned in this topic:
• An overview of OLP.
• An overview of the Process Simulate data model.
• The basics of robot models.
• The basics of RRS, RCS, and ESRC.
• How to setup the RCS and RRS.
• The steps for process generation and process to program.
• The problems that can occur if OLP is not considered.
• How to prepare the study for OLP.
• Some sources of error in OLP.

Lesson
2 Robot Programming Background

Information
Purpose
To provide information on the Default Controller, ESRC’s (Emulated Specific Robot
Controller) and Robot Programs.
Objectives
• The basic motion attributes.
• Robot configuration, 7th axis, and the robot viewer.
• Where and how to store signals and conditional statements.
• Robot program basics and robot signals.
• Robot program creation and usage.
• How to group paths using the segmentizer (instead of a program).

Robot Programming Background Information
Basic Motion Attributes (Default Controller)

This topic describes how modify basic motion attributes using the default controller.
• Motion Attributes Basics
• Robot Controller
• Motion Types
• Motion Termination (Accuracy/Zones)
• Other Default Controller Examples
• Viewing and Editing Location Attributes
• Activity: Setting up the Macro Folder
• Activity: Setting up Some Basic Robotic Operations
• Activity: Viewing Motion Zone, and Tool Frame Attribute Simulation Differences
Motion Attributes Basics
We will start by using the default controller to talk about the basic theory of motion
attributes. Later in the next chapter, we will revisit this topic using robot specific motion
attributes. Much of the information in this lesson is a review from previous Process
Simulate training.
Robot Controller
The robot controller can be set or viewed from the Controller tab of the Robot
Properties window (Robotics → Robot Properties ) in Process Simulate. It is
used to assign a Process Simulate controller and machine data to a robot; which sets the
teach pendant (containing robot specific motion parameters) and motion planner for a
robot.
For this portion of the course, we will use the Default controller. Later, we will
switch to an ESRC one.
Motion Types
On the Default controller, motion type refers to joint motion, linear motion, or circular
motion. Proper selection of motion type is very important in the design of the process.
• Motion Type – Describes how a robot will move to this location. For example
here are two most common motion types found in the default controller:

o Joint (PTP) – Typically causes the robot to move the quickest between
locations (usually resulting in a curved path).
o Linear (LIN) – Causes the robot to move straight to this location.
When to use a motion type:

• Joint (PTP) motion should be used where high speed and low accuracy of the
TCP trajectory is allowed.
• Linear (LIN) motion should be used where high accuracy of the TCP track is
required; robot speed may be somewhat curtailed.
• Circular (CIRC) motion is used when the robot TCP is required to move along a
circular arc; most often in an arc-welding or sealing process.
Motion type constraints:

The process designer must take this into account during layout of a robot path, or the
robot may want to "unwind" the wrist in a critical portion of the process.
• Linear (LIN) and Circular (CIRC) motion place constraints on how the robot is
allowed to reach the target locations.
• Configuration refers to the specific wrist pose the robot is required to attain in
reaching a location.
Configuration only applies to locations that have been taught.

Motion Termination (Accuracy/Zones)
A "zone" (a.k.a. termination zone or accuracy) in Process Simulate determines how

closely the TCPF approaches the target location. Zone types include "fine" (accurate
positioning), by distance (window), by relative distance, by speed, or by time. Zones
have different effects on TCP trajectory based on the motion type.
An absolute or relative distance constituting the radius of a sphere around

the working point, or a condition on speed or deceleration as it approaches
the destination point. When the robot reaches the zone around a location, it
immediately begins execution of the next instruction of the program.
• Zone (Called Accuracy or Term Type on various ESRC controllers) –

Describes how the robot will approach/arrive at a location. For example here are
four zones found in the default controller. Each can be mapped to a range of values
on the ESRC controllers (we will discuss this later). The two most common are
Fine and No Decel:
o Fine – causes the robot to slow and “arrive” at the location.
o Course and Medium in between Fine and No Decel.
o No Decel – cause the robot to not slow and “approach” the location
(However, arrival is not a requirement).

Curvature effect on a linear path because of a "nodecel" zone

Zone determines the precision by which the robot’s TCPF reaches intermediate
locations as it performs motion commands. Intermediate locations (via locations)
are those through which the robot passes without stopping. These are all of the
locations except the last location in a path, as well as all the locations where,
when reached by the robot, a delay or wait command is specified. The numeric
values of the different zones are defined in the robot motionparameters.e file
under the robot .cojt component directory.
Using UpgradeToVersion to convert an old .co component to a .cojt
component, will automatically convert the .e file within the component to a
motionparameters.e file.

Location Reference Frames
Scenarios for Location Reference Frames

• Method 1: Defined when the gun is mounted to the robot (for gun on robot) or
when External TCP is checked on the Operation Properties (for remote TCP). All
locations in the path use this same default TCPF position.
• Method 2: A different TCPF position can be set for each location in the path using
the Tool Frame, Remote TCP Frame, or Work Frame location attributes.
In this case there is no default TCPF position. There is only the current TCPF
position. A path can even contain a combination of locations with different location
attributes (i.e. one path with gun on robot locations and remote TCP locations).
However, it is recommended that each location have a specific TCPF position
defined. This is much closer to how the real robot operates.
When a gun is mounted to a robot, the default TCPF position is also set. Alternately if
this is not desired, a different TCPF position can be set on each location. Tool Frame
and Remote TCP Frame locations.
Location Attributes for Frame References:
• Tool Frame (for gun on robot) — this is the typical place for defining the TCPF
position on a location. Pick any frame in the Object Tree or Graphic Viewer. Make
sure the frame name is unique in the study.
• Remote TCP Frame (for an external TCP) — this field is used when the TCPF
should be on an object which is not mounted to the robot. Pick any frame in the
Object Tree or Graphic Viewer. Make sure the frame name is unique in the study.
• Work Frame — can be used if you know the gun device that has to be used with
a given TCP. Select the tool from the list of values. This list of values is populated
with the list of defined tools for this robot created using Robotics → Robot
Toolbox (More on this later).
Other Default Controller Examples
• Speed
o Speed for Joint (PTP) motion is measured as a percent of the maximum

speed.
o Speed for Linear (PTP) or Circular (CIRC) motion is measured in mm/sec.
• Wait Time is measured in seconds.

Viewing and Editing Location Attributes
These attributes can be viewed and edited in several ways in Process Simulate:
• Teach Pendant window
• Path Editor window
Both of these techniques were covered in the WKP115S Process Simulate on eMS
Basic Robotic Simulation course. We will use these techniques throughout this
course.

Inverse Kinematics Solution Selections (Configurations)

This topic describes how to view and select robotic configurations.
• Solution (Configuration) Selection Basics
• Solution and Turns
• Using the Robot Viewer
• External Axis
• Activity: Viewing and Setting Robot Configurations
• Activity: Robot Viewer
Solution (Configuration) Selection Basics
In several cases, a robot has more than one choice for Inverse Kinematics (robotic joint
angle selection to reach a specific location with its TCPF). This lesson will investigate
some of the factors affecting inverse kinematics solution selection.
Solution and Turns
Configuration - A specific combination of joint values obtained as a solution of

inverse kinematics.
Turns - A condition related to joints with greater than 360 degrees of travel.
Solutions (a.k.a. Robot Configuration) and turns can be accessed in several places in
Process Simulate. In cases where multiple inverse kinematics solutions are available to
reach a location, it allows the viewing and selection of specific solutions. Configuration
information is read from the controller, stored on a local location (our solution), and
downloaded (controller specific solution) to the program file.
The solution also affects cable rap.
Controller Selection of Solutions:

For each robot there are criteria to sort out which solution to choose (specific
configuration bits). For example, flip or no flip, overhead or not overhead, and in
general where the robot is within a 360 degree area divided into four sections, etc…
The controller translates this information into a string, depending on robot type, which
is placed in the downloaded program file. Each robot family has different key words.

Process Simulate needs to have access to the RCS for the selected robot. Otherwise, it
won’t be able to get the robot configuration string for the real robot (critical).
Communication Between Process Simulate and the RCS:
• Process Simulate gives the location information to the RCS
• The RCS gives back configuration results
• RCS can have a tolerance for configuration selection
• In some cases (i.e. Fanuc rj2ic) the RCS may have special syntax flags to say which
one to use
• We auto teach and store our configuration on a location which may be diffident
than the RCS.
The Kinematics → Jump to location command uses simple

kinematics (not RCS) to calculate the configuration.
• If not connected to the RCS then it writes the solution from the default controller.
Not having a connection will also cause it to not understand that the controller
specific OLP commands during download.
The guy on the floor doesn’t see different solutions because he teaches the
configuration solution. We are trying to solve it each time.
Solution information can be viewed or edited using:

• Robot Configuration window
• Teach Pendant window
• Path Editor
Teaching a Solution for a Location (a.k.a. Creating a Local Location):

1. Select a location.
2.
Select Robotics → Robot Configuration .
The current location configuration is bold.
3. Select a configuration from the list
4. Click Teach.
5. OR you can select a turn by clicking Turn (+/-)

OH = overhead

If you download with an RCS connection, Process Simulate writes the translated stored
version of the configuration. It should be the same as what is stored on the local location
except if there was a problem with the mapping (The connection allows the validation of
what we put in the mapping). If there is a problem, it would show in the log file.
Joint value defined locations don’t have a configuration
Using the Robot Viewer
This tool was discussed in the WKP115S Process Simulate on eMS Basic Robotic
Simulation and WKP215S Process Simulate on eMS Intermediate Robotics (CEE)
courses.
The Robot Viewer can be found by picking a robot and selecting Robotics → Robot
Viewer .
• Can be used to view joints moving along the path
• Can be used to look for steep or radical joint value changes (winding)
• Can export to excel or various picture formats

• Can gather statistics on min/max (values or %) including the applied software limits
A key OLP issue is the engineering judgment of the robot behavior over time and not
only at a specific point. The Robot Integrated Development Environment (RIDE),
available for multiple robots, contains several tools essential to robot programming and
debugging:
• Trend-like graphical presentation of robot joint values
• Easy-to-use and user initiated definition of signals for tracking
• The type of representation automatically adapts to the type of signal
• “Historical view” - the values of the information are visible over time
The Robot Viewer contains the following panels:

• Joint Monitor
• Joint Status
• Digital Signals
• Analog Signals
• TCPF Speed Monitor
• Joint Speed & Acceleration
Joint Monitor Panel:

The Joint Monitor records the robot’s joint values during simulation. It generates and
displays a graphical representation of their values at all points in time of the simulation.
The trace for each joint of the selected robot is displayed in a different color.
You can display the lower and upper limits for each joint as a dashed line, providing a
visual impression of the state of the joint (but does not generate alarms).

The Joint Monitor panel also displays statistics concerning joint values during
simulation. The statistics area shows the minimum and maximum values for each joint
of the selected robot during the current simulation. When the joint value enters one of
the working limits, its value is displayed in orange and when it reaches its minimum or
maximum value, it is displayed in red.
The Joint Monitor is only updated during a robot simulation.
Joint Status Panel:
The Joint Status panel shows the current value for each joint of the selected robot
(including external joints). Alternatively, you can display the current joint value as a
percentage of the joint range.
External Axis
For more information on external axis usage and kinematic definition, see the
WKP115S Process Simulate on eMS Basic Robotics Simulation course.
External axis – (i.e. 7th axis). A typical example is a robot on a rail, where the rail is
the external axis. This allows multiple solutions to a location, based on the position of
the robot on the external axis. This information is stored on the compound location.
External Axis process overview:
• The external device (i.e. rail) is created as a separate component with (at least) one
joint.
• The robot base must be attached to the carriage (i.e. slider) entity of the external
device.
• The robot is made the active mechanism by selecting it.
• Add the joints from the external device to the robot’s joint list.
• Mark compound locations (i.e. to store the position of the robot on the external
device’s joints onto the location that is being reached)

Review of Robot Programs and Robot Signals

This topic reviews robot programs and robot signal topics from the WKP215 Process
Simulate on eMS Intermediate Robotics (CEE) course.

• Robot Programs
• Robot Signals
• Status Signals
• Robot Path Reference Operation
• Robot Program
Robot Programs
RCS/RSS simulation does require the definition of a Process Simulate program.

It can be used with just one simple robotic operation (i.e. one path). A Process
Simulate program is used when switching, during simulation, between several
robotic operations using logic, or when downloading.
A robot has as task to be executed. Normally it is made up of motion tasks and logic
instructions organized in a robot program. Almost all robot programs have the same
basic skeleton:

To guarantee correct behavior all robot vendors enforce a predefined sequence of signal
exchange:
• To prevent the robot from starting to move in an uncontrolled way.
• To continue its motion until the end of its task.
The Siemens PLM Software default behavior doesn’t simulate all of the signals used
by a real robot. Those significant signals for the correct process behavior are included
in the default behavior. Specific behavior may be implemented in the relevant ESRC
(Emulated Specific Robot Controller), which has to be purchased separately and has its
own documentation.
In the WKP215S Process Simulate on eMS Intermediate Robotics (CEE) course,
we discussed how to create a simulation where logic is used to switch between
the different robot paths (i.e. trigger them) that are part of a robot program (i.e.
when to run path 1, path 2, etc…).
Robot Signals
In the WKP215S Process Simulate on eMS Intermediate Robotics (CEE) course,

we discussed how create and use robot signals and associate them to signals on

a PLC in order to control the simulation (i.e. trigger the execution of various
events).
A robot program is a series of instructions to the robot. For example:
It’s easy to see that some of the signal values will only be checked when a specific
location has been reached. Such signals are called robot signals (might be of type Input/
Output/Memory).
In the example it can be seen that the value of $OUT [17] is set only on the on
“POINT2” location (i.e. it is a robot signal).
Status Signals
Status signals play a different role. They are continuously evaluated by the robot
controller (either Input e.g. emergency stop or output e.g. pose signal). They are a
way of simulating behavior that can be downloaded. Using status signals, paths can be
simulated like robot programs using path numbers inside the program.
Default (PLC) output signals:
• startProgram (signal function = Starting Program)
• programNumber (signal function = Program Number)
• emergencyStop (signal function = Program Emergency Stop)
• programPause (signal function = Program Pause)
Default (PLC) input signals:

• programEnded (signal function = Ending Program)
• mirrorProgramNumber (signal function = Mirror Program Number)
• errorProgramNumber (signal function = Error Program Number)
• robotReady (signal function = Robot Ready)
• HOME (signal function = Pose Signal)

Robot Path Reference Operation
The Operations → New Operation → New Robot Path Reference

Operation command enables you to run robotic operations of a robotic program in a
line simulation.
• A robot path reference operation activates one or more specific operations within a
robotic program via the path number.
• You can run it in a line simulation.
• Because the robot path reference operation refers to the robotic operation only by
its path number, you can change the target of it by re-assigning a path number to a
different robotic operation.
Creating robot path reference operation:
• Keeps the part associated to a material flow alive
• Allows full flexibility in changing paths without changing anything in the Gantt
chart
• Will only be executed using robot program parameters (robot status signals)

Robot Program
The following schematic diagram shows the general robot behavior based on a path
view:


Creating Robot Programs (Default Controller)

This topic describes how to create robot programs using the default controller.
• Robot Program Basics
• Methods to Create and Edit a Program
• Creating a Robotic Program from a Compound Operation
• Activity: Creating a Robot Program and Using Default Signals (Review)
• Activity: Creating an Excel Spreadsheet of a Path (Review)
Robot Program Basics
In order to download paths you need to make a program.

• A program is an object
• It can be downloaded and simulated
• It can contain several paths and can be edited
Program Features in the Path Editor:

• The Path Editor supports opening robot programs and robotic paths
• Used to setting robot programs as an executable program – like in a real robot
• Used to add robot paths to a program by drag and drop to the program
• A program can be renamed by selecting it in the Path Editor, pressing [F2], and
entering a new name.
Methods to Create and Edit a Program
Methods to create a robotic program:

• Manually create it using a combination of the Program Inventory window and the
Path Editor. This technique will be described in this lesson.
• Select a compound operation containing the desired robotic operations and select
Robotics → Robot Program → Create Robotic Program for Compound
Operation .

Alternately, you can right click a compound operation in the Operation Tree
and select Create Robotic Program for Compound Operation .
•
Use the Segmentizer (more on this in the next lesson)
View or edit the contents of a robotic program:

In the Program Inventory window, select the program and click Open in Program
Editor to edit or show a program’s contents in the Path Editor.
Creating a Robotic Program from a Compound Operation
The Robotics → Robot Program → Create Robotic Program for Compound
Operation option searches for robotic paths in the selected compound operation. If
all the paths it locates are assigned to the same robot, the system creates a new robotic
program for the robot and names it after the name of the selected compound operation
with an _program suffix. The system then inserts all the paths from the compound
operation under the new robotic program. The order of paths in the new robotic program
is the order in which the paths run in the compound operation. The command is enabled
when you select one or more compound operations (or PrStationProcess objects).
• If you select multiple compound operations, the system repeats the process for each
one and creates a new robotic program for each one.
• The compound operation remains unchanged.
• Paths inserted in the new robotic program are retained by the robotic programs to
which they have previously been assigned.
• If there is no robotic path under the selected compound(s), the system does not
create a program. No error message is issued.
• The system ignores operations that are not robotic paths. No error message is
issued.
• If you selected paths assigned to different robots, the system does not create a
program and issues the following message: "The system was unable to create a
Robotic Program for one or more Compound Operations, which contain operations
performed by different robots: < list of compound_operation_names>".

Segmentizer
This topic describes how to use the Segmentizer to create robot programs.
• Segmentizer Basics
• Activity: Segmentizing a Robotic Operation
Segmentizer Basics
This tool has own executable which must be installed first. It can be downloaded
from the GTAC FTP site separately from Process Simulate: from ftp.ugs.com/
tecnomatix, browse to Planning Applications → Robot Controllers →
v10.1 → Tools → Segmentizer and download it (either 32 or 64 bit).
The segmentizer can be used to divide one path into several for downloading.
• Use it to go from one early up-front single path to multiple paths by breaking it up
by logic (a.k.a. keyword).
• Use it to just create the scheduler for only one path if no key word is added to break
up the path.
Need criteria to say how to split it (i.e. the wait signal).

Controlling logic is in the main program not in the path.
The paths that are created are GenericRoboticOperations.
Workflow:
• Select a compound operation (which contains at least one robotic operations) or a
robotic program to enable the Segmentizer button and click it.
• The Segmentizer uses the settings from the Segmentizer Setup to search
segmentizing commands and to name the segments.
• The Segmentizer will segment all robotic operations inside the compound
operation/robotic program and create an additional robotic operation, called
the Scheduler which will contain the calls to the segments and the segmenting
commands. This scheduler is created inside the selected compound operation (in
case we segment a compound operation), or inside the parent compound operation
of the first robotic operation (in case we segment a robotic program).
• In case we segment a compound operation, the Segmentizer will also create a

Robotic Program from the Scheduler and segments operations.

• Continuous operations:
• A seam operation cannot contain any segmenting command.
• Only the last seam location of a seam operation can contain segmentizing
commands.
Weld Operation Example:

Start with:
• Compound operation
o WeldOperation1
■ via1
■ via2 (segmenting string)
■ weld3
■ via4 (segmenting string)
■ weld5
■ via6
Result is:
o WeldOperation1Seg1
■ via1
■ via2
■ weld3
■ via4
■ weld5
■ via 6
o Scheduler
The resulting compound operation contains a schedule and creates a robotic program
automatically.
Continuous Operation Example:

Start with:
o ContinuousOperation1
■ via1
■ via2
■ SeamOperation1
◊ SeamLoc3
◊ SeamLoc4 (segmenting string)
■ via5
■ SeamOperation2
◊ SeamLoc6
◊ SeamLoc7
◊ SeamLoc8
Result is:
o ContinuousOperation1Seg1
■ via1
■ via2
■ SeamOperation1
◊ SeamLoc3
◊ SeamLoc4 (segmenting string)
o ContinuousOperation1Seg2
■ via5
■ SeamOperation2
◊ SeamLoc6
◊ SeamLoc7

◊ SeamLoc8
o scheduler
The resulting compound operation contains a schedule and creates a robotic program
automatically.
There is also an “unsegmentizer” tool (i.e. for uploaded data).
Unsegmentizer Workflow:
•
To enable the UnSegmentizer button a selected compound operation, which
have been previously segmentized, must be selected (i.e. contains Scheduler and
at least one robotic operation).
• It may contain other kind of operations as well
• The UnSegmentizer uses the settings from the Segmentizer Setup to search
segmentizing commands and to name the segments.
• The UnSegmentizer will unsegmentize all robotic operations inside the compound
operation in order to recreate the compound operation as it was before segmentation
was performed.
• It will move the segmentize instructions back to the location, join the segments and
remove the scheduler operation.

Summary
• The basic motion attributes.
• Robot configuration, 7th axis, and the robot viewer.
• Where and how to store signals and conditional statements.
• Robot program basics and robot signals.
• Robot program creation and usage.
• How to group paths using the segmentizer (instead of a program).

Lesson
3 ESRC Setup and Motion Parameters
Purpose
To describe how to setup and setup and add motion parameters to paths using emulated
robot specific controllers (ESRC).
Objectives
• Got an overview of OLP features.
• How to setup a basic robotic study that we can use to learn about ESRC.
• How to select a controller and view the teach pendant.
• How to do some basic setup of a robot and robot controller.
• How to test a teach pendant and fix some setup problem.
• How to reset the RCS and decouple it.
• How to setup and use the robot toolbox.
• How to setup specific controller frames using the Teach Pendant and other specific
setup.
• How to set specific controllers motion attributes using the teach pendant.
• How to create a program.

ESRC Setup and Motion Parameters
• How to simulate a process and create configurations.

Process Simulate OLP Introduction

This topic describes the basics of ESRC.
We will begin using the RCS to control our simulations. We will farther discuss how
using a specific controller differs from using the default controller.
It contains the following subtopic:
• How to Setup a RRS Simulation Overview
How to Setup a RRS Simulation Overview
1. Setup and configure all guns that can be mounted on the robot. Tell which is gun1
and gun2 (can have two for Fanuc) and if is it a pneumatic or servo gun.
2. Verify the setup of the rrs.xml file for all robots by vendor. This file contains
configuration information for all robot vendor RCS modules. It contains
information such as where the RCS installed and which version is installed. (i.e. for
ABB the Module Path would be: .\rrs_bin\rcs_abb\rcsabb\rcsabb_tune.exe).
This information needs to be maintained manually (i.e. as new versions of RCS are
installed, this file needs to be updated accordingly).
3. Configure the RCS for a specific robot instance: Right click the robot and select
Robot Properties. Select the Controller tab. Select the Controller, RCS
Version, and Controller version. Enter the Manipulator Type (the machine
data entered must be precise). Usually in the syntax of RCS software version and
robot description (robot model, arm configuration, 7th axis, servo, etc…). This is
stored in the study data.
4. If the robot is using specific machine data (ex : robot with external axes): In Setup
window, select Robot Settings → Load Machine data and import the desired
file from the robot.
5. Select Robot Settings → Create/Update System frames to create all

required frames (i.e. world, tool, wobj, etc…)
6. Setup the Tool and Base definitions. They are stored at the study level.
7. Start the RCS (if required) and connect to it
8. Setup the desired attributes on the teach pendant and run the simulation.

Basic Study Setup

This topic describes how to a basic study.
• Study Setup Basics
• Activity: Basic Study Setup
Study Study Basics
In this lesson we will load a study, mount the gun, and create a small path that we will
later download. All the steps covered in this lesson should be a review of what was
learned in the WKP115S Process Simulate on eMS Basic Robotics Simulation course.
Process Simulate Robot Controller Application Support:
Material
(Robot) Continuous
Arc Support Handling Spot Support
Controller App. Support
Support
Paint,
Abb-Rapid Yes Yes Yes
Dispensing
Paint,
Dispensing,
Abb-Rapid- Laser Weld,
Yes Yes Yes
Volvo Laser Braze,
Nut Run, Seal,
Stud
Comau-Pdl ---- Yes Yes ----
Stud, Nut,
Comau-Pdl-
---- Yes Yes Glue, Laser
Volvo
Weld
Duerr-Ecotalk ---- ---- ---- Paint
Fanuc-F100iA ---- Yes ---- ----
Fanuc-RJ Yes Yes Yes Sealing
Fanuc-Japan Yes Yes Yes Sealing
Fanuc-Vw Yes Yes Yes Sealing
Kawaski-As ---- ---- Yes ----
Kuka-Krc ---- Yes Yes ----
Kuka-Krc-
---- Yes Yes Nut, Glue
Volvo

Kuka-Vkrc ---- Yes Yes ----

NC-Code ---- ---- ---- Machining
Reis-Robstar Yes Yes Yes ----
Trallfa-Robtalk ---- ---- ---- Paint
Yaskawa-
Yes ---- Yes ----
Inform

Robot Controller Selection

This topic describes how to select the robot controller for a specific robot.
• Robot Controller Selection Basics
• How to Figure Out the Manipulator Type?
• Activity: Controller Selection
Robot Controller Selection Basics
Selecting the Controller affects this information for the selected robot instance:
• The motion planner used during simulation (i.e. RCS-based or MOP-based)
•
Teach Pendant
•
Robot Setup
•
Download to Robot
•
Upload Programs
• Simulation
• Path Editor window
On the Controller tab of the Robot Properties window, there are four parameters that
are typically related to selecting a controller for a specific robot instance:
• Controller
o This list is populated based on which Process Simulate controllers (teach
pendants) have been installed (development specified). (Each is a separate
install, as we have seen in chapter 1)
o As we have seen in chapter 1: For RCS-based controllers, an entry for each

controller in this list should be in the rrs.xml file (user specified)
• RCS version
o Comes from the rrs.xml file (user specified)
o Set on the Robot Properties window

o Only used to select which RCS to use during simulation
• Manipulator type
o For RCS-based controllers, it is user specified and must match a valid value on
the RCS
• Controller version
o Hard-coded in the controller (development specified)
o
Set either on the Robot Properties window or the Robot Setup →
Controller version window.
o Handles any slight difference in the software such as features available in the
teach pendant, download syntax, simulation, etc…
Other Controller Topics:
• Connect / Disconnect – used to decide whether to connect to the specified RCS.
•
Validate RCS – located on the Controller tab of the Robot Properties
window, it becomes available when connected to the RCS. It checks the
compatibility between the selected RCS Version and selected Controller Version.
As of v10.0, this feature is not currently supported for all controllers.

However, it does work for the Fanuc controller.
•
Robot Setup - This will be described in the coming lessons.
Opening the Controller tab of the Robot Properties window:
•
Select a robot and choose Robotics → Robot Properties or right click
the robot and select Configuration, Properties and Settings → Robot
Properties .

How to Figure Out the Manipulator Type?
Check the .rrs file located under the .\sysroot\..\robot-prototype.co\rrs folder.

The file is used by Robcad and may not available if the .CO was converted
to .COJT
Abb:
• For a Robcad cell connected to Process Simulate, just look at the .rrs file either
under the <cell>/<robot>_rrs folder or robot prototype folder and use same value
as defined for ManipulatorType
• For a new study: See the s4c.cfg, s4cplus.cfg, or irc5.cfg files under the ABB RCS
install folder.
Comau:
• Typically it will be the name of the .rcs file located in the .\sysroot\..\robot-
prototype.co\rrs folder.

Fanuc:
• For a temp robot: see rcsfr13/robcad.bin/VERSION/<RCS Version>/
standard.cfg inside RCS module folder (client)
o <RCS Version>,<Temp Robot>
o Example : V7.40,R2000IF-165KG
• For a named robot, use following manipulator type format :

o <RCS Version>@<Named Robot>
o Example : V7.40@r2000if_165_rcs640
Kuka:
• Check MADA directory for the right name under the Kuka RCS install folder.

Robot Controller Setup

This topic describes how to set up various robot controllers.

• Robot Controller Setup Basics
• Accessing Robot Setup Using Method 1
• ABB Robot Setup window – First Buttons
• Comau Robot Setup window – First Buttons
• Duerr Robot Setup window – First Buttons
• Fanuc Robot Setup window – First Buttons
• Kawasaki Robot Setup window – First Buttons
• Kuka Robot Setup window – First Buttons
• NC Code Robot Setup window – First Buttons
• Reis Robot Setup window – First Buttons
• (ABB) Trallfa Robot Setup window – First Buttons
• Yaskawa Robot Setup window – First Buttons
• ABB Activity: Setting up the Controller
• Comau Activity: Setting up the Controller
• Duerr Activity: Setting up the Controller
• Fanuc Activity: Setting up the Controller
• Kawasaki Activity: Setting up the Controller
• Kuka Activity: Setting up the Controller
• Reis Activity: Setting up the Controller
• Yaskawa Activity: Setting up the Controller
Robot Controller Setup Basics

In this lesson we will discuss basic controller setup using the Robot Setup window. This
button can be found in two places:
•
Method 1: Click Robot Setup on the Robot Properties window opened for a
specific robot.
•
Method 2: Click Robot Setup on the relevant Teach Pendant window (i.e.
ABB-Rapid, ABB-Rapid-Volvo, Comau-Pdl, Comu-Pdl-Volvo, Default, Duerr-
Ecotalk, Fanuc-F100ia, Fanuc-Rj, Fanuc-Rj-Japan, Fanuc-Vw, Kawasaki-As,
Kuka-Krc, Kuka-Krc-Volvo, Kuka-Vkrc, Reis-Robstar, Trallfa-Robtalk, Yaskawa-
Inform, etc…) opened for a specific robotic operation.
Setup must be done to define / upload:

• Machine data (i.e. must always be done for Kuka and Comau)
• System data (Tool, Base, Load, …)
• Creation / Update of system frames
• Simulation & Download settings
• Program template definition
Accessing Robot Setup Using Method 1
Robot Setup is located on the Robot Properties window. To open this window:
• Right click a robot in the Graphic Viewer and selecting Configuration,
Properties and Settings → Robot Properties .
• In the Robot Properties window, select the Controller tab

The controller information must be filled in.
•
Click the Robot Setup button.
Robot Setup is located in every Teach Pendant window. To open this window:
• Right click a robotic path in the Operation Tree (the robot must be assigned to
operation) and select Teach Pendant .

A robot must be assigned to the operation and a robot controller, besides the
Default, assigned to the assigned robot.
•
From the Teach Pendant window, click Robot Setup .
ABB Robot Setup window – First Buttons
• Load Machine Data – If the robot is using specific machine data (ex : robot with
external axes): In Setup window, select Load Machine data. In Load Machine
Data window, select the desired moc.CFG file. (There are some samples on GTAC
for a 7th axis). Close the window by clicking [OK].
• Create / Update System Frames – Creates all ABB system frames (if not
already existing) and places them in the study with respect to the machine data:
o <robot>.w - RCS world frame created in the Frames folder of the Object
Tree.

o <robot>_<mechUnit>_base and <robot>_<mechUnit> - system frames for

external manipulators. Only available for robot with external manipulators
(turn table,...) configurations.
o In case of a conflict in the robot orientation on the rail, the user will be
prompted whether he would like the application to align the robot position in
the cell with the Machine data definition, or update the Machine data.
o Pushing this button resets the tool frame and wobj frame in the study to its
initial positions corresponding to data definition
Comau Robot Setup window – First Buttons
• Load Machine Data – Used to load the .rcs file related to this robot. Typically it
will be located in the .\sysroot\..\robot-prototype.co\rrs folder. (The file is used
by Robcad and might not available if the .co was converted to .cojt).
• Create/Update System Frames - Creates all Comau system frames (if not
Tree.
o In case of a conflict in the robot orientation on the rail, the user will be
prompted whether he would like the application to align the robot position in
the cell with the Machine data definition, or update the Machine data.

o Pushing this button resets tool frame and wobj frame in the cell on its initial
positions corresponding to data definition
Duerr Robot Setup window – First Buttons
• Load Machine Data – If the robot is using specific machine data (ex : robot with
external axes): In Setup window, select Load Machine data. Select the relevant
const.RC and device.CFG files. Close the window by clicking [OK].
• Create/Update System Frames – Creates all Duerr system frames (if not
Tree.
Fanuc Robot Setup window – First Buttons

• Create/Update system frames – Creates all Fanuc system frames (if not
Tree.
o Potential conflict between robot orientation on rail (between cell and machine
data) is NOT checked
Kawasaki Robot Setup window – First Buttons

• Create/Update System Frames – Creates all Kawasaki system frames (if not
Tree.
Kuka Robot Setup window – First Buttons

• Load Machine Data – In Robot Setup window, select Load Machine data.
In the Load Machine Data window, Browse and select the R1 and STEU folders
(mandatory).
Selecting the $config.dat file is optional.
• Create/Update System Frames – Creates all Kuka system frames (if not
o <robot>.bf0 - RCS world frame created in the Frames folder of the Object
Tree.
o <robot>.sim_bf0 - rail base frame (a.k.a. ERSYSROOT frame). Only

available for robot on rail configurations.

o <robot>.base_easys, <robot>.object_easys ... <robot>.base_efsys,

<robot>.object_efsys - system frames for external manipulators. Only
available for robot with external manipulators (turn table,...) configurations.
o In case of major conflict between Process Simulate layout and the MADA
layout (number/type of external axes), a warning message is displayed.
o In case of conflict between robot orientation on rail, the user will be prompt
whether he would like the application to align the robot position in the cell
with the MADA definition.
NC Code Robot Setup window – First Buttons
• Origin Definition – creates origin frames (robot base frames) with names from
G54 to G59. Euler angle is used for the orientation ( , , ).
o <robot>.g54 - RCS world frame created in the Frames folder of the Object
Tree.
• Create/Update System Frames – (Not currently used) Creates all NC Code

system frames (if not already existing) and places them in the study with respect to
the machine data:
o <robot>.of_g53 - RCS world frame created in the Frames folder of the
Object Tree.
Reis Robot Setup window – First Buttons

• Create/Update System Frames – Creates all Reis Robstar system frames (if
not already existing) and places them in the study with respect to the machine data:
o <robot>.uf0 - RCS world frame created in the Frames folder of the Object
Tree. This frame is the reference for the user frames and is superimposed on
the robot BASEFRAME.
(ABB) Trallfa Robot Setup window – First Buttons

• Load Machine Data – In Robot Setup window, select Load Machine data.
In the Load Machine Data window, click Add and select a .i machine data file
(mandatory).
• Create/Update System Frames – Creates all Trallfa system frames (if not
o <robot>.bf - RCS world frame created in the Frames folder of the Object
Tree.
o <robot>.uf - UserFrame (Disp Base from a robot.ix MADA file)
o <robot>.of - TrackFrame for conveyor
o <robot>.ut<n> - TcpFrame
o <robot>.uf<n> - DispFrame
Yaskawa Robot Setup window – First Buttons
• Load Machine Data – If the robot is using specific machine data (i.e. a robot with
external axes): In Setup window, select Load Machine data. Select the relevant
all.PRM, tool.CND, uframe.CMD, sgun.DAT, spress.cnd, and clearnce.DAT files.
Close the window by clicking [OK].

• Create/Update System Frames – Creates all Yaskawa system frames (if not
Tree.

Testing the Teach Pendant and Fixing Setup Problems

This topic describes how to test the teach Pendant and fix setup problems.
We will open the teach pedant for the robot associated to a robotic path and see if the
related RCS can be accessed.
• Teach Pendant Testing Basics
• RCS Shell
• RCS Logs
• Activity: Testing the Teach Pendant
• Activity: Using the RCS Shell
• Activity: Using the RCS Logs
Teach Pendant Testing Basics
There are several ways to find problems in the setup:

• Look over your installation again (i.e. the information from chapter 1).
• Turn on log files and look at the resulting logs
• Look at the messages shown in the error popup window during simulation.
• Turn on the RCS console window and view the messages
• Finally, work with GTAC to help resolve the problem
RCS Shell
First turn it on:

•
Select Robotics → Visible Shell On/Off .
Then View the resulting in the RCS shell window:

• This window opens whenever the Robot Setup or Teach Pendant windows are
opened.
RCS Logs

First turn them on using the Robot Setup window:

Simulation Settings:
• RRS Debug - turn on/off RRS debug mode. If on, simulation will create a debug
file named rcs<RobotVendor>.<robotName> with the dialog between Process
Simulate and the RCS. View the resulting log file in the C:\temp folder.
• Simulation Debug Trace - activate/deactivate debug trace mode
• Reset Conveyor Position - reset conveyor to zero position (might be require

after using Jump To Location on tracking locations). Available on some controllers
such as Abb-Rapid.

RCS Management
This topic describes how to manage the RCS.
• RCS Management Basics
• Reset RCS Module
• RCS Decoupling
• Limitations on Decouple Mode
• Activity: RCS Management
RCS Management Basics
In order to simulate, use some functions of the teach pendant, or upload/download the
RCS module must be loaded. Normally, it is loaded in several ways:
• When the Teach Pendant window is opened.
• When the Robot Properties windows is opened.
• When a robotic simulation is run which uses a non-default controller robot.
Reset RCS Module
Drops and reestablishes the connection to the RCS (i.e. stops and restarts the RCS
module). This is useful if the RCS connection hangs. The only other way to do this
would be to stop and start your Process Simulate session.
This does not release the RCS license.
Usage:
1. Select the robot using a loaded RCS robot controller.
2.
Select Robotics → Reset RCS Module .
RCS Decoupling
The RCS Decoupling command is used to break the connection to the RCS and
allow commands that normally require the RCS to be run without it. The main caveat is
that the motion will be performed using the default controller instead of the RCS.

It is possible to run robot-customized, non-RCS actions without launching the RCS

module and without an RCS license, since this is Siemens PLM development, not
dependant on the robot manufacturer.
For each robot controller, check or clear the following:

• Non Simulation Actions - For example, Teach Pendant and Downloading
Programs.
• Simulation Actions - For example, OLP commands, RCS simulation, and ESRC
functionality.
Not all RCS modules support decoupling. Grayed out fields do not support
decoupling. For exact motion, the RCS module is still mandatory for all
controllers.
The default value for decoupling can also be setup in the
rrs.xml file on the controller line. For example: <Controller
Name="Fanuc-Rj"RCSDecoupleSimulationAction="False"
RCSDecoupleNonSimulationAction="False">
To break the connection to the RCS:
Select Robotics → Controller Settings .

Your Controller Settings window may contain different robot controllers than
shown in the picture above.
Check the desired checkboxes.
Check [OK].
To reestablish the connection to the RCS:
Select Robotics → Controller Settings , again.

Uncheck the checkbox.
Check [OK].

Limitations on Decouple Mode
Robot Setup:
• External axes mapping definition is not available
• When performing Create/Update System Frames, transformation from robot

WORLD to robot BASE cannot be retrieved from the RCS module, therefore this
information is assumed to be Identity Matrix. If this assumption is wrong, it might
be necessary to manually relocate the robot WORLD frame in the study.
• In Moving frames configuration, when performing Create/Update System

Frames, the information on the moving frames cannot be retrieved from the RCS
module. These system frames should therefore be created, located and attached
manually.
Download:
• Logical Axes Map information from the RCS module cannot be used. As a
consequence, external axes are downloaded in the same order and with same
indices as they are defined in Process Simulate. It might be necessary to post-
process the robot targets in the download file in case this assumption is wrong.
• Conversion from Process Simulate to RCS config string is done manually
Upload:
• Logical Axes Map information from the RCS module cannot be used. As a
consequence following workaround is implemented for the upload of external
axes :
• The application looks for defined external axes in the ABB externals string (the
ones which value is not 9E9)
• The Ith axis that is defined is supposed to be mapped to the i th external axis in
Process Simulate
• Conversion from RCS config string to Process Simulate config to is done manually

Methods to Define TCPF Positions for the RCS

This topic describes how to define TCPF positions for the RCS.
• TCPF Definition Basics
• Robot Toolbox
• Activity: Using the Robot Toolbox
TCPF Definition Basics
Currently, there are two ways to define the TCPF positions for the RCS:
•
Method 1 and Method 2: Using the Teach Pendant (or Robot
Properties ) – Defines it as engineering data stored in the study. This is the way
that Robcad used to do it. We will describe this method in more detail in the next
lesson.
•
Method 3: Using the Robot Toolbox – Defines it as an object stored with the
robot, which is not dependant on the robot’s name. This is the newer, preferred
technique.
Currently, there is only one way to define the BASEFRAME (REF FRAME) positions
for the RCS:
•
Using the Robot Setup from Teach Pendant (or Robot Properties)
Robot Toolbox
The Robotics → Robot Toolbox enables you to assign tools (TCPF positions)
to a robot and view sets of tools assigned to robots. The assigned tools are available to
the robot throughout the simulation. The Robot Toolbox includes information about the
tools assigned to the robot and buttons to perform functions on the tools.
Often, it is useful to include tools that are not yet fully-designed in a simulation.
The Robot Toolbox enables you to assign incomplete tools, requiring only the
tool's TCP frame information. Incomplete tools included in the Robot Toolbox are
called virtual tools.
The Robot Tools list displays the tools assigned to the selected robot. For each tool, a
Mounted checkbox indicates whether the tool is mounted on the robot. Use the Mount
or Unmount buttons to mount or unmount a tool on the robot.

In order to use the tools you have defined in the Robot Toolbox, you must define a
specific tool to be used in an operation. This is done by adding a Work Tool to the
default Teach Pendant.
To open the Robot Toolbox:
1. Select a robot in the Graphic Viewer or Object Tree.
2.
Select Robotics → Robot Toolbox .
3. The Robot Toolbox window appears, displaying the tools associated with the
selected robot.

Robot Controller Specific Frames and Setup

This topic describes how to setup robot controller specific frames.
• Robot Setup Basics
• ABB Robot Setup window - Continued
• Comau Robot Setup window - Continued
• Duerr Robot Setup window - Continued
• Fanuc Robot Setup window - Continued
• Kawasaki Robot Setup window - Continued
• Kuka Robot Setup window - Continued
• NC Code Robot Setup window - Continued
• Reis Robot Setup window - Continued
• (ABB) Trallfa Robot Setup window - Continued
• Yaskawa Robot Setup window - Continued
• Controller Specific Frames
• ABB Activity: Tool and Base Data Setup
• Comau Activity: Tool and Base Data Setup
• Duerr Activity: Tool and Base Data Setup
• Fanuc Activity: Tool and Base Data Setup
• Kawasaki Activity: Tool and Base Data Setup
• Kuka Activity: Tool and Base Data Setup
• Reis Activity: Tool and Base Data Setup
• Yaskawa Activity: Tool and Base Data Setup
Robot Setup Basics

In this lesson we will discuss controller specific frame creation and other specific setup
tasks. In this lesson we will reference Method 1 and Method 2 as briefly described in the
previous lesson: clicking Robot Setup . This button can be found in two places:
• Method 1: The Robot Properties window.
• Method 2: The relevant Teach Pendant window (i.e. ABB-Rapid, ABB-Rapid-

Volvo, Comau-Pdl, Comu-Pdl-Volvo, Default, Duerr, Fanuc-F100ia, Fanuc-Rj,
Fanuc-Rj-Japan, Fanuc-Vw, Kuka-krc, Kuka-Krc-Volvo, Kuka-Vkrc, Reis-
Robstar, Trallfa-Robtalk, or YaskawaTeach Pendant windows).
Robot Controller Created Frames:

• They are created under the Frames folder in the Object Tree.
• Process Simulate creates a robot system frame <robot>.w (before it created a study
frame <robot>_w). The robot system frames are shown in the object tree but they
are stored on the robot instance (meaning they come with the robot if you put a
same robot instance in another study).
Setup must be done to define / upload:
• Machine data (i.e. must always be done for Kuka)
• System data (Tool, Base, Load, …)
• Creation / Update of system frames
• Simulation & Download settings
• Program template definition
Robot Setup is located on the Robot Properties window. To open this window:
•
Right click a robot in the Graphic Viewer and selecting Robot Properties .
• In the Robot Properties window, select the Controller tab.
The controller information must be filled in. For example:

•
Click the Robot Setup button.
Robot Setup is located in every Teach Pendant window. To open this window:
• Right click a robotic path in the Operations Tree (the robot must be assigned to
operation) and select Teach Pendant .
•
From the Teach Pendant window, click Robot Setup .
For example:

ABB Robot Setup window - Continued
• Download Settings – Set the type of program to download.

• Explicit Data Upload – Used to:
o Import data definition files (for instance the base.sys that is located under the
robot component folder in Robcad) into Process Simulate
o Maintain the list of explicitly uploaded files
o The selected files are copied under the robot private folder (same folder as the
one used to copy the machine data file needed for the RCS)
o The list of explicitly uploaded files are stored as a robot parameter

• Load Local Data Definitions – Used to import the Robcad .robdata.sys file
definitions into Process Simulate. The definitions are stored as a robot parameter.
• Down Local Data Definitions – Copies all local data definitions into the
LocalDataDefinition.sys file in the <SYSROOT>/RobotsMachineDataFiles/
<RobotExtId>/SystemFiles folder.
• Base Data Definition
o All data definition interface :
■ Edit existing (only local ) data by selection from list of data
■ Create new data: select data from list for display the needed values and
replace data name by new data name and validate by click [Enter]
■ Add new data by clicking Store

■ Delete (only local) data by clicking Delete
o Tool data, Wobj data:
■ Robcad tools are supported (frame <robot>_<tooldata>_tf)
■ Robcad object frames are supported (frame <robot>_<wobjdata>_of)
■ RobotToolBox WorkTool are also supported.
■ Naming convention for ABB is that WorkTool name should match the
ABB tooldata name. For a given tooldata, WorkTools have priority upon
Process Simulate frame tools.
• Process Data Definition – Spot data, Gun data:
o Spot data definition is different for pneumatic or servo gun ;
o User can select between these 2 possibilities of parameters
o Gun data is the same for pneumatic and servo gun
• Custom Data Definition – described later in this course
• External Axis Map Setup
o For each Mechanical unit can be defined a device from devices list

o For each Mechanical unit logical axes can be associated the joint of the
selected device
Program Templates – described later in this course
Comau Robot Setup window - Continued
• Program Templates – described later in this course
• Tool & Frame Setup (Normal tab)

o Edit existing bases and tools by selection from list
o Create new base or tool :

■ Select base or tool from list for display the needed values.
■ Upload base or tool by clicking Upload.
o Add new data automatically.
o Delete data by clicking Delete.
• Download Settings – Can be used to filter what is output to the resulting file
output for the robot.
• Explicit Data Upload – Used to explicitly upload a tool file (i.e. tt_tool1.lsv) or
frame file (i.e. tuvframe.lsv).

• Robot World Setup – Setup the position and orientation of the robot world
frame.
Duerr Robot Setup window - Continued
• Explicitly Uploaded Data Files – allows uploading system (.TID) files.

This file is needed in order to initialize the RCS.
• Profile Data – allows defining velocity, acceleration, overlap, ramp, jerk, and
interpolation list of values data.
• Process Data – allows defining triggerPar (brush) data.
• Frame Data – allows defining tool frame (i.e. tf_robtcp), base frame, and object
frame data.
• Local Machine Data – allows specifying const (.RC), device (.CFG), and motion
(.CFG) files.

The const (.RC) and device (.CFG) files are needed in order to initialize the
RCS.
Robcad tool frames are supported (frame <robot>_ut<num>) and base frames
have the same naming convention as in Robcad (frame <robot>_uf<num>).
Fanuc Robot Setup window – Continued
• Download Settings – several options for downloading such as simulation

commands, download point frame, RTCP location coordinates, Utool/Uframe
declaration insertion, and aborting download on error. These values will be stored
in the user DownloadSettings.xml file located in the .\eMPower\Olp\Robotics
\Fanuc-Rj\Settings folder.
• Robot And Guns Setup

o Definition of the robot ID
o Definition of 2 guns with, for each gun:

■ Name (entered or picked)

■ Type: Pneumatic or Servo Gun (automatically deduced)
■ MultiPressure: YES / NO for Servo Gun and NONE / LOW-HIGH /

LOW-MEDIUM-HIGH for Pneumatic guns
■ Backup: YES / NO
■ Backup Mapping
o The gun definitions are used in the Teach Pendant to show or not show some
process parameters.
o As for these definitions, the following rules apply:
■ You cannot define one pneumatic gun and one servo gun.
■ If you define one servo gun, it must be the gun 1.
■ You cannot use the same device to define the 2 guns.
• External Axis Mapping – this option is available when an external axis is

present on the robot.
• Tools & Bases Definition
o Tools
■ Robcad tools are supported (frame <robot>_ut<num>)
■ Robot ToolBox WorkTools are also supported. The naming convention

for FanucRj is Tool<Num>. For a given tool number, WorkTools have
priority over Robcad frame tools.
o Bases
■ Same naming convention as in Robcad (frame <robot>_uf<num>)
• Payload Definitions – used to either define or upload a payload definition for the
robot.
• Armload Definitions – used to define an arm load for the robot.
• Export Definitions – used to export tool data to a .LS file.
• Explicit Data Upload – used to upload a .VA file (i.e. upload payload definitions
from a SYMOTN.VA or SYSTEM.VA file)

Kawasaki Robot Setup window – Continued
• Download Settings – Used to setup the default clamp command in pneumatic or

servo gun contexts.
• Gun Definition - allows the user to map a gun number to a specific gun device in
the study
• Data Definition – allows removing, loading, and exporting the AUX data file.
Also allows editing speed, accuracy, timer, clamp application, clamp condition, and
gun parameters.
• Tool Setup
o Tools as frames are supported (frame name: <robot>.tl<num>)
o Robot Toolbox Worktools are also supported with the following naming
convention: Tool<num>
o Users can upload one or all Tool definitions from a robot.aux file
• Work Setup
o Only the Work frame is supported (frame <robot>.w<num>)
o User can upload one or all Work definitions from loaded robot.aux file
• FTool Setup
o FTools as a frame are supported (frame <robot>.ftl<num>)

o Robot Toolbox Worktools are also supported with following naming

convention: FTool<num>
o Users can upoad one or all FTool definitions from a robot.aux file
Kuka Robot Setup window - Continued

• Load Robot Backup - Reads a robot backup .ZIP file and copies the files to the
robot private folder.

• Tool & Base Definition or Tool & Base

o Edit existing bases and tools by selection from list
o Create new base or tool :
■ Select base or tool from list for display the needed values.
■ Upload base or tool from MADA by clicking Upload.
o Add new data automatically.
o Delete data by clicking Delete.

• External Manipulator Setup – This option is available when an external axis

is defined for the robot. The display and edit external moving bases attached to an
external manipulator.
• Settings – contains download, upload, and display settings.
• Download Settings – (VKRC only) set the type of program to download.
• Load Definition – Setup the payload
• Gun Definitions – allows defining a gun.
NC Code Robot Setup window – Continued
• Download Settings – Various download settings such as circular interpolation

method, robot number, line numbering, program file extension, coordinate
mapping, and multi-file settings.

Reis Robot Setup window – Continued
• Download Settings – Allows setting various settings for download including

language and the display of comments.
• Tool Definition
o Only mounted tool configuration is supported.
o Tool Coordinates are relative to the robot ToolFrame
o Naming convention for the tools in the study: _t_<Toolname> for a frame or
<ToolName> for a workTool
o Tools can be created, modified and removed with Tool definition setup
o Tool Coordinates are relative to the robot ToolFrame
• User Frame Definition
o Reis controller supports User Frames defined by name.
o Naming convention for User frames in the study: _uf_<name>
o There are two types of UserFrames: STATIC and DYNAMIC
o The dynamic option is available only for a robot with external axis
o If the dynamic type is selected, the created frame should be attached to the
selected external device’s last link

o A User Frame can be created, modified and removed with the User Frame
definition setup
o User Frame Coordinates are relative to the robot RrsWorldFrame
(ABB) Trallfa Robot Setup window – Continued
• Download Settings - Select the ROBOT_ID to select the system files and set
the binary file name of the downloaded file.
• Tcp Tool Definition

o Robcad tools are supported (frame <robot>.ut<num>, or Robot Toolbox
Worktool Tool<num>)
o Update all or one tool from the robot.i<robotId> MADA file.
• Disp Base Definition

o Robcad disps are supported (frame <robot>.uf<num>)
o Update all or one disp from the robot.i<robotId> MADA file.
Yaskawa Robot Setup window - Continued

• UTool/UFrame Definition
o Robcad Utools are supported (frame <robot>.tl<num>, or Robot Toolbox
Worktool Tool<num>)
o UFrames have the same naming convention as in Robcad (frame

<robot>.user<num>)
• Robot and External Axes Setup – This option is available for robots with an
external axis defined.
• System Information – Allows entering or editing pulse (encoder) factors,

offsets, and order.
• Gun Definition – Allows associating a gun device with a gun file number
Controller Specific Frames
Almost every controller needs a different frame created to represent the TCPF. The
TCPF information must exist in the study and in the teach pendant. There are several
ways to define the TCPF:
• The frame can either be directly created in the study and then the coordinates read
from the study to the teach pendant.

• The TCPF can defined in the teach pendant which creates the frame in the study
automatically.
• The information can be read from files output from the actual robot controller (with
many Process Simulate teach pendants).
o Robot_wf – robot world frame created automatically when the RCS is

initialized. It is the robot origin frame and is typically at the intersection
of J1 and J2. It’s not needed for downloading.
o BASEFRAME – robot origin frame that is part of the robot’s kinematic

definition. It should match the robot_wf.
o REFFRAME – part of the robot’s kinematic definition and is related

to the BASEFRAME. The Robot Setup window is used to define a
special ESRC frame at the desired position) of the reference frame. The
positions of all downloaded locations are according to the reference
frame. The car part origin, or somewhere on the tooling, are good places
for this. Two stations serviced by one robot may each have their own
reference frame or a moving line may have multiple reference frames.
o TCPF – frame that is part of the robot’s kinematic definition. The

Robot Setup window is used to define a special ESRC frame at the exact
position of the TCP.
Here are some sample controllers:
ESRC Reference
TCPF (name of special
name (i.e. default
Robot (controller) ESRC frame attached to
is BASEFAME /
the TCPF)
REFFRAME)
set W_OBJECT
robotName_tf# (i.e.
Abb-Rapid variable to a frame (i.e.
irb6600_tool1_tf)
irb6600_wobj0_uf)
robotName_uf# (i.e. robotName_ut# (i.e.
Fanuc-Rj
s430i_uf0) r2000iaf_ut1)
Kawasaki-As
robotName_t# (i.e.
Kuka-Krc (BASEFRAME)
kr30_1_t1)
Yaskawa-Inform
Use this table as reference to perform the activities. Note that each robot settings
and teach pendant have several differences. Reference the online help for setup,
configuration and usage details of specific controllers.

It is the users’ responsibility to set these frames on the real robot (we don’t do
this automatically since two programs could use the same def file. The tool
definition could be added to program download template as well as home pose.

Setting Controller Specific Motion Attributes

This topic describes how to set controller specific motion attributes.
• Controller Specific Motion Basics
• Controller Specific Attributes in Path Editor
• ABB Motion Attributes
• Comau Motion Attributes
• Duerr Motion Attributes
• Fanuc Motion Attributes
• Kawasaki Motion Attributes
• Kuka Motion Attributes
• Reis Motion Attributes
• NC Motion Attributes
• (ABB) Trallfa Motion Attributes
• Yaskawa Motion Attributes
• ABB Activity: Specific Teach Pendant Motion Attributes
• Comau Activity: Specific Teach Pendant Motion Attributes
• Duerr Activity: Specific Teach Pendant Motion Attributes
• Fanuc Activity: Specific Teach Pendant Motion Attributes
• Kawasaki Activity: Specific Teach Pendant Motion Attributes
• Kuka Activity: Specific Teach Pendant Motion Attributes
• Reis Activity: Specific Teach Pendant Motion Attributes
• Yaskawa Activity: Specific Teach Pendant Motion Attributes
Controller Specific Motion Basics
In this lesson, we will look at controller specific motion attributes. There are two ways
to do this:

• Using the Path Editor
• Using the Teach Pendant
The following information provides selected details for each specific teach
pendant. It should not be considered a replacement to the online help or other
more complete reference sources for these teach pendants or the robotic
languages themselves
ABB Motion Attributes
• Motion Type – Four choices including:

o MoveJ – use joint motion
o MoveL– use linear motion
o MoveC – use circular motion
o MoveABSJ Home
• Speed – Two ways to record speed:

o V (Tcp Speed) v5, v10, v20, etc…, v7000, vmax
These definitions can come from your SYS file.
o T (Motion Time) measured in seconds
• Zone – Several choices:

o Fine Point – like fine on the default controller
o z0 – like fine on the default controller
o z1 to z29 – like medium on the default controller
o z30 to z119 – like coarse on the default controller
o z120 and up – like no decel on the default controller
These definitions can come from your SYS file.
Comau Motion Attributes
• Motion Type – Several choices:

o Joint – use joint motion
o Joint POS : Home
o Linear – use linear motion
o Circular – use circular motion
• Term Type – Three choices:

o Fine
o Course
o No Settle
• Speed Control – Several choices:
o Const (in %) - Percent of max speed.
o Lin (in m/s)
o Rot (in rad/s)
• Fly Type (Zone) – Several choices:
o Off – like fine on the default controller
o For Cart (in mm) of Norm (in %):
o 1 to 4 – like fine on the default controller
o 6 to 29 – like medium on the default controller
o 31 to 74 – like coarse on the default controller
o 76 to 99 – like nodecel on the default controller
Duerr Motion Attributes
• Motion Type
o PTP – use joint motion
o LIN – use linear motion
o CIRC – use circular motion
• Overlap (Zone)

o FINE
o LOW
o MID
o COURSE
o NODEC50
o NODEC100
o NODEC150
o NODEC200
• Vel (Velocity or Speed)

o V200
o V300
o etc ...
o V1400
o V1500
Fanuc Motion Attributes
• Motion Type – Three choices:

o Circular – use circular motion
• Termination Type (Zone) – Several choices:

o CNT0 to CNT10 (or Fine) – like fine on default controller
o CNT11 to CNT40 - like medium on default controller
o CNT41 to CNT80 - like course on default controller
o CNT81 to CNT100 (or CD) - like no decel on default controller
• Speed – Two ways to record speed:

o Percent of max speed.
o Time measured in seconds.
Kawasaki Motion Attributes
• Move (Motion Type) – Two choices:

• Accuracy (Zone) – Several choices:

o 1 mm to 4 mm – like fine on default controller
o 6 to 29 – like medium on default controller
o 31 to 74 – like course on default controller
o 76 and up – like no decel on default controller
• Speed – One way to record speed:

o Index value – 0 through 9 (where 9 is 100%).
Kuka Motion Attributes
• Motion Type – Four choices:

o Ptp – use joint motion
o #Ptp axis : Home
o Lin – use linear motion
o Circ – use circular motion
• Accuracy - One way to record it:

o measured as a percentage
• Zone – Several choices:

o C_PTP
■ 0 to 10 – like fine on default controller
■ 10 to 40 – like medium on default controller

■ 40 to 80 – like course on default controller
■ 80 to 100 – like no decel on default controller
o C_DIS
■ 0 to 2 – like fine on default controller
■ # 2 to 7 – like medium on default controller
■ 7 to 15 – like course on default controller
■ Greater than 15 – like no decel on default controller
o C_VEL – like no decel on default controller
o C_ORI – like no decel on default controller
• Velocity (Speed) – One way to record speed:

o Joint Speed measured as a percentage
o Linear Speed measured in mm/sec.
NC Motion Attributes
• Motion type
o G00 - PTP
o G01 - LIN
o G02/G03 - CIRC
■ G02 = CW circle
■ G03 = CCW circle
• Zone (must be defined in the robot’s MotionParameters.e file)
Reis Motion Attributes
• Motion Type
o #PTP – use joint motion

o #CP_LIN – use linear motion
o #CP_CIRC – use circular motion
• FlyBy (Zone)
o #OFF – like fine on default controller (for all motion types)
o #ON - like nodecel on default controller for #PTP motion type. For other
motion types it will use the closest distance cartesian zone defined in the
MotionParameters.e file. See the online help for details.
• Speed
o PTP Speed – speed for joint motion in %.
o CP Speed – speed for linear or circular motion in mm/sec.
(ABB) Trallfa Motion Attributes
• Motion Type
o RC
o CC
o CIRC
• Zone (Interpolation Type)

o Int0: Fine
o Int1: NoDecel
Yaskawa Motion Attributes
• Motion Type
o MOVJ – move joint
o MOVL – move linear
o MOVC – move circular
o MOVC (start) – move circular start
o MOVS – move s

• Destination Type
o ABS, P1, P2, P3, etc…
• Fly Level (Zone)

o Cont – like no decel on default controller
o PL=0 – like fine on default controller
o PL=1 - like medium on default controller
o PL=2 to PL=8 – like coarse on default controller
• Speed type
o VJ – for joint motion type (a % of maximum speed)
o V – for linear or circular motion type (Cartesian position speed)
o VR – for linear or circular motion type (Cartesian orientation speed)

Program Creation
This topic describes how to create a program.
• Program Creation Basics
• Activity: Program Creation
Program Creation Basics
We covered program creation in great detail earlier in class. Now we will use it in the
context of this continuing activity.

Process Simulation and Robot Configurations

This topic describes process simulation and robot configurations.
• Robot Configuration Basics
• Teaching and Clearing Robot Configurations
• Simulate Robot Paths
• Activity: Process Simulate and Robot Configurations
Robot Configuration Basics
Process or motion attributes are simulated in the same way as they would appear on the
factory floor.
The creation of robot configurations is critical to the download process, since they
store the robot configuration from the RCS and are tied to the robot BASEFRAME
(or UFrame specified on the location). Whereas, global locations are in reference to the
working frame of the study and do not store the robot configuration.
To prepare for download, the process must be "taught". This step must be performed in
order to apply the configuration data to the locations.
There are multiple techniques to generate robot configurations (attributes on top of the
locations). All process attributes are preserved on the location, and all configuration
parameters (turns, flips) are stored as well.
The configuration can also be viewed on the Teach Pendant or Path Editor.
After teaching a solution, the robot uses it during subsequent simulations and
downloads.
Teaching and Clearing Robot Configurations
To add robot configurations to locations, use one of these methods:

1.
Method 1: Select a location, click Robotics → Robot Configuration , select
a configuration, and click Teach.
2. Method 2: Add the path to the Sequence Editor or Path Editor, click Auto
Teach , and then run the simulation as usual

When running Auto Teach from the Sequence Editor, you must first
select the robot, click Robotics → Set Robots for Auto Teach , and
click [OK].
To remove robot configurations from locations, use one of these methods:
1.
Method 1: Select a location, click Robotics → Robot Configuration , select
a configuration, and click Clear.
2. Method 2: Select one or many locations, click Robotics → Clear Teach

Location , and click [OK]. The Robotics → Clear Teach Location
option clears turns and solutions, causing simulations as well as downloads to use
the locations' initial, pre-taught values
Simulate Robot Paths
• Analyze path and cycle time
• Teach
o Configuration and Turns
o Needed for Download


Summary
• Got an overview of OLP features.
• How to setup a basic robotic study that we can use to learn about ESRC.
• How to select a controller and view the teach pendant.
• How to do some basic setup of a robot and robot controller.
• How to test a teach pendant and fix some setup problem.
• How to reset the RCS and decouple it.
• How to setup and use the robot toolbox.
• How to setup specific controller frames using the Teach Pendant and other specific
setup.
• How to set specific controllers motion attributes using the teach pendant.
• How to create a program.
• How to simulate a process and create configurations.

Lesson
4 Uploading and Downloading
Purpose
To describe how to upload and download.
Objectives
• How to select and create program templates for downloading.
• How to download a process.
• How to look at the files produced by the Download command.
• How to upload a process from Robcad.
• How to upload a process directly in Process Simulate.

Uploading and Downloading
Program Templates for Downloading

This topic provides an overview of program templates for downloading.

• Program Template Basics
• Editing Program Templates
• Program Template Selection
• Template Locations
• Example Robot Specific Template Keywords
• Example Template Use
• Activity: Creating a New Program Template
• Activity: Selecting a Program Template
Program Template Basics
In this lesson we will discuss program templates. The template defines the header
format including which keywords will be included. It can describe some elements you
want in program (i.e. who generates/when/from which study). Several key words are
provided (listed in the documentation).
Editing Program Templates
Usage:
1.
Click the Robot Setup from the Controller tab of the Robot Properties
window.
2. From the Robot Setup window, click Program Templates Edition.

3. Edit the template by double clicking on the file.
• Use this menu to edit the available program templates or to add/remove

program templates.
There are two levels of templates:

• global templates in the <ControllerInstallationFolder>\Templates
\Programs folder
• private templates in the <SYSROOT>\RobotsMachineDataFiles

\<RobotExtId>\Templates\Programs folder.
Program Template Selection
Usage:
1.
Click the Robot Setup from the Controller tab of the Robot Properties
window.
2. From the Robot Setup window, click Program Template Selection.

3. Select the active program template.
4. Click Close.
If no specific templates are selected the default ones shipped with the
distribution will be used during download
Template Locations
The download file header templates are located in specific folders depending on the
controller used:
• ABB – Located in .\Tecnomatix\ eMPower\Robotics\OLP\Abb-Rapid
\Templates\programs folder and is named either default.tmod or default.tprg.
• ABB (Volvo) – Located in .\Tecnomatix\ eMPower\Robotics\OLP\Abb-Rapid-

Volvo\Templates\programs folder and is named either *.tmod, default.tmod or
default.tpl.
• Comau – Located in .\Tecnomatix\ eMPower\Robotics\OLP\Comau-Pdl

\Templates\programs folder and is named either default.tpdl or default.tlsv
(c3g).
• Comau (Volvo) – Located in .\Tecnomatix\ eMPower\Robotics\OLP\Comau-

Pdl-Volvo \Templates\programs folder and is named either *.proc, *.tolp, *.tpl,
*.tpdl, *.tlsv, default.tpdl, or default.tlsv.
• Fanuc – Located in .\Tecnomatix\ eMPower\Robotics\OLP\Fanuc-Rj

\Templates\programs folder and is named default.tls.
• Kuka – Located in .\Tecnomatix\ eMPower\Robotics\OLP\Kuka-Krc

\Templates\programs folder and is named either default.tdat or default.tsrc.
• Kuka (Volvo) – Located in .\Tecnomatix\ eMPower\Robotics\OLP\Kuka-Krc-

Volvo \Templates\programs folder and is named either *.tpl, default.tdat or
default.tsrc.
• Kuka (vkrc) – Located in .\Tecnomatix\ eMPower\Robotics\OLP\Kuka-vKrc

\Templates\programs folder and is named either *.tdat or *.tsrc.

Template Keywords:
The sample templates shipped with the controllers are a reference for the available
keywords. Some keywords are common to all controllers (i.e. <RobotName>), some
are specific to the controller (these ones should be in the sample templates). Here are the
common keywords:
• Body
• Date
• FileBaseName
• ProgName
• Study
• TecnomatixSoftware
• Time
• RobotName
• UserName
Example Robot Specific Template Keywords
Aditional ABB Template Keywords:

• Robtarget
• GundataTitle
• Gundata
• SpotdataTime
• Spotdata
• SpeeddataTitle
• Speeddata
• ZonedataTitle
• Zonedata
• TooldataTitle
• Tooldata

• LoaddataTitle
• Loaddata
• WobjdataTitle
• Wobjdata
• BeaddataTitle
• Breaddata
• WelddataTitle
• Welddata
• WeavedataTitle
• Weavedata
• CustomdataTitle
• Customdata
• MainBlockBody
• MoveBlockBody
• Robtarget
• JointTarget
Aditional Comau Template Keywords:
• LocVar
• DataVar
• SchedulerCalls
• JointPosition
• CartPosition
• AllAxesNumber
• ExtAxesNumber
• JointMask
• ToolNumbers

• ToolNumbersRmt
• FrameNumbers
• FrameNumbersRmt
• ImplPayLoadMass
• ImplPayLoadCenter
• ImplinertiaX
• ImplinertiaY
• ImplinertiaZ
• ImplPayLoadMassRmt
• ImplPayLoadCenterRmt
• ImplinertiaXRmt
• ImplinertiaYRmt
• ImplinertiaZRmt
Aditional Fanuc Template Keywords:
• LineCount
• DefaultGroup
• ControlCode
• GunNumber
• MainBlockBody
• PosBlockBody
Aditional Kuka Template Keywords:
• TecnomatixControllerVersion
• E6Pos
• E6Axis
• BaseData
• MovingBaseData

• ToolData
• LoadData
Example Template Use
In this Fanuc example a header and footer in the template with line number is setup like
this:
/MN
1:UFRAME_NUM = 1;
2:UTOOL_NUM = 1;
3:PAYLOAD[1];
4:! Start Program;
<MainBlockBody>
<FOOTER_LINE_N_1>:! End Program;
<FOOTER_LINE_N_2>:ABORT;
/POS
In order to have the following downloaded text:
/MN
1:UFRAME_NUM = 1;
2:UTOOL_NUM = 1;
3:PAYLOAD[1];
4:! Start Program;
5:J P[1:"lo1"] 100% FINE;
6:L P[2:"lo2"] 500mm/sec FINE SPOT[S=1];
7:L P[3:"lo3"] 500mm/sec FINE;
8:L P[4:"lo4"] 500mm/sec FINE;
10:J P[6:"lo6"] 100% FINE;
12:J P[8:"lo8"] 100% FINE;
13:J P[9:"lo9"] 100% FINE BACKUP=O;

14:L P[10:"lo10"] 100mm/sec FINE;

15:L P[11:"lo11"] 100mm/sec FINE;
16:L P[12:"lo12"] 500mm/sec FINE;
17:! End Program;
18:ABORT;
/POS

Process Download
This topic describes how to download a program.
• Download Basics
• Activity: Process Download
Download Basics
Any process created in a Process Simulate application can be transformed into a robot
program through the OLP/Download facility. The robot programs will include:
• Process attributes (per path or location)
• Motion Attributes
• Control and logic statements
Thus, the work put into process design is automatically reflected in fully-verified
robot programs. The generated programs may be further edited if desired, and then
downloaded to the actual robots on the factory floor.
To Download:
1. With the robot specific Teach Pendant set, make sure that you have specified the
TCPF, motion type, and zone on the locations.
2. With the robot specific Teach Pendant set, teach locations in order to store the
robot configurations (solutions) on the locations (i.e. using Auto Teach on the
Sequence Editor).
3.
Select Robotics → Robotic Program → Robotic Program Inventory .

4. Select a program from the list.

The program can contain one or several paths.
5. Start download: From the Robot Program Inventory click Download
Program
6. Check and store results.
The previously selected template is automatically applied.

Examining Output Files

This topic examines the files output by the download of the program.
• Output File Basics
• ABB Activity: Examining a PRG File
• Comau Activity: Examining a PDL File
• Duerr Activity: Examining a TIS File
• Fanuc Activity: Examining a PE File
• Kawasaki Activity: Examining a PG File
• Kuka Activity: Examining a SRC File
• Reis Activity: Examining a SRC File
• Yaskawa Activity: Examining a JBI File
Output File Basics
In this lesson we will examine the files output from the download. The same procedure
could be used to examine files from the robot to be uploaded into Process Simulate.

Process Upload from Robcad

This topic describes how to upload from Robcad.
• Robcad Upload Basics
Robcad Upload Basics
IMPORTANT NOTE
This is not the primary way to upload directly from the robot to Process Simulate.
This technique is for a special situation where you want to transfer paths, which
were uploaded to Robcad, to Process Simulate. For the more typical case of
uploading directly from the robot to Process Simulate, see the next lesson.
There are two ways to upload:
• Method 1: Upload a program from Robcad to Process Simulate (that was uploaded
from a real robot controller)
• Method 2: Upload directly to Process Simulate (typical method)

This method will be discussed in the next lesson.
Uploading from Robcad

Programs can be uploaded into Robcad, output from Robcad, and then input into
Process Simulate using Robotics → Robot Program → Upload Robcad
Robotic Program .
A special default.apg file must be copied to Robcad installation (i.e. $Robcad
\dat\olp\default\).
Here is how (NOT an activity):
1. Do these steps in Robcad:
• Setup Tool & Base data for the specific robot controller.
• Define all parameters for the locations of the path to be exchanged.
• Teach axis configuration (local locations).
• Simulate / test the path with the RCS.
• Change to the Default controller.
• Download path as localname.default file.

2. Do these steps in Process Simulate:

• Select Robotics → Robot Program → Upload Robcad Robotic

Program .
• Select robot.
• For Robcad Attributes, define path to the Robcad attributes file. The
default attributes file is located under $Robcad\dat
• Choose how the Robot turns should be by default.
• For Standard Settings, there are pre settings for ABB, Fanuc and Kuka.

• Click Add and select Robcad programs (.default) to the Selected Program
Files list.

• Click Upload.

• A message will showing the upload process was successful.
• The path will be added as Weld Operation to the Operation Viewer.
• All system frames and parameters will be uploaded too.


Direct Process Upload

This topic describes how to upload a program into this system.
• Upload Basics
• Robot Operation Merge
• Robot Operation Merge Basics
Upload Basics
The Upload Programs command receives information from a robot (in specific
controller syntax) and saves it as robotic operation and/or program.
Here is how (NOT an activity):
1. Select a robot from the Graphic Viewer.
A robot controller other than Default must be selected.
2.
Select Robotics → Robotic Program → Robotic Program Inventory .
Do NOT select a program in the list.
3.
From the Program Inventory window, click Upload Programs .
This picture shows the file types for Fanuc-Rj. The file types shown depend
on the controller selected.
4. In the Open window, browse to the desired folder and select the desired file.
The available Files of type are specific to the selected robot controller.
5. Click Open.
For each file, Process Simulate runs the upload mechanism to read the file
and create a robotic operation and/or robotic program.

Overview of Robot Operation Merge
The Robotics → Robotic Operation Merge command enables you to merge

two robotic operations into a single operation. After merging the source operation with
the target operation, the updated target operation contains the new set of information.
This is useful if, for example, you have used Download Programs to load your
program on a shop-floor robot. You can then edit and fine-tune the program on the robot
itself and use Upload Programs to store the updated program back to eMServer.
In order to make use of your shop-floor improvements, you can merge the changes in
the shop-floor program (the source) into your original program (the target).
The Robotic Operation Merge window enables you to manually select which source
locations to merge with which target locations. Alternatively, you can perform an
automatic merge of the entire source operation with the target operation. The automatic
merge may be performed either by merging source and target locations sharing the same
name or merging locations in close proximity. You can also edit the order of locations in
the target operation. Additionally, you can specify which source data to merge with the
target.
Robot Operation Merge Basics
1. Select Robotics → Robotic Operation Merge .
If you select an operation before picking Robotics → Robotic

Operation Merge , this operation appears in Target Operation.
2. Click in Target operation and select the target operation in the Operation
Tree (or other relevant viewer). This is the operation you wish to update with
information from another operation.
3. Click in Source operation and select the source operation in the Operation Tree.
This is the operation from which you wish to retrieve information.
4. Click [OK]. The Robotic Operation Merge window appears displaying the Target
Operation as a tree together with its locations in blue text in the left pane and the
Source Operation tree together with its locations in red text in the right pane.

5.
Click Select Operations to replace the selected operations with a different
source and target operation.
6. Configure either manual or automatic matching, as follows: If you wish to

match locations manually, select a source location and a target location and click
Match .
7. If you wish to match source operations with target operations automatically, click
Automatic Match . The system matches up pairs of locations either by name
or by distance (depending on the criteria set in Robotic Operation Merge
Settings ) and displays them as matched pairs.
If you set manual matches before invoking automatic match, the

system retains your manual matches and matches all the other locations
automatically.
8.
If necessary, click Erase Match to unmatch selected matched pairs. For each
matched pair, the source location is removed from Match, the distance from
Distance, Merge is cleared, and is removed from the source location (unless this
is still matched with another target location).

9. Click Execute. The system performs the merge and the Robotic Operation Merge
window reloads the target operation.

Summary
• How to select and create program templates for downloading.
• How to download a process.
• How to look at the files produced by the Download command.
• How to upload a process from Robcad.
• How to upload a process directly in Process Simulate.

Lesson
5 ESRC OLP Commands
Purpose
To describe how to use the OLP commands section of the emulated robot specific
controllers (ESRC).
Objectives
• How use the standard OLP commands of emulated robot specific controllers
(ESRC).
• Various commands supported in simulation on all controllers which must be

entered as free text.
• The list of the supported OLP commands for several of the robot controllers.
• Compared the various methods available in Process Simulate.

ESRC OLP Commands
Standard OLP Commands

This topic describes standard OLP commands.
• OLP Command Basics
• Basic OLP Commands
• Activity: Looking at and Using a Basic OLP Command
OLP Command Basics
Much of what is downloaded is stored on the locations in the path as OLP commands.
This is where logic statements are placed for download to the program file. This chapter
will cover all sorts of OLP commands which can be used in Process Simulate. While
some commands can only be simulated, others can be simulated and downloaded.
Here are some examples of OLP commands:
• Boolean output signals
o DO, RDO, RO, SDO, SO, UO, PULSE
• Analog output signals

o A0, G0
• Macros
• Other commands
o payload
o pause, abort
o send Boolean signals
o send analog signals
o wait delay or signal expressions
o register assignment
o call, if call
o if jump label (LBL)
Basic OLP Commands

ESRC OLP Commands
On the Teach Pendant after clicking Add, the Standard Commands menu is
available. These commands are available during simulation, but either do not download
or download as comments. They work the same as their default controller equivalent.
Several examples of OLP commands were discussed in the WKP115S Process

Simulate on eMS Basic Robotic Simulation and WKP215S Process Simulate on
eMS Intermediate Robotics (CEE) courses.
Contents of the Standard Commands Menu:

• Graphics
o
# Blank - Blank an object.
o
# Display - Display an object
o
# TCP Tracker - Enables you to start, pause, resume, or stop the TCP
Tracker for the robot assigned to the current operation.
• Paint
o
# OpenPaintGun - Marks the location where painting should start.
(Review from the WKP115S course)
o
# ClosePaintGun - Marks the location where painting should stop.
o
# ChangeBrush - Marks the location where the painting style should be
changed (i.e. Brush 1, 2, 3, etc…) (Review from the WKP115S course)
• PartHandling
o
# Attach - Attach a selected component to another component or link.
o
# Detach - Attach a selected component to another component or link.
o # Grip – moves the gripper to the specified pose and attaches the part to it.
o # Release – moves the gripper to the specified pose and detaches the part
from it. (Review from the WKP215S course)
• ProgramFlow
o # Macro - executes the specified macro located in the <robot

controller>.macros file located in the Macros folder defined in Tools

ESRC OLP Commands
→ Options. The file can contain any OLP command for the selected robot
controller. (Review from the WKP215S course)
o # CallPath – in the middle of executing a path (i.e. pa1), another path (i.e.
pa2) can be executed. Once pa2 is finished, it will pick up where it left off in
pa1.
o # CallProg – similar to CallPath, except for programs instead of paths.
• Synchronization
o # SendSignal – The robot sends a robot signal to the PLC (PLC input)
(Review from the WKP115S and WKP215S courses)
o # WaitSignal – The robot waits for a robot signal from the PLC (PLC output)
(Review from the WKP115S and WKP215S courses)
o # WaitTime – The robot waits the specified number of seconds before the
next command is performed.
• ToolHanding
o # Connect – connect the specified joint from the specified device as an
external axis of the robot
o # Disconnect – disconnect all external axis joints of the specified device

from the robot.
o # DriveDevice - Moves the selected device to the selected target pose.

o # GunToState - Instructions for moving the gun to its specified pose, as

specified in the Gun State parameter. (Review from the WKP115S course)
o
# Mount - Mount a new tool on the robot
o
# UnMount - Unmount the existing tool on the robot
o # WaitDevice – Waits until the selected device reaches the selected target
pose. (Review from the WKP115S course)

ESRC OLP Commands
Free Text Standard Commands

This topic describes how to enter standard commands as free text in the OLP commands
area of the controller teach pendant.
• Free Text Basics
• Activity: Entering Basic OLP Commands as Free Text
Free Text Basics
This lesson describes various commands supported in simulation on all controllers

which must be entered as free text.
Other Simulation Supported Default Controller Commands:
These commands can be entered as free text:
• ; <String>- Allows textual comments to be inserted into the OLP command list.
• #DriveDeviceToValues <DeviceName> – Drive the specified joint of the

specified device.
• # DriveDeviceToValuesSync <DeviceName> – Like # DriveDeviceToValues

except, the device motion can be synchronized with the robot’s movement to the
next location in the path.
• # CallToolPath <opName> <toolName> - Calls the specified operation while

verifying that the assigned tool on this operation is the specified tool.
• # Note <message> - Displays the message in the Process Simulate error window
after the simulation is stopped including the location where it was executed. Use
double quotes to evaluate variables and signals
• Setting the value of signals and variables with expressions

o # SetSignal <signal> <expression> (or # SetSignal <signal> =
<expression> )
o # SetVariable <var> <expression>
• If then else syntax

o # If <condition> Then
[ex # If (a + b) > c Then]
o # Elsif <condition> Then

ESRC OLP Commands
[Ex # Elsif A OR B Then]
o # Else
o # Endif
• Switch syntax
o # Switch <expression>
[Ex # Switch (a+b)]
o # Case <val1>, <val2>

[Ex # Case 2 or # Case 2,3]
o # Default
o # Endswitch
• For loop syntax

o # For <var> From <start> To <end> Step <step> Do
[ex # For I From 1 To 10 Step 2 Do]
o # For <var> From <start> To <end> Do
o # Endfor
• While loop syntax

o # While <expression> Do
[Ex # While a < 100 Do]
o # Endwhile

ESRC OLP Commands
Supported Controller Specific OLP Commands

This topic describes how to enter standard commands as free text in the OLP commands
area of the controller teach pendant.
We will describe what commands are supported for the various controllers.
• Controller Specific OLP Command Basics
• ABB-Rapid
• Comau-Pdl
• Duerr-EcoTalk
• Fanuc-RJ
• Kawasaki-As
• Kuka-Krc
• Reis-Robstar
• (ABB) Trallfa-Robtalk
• Yaskawa-Inform
• Activity: Adding Digital Input and Digital Output OLP Commands to Locations
Controller Specific OLP Command Basics
The support in this area of ESRC is continuing to improve. For the latest
list of supported robot specific commands, see the GTAC support website
(support.industrysoftware.automation.siemens.com/gtac.shtml). The latest ESRC
controllers and related documentation can be downloaded the updates area of the
website.
ABB-Rapid
Additional OLP Commands:

On the Teach Pendant after clicking Add, the following menu is available beyond the
basic OLP commands:
• Free Text
• GridLoad
• Line Tracking – WaitWobj, and DropWobj

ESRC OLP Commands
• Paint – SetBrush, SetColor, EnableEquip, DisableEquip, and

UseBrushTab
AbbRapid Specifics:
• Baseware,Spotware, and Dispenseware are supported
Free text commands only supported in simulation:

Any basic OLP command described earlier, including the following ones which must be
entered as free text:
• Relative Motion simulation commands
o # MoveRelBase [<RefLoc>] <X> <Y> <Z> [<RX> <RY'> <RZ">]
o Move the robot with an offset expressed in wobjdata object frame coordinates
system.
o The offset is relative to:

■ RefLoc if the optional <RefLoc> parameter is specified (RefLoc should
be the name of a location inside the current robotic operation)
■ otherwise, to the current location
■ otherwise (if defined at operation level), to the current robot TCPF
o The optional rotational part of the offset are rotation angles in degrees
expressed in wobj data object frame coordinate system (rotations are
performed one after the other in the rotating frame)
o The current location motion type, speed, zone are used to move to the offset
position
• # MoveJRelBase [<RefLoc>] <X> <Y> <Z> [<RX> <RY'> <RZ">]

o Same as # MoveRelBase, except that motion type to the offset position is
forced to Joint
• # MoveLRelBase [<RefLoc>] <X> <Y> <Z> [<RX> <RY'> <RZ">]

forced to Linear
• # MoveRelTool [<RefLoc>] <X> <Y> <Z> [<RX> <RY'> <RZ">]

o Move the robot with an offset expressed in location self coordinates system.

■ RefLoc if the optional <RefLoc> parameter is specified (RefLoc should
be the name of a location inside the current robotic operation)

ESRC OLP Commands
■ otherwise, to the current location
■ otherwise (if defined at operation level), to the current robot TCPF
expressed in reference location self coordinate system (rotations are performed
one after the other in the rotating frame)
position
o # MoveJRelTool [<RefLoc>] <X> <Y> <Z> [<RX> <RY'> <RZ">]

■ Same as # MoveRelTool, except that motion type to the offset position is
forced to Joint
o # MoveLRelTool [<RefLoc>] <X> <Y> <Z> [<RX> <RY'> <RZ">]
■ Same as # MoveRelTool, except that motion type to the offset position is

forced to Linear
Motion Parameters: By default, the current modal motion parameters (speed,

zone, tool, etc..) will be used. It is also possible to define explicit motion
parameters with following syntax: # MoveRelBase <X> <Y> <Z> [Speed Data
= v500] [Zone Data = z100]. These explicit motion parameters will be inherited
on any subsequent relative motions
Fee text commands only supported in simulation and download:
These commands must be entered as free text or using a custom XML (described
in the next chapter).
• SetDO (with optional delay) as SendSignal
• Set as SendSignal
• Reset as SendSignal
• SetAO / SetGO as SendSignal
• WaitDI (with optional timeout) as WaitSignal
• WaitUntil (with optional \MaxTime and \TimeFlag options) as WaitSignals
• WaitTime as Delay
• WaitWobj (with optional RelDist), both on tracking and non-tracking locations
• UseBrushTab as storing the current active Brush Table for further use in Change
Brush trigger simulation

ESRC OLP Commands
• ConfJ/ConfL
• Singarea
• GripLoad
• ActUnit / DeActUnit
• variable assignation (<var>:=<expression>;)
• variable assignation from function call (<var> := <FunctionCall>)
• IF <condition> <action>; (compact if)
• IF <condition>THEN ... ELSEIF <condition> THEN ... ELSE ... ENDIF
• If <FuntionCall> THEN ... ELSEIF <condition> THEN ... ELSE ... ENDIF
• WHILE <condition> DO ... ENDWHILE
• FOR <var> FROM <start> TO <end> [STEP <step>] DO ... ENDFOR
• TEST <var> ... CASE <val1>,<val2>: ... DEFAULT: ... ENDTEST
• TEST <FunctionCall> ... CASE <val1>,<val2>: ... DEFAULT: ... ENDTEST
• RETURN
• RETURN <expression>
• <Name>; simulated as, in priority order, :
• call to robot module procedure <Name>
• call to macro <Name>
• call to operation <Name>
• call to operation <Robot><Name>
• call to operation <Robot>_<Name>
• call to robotic program <Name>
• call to robotic program <Robot><Name>
• call to robotic program <Robot>_<Name>
Simulation keywords:
The following simulation keywords are supported and automatically substituted in

macros, robot modules and XML simulation layers :

ESRC OLP Commands
• ${ActiveGun}
• ${Robot}
RCS Decouple mode:
• If RCS for simulation actions is selected, a MOP simulation will replace the RRS
based simulation
• All Commands supported in RRS simulation (see above) will also be simulated in
MOP simulation, except :
o ConfJ/ConfL
o SingArea
o GripLoad
o ActUnit/DeActUnit
• Motion parameters are mapped as follows:
o SpeedData → Cartesian Speed:
■ ...use SpeedData.VTcp
■ ...apply modal OverrideSpeed factor if any (from VelSet motion

property)
■ ...apply modal MaxSpeed parameter if any (from VelSet motion

property)
o ZoneData→ Zone:
■ ZoneData.FinePoint = true : fine
■ ...Otherwise use ZoneData.PathZoneTcp:
■ ...PathZoneTcp < 1 : fine
■ ...1 <= PathZoneTcp < 30 : medium
■ ...30 <= PathZoneTcp < 120 : coarse
■ ...PathZoneTcp >= 120 : nodecel
Supported configurations:
• mounted gun
• mounted workpiece

ESRC OLP Commands
• robot on rail
• robot with one servo gun
• robot on rail with one servo gun
• robot with moving object frame (object attached to an external mechanical unit, like
a turn table)
• robot with conveyor
• robot on rail with conveyor
Comau-Pdl

basic OLP commands:
• Free Text

• DELAY <val>, as delay in ms
• $DOUT := <boolean expression> (as well $SDOUT and $FDOUT), as SendSignal
• $TIMER := <val>, as timer value memorization
• $<Var> := <val> or $ARM_DATA[<num>].<Var> := <val>, as system variable

assignation
o Special case for following recognized variables (handled as modal motion
parameters modification)
■ $ARM_OVR
■ $SPD_OPT
■ $GEN_OVR
■ $LIN_SPD
■ $ROT_SPD
■ $PROG_SPD_OVR
■ $ARM_SPD_OVR

ESRC OLP Commands
■ $PROG_ACC_OVR
■ $PROG_DEC_OVR
■ $ARM_ACC_OVR
■ $ARM_DEC_OVR
■ $TERM_TYPE
■ $FLY_TYPE
■ $FLY_PER
■ $FLY_DIST
■ $FLY_TRAJ
■ $ORNT_TYPE
• Other system variables assignations are send as is to the RCS via

RcsModifyRcsData
• <var> := <expression>, as SendSignal if <var> is the name of a robot output signal

otherwise as an assigned variable
• <var> := <FunctionCall>
• WAIT FOR <signal expression>, as wait for signals
• WAIT FOR <signal expression> OR ($TIMER[i] > <val>) (as well >= <val>), as
wait for signal with timeout (timeout equal to val - current timer memorized value)
• IF <condition>THEN ... ELSE ... ENDIF
• IF <FunctionCall> THEN ... ELSE ... ENDIF
• WHILE <condition> DO ... ENDWHILE
• REPEAT ... UNTIL <condition>
• FOR <var> :=<start> TO <end> [STEP <step>] DO ... ENDFOR
• SELECT (<var>) OF ... CASE (<val1>, <val2>) : ... ELSE : ... ENDSELECT
• SELECT (<FunctionCall>) OF ... CASE (<val1>, <val2>) : ... ELSE : ...

ENDSELECT
• GOTO label / label ::
• RETURN

ESRC OLP Commands
• RETURN <Expression>
• <Name>; simulated as, in priority order:

o call to macro <Name>
o call to operation <Name>
o call to operation <Robot><Name>
o call to operation <Robot>_<Name>
o call to robotic program <Name>
o call to robotic program <Robot><Name>
o call to robotic program <Robot>_<Name>
Following simulation keywords are supported and automatically substituted in macros,
robot modules and XML simulation layers :
• ${ActiveGun}
• ${Robot}
MOP Simulation (RCS Decouple mode):

based simulation
o System variables assignation

o Speed:
■ SpeedControl = SPD_NORM
◊ speed : joint speed in % and joint acceleration in %
■ SpeedControl = SPD_LIN
◊ speed : cartesian speed
o Zone
■ $FLY_TYPE = $FLY_OFF, : fine
■ 0 < fly param ($FLY_DIST or $FLY_PER) < 5 : fine

ESRC OLP Commands
■ 5 < fly param ($FLY_DIST or $FLY_PER) < 30 : medium
■ 30 < fly param ($FLY_DIST or $FLY_PER) < 75 : coarse
■ 75 < fly param ($FLY_DIST or $FLY_PER) < 100 : nodecel
• mounted gun
• robot on rail
Duerr-EcoTalk

basic OLP commands:
• Free Text
Commands supported in simulation:

See GTAC for more info
based simulation
MOP simulation, except:
• Pneumatic mounted gun
• Mounted workpiece with pneumatic remote gun
• Robot on rail
• Robot with one servo gun
• Robot on rail with one servo gun

ESRC OLP Commands
Fanuc-RJ

basic OLP commands:
• Free Text
• Motion – UFRAME_NUM, UTOOL_NUM, PAYLOAD, JOINT_MAX_SPEED,

JOINT_MAX_SPEED, JOINT_MAX_SPEED_REG, and
JOINT_MAX_SPEED_REG
• Branch – LABEL, JUMP_LABEL
• I/O – PULSE, Wait Signals, Digital Output, Robot Digital Output, User Digital
Output, System Digital Output, Group Signal Output, and Analog Signal Output
• Conditions – Skip Condition
• Control – UALM, PAUSE, ABORT, WAIT, and TIMER
• Arc – Weave Start, Weave End, Track TAST, and Track End
• MESSAGE
• REMARK
• RSR ENABLE
• RSR DISABLE
• Register Assignment
Signal Name Limitations:

• Supported Numeric Input Signals:
o AI – for example AI[1]
o GI
• Supported Numeric Output Signals:

o AO
o GO
• Supported Boolean Input Signals:

o DI
o RDI

ESRC OLP Commands
o SDI
o UI
• Supported Boolean Output Signals:

o DO
o RDO
o SDO
o UO

• Commands interpreted at location:
o Payload : PAYLOAD[<num>]
o PAUSE as simulation stop
o ABORT as simulation stop
o Pulse signals : <Boolean output signal>[<num> or <register>] = PULSE
o Pulse signals with explicit duration : <Boolean output signal>[<num> or

<register>] = PULSE, <duration> sec
o Boolean signals sending : <Boolean output signal>[<num> or <register>] =

<Boolean expression>
o Analog signals sending : <analog output signal>[<num> or <register>] =

<arithmetic expression>
o Wait time : WAIT <delay> sec
o Wait signals : WAIT <signals expression>
• Commands interpreted during pre-calculation (3 locations ahead [RCS 6.x] or 4

locations ahead [RCS 7.x]) :
o Register assignation : R[i] = <arithmetic or Boolean expression>
o Call : CALL <prog>, simulated in priority order as :
o call to macro <prog>
o call to operation <Name>

ESRC OLP Commands
o call to operation <Robot><prog>
o call to operation <Robot>_<prog>
o call to robotic program <prog>
o call to robotic program <Robot><prog>
o call to robotic program <Robot>_<prog>
o Jump : JMP LBL[<num>:<comment>]
o Conditional Call : IF <Boolean expression>, CALL <prog>
o Conditional Jump : IF <Boolean expression>, JMP LBL[<num>:<comment>]
Limitations:
Conditions (IF, SELECT) and register operations (R[i] = ) are evaluated in pre-
calculation.
In the case below, RDI[i] signal will be checked after sending the P[2] target to the RCS
(so before the robot even starts to move to P[1]).
• L P[1]
• L P[2]
• IF RDI[1] = ON, JMP LBL[1]
• L P[3]
• LBL[1]
• L P[4]
• L P[5]
This is a constraint of RRS1 and the FANUC RCS.

However signal sending and signal waiting are performed at the location (or location
zone).
In the case below, WAIT RDI[1] will be executed when really entering the zone of P[2]
(meaning after P[3] and P[4] have already been fed to the RCS).
• L P[1]
• L P[2]
• WAIT RDI[1] = ON
• L P[3]

ESRC OLP Commands
• L P[4]
• L P[5]
RCS Decouple mode:

based simulation
o Payload
• Motion parameters are mapped as follow :

o Cartesian Speed / Joint speed : direct mapping
o TermType → Zone :
■ FINE : fine
■ CNT81-CNT100 : nodecel
■ CNT41-CNT80 : coarse
■ CNT11-CNT40 : medium
■ CNT0-CN10 : fine
■ CD : nodecel
• Robot on rail
Kawasaki-As

basic OLP commands:

ESRC OLP Commands
• Free Text
• Any basic OLP command described earlier, including the following ones which
must be entered as free text:
o Relative Motion simulation commands
o # MoveRelBase [<RefLoc>] <X> <Y> <Z> [<RX> <RY'> <RZ">]
o Move the robot with an offset expressed in location object frame coordinates
system.
o RefLoc if the optional <RefLoc> parameter is specified (RefLoc should be the

name of a location inside the current robotic operation)
o otherwise, to the current location
o otherwise (if defined at operation level), to the current robot TCPF
expressed in location object frame coordinate system (rotations are performed
position
o # MoveJRelBase [<RefLoc>] <X> <Y> <Z> [<RX> <RY'> <RZ">]

forced to Joint
o # # MoveLRelBase [<RefLoc>] <X> <Y> <Z> [<RX> <RY'> <RZ">]

forced to Linear
o # MoveRelTool [<RefLoc>] <X> <Y> <Z> [<RX> <RY'> <RZ">]
o Move the robot with an offset expressed in location self coordinates system.
o RefLoc if the optional <RefLoc> parameter is specified (RefLoc should be the

name of a location inside the current robotic operation)
o otherwise, to the current location

ESRC OLP Commands
o otherwise (if defined at operation level), to the current robot TCPF
expressed in reference location self coordinate system (rotations are performed
position
o # MoveJRelTool [<RefLoc>] <X> <Y> <Z> [<RX> <RY'> <RZ">]
o Same as # MoveRelTool, except that motion type to the offset position is

forced toJoint
o # MoveLRelTool [<RefLoc>] <X> <Y> <Z> [<RX> <RY'> <RZ">]
o Same as # MoveRelTool, except that motion type to the offset position is

forced to Linear
o Motion Parameters:
o By default, the current modal motion parameters (speed, zone, tool, etc..) will
be used.
o It is also possible to define explicit motion parameters with following

(controller specific) syntax:
o # MoveRelBase <X> <Y> <Z> [Speed = 2] [Accu = 4]
o These explicit motion parameters will be inherited on any subsequent relative

motions
• If RCS in Simulation is disconnected, a MOP simulation will replace the RRS

based simulation
o payload
o Speed value in % is converted to mm/s (via cart_max_lin_speed entry in

MotionParameters.e) for linear motions
• Accuracy:

ESRC OLP Commands
o If ACCU<i> zone is defined in the MotionParameters.e file, this actual

zone will be used
o Otherwise conversion from accuracy value (in mm) to default zones is as

follow:
o 0 < val < 5: fine
o 5 < val < 30: medium
o 30 < val < 75: coarse
o 75 < val: nodecel
• mounted gun
• robot on rail
Kuka-Krc

basic OLP commands:
• Free Text
• Gripper – Check Grp and Set Grp
• I/O – Wait Time, Out, Pulse, Syn Out, Syn Pulse, Wait For signal, and Wait For
Expr.
• Misc – KRC (Fold) Comment and KRL Comment
Kuka Krc Specifics:

• Only Basis motions are supported.
In addition to the KRC Fold commands supported in simulation (see below), the
following additional KRC Fold commands are also supported in download:
• PROGRAM.GUN <gun_num> PRG = <prog> PART = <move> mm FORCE =
<pressure> daN
o example: PROGRAM.GUN 1 PRG=2 PART = 3mm FORCE = 10 daN
• INIT.GUN<gun_num>

ESRC OLP Commands
o example: INIT.GUN1
• SET GRP <num> STATE= <OPN|CLO> (CONT) at <START|END> DELAY=

<Delay> ms
o example: SET GRP 1 STATE =OPN at START DELAY = 5 ms
• SET GRP <Number> STATE= <OPN|CLO>
o example: SET GRP 2 STATE =CLO
• CHECK GRP <num> STATE= <OPN|CLO> at <START|END> DELAY=

<Delay> ms
o example: CHECK GRP 1 STATE =OPN at END DELAY = 5 ms
• OUT <num> '<signal_name>' STATE=<TRUE|FALSE> (CONT)
o example: OUT 1 'mysignal' STATE=TRUE CONT
• PULSE <num> '<signal_name>' STATE=<TRUE|FALSE> (CONT)

TIME=<time> sec
o example: PULSE 1 'mysignal' STATE=TRUE CONT TIME= 2.2 sec
o SYN OUT <num> '<signal_name>' STATE=<TRUE|FALSE> at <START|

END|PATH=<distance> mm> DELAY= <delay> ms
o example: SYN OUT 2 'mysignal' STATE=FALSE at PATH=3 mm DELAY=

100 ms
Expr in Krl = (NOT) $<IN|OUT|CYCFLAG|TIMER|FLAG>[<Num>]
• SYN PULSE <num> '<signal_name>' STATE=<TRUE|FALSE> at <START|END|

PATH=<distance> mm> TIME=<time> sec DELAY= <delay> ms
o example: SYN OUT 2 'mysignal' STATE=FALSE TIME= 3 sec AT END

DELAY= 100 ms
• WAIT FOR (NOT) ( <IN|OUT|CYCFLAG|TIMER|FLAG> <num>

'<signal_name' ) (CONT)
o example: WAIT FOR NOT ( IN 1 'mysignal' ) CONT
o Move to format 5.4.33
• WAIT FOR (NOT) ((expr) <AND|OR...> (Expr) ... ) (CONT), as WaitSignal

$IN[<Num>] or $OUT[<Num>]
o Expr in Krc = (NOT) <IN|OUT|CYCFLAG|TIMER|FLAG> <Num>

'<SignalName>'

ESRC OLP Commands
o example: WAIT FOR ( IN 1 '' and IN 2 'mysignal2' )
o example: WAIT FOR ( $IN[1] and $IN [2] )
o Move to format 5.4.33
• KRC Fold commands
o ($)OUT <Num> State = <TRUE|FALSE> (CONT) '<Signal Name>', as

SendSignal OUT<Num>
■ ...example : OUT 3 State = TRUE 'signal 1'
■ ...simulated as SendSignal OUT3
o WAIT Time = <Time> sec, as delay
■ ...example : WAIT Time = 3 sec
o WAIT FOR (NOT) ((expr) <AND|OR...> (expr) ... ) (CONT), as WaitSignal

$IN[<Num>] or $OUT[<Num>]
■ Expr = (NOT) <IN|OUT|CYCFLAG|TIMER|FLAG> <Num>

'<SignalName>'
■ example : WAIT FOR (IN 2 'signal 2') and (not OUT 3 '')
■ simulated as WaitSignal $IN[2] True and OUT 3 false
■ ...example: WAIT FOR signal1 or !signal2
o PULSE <Num> State = <TRUE|FALSE> Time = <Duration> sec (CONT)

'<SignalName>', as pulse signal OUT<Num>
■ ...example : PULSE 3 State = TRUE Time = 0.1 sec 'signal 3'
■ ...simulated as Pulse Signal OUT 3 (set to value 1, then set to value 0 after
0.1 sec)
o SET GRP <num> STATE= <OPN|CLO> CONT
■ example: SET GRP 1 STATE =OPN CONT at START DELAY = 5 ms
■ simulated as call to H50(GRP_APO, <num>, <STATE>, GCONT)
o SET GRP <Number> STATE= <OPN|CLO>
■ example: SET GRP 2 STATE =CLO

ESRC OLP Commands
■ simulated as call to H50(GRP, <num>, <STATE>, GCONT), with

<STATE> = 1 for OPN and 2 for CLO
o CHECK GRP <num> STATE= <OPN|CLO> at <START|END> DELAY=

<Delay> ms
■ example: CHECK GRP 1 STATE =OPN at END DELAY = 5 ms
■ simulated as a delay and then a call to H50(CHK_APO_UP, <num>,

<STATE>, GCONT), with <STATE> = 1 for OPN and 2 for CLO
• KRL commands
o assignation of following special system variables (as RRS motion parameters

change):
o $VEL.CP
o $VEL.ORI1
o $VEL.ORI2
o $ACC.CP
o $ACC.ORI1
o $ACC.ORI2
o variable assignation (<var>=<expression>;)
o IF <condition>THEN ... ELSE ... ENDIF
o IF <FunctionCall> THEN ... ELSE ... ENDIF
o WHILE <condition> ... ENDWHILE
o REPEAT ... UNTIL <condition>
o LOOP....ENDLOOP
o FOR <var> = <start> TO <end> [STEP <step>] ... ENDFOR
o SWTCH <var> ... CASE <val1>,<val2>: ... DEFAULT: ... ENDSWITCH
o SWITCH <FunctionCall> ... CASE <val1>,<val2> ... DEFAULT ...

ENDSWITCH
o WAIT SEC <Time>, as a delay
o WAIT FOR <Signal> == TRUE/FALSE, as WaitSignal

ESRC OLP Commands
o (SET) <Signal> = <expression>, as SendSignal (only if <Signal> is defined as

a robot output signal)
o WAIT FOR <expression>
o HALT to exit program
o EXIT to exit from a loop
o GOTO <label> jump to label. ( jump from outside into a loop instruction bloc
is forbidden )
o example: WAIT FOR $IN[1] OR NOT $IN[2], as WaitSignals
o (SET) <Signal> = <expression>, as SendSignal (only if <Signal> is defined as

a robot output signal)
o <label>: destination of a goto instruction
o RETURN
o RETURN <Expression>
o PULSE($OUT[<num>], TRUE/FALSE, <duration>)
• [Name](), simulated as, in priority order:
o call to macro [Name]
o call to operation [Name]
o call to operation [Robot][Name]
o call to operation [Robot]_[Name]
o call to robotic program [Name]
o call to robotic program [Robot][Name]
o call to robotic program [Robot]_[Name]
• # CallToolPath <opName> <toolName> as call to operation <opName> while

taking care that the assigned tool on this operation is <toolName>
Following simulation keywords are supported and automatically substituted in macros,

robot modules and XML simulation layers :
• ${ActiveGun}

ESRC OLP Commands
• ${Robot}
based simulation
• System variables assignment (like $ACC.ORI1, etc...)
o Cartesian Speed / Joint speed : direct mapping
• Zone:
o FINE → fine
• C_PTP
o 0-10 : fine
o 10-40 : medium
o 40-80 : coarse
o 80-100 : nodecel
• C_DIS
o 0-2 : fine
o 2-7 : medium
o 7-15 : coarse
o > 15 : nodecel
• C_VEL → nodecel
• C_ORI → nodecel
• mounted gun
• robot on rail

ESRC OLP Commands
• moving bases (bases attached to an external manipulator)
Reis-Robstar

basic OLP commands:
• Free Text
• I/O – WRITE_BIT, WAIT_BIT, and WAIT
• Control Flow – CALL, PROGRAM, LABEL, BRANCH, TEST_BIT, TEST

#VARIABLE, TEST #INPUT, and TEST #MARKER
• Arithmetics – COPY, ADD, SUB, MUL, DEIV, MODULO, NEG, and

ABS_VALUE

(ABB) Trallfa-Robtalk

basic OLP commands:
• Free Text
• Robtalk – Gun/Brush pick, and Move Offs

• Block Instructions

ESRC OLP Commands
o JUMP num
o LABEL num
o IF cond
o instr
o IF num cond THEN ... ELSE num ... ENDIF num
o cond
o OUTPUT num ON/OFF
o INPUT num
o REG num op expression
o VAR num op expression
o OBJPOS [XYZ] [<>] expression
o when used in association with a JUMP action, this condition is simulated as

tracking the current location
o op
o <
o >
o #
o CALL SUB num - as call to operation <MainProgramName>_SUB<Num>
o CALL PATH num - as call to robotic operation

<MainProgramName>_PATH<Num>
o CALL PROG Name - simulated as (in priority order):

■ call to robot module procedure <Name>
■ call to macro <Name>
■ call to operation <Name>
■ call to operation <Robot><Name>
■ call to operation <Robot>_<Name>

ESRC OLP Commands
■ call to robotic program <Name>
■ call to robotic program <Robot><Name>
■ call to robotic program <Robot>_<Name>
INTERNAL_HALT
• Other instructions
o MOVE OFFS num
o Cannot execute if a MOV OFFs num ;@@ [ x, y, z, a, b, c, r] was not executed

first.
o MOVE OFFS num ;@@ [ x, y, z, a, b, c, r] with r is an external axis (rail)
o LET VAR num = expression
o LET REG num = expression
o WAIT INPUT num ON/OFF - as WaitSignal INPUT[num]
o WAIT OBJPOS X|Y|Z >|< value - as a wait for specific conveyor position
o WAIT TIME duration - as a delay of duration ms
o OUTPUT num ON/OFF - as SendSignal OUTPUT[num]
• Gun/ Brush instructions
o BRUSH num cond
o BRUSH num
o GUN ON|OFF cond
o GUN ON|OFF
Limitations:
• Following commands are not supported in simulation:
o #include filename
o REL
o MOVE NEGOFFS
o MOVE POSREG
o LET POSREG num = position expression

ESRC OLP Commands
o INC POSREG num [XYZ] BY expression

based simulation
o Gun/Brush instructions with condition
o Wait conveyor while tracking (IF OBJPOS)
• mounted gun
• robot on rail
• robot with one conveyor
Yaskawa-Inform

basic OLP commands:
• Free Text
Yaskawa Inform Specifics:

• Download is using Program Template mechanism
Free text commands:

• Supported I/O Instructions:
o DOUT
o AOUT
o WAIT
o PULSE
• Supported Operating Instructions

ESRC OLP Commands
o SET
o CLEAR
o INC
o DEC
o ADD/SUB
o MUL/DIV
o AND/OR/NOT/XOR
• Supported Control Instructions

o JUMP
o CALL
o TIMER
o RET
o CWAIT
Limitations:
• In the case of JUMP JOB:<job name> UF#(<user frame no>) the UF# part is not
simulated

based simulation
• The following lines should be added to rrs.xml file under .\eMPower\Robotics

\Olp for the MOP simulation
o <Controller Name="Yaskawa-Inform" RCSDecoupleSimulationAction="True"
RCSDecoupleNonSimulationAction="True">
o </Controller>
• Motion parameters are mapped as follow
• Speed
o SpeedType = VJ

ESRC OLP Commands
o speed : joint speed in %
o SpeedType = V
o speed : cartesian position speed
o SpeedType = VR
o speed : cartesian orientation speed
• Zone
o FlyLevel
o CONT : nodecel
o PL0: fine
o PL1: medium
o PL2…PL8: coarse
• Robot on rail

ESRC OLP Commands
Comparison of Various Methods for Handling Robot Macros

This topic compares various methods for handling robot macros.
• Entering OLP Commands
• Entering OLP Commands Method Comparison
• Conditional Statement Notes
Entering OLP Commands
• Robot Macros - Entered in a robot macro file and referenced as OLP commands
on a location (i.e. grip which executes a series of commands). A macro is
downloaded as just the macro name (the contents of the macro are not downloaded.
• Robot Module - (i.e. tip dress/counter, sub program), setting up logic that can be
simulated.
o Can load modules from the program
o The robot’s database can be stored in an instance.
OLP Customization:
In the next chapter we will discuss how to create customized OLP and Motion
commands and which ESRC support it.

ESRC OLP Commands
• User editable configuration XML file including:

o UI description - Parameter names, ranges, dependencies, default values,
etc…
o Controller syntax - user level and advanced level
o Upload / Download Format
Entering OLP Commands Method Comparison
Different levels of simulation requirements:

• Option 1: just a reach study (pick and place operation)
• Option 2: use programming standard macro “close gripper”

Can generate an appearance of IPA in using CEE simulation.
• Option 3: close gripper using logic (i.e. a logic block/smart component)
Details of Options:
• option 1a: gripper device and gripper locations
• option 1b: Robcad way: OLP commands:

o # drive device griper close
o # wait device gripper close
o # attach part to gripper
• option 2: create macro, can take parameters for attach

o Add standard commands (blank, display, macro, grip) or free text.
• option 3: gripper, kinematic with logic block (open/close - PICTURE) OLP

o request to open references at close signal
o request to close references at open signal
o DO(1) = ON (digital output \ attached when closed)
Conditional Statement Notes
• Conditional statements can’t be processed ahead of time because the “look ahead”
for motion smoothing

ESRC OLP Commands
• So need to cancel existing motion and them start it again with another point
• Can avoid not knowing the start point between 2 paths by always stopping at the
same point.

ESRC OLP Commands
Summary
• How use the standard OLP commands of emulated robot specific controllers
(ESRC).
• Various commands supported in simulation on all controllers which must be

entered as free text.
• The list of the supported OLP commands for several of the robot controllers.
• Compared the various methods available in Process Simulate.

ESRC OLP Commands

Lesson
6 Calibration
Purpose
To describe how to use the Process Simulate calibration tools.
Objectives
• An overview of the concepts of calibration.
• How to create a calibration and use it to calibrate the position of a path relative to a
robot.

Calibration
Calibration Introduction
This topic provides an overview of the concepts of calibration.
• Calibration Basics
• What is Calibration?
• Calibration Sets
• The Math behind Calibration
• Calibration Results
Calibration Basics
In general, Process Simulate calibration attempts to:

• Eliminate and/or compensate for any differences that may exist between the
Process Simulate and actual studies, in order to ensure precise download of robot-
program destinations from Process Simulate to the actual robot.
• Enable downloading a robot program from an Process Simulate study to several

robot studies on the factory floor which are theoretically identical but in practice
have differences in layout and component performance.
• Enable transferring on-line teach programs from one robot study to another study
that is theoretically identical, without requiring manual corrections of robot
destinations.
What is Calibration?
Calibration is the process of bringing the modeled Process Simulate study into
conformity with the real-world study. This is done by creating a filter which describes
how the real-world study differs from the Process Simulate model. This filter is called a
"calibration set".
Calibration is needed by those users who require high accuracy in the downloaded
program locations, or in programs with a large number of locations, in order to avoid
manual touchups. Calibration would not be required in a program with few locations
needing high accuracy; manual touchups in this case would be more efficient.
The calibration process involves measuring the real study in some manner, and bringing
that information into Process Simulate. The robot itself is the primary method of study

Calibration
measurement. However, external systems such as theodolites can be used to bring XYZ
coordinate data into Process Simulate.
Process Simulate calibration (Robotics → Calibration ) gives users a set of

software tools used to build the calibration set. In this class we will demonstrate how to
use these tools to achieve good results in the OLP process.
Calibration Sets
After creating objects in Process Simulate, it is possible to measure the equivalent real
objects on the shop floor. In this case, you may wish to calibrate (transform) the source
points to be as close as possible to the destination points, as measured and stored in
Process Simulate. The Robotics → Calibration command accepts multiple pairs
of points (each pair consists of a source point and an destination point) and uses an
algorithm to adjust the position and orientation of the source pairs so that the average
distance between the sources and destinations is as small as possible. The algorithm
calculates the optimum transformation for all the pairs - there will be an improvement
for most of the pairs but one or two may not be improved. Siemens recommends using
not more than ten pairs to maintain system performance.
After adding all the desired pairs, the system calculates the transformation and you can
apply it if you are satisfied. You can Apply more transformations and Unapply them.
At the end of your session, you can store the calibration set in the eMServer.
There must be at least three calibration pairs to enable calibration calculation (because
three pairs define a plane).

Calibration
The user can produce more than one calibration set for the same Process Simulate
study, in order to account for more than one actual study. Each set has a unique identity.
Any set can be used when a robot program is downloaded. In addition, a program
can be uploaded from the actual robot study with the use of one set, and then can be
downloaded to another actual study with the use of another set.
The Math Behind Calibration
In mathematics, root mean square (abbreviated RMS or rms) is a statistical measure of

the magnitude of a varying quantity. It can be calculated for a series of discrete values
or for a continuously varying function. The name comes from the fact that it is the

Calibration
square root of the mean of the squares of the values. It is a power mean with the power t
= 2.
The rms for a collection of N values is:
and the corresponding formula for a continuous function f(t) defined over the interval
is:
Calibration Results
The calibration calculation runs in real time, updating the Calibration Results
automatically when new calibration pairs are added, removed, activated, or deactivated.
The system displays the following results.
• dX, dY, and dZ - Displays the transformation distance results on the X, Y, and Z
axes.
• Rx, Ry, and Rz - Displays the transformation rotation results around the X, Y, and
Z axes.
• Maximum distance - Displays the distance between a transformed object and the
original object for the calibration pair with the largest average distance.
• Average distance - Displays the average distance between all the transformed
objects and the original objects.
• RMS - Displays the RMS (root mean square) distance between all the transformed
objects and the original ones.

Calibration
Robot to Part Calibration

This topic describes how to create a calibration and use it to calibrate the position of a
path relative to a robot.
• Robot to Part Calibration Basics
• Calibration Steps Overview
• Activity: Creating a Calibration Set
• Activity: Using a Calibration Set
Robot to Part Calibration Basics
Study calibration is used to calculate the actual location of the robot relative to the
workpiece.
What we will need to do is independently create a path on the real robot and the Process
Simulate robot that includes the robot touching the same three points on the workpiece.
Then we will would upload the path from the real robot and use the calibration window
to reconcile them. In doing so, we create a calibration set that can act as a filter to adjust
the downloaded path from Process Simulate to better fit to environment of the real
robot.
Calibration Pairs are used to effect the rms calculation by means of pairs of download
and upload locations: locations placed in the Process Simulate study are downloaded
to the actual study, they are corrected according to the actual, relative placement of
the robot and workpiece, and the corrected locations are uploaded back to the Process
Simulate study.
The Calibration command is used to perform the rms calculation based on user-
supplied data, and then display the results of the calculation and apply the results to a
selected component as a transformation to the location of that component.
Calibration Steps Overview
1. In Process Simulate, create (i.e. three) locations in a path to define the workpiece
calibration. These points are typically on known common “landmarks” such as
point on the fixture blocks.
2. Verify the locations in the path can be reached by the robot.
3. On the real robot, teach the same three locations into a new program.
4. Upload the program from the real robot into Process Simulate.

Calibration
5. Using the Process Simulate Calibration window, create a calibration set with these
two paths as input.
6. Apply the calibration set to the desired robotic path created in Process Simulate to
properly locate it relative to the robot.
7. Verify motion, cycle, and configuration location information through simulation.
8. Download the desired robotic path to the real robot.

Calibration
Summary
• An overview of the concepts of calibration.
• How to create a calibration and use it to calibrate the position of a path relative to a
robot.

Lesson
7 OLP Command XML Customization
Purpose
To describe how to do OLP customization.
Objectives
• Got an overview of the capabilities in this area.
• How to create an enhanced OLP command.
• How to create a custom command and macro

OLP Command XML Customization
Overview of Customizing Robot Controller Interfaces

This topic provides an overview of the basic areas of the .XML file.
• OLP Command Customization Basics
• The Customizable User Interface's Layers
• Dialog Standards
OLP Command Customization Basics
Customized
Customized OLP Robot Path
Controller Motion
Configuration Template
Configuration
ABB Yes Yes Yes
ABB Volvo (Volvo
Yes No Yes
only)
Comau Yes Yes Yes
Comau Volvo
Yes No Yes
(Volvo only)
Duerr Yes No Yes
Fanuc F100iA
Yes No Yes
(CFLEX)
Fanuc Yes Yes Yes
Fanuc Japan (Japan
Yes No Yes
only)
Fanuc VW (VW
Yes No Yes
only)
Kawasaki Yes No Yes
Kuka Yes Yes Yes
Kuka Volvo (Volvo
Yes No Yes
only)
Kuka VKRC (VW
Yes No Yes
only)
NC Code Yes Yes Yes
Reis Yes Yes Yes
(ABB) Trallfa Yes No Yes

Yaskawa
Yes No Yes
(Motoman)
Siemens PLM Software, together with its customers, invests a lot of effort, based
on broad knowledge gained over many years, to offer advanced OLP programming
capabilities. The availability of the Teach Pendants, and in more recent versions, the
greater use of the Path Editor, provides our users a much greater scope of functionality
than in the past. Nevertheless, there is always room for user customization and the
flexible application of customer "flavors".
Open System – Complex User Requirements:
As the environment becomes ever more complex, the only solution that can serve users'
needs is an open solution. This is due to the following constraints:
• There are very few robotic program specialists.
• Multi-variant production requires complex synchronization.
• The system must be flexible enough to add commands which utilize correct syntax
but are still easy to use.
• No API or C/C++ programming.
Use of ESRC Enhances Verification Capabilities:
ESRC technology allows simulation and verification of many of the commands. The
customizable User Interface, based on ESRC, is designed to take advantage of these
capabilities.
The Customizable User Interface's Layers
In Process Simulate, we use XML files to support customization of OLP commands and
motion commands ... WYSIWYG

• The first layer, the User Interface Layer, defines the dialog that can be opened
from within the Teach Pendant during the session.
• The subsequent Simulation Layer includes the instructions as they have to

be executed during the simulation (CEE type). Define the behavior using the
parameters and controls in the User Interface dialog.
• The Download Layer is the last and probably most important of the three layers.
Here users define the actual controller specific commands from a form in the dialog
from the User Interface layer.
• Finally there are Upload Capabilities to reuse the definition and present the data in
a form to the user.
Automatic Generation of OLP Commands Dialogs – the User Interface Layer:

The entire customization is done by the user in a configuration file. The exact order of
elements and the obligatory and optional elements can be found in the example later in
this chapter.
The system automatically generates an OLP command dialog with the appropriate
information from the configuration file.
Simulation and Download Layers:
Parameters used in the User Interface (UI) dialog are then used to generate the needed
OLP strings for the simulation needs as well as for the download to the real controller.
It is possible to define multi-line commands, meaning several lines of actual OLP code.
Changes Without Re-launching Process Simulate
When making changes in the configuration file, there is no need to close the Process
Simulate application. A simple check request in the Customized Command XML

Checker will load the new configuration. (Closing the Teach Pendant and re-
opening it will also load the new configuration).
Dialog Standards
All OLP command dialogs are generated with the same layout.
Dialog Size:
The size of the dialog should be automatically calculated according to configuration file
data.
Custom OLP Command Example:
This is not an exercise. A detailed exercise on this topic can be found later in this
chapter.
• With the desired robot controller set for the assigned robot: Right click a robotic
operation and select Teach Pendant .
• From the Teach Pendant, click Add.
• Slide across Customized and notice the two custom commands.
• Look at the Gripper Instructions command.
• Look at the Collision command.

Custom Motion Example:
This is not an exercise. A detailed exercise on this topic can be found in the next
chapter.
• With the desired robot controller set for the assigned robot: Add the path to the
Path Editor (and the Customized Motion, Customized Debug, and Process
type Columns).
• Open the Teach Pendant window.
• Look at the custom user interface results in the bottom half of the Teach Pendant
window.


Introduction to the Customized OLP Commands XML File

This topic provides an introduction to the customized OLP commands .XML file.
• Customized XML Basics
• The Basic Sections of the File
Customized XML Basics
The rest of this chapter deals with OLP command customization. The next
chapter will tackle motion command customization.
For each controller there may be several configuration files. During the OLP package
installation, the configuration files should be installed in the OLPConfiguration
subfolder (.\Tecnomatix\eMPower\Robotic\Olp\<Controller name>/
OLPConfiguration/*.xml). Users can assign any names they wish to configuration
files.
The following illustrates an example installation with a customized user interface for
Kuka:
The Basic Sections of the File

The XML file must start and end with the RobotController element. This tab contains
three other elements which represent the three main parts of the file:
• RobotController - This element must occur only once and be the root. It contains
these attributes:
o The Name must appear in the RobotController element. It should be the
robot controller as specified in the rrs.xml file. Example value: “Fanuc-Rj”
o Version (of the controller) can also be specified
• RoboticParams
• OlpCommands
• OlpDialogs
Here is the basic skeleton:

Robotic Parameters Section of the File

This topic describes how to setup the robotic parameters section of the file.
• Robotic Params Section Basics
• Defining a List of Values
• More on TxObject ValueTypes
Robotic Params Section Basics
This element includes all the robotic parameters (Param elements) which are used by
customized OLP/Motion commands. Process Simulate reads this section from within all
the relevant XML files (per controller per version) into one cache which is used by all
customized commands. Therefore it is necessary for each robotic parameter name to be
unique.
It is used to define the parameters (i.e. the parameter’s type, list of values, min, max
values, etc…)
Basic Description:
Each parameter (Param element) should have a name, a type and (optionally) a value.
It contains these attributes:
• Name - This element determines the name of the parameters
• ValueType - This element must occur only once. Values are either:
o Int – a number
o Double – a number
o String – text
o TxObject - Tecnomatix objects, such as robot gun, signal, etc.
• MaxVal – for numbers only (double and int)
• MinVal – for numbers only (double and int)

• Default - Example value: “2”
• Multiline – for strings only
Defining a List of Values
• ComboDef – Defines a list of values. Should contain at least one ElmDef.
• ElmDef – defines of the values of the list
More on TxObject ValueTypes
TxObjects must be only:

• compound,
• part_instance,
• part_physical_appearance,
• part_prototype_assignment,
• compound_resource,
• resource_instance,

• resource_prototype_assignment and any physical object in a component scope.
TxObject selection filtering options:

• Allow any object to be selected
• Allow only specific pick types using the PickTypes element
• Allow only filtered objects from a list using the ShowList attribute of the
PickTypes tab
• Allow only objects based on the type using the TxValidatorType attribute of the
Param tab.

OLP Commands Section of the File

This topic describes how to setup the OLP commands section of the file.
• OLP Commands Section Basics
• Layers
OLP Commands Section Basics
This element includes all the OLP commands (Command elements) which are used by
customized OLP commands. The Process Simulate application reads this section from
all relevant XML files (per controller per version) into one cache which is used by all
customized commands. Therefore, each OLP command name must be unique.
• Command – This element represents one customized OLP command
and it contains the command name and parameters names. Contains the
RoboticParamRef and Layers elements. Attributes for this element:
o Name - Example value: “Do Something”
• RoboticParamRef – Contains the Param elements used in the command.
• Layers - This element is optional, but can occur only once. This element contains
the primary layers: UILayer, SimulationLayer, and DownloadLayer.
Layers
The Three Layers:

• UILayer – This element represents one customized OLP command in the Teach
Pendant or Path Editor. It is optional, but it can occur only once. It contains the
Lines (and items) for the user interface to be shown.
• SimulationLayer - This element is optional, but can occur only once. It defines
how the customized OLP command will be simulated. During simulation, when the
controller encounters a customized OLP Command, replaces it with its simulation
layer and interprets this simulation layer instead. Inside the simulation layer, users
can write any elementary command (one per <line> ... </line> section) that is
understood by the controller:
o "default controller" standard commands (ex : # SendSignal sig1, # WaitTime
2, # Blank PaintFanEntity,....)
o native controller syntax supported by the controller simulation (ex : IF var1 =

3 THEN, call to macros, call to robot module procedure,....)

o Inside the simulation layer, it is fully permissible to mix "default controller"

commands with commands in native controller syntax.
• DownloadLayer – It defines what will be output when the program is

downloaded. It has the same capabilities as UILayer and supports several lines.
This element is optional, but can occur only once.
The content of a layer:

• Line - Defines a line break. It contains Item elements.
• Item - Only allowed below Line elements. Contains the Type attribute as well as
either a parameter name (when the type is parameter) or a constant. Attributes for
this element:
o Type – Values are either const, optional, or parameter, or
dynamicParameter

OLP Dialogs Section of the File

This topic describes how to use the OLP dialogs section of the file.
• OLP Dialogs Section Basics
• OLP Command XML Structure Example
OLP Dialogs Section Basics
The OlpDialogs element contains a list of dialogs, each of which allows you to create
one or more OLP commands. It contains one or more Dialog elements.
• Dialog - Attributes for this element:
o Title - Shows the title of the dialog in the Teach Pendant. Each ‘|’ is a new
subdirectory. For example: Title="MyTest|Customized|ChooseLocation"
o Description - A short description inside the dialog for the user. For example:
Description=”Please select a location”
o Icon – The icon of the dialog. For example: Icon=”gripperOp.ico”

These icons should be placed in the …\eMPower\Robotics\Olp

\CustomizedIcons folder (or in a folder relative to this folder, such as a
sub-folder). This folder is used by all controllers and custom dialogs.
• OlpCommandRef – Contains the OlpCommand element.
• OlpCommand – References Command elements from the OlpCommands

element.
OLP Command XML Structure Example
<RobotController Name=””>
<RoboticParams>
<Param Name=”” ValueType=”” Default=””>
<ComboDef>
<ElmDef>xxx<ElmDef/>
</ComboDef>
</Param>
</RoboticParams>
<OlpCommands>
<Command Name=””>

<RoboticParamRef>
<Param>xxx</Param>
</RoboticParamRef>
<Layers>
<UILayer>
<Line>
<Item Type="">xxx</Item>
</Line>
</UILayer>
<SimulationLayer>
<Line>
</Line>
</SimulationLayer>
<DownloadLayer>
<Line>
</Line>
</DownloadLayer>
</Layers>
</Command>
</OLPCommands>
<OLPDialogs>
<Dialog Title="" Description="">
<OlpCommandRef>
<OlpCommand>xxx</Param>
</ OlpCommandRef >
</Dialog>
</OLPDialogs>
</RobotController>

Send Signal and Wait Signal Example

This topic describes how to create custom OLP commands, for various robot controllers,
for send signal and wait signal.
• Send Signal and Wait Signal Basics
• ABB Activity: Creating a Custom Command for Send Signal and Wait Signal
• Fanuc Activity: Creating a Custom Command for Send Signal and Wait Signal
• Kuka Activity: Creating a Custom Command for Send Signal and Wait Signal
• Yaskawa Activity: Creating a Custom Command for Send Signal and Wait Signal
Send Signal and Wait Signal Basics
In this lesson we will create a custom command for send signal and wait signal in the
robot controller’s specific language (i.e. it will be downloadable).
Note: The below examples assume that we have a PLC Input (and robot) signal defined
named DO[2] and a PLC Output (and robot) signal defined named DI[1].
For ABB-Rapid:
• Send Signal: SetDO DO[2], 1;
• Wait Signal: WaitDI DI[1], 1;
For Fanuc-Rj:
• Send Signal: DO[2] = ON
• Wait Signal: Wait DI[1]
For Kuka-Krc:
• Send Signal: OUT 1 ‘DO[2]’ State= TRUE
• Wait Signal: Wait FOR (IN 1, ‘DI[1]’)
For Yaskawa-Inform:
• Send Signal: DOUT OT#(2) ON
• Wait Signal: Wait IN#(1) OFF

Custom OLP Command and Macro Example

This topic we will discuss creating a custom OLP command that calls a macro from the
macro file.
• Macro File Example
• OLP Command XML File Requirement for Example
Macro File Example
A possible macro could look like this – although it should be mentioned that this macro
is specific (“hardcoded”) for a predefined equipment name:
Macro METHOD1_RIVET
# Destination xyz_riveter_rr_01
# Drive CLOSE
# Destination xyz_ riveter _rr_01
# WaitDevice CLOSE
# WaitTime 2
# Destination xyx_ riveter _rr_01
# Drive OPEN
# Destination xyz_ riveter _rr_01
# WaitDevice OPEN
Macro files must be stored in the defined macro folder under the system root (as
defined in Tools → Options) and named with a .macro file extension.
The advantage of this solution is the fact that the original .cojt including only
kinematics can be used.
The disadvantage of using this kind of macro is being it not flexible at all for any kind
of equipment change.
A much more and realistic way is turning the xyx_ riveter _rr_01 into a smart
component (which provides built in joint value sensors and the ability to move to a pose
using a signal). The entries and exists of this smart component could be connected to
generic signal names which follow our company standard.
Then we can reference these signals in our macro.
• Digital Output Signals:

o do9 used to move to open
o do10 used to move to close
o di7 used to verify moved to close OK
o di8 used to verify moved to open OK
Then a module or macro could be written in the following form:

Macro METHOD2_RIVET
# Send do10 1
# WaitSignal di7
# WaitTime 2
# Send do10 0
# Send do9 1
# WaitSignal di8
# Send do9 0
OLP Command XML File Requirement for Example
The following would be added to the SimulationLayer of the OLP Command XML
file:
<SimulationLayer>
<Line>
<Item Type=”const”>METHOD2_RIVET<Item>
</Line>
The .macro file must already exist, since this tool checks for the file before
offering it as a choice.

Summary
• Got an overview of the capabilities in this area.
• How to create an enhanced OLP command.
• How to create a custom command and macro


Lesson
8 Motion and Robotic Path Template

XML Customization
Purpose
To provide a description on how to do Motion and Robotic Path Template
customization.
Objectives
• How to create an enhanced motion XML
• How to create a robotic template XML
• Other selected custom XML topics

Motion and Robotic Path Template XML Customization
Motion Command Customization Introduction

This topic provides an introduction to motion command customization .XML files.
We will cover some additional functionality concerning custom motion commands.
• Motion Customization Basics
• Custom Motion Type Configuration
• Description
Motion Customization Basics
A lot of companies have implemented their own standards to create a combination of

existing “official” robot motion commands with their own enhancements. Siemens PLM
Software supports these requirements in the same way as for the Customized OLP User
Interface. This user customization must be kept the flexible to allow customer "flavors"
without the need to hard code them.
For each combination of location and process types (a column under the controller name
section), a different dialog can be used to edit the relevant robotic parameter.
• For Weld locations, these options are shown:
• For Via locations, these options are shown:
By choosing a value, users can customize the location.
Custom Motion Type Configuration

As explained in the introduction, specific user defined process related commands

can be defined in all existing robot controllers. In order to support these commands,
the customized User Interface mechanism includes motion parameters. As they may
influence several columns also a specific new column in the path editor has been
introduced “PROCESS TYPE” – as shown in the introduction of this exercise.
For each controller there may be several OLP and motion configuration files. After
the OLP controller installation, your custom configuration files should be installed
in the MotionConfiguration folder (.\eMPower\Robotics\Olp\<Controller>
\MotionConfiguration). Users can assign any names they wish to configuration files.
The MotionConfiguration-subfolder must contain at least one file for each

configuration file type.
Description
All the syntax of the OLPConfiguration elements can be used here as well.
Representation of Layers of motion commands:
Customized motion commands are stored in the Database only one time, but for each
motion command, there are three different representations. (User Interface, Simulation
and Download)
The purpose of this service is to retrieve the right motion command representation
according the user needs.
In the XML file, for each location type and each process type, there will be three layers:
1. UILayer – The user interface layer shows what will be shown in Process Type
column of Path Editor.
2. SimulationLayer - The simulation layer will describe what needs to be simulated
3. DownloadLayer - The download layer will describe what needs to be

downloaded.
User Interface Layer:
1. When the user clicks in the ProcessType column in the Path Editor, the service
read the XML (only the first time and saves it in a cache for reusability) and an
appropriate list of process types (according to the suitable location type) will be
shown for the user to select.
2. When the user chooses a value – a custom user interface is opened with the current
values displayed.

3. After setting the desired values and click [OK], the values are set on all the
referenced location attributes.
The Customized Motion and Customized Debug columns can be
added to the Path Editor as well. If the location has not been customized,
there won’t be a value in these fields.

Additional Elements of Motion Command XML Files

This topic describes additional elements of custom motion command .XML files (as
apposed to custom OLP command .XML files).
It contains the following subtopic:
• Motion Command Basics
Motion Command Basics
For motion command XML files the RobotController element contains the
RoboticParams and Location elements.
Location – This element represents the type of the location the user will select and
contains a Type attribute which can have these values: VIA, WELD, Seam Start,
Seam End, Seam Middle
• Process – This element is one of the values of the list of values shown for the
selected location type. This is the value that will be shown in the Process Type
column. Several of these elements can be placed within a Location element.
o Force - Once users select a process type for a location, the application forces
new values for specific robotic parameters.
o Dialog – Contains the Title and Description attribute and the

RoboitcParamRef element. See the description provided in the previous
chapter.
o UILayer - See the description provided in the previous chapter.
o SimulationLayer - See the description provided in the previous chapter.
o Motion – The type of motion with the following Types: 1 Joint, 2 Linear, 3
Slew, 4 Circular Via, 5 Circular2, 6 Circular Radius, 7 Circular Full, and 8
Spline.
This element contains the DownloadLayer

Motion Command Customization Example

This topic describes how to create a custom motion command .XML file.
We will cover a motion customization example.
• Motion Example Basics
• Activity: Creating Customized Motion Commands
• Activity: Using Customized Motion Commands
Motion Example Basics
Your custom motion XML will show a specific list of values for the Process Type
based on location type. For example for Weld locations, the user has the ability to
choose either Style1 or Style2 for the Process Type (in the Path Editor).
Each Process type can have its own dialog which can be opened from the
Customized Motion column of the Path Editor.
One or all layers can be filtered based on the assigned motion type.
For example:
• Weld (location type)
o Style1 (process type) — Weld location dialog for Style1
■ PTP (motion type)
◊ User Interface layer
◊ Simulation layer
◊ Download layer
■ Lin (motion type)
◊ Download layer
■ Circ (motion type)

◊ Download layer
o Style2 (process type) — Weld location dialog for Style2
■ PTP
◊ Download layer
• Via (location type)
o Style 2 (process type) — Via location dialog for Style2
■ PTP (motion type)
◊ Download layer
■ Lin (motion type)
◊ Download layer
■ Circ (motion type)
◊ Download layer
o Style3 (process type) — Via location dialog for Style3
■ PTP

◊ Download layer
Simulation & Download layers:

When a location is marked as “customized”, the controller uses the XML simulation/
download layer, instead of performing the default simulation/download.
Each layer consists of hard coded strings, and robotic parameters (not necessarily the
ones which appear in the dialog). Process Simulate reads the related section in the XML
file and converts it with the following rules:
• The hard coded string - will stay as is.
• The regular parameters – the service should find their value on the location,
• The controller parameters – the service will get their values by API from the
controller.
• Finally, Process Simulate will return one string to the controller with everything it
needs (or an empty string if it required)

Robotic Path Template Customization Introduction

This topic describes how to create a custom robotic path template .XML file.
• Path Template Basics
• Capabilities
• Description
Path Template Basics
It is often necessary to configure location parameters (tool, speed, zone, etc.) to define
a path for a specific process. Additionally, approach and depart via locations with the
same parameters are added to the path. Each action can add locations to the selected
path, and/or change location orientation and robotic parameters, and OLP commands.
For example, in a gluing operation, the user configures the gluing start, stop, and robot
speed. These are process specific parameters to be applied to each gluing path.
Process Simulate enables you to define actions in an XML template and apply the
actions to multiple operations. You can set parameters and OLP commands for
locations, add approach and depart via locations, and set their coordinates. You can
define many actions in the XML template and apply them with a single click, saving
repetitive manual configuration, increasing productivity, and reducing errors.
The robotic templates are stored as XML files in dedicated folders. Since each robot
controller has its own OLP commands (standard, specific, and customized) and
motion parameters (regular, complex, and customized), each controller requires its
own PathTemplateConfiguration folder for storing template files. The folder is
created during controller installation and is located under …\eMPower\Robotics\Olp
\<Controller>\PathTemplateConfiguration. All the XML files in this folder are taken
in account, without any dependency on their names.
The following is an example of simple actions:
• Action A: For the first seam location with the Polishing process type:
o Set RRS_MOTION_TYPE to 2
o Add the OLP command OpenPaintGun
o Add the OLP command SetPaintBrush 3
o Change the location color to be Yellow
• Action B: For the last seam location with the Polishing process type:

o Set RRS_MOTION_TYPE to 2
o Add the OLP command ClosePaintGun
o Change the location color to be Red
The user can apply actions on selected operations.
Basic Steps:
• Create custom path template XML file.
• Use the custom path template XML in Process Simulate by selecting Operations
→ Path Editing → Apply Path Template Action .

Capabilities
• Execute configurable templates of actions on list of operations
• Perform multiple actions to manipulate the paths at once
• Support different actions:
• Adding removing robotic parameters
• adding/removing of OLP commands
• Adding locations
• Set Paint gun off / on
• Support different templates for each controller, with and without parameters
Description
For robot path template XML files the RobotController element contains the
ActionList and ActionFilter elements.
• ActionList - This element contains a list of Action elements.
• ActionFilter
• Action – this element has several attributes such as:

o Name - The name of the action, this must be unique. The following example
shows that when the name includes ‘|‘, this is a sub menu, and when it includes
‘-‘ at the end, this is a separator
o SeamRange - Defines the seam operations (under the selected continuous

compound operation) upon which this action should be performed. The
possible values are: All (including all via and seam locations, this is the default
value), First, Last, n1, Last – n1, ”n1-n2”, ”n1,n2,n3”.
o LocRange- Defines the locations on which this action should be performed.

The possible values are: All (this is the default value), First, Last, n1, Last –
n1, ”n1-n2”, ”n1,n2,n3”, Operation. The Operation value does not work with

any other filters; use it only for OLP commands, color, and motion for the
selected operation level.
o LocIndex (with values such as First, Last, All)
o LocationTypes - Filters the locations by their support for customized

motion. The possible values are: Via, Weld, Seam Start, Seam End, Seam
Middle.
o Processtypes - Filters the locations by the process type defined in the

customized motion XML file (see also in Process Type column in the Path
Editor). This attribute can take more than one value.
o MotionTypes - Filters the locations by motion type. This attribute can take
more than one value.
o Description - The description of the action to be shown in the Apply Path

Template Action window in Process Simulate.
o etc …
Action content overview:

The Action element can contain several elements:
• Param - This is fully defined (min, max, list, type, etc.) in the customized motion
XML file. This attribute is mandatory unless you use the RemoveAll attribute.
• Olp - For a standard or controller specific controller, the system creates a free text
command at the location. For a standard customized controller, the system creates
a composite command at the location. If there is already an OLP command with the
same name at the location, a new OLP command is added.
• Color - The possible values are: Red, green, yellow, blue, magenta, cyan, orange,
white, pink, gray, brown, wood, dark green, dark red, dark brown, light blue, black.

• MoveLoc - This element describes the moving of locations in single or several

coordinates. For weld locations, only the Rx, Ry, Rz coordinates are set. If,
however, these coordinates are bigger or smaller than the range defined in
the Option window, they are set to the minimum or maximum value (unless
IgnoreLimitations is set to True).
• Relocate - This element describes relocating locations according to the difference

between two TCP frames. For example, if you change a weld gun for another gun
with a different x-axis.
o Add the following to the customized motion XML file:
o Also add the following to the customized motion XML file:
o To create this UI:

• AddLoc - This element describes the creation of a new via location and setting
its coordinates in degrees (double) value. In the AddLoc element, the user should
define what to do with the new via location. Outside the AddLoc element, the
system checks again that the filter is on the fixed operation. It then continues with
the new output of the filter.
If several locations pass the action filter, each location entering the operation
may change the location pointed to by RefLoc.

• ActionRef - This element describes a reference to a single existing action and is

for reusing of the XML action definitions.
ActionFilter content example:

A filter determines what object types the action is shown.

Robotic Path Template Customization Example

This topic describes how to create an example robot path template customization .XML
file.
• Path Template Example Basics
• Activity: Creating Robotic Path Templates
• Activity: Using Robotic Path Templates
Path Template Example Basics
In this lesson, we will describe how to create an example robotic path template
customization file and use it in Process Simulate.
For example:
We want to define a path template XML to:
• Give the abilities to apply all defined path templates
• Give the abilities to apply specific path templates:

o Change the color of all welds in the path to red
o Change the color of all via locations in the path to black
o Add a location before the first location in the path, offset -100 along the X-
axis, and 100 along the Y-axis.
o Add a location before each weld location, offset -5 along the X, add an _01
suffix to the name, and set its color to yellow. Also on these locations: set the
zone to z30, the speed to v1000, and the motion type to 1 (joint motion).
o Add a location after each weld location, offset -5 along the X, add an _02
suffix to the name, and set its color to blue. Also on these locations: set the
zone to z80, the speed to v600, and the motion type to 1 (joint motion).

Other XML Customization Topics

This topic lists several other interesting features of the custom XML files.

• Custom Debugging
• Multi Editing of Customized Motion
• Picture Attribute
• Adding your Own Online Help for Customized Dialogs
• Centralize all XML files under single shared folder
• Encryption of Customized XML Files
Custom Debugging
For Custom OLP commands:
From the Teach Pendant right click the command in the OLP commands list and select
Show Layers or Customized Upload Parameter Checker.
For Custom Motion:
Can be done in the Path Editor by picking in the Custom Debug column and select
Show Layers or Custom Checker.
Multi Editing of Customized Motion
In order to set values for customized motion only once for several locations:
In the Path Editor, select several locations and click Set Locations Properties .
In the Set Locations Properties window, set the process type for all locations, and then
select the Customized motion row, and click in order to open the window.

Picture Attribute
The picture in the dialog changes dynamically according to the combobox selection.
This aids you in selecting the correct gun.
Picture is an optional attribute. Its value is the relative path from the
CustomizedPictures folder.
The Picture path is relative to ..\eMPower\Robotics\Olp\CustomizedPictures.
Under this folder, the user can manage pictures with nested subfolders as desired. For
example:
…\eMPower\Robotics\Olp\ CustomizedPictures \Laser\appzc5299228.jpg for
<ElmDef Picture =" Laser\appzc5299228.jpg ">Weld 10Am</ElmDef>
This attribute is available in Custom OLP files only.

the ..\eMPower\Robotics\Olp\CustomizedIcon folder was discussed earlier. It

is where the custom icon that shows in the upper left corner of the window are
placed by default.

Adding your Own Online Help for Customized Dialogs
Add the Help attribute to the Dialog element will add a help button to the UI. This
attribute is available in Custom Motion and OLP files.
The Help path is relative to ..eMPower\Robotics\Olp\CustomizedHelp.
If you wish to launch a URL, add the shortcut to the folder and the XML (using the
shortcut name and ".url").
• You can now launch the desired item over the net (internet, intranet).
• You can store all items on a single server and use shortcuts to access them.
Centralize all XML files under single shared folder
Users can place all the .XML files under a shared folder in single location, allowing
all users to just point to this folder by adding the CustomizedPath attribute to the
Version element in the rrs.xml file. Typically this folder would be a shared drive such
as N:\sysroot\Kuka-Krc or \\ilhzsomebody\Kuka-Krc. This folder would contain
all of the .XML customization folders that are found under the install folder (i.e. .
\Tencomatix\eMPower\Robotics\OLP\Kuka-Krc (of course it would not include the
executables for the robot controller).

We will not discuss DataConfiguration in this course, since it is beyond the

scope of this course. It is a way to create your all data types which can be used in
your other custom .XML files.
Encryption of Customized XML Files
To protect customized .XML files, it is possible to use encryption. To do so, select

the Encrypt button from the Customized Commands XML Checker window (click
Customized Commands XML Checker in Process Simulate) and select
the .XML files to encrypt. The encrypted files are created with the .XMLC suffix and
can be safely shipped to contractors and suppliers. Process Simulate handles both .XML
and .XMLC files transparently.

Summary
• How to create an enhanced motion XML
• How to create a robotic template XML
• Other selected custom XML topics

Lesson
9 Final Comments
Purpose
To various other interesting topics related to robotics that have not been covered in the
previous courses.
Objectives
• An overview of the robotic parameters viewer
• An overview of robot modules
• An overview of the roller hemming tool
• An overview of the OLP tools
• An overview of creating an OLP procedure
• How to put it all together.

Final Comments
Overview of the Robotic Parameters Viewer

This topic describes the robotic parameters viewer.

• Robotic Parameters Viewer Basics
Robotic Parameters Viewer Basics
tecnomatix, browse to Tecnomatix → Planning Applications → Robot
Controllers → v10.1 → Tools → Robotic Parameters Viewer and
download it.
After this viewer is installed, it will then be available in Tools → Customize list
under the OLP category. Add it to the Robotics menu.
Usage:
Select Robotics → RoboticParametersViewer .
Select an operation or a location (or a robot when the API will be available).
All the object parameters (with their value) are automatically displayed in the viewer.
You can select another object while the RoboticParametersViewer is open and it will
update the parameters list.

Final Comments

Final Comments
Overview of Robot Modules

This topic describes how to describe robot modules.
• Robot Modules Basics
Robot Modules Basics
To open the Robot Modules window, select the desired robot instances and then select
Robotics → Robot Modules .
• Robot modules should be loaded / edited with the Robot Modules standard tool in
Process Simulate.
• Those modules can contain any number of procedures or functions defined in the
controller native language syntax (standard controller syntax [# commands] can
also be used if needed in the procedure body)
• In the teach pendant, the procedure/function calls should be entered manually, in

free text, in the controller native language syntax.
• In simulation, the procedure call is replaced by the procedure body (in which the
procedure parameters have been replaced with the call arguments).
• In download, the procedure call is downloaded as is.
Controller Modules Support

ABB Yes
ABB Volvo (Volvo only) Yes

Final Comments
Comau Yes
Comau Volvo (Volvo only) Yes
Duerr No
Fanuc CFLEX (F100iA) No
Fanuc Yes
Fanuc Japan (Japan only) Yes
Fanuc VW (VW only) Yes
Kawasaki No
Kuka Yes
Kuka Volvo (Volvo only) Yes
Kuka VW (VW only) Yes
Reis (Not covered in class)
Trallfa No
Yaskawa / Motoman No
Basic Usage:
1. Select a robot in the Graphic Viewer or Object Tree.
2.
Select Robotics → Robot Modules .
3. Performed the desired action
4. Close the window.

Final Comments
Overview of the Roller Hemming Tool

This topic provides an overview of the roller hemming tool.
According to www.Wikipedia.org: Robot hemming uses a standard industrial
robot integrated with a roller hemming head to provide a flexible solution to
closure manufacture. The flange of the outer panel is bent over the inner panel in
progressive steps by means of the roller hemming head. The process allows the
advantage of using the robot controlled hemming head to hem several different
components in a single cell.
• Roller Hemming Basics
Roller Hemming Tool Basics
The Roller Hemming Tool is a set of tools that provide functionalities for
RollerHemming process that are missing inside Process Simulate standard commands.
The currently available tool is named Assign Servo Value And Speed
Controllers → v10.1 → Tools → Roller Hemming Tool and download it.
After this viewer is installed, it will then be available in Tools → Customize list
under the OLP category. Add it to the Robotics menu.
Usage:
Select Robotics → Roller Hemming — Assign Servo Value and Speed .

Assign Servo Value and Speed:
Start Servo Value, Servo Direction, Servo Override and OK / Apply buttons are enabled
if and only if:
• Start and end locations have been selected
• Start and end locations belong to the same robotic operation, and start location is
before end location
• The robot that operates the robotic operation has a servo gun
• In case Apply Speedis checked, the application will also check the validity of the
Distance to speed Table grid (no interval should intersect)

Final Comments
When these conditions are fulfilled, the min and max of Start Servo field should be
initialized with the Min and Max joint limits of the servo gun.
Assign Servo Value:

The robot controller expects the distance between the different locations as value for the
servo motor.
This distance will be recalculated for all location between the 2 selected ones: Start and
End
The Start location will have the servo value equal to Servo Start Value
For the other location the Servo Value will be calculated like follow :
ServoValue (loc N) = ServoValue (loc N-1) + Distance (loc N and loc N-1) *
Override Value
Override is calculated as POSITIVE or NEGATIVE value by the option.
The % of override can take value from -100% to +100% according to this formula:
Override Value = ( 100 + [-100 ÷ 100] ) / 100
ServoValue (loc N) = ServoValue (loc N-1) + Distance (loc N and loc N-1) * [0 ÷ 2]
In case the calculated servo gun value is beyond the servo gun limits, a warning
message will be logged but the servo value will be assigned anyway
Assign Speed Value:
Accordingly to the Distance to speed mapping table the speed of the all location
belong the current selection will be updated.

Final Comments
Speed will be calculated only if Include speed calculatingcheck box is checked

The start location will have the default speed value = 500 mm/sec
For the other location speed value will be taken from the mapping table accordingly to
the distance between the locations.
The distance intervals are checked for the intersection. If that occurs, the [OK] and
Apply buttons are deactivated.
In case the distance is not in any of the defined distance intervals, an error message will
be logged and speed will not be assigned to the location
At the end of the process, a window will display all errors/warnings that occurred (if
any)
Otherwise a message informing that the command was successful will be shown in the
status window.
The Speed table grid settings will be stored from session to session, so that settings,
from previous run, are automatically displayed in the window when launching the
command.

Final Comments
Overview of the OLP Tools

This topic describes how to use the various OLP tools.
• OLP Tools Basics
• Convert to Via Location
• Convert to Weld Location
• Create Seam Operation
• Mark Current Rail Value
• Rail Jog with Locked TCPF
• Shift Rail Value
• Smooth External
• Smooth Rail
OLP Tools Basics
Controllers → v10.1 → Tools → OLP Tool and download it.
After this is installed, several new commands will become available in Tools →
Customize list under the OLP category:
Convert to Via Location
Convert to Weld Location
Create Seam Operation
Define Gun Main Joint
Mark Current Rail Value
Rail Jog with Locked TCPF

Final Comments
Shift Rail Value
Smooth External
Smooth Rail
Detailed descriptions follow later in this lesson.
Add the desired commands to the Robotics menu or the toolbar.
OLP Tools are a set of commands which are necessary to do several things, including
define attributes needed by the controllers.
Convert to Via Location
This tool allows the conversion of weld locations into robotic via locations.
To use it:
1. Select one or several weld locations. It is also possible to select weld operations (in
this case all weld locations inside the operations will be considered selected).

Final Comments
2.
Select Robotics → Convert to Via Location .
The selected weld locations are converted into via locations.
Convert to Weld Location
This tool allows the conversation of robotic via locations into weld locations.
To use it:
1. To enable the command, select one or several via locations. It is also possible to
select weld operations (in this case all via locations inside the operations will be
considered selected).
2.
Select Robotics → Convert to Weld Location .
3. In the Convert to Weld Location window, you can select the discrete process
(SPOT, STUD, etc...). This will determine the discrete MFG type that will be
created.
4. Click Apply.
The selected via locations are converted into weld locations.
Create Seam Operation
This tool allows the conversion of robotic via locations into seam locations gathered
into seam operations.
To use it:
1. To enable the command, select a list of robotic via locations inside a continuous
operation
2.
Select Robotics → Create Seam Operation .

Final Comments
3. In the Create Seam Operation window, you can select the continuous process
(GLUE, ARC, PAINT, etc..). This will determine the continuous MFG type that
will be created.
4. Click Apply.
The selected via locations are converted to seam locations and are put inside
seam operations.
Define Gun Main Joint
This tool allows users to define the main joint of a servo or pneumatic servo gun (this
step is required for pneumatic servo gun simulation as well as for servo gun hot swap
simulation, in case the gun is modeled with more than one prismatic joint).
To use it:
1. Select a servo or pneumatic servo gun.
2.
Select Robotics → Define Gun Main Joint .
3. In the Define Gun Main Joint window, select the Main Joint.
4. Click Apply to store your choice, or Remove to delete your choice.
Mark Current Rail Value
This tool allows the automatic setting of current rail value to a list of locations.
To use it:

Final Comments
1. Select one or several locations (locations should belong to a robot on a rail). It is

also possible to select operations (in this case all locations inside the operations will
be considered selected).
2.
Select Robotics → Mark Current Rail Value .
The command will create/update the rail value on all locations with the
current rail position.
Rail Jog with Locked TCPF
This tool allows jogging a rail while keeping the robot TCPF in a fixed position.
To use it:
1. Select one location.
2.
Select Robotics → Rail Jog with Locked TCPF .
3. In the Rail Jog with Locked TCPF window, you can jog the rail with the slider or
by typing a numerical value in the numeric control.
• You can change the step of the numeric control via the Step link
If robot cannot maintain its TCPF at the location, the Update Location
button will be disabled.
• Reset will revert back the rail at the rail value as stored in the location
external axes ("Reset" is disabled in case the location does not have yet a rail
value).
• Update Location will update the location external axes with the current rail
value.
Shift Rail Value

Final Comments
This tool allows the shifting of rail value on a list of locations.

To use it:
1. Select one or several locations (locations should belong to a robot on a rail). It is
also possible to select operations (in this case all locations inside the operations will
be considered selected).
2.
Select Robotics → Shift Rail Value .
3. Select the amount of mm you would like to shift the rail value on the selected
locations (the numeric control automatically limits the possible values so that no
rail values on any of the selected locations could be outside limits)
4. Click [OK].
The rail value will be updated accordingly on all selected locations (locations
without existing rail value will be left unchanged).
Smooth External
This tool allows the automatic setting of external axis values along a path.
To use it:
1. Select a robot.
2.
Select Robotics → Smooth External .
3. Select a start and an end location inside a robotic operation.

Final Comments
These locations should already have an external value defined.
4. If the robot has more than one external axis, select the external joint you want to
interpolate
5. Click [OK] or Apply.
The application will create/update the external joint values on all locations
between the selected ones. It will interpolate the external joint values set on
the start and end locations with the relative Cartesian travel distance from the
start location, along the path.
Smooth Rail
This tool allows the automatic setting of rail values along a path.
To use it:
1.
Select Robotics → Smooth Rail .
2. In the Smooth Rail window, select a start and an end location inside a robotic
operation. These locations should already have an external axis value defined.
3. For Method, select either Interpolate On Travel Distance or Project

Locations on Rail Axis.
• Interpolate On Travel Distance - The application interpolates the rail
values set on the start and end locations with the relative Cartesian travel
distance from the start location, along the path
• Project Locations On Rail Axis - The application interpolates the rail

values set on the start and end locations with the relative positions of each
locations along the rail.

Final Comments
4. Click [OK] or Apply. The application will create/update the rail values on all
locations between the selected ones.

Final Comments
Creating an OLP Procedure (Putting It All Together)

This topic provides an review of the multi-step OLP procedure.

• A Multi-Step OLP Procedure
A Multi-Step OLP Procedure
An OLP/calibration procedure definition should be a goal of anyone attempting an

OLP procedure of any size. It will enable the OLP provider to efficiently program and
calibrate a line of robots without wasting the time allowed for the task. An overview of
a sample procedure is outlined below.
A Multi-Step OLP Procedure:
1. Prepare the OLP materials - This step is also accomplished by the Process
Simulate user, who will create the program files, and prepare the OLP
documentation, which is a reproduction of the study layout, gun mounting, and
locations of calibration points.
2. Verify robot and study installation - This step is done by the robot programmer,
who uses the OLP materials to verify that the robot, tool, and study infrastructure
match the Process Simulate layout.
3. Generate robot program and download - The final step is combined action by
the process designer and robot programmer. The user creates the robot program,
which is input by the robot programmer.

Final Comments

Final Comments
Putting It All Together

At the beginning of this class you had little or no knowledge of Process Simulate.
Through class you have been exposed to many Process Simulate features and had
time to practice what you have seen. You must continue to use this tool after class in
conjunction with other users in your company, additional training classes, and Siemens
PLM Software services personnel in order to become an expert.

Final Comments
Summary
• An overview of the robotic parameters viewer
• An overview of robot modules
• An overview of the roller hemming tool
• An overview of the OLP tools
• An overview of creating an OLP procedure
• How to put it all together.

MTXW315S S 101 - 272pages PDF

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Process Simulate on eMS

Advanced Robotics (OLP)

Advanced Robotics (OLP) Course Overview. . . . . . . . . . . . . . . . . . . . . . . 11

MTXW315S-S-101 Process Simulate on eMS Advanced Robotics (OLP) 3

4 Process Simulate on eMS Advanced Robotics (OLP) MTXW315S-S-101

MTXW315S-S-101 Process Simulate on eMS Advanced Robotics (OLP) 5

6 Process Simulate on eMS Advanced Robotics (OLP) MTXW315S-S-101

MTXW315S-S-101 Process Simulate on eMS Advanced Robotics (OLP) 7

8 Process Simulate on eMS Advanced Robotics (OLP) MTXW315S-S-101

MTXW315S-S-101 Process Simulate on eMS Advanced Robotics (OLP) 9

The RobotExpertProcess Simulate on eMS Advanced Robotics course provides step-

• Introduction to RCS, RRS, and ESRC

• Setting up the RCS, RRS, and ESRC

• Creating Robot Programs

• Inverse Kinematics Solution Selections (Robot Configurations)

• Robot Controller Selection and Setup

• Testing the Teach Pendant and Fixing Setup Problems

• Robot Controller Specific Frames, Setup, and Motion Attributes

MTXW315S-S-101 Process Simulate on eMS Advanced Robotics (OLP) 11

• ESRC OLP Commands

• OLP Command XML Customization

• Motion XML Customization

• Robotic Path Template XML Customization

• Other XML Customization Topics

• OLP Add-ons and OLP Tools

Advanced Robotics Prerequisites

• WKP215S – Process Simulate on eMS Intermediate Robotics

Advanced Robotics Audience

• WKP106S – Process Simulate on eMS Human Simulation

• WKP115S – Process Simulate on eMS Basic Robotic Simulation

• WKP215S – Process Simulate on eMS Intermediate Robotics

• WKP315S – Process Simulate on eMS Advanced Robotics

12 Process Simulate on eMS Advanced Robotics (OLP) MTXW315S-S-101

The following steps show you how to launch an activity.

2. Click Launch the activity to open the activity window.

MTXW315S-S-101 Process Simulate on eMS Advanced Robotics (OLP) 13

14 Process Simulate on eMS Advanced Robotics (OLP) MTXW315S-S-101

16 Process Simulate on eMS Advanced Robotics (OLP) MTXW315S-S-101

1 Introduction to Advanced Robotics

• An overview of theProcess Simulate data model.

• The basics of robot models.

• The basics of RRS, RCS, and ESRC.

• How to setup the RCS and RRS.

• The steps for process generation and process to program.

• The problems that can occur if OLP is not considered.

• How to prepare the study for OLP.

• Some sources of error in OLP.

Process Simulate on eMS Advanced Robotics (OLP) 1-1

This course focuses on portion of Process Simulate known as Process Simulate

1-2 Process Simulate on eMS Advanced Robotics (OLP) MTXW315S-S-101

• Program – A collection of paths (and or locations) used for downloading.

Process Simulate on eMS Advanced Robotics (OLP) 1-3

Review of the Data Model

• Robotic Simulative Operations

• OLP Software Packages

Data Model Basics

In general, the data can be initially found in these viewers:

• Operations are found in the Operations Tree viewer.

• Manufacturing Features can be found in the Mfg Viewer.

1-4 Process Simulate on eMS Advanced Robotics (OLP) MTXW315S-S-101

• Device operation - a simulative operation consisting of any mechanical device

• Robotic operation - a simulative operation consisting of a sequence of locations