KSS 8.3 System Intergrators.pdf

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KUKA System Software
KUKA Roboter GmbH
KUKA System Software 8.3
Operating and Programming Instructions for System Integrators
Issued: 22.01.2013
Version: KSS 8.3 SI V1 en (PDF)
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KUKA System Software 8.3
© 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
Publication:
Pub KSS 8.3 SI (PDF) en
Bookstructure:
KSS 8.3 SI V1.3
Version:
KSS 8.3 SI V1 en (PDF)
2 / 457
Issued: 22.01.2013 Version: KSS 8.3 SI V1 en (PDF)
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Contents
Contents
1
Introduction ..................................................................................................
15
1.1
Target group ..............................................................................................................
15
1.2
Industrial robot documentation ...................................................................................
15
1.3
Representation of warnings and notes ......................................................................
15
1.4
Trademarks ................................................................................................................
16
2
Product description .....................................................................................
17
2.1
Overview of the industrial robot .................................................................................
17
2.2
Overview of KUKA System Software (KSS) ..............................................................
17
2.3
System requirements .................................................................................................
18
2.4
Intended use of the KUKA System Software .............................................................
18
2.5
KUKA USB sticks .......................................................................................................
18
3
Safety ............................................................................................................
21
3.1
General ......................................................................................................................
21
3.1.1
Liability ..................................................................................................................
21
3.1.2
Intended use of the industrial robot ......................................................................
21
3.1.3
EC declaration of conformity and declaration of incorporation .............................
22
3.1.4
Terms used ...........................................................................................................
22
3.2
Personnel ...................................................................................................................
24
3.3
Workspace, safety zone and danger zone .................................................................
26
3.4
Triggers for stop reactions .........................................................................................
26
3.5
Safety functions .........................................................................................................
27
3.5.1
Overview of the safety functions ...........................................................................
27
3.5.2
Safety controller ....................................................................................................
28
3.5.3
Mode selection ......................................................................................................
28
3.5.4
Operator safety .....................................................................................................
29
3.5.5
EMERGENCY STOP device ................................................................................
29
3.5.6
Logging off from the higher-level safety controller ................................................
30
3.5.7
External EMERGENCY STOP device ..................................................................
30
3.5.8
Enabling device ....................................................................................................
31
3.5.9
External enabling device .......................................................................................
31
3.5.10
External safe operational stop ..............................................................................
31
3.5.11
External safety stop 1 and external safety stop 2 .................................................
31
3.5.12
Velocity monitoring in T1 and CRR .......................................................................
32
3.6
Additional protective equipment .................................................................................
32
3.6.1
Jog mode ..............................................................................................................
32
3.6.2
Software limit switches .........................................................................................
32
3.6.3
Mechanical end stops ...........................................................................................
32
3.6.4
Mechanical axis range limitation (optional) ...........................................................
32
3.6.5
Axis range monitoring (optional) ...........................................................................
33
3.6.6
Devices for moving the manipulator without the robot controller (options) ...........
33
3.6.7
Labeling on the industrial robot .............................................................................
34
3.6.8
External safeguards ..............................................................................................
35
3.7
Overview of operating modes and safety functions ...................................................
35
3.8
Safety measures ........................................................................................................
36
3.8.1
General safety measures ......................................................................................
36
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KUKA System Software 8.3
3.8.2
Transportation ......................................................................................................
37
3.8.3
Start-up and recommissioning ..............................................................................
37
3.8.3.1
Checking machine data and safety-relevant control configuration .......................
38
3.8.3.2
Start-up mode .......................................................................................................
39
3.8.4
Manual mode ........................................................................................................
40
3.8.5
Simulation .............................................................................................................
41
3.8.6
Automatic mode ...................................................................................................
41
3.8.7
Maintenance and repair ........................................................................................
41
3.8.8
Decommissioning, storage and disposal ..............................................................
43
3.8.9
Safety measures for “single point of control” ........................................................
43
3.9
Applied norms and regulations ..................................................................................
44
4
Operation ......................................................................................................
47
4.1
KUKA smartPAD teach pendant ................................................................................
47
4.1.1
Front view .............................................................................................................
47
4.1.2
Rear view .............................................................................................................
49
4.1.3
Disconnecting and connecting the smartPAD ......................................................
50
4.2
KUKA smartHMI user interface .................................................................................
51
4.2.1
Status bar .............................................................................................................
52
4.2.2
Keypad .................................................................................................................
53
4.2.3
Minimizing KUKA smartHMI .................................................................................
54
4.3
Switching on the robot controller and starting the KSS .............................................
54
4.4
Calling the main menu ...............................................................................................
54
4.5
Defining the start type for KSS ..................................................................................
55
4.6
Exiting or restarting KSS ...........................................................................................
55
4.7
Switching the robot controller off ...............................................................................
58
4.8
Setting the user interface language ...........................................................................
58
4.9
Online documentation and online help ......................................................................
59
4.9.1
Calling online documentation ...............................................................................
59
4.9.2
Calling online help ................................................................................................
59
4.10
Changing user group .................................................................................................
62
4.11
Changing operating mode .........................................................................................
63
4.12
Coordinate systems ...................................................................................................
64
4.13
Jogging the robot .......................................................................................................
65
4.13.1
“Jog options” window ............................................................................................
66
4.13.1.1 “General” tab ........................................................................................................
67
4.13.1.2 “Keys” tab .............................................................................................................
67
4.13.1.3 “Mouse” tab ..........................................................................................................
68
4.13.1.4 “KCP pos.” tab ......................................................................................................
69
4.13.1.5 “Cur. tool/base” tab ...............................................................................................
69
4.13.2
Activating the jog mode ........................................................................................
70
4.13.3
Setting the jog override (HOV) .............................................................................
70
4.13.4
Selecting the tool and base ..................................................................................
70
4.13.5
Axis-specific jogging with the jog keys .................................................................
71
4.13.6
Cartesian jogging with the jog keys ......................................................................
71
4.13.7
Configuring the Space Mouse ..............................................................................
71
4.13.8
Defining the alignment of the Space Mouse .........................................................
73
4.13.9
Cartesian jogging with the Space Mouse .............................................................
74
4.13.10
Incremental jogging ..............................................................................................
75
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Contents
4.14
Jogging external axes ................................................................................................
76
4.15
Bypassing workspace monitoring ..............................................................................
76
4.16
Monitor functions ........................................................................................................
77
4.16.1
Measuring and displaying energy consumption ....................................................
77
4.16.2
Displaying the actual position ...............................................................................
79
4.16.3
Displaying digital inputs/outputs ...........................................................................
79
4.16.4
Displaying analog inputs/outputs ..........................................................................
81
4.16.5
Displaying inputs/outputs for Automatic External .................................................
81
4.16.6
Displaying and modifying the value of a variable ..................................................
82
4.16.7
Displaying the state of a variable ..........................................................................
83
4.16.8
Displaying the variable overview and modifying variables ....................................
84
4.16.9
Displaying cyclical flags ........................................................................................
85
4.16.10
Displaying flags .....................................................................................................
86
4.16.11
Displaying counters ..............................................................................................
87
4.16.12
Displaying timers ..................................................................................................
88
4.16.13
Displaying calibration data ....................................................................................
89
4.16.14
Displaying information about the robot and robot controller .................................
90
4.16.15
Displaying/editing robot data ................................................................................
90
4.17
Displaying the battery state ........................................................................................
92
5
Start-up and recommissioning ...................................................................
95
5.1
Start-up wizard ...........................................................................................................
95
5.2
Checking the machine data .......................................................................................
95
5.3
Defining hardware options .........................................................................................
96
5.4
Changing the safety ID of the PROFINET device ......................................................
96
5.5
Jogging the robot without a higher-level safety controller ..........................................
97
5.6
Checking the activation of the positionally accurate robot model ..............................
98
5.7
Activating palletizing mode ........................................................................................
99
5.8
Copying machine data ...............................................................................................
99
5.9
Mastering ...................................................................................................................
100
5.9.1
Mastering methods ...............................................................................................
101
5.9.2
Moving axes to the pre-mastering position ...........................................................
102
5.9.3
Mastering with the EMD ........................................................................................
103
5.9.3.1
First mastering (with EMD) ...................................................................................
104
5.9.3.2
Teach offset (with EMD) .......................................................................................
106
5.9.3.3
Check load mastering with offset (with EMD) .......................................................
107
5.9.4
Mastering with the dial gauge ...............................................................................
108
5.9.5
Mastering external axes ........................................................................................
110
5.9.6
Reference mastering ............................................................................................
110
5.9.7
Mastering with the MEMD and mark .....................................................................
111
5.9.7.1
First mastering (with MEMD) ................................................................................
112
5.9.7.2
Teach offset (with MEMD) ....................................................................................
115
5.9.7.3
Check load mastering with offset (with MEMD) ....................................................
116
5.9.8
Manually unmastering axes ..................................................................................
118
5.10
Modifying software limit switches ...............................................................................
118
5.11
Calibration ..................................................................................................................
120
5.11.1
Defining the tool direction .....................................................................................
120
5.11.2
Tool calibration .....................................................................................................
121
5.11.2.1 TCP calibration: XYZ 4-point method ...................................................................
122
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