KUKA System Technology KUKA Roboter GmbH

KUKA.Gripper&SpotTech 2.5

For KUKA System Software 5.2, 5.3, 5.4, 5.5, 5.6, 7.0, 7.1

Issued: 23.08.2011

Version: KST GripperSpotTech 2.5 V1 en

 KUKA.Gripper&SpotTech 2.5

© Copyright 2011
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 KST GripperSpotTech 2.5 en

Bookstructure: KST GripperSpotTech 2.5 V1.1
Version: KST GripperSpotTech 2.5 V1 en

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 Contents

Contents
1 Introduction .................................................................................................. 5
1.1 Target group .............................................................................................................. 5
1.2 Industrial robot documentation ................................................................................... 5
1.3 Representation of warnings and notes ...................................................................... 5
1.4 Terms used ................................................................................................................ 6

2 Product description ..................................................................................... 7

2.1 Overview of Gripper&SpotTech ................................................................................. 7
2.2 Gripper types ............................................................................................................. 7
2.3 KUKA.SpotTech – overview of functions ................................................................... 8
2.3.1 SpotTech: sequence of a weld program ............................................................... 9
2.3.2 Synchronization with KUKA.RoboTeam ............................................................... 10

3 Safety ............................................................................................................ 13
4 Installation ................................................................................................... 15
4.1 System requirements ................................................................................................. 15
4.2 Installation for KUKA System Software (KSS) 5.4, 5.5, 5.6, 7.0, 7.1 ......................... 15
4.2.1 Installing or updating KUKA.Gripper&SpotTech ................................................... 15
4.2.2 Uninstalling KUKA.Gripper&SpotTech .................................................................. 15
4.3 Installation for KUKA System Software (KSS) 5.2, 5.3 .............................................. 15
4.3.1 Installing KUKA.Gripper&SpotTech ...................................................................... 15
4.3.2 Uninstalling KUKA.Gripper&SpotTech .................................................................. 16
4.3.3 Reinstalling KUKA.Gripper&SpotTech .................................................................. 16

5 Operation ...................................................................................................... 17
5.1 GripperTech: manual gripper control ......................................................................... 17
5.2 SpotTech: manual weld gun control ........................................................................... 17

6 Configuration ............................................................................................... 19
6.1 Configuration .............................................................................................................. 19
6.1.1 Overview of configurable gripper types ................................................................ 19
6.1.2 Creating user-specific grippers ............................................................................. 19
6.1.3 Configuring I/Os .................................................................................................... 19
6.2 SpotTech: configuration ............................................................................................. 20
6.2.1 SPOTTECH GLOBALS fold in $CONFIG.DAT ..................................................... 20
6.2.2 Skeleton program USERSPOT.SRC .................................................................... 21
6.3 Configuration of manual gun control .......................................................................... 23
6.3.1 Controlling RETRACT and SPOT separately ....................................................... 23
6.3.2 Controlling RETRACT and SPOT in series .......................................................... 23

7 Programming ............................................................................................... 25
7.1 GripperTech: programming ........................................................................................ 25
7.1.1 Programming the inline form “Gripper” ................................................................. 25
7.1.2 Programming the inline form “CheckGripper” ....................................................... 26
7.2 SpotTech: programming ............................................................................................ 27
7.2.1 Programming the inline form “SPOT” ................................................................... 27
7.2.2 Programming the inline form “RETRACT” ............................................................ 27
7.2.3 Programming the inline forms SPOT and RETRACT with KUKA.RoboTeam ...... 28

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 KUKA.Gripper&SpotTech 2.5

7.2.4 Primary weldset option window ............................................................................ 29

7.2.5 PRESPOT option window ..................................................................................... 29
7.2.6 Synchronization option window with KUKA.RoboTeam ....................................... 30
7.2.7 Activating/deactivating collision detection ............................................................ 30

8 Examples ...................................................................................................... 31
8.1 Configuration example: user-specific gripper ............................................................ 31
8.1.1 Assigning the gripper type – $CONFIG.DAT ........................................................ 31
8.1.2 Configuring gripper parameters – USER_GRP.DAT ............................................ 32
8.1.3 Programming gripper functions – USER_GRP.SRC ............................................ 32
8.2 Example program USERSPOT.SRC ......................................................................... 34
8.2.1 Overview of I/Os – robot controller (KR C) / weld controller (PLC) ...................... 36
8.2.2 Signal diagram: SPOT without the options RETRACT and PRESPOT ................ 37
8.2.3 Signal diagram: SPOT with the options RETRACT and PRESPOT ..................... 39

9 Messages ...................................................................................................... 41
9.1 GripperTech: error messages .................................................................................... 41
9.2 SpotTech: error messages ........................................................................................ 41

10 KUKA Service ............................................................................................... 43

10.1 Requesting support ................................................................................................... 43
10.2 KUKA Customer Support ........................................................................................... 43

Index ............................................................................................................. 51

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 1 Introduction

1 Introduction

1.1 Target group

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 KUKA System Software
 Documentation relating to options and accessories
 Parts catalog on storage medium
Each of these sets of instructions is a separate document.

1.3 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 physical injury will occur, if no pre-
cautions are taken.

These warnings mean that death or severe physical inju-

ry may occur, if no precautions are taken.

These warnings mean that minor physical 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 precautionary measures.

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

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

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 KUKA.Gripper&SpotTech 2.5

1.4 Terms used

Term Description
Gripper Gripper
KUKA.RoboTeam KUKA.RoboTeam is a software module that
enables cooperation between several robots.
The CP motions of the cooperating robots can
be synchronized and geometrically coupled.
SPOT Working stroke, i.e. the opening of the weld gun
used to execute a weld spot
RETRACT Retract stroke, i.e. the complete opening of the
weld gun
PRESPOT Early closing of the weld gun
The closing of the working stroke does not start
after the point for the weld spot has been
reached, but while the robot is still moving to the
point.
Weld timer Hardware for controlling the welding time and
welding current
PLC The PLC (Programmable Logic Controller) is an
electronic module that is used for higher-level
control tasks, e.g. the weld controller.
Trigger Software command for triggering a switching
operation

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 2 Product description

2 Product description

2.1 Overview of Gripper&SpotTech

Gripper&SpotTech is an add-on technology package with the following func-

tions:

Functions  Inline forms for gripper programming

 Programming gripper actions
 Controlling and monitoring gripper actions
 Inline forms for programming spot welding applications
 Moving to the point for the weld spot and programming the weld oper-
ation
 Controlling and monitoring the weld operation
 Grippers can also be actuated manually.
 16 grippers can be configured.
 There are 5 predefined gripper types available.
 User-specific gripper types can be created.

Weld guns are considered as grippers.

Areas of appli- Almost all industrial applications, e.g.:

cation  Spot welding applications
 Arc welding
 Assembly
 Machine tending
 Transfer
 Order picking

2.2 Gripper types

Description Gripper&SpotTech contains 5 gripper types. If these types are not sufficient,
additional gripper functions can be programmed.
(>>> 6.1.2 "Creating user-specific grippers" Page 19)

Type 1 Simple gripper

 2 switching states: Open, Closed
 2 outputs
 4 inputs
I/Os Open Closed
OUT 1 TRUE FALSE
OUT 2 FALSE TRUE
IN 1 TRUE FALSE
IN 2 FALSE TRUE
IN 3 TRUE FALSE
IN 4 FALSE TRUE

Type 2 Gripper with mid-position valve

 3 switching states: Pos1, Middle, Pos2

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 KUKA.Gripper&SpotTech 2.5

 2 outputs
 2 inputs
I/Os Pos1 Middle Pos2
OUT 1 TRUE FALSE FALSE
OUT 2 FALSE TRUE FALSE
IN 1 TRUE FALSE FALSE
IN 2 FALSE TRUE FALSE

Type 3 Vacuum gripper with 2 valves

 3 switching states: Suction, Release, Off
 2 outputs
 2 inputs
I/Os Suction Release Off
OUT 1 TRUE FALSE FALSE
OUT 2 FALSE TRUE FALSE
IN 1 TRUE FALSE FALSE
IN 2 FALSE TRUE FALSE

Type 4 Vacuum gripper with 3 valves

 3 switching states: Suction, Release, Off
 3 outputs
 2 inputs
I/Os Suction Release Off
OUT 1 TRUE FALSE FALSE
OUT 2 FALSE TRUE FALSE
OUT 3 FALSE TRUE FALSE
IN 1 TRUE FALSE FALSE
IN 2 FALSE TRUE FALSE

Type 5 Simple gripper with pulse valve

 2 switching states: Open, Closed
 2 outputs
 4 inputs
I/Os Open Closed
OUT 1 TRUE FALSE
OUT 2 FALSE TRUE
IN 1 TRUE FALSE
IN 2 FALSE TRUE
IN 3 TRUE FALSE
IN 4 FALSE TRUE

The pulse duration is defined using the variable GRP_PULSE_TI in $CON-

FIG.DAT. (Default: 0.5 s)

2.3 KUKA.SpotTech – overview of functions

Overview KUKA.SpotTech contains 2 inline forms for programming spot welding appli-
cations:
 SPOT

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 2 Product description

 RETRACT

SPOT The inline form SPOT is used to program the following functions:
 Move to point for weld spot with PTP, LIN or CIRC
 PRESPOT: Close weld gun while the robot is moving to the weld point.

 Weld operation
 Retract stroke of the weld gun following the weld operation
 Synchronization with KUKA.RoboTeam
 Collision detection (KSS 5.5 or later)
(>>> 7.2.7 "Activating/deactivating collision detection" Page 30)

RETRACT The inline form RETRACT is used to program the following functions:
 Move to end point with PTP, LIN or CIRC
 Retract stroke of the weld gun on reaching the end point
 Synchronization with KUKA.RoboTeam
 Collision detection (KSS 5.5 or later)
(>>> 7.2.7 "Activating/deactivating collision detection" Page 30)

Fig. 2-1: RETRACT and SPOT functions

Item Description
1 Retract stroke open (RETR OPN)
2 Retract stroke closed (RETR CLS)
3 Working stroke closed (SPOT)

2.3.1 SpotTech: sequence of a weld program

Description The diagram shows the sequence of a welding program between two weld
spots.

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 KUKA.Gripper&SpotTech 2.5

Fig. 2-2: Spot weld program sequence

Element Description
P1 Starting point / previous weld spot
RETRACT Status of the weld gun at the start of the program
OPEN
Two options can be programmed in the inline form:
RETRACT
CLOSED  Retract stroke open (RETR OPN)
 Retract stroke closed (RETR CLS)
ADVSPOT Communication with the weld controller
Configuration of ADVSPOT in USERSPOT.SRC, so
that the required weld data are available when the end
point is reached.
(>>> 8.2 "Example program USERSPOT.SRC"
Page 34)
PRESPOT Early closing of the weld gun

SPOT The weld operation is started with the signal

WLD_START from the robot controller (KRC) to the
weld controller (PLC) and stopped when the weld com-
plete signal WLD_CMP is set in the weld controller
(PLC).
(>>> 8.2.1 "Overview of I/Os – robot controller (KR C) /
weld controller (PLC)" Page 36)
P2 Weld spot

2.3.2 Synchronization with KUKA.RoboTeam

Description KUKA.SpotTech can be used with KUKA.RoboTeam.

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 2 Product description

In this case, the inline forms SPOT and RETRACT in the option window Syn-
chronization can be used to define which slave robots in a cell configuration
are to be synchronized with the master robot after the motion block.

Further information about the synchronization and configuration of

cooperating robots can be found in the operating and programming
instructions “KUKA.CR Program Cooperation” and “KUKA.CR Motion
Cooperation”.

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 3 Safety

3 Safety
This documentation contains safety instructions which refer specifically to the
software described here.
The fundamental safety information for the industrial robot can be found in the
“Safety” chapter of the Operating and Programming Instructions for System In-
tegrators or the Operating and Programming Instructions for End Users.

The “Safety” chapter in the operating and programming instructions

must be observed. Death to persons, severe physical injuries or con-
siderable damage to property may otherwise result.

 The robot system with KUKA.Gripper&SpotTech must be operated in ac-

cordance with the applicable national laws, regulations and standards.
 All KRL programs created with KUKA.Gripper&SpotTech must be tested
at reduced program velocity in the operating modes T1 and T2.

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 4 Installation

4 Installation

4.1 System requirements

Hardware  KR C2, KR C2 edition2005

Software  KUKA System Software 5.2, 5.3, 5.4, 5.5, 5.6, 7.0 and 7.1

4.2 Installation for KUKA System Software (KSS) 5.4, 5.5, 5.6, 7.0, 7.1

4.2.1 Installing or updating KUKA.Gripper&SpotTech

Precondition  If necessary: connect USB CD/DVD drive

 Insert CD.

It is advisable to archive all relevant data before installing or updating

a software package.

Procedure 1. Select the menu sequence Setup > Install Additional Software.
2. Press the New SW softkey. If a technology package on the CD-ROM in
the drive is not yet displayed, press the Refresh softkey.
3. Select the technology package to be installed and press the softkey In-
stall. Answer the request for confirmation with Yes. The files are copied
onto the hard drive.
4. Depending on the specific technology package, it may be necessary to re-
boot the controller. In this case, a corresponding prompt will be displayed.
Confirm with OK and restart the robot controller. The installation is re-
sumed and completed.

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

4.2.2 Uninstalling KUKA.Gripper&SpotTech

Precondition  KUKA.Gripper&SpotTech is installed.

 “Expert” user group
 Windows interface (CTRL+ESC)

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

package.

Procedure 1. Start the Uninstall.exe program in the directory C:\KRC_OPTION\GRIP-

PER-&SPOTTECH\UNINST. Uninstallation is prepared.
2. Confirm the reboot prompt with OK.
3. Reboot the robot controller.

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

4.3 Installation for KUKA System Software (KSS) 5.2, 5.3

4.3.1 Installing KUKA.Gripper&SpotTech

Precondition  User group “Expert”

 Windows interface (CTRL+ESC)

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 KUKA.Gripper&SpotTech 2.5

Procedure 1. Start the program Setup.exe from the CD-ROM. The files are copied onto
the hard drive.
2. Confirm the reboot prompt with OK.
3. Reboot the robot controller. The installation is resumed and completed.

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

4.3.2 Uninstalling KUKA.Gripper&SpotTech

Precondition  KUKA.Gripper&SpotTech is installed.

 “Expert” user group
 Windows interface (CTRL+ESC)

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

package.

Procedure 1. Start the Uninstall.exe program in the directory C:\KRC_OPTION\GRIP-

PER-&SPOTTECH\UNINST. Uninstallation is prepared.
2. Confirm the reboot prompt with OK.
3. Reboot the robot controller.

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

4.3.3 Reinstalling KUKA.Gripper&SpotTech

Precondition  KUKA.Gripper&SpotTech is uninstalled.

 User group “Expert”
 Windows interface (CTRL+ESC)

Procedure 1. Start the Reinstall.exe program in the directory C:\KRC_OPTION\GRIP-

PER-&SPOTTECH\REINST. Setup is prepared.
2. Confirm the reboot prompt with OK.
3. Reboot the robot controller.

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

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 5 Operation

5 Operation

5.1 GripperTech: manual gripper control

Operator control Status key Description

elements

Select gripper.

Control gripper.
The gripper function depends on the configured gripper
type.

Precondition  A program is selected.

 T1 or T2 operating mode
 Enabling switch is pressed.

Procedure 1. Use status key to select gripper.

2. Use status key to control gripper.

5.2 SpotTech: manual weld gun control

Operator control Status key Description

elements

Select gripper.

Control weld gun.

The gripper function is dependent on the configuration
of the manual gun control.
(>>> 6.3.1 "Controlling RETRACT and SPOT sepa-
rately" Page 23)
(>>> 6.3.2 "Controlling RETRACT and SPOT in series"
Page 23)

Precondition  Manual gun control is configured.

(>>> 6.3 "Configuration of manual gun control" Page 23)
 A program is selected.
 T1 or T2 operating mode
 Enabling switch is pressed.

Procedure 1. Use status key to select gripper.

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2. Use status key to control weld gun.

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 6 Configuration

6 Configuration

6.1 Configuration

6.1.1 Overview of configurable gripper types

Overview Number of out- Number of in- Number of switching

puts puts states
Type 1 2 4 2
Type 2 2 2 3
Type 3 2 2 3
Type 4 3 2 3
Type 5 2 4 2
Free type Further freely definable types of gripper function

A maximum of 16 grippers can be configured.

6.1.2 Creating user-specific grippers

Overview Step Description

1 Assign the gripper the type 100 in the GRIPPERTECH GLO-
BALS fold in $CONFIG.DAT.
(>>> 8.1.1 "Assigning the gripper type – $CONFIG.DAT"
Page 31)
2 Configure the gripper parameters in USER_GRP.DAT.
 Switching states
 Structure data type
 Assignment of the outputs
(>>> 8.1.2 "Configuring gripper parameters –
USER_GRP.DAT" Page 32)
3 Program the gripper functions in USER_GRP.SRC.
(>>> 8.1.3 "Programming gripper functions –
USER_GRP.SRC" Page 32)

Example (>>> 8.1 "Configuration example: user-specific gripper" Page 31)

6.1.3 Configuring I/Os

Precondition  User group “Expert”

 No program is selected in the Navigator.

Procedure 1. Select the menu sequence Configure > I/O > Gripper.
The window for I/O configuration is opened.
2. Select the gripper by pressing the softkeys Next or Previous.
3. Assign I/Os.
4. Save the settings with the Change softkey.

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 KUKA.Gripper&SpotTech 2.5

Description

Fig. 6-1: I/O configuration window

Item Description Range of values

1 Gripper type 1...5, 100

2 Name of the gripper Freely selectable

3 Description of the gripper Dependent on the gripper
type
4 Gripper switching states Dependent on the gripper
type
5 Assign outputs. Dependent on the gripper
type
6 Assign inputs. Dependent on the gripper
type

6.2 SpotTech: configuration

6.2.1 SPOTTECH GLOBALS fold in $CONFIG.DAT

Description The specific data sets, variables and parameters for the configuration are de-
fined in the SPOTTECH GLOBALS fold in $CONFIG.DAT.

SPOTTECH The file $CONFIG.DAT is located in the directory C:\KRC\ROBOT-

GLOBALS ER\KRC\R1\System.

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 6 Configuration

1 ;==================================
2 ; Structures:
3 ;==================================
4 ENUM S_COMMAND SPOT,RETR,PRESPOT,INIT,ADVSPOT
5 ENUM S_PAIR_SLCT FIRST,SECOND,BOTH
6
7 STRUC SPOT_SUGG_T CHAR GUN[24],RETR_CMD[24],CHOISE[24],
CLO_TM[24],PGNO1[24],PRESS1[24],PGNO2[24],PRESS2[24],
SPOT_PARAMS[24]
8 STRUC SPOT_TYPE INT GUN,S_PAIR_SLCT PAIR,COMMAND RETR,
INT CLO_TM,INT PGNO1,REAL PRESS1,INT PGNO2,REAL PRESS2
9
10 ;==============================
11 ; External declarations:
12 ;==============================
13 EXT USERSPOT (S_COMMAND :IN,SPOT_TYPE :IN )
14
15 ;==============================
16 ; Variables:
17 ;==============================
18 DECL SPOT_TYPE SDEFAULT={GUN 1,PAIR #FIRST,RETR #OPN,
CLO_TM 0,PGNO1 1,PRESS1 0.0,PGNO2 0,PRESS2 0.0}
19 DECL SPOT_TYPE S_ACT
20 DECL INT S_ACT_DELAY
21 DECL BOOL S_READY

6.2.2 Skeleton program USERSPOT.SRC

Description The file USERSPOT.SRC is a skeleton program that can be used for creating
user-specific spot welding programs.
(>>> 8.2 "Example program USERSPOT.SRC" Page 34)

USERSPOT.SRC The file is located in the directory C:\KRC\ROBOT-

ER\KRC\R1\TP\Gripper_SpotTech.

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1 &COMMENT USERSPOT package

2 DEF USERSPOT (CMD :IN,S :IN )
...
9 DECL S_COMMAND CMD
10 DECL SPOT_TYPE S
11
12 SWITCH CMD
13
14 CASE #INIT
15 INIT ( )
16
17 CASE #ADVSPOT
18 ADVSPOT (CMD,S )
19
20 CASE #PRESPOT
21 PRESPOT (CMD,S )
22
23 CASE #SPOT
24 SPOT (CMD,S )
25 S_READY=TRUE
26
27 CASE #RETR
28 RETRACT (CMD,S )
29 S_READY=TRUE
30
31 ENDSWITCH
32 ;*****************************
33 DEF ADVSPOT (CMD :IN,S :IN )
34
35 DECL S_COMMAND CMD
36 DECL SPOT_TYPE S
37
38 END ;(ADVSPOT)
39 ;*****************************
40 DEF PRESPOT (CMD :IN,S :IN )
41
42 DECL S_COMMAND CMD
43 DECL SPOT_TYPE S
44
45 END ;(PRESPOT)
46 ;*****************************
47 DEF SPOT (CMD :IN,S :IN )
48
49 DECL S_COMMAND CMD
50 DECL SPOT_TYPE S
51
52 END ;(SPOT)
53 ;*****************************
54 DEF RETRACT (CMD :IN,S :IN )
55
56 DECL S_COMMAND CMD
57 DECL SPOT_TYPE S
58
59 END ;(RETR)
60 ;*****************************
61 DEF INIT ( )
62 END ;(INIT)

Line Description
14 Initialization
17 Weld controller call
20 Triggering: early closing of the weld gun
23 Triggering: weld start in weld spot position
27 Triggering: retract stroke of the weld gun
25, 29 Enable for further program execution
33 User data for ADVSPOT
40 User data for PRESPOT

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Line Description
47 User data for SPOT
54 User data for RETRACT
61 User data for INIT

6.3 Configuration of manual gun control

6.3.1 Controlling RETRACT and SPOT separately

Description The retract stroke (RETRACT) and the working stroke (SPOT) of the weld gun
are to be controlled separately.
(>>> 5.2 "SpotTech: manual weld gun control" Page 17)
There are 2 gripper types available in GripperTech for this configuration:
 If static valves are used: Type 1
 If pulse valves are used: Type 5
I/Os Open Closed
OUT 1 TRUE FALSE
OUT 2 FALSE TRUE

Procedure 1. In $CONFIG.DAT, define 2 grippers of type 1 or type 5.

2. Assign 2 outputs to each gripper.

The assignment of the inputs is not necessary for manual gun control.

Example 1 ;==================================
2 ; Definition of grippers
3 ;==================================
4 INT MAXGRIPPER=16
5
6 DECL GRP_TYPES GRIPPER[16]
7
8 GRIPPER[1]={TYPE 5,OUT1 10,OUT2 11,OUT3 0,OUT4 0,IN1 0,IN2 0,
IN3 0,IN4 0,GRP_OLD 1}
9 GRIPPER[2]={TYPE 5,OUT1 12,OUT2 13,OUT3 0,OUT4 0,IN1 0,IN2 0,
IN3 0,IN4 0,GRP_OLD 1}
10
11 ...
12
13 REAL GRP_PULSE_TI=0.5 ; pulse time for gripper type 5

Line Description
4 Maximum number of configurable grippers
8 The gripper [1] is assigned type 5 and outputs 10 and 11.
(Control of the retract stroke)
9 The gripper [2] is assigned type 5 and outputs 12 and 13.
(Control of the working stroke)

6.3.2 Controlling RETRACT and SPOT in series

Description The retract stroke (RETRACT) and the working stroke (SPOT) of the weld gun
are to be controlled in series.
(>>> 5.2 "SpotTech: manual weld gun control" Page 17)
Gripper type 4 is available in GripperTech for this configuration.

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 KUKA.Gripper&SpotTech 2.5

I/Os OUT 2 OUT 3

Retract stroke open, working stroke FALSE FALSE
open
Retract stroke closed, working TRUE FALSE
stroke open
Retract stroke closed, working TRUE TRUE
stroke closed

Procedure 1. In $CONFIG.DAT, define 1 gripper of type 4.

2. Assign 2 outputs to the gripper.

The assignment of the inputs is not necessary for manual gun control.

Example 1 ;==================================
2 ; Definition of grippers
3 ;==================================
4 INT MAXGRIPPER=16
5
6 DECL GRP_TYPES GRIPPER[16]
7
8 GRIPPER[1]={TYPE 4,OUT1 10,OUT2 11,OUT3 0,OUT4 0,IN1 0,IN2 0,
IN3 0,IN4 0,GRP_OLD 1}

Line Description
4 Maximum number of configurable grippers
8 The gripper [1] is assigned type 4 and outputs 10 and 11.

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7 Programming

7.1 GripperTech: programming

7.1.1 Programming the inline form “Gripper”

Precondition  Program is selected.

 Operating mode T1 or T2.

Procedure 1. Select the menu sequence Technology > GripperTech > Gripper.
2. Set the parameters in the inline form.
3. Save by pressing the Cmd Ok softkey.

Fig. 7-1: Inline form for gripper with approximate positioning

Fig. 7-2: Inline form for gripper without approximate positioning

Item Description Range of values

1 Select gripper. GRP 1...GRP n
n: number of configured
grippers
2 Select the switching state of the Dependent on the gripper
gripper. type
3 Activate approximate positioning. CONT, [blank]
 CONT: end point is approximat-
ed.
 [blank]: the motion stops exactly
at the end point.
4  START: The gripper function is START, END
executed at the start point of the
gripper motion.
 END: The gripper function is ex-
ecuted at the end point of the
gripper motion.
Input box only available if CONT
selected.

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 KUKA.Gripper&SpotTech 2.5

Item Description Range of values

5 Define a wait time, relative to the -200 to 200 ms
start or end point of the gripper
motion, for execution of the gripper
function.
Input box only available if CONT
selected.
6 Data set with gripper parameters Freely selectable
The following parameters are set in
the corresponding option window:
 Sensor interrogation: ON, OFF
Default: OFF
 Wait time after which the pro-
grammed gripper motion is re-
sumed (0 to 10 s).
Input box only available if [blank]
selected.

7.1.2 Programming the inline form “CheckGripper”

Precondition  Program is selected.

 Operating mode T1 or T2.
 The command is located before a motion block.

Procedure 1. Select the menu sequence Technology > GripperTech > CheckGripper.
2. Set the parameters in the inline form.
3. Save by pressing the Cmd Ok softkey.

Fig. 7-3

Item Description Range of values

1 Select gripper. GRP 1...GRP n
n: number of configured
grippers
2 Select the switching state of the Dependent on the gripper
gripper. type
4 Select the time at which the sensor START, END
interrogation is executed.
 START: The sensor interroga-
tion is executed at the start point
of the gripper motion.
 END: The sensor interrogation
is executed at the end point of
the gripper motion.
5 Define a wait time, relative to the -200 to 200 ms
start or end point of the gripper
motion, for execution of the sensor
interrogation.

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 7 Programming

7.2 SpotTech: programming

7.2.1 Programming the inline form “SPOT”

Precondition  Program is selected.

 Operating mode T1 or T2.

Procedure 1. Select the menu sequence Technology > SpotTech > SPOT > motion
type (PTP, LIN, CIRC).
2. Teach auxiliary point. (Only if CIRC selected)
3. Teach a weld spot.
4. Set the parameters in the inline form.
5. Save by pressing the Cmd Ok softkey.

Fig. 7-4: Inline form “SPOT”

Item Description Range of values

1 Select motion type. PTP, LIN, CIRC
2 Teach auxiliary point and assign a Freely selectable
name.
Input box only available if CIRC
selected.
3 Teach weld spot and assign a Freely selectable
name.
4 Data set with motion parameter Freely selectable
5 Select weld gun. 1...5
6 Define retract stroke after the weld- OPN, CLO
ing operation.
 OPN: retract stroke open
 CLO: retract stroke closed
7 Data set with weld parameter Freely selectable

7.2.2 Programming the inline form “RETRACT”

Precondition  Program is selected.

 Operating mode T1 or T2.

Procedure 1. Select the menu sequence Technology > SpotTech > RETRACT > mo-
tion type (PTP, LIN, CIRC).
2. Teach auxiliary point. (Only if CIRC selected)
3. Teach an end point.
4. Set the parameters in the inline form.
5. Save by pressing the Cmd Ok softkey.

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 KUKA.Gripper&SpotTech 2.5

Fig. 7-5: Inline form “RETRACT”

Item Description Range of values

1 Select motion type. PTP, LIN, CIRC
2 Teach auxiliary point and assign a Freely selectable
name.
Input box only available if CIRC
selected.
3 Teach weld spot and assign a Freely selectable
name.
4 Data set with motion parameter Freely selectable
5 Define retract stroke on reaching OPN, CLO
the end point.
 OPN: retract stroke open
 CLO: retract stroke closed
6 Select weld gun. 1...5

7.2.3 Programming the inline forms SPOT and RETRACT with KUKA.RoboTeam

Precondition  KUKA.CR Program Cooperation is installed.

 KUKA.CR Motion Cooperation is installed.
 LIN or CIRC has been selected in the inline form.

Description

Fig. 7-6: Example of an inline form with KUKA.RoboTeam

The input boxes for synchronization with KUKA.RoboTeam are dis-

played or hidden with the Syn/Unsyn softkey.

Item Description Range of values

1 Define the name of the synchroni- Freely selectable
zation point.
If no name is assigned, automatic
synchronization of the system.
2 Data set with the synchronized Dependent on the cell
robots of a cell configuration configuration

Further information about the synchronization and configuration of

cooperating robots can be found in the operating and programming
instructions “KUKA.CR Program Cooperation” and “KUKA.CR Motion
Cooperation”.

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 7 Programming

7.2.4 Primary weldset option window

This option window is called from the SPOT inline form:

(>>> 7.2.1 "Programming the inline form “SPOT”" Page 27)

The Primary weldset option window appears in conjunction with the

PRESPOT option window.

Fig. 7-7: Primary weldset option window

Item Description Range of values

1 Timer program for first electrode pair 1...99
2 Gun pressure for first electrode pair 0...9.9

7.2.5 PRESPOT option window

This option window is called from the SPOT inline form:

(>>> 7.2.1 "Programming the inline form “SPOT”" Page 27)

The Primary weldset option window appears in conjunction with the

PRESPOT option window.

Fig. 7-8: PRESPOT option window

Parameter Description Range of values

Early gun close time The time at which closure of -1000...0 ms
the weld gun commences
before the weld spot is
reached.

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 KUKA.Gripper&SpotTech 2.5

The weld spot is executed incorrectly if the weld gun al-

ready closes completely while the robot is still moving.
This can result in damage to the robot, the weld gun or the workpiece.
Before setting the parameter, it is advisable to measure the current closing
time of the weld gun. Variations in air pressure or the orientation of the gun
may produce different closing times for the gun.

7.2.6 Synchronization option window with KUKA.RoboTeam

This option window is called from the SPOT and RETRACT inline forms.

Fig. 7-9: Example of a synchronization option window

Parameter Description Range of values

RoboTeam Slave Name of the slave robot of a TRUE, FALSE
cell configuration
 TRUE: the slave robot is
synchronized with the
master robot.
 FALSE: the slave robot
is not synchronized with
the master robot.

Further information about the synchronization and configuration of

cooperating robots can be found in the operating and programming
instructions “KUKA.CR Program Cooperation” and “KUKA.CR Motion
Cooperation”.

7.2.7 Activating/deactivating collision detection

Precondition  KUKA System Software (KSS) 5.5

Description Collision detection can be activated or deactivated for every motion via the
Frames option window.

Further information about collision detection is contained in the “Op-

erating and Programming Instructions for System Integrators”.

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 8 Examples

8 Examples

8.1 Configuration example: user-specific gripper

Description A gripper with 3 switching states is configured:

 Retract stroke open
 Retract stroke closed
 Working stroke closed
This gripper is controlled manually.

The gripper used consists of 2 double-acting pneumatic cylinders controlled

via electromagnetically operated 4/2-way valves.

Fig. 8-1: Configuration example

1 Retract stroke cylinder 4 Output: OUT 2

2 Working stroke cylinder 5 Output: OUT 3
3 Output: OUT 1 6 Output: OUT 4

I/Os Retract stroke open Retract stroke Working stroke

closed closed
OUT 1 FALSE TRUE TRUE
OUT 2 TRUE FALSE FALSE
OUT 3 FALSE FALSE TRUE
OUT 4 TRUE TRUE FALSE

8.1.1 Assigning the gripper type – $CONFIG.DAT

Description The file $CONFIG.DAT is located in the directory C:\KRC\ROBOT-

ER\KRC\R1\System.
1 ;==================================
2 ; Definition of grippers
3 ;==================================
4 INT MAXGRIPPER=16
5
6 DECL GRP_TYPES GRIPPER[16]
7
8 GRIPPER[6]={TYPE 100,OUT1 0,OUT2 0,OUT3 0,OUT4 0,IN1 0,IN2 0,
IN3 0,IN4 0,GRP_OLD 1}

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Line Description
4 Maximum number of configurable grippers
8 The gripper [6] is assigned type 100.

8.1.2 Configuring gripper parameters – USER_GRP.DAT

Description The file USER_GRP.DAT is located in the directory C:\KRC\ROBOT-

ER\KRC\R1\TP\Gripper_SpotTech.
1 DEFDAT USER_GRP
2
3 ENUM GUN_STAT RET_OPN,RET_CLS,WRK_CLS,WRK_OPN
4
5 STRUC MY_GUN INT RET_OPN,RET_CLS,WRK_OPN,WRK_CLS,GUN_STAT STAT
6
7 DECL MY_GUN MY_GUN1={RET_OPN 100,RET_CLS 101,WRK_OPN 102,
WRK_CLS 103,STAT #RET_OPN}
8
9 ENDDAT

Line Description
3 Configure gripper switching states.
5 Configure structure data type MY_GUN.
7 Assign 4 outputs to the gripper MY_GUN1 of structure type
MY_GUN.

8.1.3 Programming gripper functions – USER_GRP.SRC

Description The file USER_GRP.SRC is located in the directory C:\KRC\ROBOT-

ER\KRC\R1\TP\Gripper_SpotTech.
1 $OUT[MY_GUN1.RET_OPN]=FALSE
2 $OUT[MY_GUN1.RET_CLS]=FALSE
3 $OUT[MY_GUN1.WRK_OPN]=FALSE
4 $OUT[MY_GUN1.WRK_CLS]=FALSE
5
6 SWITCH MY_GUN1.STAT
7 CASE #RET_OPN
8 PULSE($OUT[MY_GUN1.RET_CLS],TRUE,0.3)
9 MY_GUN1.STAT=#RET_CLS
10
11 CASE #RET_CLS
12 PULSE($OUT[MY_GUN1.WRK_CLS],TRUE,0.3)
13 MY_GUN1.STAT=#WRK_CLS
14
15 CASE #WRK_CLS
16 PULSE($OUT[MY_GUN1.WRK_OPN],TRUE,0.3)
17 MY_GUN1.STAT=#WRK_OPN
18
19 CASE #WRK_OPN
20 PULSE($OUT[MY_GUN1.RET_OPN],TRUE,0.3)
21 MY_GUN1.STAT=#RET_OPN
22
23 DEFAULT
24 ENDSWITCH

Line Description
1…4 Reset outputs.
6 … 24 Poll gripper switching state.
7 Case 1: Retract stroke open
8 Trigger for closing the retract stroke: a 0.3 s pulse is sent to
the output of RET_CLS.

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 8 Examples

Line Description
9 The gripper is set to the switching state “Retract stroke
closed”.
11 Case 2: Retract stroke closed
12 Trigger for closing the working stroke: a 0.3 s pulse is sent to
the output of WRK_CLS.
13 The gripper is set to the switching state “Working stroke
closed”.
15 Case 3: Working stroke closed
16 Trigger for opening the working stroke: a 0.3 s pulse is sent to
the output of WRK_OPN.
17 The gripper is set to the switching state “Working stroke
open”.
19 Case 4: Working stroke open
20 Trigger for opening the retract stroke: a 0.3 s pulse is sent to
the output of RET_OPN.
21 The gripper is set to the switching state “Retract stroke open”.
23 If none of the switching states occurs, the program is
resumed after ENDSWITCH.

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 KUKA.Gripper&SpotTech 2.5

8.2 Example program USERSPOT.SRC

Description 1 &COMMENT USERSPOT package

2 DEF USERSPOT (CMD :IN,S :IN )
...
10 DECL S_COMMAND CMD
11 DECL SPOT_TYPE S
12 ;Program-No.
13 SIGNAL PNUM $OUT[1] TO $OUT[8]
14 ;GUN-RETRACT
15 SIGNAL GUN_RET $OUT[10] TO $OUT[11]
16 ;State RETRACT
17 SIGNAL RET_STAT $IN[10] TO $IN[11]
18 ;GUN work (SPOT)
19 SIGNAL GUN_WRK $OUT[12] TO $OUT[13]
20 ;State SPOT
21 SIGNAL WRK_STAT $IN[12] TO $IN[13]
22 ;Weld Start
23 SIGNAL WLD_STRT $OUT[15]
24 ;Weld done
25 SIGNAL WLD_CMP $IN[15]
26 ;=================================
27 ;GROUP-Definitions
28 INT R_CLO,R_OPN,W_CLO,W_OPN
29 R_CLO=’B0001’
30 R_OPN=’B0010’
31 W_CLO=’B0001’
32 W_OPN=’B0010’
33 ;=================================
34 SWITCH CMD
35 CASE #INIT
36 INIT ( )
37 CASE #ADVSPOT
38 ADVSPOT (CMD,S )
39 CASE #PRESPOT
40 PRESPOT (CMD,S )
41 CASE #SPOT
42 SPOT (CMD,S )
43 S_READY=TRUE
44 CASE #RETR
45 RETRACT (CMD,S )
46 S_READY=TRUE
47 ENDSWITCH
48 END ; END OF MAIN

Line Description
12 … 25 Assignment of the I/Os to the interface between robot control-
ler (KR C) and weld controller (PLC)
(>>> 8.2.1 "Overview of I/Os – robot controller (KR C) / weld
controller (PLC)" Page 36)
13 Program number: Outputs 1 to 8
15 Activation of retract stroke: Outputs 10 to 11
17 Status of retract stroke: Inputs 10 to 11
19 Activation of working stroke: Outputs 12 to 13
21 Status of working stroke: Inputs 12 to 13
23 Weld start: Output 15
25 Weld complete signal: Input 15
28 … 32 Definition of the weld gun switching states:
 R_CLO: Retract stroke closed
 R_OPN: Retract stroke open
 W_CLO: Working stroke closed
 W_OPN: Working stroke open

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 8 Examples

49 ;*****************************
50 DEF ADVSPOT (CMD :IN,S :IN )
51 WLD_STRT=FALSE
52 PNUM=S.PGNO1
53 END ;(ADVSPOT)
54 ;*****************************
55 DEF PRESPOT (CMD :IN,S :IN )
56 GUN_RET=R_CLO
57 WAIT FOR RET_STAT==R_CLO
58 GUN_WRK=W_CLO
59 END ;(PRESPOT)
60 ;*****************************
61 DEF SPOT (CMD :IN,S :IN )
62 WAIT FOR WRK_STAT==W_CLO
63 WLD_STRT=TRUE
64 WAIT FOR WLD_CMP
65 PNUM=0
66 WAIT FOR NOT (WLD_CMP)
67 WLD_STRT=FALSE
68 GUN_WRK=W_OPN
69 WAIT FOR WRK_STAT==W_OPN
70 SWITCH S.RETR
71 CASE #OPN
72 GUN_RET=R_OPN
73 WAIT FOR RET_STAT==R_OPN
74 ENDSWITCH
75 END ;(SPOT)
76 ;*****************************
77 DEF RETRACT (CMD :IN,S :IN )
78 SWITCH S.RETR
79 CASE #OPN
80 GUN_RET=R_OPN
81 WAIT FOR RET_STAT==R_OPN
82 CASE #CLO
83 GUN_RET=R_CLO
84 WAIT FOR RET_STAT==R_CLO
85 ENDSWITCH
86 END ;(RETR)
87 ;*****************************
88 DEF INIT ( )
89 PNUM=0
90 WLD_STRT=FALSE
91 GUN_WRK=W_OPN
92 WAIT FOR WRK_STAT==W_OPN
93 GUN_RET=R_OPN
94 WAIT FOR RET_STAT==R_OPN
95 S_READY=TRUE
96 END ;(INIT)

Line Description
50 … 53 User data for ADVSPOT
51 Reset weld start.
52 Set program number.
55 … 59 User data for PRESPOT
56 Close retract stroke.
57 Wait for “Retract stroke closed”.
58 Close working stroke.
61 … 75 User data for SPOT
62 Wait for “Working stroke closed”.
63 Set weld start.
64 Wait for weld complete signal (TRUE).
65 Set program number to “0”.
66 Wait for weld complete signal (FALSE).
67 Reset weld start.

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 KUKA.Gripper&SpotTech 2.5

Line Description
68 Open working stroke.
69 Wait for “Working stroke open”.
70 … 74 Query which retract stroke has been programmed after the
weld spot.
71 Condition: “RETR OPN” is programmed.
72 Open retract stroke.
73 Wait for “Retract stroke open”.
77 … 86 User data for RETRACT
78 Query which retract stroke has been programmed.
79 Condition 1: “RETR OPN” is programmed.
80 Open retract stroke.
81 Wait for “Retract stroke open”.
82 Condition 2: “RETR CLO” is programmed.
83 Close retract stroke.
84 Wait for “Retract stroke closed”.
88 … 96 User data for INIT
89 Set program number to “0”.
90 Reset weld start.
91 Open working stroke.
92 Wait for “Working stroke open”.
93 Open retract stroke.
94 Wait for “Retract stroke open”.
95 Enable for further program execution

8.2.1 Overview of I/Os – robot controller (KR C) / weld controller (PLC)

Overview The I/Os in the following overview refer to the example program.
(>>> 8.2 "Example program USERSPOT.SRC" Page 34)
Signal Description Permissible values I/Os
PNUM Weld program number The number can have a maxi- Outputs 1 to 8
mum length of 255 characters.
WLD_STR Weld start FALSE, TRUE Output 15
T
WLD_CMP Weld complete signal from FALSE, TRUE Input 15
weld controller
GUN_WRK Activation of working W_CLO W_OPN
stroke
Close TRUE FALSE Output 10
Open FALSE TRUE Output 11
WRK_STAT Status of working stroke W_CLO W_OPN
Closed TRUE FALSE Input 10
Open FALSE TRUE Input 11
GUN_RET Activation of retract stroke R_CLO R_OPN
Close TRUE FALSE Output 12
Open FALSE TRUE Output 13
RET_STAT Status of retract stroke R_CLO R_OPN
Closed TRUE FALSE Input 12
Open FALSE TRUE Input 13

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 8 Examples

8.2.2 Signal diagram: SPOT without the options RETRACT and PRESPOT

Fig. 8-2: Weld program – SPOT without RETRACT

Description 1. The following signals are set simultaneously after point “P1” has been
welded:
 The weld complete signal “WLD_CMP=TRUE” triggers, with falling
edge “WLD_CMP=FALSE”, the signal to open the working stroke of
the weld gun (“GUN_WRK=W_OPN”).
 The weld start signal is reset (“WLD_STRT=FALSE”).
 The weld program number is set to “0” (“PNUM=0”).

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 KUKA.Gripper&SpotTech 2.5

2. The robot controller waits for the weld controller signal indicating that the
working stroke of the gun is open (“WRK_STAT=W_OPN”).
3. If no retract stroke or “RETR CLO” has been programmed in the inline
form, the robot motion to weld spot “P2” is enabled when the signal indi-
cating that the working stroke is open is set.
4. To ensure that all required weld data are available at weld spot “P2”, the
weld program number is set while the robot is still moving
(“PNUM=S.PGN01”).
5. At weld spot “P2”, the signal to close the working stroke is set
(“GUN_WRK=W_CLO”).
6. The weld controller signal indicating that the working stroke is closed
(“WRK_STAT=W_CLO”) triggers the weld start (“WLD_STRT=TRUE”).
7. The described sequence starts once again after point “P2” has been weld-
ed.

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 8 Examples

8.2.3 Signal diagram: SPOT with the options RETRACT and PRESPOT

Fig. 8-3: Weld program – SPOT with RETRACT

Description 1. The following signals are set simultaneously after point “P1” has been
welded:
 The weld complete signal “WLD_CMP=TRUE” triggers, with falling
edge “WLD_CMP=FALSE”, the signal to open the working stroke of
the weld gun (“GUN_WRK=W_OPN”).
 The weld start signal is reset (“WLD_STRT=FALSE”).
 The weld program number is set to “0” (“PNUM=0”).

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 KUKA.Gripper&SpotTech 2.5

2. The robot controller waits for the weld controller signal indicating that the
working stroke of the gun is open (“WRK_STAT=W_OPN”).
3. If “RETR OPN” has been programmed in the inline form, the signal to open
the retract stroke (“GUN_RET=R_OPN”) is set when the signal indicating
that the working stroke is open is set.
4. The robot controller waits for the weld controller signal indicating that the
retract stroke of the gun is open (“RET_STAT=R_OPN”).
5. The robot motion to weld spot “P2” is enabled when the signal indicating
that the retract stroke is open is set.
6. To ensure that all required weld data are available at weld spot “P2”, the
weld program number is set while the robot is still moving
(“PNUM=S.PGN01”).
7. At weld spot “P2”, the signal to close the retract stroke is set
(“GUN_RET=R_CLO”).
8. The signal to close the working stroke (“GUN_WRK=W_CLO”) is triggered
when the signal indicating that the retract stroke is closed
(“RET_STAT=R_CLO”) is set.
9. The weld controller signal indicating that the working stroke is closed
(“WRK_STAT=W_CLO”) triggers the weld start (“WLD_STRT=TRUE”).
10. The described sequence starts once again after point “P2” has been weld-
ed.

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 9 Messages

9 Messages

9.1 GripperTech: error messages

Message Cause Remedy

Gripper not Proximity switches are not  Check gripper.
closed or still signaling a clear “Gripper  Check proximity
open. closed” state. switches.
Gripper not open Proximity switches are not  Check gripper.
or still closed. signaling a clear “Gripper  Check proximity
open” state. switches.
Gripper state Invalid gripper type in the Assign valid gripper
unknown. configuration type in the configura-
tion.
Gripper type Invalid gripper type in the Assign valid gripper
inadmissible configuration type in the configura-
tion.
Invalid gripper KRL program is attempt-  Configure the grip-
state ing to assign the gripper per.
an invalid or undefined  Check the KRL pro-
status. gram.
Gripper type KRL program is attempt-  Configure the grip-
error; check con- ing to access a gripper of per.
figuration an invalid type.  Check the KRL pro-
gram.
Gripper not The index of the gripper is  Configure the grip-
defined higher than the variable per.
MAXGRIPPER.  Adapt the variable
MAXGRIPPER in
$CONFIG.DAT.
The variable The variable MAXGRIP- Initialize the variable
MAXGRIPPER is PER is not initialized. MAXGRIPPER in
invalid. $CONFIG.DAT.
The variable The variable MAXGRIP- Declare the variable
MAXGRIPPER is PER is not declared. MAXGRIPPER in
not available. $CONFIG.DAT.

9.2 SpotTech: error messages

Message Cause Remedy

Inadmissible Impermissible character in Do not use special
KRL-name! the character string, e.g. ä, ö, characters in KRL
", %, etc. names.

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 10 KUKA Service

10 KUKA Service

10.1 Requesting support

Introduction The KUKA Roboter GmbH documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.

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

 Model and serial number of the robot
 Model and serial number of the controller
 Model and serial number of the linear unit (if applicable)
 Version of the KUKA System Software
 Optional software or modifications
 Archive of the software
For KUKA System Software V8: instead of a conventional archive, gener-
ate the special data package for fault analysis (via KrcDiag).
 Application used
 Any external axes used
 Description of the problem, duration and frequency of the fault

10.2 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 Headland Machinery Pty. Ltd.

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

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Belgium KUKA Automatisering + Robots N.V.

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

Brazil KUKA Roboter do Brasil Ltda.

Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guançã
CEP 02151 900 São Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
[email protected]

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 Automation Equipment (Shanghai) Co., Ltd.

Songjiang Industrial Zone
No. 388 Minshen Road
201612 Shanghai
China
Tel. +86 21 6787-1808
Fax +86 21 6787-1805
[email protected]
www.kuka.cn

Germany KUKA Roboter GmbH

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

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France KUKA Automatisme + Robotique SAS

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.

Daiba Garden City Building 1F
2-3-5 Daiba, Minato-ku
Tokyo
135-0091
Japan
Tel. +81 3 6380-7311
Fax +81 3 6380-7312
[email protected]

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]

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Malaysia KUKA Robot Automation Sdn Bhd

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

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

Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
[email protected]

Norway KUKA Sveiseanlegg + Roboter

Bryggeveien 9
2821 Gjövik
Norway
Tel. +47 61 133422
Fax +47 61 186200
[email protected]

Austria KUKA Roboter Austria GmbH

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

Poland KUKA Roboter Austria GmbH

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]

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Portugal KUKA Sistemas de Automatización S.A.

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

Russia OOO KUKA Robotics Rus

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

Sweden KUKA 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

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
Fax +34 93 8142-950
[email protected]
www.kuka-e.com

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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]

Hungary KUKA Robotics Hungaria Kft.

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

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USA KUKA Robotics Corp.

22500 Key Drive
Clinton Township
48036
Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
[email protected]
www.kukarobotics.com

UK KUKA Automation + Robotics

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

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 Index

Index
Symbols P
$CONFIG.DAT 8, 20, 31 PLC 6
PNUM (signal) 36
C PRESPOT 6, 9
CheckGripper, inline form 26 PRESPOT, option window 29
Collision detection 30 Primary weldset, option window 29
Configuration 19 Product description 7
Configuration, gripper 19 Programming 25
Configuration, gripper parameters 32 Programming, CheckGripper 26
Configuration, gripper, example 31 Programming, Gripper 25
Configuration, manual control 23 Programming, gripper functions 32
Configuration, SpotTech 20 Programming, RETRACT 27, 28
Configuring I/Os 19 Programming, SPOT 27, 28
Control, manual 17
R
D Reinstallation, KUKA.Gripper&SpotTech 16
Documentation, industrial robot 5 RET_STAT (signal) 36
RETRACT 6, 9
E Retract stroke 6
Examples 31 RETRACT, inline form 27

G S
Gripper 6 Safety 13
Gripper functions, programming 32 Safety instructions 5
Gripper parameters, configuring 32 Service, KUKA Roboter 43
Gripper type, assigning 31 Signal diagram, SPOT with RETRACT 39
Gripper types 7 Signal diagram, SPOT without RETRACT 37
Gripper, configuring 19 SPOT 6, 9
Gripper, inline form 25 SPOT, inline form 27
Gripper, manual control 17 SPOTTECH GLOBALS (fold) 20
GRP_PULSE_TI 8 Support request 43
GUN_RET (signal) 36 Synchronization 10, 28
GUN_WRK (signal) 36 Synchronization, option window 30
System requirements 15
I
I/Os, configuration 19 T
Installation 15 Target group 5
Installation, KSS 5.2, 5.3 15 Terms 6
Installation, KSS 5.4, 5.5, 5.6, 7.0, 7.1 15 Terms used 6
Installation, KUKA.Gripper&SpotTech 15 Training 5
Introduction 5 Trigger 6

K U
KUKA Customer Support 43 Uninstallation, KUKA.Gripper&SpotTech 15, 16
KUKA.RoboTeam 6, 10, 28 Update, KUKA.Gripper&SpotTech 15
USER_GRP.DAT 32
M USER_GRP.SRC 32
Messages 41 USERSPOT.SRC, description 21
USERSPOT.SRC, example 34
O
Operation 17 W
Option window, PRESPOT 29 Warnings 5
Option window, Primary weldset 29 Weld gun, manual control 17
Option window, Synchronization 30 Weld guns 7
Overview, gripper types 19 Weld timer 6
Overview, Gripper&SpotTech 7 WLD_CMP (signal) 36
WLD_STRT (signal) 36
Working stroke 6

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 KUKA.Gripper&SpotTech 2.5

WRK_STAT (signal) 36

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