KUKA System Technology

KUKA.CNC 2.1
For KUKA System Software 8.3

Issued: 09.04.2013

Version: KUKA CNC 2.1 V1 en (PDF)

KUKA Roboter GmbH

KUKA.CNC 2.1

Copyright 2013
KUKA Roboter GmbH
Zugspitzstrae 140
D-86165 Augsburg
Germany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC

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Publication:

Pub KUKA CNC 2.1 (PDF) en

Bookstructure:

KUKA CNC 2.1 V1.1

Version:

KUKA CNC 2.1 V1 en (PDF)

Issued: 09.04.2013 Version: KUKA CNC 2.1 V1 en (PDF)

Contents

Contents
1

Introduction ..................................................................................................

1.1

Target group ..............................................................................................................

1.2

Industrial robot documentation ...................................................................................

1.3

Representation of warnings and notes ......................................................................

1.4

Terms used ................................................................................................................

Product description .....................................................................................

2.1

Overview of KUKA.CNC ............................................................................................

Safety ............................................................................................................

Installation ...................................................................................................

11

4.1

System requirements .................................................................................................

11

4.2

Installing or updating KUKA.CNC ..............................................................................

11

4.3

Uninstalling KUKA.CNC .............................................................................................

12

4.4

Installing the CNC development environment for Multiprog .......................................

12

Planning .......................................................................................................

13

5.1

Positioning the milling table and workpiece ...............................................................

13

Start-up and configuration .........................................................................

15

6.1

Technology functions of the CNC ..............................................................................

15

6.1.1

Predefined technology functions ...........................................................................

15

6.1.2

User-defined technology functions .......................................................................

16

6.1.3

Mapping technology functions to the periphery ....................................................

18

Mapping by means of the Multiprog CNC template .........................................

Mapping by means of the CNC WorkVisual catalog element ..........................

19
20

6.2

Base for KUKA.CNC ..................................................................................................

21

6.3

Tool management and tool change ...........................................................................

21

6.3.1

Tool management via KRC ...................................................................................

23

6.3.2

Tool management via CNC ..................................................................................

23

Tool calibration ................................................................................................

Configuring the CNC tool data .........................................................................
Programming a tool change in the NC program ..............................................

23
24
26

Managing NC programs .............................................................................................

26

6.4.1

Toggling the NC program directory .......................................................................

27

6.4.2

Creating new NC programs ..................................................................................

27

6.4.3

Editing NC programs ............................................................................................

29

6.4.4

Deleting NC programs ..........................................................................................

30

6.4.5

Saving NC programs under a different name .......................................................

32

6.4.6

Editing internal NC programs ................................................................................

33

6.4.7

Importing NC programs ........................................................................................

35

6.5

Configuring zero offset data .......................................................................................

37

6.6

Configuring clamp offset data ....................................................................................

38

6.7

6.1.3.1
6.1.3.2

6.3.2.1
6.3.2.2
6.3.2.3
6.4

Channel parameters ..................................................................................................

39

6.7.1

Configuring axis groups ........................................................................................

40

6.7.2

Configuring spindles .............................................................................................

41

6.7.3

Synchronization of user-defined technology functions .........................................

42

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Operation ......................................................................................................

43

7.1

Menus ........................................................................................................................

43

7.2

KUKA.CNC-HMI user interface .................................................................................

43

7.2.1

Status bar .............................................................................................................

45

7.2.2

Display of the axis-specific position (ACS) ...........................................................

46

7.2.3

Display of the Cartesian position (PCS) ...............................................................

47

7.2.4

Technology settings .............................................................................................

48

7.2.5

Operating mode Automatic mode ......................................................................

50

7.2.6

Operating mode MDI mode ................................................................................

51

7.2.7

Teach mode .........................................................................................................

52

7.2.8

Edit mode .............................................................................................................

52

7.3

Activating CNC operation ..........................................................................................

53

7.4

Selecting an NC program ..........................................................................................

54

7.4.1

Program run modes ..............................................................................................

54

7.5

Deselecting an NC program ......................................................................................

55

7.6

Stopping and restarting an NC program (Automatic mode) ......................................

55

7.7

Jogging the robot .......................................................................................................

56

Diagnosis ......................................................................................................

57

8.1

Diagnostic functions ..................................................................................................

57

Displaying TRACE data with ISG monitor ............................................................

58

Programming ...............................................................................................

59

9.1

Structure of an NC subprogram .................................................................................

59

9.2

Teaching points in the NC program ...........................................................................

59

9.3

Re-teaching points in the NC program changing the orientation ............................

60

9.4

Programming a tool change ......................................................................................

60

9.5

Batch mode ...............................................................................................................

61

10

Troubleshooting ..........................................................................................

63

10.1 Errors in NC operation ...............................................................................................

63

KUKA Service ...............................................................................................

65

8.1.1

11

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11.1 Requesting support ...................................................................................................

65

11.2 KUKA Customer Support ...........................................................................................

65

Index .............................................................................................................

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1 Introduction

Introduction

1.1

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

Advanced KRL programming skills

Advanced knowledge of the robot controller system

For optimal use of our products, we recommend that our customers

take part in a course of training at KUKA College. Information about
the training program can be found at www.kuka.com or can be obtained directly from our subsidiaries.

1.2

Industrial robot documentation

The industrial robot documentation consists of the following parts:

Documentation for the manipulator

Documentation for the robot controller

Operating and programming instructions for the KUKA System Software

Documentation relating to options and accessories

Parts catalog on storage medium

Each of these sets of instructions is a separate document.

1.3
Safety

Representation of warnings and notes

These warnings are relevant to safety and must be observed.
These warnings mean that it is certain or highly probable
that death or severe injuries will occur, if no precautions
are taken.
These warnings mean that death or severe injuries may
occur, if no precautions are taken.
These warnings mean that minor injuries may occur, if
no precautions are taken.
These warnings mean that damage to property may occur, if no precautions are taken.
These warnings contain references to safety-relevant information or
general safety measures.
These warnings do not refer to individual hazards or individual precautionary measures.
This warning draws attention to procedures which serve to prevent or remedy
emergencies or malfunctions:
Procedures marked with this warning must be followed
exactly.

Notes

These hints serve to make your work easier or contain references to further
information.

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KUKA.CNC 2.1

Tip to make your work easier or reference to further information.

1.4

Terms used
Term

Description

EMI

External Motion Interface

EMI is an interface that enables the robot to be moved
on the basis of an NC program. (That is, the robot is
not moved in the conventional manner on the basis of a
KRL program with taught points.)

CAD

Computer-aided design
In CAD, special software is used to create a 3D model
on the computer, e.g. of a workpiece. This model can
then be integrated into an NC program by means of a
CAM system.

CAM

Computer-aided manufacturing
CAM designates the manufacturing steps leading from
a CAD model to an NC program. The software used for
this is independent of the CNC machine, so an NC program can be created during the work preparation
phase.

G-code

Computer language for controlling CNC machines

NC programs are created in G-code.

KR C

KUKA Robot Controller

KRL

KUKA Robot Language

KUKA.CNCHMI

User interface of the KUKA.CNC technology package

on the KUKA smartHMI (CNC.Human-Machine Interface)

KUKA smartHMI

User interface of the KUKA System Software (KUKA

smart Human-Machine Interface)

MDI

Manual data input

Operating mode for set-up of the CNC machine. Short
NC blocks can be specified in an MDI block.

NC

Numerical control
The NC is an electronic device for the computer-aided
control of machine tools. The NC is able to read a data
set of control commands from a storage medium, convert them to work and motion sequences, and process
them one after the other.

NC program

NC programs are an integral part of the NC control

data, like the tool data and the zero point offset data.
NC programs describe the sequence of machining processes.

PLC

Programmable Logic Controller

The PLC is a module for higher-level control tasks in a
plant bus system.

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2 Product description

Product description

2.1

Overview of KUKA.CNC

Functions

Areas of application

KUKA.CNC is an add-on technology package with the following functions:

Execution of NC programs of a CAD/CAM system and MDI blocks

Program execution control by displaying runtime data

Editing of NC programs and MDI blocks

Teaching of robot positions in NC programs (Teach mode)

Machining tasks in which low process forces are generated:

Water-jet cutting

Laser cutting

Milling of shaped parts from soft materials, e.g. wood, plastic, foam
material, etc.

Machining tasks in which high process forces are generated, but with low
accuracy requirements:

Pre-machining of metal workpieces, e.g. roughing of aluminum

Fig. 2-1: Milling application example

Software components

Robot

Tool

Workpiece

The following components are included in the scope of supply of KUKA.CNC:

KUKA.CNC

CNC development environment for Multiprog

CNC WorkVisual catalog element

The CNC development environment must be installed on a start-up computer

together with WorkVisual and Multiprog. It contains the Multiprog libraries required for the CNC and a CNC template that can be used in Multiprog.

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KUKA.CNC 2.1

The programming of CNC using G-code is not covered by this documentation. The CNC documentation, e.g. the CNC programming and
diagnostic instructions, descriptions of functions and parameters,
etc., are supplied with the software on the KUKA.USBData stick (directory
DOC\pdf).
Functional
principle

Using the NC controller kernel on the robot controller means that NC programs
can be processed directly, i.e. without prior conversion to KRL programs, and
executed by the robot.

Communication

The robot controller communicates with the technology controller via a field
bus. There are different bus systems for the robot controller that are configured with WorkVisual.
Further information about the bus systems can be found in the corresponding KUKA documentation. Information about bus configuration
is contained in the WorkVisual documentation.

Teach mode

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Teach mode is provided for the following applications:

Programming a suitable start position (approach motion of robot to workpiece)

Programming axis space motions, e.g. on status change

Programming orientation changes, e.g. in the case of axis space errors or

singularity positions

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3 Safety

Safety
This documentation contains safety instructions which refer specifically to the
software described here.
The fundamental safety information for the industrial robot can be found in the
Safety chapter of the Operating and Programming Instructions for System Integrators or the Operating and Programming Instructions for End Users.
The Safety chapter in the operating and programming instructions
must be observed. Death to persons, severe injuries or considerable
damage to property may otherwise result.
When using the CNC Multiprog template and programming with Multiprog, the relevant specifications from the Safety chapters in the
documentation for KUKA.PLC ProConOs and KUKA.PLC Multiprog
must always be observed.

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4 Installation

Installation

4.1

System requirements
KR C4 or KR C4 compact

Hardware

Software

Robot controller:

KUKA System Software 8.3

KUKA.PLC ProConOS 4-1 4.1

Standard laptop/PC:

Compatibility

WorkVisual 3.0 or higher

KUKA.PLC Multiprog 5-35 4.1

KUKA.CNC must not be installed on a robot controller together with the following technology packages:

KUKA.ConveyorTech

KUKA.CNC can be used with KUKA.RoboTeam, but only for program synchronization (Program Cooperation) and not for motion synchronization (Motion Cooperation).
The KRC function generator may only be used together with KRL programs.
Use in conjunction with NC programs is not possible.

4.2

Installing or updating KUKA.CNC

It is advisable to archive all relevant data before updating a software
package.

Precondition

Software on KUKA.USBData stick

No program is selected.

T1 or T2 operating mode

Expert user group

Only the KUKA.USB data stick may be used. Data may
be lost or modified if any other USB stick is used.

Procedure

1. Plug in USB stick.

2. Select Start-up > Install additional software in the main menu.
3. Press New software. If a software package that is on the USB stick is not
displayed, press Refresh.
4. Select the entry KUKA.CNC and press Install. Reply to the request for
confirmation with Yes. The files are copied onto the hard drive.
5. Remove USB stick.
6. Reboot the robot controller. Installation is completed once the system has
rebooted.

LOG file

A LOG file is created under C:\KRC\ROBOTER\LOG.

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KUKA.CNC 2.1

4.3

Uninstalling KUKA.CNC
It is advisable to archive all relevant data before uninstalling a software package.
Expert user group

Precondition

Procedure

1. Select Start-up > Install additional software in the main menu. All additional programs installed are displayed.
2. Select the entry KUKA.CNC and press Uninstall. Reply to the request for
confirmation with Yes. Uninstallation is prepared.
3. Reboot the robot controller. Uninstallation is resumed and completed.
A LOG file is created under C:\KRC\ROBOTER\LOG.

LOG file

4.4

Installing the CNC development environment for Multiprog

Description

The CNC development environment must be installed on the start-up computer together with WorkVisual and Multiprog. It contains the Multiprog libraries
required for the CNC and a CNC template that can be used in Multiprog.

Precondition

WorkVisual is installed.

KUKA.PLC Multiprog is installed.

Administrator access rights

Start the program development.exe under MULTIPROG\development.

Procedure

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5 Planning

Planning

5.1

Positioning the milling table and workpiece

Description

NC programs created in CAD are independent of the type of machine with

which they are executed. They describe motions in Cartesian space without
the additional status and turn information used by the controller of a jointedarm robot to ensure an unambiguous transformation to axis positions.
A conventional machine tool has 3 main linear axes. For this reason, when NC
programs are executed, the transformation to axis positions is unambiguous.
There is a linear relationship between the Cartesian path or orientation velocities and the resulting axis velocities, i.e. within the workspace limits of a machine tool, it is simple to use the same G-code to machine several identical
surfaces of a workpiece or even multiple workpieces clamped adjacent to one
another.
KRL programs, on the other hand, are taught for a specific robot type and with
reference to a base, i.e. a specific workpiece position. Only then is it assured
that execution of the KRL programs with a jointed-arm robot will not exceed
the dynamic capabilities of the robot axes.
In order not to lose the advantage of G-code portability, we recommend positioning the milling table in such a way that, for the expected applications, the
motions stay well clear of the singularity positions of the robot. If this is not taken into consideration during system planning, the machining time is increased,
as the NC automatically reduces the path velocity as required. Furthermore,
non-constant path velocities have a detrimental effect on the process quality.
The following remedies are possible, however, in the case of singularities or
motions that exceed the dynamic capabilities (additional effort during start-up):

Switch to axis space motion in the NC program (G-code).

Program a rotation about the spindle axis in the NC program (G-code).

Teach intermediate positions or a change of orientation.

(>>> 9.3 "Re-teaching points in the NC program changing the orientation" Page 60)

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6 Start-up and configuration

Start-up and configuration

6.1

Technology functions of the CNC

Technology functions, such as switching operations in the PLC, can be triggered in the NC program by means of M, S and T functions. The predefined
and user-specific technology functions available in KUKA.CNC are described
below.
The technology functions of the CNC are mapped to global PLC variables and
can be linked to the field bus I/Os via WorkVisual.

6.1.1

Predefined technology functions

Function

PLC signal name

Type

Description

M2

CNC_M02_Out

BOOL

M2 sets the output at the end of the NC

program.

CNC_M02_In

BOOL

Acknowledgement input for M2.

CNC_Spindle_CW_Out

BOOL

M3 sets the output and the spindle is

started clockwise.

CNC_Spindle_CW_In

BOOL

Acknowledgement input for M3 when

the specified spindle speed has been
reached.

CNC_Spindle_CCW_Out

BOOL

M4 sets the output and the spindle is

started counterclockwise.

CNC_Spindle_CCW_In

BOOL

Acknowledgement input for M4 when

the specified spindle speed has been
reached.

CNC_Spindle_Stop_Out

BOOL

M5 sets the output and the spindle is

stopped.

CNC_Spindle_Stop_In

BOOL

Acknowledgement input for M5 when

the spindle speed has come to a standstill.

CNC_ToolChange_Out

BOOL

M6 sets the output and the tool is

changed.

CNC_ToolChange_In

BOOL

Acknowledgement input for M6 when

the tool has been changed.

CNC_Cooling_OnOff_Out

BOOL

M8 sets the output and the cooling is

switched on. M9 resets the output and
the cooling is switched off.

CNC_Cooling_On_In

BOOL

Acknowledgement input for M8 when

the cooling is switched on.

CNC_Cooling_Off_In

BOOL

Acknowledgement input for M9 when

the cooling is switched off.

CNC_Vacuum_OnOff_Out

BOOL

M10 sets the output and the vacuum is

switched on. M11 resets the output and
the vacuum is switched off.

CNC_Vacuum_On_In

BOOL

Acknowledgement input for M10 when

the vacuum is switched on.

CNC_Vacuum_Off_In

BOOL

Acknowledgement input for M11 when

the vacuum is switched off.

M3

M4

M5

M6

M8/M9

M10/M11

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KUKA.CNC 2.1

Function

PLC signal name

Type

Description

M30

CNC_M30_Out

BOOL

M30 sets the output at the end of the

NC program and the spindle and cooling are switched off.

CNC_M30_In

BOOL

Acknowledgement input for M30 when

the spindle is stopped and the cooling
is switched off.

CNC_Tool_Number

INT

Tool number display

CNC_Spindle_Speed

INT

Spindle speed display (unit: rpm)

With use of the KUKA.CNC template in Multiprog, the PLC signals

from the above table can be found in the declaration of the global variables under the group System M-Function I/O.
The following global PLC variables can be used to access the predefined technology functions via the PLC program.
PLC variable

Type

Description

CNC_Cooling_OnOff

BOOL

Switch cooling on/off

CNC_Spindle_OnOff

BOOL

Switch spindle on/off

CNC_Vacuum_OnOff

BOOL

Switch suction on/off

With use of the KUKA.CNC template in Multiprog, these PLC variables can be found in the declaration of the global variables under the
group System M-Function signals.

6.1.2

User-defined technology functions

Description

There are 16 user-specific digital I/O data available in the KUKA.CNC. In the
NC program, a digital output is always switched on by an M function (e.g.
M100) and switched off again by a second M function (e.g. M101). M functions
M100 to M131 are thus available for the user-defined technology functions.
If additional M functions are required, these can be integrated into the
KUKA.CNC after consultation with KUKA Roboter GmbH.
(>>> 11 "KUKA Service" Page 65)
Example of a user-defined output:

Function

PLC signal name

Type

Description

M100/M101

CNC_M100_M101_Out

BOOL

M100 sets the user-defined output.

M101 resets the user-defined output.

CNC_M100_In

BOOL

Acknowledgement input for M100.

CNC_M101_In

BOOL

Acknowledgement input for M101.

With use of the KUKA.CNC template in Multiprog, the PLC signals

from the above table can be found in the declaration of the global variables under the group User M-Function I/O.
The following global PLC variables can be used to access the user-defined
technology functions via the PLC program.

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PLC variable

Type

Description

CNC_M100_M101_OnOff

BOOL

Switch technology M100 on/off

CNC_M102_M103_OnOff

BOOL

Switch technology M102 on/off

CNC_M104_M105_OnOff

BOOL

Switch technology M104 on/off

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6 Start-up and configuration

PLC variable

Type

Description

CNC_M106_M107_OnOff

BOOL

Switch technology M106 on/off

CNC_M108_M109_OnOff

BOOL

Switch technology M108 on/off

CNC_M110_M111_OnOff

BOOL

Switch technology M110 on/off

CNC_M112_M113_OnOff

BOOL

Switch technology M112 on/off

CNC_M114_M115_OnOff

BOOL

Switch technology M114 on/off

CNC_M116_M117_OnOff

BOOL

Switch technology M116 on/off

CNC_M118_M119_OnOff

BOOL

Switch technology M118 on/off

CNC_M120_M121_OnOff

BOOL

Switch technology M120 on/off

CNC_M122_M123_OnOff

BOOL

Switch technology M122 on/off

CNC_M124_M125_OnOff

BOOL

Switch technology M124 on/off

CNC_M126_M127_OnOff

BOOL

Switch technology M126 on/off

CNC_M128_M129_OnOff

BOOL

Switch technology M128 on/off

CNC_M130_M131_OnOff

BOOL

Switch technology M130 on/off

With use of the KUKA.CNC template in Multiprog, the PLC variables

can be found in the declaration of the global variables under the group
User M-Function signals.
Synchronization

If execution of the NC program is to be synchronized with an M function, the

synchronization type must be set accordingly in the channel parameter configuration.

Precondition

Procedure

1. Open the channel parameter configuration via the menu sequence CNC >
Configuration > Channel parameters.

Expert user group

2. Click twice on Next to switch to the configuration page of the synchronization parameters.
3. Configure the desired synchronization type and if necessary the additive
parameter for the corresponding user-defined M command.

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Fig. 6-1: Synchronization parameters

Item

Description

Selection of the synchronization type for the chosen user-defined M command.

Selection of the user-defined M command to be configured.

Additive parameters which can be configured for the user-defined M command in addition to the synchronization type.
Green check mark = additive parameters activated for the M
command selected in point 1

4. Click on Save to save the changes.

5. Perform a reconfiguration of the controller in order to apply the changes.
6.1.3

Mapping technology functions to the periphery

Description

There are two methods for mapping technology functions to the periphery:

Mapping via the KUKA.CNC Multiprog template

Mapping via the KUKA.CNC WorkVisual catalog element

The I/O mapping itself is performed in the same way in both cases. The two
methods differ in terms of the operator actions carried out before mapping.
The mapping method via the KUKA.CNC WorkVisual
catalog element should only be used if Multiprog is not
available.

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6 Start-up and configuration

Procedure

PLC variables and thus also the technology functions are

mapped in WorkVisual in the same way as the I/O signals. The exact procedure for bus mapping and transferring the project to the
robot controller is described in the WorkVisual documentation.

Example

In this example, an Interbus is configured. 2 outputs of the Interbus have been

linked to a PLC variable.

Fig. 6-2: Mapping technology functions to field bus I/Os

6.1.3.1

PLC tab select Global_Variables.

List of available PLC variables

Field buses tab select the field bus

List of configured field bus I/Os

List of mapped field bus I/Os

Mapping by means of the Multiprog CNC template

Precondition

Procedure

WorkVisual 3.0 is installed.

KUKA.PLC Multiprog 5-35, V4.1 is installed.

The KUKA.CNC development environment for Multiprog is installed.

Field bus and field bus I/Os are configured.

1. Start WorkVisual and open the desired project.

2. Add the catalog element PROCONOS 4-1 to the robot controller.
On the Hardware tab, select Add in the context menu of the robot controller.
Add the catalog element PROCONOS 4-1. PROCONOS 4-1 is displayed
in the robot controller under Options.
3. Set the robot controller as the active controller via the context menu. Select the correct version of the system software.
The Multiprog project is created and the Select template window is
opened. If the window does not open automatically, the window can be
opened by double-clicking on the option Open PROCONOS 4-1 geffnet
werden.
4. In the Select template window, select the template KRC4 CNC and accept it with OK. The mapping editor in WorkVisual and the Multiprog appli-

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cation are opened automatically. On the PLC tab of the mapping editor,
the technology functions of KUKA.CNC are available as global variables
in the groups User M-Functions I/O and User M-Functions signals.
5. Connect the required PLC variables to the field bus I/Os by means of
Drag&Drop.
Once all the required I/Os have been mapped, code generation can be
started and the project can then be transferred to the robot controller and
activated. Once the project has been activated, the signal goes via the
field bus to the periphery when a mapped technology function is called in
the NC program.
6.1.3.2

Mapping by means of the CNC WorkVisual catalog element

Description

The KUKA.CNC catalog element can be used to map technology functions to

the periphery.
The KUKA.CNC catalog element is located on the KUKA.CNC option in the
WoV directory.

Precondition

Procedure

WorkVisual 3.0 is installed.

Field bus and field bus I/Os are configured.

1. Start WorkVisual.
The Project Explorer is displayed.
2. Load the current controller project.
3. Open the Catalog Management via the menu sequence File > Catalog
Management....
4. Click on Open in the Catalog Management.
5. Navigate to the catalog element and open it.
The KUKA.CNC catalog element is automatically added to the list of project catalogs for the current project.
6. Close the Catalog Management.
The KUKA.CNC catalog element is displayed in the view of catalogs that
are available in the project.
7. Add the KUKA.CNC catalog element to the robot controller:
On the Hardware tab, select Add in the context menu of the robot controller.
The catalog element KUKA.CNC is located on the KUKA.CNC tab. Add
the KUKA.CNC catalog element. KUKA.CNC is now displayed in the robot controller under Options.
8. Set the robot controller as the active controller via the context menu. Select the correct version of the system software. The mapping editor opens
automatically.
The technology functions User M-Functions are now available on the
PLC tab.
9. Connect the required PLC variables to the field bus I/Os by means of
Drag&Drop.
Once all the required PLC variables have been mapped, code generation
can be started and the project can then be transferred to the robot controller and activated.
Once the project has been activated, the signal goes via the field bus to
the periphery when a mapped technology function is called in the NC program.

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6.2

Base for KUKA.CNC

The zero point for KUKA.CNC on the KRC is determined by $BASE, i.e. the
last base active before activation of CNC mode is used. An additional zero
point offset can be programmed in the CNC code.

Fig. 6-3: Base for KUKA.CNC

6.3

Tool management and tool change

Description

In many cases, it is necessary to work with several different tools. For example, different milling heads may be used in a milling application. For this purpose, it is possible to perform a tool change.
The TCP data for the CNC are determined by $Tool in the KRC. Unlike in the
case of the base, the last valid TCP is not used for CNC mode; instead, the
tool data or number can be specified via the CNC. To update the TCP, CNC
mode is interrupted, $Tool is updated and CNC mode is restarted.
Determination of the TCP data varies according to the variable cncReferenceTool (local integer variable in the program CNCMotion.dat).

Variant 1

If the variable cncReferenceTool = 0, only the tool number is transferred by

the CNC code (X) and the corresponding tool data are loaded from $config.dat.

Fig. 6-4: Tool change variant 1

Variant 2

If the variable cncReferenceTool > 0, a reference TCP is loaded from $config.dat and used to define the spindle mount. Based on this TCP, when a tool
is selected in the CNC code (X), the values from the CNC tool configuration

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KUKA.CNC 2.1

for the selected tool X are linked to the data of the reference tool and $Tool is
updated with the result.

Fig. 6-5: Tool change variant 2

Fig. 6-6: Tool change flowchart

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6.3.1

Tool management via KRC

Description

The default tool change method of the KRC can also be used with KUKA.CNC.
For this purpose, all the tools to be used must be calibrated using the customary calibration methods of the KRC and correspondingly entered in the tool
management ($config.dat) of the KRC. The tool change is performed as usual
via a KRL program. For this method, the value of cncReferenceTool must be
0 (variant 1) .
Further information is contained in the operating and programming instructions for the KUKA System Software (KSS).

6.3.2

Tool management via CNC

Description

6.3.2.1

For the NC controller, the tool is e.g. the milling head mounted on the spindle
mount. The tool offset from the spindle mount to the TCP (= tip of spindle) must
be measured for every tool. A reference tool must be calibrated in the KRC
and its index stored in cncReferenceTool (variant 2). The offsets entered in
the CNC tool configuration are accordingly linked to this reference tool in the
case of a tool change.

Tool calibration

Description

The CNC tool data refer to a reference tool on the KRC. For this reference tool,
the offset from the robot flange to the tool mount, e.g. of the milling spindle, is
measured. The standard KUKA tool calibration methods can be used for this,
e.g. the XYZ 4-point and ABC 2-point methods.
The calibration data must be saved under the tool number used for CNC operation. For subsequent CNC operation, the index of the reference tool must
be entered as the value of the variable cncReferenceTool in the data list
KRC:\R1\TP\CNC\cncMotion.dat, e.g.:
cncReferenceTool = 5

The tool offset from the spindle mount to the TCP (= tip of spindle) must be
measured mechanically for every tool by means of a coordinate measuring
machine and entered in the CNC tool configuration.

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Fig. 6-7: Calibrating the reference tool

6.3.2.2

Spindle mount

Tool offset (= offset from spindle mount to TCP)

Configuring the CNC tool data

Description

The tool data configuration can be found in the menu of the configuration interface under CNC > Configuration > Tool data. On this configuration page,
tools of the CNC can be selected and the corresponding tool data entered or
changed.
Tool data can also be modified online by means of variable access in
the NC program. Information about this can be found in the CNC programming instructions.

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Fig. 6-8: Tool data

Item

Description

Close the tool configuration.

If data have been changed, a request for confirmation is generated when the window is closed, asking whether the changed
data are to be saved.
The changes will be discarded if they are not saved. The changes are only applied after a reconfiguration or a cold start of the
controller.

Selection of the tool to be configured.

The number of the tool displayed here is used when programming the tool change in the NC program.

Indicates whether the currently selected tool is active, so that it

is possible to change to this tool from the NC program.
Green check mark = tool available for tool change.
No check mark = tool not available for tool change.
Pressing the button toggles between active and inactive.

Radius of the currently selected tool in millimeters, e.g. radius of

a milling head, which is to be used for a tool radius correction.

Dimension of the tool in the X direction in millimeters, e.g. length

of a milling head

Dimension of the tool in the Y direction in millimeters

Dimension of the tool in the Z direction in millimeters

Orientation of the tool about the Z axis in degrees

Orientation of the tool about the Y axis in degrees

10

Orientation of the tool about the X axis in degrees

11

Accept and save the entered tool data for the current tool

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Following installation of KUKA.CNC, the CNC tool configuration already contains a number of activated tools
that must be adapted by the start-up technician according to the tools actually
used. Tools that are not required must be deactivated and any further tools
required must be activated.
If the CNC function tool radius correction is to be used, the tool radius must be correctly configured. This applies for both variant 1 and
variant 2 of the tool change.
Incorrectly configured tool data may result in damage to
the workpiece, the machine or other objects in the vicinity
of the robot. In such cases, this may also constitute a danger to persons. After a change to the tool data, these should therefore be checked for correctness in the set-up mode T1.
6.3.2.3

Programming a tool change in the NC program

The technology function M6 is available for programming a tool change in the
NC program. It is called using the number of the new tool.
%Move_Vertical
N010
N020
N030
N040
N050
N060
N070

G01 G91
T4 M6
G01 G91
T5 M6
G01 G91
T0 M6
G01 G91

Z100 F1000
Z100 F1000
Z100 F1000
Z-300 F1000

N080 M30

The command T4 M6 in the above example means that the tool with the number 4 (T4 = Tool 4), that was configured via the tool data during start-up, is to
be selected.

6.4

Managing NC programs

Description

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The CNC HMI offers the following options for NC programs:

Switching the current NC program directory

(>>> 6.4.1 "Toggling the NC program directory" Page 27)

Creating new NC programs

(>>> 6.4.2 "Creating new NC programs" Page 27)

Editing NC programs
(>>> 6.4.3 "Editing NC programs" Page 29)

Deleting NC programs
(>>> 6.4.4 "Deleting NC programs" Page 30)

Saving NC programs under another name

(>>> 6.4.5 "Saving NC programs under a different name" Page 32)

Editing internal NC programs

(>>> 6.4.6 "Editing internal NC programs" Page 33)

Importing NC programs from other sources, e.g. from a network drive

(>>> 6.4.7 "Importing NC programs" Page 35)

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6 Start-up and configuration

6.4.1

Toggling the NC program directory

Description

Depending on the user that is currently logged on, it is possible to toggle between two or three directories for the current NC program directory.

The directory prg_intern contains internal utility programs

(>>> 6.4.6 "Editing internal NC programs" Page 33) and can only be selected if the current user has Expert privileges or higher.

The directory prg contains NC programs which are not archived.

The directory prg_sync contains NC programs which are archived.

The distinction between prg and prg_sync is necessary

because very large NC programs of several hundred MB
cannot be archived for system reasons and should therefore be saved under
prg. These NC programs must be archived manually. All NC programs saved
under prg_sync are archived automatically when an archive is created. The
procedure for creating an archive is described in the system software documentation.

Fig. 6-9: Toggling the NC program directory

6.4.2

Creating new NC programs

Description

New NC programs can be created via the CNC HMI. The newly created NC
programs are saved to the hard drive in the currently selected NC working directory.

Procedure

1. Switch to the view of available NC programs.

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Fig. 6-10: Switching to the view of NC programs

2. If necessary, toggle to the directory in which the new program is to be created.
3. Create a new NC program.

Fig. 6-11: Creating a new NC program

4. Enter a name for the NC program, and confirm.
5. The new NC program is displayed in the list of available programs.

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Fig. 6-12: Program list

6.4.3

Editing NC programs

Description

NC programs can be edited via the CNC HMI.

Procedure

1. Switch to the view of available NC programs.

Fig. 6-13: Switching to the view of NC programs

2. Select the NC program to be edited, and press Edit.

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KUKA.CNC 2.1

Fig. 6-14: Selecting the NC program

3. The NC program is opened in the editor and can be edited.

Fig. 6-15: Editor

Item

Description

Quit program editing.

If an NC program is closed without saving, the changes are discarded.

6.4.4

Save the changes that have been made.

Save the NC program under a different name

(>>> 6.4.5 "Saving NC programs under a different name"
Page 32).

Deleting NC programs

Description

NC programs which are no longer required can be deleted via the CNC HMI.
If an NC program is deleted, it is removed from the hard
drive and can no longer be restored. It is advisable to
back up the NC programs at regular intervals using the KRC archiving mechanism.

Precondition
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Expert user group

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6 Start-up and configuration

Procedure

1. Switch to the view of available NC programs.

Fig. 6-16: Switching to the view of NC programs

2. Select an NC program and delete it using the corresponding button.

Fig. 6-17: Deleting an NC program

3. Confirm the request for confirmation.

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KUKA.CNC 2.1

Fig. 6-18: Request for confirmation before deleting a file

6.4.5

Item

Description

Delete. The file is removed from the hard drive.

Cancel the action. The file is not deleted.

Saving NC programs under a different name

Description

After editing, an NC program can be saved under a new name, with all the
changes made. Saving an NC program under a new name without making any
changes duplicates the content of the file in a second file with a different name.

Procedure

1. Open the file in Edit mode.

2. Make any changes required and press the Save as button.

Fig. 6-19: Saving an NC program under another name

3. Enter a file name for the new file and save it.

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6 Start-up and configuration

Fig. 6-20: Entering a file name

4. Save the file under the specified name.

Fig. 6-21: Saving the file name

Item

Description

Save. The file is saved under the specified name.

Cancel the action. The file is not saved.

If a file is already saved under the same name, a message is displayed to the effect that this file already exists.
The file is therefore not saved. In this case, steps 3 and 4 must be repeated
and a different name must be entered.

6.4.6

Editing internal NC programs

Description

The directory prg_intern contains system-internal utility programs which need

to be modified under certain conditions, e.g. cycle for pocket milling. Should
this be necessary, the CNC HMI provides a way of modifying these NC programs.

Precondition

Procedure

1. Switch to the view of available NC programs.

Expert user group

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KUKA.CNC 2.1

Fig. 6-22: Switching to the view of NC programs

2. All the user and example programs in the directory prg are displayed.

Fig. 6-23: prg directory

3. Switch to the directory prg_intern.

Fig. 6-24: Switching to the prg_intern directory

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6 Start-up and configuration

This button is only displayed if the user is logged on in the Expert

user group. The log-on procedure is described in the KSS documentation.
4. The NC programs available in the directory prg_intern are displayed.

Fig. 6-25: prg_intern directory

5. Select the NC program to be edited, and switch to Edit mode.
6.4.7

Importing NC programs

Description

NC programs can be imported via the CNC HMI. For example, these may be
NC programs on network drives enabled on the controller, on USB sticks
plugged into the controller or on one of the partitions of the controller. The files
are copied using the import mechanism into the prg directory, where they can
then be edited and run.

Procedure

1. Switch to the view of available NC programs.

Fig. 6-26: Switching to the view of NC programs

2. Click on the Import file button.

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KUKA.CNC 2.1

Fig. 6-27: Importing an NC program

3. Navigate to the location of the NC program that is to be imported, and select the NC program.

Fig. 6-28: Selecting a program

4. Click on the Start import button.

Fig. 6-29: Starting the NC program import

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6 Start-up and configuration

Item

Description

Start import. The file is copied to the prg directory.

Cancel import. The file is not copied.

5. The file is located in the prg directory and can now be used.

6.5

Configuring zero offset data

Description

Various zero point offset groups can be specified and selected in the NC program using the G commands G54 to G59. In each of these groups, an offset
can be specified in the X, Y and Z directions.
The groups G54 to G59 can be used to activate zero point offsets within an
NC program. The command G53 resets the currently selected zero point offset.
The zero offset data are configured via the corresponding configuration page
on the KRC user interface. The configuration page is accessed via the menu
sequence CNC > Configuration > Zero offsets.
Further information about the zero offset data and their
use can be found in the NC documentation and in the
CNC online help. The CNC online help is located in the KUKA.CNC option
in the DOC directory.

Overview

Fig. 6-30: Zero offset data

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KUKA.CNC 2.1

Item

Description

Selection of the zero point offset group which is to be used by

the NC controller by default if no other offset is specified.

Selection of the zero point offset group to be configured.

Zero point offset of the group selected under item 2, in the direction of the X axis in millimeter.

Zero point offset of the group selected under item 2, in the direction of the Y axis in millimeter.

Zero point offset of the group selected under item 2, in the direction of the Z axis in millimeter.

Accept and save the entered zero offset data.

If the configuration page is closed without saving, all changes
made since last saving are discarded.

6.6

Configuring clamp offset data

Description

The configuration page for clamp offset data allows different clamp offset
groups to be selected and the corresponding clamp offset data to be specified.
The configuration page is accessed via the menu sequence CNC > Configuration > Clamp offsets.
Selecting the clamp offset index before NC program start allows the corresponding clamp offset group to be loaded. Each clamp offset group contains
the clamp offset data for the X, Y and Z directions.
When the NC program is started, the selected clamp offset data are taken into
account in the coordinates. The start axis configuration of the NC channel is
defined in the channel parameters.
Further information about the clamp offset data and their use can be
found in the NC documentation and the CNC online help. These are
located in the KUKA.CNC option in the DOC directory.

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6 Start-up and configuration

Overview

Fig. 6-31: Clamp offset data

6.7

Item

Description

Selection of the clamp offset group to be configured.

Clamp offset of the group selected under item 1, in the direction

of the X axis in millimeter.

Clamp offset of the group selected under item 1, in the direction

of the Y axis in millimeter.

Clamp offset of the group selected under item 1, in the direction

of the Z axis in millimeter.

Accept and save the entered clamp offset data for the currently
selected group. If configuration page is closed without saving,
any changes made are discarded.

Channel parameters

Description

The configuration interface for the general channel parameters is opened via
the menu sequence CNC > Configuration > Channel parameters. The configuration interface consists of several pages, which can be toggled using the
buttons Next and Back. Before switching pages or closing the configuration
interface, any changes made should be saved using the Save button. Unsaved changes will be rejected.

Precondition

Expert user group

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KUKA.CNC 2.1

6.7.1

Configuring axis groups

Description

This configuration page is used to add axes to the current axis group or to remove them. In addition, a number and a name can be assigned to each axis.
Further information about the axis groups and their use can be found
in the NC documentation and the CNC online help. These are located
in the KUKA.CNC option in the DOC directory.

Overview

Fig. 6-32: Configuring axes

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Item

Description

List of axes that have not yet been assigned to an axis group.

List of axes that are assigned to the axis group. The axis itself,
and the number and name of this axis within the axis group are
displayed.

Number of the axis selected in list 2 within the group. This box
can be used to change the number of the axis.

Name of the axis selected in list 2 within the group. This box can
be used to change the name of the axis.

This button can be used to assign the ungrouped axis selected

in list 1 to the axis group.

This button is used to remove the axis selected in list 2 from the
axis group, thereby making it an ungrouped axis again.

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6 Start-up and configuration

6.7.2

Configuring spindles

Description

This configuration page allows the configuration of spindles. It must be ensured that only the spindles configured here are addressed in the NC program.
This applies to both position-controlled and PLC-controlled spindles.

Overview

Fig. 6-33: Configuring a spindle

Item

Description

Number of available spindles.

Selection of the spindle to be configured.

Name of the spindle to be configured.

Logical axis number of the spindle to be configured.

This button is used to define whether the selected spindle is to

be controlled via a PLC program or directly by the NC controller.
If the button is activated, the selected spindle is controlled by a
PLC program.

Synchronization type of the spindle to be configured.

Further information about the spindles and their use can be found in
the NC documentation and the CNC online help. These are located in
the KUKA.CNC option in the DOC directory.

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6.7.3

Synchronization of user-defined technology functions

Description

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The configuration options provided on this configuration page are described in Section (>>> 6.1.2 "User-defined technology functions"
Page 16).

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7 Operation

Operation

7.1

Menus
The following menus and commands are specific to this technology package:
Display

CNC

7.2

CNC-HMI

KUKA.CNC-HMI user interface

Call

Select Display > CNC > CNC-HMI in the main menu.

The user interface is opened in Standby mode.

Overview

Fig. 7-1: KUKA.CNC-HMI user interface (Standby mode)

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KUKA.CNC 2.1

Item
1

Description
CNC-HMI window
The window contains information about the axis positions and the
status of the CNC.
It is possible to switch between the display of the axis-specific position (ACS) and the Cartesian position (PCS).

Operation mode button

(>>> "Operation mode" Page 44)

ACS/PCS view button

(>>> "ACS/PCS view" Page 44)

Diagnosis & Settings button

Status bar

Main window
The window contains the display and operator control elements of
the selected operating mode.

Operation mode

This button can be used to select the operating mode:

Button

Description
Operating mode Standby mode
The version information is displayed in Standby mode.
Operating mode Automatic mode

Operating mode MDI mode

ACS/PCS view

Button

Description
In the CNC-HMI window, the axis-specific position
(ACS) is displayed.
Pressing the button switches to the display of the Cartesian position (PCS).
(>>> 7.2.3 "Display of the Cartesian position (PCS)"
Page 47)
In the CNC-HMI window, the Cartesian position (PCS)
is displayed.
Pressing the button switches to the display of the axisspecific position (ACS).
(>>> 7.2.2 "Display of the axis-specific position (ACS)"
Page 46)
This button is only available if the diagnosis or the spindle configuration has been opened and edit mode is active.
Switches back to the display of the axis-specific position
(ACS).

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Diagnosis &
Settings

This button can be used to select the following functions:

Button

Description
In the CNC-HMI window, it switches to the axis positions.
In the CNC-HMI window, it switches to the diagnostic
functions.
In the CNC-HMI window, it switches to the technology
settings.
Switches the selected NC program in the main window
to Teach mode. Robot positions can be taught.
The information window is minimized.

7.2.1

Status bar
The status bar indicates the status of the CNC interface and the CNC, the current error status, and information about override and velocity. The status bar
is always visible as long as the information window is not hidden.

Overview

Fig. 7-2: Status bar

Item
1

Description
Status of the CNC interface
(>>> "Status of CNC interface" Page 45)

Status of the CNC

(>>> "Status of CNC" Page 46)

Causes of the CNC stop

Current velocity

Command velocity

Current program override (POV)

Status of the Soft PLC

The program override is set via the smartHMI.

Status of CNC
interface

Icon

Description
CNC interface is not active.
CNC interface is active.

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KUKA.CNC 2.1

Status of CNC

Icon

Description
CNC is not active.
CNC is active. NC program or MDI block is being executed.
CNC has been stopped. NC program or MDI block has
been stopped.
CNC signals an error.

Causes of the
CNC stop

The cause of the CNC stop is indicated by the LED on the icon lighting up yellow.
Icon

Description
The motion has been stopped, e.g. due to a programmed
stop or because the Stop CNC button has been pressed.
Program run mode Single Step is active.
Waiting for wait time to elapse (G04 in the NC program)
The interpolator has no motion blocks available.
Program run mode Single Step: Stop after every program
line
Waiting for acknowledgement of PLC
Waiting for axis, e.g. axis exchanged (NC command
#CALL AX)
Current program override (POV) is 0%.
Status of the Soft PLC
White = Soft PLC running
Yellow = Soft PLC not running

7.2.2

Display of the axis-specific position (ACS)

The positions of axes A1 to Ax and spindles S1 and Sx are displayed. If external axes are being used, the position of the external axes is also displayed
(here A7).

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7 Operation

Fig. 7-3: Display of axis-specific position (ACS)

Item

Description

Name of axis or spindle

Axis-specific actual position

Axis-specific setpoint position

Axis-specific difference from setpoint position

Status of axis or spindle

The following icons indicate the status of the axis or spindle:

Icon

Description
Axis or spindle at standstill
Axis or spindle in motion
The axis is mastered.
The axis is not mastered.
The axis or spindle has reached the target position.
If the target position has not yet been reached, no icon is
displayed.

7.2.3

Display of the Cartesian position (PCS)

The position (X, Y, Z) and orientation (A, B, C) of the TCP and the position of
spindles S1 to Sx are displayed. If external axes are being used, the position
of the external axes is also displayed (here Y1).

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KUKA.CNC 2.1

Fig. 7-4: Display of Cartesian position (PCS)

Item

Description

Components of the Cartesian position or name of the external axis

or spindle

Cartesian actual position

Cartesian setpoint position

Cartesian difference from setpoint position

Status of axis or spindle

In some cases, the display of the Cartesian position on the KUKA.CNC-HMI does not match the display of the Cartesian position on
the KUKA smartHMI. The reason for this is that the robot controller,
unlike the NC controller kernel, uses status and turn values.
The following icons indicate the status of the axis or spindle:
Icon

Description
Axis or spindle at standstill
Axis or spindle in motion
The axis is mastered.
The axis is not mastered.

7.2.4

Technology settings
Here it is possible to switch the external spindle, the vacuum and the spindle
cooling on and off, and to set the spindle speed and override.

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7 Operation

Fig. 7-5: Technology settings

The following buttons are available:
Button

Description
Spindle ON button
The spindle is switched off. Pressing the button switches the spindle on.
Spindle OFF button
The spindle is switched on. Pressing the button switches the spindle off.
Vacuum ON button
The vacuum is switched off. Pressing the button switches the vacuum on.
Vacuum OFF button
The vacuum is switched on. Pressing the button switches the vacuum off.
Cooling ON button
The cooling is switched off. Pressing the button switches the cooling on.
Cooling OFF button
The cooling is switched on. Pressing the button switches the cooling off.
Accepts the spindle speed entered in the box to the left
of the button
Unit: RPM
Decreases the spindle override (increment 5%)

Increases the spindle override (increment 5%)

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7.2.5

Operating mode Automatic mode

In Automatic mode, an NC program can be selected, executed and edited.

Fig. 7-6: Automatic mode

Item

Description

Program run modes

Name of the main program

Name of the currently executed program (main program or subprogram)

Line number in the program

Program progress

(>>> 7.4.1 "Program run modes" Page 54)

The following buttons are available:

Button

Description
Select NC program button
The file view is opened and the NC program can be selected.
Edit button
Opens the selected NC program in the CNC-HMI window. The program can be edited.
Start CNC button
Starts the selected NC program.
Stop CNC button
Stops the NC program.

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Button

Description
Reset CNC button
Resets the NC program.
Maximize button
If the information window is hidden, the button for displaying the information window is displayed at the bottom of the screen.

7.2.6

Operating mode MDI mode

In MDI mode, an MDI block can be executed and edited.

Fig. 7-7: MDI mode

Item
1

Description
Program run modes
(>>> 7.4.1 "Program run modes" Page 54)

Line number in the program

Program progress

The following buttons are available:

Button

Description
Edit button
Opens the MDI block in the CNC-HMI window. The MDI
block can be edited.
Start CNC button
Starts the MDI block.
Stop CNC button
Stops the MDI block.
Reset CNC button
Resets the MDI block.

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7.2.7

Teach mode
Robot positions can be taught in Teach mode, e.g. to program the approach
motion of the robot. During teaching, an NC subprogram call is inserted into
the NC program. The taught motion blocks are saved in this subprogram.
The subprogram name has the following structure:
L NC program name_TTime stamp_Subprogram number.sub
Example: L default_T20110621_155955.sub

NC program name: default

Time stamp: 20110621

Subprogram number: 155955

Fig. 7-8: Teach mode

The following buttons are available:
Button

Description
Start teach mode button
Activates Teach mode and inserts a subprogram call
into the line indicated in red in the editor.
Teach button
Writes the current robot position into the subprogram.
This button is only available if Teach mode is activated.
Save button
Saves the subprogram in the program directory
C:\KRC\ROBOTER\Isgnc\prg and terminates Teach
mode. Switches to Standby mode.

7.2.8

Edit mode
The NC blocks of an NC program and MDI blocks can be edited in Edit mode.
Detailed information about the scope of the NC language can be
found in the CNC programming instructions.

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7 Operation

Fig. 7-9: Edit mode (MDI)

The following buttons are available:
Button

Description
Terminates Edit mode and switches back to the display
of the axis-specific position (ACS).
Save button
Saves the changes in the NC program or MDI block.

7.3

Activating CNC operation

In order to execute NC programs on the robot controller, CNC operation must
be activated via a robot program. This can either be done in batch mode by
calling the KRL function gCodeExecute() (see 6.4) or in interactive mode by
calling the KRL function cncMotion().
In interactive mode, the CNC interface is permanently activated and not deactivated again until the robot program is stopped. Interactive mode can be used,
for example, for setting up programs or in continuous operation if there are no
KRL commands to be executed between execution of NC programs. The KRL
function cncMotion() is called without parameters and does not send back a
return value.

Expert user group

Custom-made KRL program with the command cncMotion()

Procedure

Select the created KRL program, start it and execute it as far as the CNC
selection block (MOVE EMI).

Description

As soon as the KRL interpreter reaches the CNC selection block

(MOVE_EMI), it stops at this block:

Precondition

MOVE_EMI deviceName[] "MCS" FLT 0

CNC operation is now active and the message CNC_ADAPTER: CNC motion
active (Axial) is displayed in the message window. NC programs can now be
executed.

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In interactive mode, the robot remains under servo-control, even if no NC program is currently being executed.

7.4

Selecting an NC program

Precondition

Procedure

Operating mode Automatic mode

CNC operation is activated.

1. Press the Select NC program button.

The file view Select nc program is opened.
2. Select the desired NC program and press the Select button.
The NC program is displayed in the main window and can be started.
If the NC program is executed in T1 or T2 mode, the enabling switch
and Start key on the smartPAD must be pressed and held down.

Description

Fig. 7-10: File view Select nc program

The following buttons are available:
Button

Description
Switches back to the main window.

Edit button
Opens the selected NC program in the CNC-HMI window. The program can be edited.
Select button
Opens the selected NC program in the main window.

7.4.1

Program run modes

By default, the NC programs or NC blocks are executed through to the end
without stopping. The following program run modes can also be activated via
buttons:

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7 Operation

Program run mode

Button

Description
Run mode is inactive.

Backwards

Run mode is active.

The NC program is executed backwards.
Run mode is inactive.

Single step

Run mode is active.

The NC program is executed with a stop after each
program line. The Start CNC button must be
pressed again for each line.
Run mode is inactive.

Optional stop

Run mode is active.

The NC program is stopped at an NC block with the
machine function M01. To continue the program,
the Start CNC button must be pressed.
Run mode is inactive.

Block skip

Run mode is active.

When the NC program is executed, NC blocks preceded by the character / are skipped.
Further information about the functions Optional stop and Block
skip can be found in the CNC programming instructions.

7.5

Deselecting an NC program
In the CNC, it is not necessary to deselect NC programs. An NC program remains selected until another NC program is selected.

7.6

Stopping and restarting an NC program (Automatic mode)

If an NC program is executed in the robot operating mode Automatic, program
execution can be stopped by pressing the STOP key or the EMERGENCY
STOP button on the smartPad. Following such a stop, the NC program can be
resumed by pressing the Start key on the smartPad.

Procedure

Restarting the NC program after it has been stopped with the STOP key:

Press the Start key.

Restarting the NC program after it has been stopped with the EMERGENCY
STOP button:
1. Release the EMERGENCY STOP pushbutton.
2. Acknowledge acknowledgement messages in the message window of the
smartHMI.
3. Switch on the drives.
4. Press the Start key.
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If an NC program is stopped with the Stop CNC button

of the CNC-HMI, the robot remains under servo-control.
To avoid damage to the gear unit or motor, it is advisable not to leave the robot under servo-control for prolonged periods of time, e.g. overnight.

7.7

Jogging the robot

In CNC operation the robot cannot be jogged. For this reason, the CNC operation must be interrupted by means of the STOP key of the smartPAD. The
CNC interface is deactivated.
Following jogging, the CNC interface can be reactivated by means of the Start
key of the smartPAD.

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8 Diagnosis

Diagnosis

8.1

Diagnostic functions

Overview

Irrespective of the operating mode, the following diagnostic functions are

available on the KUKA.CNC-HMI:

Display of CNC error messages

Channel errors

General errors

CNC and PLC diagnosis

Diagnosis of the CNC kernel: the diagnostic file diag_data_yyyymm-dd-hh-mm-ss.txt is written.

The file contains status information about the status of the CNC.

Diagnosis of the PLC: the diagnostic file

PLCaxes_Diagnostic_yyyymmdd_hhmmss.log is written.
The file contains status messages of the CNC kernel and PLC, and
commands that have been executed by the PLC.

TRACE function
The following CNC data can be recorded:

Command and actual values of the position controller, e.g. velocity

and acceleration
The position controller data are written to the TRACE file
AxesTrace_yyyy_mm_dd_hhmmss00.log.

Command and actual values of the CP motion, e.g. velocity and acceleration
The path data are written to the TRACE file
PathTrace_yyyy_mm_dd_hhmmss00.log.

The error logs are written to the directory C:\KRC\ROBOTER\ISGNC\DIAGNOSE.

The diagnostic files and the TRACE files are written to the directory
C:\KRC\ROBOTER\LOG.

Fig. 8-1: Overview of diagnostic functions

The following buttons are available:

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Button

Description
The channel error messages are displayed in the CNCHMI window.
Pressing the button switches to the display of the general errors (Gen.).
The general error messages are displayed in the CNCHMI window.
Pressing the button switches to the display of the channel errors (Chn.).
The CNC diagnosis is carried out.

The PLC diagnosis is carried out.

Axes trace button (function inactive)

Pressing the button switches on the recording of the position controller data.
Axes trace button (function active)
Pressing the button switches off the recording of the position controller data.
Path trace button (function inactive)
Pressing the button switches on the recording of the
path data.
Path trace button (function active)
Pressing the button switches off the recording of the
path data.
8.1.1

Displaying TRACE data with ISG monitor

Description

The ISG monitor Display R2 is available under C:\KRC\ROBOTER\ISGNC\TOOLS\DISPLAY R2. This monitor can be used to display the recorded
TRACE data as curves. Precise information about operation of the monitor can
be found in the help file Display.HLP.
Alternatively, the recorded TRACE data can be opened in a spreadsheet, e.g.
to create diagrams.

Procedure

1. Start the program Display.exe.

The ISG monitor Display R2 is opened.
2. Select the TRACE file and display the desired measurement values as
curves.

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9 Programming

Programming

9.1

Structure of an NC subprogram

Description

Robot positions can be taught in the NC subprogram as axis-specific positions

(ACS) or Cartesian positions (PCS). When an ACS position is taught, a switch
is made by default to the machine coordinate system (NC command #MCS
ON). In this way, singularities can be avoided, e.g. when approaching a workpiece.

Example

NC subprogram with 2 taught ACS positions and 1 taught PCS position:

#MCS ON
G01 G90 F1000 X=-10.0353 Y=-59.8777 Z=69.6935 A=-0.2071 B=-9.8159
C=0.2041 Y1=0
#MCS OFF
#MCS ON
G01 G90 F1000 X=-50.0735 Y=-69.9876 Z=69.6935 A=-0.2071 B=-9.8159
C=0.2041 Y1=0
#MCS OFF
G01 G90 F5000 X=1801.3228 Y=318.6284 Z=1353.2956 A=-30.5522 B=90 C=40.5522
M29

If required, the subprogram can be edited, e.g. to remove unnecessary MCS

selection and deselection commands:
#MCS ON
G01 G90 F1000 X=-10.0353 Y=-59.8777 Z=69.6935 A=-0.2071 B=-9.8159
C=0.2041 Y1=0
G01 G90 F1000 X=-50.0735 Y=-69.9876 Z=69.6935 A=-0.2071 B=-9.8159
C=0.2041 Y1=0
#MCS OFF
G01 G90 F5000 X=1801.3228 Y=318.6284 Z=1353.2956 A=-30.5522 B=90 C=40.5522
M29

9.2

Teaching points in the NC program

Precondition

Procedure

NC program is selected.

Operating mode T1

1. Select the Diagnosis & Settings button and switch the NC program to
Teach mode.
2. Position the cursor in the line into which a subprogram call is to be inserted. The line is marked in red.
3. Press the Start teach mode button. Teach mode is activated and a subprogram call is inserted.
4. Move the robot to the desired position by jogging with the jog keys.
5. In the CNC-HMI window, display either the axis-specific position (ACS) or
the Cartesian position (PCS). During teaching, either the axis-specific position or the Cartesian position is written to the subprogram accordingly.
6. Press the Teach button. The position is written to the subprogram.
7. If additional points are to be taught in the subprogram, repeat steps 4 to 6.
8. Press the Save button. The subprogram is saved and Teach mode is terminated.

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9.3

Re-teaching points in the NC program changing the orientation

Description

If, for example when approaching a workpiece, axis space errors or errors arising from singularities occur, the orientation of the robot must be changed and
re-taught.

Precondition

NC program is selected.

Operating mode T1

Procedure

1. Open the NC program with Edit and delete the NC line that contains the
subprogram call and the position to be re-taught.
2. Save the NC program with Save.
3. Select the Diagnosis & Settings button and switch the NC program to
Teach mode.
4. Position the cursor in the line into which a new subprogram call is to be
inserted. The line is marked in red.
5. Press the Start teach mode button. Teach mode is activated and a subprogram call is inserted.
6. Move the robot to the new position with the desired orientation by jogging
with the jog keys.
7. In the CNC-HMI window, display either the axis-specific position (ACS) or
the Cartesian position (PCS). During teaching, either the axis-specific position or the Cartesian position is written to the subprogram accordingly.
8. Press the Teach button. The position is written to the subprogram.
9. If additional points are to be re-taught in the subprogram, repeat steps 6
to 8.
10. Press the Save button. The subprogram is saved and Teach mode is terminated.

9.4

Programming a tool change

Description

A tool change is programmed in the NC program with the T number for the tool
selection and machine function M06 for the tool change. By default, M06 calls
a subprogram so that the robot automatically moves to the tool magazine, for
example, and changes the tool there.
In the case of a manual tool change, the motion to the tool magazine is dispensed with. The new tool must also be selected in the same way with the T
number and M06, however.

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9 Programming

Fig. 9-1: Programming a tool change

The tools with the numbers 1 (T1) and 2 (T2) are selected and automatically
changed.

Example

...
N010
N020
N030
N040
N050
N060
...

9.5

G01 G90 X100 F5000

T1 M6 (Selection Tool Nr.1)
G01 G41 X110
X200
T2 M6 (Selection Tool Nr.2)
X300

Batch mode

Description

It is possible to execute an NC program once from a KRL program and then

resume work in the KRL program. The KRL function DEF gCodeExecute
(GCodeFileName:IN) available in KUKA.CNC can be used for this. The name
of the NC program to be executed is transferred as the transfer parameter.
This function can be used to implement a batch mode. Using a KRL program,
NC programs can be executed, for example, between the handling tasks programmed in KRL.
Excerpt from a KRL program:
LOOP
gCodeExecute("move_vertical.nc")
$BASE.X = $BASE.X+100
WAIT SEC 3.0
gCodeExecute("move_to_safe_pos.nc")
WAIT SEC 3.0
ENDLOOP

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10 Troubleshooting

10

Troubleshooting

10.1

Errors in NC operation
In the case of errors in NC operation, an error message is generated by the
CNC and displayed in the message window. At the same time, program execution is canceled and, if possible, the motion is stopped on the contour.
NC errors must be acknowledged via the KUKA.CNC-HMI by means of the
Reset CNC button. The program is reset. When restarted, program execution
starts again at the beginning of the program.
The CNC error messages, the causes of the errors and the remedies
are described in the documentation CNC diagnostic instructions.

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11 KUKA Service

11

KUKA Service

11.1

Requesting support

Introduction

The KUKA Roboter GmbH documentation offers information on operation and

provides assistance with troubleshooting. For further assistance, please contact your local KUKA subsidiary.

Information

The following information is required for processing a support request:

Model and serial number of the robot

Model and serial number of the controller

Model and serial number of the linear unit (if applicable)

Model and serial number of the energy supply system (if applicable)

Version of the KUKA System Software

Optional software or modifications

Archive of the software

For KUKA System Software V8: instead of a conventional archive, generate the special data package for fault analysis (via KrcDiag).

11.2

Application used

Any external axes used

Description of the problem, duration and frequency of the fault

KUKA Customer Support

Availability

KUKA Customer Support is available in many countries. Please do not hesitate to contact us if you have any questions.

Argentina

Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
[email protected]

Australia

Headland Machinery Pty. Ltd.

Victoria (Head Office & Showroom)
95 Highbury Road
Burwood
Victoria 31 25
Australia
Tel. +61 3 9244-3500
Fax +61 3 9244-3501
[email protected]
www.headland.com.au

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Belgium

KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
[email protected]
www.kuka.be

Brazil

KUKA Roboter do Brasil Ltda.

Travessa Claudio Armando, n 171
Bloco 5 - Galpes 51/52
Bairro Assuno
CEP 09861-7630 So Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
[email protected]
www.kuka-roboter.com.br

Chile

Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
[email protected]
www.robotec.cl

China

KUKA Robotics China Co.,Ltd.

Songjiang Industrial Zone
No. 388 Minshen Road
201612 Shanghai
China
Tel. +86 21 6787-1888
Fax +86 21 6787-1803
www.kuka-robotics.cn

Germany

KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
[email protected]
www.kuka-roboter.de

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France

KUKA Automatisme + Robotique SAS

Techvalle
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
[email protected]
www.kuka.fr

India

KUKA Robotics India Pvt. Ltd.

Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
[email protected]
www.kuka.in

Italy

KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
[email protected]
www.kuka.it

Japan

KUKA Robotics Japan K.K.

YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7691
Fax +81 45 744 7696
[email protected]

Canada

KUKA Robotics Canada Ltd.

6710 Maritz Drive - Unit 4
Mississauga
L5W 0A1
Ontario
Canada
Tel. +1 905 670-8600
Fax +1 905 670-8604
[email protected]
www.kuka-robotics.com/canada

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Korea

KUKA Robotics Korea Co. Ltd.

RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
[email protected]

Malaysia

KUKA Robot Automation Sdn Bhd

South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
[email protected]

Mexico

KUKA de Mxico S. de R.L. de C.V.

Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de Mxico
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
[email protected]
www.kuka-robotics.com/mexico

Norway

KUKA Sveiseanlegg + Roboter

Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
[email protected]

Austria

KUKA Roboter Austria GmbH

Vertriebsbro sterreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
[email protected]
www.kuka-roboter.at

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Poland

KUKA Roboter Austria GmbH

Spka z ograniczon odpowiedzialnoci
Oddzia w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
[email protected]

Portugal

KUKA Sistemas de Automatizacin S.A.

Rua do Alto da Guerra n 50
Armazm 04
2910 011 Setbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
[email protected]

Russia

OOO KUKA Robotics Rus

Webnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
kuka-robotics.ru

Sweden

KUKA Svetsanlggningar + Robotar AB

A. Odhners gata 15
421 30 Vstra Frlunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
[email protected]

Switzerland

KUKA Roboter Schweiz AG

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
[email protected]
www.kuka-roboter.ch

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Spain

KUKA Robots IBRICA, S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltr (Barcelona)
Spain
Tel. +34 93 8142-353
Fax +34 93 8142-950
[email protected]
www.kuka-e.com

South Africa

Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

Taiwan

KUKA Robot Automation Taiwan Co., Ltd.

No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
[email protected]
www.kuka.com.tw

Thailand

KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
[email protected]
www.kuka-roboter.de

Czech Republic

KUKA Roboter Austria GmbH

Organisation Tschechien und Slowakei
Sezemick 2757/2
193 00 Praha
Horn Poernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
[email protected]

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11 KUKA Service

Hungary

KUKA Robotics Hungaria Kft.

F t 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
[email protected]

USA

KUKA Robotics Corporation

51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
[email protected]
www.kukarobotics.com

UK

KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
[email protected]

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Index

Index
A
ACS 46
Areas of application 7
Axis groups, configuring 40
C
CAD 6
Calibration, tool 23
CAM 6
Channel parameters 39
Clamp offset data, configuration 38
CNC interface, status 45
CNC operation, activating 53
CNC stop, causes 46
CNC tool data, configuring 24
CNC, status 46
Communication 8
Compatibility 11
Configuration 15
Configuration, axes 40
D
Diagnosis 57
Diagnosis, functions 57
Display, axis-specific position 46
Display, Cartesian position 47
Documentation, industrial robot 5
E
Edit mode 52
EMERGENCY STOP 55
EMI 6
F
Functional principle 8
Functions 7
G
G-code 6
H
Hardware 11
I
Installation 11
Installation, CNC development environment for
Multiprog 12
Installation, KUKA.CNC 11
Internal NC programs, editing 33
Introduction 5
J
Jogging, robot 56
K
Knowledge, required 5
KR C 6
KRL 6
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KUKA Customer Support 65

KUKA.CNC-HMI 6, 43
M
M function, synchronization 17
Mapping by means of the Multiprog CNC template 19
MDI 6
Menus 43
N
NC 6
NC program 6
NC program directory, toggling 27
NC program, deselecting 55
NC program, executing in T1/T2 54
NC program, restarting 55
NC program, selecting 54
NC program, stopping 55
NC programs, creating 27
NC programs, deleting 30
NC programs, editing 29
NC programs, importing 35
NC programs, managing 26
NC programs, saving under a different name 32
NC subprogram, structure 59
O
Operating mode, Automatic mode 50
Operating mode, MDI mode 51
Operation 43
Orientation, changing 60
Overview, KUKA.CNC 7
P
PCS 47
PLC 6
Points, re-teaching 60
Points, teaching 59
Product description 7
Program run modes 54
Programming 59
S
Safety 9
Safety instructions 5
Service, KUKA Roboter 65
smartHMI 6
Software 11
Spindle 48
Spindle configuration 41
Start-up 15
Status bar 45
Status, CNC 46
Status, CNC interface 45
Support request 65
Synchronization, M function 17
Synchronization, user-defined technology func-

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tions 42
System requirements 11
T
Target group 5
Teach mode 8, 52
Technology functions 15
Technology functions, CNC 15
Technology functions, mapping to the periphery
18
Technology functions, synchronization 42
Technology functions, user-defined 16
Technology, settings 48
Terms used 6
Terms, used 6
Tool calibration 23
Tool change 21
Tool change, NC program 26
Tool change, programming 60
Tool management 21
Tool management via CNC 23
TRACE data, displaying 58
Training 5
Troubleshooting 63
U
Uninstallation, KUKA.CNC 12
Updating, KUKA.CNC 11
User interface, KUKA.CNC-HMI 43
W
Warnings 5
Z
Zero offset data, configuring 37

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