KST TouchSense 20 en PDF
KST TouchSense 20 en PDF
KUKA.TouchSense 2.0
Issued: 25.07.2013
© Copyright 2013
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
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
3 Safety ............................................................................................................ 11
4 Installation ................................................................................................... 13
4.1 System requirements ................................................................................................. 13
4.2 Installing or updating TouchSense ............................................................................. 13
4.3 Uninstalling TouchSense ........................................................................................... 14
5 Operation ...................................................................................................... 15
5.1 Menus ........................................................................................................................ 15
5.2 Status keys ................................................................................................................ 15
6 Configuration ............................................................................................... 17
6.1 Configuring TouchSense via the smartHMI ............................................................... 17
6.1.1 “General settings” tab ........................................................................................... 17
6.1.2 “Search dynamic” tab ............................................................................................ 18
6.1.3 “Sensor configuration” tab .................................................................................... 19
6.2 Configuring TouchSense with WorkVisual ................................................................. 19
6.2.1 Setting parameters ............................................................................................... 20
7 Programming ............................................................................................... 21
7.1 Instructions for programming ..................................................................................... 21
7.2 Preparation ................................................................................................................ 21
7.3 Inline form “Search” ................................................................................................... 21
7.3.1 Option window “Set new reference” ...................................................................... 23
7.3.2 Option window “Search parameter” ...................................................................... 24
7.4 Linked search ............................................................................................................. 25
7.4.1 Example of a linked search: searching for the position of a single-V butt weld .... 26
7.5 Programming a correction instruction ........................................................................ 27
7.5.1 Inline form “Corr” (1-dimensional) ......................................................................... 27
7.5.2 Inline form “Corr” (2-dimensional) ......................................................................... 28
7.5.3 Inline form “Corr” (3-dimensional) ......................................................................... 29
7.5.4 Inline form “Corr” (freely programmable) .............................................................. 30
7.5.4.1 Freely programmable correction – detailed explanation .................................. 32
7.5.5 Inline form “Corr Off” ............................................................................................. 33
7.5.6 Inline form “Check Point” ...................................................................................... 33
7.5.6.1 Option window “Position evaluation criteria” .................................................... 35
9 Messages ...................................................................................................... 39
9.1 Error messages ......................................................................................................... 39
Index ............................................................................................................. 51
1 Introduction
This documentation is aimed at users with the following knowledge and skills:
Advanced knowledge of the robot controller system
Advanced KRL programming skills
Notes These hints serve to make your work easier or contain references to further
information.
Term Description
Square butt A square butt weld is formed when 2 workpieces, e.g. 2
weld plates, lie parallel to each other. A square butt weld
takes the form of a straight line.
Single-V butt A single-V butt weld is formed when 2 workpieces
weld stand at right angles to each other. A single-V butt weld
takes the form of a triangle with two sides of equal
length.
Fast Measure- Fast Measurement interface X33 can be used to pro-
ment gram search commands in the robot controller for mea-
suring workpieces using digital sensors. Interface X33
is located on the connection panel of the robot control-
ler.
2 Product description
Functional The original position of the workpiece is detected using the sensor, a live weld-
principle ing wire. This is done by means of search instructions which are programmed
via inline forms. When the welding wire touches the workpiece, the current
flow is registered. At the same time, the search motion is interrupted by an in-
terrupt signal and the position of the robot when the welding wire touches the
workpiece is saved. Depending on the workpiece, one or more search instruc-
tions must be programmed.
If the workpiece is then offset, the new position of the workpiece is determined
using the same program. The robot controller calculates correction data sets
from the difference between the original position and the new position.
When making the correction, the programmed path data are offset by the cor-
rection data. This is done by means of one or more correction instructions,
which are likewise programmed via inline forms.
2.2 Communication
can thus be detected. The search path is dependent on the search distance X,
which is set in the Search Parameter option window.
This method can be used to determine the center of a gap between 2 work-
pieces, e.g. for a square butt weld.
The start point of the search lies within the gap. The search direction is defined
by the Via point. The search motion is stopped when the sensor touches the
side of the gap. The search is then started automatically in the opposite direc-
tion. The search motion is stopped when the sensor touches the other side of
the gap.
From the axis values determined during the search, the center of the gap is
calculated and saved as a correction data set. The robot then returns to the
start point.
The start point and the search path must be programmed in such a way that
both the original and new positions of the gap lie within the limits of the search
motion and can thus be detected. The search path is dependent on the search
distance X, which is set in the Search Parameter option window.
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.
4 Installation
Robot Hardware:
controller KR C4 with interface X33
Software:
KUKA System Software 8.3.2 or higher
Laptop/PC Software:
WorkVisual 3.0
The requirements for installation of WorkVisual are contained in the
WorkVisual documentation.
Procedure 1. In the main menu, select Start-up > Additional software. All additional
programs installed are displayed.
2. Select the entry TouchSense and click on Uninstall. Reply to the request
for confirmation with Yes. Uninstallation is prepared.
3. Reboot the robot controller. Uninstallation is resumed and completed.
5 Operation
5.1 Menus
The following menus and commands are specific to this technology package:
Main menu:
Configuration > TouchSense
Menu sequence:
Commands > TouchSense
Search
Correction
Switch off correction
Check position correction
Description The status keys are only available if the following conditions are met:
“Expert” user group
Operating mode T1 or T2
Program is selected
Submit interpreter running
The parameter TouchSense active is activated in the configuration
The enabling switch is pressed (only for status key Sensor On)
TouchSense is activated via the status key Option Off (only for status key
Sensor On)
Status key Description
Status key Option Off (not pressed)
TouchSense is active. Search and correction are carried
out.
Pressing the status key deactivates TouchSense.
Status key Option Off (pressed)
TouchSense is not active. Neither search nor correction is
carried out.
Status key Force Mastering (pressed)
Remastering is active. At the next search routine, the posi-
tion data of the workpiece will be saved as reference data.
In the case of a reference run, the reference coordinates
are recalculated. The reference coordinates of the previous
mastering are overwritten.
Status key Force Mastering (not pressed)
Remastering is not active.
Pressing the status key activates remastering.
Status key Corr Off (not pressed)
Correction is not active.
6 Configuration
Parameter Description
TouchSense active Activate or deactivate TouchSense.
Activated: TouchSense is active; the TouchSense commands are
executed.
Deactivated: TouchSense is inactive; the TouchSense commands
are ignored.
Steps for messaging Set the messaging level.
Low: Only the most important messages are displayed, including
safety messages.
Medium: The displayed messages enable a diagnosis to be carried
out by the user.
High: The displayed messages enable a diagnosis to be carried out
by the expert.
Default setting: Low
Note: Performance is highest with the setting Low, as every message is
prepared and logged in the system.
Number of search or If an error (e.g. component not found) occurs during a search or mea-
measurement repeats surement, the robot controller automatically repeats the search up to the
after error specified number of retries (as long as errors still occur). Following the
last repetition, and depending on the setting of the parameter Display
dialog in event of error, either a dialog message is generated or the
program stops with an acknowledgement message.
0…5
Default setting: 0
Note: In the case of a search with welding wire, it is advisable to set this
parameter to the value 0. Otherwise, the welding wire may bend in the
case of a faulty search. If the search is repeated, this leads to incorrect
measurement values.
Wait time before auto- Before the repetitions configured under Number of search or mea-
matic repeat [s] surement repeats after error, the robot controller waits for the time
specified here.
0.3 … 2.00 s
Default setting: 0.3 s
Parameter Description
Show dialog message This parameter determines whether a dialog message is displayed in
in case of error the case of an error.
No dialog: No dialog message is displayed; the robot stops the pro-
gram.
Always: A dialog message is displayed in all operating modes.
T1|T2: A dialog message is only displayed in operating modes T1
and T2.
T1|T2|AUT: A dialog message is only displayed in operating modes
T1, T2 and AUT.
Default setting: T1|T2
Output number for This parameter determines whether an output is set in the event of a
error correction error, in order to signal the error to the PLC.
0: No output is set.
≠0: The output with the specified number is set.
Default setting: 0
Interrupt priority char- Priority of the interrupt for detection of the feature
acteristic found
10 … 32
Default setting: 15
Note: The priority of this parameter must be lower than the priority of the
parameter Interrupt priority technology package. Only alter the
default setting if the value is already assigned.
Interrupt priority tech- Priority of the interrupt for the technology package in the case of an error
nology package
11 … 32
Default setting: 16
Note: The priority of this parameter must be higher than the priority of
the parameter Interrupt priority characteristic found.
Description In the option window Search parameter set a dynamic profile can be selected
for the search (Fast, Medium or Slow).
(>>> 7.3.2 "Option window “Search parameter”" Page 24)
Here on the Search dynamic tab, the following velocities and accelerations
can be configured for each profile:
Parameter Description
Search velocity [mm/ Velocity for the search
s]
2 … 250 mm/s
Retract velocity [mm/ Velocity at which the robot returns to the start point after the search
s]
2 … 2000 mm/s
Search acceleration Acceleration for the search and return motion
[%]
The value refers to the maximum value specified in the machine data.
Return acceleration The maximum value depends on the robot type and the selected operat-
[%] ing mode.
1 … 100%
Parameter Description
Sensor name Name of the sensor
Note: The name must not exceed 24 characters.
Output number touch Number of the output for activating the touch voltage
voltage
0: No input configured
Default setting: 0
Input number system Number of the input used by the external system to communicate to the
ready robot that it is ready
0: No input configured
Default setting: 0
Compensation time Wait time between the setting of the output “Touch voltage” and the start
[s] of the search motion. The compensation time ensures that the touch
voltage is set by the power source and is stable at the welding wire.
0.0 … 1.0 s
Default setting: 0.1 s
Input number touch Number of the input that is used to signal that the component has been
signal found. This input can be defined as a Fast Measurement input or stan-
dard input.
Default setting: 1
Kind of the touch Type of touch signal
input
Fast: The input is defined as a Fast Measurement input.
Standard: The input is defined as a standard input (via a field bus).
Note: The stop reaction and the position data acquisition of the robot
are fastest and most accurate with a Fast Measurement input. If a stan-
dard input is used, the search velocity should not be greater than
10 mm/s.
Switching level of the Type of touch signal level when the component is found
touch input
High active: The edge from Low to High signals that the component
has been found.
Low active: The edge from High to Low signals that the component
has been found.
Step Description
1 Install the TouchSense option package in WorkVisual.
2 Transfer the project from the robot controller to WorkVisual.
Precondition: TouchSense is installed on the robot controller.
Note: This project should be used for the configuration of
TouchSense in WorkVisual, otherwise the entries installed on
the robot controller by TouchSense could be lost when the
project is transferred back to the robot controller (see step 4).
3 Configure TouchSense in the Editor TouchSense Configura-
tion.
(>>> 6.2.1 "Setting parameters" Page 20)
4 Transfer the project from WorkVisual to the robot controller.
Note: During project transfer, the technology-specific files are
copied to the robot controller and activated. If an earlier proj-
ect has already been transferred, the files of this project are
overwritten. It is therefore recommended to archive the files of
the earlier project before transferring the new project.
Procedure 1. Open the editor TouchSense Configuration: menu sequence Editors >
Options packages > Configure TouchSense....
2. Set the parameters on the tabs as required.
(>>> 6.1.1 "“General settings” tab" Page 17)
(>>> 6.1.2 "“Search dynamic” tab" Page 18)
(>>> 6.1.3 "“Sensor configuration” tab" Page 19)
3. Save the settings.
7 Programming
7.2 Preparation
Procedure 1. Select the menu sequence Commands > TouchSense > Search.
2. Select the motion type in the inline form.
3. Only if CIRC or SCIRC has been selected as the motion type:
Move the TCP to the position for the auxiliary point. Press Teach Aux.
4. Move the TCP to the position for the end point (= start point for the search).
Press Touchup.
The start point must be approached in such a way that the welding wire is
not perpendicular to the workpiece during the search, otherwise the resul-
tant correction data will be falsified. Ideally, the welding wire should be po-
sitioned at an angle of approx. 45° to the search direction at the start
position.
Item Description
1 Via point
The Via point defines the direction of the search. It does not spec-
ify the end point of the search. (This is derived from the search
distance.)
The system automatically generates a name. The name can be
changed.
2 Name of the feature.
The system automatically generates a name. The name can be
changed. Touch the arrow to edit the data. The corresponding
option window is opened.
(>>> 7.3.1 "Option window “Set new reference”" Page 23)
3 Search parameter
The system automatically generates a name. The name can be
changed. Touch the arrow to edit the data. The corresponding
option window is opened. The search distance and the velocity
profile for the search are defined here.
(>>> 7.3.2 "Option window “Search parameter”" Page 24)
Item Description
1 Set new reference
Yes: The position of the reference workpiece is referenced
again for the search. Once referencing has been carried out,
this parameter is automatically set to No so that the referenc-
ing is not overwritten.
No: The position of the reference workpiece is not referenced
again for the search.
Item Description
1 Enter the search distance.
5 … 250 mm
Default value: 50 mm
2 Set the velocity and acceleration for the search.
Slow, Medium or Fast
The exact values can be configured on the Search dynamic tab.
(>>> 6.1.2 "“Search dynamic” tab" Page 18)
3 Select the Touch mode.
Single Touch
(>>> 2.3.1 "Single Touch mode" Page 8)
Double Touch
(>>> 2.3.2 "Double Touch mode" Page 9)
4 Select the sensor to be used for the search.
The stop reaction and the position data acquisition of the robot are
fastest and most accurate with a Fast Measurement input. If a stan-
dard input is used, the search velocity should not be greater than 10
mm/s.
Description With searches consisting of more than one search motion, there may be such
a large deviation in one direction that a further search instruction no longer lo-
cates the workpiece. This can be avoided by linking searches as illustrated in
the following diagrams.
Linking the searches leads to a higher hit rate and greater accuracy. The
linked search is suitable for all linear offsets and slight rotations.
Example ...
LIN P1 TouchSense SEARCH VIA P2 CD1
LIN P3 TouchSense SEARCH VIA P4 CD2
TouchSense Corr 2D CD1 CD2
...
Remedy: Program a linked search. The second search command then takes
into account the first change in position.
...
LIN P1 TouchSense SEARCH VIA P2 CD1
TouchSense Corr 1D CD1
LIN P3 TouchSense SEARCH VIA P4 CD2
TouchSense Corr 2D CD1 CD2
...
7.4.1 Example of a linked search: searching for the position of a single-V butt weld
Item Description
1 Start point P1 of the search
2 Via point P2 of the search: determines the search direction
3 Touch position: upper edge of the weld
4 Workpiece
Item Description
1 Start point P3 of the search
2 Via point P4 of the search: the search direction must be pro-
grammed so that it is perpendicular to the upper edge of the weld.
3 Touch position 1: from this point, the search motion is started in
the opposite direction.
4 Touch position 2
5 Workpiece
Example 1 ...
2 LIN P3 TouchSense SEARCH VIA P4 CD1
3 TouchSense Corr 1D CD1
4 LIN P1 TouchSense SEARCH VIA P2 CD2
5 TouchSense Corr 2D CD1 CD2
6 ...
Line Description
2 Search instruction for determining the center of the weld
(Double Touch)
3 Correction instruction 1 dimensional: Correction of the hori-
zontal offset of the weld
4 Search instruction for determining the upper edge of the weld
(Single Touch)
5 Correction instruction 2 dimensional: Correction of the hori-
zontal offset of the weld, linked to correction of the vertical off-
set of the weld
6… Weld program
Description This correction instruction is used if the workpiece has a linear offset in one
direction:
Length
Width
or height
A correction instruction overwrites the data of a previous correction instruction.
Procedure 1. Select the menu sequence Commands > TouchSense > Correction.
2. Select 1D in the inline form.
Item Description
1 Enter the correction data set.
All correction data sets created in the current program can be
entered.
Description This correction instruction is used if the workpiece has a linear offset in two
directions:
Length
Width
or height
A correction instruction overwrites the data of a previous correction instruction.
The following example is valid for an unlinked search.
Procedure 1. Select the menu sequence Commands > TouchSense > Correction.
2. Select 2D in the inline form.
Item Description
1, 2 Enter the correction data set.
All correction data sets created in the current program can be
entered.
Description This correction instruction is used if the workpiece has a linear offset in all di-
rections:
Length
Width
and height
A correction instruction overwrites the data of a previous correction instruction.
The following example is valid for an unlinked search.
Procedure 1. Select the menu sequence Commands > TouchSense > Correction.
2. Select 3D in the inline form.
Item Description
1…3 Enter the correction data set.
All correction data sets created in the current program can be
entered.
Description This correction instruction is used if the workpiece is rotated in one or more
directions:
Length
Width
Height
The workpiece may additionally have a linear offset in the other directions.
A correction instruction overwrites the data of a previous correction instruction.
Procedure 1. Select the menu sequence Commands > TouchSense > Correction.
2. Select Free in the inline form.
Item Description
1…6 Enter the correction data set.
All correction data sets created in the current program can be
entered.
Description
Point Description
CD1 Defines the surface.
CD2 1st rotational dimension of the surface
CD3 2nd rotational dimension of the surface
CD4 Defines the line.
CD5 1st rotational dimension of the line
CD6 Defines the offset.
Example
Description Each correction instruction switches the correction mode on. This instruction
switches the correction mode off. This means that all following motion com-
mands are executed without correction.
Procedure Select the menu sequence Commands > TouchSense > Switch off cor-
rection.
Description This instruction checks whether a point is still within certain limits after the cor-
rection. If the limits are exceeded, a message is displayed. This enables incor-
rectly loaded workpieces to be detected, for example.
The instruction Check Point should be programmed directly after the correc-
tion instruction. It may be inserted at any distance before the point to be
checked.
The limits can be defined as a sphere about the original point, or as X, Y, Z
and angle values.
Procedure Select the menu sequence Commands > TouchSense > Check position
correction.
The Set box can be displayed by pressing the Parameter button. The Radius
box can be displayed by pressing the Radius button.
Item Description
1 Point whose position is to be checked.
All points created in the current program are available for selec-
tion.
2 The system checks whether the point is still within a sphere of this
radius.
0.1 … 200 mm
3 The system checks whether the point lies within the defined limits.
Name of the data set containing the limit values. The system auto-
matically generates a name. The name can be overwritten.
Touch the arrow to edit the limits. The corresponding option win-
dow is opened.
(>>> 7.5.6.1 "Option window “Position evaluation criteria”"
Page 35)
Item Description
1 Permitted deviation in the X values
2 Permitted deviation in the Y values
3 Permitted deviation in the Z values
4 Permitted deviation in the angle values
8 Example programs
Line Description
29 The instruction checks that point P17 is within the limits de-
fined in the Correction set option window.
30 The instruction checks that point P18 is no more than 5 mm
away from the original position following the correction.
32 … 37 These motions are executed with the data from the 3-dimen-
sional correction instruction.
39 The HOME position is not affected by the correction.
9 Messages
10 KUKA Service
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.
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Index
C Single Touch 8
Check Point (inline form) 33 Single-V butt weld 6
Communication 7 Square butt weld 6
Configuration 17 Status keys 15
Corr Off (inline form) 33 Support request 43
Correction, 1D (inline form) 27 System requirements 13
Correction, 2D (inline form) 28
Correction, 3D (inline form) 29 T
Correction, freely programmable (inline form) 30 Terms used 6
Correction, programming 27 TouchSense, configuring (HMI) 17
TouchSense, configuring (WorkVisual) 19
D Training 5
Documentation, industrial robot 5
Double Touch 8 U
Uninstalling TouchSense 14
E Updating TouchSense 13
Error messages 39
Example programs 37 V
Via point 23
F
Fast Measurement 6 W
Fixed sensor 21 Warnings 5
Functional principle 7
G
General settings (tab) 17
I
Installation 13
Installing TouchSense 13
Introduction 5
K
KUKA Customer Support 43
M
Menus 15
Messages 39
O
Operation 15
Overview, KUKA.TouchSense 7
P
Parameters, setting 20
Product description 7
Programming 21
Programming, correction 27
Programming, instructions 21
S
Safety 11
Safety instructions 5
Search (inline form) 21
Search dynamic (tab) 18
Sensor configuration, tab 19
Sensor, fixed 21
Service, KUKA Roboter 43