Expert Documentation KUKA Roboter GmbH

Configuration of Kinematic Systems

For KUKA System Software 8.5

Assembly and Operating Instructions

Configuration

of Kinematic

Systems

Issued: 24.05.2017

Version: KSS 8.5 configuration of kinematic systems V2

 Configuration of Kinematic Systems

© Copyright 2017
KUKA Roboter 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 Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC

Publication: Pub KSS 8.5 Konfiguration von Kinematiken (PDF) en

Book structure: KSS 8.5 Konfiguration von Kinematiken V2.2
Version: KSS 8.5 configuration of kinematic systems V2

2 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 Contents

Contents
1 Introduction .................................................................................................. 7
1.1 Target group .............................................................................................................. 7
1.2 Industrial robot documentation ................................................................................... 7
1.3 Representation of warnings and notes ...................................................................... 7
1.4 Terms used ................................................................................................................ 8

2 Fundamentals .............................................................................................. 9
2.1 Distinction between external axis and kinematic system ........................................... 9
2.2 Kinematic system types ............................................................................................. 9
2.3 Motion types ............................................................................................................... 11
2.4 Master/slave operation ............................................................................................... 13

3 Hardware ...................................................................................................... 15
3.1 Maximum values for external axis systems ............................................................... 15

4 Safety ............................................................................................................ 17
5 Operation ...................................................................................................... 19
5.1 Coordinate systems ................................................................................................... 19
5.1.1 Kinematic chain with BASE kinematic system ...................................................... 19
5.1.2 Kinematic chain of a ROBROOT kinematic system .............................................. 20
5.2 Jogging external axes ................................................................................................ 22
5.3 Mathematical coupling ............................................................................................... 22
5.3.1 Manually activating a mathematical coupling ....................................................... 23
5.3.2 Activating a mathematical coupling via a program ............................................... 23
5.4 Moving the linear unit and robot together .................................................................. 23
5.4.1 EO driver settings ................................................................................................. 25
5.5 Offsetting the zero position of the linear unit .............................................................. 25

6 System planning .......................................................................................... 27

6.1 Planning external axis systems .................................................................................. 27

7 Configuration ............................................................................................... 29
7.1 WorkVisual Catalog Editor ......................................................................................... 29
7.1.1 Button bar ............................................................................................................. 30
7.1.2 Starting WorkVisual catalog editor ........................................................................ 30
7.1.3 Displaying/hiding windows .................................................................................... 30
7.1.4 Creating a new catalog ......................................................................................... 30
7.1.5 Adding a catalog ................................................................................................... 31
7.1.6 Setting access rights ............................................................................................. 31
7.1.7 Saving a catalog ................................................................................................... 32
7.1.8 Closing a catalog .................................................................................................. 32
7.1.9 Closing the WorkVisual Catalog Editor ................................................................. 32
7.2 Configuring kinematic systems – overview ................................................................ 32
7.2.1 Configuring a KUKA linear unit ............................................................................. 33
7.2.2 Configuring a kinematic system with KUKA MGU or KUKA motor ....................... 34
7.2.3 Configuring a kinematic system with master/slave motors ................................... 35
7.2.3.1 Master / slave parameters ............................................................................... 36
7.2.4 Configuring a CK .................................................................................................. 37

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 3 / 123

 Configuration of Kinematic Systems

7.3 Transformation .......................................................................................................... 37

7.3.1 Transformation of BASE kinematic system .......................................................... 37
7.3.2 Transformation of ROBROOT kinematic system .................................................. 39
7.4 Optimizing machine data with the oscilloscope ......................................................... 39
7.4.1 Optimization sequence ......................................................................................... 40
7.4.2 Optimizing controller parameters .......................................................................... 40
7.4.2.1 Optimizing the proportional component of the speed controller ...................... 40
7.4.2.2 Optimizing the integral component of the speed controller ............................. 42
7.4.2.3 Optimizing the proportional component of the position controller ................... 43
7.4.3 Optimizing acceleration parameters ..................................................................... 45
7.4.3.1 Optimizing axis ramp-up time .......................................................................... 45
7.4.3.2 Optimizing the reduction factor for the Emergency Stop ramp ........................ 46
7.4.3.3 Optimizing the braking ramp for dynamic braking ........................................... 47
7.4.3.4 Configuration examples ................................................................................... 48
7.4.4 Checking the optimization results ......................................................................... 50
7.5 Simulating axes ......................................................................................................... 50
7.6 Configuring axes as couplable .................................................................................. 50
7.7 Creating coupling groups ........................................................................................... 51

8 Start-up and recommissioning ................................................................... 53

8.1 Start-up of kinematic systems ................................................................................... 53
8.1.1 Starting up a KUKA linear unit .............................................................................. 53
8.1.2 Starting up a KUKA kinematic system .................................................................. 53
8.1.3 Starting up a kinematic system with KUKA MGU ................................................. 54

9 System variables ......................................................................................... 55

9.1 System variables for configuring external axes ......................................................... 55
9.2 Asynchronous, uncoordinated external axes ............................................................. 55
9.2.1 $ZUST_ASYNC .................................................................................................... 55
9.2.2 $ASYNC_AX… ..................................................................................................... 55
9.3 Asynchronous, coordinated external axes (ASYPTP) ............................................... 56
9.3.1 $ASYNC_T1_FAST .............................................................................................. 56
9.3.2 $ASYNC_MODE .................................................................................................. 57
9.4 Permanently asynchronous external axes ................................................................. 58
9.4.1 $EX_AX_ASYNC ................................................................................................. 58
9.5 System variables for offsetting the zero position of a linear unit ............................... 59
9.5.1 $JOINT_OFFSET ................................................................................................. 59
9.5.2 $JOINT_OFFSET_C ............................................................................................ 60
9.5.3 $EO_DEVICES .................................................................................................... 60

10 Programming ............................................................................................... 61
10.1 Programming motions for external axes .................................................................... 61
10.2 Programming synchronous external axes ................................................................. 61
10.2.1 Programming a mathematically coupled motion ................................................... 62
10.3 Programming asynchronous external axes ............................................................... 62
10.3.1 $ASYNC_AXIS ..................................................................................................... 62
10.3.2 ASYPTP ............................................................................................................... 63
10.3.3 $OV_ASYNC ........................................................................................................ 64
10.3.4 $ASYNC_FLT ....................................................................................................... 65
10.3.5 ASYSTOP ............................................................................................................ 65

4 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 Contents

10.3.6 ASYCONT ............................................................................................................ 65

10.3.7 ASYCANCEL ........................................................................................................ 66
10.3.8 $ASYNC_STATE .................................................................................................. 66

11 Examples ...................................................................................................... 69
11.1 Transformation for DKP 400 ...................................................................................... 69
11.2 Transformation for KL 1500-3 .................................................................................... 72

12 Appendix ...................................................................................................... 75
12.1 Machine data for configuring the transformation ........................................................ 75
12.1.1 $ET1_TA1KR ........................................................................................................ 75
12.1.2 $ET1_TA2A1 ........................................................................................................ 75
12.1.3 $ET1_TA3A2 ........................................................................................................ 76
12.1.4 $ET1_TFLA3 ........................................................................................................ 76
12.1.5 $ET1_TPINFL ....................................................................................................... 76
12.2 Machine data for configuring axes ............................................................................. 77
12.2.1 $AXIS_TYPE[] ...................................................................................................... 77
12.2.2 $RED_VEL_AXC[] ................................................................................................ 78
12.2.3 $VEL_AX_JUS[] ................................................................................................... 78
12.2.4 $L_EMT_MAX[] .................................................................................................... 78
12.2.5 $APO_DIS_PTP[] ................................................................................................. 79
12.2.6 $IN_POS_MA[] ..................................................................................................... 79
12.2.7 $RED_ACC_OV[] ................................................................................................. 80
12.2.8 $VEL_AXIS_MA[] ................................................................................................. 81
12.2.9 $RED_ACC_AXC[] ............................................................................................... 81
12.2.10 $INC_AXIS[] ......................................................................................................... 81
12.2.11 $INC_EXTAX[] ...................................................................................................... 82
12.2.12 $ST_TOL_VEL[] ................................................................................................... 82
12.2.13 $TIME_POS[] ........................................................................................................ 83
12.2.14 $AXIS_JERK[] ...................................................................................................... 83
12.2.15 $VEL_CPT1_MA[] ................................................................................................ 83
12.2.16 $JERK_MA ........................................................................................................... 84
12.2.17 $EX_AX_ASYNC .................................................................................................. 84
12.2.18 $SOFTN_END[] .................................................................................................... 85
12.2.19 $SOFTP_END[] .................................................................................................... 85
12.2.20 $RAT_MOT_AX[] .................................................................................................. 85
12.2.21 $ASYNC_EX_AX_DECOUPLE – KUKA System Software 8.5 ............................ 86
12.2.22 $COUP_COMP[] ................................................................................................... 87
12.2.23 $IN_STILL_MA ..................................................................................................... 88
12.2.24 $INC_CAR[] .......................................................................................................... 88
12.2.25 $SEP_ASYNC_OV ............................................................................................... 89
12.3 Machine data for configuring motors .......................................................................... 89
12.3.1 $IN_POS_MA[] ..................................................................................................... 89
12.3.2 $VEL_AXIS_MA[] ................................................................................................. 90
12.4 Machine data for configuring a CK ............................................................................. 90
12.4.1 $MAIN_AXIS ......................................................................................................... 90
12.4.2 $WRIST_AXIS ...................................................................................................... 94
12.4.3 $TIRORO .............................................................................................................. 95
12.4.4 $LENGTH_A ......................................................................................................... 96

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 5 / 123

 Configuration of Kinematic Systems

12.4.5 $LENGTH_B ........................................................................................................ 97

12.4.6 $A4PAR ................................................................................................................ 97
12.4.7 $TRAFONAME[] ................................................................................................... 97
12.4.8 $ROBROOT ......................................................................................................... 97
12.4.9 $ACTIVE_KAR_MASK ......................................................................................... 98
12.4.10 $RED_VEL_CPC .................................................................................................. 99
12.4.11 $TECH_MAX ........................................................................................................ 99
12.4.12 $VEL_CP_T1 ....................................................................................................... 99
12.4.13 $RED_ACC_DYN ................................................................................................. 100
12.4.14 $INDIVIDUAL_MAMES ........................................................................................ 100
12.4.15 $KINCLASS .......................................................................................................... 100
12.4.16 $RED_ACC_CPC ................................................................................................. 101
12.4.17 $WARMUP_TIME ................................................................................................. 101
12.4.18 $WARMUP_RED_VEL ......................................................................................... 101
12.4.19 $COOLDOWN_TIME ........................................................................................... 102
12.4.20 $WARMUP_SLEW_RATE ................................................................................... 102
12.4.21 $WARMUP_CURR_LIMIT .................................................................................... 102
12.4.22 $WARMUP_MIN_FAC ......................................................................................... 102
12.4.23 $JERK_MA ........................................................................................................... 103
12.4.24 $RED_T1 .............................................................................................................. 103
12.4.25 $DEF_FLT_PTP ................................................................................................... 103
12.4.26 $DEF_FLT_CP ..................................................................................................... 104
12.4.27 $DEF_OV_JOG .................................................................................................... 104
12.4.28 $BRK_DEL ........................................................................................................... 104
12.4.29 $GEARTORQ_MON ............................................................................................. 105
12.4.30 $ACC_ACT_MA ................................................................................................... 105
12.4.31 $VEL_ACT_MA .................................................................................................... 105
12.4.32 $IN_POS_CAR ..................................................................................................... 106
12.4.33 $IN_POS_ORI ...................................................................................................... 107
12.4.34 $DIS_WRP1 ......................................................................................................... 107
12.4.35 $DIS_WRP2 ......................................................................................................... 107
12.4.36 $TFLWP ............................................................................................................... 108
12.4.37 $TX3P3 ................................................................................................................ 108
12.4.38 $ACC_MA ............................................................................................................ 109
12.4.39 $VEL_MA ............................................................................................................. 109
12.4.40 $OPT_MOVE ....................................................................................................... 109
12.4.41 $PROG_TORQ_MON .......................................................................................... 110
12.4.42 $USE_CUSTOM_MODEL .................................................................................... 110
12.5 Machine data for kinematic systems without a dynamic model ................................. 110

13 KUKA Service ............................................................................................... 113

13.1 Requesting support ................................................................................................... 113
13.2 KUKA Customer Support ........................................................................................... 113

Index ............................................................................................................. 121

6 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 1 Introduction

1 Introduction
t

1.1 Target group

t

This documentation is aimed at users with the following knowledge and skills:
 Advanced knowledge of the robot controller system
 Advanced KRL programming skills

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

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

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

 Documentation for the manipulator
 Documentation for the robot controller
 Operating and programming instructions for the System Software
 Instructions for options and accessories
 Parts catalog on storage medium
Each of these sets of instructions is a separate document.

1.3 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable

that death or severe injuries will occur, if no precautions
are taken.

These warnings mean that death or severe injuries may

occur, if no precautions are taken.

These warnings mean that minor injuries may occur, if

no precautions are taken.

These warnings mean that damage to property may oc-

cur, if no precautions are taken.

These warnings contain references to safety-relevant information or

general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.

This warning draws attention to procedures which serve to prevent or remedy

emergencies or malfunctions:

The following procedure must be followed exactly!

Procedures marked with this warning must be followed exactly.

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

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 7 / 123

 Configuration of Kinematic Systems

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

1.4 Terms used

Term Description
Axis One motor with gear unit, or multiple motors with
gear units in the case of master/slave operation
CK Customer-built Kinematics
EO driver External offset driver
The EO driver offsets the zero position of a linear
unit relative to a tracking point. In this way, the
linear unit can be moved together with the robot.
Catalog Can contain different elements, e.g. templates,
components, kinematic systems.
KPP KUKA Power Pack (drive power supply with
drive controller)
KSP KUKA Servo Pack (drive controller)
KUKA.HMI Human/Machine Interface
KUKA.HMI is the KUKA user interface.
MCFB Motion Control Function Block
Program module for programming motion tasks.
These modules are PLC-compliant and KUKA-
specific.
MGU Motor/gear unit
KUKA motor/gear combination for kinematic sys-
tems
Motor Servomotor with resolver, without gear unit
RDC Resolver Digital Converter
WorkVisual Catalog Software for creating catalog elements for
Editor WorkVisual.

8 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 2 Fundamentals

2 Fundamentals
2

2.1 Distinction between external axis and kinematic system

t

s
 The robot controller can control a manipulator or a CK with up to 6 axes.
 In addition to the manipulator or CK, up to 6 external axes can be con-
trolled.
 The external axes can be combined to form kinematic systems with up to
3 axes.
 It is not possible to operate 2 manipulators or CKs.

Areas of appli- Kinematic systems are used if the manipulator has to work on a moving work-
cation piece.
 Kinematic systems extend the workspace of the manipulator, e.g. linear
units, Cartesian gantries.
 Kinematic systems improve the accessibility of the workpiece, e.g. turn-tilt
table, positioner.
External axes are used if the manipulator is not working on the workpiece that
has to be moved.
 External axis that turns the workpiece ready for a subsequent operation,
e.g. loading device
 External axis as drive unit for tools, e.g. electric motor-driven welding gun
(KUKA.ServoGun)

2.2 Kinematic system types

Overview The following kinematic system types are implemented by KUKA:

 External ROBROOT kinematic system
 External BASE kinematic system
 External TOOL kinematic system

ROBROOT ROBROOT kinematic systems move the robot, e.g. the KUKA linear unit.
kinematic system

Fig. 2-1: Robot on linear unit

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 9 / 123

 Configuration of Kinematic Systems

BASE kinematic BASE kinematic systems move the workpiece, e.g. turn-tilt table and position-
system er.

Fig. 2-2: Two-axis positioner

Fig. 2-3: Three-axis positioner

TOOL kinematic TOOL kinematic systems move the tool, e.g. the external adhesive nozzle for
system the application of adhesive to glass.

10 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 2 Fundamentals

Fig. 2-4: External adhesive nozzle

2.3 Motion types

Overview External axes can be moved synchronously or asynchronously to the robot ax-
es. In order to execute asynchronous motions, external axes must be switched
to asynchronous mode.

In the case of an industrial robot with the SafeOperation option in-

stalled, the brake test for asynchronous external axes can only be
performed if the external axis is switched to synchronous mode.

The following options are available for switching external axes to asynchro-
nous mode:
 KRL statement ASYPTP: can be used in the robot and submit interpreters
and in interrupt programs.
(>>> 10.3.2 "ASYPTP" Page 63)
 System variable $EX_AX_ASYNC
(>>> 9.4.1 "$EX_AX_ASYNC" Page 58)
Asynchronous external axes cannot be moved asynchronously of one anoth-
er. Simultaneous motions are possible, e.g.:
...
ASYPTP {E1 90, E2 20}
...

If 2 consecutive ASYPTP statements are programmed, the second motion

does not start until the first motion has been completed, e.g.:
...
ASYPTP {E1 90}
ASYPTP {E2 20}
...

Synchronous In the case of a synchronous motion, all the axes involved (robot axes and ex-
ternal axes) execute a common motion, starting simultaneously and stopping
simultaneously. The axis position of the external axes is contained in every
taught point (E6POS).

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 11 / 123

 Configuration of Kinematic Systems

Fig. 2-5: Synchronous robot and external axis motion

1 Robot motion
2 Synchronous motion of an external axis

Synchronous motions
Mathematically coupled Non-coupled
The robot calculates its motion path The robot calculates its motion path
in relation to the position of the without taking the position of the
kinematic system. external axis into consideration.
The kinematic system must be cali- The external axis need not be cali-
brated. brated.
Example: Example:
 Turn-tilt table, positioner  Electric motor-driven welding
 KUKA linear unit gun in program mode
Note: A ROBROOT kinematic  Turnover positioner
system is always mathematical-
ly coupled and is not calibrated.

Asynchronous In the case of an asynchronous motion, the external axes execute a motion
that is not synchronized with the robot axes.

Fig. 2-6: Asynchronous robot and external axis motion

12 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 2 Fundamentals

1 Robot motion
2 Asynchronous motion of an external axis

Asynchronous motions
Coordinated Uncoordinated
The asynchronous external axis is The asynchronous external axis is
controlled via the KRL program controlled via a separate operating
“ASYPTP”. panel.
Example: Example:
 Loading device  Manual loading area: the opera-
 Electric motor-driven weld gun: tor can move the external axis to
operated by means of status a convenient position.
keys.

Example

Fig. 2-7: System with synchronous and asynchronous external axes

1 Mathematically coupled synchronous motion of robot and kinematic

system
2 Asynchronous motion of the external axis

2.4 Master/slave operation

Description In master/slave operation, 1 axis can be driven by multiple motors. 1 master

can have up to 15 slaves.
There are 3 types of drive control in master/slave operation:
 Position control
 Torque control
 Tension control
Each axis has at least 1 position-controlled motor. The master motor is always
position-controlled. The slave motors are either position-controlled, torque-
controlled or tension-controlled. Which variant is selected for the slave de-
pends on the mechanical stiffness between master and slave.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 13 / 123

 Configuration of Kinematic Systems

Stiffness Drive control of master/slave axis

High Torque-controlled slave
Stiff mechanical coupling between master and slave: slave
mechanically follows master (torque is transmitted).
Example: KUKA linear unit is driven by 2 motors for faster
acceleration.
Middle Selection must be tested.
Low Position-controlled slave
Low-stiffness mechanical coupling between master and
slave: slave does not mechanically follow master (position
is synchronized).
Example: 2-column lifting device (>>> Fig. 2-8 )

Only 1 tension-controlled slave motor can be assigned to a master motor, as

the axis has exactly 2 drives. The master motor and slave motors and their
KSPs and KPPs must all be of the same type. 1 position-controlled slave mo-
tor can be the master of another tension-controlled slave motor.

Fig. 2-8: Example: slave position-controlled

1 Master motor
2 Slave motor

14 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 3 Hardware

3 Hardware
w

3.1 Maximum values for external axis systems

Robot controller  The KR C4 can operate a maximum of 8 motors.

 The KR C4 extended can operate a maximum of 16 motors.
 The KSS 8.5 can operate 6 robot axes or CK axes and 6 external axes.
 The operation of further axes requires the MCFB function.

Further information is contained in the assembly or operating instruc-

tions for the robot controller.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 15 / 123

 Configuration of Kinematic Systems

16 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 4 Safety

4 Safety
4

y This documentation contains safety instructions which refer specifically to the

software described here.
The fundamental safety information for the industrial robot can be found in the
“Safety” chapter of the Operating and Programming Instructions for System In-
tegrators or the Operating and Programming Instructions for End Users.

The “Safety” chapter in the operating and programming instructions

of the KUKA System Software (KSS) must be observed. Death to per-
sons, severe injuries or considerable damage to property may other-
wise result.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 17 / 123

 Configuration of Kinematic Systems

18 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 5 Operation

5 Operation

5.1 Coordinate systems

t

5.1.1 Kinematic chain with BASE kinematic system

Overview The following Cartesian coordinate systems are defined in the robot controller
for a mathematically coupled BASE kinematic system:
 WORLD
 ROBROOT
 ROOT
 FLANGE
 OFFSET
 TOOL

Fig. 5-1: Kinematic chain with DKP 400

Description WORLD
The WORLD coordinate system is a permanently defined Cartesian coordi-
nate system. It is the root coordinate system for the ROBROOT and ROOT co-
ordinate systems.
By default, the WORLD coordinate system is located at the robot base.
ROBROOT
The ROBROOT coordinate system is a Cartesian coordinate system, which is
always located at the robot base. It defines the position of the robot relative to
the WORLD coordinate system.
By default, the ROBROOT coordinate system is identical to the WORLD coor-
dinate system. $ROBROOT allows the definition of an offset of the robot rela-
tive to the WORLD coordinate system.
ROOT

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 19 / 123

 Configuration of Kinematic Systems

The ROOT coordinate system is a Cartesian coordinate system which is locat-

ed in the root point of the BASE kinematic system. It defines the position of the
kinematic system relative to the WORLD coordinate system.
During root point calibration, the robot controller saves the coordinates of the
root point as the BASE coordinate system.

Further information about root point calibration of an external kine-

matic system is contained in the Operating and Programming Instruc-
tions for System Integrators.

FLANGE
The FLANGE coordinate system is a Cartesian coordinate system which is lo-
cated at the flange center point of the BASE kinematic system.
OFFSET
The OFFSET coordinate system (= workpiece base) is a Cartesian coordinate
system that defines the position of the workpiece on the BASE kinematic sys-
tem. It is relative to the FLANGE coordinate system.
During calibration, the robot controller saves the coordinates of the workpiece
base as the BASE coordinate system. If no workpiece base is calibrated, the
FLANGE coordinate system of the kinematic system is taken as the base.

Further information about calibration of the workpiece base of an ex-

ternal kinematic system is contained in the Operating and Program-
ming Instructions for System Integrators.

The OFFSET coordinate system is mobile relative to the WORLD coordinate

system, i.e. the position of the workpiece on the kinematic system changes
with the motion of the kinematic system.

The current position of the workpiece in the WORLD coordinate sys-

tem can be displayed by means of the system variable $BASE_C.

TOOL
The TOOL coordinate system is a Cartesian coordinate system which is locat-
ed at the tool center point. By default, it is relative to the FLANGE coordinate
system of the kinematic system.
If a workpiece base is calibrated, the TOOL coordinate system is relative to the
OFFSET coordinate system.

5.1.2 Kinematic chain of a ROBROOT kinematic system

A ROBROOT kinematic system is automatically mathematically cou-

pled. The mathematical coupling cannot be deactivated.

Overview The linear unit is a ROBROOT kinematic system. The following Cartesian co-
ordinate systems are defined in the robot controller for a ROBROOT kinematic
system:
 WORLD
 ERSYSROOT
 ROBROOT

20 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 5 Operation

Fig. 5-2: ROBROOT kinematic system – linear unit

Description WORLD
The WORLD coordinate system is a permanently defined Cartesian coordi-
nate system. It is the root coordinate system for the ROBROOT and ERSYS-
ROOT coordinate systems.
By default, the WORLD coordinate system is located at the root point of the
linear unit.
ERSYSROOT
The ERSYSROOT coordinate system is a Cartesian coordinate system which
is located at the root point of the linear unit. The root point is situated by default
at the zero position of the linear unit and is not dependent on $MAMES.
By default, the ERSYSROOT coordinate system is identical to the WORLD co-
ordinate system. $ERSYSROOT allows the definition of an offset of the linear
unit relative to the WORLD coordinate system.
ROBROOT
The ROBROOT coordinate system is a Cartesian coordinate system, which is
located at the robot base. When the linear unit is moved, the position of the
robot in the WORLD coordinate system changes. The current position of the
robot in the WORLD coordinate system is defined by the vector
$ROBROOT_C.
$ROBROOT_C consists of:
 $ERSYSROOT (static component)
Root point of the linear unit relative to $WORLD
 #ERSYS (dynamic component)
Current position of the robot on the linear unit relative to $ERSYSROOT

The current position of the robot in the WORLD coordinate system

can be displayed by means of the system variable $ROBROOT_C.

The robot is standing on the flange of the linear unit. Ideally, the ROBROOT
coordinate system of the robot should be identical to the FLANGE coordinate
system of the linear unit. In reality, there are often slight discrepancies which
mean that positions cannot be moved to correctly. These discrepancies can
be corrected mathematically when the linear unit is calibrated.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 21 / 123

 Configuration of Kinematic Systems

Further information about calibration of a linear unit is contained in the

Operating and Programming Instructions for System Integrators.

5.2 Jogging external axes

Description External axes cannot be moved using the Space Mouse. If “Space Mouse”
mode is selected, only the robot can be jogged with the Space Mouse. The ex-
ternal axes, on the other hand, must be jogged using the jog keys.

Precondition  The jog mode “Jog keys” is active.

 Operating mode T1

Procedure 1. Select the desired kinematics group, e.g. External axes, on the Keys tab
in the Jog options window.
The type and number of kinematics groups available depend on the sys-
tem configuration.
2. Set jog override.
3. Hold down the enabling switch.
The axes of the selected kinematics group are displayed next to the jog
keys.
4. Press the Plus or Minus jog key to move an axis in the positive or negative
direction.

Kinematic groups Depending on the system configuration, the following kinematics groups may
be available.

Kinematics group Description

Robot axes The robot axes can be moved using the jog keys.
The external axes cannot be jogged.
External axes All configured external axes (e.g. external axes
E1 to E5) can be moved using the jog keys.
NAME / The axes of an external kinematics group can be
moved using the jog keys.
External Kinematics
Group n The name is taken from the system variable
$ETn_NAME (n = number of the external kinemat-
ic system). If $ETn_NAME is empty, the default
name External Kinematics Group n is dis-
played.
[User-defined kinemat- The axes of a user-defined kinematics group can
ics group] be moved using the jog keys.
The name corresponds to the name of the user-
defined kinematics group.

5.3 Mathematical coupling

Description In the case of mathematical coupling, the robot calculates its motion path in
relation to the position of the kinematic system. If the kinematic system moves,
the robot follows it with the TCP so that the position of the TCP remains con-
stant relative to the moving base of the kinematic system.
The mathematical coupling must be activated for BASE kinematic systems. In
the case of BASE kinematic systems, a mathematical coupling is active in the
TOOL or BASE coordinate system.
A ROBROOT kinematic system is automatically mathematically coupled. It
cannot be deactivated. In the case of ROBROOT kinematic systems, the

22 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 5 Operation

mathematical coupling is active in the TOOL, BASE or WORLD coordinate

system.

Overview The mathematical coupling can be activated as follows for Cartesian jogging:
 Manually via KUKA.HMI
(>>> 5.3.1 "Manually activating a mathematical coupling" Page 23)
 By starting a mathematically coupled motion in a program
(>>> 5.3.2 "Activating a mathematical coupling via a program" Page 23)

5.3.1 Manually activating a mathematical coupling

Description The current tool (TOOL coordinate system) and the workpiece base (BASE
coordinate system of the kinematic system) must be selected for Cartesian
jogging.

The coordinates of a workpiece base are saved as

BASE_DATA[17...22].

Precondition  Root point of the kinematic system has been calibrated.

Further information about root point calibration of an external kine-

matic system is contained in the Operating and Programming Instruc-
tions for System Integrators.

Procedure 1. Select the menu sequence Configure > Set tool/base.

2. In the softkey bar, select whether a fixed tool is to be used:
 ext. Tool: the tool is a fixed tool.
 Tool: The tool is mounted on the mounting flange.
3. Enter the number of the desired tool in the box Tool no..
4. Enter the number of the desired base in the box Base No..
5. Press OK.

5.3.2 Activating a mathematical coupling via a program

Precondition  Program is selected.

 Operating mode T1 or T2
 Root point of the kinematic system has been calibrated.

Further information about root point calibration of an external kine-

matic system is contained in the Operating and Programming Instruc-
tions for System Integrators.

Procedure 1. Perform block selection to a motion instruction with coupled BASE of the
kinematic system.
2. Recommendation: set program override to 0%.
3. Start the program in order to load the data.
The mathematical coupling is now active and can be used for the Carte-
sian jogging.

5.4 Moving the linear unit and robot together

Description In order to move a linear unit together with a robot, an EO driver must be add-
ed and configured in WorkVisual. The EO driver offsets the zero position of the

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 23 / 123

 Configuration of Kinematic Systems

linear unit. This zero position refers to the tracking point. The tracking point
can be defined by the user. The following options are available for selection:
 TCP
 Wrist root point
 Robot flange
 Defined base
The current zero position is determined by projecting the tracking point onto
the linear unit. If the position of the tracking point changes as a result of moving
the robot, the zero position of the linear unit also changes. In this way, the lin-
ear unit automatically follows the robot; it is thus not necessary to program the
motion of the linear unit separately. An additional offset can be set from the
changed zero position.

Fig. 5-3: Example: Robot on linear unit

Item Description
1 Mastering position of the linear unit
2 Current zero position
3 Offset
4 Tracking point

Precondition  A linear unit is added to the project.

 The robot is mounted on the linear unit.

Procedure 1. Select the menu sequence Editors > Tool/base management.

2. In the Available tools, bases and EO drivers area, click on the button.
A window opens.
3. Enter a name for the driver in the Name box.
4. Open the Details box. If the Static use check box is activated, deactivate
it.
5. Make the desired settings (>>> 5.4.1 "EO driver settings" Page 25).
6. Click on OK. The driver is created.
7. Drag the driver manipulator onto the desired BASE coordinate system by
means of Drag&Drop. The driver is assigned to the BASE coordinate sys-
tem.
8. Optional: Enter an offset relative to the changed zero position of the linear
unit:
a. Double-click on the BASE coordinate system.

24 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 5 Operation

b. A window opens. Open the Details box and enter the offset in the Off-
set box.
c. Close the window by clicking on OK.
9. Save the project.

5.4.1 EO driver settings

Option Description
Static use  Check box active: The distance between the mastering position
and the current zero position of the linear unit does not change
when the robot is moved. The current zero position refers to the
mastering position of the linear unit.
 Check box not active: The distance between the mastering posi-
tion and the current zero position of the linear unit changes when
the robot is moved. The current zero position refers to the tracking
point. The linear unit automatically moves with the robot.
Compensation Way in which the robot deviates in one direction if the minimum com-
maneuver pensation distance is violated
 Neither: Robot does not deviate
 Best: Robot selects the direction itself
 Plus: Robot deviates in the positive direction of the linear unit
 Minus: Robot deviates in the negative direction of the linear unit
Compensation dis- Distance between robot base and tracking point at which the robot
tance starts to deviate in the configured direction
Tracking point Point that the robot tracks
 Tcp: TCP
 Wrist: Wrist root point
 Flange: Robot flange
 Base: Basic
Min. distance from The distance as a percentage between the zero position and the soft-
software limit switch ware limit switch of the linear unit beyond which the linear unit stops
Note: If a negative value is entered, the parameter is deactivated. The
linear unit then continues moving to the software limit switch.

5.5 Offsetting the zero position of the linear unit

Description The zero position of a linear unit can be offset using the EO driver in WorkVi-
sual. The current zero position refers to the mastering position of the linear unit
and is shifted by means of an offset. This can be used, for example, if a robot
on a linear unit is working at two machining stations that only differ in terms of
the position of the robot on the linear unit. The offset of the zero position
means that the same program can be used for machining.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 25 / 123

 Configuration of Kinematic Systems

Fig. 5-4: Example: Robot on linear unit

Item Description
1 Mastering position of the linear unit
2a/2b Offset relative to current zero position
3a/3b Current zero position

Precondition  A linear unit is added to the project.

 The robot is mounted on the linear unit.

Procedure 1. Select the menu sequence Editors > Tool/base management.

2. In the Available tools, bases and EO drivers area, click on the button.
A window opens.
3. Enter a name for the driver in the Name box.
4. Open the Details box and activate the Static use check box. The other
settings are then no longer relevant and are grayed out.
5. Click on OK. The driver is created.
6. Double-click on the desired BASE coordinate system. A window opens.
7. Open the Details box and select the EO driver in the Driver box.
8. Enter the offset relative to the mastering position of the linear unit in the
Offset box.
9. Close the window by clicking on OK and save the project.

26 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 6 System planning

6 System planning
y

6.1 Planning external axis systems

KUKA supplies kinematic systems for applications, such as welding, adhesive

bonding and laser machining.
The customer can also design his own mechanical systems, however. In this
case, either KUKA motors with their own gear units or KUKA motor/gear units
– MGUs – must be used.
KUKA MGUs are only to be used for driving rotational positioners, i.e. rotation-
al kinematic systems. Linear units, Cartesian gantries, etc., can only be de-
signed with KUKA motors with their own gear units.
Correct system planning according to the task and correct drive dimensioning
in accordance with the load and desired acceleration and velocity are prereq-
uisites for error-free operation.

It is always advisable to discuss the project with KUKA Roboter

GmbH to ensure that the correct components are selected and or-
dered for an external axis system.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 27 / 123

 Configuration of Kinematic Systems

28 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 7 Configuration

7 Configuration
f

7.1 WorkVisual Catalog Editor

t

Overview The WorkVisual Catalog Editor can be used to create catalogs. These cata-
logs can be used in WorkVisual.
Not all elements on the graphical user interface are visible by default, but they
can be shown or hidden as required.
There are other windows and editors available in addition to those shown here.
These can be displayed via the View and Editors menus.

Fig. 7-1: Overview of WorkVisual Catalog Editor

Item Description
1 Menu bar
2 Button bar
(>>> 7.1.1 "Button bar" Page 30)
3 Editor area
If an editor is open, it is displayed here. More than one editor can
be open simultaneously. In this case, they are stacked one on top
of the other and can be selected via tabs.
4 Catalogs window
All catalogs added are displayed in this window. The elements in
the catalogs can be inserted by Drag&Drop in the Solution Views
window.
5 Templates window
All available templates are displayed in this window. The elements
can be inserted by Drag&Drop in the Solution Views window.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 29 / 123

 Configuration of Kinematic Systems

Item Description
6 Properties window
If an object is selected, its properties are displayed in this window.
The properties can be changed. Individual properties in gray boxes
cannot be changed.
7 Message window
Errors, warnings and messages are displayed in this window.
8 Solution Views window
Objects from catalogs and templates can be added to a catalog
folder in this window. The properties of the objects can be edited.

7.1.1 Button bar

Button Name / description

Open existing file
Opens an existing catalog.
Save current file to hard drive
Saves the currently displayed catalog.
Cut
Deletes the selected element from its original position and
copies it to the clipboard.
Copy
Copies the selected element to the clipboard.
Paste
Inserts the cut or copied element at the selected position.
Undo
Undoes the last action.
Redo
Redoes the action that was undone.

7.1.2 Starting WorkVisual catalog editor

Procedure 1. Open the program directory in Windows Explorer.

2. Double-click on the file WorkVisualCatalogEditor.exe in the folder
WorkVisual 5.0.

7.1.3 Displaying/hiding windows

Procedure 1. Select the menu item View. A list of available windows opens.
2. Click on a window in the list in order to display or hide it on the graphical
user interface.

7.1.4 Creating a new catalog

Procedure 1. Select the menu sequence File > New.... The new catalog is displayed in
the Solution Views window.
2. Select the menu sequence Edit > Add catalog folder (optional). A folder
is added underneath the catalog.

30 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 7 Configuration

7.1.5 Adding a catalog

Precondition  A catalog is open.

Procedure 1. Select the menu sequence File > Add catalog....

2. Under Available catalogs, select the required catalogs and click on the
Right arrow button.
If all catalogs are to be accepted, click on the Double right arrow button.
3. The selected catalogs are displayed under Project catalogs. Click on
Close.

Description The following catalogs are available by default in the WorkVisual Catalog Ed-
itor:

Catalog Catalog contains ...

DtmCatalog Device description files
KRL Templates KRL program templates
KukaControllers Robot controllers, hardware components for
robot controllers, safety options, PROCONOS
option
KukaDriveKinematics External kinematic systems with KUKA motors
An element from this catalog is used if a non-
KUKA external axis fitted with a KUKA motor is
used with the real controller.
KukaDrives KUKA motors
KukaExternalKinemat- KUKA linear units, KUKA positioners
ics
KukaRobots KUKA robots
VW templates VW program templates

7.1.6 Setting access rights

Description Display, write and read access rights can be issued for WorkVisual, smartHMI
and the catalog editor. If the Allow check box is activated, the parameter is
displayed in accordance with the user group. If the Deny check box is activat-
ed, the parameter is not visible, irrespective of which user group is selected. If
no check box is activated, the parameter is only visible for the user group “Ad-
ministrator”.

In the case of the Catalog Editor application, “Deny” means that the
parameter will no longer be displayed after the editor has been
closed. This cannot be undone!

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 31 / 123

 Configuration of Kinematic Systems

Fig. 7-2: Setting access rights

Precondition  Editor is open with various parameters, e.g. machine data

Procedure
1. Click on the button. A window for setting the access rights is displayed.
2. Activate the desired check boxes in the columns Allow and Deny.
3. Close the window.

7.1.7 Saving a catalog

Description A catalog can be saved with one of the following functions:

 Save: Saves the open catalog.
 Save as: This function is used to save a copy of the open catalog.
The open catalog itself is closed and remains unchanged.

Procedure for  Select the menu sequence File > Save.

Save Or click on the Save current file to hard drive button.

Procedure for 1. Select the menu sequence File > Save as....
Save as The Save as window is opened. A file location for the catalog can be se-
lected here.
2. Enter a name in the File name box and click on the Save button.

7.1.8 Closing a catalog

Procedure  Select the menu sequence File > Close.

If changes have been made, a request for confirmation is displayed, ask-
ing if the catalog should be saved.

7.1.9 Closing the WorkVisual Catalog Editor

Procedure  Select the menu sequence File > Exit.

If a catalog is open, a request for confirmation is displayed, asking if the
catalog should be saved.

7.2 Configuring kinematic systems – overview

The steps required for configuration vary, depending on the kinematic system
used.

32 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 7 Configuration

Kinematic system Description

KUKA linear unit (>>> 7.2.1 "Configuring a KUKA linear
unit" Page 33)
Kinematic system with (>>> 7.2.2 "Configuring a kinematic sys-
MGU or KUKA motor tem with KUKA MGU or KUKA motor"
Page 34)
Kinematic system with mas- (>>> 7.2.3 "Configuring a kinematic sys-
ter/slave motors tem with master/slave motors" Page 35)
CK (>>> 7.2.4 "Configuring a CK" Page 37)

7.2.1 Configuring a KUKA linear unit

Precondition  A project has been created and opened in WorkVisual.

 A robot controller has been added and set as active.
 The catalogs KukaRobots and KukaExternalKinematics are open.

Procedure 1. Select the manipulator used from the catalog KukaRobots and drag it
onto the robot controller by means of Drag&Drop.
2. Select the linear unit used from the catalog KukaExternalKinematics and
drag it onto the robot controller by means of Drag&Drop.
3. Switch to the Geometry tab and open the structure of the linear unit.
4. Drag the manipulator onto the flange of the linear unit by means of
Drag&Drop.

Fig. 7-3: Configuring a KUKA linear unit

1 Flange of the linear unit 2 Manipulator

5. Click on the Configuration proposal... button and select the proposal that
corresponds to the available hardware.
6. Click on Accept.
The configuration of the Controller Bus is automatically generated. The lin-
ear unit is now configured and ready for operation.
7. If required, modify the transformation data and make further settings: Dou-
ble-click on the linear unit. The editor for the machine data configuration
opens.
(>>> Fig. 7-4 )
8. Make the desired settings. The selected frame is displayed in the graphic
for the transformation data.
(>>> 12.1 "Machine data for configuring the transformation" Page 75)
9. Close the window and respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.

Additional information about procedures in WorkVisual is contained in

the WorkVisual documentation.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 33 / 123

 Configuration of Kinematic Systems

Fig. 7-4: Machine data configuration editor

Item Description
1 Buttons
(>>> "Buttons" Page 34)
2 Graphically indicates changes to the settings.
3 Settings for the linear unit
4 Only with linear units that support the dynamic model:
Settings for the dynamic model

Buttons
Button Description
Undo
Undoes the last action.
Restore
Redoes the action that was undone.
Perspective
Switches between the standard and mirrored versions of the lin-
ear unit.
Import
Imports the configuration from an XML file.
Export
Exports the configuration to an XML file.

7.2.2 Configuring a kinematic system with KUKA MGU or KUKA motor

Precondition  A catalog has been created and opened in the WorkVisual catalog editor.
 The catalog KukaDrives is open.

34 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 7 Configuration

Procedure 1. Select the kinematic system used from the Templates window and drag it
onto the catalog folder by means of Drag&Drop. Kinematic systems with
different numbers of axes are available.
2. Open the structure of the kinematic system.
3. Select the motor used for each axis from the catalog KukaDrives and drag
it onto the axis by means of Drag&Drop.
4. Double-click on the kinematic system. The parameters for the transforma-
tion are displayed. A brief description is displayed on the user interface for
each parameter. A variable is specified in each brief description. These
variables are described in detail in the following section:
(>>> 12.1 "Machine data for configuring the transformation" Page 75)
5. Set the transformation parameters. The selected frame is displayed in the
graphic.
6. If required, user-specific graphics can be added: Click on the “Add” button,
select a file and click on Open. The graphic is added.
7. Close the window and respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.
8. Double-click on the axis. The axis parameters are displayed. A brief de-
scription is displayed on the user interface for each parameter. For some
parameters, a variable is specified. These variables are described in detail
in the following section:
(>>> 12.2 "Machine data for configuring axes" Page 77)
The acceleration parameters and how to optimize them are described in
detail in the following section:
(>>> 7.4.3 "Optimizing acceleration parameters" Page 45)
9. Set the axis parameters. In the case of KUKA motors, additionally set the
gear ratio.
10. Close the window and respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.
11. In the case of a kinematic system with more than 1 axis: Repeat steps 7
to 9 for the other axes.
12. Double-click on the motor. The motor parameters are displayed. A brief
description is displayed on the user interface for each parameter. For
some parameters, a variable is specified. These variables are described
in detail in the following section:
(>>> 12.3 "Machine data for configuring motors" Page 89)
The controller parameters and how to optimize them are described in de-
tail in the following section:
(>>> 7.4.2 "Optimizing controller parameters" Page 40)
13. Set the motor parameters.
14. Close the window and respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.
15. Select the menu sequence File > Save. The catalog is saved.
The created catalog can now be used in WorkVisual. The set parameters
can be modified in WorkVisual.

7.2.3 Configuring a kinematic system with master/slave motors

Precondition  A catalog has been created and opened in the WorkVisual catalog editor.
 The catalog KukaDrives is open.
 A kinematic system has been added to the catalog folder.
 The transformation parameters and axis parameters are configured.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 35 / 123

 Configuration of Kinematic Systems

 The master motors have been added to the kinematic system and the mo-
tor parameters have been configured.

Procedure 1. Open the structure of the kinematic system.

2. For each master motor, select the corresponding slave motor from the cat-
alog KukaDrives and drag it onto the master motor by means of
Drag&Drop.

The master and slave motors must be of the same motor type.

3. Double-click on the slave motor. The parameters for the slave motor are
displayed. A brief description is displayed on the user interface for each
parameter. For some parameters, a variable is specified. These variables
are described in detail in the following section:
(>>> 12.3 "Machine data for configuring motors" Page 89)
The master/slave parameters are described in detail in the following sec-
tion:
(>>> 7.2.3.1 "Master / slave parameters" Page 36)
The controller parameters and how to optimize them are described in de-
tail in the following section:
(>>> 7.4.2 "Optimizing controller parameters" Page 40)
4. Set the parameters for the slave motor.
5. Close the window and respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.
6. Select the menu sequence File > Save. The catalog is saved.
The created catalog can now be used in WorkVisual. The set parameters
can be modified in WorkVisual.

7.2.3.1 Master / slave parameters

Parameter Description
Slave type  PositionSlave: Position-controlled slave
 TorqueSlave: Torque-controlled slave
 TensionSlave: Tension-controlled slave
Direction reversal The parameter is relevant for all slave types.
Speed lag The parameter is only relevant for the slave type TorqueSlave.
Unit: °/s or mm/s
Torque ratio The parameter is only relevant for the slave type TorqueSlave.
The value 5 means that the slave receives a torque that is 5 times
greater than that received by the master. The value 1 means that the
master and slave receive the same torque.
Position lag The parameter is only relevant for the slave type PositionSlave.
The value should not be greater than the value of the following error.
Unit: ° or mm
Tensioning Tension between master and TensionSlave
The parameter is only relevant for the slave type TensionSlave.
Unit: Nm (optional)

36 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 7 Configuration

7.2.4 Configuring a CK

Precondition  A catalog has been created and opened in the WorkVisual catalog editor.
 The catalog KukaDrives is open.

Procedure 1. Select the CK used from the Templates window and drag it onto the cat-
alog folder by means of Drag&Drop. CKs with different numbers of axes
are available.
2. Open the structure of the CK.
3. Select the motor used for each axis from the catalog KukaDrives and drag
it onto the axis by means of Drag&Drop.
4. Double-click on the kinematic system. The parameters for the CK are dis-
played. A brief description is displayed on the user interface for each pa-
rameter. For some parameters, a variable is specified. These variables are
described in detail in the following section:
(>>> 12.4 "Machine data for configuring a CK" Page 90)
5. Set the parameters for the CK.
6. Close the window and respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.
7. Double-click on the axis. The axis parameters are displayed. A brief de-
scription is displayed on the user interface for each parameter. For some
parameters, a variable is specified. These variables are described in detail
in the following section:

8. Set the axis parameters. In the case of KUKA motors, additionally set the
gear ratio.
9. Close the window and respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.
10. In the case of a kinematic system with more than 1 axis: repeat steps 7 to
9 for the other axes.
11. Double-click on the motor. The motor parameters are displayed. A brief
description is displayed on the user interface for each parameter. For
some parameters, a variable is specified. These variables are described
in detail in the following section:
(>>> 12.3 "Machine data for configuring motors" Page 89)
The controller parameters and how to optimize them are described in de-
tail in the following section:
(>>> 7.4.2 "Optimizing controller parameters" Page 40)
12. Set the motor parameters.
13. Close the window and respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.
14. Select the menu sequence File > Save. The catalog is saved.
The created catalog can now be used in WorkVisual. The set parameters
can be modified in WorkVisual.

7.3 Transformation

7.3.1 Transformation of BASE kinematic system

Description The transformation starts at the root point of the kinematic system and ends at
the reference pin of the kinematic system. The reference pin is the reference
point for root point calibration of the kinematic system.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 37 / 123

 Configuration of Kinematic Systems

Further information about root point calibration of an external kine-

matic system is contained in the Operating and Programming Instruc-
tions for System Integrators.

Fig. 7-5: Transformation chain of a BASE kinematic system

Procedure 1. Define the root point of the kinematic system.

2. Define the joints and rotational axes of the kinematic system.
3. Define a reference point for the root point calibration (reference pin).
4. Starting at the root point of the kinematic system, offset the coordinate sys-
tem into the first joint (translation in X, Y and Z direction).
5. There, rotate the coordinate system so that the positive Z axis corre-
sponds to the rotational axis of the first axis (rotation about the angles A,
B, C).

Rotation must always be carried out in the sequence A, B, C.

6. If required, offset the coordinate system from the first joint to the second
joint and from the second joint to the third joint by means of translation and
rotation.
7. Starting at the last joint, offset the coordinate system to the flange center
point by means of translation and rotation.
8. Starting at the flange center point, offset the coordinate system to the ref-
erence pin on the kinematic system by means of translation and rotation.

Example

38 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 7 Configuration

7.3.2 Transformation of ROBROOT kinematic system

Description In the case of ROBROOT kinematic systems, the robot stands on the flange
of the kinematic system, e.g. KUKA linear unit. The flange is the baseplate on
the linear unit.
The following rules apply to the transformation of ROBROOT kinematic sys-
tems:
 In the case of kinematic systems with one axis, only $ETx_TA1KR is taken
into consideration.
 In the case of kinematic systems with 2 axes, $ETx_TA1KR and
$ETx_TA2A1 are taken into consideration.
 In the case of kinematic systems with 3 axes, $ETx_TA1KR, $ETx_TA2A1
and $ETx_TA3A2 are taken into consideration.
 $ETx_FLA3 defines the offset and orientation of the robot in the FLANGE
coordinate system of the kinematic system and is always taken into con-
sideration.

Procedure Here, the transformation is described using the example of a 1-axis ROB-
ROOT kinematic system, i.e. a linear unit.
1. Define the root point of the kinematic system.
2. Starting at the root point of the kinematic system, offset the coordinate sys-
tem into the flange center point of the kinematic system (translation in X,
Y and Z direction).
3. There, rotate the coordinate system so that the positive Z axis corre-
sponds to the direction of travel (rotation about the angles A, B, C).

Rotation must always be carried out in the sequence A, B, C.

4. Rotate the coordinate system is such a way that the X axis, starting at the
connector panel of the robot, points in the positive direction.

Example

7.4 Optimizing machine data with the oscilloscope

Function The oscilloscope is a function of KUKA.HMI and WorkVisual. This function can
be used to record, display and analyze different variables with the program
running, e.g. actual current, setpoint current, following error, etc.

Detailed information about the oscilloscope is contained in the Oper-

ating and Programming Instructions for System Integrators or in the
WorkVisual documentation.

Overview The oscilloscope is used to optimize machine data for external axes and CKs.
Machine data must only be optimized after the kinematic system has warmed
up. During operation, gear units and other mechanical components begin to
run more smoothly. Optimization with cold drives can result in the kinematic
system being over-optimized.
The following objectives are to be met:
 Reduction of the cycle time
For this purpose, the following acceleration parameters are optimized:
 Acceleration and braking ramp: Axis ramp-up time
 Ramp for path-oriented braking in the case of maximum braking
(STOP 0): Braking ramp for dynamic braking

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 39 / 123

 Configuration of Kinematic Systems

 Ramp for path-maintaining braking after EMERGENCY STOP

(STOP 1): $RED_ACC_EMX
(>>> 7.4.3 "Optimizing acceleration parameters" Page 45)
 Increase of path and velocity accuracy
For this purpose, the following controller parameters are optimized:
 Proportional component of speed controller: VelGain (PTP, CP)
 Integral component of speed controller: VelIntTime (PTP, CP)
 Position controller: PosGain (PTP, CP)
(>>> 7.4.2 "Optimizing controller parameters" Page 40)

7.4.1 Optimization sequence

The following sequence must be adhered to when optimizing the parameters

for external axes or CKs by means of the oscilloscope:

Step Optimization
1 Proportional component of the speed controller
2 Integral component of the speed controller
3 Proportional component of the position controller
4 Axis ramp-up time [ms]
5 Reduction factor for Emergency Stop ramp [%]
6 Braking ramp for dynamic braking [ms]

7.4.2 Optimizing controller parameters

It is advisable to optimize controller parameters with the maximum load that

occurs during operation. Trouble-free operation cannot otherwise be assured.

7.4.2.1 Optimizing the proportional component of the speed controller

Description The proportional component of the speed controller VelGain (PTP, CP) influ-
ences the dynamics of the velocity control.
 The higher the proportional component, the greater the reaction of the
controller output to a new setpoint value.
 The higher the proportional component, the lower the following error.
 The higher the proportional component, the greater the current pulse
height.
 If the control value is set too high, this causes the axis to overshoot and
buzz.
 If the control value is set too low, this results in termination of the motion
with an error message.
The aim of the optimization is to reduce the following error as far as possible
without causing the axis to overshoot or buzz. The optimized value for VelGain
depends on the motor type, the size of the kinematic system and the maximum
load to be moved.

Depending on the motor, suitable values for VelGain are between

0.0001 and 0.1. The range of values for each motor can be found in
the motor data documentation.

Procedure 1. Set the integral component of the speed controller VelIntTime (PTP) to a
high value (e.g. 10 s) in order to deactivate its function.
2. Set the proportional component of the speed controller VelGain (PTP).

40 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 7 Configuration

3. Increase or decrease VelGain (PTP) in increments until dynamic control

without current pulses and with a low following error is achieved.
4. Accept the optimized value for VelGain (CP).

Soft servo control

Fig. 7-6: Example of soft servo control

 Following error: red

 Motor torque: blue
The value set for VelGain (PTP) is too low. The following error is too great.

Hard servo
control

Fig. 7-7: Example of hard servo control

 Following error: red

 Motor torque: blue
The value set for VelGain (PTP) is too high. The following error is low, but the
current pulses are too strong.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 41 / 123

 Configuration of Kinematic Systems

Optimized servo
control

Fig. 7-8: Example of optimized servo control

 Following error: red

 Motor torque: blue

7.4.2.2 Optimizing the integral component of the speed controller

Description The integral component of the speed controller VelIntTime (PTP, CP) influenc-
es the transient response of the axis to the nominal speed and stabilizes the
control loop.
 The lower the integral component, the faster the reaction of the controller
output to a new setpoint value.
 The higher the integral component, the greater the following error.
 The integral component has no effect on the current pulse height.
 If the control value is too low, this causes the axis to vibrate.
The aim of the optimization is to reduce the following error as far as possible
without causing the axis to vibrate. The optimized value for VelIntTime de-
pends on the motor type, the size of the kinematic system and the maximum
load to be moved.

Depending on the motor, suitable values for VelIntTime are between

0.04 and 0.8. The range of values for each motor can be found in the
motor data documentation.

Procedure 1. Set the integral component of the speed controller VelIntTime (PTP).
2. Increase or decrease VelIntTime (PTP) in increments until fast servo con-
trol with a low following error is achieved and without the axis vibrating.
3. Accept the optimized value for VelIntTime (CP).

Slow servo
control

Fig. 7-9: Example of slow servo control

42 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 7 Configuration

 Following error: red

 Motor torque: blue
The value set for VelIntTime (PTP) is too high. The following error is slightly
too high and the servo control too slow.

Fast servo
control

Fig. 7-10: Example of fast servo control

 Following error: red

 Motor torque: blue
The value set for VelIntTime (PTP) is too low. The following error is low, but
the servo control is too fast. The axis vibrates.

Optimized servo
control

Fig. 7-11: Example of optimized servo control

 Following error: red

 Motor torque: blue

7.4.2.3 Optimizing the proportional component of the position controller

Description The proportional component of the position controller PosGain (PTP, CP) in-
fluences the path-maintaining ability.
 The higher the proportional component, the greater the reaction of the
controller output to a new setpoint value.
 The higher the proportional component, the lower the following error.
 The higher the proportional component, the greater the current pulse
height.
 If the control value is set too high, this causes the axis to overshoot and
buzz.
The aim of the optimization is to reduce the following error as far as possible
without causing the axis to overshoot or buzz. The optimized value for Pos-

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 43 / 123

 Configuration of Kinematic Systems

Gain depends on the motor type, the size of the kinematic system and the
maximum load to be moved.

Depending on the motor, suitable values for PosGain are between 20

and 90. The range of values for each motor can be found in the motor
data documentation.

Procedure 1. Set the proportional component of the position controller PosGain (PTP).
2. Increase or decrease PosGain (PTP) in increments until dynamic control
without current pulses and with a low following error is achieved.
3. Accept the optimized value for PosGain (CP).

Soft servo control

Fig. 7-12: Example of soft servo control

 Following error: red

 Motor torque: blue
The value set for PosGain (PTP) is too low. The following error is too great.

Hard servo
control

Fig. 7-13: Example of hard servo control

 Following error: red

 Motor torque: blue
The value set for PosGain (PTP) is too high. The following error is low, but the
setpoint value is too high.

44 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 7 Configuration

Optimized servo
control

Fig. 7-14: Example of optimized servo control

 Following error: red

 Motor torque: blue

7.4.3 Optimizing acceleration parameters

It is advisable to optimize acceleration parameters with the maximum load that

occurs during operation. Trouble-free operation cannot otherwise be assured.

7.4.3.1 Optimizing axis ramp-up time

Description The axis ramp-up time is the time in which an axis is accelerated to rated
speed. The aim of the optimization is to move the axes as fast as possible with-
out exceeding the maximum permissible current.
 Too high a value leads to slow accelerations and unnecessarily long cycle
times.
 Too low a value leads to fast accelerations so that the axis goes into cur-
rent limitation. This results in overshoot and following errors.
The required system-specific or customer-specific acceleration and decelera-
tion times must be checked for feasibility. If no value is specified, it is advisable
to commence optimization with a start value of 500 ms. This is a feasible value
for most kinematic systems.
For optimization, the value for the axis ramp-up time must be reduced in incre-
ments in the machine data. During testing of the axis motion, the current must
not exceed 90% of the maximum value.

In the case of very large kinematic systems, a start value of 500 ms

may be too low. In this case, the value for the optimization must be
increased in increments. Suitable values for most kinematic systems
range from 150 to 1,000 ms.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 45 / 123

 Configuration of Kinematic Systems

Fig. 7-15: Axis ramp-up time = 500 ms

7.4.3.2 Optimizing the reduction factor for the Emergency Stop ramp

Description The reduction factor for the Emergency Stop ramp defines a braking ramp for
the path-maintaining EMERGENCY STOP. The value is specified as a per-
centage and refers to the axis ramp-up time, e.g. a value of 200% means that
the EMERGENCY STOP braking ramp is twice as steep as the acceleration
ramp.
The aim of the optimization is to brake the axes as quickly as possible in the
event of an EMERGENCY STOP, without exceeding the maximum permissi-
ble current.
 If the braking ramp is too shallow, path-maintaining braking is ensured, but
the braking distance is too long for an EMERGENCY STOP.
 If the braking ramp is too steep, the axis goes into current limitation and
path-maintaining braking is lost, i.e. the programmed path is left in the
case of an EMERGENCY STOP.
The required system-specific or customer-specific deceleration times must be
checked for feasibility. If no value is specified, it is advisable to commence op-
timization with a start value of 100%.
For optimization, the value for the reduction factor must be increased in incre-
ments in the machine data. When an EMERGENCY STOP button is pressed,
the current must not exceed 90% of the maximum value.

46 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 7 Configuration

Fig. 7-16: $RED_ACC_EMX=100

Example Data for the reduction factor for the Emergency Stop ramp of a 10-axis indus-
trial robot
INT $RED_ACC_EMX[12]

$RED_ACC_EMX[1]=190
$RED_ACC_EMX[2]=300
$RED_ACC_EMX[3]=300
$RED_ACC_EMX[4]=250
$RED_ACC_EMX[5]=250
$RED_ACC_EMX[6]=250

$RED_ACC_EMX[7]=300
$RED_ACC_EMX[8]=1000
$RED_ACC_EMX[9]=300
$RED_ACC_EMX[10]=150
$RED_ACC_EMX[11]=100
$RED_ACC_EMX[12]=100

7.4.3.3 Optimizing the braking ramp for dynamic braking

Description The parameter is used to define a braking ramp for path-oriented maximum
braking. The axes are stopped in the time defined by the parameter, with the
axis speed being reduced from maximum to zero.
In the case of maximum braking, the current actual speed value is taken as the
command speed and linearly reduced to zero using the set ramp. The ramp
prevents the command speed from falling too quickly and causing the current
controller to go into limitation, which in turn would prevent the robot from being
braked in a controlled manner.
The ramp for every axis is calculated from the optimized values for the axis
ramp-up time and the reduction factor for the Emergency Stop ramp:
Braking ramp for dynamic braking = Axis ramp-up time * 100% / Reduction fac-
tor for Emergency Stop ramp

Following optimization, the acceleration parameters are independent

of one another. The value for the braking ramp for dynamic braking
must be at least 180 ms, even if the calculation gives a smaller value.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 47 / 123

 Configuration of Kinematic Systems

7.4.3.4 Configuration examples

Non-optimized The axes of most kinematic systems can follow the programming without any
problem using the non-optimized start values, but they are moved too slowly.
Parameters:
 Axis ramp-up time in ms
 $RED_ACC_EMX in %
 Braking ramp for dynamic braking in ms

Fig. 7-17: Non-optimized basic setting

1 Current limitation: 16 A
2 EMERGENCY STOP

Only part of the torque is used (current approx. 8 A) to accelerate the axis to
the rated speed. In the event of an EMERGENCY STOP, the axis does not
brake with the maximum possible torque. The braking distance is long.

Over-optimized With over-optimized values, the axes move at maximum velocity, but can no
longer follow the programming. During acceleration or braking, the axes leave
the programmed path and the setpoint speeds of the motors exceed the val-
ues actually reached. In the oscilloscope trace, the axis overshoot and the fol-
lowing errors become visible.
Parameters:
 Axis ramp-up time in ms
 $RED_ACC_EMX in %
 Braking ramp for dynamic braking in ms

48 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 7 Configuration

Fig. 7-18: Over-optimized setting

1 Current limitation: 16 A
2 EMERGENCY STOP

The axis attempts to follow the setpoint speed. The actual speed deviates from
the setpoint speed because of current limitation; the following error is large.

Optimized With optimized values, the axes are accelerated and braked with their maxi-
mum values, without leaving the programmed path.
Parameters:
 Axis ramp-up time in ms
 $RED_ACC_EMX in %
 Braking ramp for dynamic braking in ms

Fig. 7-19: Optimized setting

1 Current limitation: 16 A
2 EMERGENCY STOP

The maximum torque is used (current approx. 14 A) to accelerate the axis to

the rated speed. In the event of an EMERGENCY STOP, the axis brakes with
the maximum possible torque. The actual speed is virtually identical to the set-
point speed; the following error is virtually zero.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 49 / 123

 Configuration of Kinematic Systems

7.4.4 Checking the optimization results

The optimization results must be checked with the aid of the oscilloscope func-
tion.
The following tests must be carried out:
 Motion program in Automatic mode
 EMERGENCY STOP in Automatic mode
 Path-oriented braking in T2 mode after releasing the enabling switch
The following phenomena must not occur:
 Strong current pulses, i.e. axis hums during motion or vibrates.
 Axis goes into current limitation.
 Permissible following error is exceeded, i.e. motion is aborted with an error
message.

7.5 Simulating axes

Description Axis simulation can be used, for example, if an external axis is not yet present
or connected, but the drive module has already been installed.

Precondition  A project has been created and opened in WorkVisual.

 The robot controller has been added and set as active.
 A kinematic system has been added to the robot controller.
 A motor has been added to the axis.

Procedure 1. Open the structure of the kinematic system.

2. Double-click on the axis . The axis parameters are displayed.

3. Activate the filter Drive 1 - Name of drive.
4. Set the parameter Motion driver simulation to On.

Setting Description
On The axis is simulated. The robot controller does not
expect a motor or resolver.
Off The axis is connected and can be moved.

5. Close the window and respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.
6. Only if drive hardware (KSP, KPP) is present: Right-click on the kinematic
system and select Drive configuration. The drives and their connections
are depicted graphically. The simulated motor has no connections.
7. Add the connections manually and close the window. The drive hardware
is configured and the motor is simulated.

Additional information about procedures in WorkVisual is contained in

the WorkVisual documentation.

7.6 Configuring axes as couplable

Description In order for axes to be decoupled and recoupled during operation, the axes
must be configured as couplable.

Precondition  A project has been created and opened in WorkVisual.

 The robot controller has been added and set as active.
 A kinematic system has been added to the robot controller.

50 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 7 Configuration

 The motors that are to be coupled are added to the axis and mapped.

Procedure 1. Select the menu sequence Editors > Drive configuration.

2. Select the motors to be coupled.
3. Right-click on the motors and select Enable axis coupling from the con-
text menu. The motors are now displayed as coupling axes.

Fig. 7-20: Couplable axis

7.7 Creating coupling groups

Description To exchange different tools with a different number and/or type of motors dur-
ing operation, these motors must be grouped together in coupling groups.

Precondition  A project has been created and opened in WorkVisual.

 The robot controller has been added and set as active.
 A kinematic system has been added to the robot controller.
 The motors that are to be coupled are added to the project or robot con-
troller and mapped.

Procedure 1. Select the menu sequence Editors > Drive configuration.

2. Select the motors to be coupled.
3. Right-click on the motors and select Create coupling group from the con-
text menu. The motors are now displayed as a coupling group.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 51 / 123

 Configuration of Kinematic Systems

Fig. 7-21: Coupling group

52 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 8 Start-up and recommissioning

8 Start-up and recommissioning

t

8.1 Start-up of kinematic systems

Installation, mastering, optimization and approval of external kine-

matic systems for production operation must be performed only as
specified in the operating or assembly instructions for the relevant
component and only by personnel specially trained for this purpose.

Overview The steps required for start-up vary, depending on the kinematic system used.

Kinematic system Description

KUKA linear unit (>>> 8.1.1 "Starting up a KUKA linear unit"
Page 53)
KUKA kinematic sys- (>>> 8.1.2 "Starting up a KUKA kinematic sys-
tem tem" Page 53)
Kinematic system with (>>> 8.1.3 "Starting up a kinematic system with
MGU KUKA MGU" Page 54)

8.1.1 Starting up a KUKA linear unit

Procedure 1. Master the KUKA linear unit.

2. If necessary, calibrate the KUKA linear unit.

Further information about calibration of a linear unit is contained in the

Operating and Programming Instructions for System Integrators.

3. Configure the linear unit in WorkVisual.

(>>> 7.2.1 "Configuring a KUKA linear unit" Page 33)
4. Transfer the configuration from WorkVisual to the robot controller and ac-
tivate it there.

8.1.2 Starting up a KUKA kinematic system

The machine data of the KUKA kinematic system are loaded into the
robot controller by KUKA Roboter GmbH during commissioning. The
machine data can also be found on the CD supplied.

Procedure 1. Check that all hardware components are present and correct, install and
connect them.
2. Master KUKA kinematic system.
3. If required: optimize controller parameters under maximum load using the
TRACE recording.
4. If required: optimize acceleration parameters under maximum load using
the TRACE recording.
5. If required: calibrate KUKA kinematic system.

Further information about calibration of an external kinematic system

is contained in the Operating and Programming Instructions for Sys-
tem Integrators.

6. Archive all relevant data, including all TRACE recordings.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 53 / 123

 Configuration of Kinematic Systems

8.1.3 Starting up a kinematic system with KUKA MGU

Technical data and configuration data for KUKA motor/gear units can
be found in the MGU documentation.

Precondition  The minimum bending radii and specified cable carrier properties for the
cables used must be adhered to.
 For KUKA motors only: Dimensioning of the gear unit and drive rating by
system builder or KUKA Roboter GmbH.

Procedure 1. Check that all hardware components are present and correct, install and
connect them.
2. Check the compatibility of the serial numbers and version numbers of the
hardware, software and machine data.
3. Define mastering position and axis ranges / software limit switches of the
external axes.
4. Configure the kinematic system in the WorkVisual Catalog Editor and in
WorkVisual.
(>>> 7.2.2 "Configuring a kinematic system with KUKA MGU or KUKA
motor" Page 34)
5. Transfer the configuration from WorkVisual to the robot controller and ac-
tivate it there.
6. Move the axes in axis-specific mode, set motion directions, check gear ra-
tios.
7. Master external axes.
8. Check transformation: move axes in the WORLD coordinate system,
check the directions of motion in the WORLD coordinate system.
9. Optimize controller parameters under maximum load using the TRACE re-
cording.
10. Optimize acceleration parameters under maximum load using the TRACE
recording.
11. If required: define reference point and tool base for calibration of the kine-
matic system.
12. If required: calibrate kinematic system.

Further information about calibration of an external kinematic system

is contained in the Operating and Programming Instructions for Sys-
tem Integrators.

13. Archive all relevant data, including all TRACE recordings.

54 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 9 System variables

9 System variables
y

9.1
v
System variables for configuring external axes

Asynchronous, uncoordinated external axes

$ASYNC_AX... (>>> 9.2.2 "$ASYNC_AX…" Page 55)
$ZUST_ASYNC (>>> 9.2.1 "$ZUST_ASYNC" Page 55)

Asynchronous, uncoordinated external axes (ASYPTP)

$ASYNC_MODE (>>> 9.3.2 "$ASYNC_MODE" Page 57)
$ASYNC_T1_FAST (>>> 9.3.1 "$ASYNC_T1_FAST" Page 56)

Permanently asynchronous external axes

$EX_AX_ASYNC (>>> 9.4.1 "$EX_AX_ASYNC" Page 58)

9.2 Asynchronous, uncoordinated external axes

9.2.1 $ZUST_ASYNC

Description Signal input for enabling switch

A separate enabling switch must be pressed for asynchronous, uncoordinated
motions. Releasing the enabling switch terminates the motion.
A digital input must be assigned to this enabling switch by means of the vari-
able in the directory KRC:\STEU\MADA\$MACHINE.DAT with a signal decla-
ration.

There is only one signal input available for asynchronous external ax-
es. If the input is not required, it can be deactivated in conjunction with
the keyword FALSE.

Syntax SIGNAL $ZUST_ASYNC $IN[Input number]

Explanation of
Element Description
the syntax
Input number Type: INT
 1 ... 4 096

Example SIGNAL $ZUST_ASYNC $IN[105]

The enabling switch is connected to input 105.

9.2.2 $ASYNC_AX…

Description Motion direction of the asynchronous, uncoordinated external axes

Asynchronous, uncoordinated external axes must be assigned one digital in-
put for the positive motion direction and one digital input for the negative mo-
tion direction by means of the variable in the directory KRC:\STEU\MADA\
$MACHINE.DAT.

Syntax SIGNAL $ASYNC_AXAxis number_P$IN[Input number]

SIGNAL $ASYNC_AXAxis number_M$IN[Input number]

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 55 / 123

 Configuration of Kinematic Systems

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: external axis E1 … E6
Input number Type: INT
 1 ... 4 096
_P $IN Input for positive motion direction
_M $IN Input for negative motion direction

Example SIGNAL $ASYNC_AX1_P $IN[100]

...
SIGNAL $ASYNC_AX1_M $IN[101]

External axis E1 is moved asynchronously in the positive direction by means

of input 100 and in the negative direction by means of input 101.

9.3 Asynchronous, coordinated external axes (ASYPTP)

9.3.1 $ASYNC_T1_FAST

Description Velocity reduction in test mode T1

The velocity reduction for ASYPTP motions can be deactivated using the vari-
able in the directory KRC:\R1\MADA\$MACHINE.DAT. If velocity reduction is
deactivated, ASYPTP movements can be executed in T1 mode at the pro-
grammed velocity.

Velocity reduction for ASYPTP motions may only be deactivated for

external axis applications that are not safety-relevant.

Syntax $ASYNC_T1_FAST=n-bit value

Explanation of
Element Description
the syntax
n-bit value The value specifies the external axes for which the velocity
reduction is deactivated:
 Bit n = 0: velocity reduction is activated.
 Bit n = 1: velocity reduction is deactivated.
Note: Bits may only be set for external axes that have been
configured via $EX_AX_NUM. If no external axes have
been configured ($EX_AX_NUM=0), the value is not
checked.
Bit value:
 LSB: External axis E1
 MSB: External axis E6

Bit n 5 4 3 2 1 0
Axis E6 E5 E4 E3 E2 E1

Example 1 The following ASYPTP movement is programmed in the KRL program:

ASYPTP={E1 20.0}

In order for asynchronous external axis E1 to be able to be moved to position

20° at programmed velocity in T1 mode, the following must apply:

56 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 9 System variables

$ASYNC_T1_FAST='B0001'

Example 2 The following ASYPTP movement is programmed in the KRL program:

ASYPTP={E1 20.0, E2 50.0}

In order for asynchronous external axes E1 and E2 to be able to be moved to

positions 20° and 50° at programmed velocity in T1 mode, the following must
apply:
$ASYNC_T1_FAST='B0011'

In order for an ASYPTP motion to be executed at the programmed velocity in

T1 mode, velocity reduction must be deactivated for all axes involved in the
ASYPTP motion. If, for example, only velocity reduction for external axis E1 is
deactivated, the asynchronous external axes E1 and E2 are still moved to po-
sitions 20° and 50° at the reduced velocity in T1 mode.
$ASYNC_T1_FAST='B0001'

9.3.2 $ASYNC_MODE

Description Modes for asynchronous external axes

4 different modes for asynchronous external axes can be set using the vari-
able in the directory KRC:\STEU\MADA\$CUSTOM.DAT.

If the industrial robot is in operation, this variable cannot be modified.

Syntax $ASYNC_MODE=Bit array

Explanation of Element Description

the syntax
Bit array Only bit 0 and bit 1 are used.
 Bit 0: ASYPTP response in the submit interpreter
 Bit 1: ASYPTP response during block selection

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 57 / 123

 Configuration of Kinematic Systems

Bit Description
0 ASYPTP response in the submit interpreter
 Bit 0 = 0: Default mode
ASYPTP is possible in the submit interpreter, irrespective of
the status of the robot interpreter.
The return position of the asynchronous motions is saved,
i.e. repositioning is not carried out in the submit interpreter
following asynchronous motions.
In this mode, all external axes involved in an ASYPTP mo-
tion must be switched to asynchronous mode.
 Bit 0 = 1: Mode 1
ASYPTP is only possible in the submit interpreter if the robot
interpreter is not active ($PRO_STATE <> #P_ACTIVE).
The return position of the asynchronous motions is not
saved, i.e. repositioning is carried out in the submit interpret-
er following asynchronous motions.
In this mode, the external axes involved in an ASYPTP mo-
tion do not have to be switched to asynchronous mode.
In this mode, it is possible to execute individual motion se-
quences manually in PLC programs, e.g. manual welding
with an electric motor-driven welding gun. The gun welds
when the operator presses an assigned status key and is re-
positioned when the program is started.
1 ASYPTP response during block selection
The response configured here also applies in the case of
implicit block selection, e.g. for backward motion, reteaching a
point, deleting a point or executing a program in the program
run modes MSTEP and ISTEP.
 Bit 1 = 0: Default mode
In the case of a block selection, the system variable
$ASYNC_AXIS is set to the value of $EX_AX_ASYNC.
 Bit 1 = 1: Mode 2
In the case of a block selection, the system variable
$ASYNC_AXIS is not changed.

Example 1 Default mode

$ASYNC_MODE='B0000'

Example 2 Default mode in the Submit interpreter and mode 2 for block selection
$ASYNC_MODE='B0010'

9.4 Permanently asynchronous external axes

9.4.1 $EX_AX_ASYNC

Description Asynchronous external axes

External axes can be switched permanently to asynchronous mode and re-
moved from the display using the variable in the directory KRC:\R1\MA-
DA\$MACHINE.DAT.
The axis position of external axes is contained in every taught point (E6POS).
Asynchronous external axes are not moved when a taught point is addressed,
e.g. PTP XP1.

58 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 9 System variables

If external axes are switched to asynchronous mode using this vari-

able, they cannot be switched back to synchronous mode by means
of KRL statements.

Syntax $EX_AX_ASYNC=n-bit value

Explanation of
Element Description
the syntax
n-bit value The value specifies which external axes are switched to
asynchronous mode:
 Bit n = 0: External axis can be moved as synchronous
or as asynchronous axis.
 Bit n = 1: External axis can only be moved as an asyn-
chronous axis.
Bit value:
 LSB: External axis E1
 MSB: External axis E6

Bit n 5 4 3 2 1 0
Axis E6 E5 E4 E3 E2 E1

Example 3-axis positioner

$EX_AX_ASYNC='B0001'
...
PTP XP1

External axis E1 can only be moved asynchronously with ASYPTP. External

axes E2 and E3 can be moved synchronously or asynchronously. If point P1
is addressed with a PTP motion, external axis E1 is not moved.

9.5 System variables for offsetting the zero position of a linear unit

9.5.1 $JOINT_OFFSET

Description Offset of the zero position of the linear unit in the advance run
In the event of a static offset: The variable indicates the value by which the
zero position of the linear unit is to be offset.
In the event of a dynamic offset: The variable indicates how the zero position
of the linear unit is to be offset relative to the defined tracking point. An EO driv-
er is used here.

Syntax Static: $JOINT_OFFSET[Axis number]=Offset

Dynamic: $JOINT_OFFSET[Axis number]=EO("Name",Offset)

Explanation of
Element Description
the syntax
Axis number Type: INT
 7 ... 12: External axis E1 ... E6
Offset Offset of the zero position of the linear unit in [mm]
Name Type: CHAR
Name of the EO driver used: Maximum 15 characters
Offset Additional offset relative to the changed zero position of the
linear unit in [mm]

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 59 / 123

 Configuration of Kinematic Systems

Example, static JOINT_OFFSET[7]=50

The zero position of axis E1 is offset 50 mm.

Example, JOINT_OFFSET[7]=EO("EO_DEVICE1",15)
dynamic
The zero position of axis E1 is offset with the EO driver EO_DEVICE1. The off-
set is relative to the defined tracking point and has an additional offset of
15 mm.

9.5.2 $JOINT_OFFSET_C

Description Offset of the zero position of the linear unit in the main run
In the event of a static offset: The variable indicates the value by which the
zero position of the linear unit is currently offset.
In the event of a dynamic offset: The variable indicates how the zero position
of the linear unit is currently offset relative to the defined tracking point. An EO
driver is used here.

The variable is write-protected and can only be read.

Syntax $JOINT_OFFSET[Axis number]=Offset

Explanation of
Element Description
the syntax
Axis number Type: INT
 7 ... 12: External axis E1 ... E6
Offset Offset of the zero position of the linear unit in [mm]

9.5.3 $EO_DEVICES

Description List of active EO drivers

The variable contains a list of the currently active EO drivers and the axes to
which they are assigned.

Syntax $EO_DEVICES[]="Information"

Explanation of
Element Description
the syntax
Information Names of the currently active EO drivers and the axes to
which they are assigned

60 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 10 Programming

10 Programming

10.1 Programming motions for external axes

Description It is possible to switch between synchronous and asynchronous motions of the

external axes within a program. Whether an external axis is programmed as
synchronous or asynchronous depends on the specific task.

Example Welding system with one robot and 2 two-axis positioners

Fig. 10-1: Example: welding system

A robot welds workpieces that are loaded manually into 2 different two-axis po-
sitioners. One two-axis positioner moves the workpiece to a convenient weld-
ing position during the welding operation. While the robot is welding, the other
two-axis positioner is moved to a convenient position so that the operator can
exchange the workpiece.
The motion of the two-axis positioner at which welding is being carried out
must be coupled to that of the robot, both synchronously and mathematically:
 The position of the two-axis positioner must be adapted to every welding
step.
 The relative positions of the workpiece and robot must be defined at all
times to exclude the possibility of collisions.
 The weld seam is to be programmed with weld velocity.
The two-axis positioner for the workpiece change must be moved asynchro-
nously, independently of the robot:
 The two-axis positioner must be moved manually by means of a separate
operating panel.
 The asynchronous motions must be enabled by the KRL program and are
not coordinated with it.
As long as the robot is working at the two-axis positioner, the positioner
cannot be moved manually. Only when the robot has finished working and
moved to the other two-axis positioner are the uncoordinated motions en-
abled by the KRL program.

10.2 Programming synchronous external axes

Description The axis position of external axes is contained in every taught point (E6POS).
If positions are taught relative to a static base, the robot and external axis mo-
tions are synchronized, but without being mathematically coupled. The robot
calculates its motion path independently of the position of the external axes.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 61 / 123

 Configuration of Kinematic Systems

If positions are taught relative to a moving base, the robot and external axis
motions are synchronized and mathematically coupled. The robot calculates
its motion path in relation to the position of the kinematic system.

10.2.1 Programming a mathematically coupled motion

Precondition  Program is selected.

 Operating mode T1 or T2
 Root point of the kinematic system has been calibrated.

Procedure 1. Program motion with inline form.

2. To activate mathematical coupling, select the workpiece base in the option
window Frames as the base to which the robot motion is relative.

The coordinates of a workpiece base are saved as

BASE_DATA[17...22].

10.3 Programming asynchronous external axes

Overview The following system variables and KRL instructions are available for pro-
gramming asynchronous external axes:

System variable Description

$ASYNC_AXIS (>>> 10.3.1 "$ASYNC_AXIS" Page 62)
$ASYNC_FLT (>>> 10.3.4 "$ASYNC_FLT" Page 65)
$ASYNC_STATE (>>> 10.3.8 "$ASYNC_STATE" Page 66)
$OV_ASYNC (>>> 10.3.3 "$OV_ASYNC" Page 64)

KRL instruction Description

ASYCANCEL (>>> 10.3.7 "ASYCANCEL" Page 66)
ASYCONT (>>> 10.3.6 "ASYCONT" Page 65)
ASYPTP (>>> 10.3.2 "ASYPTP" Page 63)
ASYSTOP (>>> 10.3.5 "ASYSTOP" Page 65)

10.3.1 $ASYNC_AXIS

Description Bit array for switching external axes to asynchronous mode

By means of a value assignment to $ASYNC_AXIS in the robot program, ex-
ternal axes can be switched to asynchronous mode and back to synchronous
mode. Mechanically coupled external axes must always be switched to asyn-
chronous mode together.
If the variable $ASYNC_AXIS is rewritten, the robot controller triggers an ad-
vance run stop. The new value is not saved until all synchronous and asyn-
chronous movements have been completed and all axes are in position.

Axes of a ROBROOT kinematic system and axes of a mathematically

coupled BASE kinematic system cannot be switched to asynchro-
nous mode.

Syntax $ASYNC_AXIS=Bit array

62 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 10 Programming

Explanation of
Element Description
the syntax
Bit array Bit array with which external axes can be switched to syn-
chronous or asynchronous mode.
 Bit n = 0: External axis is switched to synchronous
mode.
Precondition:
 External axis is not permanently switched to asyn-
chronous mode. ($EX_AX_ASYNC)
 Bit n = 1: External axis is switched to asynchronous
mode.
Precondition:
 Asynchronous external axes are enabled.
($ASYNC_OPT=TRUE)
 Mathematical coupling is canceled.
Note: Following a reset, asynchronous external axes are
automatically switched back to synchronous mode.

Bit n 5 4 3 2 1 0
Axis E6 E5 E4 E3 E2 E1

Example PTP P10 VEL = 100% PDAT50 Tool[1]:Pen Base[17]:DKP-400

PTP P11 VEL = 100% PDAT5 Tool[1]:Pen Base[0]
$ASYNC_AXIS = 'B0100'

The mathematical coupling is canceled by programming a motion block with a

static base. External axis E3 is switched to asynchronous mode.

10.3.2 ASYPTP

Description Asynchronous coordinated motions

The KRL instruction can be used to program coordinated motions of asynchro-
nous external axes. ASYPTP motions cannot be approximated.

ASYPTP can be used in the Submit interpreter or in an interrupt pro-

gram. The response of ASYPTP in the Submit interpreter is config-
ured with the variable $ASYNC_MODE.
(>>> 9.3.2 "$ASYNC_MODE" Page 57)

The instruction is executed in the advance run. There may be a maximum of

3 ASYPTP motions in the motion buffer. The first ASYPTP motion must be
completed when the fourth ASYPTP motion is planned. If necessary, succes-
sive ASYPTP motions must therefore be synchronized.
ASYPTP motions can be synchronized in the following ways:
 Assign a new value to the external axes with $ASYNC_AXIS.
(>>> 10.3.1 "$ASYNC_AXIS" Page 62)
 Poll the current motion state with $ASYNC_STATE.
(>>> 10.3.8 "$ASYNC_STATE" Page 66)

Syntax ASYPTP{Target position}

OR
ASYPTP XTarget variable

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 63 / 123

 Configuration of Kinematic Systems

Explanation of
Element Description
the syntax
Target posi- The asynchronous external axes specified in the target
tion position are moved by means of axis-specific jogging.
Target Type: E6POS, E6AXIS
variable
The target variable contains a pre-taught position. The
robot controller only access the position data of the asyn-
chronous external axes.

Example 1 ASYPTP {E1 10.0, E3 20.0}

External axis E1 is moved to position 10.0° and external axis E3 is moved to

position 20.0°.

Example 2 ASYPTP XP1

Asynchronous external axes are moved to the position saved in variable P1.

Example 3 DEF Program()

PTP HOME Vel= 100 % DEFAULT
…
PTP P10
TRIGGER WHEN DISTANCE = 1 DELAY= -50 DO Async() PRIO = -1
PTP P11
…
PTP HOME Vel= 100 % DEFAULT
END

DEF Async()
ASYPTP {E1 45.0}
END

50 s before point P11 is reached, external axis E1 is moved to position 45.0°.

10.3.3 $OV_ASYNC

Description Override for coordinated asynchronous motions

The velocity of asynchronous axes is not influenced by the program override
(POV). The override for coordinated asynchronous motions (= ASYPTP mo-
tion) must be set with $OV_ASYNC in the KRL program. The override is spec-
ified as a percentage of the programmed velocity.

In T1 mode, the maximum velocity is 250 mm/s, irrespective of the

value that is set.
Exception: The velocity reduction for ASYPTP motions in T1 is deac-
tivated (variable $ASYNC_T1_FAST in the file …R1\Mada\$machine.dat).

Syntax $OV_ASYNC=Override

Explanation of
Element Description
the syntax
Override Type: INT; unit: %
 0 … 100
Default: 100

Example $OV_ASYNC=20

ASYPTP motions are carried out with 20% of the programmed velocity.

64 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 10 Programming

10.3.4 $ASYNC_FLT

Description Filter for coordinated asynchronous motions

This filter can be used to smooth ASYPTP motions.

Syntax $ASYNC_FLT=Filter value

Explanation of
Element Description
the syntax
Filter value Type: INT; unit: ms
 0 ... 16 * interpolation cycle
The value must be an integer multiple of the interpolation
cycle (12 ms).
Default: $DEF_FLT_PTP (variable in the file
…R1\Mada\$machine.dat)

Example $ASYNC_FLT = 96

Filter value = 6 * interpolation cycle

10.3.5 ASYSTOP

Description The KRL instruction can be used to stop asynchronous coordinated motions.
The ASYCONT instruction can be used to resume the motions.

Syntax ASYSTOP= Axis number

Explanation of Element Description

the syntax
Axis number Data type: INT
 0: all asynchronous motions are stopped.
 1 … $EX_AX_NUM: the number of the asynchronous
external axis whose motion is to be stopped.

Example ASYPTP {E2 40, E3 40}

WAIT SEC 2
ASYSTOP 2

An ASYPTP motion of external axes E2 and E3 is started. The ASYSTOP in-

struction only adresses external axis E2. Since external axis E3 is involved in
the asynchronous motion, both external axes are stopped after a wait time of
2 s.

10.3.6 ASYCONT

Description The KRL instruction can be used to resume asynchronous coordinated mo-
tions that have been stopped with ASYSTOP.

Syntax ASYCONT= Axis number

Explanation of
Element Description
the syntax
Axis number Data type: INT
 0: all asynchronous motions are resumed.
 1 … $EX_AX_NUM: the number of the asynchronous
external axis whose motion is to be resumed.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 65 / 123

 Configuration of Kinematic Systems

Example ASYPTP {E2 40, E3 40}

WAIT SEC 2
ASYSTOP 2
WAIT SEC 2
ASYCONT 0

An ASYPTP motion of external axes E2 and E3 is started. The ASYSTOP in-

struction only adresses external axis E2. Since external axis E3 is involved in
the asynchronous motion, both external axes are stopped after a wait time of
2 s. The ASYPTP motion is resumed after a wait time of 2 s.

10.3.7 ASYCANCEL

Description The KRL instruction can be used to cancel and delete asynchronous coordi-
nated motions. Deleted motions cannot be resumed with ASYCONT.

Syntax ASYCANCEL Axis number

Explanation of Element Description

the syntax
Axis number Data type: INT
 0: all asynchronous motions are canceled and deleted.
The asynchronous motions of individual external axes
cannot be canceled and deleted.

Example ASYPTP {E2 40, E3 40}

WAIT SEC 2
ASYCANCEL 0

An ASYPTP motion of external axes E2 and E3 is started. The ASYPTP mo-

tion is canceled and deleted after a wait time of 2 s.

10.3.8 $ASYNC_STATE

Description State of asynchronous coordinated motions

The variable can be used to poll the state of ASYPTP motions in the robot pro-
gram. The variable is write-protected.

Syntax $ASYNC_STATE=State

Explanation of
Element Description
the syntax
State Type: ENUM
 #BUSY: Asynchronous motions are active.
 #CANCELLED: There are no active or stopped asyn-
chronous motions. The last asynchronous motion was
canceled with ASYCANCEL.
 #IDLE: There are no active or stopped asynchronous
motions. The last asynchronous motion was completed
and not canceled with ASYCANCEL.
 #PEND: Asynchronous motions were stopped with
ASYSTOP.

Example ASYPTP {E2 45}

WHILE $ASYNC_STATE == #BUSY
$OUT[10] = TRUE
ENDWHILE
$OUT[10] = FALSE

66 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 10 Programming

An ASYPTP motion of external axis E2 is started. An output is set during the

motion, e.g. to activate a warning lamp. The output is reset when the ASYPTP
motion is completed.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 67 / 123

 Configuration of Kinematic Systems

68 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 11 Examples

11 Examples
x

11.1 Transformation for DKP 400

s

In addition to the standard transformation, a simplified transformation

is described. The dimensions, transformation data and machine data
specified here are examples that are intended to illustrate the trans-
formation and must not be applied to a real DKP.

Standard trans- 1. The transformation starts at the root point of the kinematic system. The po-
formation sition of the root point is to be selected such that all required dimensions
can be read from the technical drawing.
The root point is situated on the floor. The alignment of the coordinate sys-
tem axes at the root point can be freely defined. (>>> Fig. 11-1 )
2. The joints and the rotational axes are defined.
3. Starting at the root point, transformations follow the structural design of the
kinematic system from one joint to the next, up to the flange, and from
there to the reference pin (= reference point for the root point calibration).
(>>> Fig. 11-2 )

Fig. 11-1: Top view of DKP 400

1 Root point 2 Axis of symmetry

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 69 / 123

 Configuration of Kinematic Systems

Fig. 11-2: Standard transformation for DKP 400

1 Joint E1 4 Flange center point

2 Joint E2 5 Reference pin
3 Rotational axis E2 6 Rotational axis E1
7 Root point

Standard trans- 1 $ET1_TA1KR={X 0.0,Y 280.0,Z 510.0,A 0.0,B 90.0,C 0.0}

formation data 2 $ET1_TA2A1={X 0.0,Y 0.0,Z 324.0,A 0.0,B -90.0,C 0.0}
3 $ET1_TA3A2={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
4 $ET1_TFLA3={X 0.0,Y 0.0,Z 347.0,A 0.0,B 0.0,C 0.0}
5 $ET1_TPINFL={X 210.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}

Line Description
1  Translation of 280 mm in the Y direction: from the root
point to the axis of symmetry
 Translation of 510 mm in the Z direction to joint E1
 Rotation of 90° about angle B so that the positive Z direc-
tion coincides with rotational axis E1.
2  Translation of 324 mm in the Z direction: from joint E1 to
joint E2
 Rotation of -90° about angle B so that the positive Z direc-
tion coincides with rotational axis E2.
3 Since the DKP 400 has no third axis, no transformation is car-
ried out here.

70 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 11 Examples

Line Description
4 Translation of 347 mm in the Z direction: from joint E2 to the
flange center point
5 Translation of 210 mm in the X direction: from the flange cen-
ter point to the reference pin

Simplified trans- The simplification is achieved by selecting a particularly suitable root point.
formation Visible symmetries can be used here. The root point can be situated in any po-
sition, e.g. in the first joint.
These measures make it possible to reduce the reading of dimensions from
the technical drawing. Fewer translations are required.

The rotations must always be carried out.

Fig. 11-3: Simplified transformation for DKP 400

1 Joint E1/E2 4 Reference pin

2 Rotational axis E2 5 Rotational axis E1
3 Flange center point 6 Root point

The root point is situated on the floor, on rotational axis E2. Joints E1 and E2
are located at the point of intersection of rotational axes E1 and E2.

Simplified trans- 1 $ET1_TA1KR={X 0.0,Y 0.0,Z 510.0,A 0.0,B 90.0,C 0.0}

formation data 2 $ET1_TA2A1={X -347.0,Y 0.0,Z 0.0,A 0.0,B -90.0,C 0.0}

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 71 / 123

 Configuration of Kinematic Systems

3 $ET1_TA3A2={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}

4 $ET1_TFLA3={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}
5 $ET1_TPINFL={X 210.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}

Line Description
1  Translation of 510 mm in the Z direction: from the root
point to joint E1/E2
 Rotation of 90° about angle B so that the positive Z direc-
tion coincides with rotational axis E1.
2  Translation of -347 mm in the X direction: from joint E1/E2
to the flange center point
 Rotation of -90° about angle B so that the positive Z direc-
tion coincides with rotational axis E2.
3…4 Since the DKP 400 has no third axis, no transformation is car-
ried out here.
5 Translation of 210 mm in the X direction: from the flange cen-
ter point to the reference pin

11.2 Transformation for KL 1500-3

The dimensions, transformation data and machine data specified

here are examples that are intended to illustrate the transformation
and must not be applied to a real linear unit.

Description The transformation starts at the root point of the linear unit. The position of the
root point must be selected such that the required dimension can be read from
the technical drawing, e.g. the height from the base of the linear unit to the
base plate on which the robot is mounted.

Fig. 11-4: Transformation for linear unit – top view

1 Connector panel 3 Carriage

2 Robot 4 Motion direction

The root point is situated on the base of the linear unit, directly beneath the
flange center point (not visible because of the top view). The height from the
floor of the linear unit to the baseplate (flange) is 450 mm.

Transformation $ET1_TA1KR={X 0.0,Y 0.0,Z 450.0,A 0.0,B 90.0,C 0.0}

data $ET1_TA2A1={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}

72 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 11 Examples

$ET1_TA3A2={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}

$ET1_TFLA3={X 0.0,Y 0.0,Z 0.0,A 0.0,B -90.0,C 0.0}

Line Description
1  Translation of 450 mm in the Z direction: from the root
point to the flange center point of the linear unit
 Rotation of 90° about angle B so that the positive Z axis
points in the direction of motion
2…3 Since the linear unit only has one axis, no transformation is
carried out here.
4 Rotation of -90° about angle B so that the X axis, starting at the
connector panel, points in the positive direction: orientation of
the robot at the flange of the linear unit.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 73 / 123

 Configuration of Kinematic Systems

74 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

12
2
Appendix
A

12.1 Machine data for configuring the transformation

x

Overview
Variable Description
$EX_KIN Identifier of external transformations
The variable is automatically determined by WorkVi-
sual on the basis of the sequence in the tree struc-
ture.
$ETx_AX External axes of the 1st external transformation
The variable is automatically determined by WorkVi-
sual on the basis of the axes in the catalog element
for the external axis.
$ETx_TA1KR Frame between axis 1 and root point
(>>> 12.1.1 "$ET1_TA1KR" Page 75)
$ETx_TA2A1 Frame between axis 2 and axis 1
(>>> 12.1.2 "$ET1_TA2A1" Page 75)
$ETx_TA3A2 Frame between axis 3 and axis 2
(>>> 12.1.3 "$ET1_TA3A2" Page 76)
$ETx_TFLA3 Frame between flange and axis 3
(>>> 12.1.4 "$ET1_TFLA3" Page 76)
$ETx_TPINFL Frame between measurement point and flange
(>>> 12.1.5 "$ET1_TPINFL" Page 76)

12.1.1 $ET1_TA1KR

Description Position of the first transformed axis of the external transformation ET1
The variable of structure type FRAME defines the position of the first trans-
formed axis relative to the coordinate system in the root point of the external
transformation ET1.
 X, Y, Z: Offset of the origin along the axes in [mm]
 A, B, C: Rotational offset of the axis angles in [°]

The variables $ET2_TA1KR to $ET6_TA1KR are available for the ex-

ternal transformations ET2 to ET6.

Example $ET1_TA1KR={X 0.0,Y 280.0,Z 510.0,A 0.0,B 90.0,C 0.0}

The origin of the coordinate system is offset, relative to the root point of the
external transformation, 280 mm along the Y axis and 510 mm along the Z
axis into the joint of the first external axis. Axis angle B is rotated by 90° so that
the positive Z direction coincides with the rotational axis of the first external ax-
is.

12.1.2 $ET1_TA2A1

Description Position of the second transformed axis of the external transformation ET1
The variable of structure type FRAME defines the position of the second trans-
formed axis relative to the position of the first transformed axis of the external
transformation ET1.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 75 / 123

 Configuration of Kinematic Systems

 X, Y, Z: Offset of the origin along the axes in [mm]

 A, B, C: Rotational offset of the axis angles in [°]

The variables $ET2_TA2A1 to $ET6_TA2A1 are available for the ex-

ternal transformations ET2 to ET6.

Example $ET1_TA2A1={X 0.0,Y 0.0,Z 324.0,A 0.0,B -90.0,C 0.0}

The origin of the coordinate system is offset, relative to the first transformed
axis of the external transformation, 324 mm along the Z axis into the joint of
the second external axis. Axis angle B is rotated by 90° so that the positive Z
direction coincides with the rotational axis of the second external axis.

12.1.3 $ET1_TA3A2

Description Position of the third transformed axis of the external transformation ET1
The variable of structure type FRAME defines the position of the third trans-
formed axis relative to the position of the second transformed axis of the ex-
ternal transformation ET1.
 X, Y, Z: Offset of the origin along the axes in [mm]
 A, B, C: Rotational offset of the axis angles in [°]

The variables $ET2_TA3A2 to $ET6_TA3A2 are available for the ex-

ternal transformations ET2 to ET6.

Example $ET1_TA3A2={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}

The external transformation does not use a third external axis.

12.1.4 $ET1_TFLA3

Description Position of the FLANGE coordinate system of the external transformation ET1
The variable of structure type FRAME defines the position of the FLANGE co-
ordinate system relative to the position of the third transformed axis of the ex-
ternal transformation ET1.
 X, Y, Z: Offset of the origin along the axes in [mm]
 A, B, C: Rotational offset of the axis angles in [°]
In the case of ROBROOT kinematic systems, the robot stands on the flange
of the kinematic system. In this case, the variable defines the offset and orien-
tation of the robot in the FLANGE coordinate system of the kinematic system.

The variables $ET2_TFLA3 to $ET6_TFLA3 are available for the ex-

ternal transformations ET2 to ET6.

Example ROBROOT kinematic system

$ET1_TFLA3={X 0.0,Y 0.0,Z 0.0,A 0.0,B -90.0,C 0.0}

Axis angle B of the FLANGE coordinate system of the external transformation

is rotated by -90°. In this orientation, the robot stands on the flange.

12.1.5 $ET1_TPINFL

Description Position of the reference pin of the 1st external transformation

76 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

This variable of structure type FRAME describes the position of the reference
pin on the external transformation ET1 in relation to the FLANGE coordinate
system of this external transformation.
 X, Y, Z: Offset of the origin along the axes in [mm]
 A, B, C: Rotational offset of the axis angles in [°]

The variables $ET2_TPINFL to $ET6_TPINFL are available for the

external transformations ET2 to ET6.

Example $ET1_TPINFL={X 210.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}

The origin of the coordinate system is offset, relative to the flange center point
of the external transformation, 210 mm along the X axis into the reference pin.

12.2 Machine data for configuring axes

12.2.1 $AXIS_TYPE[]

Description Axis type

The axis type must be specified for all axes of the industrial robot.

Syntax $AXIS_TYPE[Axis number]=Type

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 ... E6
Type Type: INT
 1: Linear axis
The axis moves translationally, e.g. external axis E1 of
the linear unit. The axis value is converted into [mm] and
checked for software limit switches.
 3: Rotational axis
The maximum turning range is -358° to +358°. The axis
value is converted into [°] and checked for software limit
switches.
 5: Rotational axis, infinitely rotating
The axis rotates in modulo 360°, e.g. wrist axes A4 and
A6. The axis value is converted to [°].
Example: PTP {A6 370}: Axis A6 rotates from 0° to 10°.
The axis always travels the shortest distance.
Note: The axis can rotate a maximum of 180° in a single
block.

Example $AXIS_TYPE[1]=3
$AXIS_TYPE[2]=3
$AXIS_TYPE[3]=3
$AXIS_TYPE[4]=3
$AXIS_TYPE[5]=3
$AXIS_TYPE[6]=3
$AXIS_TYPE[7]=1

Axes A1 … A6 are rotational axes, external axis E1 is a linear axis.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 77 / 123

 Configuration of Kinematic Systems

12.2.2 $RED_VEL_AXC[]

Description Reduction factor for axial velocity (HOV)

The reduction factor for axial velocity during axis-specific jogging relates to the
motor speed $VEL_AXIS_MA[].

The velocity must be reduced to 250 mm/s. Otherwise

the industrial robot may be damaged.

Syntax $RED_VEL_AXC[Axis number]=Reduction factor

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Reduction Type: INT; unit: %
factor
 1 … 100

12.2.3 $VEL_AX_JUS[]

Description Velocity with which an axis is moved during EMT mastering.

The velocity of the axis must be selected so that the EMT will reliably detect
the mastering mark. For this, the vertical velocity of the EMT must be at least
±250 µm/s.

Syntax $VEL_AX_JUS[Axis number]=Velocity

Explanation of Element Description

the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Velocity Type: REAL
Unit:
 Rotational axes: °/s
 Linear axes: mm/s
Default:
 Rotational axes: 0.1
 Linear axes: 1.0

12.2.4 $L_EMT_MAX[]

Description Maximum mastering distance for EMT mastering

If the maximum mastering distance is exceeded, the robot controller aborts the
mastering and the acknowledgement message EMD mastering distance ex-
ceeded is displayed.

Syntax $L_EMT_MAX[Axis number]=Mastering distance

78 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 ... E6
Mastering Type: REAL
distance
Unit:
 Rotational axes: °
 Linear axes: mm
Default:
 Rotational axes: 2.5
 Linear axes: 10.0

12.2.5 $APO_DIS_PTP[]

Description Maximum approximation distance for PTP motions with an approximation dis-
tance of 100%

Syntax $APO_DIS_PTP[Axis number]=Approximation distance

Explanation of Element Description

the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Approxima- Type: REAL
tion distance
Unit:
 Rotational axes: °
 Linear axes: mm
Default:
 Rotational axes: 90.0
 Linear axes: 500.0
Note: A value >0.0 must be set here for all robot axes. Oth-
erwise PTP and CP movements are not approximated.

Example $APO_DIS_PTP[1]=90.0

100% approximation distance for a PTP motion gives a maximum approxima-

tion distance of 90°.

12.2.6 $IN_POS_MA[]

Description Positioning window

This variable is used to define an axis-specific tolerance window (sphere).
This window is relevant in the following cases:
 Restart of an interrupted program in T1, T2 and Automatic modes
If an axis is positioned outside the positioning window, a BCO run is per-
formed.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 79 / 123

 Configuration of Kinematic Systems

 Restart from exact positioning points

At exact positioning points, the interpolator waits until all axes have
achieved the positioning window.

Syntax $IN_POS_MA[Axis number]=Positioning window

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Positioning Type: REAL
window
Unit:
 Rotational axes: °
 Linear axes: mm
Default:
 Rotational axes: 0.1
For small motors: 0.2
 Linear axes: 1.5

12.2.7 $RED_ACC_OV[]

Description Reduction factor for acceleration ramp

The axial acceleration can be reduced to the percentage set here in the follow-
ing cases:
 In the case of a change to the program override (POV)
 In the case of ramp-down braking (STOP 2)

Syntax $RED_ACC_OV[Index]=Reduction factor

Explanation of Element Description

the syntax
Index Type: INT
Index for use of the ramp:
 1 … 12
In case of kinematic systems with a higher motion profile:
 1: The value set here is used in single blocks.
 2: The value set here is used in approximated move-
ment blocks.
 3 … 12: The values set here are disregarded.
In case of kinematic systems without a higher motion pro-
file:
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 ... E6
Reduction Type: INT; unit: %
factor
 1 … 100
Default: 100

Example For cycle time optimization in press linking, the program override is set to 50%
as long as the press is not open. When the press is opened, the program over-

80 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

ride is set to 100% again. In this case a shallow acceleration ramp may be nec-
essary.

12.2.8 $VEL_AXIS_MA[]

Description Motor speed at maximum command value

This variable defines the motor speed at a program override (POV) of 100%.
The motor speed must be less than the maximum frequency (266 Hz) of the
drive bus. This is dependent on the number of pole pairs of the motor:
$VEL_AXIS_MA[x] = (266 * 60) / Number of pole pairs

Syntax $VEL_AXIS_MA[Axis number]=Motor speed

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Motor speed Type: REAL; unit: RPM
Maximum value: Rated speed of the motor

Example $VEL_AXIS_MA[7]=1500.0

At a program override of 100% the motor speed of external axis E1 is 1500

rpm.

12.2.9 $RED_ACC_AXC[]

Description Reduction factor for axial acceleration (HOV)

The reduction factor for axial acceleration during axis-specific jogging relates
to the maximum axial acceleration.
Maximum axial acceleration = $VEL_AXIS_MA[x] / axis ramp-up time

If the reduction factor specified is too high, the axis will

vibrate when the Start key is pressed (jerking when start-
ing and stopping). If the reduction factor specified is too low, the axis will not
stop immediately when the STOP key is pressed.

Syntax $RED_ACC_AXC[Axis number]=Reduction factor

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Reduction Type: INT; unit: %
factor
 1 … 100

12.2.10 $INC_AXIS[]

Description Axis-specific increment for robot axes

Incremental jogging can be activated for jogging with the jog keys. The set
axis-specific increment is written to the variable.

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 81 / 123

 Configuration of Kinematic Systems

The increment is the distance that the robot moves when the jog key is
pressed. The robot then stops by itself.

Syntax $INC_AXIS[Axis number]=Increment

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
Increment Type: REAL
Unit:
 Rotational axes: °
 Linear axes: mm

12.2.11 $INC_EXTAX[]

Description Axis-specific increment for external axes

Incremental jogging can be activated for jogging with the jog keys. The set
axis-specific increment is written to the variable.
The increment is the distance that the robot moves when the jog key is
pressed. The robot then stops by itself.

Syntax $INC_EXTAX[Axis number]=Increment

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: External axis E1 … E6
Increment Type: REAL
Unit:
 Rotational axes: °
 Linear axes: mm

12.2.12 $ST_TOL_VEL[]

Description Velocity window for standstill detection

If the axes move within the velocity window specified here, the robot controller
detects a standstill.

Syntax $ST_TOL_VEL[Axis number]=Velocity

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Velocity Type: REAL; unit: rpmmot
Default: 15.0
Note: This value must not be changed.

82 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

12.2.13 $TIME_POS[]

Description Positioning time

If the following error measured within the positioning time lies outside the po-
sitioning window $IN_POS_MA, the error message Positioning monitoring
{(Axis number)} is displayed, and maximum braking is triggered.

Syntax $TIME_POS[Axis number]=Positioning time

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Positioning Type: INT; unit: ms
time
Default: 512
Note: This value must not be changed.

12.2.14 $AXIS_JERK[]

Description Maximum axis jerk

This variable defines the maximum axis jerk for SPLINE movements, i.e. the
maximum permissible temporal change of the axis acceleration. Precondition:
Acceleration adaptation is deactivated ($ADAP_ACC=#NONE) in the file
KRC:\R1\MADA\$ROBCOR.DAT.
If the current jerk in one of the axes exceeds the maximum permissible value,
the robot is brought to a halt with a path-maintaining EMERGENCY STOP
braking operation (STOP 1) and the acknowledgement message Jerk moni-
toring {Axis} is displayed.

Syntax $AXIS_JERK[Axis number]=Maximum jerk

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Maximum jerk Type: REAL
Unit:

 Rotational axes: °/s3

 Linear axes: m/s3

12.2.15 $VEL_CPT1_MA[]

Description Reduction factor for CP motions in test mode T1

Syntax $VEL_CPT1_MA[Axis number]=Reduction factor

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 83 / 123

 Configuration of Kinematic Systems

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Reduction Type: INT; unit: %
factor
Default: 29

12.2.16 $JERK_MA

Description Maximum jerk for SPLINE

The variable of structure type JERK_STRUC limits the change of the acceler-
ation over time during SPLINE movements.
The aggregate consists of the following components:

 CP: Change to the path acceleration in [m/s3]

 ORI: Change to the orientation acceleration in [°/s3]
 AX: Change to the axis acceleration in [°/s3] for rotational axes or in [m/s3]
for linear axes

Example $JERK_MA={CP 50.0,ORI 50000.0,AX {A1 1000.0,A2 1000.0,A3 1000.0,A4

1000.0,A5 1000.0,A6 1000.0,E1 1000.0,E2 1000.0,E3 1000.0,E4 1000.0,E5
1000.0,E6 1000.0}}

12.2.17 $EX_AX_ASYNC

Description Asynchronous external axes

This variable allows external axes to be switched permanently to asynchro-
nous mode.
Asynchronous external axes move independently of the robot axes, i.e. they
can be moved independently of the robot axes. Synchronous external axes
move in common with the robot axes, i.e. they start and end their movements
simultaneously.

If external axes are switched to asynchronous mode using this vari-

able, they cannot be switched back to synchronous mode by means
of KRL statements.

Syntax $EX_AX_ASYNC=Bit array

Explanation of
Element Description
the syntax
Bit array Bit array with which external axes can be switched to asyn-
chronous mode.
 Bit n = 0: External axis can be moved as synchronous
or as asynchronous axis.
 Bit n = 1: External axis can only be moved as an asyn-
chronous axis.

Bit n 5 4 3 2 1 0
Axis E6 E5 E4 E3 E2 E1

Example $EX_AX_ASYNC='B0100'

84 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

External axis E3 can only be moved as an asynchronous axis. External axes

E1 … E4 can be moved synchronously or asynchronously.

12.2.18 $SOFTN_END[]

Description Negative software limit switches

After the robot has been mastered, the motion range of the axes can be limited
in the negative direction by software limit switches.

Syntax $SOFTN_END[Axis number]=Negative limit switch

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Negative limit Type: REAL
switch
Unit:
 Rotational axes: °
 Linear axes: mm
 -358 … +358 (rotational axes)

12.2.19 $SOFTP_END[]

Description Positive software limit switches

After the robot has been mastered, the movement range of the axes can be
limited in the positive direction by software limit switches.

Syntax $SOFTN_END[Axis number]=Positive limit switch

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Positive limit Type: REAL
switch
Unit:
 Rotational axes: °
 Linear axes: mm
 -358 … +358 (rotational axes)

12.2.20 $RAT_MOT_AX[]

Description Motor/axis gear ratio

The ratio of the motor to the axis must be specified for each axis, so that the
axis value or position value can be calculated.
The transmission ratio is declared as structure type FRA {N, D} and is speci-
fied as a fraction:
 N = numerator
 D = denominator

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 85 / 123

 Configuration of Kinematic Systems

The gear ratio must be at least {N 15,D 1}. If the transmission ratio is
less than this, the motor can no longer be controlled. In the case of
unused axes: {N 0,D 1}

Syntax $RAT_MOT_AX[Axis number]={N numerator,D denominator}

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Numerator Type: INT
Number of motor revolutions
Note: A negative sign changes the direction of rotation of
the axis. When the value is positive, the axis must rotate
clockwise or move to the right when the PLUS key is
pressed. If the axis rotates or moves in a negative direc-
tion, the sign must be changed.
Denominator Type: INT
 For rotational axes: Number of axis revolutions
 For linear axes: Travel; unit: m
For linear axes the fraction specifies the number of mo-
tor revolutions per 1 000 mm travel.

Example 1 Rotational axis

$RAT_MOT_AX[1]={N 100,D 1}

The axis rotates 360° for every 100 motor revolutions.

Example 2 Linear axis

$RAT_MOT_AX[7]={N 345,D 10}

The motor performs 34.5 revolutions per 1000 mm distance traveled.

12.2.21 $ASYNC_EX_AX_DECOUPLE – KUKA System Software 8.5

Description Bit array for decoupling external axes

By means of a value assignment to $ASYNC_EX_AX_DECOUPLE in the ro-
bot program, external axes can be functionally decoupled and recoupled.
Properties of decoupled external axes:
 Decoupled external axes can no longer be moved by the robot controller.
All monitoring functions are deactivated.
 If an external axis is decoupled, this axis is automatically switched to asyn-
chronous mode. When it is recoupled, the external axis is automatically
switched back to synchronous mode if it was in synchronous mode when
decoupled. The value of $ASYNC_AXIS changes accordingly.
 The mastering of decoupled external axes is deleted.
 It is possible to automatically master a decoupled external axis during re-
coupling by writing the desired actual position to $AXIS_ACT prior to cou-
pling.
This typically involves saving the actual position of the axis using
$AXIS_ACT_MEAS during decoupling and assigning the saved value to
$AXIS_ACT before coupling. In this case, when recoupling an axis, it is

86 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

checked whether this axis has moved in the decoupled state. Slight devi-
ations of the resolver position are automatically compensated when mas-
tering is restored.

If the variable $ASYNC_EX_AX_DECOUPLE is rewritten, the robot

controller triggers an advance run stop. The new value is not saved
until all synchronous and asynchronous movements have been com-
pleted and all axes are in position.

Precondition Decoupling an external axis:

 The external axis is neither mathematically nor mechanically coupled to
other axes.
 The external axis is not part of an external kinematic system.
 The external axis supports individual braking control, i.e. the brake chan-
nel of the external axis does not control any brake of any other axis.

Syntax $ASYNC_EX_AX_DECOUPLE=Bit array

Explanation of
Element Description
the syntax
Bit array Bit array with which external axes can be decoupled and
recoupled.
 Bit n = 0: external axis is coupled.
 Bit n = 1: external axis is decoupled.

Bit n 5 4 3 2 1 0
Axis E6 E5 E4 E3 E2 E1

Example $ASYNC_EX_AX_DECOUPLE='B0100'

External axis E3 is decoupled.

12.2.22 $COUP_COMP[]

Description Axis coupling factor for the robot axes

This variable allows the mechanical coupling between the robot axes to be
compensated.
The axis coupling factor is declared as structure type FRA {N, D} and is stated
as a fraction:
 N = numerator
 D = denominator

The axis coupling factor must be defined for each axis combination.
If the axes are not coupled, then: {N 0, D 1}

Syntax $COUP_COMP[Axis number 1, axis number 2]={N numerator, D denominator}

Explanation of
Element Description
the syntax
Axis number Type: INT
1
 1 … 6: Robot axis A1 ... A6
Axis number Type: INT
2
 1 … 6: Robot axis A1 ... A6

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 87 / 123

 Configuration of Kinematic Systems

Element Description
Numerator Type: INT; unit: °
Angular change of axis 2 due to angular change of axis 1
Denominator Type: INT; unit: °
Angular change of axis 1

Example Robot with 6 axes

DECL FRA $COUP_COMP[6,6]
$COUP_COMP[1,2]={N 0, D 1}
...
$COUP_COMP[4,5]={N 20, D 100}
...
$COUP_COMP[6,5]={N 0, D 1}

Axes A1 and A2 are not coupled, neither are axes A5 and A6.
Axes A4 and A5 are coupled. If axis A4 rotates 100°, this causes axis A5 to
rotate 20°.

12.2.23 $IN_STILL_MA

Description Factor for the standstill window

This variable is used to define the size of the standstill window in relation to
the positioning window $IN_POS_MA:
$IN_STILL_MA * $IN_POS_MA
If all axes are in position and no new position is addressed, the position of the
axes is checked on a cyclical basis. The position of the axis must not move
outside the standstill window.

Syntax $IN_STILL_MA=Factor

Explanation of
Element Description
the syntax
Factor Type: INT
Default: 4

12.2.24 $INC_CAR[]

Description Cartesian increment

Incremental jogging can be activated for jogging with the jog keys. The set
Cartesian increment is written to the variable.
The increment is the distance that the robot moves when the jog key is
pressed. The robot then stops by itself.

Syntax $INC_CAR[Motion direction]=Increment

88 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

Explanation of
Element Description
the syntax
Motion direc- Type: INT
tion
 1, 2, 3: Cartesian motion in directions X, Y, Z
 4, 5, 6: Cartesian motion about angles A, B, C
Increment Type: REAL
Unit:
 Cartesian movement in directions X, Y, Z: mm
 Cartesian motion about angles A, B, C: °

12.2.25 $SEP_ASYNC_OV

Description Enabling of separate jog override settings for asynchronous external axes

Syntax $SEP_ASYNC_OV=State

Explanation of
Element Description
the syntax
State Type: BOOL
 TRUE: Asynchronous external axes can be jogged with
separate jog override settings.
 FALSE: Asynchronous external axes cannot be jogged
with separate jog override settings.
Default: FALSE

12.3 Machine data for configuring motors

12.3.1 $IN_POS_MA[]

Description Positioning window

This variable is used to define an axis-specific tolerance window (sphere).
This window is relevant in the following cases:
 Restart of an interrupted program in T1, T2 and Automatic modes
If an axis is positioned outside the positioning window, a BCO run is per-
formed.
 Restart from exact positioning points
At exact positioning points, the interpolator waits until all axes have
achieved the positioning window.

Syntax $IN_POS_MA[Axis number]=Positioning window

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 89 / 123

 Configuration of Kinematic Systems

Explanation of
Element Description
the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Positioning Type: REAL
window
Unit:
 Rotational axes: °
 Linear axes: mm
Default:
 Rotational axes: 0.1
For small motors: 0.2
 Linear axes: 1.5

12.3.2 $VEL_AXIS_MA[]

Description Motor speed at maximum command value

This variable defines the motor speed at a program override (POV) of 100%.
The motor speed must be less than the maximum frequency (266 Hz) of the
drive bus. This is dependent on the number of pole pairs of the motor:
$VEL_AXIS_MA[x] = (266 * 60) / Number of pole pairs

Syntax $VEL_AXIS_MA[Axis number]=Motor speed

Explanation of Element Description

the syntax
Axis number Type: INT
 1 … 6: Robot axis A1 ... A6
 7 … 12: External axis E1 … E6
Motor speed Type: REAL; unit: RPM
Maximum value: Rated speed of the motor

Example $VEL_AXIS_MA[7]=1500.0

At a program override of 100% the motor speed of external axis E1 is 1500

rpm.

12.4 Machine data for configuring a CK

12.4.1 $MAIN_AXIS

Description Main axis type

This variable is used to define the arrangement of main axes A1 … A3.
The axes are implemented as rotational or linear axes. 2 consecutive main
axes are arranged either parallel or perpendicular to each other.

Syntax $MAIN_AXIS=Main axis type

90 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

Explanation of
Element Description
the syntax
Main axis type Type: ENUM
 #SS: Gantry (>>> Fig. 12-1 )
 #CC: Scara (>>> Fig. 12-2 )
 #NR: KUKA 6-axis robot (>>> Fig. 12-3 )
 #SC (>>> Fig. 12-4 )
 #RR (>>> Fig. 12-5 )
 #CS (>>> Fig. 12-6 )
 #RN (>>> Fig. 12-7 )
 #NN (>>> Fig. 12-8 )

#SS

Fig. 12-1: Main axis type #SS - Gantry

#CC

Fig. 12-2: Main axis type #CC - Scara

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 91 / 123

 Configuration of Kinematic Systems

#NR

Fig. 12-3: Main axis type #NR - KUKA 6-axis robot

#SC

Fig. 12-4: Main axis type #SC

92 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

#RR

Fig. 12-5: Main axis type #RR

#CS

Fig. 12-6: Main axis type #CS

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 93 / 123

 Configuration of Kinematic Systems

#RN

Fig. 12-7: Main axis type #RN

#NN

Fig. 12-8: Main axis type #NN

12.4.2 $WRIST_AXIS

Description Wrist axis type

This variable allows the kinematic structure of the robot wrist to be configured.
The geometric arrangement of wrist axes A4 … A6 is defined with the Denavit-
Hartenberg transformation by the variables $DH_4 and $DH_5.

Syntax $WRIST_AXIS=Wrist axis type

94 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

Explanation of
Element Description
the syntax
Wrist axis type Type: ENUM

Wrist axis type Description

#ZEH In-line wrist
The 3 wrist axes intersect and are perpendicular to
each other.
Denavit-Hartenberg parameters:
a4 = d4 = a5 = d5 = 0, α4 = ±90°, α5 = ±90°
#SRH Oblique wrist
The 3 wrist axes intersect at a point.
Denavit-Hartenberg parameters:
a4 = d4 = a5 = d5 = 0, 10° ≤ |α4| ≤ 170°,10° ≤ |α5| ≤
170°
#DSH Triple-roll wrist
Denavit-Hartenberg parameters:
a4= d4 = a5 = d5 = 0, |α4| > 45°
#WIH Offset wrist
The 3 wrist axes are perpendicular to each other.
Denavit-Hartenberg parameters:
d4 = 0, α4 = ±90°, α5 = ±90°
The lengths a4, a5 and d5 can be freely chosen.
#WSH Oblique offset wrist
Denavit-Hartenberg parameter:
d4=0
The angles α4 and α5 and the lengths a4, a5 and d5
can be freely chosen.
#NOH No wrist transformation

12.4.3 $TIRORO

Description Position of the internal robot coordinate system

This variable of structure type FRAME describes the position of the IRO coor-
dinate system in relation to the ROBROOT coordinate system:
 X, Y, Z: Offset of the origin along the axes in [mm]
 A, B, C: Rotational offset of the axis angles in [°]

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 95 / 123

 Configuration of Kinematic Systems

Fig. 12-9: Internal transformation – coordinate systems

The root point transformation into the IRO coordinate system is the start of the
transformation of the kinematic system within the robot.
The origin of the IRO coordinate system lies at the level of rotational axis A2.

Example KR 150-2
$TIRORO={X 0.0,Y 0.0,Z 750.0,A 0.0,B 0.0,C 0.0}

The origin of the IRO coordinate system is offset 750 mm in the direction of the
Z axis in relation to the ROBROOT coordinate system.

12.4.4 $LENGTH_A

Description Main axis length A

The main axis length A depends on the main axis type $MAIN_AXIS.
For a KUKA 6-axis robot (#NR) the variable defines the eccentricity of axis A2
in relation to axis A1.
(>>> Fig. 12-9 )

Syntax $LENGTH_A=Length

Explanation of
Element Description
the syntax
Length Type: REAL; unit: mm

Example KR 150-2
$LENGTH_A=350.0

96 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

12.4.5 $LENGTH_B

Description The main axis length B depends on the main axis type $MAIN_AXIS.
For a KUKA 6-axis robot (#NR) the variable defines the length of the link arm.
(>>> Fig. 12-9 )

Syntax $LENGTH_B=Length

Explanation of
Element Description
the syntax
Length Type: REAL; unit: mm

Example KR 150-2
$LENGTH_B=1250.0

12.4.6 $A4PAR

Description Parallelism of wrist axis A4 to the last rotational main axis

Syntax $A4PAR=State

Explanation of Element Description

the syntax
State Type: INT
 0: Axis A4 is not parallel to the last rotational main axis.
 1: Axis A4 is parallel to the last rotational main axis.
 2: Not implemented

12.4.7 $TRAFONAME[]

Description Name of coordinate transformation

This variable can be used to assign the coordinate transformation a symbolic
name. This name is compared with the $ROBTRAFO[] robot name pro-
grammed on the RDC.

Syntax $TRAFONAME[]="Name"

Explanation of
Element Description
the syntax
Name Type: CHAR
Name of the coordinate transformation: max. 32 characters

Example $TRAFO_NAME[]="#KR16 C2 FLR ZH16"

12.4.8 $ROBROOT

Description Position of the robot

This variable of structure type FRAME describes the position of the ROB-
ROOT coordinate system in relation to the WORLD coordinate system:
 X, Y, Z: Offset of the origin along the axes in [mm]
 A, B, C: Rotational offset of the axis angles in [°]

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 97 / 123

 Configuration of Kinematic Systems

Fig. 12-10: Overview of coordinate systems

The ROBROOT coordinate system origin is always in the base of the robot. By
default, the ROBROOT coordinate system is identical to the WORLD coordi-
nate system.

Further information about the coordinate systems can be found in the

operating and programming instructions.

Example 1 Floor-mounted robots: By default there is no offset

$ROBROOT={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 0.0}

Example 2 Ceiling-mounted robots: Rotational offset of axis angle C = 180°

$ROBROOT={X 0.0,Y 0.0,Z 0.0,A 0.0,B 0.0,C 180.0}

Example 3 Wall-mounted
robots: Rotational offset of axis angle B = 90°
$ROBROOT={X 0.0,Y 0.0,Z 0.0,A 0.0,B 90.0,C 0.0}

Example 4 The robot is located at a certain position in the cell ($ROBROOT<> $WORLD).
The coordinates of the robot position in relation to $WORLD are entered into
$ROBROOT.

12.4.9 $ACTIVE_KAR_MASK

Description Active jog keys, Cartesian

This variable can be used to display and hide the jog keys for Cartesian jog-
ging.

Syntax $ACTIVE_KAR_MASK=Bit array

98 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2

 12 Appendix

Explanation of
Element Description
the syntax
Bit array The bit array specifies whether a jog key is displayed or
hidden.
 Bit n = 0: Jog key is hidden.
 Bit n = 1: Jog key is displayed (default).

Bit n 5 4 3 2 1 0
Jog key C B A Z Y X

Example KR 50 PA
On a 2-axis palletizing robot, only axes A2 and A3 are physically present. Axes
A1, A4, A5 and A6 are simulated.
$ACTIVE_CAR_MASK='B000110'

Cartesian movements can be executed only in the X and Y directions. The jog
keys for Cartesian movement in Z, A, B and C direction are hidden.

12.4.10 $RED_VEL_CPC

Description Reduction factor for path and orientation velocity during Cartesian jogging
(HOV)

Syntax $RED_VEL_CPC=Reduction factor

Explanation of
Element Description
the syntax
Reduction Type: REAL; unit: %
factor
Default: 2.0

12.4.11 $TECH_MAX

Description Maximum number of function generators

Syntax $TECH_MAX=Number

Explanation of
Element Description
the syntax
Number Type: INT
Default: 6

12.4.12 $VEL_CP_T1

Description Path velocity in test mode T1

Syntax $VEL_CP_T1=Path velocity

Explanation of Element Description

the syntax
Velocity Type: REAL; unit: m/s
 0.0 … 0.25
Default: 0.1

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 99 / 123

 Configuration of Kinematic Systems

12.4.13 $RED_ACC_DYN

Description Reduction factor for acceleration

This variable allows all accelerations to be reduced to the percentage set here.

Syntax $RED_ACC_DYN=Reduction factor

Explanation of
Element Description
the syntax
Reduction Type: INT; unit: %
factor
 1 … 100
Default: 100

12.4.14 $INDIVIDUAL_MAMES

Description Offset from the mastering position

This variable is used to define whether the offset data for mastering are saved.
This depends on the robot model.
 In the conventional robot calibration procedure, the mastering marks are
set exactly to the mastering position saved in $MAMES[x], e.g. 0.0, -90.0,
90.0, 0.0, 0.0, 0.0.
 For manufacturing reasons, a new procedure has been introduced. The
mastering equipment has been fixed, and during robot calibration the off-
set from the mastering position saved in $MAMES[x] is calculated.
The offset data are saved on the RDC with the file name Robot serial
number.MAM.

Syntax $INDIVIDUAL_MAMES=Offset

Explanation of
Element Description
the syntax
Offset Type: ENUM
 #NONE: No offset is saved.
 #RDC: An offset is saved.
During mastering, the robot controller accesses the off-
set data on the hard drive and calculates the exact mas-
tering position.
Note: The offset is not taken into consideration during
reference mastering.
Note: If #RDC is used, the mastering position of the ma-
nipulator must be stored in $MAMES[x].

12.4.15 $KINCLASS

Description Kinematic class

This variable is used to define whether a transformation is configured in the
machine data for the kinematic system.

Syntax $KINCLASS=Class

100 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2
 12 Appendix

Explanation of
Element Description
the syntax
Class Type: ENUM
 #STANDARD: A transformation is configured for
the kinematic system.
 #NONE: No transformation is configured for the
kinematic system, i.e. the kinematic system can
be moved only on an axis-specific basis.
If no transformation is configured, programming
can be performed only on an axis-specific basis:
 With KUKA.ExpertTech
 In the user group “Expert” using KRL syntax

12.4.16 $RED_ACC_CPC

Description Reduction factor for path and orientation acceleration during Cartesian jogging
(HOV)

Syntax $RED_ACC_CPC=Reduction factor

Explanation of
Element Description
the syntax
Reduction Type: REAL; unit: %
factor
Default: 7.0

12.4.17 $WARMUP_TIME

Description Warm-up time for the drives

This variable defines the time that a robot requires for warming up the cold
drives.
When drives are cold, the friction is greater, so the motor torque is insufficient
to allow movement at high accelerations and speeds. During the warm-up
time, the robot controller does not switch the drives off if they reach the maxi-
mum motor current of $WARMUP_CURR_LIMIT. Instead, an internal override
is reduced by the factor $WARMUP_MIN_FAC and the motor current is de-
creased by this means.
This override is then raised back to 100% step by step using the
$WARMUP_SLEW_RATE.

Syntax $WARMUP_TIME=Warm-up time

Explanation of
Element Description
the syntax
Warm-up Type: REAL; unit: min
time
Default: 30.0

12.4.18 $WARMUP_RED_VEL

Description Warm-up functionality ON/OFF

Syntax $WARMUP_RED_VEL=State

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 101 / 123
 Configuration of Kinematic Systems

Explanation of
Element Description
the syntax
State Type: BOOL
 TRUE: Warm-up functionality is activated.
 FALSE: Warm-up functionality is deactivated.
Default: FALSE

12.4.19 $COOLDOWN_TIME

Description Cool-down time of the drives

This variable defines the time after which the drives have cooled down when
the robot is stationary.

Syntax $COOLDOWN_TIME=Cool-down time

Explanation of
Element Description
the syntax
Cool-down Type: REAL; unit: min
time
Default: 360.0

12.4.20 $WARMUP_SLEW_RATE

Description Rate of increase for override during warm-up

This variable defines the rate of increase at which the internal override rises
back to 100% after it has had to be reduced due to an excessive motor current.

Syntax $WARMUP_SLEW_RATE=Rate of increase

Explanation of Element Description

the syntax
Rate of incre- Type: REAL; unit: %/s
ase
Default: 5.0

12.4.21 $WARMUP_CURR_LIMIT

Description Maximum motor current during warm-up

During the warm-up time, the motor currents are monitored for all PTP move-
ments. This variable defines the percentage of the maximum motor current
$CURR_LIM at which the velocity of the robot and thus the motor current is to
be reduced.

Syntax $WARMUP_CURR_LIMIT=Motor current

Explanation of
Element Description
the syntax
Motor current Type: INT; unit: %
Default: 99

12.4.22 $WARMUP_MIN_FAC

Description Reduction factor for override during warm-up

This variable defines by what percentage the internal override is to be reduced
if the instantaneous motor current during warm-up is greater than the maxi-
mum current $WARMUP_CURR_LIMIT.

102 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2
 12 Appendix

Syntax $WARMUP_MIN_FAC=Reduction factor

Explanation of
Element Description
the syntax
Reduction Type: INT; unit: %
factor
Default: 60

12.4.23 $JERK_MA

Description Maximum jerk for SPLINE

The variable of structure type JERK_STRUC limits the change of the acceler-
ation over time during SPLINE movements.
The aggregate consists of the following components:

 CP: Change to the path acceleration in [m/s3]

 ORI: Change to the orientation acceleration in [°/s3]
 AX: Change to the axis acceleration in [°/s3] for rotational axes or in [m/s3]
for linear axes

Example $JERK_MA={CP 50.0,ORI 50000.0,AX {A1 1000.0,A2 1000.0,A3 1000.0,A4

1000.0,A5 1000.0,A6 1000.0,E1 1000.0,E2 1000.0,E3 1000.0,E4 1000.0,E5
1000.0,E6 1000.0}}

12.4.24 $RED_T1

Description Reduction factor for test mode T1

The maximum Cartesian accelerations and velocities in T1 mode are reduced
to the percentage set here.
 Linear change in velocity:
($RED_T1/100)2 * $VEL_MA.CP
 Quadratic change in acceleration:
($RED_T1/100)2 * $ACC_MA.CP

Syntax $RED_T1=Reduction factor

Explanation of
Element Description
the syntax
Reduction Type: INT; unit: %
factor
 0 … 15

12.4.25 $DEF_FLT_PTP

Description Default filter for PTP

The variable contains the filter value recommended for PTP movements. The
filter can be used to smooth PTP movements.
The default filter for PTP motions is active only if the filter value is assigned to
the system variable $FILTER. The value is automatically assigned when the
INI line in the KRL program is executed:
BAS: (#INITMOVE, 0)

Syntax $DEF_FLT_PTP=Filter value

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 103 / 123
 Configuration of Kinematic Systems

Explanation of
Element Description
the syntax
Filter value Type: INT; unit: ms
The value must be an integer multiple of the interpolation
cycle (12 ms).
Guide values:
 The larger the kinematic system, the greater the filter
value.
 Setting the times too short increases the tendency to
oscillation.
 Typical values: 96 … 240

12.4.26 $DEF_FLT_CP

Description Default filter for CP

The variable contains the filter value recommended for CP movements. The
filter can be used to smooth CP movements.
The default filter is active only if the filter value is assigned to the system vari-
able $FILTER. The value must be assigned in the KRL program.

Syntax $DEF_FLT_CP=Filter value

Explanation of Element Description

the syntax
Filter value Type: INT; unit: ms
The value must be an integer multiple of the interpolation
cycle (12 ms).
Guide values:
 The larger the kinematic system, the greater the filter
value.
 Setting the times too short increases the tendency to
oscillation.
 Typical values: 96 … 240

12.4.27 $DEF_OV_JOG

Description Default setting for the manual override (HOV) for jogging
This manual override is set after boot-up, and also when the machine data
have been reloaded.

Syntax $DEF_OV_JOG=Jog override

Explanation of
Element Description
the syntax
Jog override Type: INT; unit: %
 1 … 100
Default: 10

12.4.28 $BRK_DEL

Description Delay time for applying the brakes

104 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2
 12 Appendix

The variable defines the time delay after the robot has completed the motion
and before the brakes are applied. The delay time applies for all interpreters.

Syntax $BRK_DEL=Delay time

Explanation of
Element Description
the syntax
Delay time Type: INT; unit: ms
Default: 20 000

12.4.29 $GEARTORQ_MON

Description Gear torque monitoring ON/OFF

The monitoring limits are defined using the dynamic model. With kinematic
systems that have no acceleration adaptation and no higher motion profile, the
torque monitoring must be deactivated.

Syntax $GEARTORQ_MON=State

Explanation of
Element Description
the syntax
State Type: BOOL
 TRUE: Torque monitoring is activated.
 FALSE: Torque monitoring is deactivated.
Default: TRUE

12.4.30 $ACC_ACT_MA

Description Limit value for command acceleration

The maximum command value for axis acceleration is dependent on the max-
imum motor speed and the axis ramp-up time:
$ACC_ACT_MA / 100 * Maximum motor speed / axis ramp-up time
Maximum motor speed:
The maximum motor speed depends on whether energy monitoring is activat-
ed or deactivated:
 $ENERGY_MON=FALSE: If energy monitoring is switched off, the maxi-
mum motor speed corresponds to $VEL_AXIS_MA.
 $ENERGY_MON=TRUE: If energy monitoring is switched on, the maxi-
mum motor speed is calculated from the dynamic model.

Syntax $ACC_ACT_MA=Limit value

Explanation of
Element Description
the syntax
Limit value Type: INT; unit: %
 ≥100
Default: 250

12.4.31 $VEL_ACT_MA

Description Limit value of the command velocity

The maximum command value for axis velocity is dependent on the maximum
motor speed and the motion type:

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 105 / 123
 Configuration of Kinematic Systems

$VEL_ACT_MA / 100 * Maximum motor speed * Reduction factor / 100

Maximum motor speed:
The maximum motor speed depends on whether energy monitoring is activat-
ed or deactivated:
 $ENERGY_MON=FALSE: If energy monitoring is switched off, the maxi-
mum motor speed corresponds to $VEL_AXIS_MA.
 $ENERGY_MON=TRUE: If energy monitoring is switched on, the maxi-
mum motor speed is calculated from the dynamic model.
Reduction factor:
The reduction factor is dependent on the motion type:
 Jog mode:
Reduction factor = $RED_VEL_AXC
 PTP motion and PTP-to-PTP motion in test mode T1:
Reduction factor = $RED_T1
 CP motion, CP-to-CP motion, CP-to-PTP motion and PTP-to-CP motion:
Reduction factor = $VEL_CPT1_MA
 BCO run with PTP:
Reduction factor = $RED_VEL_AXC
 BCO run with CP:
Reduction factor = $VEL_CPT1_MA
 Other motion types:
Reduction factor = 100%

Syntax $VEL_ACT_MA=Limit value

Explanation of
Element Description
the syntax
Limit value Type: INT; unit: %
 ≥100
Default: 110

12.4.32 $IN_POS_CAR

Only relevant if KUKA.CR Motion Cooperation or KUKA.Conveyor-

Tech is used.

Description Cartesian positioning window in relation to the translation (X, Y, Z)

This variable is used to define a tolerance window referred to the relative Car-
tesian position of a slave to the position of the master.
This window is relevant in the following cases:
 Restart of an interrupted program in T1, T2 and Automatic modes
If a slave is positioned outside the positioning window, a BCO run is per-
formed.
 Restart from exact positioning points
At exact positioning points, the interpolator checks whether all slaves are
within the positioning window.

Syntax $IN_POS_CAR=Positioning window

106 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2
 12 Appendix

Explanation of
Element Description
the syntax
Positioning Type: REAL; unit: mm
window
Default: 0.1

12.4.33 $IN_POS_ORI

Only relevant if KUKA.CR Motion Cooperation or KUKA.Conveyor-

Tech is used.

Description Cartesian positioning window in relation to the orientation (A, B, C)

This variable is used to define a tolerance window referred to the relative Car-
tesian position of a slave to the position of the master.
This window is relevant in the following cases:
 Restart of an interrupted program in T1, T2 and Automatic modes
If a slave is positioned outside the positioning window, a BCO run is per-
formed.
 Restart from exact positioning points
At exact positioning points, the interpolator checks whether all slaves are
within the positioning window.

Syntax $IN_POS_ORI=Positioning window

Explanation of
Element Description
the syntax
Positioning Type: REAL; unit: °
window
Default: 0.1

12.4.34 $DIS_WRP1

Description Average distance of the wrist root point from the overhead singularity
In the overhead singularity, the wrist root point (intersection of axes A4, A5 and
A6) is located vertically above axis 1 of the robot (α1 position).

Syntax $DIS_WRP1=Distance

Explanation of
Element Description
the syntax
Distance Type: REAL; unit: mm
The distance is dependent on the robot type.

12.4.35 $DIS_WRP2

Description Average distance of the wrist root point from the extended position singularity
In the extended position singularity, the wrist root point (intersection of axes
A4, A5 and A6) is located in the extension of axes A2 and A3 of the robot (α5
position).

Syntax $DIS_WRP2=Distance

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 107 / 123
 Configuration of Kinematic Systems

Explanation of
Element Description
the syntax
Distance Type: REAL; unit: mm
Default: 0.0

12.4.36 $TFLWP

Description Position of the FLANGE coordinate system

This variable of structure type FRAME describes the position of the FLANGE
coordinate system in relation to the wrist point coordinate system:
 X, Y, Z: Offset of the origin along the axes in [mm]
 A, B, C: Rotational offset of the axis angles in [°]
The wrist point coordinate system is the last coordinate system of the wrist
axis transformation and lies at the wrist root point (intersection of wrist axes
A4, A5 and A6).

(>>> Fig. 12-9 )

Example KR 150-2
$TFLWP={X 0.0,Y 0.0,Z 230.0,A 0.0,B 0.0,C 0.0}

The origin of the FLANGE coordinate system is offset 230 mm in the direction
of the Z axis in relation to the wrist point coordinate system.

12.4.37 $TX3P3

Description Position of the X3 coordinate system

This variable of structure type FRAME describes the position of the X3 coor-
dinate system in relation to the P3 coordinate system:
 X, Y, Z: Offset of the origin along the axes in [mm]
 A, B, C: Rotational offset of the axis angles in [°]
The X3 coordinate system is the first coordinate system of the wrist axis trans-
formation and lies at the wrist root point (intersection of the wrist axes A4, A5
and A6).
(>>> Fig. 12-9 )
The P3 coordinate system is the last coordinate system of the main axis trans-
formation.
(>>> 12.4.1 "$MAIN_AXIS" Page 90)

The Z axis of the X3 coordinate system must be parallel or anti-par-

allel to axis A4, since the wrist axis transformation is defined with De-
navit-Hartenberg parameters. In the Denavit-Hartenberg
transformation, the Z axis is by default the rotational axis.

Example KR 150-2
$TX3P3={X 1250.0,Y 0.0,Z 55.0,A 0.0,B 90.0,C 0.0}

The origin of the X3 coordinate system is offset 1250 mm in the direction of the
X axis and 55 mm in the direction of the Z axis in relation to the P3 coordinate
system. The axis angle B is rotationally offset by 90°, so that the Z axis of the
X3 coordinate system coincides with rotational axis A4.

108 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2
 12 Appendix

12.4.38 $ACC_MA

Description Maximum acceleration of the TCP

The variable of structure type CP defines the maximum Cartesian acceleration
for the following components:

 CP: Maximum path acceleration in [m/s2]

 ORI1: Maximum swivel acceleration in [°/s2]
 ORI2: Maximum rotational acceleration in [°/s2]
Cartesian movements are executed with the following accelerations:
 Path acceleration: $RED_ACC_CPC * $ACC_MA.CP
 Swivel acceleration: $RED_ACC_CPC * $ACC_MA.ORI1
 Rotational acceleration: $RED_ACC_CPC * $ACC_MA.ORI2

If these values are set too high, the axes will go into cur-
rent limitation. This can lead to overloading and damage
to the gear units.

Example $ACC_MA={CP 10.0,ORI1 1000.0,ORI2 1000.0}

12.4.39 $VEL_MA

Description Maximum velocity of the TCP

The variable of structure type CP defines the maximum Cartesian velocity that
can be used in the program for the following components:
 CP: Maximum path velocity in [m/s]
 ORI1: Maximum swivel velocity in [°/s]
 ORI2: Maximum rotational velocity in [°/s]
Cartesian movements in jog mode are executed with the following velocities:
 Path velocity: $RED_VEL_CPC * $VEL_MA.CP
 Swivel velocity: $RED_VEL_CPC * $VEL_MA.ORI1
 Rotational velocity: $RED_VEL_CPC * $VEL_MA.ORI2

If these values are set too high, the axes will go into cur-
rent limitation. This can lead to overloading and damage
to the gear units.

Example $VEL_MA={CP 3.0,ORI1 400.0,ORI2 400.0}

12.4.40 $OPT_MOVE

Description Higher motion profile

The higher motion profile is calculated from the dynamic model. If the higher
motion profile is activated, valid model data must be available.

Syntax $OPT_MOVE=Motion profile

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 109 / 123
 Configuration of Kinematic Systems

Explanation of
Element Description
the syntax
Motion profile Type: ENUM
 #NONE: The higher motion profile is deactivated.
 #STEP1: Higher motion profile without energy planning
 #STEP2: Higher motion profile with energy planning
Default: #STEP1

12.4.41 $PROG_TORQ_MON

Description Monitoring of the command torques of the gear units and motors
If the monitoring is activated, this acknowledgement message is displayed
when the operating mode is changed: Attention! Maximum velocity could be
programmed

Syntax $PROG_TORQ_MON=State

Explanation of
Element Description
the syntax
State Type: BOOL
 TRUE: Monitoring is activated.
 FALSE: Monitoring is not activated.
Default: TRUE

12.4.42 $USE_CUSTOM_MODEL

Description Use of the positionally accurate robot model loaded

Syntax $USE_CUSTOM_MODEL=State

Explanation of Element Description

the syntax
State Type: BOOL
 TRUE: The robot model is used.
 FALSE: The robot model is not used.
Default: FALSE

12.5 Machine data for kinematic systems without a dynamic model

If machine data are created for kinematic systems that are not KUKA kinemat-
ic systems with dynamic data, all dynamic models must be deactivated.

Overview The following functions in $ROBCOR.DAT in the directory KRC:\R1\MADA

must be deactivated:

System variable Function

$ADAP_ACC=#NONE Acceleration adaptation
$OPT_MOVE=#NONE Higher motion profile
$ENERGY_MON=FALSE Monitoring of the kinetic energy in
the event of a collision
$PROG_TORQ_MON=FALSE Monitoring of the command torques
of the gear units and motors
$EMSTOP_ADAP=FALSE Model-based EMERGENCY STOP

110 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2
 12 Appendix

System variable Function

$EKO_MODE=#OFF Elasticity compensation
$USE_CUSTOM_MODEL=FALSE Absolutely accurate robot model

The following function in $MACHINE.DAT in the directory KRC:\R1\MADA

must be deactivated:

System variable Function

$GEARTORQ_MON=FALSE Monitoring of the actual torques of
the gear units

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 111 / 123
 Configuration of Kinematic Systems

112 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2
 13 KUKA Service

13 KUKA Service
A

13.1 Requesting support

v

Introduction This documentation provides information on operation and operator control,

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

Information The following information is required for processing a support request:

 Description of the problem, including information about the duration and
frequency of the fault
 As comprehensive information as possible about the hardware and soft-
ware components of the overall system
The following list gives an indication of the information which is relevant in
many cases:
 Model and serial number of the kinematic system, e.g. the manipulator
 Model and serial number of the controller
 Model and serial number of the energy supply system
 Designation and version of the system software
 Designations and versions of other software components or modifica-
tions
 Diagnostic package KRCDiag
Additionally for KUKA Sunrise: Existing projects including applications
For versions of KUKA System Software older than V8: Archive of the
software (KRCDiag is not yet available here.)
 Application used
 External axes used

13.2 KUKA Customer Support

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

Argentina Ruben Costantini S.A. (Agency)

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

Australia KUKA Robotics Australia Pty Ltd

45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
[email protected]
www.kuka-robotics.com.au

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 113 / 123
 Configuration of Kinematic Systems

Belgium KUKA Automatisering + Robots N.V.

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

Brazil KUKA Roboter do Brasil Ltda.

Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
[email protected]
www.kuka-roboter.com.br

Chile Robotec S.A. (Agency)

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

China KUKA Robotics China Co., Ltd.

No. 889 Kungang Road
Xiaokunshan Town
Songjiang District
201614 Shanghai
P. R. China
Tel. +86 21 5707 2688
Fax +86 21 5707 2603
[email protected]
www.kuka-robotics.com

Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
[email protected]
www.kuka-roboter.de

114 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2
 13 KUKA Service

France KUKA Automatisme + Robotique SAS

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

India KUKA Robotics India Pvt. Ltd.

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

Italy KUKA Roboter Italia S.p.A.

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

Japan KUKA Robotics Japan K.K.

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

Canada KUKA Robotics Canada Ltd.

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

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 115 / 123
 Configuration of Kinematic Systems

Korea KUKA Robotics Korea Co. Ltd.

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

Malaysia KUKA Robot Automation (M) Sdn Bhd

South East Asia Regional Office
No. 7, Jalan TPP 6/6
Taman Perindustrian Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 (03) 8063-1792
Fax +60 (03) 8060-7386
[email protected]

Mexico KUKA de México S. de R.L. de C.V.

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

Norway KUKA Sveiseanlegg + Roboter

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

Austria KUKA Roboter CEE GmbH

Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 7 32 78 47 52
Fax +43 7 32 79 38 80
[email protected]
www.kuka.at

116 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2
 13 KUKA Service

Poland KUKA Roboter CEE GmbH Poland

Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
[email protected]

Portugal KUKA Robots IBÉRICA, S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729 780
Fax +351 265 729 782
[email protected]
www.kuka.com

Russia KUKA Robotics RUS

Werbnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
[email protected]
www.kuka-robotics.ru

Sweden KUKA Svetsanläggningar + Robotar AB

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

Switzerland KUKA Roboter Schweiz AG

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

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 117 / 123
 Configuration of Kinematic Systems

Spain KUKA Robots Ibérica, S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
[email protected]

South Africa Jendamark Automation LTD (Agency)

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

Taiwan KUKA Robot Automation Taiwan Co., Ltd.

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

Thailand KUKA Robot Automation (M)SdnBhd

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

Czech Republic KUKA Roboter Austria GmbH

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

118 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2
 13 KUKA Service

Hungary KUKA Robotics Hungaria Kft.

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

USA KUKA Robotics Corporation

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

UK KUKA Robotics UK Ltd

Great Western Street
Wednesbury West Midlands
WS10 7LL
UK
Tel. +44 121 505 9970
Fax +44 121 505 6589
[email protected]
www.kuka-robotics.co.uk

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 119 / 123
 Configuration of Kinematic Systems

120 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2
 Index

Index
Symbols $RED_T1 103
$A4PAR 97 $RED_VEL_AXC 78
$ACC_ACT_MA 105 $RED_VEL_CPC 99
$ACC_MA 109 $ROBROOT 97
$ACTIVE_KAR_MASK 98 $ROBROOT_C 21
$APO_DIS_PTP 79 $SEP_ASYNC_OV 89
$ASYNC_AX… 55 $SOFTN_END 85
$ASYNC_AXIS 58, 62 $SOFTP_END 85
$ASYNC_EX_AX_DECOUPLE 86 $ST_TOL_VEL 82
$ASYNC_FLT 65 $TECH_MAX 99
$ASYNC_MODE 57 $TFLWP 108
$ASYNC_OPT 63 $TIME_POS 83
$ASYNC_STATE 66 $TIRORO 95
$ASYNC_T1_FAST 56 $TRAFONAME 97
$AXIS_JERK 83 $TX3P3 108
$AXIS_TYPE 77 $USE_CUSTOM_MODEL 110
$BASE_C 20 $VEL_ACT_MA 105
$BRK_DEL 104 $VEL_AX_JUS 78
$COOLDOWN_TIME 102 $VEL_AXIS_MA 81, 90
$COUP_COMP 87 $VEL_CP_T1 99
$CURR_LIM 102 $VEL_CPT1_MA 83
$DEF_FLT_CP 104 $VEL_MA 109
$DEF_FLT_PTP 103 $WARMUP_CURR_LIMIT 101, 102
$DEF_OV_JOG 104 $WARMUP_MIN_FAC 101, 102
$DIS_WRP1 107 $WARMUP_RED_VEL 101
$DIS_WRP2 107 $WARMUP_SLEW_RATE 101, 102
$EO_DEVICES 60 $WARMUP_TIME 101
$ET1_TA1KR 75 $WRIST_AXIS 94
$ET1_TA2A1 75 $ZUST_ASYNC 55
$ET1_TA3A2 76
$ET1_TFLA3 76 Numbers
$ET1_TPINFL 76 2-axis palletizing robot 99
$EX_AX_ASYNC 58, 63, 84
$GEARTORQ_MON 105 A
$IN_POS_CAR 106 Access rights, setting 31
$IN_POS_MA 79, 89 Appendix 75
$IN_POS_ORI 107 ASYCANCEL 66
$IN_STILL_MA 88 ASYCONT 65
$INC_AXIS 81 Asynchronous motion 12
$INC_CAR 88 Asynchronous motion, coordinated 13
$INC_EXTAX 82 Asynchronous motion, uncoordinated 13
$INDIVIDUAL_MAMES 100 ASYPTP 55, 63
$JERK_MA 84, 103 ASYSTOP 65
$JOINT_OFFSET 59 Axis 8
$JOINT_OFFSET_C 60 Axis ramp-up time, optimizing 45
$KINCLASS 100 Axis, couplable 50
$L_EMT_MAX 78 Axis, simulating 50
$LENGTH_A 96
$LENGTH_B 97 B
$MAIN_AXIS 90 BASE kinematic system 10, 19
$OPT_MOVE 109 Braking ramp for dynamic braking, optimizing 47
$OV_ASYNC 64 Button bar 30
$PROG_TORQ_MON 110
$RAT_MOT_AX 85 C
$RED_ACC_AXC 81 Calibration, root point 20
$RED_ACC_CPC 101 Calibration, tool base 20
$RED_ACC_DYN 100 Catalog 8
$RED_ACC_OV 80 Catalog, adding 31

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 121 / 123
 Configuration of Kinematic Systems

Catalog, new 30 P
CK 8 Palletizing robot 99
Closing, catalog 32 Planning, external axis system 27
Closing, WorkVisual Catalog Editor 32 PosGain (PTP, CP) 43
Configuration 29 Programming 61
Configuration, couplable axes 50 Proportional component of the position cont-
Coordinate systems 19 roller, optimizing 43
Coupling group, creating 51 Proportional component of the speed controller,
optimizing 40
D
Displaying/hiding windows 30 R
DKP 400, transformation 69 RDC 8
Documentation, industrial robot 7 Recommissioning 53
Reduction factor, Emergency Stop ramp, optimi-
E zing 46
EO driver 8 ROBROOT coordinate system 19, 20
EO driver, settings 25 ROBROOT kinematic system 9, 20
ERSYSROOT coordinate system 20 ROOT coordinate system 19
Examples 69
External axis system, maximum values 15 S
External axis system, planning 27 Safety 17
Safety instructions 7
F Saving, catalog 32
FLANGE coordinate system 19 Service, KUKA Roboter GmbH 113
Fundamentals 9 Set tool/base (menu item) 23
Simulating, axis 50
I Start-up 53
Integral component of the speed controller, op- Start-up, kinematic system 53
timizing 42 Starting, WorkVisual catalog editor 30
Introduction 7 Support request 113
ISTEP 58 Synchronous motion 11
Synchronous motion, coupled 12
J Synchronous motion, non-coupled 12
Jogging, external axes 22 System planning 27
System variables 55
K
Kinematic system type 9 T
Kinematic system, start-up 53 Terms used 8
KL 1500-3, transformation 72 TOOL coordinate system 19
KPP 8 TOOL kinematic system 10
KSP 8 Training 7
KUKA Customer Support 113 Transformation, BASE kinematic system 37
KUKA linear unit, configuring 33 Transformation, ROBROOT kinematic system
KUKA.HMI 8 39

M V
Machine data, optimizing 39 VelGain (PTP, CP) 40
Master/slave operation 13 VelIntTime (PTP, CP) 42
Mathematical coupling 22
Mathematical coupling, activating 23 W
MCFB 8 Warnings 7
MGU 8 Windows, displaying/hiding 30
Motion types 11 WorkVisual Catalog Editor 8
Motor 8 WORLD coordinate system 19, 20
MSTEP 58

O
OFFSET coordinate system 19
Operation 19
Optimization 39
Oscilloscope 39

122 / 123 Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2
 Configuration of Kinematic Systems

Issued: 24.05.2017 Version: KSS 8.5 configuration of kinematic systems V2 123 / 123