iiQKA OS 12 en
iiQKA OS 12 en
iiQKA OS 12 en
iiQKA.OS 1.2
Operating and programming instructions
Issued: 19.01.2024
iiQKA.OS 1.2 V3
KUKA Deutschland GmbH
iiQKA.OS 1.2
© Copyright 2024
KUKA Deutschland GmbH
Zugspitzstraße 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 Deutschland 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 soft-
ware 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 regu-
lar basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Translation of the original documentation
Contents
1 Introduction.............................................................................................. 11
1.1 Target group.......................................................................................................... 11
1.2 Industrial robot documentation.............................................................................. 11
1.3 Representation of warnings and notes................................................................. 11
1.4 Licenses................................................................................................................. 12
2 Product description................................................................................. 13
2.1 Product description................................................................................................ 13
2.2 Overview of the industrial robot............................................................................ 13
2.3 System requirements............................................................................................. 14
2.4 Network connections............................................................................................. 14
2.5 Intended use and misuse...................................................................................... 15
3 Safety......................................................................................................... 17
3.1 General.................................................................................................................. 17
3.1.1 Disclaimer.............................................................................................................. 17
3.1.2 EC declaration of conformity and declaration of incorporation............................ 17
3.1.3 Terms in the “Safety” chapter............................................................................... 18
3.2 Personnel............................................................................................................... 20
3.3 Workspace, protected space and danger zone................................................... 21
3.4 Triggers for stop reactions.................................................................................... 22
3.5 Safety functions..................................................................................................... 23
3.5.1 Overview of the safety functions.......................................................................... 23
3.5.2 Safety controller..................................................................................................... 25
3.5.3 Local EMERGENCY STOP device....................................................................... 25
3.5.4 Enabling device..................................................................................................... 26
3.5.5 Velocity monitoring................................................................................................ 27
3.5.6 Signal for operator safety...................................................................................... 27
3.5.7 External EMERGENCY STOP device.................................................................. 28
3.5.8 EMERGENCY STOP output................................................................................. 29
3.5.9 Monitoring functions for collaborative operation (HRC)....................................... 29
3.5.10 External enabling device....................................................................................... 29
3.6 Additional protective equipment............................................................................ 30
3.6.1 Jog mode............................................................................................................... 30
3.6.2 Software limit switches.......................................................................................... 30
3.6.3 Options for moving the manipulator without drive energy................................... 30
3.6.4 Labeling on the industrial robot............................................................................ 30
3.6.5 External safeguards............................................................................................... 31
3.7 Mode selection...................................................................................................... 31
3.8 Safety measures.................................................................................................... 33
3.8.1 General safety measures...................................................................................... 33
3.8.2 Transportation........................................................................................................ 35
3.8.3 Start-up and recommissioning.............................................................................. 35
3.8.4 Manual mode......................................................................................................... 37
3.8.5 Simulation.............................................................................................................. 38
3.8.6 Automatic mode..................................................................................................... 38
3.8.7 Maintenance and repair........................................................................................ 39
4 General operation.................................................................................... 49
4.1 Overview of the user interface.............................................................................. 49
4.2 Changing the user interface language................................................................. 51
4.3 Shutting down or restarting the robot controller................................................... 51
4.4 Changing the operating mode.............................................................................. 52
4.5 Changing the user role......................................................................................... 53
4.6 Displaying system information.............................................................................. 54
4.7 Help........................................................................................................................ 54
4.8 Backup & Restore................................................................................................. 55
4.9 Software................................................................................................................. 57
4.9.1 Installed Toolboxes tab.......................................................................................... 57
4.9.2 Updates tab and Upgrades tab............................................................................ 58
4.9.3 Available Toolboxes tab........................................................................................ 59
4.9.4 “Settings” tab......................................................................................................... 60
4.10 Firmware updates/upgrades.................................................................................. 61
4.11 Coordinate systems............................................................................................... 61
4.12 Moving the robot manually.................................................................................... 62
4.12.1 Axis-specific jogging.............................................................................................. 63
4.12.2 Cartesian jogging................................................................................................... 64
4.12.3 Incremental jogging............................................................................................... 66
4.12.4 Aligning the tool with a base................................................................................ 67
4.12.5 Manual guidance................................................................................................... 70
4.13 Operating the user interface with the Commander.............................................. 71
4.14 Program execution................................................................................................ 73
4.14.1 Executing a program manually............................................................................. 73
5 General configuration.............................................................................. 87
5.1 User roles and rights management...................................................................... 87
5.2 System settings..................................................................................................... 87
5.2.1 Network settings.................................................................................................... 87
5.2.2 Proxy network settings.......................................................................................... 88
5.2.3 Firewall rules......................................................................................................... 89
5.2.4 Changing a user password................................................................................... 90
5.2.5 Display settings..................................................................................................... 91
5.2.6 Date and time settings.......................................................................................... 91
5.2.7 Configuring the name of the robot controller....................................................... 91
5.2.8 Service Account..................................................................................................... 92
6 I/O configuration...................................................................................... 93
6.1 Physical inputs and outputs.................................................................................. 93
6.1.1 Mapping physical inputs and outputs................................................................... 94
6.2 Signals................................................................................................................... 95
6.2.1 Signal collections................................................................................................... 96
6.2.2 Creating and mapping a new signal..................................................................... 96
6.3 Bus Topology......................................................................................................... 97
6.3.1 Compare Online/Offline topology.......................................................................... 98
6.3.2 Update PDOs........................................................................................................ 99
6.3.3 Device manager.................................................................................................... 99
6.3.4 Configuration of EtherCAT devices....................................................................... 100
6.3.5 Diagnosis............................................................................................................... 100
6.3.6 Updating MDPs..................................................................................................... 101
6.4 Configuring EtherCAT® Bridge FSoE M/M.......................................................... 101
6.4.1 Configuring the primary side in iiQKA.OS............................................................ 102
6.4.2 Configuring the secondary side on an external controller................................... 104
6.4.3 Configuring the safety interface............................................................................ 104
6.4.4 Configuring the secondary side in iiQKA.OS....................................................... 106
8 3D scene................................................................................................... 121
8.1 Overview of 3D scene........................................................................................... 121
8.2 Managing frames................................................................................................... 122
8.3 Configuring, calibrating and managing tools........................................................ 124
8.3.1 Configuring tool spheres....................................................................................... 125
8.3.2 Configuring the force interaction area.................................................................. 126
8.4 Adding tools outside the robot.............................................................................. 127
8.5 Managing workpieces............................................................................................ 127
8.6 Calibrating and managing bases.......................................................................... 129
8.7 Managing monitoring spaces: prisms and cuboids.............................................. 130
8.8 Configuring the Sick microScan3 laser scanner.................................................. 130
8.9 Deleting objects from the 3D scene..................................................................... 131
8.10 Cutting and pasting objects.................................................................................. 132
9.11 Confirmation of mastering and calibration of the joint torque sensors................ 149
9.12 Evaluating the operating mode............................................................................. 150
9.12.1 Monitoring Block “Test Mode”............................................................................... 150
9.12.2 Monitoring Block “Automatic Mode”...................................................................... 151
9.12.3 Monitoring Block “Reduced Speed Mode”............................................................ 151
9.12.4 Monitoring Block “High Speed Mode”................................................................... 151
9.13 Monitoring Block “Safety Stop”............................................................................. 151
9.14 Monitoring of operator devices............................................................................. 152
9.14.1 Monitoring of the EMERGENCY STOP device on the smartPAD pro................ 152
9.14.2 Monitoring of enabling in T1/CRR........................................................................ 152
9.15 Monitoring of enabling devices............................................................................. 153
9.15.1 Monitoring Block “Enabling Inactive”.................................................................... 153
9.15.2 Monitoring Block “Manual Guidance Inactive”...................................................... 154
9.15.3 Monitoring Block “Manual Guidance Active”........................................................ 155
9.16 Evaluation of the confirmation status of mastering and joint torque sensor cal-
ibration................................................................................................................... 155
9.16.1 Monitoring Block “Mastering Not Approved”......................................................... 155
9.16.2 Monitoring Block “JTS Adjustment Not Approved”............................................... 156
9.17 Monitoring of safety-oriented inputs...................................................................... 156
9.17.1 Monitoring Block “Input Signal”............................................................................. 156
9.17.2 Monitoring Block “Input Signal with Acknowledgement”...................................... 157
9.18 Velocity monitoring functions................................................................................. 158
9.18.1 Monitoring Block “Maximum Axis Velocity”........................................................... 158
9.18.2 Monitoring Block “Maximum Cartesian Velocity”.................................................. 158
9.18.3 Velocity monitoring in T1 and CRR...................................................................... 159
9.18.4 Velocity monitoring during manual guidance........................................................ 159
9.19 Space monitoring functions................................................................................... 160
9.19.1 Monitoring Block “Axis Work Range”.................................................................... 160
9.19.2 Monitoring Block “Axis Protection Range”............................................................ 161
9.19.3 Monitoring Block “Cartesian Monitoring Space”................................................... 162
9.19.3.1 Unexpected protected space violation at corners and edges.............................. 164
9.20 Monitoring of tool orientation................................................................................ 165
9.21 Monitoring of forces and axis torques.................................................................. 168
9.21.1 Monitoring Block “Collision”................................................................................... 168
9.21.2 Monitoring Block “Maximum TCP Force”............................................................. 170
9.22 Monitoring Block “Timer Expired”.......................................................................... 172
9.23 Safety acceptance................................................................................................. 173
9.23.1 Basic properties of the safety configuration......................................................... 174
9.23.2 Safety-oriented tools.............................................................................................. 176
9.23.2.1 Geometry data of the tool..................................................................................... 176
9.23.2.2 Tool load data........................................................................................................ 176
9.23.2.3 Tool orientation...................................................................................................... 177
9.23.3 Installation position and orientation of the robot.................................................. 177
9.23.4 Safety Rules.......................................................................................................... 177
9.23.5 Monitoring Blocks.................................................................................................. 178
9.23.5.1 Monitoring Block “Enabling Inactive”.................................................................... 179
9.23.5.2 Monitoring Block “Manual Guidance Inactive”...................................................... 179
9.23.5.3 Monitoring Block “Manual Guidance Active”........................................................ 180
9.23.5.4 Monitoring Block “Reduced Speed Mode”............................................................ 180
10 Programming............................................................................................ 189
10.1 Creating and managing programs........................................................................ 189
10.2 Node Palette: inserting nodes (program elements)............................................. 189
10.2.1 Basic nodes........................................................................................................... 190
10.2.1.1 Sequence............................................................................................................... 190
10.2.1.2 Motion group.......................................................................................................... 190
10.2.1.3 Move (motion)........................................................................................................ 192
10.2.1.4 Loop....................................................................................................................... 194
10.2.1.5 Wait........................................................................................................................ 194
10.2.1.6 Set.......................................................................................................................... 194
10.2.1.7 Grip & Release...................................................................................................... 194
10.2.1.8 GetState................................................................................................................. 195
10.2.1.9 If/else – simple branch.......................................................................................... 196
10.2.2 Advanced nodes.................................................................................................... 197
10.2.2.1 If/else group – advanced branch.......................................................................... 197
10.2.2.2 Break (exit loop or resume).................................................................................. 197
10.2.2.3 Halt (pause or reset program).............................................................................. 198
10.2.2.4 Subroutine (creating a subprogram)..................................................................... 198
10.2.2.5 Execute (execute subprogram)............................................................................. 199
10.2.2.6 Position hold (holding position under impedance control)................................... 199
10.3 Editing the program structure............................................................................... 199
10.4 Program variables................................................................................................. 200
10.4.1 Creating value with new data type....................................................................... 201
10.4.2 Example of a program variable............................................................................ 201
10.5 Creating and executing subroutines..................................................................... 202
10.6 Expression Editor.................................................................................................. 203
10.6.1 Functions in the Expression Editor....................................................................... 204
10.6.2 Namespace lang.................................................................................................... 206
10.6.2.1 lang.List data type................................................................................................. 206
11 Diagnosis.................................................................................................. 223
11.1 Creating a diagnosis package.............................................................................. 223
11.2 Message log.......................................................................................................... 224
11.3 Alert display........................................................................................................... 225
11.4 Resuming the safety controller............................................................................. 226
Index 229
Introduction
1 Introduction
Safety
These warnings are provided for safety purposes and must be observed.
DANGER
These warnings mean that it is certain or highly probable that death or
severe injuries will occur if no precautions are taken.
WARNING
These warnings mean that death or severe injuries may occur if no pre-
cautions are taken.
CAUTION
These warnings mean that minor injuries may occur if no precautions
are taken.
NOTICE
These warnings mean that damage to property may occur, if no precau-
tions are taken.
SAFETY INSTRUCTION
The following procedure must be followed exactly!
Notices
1.4 Licenses
The KUKA license terms are displayed on the user interface of the system
software:
• In the main menu under System Information, Eula tab
The license terms of the open-source software used can be displayed on
a separate laptop/PC:
1. Connect the robot controller to the network and determine the control-
ler IP.
The IP address can be found in the main menu of the system soft-
ware under System Settings > Network.
2. Enter the URL <controller IP>/licenses/ in the web browser.
Product description
2 Product description
Description
The system software iiQKA.OS 1.2 provides all the functions required for
operating the KUKA LBR iisy.
Functions
• Software
• Options, accessories
1 Manipulator
2 smartPAD pro teach pendant
3 Connecting cable / smartPAD pro
4 Robot controller
5 Connecting cable / data cable
6 Connecting cable / motor cable
The system software iiQKA.OS 1.2 can be used on the following robot
controller:
• KR C5 micro
• With “Performance” system board
Product description
Fig. 2-2: Overview of interfaces for “Performance” system board
Use
The system software iiQKA.OS 1.2 is intended exclusively for the opera-
tion of a KUKA industrial robot.
Each version of the system software is to be operated exclusively in ac-
cordance with the specified system requirements.
Misuse
Safety
3 Safety
3.1 General
3.1.1 Disclaimer
• Manipulator
• Robot controller
• Teach pendant
• Connecting cables
• Software
• Options, accessories
The industrial robot is built using state-of-the-art technology and in accord-
ance with the recognized safety rules. Nevertheless, misuse of the indus-
trial robot may constitute a risk to life and limb or cause damage to the
industrial robot and to other material property.
The industrial robot may only be used in perfect technical condition in ac-
cordance with its intended use and only by safety-conscious persons who
are fully aware of the risks involved in its operation. Use of the industrial
robot is subject to compliance with this document and with the declaration
of incorporation supplied together with the industrial robot. Any functional
disorders, especially those affecting safety, must be rectified immediately.
Safety information
EC declaration of conformity
Declaration of incorporation
Term Description
Axis range Range within which the axis may move The axis range must be de-
fined for each axis.
Workspace Area within which the robot may move. The workspace is derived
from the individual axis ranges.
Automatic (AUT) Operating mode for program execution. The manipulator moves at
the programmed velocity.
User The user of the industrial robot can be the management, employer
or delegated person responsible for use of the industrial robot.
Danger zone The danger zone consists of the workspace and the stopping dis-
tances of the manipulator.
Safety
CRR Controlled Robot Retraction
CRR is an operating mode which can be selected when the indus-
trial robot is stopped by the safety controller for one of the following
reasons:
External EMERGENCY Triggering an external EMERGENCY STOP affects the robot con-
STOP device trollers in the system that are integrated into the external EMER-
GENCY STOP circuit.
Notice: Triggering an external EMERGENCY STOP does not (!) set
the output signal for the local EMERGENCY STOP.
Safety zone The safety zone is situated outside the danger zone.
Safety stop The safety stop is triggered by the safety controller, interrupts the
work procedure and causes all robot motions to come to a stand-
still.
The safety stop can be executed as Stop category 0, as Stop cate-
gory 1 (HRC) or as Stop category 1 (path-maintaining).
Note: In this document, a safety stop of Stop category 0 is referred
to as safety stop 0, a safety stop of Stop category 1 (HRC) as
safety stop 1 (HRC) and a safety stop of Stop category 1 (path-
maintaining) as safety stop 1 (path-maintaining).
Stop category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator is stopped with path-oriented braking.
Note: This stop category is called “STOP 0” in this document.
Stop category 1 (HRC) The manipulator switches to compliance control with increased
damping in order to reduce the acting external forces and to come
to a standstill. The manipulator leaves the path in this case. At
standstill, the drives are deactivated and the brakes are applied.
If Stop category 1 (HRC) is triggered by the safety controller, the
safety controller monitors the braking process. Specifically, the Car-
tesian velocity and the external axis torques are monitored. The
brakes are applied after 1 s at the latest and the drives are deacti-
vated. Stop category 0 is executed in the event of a fault.
Note: This stop category is called “STOP 1 (HRC)” in this docu-
ment.
Stop category 1 (path- The manipulator is braked and stays on the programmed path. At
maintaining) standstill, the drives are deactivated and the brakes are applied.
If Stop category 1 (path-maintaining) is triggered by the safety con-
troller, the safety controller monitors the braking process. After a
duration of 1.5 s at the latest, or less depending on the robot type,
the brakes are applied and the drives are switched off. Stop cate-
gory 0 is executed in the event of a fault.
Note: This stop category is called “STOP 1 (path-maintaining)” in
this document.
Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator is braked with a path-maintaining braking ramp.
Note: This stop category is called “STOP 2” in this document.
System integrator The system integrator is responsible for safely integrating the indus-
(plant integrator) trial robot into a complete system and commissioning it.
3.2 Personnel
The following persons or groups of persons are defined for the industrial
robot:
• User
• Personnel
Qualification of personnel
Work on the system must only be performed by personnel that is able
to assess the tasks to be carried out and detect potential hazards.
Death, severe injuries or damage to property may otherwise result. The
following qualifications are required:
• Adequate specialist training, knowledge and experience
• Knowledge of the relevant operating or assembly instructions, knowl-
edge of the relevant standards
• All persons working with the industrial robot must have read and un-
derstood the industrial robot documentation, including the safety
chapter.
Safety
User
The user must observe the labor laws and regulations. This includes e.g.:
Personnel
• System integrator
• Operators, subdivided into:
‒ Start-up, maintenance and service personnel
‒ Operating personnel
‒ Cleaning personnel
System integrator
The industrial robot is safely integrated into a complete system by the sys-
tem integrator.
The system integrator is responsible for the following tasks:
Operators
fer areas.
If there are no physical safeguards present, the requirements for collabo-
rative operation in accordance with EN ISO 10218 must be met.
The following triggers for stop reactions are predefined by the system and
invariable:
Trigger T1, CRR AUT
Start key released STOP 2
PAUSE key pressed STOP 2
Power switched off via main switch or STOP 0
device switch
Or power failure
Internal error in non-safety-oriented part STOP 0 or STOP 1
of the robot controller
(dependent on the cause of the error)
Operating mode changed during opera- Safety stop 1 (path-maintaining)
tion
Error in the safety controller Safety stop 0 or safety stop 1 (path-maintaining)
(dependent on the cause of the error)
User-specific triggers
Safety
Trigger T1, CRR AUT
Safety gate opened (operator safety) - Safety stop 1 (path-
maintaining)
External EMERGENCY STOP pressed Safety stop 1 (path-maintaining)
(deactivated by default)
From version 1.1 onwards, the standard safety configuration of the system
software also contains the following preconfigured triggers for stop reac-
tions for collaborative operation (HRC):
Trigger T1, CRR AUT
Maximum permissible external torque Safety stop 1 (HRC)
exceeded at least one axis (30 Nm) (no
enabling signal issued via Commander)
Maximum permissible velocity Safety stop 1 (path-maintaining)
(500 mm/s) exceeded (no enabling sig-
nal issued via Commander)
The user can additionally configure further triggers for stop reactions, in-
cluding the associated stop category.
(>>> 9 "Safety configuration" Page 133)
DANGER
Risk of fatal injury due to non-operational safety functions or exter-
nal safeguards
In the absence of operational safety functions or safeguards, the indus-
trial robot can cause death, severe injuries or damage to property.
• If safety functions or safeguards are dismantled or deactivated, do
not operate the industrial robot.
In the case of a serious error in the safety controller, the following safe
state is established:
• All safety-oriented outputs are set to LOW (state “0”) or the safety-ori-
ented connection is interrupted.
• The energy supply to all safety-oriented drives is interrupted.
• Application of the holding brakes of all safety-oriented drives is activa-
ted.
Safety-oriented functions
Safety
Safety Rule must be enabled.
‒ Safety Rule “Emergency Stop Internal”
EMERGENCY STOP output
• Safety Rule Set “HRC (transient contact)” (available from version 1.1
of the system software onwards)
‒ Safety Rule “Velocity Limit HRC (transient contact)”
Maximum velocity for collaborative operation (HRC)
‒ Safety Rule “Collision detection”
Collision detection for collaborative operation (HRC)
Additional safety-oriented functions can also be configured, e.g.:
• External enabling device
• External safety stop
• Axis-specific workspace monitoring
(>>> 9 "Safety configuration" Page 133)
The safety controller is a unit inside the control PC. It links safety-relevant
signals and safety-relevant monitoring functions.
Safety controller tasks:
• Switching off the drives; applying the brakes
• Monitoring of the braking ramp
• Velocity monitoring
• Evaluation of safety-relevant signals
• Setting of safety-oriented outputs
WARNING
Danger to life and limb due to tools and equipment without EMER-
GENCY STOP
If tools and other equipment connected to the robot are not integrated
into the EMERGENCY STOP circuit, this can result in death, severe in-
juries or damage to property.
• Integrate tools and other equipment into the EMERGENCY STOP
circuit if they could constitute a potential hazard.
If a holder is used for the teach pendant and conceals the EMERGENCY
STOP device, an external EMERGENCY STOP device must be installed
that is accessible at all times.
(>>> 3.5.7 "External EMERGENCY STOP device" Page 28)
WARNING
Danger to life and limb due to lack of reaction when an enabling
switch is released
Releasing one of multiple enabling switches held in the center position
does not trigger a stop reaction.
If multiple switches are held in the center position, the robot controller
cannot distinguish whether one of them was intentionally released or if it
was unintentionally released as the result of an accident.
• Create awareness for the hazard.
Safety
industrial robot can be stopped using one of the following methods:
WARNING
Danger to life and limb due to manipulation of enabling switches
The enabling switches must not be held down by adhesive tape or other
means or tampered with in any other way. Death, severe injuries or
damage to property may result.
• Carry out a visual inspection of the enabling switches.
• Rectify tampering or remove any foreign bodies.
This safety function is preconfigured in the Safety Rule Set “Velocity Mon-
itoring”.
By default, the Cartesian velocity of the manipulator is limited. The follow-
ing Cartesian velocity limits are defined:
• Safety Rule “Velocity Limit T1”
Maximum velocity in T1/CRR: 250 mm/s
If the velocity limit is exceeded in T1 or CRR mode and manual guid-
ance is not active, i.e. no enabling switch on the Commander is press-
ed, a safety stop 1 (path-maintaining) is triggered.
In the case of manual guidance in T1/CRR, the velocity is not re-
duced, but is limited by the velocity monitoring configured in the
Safety Rule “Velocity Limit Manual Guidance”. By default, this velocity
limit is greater than 250 mm/s.
• Safety Rule “Velocity Limit Manual Guidance”
Maximum velocity for manual guidance
Preconfigured values depend on the version of the system software:
‒ Up to Version 1.0: 900 mm/s
‒ From Version 1.1 onwards: 500 mm/s
When manual guidance is active, i.e. an enabling switch on the
Commander is pressed, a safety stop 1 (path-maintaining) is triggered
if the velocity limit is exceeded.
The maximum velocity for manual guidance can be adapted. The val-
ue for this velocity limit must be defined in a risk assessment (recom-
mendation: < 1000 mm/s).
(>>> 9.18.4 "Velocity monitoring during manual guidance" Page 159)
• Safety Rule “Velocity Limit Global” (disabled by default)
Maximum global velocity: 2000 mm/s
When the Safety Rule is enabled, a safety stop 1 (path-maintaining) is
triggered as soon as the global velocity limit is exceeded.
in automatic mode if the “Safety Door” signal is set or the robot is guided
Safety
manually.
Operator safety is not active as standard in the Manual Reduced Velocity
(T1) and CRR modes. The signal is not evaluated.
If no physical safeguards are installed, the preconditions for collaborative
operation in accordance with EN ISO 10218 must be met. In this case,
the Safety Rule can be disabled or removed.
Reaction of the industrial robot in the event of a loss of signal during au-
tomatic operation (default configuration):
• The manipulator stops with a safety stop 1 (path-maintaining).
As standard, the safety gate is connected to the robot controller via input
IN_A1 of safety interface XG11.1.
Further information about the safety interface is contained in the assem-
bly instructions of the robot controller in the “Planning” chapter.
WARNING
Danger to life and limb due to resumption of automatic operation
without adequate checking
Following loss of the signal for operator safety, it must not be possible
to restart automatic operation by merely closing the safeguard. Other-
wise, for example, the safety gate could close unintentionally, thereby
causing automatic operation to resume while there are persons in the
danger zone. Death, severe injuries or damage to property may result.
• Automatic operation must not be resumed until the safeguard has
been closed and the closing has been acknowledged.
• The acknowledgement must be designed in such a way that an ac-
tual check of the danger zone can be carried out first. Acknowledge-
ment that is automatically and directly triggered by closure of the
safeguard is not permitted.
• If closure is acknowledged by a device (e.g. by the PLC), the sys-
tem integrator must ensure that the acknowledgement is preceded
by an actual check of the danger zone.
Safety
3.5.8 EMERGENCY STOP output
External enabling devices are required if it is necessary for more than one
person to be in the danger zone of the industrial robot.
Multiple external enabling devices can be connected via the safety inter-
face of the robot controller. External enabling devices are not included in
the scope of supply of the industrial robot.
Further information about the available safety interfaces is contained in
the assembly instructions of the robot controller in the “Planning” chap-
ter.
In the operating modes T1 (Manual Reduced Velocity) and CRR, the robot
controller can only execute programs in jog mode. This means that it is
necessary to hold down an enabling switch and the Start key in order to
execute a program.
• Releasing the enabling switch on the teach pendant triggers a safety
stop 1 (path-maintaining).
• Pressing the enabling switch on the teach pendant fully down triggers
a safety stop 1 (path-maintaining).
• Releasing the Start key triggers a stop of Stop category 2.
The axis ranges of all manipulator axes are limited by means of non-safe-
ty-oriented software limit switches. These software limit switches only
serve as machine protection and are preset in such a way that the manip-
ulator is stopped under servo control if the axis limit is exceeded, thereby
preventing damage to the mechanical equipment.
Safety
• Designation labels
• Cable markings
• Rating plates
The access of persons to the danger zone of the industrial robot must be
prevented by means of safeguards. It is the responsibility of the system
integrator to ensure this.
If there are no physical safeguards present, the requirements for collabo-
rative operation in accordance with EN ISO 10218 must be met.
Physical safeguards must meet the following requirements:
The operating mode can be changed by displaying the mode in the status
bar of the user interface.
Do not change the operating mode while a program is running. If the
operating mode is changed, the industrial robot stops with a safety
stop 1 (path-maintaining).
Operating modes
Operating
Use Velocities
mode
T1 Programming, teaching and testing of • Program verification:
programs
Reduced programmed velocity,
maximum 250 mm/s
• Jog mode:
Jog velocity, maximum 250 mm/s
• Manual guidance:
No limitation of the velocity, but
safety-oriented velocity monitoring
in accordance with the safety con-
figuration
AUT Automatic execution of programs • Program mode:
For industrial robots with and without Programmed velocity
higher-level controllers • Jog mode:
Not possible
• Manual guidance:
Safety-oriented velocity monitoring
in accordance with the safety con-
figuration
Safety
Operating
Use Velocities
mode
CRR CRR is an operating mode which can • Program verification:
be selected when the industrial robot
Reduced programmed velocity,
is stopped by the safety controller for
maximum 250 mm/s
one of the following reasons:
• Jog mode:
• Industrial robot violates an axis- Jog velocity, maximum 250 mm/s
specific or Cartesian monitoring
• Manual guidance:
space.
No limitation of the velocity, but
• The tool orientation is outside the
safety-oriented velocity monitoring
permitted range.
in accordance with the safety con-
• Industrial robot violates collision figuration
detection or the maximum TCP
force monitoring function.
• One or more axes are unmastered.
• Mastering of one or more axis po-
sitions is not confirmed.
• Calibration of one or more joint tor-
que sensors is not confirmed.
• Maximum Cartesian velocity has
been exceeded.
• Maximum torque of an axis has
been exceeded, e.g. due to a
crushing situation.
After changing to CRR mode, the in-
dustrial robot may once again be
moved.
If the cause of the stop is no longer
present and no further stop is reques-
ted for 4 seconds by one of the speci-
fied causes, the operating mode
switches automatically to T1.
The industrial robot may only be used in perfect technical condition in ac-
cordance with its intended use and only by safety-conscious persons. Op-
erator errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial ro-
bot even after the robot controller has been switched off and locked out.
Incorrect installation (e.g. overload) or mechanical defects (e.g. brake de-
fect) can cause the manipulator to sag. If work is to be carried out on a
switched-off industrial robot, the manipulator must first be moved into a
position in which it is unable to move on its own, whether the payload is
mounted or not. If this is not possible, the manipulator must be secured
by appropriate means.
DANGER
Risk of fatal injury due to non-operational safety functions or exter-
nal safeguards
In the absence of operational safety functions or safeguards, the indus-
trial robot can cause death, severe injuries or damage to property.
• If safety functions or safeguards are dismantled or deactivated, do
not operate the industrial robot.
DANGER
Danger to life and limb of persons under the robot arm
Sagging or falling parts can cause death or serious injuries. This applies
at all times, e.g. also for assembly tasks or with the controller switched
off.
• Never loiter under the robot arm.
Implants
WARNING
Danger to life due to malfunction of implants caused by motors
and brakes
Electric motors and brakes generate electric and magnetic fields. The
fields can cause malfunctions in active implants, e.g. pacemakers.
• Affected persons must maintain a minimum distance of 300 mm
from motors and brakes. This applies to both energized and deener-
gized motors and brakes.
smartPAD
The user must ensure that the industrial robot is only operated with the
smartPAD pro by authorized persons.
If more than one smartPAD is used in the overall system, it must be en-
sured that it is clearly recognizable which smartPAD is connected to which
industrial robot. They must not be interchanged.
The enabling switches on the smartPAD must be subjected to a function
test at least once every 12 months and in certain specific cases.
(>>> "Function test" Page 36)
Modifications
Faults
In the case of faults on the industrial robot, the following safety measures
must be implemented immediately:
• Switch off the robot controller and secure it (e.g. with a padlock) to
prevent unauthorized persons from switching it on again.
Safety
• Indicate the fault by means of a label with a corresponding warning
(tagout).
• Keep a record of the faults.
Carry out a functional test after the fault has been rectified.
3.8.2 Transportation
Manipulator
Robot controller
Before starting up systems and devices for the first time, a check must be
carried out to ensure that the systems and devices are complete and op-
erational, that they can be operated safely and that any damage is detec-
ted.
The valid national or regional work safety regulations must be observed
for this check. The correct functioning of all safety functions must also be
tested.
WARNING
Danger to life and limb due to incorrectly assigned cables
The robot controller is preconfigured for the specific industrial robot. The
manipulator and other components can receive incorrect data if they are
connected to a different robot controller. Death, severe injuries or dam-
age to property may result.
• Only connect the manipulator to the corresponding robot controller.
NOTICE
Damage to property due to condensation
If the internal cabinet temperature of the robot controller differs greatly
from the ambient temperature, condensation can form. This may result
in damage to property.
• Wait until the internal cabinet temperature has adapted to the ambi-
ent temperature in order to avoid condensation.
Function test
The following tests must be carried out before start-up and recommission-
ing:
General test:
It must be ensured that:
Safety
nents:
The following tests must be performed prior to start-up and recommission-
ing, and at least once every 12 months unless otherwise determined in
accordance with a workplace risk assessment:
• Function of all connected EMERGENCY STOP devices
Press the EMERGENCY STOP device. A message must be displayed
on the teach pendant indicating that the EMERGENCY STOP has
been actuated. At the same time, no error message may be displayed
about the EMERGENCY STOP device.
• Function of the enabling switches of all connected enabling devices
Move the robot in Test mode and release the enabling switch. The ro-
bot motion must be stopped. At the same time, no error message may
be displayed on the teach pendant about the enabling device.
The test must always be carried out for all enabling switches of a con-
nected enabling device.
If the state of the enabling device is configured at an output, the test
can also be performed via the output.
• Panic function of the enabling switches of all connected enabling devi-
ces
Move the robot in test mode, press the enabling switch down and hold
in the panic position for 3 seconds. The robot motion must be stop-
ped. At the same time, no error message may be displayed on the
teach pendant about the enabling device.
The test must always be carried out for all enabling switches of a con-
nected enabling device.
If the state of the enabling device is configured at an output, the test
can also be performed via the output.
• Switch-off capability of the safety-oriented outputs
Switch robot controller off and then on again. After it is switched on,
no error message may be displayed on the teach pendant relating to
a safety-oriented output.
Test of the functional capability of the brakes:
For the industrial robot, a brake test is available which can be used to
check whether the brake of each axis applies sufficient braking torque.
The brake test ensures that any impairment of the braking function is de-
tected, e.g. due to wear, overheating, fouling or damage, thereby eliminat-
ing avoidable risks.
Unless otherwise determined by a risk assessment, the brake test must
be performed regularly:
• The brake test must be performed for each axis before start-up and
recommissioning of the industrial robot.
• The brake test must be carried out every 48 hours during operation.
A risk assessment can be used to determine whether the brake test is re-
quired for the specific application and how often the brake test must be
performed.
General
Manual mode is the mode for setup work. Setup work is all the tasks that
have to be carried out on the industrial robot to enable automatic opera-
tion. Setup work includes:
• Jog mode
• Teaching
• Programming
• Program verification
The following must be taken into consideration in manual mode:
• New or modified programs must always be tested first in Manual Re-
duced Velocity mode (T1).
• The manipulator and its tooling must never touch or project beyond
the safety fence.
• Workpieces, tooling and other objects must not become jammed as a
result of the industrial robot motion, nor must they lead to
short-circuits or be liable to fall off.
• All setup work must be carried out, where possible, from outside the
safeguarded area.
Setup work in T1
3.8.5 Simulation
Safety
• There are no persons in the system or the requirements for collabora-
tive operation in accordance with EN ISO 10218 have been met.
• The defined working procedures are adhered to.
If the manipulator comes to a standstill for no apparent reason, the
danger zone must not be entered until an EMERGENCY STOP has been
triggered.
After maintenance and repair work, checks must be carried out to ensure
the required safety level. The valid national or regional work safety regula-
tions must be observed for this check. The correct functioning of all safety
functions must also be tested.
The purpose of maintenance and repair work is to ensure that the system
is kept operational or, in the event of a fault, to return the system to an
operational state. Repair work includes troubleshooting in addition to the
actual repair itself.
The following safety measures must be carried out when working on the
industrial robot:
• Carry out work outside the danger zone. If work inside the danger
zone is necessary, the user must define additional safety measures to
ensure the safe protection of personnel.
• Switch off the industrial robot and secure it (e.g. with a padlock) to
prevent it from being switched on again. If it is necessary to carry out
work with the robot controller switched on, the user must define addi-
tional safety measures to ensure the safe protection of personnel.
• If it is necessary to carry out work with the robot controller switched
on, this may only be done in operating mode T1.
• Label the system with a sign indicating that work is in progress. This
sign must remain in place, even during temporary interruptions to the
work.
• The EMERGENCY STOP devices must remain active. If safety func-
tions or safeguards are deactivated during maintenance or repair work,
they must be reactivated immediately after the work is completed.
DANGER
Danger to life and limb due to live parts
The robot system must be disconnected from the mains power supply
prior to work on live parts. It is not sufficient to trigger an EMERGENCY
STOP or safety stop, because parts remain live. Death or severe inju-
ries may result.
• Before commencing work on live parts, turn off the main switch and
secure it against being switched on again.
If the controller variant in question does not have a main switch
(e.g. KR C5 micro), turn off the device switch then disconnect the
power cable and secure it so it cannot be reconnected.
• Then check to ensure that the system is deenergized.
• Inform the individuals involved that the robot controller is switched
off. (e.g. by affixing a warning sign)
Robot controller
Even when the robot controller is switched off, parts connected to periph-
eral devices may still carry voltage. The external power sources must
therefore be switched off if work is to be carried out on the robot control-
ler.
The ESD regulations must be adhered to when working on components in
the robot controller.
Voltages in excess of 50 V (up to 780 V) can be present in various com-
ponents for several minutes after the robot controller has been switched
off! To prevent life-threatening injuries, no work may be carried out on the
industrial robot in this time.
On robot controllers with transformers, the transformers must be discon-
nected before working on components in the robot controller.
Water and dust must be prevented from entering the robot controller.
Hazardous substances
The following safety measures must be carried out when handling hazard-
ous substances:
• Avoid prolonged and repeated intensive contact with the skin.
• Avoid breathing in oil spray or vapors.
• Clean skin and apply skin cream.
The industrial robot can be controlled exclusively via the connected KUKA
smartPAD pro. The “Single Point of Control” principle (SPOC) has been
implemented and is assured by the system. No additional safety measures
are required.
3.9 IT security
3.9.1 Introduction
General information
Safety
Take measures to ensure IT security
IT security involves not only aspects of information and data processing
as such, but also affects at least the following areas:
• Technology, organization, personnel, infrastructure
KUKA urgently recommends that users implement an information securi-
ty management system for their products which designs, coordinates
and monitors the tasks related to information security.
The system integrator and user must take external measures to ensure
that only authorized and trained persons have physical access to the sys-
tem and its components, as well as connected systems, components and
networks. Examples of this include access restrictions to the rooms or
separately access-protected cabinets in which the respective system and
components, such as the robot controller and teach pendant, are housed
permanently or when not in use.
The system has network interfaces for integration into IT and OT net-
works. If the network connectivity enables connections where trust boun-
daries would be transgressed, the following points must be considered in
detail:
• Threats and risks associated with them
• Additional measures that may need to be taken to protect the system
Safety
Network requirements
The robot controller (including the teach pendant) may only be used in in-
ternal, segmented and inaccessible networks. Use in networks that are not
separately protected is not permitted. It is recommended to use firewall
solutions in order to allow only network connections between the robot
controller and other systems that are actually necessary.
Access to the robot controller via the teach pendant is protected so that
only authorized users can access the system and execute actions. The
default passwords preset on delivery must be changed immediately in ac-
cordance with the local IT security requirements. No passwords that are
easy to guess may be used.
Detailed information about changing the passwords can be found in the
chapter “General configuration” of the iiQKA.OS documentation.
Authorization concept
Automatic logoff
• If no actions are carried out on the user interface for a specified time,
the current user is automatically logged out. Different times apply de-
pending on the user role:
‒ User: After 30 min. of inactivity
‒ Administrator: After 10 min. of inactivity
‒ Safety Commissioning Engineer: After 5 min. of inactivity
Only trustworthy USB devices may be connected to the system. Only con-
tent that comes from trustworthy sources and, if necessary, has been pre-
viously checked with an antivirus program may be written to the USB de-
vices. The data written to USB devices in the course of a data backup or
export may contain sensitive data. Appropriate IT security measures
should therefore be taken to protect these data accordingly.
The system features emergency SSH access to the Linux kernel system,
which is not enabled by default and can only be used by the customer
and KUKA Customer Support with local access to the system. This
access (Service Account) can be temporarily enabled via the HMI or via
the KSI interface (with an enabling tool). Administrator privileges are re-
quired for enabling access. After access has been enabled, an SSH serv-
ice is active at TCP port 22 on the KLI and KSI interfaces. It is only pos-
sible to log on via SSH with the access data of KUKA Customer Support.
Access is automatically disabled 30 minutes after enabling.
If customer service is required, it must be ensured that the SSH connec-
tion is established to the correct system (e.g. using a dedicated network
cable to the robot controller). Each robot controller has an individual SSH
host key, enabling the robot controller to be identified for future connec-
tions via the fingerprint of the SSH host key.
SSH access is intended for emergencies in which analysis or repair of the
software components is not otherwise possible, and it may no longer be
available in future versions of the product.
Information about enabling customer service access (Service Account)
can be found in the chapter “General configuration” of the iiQKA.OS
documentation.
Developer mode can be activated via the Administrator user role. As long
as Developer mode is activated, the SSH service at port 22 is accessible
from the network and the user can log on to the system via SSH with the
password set when activating the mode. This SSH access can be used to
install specially signed extensions for development purposes. On exiting
Developer mode, SSH access is disabled and the system is reset to its
state before Developer mode was activated.
Safety
3.9.3 IT security features of the product
3.9.3.1 General
On the basis of threat modeling and risk analyses, potential threats were
identified and necessary protective measures for the system were derived.
The following sections outline what these basic measures are, what
threats these measures target, and what broader aspects the system inte-
grator and user additionally need to consider. Since the system is subject
to ongoing development, only the most important protective measures are
explained here.
3.9.3.2 Firewalls
Description
The system has a firewall that protects against undesired network access.
Certain connections necessary for the system to function are only allowed
via defined interfaces. All other connections are blocked by the system.
The following potential threats were considered during the planning of the
described function:
• An attacker could access internal network services of the robot con-
troller or other components via the network.
• An attacker could use the network to access network services that
have been inadvertently enabled or network services that have been
enabled for temporary purposes only (e.g. for analytics).
• An attacker could exploit another vulnerability to start their own service
for various purposes or provide an existing service via a modified con-
figuration that could allow them direct access to the system (e.g. a
shell or FTP server).
Permitted connections
From version 1.1 of the system software onwards, the firewall configura-
Safety
tion can be viewed by the user in the system settings. The following con-
nections and related services are allowed in the standard installation:
• KLI IT interface
‒ Incoming: TCP port 22 (SSH) – customer service access
‒ Incoming: TCP port 80 (HTTP) – license information
• KLI OT interface
‒ Incoming: TCP port 22 (SSH) – customer service access
‒ Incoming: TCP port 80 (HTTP) – license information
‒ Incoming: TCP port 44818 and UDP port 2222 – EtherNet/IP, can
be switched off
• KONI interface
‒ Incoming: TCP port 22 (SSH) – customer service access
• KSI interface
‒ Incoming: TCP port 22 (SSH) – customer service access
‒ Incoming: TCP port 80 (HTTP) – license information
‒ Incoming: TCP port 49162 – enabling of customer service access
by customer
Optional toolboxes can also provide additional services and open the ports
these require. The corresponding firewall rules are also displayed in the
system settings.
Unnecessary firewall rules can be deactivated in the system settings. The
correct functioning of the system or toolbox cannot be guaranteed in this
case.
Information about deactivating the firewall rules can be found in the
chapter “General configuration” of the iiQKA.OS documentation.
Description
With a few exceptions, communication with the system takes place in en-
crypted form and using procedures selected in accordance with the cur-
rent state of the art. Encrypted communication relationships:
• HTTPS between robot controller and my.kuka.com (access to software
updates)
• HTTPS between robot controller and KUKA Update Service (access to
software updates)
• SSH (if enabled) between local customer PC or customer service PC
and robot controller
Exceptions to encrypted communication:
• DHCP (local)
• DNS (local)
• HTTP access to license information
The following potential threat was considered during the planning of the
described function:
• An attacker who is able to monitor, read or redirect network traffic lo-
cally or remotely could obtain sensitive information, modify it or com-
promise the system.
Safety
Cryptographic techniques used
Description
The following potential threats were considered during the planning of the
described function:
• An attacker with temporary access to the system could gain deeper
access or persistence to the system by installing an older software ar-
tifact – and any vulnerabilities potentially contained therein.
• It should not be possible to exploit a vulnerability in the authorization
of software updates or a vulnerability that allows arbitrary software up-
dates to be copied onto the system in order to install older versions.
• If an older software update is foisted on an administrator, it should not
be possible to use it to install older versions.
Description
The following potential threats were considered during the planning of the
described function:
• A vulnerability in a single software component could be exploited to
compromise the entire system.
• A vulnerability in a single software component could be exploited to in-
fluence functions provided by other software components.
• A vulnerability in a single software component could be exploited to
obtain information that is processed, managed or saved by other soft-
ware components.
Description
The following potential threats were considered during the planning of the
described function:
• Compromise of the system through exploitation of a vulnerability in a
non-essential software component or function.
• An attacker has the opportunity to quickly and easily infiltrate the sys-
tem and achieve their objectives, as various standard applications are
available that significantly minimize the effort required to do so.
The system currently does not offer a function for securely deleting the
complete system. If there is a need to delete the complete system, KUKA
Customer Support should be contacted. Otherwise, it is recommended to
remove the hard drive and logically erase and physically destroy it de-
pending on the local IT security policies.
General operation
4 General operation
The basic elements of the user interface are described here. The following
elements are always present:
• Status bar (upper edge of screen)
• Control bar for jogging (right-hand edge of screen)
• Program control bar (left-hand edge of screen)
• Main view in the center
Item Description
1 Main menu
The main menu can be used, for example, to execute system
functions, configure network settings or display system informa-
tion and help.
2 Feature menu
The Feature menu offers all the functions required for start-up,
configuration and programming of the robot.
3 Alert display
Further information about the alert display can be found in the
help function under “Diagnosis”.
4 Display/selection of the operating mode
It is possible to change the operating mode via the display.
(>>> 4.4 "Changing the operating mode" Page 52)
Item Description
5 Display of the tool and display/setting of the motion frame and
the reference system for jogging
General operation
Item Description
14 Program control bar
Displays by means of icons the current function that can be
executed using smartPAD keys. The icon is highlighted in white
if the function is available.
• Pause key
The Pause key can be used to pause a running program or
to reset a paused program.
• Start key
The Start key can be used to start a program or to resume
a paused program. The Start key can also be used to man-
ually address frames or to move the robot back onto the
programmed path.
• Start backwards key (without function)
(>>> 4.14 "Program execution" Page 73)
The language of the user interface can be changed. To do so, select Lan-
guage in the main menu.
The following languages are available:
Chinese (simplified) Dutch
Danish Polish
German Portuguese
English Romanian
Finnish Swedish
French Slovak
Italian Spanish
Japanese Czech
Korean Turkish
Hungarian
Description
The robot controller can be shut down or restarted via the main menu.
Precondition
• Operating mode T1
Procedure
The operating mode can be changed by displaying the mode in the status
bar of the user interface.
Do not change the operating mode while a program is running. If the
operating mode is changed, the industrial robot stops with a safety
stop 1 (path-maintaining).
Operating
Use Velocities
mode
T1 Programming, teaching and testing of • Program verification:
programs
Reduced programmed velocity,
maximum 250 mm/s
• Jog mode:
Jog velocity, maximum 250 mm/s
• Manual guidance:
No limitation of the velocity, but
safety-oriented velocity monitoring
in accordance with the safety con-
figuration
AUT Automatic execution of programs • Program mode:
For industrial robots with and without Programmed velocity
higher-level controllers • Jog mode:
Not possible
• Manual guidance:
Safety-oriented velocity monitoring
in accordance with the safety con-
figuration
General operation
Operating
Use Velocities
mode
CRR CRR is an operating mode which can • Program verification:
be selected when the industrial robot
Reduced programmed velocity,
is stopped by the safety controller for
maximum 250 mm/s
one of the following reasons:
• Jog mode:
• Industrial robot violates an axis- Jog velocity, maximum 250 mm/s
specific or Cartesian monitoring
• Manual guidance:
space.
No limitation of the velocity, but
• The tool orientation is outside the
safety-oriented velocity monitoring
permitted range.
in accordance with the safety con-
• Industrial robot violates collision figuration
detection or the maximum TCP
force monitoring function.
• One or more axes are unmastered.
• Mastering of one or more axis po-
sitions is not confirmed.
• Calibration of one or more joint tor-
que sensors is not confirmed.
• Maximum Cartesian velocity has
been exceeded.
• Maximum torque of an axis has
been exceeded, e.g. due to a
crushing situation.
After changing to CRR mode, the in-
dustrial robot may once again be
moved.
If the cause of the stop is no longer
present and no further stop is reques-
ted for 4 seconds by one of the speci-
fied causes, the operating mode
switches automatically to T1.
The user role can be changed by means of the user button in the status
bar of the user interface. Each user role is protected by means of a pass-
word.
• Change Role
The current user remains logged on until another user has logged on
with entry of the password. The role change can be canceled (close
the dialog via the X).
• Logout
The current user is logged out. To close the dialog, the user must log
on again with entry of the password.
• If no actions are carried out on the user interface for a specified time,
the current user is automatically logged out. Different times apply de-
pending on the user role:
‒ User: After 30 min. of inactivity
‒ Administrator: After 10 min. of inactivity
‒ Safety Commissioning Engineer: After 5 min. of inactivity
• If no user is logged on, the following operator actions are still possible:
‒ Stopping or pausing a program using the buttons on the smart-
PAD.
Description
Procedure
4.7 Help
Description
Procedure
General operation
2. On the user interface, select the feature for which the context aid is to
be displayed.
3. If no context help is available for the selected feature, this is indicated
in a pop-up message: The help center can be called using the Open
Help button.
Description
The Backup & Restore dialog makes it possible to back up and restore
user-specific data. These data are:
• System settings
• I/O configuration
• Safety configuration
• Scene
• All programs
A USB stick is required as the storage medium. The USB stick must meet
the following requirements:
• Formatted as FAT32 or exFAT
• Sufficient free space
NOTICE
Data loss due to defective USB stick
A defect on the USB stick can cause a faulty backup to be created. In
this case, the backup cannot be restored. Restoration can also fail if a
correct backup has been created and a defect subsequently occurs on
the USB stick.
• Before every backup process, check the functionality of the USB
stick.
• Beyond this, save each backup at a second external storage loca-
tion.
Overview
The following functions are available in the Backup & Restore dialog win-
dow:
• Create a new backup
• Restoring a backup
• Deleting a backup
1 Main menu
2 New backup button
3 List of available backups
4 Restore button
5 Delete button (recycle bin)
6 Close button
Precondition
Procedure
Creating a backup:
1. Open the Backup & Restore dialog window via the main menu and
select the New backup button.
2. Enter a name for the backup and start the creation process using the
Create backup button.
The progress of the process is displayed. Once the process is com-
plete, the robot controller is automatically restarted.
NOTICE
Data loss due to premature removal of the USB stick
If the USB stick is removed while data are still being written, data may
be lost.
• Do not remove the USB stick until the robot controller has rebooted.
Restoring a backup:
1. Open the Backup & Restore dialog window via the main menu and
begin restoring the desired backup using the corresponding Restore
button.
General operation
plete, the robot controller is automatically restarted.
2. If the restored safety configuration differs from the previous one, it
must be re-approved.
Deleting a backup:
• Open the Backup & Restore dialog window via the main menu and
delete the desired backup using the corresponding Delete button (re-
cycle bin).
4.9 Software
Description
The Software dialog window allows you to search for updates and up-
grades for the packages installed on the robot controller as well as to ex-
ecute updates and upgrades. It is also possible to search for compatible
toolboxes and to install and uninstall the toolboxes.
Procedure
Overview
Software sources
Description
Precondition
Procedure
1. Select the desired toolboxes for uninstallation (activate the check box).
2. Select the Continue to uninstall button. A list of the toolboxes selec-
ted for uninstallation is displayed.
• The delete button (recycle bin) can be used to remove a toolbox
from the list.
• To make a new selection, select the Go back button or remove all
toolboxes from the list.
3. Select the Uninstall button. A confirmation dialog window in which the
uninstallation can be canceled or started is displayed for 60 seconds.
4. Once the 60 seconds have elapsed, uninstallation starts automatically.
To start the uninstallation immediately, select the Start button.
• The progress of the uninstallation process is displayed.
• The uninstallation can be canceled at any time.
• Once the uninstallation is complete, the user interface is refreshed.
Description
Precondition
General operation
• “Administrator” user role
• Operating mode T1 or CRR
• No program is running.
• No motion is being executed.
Procedure
1. Start the search for updates/upgrades under the corresponding tab us-
ing the Check for updates/Check for upgrades button.
• All available software sources are included in the search.
• If no software source is available, a corresponding error message
is displayed. For example, in the following cases:
‒ User not logged into my.KUKA and USB switch deactivated
‒ USB switch activated and no USB stick connected to the robot
controller
‒ USB switch activated and no update/upgrade available on the
USB stick
2. Select the Update/Upgrade button on the corresponding tab. A confir-
mation dialog window in which the update/upgrade can be canceled or
started is displayed for 60 seconds.
3. Once the 60 seconds have elapsed, the update/upgrade is started au-
tomatically. To start immediately, select the Start button.
• The progress of the update/upgrade is displayed.
• The update/upgrade can be canceled at any time.
• Once the update/upgrade is complete, depending on the software,
the robot controller is restarted or the user interface is refreshed.
Description
Precondition
Procedure
1. Start the search for toolboxes using the Check for toolboxes button.
• All available software sources are included in the search.
• If no source is available, a corresponding error message is dis-
played. For example, in the following cases:
Description
Software sources
• USB
This switch can be used to enable and disable a USB stick connected
to the robot controller as a source of software (precondition: “Adminis-
trator” user role).
• my.KUKA - Authentication
Displays the current authentication status for my.KUKA.
In order to be able to check whether new software or updates/
upgrades are available online, it is necessary to log into my.KUKA. To
be able to access my.KUKA, the robot controller must be connected to
the Internet.
• Authenticate
A user who is not logged in can use this button to start the authenti-
cation. The user is automatically redirected to the my.KUKA login page
and can log in there with the credentials of his or her my.KUKA profile.
‒ If no profile has been created yet, register with my.KUKA first (not
possible using the smartPAD).
‒ After successfully logging in, the user is returned to the scene
view and must reopen the Software dialog window.
• Logout from my.KUKA
A logged-in user can use this button to sign out of my.KUKA again.
General operation
Developer mode
• Activate/Deactivate
This button can be used to activate/deactivate Developer mode (pre-
condition: “Administrator” user role).
‒ The progress of the activation/deactivation process is displayed.
‒ Once activation/deactivation is complete, the robot controller is au-
tomatically restarted.
‒ A reboot is also carried out if activation/deactivation fails or is
aborted.
Description
Procedure
WORLD
BASE
FLANGE
The FLANGE coordinate system describes the current position and orien-
tation of the robot flange center point. It does not have a fixed location
and is moved with the robot.
The FLANGE coordinate system is used as an origin for coordinate sys-
tems which describe tools mounted on the flange.
TOOL
Coordinate Description
X Translation along the X axis of the reference
coordinate system
Y Translation along the Y axis of the reference
coordinate system
Z Translation along the Z axis of the reference coordinate
system
Coordinate Description
Rx Rotation about the X axis of the reference coordinate
system
Ry Rotation about the Y axis of the reference coordinate
system
Rz Rotation about the Z axis of the reference coordinate
system
these axes using the jog keys on the smartPAD. Incremental jogging
General operation
can also be activated.
Precondition: Operating mode T1 or CRR
• Manual guidance
The robot can be moved in all directions using a hand guiding device.
The payload data are taken into consideration both in axis-specific and
Cartesian jogging and in manual guidance. It is possible to switch be-
tween different payloads, e.g. to move the robot manually with an empty
gripper or with a gripped workpiece.
Description
Override
To move the robot more quickly or slowly, an override (in percent from 0
to 100%) can be set.
• The override refers to the maximum permissible velocity during jogging
(250 mm/s).
• The override button opens/closes the override window and displays
the current override setting.
Motion enable
Axis limits
The Axis limits window can be opened in order to move to a specific po-
sition in a more precise manner as well as to visualize the motion range.
• In the window, the current position of each axis relative to the
software limit switches is depicted graphically and in text form.
• The window can be freely moved on the user interface, so that it does
not conceal any currently required contents.
Description
General operation
Fig. 4-4: Cartesian jogging
Override
To move the robot more quickly or slowly, an override (in percent from 0
to 100%) can be set.
• The override refers to the maximum permissible velocity during jogging
(250 mm/s).
• The override button opens/closes the override window and displays
the current override setting.
• The override can be set either by means of the corresponding plus/
minus key on the smartPAD or via the slider in the override window.
‒ Plus/minus key: The override can be set in steps to the following
values: 100%, 75%, 50%, 30%, 10%, 5%, 3%, 1%, 0%
‒ Slider: The override can be adjusted in 1% steps.
Motion enable
• The coordinate system, the TCP or motion frame and the directions of
motion are displayed in the 3D scene. The directions of motion are in-
dicated in color in the 3D scene and the control bar and assigned to
the jog keys.
Axis limits
The Axis limits window can be opened in order to move to a specific po-
sition in a more precise manner as well as to visualize the motion range.
• In the window, the current position of each axis relative to the
software limit switches is depicted graphically and in text form.
• The window can be freely moved on the user interface, so that it does
not conceal any currently required contents.
Description
General operation
Increments
Increment Description
100 mm / 10° 1 increment = 100 mm or 10°
10 mm / 3° 1 increment = 10 mm or 3°
1 mm / 1° 1 increment = 1 mm or 1°
0.1 mm / 0,005° 1 increment = 0.1 mm or 0.005°
Increments in mm:
Precondition
Procedure
Description
The Align Tool jogging option makes it possible to align the tool to a
base. The WORLD coordinate system can also be selected as the base.
• The tool can be aligned perpendicular to a plane of the selected base.
The plane can be selected:
‒ XY-Plane: Alignment to Z axis of the base
‒ XZ-Plane: Alignment to Y axis of the base
‒ YZ-Plane: Alignment to X axis of the base
• The tool can be aligned parallel to the selected plane.
• The motion between “perpendicular” and “parallel” can be continuous
or incremental.
Jog keys
Special jog keys are available for the Align Tool jogging option.
The tool is aligned with the base using key 4. The other keys are as-
signed other jog options.
Key Icon Description
1+2 Example: Moving the tool along the base
When the jog keys are pressed, the TCP moves along the selected
plane of the base (in the example: XY plane).
Note: The axis of the base on which the tool is aligned is always the ax-
is perpendicular to the plane. This means the axis that is not (!) indica-
ted by an icon (in the example: Z axis).
General operation
Key Icon Description
4 Aligning the tool with a base
The decisive factor is the axis that is perpendicular to the selected
plane. In the example above for keys 1+2: the Z axis in the XY plane).
• Plus: The Z axis of the TCP moves in the direction of the perpendic-
ular of the selected plane
• Minus: The Z axis of the TCP moves in the direction of the counter-
perpendicular of the selected plane
The motion extends over a maximum of 180°.
If, during the motion, the Z axis of the TCP reaches the position in which
it is aligned parallel to the selected plane (i.e. 90° to the perpendicular of
the plane), the robot stops there automatically.
The motion can be resumed by pressing the jog key again.
5 Rotate tool
The tool rotates about the Z axis of the TCP.
• Plus: Clockwise
• Minus: Counterclockwise
6 Swivel tool
The tool pivots about the axis perpendicular to the selected plane. The
angle relative to the base is not changed.
• Plus: Clockwise
• Minus: Counterclockwise
Precondition
Procedure
1. Move the TCP to the position from which the tool is to be aligned.
2. Align the tool to the desired base using key 4.
The orientation of the tool is visualized in the scene view.
1 Selected plane
2 Current tool orientation (Z axis of the selected TCP)
3 Perpendicular to the selected plane
4 Current direction of motion (here: plus direction / direction of
the perpendicular)
3. If the tool does not start to align, it may not be possible to address
the end point from the current position.
In this case, it is advisable to move incrementally and gradually ap-
proach the end point.
(>>> 4.12.3 "Incremental jogging" Page 66)
4. The motion extends over a maximum of 180°. If, during the motion,
the tool reaches the position in which it is aligned parallel to the selec-
ted plane, the robot stops there automatically.
5. The motion can be resumed by pressing the jog key again. As soon
as the tool is aligned perpendicular to the selected plane, the robot al-
so stops there automatically.
Description
The robot can be guided manually with the LBR iisy Commander in all op-
erating modes.
Procedure
1. For manual guidance, grip the Commander on the robot with both
hands.
2. Press and hold down one of the enabling switches until the brakes re-
lease.
General operation
Fig. 4-8: Enabling switches on the Commander
Description
• Turn clockwise:
Switches to the next element down or to the right that can be focused
on.
• Turn counterclockwise:
Switches to the next element up or to the left that can be focused on.
• Short press:
Selects the currently focused element or triggers an action.
• Long press:
Opens a context menu if available in the focused element.
• Double press:
Opens or hides the focused element if it contains child elements.
• Short press:
Closes the context menu or dialog window and returns to the last fo-
cused element.
• Long press:
No function
• Double press:
No function
General operation
Fig. 4-10: Operating the user interface with the Commander
A paused program can be resumed at any time from the position at which
the program was interrupted. If the robot was moved manually during the
pause, the robot must first be returned to this position.
• The motion back to the starting position can be started in T1 and AUT
modes (using the Start key on the smartPAD).
• The enabling switch and Start key must be held down in T1 mode.
Otherwise, the motion will be stopped.
• The motion is executed automatically in AUT mode after the Start key
has been pressed. The motion can be stopped by pressing the Pause
key.
• Once the position at which the program can be resumed has been
reached, a confirmation dialog is displayed.
• The program is resumed by pressing the Start key on the smartPAD
again.
Each robot axis has at least one holding brake integrated into the motor.
The brake test checks whether the braking torque is high enough. If the
brake test for an axis fails, the brake is defective and must be replaced.
The brake test ensures that any impairment of the braking function is de-
tected, e.g. due to wear, overheating, fouling or damage, thereby eliminat-
ing avoidable risks.
Unless otherwise determined by a risk assessment, the brake test must
be performed regularly for all axes:
• Before start-up and recommissioning of the industrial robot
General operation
• Every 48 hours during operation
A risk assessment can be used to determine whether the brake test is re-
quired for the specific application and how often the brake test must be
performed.
Description
The view displays the brake test status of the individual robot axes.
Functions:
Procedure
• To open the view, select Setup > Brake Test in the Feature menu.
Description
In the settings, the cyclical brake test can be activated and the brake test
cycle time can be set. The cycle time is composed of the following ele-
ments:
• Test interval
Once this time has elapsed, the brake test is requested.
• Grace period
Once the test interval has elapsed, the grace period within which the
brake test has to be performed begins. When the grace period has
elapsed, the robot stops.
WARNING
Danger to life and limb due to inadmissible program start
Program execution must not be resumed following a failed brake test or
after the grace period has elapsed. Death, severe injuries or damage to
property may otherwise result.
• Shut down the robot immediately after a failed brake test and re-
place the defective brake.
• Do not restart the program after the grace period has elapsed. Per-
form the brake test first.
• Only restart the program after a successful brake test.
Procedure
Description
The brake test can be performed for all axes or for individual axes. A wiz-
ard guides you through the required steps.
Precondition
Procedure
1. Start the brake test for all axes or an individual axis using the corre-
sponding button. The wizard opens.
2. Follow the instructions in the wizard.
3. Once the brake test has been successfully performed, the wizard is
automatically closed. The result of the brake test for each axis is dis-
played in the parameter view.
WARNING
Danger to life and limb due to inadmissible program start
Program execution must not be resumed following a failed brake test or
after the grace period has elapsed. Death, severe injuries or damage to
property may otherwise result.
• Shut down the robot immediately after a failed brake test and re-
place the defective brake.
• Do not restart the program after the grace period has elapsed. Per-
form the brake test first.
• Only restart the program after a successful brake test.
General operation
4.16 Mastering
Overview
MMD mastering
All robot axes equipped with a magnetic mastering sensor (MMD) can be
mastered automatically. The mastering position of the axis (zero position)
is located in the center of a defined series of magnets. It is automatically
detected by the mastering sensor when it passes over the series of mag-
nets during a rotation of the axis.
Overview
The mastering view shows the mastering status of the individual robot ax-
es and enables the robot to be mastered. It is possible to master all axes
together in a single run or individual axes.
To open the mastering view, select Setup > Mastering in the Feature
menu.
• When the view is opened, the first unmastered axis is selected by de-
fault. Once all axes have been mastered, the first axis is selected.
• Mastering can be started using the following buttons:
‒ Master all axes button in the main view
‒ Master axis button in the detail view of a selected axis
A wizard opens which guides the user through all the required master-
ing steps.
Description
General operation
As soon as all axes are mastered again, it is advisable to define
a suitable robot pose for mastering and to modify the pose ac-
cordingly.
Precondition
Description
The Master all axes and Master axis buttons in the mastering view open
a wizard that guides the user through the required mastering steps. These
steps are essentially independent of whether all axes are mastered in a
single run or a single axis is mastered.
Mastering rules
Precondition
Procedure
The following pages in the wizard must be executed one after the other in
order to master the robot. Once a step has been successfully completed,
it is possible to switch to the next page with the Next button.
1. Set preconditions
• Set mastering tool
for mastering. If the active tool differs from the tool used for the
previous mastering, the user has the following options:
‒ Use the load data of the tool from the previous mastering
again.
‒ Use the load data of the currently active tool.
NOTICE
Damage to property due to use of incorrect load data
The load data of the tool selected in the wizard are used for the
mastering motion. If a tool with different load data is mounted on
the robot, this can result in unexpected robot motions and dam-
age to property.
‒ Make sure that the selected tool is actually mounted on the
robot.
Press and hold down the enabling switch and Start key on the smart-
General operation
PAD as long as the mastering motion is in progress. Otherwise mas-
tering will be aborted.
3. Check result
The page is only displayed if all axes to be mastered had already
been mastered before mastering is performed.
(>>> 4.16.4 "Check result" Page 81)
4. Move to pose for mastering approval
In mastering confirmation, the correctness of the mastering is checked.
• After mastering, the robot is generally already in the defined pose
for mastering confirmation. The page is then skipped.
• If the robot is not yet correctly positioned, the following options are
available:
‒ Option Move to pose
If the option is activated, the robot can automatically move to
the defined pose when an enabling switch and the Start key
on the smartPAD are pressed.
‒ Alternatively, each axis can be moved to the defined pose indi-
vidually using the jog keys on the smartPAD.
5. Execute mastering approval
Press and hold down the enabling switch and Start key on the smart-
PAD as long as mastering confirmation is in progress. Otherwise, mas-
tering confirmation will be aborted.
Individual axes or all axes of a robot that has already been mastered can
be remastered in order to check the mastering result.
Once mastering has been carried out, the difference from the last master-
ing procedure is displayed on the Check result page. It is possible to as-
sess on the basis of the differences whether the previous mastering can
be retained or the new mastering applied.
• Discard button
Previous mastering is retained and wizard is closed.
• Apply mastering
New mastering is applied and wizard switches to next page.
NOTICE
Damage to property due to modified mastering data
Following a change to the mastering data, frames that have already
been taught may no longer be addressed correctly. Damage to property
may result.
• Reteach frames that have already been taught.
Description
The robot is supplied with calibrated joint torque sensors and can general-
ly be put into operation without recalibration. Calibration of the joint torque
sensors is only necessary if the factory settings no longer match. This can
be recognized as follows:
• Confirmation of the calibration of the joint torque sensors fails.
• The robot begins to drift during manual guidance. If the enabling sig-
nal for manual guidance has been issued, the robot does not remain
stationary in its position. It drifts away, so slight counterpressure is
needed to keep it in position.
The following functions are available in the view for calibration of the joint
torque sensors:
• Adjust all sensors button
Opens a wizard for calibration of the joint torque sensors.
• Factory reset button
Opens a dialog for resetting the joint torque sensors to the factory set-
tings.
The view also shows the robot pose required for the calibration. Calibra-
tion is only available for floor-mounted robots.
Procedure
• To open the view, select Setup > Service > Joint torque sensor in
the Feature menu.
Description
The Adjust all sensors wizard guides the user through all the required
steps.
Precondition
Procedure
General operation
‒ No external forces are applied to the robot during execu-
tion, e.g. by touching it.
• Move to pose for adjustment
The robot must be in a defined pose.
‒ Option Move to pose
If the option is activated, the robot can automatically move
to the defined pose when an enabling switch and the Start
key on the smartPAD are pressed.
‒ Alternatively, each axis can be moved to the defined pose
individually using the jog keys on the smartPAD.
b. Execute adjustment
Press the enabling switch and Start key on the smartPAD and hold
down until the process is completed.
Once calibration has been carried out successfully, the system au-
tomatically switches to the next page.
c. Move to pose for adjustment approval
• Option Move to pose
If the option is activated, the robot can automatically move to
the defined pose when an enabling switch and the Start key
on the smartPAD are pressed.
• Alternatively, each axis can be moved to the defined pose indi-
vidually using the jog keys on the smartPAD.
d. Execute adjustment approval
Press the enabling switch and Start key on the smartPAD and hold
down until the process is completed.
Once calibration has been successfully confirmed, the wizard is
automatically closed.
Description
The Factory reset dialog makes it possible to reset the sensors to the
factory settings.
Precondition
Procedure
Description
For start-up, it is necessary to check and confirm that the robot axes have
been correctly mastered and that the joint torque sensors have been cor-
rectly calibrated:
• Confirmation of mastering
The mastering of the axis position sensors of a kinematic system is
checked. This means that a check is performed as to whether the ac-
tual mechanical axis position matches the measured axis position.
• Confirmation of calibration of the joint torque sensors
The calibration of the joint torque sensors of a kinematic system is
checked. For this purpose, checks are made at various measurement
positions to determine whether the expected torques of the axes cor-
respond to the actual axis torques. The expected axis torques are cal-
culated on the basis of the robot model and the configured load data.
“Approval” view
The view shows the status of the mastering confirmation and the status of
the calibration confirmation for each axis.
To open the view, select Setup > Approval in the Feature menu.
Approval settings
General operation
system (e.g. mobile platform, linear unit), the following points must be en-
sured as well:
• The carrier kinematic system must not be moved while the confirma-
tion is being performed.
• The mounting direction of the kinematic system to be checked may
not differ from the configured mounting direction during confirmation
(e.g. due to tilting of the mobile platform).
If any of these points are not met, the safety integrity of the confirmation
is not given.
Procedure
General configuration
5 General configuration
A user has certain rights depending on the role. Each user role is protec-
ted with an initial default password. The default password for all user roles
is “kukakuka”. The password can be changed for each user role.
(>>> 5.2.4 "Changing a user password" Page 90)
Change default passwords
If the default passwords are not changed, this enables unauthorized
persons to log on.
• Before start-up, change the password for all user roles.
• Only communicate the passwords to authorized personnel.
Description
The network addresses for the following Ethernet interfaces of the robot
controller can be configured in the system settings:
• KLI OT, interface XF5
• KLI IT, interface XF2
• KONI, interface XF7
The interfaces can be assigned either a static network address or a dy-
namic network address:
• Automatic (DHCP)
If this option is selected, a DHCP server in the network automatically
assigns all settings.
• Manual (static)
If this option is selected, all settings can be entered manually.
• Optionally, a description or a comment can be entered for each inter-
face.
1 Main menu
2 Assignment options
3 IP Address
4 Subnet mask
5 Gateway
6 Preferred DNS server
7 Alternative DNS server
8 Description/comment (optional)
Precondition
Procedure
Description
General configuration
Precondition
Procedure
Description
The firewall rules defined for the robot system can be displayed in the
system settings.
• Each firewall rule includes the following information:
‒ Network protocol, e.g. TCP or UDP
‒ Port number
‒ Status
‒ Name and description
‒ Origin, e.g. system or toolbox
‒ Network interface, e.g. KLI IT, KLI OT, KONI or KSI
• Firewall rules can be sorted by name, protocol, port and status (in de-
scending/ascending order).
• Each firewall rule opens a specific port via the defined network inter-
face. To close a specific port, the corresponding rule can be deactiva-
ted.
Deactivating a rule can limit the functionality of the system, toolbox,
etc.
1 Main menu
2 Open/close all rules
3 Sorting options, descending/ascending
4 Rule open
5 Status switch activated
Precondition
Procedure
Description
The password for each user role can be changed in the system settings.
Precondition
Procedure
General configuration
5.2.5 Display settings
Description
Procedure
Description
The time zone, date and time can be set in the system settings. Once the
date and time have been changed, the controller is restarted.
Precondition
Procedure
1. In the main menu, select System Settings > Date and Time.
2. Make the desired settings.
3. To save, select the Apply or Apply and restart button.
Description
The name of the robot controller can be configured in the system settings.
Precondition
Procedure
Description
Precondition
Procedure
I/O configuration
6 I/O configuration
Description
Physical inputs and outputs are made available by the devices connected
to the bus. The system may contain multiple physical inputs and outputs
that can be displayed, parameterized or mapped as required. Inputs are
signals that the controller receives from an external source, e.g. the val-
ues of a sensor, while outputs are signals that the controller sends to ex-
ternal equipment, e.g. instructions to a gripper. The various inputs and
outputs are managed on the main page of the Physical I/O interface.
Changes to physical inputs and outputs can only be carried out in T1
mode. In the case of safe physical inputs and outputs, changes are only
possible with the Safety Commissioning Engineer role.
It is advisable to make all desired changes before saving the changes
via the Apply button.
Overview
Item Description
1 Select the bus instance
Item Description
4 Show and hide columns
Note: Hiding columns allows long I/O names to be displayed in
full.
5 I/O filter
The I/Os can be filtered by direction, safety and mapping.
6 Display of the mapped signals in the Mapped To area
The following actions can be executed by touching a mapped
signal:
Precondition
Procedure
4. Press Continue to switch to the Map selected bits to... page and se-
lect the desired mapping option:
• Option Map to existing signal
• Option New signal
5. Press Continue to switch to the mapping page.
6. If the Map to existing signal option is selected:
a. Select the signal that is to be mapped.
All available signals are displayed. If necessary, filter the availa-
ble signals.
I/O configuration
By default, the parameters (direction, safety, name) of the selec-
ted I/Os are applied for the new signal.
6.2 Signals
Description
Signals are the interface on the controller to physical inputs and outputs.
The system may contain multiple signals that can be displayed, parame-
terized or mapped as required. The different signals are managed on the
main page of the signals interface. Signals can be set in different data
types. The data types BOOL, Number and RAW are supported.
Changes to signals can only be made in T1 mode. In the case of safe
signals, changes are only possible with the Safety Commissioning Engi-
neer role.
It is advisable to make all desired changes before saving the changes
via the Apply button.
Overview
Item Description
1 Create new signal
2 Delete non-mapped signals
3 Accept changes
Note: The button is active if changes have been made in T1
mode and no program is running.
Item Description
4 Discard changes
5 Show and hide columns
Note: Hiding columns allows long I/O names to be displayed in
full.
6 I/O filter
The I/Os can be filtered by direction, safety and mapping.
7 Detail view of the signal parameters
8 Detail view for signal mapping
If an unmapped signal is selected, the Map signal button is dis-
played.
If a mapped signal is selected, the Unmap signal button is dis-
played.
The scaling parameters can be edited using the Edit scaling
button.
9 Expand and collapse signal collection
10 Signals belonging to the selected signal collection
User Signals
New signals can be created and mapped on the main page of the signals
interface.
Procedure
I/O configuration
2. Set the signal parameters.
3. Press Continue to switch to the mapping page.
Alternative: Press Finish to create the new signal without mapping. It
can subsequently be mapped in the detail view of the signal.
4. On the mapping page, select the physical I/O that is to be mapped.
If the list of I/Os displayed is too long, it is possible to filter for the bus
and device.
Multiple mapping is not possible.
Description
The bus topology defines the structure of the bus system with all connec-
ted devices and their connections to one another.
The various buses are displayed on the main page of the Bus Topology
interface.
As standard, the bus topology configured on the controller and the de-
vice parameters available offline are displayed. For comparison with the
real bus structure – the display of the online parameters of the devices
including diagnostic information – the bus system must be updated.
Overview
Item Description
1 Expand and collapse bus topology with device connections
2 Add device to KUKA Extension Bus (SYS-X44) or PROFINET
3 Delete device from KUKA Extension Bus (SYS-X44) or PROFI-
NET
4 Accept changes
Note: The button is active if changes have been made in T1
mode and no program is running.
5 Discard changes
6 Open I/O configuration settings
The KUKA Extension Bus (SYS-X44) and the PROFINET bus
instance can be enabled/disabled in the configuration settings.
In this way, the activated bus instance is added to/removed
from the bus topology.
7 Open Device manager
8 Parameter view of the selected device
9 Diagnostic data of the selected EtherCAT bus topology
Description
I/O configuration
vice. The default configuration is then automatically assigned to the origi-
nal device.
Precondition
• The device description files of the connected devices have been im-
ported.
Description
In the parameter view of a device in the KUKA Extension Bus, the proc-
ess data objects (PDOs) can be updated using the Update PDOs button.
The process data objects of a device can be displayed using the Open
device configuration button.
Precondition
Device overview
• List of available devices with the name of the vendor, the version of
the device and the device description file
• Search box for quickly locating a device
• List of devices already imported with the name of the vendor and the
devices it contains
• Search box for quickly locating a file or device in a file
• Select a specific vendor
• Delete selected files
• Only EtherCAT device description files are supported (ESI files)
Import
The following steps are required in order to import device description files
from a USB stick:
1. Prepare the USB stick with the KUKA folder at the top level.
2. Download the required device description files from the vendor and
save them in the KUKA folder.
3. Plug the USB stick into the robot controller.
4. Press the Refresh button.
A confirmation is displayed when the import has been successfully
completed.
On the main page of the Bus Topologyinterface, the user can make the
following changes to EtherCAT devices.
By means of the Add device button:
• Add a bus instance
• Add a device at the end of an EtherCAT branch
• Continuous addition: Add a device with the option of directly adding
its children
• Add a device between two other devices
Only compatible devices are displayed for adding.
6.3.5 Diagnosis
Icon Status
OK
There are no error messages.
Solvable problem
The device is sending error messages, but the problem can
be solved.
Device must be replaced
The device is defective and must be replaced.
Not available
The device has been configured but is not available in the
network.
Need to refresh
An update is required to retrieve the current device status.
I/O configuration
6.3.6 Updating MDPs
Description
In the parameter view of a device in the KUKA Extension Bus, the Ether-
CAT Modular Device Profiles (MDPs) can be updated using the Update
MDPs button. The device’s added modules can be displayed using the
Open device configuration button.
Precondition
Procedure
Description
Communication
Configuration
EtherCAT® Bridge FSoE M/M consists of a bus coupler and the Ether-
CAT® bridge terminal.
Bus coupler: primary side
The KUKA robot controller connected to the bus coupler is connected to
the primary side of the bridge terminal.
• A KUKA robot controller must always be connected to the primary
side.
The primary side must be configured in iiQKA.OS.
Bridge terminal: secondary side
The controller that is connected to the bridge terminal itself is connected
to the secondary side.
• An external controller (e.g. PLC) can be connected to the secondary
side.
• Or a second KUKA robot controller.
The secondary side must be configured on the external controller or in
iiQKA.OS (on the second robot controller).
Description
Precondition
I/O configuration
• Device description file for bus coupler is available.
The device description file can be obtained from the manufacturer of
the bus coupler.
• Only if safe communication is to be set up:
“Safety maintenance” user role
Procedure
1. Import the device description file of the bus coupler into iiQKA.OS.
Information about importing device description files can be found in
the help function under “I/O configuration”.
11. The remaining steps only need to be carried out in the following case:
• The external controller is a PLC.
• And: Safe communication is to be established.
Steps:
a. In the Feature menu, select Setup > Safety and switch to the EN-
GINEERING tab.
b. Touch the cogwheel icon. The “Safety Settings” dialog opens.
Description
This procedure must be carried out for the following communication types:
• Robot controller – external controller (safe)
• Robot controller – external controller (not safe)
Precondition
Procedure
Description
This procedure must only be carried out for the following communication
type:
• Robot controller – external controller (safe)
In order to be able to use terminal “EtherCAT® Bridge FSoE M/M” also
for the safety interface, the described settings must be carried out in the
project of the external controller.
Procedure
I/O configuration
Data (8 bytes), ID 0x00000102
b. Add the module.
The FSoE address of the EtherCAT Bridge in the project of the external
controller must correspond to the FSoE address in the safety configuration
of the robot controller.
• The address must be in the range from 1 to 65 535.
Default IP address: 999
• The watchdog times of the parameters for communication via the
FSoE must be in the range from 64 to 32 767 ms.
Description
This procedure must only be carried out for the following communication
type:
• Robot controller – robot controller (not safe)
Precondition
Procedure
I/O configuration
• Process data objects, synchronization bits, size of the non-safe
I/Os
Accept the changes with Confirm changes.
7. Select the Physical I/O tab and select the bus instance KUKA Exten-
sion Bus.
8. Open the device KRC4 Secondary EL6695-1001.
Map the inputs/outputs.
Information about mapping can be found in the help function under
“I/O configuration”.
Payload configuration
7 Payload configuration
Payloads are all the loads mounted on the robot flange. These include the
following loads:
• Load of the tool mounted on the robot flange
• Load of the workpiece picked up by the tool
Description
A tool can be added to the robot, configured and calibrated in the tool
configuration editor. This tool is automatically connected to the robot
flange.
• Only one tool can be configured in the tool configuration editor.
• Additional tools outside the robot can be added in the scene editor.
This enables access to the capabilities of these tools.
Tools outside the robot cannot be used for jogging or for program mo-
tions.
Procedure
• To access the editor, select the Tool tab under Setup > Payload in
the Feature menu.
1 Main view
2 Detail view
3 Select and add tool/TCP
4 Configured tool (tree structure)
Main view
The main view shows the tool configuration as a tree structure and offers
the following functions:
• Select and add Tool.
‒ Generic tool
‒ Or tool from one of the installed toolboxes
• Select and add TCP.
Each tool includes at least one TCP. Further TCPs can be created.
• The toolbar at the bottom of the screen offers the following functions
for modifying the tool configuration:
‒ Delete selected element (recycle bin).
‒ Copy selected element.
‒ Paste copied element.
Detail view
The detail view displays the properties and parameters of the element se-
lected in the configuration tree in the main view.
Payload configuration
• Parameters tab
The parameters of the selected tool or TCP can be entered manually.
Or calibration data have been saved.
• Capabilities tab (if a tool from a toolbox is selected)
‒ Gripper Capability
It is possible to switch to the available gripper capabilities in order
to configure the gripper functions.
‒ Actions
The gripper functions Grip and Release configured in the capabili-
ties can be executed and tested.
‒ Signals
The current values of the configured gripper signals are displayed.
It is possible to switch to the I/O configuration via the I/O names.
• Calibration tab (if a TCP is selected)
The tool can be calibrated here.
Load data
Only a Safety Commissioning Engineer can enter and edit the load data
of the tool.
• M
Mass of the tool
• Lx, Ly, Lz
Position of the center of mass in the FLANGE coordinate system
• lx, ly, lz
Mass moments of inertia about the principal inertia axes
• Rx, Ry, Rz
Orientation of the principal inertia axes relative to the FLANGE coordi-
nate system
TCP data
The TCP data can be entered manually or defined with the tool calibra-
tion. The following data are saved:
• X, Y, Z
Origin of the TOOL coordinate system relative to the FLANGE coordi-
nate system
• Rx, Ry, Rz
Orientation of the TOOL coordinate system relative to the FLANGE co-
ordinate system
The TOOL coordinate system has its origin at a user-defined point. This
Payload configuration
point is called the TCP (Tool Center Point). A tool can have multiple
TCPs.
The TCP of a tool can be calibrated in the parameter view of the TCP on
the Calibration tab:
• The origin and orientation of the TOOL coordinate system are calibra-
ted separately.
• It is possible to calibrate only the origin and enter the orientation man-
ually or vice versa.
• To start the calibration, select Calibrate/Recalibrate.
A wizard opens which guides you through all the required calibration
steps.
• Calibration can also be carried out by means of manual guidance on
the Commander. By turning the jog dial, the selection of the measure-
ment point can be changed and by pressing the jog dial, a touch-up
can be carried out.
To calibrate the orientation Rx, Ry and Rz, the following points on the tool
are moved to a reference point and the measurement pose is taught:
• Origin of the TOOL coordinate system
• Point in negative tool direction (in relation to the origin)
• Point on the XY plane of the TOOL coordinate system with a positive
Y value
The robot controller uses these 3 measurement poses to calculate the ori-
entation of the TCP.
Description
Procedure
• To access the editor, select the Workpiece tab under Setup > Pay-
load in the Feature menu.
Payload configuration
Fig. 7-2: Workpiece configuration editor
1 Main view
2 Detail view
3 Add workpiece or open workpiece wizard
4 List of created workpieces
Main view
The main view displays the created workpieces and offers the following
functions:
• Create a workpiece manually
To do so, select Add workpiece in the Editor menu.
• Create a workpiece using a wizard
The workpiece wizard can be started via the corresponding entry in
the Editor menu. If no workpieces have been created yet, the work-
piece wizard can also be started using the Start workpiece wizard
button. The workpiece wizard guides you step by step through the
configuration of the workpiece and provides additional written and
graphical help.
• Delete a selected workpiece via the toolbar at the bottom of the
screen (recycle bin)
Detail view
The detailed view shows the properties and parameters of the selected
workpiece.
• Parameters tab
The load data of the workpiece can be entered here and the motion
frame can be selected.
• Origin tab
The origin of the workpiece can be defined here.
• Shape tab
A basic form for the workpiece in the 3D scene can be defined here
(optional).
Parameters
Origin
Shape
Payload configuration
7.4 Gripper toolboxes
Overview
Capabilities
Further information about the gripper commands and the quick access
buttons can be found in the help function under “Programming”.
Description
Procedure
1. To open the view, select Setup > Capabilities in the Feature menu.
2. Select the desired gripper capability in the drop-down menu of the
view.
• Main view: Displays the capability as a tree structure.
1 Gripper capability
2 General settings
3 Grip settings
4 Release settings
Gripper capability
Payload configuration
switch. The status can also be opened in a separate window. All quer-
ies can be activated or deactivated simultaneously using the Activate
All and Deactivate All buttons.
• Actions
The gripper functions Grip and Release configured in the capabilities
can be executed and tested.
• Signals
The current values of the configured gripper signals are displayed. It is
possible to switch to the I/O configuration via the I/O names.
General settings
Grip settings
Release settings
Gripper capability
• Properties
A service runs in the background in the toolbox, which queries the sta-
tus of the gripper every 300 ms. This status (e.g. Gripped) can be
used as a return value in the programming. The querying of an indi-
vidual status can be activated or deactivated using the Refresh
switch. The status can also be opened in a separate window. All quer-
ies can be activated or deactivated simultaneously using the Activate
All and Deactivate All buttons.
• Actions
The gripper functions Grip and Release configured in the capabilities
can be executed and tested.
• Signals
The current values of the configured gripper signals are displayed. It is
possible to switch to the I/O configuration via the I/O names.
Grip settings
Description
In the parameter view of the gripper capability, buttons are available for
executing and testing the configured gripper functions:
• Grip
• Release
The buttons are also available under Setup > Payload in the parameter
view of the tool (Capabilities tab).
Precondition
Payload configuration
Fig. 7-4: Executing and testing gripper functions
3D scene
8 3D scene
The scene view shows the 3D visualization of the scene. To display it, se-
lect Scene in the Feature menu.
The 3D scene shows the model of the objects that are present in the
project. These include:
• Robot in the current pose
• All frames and bases
• All cuboids and prisms (monitoring spaces)
• Physical objects, e.g. SICK safety laser scanners
• Tool spheres and force interaction areas
• Workpiece with which the robot moves
• Safety spheres of the robot structure
Frames
Parameters of a frame
• 6D coordinates:
‒ X, Y and Z coordinates: These 3 values determine the position of
the frame in space
‒ Rx, Ry, Rz: These 3 values specify the rotation angle about the X,
Y and Z axes. They determine the orientation of the frame in
space.
• Parent: Specifies the reference system for the frame.
All coordinates and rotation angles are specified relative to this refer-
ence system. If the reference system is changed, the absolute position
of the frame in space also changes. Further information about this can
be found in the section on bases.
If a frame is displayed under another object or frame in the object
tree, this means that this other object is the Parent of the frame.
Frames can be either shared with all programs in the project or not
shared.
Unshared frames
3D scene
• Unshared frames are only visible in the robot program in which they
were created.
• Unshared frames cannot be created or modified in the 3D scene, but
only on the programming interface.
• Unshared frames are only visible in the 3D scene if the program to
which they belong is open in the programming interface.
• The use of unshared frames within a program ensures that no other
programs are affected if the unshared frame is modified or deleted.
Frames shared in the project
• Shared frames are visible for all robot programs in the current project.
• Shared frames can be created either in the programming interface or
directly in the 3D scene.
• Shared frames are used, for example, for defined reference positions
of the robot.
Shared and unshared frames can be converted from one to the other. If
an unshared frame is to be split subsequently, either a new shared frame
can be created for this, or an existing shared frame can be used.
Creating frames
Description
Tool configuration
3D scene
During configuration of the Tool Orientation Monitoring Monitoring
Block in the safety configuration editor, one of the available TCPs can
be selected as a tool orientation frame. The following applies in this
case:
• The selected TCP cannot be deleted from the scene editor.
• To edit the TCP data, a Safety Commissioning Engineer must be
logged on.
Tool calibration
Description
Up to 6 spheres can be configured for a tool. The tool spheres are rele-
vant for Cartesian velocity monitoring and space monitoring functions.
The tool spheres are monitored if the tool is selected as the structure to
be monitored in the corresponding Monitoring Blocks in the safety configu-
ration.
Further information about the monitoring functions can be found in the
help function under “Safety configuration”.
Precondition
Example
Description
The force interaction area is defined as a sphere that contains all the
points of a safety-oriented tool where expected external forces can occur.
Further information about the force interaction area can be found in the
help function under “Safety configuration”, in the section “Monitoring
Block Maximum TCP force”.
The more accurately the position of the force interaction point is defined
(i.e. the smaller the radius of the force interaction area is configured), the
better the Monitoring Block Maximum TCP Force can be used near sin-
gularities.
Precondition
Example
Configuration example for the force interaction area for a SCHUNK Co-Act
ESG 60 gripper:
3D scene
Predefined position of the force interaction area
Sphere Offset relative to the FLANGE coordinate system Radius
1 X = 0 mm, Y = 0 mm, Z = 125 mm 50 mm
The force interaction area for other tools can be configured analogously to
this example.
• In the parameter view, the force interaction area can be shifted and
the radius changed by entering coordinates.
• The force interaction area should cover the collision area, but should
be kept as small as possible to make efficient use of the workspace.
Description
Additional tools outside the robot can be added in the scene editor. This
enables access to the capabilities of these tools.
Tools outside the robot cannot be used for jogging or for program motions.
Procedure
1. In the World tree view and in the object selection menu, select Tool.
2. Select and add the desired tool.
3. To configure the tool, select the tool added in the tree view:
• The name can be changed in the detail view on the Parameters
tab. The load data for tools that are not connected to the robot
flange are irrelevant and cannot be edited.
• The capabilities can be configured as required in the detail view
on the Capabilities tab.
‒ Link to the capability configuration
It is possible to switch to the capability configuration.
‒ Actions
The functions configured in the capabilities can be executed
and tested.
‒ Signals
The current values of the signals configured in the capabilities
are displayed. The signals can be used to switch to the signal
configuration in the I/O configuration.
Description
The workpiece with which the robot is currently moving is displayed in the
3D scene and in the object tree.
Detail view
The detailed view shows the properties and parameters of the selected
workpiece.
• Parameters tab
The load data of the workpiece can be entered here and the motion
frame can be selected.
• Origin tab
The origin of the workpiece can be defined here.
• Shape tab
A basic form for the workpiece in the 3D scene can be defined here
(optional).
Parameters
Origin
Shape
3D scene
8.6 Calibrating and managing bases
Creating bases
• A base can be set to active in the status bar. Jogging can be carried
out manually in the active base.
• Bases can be nested, i.e. a base can be created with another base as
its reference, e.g. a workpiece on a work surface.
Cuboids and prisms used in the safety configuration can only be edited in
the Safety Commissioning Engineer user role. In order to be able to de-
lete such spaces, they must first be removed in the safety configuration.
In order to start up a SICK safety laser scanner, the laser scanner must
be configured in the scene editor. For this, an object of type SICK micro-
Scan3 is created in the scene editor.
In addition to the coordinates of the laser scanner in space, the checksum
of the laser scanner must be entered. The checksum can be found in the
scanner settings in the Safety Designer configuration tool under Check-
sum of the configuration (function).
3D scene
Fig. 8-7: Determining the checksum in Safety Designer
Further information about the bus scan can be found in the help func-
tion under “I/O configuration”.
• Objects can be deleted from the 3D scene using the recycle bin icon.
• Deleted objects cannot be restored.
• If an object that is selected for deleting has child objects assigned to
it, there are various options:
‒ Delete the object and all child objects.
‒ Delete only the object itself. The child objects are automatically
pushed up one level.
The child objects maintain their absolute position in space. They
can thus continue to be used in programs without restrictions.
• Objects that are used in the safety configuration (e.g. as a monitoring
space) cannot be simply deleted. This applies to direct deletion and al-
so if an object is to be deleted as a child object of a parent object.
‒ The safety configuration must first be edited in such a way that the
object is no longer used.
‒ A dialog displays the relevant points in the safety configuration
and it is possible to switch directly to the relevant point in the safe-
ty configuration.
‒ The Safety Commissioning Engineer user role is required for this.
Other user roles cannot delete or edit safety-relevant objects.
• Frames, bases, cuboids and prisms can be cut from the object tree
using the scissors icon.
• Cut objects are saved to a clipboard.
• Cut objects can be pasted back into the object tree from the clipboard.
• If an object has been cut unintentionally, there are several ways to un-
do the cut action:
‒ Press the Cancel button in the pop-up message.
‒ Press the scissors icon again.
‒ Paste the cut object back in the same place.
• Objects that are used in the safety configuration (e.g. as a monitoring
space) cannot be simply cut.
• The object tree can be restructured by cutting and pasting objects.
• A cut frame that is pasted under another Parent remains in the identi-
cal location, but the coordinate values change, as they refer to the Pa-
rent.
• If a Parent is cut, the child objects are also cut.
Safety configuration
9 Safety configuration
The safety configuration defines the safety-oriented functions in order to
integrate the industrial robot safely into the system. Safety-oriented func-
tions serve to protect human operators when they work with the robot.
The system integrator determines the required safety functions using the
risk assessment as a basis. The Safety Commissioning Engineer imple-
ments the safety specifications.
Verification of safety in the case of HRC
The safety configuration must sufficiently reduce the risks during collab-
orative operation (HRC). Death, severe injuries or damage to property
may otherwise result.
• The system integrator must verify that the safety configuration meets
the safety requirements for HRC systems.
• It is advisable to perform this verification in accordance with the in-
formation and instructions for operating collaborative robots in
ISO/TS 15066.
Safety Rule Sets are higher-level structure elements of the safety configu-
ration. They group together one or more Safety Rules that jointly imple-
ment a specific safety function or support a device. All Safety Rules con-
tained in the Safety Rule Sets are processed in parallel by the safety sys-
tem. The grouping of various Safety Rules into Safety Rule Sets thus has
no effect on the execution of the configured safety monitoring functions.
One example is the triggering of several different safety reactions if a cer-
tain combination of Monitoring Blocks is violated, e.g. a safety stop and a
safe output. For this purpose, 2 Safety Rules with identical Monitoring
Block combinations can be included in the same Safety Rule Set.
To access the editor, select Setup > Safety in the Feature menu and
switch to the ENGINEERING tab.
On the tab, the Safety Commissioning Engineer can edit and approve the
safety configuration.
Safety configuration
Fig. 9-1: Safety configuration editor
1 Feature menu
2 Add configuration element
3 Apply modified safety configuration
4 Approve safety configuration
5 Open safety settings
6 Display of grace period (safety stop canceled)
7 Cancel safety stop if safety configuration not approved
8 Main view
9 Parameter view
The editor contains the following elements:
• Main view: Shows the safety configuration as a tree structure.
• Parameter view: Displays the properties and parameters of the ele-
ment selected in the configuration tree in the main view. The parame-
ters can be edited.
(>>> 9.2.1 "Editing parameters" Page 136)
• Buttons with the following functions (log-on as Safety Commissioning
Engineer required):
‒ Add configuration element to the safety configuration:
‒ Safety Rule Set
‒ Safety Rule (below the selected Safety Rule Set)
‒ Monitoring Block (below the selected Safety Rule)
‒ Select and remove configuration element from the tree (recycle
bin).
‒ Apply modified safety configuration (Apply button).
(>>> 9.2.2 "Applying the safety configuration" Page 136)
‒ Cancel safety stop if safety configuration not approved (Unblock
button).
The button is only available after a modified safety configuration
has been applied. As soon as the safety configuration has been
approved, the button is no longer displayed.
(>>> 9.2.3 "Canceling the safety stop if the safety configuration is
not approved" Page 137)
Description
Precondition
Description
Each safety configuration has a unique activation ID. With this ID, the
Safety Commissioning Engineer can unambiguously identify the safety
configuration on the robot controller.
• If changes are made to the safety configuration on the ENGINEERING
tab, the activation ID also changes.
Safety configuration
• The modified safety configuration is no longer identical to the safety
configuration currently running on the robot controller and displayed on
the RUNTIME tab. This is indicated on the RUNTIME tab by a
crossed-out activation ID.
• If the modified safety configuration is applied, the safety configuration
on the RUNTIME tab is updated and the new activation ID is dis-
played.
Any modification of the activation ID requires a complete check of
all configuration parameters. It is not sufficient to check the modified
parameters only.
• The safety configuration is not yet enabled when the changes have
been applied.
The robot cannot be moved. A safety stop 1 (path-maintaining) is ac-
tive and all safe output signals are set to “0” (LOW level).
Precondition
Procedure
9.2.3 Canceling the safety stop if the safety configuration is not approved
Description
The safety stop activated after a modified safety configuration has been
applied can be canceled for a grace period of 4 hours. The deactivation of
the safe output signals is also canceled during the grace period.
During the grace period, the robot can be moved in order to check the
safety configuration.
Precondition
Procedure
3. As long as the started grace period has not yet elapsed, a message
with the remaining grace period is displayed in the safety configuration
editor.
4. The grace period that is already running can be extended. To do so,
select the Unblock button again and start the grace period from the
beginning.
Description
The safety configuration must not be approved until the correctness of all
configuration parameters has been successfully verified (safety accept-
ance).
Precondition
Procedure
1. Select the Start Approval button. A dialog opens displaying the safety
configuration report.
The report contains all data that the Safety Commissioning Engineer
must check before the safety configuration is approved.
2. The following actions are available:
• Download to USB
The safety configuration report can be downloaded.
The button is active if a USB stick is connected to the smartPAD.
• Approve safety configuration
Approves the safety configuration.
Before approval, the activation ID in the safety configuration report
must be compared with the activation ID displayed on the RUN-
TIME tab. The IDs must match.
• Close
Closes the dialog.
Description
The report can only be created for the safety configuration that is currently
running on the robot controller. The report can also be downloaded to a
USB stick and used, for example, to document the successful verification
and validation of the safety configuration.
The report can be created from both tabs of the safety configuration edi-
tor. On the ENGINEERING tab, however, only in the context of enabling a
safety configuration after any changes in the safety configuration have
been applied.
Precondition
Safety configuration
‒ Changes have been saved.
(>>> 9.2.2 "Applying the safety configuration" Page 136)
Procedure
Description
The RUNTIME tab of the safety configuration editor shows the safety con-
figuration currently running on the robot controller as a tree structure. The
activation ID of the safety configuration and diagnostic states for Safety
Rules and Monitoring Blocks are also displayed.
Procedure
• To access the tab, select Setup > Safety in the Feature menu.
Activation ID
The status is displayed in the line with the Safety Rule. Safety Rules can
have the following statuses:
• Violated
‒ Red icon with exclamation mark at the beginning of the line
‒ Highlighted line with red background color
A safety rule is violated if all of the contained monitoring blocks are
violated or invalid. The configured safety reaction is then triggered.
• Muted
‒ Gray icon with Reaction Muted display at the end of the line
A Safety Rule is triggered if the safety reaction has been canceled
through CRR mode.
• Not violated
‒ No icon
A Safety Rule is not violated if at least one of the contained monitor-
ing blocks is not violated.
When a Safety Rule Set is collapsed in the tree view, the aggregated vio-
lation status of the Safety Rules contained in it is displayed.
An appropriate safety reaction is defined for each Safety Rule. This reac-
tion must take place in the event of an error and switch the system to a
safe state.
The following safety reactions can be configured:
Safety configuration
• Safety stop 1 (path-maintaining) is triggered.
The manipulator is braked on the programmed path. At standstill, the
drives are switched off and the mechanical brakes are applied.
The safety controller monitors the braking process. After a duration of
1.5 s at the latest, or less depending on the robot type, the brakes are
applied and the drives are switched off. In the event of an error, the
drives are switched off and the mechanical brakes are applied immedi-
ately (safety stop 0).
WARNING
Risk of injury due to safety stop 1 (path-maintaining) in safety
functions for detecting crushing situations
In crushing situations, safety stop 1 (path-maintaining) can lead to
higher crushing forces due to the controlled stopping on a planned
braking path. For this reason, safety stop 1 (path-maintaining) is not
suitable for safety functions for detecting crushing situations, e.g. by
means of the Monitoring Block Maximum TCP Force.
‒ Use safety stop 1 (HRC) for safety functions for detecting crush-
ing situations.
The following points must be observed when using Safety Rules with a
safety-oriented output as a reaction:
• All the safety-oriented outputs use LOW as the safe state.
• If a Safety Rule is violated that uses a safety-oriented output as a re-
action, the output is immediately set to LOW.
• Once the violation state has been resolved, the output is not reset to
HIGH until the following conditions are met:
‒ The Safety Rule is not violated for at least 24 ms. The reaction to
resolution of the violation state is always delayed.
‒ If the discrete safety interface is used:
The output has the LOW level for at least 200 ms beforehand. If
the LOW level has not yet been active for this time, the level is
not changed to HIGH until the period of 200 ms has elapsed.
‒ If the Ethernet safety interface is used:
The output has the LOW level for at least 500 ms beforehand. If
the LOW level has not yet been active for this time, the level is
not changed to HIGH until the period of 500 ms has elapsed.
• The level change from LOW to HIGH does not have to be acknowl-
edged.
• Connection errors are automatically acknowledged by the safety con-
troller at safety-oriented inputs/outputs once the connection has been
restored. The output level can therefore switch from LOW to HIGH af-
ter restoration of the connection.
WARNING
Danger to life and limb due to automatic restart of peripheral devi-
ces
Using Safety Rules with a safety-oriented output as a reaction may re-
sult in an automatic restart of peripheral devices connected to this out-
put. Death, severe injuries or damage to property may result.
• The Safety Commissioning Engineer must take appropriate meas-
ures to ensure that no automatic restart is possible.
Safety configuration
• Load data
The load data can be configured both in the tool configuration editor
and in the scene editor. The load data are taken into consideration
when the following Monitoring Blocks are used:
‒ Collision
‒ Maximum TCP Force
• TCP for monitoring the tool orientation
The TCP can be configured both in the tool configuration editor and in
the scene editor. The TCP can be selected as a tool orientation frame
when configuring the following Monitoring Block:
‒ Tool Orientation Monitoring
The same TCP is monitored in all Monitoring Blocks of the type Tool
Orientation Monitoring.
• Safety spheres
Up to 6 spheres can be configured in the scene editor for modeling
the tool geometry. The spheres are taken into consideration when the
following Monitoring Blocks are used, provided they are configured as
a structure to be monitored:
‒ Maximum Cartesian Velocity
‒ Cartesian Monitoring Space
• Force interaction area
A force interaction area can be configured in the scene editor. The
area is defined as a sphere that contains all the points of a safety-ori-
ented tool where expected external forces can occur. The area is used
by the following Monitoring Block:
‒ Maximum TCP Force
Further information can be found in the help function under “3D scene”
or under “Payload configuration”.
Various safety interfaces are available for exchanging safe signals be-
tween a higher-level controller and a robot controller.
• The safety-oriented inputs of these interfaces can be used for connect-
ing safety devices, e.g. external EMERGENCY STOP devices or safe-
ty gates, and for evaluating the corresponding input signals.
• The safety-oriented outputs of these interfaces can be used to signal
the violation of Safety Rules.
Use
Use
Configuration
Safety configuration
9.7.3 Safety interface for external laser scanner
Configuration
The following settings in the configuration of the laser scanner are re-
quired for use with the system software iiQKA.OS:
• Set the FSoE address of the laser scanner to 777. The system soft-
ware only supports this FSoE address.
• Select the small process data object (PDO) for the FSoE PDO that is
used. The system software supports the module “Small process data
set”.
• It is recommended not to use the internal restart interlock of the laser
scanner. The system software does not support the resetting of the
lock via a network input signal from the scanner.
• Configure the response to a loss of connection as “Automatic start af-
ter reconnection”. The system software does not support a comman-
ded restart via the network.
For start-up, the laser scanner must be integrated into the 3D scene.
Further information can be found in the help function under “3D scene”.
Restart interlock
A restart interlock, e.g. to prevent the robot from restarting when a protec-
tive field is entered, can be implemented using the Monitoring Block Input
Signal with Acknowledgement. After an interruption of the protective
field, this monitoring function remains violated until this interruption has
been eliminated and a separate safe acknowledgement signal is set. For
example, the acknowledgement signal can be set by means of a connec-
ted pushbutton outside the danger zone.
The system software iiQKA.OS does not support the internal function of
the Sick safety laser scanner to switch between multiple monitoring cases.
It only supports monitoring case 1, which is permanently active.
As an alternative to the monitoring cases, the system software offers the
Safety Rule mechanism. A Safety Rule can be used to change the system
reaction to interruption of a protective field.
Description
The safe signals are configured in the I/O configuration editor. The availa-
ble physical I/Os, the signal mapping and the bus topology are specified
there.
There are also internal safe signals of the KUKA smartPAD pro and the
LBR iisy Commander (if present). These signals are not displayed in the I/
O configuration editor. They are predefined and can be selected directly in
the safety configuration.
Procedure
• To open the editor, select Setup > I/O from the Feature menu.
Description
Safety configuration
• Enabling Inactive
• Manual Guidance Inactive
2 safe input signals must be configured per enabling device (device). One
of the safe input signals supplies the signal from the enabling switches
and the other safe input signal supplies the signal from the panic
switches.
Signal selection
Monitoring Blocks for evaluating the confirmation status of mastering and joint torque
sensor calibration
Safety configuration
Monitoring Block Description
Cartesian Monitoring Space Checks whether a part of the monitored structure of a kine-
matic system is located inside or outside of a Cartesian mon-
itoring space
The confirmation checks and confirms the mastering of the axis position
sensors and the calibration of the joint torque sensors of a kinematic sys-
tem.
Further information about performing the confirmation can be found in
the help function under “General operation”.
Confirmation of joint
Confirmation of mas-
Monitoring Block torque sensor calibra-
tering
tion
Axis Work Range
Collision
The Monitoring Block Test Mode can be used to check whether a test
mode (T1, CRR) is active.
The Monitoring Block is required for safety monitoring functions that are
dependent on the operating mode, e.g. operator safety.
The Monitoring Block is violated if a test mode (T1, CRR) is active.
Safety configuration
9.12.2 Monitoring Block “Automatic Mode”
Description
Example
The Monitoring Block High Speed Mode can be used to check whether
an operating mode with high velocity (AUT) is active.
In combination with other Monitoring Blocks, the Monitoring Block can be
used to disable the reaction of a Safety Rule in the case of an operating
mode with reduced velocity.
The Monitoring Block is violated if an operating mode with high velocity
(AUT) is active.
Description
The Monitoring Block Safety Stop checks whether a safety stop is active.
The Monitoring Block is required, for example, in the case of a safety stop
to set an output that affects the connected peripheral equipment.
The Monitoring Block is violated if a safety stop is active.
The “Brake” safety reaction is not a safety stop and does not cause a
violation.
Example
Safety Rule
Monitoring Block 1 Monitoring Block 2 Reaction
Safety Stop Input Signal (safety gate) Safe Output
The KUKA smartPAD pro and the LBR iisy Commander are used as
standard for operator control of the robot.
The preconfigured Safety Rule Set “Operator Devices” is essential for the
integration of operator devices. It contains the following Safety Rules:
• “Emergency Stop Operator Device”
(>>> 9.14.1 "Monitoring of the EMERGENCY STOP device on the
smartPAD pro" Page 152)
• “Enabling in Test Mode”
(>>> 9.14.2 "Monitoring of enabling in T1/CRR" Page 152)
The enabling devices on the smartPAD and LBR iisy Commander are
monitored using the Safety Rule “Enabling in Test Mode”. In the following
cases, a safety stop 1 (path-maintaining) is triggered in T1 and CRR
modes:
• All enabling switches of both operator devices are released or one of
their enabling switches is fully pressed (panic position).
• An enabling switch on the Commander and an enabling switch on the
smartPAD are simultaneously held in the center position.
Safety configuration
9.15 Monitoring of enabling devices
Description
Parameter
Parameter Description
Enable Safe input signal used for the enabling switches of the ena-
bling device
A predefined input signal is available for the KUKA smartPAD.
Panic Safe input signal used for the panic switches of the enabling
device
A predefined input signal is available for the KUKA smartPAD.
Description
Parameter
Parameter Description
Enable Safe input signal used for the enabling switches of the ena-
bling device
For robots equipped with a hand guiding device, e.g. LBR iisy
Commander, a predefined input signal is available.
Panic Safe input signal used for the panic switches of the enabling
device
For robots equipped with a hand guiding device, e.g. LBR iisy
Commander, a predefined input signal is available.
Safety configuration
9.15.3 Monitoring Block “Manual Guidance Active”
Description
The Monitoring Block Manual Guidance Active checks whether the ena-
bling signal has been issued on a hand guiding device.
The Monitoring Block can be used in a Safety Rule to activate another
Monitoring Block. This can be a Cartesian velocity monitoring function, for
example, which is then active during manual guidance.
The Monitoring Block is violated if the enabling signal for manual guidance
has been issued:
• The configured input signals of the Monitoring Block Manual Guid-
ance Inactive are used for evaluating the Monitoring Block.
• The Monitoring Block constitutes an inversion of the Monitoring Block
Manual Guidance Inactive:
‒ The Monitoring Block Manual Guidance Active is violated if the
Monitoring Block Manual Guidance Inactive is not violated.
‒ If the Monitoring Block Manual Guidance Active is invalid, the
Monitoring Block Manual Guidance Inactive is also invalid.
Example
Description
Example
Safety Rule
Monitoring Block 1 Monitoring Block 2 Reaction
High Speed Mode Mastering Not Approved Stop 1 on Path
Description
Description
The Monitoring Block Input Signal can be used to monitor the status of
an input signal.
The Monitoring Block can be implemented as follows, for example:
• Monitor safety equipment that is connected via a safety-oriented input.
• Deactivate monitoring via a safety-oriented input.
• Trigger a stop via a safety-oriented input.
Parameter Description
Input Signal Input signal to be monitored
The Monitoring Block is violated if the input signal is LOW (state “0”).
Example 1
Predefined Safety Rule “Safety Door” in the Safety Rule Set “Standard
Safety Interface” (standard safety configuration)
If the following conditions apply, a safety stop 1 (path-maintaining) is exe-
cuted:
• Operating mode is AUT.
• Safety gate connected via XG11.1 is open.
• Enabling switches on the Commander are not actuated.
Safety configuration
Safety Rule Set “Standard Safety Interface”
Safety Rule “Safety Door”
Monitoring Block 1 Monitoring Block 2 Monitoring Block 3 Reaction
Automatic Mode Input Signal (safety Manual Guidance In- Stop 1 on Path
gate) active
Example 2
Predefined Safety Rule “Emergency Stop External” in the Safety Rule Set
“Standard Safety Interface” (standard safety configuration)
If the following condition is met, a safety stop 1 (path-maintaining) is exe-
cuted:
• External EMERGENCY STOP device connected via XG11.1 is press-
ed.
The Safety Rule is disabled by default. In order to be able to use the
functionality, the Safety Rule must be enabled.
Safety Rule Set “Standard Safety Interface”
Safety Rule “Emergency Stop External”
Monitoring Block 1 Reaction
Input Signal (EMERGENCY STOP) Stop 1 on Path
Description
Parameter Description
Input Signal Input signal to be monitored
Ack. Signal Input signal to be used for acknowledgement
The Monitoring Block is violated in the following cases:
• Input signal is LOW (state “0”).
• Input signal is HIGH (state “1”) but has not yet been confirmed by the
acknowledgement signal.
Example
Safety Rule
Monitoring Block 1 Monitoring Block 2 Reaction
Input Signal with Acknowl- High Speed Mode Stop 1 on Path
edgement
The Monitoring Block Maximum Axis Velocity can be used to monitor the
velocity of an axis.
The Monitoring Block is violated if the absolute velocity of the monitored
axis exceeds the configured limit value.
Parameter Description
Monitored Axis Axis to be monitored
Maximum Velocity Maximum velocity at which the monitored axis may move in
the positive and negative direction of rotation
Parameter Description
Structure Structure to be monitored
• Robot and Tool: The center points of the robot axes and
the safety spheres on the tool are monitored.
• Robot: The center points of the robot axes are monitored.
• Tool: The center points of the safety spheres on the tool
are monitored.
Maximum Velocity Maximum Cartesian velocity that must not be exceeded at
any of the monitored points
The following points must be observed when using the Monitoring Block
Maximum Cartesian Velocity:
• The system does not monitor the entire structure of the robot and tool
for violation of a velocity limit, but only defined points of the robot
structure and the center points of the safety spheres of the tool.
A total of up to 6 safety spheres can be configured for a tool in the
scene editor.
Safety configuration
Further information about the configuration of the safety spheres of
the tool can be found in the help function under “3D scene”.
In the Safety Rule “Velocity Limit T1” in the Safety Rule Set “Velocity
Monitoring” of the standard safety configuration, a safety-oriented velocity
monitoring function for the T1 and CRR operating modes is predefined:
• If the maximum Cartesian velocity of 250 mm/s is exceeded in the T1
or CRR operating mode and no enabling switch is pressed on the
Commander, a safety stop 1 (path-maintaining) is triggered.
• It is necessary for the Monitoring Block Maximum Cartesian Velocity
to be linked to the Monitoring Block Manual Guidance Inactive in or-
der to enable manual guidance at a velocity of more than 250 mm/s.
For manual guidance, a maximum velocity must be defined that may not
be exceeded during manual guidance. The value for this velocity limit
must be defined in a risk assessment.
In the Safety Rule “Velocity Limit Manual Guidance” in the Safety Rule
Set “Velocity Monitoring” of the standard safety configuration, a safety-ori-
ented velocity monitoring function for manual guidance is predefined:
• If an enabling switch on the Commander is pressed and the Cartesian
velocity of 500 mm/s is exceeded, a safety stop 1 (path-maintaining) is
triggered.
• The configured maximum Cartesian velocity is valid in all operating
modes. In other words, also for manual guidance in T1/CRR.
• If required by the risk assessment, the value for the maximum Cartesi-
an velocity must be reduced.
The robot environment can be divided into areas in which it must be loca-
ted for execution of the application (workspace) and areas which it must
not enter or may only enter under certain conditions (protected space).
The system must then continuously monitor whether the robot is inside or
outside such a monitoring space.
The following Monitoring Blocks are available for this purpose:
• Axis Work Range
• Axis Protection Range
• Cartesian Monitoring Space
By linking these to other Monitoring Blocks, it is possible to define further
conditions that must be met if a monitoring space is violated. A monitoring
space can be activated via a safe input, for example, or may be applica-
ble in automatic mode only.
If the robot has violated a monitoring space and been stopped by the
safety controller, the robot can be moved out of the violated area in
CRR mode.
Stopping distance
Further information about the stopping distances and stopping times can
be found in the assembly instructions of the relevant robot.
Description
The Monitoring Block Axis Work Range can be used to define for each
axis a permissible axis range that the axis must not leave.
The Monitoring Block is violated in the following cases:
Safety configuration
• Monitored axis is located outside the permissible axis range.
The Monitoring Block becomes invalid in the following cases:
• The position of one or more axes is unmastered.
• Confirmation of mastering of the monitored axis has failed.
Parameter Description
Monitored Axis Axis to be monitored
Lower Limit Lower limit of the permissible axis range in which the moni-
tored axis may move
Upper Limit Upper limit of the permissible axis range in which the moni-
tored axis may move
The following points must be observed when using the Monitoring Block
Axis Work Range:
• The value for the lower limit must be less than the value for the upper
limit.
• For personnel protection, only the axis position is relevant. For this
reason, the positions are converted to the axis range -180° … +180°,
even for axes which can rotate more than 360°.
• The limited range of values for the lower and upper limits does not al-
low the Monitoring Block to be used if the axis position at ±180° lies
within the permissible axis range. In this case, the Monitoring Block
Axis Protection Range must be used instead.
The diagram (>>> Fig. 9-4) shows an axis-specific work range from
90° to 360°. Since the axis position at 180° is located in this work
range, the Monitoring Block Axis Work Range cannot be used to
monitor whether the axis is within this range. Instead, the Monitoring
Block Axis Protection Range can be used to define a protected axis
range from 0° to 90°.
Description
The Monitoring Block Axis Protection Range can be used to define for
each axis a protected axis range that the axis must not enter.
The Monitoring Block is violated in the following cases:
Parameter Description
Monitored Axis Axis to be monitored
Lower Limit Lower limit of the protected axis range in which the monitored
axis must not move
Upper Limit Upper limit of the protected axis range in which the monitored
axis must not move
The following points must be observed when using the Monitoring Block
Axis Protection Range:
• The value for the lower limit must be less than the value for the upper
limit.
• For personnel protection, only the axis position is relevant. For this
reason, the positions are converted to the axis range -180° … +180°,
even for axes which can rotate more than 360°.
• The limited range of values for the lower and upper limits does not al-
low the Monitoring Block to be used if the axis position at ±180° lies
within the protected axis range. In this case, the Monitoring Block
Axis Work Range must be used instead.
The diagram (>>> Fig. 9-5) shows an axis-specific protection range
from 90° to 270°. Since the axis position at 180° is located in this pro-
tection range, the Monitoring Block Axis Protection Range cannot be
used to monitor whether the axis is within this range. Instead, the
Monitoring Block Axis Work Range can be used to define a permissi-
ble axis range from -90° to 90°.
Description
Safety configuration
Further information about managing Cartesian monitoring spaces
can be found in the help function under “3D scene”.
Parameter
Parameter Description
Workspace|Protected Select Space Shape
Space
The spaces created in the scene editor can be
(Depending on selec- selected using the button.
tion Space Type)
Space Type Space type
• Workspace
• Protected Space
Structure Structure to be monitored
to the lower and upper edges and corners of the prism as the safety
Safety configuration
sphere could. This can result in unexpected violation of the protected
space.
1 3D view of cuboid
2 Side view of cuboid
3 3D view of prism
4 Side view of prism
Description
Safety configuration
Parameter
Parameter Description
Monitored TCP Selection of the TCP whose orientation is to be
monitored (tool orientation frame)
The robot flange and all TCPs created in the
tool configuration editor or in the scene editor
for the tool used are available for selection.
The monitored TCP that is configured is jointly
used by all instances of the Tool Orientation
Monitoring Monitoring Block in the safety con-
figuration. If the monitored TCP that is config-
ured is edited, it is changed for all instances of
the Tool Orientation Monitoring Monitoring
Block.
Note: As soon as a TCP is configured as a
monitored TCP, the tool and the TCP can no
longer be deleted. To edit the TCP data, a
Safety Commissioning Engineer must be log-
ged on.
Reference Vector Reference vector with fixed orientation relative
(relative to World) to the WORLD coordinate system
• Rx
Rotation about the X axis of the WORLD
coordinate system
• Ry
Rotation about the Y axis of the WORLD
coordinate system
• Rz
Rotation about the Z axis of the WORLD
coordinate system
The orientation can be entered manually or
taught.
Allowed Deviation Permissible deviation relative to the reference
vector
The specified angle defines a monitoring cone.
The Z axis of the monitored TCP may move
within this cone.
WARNING
Risk of injury due to moving carrier kinematic system during moni-
toring of the tool orientation
If the monitored kinematic system is fastened to a carrier kinematic sys-
tem (e.g. mobile platform, linear unit), it must be taken into considera-
tion that the orientation of the reference vector is relative to the coordi-
nate system of the carrier kinematic system. This means that the refer-
ence orientation – for example, in the case of a change in inclination of
the carrier kinematic system – is moved along to a ramp.
• The carrier kinematic system must come to a standstill during moni-
toring and must not move.
Forces and axis torques can only be monitored on robots equipped with
position and joint torque sensors.
The accuracy of the monitoring of forces and axis torques depends on the
dynamics of the robot motion. If these monitoring functions are triggered
incorrectly, it is advisable to reduce the dynamics of the robot motion in
programs. This can be achieved by reducing the parameters “Velocity”
and “Acceleration” of the Motion group commands.
Further information about reducing the dynamics of the robot motion in
programs can be found in the help function under “Programming”.
WARNING
Risk of injury due to incorrectly configured workpiece pick-up
How workpiece load data affect the load-dependent Monitoring Blocks
Collision and Maximum TCP Force depends on how the workpiece is
picked up.
• The pick-up point of the workpiece and the resulting center of mass
must match the pick-up point and center of mass configured for the
workpiece in the payload configuration.
Description
The Monitoring Block Collision can be used to monitor the external axis
torques of all axes of a kinematic system.
The Monitoring Block is violated in the following cases:
• The external torque exceeds the configured limit on at least one axis
of the monitored kinematic system.
The Monitoring Block becomes invalid in the following cases:
• Confirmation of the calibration of one or more joint torque sensors has
failed.
Parameter
Parameter Description
External Torque Limit Maximum external axis torque
The external axis torque is defined as that part of the torque on an axis
which is generated by the forces/torques occurring as the robot (and/or
the tools) interact(s) with its environment.
The external axis torque is not measured directly but is rather calculated
using the dynamic robot model. The accuracy of the calculated values de-
pends, among other things, on the dynamics of the robot motion and of
the interaction forces of the robot with its environment.
Safety configuration
WARNING
Risk of injury due to incorrect use of the Monitoring Block “Colli-
sion”
The Monitoring Block Collision serves exclusively to reduce the risk of
transient collisions. A transient collision is the momentary impact of the
robot with an obstacle, e.g. if the obstacle can retract after the collision.
• Do not use the Monitoring Block to reduce pinching and crushing
hazards.
• Avoid pinching and crushing hazards through other measures, e.g.:
‒ Appropriate design of the robotic cell
‒ Cartesian or axis-specific workspace/protected space monitoring
functions
‒ Maximum TCP force monitoring
‒ Tool orientation monitoring
WARNING
Risk of injury due to errors in the workpiece load data
The Monitoring Block Collision does not automatically allow for possible
errors in the load data of the workpiece. Errors in the load data lead to
incorrectly determined external axis torques. Severe injuries or damage
to property may result.
• Configure the lowest possible values for the maximum external axis
torques for collision detection.
In this way, significant deviations in the load data are interpreted as
a collision and cause a violation of the Monitoring Block.
WARNING
Risk of injury due to loss of workpiece during collision monitoring
If workpieces that have been picked up are inadvertently released and
fall off while collision monitoring is active, this results in an error in de-
termining the external axis torques. Severe injuries or damage to prop-
erty may result.
• If the Monitoring Block Collision is used, test the gripper with the
workpiece in the application. It must be ensured that the workpiece
cannot be released, fall off or break during collision monitoring.
WARNING
Risk of injury due to non-reduced velocity during collision monitor-
ing
If violation of the Monitoring Block Collision triggers a safety stop in a
Safety Rule, the interaction forces may increase due to the stopping dis-
tance of the robot. A reduction of the velocity compensates for the pos-
sible increase of the interaction forces.
• Only use the Monitoring Block Collision at reduced velocity.
• To reduce the velocity using safe technology, the Monitoring Block
Collision must be combined with one of the following Monitoring
Blocks:
‒ Maximum Cartesian Velocity
‒ Maximum Axis Velocity
WARNING
Risk of injury due to moving carrier kinematic system during colli-
sion monitoring
If the monitored kinematic system is fastened to a carrier kinematic sys-
tem (e.g. mobile platform, linear unit), the following applies:
• The carrier kinematic system must come to a standstill during moni-
toring and must not move.
The safety integrity of the Monitoring Block Collision is not assured
when the carrier kinematic system is moving.
WARNING
Risk of injury due to deviation from the installation position
If the monitored kinematic system is fastened to a carrier kinematic sys-
tem (e.g. mobile platform, linear unit), the following applies:
• The installation position of the monitored kinematic system must not
deviate from the configured installation position.
A deviation is given, for example, if the “floor” installation position is
configured, but the mobile platform moves onto a ramp and is thus
in an inclined position.
The safety integrity of the Monitoring Block Collision is otherwise not
assured.
Description
The Monitoring Block Maximum TCP Force can be used to monitor the
external force acting on the tool or the robot flange of a kinematic system
(on a point within the configured force interaction area).
The force interaction area for a tool can be configured in the scene editor.
Further information about tool management and the force interaction
area can be found in the help function under “3D scene”:
Parameter
Parameter Description
Force Interaction Open in Scene
Area
The link can be used to open the configuration
of the force interaction area in the scene.
Max TCP force Maximum external force on the TCP
The force interaction area is defined as a sphere that contains all the
points of a safety-oriented tool where expected external forces can occur.
It is used by the Monitoring Block Maximum TCP Force to determine the
safe external TCP forces.
The size of the force interaction area affects the accuracy of the TCP
Safety configuration
force calculation in robot poses near singularities. The more accurately the
position of the force interaction point is defined (i.e. the smaller the radius
of the force interaction area is configured), the better the Monitoring Block
Maximum TCP Force can be used near singularities.
Furthermore, the accuracy of the TCP force calculation depends on the
dynamics of the robot motion and of the interaction forces of the robot
with its environment.
WARNING
Risk of injury due to incorrect configuration of the force interaction
area
Incorrect configuration of the force interaction area may result in a loss
of the safety integrity when using the Monitoring Block Maximum TCP
Force.
• Select the interaction area so that all expected forces acting on the
tool lie within the configured area.
• If the TCP force monitoring is active, no forces may be applied out-
side the configured area, e.g. by pulling or pushing the robot struc-
ture.
WARNING
Risk of injury due to incorrectly configured mass of the heaviest
workpiece
Incorrect configuration of the mass of the heaviest workpiece may result
in a loss of the safety integrity when using the Monitoring Block Maxi-
mum TCP Force.
• The configuration must be verified when approving the safety config-
uration (safety acceptance).
(>>> 9.23.6.1 "Mass of the heaviest workpiece" Page 188)
WARNING
Risk of injury due to loss of workpiece during monitoring of the
maximum TCP force
If workpieces that have been picked up are inadvertently released and
fall off while TCP force monitoring is active, this results in an error in
determining the external force on the TCP. Severe injuries or damage to
property may result.
• If the Monitoring Block Maximum TCP Force is used, test the grip-
per with the workpiece in the application. It must be ensured that
the workpiece cannot be released, fall off or break during TCP force
monitoring.
WARNING
Risk of injury due to non-reduced velocity during monitoring of the
maximum TCP force
If violation of the Monitoring Block Maximum TCP Force triggers a
safety stop in a Safety Rule, the interaction forces may increase due to
the stopping distance of the robot. A reduction of the velocity compen-
sates for the possible increase of the interaction forces.
• Only use the Monitoring Block Maximum TCP Force at reduced ve-
locity.
• To reduce the velocity using safe technology, the Monitoring Block
Maximum TCP Force must be combined with one of the following
Monitoring Blocks:
‒ Maximum Cartesian Velocity
‒ Maximum Axis Velocity
WARNING
Risk of injury due to moving carrier kinematic system during moni-
toring of the maximum TCP force
If the monitored kinematic system is fastened to a carrier kinematic sys-
tem (e.g. mobile platform, linear unit), the following applies:
• The carrier kinematic system must come to a standstill during moni-
toring and must not move.
The safety integrity of the Monitoring Block Maximum TCP Force is not
assured when the carrier kinematic system is moving.
WARNING
Risk of injury due to deviation from the installation position
If the monitored kinematic system is fastened to a carrier kinematic sys-
tem (e.g. mobile platform, linear unit), the following applies:
• The installation position of the monitored kinematic system must not
deviate from the configured installation position.
A deviation is given, for example, if the “floor” installation position is
configured, but the mobile platform moves onto a ramp and is thus
in an inclined position.
The safety integrity of the Monitoring Block Maximum TCP Force is
otherwise not assured.
Description
Safety configuration
Parameter Description
Timer Expired Delay time
Each delay is a multiple of 12 ms. In other words, each delay
is rounded up to the next multiple of 12, e.g.:
Example
The application requires that the robot can still be moved in automatic
mode for a limited time, e.g. 2 hours, if mastering is not confirmed. Once
this time has elapsed, a safety stop 1 (path-maintaining) is triggered.
Safety Rule
Monitoring Block 1 Monitoring Block 2 Monitoring Block 3 Reaction
Automatic Mode Mastering Not Ap- Timer Expired Stop 1 on Path
proved
Description
The system must not be put into operation until the safety acceptance
procedure has been completed successfully. Checklists must be used to
check and demonstrate that all monitoring functions are correctly config-
ured and work correctly.
Safety acceptance must be carried out in the following cases:
• For initial start-up and recommissioning of the industrial robot
If the preinstalled safety configuration is adopted without any changes,
it is sufficient to check its suitability on the basis of a risk assessment.
• After a change to the industrial robot
• After exchanging the robot controller
It is sufficient to check whether the activation ID of the loaded safety
configuration matches the activation ID of the desired safety configura-
tion.
• After a change to the safety configuration/activation ID
Any modification of the activation ID requires a complete check of
all configuration parameters. It is not sufficient to check the modified
parameters only.
Checklists
The safety acceptance procedure can be carried out and documented us-
ing the following checklists or using your own checklists.
• The items in the checklist must be completed fully and confirmed in
writing.
• The checklists confirmed in writing are to be kept as documentary evi-
dence.
Safety configuration
No. Task Yes Not relevant
18 Collision detection: has it been taken into consideration that
the Monitoring Block Collision is only approved for the re-
duction of hazards associated with transient contact (free
collisions), but not for crushing situations?
19 Collision detection: has it been configured in such a way
that velocity monitoring is always active when the Monitoring
Block Collision is active?
20 TCP force monitoring: has it been configured in such a way
that velocity monitoring is always active when the Monitoring
Block Maximum TCP Force is active?
21 TCP force monitoring: has a force interaction area been con-
figured?
22 If axis torque-specific Monitoring Blocks are used: is the limi-
ted safety integrity of the axis torque-specific Monitoring
Blocks taken into consideration when mastering and/or joint
torque sensor calibration has not been confirmed?
Note: Initiation of the safe state when mastering and/or joint
torque sensor calibration has not been confirmed can be
configured using the Monitoring Block Mastering Not Ap-
proved and/or JTS Adjustment Not Approved.
23 If axis torque-specific Monitoring Blocks are used: have the
mastering of all axis positions and the calibration of all joint
torque sensors been successfully confirmed?
24 Safety Rules: has it been taken into consideration that the
safe state of the Monitoring Blocks is the “violated” state
(state “0”)?
Note: In the event of an error, a Monitoring Block switches
to the safe state.
25 Safety Rules: in the configuration of the output signals for
the safety reaction, has it been taken into consideration that
an output is LOW (state “0”) in the safe state?
26 If the monitored kinematic system is fastened to a carrier
kinematic system (e.g. mobile platform, linear unit):
has it been taken into consideration that in the case of the
Monitoring Block Cartesian Monitoring Space the safety
monitoring is based on a fixed position of the monitoring
space relative to the carrier kinematic system? For this rea-
son, the monitoring space is also moved in the event of a
change in position or inclination of the carrier kinematic sys-
tem.
27 If the monitored kinematic system is fastened to a carrier
kinematic system (e.g. mobile platform, linear unit):
has it been taken into consideration that the Monitoring
Block Maximum Cartesian Velocity does not monitor the
absolute velocity in space, but the velocity of the monitored
kinematic system relative to the carrier kinematic system?
28 If the monitored kinematic system is fastened to a carrier
kinematic system (e.g. mobile platform, linear unit):
has the fact been taken into consideration that, with the
Tool Orientation Monitoring Monitoring Block, the
reference orientation is defined relative to the carrier kine-
matic system and moves with the carrier kinematic system?
Precondition
Configuration
Tool name: ______________
Tool sphere data:
Configuration of the tool load data has an effect on the monitoring behav-
ior of the following Monitoring Blocks:
• Collision
Safety configuration
• Maximum TCP Force
Explicit verification of the tool load data is not required, as it is implicitly
included in the test procedures of the aforementioned Monitoring Blocks.
The installation position and orientation of the robot have an effect on the
monitoring behavior of the following Monitoring Blocks:
• Cartesian Monitoring Space
• Tool Orientation Monitoring
• Collision
• Maximum TCP Force
Explicit verification of the installation position and orientation of the robot
is not required, as it is implicitly included in the test procedures of the
aforementioned Monitoring Blocks.
Description
A Safety Rule can be tested by violating all but one of the contained Mon-
itoring Blocks simultaneously. The remaining Monitoring Block can then be
tested separately in a targeted manner.
Each Safety Rule must then be tested to determine whether the config-
ured safety reaction is triggered. If the reaction is to switch off an output,
the test must also ensure that the output is correctly connected.
Safety Rules with the Monitoring Block Maximum Cartesian Velocity and
a Stop or Brake as a reaction can be tested as follows:
1. Move the robot at a velocity exceeding the limit value of the Monitor-
ing Block involved Maximum Cartesian Velocity.
2. Once all other Monitoring Blocks of the Safety Rule have been viola-
ted, reduce the velocity to a value below this limit value.
• Stop as reaction: Stop until complete standstill
• Brake as reaction: No stop until complete standstill
Configuration
Safety Rule Set name: ______________
Safety Rule name: ______________
Safety Rule ID: ______________
Safety configuration
No. Activity Yes Not relevant
1 The Monitoring Block is violated if all enabling switches of
enabling device 1 have been released.
2 The Monitoring Block is violated if any enabling switch of en-
abling device 1 is fully pressed (panic position).
3 The Monitoring Block is violated if all enabling switches of
enabling device 2 have been released.
4 The Monitoring Block is violated if any enabling switch of en-
abling device 2 is fully pressed (panic position).
5 The Monitoring Block is violated if all enabling switches of
enabling device 3 have been released.
6 The Monitoring Block is violated if any enabling switch of en-
abling device 3 is fully pressed (panic position).
Configuration
Signal for the enabling switch(es) of enabling device 1: _______________
Signal for the panic switch(es) of enabling device 1: _______________
Signal for the enabling switch(es) of enabling device 2: _______________
Signal for the panic switch(es) of enabling device 2: _______________
Signal for the enabling switch(es) of enabling device 3: _______________
Signal for the panic switch(es) of enabling device 3: _______________
Configuration
Signal for the enabling switch(es) of hand guiding device 1: _____________
Signal for the panic switch(es) of hand guiding device 1: ______________
Signal for the enabling switch(es) of hand guiding device 2: _____________
Signal for the panic switch(es) of hand guiding device 2: _____________
Signal for the enabling switch(es) of hand guiding device 3: _____________
Signal for the panic switch(es) of hand guiding device 3: _____________
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
Input signal: ______________
Safety configuration
No. Activity Yes
1 The Monitoring Block is violated if the input signal is LOW (state “0”) or
if the input signal is HIGH (state “1”) but has not yet been acknowl-
edged.
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
Input signal: ______________
Acknowledgement signal: ______________
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
The Monitoring Block can be tested by moving the monitored axis at a ve-
locity of approx. 10% above the configured velocity limit.
No. Task Yes
1 The Monitoring Block is violated if the maximum permissible axis velocity
is exceeded.
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
Monitored axis: ______________
Maximum velocity: ______________
Precondition
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
Monitoring range type (work range or protection range): ______________
Monitored axis: ______________
Lower limit: ______________
Upper limit: ______________
In order to test the configured velocity limit of the Monitoring Block, the
monitored kinematic system must be moved in such a way that the moni-
tored point that moves fastest is moved at a velocity of approx. 10%
above the configured limit value.
• If the safety reaction of the Safety Rule is a safety stop or a Brake,
this requires violation of another Monitoring Block of the Safety Rule,
as the controller would otherwise avoid violating the velocity limit.
• If the Safety Rule does not contain a second Monitoring Block, the ve-
locity limit can be checked by observing the automatic velocity limita-
tion of the controller. The controller reduces the programmed velocity
to a value below the velocity limit of the Monitoring Block.
It must also be checked whether the structure to be monitored is config-
ured correctly:
• If both structures (robot and tool) are monitored, the velocity monitor-
ing must be violated both by the monitoring points on the robot and by
the monitoring points on the tool.
• If only one of the two structures (robot or tool) is monitored, the veloc-
ity monitoring must be violated either by the monitoring points on the
robot or by the monitoring points on the tool.
Precondition
Safety configuration
No. Task Yes Not relevant
3 The Monitoring Block is violated if the velocity monitoring is
violated exclusively by monitoring points on the tool.
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
Monitored structure: ______________
Maximum velocity: ______________
Description
It must be checked whether the orientation and size of the cuboid have
been correctly configured:
• In order to check the orientation, a first cuboid surface must be viola-
ted at 3 or more different points and an adjacent cuboid surface at 2
or more different points.
• In order to check the size, the other space surfaces must be violated
at 1 point in each case.
• In total, at least 9 points must be addressed.
It must also be checked whether the structure to be monitored is config-
ured correctly:
• If both structures (robot and tool) are monitored, the space monitoring
must be violated both by the safety spheres on the robot and by the
safety spheres on the tool.
• If only one of the two structures (robot or tool) is monitored, the space
monitoring must be violated either by the safety spheres on the robot
or by the safety spheres on the tool.
Precondition
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
Monitored structure: ______________
Monitoring space type (workspace or protected space): ______________
Cuboid parameters:
Description
It must be checked whether all corners, the Z coordinate and the orienta-
tion of the prism base and the height of the prism have been configured
correctly:
• In order to check the correct position of all corners, 2 different points
on each side surface of the prism must be violated. These 2 points
must differ in each case in the X or Y coordinate relative to the base
frame.
• In order to check the Z coordinate and the orientation of the prism
base, the monitoring function must be violated at 3 points of the prism
base in each case.
• In order to check the height of the prism, the monitoring function must
be violated at a point on the cover of the prism.
• In total, at least 4 + 2*(number of corners) points must be addressed.
It must also be checked whether the structure to be monitored is config-
ured correctly:
• If both structures (robot and tool) are monitored, the space monitoring
must be violated both by the safety spheres on the robot and by the
safety spheres on the tool.
• If only one of the two structures (robot or tool) is monitored, the space
monitoring must be violated either by the safety spheres on the robot
or by the safety spheres on the tool.
Precondition
Safety configuration
No. Task Yes Not relevant
3 The correct configuration of the prism height has been
checked as described above. The Monitoring Block is viola-
ted every time a monitoring space is violated.
4 The Monitoring Block is violated if the space monitoring is
violated by the safety spheres on the robot.
5 The Monitoring Block is violated if the space monitoring is
violated by the safety spheres on the tool.
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
Monitored structure: ______________
Monitoring space type (workspace or protected space): ______________
Prism parameters:
Description
permissible deviation angle and the tool orientation frame are correctly
Safety configuration
configured.
The orientation angles of the Z axis of the tool orientation frame (moni-
tored TCP) are defined using 3 straight lines situated on the edge of the
monitoring cone and offset at 120° to one another. These orientation an-
gles must be set in order to test the Monitoring Block Tool Orientation
Monitoring. The Monitoring Block must be violated if all 3 orientation an-
gles are exceeded.
Precondition
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
Rotation of the reference vector (relative to WORLD):
Precondition
Safety configuration
No. Task Yes
1 Robot position 1:
The Monitoring Block is violated if collision forces are exerted on the
monitored kinematic system. The test is successful for several different
directions in which the force is applied.
2 Robot position 2:
The Monitoring Block is violated if collision forces are exerted on the
monitored kinematic system. The test is successful for several different
directions in which the force is applied.
3 Robot position 3:
The Monitoring Block is violated if collision forces are exerted on the
monitored kinematic system. The test is successful for several different
directions in which the force is applied.
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
Maximum external axis torque: ______________
Precondition
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
Maximum TCP force: ______________
Configuration
Monitoring Block name: ______________
Monitoring Block ID: ______________
Delay time: ______________
Configuration
Mass of the heaviest workpiece: ______________
Programming
10 Programming
The system can contain multiple programs that can be opened, edited or
executed if required. The various programs are managed in the Feature
menu Program.
• The node palette can be moved freely on the interface so that it does
not conceal any currently required content.
• The nodes in the pallet are divided into the categories BASIC and
ADVANCED.
• Press a node to insert it below the node selected in the program.
New nodes can be inserted as the last element below the current
node (Last child), or at the same hierarchy level behind the current
node (Sibling after).
The insertion position is indicated in the program tree structure.
10.2.1.1 Sequence
Description
Programming
Parameters
CAUTION
Risk of injury and damage to property due to subsequent modifica-
tion of the payload
If the payload (and thus also the TCP) is modified after motion seg-
ments have already been inserted, all motion segments use the new
payload. This results in a different robot pose and the robot may exe-
cute unexpected motions. Injuries or damage to property may result.
• Always test new or modified programs in operating mode T1 first.
Sensitivity
Settings to move the robot under impedance control can be made on the
Sensitivity tab.
(>>> 10.7 "Programming of a compliant robot" Page 209)
Triggers
Description
The Move node is always part of a motion group (Motion group). The
node can be used to program the following motions:
• Absolute motion
By default, absolute motion is preselected.
• Relative motion
Absolute Motion
If absolute motion is selected, the Move node defines the motion type and
the target frame of the motion:
• The motion type must conform to the motion type of the motion group
(Motion group node):
‒ A Cartesian motion group can contain linear, circular and spline
motions.
‒ An axis-specific motion group can only contain Axis (PTP) motions.
• Target frames are the coordinates of the target position relative to the
TCP. The frame coordinates can be entered manually or taught. When
adding a new Move node, an unshared frame is automatically created.
The functional principle of frames is described in the 3D scene.
• Unshared frames can subsequently be converted to project frames
and vice versa. To do so, change the selection in Target Type. Project
frames are known in the entire project on the robot controller and can
be used in every program.
NOTICE
Unexpected robot motion due to retaught frames
If a frame is retaught, the change affects all motions that move to
this frame.
‒ If Move nodes with frames that have already been taught are
copied in order to use them for new motions, make sure to cre-
ate and teach new frames in the respective segments.
‒ To create a new frame, select Select or add frame and then
New project frame or New unshared frame in the Frame
menu.
Do not press the Touch up button. This button does not create
a new frame, but overwrites the existing frame with new coordi-
nates. If it is a global frame, it is modified in all programs that
use it.
Programming
• The link Open in scene can be used to display the current frame in
the 3D scene in order to be able to visualize its position better.
In the scene, press the program name in the status bar at the top to
return to the program.
Relative Motion
If relative motion is selected, the Move node defines the motion type and
the target or rotational position of the motion:
• The motion type must conform to the motion type of the motion group
(Motion group node):
‒ A Cartesian motion group can contain linear, circular and spline
motions.
‒ An axis-specific motion group can only contain Axis (PTP) motions.
• The reference determines the direction of the relative motion. By de-
fault, the reference is set to the TCP of the Motion group. Alternative-
ly, the reference can be set to the WORLD coordinate system.
• The Position offset parameter can be used to specify the relative mo-
tion from the current position of the robot. Depending on this position
and the respective reference coordinate system, the target position of
the relative motion is obtained.
• The Angle offset parameter can be used to specify a relative rotation
about each axis. This rotation is carried out relative to the previous ro-
tational position and depends on the respective reference coordinate
system.
Move type
• Axis (PTP):
The robot guides the TCP (Tool Center Point) along the fastest path to
the target point. Since the motions of all robot axes to the target point
are simultaneous and rotational, the resulting path is a curved path.
The axis (joint) motion is a fast positioning motion. The exact path of
the motion cannot be predicted and depends on the override, velocity
and acceleration, but can always be reproduced identically as long as
these general conditions are not altered.
• Linear:
The robot guides the TCP (Tool Center Point) at a defined velocity
and acceleration along a straight line to the target point.
• Circle:
The robot guides the TCP (Tool Center Point) at a defined velocity
and acceleration along a circular segment to the end point. In order to
define the radius of the circle segment, a circular segment requires
two end points: the end point of the motion (Target frame 2) and an
auxiliary point (Target frame 1) situated on the circular segment that
is passed through on the way to the end point.
• Spline:
Spline is a motion type that is particularly suitable for complex, curved
paths. The path is defined by several commands of type Move whose
end frames are located on the path. The desired path can thus be
generated easily. The path always remains the same, irrespective of
the override setting, velocity or acceleration. The robot moves as fast
as possible within the constraints of the programmed velocity, i.e. as
fast as its physical limits will allow.
10.2.1.4 Loop
Programming
A loop repeats all subordinate nodes in the specified order until a certain
condition is met.
Possible conditions for exiting the loop are:
• Count
The loop is executed exactly n times.
• Timeout
The loop is executed for n milliseconds.
• Infinite
The loop is executed for an infinite duration and not exited.
This is suitable if the break condition is to be programmed within the
loop.
• While
The loop is executed as long as a condition is met, e.g. as long as a
specific signal is present.
• Until
The loop is executed as long as a condition is met, e.g. until a
specific signal is present.
Conditions for exiting the loop cannot be nested or linked.
10.2.1.5 Wait
10.2.1.6 Set
The two nodes of type Capability are only available if a gripper is selec-
ted from a preinstalled toolbox. Both nodes open or close the gripper on
the robot flange. The gripper must be configured for this.
Further information can be found in the help function under “Payload
configuration”.
Programming
Fig. 10-3: Grip / Release
10.2.1.8 GetState
Programming
10.2.2 Advanced nodes
Description
The Break node can be used to exit a loop or resume it. The following
break types can be selected in the parameter view of the node:
• Break
Aborts the execution of the loop. The loop is exited and the program
is resumed with the next command.
• Continue
Aborts the current loop execution. The loop is resumed with the next
loop execution.
Example
edited there. In the program, the subroutine is declared below the first Se-
Programming
quence node.
(>>> 10.5 "Creating and executing subroutines" Page 202)
• To move a node and all its child nodes, hold it down until it is highligh-
ted.
• Drag the node to the desired position. A white line displays the inser-
tion position and the hierarchy level at which the node will be inserted.
• If nodes are nested in an impermissible manner and the hierarchy is
invalid, the node in question is highlighted in yellow.
• The tool bar at the bottom of the screen contains additional functions
for modifying the program structure:
‒ Cut selected nodes.
‒ Copy nodes.
‒ Paste copied nodes.
Node deletion cannot be undone and moved nodes can only be man-
ually moved back to their previous position. For this reason, save
changes regularly during programming. Undesired changes can then be
discarded by closing the program without saving.
Overview
Programming
Fig. 10-9: Variables
Description
Procedure
1. Deleting default value/current value: To do so, select the value and se-
lect Delete from the context menu.
2. The value is now undefined. Select a new data type in the selection
menu of the Expression Editor.
Description
Procedure
Create variable:
1. Add a new variable, select the default value and delete it via the con-
text menu.
2. To enter axis positions in degrees, select LIBRARY > Functions > ro-
bot > Joint6 > from-deg() in the selection menu.
4. Apply the variable in the target type: For this, select the variable under
LIBRARY > Variables.
Description
Programming
Procedure
Creating subroutines:
1. In the Program Feature menu, open the Subroutines tab.
2. Press New subroutine.
3. Assign a name for the subroutine.
4. Create the subroutine by adding nodes.
Nodes can also be copied from the program and inserted into the sub-
routine.
5. Save the subroutine.
Executing subroutines:
1. In the Program Feature menu, open the Program tab.
2. Open the node palette and switch to the ADVANCED tab.
3. Insert the Execute node at the desired point.
4. Select the desired subroutine in the parameter view under Subrou-
tine.
Description
The Expression Editor can be opened in full screen mode in order to edit
complex expressions in a larger view. To do so, select the desired expres-
sion and open the context menu at the side.
Description
Programming
Name-
Description
space
geo Functions and data types with reference to the modeled
world
kuka Functions and data types from toolboxes
lang Basic functions and data types
math Computational functions and mathematical data types
nodes Data types with reference to specific nodes
robot Functions and data types with reference to the robotics
trigger Functions and data types for configuring triggers
The elements of a namespace are divided into the following menus by
means of automatic categorization:
• Data
The elements used to generate a data structure directly are always lo-
cated under Data. These elements are referred to as constructors.
• Functions
All remaining functions can be found under Functions.
• Variables
All remaining values that are not functions can be found under Varia-
bles.
Structure of Expressions
Functions as value
It is possible to treat functions as values. Functions proposed as “Func-
tion as value” can be transferred to other functions or saved as varia-
bles.
Description
Expressions
Call:
Expression Expression
Description
1st level 2nd level
Ref get-id Function accepts a lang.Ref and returns
the value of the attribute "id".
? = ? Function compares if 1st and 2nd parame-
ters are equal.
? != ? Function compares if 1st and 2nd parame-
ters are unequal.
? or ? Function checks whether 1st or 2nd pa-
rameter is true.
not(?) Function negates a logical expression.
? and ? Function checks whether the 1st and 2nd
parameters are true.
if(cond: ?, Conditional expression:
then: ?,
Function accepts a Boolean value cond as
else: ?)
well as the values then and else. If cond
is true, the result is then. Otherwise, it is
else.
Description
Expressions
Call:
Expression Expression
Description
1st level 2nd level
Cons get-head(?) Function reads the header element of a
non-empty list.
get-tail(?) Function reads the rest (all elements ex-
cept header elements) of a non-empty list.
Programming
Expression Expression
Description
1st level 2nd level
is-Nil?(?) Function checks whether a list is an emp-
ty list.
? concat ? Function appends the second list to the
first.
get(value: ?, Function accepts a list value value and a
at: ?) number at. Function returns the list ele-
ment at this index.
filter(pred: ?, Function returns a list containing only the
value: ?) value elements that are true when applied
to pred.
map(func: ?, Function returns a new list where each el-
value: ?) ement has been converted from value to
func through application.
reverse(?) Function returns a list consisting of the el-
ements of value in reverse order.
set(value: ?, Function returns a list. The element at is
at: ?, to: ?) replaced by to.
length(?) Function returns the number of characters
or elements in this object.
is-Cons?(?) Function checks whether a list is a non-
empty list.
Constructors
Call:
Constructor Description
Cons(head: ?, Constructor generates a list from a header element
tail: ?) and another list.
Nil The constant Nil is an empty list.
Description
Expressions
Call:
Expression Description
get-value(?) Function returns the value of a Maybe if it was cre-
ated via Just.
is-Nothing?(?) Function checks whether a Maybe really is a Nothing.
An optional value is missing.
is-Just?(?) Function checks whether a Maybe really is a Just. An
optional value is present.
Constructors
Call:
Constructor Description
Just(?) Constructor creates a Maybe with a contained value.
Nothing Nothing is the constant for a Maybe with no value in
it.
Description
Expressions
Call:
Expression Expression
Description
1st level 2nd level
Vec3 get-x(?) Function supplies the X component of the
3 vector.
get-y(?) Function supplies the Y component of the
3 vector.
from- Function creates a vector (in m) from
mm(x: ?, components in millimeters.
y: ?, z: ?)
get-z(?) Function supplies the Z component of the
3 vector.
Vec6 get- Function supplies the X1 … X6 compo-
x1(?) … get- nent of the 6 vector.
x6(?)
Quaternion Rota- Generates a quaternion from three Euler
tion(rx: ?, angles in the KUKA convention. Here, the
ry: ?, rz: ?) angles are specified in degrees.
get- Function supplies the W, X, Y or Z com-
w(?) … get- ponent of the quaternion.
z(?)
? + ? Function adds the 1st and 2nd parameter.
cos(?) Cosine function
The argument is expected in radians.
? * ? Function multiplies the 1st and 2nd pa-
rameter.
? >= ? Function compares whether the 1st pa-
rameter is greater than the 2nd parameter
or equal to the 2nd parameter.
? <= ? Function compares whether the 1st pa-
rameter is smaller than the 2nd parameter
or equal to the 2nd parameter.
Programming
Expression Expression
Description
1st level 2nd level
? - ? Function subtracts the 2nd parameter from
the 1st.
? / ? Function divides the 1st parameter by the
2nd.
neg(?) Function negates the parameter.
deg-to-rad(?) Function converts from degrees to radi-
ans.
sin(?) Sine function
The argument is expected in radians.
rad-to-deg(?) Function converts from radians to de-
grees.
? < ? Function compares whether the 1st pa-
rameter is smaller than the 2nd parameter.
? > ? Function compares whether the 1st pa-
rameter is greater than the 2nd parameter.
? % ? Function carries out integer division using
the 1st and 2nd parameter and returns
the remainder.
Constructors
Call:
Constructor Description
Rotation(rx: 0, Constructor creates a rotation from three Euler an-
ry: 0, rz: 0) gles.
The resulting value is of type math.Quaternion.
Vec3(x: ?, y: ?, Constructor creates a 3 vector.
z: ?)
Vec6(x1: ?, Constructor creates a 6 vector.
x2: ?, x3: ?,
x4: ?, x5: ?,
x6: ?)
Overview
Robots with integrated joint torque sensors can be moved under impe-
dance control. Impedance control can be parameterized for a motion
group (node Motion group) and for the motion command Position hold.
(>>> 10.7.3 "Holding position under impedance control" Page 214)
The following control modes are available on the Sensitivity tab of the
specified nodes:
• Position Control (default)
Position control is preselected by default. In position control, the robot
is not compliant and follows the programmed path as accurately as
possible. Position control has no adjustable parameters.
• Cartesian impedance
Cartesian impedance control can be used if the robot is to react in a
compliant manner to external forces/torques, e.g. to obstacles on the
programmed path or process forces.
(>>> 10.7.1 "Cartesian impedance control" Page 210)
• Axis impedance
Axis impedance control can be used if one or more axes are to react
in a compliant manner to external forces/torques.
(>>> 10.7.2 "Axis impedance control" Page 213)
The control mode selected in a Motion group node as well as its param-
eters apply to all motions of this motion group.
Description
Stiffness
The stiffness parameters determine how much the robot yields when a
force is applied.
• If a low stiffness is set for a degree of freedom, the robot is very com-
pliant in this direction. It reacts to obstacles and external forces by de-
viating from its path.
• Conversely, high stiffness leads to good path tracking with low compli-
ance along the degree of freedom.
WARNING
Risk of unpredictable motions with zero stiffness
Setting zero stiffness can cause the robot to move freely and uncontrol-
lably in the corresponding directions. This particularly applies to joint tor-
que sensors that are not properly mastered. Injuries or damage to prop-
erty may result.
• Use zero stiffness values only in contact situations combined with
external force application in order to achieve a controlled application
of force.
Programming
Damping
The damping parameters determine how much the robot oscillates after a
force has been applied.
• If high damping is set for a degree of freedom, the oscillation is re-
duced in this direction.
Force/Torque overlay
External Cartesian forces and torques can also be applied here. These
overlay the Cartesian forces and torques that result from the spring stiff-
ness.
WARNING
Risk of injury and damage to property due to strong acceleration
of the robot in the direction of force application
An application of force can result in strong acceleration and rapid mo-
tion of the robot in the corresponding direction. Injuries or damage to
property may result.
• Only apply forces if the robot has already moved on contact in the
corresponding direction.
Example
High stiffness is set in the Z direction of the TCP (motion frame) and low
stiffness in the X/Y direction. In this way, the TCP can follow the program-
med path well during a motion in the tool direction Z and at the same
time swerve in the XY plane.
Description
1 Deflection Δx
2 Virtual spring
3 Actual position
4 Resulting force F
5 Setpoint position
If the robot is at a resistance, it exerts the calculated force. If it is in free
space, it moves to the setpoint position. On the way to the setpoint posi-
tion, path deviations occur due to internal frictional forces in the joints.
The extent of these deviations depends on the set spring stiffness. Higher
stiffness values lead to smaller deviations.
If the robot is already at the setpoint position and an external force is ap-
plied to the system, the robot yields to this force until the forces resulting
from compliance control cancel out the external forces.
Examples
The force exerted at the contact point depends on the difference between
the setpoint position and the actual position and the set stiffness.
As shown in the figure (>>> Fig. 10-16), a large position difference and
low stiffness can result in the same force as a smaller position difference
and greater stiffness. If the force is increased by a motion in a contact sit-
uation, the time required to reach this force differs if the Cartesian velocity
is identical.
If higher stiffness values are used, a desired force can be reached earlier,
as only a small position difference is required. Since the setpoint position
is reached quickly, a jerk can be produced in this way.
Fig. 10-17: Force over time (high stiffness, small position difference)
In the case of a large position difference and low stiffness, the force is
built up more slowly. This can be used, for example, if the robot moves to
the contact point and the impact loads are to be reduced.
Programming
Fig. 10-18: Force over time (low stiffness, large position difference)
Description
With axis impedance control, the following parameters can be set for each
individual axis:
• Stiffness
The stiffness parameter determines the degree of compliance of an
axis when force is applied
‒ If a low stiffness is set for an axis, the axis is very compliant and
can be easily moved by hand.
‒ Conversely, high stiffness for an axis results in low compliance.
WARNING
Risk of unpredictable motions with zero stiffness
Setting zero stiffness can cause the robot to move freely and uncon-
trollably in the corresponding directions. This particularly applies to
joint torque sensors that are not properly mastered. Injuries or dam-
age to property may result.
‒ Use zero stiffness values only in contact situations combined
with external force application in order to achieve a controlled
application of force.
• Damping
The damping parameters determine how much an axis oscillates after
a force has been applied
‒ If high damping is set for an axis, the oscillation is reduced.
Description
Using the Position hold motion command, the robot can hold its Cartesi-
an setpoint position over a set period of time and remain under servo con-
trol.
This can be used in combination with corresponding settings for impe-
dance control so that the robot exerts corresponding forces and/or torques
at the current position. In addition, the impedance-controlled robot can re-
spond in a compliant manner to external forces – thus enabling, for exam-
ple, position corrections.
During a Position Hold, the impedance-controlled robot can be brought
away from its setpoint position by external forces. Whether and in which
direction the robot moves from the setpoint position depends on the set
controller parameters and the resulting forces.
Parameters
Triggers
Programming
Example
Setpoint-actual comparison
Repositioning
WARNING
Risk of injury and damage to property due to strong acceleration
of the robot during repositioning with external force application
If an impedance-controlled motion with external force application has
been paused, repositioning with external force application also takes
place. If the robot is in free space during repositioning, this can lead to
strong accelerations of the robot. Injuries or damage to property may re-
sult.
• Manually bring the robot back in contact before repositioning.
Description
Triggers can be programmed in the Motion group node and the Position
hold node.
Triggers consist of a condition and an action. The action is executed if the
condition is fulfilled.
The following condition types can be programmed on the Triggers tab of
the above-mentioned nodes:
• Force component condition
The condition is met if the external Cartesian force measured along
the set axis of the set TCP lies outside a defined range (Min…Max).
• Torque component condition
The condition is met if the external Cartesian torque measured about
the set axis of the set TCP lies outside a defined range (Min…Max).
If the condition is met, the Break action is triggered by default. This action
ends the current motion (Motion group or Position hold) and executes
the next program command. Other actions cannot be programmed.
Programming
Fig. 10-21: Trigger: Cancellation of motion due to force or torque
(negation “not”)
Procedure
Example
If, in the search direction, a force of < -10 N is measured during the
search run, the trigger is triggered and the motion stops. The meas-
ured contact forces act against the direction of travel.
Description
Whether a trigger programmed for a motion group has been triggered can
be checked as follows.
Programming
Procedure
The return variable has the same name as the motion group.
Overview
The Grid Patterns toolbox is pre-installed on the robot controller. Grid pat-
terns make it possible to move the robot by means of a programmed pat-
tern.
Grid patterns are defined in the scene editor and in the capabilities. Grid
patterns can be integrated into programs.
Procedure
3. Show the object tree and check whether the grid pattern has been
created.
4. Rename grid pattern.
5. Manually enter coordinates in the parameter view.
6. In the object tree, select World.
7. Select Frame in the object selection menu. The first frame is added.
Overall, the following frames must be created:
• Origin
• Corner X
• Corner Y
• Iteration
8. Specify frame accordingly.
9. Move the robot to the desired position by jogging or manual guidance
and record the frame via Touch up.
1 Grid Patterns
2 Origin
This frame defines the gripper orientation at the removal points.
By default, the cell index is 0. The cell index can be changed man-
ually in the Feature menu Capabilities in the Parameter view.
(>>> 10.9.2 "Defining grid patterns in capabilities" Page 220)
3 Corner X
This frame defines the direction of the first iteration.
4 Corner Y
This frame defines the direction of the second iteration.
5 Iteration
This frame can be generated at any position.
Precondition
• At least one grid pattern has already been created in the scene editor.
Procedure
Programming
6. Select the frame references for the respective frames Origin, Corner
X, Corner Y and Iteration:
• New project frame
• Existing project frame...
7. If New project frame is selected:
• Frame is created at the current position.
8. If Existing project frame... is selected:
a. A dialog is opened. Show object tree.
b. Select frame.
c. Press Select target. The assignment is applied.
9. Optional: Change index.
The index is preset to 0 by default.
10. Click on Apply to save the change.
Procedure
Example
Nodes
Diagnosis
11 Diagnosis
Description
Precondition
Procedure
NOTICE
Incomplete data due to premature removal of the storage medium
If the storage medium is removed while data are still being written, the
diagnosis package is incomplete.
• Do not remove the storage medium until the message indicating
completion of the creation process has been displayed.
Description
All messages about events and changes in state of the system are log-
ged. The message log displays the messages in the order in which they
occur.
• The messages can be filtered by time interval, source and category.
• The filter window can be moved on the user interface.
• Depending on the filter and the number of messages, the messages
are displayed on one or more pages (maximum 20 messages per
page).
• The category of the messages is displayed using symbols (icons).
• If a message is selected that is related to other messages, this is rep-
resented graphically as follows:
‒ Solid gray line with nodes for the associated messages, e.g. be-
tween the error message and the notification message that signals
the elimination of the underlying error.
‒ Broken gray line for messages that are not loaded.
‒ Messages that are not related to the selected message can be
hidden. See filter button (>>> Fig. 11-2).
• The detail view shows the details of a selected message.
1 Message log
2 Detail view
Diagnosis
3 Message filter
4 Filter by category
5 Filter button (inactive)
6 Associated messages
7 Navigation between the pages
8 To top of page
Procedure
Description
An alarm indicator in the status bar of the user interface indicates the
number of warning and error messages that are currently active.
Procedure
• To display more details about the warning and error messages, tap on
the display in the status bar.
Overview
1 Alert display
2 Safety-related message
3 Alert filter
4 Alert details
5 Show Message History
Functions
KUKA Service
12 KUKA Service
Introduction
Information
Index F
3D scene...................................................... 121 Faults.............................................................. 34
Function test................................................... 36
Functions
A Expression Editor.................................... 204
Accessories.............................................. 14, 17
Advanced nodes...........................................197
AUT (operating mode)....................................18 G
Automatic (operating mode)...........................18 General configuration..................................... 87
Automatic mode..............................................38 General operation...........................................49
Axis range.......................................................18 General safety measures............................... 33
B H
Basic nodes.................................................. 190 Hazardous substances................................... 40
Brake defect................................................... 33 Hooke’s law.................................................. 211
Braking distance............................................. 18 HRC................................................................ 19
C I
CE mark..........................................................18 I/O configuration............................................. 93
Cleaning work.................................................39 Industrial robot......................................... 13, 17
Collaborative operation, HRC........................ 29 Intended use...................................................15
Commander.................................................... 18 Introduction..................................................... 11
Configuration, primary side.......................... 102
Configuration, secondary side............. 104, 106
Connecting cables....................................13, 17 J
CRR................................................................ 19 Jog mode........................................................30
D K
Danger zone.............................................18, 21 KUKA Customer Support............................. 227
Declaration of conformity............................... 17 KUKA Service...............................................227
Declaration of incorporation.....................17, 18 KUKA smartPAD pro...................................... 19
Decommissioning............................................40
Diagnosis...................................................... 223
Diagnosis package....................................... 227
Disclaimer....................................................... 17
L
Labeling.......................................................... 30
Disposal.......................................................... 40
Laser scanner, external................................145
Documentation, industrial robot......................11
Licenses..........................................................12
Low Voltage Directive.....................................18
E
EC declaration of conformity......................... 17
EMC Directive.................................................18
M
Machinery Directive........................................ 18
EMERGENCY STOP
Maintenance................................................... 39
External......................................................19
Manipulator........................................ 13, 17, 19
Local.......................................................... 19
Manual mode..................................................37
EMERGENCY STOP device................... 25, 28
Misuse.............................................................15
External......................................................19
Mode selection............................................... 31
Local.......................................................... 19
Monitoring Block........................................... 134
EMERGENCY STOP device, local................ 25
Monitoring, physical safeguards.....................27
EMERGENCY STOP, external.......................28
EMERGENCY STOP, output..........................29
Enabling device.............................................. 26
Enabling device, external............................... 29 N
Enabling switches...........................................26 Network connections...................................... 14
New signal, creating.......................................96
New signal, mapping......................................96
O STOP 0...........................................................19
Open-source................................................... 12 STOP 2...........................................................20
Operator safety........................................ 24, 27 Stop category 0.............................................. 19
Operators........................................................ 21 Stop category 2.............................................. 20
Options..................................................... 14, 17 Stop category 1 (HRC).................................. 20
Overload......................................................... 33 Stop category 1 (path-maintaining)............... 20
Overview of the industrial robot.....................13 Stop reactions.................................................22
STOP 1 (HRC)............................................... 20
STOP 1 (path-maintaining)............................ 20
Stopping distance.................................. 18, 160
P Storage........................................................... 40
Panic position................................................. 26 Support request............................................ 227
Performance Level......................................... 23 System integrator.............................. 18, 20, 21
Personal protective equipment...................... 21 System requirements......................................14
Personnel........................................................20
Physical inputs and outputs...........................93
Plant integrator............................................... 20
PPE.................................................................21
T
Preventive maintenance work........................ 39 T1 (operating mode).......................................20
Product description.........................................13 Teach pendant......................................... 13, 17
Programming................................................ 189 Terms, safety.................................................. 18
Protected space..............................................21 Training........................................................... 11
Protective equipment......................................30 Transportation................................................. 35
R U
Reaction distance........................................... 18 User.......................................................... 18, 21
Recommissioning............................................35
Repair............................................................. 39
Robot controller........................................13, 17 V
Velocity monitoring......................................... 27
S
Safeguards, external...................................... 31 W
Safety..............................................................17 Warnings......................................................... 11
Safety-oriented tools.....................................176 Workspace................................................18, 21
Safety acceptance........................................ 173
Safety configuration......................................133
Safety controller..............................................25
Safety functions.............................................. 23
Safety functions, overview............................. 23
Safety instructions.......................................... 11
Safety interfaces...........................................144
Safety reactions............................................140
Safety Rule................................................... 134
Safety Rule Set............................................ 134
Safety stop......................................................19
Safety stop 0.................................................. 19
Safety stop 1 (HRC)...................................... 19
Safety stop 1 (path-maintaining)....................19
Safety zone.....................................................19
Safety, general................................................17
Signals............................................................ 95
Simulation....................................................... 38
Single Point of Control...................................40
smartPAD........................................................34
Software................................................... 14, 17
Software limit switches...................................30
SPOC..............................................................40
Start-up........................................................... 35