Kawasaki Robot

D/E Controller

Collision
Detection Manual
(Option)

Kawasaki Heavy Industries, Ltd.

90210-1182DEB
D/E Series Controller
Kawasaki Robot Collision Detection Manual

PREFACE

This manual gives instructions for using the Collision Detection function with the D/E series
controller.

This manual provides as much detailed information as possible on the standard operating methods
for using this function. However, not every possible operation, condition or situation that should
be avoided can be described in full. Therefore, should any unexplained questions or problems
arise during robot operation, please contact Kawasaki Machine Systems. Refer to the contact
information listed on the rear cover of this manual for the nearest Kawasaki Machine Systems
office.

Read the Basic Manuals (including safety manual) for D/E series controller, delivered with the
robot, without fail together with this manual. Do not perform any procedure described herein
until the contents of this manual are fully understood.

The descriptions in this manual are common to D and E series controllers, unless otherwise
specified. Simple differences between them are described by using “/” in order of D series
controller / E series controller.

1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems
relating to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching,
maintenance or inspection of the robot attend the necessary education/training course (s)
prepared by Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is
reinstalled or moved to a different site or sold off to a different user, attach this manual to the
robot without fail. In the event the manual is lost or damaged severely, contact Kawasaki.
Copyright © 2009 by Kawasaki Heavy Industries Ltd. All rights reserved.

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SAFETY

The items that require special attention in this manual are designated with the following symbols.

Ensure proper and safe operation of the robot and prevent physical injury or property damages by
complying with the safety matters given in the boxes with these symbols.

！ DANGER

Failure to comply with indicated matters can result in

imminent injury or death.

！ WARNING

Failure to comply with indicated matters may possibly

lead to injury or death.

！ CAUTION

Failure to comply with indicated matters may lead to

physical injury and/or mechanical damage.

[ NOTE ]
Denotes precautions regarding robot specification,
handling, teaching, operation, and maintenance.

！ WARNING

1. The accuracy and effectiveness of the diagrams, procedures, and detail

explanations given in this manual cannot be confirmed with absolute certainty.
Accordingly, it is necessary to give one’s fullest attention when using this
manual to perform any work.
2. Safety related contents described in this manual apply to each individual work
and not to all robot work. In order to perform every work in safety, read and
fully understand the safety manual, all pertinent laws, regulations and related
materials as well as all the safety explanations described in each chapter, and
prepare safety measures suitable for actual work.

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INTRODUCTORY NOTES

1. HARDWARE KEYS AND SWITCHES (BUTTON)

D/E series controller provides hardware keys and switches on the operation panel and the teach
pendant for various kinds of operations. In this manual the names of the hardware keys and
switches are enclosed with a square as follows. The terms “key” or “switch” which should
follow the relevant names are sometimes omitted for simpler expression. When pressing two or
more keys at the same time, the keys are indicated by “+” as shown in the example below.

EXAMPLES

STEP: expresses the hardware key “STEP”.

TEACH/REPEAT: indicates the mode switch “TEACH/REPEAT” on the operation panel.
A+MENU: indicates pressing and holding down A then pressing MENU.

2. SOFTWARE KEYS AND SWITCHES

E series controller provides software keys and switches which appear on the screen of the teach
pendant for various kinds of operations depending on specifications and situations. In this manual,
the names of software keys and switches are enclosed by “< >” parentheses. The terms “key” or
“switch” which should follow the relevant names are sometimes omitted for simpler expression.

EXAMPLES

<ENTER>: expresses an “ENTER” key that appears on the teach pendant screen.
<NEXT PAGE>: expresses a “NEXT PAGE” key on the teach pendant screen.

3. SELECTION ITEMS

Very often an item must be selected from a menu or pull-down menu on the teach pendant screen.
In this manual the names of these menu items are enclosed in brackets [XXX].

EXAMPLES

[Auxiliary Function]: Expresses the item “Auxiliary Function” in a menu. To select it, move the
cursor to the relevant item by the arrow keys, and press the ↵ key. For
detailed description, this procedure should be described every time, but
“select [XXX] item” will be used instead for simpler expression.

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CONTENTS

Preface ..................................................................................................................................................1
Safety....................................................................................................................................................2
Introductory Notes ...............................................................................................................................3

1.0 Collision Detection..................................................................................................................5

1.1 Overview .................................................................................................................................5
1.2 Procedures to Set Collision Detection....................................................................................7
1.2.1 Basic Procedure.......................................................................................................................7
1.2.2 Applications (Using Setcolthid Instruction)...........................................................................9
1.2.3 Restoration Procedure ...........................................................................................................10
1.3 Setting and Using Collision Detection .................................................................................11
1.3.1 Setting Tool Data ..................................................................................................................11
1.3.2 Setting Thresholds.................................................................................................................13
1.3.2.1 Range of Threshold...............................................................................................................13
1.3.2.2 Setting Threshold by Auxiliary Function.............................................................................14
1.3.3 Sample Programs ..................................................................................................................17
1.3.3.1 Sample Program (1) ..............................................................................................................17
1.3.3.2 Setting Thresholds for Sample Program (1).........................................................................19
1.3.3.3 Sample Program (2) (Using SETCOLTHID Instruction and Threshold ID) .....................20

2.0 AS Language Reference .......................................................................................................22

3.0 Operation after Collision.......................................................................................................40

Appendix 1 Trouble Shooting ........................................................................................................ A-1

Appendix 2 AS Language List ....................................................................................................... A-2

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1.0 COLLISION DETECTION

Collision detection is a function that detects collision or interference of the robot arm or tool with
the workpiece or jig and decreases damages given to the robot’s tool, workpiece, etc.. The robot
retracts and stops to avoid further damage. This function enables collision detection without the
need of a shock sensor; the software detects the collision.

！ DANGER

This function cannot completely prevent damage given by

collision. Also, the safety of persons around the robot is not
guaranteed by this function. All safety procedures must be
followed and your own safety and the safety of others in the
immediate area should always be ensured.

1.1 OVERVIEW

In the collision detection function, collisions are sensed by detecting the collision or shock given
to the robot arm or tool. These functions are called collision detection and shock detection,
respectively.

In collision detection, the current motor current is monitored, and when the peak current
exceeds the set threshold, the robot considers it has collided.

In shock detection, changes in the motor current per unit time are monitored, and when the
amount of change exceeds the set threshold, the robot considers it has collided. This function
detects collision faster than the collision detection described above, and is efficient in lessening
the damage given to the robot or tool.

The thresholds for collision detection and for shock detection are set prior to shipment from the
factory. Thresholds are set for each joint, and separately for teach/check mode and for repeat
mode. The thresholds can be used at the set values, but in cases such as when special care to
avoid collision is necessary, change the thresholds to adjust the sensitivity.

The thresholds for repeat mode can be registered under threshold ID numbers from 1 to 9.
The threshold ID numbers can be used within programs.

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！ CAUTION

The thresholds for collision detection are set at the level where collision can be
correctly detected when the robot moves at maximum speed with the rated
load. Therefore, this function can be used as is without having to set the
thresholds. In particular motions where damage is to be kept minimal, adjust
the sensitivity of this function by changing the thresholds. Also, this function
is automatically turned OFF when the moving tip of the weld gun comes in
contact with the workpiece in spot welding applications.

The threshold is set prior to shipment using the rated load, but by setting the
tool data accurately, the sensitivity of the collision detection will be increased.

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1.2 PROCEDURES TO SET COLLISION DETECTION

The following flow charts explain the procedures to use this function in AS language
programming and block teaching.

1.2.1 BASIC PROCEDURE

AS Language Programming Start procedure Block Teaching

WEIGHT instruction (p.34) Set tool data, Aux. Func. 0304: Tool
Add to program every time center of gravity Coordinates (p.11)
tool is changed. Enter tool data. (Tool number
1 – 9)
Set/adjust threshold for
teach/check or repeat mode

<Teach/Check> Select teach/check Aux. Func. 0510: Collision

COLTOFF, COLTJOFF or repeat mode detection
(p.28, p.30) 1 Set threshold for teach mode
2 Set threshold for repeat mode
<Repeat> (p.14)
Disable collision
COLROFF, COLRJOFF detection
(p.24, p.26)

COLCALON (p.32) Turn ON Aux. Func. 0510: Collision

auto-calibration Detection
4 Auto calibration (p.16)

Execute robot
(The threshold is set automatically)
motion

COLCALOFF (p.32) Turn OFF Aux. Func. 0510:

auto-calibration 4 Auto calibration (p.16)

<Teach/Check> Enable collision Aux. Func. 0510: Collision

COLTON, COLTJON detection detection
(p.28, p.30) 1 Set threshold for teach mode
2 Set threshold for repeat mode
<Repeat> (p.14)
COLRON, COLRJON End procedure
(p.24, p.26)

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！ CAUTION

When setting the threshold by auto calibration, make sure the

desired motion mode (Teach/Check, Repeat) is correctly selected
to avoid setting of the threshold of the undesired mode. The
threshold of the motion mode selected when auto-calibration is
executed will be set.

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1.2.2 APPLICATIONS (USING SETCOLTHID INSTRUCTION)

The chart below shows the procedures for auto calibration of thresholds using SETCOLTHID
instruction.

Using AS language Start Procedure Block Teaching

WEIGHT instruction (p.34) Set tool data, center Aux. Func. 0304: Tool
Add to program every time of gravity Coordinates (p.11)
tool is changed. Enter tool data. (Tool number
1 – 9)
Prepare motion
program

SETCOLTHID (p.36) Add SETCOLTHID Use AS edit function

(1.3.3.3 Sample Program (2) instruction at the beginning SETCOLTHID (p.36)
p.20) of motion block to change (1.3.3.3 Sample Program (2)
the threshold p.20)

Select repeat mode

COLROFF (p.24) Disable collision Aux. Func. 0510: Collision

detection for repeat detection
mode 2 Set threshold for repeat mode
(p.14)

COLCALON (p.32) Turn ON auto Aux. Func. 0510:

calibration 4 Auto calibration (p.16)

Execute program

COLCALOFF (p.32) Turn OFF auto Aux. Func. 0510:

calibration 4 Auto calibration (p.16)

COLRON (p.24) Enable collision Aux. Func. 0510:

detection 2 Set threshold for repeat mode
(p.14)

End procedure

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1.2.3 RESTORATION PROCEDURE

Movement of robot after collision When in teach mode: stops immediately

When in repeat mode: retracts then stops.
(Only when COLMVON is instructed. (see p.31))

When the robot stays in contact with the obstacle after the collision, depending on
the residual stress, the collision detection error status may continue.

Ø
To proceed with the restoration procedure,
temporarily disable the collision detection function.

Start restoration

Eliminate collision
Select teach mode manually in teach mode

Collision
detection
Collision does not occur error
(Interference with the Collision occurs (the robot is
workpiece is removed) in contact with the workpiece)
Disable collision Aux. func. 0510
detection 1 Set threshold in teach
mode (p.14)
or
COLTOFF，COLTJOFF
Move the robot to Move the robot to
original pose remove interference (p.28, p.30)

Enable collision Aux. func. 0510

detection 1 Set threshold in teach
mode (p.14)
or
COLTON，COLTJON
End restoration (p.28, p.30)

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1.3 SETTING AND USING COLLISION DETECTION

1.3.1 SETTING TOOL DATA

To use the collision detection function, the tool data has to be set accurately to simulate the robot
motion.

The tool data can be set using the AS language command (WEIGHT instruction/command) or by
using the Auxiliary Function screen on the teach pendant.

In block teaching, the load data can be set by directly entering the necessary data in Auxiliary
Function 0304 Tool Coordinate or by automatically calculating the tool load (Automatic Load
Measurement). In the following example, the tool data is set by directly entering the tool load
data via Aux. Function 0304 Tool Coordinate. For information on Automatic Load
Measurement, refer to the Operation Manual. WEIGHT instruction/command will be explained
in chapter 2 of this manual.

Data set in Aux. Function 0304 are: dimensions to the tool coordinate origin in the directions
of X, Y, and Z measured from the origin of the wrist flange, rotation angle of the tool
coordinates, mass and center of gravity of tool, and inertia moment. Data for 9 tools can be
registered.

Acceptable range for each data is: NOTE* Xg, Yg, Zg axes pass through
Load mass: 0 to maximum load the center of gravity and are
Center of gravity: -9999.9 to 10000.0 parallel to the X, Y, Z axes of
Inertia moment: 0 to 999.99 Xg axis* the null tool coordinates.
Ix
Mt Iz
Flange surface
Zg axis*
Center of gravity
X axis (Xt,Yt,Zt)
Iy
Yg axis*

Z axis
Mt: Mass of tool
Xt: Center of gravity X
Yt: Center of gravity Y Center of gravity
Zt: Center of gravity Z of tool
Y axis
Ix: Moment of inertia around tool Xg axis
Null tool coordinates Iy: Moment of inertia around tool Yg axis
Iz: Moment of inertia around tool Zg axis
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Select Auxiliary function from the menu in the teach pendant screen. Enter 0304 (Tool
coordinates) and press ↵, or select [4. Tool coordinates] from auxiliary group [3. Aux. Data
Setting].

1. Move cursor to each item and

input required data by NUMBER
(0 - 9). When using several
tools, press <Next Page> to move
to the next page and input the
tool data. Press ↵ when all data
are input.

2. If there is no error, “Setting

complete.” is displayed, and the
tool setting is completed.

！ CAUTION

When the input value is out of acceptable range, the message,

“Value is out of range” will appear followed by a prompt for
entering new values.

！ CAUTION

This function uses the tool load data to simulate the robot motion by
the dynamics model for monitoring collisions and external shock
disturbances. Therefore, if this tool data is not set accurately, it
may result in false detection or the setting of high detection
sensitivity may become impossible. To use this function efficiently,
ensure accurate tool load data.

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1.3.2 SETTING THRESHOLDS

1.3.2.1 RANGE OF THRESHOLD

To utilize the collision detection function in teach/check or repeat modes, two types of thresholds,
for collision detection and shock detection, are set for each joint.

When the thresholds are to be changed within a program or when the threshold is to be used with
a particular tool, register the thresholds (for collision detection and shock detection) to the
threshold ID numbers 1 to 9.

The thresholds are expressed in percentage with the rated current as 100 %. The acceptable
range for thresholds for collision detection is 0 to 500, and for shock detection, 0 to 200. They
are expressed in integers only.

Set or check the thresholds using the teach pendant or PC. The next section explains how to set
the thresholds using the auxiliary functions using the teach pendant. (See 2.0 AS Language
Reference for setting thresholds via PC using AS language.)
Aux.func.0510 AS monitor
Acceptable
Collision Detection command/program
Range
settings instruction
Threshold for collision
COLT 0 – 500
detection
Teach/check

Collision detection ON/OFF COLTON/COLTOFF ON/OFF

mode

Threshold for shock

COLTJ 0 – 200
detection
Shock detection ON/OFF COLTJON/COLTJOFF ON/OFF
Threshold for collision
COLR 0 – 500
Repeat mode

detection
Collision detection ON/OFF COLRON/COLROFF ON/OFF
Threshold for shock
COLRJ 0 – 200
detection
Shock detection ON/OFF COLRJON/COLRJOFF ON/OFF
Threshold ID SETCOLTHID 1–9
Auto calibration of threshold COLCALON/COLCALOFF ON/OFF
Property for Collision
detection (Setting threshold
ID for tools)

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1.3.2.2 SETTING THRESHOLD BY AUXILIARY FUNCTION

Select Auxiliary function from the menu in the teach pendant screen. Enter 0510 (Collision
Detection Function) and press ↵ or select [10. Collision Detection Function] from auxiliary group
[5. Advanced Setting].

[1 Set the threshold for Teach Mode], [2 Set the threshold for Repeat Mode]
Select the mode, and then enter the threshold for each joint. Set the desired functions ON
(enable) or OFF (disable) for each mode.

[1. Set the threshold for Teach Mode]

[2. Set the threshold for Repeat Mode]

Move the cursor to the desired field. Enter the thresholds using the NUMBER. The
acceptable range for collision detection is 0 to 500 (for shock detection, 0 to 200). Enter 0 for
joints where collision is not to be detected.

Select [Enable] to enable the threshold for the desired detection. The values in parentheses are
values at which collision occurred the last time.

When all data are input, press ↵. If there is no error, “Setting complete” is displayed.

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！ CAUTION

The acceptable range of threshold for collision detection is 0 to 500 for both
teach mode and repeat mode. For shock detection, it is 0 to 200. When a
value that is out of rage is entered and ↵ is pressed, the message “Value is
out of range” will be displayed followed by a prompt for modification.

The setting must be done in Teach mode. If not, the message “Change to
Teach mode” will appear followed by a prompt for re-entering.

[3 Setting threshold ID]

Thresholds for collision and shock detection in repeat mode can be registered under threshold ID
numbers 1 - 9.

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[4 Auto calibration]
Select ON or OFF and press ↵. When starting calibration, the message “Are you sure?” will
appear. Enter 1 to continue or 0 to cancel. When 1 is selected, auto calibration will start and
the thresholds will keep on updating until it is turned OFF or the motion mode is changed. The
threshold set here will be valid from the motion immediately following the auto calibration. The
thresholds for shock detection will be changed together with the thresholds for collision detection.

！ CAUTION

Change to the motion mode in which you want to set the thresholds
before starting auto calibration. To set the thresholds for repeat
mode, start auto calibration in repeat mode. To set threshold in
teach mode, change to teach mode before starting auto calibration.

[5 Property]
When certain thresholds are to be used with certain tools, you can register the Threshold ID to
tool numbers.
1. Enter the threshold ID under the
tool number. Enter a threshold
ID for every tool number.

2. When 0 is entered, the message

“Threshold ID for every tool will
be set 0. Are you sure?” will
appear. When you want to
reset all threshold ID, select
1:YES.
！ CAUTION

Set a threshold ID for every tool number. Do not leave any tool number
with threshold ID 0. If there is even one 0, all the tools will be set to 0.

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1.3.3 SAMPLE PROGRAMS

In this section, programs using the collision detection function are explained.

1.3.3.1 SAMPLE PROGRAM (1)

In this program, the robot performs arc welding. The robot moves the torch to the start point of
the welding operation by moving from #a1 to #a2 and welds while moving from #a2 to #a3.
Then, it moves back to #a1 from #a3. The sensitivity of collision detection should be increased
when approaching the workpiece (#a1 → #a2). Also, collision may occur when welding
between #a2 and #a3, or when moving between #a3 and #a1, so collision detection function is
enabled during the whole operation. In this example, the steps instructing the actual arc welding
operation are omitted.

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PROGRAM COLLISION_DETECT
1 COLRON Enables collision detection in repeat mode.
2 SPEED 1400 MM/S ALWAYS
3 WEIGHT 10, 100, 40, 40 Sets tool load data.
4 COLR 60, 35, 60, 120, 140, 110 Sets repeat motion thresholds (threshold A).
5 JMOVE #a1 Moves to #a1.
6 COLR 38, 30, 58, 60, 80, 90 Sets thresholds for the approaching motion
(threshold B)
7 SPEED 200 MM/S
8 LMOVE #a2 Approaches the workpiece (#a2).
9 DELAY 1
10 SPEED 300 MM/S
11 COLR 50, 48, 62, 82, 91, 98 Sets thresholds for the welding motion (threshold C)
12 LMOVE #a3
13 COLR 60, 35, 60, 120, 140, 110 Sets thresholds for motion from #a3 to #a1
(threshold A)
14 LMOVE #a1

The figure below describes the motion throughout the program.

Program start #a1 #a2 #a3 #a1

Set SPEED Speed Speed Speed
Set tool 200mm/s 300mm/s 200mm/s
Main System

JMOVE #a1 LMOVE #a2 LMOVE #a3 LMOVE #a1

Set COLRON threshold
Collision Detection

Change threshold

Change threshold

Change threshold
Threshold for Jt1

60 60
50

38

0
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1.3.3.2 SETTING THRESHOLDS FOR SAMPLE PROGRAM (1)

Thresholds can be obtained easily by auto calibration using a motion program.

This section explains the procedures to obtain the three thresholds used in the sample program
COLLISION_DETECT. Set the robot motion and tool data to emulate the actual operation
conditions as closely as possible.

Threshold A
Threshold A is effective throughout the program. Therefore, use program
COLLISION_DETECT to set this threshold automatically. First, delete or comment out the
threshold data in line 4. Then, set up the actual operation conditions (set workpiece in place,
etc). Set the tool data accurately in the program (WEIGHT instruction).

Now, start auto calibration using COLCALON command or auxiliary function 0510 and execute
the program.

After executing the program several times, terminate auto calibration using COLCALOFF
command or auxiliary function 0510. Check the threshold values for repeat mode using COLR
command or auxiliary function 0510. Program the obtained values in line 4 of
COLLISION_DETECT.

Threshold B
Threshold B is only valid during motion from #a1 to #a2. Create a separate program for motion
#a1 to #a2 and #a2 to #a1, and use that program to obtain the threshold.

.PROGRAM CALIB1 ( )
WEIGHT 10, 100, 40, 40
SPEED 200 MM/S ALWAYS
JMOVE #a1
10
LMOVE #a2
DELAY 1
LMOVE #a1
GOTO 10
.END

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Threshold C
ThresholdC is valid during motion #a2 to #a3. In the same manner as threshold B, create a
program that moves the robot from #a2 to #a3 and use that program to obtain threshold C.

.PROGRAM CALIB2( )
WEIGHT 10, 100, 40, 40
SPEED 200 MM/S ALWAYS
JMOVE #a2
10
LMOVE #a2
DELAY 1
LMOVE #a3
DELAY 1
GOTO 10
.END

！ CAUTION

Collision detection is in effect even while auto calibration is running.

Therefore, false detection may occur if the current threshold values
are too small. Reset the threshold to the values set at factory
shipment. If false detection still occurs, set a greater threshold.

1.3.3.3 SAMPLE PROGRAM (2) (USING SETCOLTHID INSTRUCTION AND

THRESHOLD ID)

Thresholds can be changed within a program using the SETCOLTHID instruction and the
thresholds registered under threshold IDs 1 to 9. The following sample program changes the
threshold according to the motion.

In this program, there are three motion blocks: A, B, C. Different thresholds are set for each
motion block. Write the SETCOLTHID instruction at the beginning of each motion block to
specify the ID number of the threshold to be used in that motion. Register the thresholds using
the auxiliary functions or SETCOLTHID command.

When auto calibration is done using this program, the values for all threshold IDs used in the
program are set automatically. If necessary, reset the values of the threshold IDs to 0 before
starting auto calibration. (See COLINIT command.)

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Motion block A is monitored by thresholds registered in threshold ID number 1.

Motion block B is monitored by thresholds registered in threshold ID number 2.
Motion block C is monitored by threshold values specified in the program.

PROGRAM CHG_TH
1 SETCOLTHID 1
2 CALL COLLISION_DETECT........Motion Block A
3 SETCOLTHID 2
4 WEIGHT 8, 10, 0, 25
5 C1MOVE #C1
6 C1MOVE #C2 .............Motion Block B
7 C1MOVE #C3
8 C1MOVE #a1
9 COLR 30, 20, 40, 30, 30, 30
10 JMOVE #home ................Motion Block C

PROGRAM COLLISION_DETECT
1 WEIGHT 10, 100, 40,40
2 JMOVE #a1
3 LMOVE #a2
4 LMOVE #a3
5 LMOVE #a1

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2.0 AS LANGUAGE REFERENCE

The following AS language commands and instructions are used with the collision detection
function.

COLR command/instruction
COLRON/OFF command/instruction
COLRJ command/instruction
COLRJON/OFF command/instruction
COLT command
COLTON/OFF command
COLTJ command
COLTJON/OFF command
COLMVON/OFF command
COLCALON/OFF command
COLCOLDON/OFF command
WEIGHT command/instruction
SETCOLTHID command/instruction
COLINIT command
COLSTATE command

Example

Keyword Parameter

COLRJ JT1 threshold, JT2 threshold, …JTn threshold

Parameters marked with can be omitted.

Always enter a space between the keyword and the parameter.

↵ represents the Enter key in the examples.

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Monitor command
Program instruction
COLR Jt1 threshold, Jt 2 threshold,…,Jt6 threshold(,…Jtn threshold )

Function
Sets the threshold for collision detection in repeat mode.

Parameter
Jt1 threshold，…，Jtn threshold
Sets the threshold for each joint in integers. Acceptable range is 0 to 500. Setting 0 disables
collision detection for that joint. Unit is percentage (%). (The rated current is 100 %)

When used as a monitor command and no parameters are specified, the current values are
displayed for modification.

Explanation
In collision detection, the robot determines that a collision has occurred when the force applied to
the joint exceeds the set threshold. Therefore, the smaller the threshold, the more sensitive the
detection will be. However, if the threshold is set too small, the robot may mistake the torque
load caused by its own motion as collision. Preferably use the threshold obtained from the auto
calibration using COLCAL command. If false detection occurs repeatedly, set the threshold
greater, e.g. multiply current value by 1.2. (See also COLRJ.)

This command/instruction is only effective in repeat mode.

Example (When UX120 is used)

The robot moves from #a1 to #a2，#a2 to #a3, and the threshold is changed for each motion
block. #a1 #a2
1 COLR 0, 40, 52, 81, 72, 68
2 JMOVE #a1
3 JMOVE #a2
4 COLR 40, 0, 56, 90, 83, 75
#a3
5 JMOVE #a3
In this example, collision is not detected in joint 1 when moving from #a1 to #a2, and in joint2
when moving from #a2 to #a3.

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Monitor command
Program instruction
COLRON
COLROFF

Function
Enables/disables collision detection in repeat mode.

Explanation
COLRON starts monitoring for any irregular load that may occur during repeat mode.
COLROFF stops monitoring.

When these commands/instructions are used, the setting remains in effect until reset. The
default setting is ON.

Use COLSTATE command to check the current ON/OFF status.

Example
Collision is only detected during motion #a2 to #a3, in a program that moves the robot from #a1
to #a2 to #a3 to #a4.

1 COLR 38, 40, 52, 81, 72, 68

2 COLROFF #a1 #a2

3 JMOVE #a1
#a3
4 JMOVE #a2
5 COLRON
6 JMOVE #a3 #a4
7 COLOROFF
8 JMOVE #a4

When spot welding, collision detection is not effective while the weld gun is operating.

！ CAUTION

Do not put a space in between COLR and ON/OFF in COLRON

and COLROFF commands/instructions.

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Monitor command
Program instruction
COLRJ Jt1 threshold, Jt2 threshold, …Jtn threshold

Function
Sets the thresholds for shock detection in repeat mode.

Parameter
Jt1 threshold，…，Jtn threshold
Sets the thresholds for each joint in integers. Acceptable range is 0 to 200. Setting 0 disables
shock detection for that joint. Unit is %/msec.

When used as a monitor command and no parameters are specified, the current values are
displayed for modification.

Explanation
In shock detection, the robot monitors the changes in force put to the joint per unit time and
detects shock/collision when the amount of change exceeds the threshold set here. This function
is effective in reducing damage to the robot or tool by detecting collision as soon as possible. (See
also COLR.)

This function is sensitive to even small changes of the robot motion. Use this function when
collision has to be detected sensitively, e.g. when the tool approaches the workpiece.

Use the threshold values obtained by COLCALON/COLCALOFF.

This command/instruction is effective only in repeat mode. Use in the same manner as COLR
command/instruction.

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D/E Series Controller 2. AS Language Reference
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Monitor command
Program instruction
COLRJON
COLRJOFF

Function
Enables/disables shock detection in repeat mode.

Explanation
This command/instruction is valid only in repeat mode.

It is not recommended that COLRJON should not be applied to operations with extreme motion.
The robot may detect its own motion as collision.

Use these commands/instructions in the same way as COLRON/OFF commands/instructions.

Use COLSTATE command to check the current ON/OFF status.

！ CAUTION

Do not put a space in between COLRJ and ON/OFF when

writing COLRJON and COLRJOFF commands/instructions.

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D/E Series Controller 2. AS Language Reference
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Monitor command
COLT Jt1 threshold, Jt2 threshold, … Jt6 threshold(, …Jtn threshold)

Function
Sets the thresholds for collision detection in teach/check mode.

Parameter
Jt1 threshold，…，Jtn threshold
Sets the threshold for each joint in integers. Acceptable range is 0 to 500. Setting 0 disables
collision detection for that joint. Unit is %. (The rated current is 100 %).

When used as a monitor command and no parameters are specified, the current values are
displayed for modification.

Explanation
This command is valid only in teach/check mode.

Use this command in the same way as COLR command.

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D/E Series Controller 2. AS Language Reference
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Monitor command
COLTON
COLTOFF

Function
Enables/disables collision detection in teach/check mode.

Explanation
COLTON starts monitoring for any irregular load that may occur during teach/check mode.
COLTOFF stops monitoring.

When these command/instruction are used, the setting remains in effect until reset. The default
setting is ON.

Use COLSTATE command to check the current ON/OFF status.

！ CAUTION

Do not put a space in between COLT and ON/OFF when

writing COLTON or COLTOFF commands/instructions.

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Monitor command
COLTJ Jt1 threshold, Jt2 threshold, (…，Jtn threshold)

Function
Sets threshold for shock detection in teach/check mode.

Parameter
Jt1 threshold，…，Jtn threshold
Sets the threshold for each joint in integers. Acceptable range is 0 to 200. Setting 0 disables
shock detection for that joint. Unit is %/msec.

If the parameters are not specified when used as a monitor command, the current values are
displayed for modification.

Explanation
This command/instruction is effective only in teach/check mode. Use this command/instruction
in the same way as COLR command/instruction.

Use the threshold values obtained by COLCALON/COLCALOFF commands.

This function is sensitive to even small changes in robot motion. Use this function when
collision has to be detected sensitively, e.g. when the tool approaches the workpiece.

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Monitor command
COLTJON
COLTJOFF

Function
Enables/disables shock detection in teach/check mode.

Explanation
This command is effective only in teach/check mode.

When shock detection is enabled in teach mode, the robot motion itself is may easily be
mis-detected as collision. If false detection occurs repeatedly, set the threshold again by using
COLCALON/COLCALOFF or turn OFF this function.

！ CAUTION
Do not put a space in between COLTJ and ON/OFF when
writing COLTJON or COLTJOFF commands/instructions.

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D/E Series Controller 2. AS Language Reference
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Monitor command
COLMVON
COLMVOFF

Function
Sets whether or not retraction is performed after collision is detected. COLMVON enables
retraction, and COLMVOFF disables it.

Explanation
When COLMVON is entered (retraction enabled), the robot will relieve the stress caused by the
collision by retracing backwards the trajectory the robot has drawn before the collision. The
amount of retraction depends on the speed of the TCP before the collision. The faster the speed,
the more the tool retracts.

When retracting, the robot takes a shortcut passing inside the path of the trajectory it has drawn
up to the collision. Therefore, when operating the robot in a crowded environment, it might be
better to cancel retraction to avoid unnecessary interferences.

When these command/instruction are used, the setting remains in effect until reset. The default
setting is ON.

Check the current setting using COLSTATE command.

Example of case in which retraction

should be canceled:

trajectory of retraction
motion If collision is detected in point
Direction of motion

B, there is high possibility of the

tool interfering with the
collision workpiece while retracting. (If
detection collision occurs in A, the tool
will retract without interfering
with the workpiece.)

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D/E Series Controller 2. AS Language Reference
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Monitor command
COLCALON
COLCALOFF

Function
Automatically calibrates the most appropriate threshold in a motion.

Explanation
Calculates the optimal threshold for a motion by measuring the greatest external force given to
the joints during the motion executed between COLCALON and COLCALOFF commands.

To obtain the thresholds effective for the whole motion in program a ( ), execute that program
after entering COLCALON ↵ . When the program has finished executing, enter
COLCALOFF ↵ . The threshold that best suits the motion is automatically calculated.
Execute COLSTATE command to check the thresholds. Include these thresholds in the
beginning of the program to run the program using them.

To find out the threshold used in a certain motion in a program, create a program that repeats only
that motion, and execute COLCALON/COLCALOFF commands using the program. Include
the threshold before that motion so that the motion block is monitored using that threshold.
When specifying the threshold for a certain motion block, make sure to reset the threshold at the
end of that motion block.

When SETCOTHID instruction is used in a program and the thresholds are specified by threshold
ID, COLCALON/COLCALOFF calibrates all the thresholds registered under the ID used in the
program. Enter COLCALON ↵ and execute the program. When the execution is completed,
enter COLCALOFF ↵ . To check the thresholds set to a particular ID, execute COLSTATE
command specifying the desired threshold ID.

！ CAUTION

Do not put a space between COLCAL and ON/OFF when

writing COLCALON and COLCALOFF commands.

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D/E Series Controller 2. AS Language Reference
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Monitor command
COLCOLDON
COLCOLDOFF

Function
If robot suspends motion for a long time, changes the thresholds until the robot has moved for
over a certain period of time and minimizes false detection.

Explanation
If the robot suspends motion for a long period of time, the friction of the reduction gear
temporarily increases. This may result in the occurrence of the false detection when the robot
restarts moving after a long stop. Using COLCOLDON command temporarily decreases the
collision detection sensitivity to prevent the false detection when the robot suspends motion for
eight hours or more. The sensitivity will recover after a certain period of operation of the robot.
When the robot has not stopped for a long period of time, in other words, has moved within the
last eight hours, execution of COLCOLDON command is invalid and the collision detection
sensitivity will not change. The default setting is ON. Use COLSTATE command to check the
current ON/OFF status.

Example
Function ON (Normal collision detection sensitivity)
COLT........................ON COLTJ ............ ON
COLR .......................ON COLRJ............ ON
COLMV ....................OFF COLCAL......... OFF
COLCOLD................ON

Function ON (Changing collision detection sensitivity)

COLT........................ON COLTJ ............ ON
COLR .......................ON COLRJ............ ON
COLMV ....................OFF COLCAL......... OFF
COLCOLD................ON (COLD)

Function OFF
COLT........................ON COLTJ ............ ON
COLR .......................ON COLRJ............ ON
COLMV ....................OFF COLCAL......... OFF
COLCOLD................OFF

！ CAUTION

Do not put a space in between COLCOLD and ON/OFF in

COLCOLDON and COLCOLDOFF commands/instructions.

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D/E Series Controller 2. AS Language Reference
Kawasaki Robot Collision Detection Manual

Monitor command
Program instruction
WEIGHT tool mass, center of gravity Xt, center of gravity Yt, center of gravity
Zt, inertia moment ab. Xg axis, inertia moment ab. Yg axis,
inertia moment ab. Zg axis

Function
Sets tool mass, center of gravity, and inertia moment around the tool axis.

Parameter
Tool mass
Sets tool mass data. The unit is kilograms (kg). Acceptable range: 0 kg to maximum load

Center of gravity Xt, center of gravity Yt, center of gravity Zt

Sets the center of gravity X, Y, Z as seen from the null tool coordinates. The unit is millimeters
(mm).

Inertia moment about Xg axis, inertia moment about Yg axis, inertia moment about Zg axis
Sets the inertia moment around Xg, Yg, Zg axes. Unit is kg·m2.

Explanation
The robot moves based on the values set by this command/instruction. Ensure accurate data.
The center of gravity Xt, Yt, Zt is defined relative to the null tool coordinates.

The inertia moment about each axis (Xg, Yg, Zg) is defined as the moment around the each axis
of coordinates whose origin is the center of tool gravity and parallel to the null tool coordinates.

When the parameters are omitted in monitor command, the current setting will be displayed for
modification.

When the parameters are omitted in program instruction, the maximum load will be set.

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D/E Series Controller 2. AS Language Reference
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Flange surface Xg axis*

Ix
Mt Iz
X axis Zg axis*
Center of gravity
(Xt,Yt,Zt)
Iy
Z axis
Yg axis*

NOTE* Xg, Yg, Zg axes pass through the center

Y axis of gravity and are parallel to the X, Y, Z
Null tool coordinates axis of the null tool coordinates

Mt: Mass of tool

Xt: Center of gravity X
Center of
Yt: Center of gravity Y gravity of tool
Zt: Center of gravity Z
Ix: Inertia moment around tool Xg axis
Iy: Inertia moment around tool Yg axis
Iz: Inertia moment around tool Zg axis

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D/E Series Controller 2. AS Language Reference
Kawasaki Robot Collision Detection Manual

Monitor command
Program instruction
SETCOLTHID threshold ID

Function
When used as a monitor command, this command displays and allows modification of the
threshold values registered under the specified threshold ID.

When used as program instruction, this instruction applies the threshold values registered under
the specified threshold ID to the robot motion.

Parameter
Threshold ID
Specifies the threshold ID in integer from 1 to 9. Cannot be omitted.

Explanation
When used as a monitor command, the current values of the threshold for collision detection in
repeat mode are displayed followed by a message “Change?”. To change the registered values,
enter the values separating each with comma and press ↵ . To exit without making any
changes, press only ↵ . Next, the threshold for shock detection in repeat mode is displayed.
Change the values in the same way as above.

When used in a program, the threshold values specified in this instruction will be used to monitor
all motions thereafter and until the values are changed.

When auto calibration is run for a program that includes SETCOLTHID instruction, the threshold
values registered under the threshold ID used in the program are calibrated.

To check the threshold values registered under each threshold ID, execute COLSTATE command
specifying the desired ID number.

To reset the threshold values registered under each ID number to zero, execute COLINIT
command specifying the desired threshold ID.

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D/E Series Controller 2. AS Language Reference
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Monitor command
COLINIT threshold ID

Function
Initializes the threshold.

Parameter
Threshold ID
Specifies the threshold ID in integers from 1 to 9. When omitted, the threshold currently
effective is reset to the values set at factory shipment.

Explanation
When this command is used without the threshold ID, the threshold currently effective is reset to
the values set at factory shipment.

When this command specifies a threshold ID, the threshold values for both collision detection and
shock detection registered under the specified ID are reset to 0.

！ CAUTION

The thresholds for collision detection are set at the level where collision can be
correctly detected when the robot moves at maximum speed with the rated
load. Therefore, this function can be used as is without having to set the
thresholds. In particular motions where damage is to be kept minimal, adjust
the sensitivity of this function by changing the thresholds. Also, this function
is automatically turned OFF when the moving tip of the weld gun comes in
contact with the workpiece in spot welding applications.

The threshold is set prior to shipment using the rated load, but by setting the
tool data accurately, collision detection sensitivity will be increased.

The currently effective threshold is displayed with COLSTATE command (without parameter).
To display the values registered under each threshold ID, execute COLSTATE specifying the
desired ID number.

To change the values registered under each threshold ID, execute SETCOLTHID command.

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D/E Series Controller 2. AS Language Reference
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Monitor command
COLSTATE threshold ID

Function
Displays the current settings and thresholds for the collision detection function.

Parameter
Threshold ID
Specifies the threshold ID in integers from 1 to 9. When omitted, the values for the currently
effective threshold are displayed.

Explanation
This command functions differently when and when not specifying the parameter.

When the ID number is not specified, the current values for each of the motion modes are
displayed. In other words, latest set of values from either 1 or 2 below are displayed:
1. the thresholds set using the COLR or COLT command/instruction
2. the last thresholds used in a program.
The ON/OFF status of the thresholds in each motion mode is also displayed.

When the threshold ID is specified as the parameter, the thresholds currently registered under that
ID number are displayed.

COLR................................... collision detection in repeat mode

COLRJ................................. shock detection in repeat mode
COLT................................... collision detection in teach/check mode
COLTJ ................................. shock detection in teach/check mode
COLMV................................ retraction
COLCAL .............................. auto calibration of thresholds
COLCOLD .......................... auto change of collision detection sensitivity

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D/E Series Controller 2. AS Language Reference
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Example
>colstate
Thresholds for collision detection in teach mode
JT1/JT8 JT2/JT9 JT3/JT10 JT4/JT11 JT5/JT12 JT6/JT13 JT7/JT14
15 35 42 120 110 160

Thresholds for shock detection in teach mode

JT1/JT8 JT2/JT9 JT3/JT10 JT4/JT11 JT5/JT12 JT6/JT13 JT7/JT14
5 6 4 15 44 23

Threshold for collision detection in repeat mode

JT1/JT8 JT2/JT9 JT3/JT10 JT4/JT11 JT5/JT12 JT6/JT13 JT7/JT14
45 60 75 235 305 225

Threshold for shock detection in repeat mode

JT1/JT8 JT2/JT9 JT3/JT10 JT4/JT11 JT5/JT12 JT6/JT13 JT7/JT14
3 5 5 11 11 15
COLT........................ON COLTJ ............ ON
COLR .......................ON COLRJ............ ON
COLMV ....................OFF COLCAL......... OFF
COLCOLD................ON
>

>colstate 3
Threshold for collision detection in repeat mode
JT1/JT8 JT2/JT9 JT3/JT10 JT4/JT11 JT5/JT12 JT6/JT13 JT7/JT14
20 35 60 112 120 116
Threshold for shock detection in repeat mode
JT1/JT8 JT2/JT9 JT3/JT10 JT4/JT11 JT5/JT12 JT6/JT13 JT7/JT14
3 4 3 6 7 6
>

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D/E Series Controller 3. Operation after collIsion
Kawasaki Robot Collision Detection Manual

3.0 OPERATION AFTER COLLISION

The following error message will appear when collision is detected. The cause of the error and
its countermeasure are as follows:

(Error: E1130) Jt-XX-M collision is detected.

Cause: An unpredictable torque was detected in the motor of the specified joint and
robot has detected it as collision.
Countermeasure: Remove the obstacles in the robot motion area.

If this error occurs frequently where there is no obstacle, try increasing the threshold by 1.2 times
its current value. Also, check if the tool data is set accurately.

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D/E Series Controller Appendix 1 Trouble Shooting
Kawasaki Robot Collision Detection Manual

APPENDIX 1 TROUBLE SHOOTING

The following table shows typical troubles that may occur in applying this function and the
countermeasures for each case:

Trouble Countermeasure
Frequent false detection 1. Check if the tool data is accurate.
2. Retry auto calibration of threshold.
3. If false detection occurs when the robot restars moving
after a long stop, execute COLCOLDON comand to
minimize false detections.
4. If false detection still occurs, manually change the
thresholds to greater values.

Detection is slow/ 1. Check if the tool data is accurate.

not sensitive 2. Retry auto calibration of threshold

Does not detect collision Check if collision detection is ON. Also, be aware that if 0
is set as the threshold, collision is not detected in that joint.

Retraction too big If the robot retracts too much and if it seems dangerous,
turn OFF the retraction using COLMVOFF command/
instruction.

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D/E Series Controller Appendix 2 AS Language List
Kawasaki Robot Collision Detection Manual

APPENDIX 2 AS LANGUAGE LIST

Abbrevia
Name Function Format (parameter) Pg.
-tion
COLCALON/OFF Auto calibration of M COLCALON/OFF 32
threshold
COLCOLDON/OFF Auto change of M COLCOLDON/OFF 33
collision detection
sensitivity
COLINIT Initializes thresholds M COLINIT threshold ID 37
COLMVNON/OFF Turns ON/OFF M COLMVON/OFF 31
retraction
COLMVNON/OFF Turns ON/OFF P COLMVON/OFF 31
retraction
COLR Sets threshold for M COLR Jt1 threshold , Jt2 23
collision detection in threshold , ･･･ , Jt6 threshold
repeat mode (,… Jtn threshold)
COLR Sets threshold for P COLR Jt1threshold , 23
collision detection in Jt2threshold , … , Jt6threshold
repeat mode (, … Jtnthreshold)
COLRJ Sets threshold for M CORJ Jt1threshold , 25
shock detection in Jt2threshold, ･･･ , Jtnthreshold
repeat mode
COLRJ Sets threshold for P CORJ Jt1threshold , 25
shock detection in Jt2threshold , … , Jtn threshold
repeat mode
COLRJON/OFF Turns ON/OFF M COLRJON/OFF 26
collision detection in
repeat mode
COLRJON/OFF Turns ON/OFF P COLRJON/OFF 26
collision detection in
repeat mode
COLRON/OFF Turns ON/OFF shock M COLRON/OFF 24
detection in repeat
mode
COLRON/OFF Turns ON/OFF shock P COLRON/OFF 24
detection in repeat
mode
COLS COLSTATE Displays current state M COLSTATE threshold ID 38
of thresholds
COLT Sets threshold for M COLT Jt1 threshold , Jt2 27
collision detection in threshold , … , Jt6 threshold
teach mode (, … Jtn threshold)
COLTJ Sets threshold for M COLTJ Jt1 threshold , Jt2 29
shock detection in threshold , … , Jt6 threshold
teach mode (, … Jtn threshold)
COLTJON/OFF Turns ON/OFF shock M COLTJON/OFF 30
detection in teach
mode
COLTON/OFF Turns ON/OFF M COLTON/OFF 28
collision detection in
teach mode

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D/E Series Controller Appendix 2 AS Language List
Kawasaki Robot Collision Detection Manual

Abbrevia
Name Function Format (parameter) Pg.
-tion
SETCOL SETCOLTHID Sets thresholds M SETCOLTHID threshold ID 36
SETCOL SETCOLTHID Registers thresholds to P SETCOLTHID threshold ID 36
threshold ID
WE WEIGHT Sets tool mass, center M WEIGHT tool mass, center of 34
of gravity, inertia gravity X, center of gravity Y,
moment center of gravity Z, inertia moment
ab X, inertia moment ab Y, inertia
moment ab Z
WE WEIGHT Sets tool mass, center P WEIGHT tool mass, center of 34
of gravity, inertia gravity X, center of gravity Y,
moment center of gravity Z, inertia moment
ab X, inertia moment ab Y, inertia
moment ab Z

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D/E Series Controller Appendix 2 AS Language List
Kawasaki Robot Collision Detection Manual

MEMO

A-4
 Kawasaki Robot D/E Series Controller
Collision Detection Manual (Option)

Feburuary 2002 : 1st Edition

March 2009 : 2nd Edition

Published by KAWASAKI HEAVY INDUSTRIES, LTD.

90210-1182DEB

All rights reserved. Copyright © 2009 by KAWASAKI HEAVY INDUSTRIES, LTD.