Gripperspottech r21 en

SOFTWARE
KR C...
KUKA.Gripper- and SpotTech 2.2
for KUKA.KR C 5.2, 5.3, 5.4
Issued: 09 Nov 2004

GripperSpotTechKRS2.2, 11.04.00 en
Version: 00
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e Copyright
KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers. Other functions not described in this documentation may be operable in the controller. The user has no claim 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, however, and necessary corrections will be incorporated in subsequent editions. Subject to technical alterations without an effect on the function.
PD Interleaf
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Contents
1 2 3
3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.6.1 3.1.7 3.2 3.3 3.3.1 3.3.2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation / uninstallation / update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GripperTech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic gripper functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 1 2 outputs, 4 inputs, 2 switching states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 2 2 outputs, 2 inputs, 3 switching states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 3 2 outputs, 2 inputs, 3 switching states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 4 3 outputs, 2 inputs, 3 switching states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 5 2 outputs, 4 inputs, 2 switching states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Freely programmable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initialization and configuration examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manually operating a gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming gripper functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 7 8
8 8 8 8 8 9 9 9 13 14 15 15 18
4
4.1 4.1.1 4.1.2 4.2 4.2.1 4.2.1.1 4.2.1.2 4.2.2 4.2.3 4.2.3.1 4.2.3.2 4.2.3.3 4.2.4 4.2.4.1 4.2.4.2 4.2.4.3 4.2.4.4 4.2.4.5 4.2.5 4.2.5.1 4.2.5.2 4.2.6 4.2.7 4.3 4.3.1 4.3.1.1 4.3.1.2
SpotTech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic SpotTech user functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Range of commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The functions SPOT and RETRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General information on programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variables in input boxes of the inline forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of the inline forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spot welding (SPOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point--to--point (PTP) motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motion along a straight line (LIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motion along a circular path (CIRC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming a weld spot (SPOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The inline form and the parameter lists for the welding command SPOT . . . . . . . . . . . . . Selecting the welding gun (Gun = n) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retract stroke after the welding process (RETR OPN / CLO) . . . . . . . . . . . . . . . . . . . . . . . . Weld parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opening/closing the welding gun retract stroke (RETRACT) . . . . . . . . . . . . . . . . . . . . . . . . . Types of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming the retract stroke (RETRACT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motion commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reorientation of the welding gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Creating a new program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding the first spot sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding the second spot sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
20 20 20 21 21 21 21 22 22 22 22 22 23 23 23 25 25 25 26 27 27 29 30 31 31 35 36
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KUKA.Gripper- and SpotTech 2.2 4.3.1.3 4.4 4.4.1 4.4.2 4.4.3 4.4.3.1 4.4.3.2 4.4.3.3 4.4.3.4 4.4.3.5 4.4.3.6 4.4.3.7 4.5 4.5.1 4.5.2 4.5.3 4.6 4.6.1 4.6.2 4.7 4.7.1 4.7.2 4.7.2.1 4.7.2.2 4.7.2.3 4.7.2.4 4.8 4.9 4.9.1 4.9.1.1 4.9.2 Moving from the end of the spot seam to the home position . . . . . . . . . . . . . . . . . . . . . . . . . . Altering existing programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Altering command lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deleting command lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adding commands to an existing program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of the alteration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the position of the welding gun (point in space P10) . . . . . . . . . . . . . . . . . . . . . . . . Reorientation of the welding gun -- inserting the command Motion (P11) . . . . . . . . . . . . . . Moving to the point in space P12 -- inserting the command Motion . . . . . . . . . . . . . . . . . . . Welding spot P13 -- inserting the command SPOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving to the weld spot P16 and welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving to the home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SpotTech configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retract stroke (RETRACT) and working stroke (SPOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Early closing of the gun (PRESPOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of the SpotTech package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPOT Tech--specific files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adaptation to the periphery, configurable options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOLD SPOT in the file $CONFIG.DAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The user--specific program USERSPOT.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic sequence diagram for SPOT (without RETRACT) . . . . . . . . . . . . . . . . . . . . . . . . Schematic sequence diagram for SPOT (with RETRACT) . . . . . . . . . . . . . . . . . . . . . . . . . . . Robot controller -- welding controller interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program example for the file USERSPOT.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual operation of the welding gun using the status keys . . . . . . . . . . . . . . . . . . . . . . . . . . Separate control of RETRACT and SPOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition of function type and assignment of physical outputs . . . . . . . . . . . . . . . . . . . . . . . . Manual control of RETRACT and SPOT in series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 37 37 37 38 39 39 39 40 40 40 40 41 41 42 42 44 44 44 45 45 46 47 48 49 49 52 53 53 53 55
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General
The software packages GripperTech and SpotTech are supplied together on a Setup CD and expand the scope of the basic KRC software. -- The functions of the GripperTech technology package (gripper programming) enable the robot system to control and monitor tools and devices in its work environment. -- The SpotTech technology package is used for the convenient programming of spot welding applications.
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Installation / uninstallation / update

From system software version 5.1 onwards, technology packages are offered exclusively as add--on software modules. These are available on CD--ROM. Should you be interested in purchasing further modules, please contact KUKA Support. The installation procedure is the same for all technology packages and is described in a separate documentation module.
The installation, uninstallation, reinstallation and update of technology packages are described in detail in the documentation Installation/Uninstallation/Update of Tech Packages.
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3
3.1
GripperTech
Basic gripper functions
The GripperTech technology package includes five basic types of gripper control, with whose logic functions the majority of applications that occur are covered. If these basic types prove to be insufficient at any time, any additional gripper functions can be freely programmed. Each gripper must be assigned a function type. If a gripper is to be temporarily or permanently excluded from use, it must be assigned gripper type 0.
3.1.1
Type 1
2 outputs, 4 inputs, 2 switching states

e.g. a simple gripper with the functions OPEN and CLOSE; State A B OUT1 TRUE OUT2 FALSE IN1 TRUE IN2 IN3 FALSE IN4 FALSE TRUE FALSE TRUE
FALSE TRUE
FALSE TRUE
3.1.2
Type 2

e.g. a slide with a center position; State A B C OUT1 TRUE OUT2 FALSE IN1 TRUE IN2 FALSE
FALSE TRUE
FALSE TRUE
FALSE FALSE FALSE FALSE
3.1.3
Type 3

e.g. a vacuum gripper with the functions VACUUM, BLOW and OFF; State A B C OUT1 TRUE OUT2 FALSE IN1 TRUE IN2 FALSE
FALSE TRUE
FALSE TRUE
FALSE FALSE FALSE FALSE
3.1.4
Type 4

The same as type 3 but with three control outputs (type 3 has two outputs); State A B C OUT1 TRUE OUT2 OUT3 TRUE IN1 IN2 FALSE FALSE FALSE TRUE
FALSE TRUE FALSE TRUE
FALSE TRUE
FALSE FALSE FALSE
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3.1.5
Type 5

The same as type 1 but with a pulse signal instead of a continuous signal. State A B OUT1 TRUE OUT2 FALSE IN1 TRUE IN2 IN3 FALSE IN4 FALSE TRUE FALSE TRUE
FALSE TRUE
FALSE TRUE
In contrast to gripper type 1, a continuous signal is not applied here, but a pulse of variable duration is transmitted whenever the signal level changes. It is set by modifying the variable GRP_PULSE_TI. During controller operation, this variable can be altered by means of the Modify -- Variable options in the Monitor menu. More detailed information on how to modify the values of system variables during controller operation can be found in the chapter Monitor Functions, section Variables.
3.1.6
Freely programmable type

A freely programmable gripper type has been integrated in order to cover all user requirements. Any number of completely freely definable grippers can be configured by means of entries in the files $CONFIG.DAT, USERGRP.DAT and USER_GRP.SRC.
3.1.6.1
Programming example Requirement A welding gun is to switch between the positions OPEN -- RETRACT -- WORKING STROKE -- RETRACT -- OPEN when the status key Manual gripper operation is pressed.
OPEN Position A
RETRACT Position B
WORKING STROKE Position C
RETRACT Position B
OPEN Position A
This task requires the use of two double--acting pneumatic cylinders controlled via electromagnetically operated 4/2--way valves.
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Retract cylinder
Working stroke cylinder
Output 1
Output 2
Output 3
Output 4
State Output1 A B C TRUE TRUE
Control Output2 Output3 Output4
FALSE TRUE FALSE
FALSE TRUE TRUE FALSE
FALSE FALSE TRUE
Programming In order to implement the example described, make the following changes or additions to the data shown below. Entries in the file $CONFIG.DAT The freely programmable gripper is defined with the identification number 100. ;================================== ; Definition of grippers ;================================== DECL GRP_TYPES GRIPPER[8] GRIPPER[1]={TYPE 100}
Entries in the file $USER_GRP.DAT: &ACCESS RP &COMMENT USER GRIPPER package DEFDAT USER_GRP ... ENUM GUN_STAT RET_OPN,RET_CLS,WRK_CLS,WRK_OPN Data type, enumeration of gun states:
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STRUC MY_GUN INT RET_OPN,RET_CLS,WRK_OPN,WRK_CLS,GUN_STAT STAT Structure of the user-defined data type MY_GUN: DECL MY_GUN MY_GUN1={RET_OPN 100,RET_CLS 101,WRK_OPN 102,WRK_CLS 103,STAT #RET_OPN} Assignment of outputs for the welding gun MY_GUN1 of type MY_GUN: ... ENDDAT Entries in the file USER_GRP.SRC DEF GRP_MANUAL ( ) ;================= ;part for manual functions ;===================================== SWITCH GRIPPER[G_NO].TYPE ;switch type of gripper
;end of example for new gripper CASE 100 $OUT[MY_GUN1.RET_OPN]=FALSE $OUT[MY_GUN1.RET_CLS]=FALSE $OUT[MY_GUN1.WRK_OPN]=FALSE $OUT[MY_GUN1.WRK_CLS]=FALSE SWITCH MY_GUN1.STAT CASE #RET_OPN Reset output Reset output Reset output Reset output Start of the control structure If the state of the gun MY_GUN1.STAT has the value #RET_OPN (retract stroke open)
PULSE($OUT[MY_GUN1.RET_CLS],TRUE,0.3) send a 0.3 second pulse to the output RET_CLS (retract stroke closes) MY_GUN1.STAT=#RET_CLS set the state of the gun MY_GUN1.STAT to #RET_CLS (retract stroke closed) If the state of the gun MY_GUN1.STAT has the value #RET_CLS (retract stroke closed)
CASE #RET_CLS
PULSE($OUT[MY_GUN1.WRK_CLS],TRUE,0.3) send a 0.3 second pulse to the output WRK_CLS (working stroke closes) MY_GUN1.STAT=#WRK_CLS set the state of the gun MY_GUN1.STAT to #WRK_CLS (working stroke closed)
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CASE #WRK_CLS
If the state of the gun MY_GUN1.STAT has the value WRK_CLS (working stroke closed)
PULSE($OUT[MY_GUN1.WRK_OPN],TRUE,0.3) send a 0.3 second pulse to the output WRK_OPN (working stroke opens) MY_GUN1.STAT=#WRK_OPN set the state of the gun MY_GUN1.STAT to #WRK_OPN (working stroke open) If the state of the gun MY_GUN1.STAT has the value #WRK_OPN (working stroke open)
CASE #WRK_OPN
PULSE($OUT[MY_GUN1.RET_OPN],TRUE,0.3) send a 0.3 second pulse to the output RET_OPN (retract stroke opens) MY_GUN1.STAT=#RET_OPN set the state of the gun MY_GUN1.STAT to #RET_OPN (retract stroke open) If none of the states listed so far appears, execute the following instructions End of the control structure
DEFAULT
ENDSWITCH ...
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3.1.7
Initialization and configuration examples
Example_1
Not defined 17 --18 0 0 22 23 0 0
On switching to state A (Open), output 17 will be set to TRUE and output 18 (inverted) also to TRUE. When scanned, input 22 must have the state TRUE and input 23 the state FALSE so that the motion program can continue. On switching to state B (Closed), output 17 will be set to FALSE and output 18 (inverted) also to FALSE. When scanned, input 22 must have the state FALSE and input 23 the state TRUE so that the motion program can continue.
Example_2
Not defined 19 21 0 0 22 --23 24 --25
On switching to state A (Open), output 19 will be set to TRUE and output 21 to FALSE. When scanned, input 22 must have the state TRUE, input 23 (inverted) the state TRUE, input 24 the state TRUE and input 25 (inverted) also the state TRUE so that the motion program can continue. On switching to state B (Closed), output 19 will be set to FALSE and output 21 to TRUE. When scanned, input 22 must have the state FALSE, input 23 (inverted) also the state FALSE, input 24 the state FALSE and input 25 (inverted) also the state FALSE so that the motion program can continue.
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3.2
Manually operating a gripper

A configured gripper can only be operated in the modes: G G TEST1 (reduced velocity) or TEST2 (programmed velocity),
with an enabling switch being held down. Use the top status key shown on the left to select from the configured grippers the one that you would like to operate.
You can then switch between the gripper functions using the bottom status key shown on the left.
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3.3
Programming gripper functions

Pay attention to the position of the edit cursor. The next program line created by you will be inserted as a new line after the cursor.
3.3.1
Gripper
Open the menu using the menu key Technology. Then select GRIPPERTech. The following submenu is displayed:
As a gripper function is to be programmed, confirm the offered selection Gripper. An inline form for entering the parameters that are required for executing a gripper function is opened in the programming window.
The assignment of the softkey bar changes at the same time:
It is possible to abort programming of the gripper function at any time by pressing the softkey Cmd Abort or the ESC key. The command will not be saved in this case. If the programming window is in focus, the various input windows can be selected using the and arrow keys. The window that is currently selected is highlighted by a color background. The programming window can be activated by repeatedly pressing the Window selection key until the entire window is highlighted in color. Move the cursor to the input box SET. The status key (at the bottom right of the display) changes its assignment. You can choose between the configured grippers using this status key.
Move the cursor to the input box State. The status key (at the bottom right of the display) changes its assignment. You can use this status key to choose between the functions that have been defined for the selected gripper.
Move the cursor to the next input box on the right. The status key (at the bottom right of the display) changes its assignment.
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KUKA.Gripper- and SpotTech 2.2 The approximate positioning function can be switched on or off using this status key. If you switch the approximation function off, a further input box, GDATn, appears on the right, in this case GDAT1.
If the cursor is moved to this box with the arrow key, a status window is opened. Data that more precisely characterize the gripper function must be entered here. Activate this status window using the Window selection key.
Decide at this point whether any sensors that may be fitted on the gripper are to be interrogated or whether a wait time is to be used to ensure that the functions that have been programmed are fully executed. Wait Time: If Check Gripper is switched off because, for example, it is not possible to interrogate the sensors, a wait time of up to ten seconds can be defined here. Check Gripper: Here you can specify whether the sensors on the gripper are to be interrogated before the robot starts moving again (it is only possible to interrogate the sensors if approximate positioning is switched off in this block). If the sensors do not return a status message, the controller allows you to set the inputs so that execution of the program can continue unhindered. Only use this simulation if you are sure that it cannot result in any unexpected situations! If you switch the approximation function on, two further input boxes, at and Delay, appear on the right.
Other than in the case of the gripper function without approximation, the robot does not stop here after reaching the end point in order to activate the gripper.
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Motion block 1
End point
Motion block 1
End point
Execute gripper function
The gripper function is executed along this line
Motion block 2
End point
Motion block 2
End point
Without approximate positioning
With approximate positioning
The parameters START, END and Delay are used to define the point at which the gripper function is executed. START
Delay positive
Delay negative
END
The reference point for activation of the gripper is determined using the status key (at the bottom, to the right of the display). Then move the cursor to the box Delay. You can enter a value here, using the numeric keypad, or change the default value by increments of 1 ms using the status key (at the bottom, to the right of the display). Then press the softkey Cmd Ok. The gripper function is now fully programmed and saved.
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3.3.2
Check Gripper
This command is only executed if it is located before a motion instruction. Any sensors fitted on the gripper can be interrogated using this command. If the conditions defined by the function type and configuration of the gripper are not satisfied, the robot stops moving. It does not continue the motion program until the conditions are met. Now open the menu by means of the menu key Technology. Then select GRIPPERTech. (The menu items contained in this menu depend on the specific software configuration.)
As a gripper sensor interrogation is to be programmed, select the option Check Gripper. The inline form for entering the parameters that are required for executing a gripper sensor interrogation is opened in the programming window.
The assignment of the softkey bar changes at the same time:
It is possible to abort programming of the gripper sensor interrogation at any time by pressing the softkey Cmd Abort or the ESC key. The command will not be saved in this case. If the programming window is in focus, the various input windows can be selected using the and arrow keys. The window that is currently selected is highlighted by a color background. The programming window can be activated by repeatedly pressing the Window selection key until the entire window is highlighted in color. Move the cursor to the input box CHECK. The status key (at the bottom right of the display) changes its assignment. You can choose between the configured grippers using this status key.
Move the cursor to the input box State. The status key (at the bottom right of the display) changes its assignment. You can use this status key to choose between the functions that have been defined for the selected gripper.
Move the cursor to the input box at. The status key (at the bottom right of the display) changes its assignment. The reference point for the gripper interrogation is determined using this status key.
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Motion block 1
End point
The gripper function is executed along this line
End point
Motion block 2
The parameters START, END and Delay are used to define the point at which the gripper function is executed. START
Delay positive
Delay negative
END
Then move the cursor to the box Delay. You can enter a value here, using the numeric keypad, or change the default value by increments of 1 ms using the status key (at the bottom, to the right of the display). Then press the softkey Cmd Ok. The gripper interrogation function is now fully programmed and saved.
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4
4.1
SpotTech
Basic SpotTech user functions
Once the technology package has been correctly installed, additional commands are available in the SpotTech package for spot welding applications.
4.1.1
Range of commands
An initialization command and two program commands, which are used to control the welding equipment, are basically available for spot welding. These are: G INI This initialization command is automatically entered at the beginning of each new program that is to be created (skeleton program). This sets the basic parameters for the robot and the application program and initializes the welding and motion commands and approximate positioning. G SPOT The command SPOT controls the robot motion to a weld spot, and the welding process. The opening and closing of the welding gun retract stroke after the welding process can also be programmed by means of this command. G RETRACT The command RETRACT controls the robot motion to any point, and the opening and closing of the welding gun retract stroke after reaching the end point. This function is required, for example, if access to weld spots or auxiliary points with the retract stroke of the welding gun fully open or closed is impeded by obstructing contours. Motions that do not include a welding operation and do not change the state of the welding gun retract stroke or which are used for reorientating the welding gun are programmed by means of a command belonging to the group Motion.
4.1.2
The functions SPOT and RETRACT

The SpotTech basic functions SPOT and RETRACT are shown in the following sketch.
Welding gun
Component
Retract stroke open RETR OPN
Working stroke Retract stroke closed RETR CLO Welding process SPOT
Retract stroke
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4.2
Programming and operation

This section describes how to create spot welding programs and how to program welding and motion commands. It also contains information on everything that has to be taken into account when setting individual parameters. SpotTech has a universal basic structure and each of the programming possibilities given here is dependent on the welding equipment and user--specific subprograms that are used.
4.2.1
General information on programming
4.2.1.1
Variables in input boxes of the inline forms
The inline forms contain a series of input boxes, whose designations are freely selectable. This applies to the boxes P1 ... PDAT1 ..., CPDAT1 ... SDAT1 ... Designation of the end point Designation of the Movement parameters data set Designation of the Weld parameters data set
The following must always be observed: -- The designation can consist of letters and numbers. Special characters apart from the underscore _ cannot be used. -- The first character of a designation must always be a letter. -- The designation is entered unchanged as a pure character string into all of the subsequent program lines. -- If the last character is a number, the value of this number is automatically incremented (n+1), e.g. SDAT1, SDAT2 ... SDATn or SEAM_FRONT1, SEAM_FRONT2 ... SEAM_FRONT99, in the subsequent commands. If a number is entered at the end of the designation -- this number being incremented (n+1) in each subsequent command -- please remember that the number of characters increases by 1 when going from 9 to 10.
4.2.1.2
Overview of the inline forms The following sections contain screenshots of the inline forms assigned to each of the SpotTech commands, showing both the input boxes and the parameter lists that can be opened in the status window if the cursor is moved to the appropriate box in the inline form. The operator control elements and symbols that are used here are explained below: If the inline form is active, the desired input box can be selected by means of the arrow keys. The selected box is displayed in white lettering on a blue background. The operator control elements shown below the inline form are intended to be an additional aid to familiarize you with the possibilities of making entries in inline forms and parameter lists. These have the meanings described below:
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KUKA.Gripper- and SpotTech 2.2 If the cursor is positioned in the appropriate box of the inline form, the bottom right status key can be used to alter the parameters or to select data sets that have already been defined.
It is possible to both enter and alter commands and parameters by means of the keypad (by pressing the initial letter of the command/parameter). This symbol indicates that a parameter list (movement or weld parameters) is assigned to the input box in the inline form. The status window together with the appropriate parameter list is activated when the Window selection key on the graphical user interface is pressed. This softkey (which is only available when a parameter list is active in the status window) is used to exit the status window and activate the corresponding input box in the inline form.
4.2.2
Spot welding (SPOT)

The command SPOT controls the robot motion to a weld spot, and the welding process. It can also be used to control the opening and closing of the welding gun retract stroke (RETRACT) after the welding process. This command primarily contains the type of motion (PTP, LIN, CIRC), the designation of the weld spot (Pn), the movement parameters (PDATn or CDATn), the weld parameters (SDATn) and the designation of the welding gun (Gun= n).
4.2.3
Types of motion
Three types of motion can be selected for the command SPOT: PTP, LIN and CIRC. Since the robot must be exactly positioned to each weld spot, the approximate positioning function is not included.
4.2.3.1
Point-to-point (PTP) motion PTP (point--to--point) motion allows the robot to be moved to the end position at the highest possible velocity. This motion is the most efficient. For spot welding seams, most robot motions between the individual weld spots are generally executed as PTP motions. However, it must be remembered that: The path cannot be predicted exactly for PTP motions! The motion characteristics of the robot with greater distances between points and near obstacles should therefore be checked in a test run.
4.2.3.2
Motion along a straight line (LIN) LIN (linear) motions are used whenever the robot has to follow an exact path to the end point.
4.2.3.3
Motion along a circular path (CIRC) In the case of CIRC motions, the welding gun is moved along a circular path. This type of motion is selected whenever the gun cannot be positioned to the end point using a linear motion.
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4.2.4
4.2.4.1
Programming a weld spot (SPOT)

Menu
After selecting the relevant option (SPOT Tech -- SPOT -- PTP in this example) by means of the menu key Technology, the inline form described in the next section is opened. 4.2.4.2 The inline form and the parameter lists for the welding command SPOT
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Frames
Example of a weld parameter list Early closing of the welding gun
Tool coordinate system Base coordinate system Ext. TCP True or False
Timer program for the 1st gun pair Pressure for the 1st gun pair
LIN/CIRC LIN/CIRC motion Velocity (0.001 to 2 m/s) Acceleration (1 to 100 %)
PTP PTP motion
Velocity (1 to 100 %) Acceleration (1 to 100 %)
Softkey bar when the inline form is active
Softkey bar when a parameter list is active
You can switch to the commands RETRACT or Motion and change the motion type (PTP, LIN or CIRC) at any time during programming, until this is concluded using Cmd Ok. Brief description of the input boxes of the inline form (from left to right), their functions and their range of values where applicable: Box PTP Function Type of motion Range of values, Comments PTP, LIN, CIRC Change using bottom right status key, softkey or keypad.
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P2
Designation of the end point; with CIRC motions, a further input box is available for the auxiliary point. Designation of the movement parameters Designation of the welding gun Retract stroke after the welding process (RETRACT) Designation of the weld parameters
Freely selectable Change the designation Pn by using the keypad or the bottom right status key. Freely selectable (see Section 4.2.1.1). Select from up to 5 guns. CLO = retract stroke closed OPN = retract stroke open Freely selectable (see Section 4.2.1.1).
PDAT2 SPOT Gun= 1 RETR OPN SDAT1
4.2.4.3
Selecting the welding gun (Gun = n) It is possible to select from up to 5 welding guns. This is dependent on the welding equipment that is used.
4.2.4.4
Retract stroke after the welding process (RETR OPN / CLO) In this input box, you define whether the welding gun retract stroke is to be open or closed after the welding process. Welding gun
Retract stroke
Component
Retract stroke closed RETR CLO
You can switch between Retract stroke open (RETR OPN) and Retract stroke closed (RETR CLO) by pressing the bottom right status key. This status key has a toggle function in this instance. The pulldown menu will be opened and closed automatically after a short time. Alternatively, the respective initial letter (O = OPN = open; C = CLO = closed) can be entered by means of the keypad. The cursor must be positioned in the input box next to RETR in this case. 4.2.4.5 Weld parameter list Due to the universal basic structure of the spot welding technology, the parameters for the welding data can be adapted individually to the requirements of both the user and the welding equipment that is used. The option of closing the welding gun early is described below on the basis of a spot welding application.
Working stroke
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Early closing of the welding gun (early closing time) -- 1000 to 0 milliseconds
Working stroke Start of early closing of gun
Weld spot position Pn reached
Early closing time
Early closing distance Pn
Gun closed
The point of closing the gun early (early closing time) is to optimize the time taken to execute the spot welding process. Whilst the welding gun is still moving to the weld spot, the closing operation is already starting. In this instance, it must be ensured that the gun is not closed completely until just after the end position Pn is reached. Variations in air pressure, the position of the gun and other factors may produce different opening and closing times for the gun. The closing time of the welding gun must therefore be checked in a test run. Closing the gun too early while the robot is still moving results in the weld spot being incorrectly positioned and may cause the component and the tool to be damaged!
4.2.5
Opening/closing the welding gun retract stroke (RETRACT)

The command RETRACT controls the robot motion to any point, and the opening and closing of the welding gun retract stroke. This function is required, for example, if access to weld spots or auxiliary points with the gun fully open or closed as far as the working stroke, is impeded by obstructing contours.
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In addition to the type of motion (PTP, LIN, CIRC), the name of the end point (Pn), the movement parameters (PDATn or CDATn) and the designation of the welding gun (Gun= n), this command also contains an instruction specifying whether the gun retract stroke is to be open (OPN) or closed (CLO) after the end point has been reached. 4.2.5.1 Types of motion Three types of motion can be selected for the command RETRACT: PTP, LIN and CIRC. Approximate positioning is not possible; the robot is exactly positioned to each point. Further details on this are given in Section 4.2.3.
4.2.5.2
Programming the retract stroke (RETRACT) Menu (The menu items contained depend on the specific software configuration.)
After selecting the relevant option by means of the menu key Technology (SPOT Tech -RETRACT -- PTP in this example), the inline form described in the next section is opened.
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KUKA.Gripper- and SpotTech 2.2 The inline form and the parameter lists for the command RETRACT
Frames
Tool coordinate system Base coordinate system Ext. TCP True or False LIN/CIRC LIN/CIRC motion Velocity (0.001 to 2 m/s) Acceleration (1 to 100 %) PTP PTP motion Velocity (1 to 100 %) Acceleration (1 to 100 %)
Softkey bar when the inline form is active
Softkey bar when a parameter list is active
You can switch to the commands SPOT or Motion and change the motion type (PTP, LIN or CIRC) at any time during programming, until this is concluded using Cmd Ok. Brief description of the input boxes of the inline form (from left to right), their functions and their range of values where applicable:
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Box PTP
Function Type of motion Designation of the end point; with CIRC motions, a further input box is included for the auxiliary point. Designation of the movement parameters. Retract stroke after reaching the end point. Designation of the welding gun
Range of values, Comments PTP, LIN, CIRC Change using bottom right status key, softkey or keypad Freely selectable Change the designation Pn by using the keypad or the bottom right status key. Freely selectable OPN = retract stroke open CLO = retract stroke closed Select from up to 5 guns.
P1
PDAT1 RETR OPN SPOT Gun= 1
Retract stroke after reaching the end point (RETR OPN / CLO) In this box, you define whether the welding gun retract stroke is to be open or closed after the end point has been reached. Welding gun
Retract stroke
Component
Retract stroke closed RETR CLO
You can switch between Retract stroke open (RETR OPN) and Retract stroke closed (RETR CLO) by pressing the bottom right status key. This status key has a toggle function in this instance. The pulldown menu will be opened and closed automatically after a short time. Alternatively, the respective initial letter (O = OPN = open; C = CLO = closed) can be entered by means of the keypad. The cursor must be positioned in the input box next to RETR in this case.
4.2.6
Motion commands
Motions of the tool which do not feature a welding operation and which do not change the welding gun retract stroke can be programmed by means of the command Motion from the Commands menu. A corresponding inline form is opened by means of the softkey Motion, with the motion type (PTP, LIN or CIRC) that was predefined with the last command being displayed; this must be changed, if necessary.
Working stroke
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4.2.7
Reorientation of the welding gun
Pn (P2)
Pn (P3)
P4 P1 P3 P2 Reorientation of the welding gun by 90 If the spot welding plane changes -- as shown in the sketch above -- the welding gun must be reorientated. To do so, the gun must first be moved into a position (P2) where there is no risk of it colliding with the component or with other obstructing contours during reorientation. The reorientation (point in space P2 to P3) is carried out using the command Motion -- LIN or -- if the gun retract stroke (RETRACT) is to be changed during the same operation -- SPOT Tech -- RETRACT -- LIN (see Section 4.2.5). The gun can subsequently be positioned to the next weld spot (P4). Depending on the position of the robot axes, it may also be possible to select a PTP motion. As PTP motions cannot be predicted exactly, a test run should be carried out.
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4.3
Program example
In this section, the use of the basic commands of the spot welding technology will be described step by step on the basis of a simple program example. The assembly shown below, consisting of three individual parts, is to be fabricated by means of spot welding.
Home position
4.3.1
Creating a new program

To create a new program, press the softkey New and enter a program name (e.g. Test) in the input box. Now press the softkey Select. The following skeleton program is displayed in the programming window:
Pay attention to the position of the edit cursor. The following program line created by you will be inserted as a new line after the cursor. Alternatively, you can program in edit mode by means of the softkey Edit. The syntax will not be checked, however.
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KUKA.Gripper- and SpotTech 2.2 The first weld spot
Home position
When moving the welding gun from the home position to the first weld spot, it must be ensured that no obstructing contours (e.g. those of the component) can cause a collision. For example, the path of the PTP motion cannot be exactly predicted! The motion characteristics of the robot near obstacles should therefore always be checked in a test run. The diagram given below shows a collision situation on the left. As can be seen in the situation on the right, you can ensure that the welding gun is positioned safely to the first weld spot (P2) by inserting an additional point in space (P1).
Risk of a collision with the component! Home position PTP motion
End position
Component
Point in space P1
1st weld spot P2 Component
Home position
Positioning the welding gun directly to the end point
Inserting an additional point in space
If the motion between the point in space P1 and the first weld spot (P2) is executed as a PTP motion, the distance between these two points should not be too great. The robot can use approximate positioning for moving from the home position to P2 via P1 because exact positioning is not required until the welding gun moves to the position of the weld spot.
Moving from the home position to the point in space P1 - RETRACT The welding gun is moved from the home position to the point in space P1 by means of a PTP motion. During the same operation, you ensure that the retract stroke is open after the point has been reached. Press the menu key Technology and select the options shown below (menu items in white lettering on a blue background):
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After selecting the command SPOT Tech -- RETRACT -- PTP, the following inline form is opened on the screen:
If the programming window is active, the input boxes can be selected by means of the arrow keys. The selected box appears in white lettering on a blue background. At the same time that the inline form given above is opened, the assignment of the softkey bar changes to that shown below:
You can also correct your original selection (SPOT, Motion and type of motion) by means of this softkey. The inline form changes accordingly when a selection is made. The command can be aborted by means of the softkey Cmd Abort or the ESC key. This will close the inline form. The welding gun retract stroke must be open after the point in space P1 has been reached. This is set in the input box RETR. In the example given above, OPN (open) is already entered; otherwise, CLO (closed) appears here. To change the setting, move the cursor to the input box RETR. You can switch between RETR CLO and RETR OPN by means of the bottom right status key. This status key has a toggle function. Alternatively, the letter C (=closed) or O (=open) can be entered by means of the keypad. In this case, enter O. For the purpose of positioning the welding gun, move it to the position P1 by means of the Space Mouse or the traversing keys. Information on controlling motions of the robot manually can be found in the chapter [Manual traversing of the robot]. You can now press the softkey Touch Up. In this case, press the softkey Yes to confirm the query Touchup (Y/N)? that is displayed in the message window. Alternatively, press the softkey Cmd Ok or the Enter key. The current robot coordinates are automatically saved. The command is ended by pressing the softkey Cmd Ok or the Enter key. If the point P1 has not yet been touched up, the current robot coordinates are now automatically saved. The information message Point P1 created automatically is displayed in the message window. The inline form is closed and the generated program line is inserted into the program form afterwards. The numbers of the following program lines are automatically updated.
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KUKA.Gripper- and SpotTech 2.2 Setting the first weld spot (SPOT) A PTP motion is used to move the welding gun from the point in space P1 to the weld spot P2. The gun is exactly positioned to point P2 where the welding process will then be executed. Since a sequence of further spot welds follows P2, the retract stroke can remain closed. Press the menu key Technology and select the options shown below (menu items in white lettering on a blue background):
After selecting the command SPOT Tech -- SPOT -- PTP, the following inline form appears on the display.
Alternatively, you can also press the softkey Last Cmd. If you had last entered a RETRACT command, an inline form for the command RETRACT is displayed. SPOT can then be called by means of the softkey SPOT. The same inline form is thus available. As can be seen, the names for the end point (P2) and the data set (PDAT2) have been adapted. A further box is also displayed: the designation of the weld parameter set (SDAT1). The welding gun retract stroke can be left closed (RETR CLO) in this program example. If the first command to be entered was RETR OPN (retract stroke open), this has been used as a default setting in the input box of the new inline form. To change the setting, move the cursor to the input box RETR. Press the bottom right status key or enter the letter C by means of the keypad. CLO (=closed) subsequently appears in the input box of the inline form. Enter the movement and weld parameters into both the inline form and the parameter lists and move the welding gun to the desired position P2. If your welding system has been configured appropriately, the functioning of the gun can be checked at this point by means of the gun status keys. For information on this, see Section 4.9 and the chapter [SPOT Tech -- Expert Programming]. After entering all of the parameters, press the softkey Cmd Ok. The current robot coordinates are saved and the program form is updated accordingly.
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4.3.1.1
Welding the first spot sequence
P5
P4
P3
P2
RETR OPN
RETR CLO
The further points (P3 to P5) can be programmed using the procedure described in the last section. In this case, leave the welding gun retract stroke closed (RETR CLO) for P3 and P4. As the welding gun is to be positioned to the first weld spot (P6) of the second welding sequence (see the sketch at the beginning of Section 4) after P5, the retract stroke must be opened at P5. To do so, select the option RETR OPN when programming P5. After all of the entries for the first spot sequence have been made, the program form appears as follows:
As can be seen, the numeric values for the designation of the movement parameters (PDATn) have each been increased by 1 in command lines 4 to 7. The numeric values for the designation of the weld parameters (SDATn) have likewise been increased. The parameters entered in SDAT1 have automatically been entered in SDAT2 .... SDAT4. For spot sequences that are to be welded with the same welding tool and the same weld parameters, programming can be simplified if each weld spot is not programmed individually but by using the procedure described below: G Program the first weld spot of the sequence. G Determine the number of spots that are to be welded after the first spot. G Press the softkey Last Cmd and then the softkey Cmd Ok. Repeat this according to the number of weld spots. G To save the robot coordinates, subsequently move the edit cursor (vertical line) to the appropriate line of the program form in sequence. Position the robot manually to the respective point, press the softkey Touch Up and confirm the request for confirmation to save the coordinates. The current robot coordinates are saved for the point that is currently selected. With the motion type CIRC, the coordinates for the required auxiliary point must always be touched up manually.
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KUKA.Gripper- and SpotTech 2.2 4.3.1.2 Welding the second spot sequence The second spot sequence begins at P6. A PTP motion can be used between the weld spots P5 and P6 as the distance between them is small and the welding gun retract stroke is open. The weld spot P6 can be programmed in the program example given above. Now program the weld spots P7 to P9 following the description given in the previous section. Select the option RETR OPN again for the last weld spot (P9) to open the welding gun retract stroke after P9 has been welded. 4.3.1.3 Moving from the end of the spot seam to the home position To move the welding gun back to the home position, a further point in space outside the component is required so that a collision is safely avoided. This is P10 in this program example, where it is assumed that there are no obstacles between P10 and the home position. The path between the weld spot P9 and the point in space P10 is executed as a PTP motion. Press the softkey Motion. An inline form is opened:
After entering the parameters, press the key Cmd Ok. Alternatively, this motion can also be programmed by means of the command SPOT Tech -- RETRACT -- PTP. The motion from P10 to the home position (PTP -- HOME) is already included in the skeleton program. Programming of this program example is thus completed.
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4.4
Altering existing programs

It is possible to alter commands and/or parameters and to delete command lines in an existing program at any time. Two examples are given below.
4.4.1
Altering command lines

The procedure for altering command lines is demonstrated below by using a different type of motion for the command SPOT -- RETRACT to the point in space P1 to that used in the above program example. The parameter PTP for P1 is to be changed to LIN.
Move the edit cursor to line 3 by means of the arrow keys. Press the softkey Change. The inline form for this command line is opened. Move the cursor to the first input box on the left. Press the bottom right status key until LIN appears in the input box.
Then press the softkey Cmd Ok. The inline form is closed and the program form is updated accordingly.
4.4.2
Deleting command lines

The motion command that appears in line 13 of the program form given below (P11) is to be deleted. To do so, move the edit cursor to line 13.
Press the menu key Program
and select Delete by means of the arrow key. Then press the Enter key. The key 1 in the numeric keypad can also be pressed (do not press Enter).
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KUKA.Gripper- and SpotTech 2.2 Line 13 has been deleted and the original line 14 is now line 13.
4.4.3
Adding commands to an existing program

The procedure for adding commands to an existing program is given below. A further part is added to the welded assembly described in Section 4.3:
Home position
Reorientation of the welding gun by 90
The new part is welded to the two brackets by means of two spots (P13 and P16 in the diagram). As the welding gun has to be reorientated by 90 to weld these two spots in relation to welding the spot sequences P2 to P5 and P6 to P9, it is advisable to weld them before welding spot sequences P2 to P9. In this example, these two spots are to be welded after weld spot P9. This requires the following changes to be made to the program: -- Alter the command Motion (P10) -- Insert the command Motion (P11) to reorientate the welding gun -- Insert the command Motion (P12) -- Insert the command SPOT -- SPOT (P13) -- Insert the command Motion (P14) -- Insert the command Motion (P15) -- Insert the command SPOT -- SPOT (P16) -- Insert the command RETRACT (P17) -- Insert the command Motion (P18)
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4.4.3.1
Description of the alteration Open the program form from the previous section.
4.4.3.2
Changing the position of the welding gun (point in space P10) Move the edit cursor to line 12. Position the welding gun to the point in space P10. When doing so, ensure that it cannot collide with the component or with other obstructing contours during the following reorientation to P11. Press the softkey Touch Up to save the new robot coordinates.
4.4.3.3
Reorientation of the welding gun - inserting the command Motion (P11)
P10
P11
Ensure that the edit cursor is positioned in line 12 (P10). An inline form is opened by pressing the softkey Motion.
Select the motion type LIN. Use the traversing keys or the Space Mouse to align the welding gun accordingly (rotate by 90). Save the current robot coordinates (Touch Up) and press the softkey Cmd Ok after entering all the parameters.
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KUKA.Gripper- and SpotTech 2.2 4.4.3.4 Moving to the point in space P12 - inserting the command Motion Now insert the command Motion -- PTP to move the welding gun to the point in space P12, which is located above the weld spot P13.
4.4.3.5
Welding spot P13 - inserting the command SPOT Select SPOT Tech -- SPOT -- PTP. Select the option RETR OPN in the inline form, enter the required parameters and close the inline form with Cmd Ok.
4.4.3.6
Moving to the weld spot P16 and welding The welding gun is moved to the weld spot P16 via the points in space P14 and P15. Two PTP motions are programmed from P13 to P14 and from P14 to P15. The appropriate inline forms are shown below:
This is followed by the welding command SPOT Tech -- SPOT -- PTP:
4.4.3.7
Moving to the home position The welding gun is moved to the home position via the points in space P17 and P18. The motions from P16 to P17 and from P17 to P18 are to be programmed. The motion to PTP -- HOME is already included in the skeleton program. Alteration of the program is now completed.
The altered line 12 (P10) and the new lines 13 to 20 (P11 to P18) are indicated by the white line on the left in the diagram.
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4.5
SpotTech configuration
Configuration of the SpotTech software package is only possible in expert mode.
4.5.1
Program sequence
The following diagram shows the basic sequence of a spot welding program between two weld spots. Trigger Trigger PRESPOT SPOT Weld spot Pn
Weld spot P(n--1) or starting point RETRACT Retract open (if programmed) Working stroke open ADVSPOT Robot motion Time t
t Communication with the welding controller (e.g.

setting program parameters)
ADVSPOT
PRESPOT
Gun closing time t
SPOT Weld complete WLD_CMP Weld start WLD_STRT Weld duration
(weld start -weld complete)
The usable functions depend on the type of welding gun used as well as its controller. The individual functions: Name Retract stroke RETRACT Working stroke ADVSPOT Description Retract stroke of the welding gun. Completely opens the gun, for example, to approach weld spots over component edges. Working stroke of the welding gun. The working stroke is generally sufficient for spot sequences along even surfaces. Advance communication with the welding controller (during gun movement) so that all required weld data are available when the end point is reached.
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KUKA.Gripper- and SpotTech 2.2 Early closing of the gun; programmable in the parameter list Selection. The closing operation already starts while the welding gun is still moving to the weld spot. The actual welding process, initiated with the Weld start command (WLD_STRT) to the welding periphery until the arrival of the Weld complete signal (WLD_CMP).
PRESPOT
SPOT
4.5.2
Retract stroke (RETRACT) and working stroke (SPOT)

The basic SpotTech functions SPOT and RETRACT are shown schematically in the following sketch.
Welding gun Working stroke Retract stroke closed RETR CLO Working stroke closed SPOT Retract stroke
Component
4.5.3
Early closing of the gun (PRESPOT)

The PRESPOT function allows the gun to close while the welding gun is moving to the end point.
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Trigger for early gun closing (PRESPOT) TRIGGER WHEN DISTANCE=1 DELAY=SSDAT1.CLO_TM DO USERSPOT(#PRESPOT,S_ACT) PRIO= -1
Working stroke
Weld spot position Pn reached
Early closing time
Early closing distance Welding gun closed Trigger for weld start TRIGGER WHEN DISTANCE=1 DELAY=0.0 DO USERSPOT (#SPOT,S_ACT) PRIO= -1 Pn
The point of closing the gun early (PRESPOT) is to optimize the time taken to execute the spot welding process. The closing operation already starts while the welding gun is still moving towards the weld spot. In this instance, it must be ensured that the gun is not closed completely until just after the end position Pn is reached.
Variations in air pressure, the orientation of the gun and other factors may produce different gun opening and closing times. The closing time of the welding gun must therefore be checked in a test run. Closing the gun too early while the robot is still moving results in the weld spot being incorrectly positioned and may cause the component and the tool to be damaged!
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4.6
4.6.1
Components of the SpotTech package

Program structure
The interface to the welding controller is implemented in the form of a configurable handshake. The settings and assignments of the physical inputs and outputs are defined in the file $CONFIG.DAT. In the following block diagram the program structure of the KR C1 robot controller is shown in the Spot welding robot configuration. $CONFIG.DAT USERSPOT PACKAGE CELL.SRC Technology-specific organization program SPS.SUB
DEF SPS() CWRITE (...RUN /R1/CELL()) LOOP ... ENDLOOP
Part 1 *.SRC *.DAT BAS(...) H50(...) USERSPOT
Part 2 *.SRC *.DAT BAS(...) H50(...) USERSPOT
...
Part n *.SRC *.DAT BAS(...) H50(...) USERSPOT
H50.SRC Functions for gripper control
BAS.SRC Functions for robot motion
USERSPOT.SRC Functions for spot welding
P00.SRC Functions for Automatic External
IR_STOPM.SRC Routines for handling faults
KR C1 program structure
4.6.2
SPOT Tech-specific files

The following files, which are included in the SPOT Tech package, are required for executing spot welding applications. You will always see the symbols shown on the left with the file names throughout this document whenever the corresponding file or parts of it are described. $CONFIG.DAT Contains data specific to SPOT Tech within the Fold USERSPOT. This file is supplied as a skeleton program. This is where you enter data for your own spot welding programs, e.g. for initializing, for RETRACT, ADVSPOT, SPOT, etc.
USERSPOT.SRC
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4.7
Adaptation to the periphery, configurable options

This section describes the SpotTech peripheral interfaces with an example illustrating the assignment of the digital outputs and inputs. The Fold USERSPOT contained in the file $CONFIG.DAT as well as the file USERSPOT.SRC are described.
4.7.1
FOLD SPOT in the file $CONFIG.DAT

The Fold SPOT from the file $CONFIG.DAT is shown below. ;FOLD SPOT GLOBALS; ;================================== ; Structures: ;================================== ENUM S_COMMAND SPOT,RETR,PRESPOT,INIT,ADVSPOT
Branch SWITCH CMD in file USERSPOT.SRCC Gun-specific parameters
ENUM S_PAIR_SLCT FIRST,SECOND,BOTH
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] STRUC SPOT_TYPE INT GUN,S_PAIR_SLCT PAIR,COMMAND RETR,INT CLO_TM, INT PGNO1,REAL PRESS1,INT PGNO2,REAL PRESS2 ;============================== ; External declarations: ;============================== EXT USERSPOT (S_COMMAND :IN,SPOT_TYPE ;============================== ; Variables: ;============================== DECL SPOT_TYPE SDEFAULT={GUN 1,PAIR #FIRST,RETR #OPN,CLO_TM 0,PGNO1 1, PRESS1 0.0,PGNO2 0,PRESS2 0.0} DECL SPOT_TYPE S_ACT DECL INT S_ACT_DELAY DECL BOOL S_READY INT BOSCHCMD_OK=534 INT BOSCHSTAT_OK=528 ;============================== ; all for Bosch-Serial-Interface ;============================== EXT BOSCH (INT :IN,INT :IN,INT :OUT ) ; BOSCH-OUTWORD 1 (513-528) param SIGNAL BOSCHPAR $OUT[513] TO $OUT[528] ; BOSCH-OUTWORD 2 (529-544) command SIGNAL BOSCHCMD $OUT[529] TO $OUT[533] ; BOSCH-INWORD 1 (513-528) status+validbit SIGNAL BOSCHSTAT $IN[513] TO $IN[527] ;ENDFOLD If adaptation to the peripheral hardware used is required, please consult the corresponding documentation.
:IN )
Default data set for SPOT Global variables that are used in the robot program.
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4.7.2
The user-specific program USERSPOT.SRC

The skeleton program USERSPOT.SRC provided in the SpotTech technology package serves as the framework for applications individually tailored to the welding equipment being used. In the following sections, you will find examples of the configuration options available. &COMMENT USERSPOT package DEF USERSPOT (CMD :IN,S :IN ) ;******************************** ; USERSPOT - Package KR C1 ; R2.2.x ; Date: 23.03.98 ; ;******************************** DECL S_COMMAND CMD DECL SPOT_TYPE S SWITCH CMD Initialization (contained in INI FOLD) Call during advance run Triggering of early closing of the welding gun Triggering Weld start at weld spot position Enable for further program execution Gun retract stroke (RETRACT) CASE #INIT INIT ( ) CASE #ADVSPOT ADVSPOT (CMD,S ) CASE #PRESPOT PRESPOT (CMD,S ) CASE #SPOT SPOT (CMD,S ) S_READY=TRUE CASE #RETR RETRACT (CMD,S ) S_READY=TRUE ENDSWITCH END ; END OF MAIN ;***************************** DEF ADVSPOT (CMD :IN,S :IN ) DECL S_COMMAND CMD DECL SPOT_TYPE S END ;(ADVSPOT) ;***************************** DEF PRESPOT (CMD :IN,S :IN ) DECL S_COMMAND CMD DECL SPOT_TYPE S END ;(PRESPOT) ;***************************** DEF SPOT (CMD :IN,S :IN ) DECL S_COMMAND CMD DECL SPOT_TYPE S END ;(SPOT) ;***************************** DEF RETRACT (CMD :IN,S :IN ) DECL S_COMMAND CMD DECL SPOT_TYPE S END ;(RETR) ;***************************** DEF INIT ( ) END ;(INIT) User data for ADVSPOT
User data for PRESPOT
User data for SPOT
User data for RETRACT
User data for INIT
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4.7.2.1
Schematic sequence diagram for SPOT (without RETRACT) The following diagram shows the basic program sequence of the command SPOT. The options PRESPOT (early closing of the gun) and RETRACT (open/close retract stroke of the gun) are not shown. Weld parameter designation S01 (Auxiliary point) S02
Robot motion GUN_WRK Working stroke OPEN activation (output) WRK_STAT Working stroke OPEN status (input) WLD_STRT Weld start (output) WLD_CMP Weld complete (input) PNUM Program number (output)
CLOSE
CLOSE TRUE FALSE TRUE FALSE
t ADVSPOT S.PGN01 0 t
After welding the spot S01 the weld complete signal (WLD_CMP=TRUE) triggers, with its falling edge (WLD_CMP=FALSE), the instruction for opening the working stroke of the welding gun (GUN_WRK=G_OPN). At the same time the weld start signal WLD_STRT=FALSE as well as the program number PNUM=0 are set. The robot controller now waits for the status message WRK_STAT==G_OPN indicating that the working stroke of the gun is open. This signal enables robot movement to the next weld spot. To ensure that all the data required for welding are available at the end point (in this example point S02), the welding program number, for example PNUM=S.PGN01, is already output during the actual movement, provided this has been configured in the section ADVSPOT of the file USERSPOT.SRC. At the end point (in this example point S02), the control instruction is given to close the working stroke (GUN_WRK=W_CLO). The status message from the welding controller that the working stroke is closed (WRK_STAT=W_CLO) triggers the weld start (WLD_STRT=TRUE). At the conclusion of the welding process, the instruction is given once again, by means of the falling edge of the weld complete signal (WLD_CMP=FALSE), to open the working stroke of the gun (GUN_WRK=G_OPN) as well as to set the weld start signal WLD_STRT to FALSE and the program number PNUM to ZERO.
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KUKA.Gripper- and SpotTech 2.2 4.7.2.2 Schematic sequence diagram for SPOT (with RETRACT) S01 (Auxiliary point) S02
Robot motion GUN_RET Retract stroke OPEN activation (output) CLOSE RET_STAT Retract stroke OPEN status (input) CLOSE GUN_WRK Working stroke OPEN activation (output) CLOSE WRK_STAT Working stroke OPEN status (input) CLOSE WLD_STRT Weld start (output) WLD_CMP Weld complete (input) PNUM Program number (output) TRUE FALSE TRUE FALSE TRUE FALSE 0 ADVSPOT S.PGN01 With PRESPOT
t If RETR OPN selected t If RETR CLO selected t
After welding the spot S01 the weld complete signal (WLD_CMP=TRUE) triggers, with its falling edge (WLD_CMP=FALSE), the instruction for opening the working stroke of the welding gun (GUN_WRK=G_OPN). At the same time the weld start signal WLD_STRT=FALSE as well as the program number PNUM=0 are set. When the status message WRK_STAT==G_OPN is given, indicating that the working stroke of the gun is open, movement is initiated to the next weld spot, provided the option RETR CLO (gun retract stroke remains closed) has been programmed with the SPOT command. If the option RETR OPN has been programmed (the gun retract stroke is opened after the spot has been welded), the command GUN_RET=G_OPN is executed. In this case, movement to the next weld spot is not enabled until the status signal RET_STAT=OPEN is set. During this movement, the welding program number (PNUM) is output if this has been configured in the section ADVSPOT of the file USERSPOT.SRC.
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At the end point (in this example point S02), the control instruction is given to close the working stroke (GUN_WRK=CLOSE). The welding program number (PNUM) is output at the same time. If the retract stroke at point S02 is open (RET_STAT=OPEN), the corresponding close instruction (GUN_RET=CLOSE) is given first of course. The status message from the welding controller that the working stroke is closed (WRK_STAT=W_CLO) triggers the weld start (WLD_STRT=TRUE). At the conclusion of the welding process, an instruction is given once again by means of the weld complete signal (WLD_CMP) to open the working stroke of the gun (GUN_WRK=G_OPN). 4.7.2.3 Robot controller - welding controller interface The following table provides an overview of the configurable physical inputs and outputs. The addresses refer to the extension of the file USERSPOT.SRC shown in Section 4.7.2.4. Name PNUM WLD_STRT WLD_CMP Description, signal states Welding program no. (max. 255 characters) Weld start Weld complete signal (from welding controller) Working stroke control (SPOT) GUN WRK GUN_WRK Close stroke TRUE FALSE Stroke closed TRUE FALSE Close stroke TRUE FALSE Stroke closed TRUE FALSE Open stroke FALSE TRUE Stroke open FALSE TRUE Open stroke FALSE TRUE Stroke open FALSE TRUE Input 12 Input 13 Output 12 Output 13 Input 10 Input 11 Output 10 Output 11 Output / Input (example) Output 1 ... 8 Output 15 Input 15
Working stroke status message (SPOT) WRK STAT WRK_STAT
Retract stroke control (RETRACT) GUN RET GUN_RET
Retract stroke status message (RETRACT) RET STAT RET_STAT
4.7.2.4
Program example for the file USERSPOT.SRC &COMMENT USERSPOT package DEF USERSPOT (CMD :IN,S :IN ) ;******************************** ; USERSPOT - Package KR C1 ; R2.2.x ; Date: 23.03.98 ; Example No 1 ; SPOT / RETRACT ;******************************** DECL S_COMMAND CMD
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KUKA.Gripper- and SpotTech 2.2 DECL SPOT_TYPE S ;Program No. SIGNAL PNUM $OUT[1] TO $OUT[8] ;GUN-RETRACT SIGNAL GUN_RET $OUT[10] TO $OUT[11] ;State RETRACT SIGNAL RET_STAT $IN[10] TO $IN[11] ;GUN work (SPOT) SIGNAL GUN_WRK $OUT[12] TO $OUT[13] ;State SPOT SIGNAL WRK_STAT $IN[12] TO $IN[13] ;Weld Start SIGNAL WLD_STRT $OUT[15] ;Weld done SIGNAL WLD_CMP $IN[15] ;================================= ;GROUP Definitions INT R_CLO,R_OPN,W_CLO,W_OPN R_CLO=B0001 R_OPN=B0010 W_CLO=B0001 W_OPN=B0010 ;================================= SWITCH CMD CASE #INIT INIT ( ) CASE #ADVSPOT ADVSPOT (CMD,S ) CASE #PRESPOT PRESPOT (CMD,S ) CASE #SPOT SPOT (CMD,S ) S_READY=TRUE CASE #RETR RETRACT (CMD,S ) S_READY=TRUE ENDSWITCH END ; END OF MAIN ;********************************* DEF ADVSPOT (CMD :IN,S :IN ) WLD_STRT=FALSE PNUM=S.PGNO1 END ;(ADVSPOT) ;***************************** DEF PRESPOT (CMD :IN,S :IN ) GUN_RET=R_CLO WAIT FOR RET_STAT==R_CLO GUN_WRK=W_CLO END ;(PRESPOT) Close retract stroke (RETRACT) Waiting for Retract closed Close working stroke Reset weld start Issue program number
Assignment of inputs/outputs Program number, outputs 1...8 Retract stroke (RETRACT), outputs 10, 11 Retract stroke status, inputs 10, 11 Working stroke (SPOT), outputs 12, 13 Working stroke status, inputs 12, 13
Weld start, output 15
Weld complete signal, input 15 Retract stroke / working stroke states
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;***************************** DEF SPOT ( ) WAIT FOR WRK_STAT==W_CLO WLD_STRT=TRUE WAIT FOR WLD_CMP PNUM=0 WAIT FOR NOT (WLD_CMP)
WLD_STRT=FALSE GUN_WRK=W_OPN WAIT FOR WRK_STAT==W_OPN SWITCH S.RETR CASE #OPN GUN_RET=R_OPN WAIT FOR RET_STAT==R_OPN ENDSWITCH END ;(SPOT) ;***************************** DEF RETRACT ( ) SWITCH S.RETR CASE #OPN GUN_RET=R_OPN WAIT FOR RET_STAT==R_OPN CASE #CLO GUN_RET=R_CLO WAIT FOR RET_STAT==R_CLO ENDSWITCH END ;(RETR) ;***************************** DEF INIT ( ) PNUM=0 WLD_STRT=FALSE GUN_WRK=W_OPN WAIT FOR WRK_STAT==W_OPN GUN_RET=R_OPN WAIT FOR RET_STAT==R_OPN S_READY=TRUE END ;(INIT)
Waiting for Working stroke closed Set weld start Waiting for weld complete signal (TRUE) Set program number to ZERO Waiting for weld complete signal (FALSE) Reset weld start (FALSE) Open working stroke Waiting for Working stroke open If RETR OPN programmed after weld spot: open retract stroke (RETRACT) Waiting for Retract stroke open
Retract stroke (RETRACT) If RETR OPN programmed: open retract stroke (RETRACT) Waiting for Retract stroke open If RETR CLO programmed: close retract stroke Waiting for Retract stroke closed
Set program number to ZERO Reset weld start Open working stroke (SPOT) Waiting for Working stroke open Open retract stroke (RETRACT) Waiting for Retract stroke open Enable for further program execution
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4.8
Program example
A simple demonstration program (for example, DEMO01.SRC) for welding a single spot is described in the following. Add the command SPOT Tech--SPOT--PTP to a skeleton program as shown in program line 4 below.
Now move the edit cursor to line 4 and select FOLD -- Act FOLD op/cl with the menu function Program (to do so you must be within the user group Expert). You will now see the complete program listing for the entered command. File DEMO01.SRC PTP P1 PDAT1 SPOT Gun= 1 RETR OPN SDAT PDAT_ACT=PPDAT1 BAS (#PTP_DAT ) FDAT_ACT=FP1 BAS (#FRAMES ) BAS (#VEL_PTP,PPDAT1.VEL )
Motion parameters Ref. to data set (for precalculation) Selection of welding gun (1...5) Selection of gun pair Retract stroke open Welding program number
S_ACT.GUN=1 S_ACT.PAIR=SDEFAULT.PAIR S_ACT.RETR=#OPN S_ACT.CLO_TM=SSDAT1.CLO_TM S_ACT.PGNO1=SSDAT1.PGNO1 S_ACT.PGNO2=SDEFAULT.PGNO2 S_ACT.PRESS1=SSDAT1.PRESS1 S_ACT.PRESS2=SDEFAULT.PRESS2 S_READY=FALSE USERSPOT (#ADVSPOT,S_ACT ) TRIGGER WHEN DISTANCE=1 DELAY=SSDAT1.CLO_TM DO USERSPOT (#PRESPOT,S_ACT ) PRIO= -1 TRIGGER WHEN DISTANCE=1 DELAY=0.0 DO USERSPOT (#SPOT,S_ACT) PRIO= -1 PTP XP1 WAIT FOR S_READY
Trigger for gun closing (working stroke) Trigger for early gun closing (PRESPOT) Trigger for weld start (SS)
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4.9
Manual operation of the welding gun using the status keys

When carrying out tests, it is useful to be able to test the retract stroke (RETRACT) and working stroke (SPOT) functions of the gun in addition to the gun movement, without actually welding.
4.9.1
Separate control of RETRACT and SPOT

The configuration described below allows separate manual control of the gun retract stroke (RETRACT) and working stroke (SPOT). Using the Gripper selection status key, you can choose from the following: -- Retract stroke (RETRACT) -- Working stroke (SPOT) --(Gripper) no. 1 and (Gripper) no. 2
The retract stroke (1) or the working stroke (2) can be controlled corresponding to the selection you make with the status key for manual gripper operation. Retract/working stroke selection Retract stroke (RETRACT) OPEN GUN_RET CLOSE OPEN Working stroke (SPOT) GUN_WRK CLOSE
OPEN
OPEN
Operation of retract stroke 4.9.1.1 Definition of function type and assignment of physical outputs
Operation of working stroke
The GRIPPER Tech package provides a number of gripper function types. Two function types are available for implementing the above configuration: Function type 1 Function type 5 static outputs pulse outputs (for static valves) (for pulse valves)
Logic table for function types 1 and 5: State A B OUT1 TRUE FALSE OUT2 FALSE TRUE
The changes required in the file $CONFIG.DAT for manual gun operation are described below. Static outputs Entries in the file $CONFIG.DAT when using gripper function type 1: ; Definition of grippers ;================================== INT MAXGRIPPER=8 DECL GRP_TYPES GRIPPER[8]
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GRIPPER[1]={TYPE 1,OUT1 10,OUT2 11, OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, IN4 0,GRP_OLD 1} GRIPPER[2]={TYPE 1,OUT1 12,OUT2 13, OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, IN4 0,GRP_OLD 1}
Retract stroke (RETRACT) Definition of function type (1) and assignment of the physical outputs (in this example 10 and 11) Working stroke (SPOT) Definition of function type (1) and assignment of the physical outputs (in this example 12 and 13)
Pulse outputs Entries in the file $CONFIG.DAT when using gripper function type 5: ; Definition of grippers ;================================== INT MAXGRIPPER=8 DECL GRP_TYPES GRIPPER[8] GRIPPER[1]={TYPE 5,OUT1 10,OUT2 11, OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, IN4 0,GRP_OLD 1} GRIPPER[2]={TYPE 5,OUT1 12,OUT2 13, OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, IN4 0,GRP_OLD 1} Retract stroke (RETRACT) Definition of function type (5) and assignment of the physical outputs (in this example 10 and 11) Working stroke (SPOT) Definition of function type (5) and assignment of the physical outputs (in this example 12 and 13)
The pulse duration for function type 5 is preset to 0.5 seconds. It is possible to make a change at the end of the block Definition of grippers in the file $CONFIG.DAT. REAL GRP_PULSE_TI=0.5 ; pulse time for gripper type 5 Corresponding entry using the menu function Monitor -- Variable -- Modify: Variable GRP_PULSE_TI Default (sec.) 0.500
The inputs (IN1 ... IN4) are not polled in these examples because the mechanical gun function can be checked visually. For this reason the configuration and addressing of the physical inputs are irrelevant for the manual gun control function. In the examples above, the retract stroke control for gripper no. 1 and working stroke control for gripper no. 2 were assigned. You can also assign other numbers if these numbers are reserved for other applications, for example.
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The assignment of gripper no. 8, for example, requires the following entry in the file $CONFIG.DAT: GRIPPER[8]={TYPE 1,OUT1 10,OUT2 11, ... Note that the value of the variable MAXGRIPPER must be at least as high as the configured gripper number. MAXGRIPPER=8 is the default setting.
4.9.2
Manual control of RETRACT and SPOT in series

The following example describes how the retract stroke and working stroke of guns with 4--way valves can be manually controlled. Switching between the following states should be possible using the status key for manual gripper control: -- Retract stroke (RETRACT) open, working stroke (SPOT) open -- Retract stroke closed, working stroke closed -- Retract stroke closed, working stroke open Selection of welding gun 1 / 2 GUN_RET GUN_WRK OPEN OPEN CLOSE CLOSE CLOSE OPEN OPEN OPEN
Operation
Definition of function type and assignment of physical outputs For implementation of the above configuration, the GRIPPER Tech H50 package provides function type 4, with only the outputs 2 and 3 being used. Logic table of function type 4, outputs 2 and 3: State A B C OUT2 FALSE TRUE TRUE OUT3 FALSE TRUE FALSE
The changes required in the file $CONFIG.DAT for manual gun operation are described below. ; Definition of grippers ;================================== INT MAXGRIPPER=8 DECL GRP_TYPES GRIPPER[8]
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GRIPPER[1]={TYPE 4,OUT1 10,OUT2 12, OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, IN4 0,GRP_OLD 1}
1
Retract (OUT 10) and working stroke (OUT 12), definition of the function type (4) and assignment of the physical outputs (e.g. 10 and 11)
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Index
Zeichen
$CONFIG.DAT, 9, 10, 44, 45, 53
F
FOLD, 52 Function type, 8
Zahlen
4/2--way valves, 9
G
GDAT, 16 Gripper sensor interrogation, 18 GRIPPERTech, 15, 18 GRP_PULSE_TI, 9 Gun, 22 Gun opening and closing times, 43
A
Adding commands, 38 ADVSPOT, 41, 47, 48 Altering existing programs, 37 Approximation function, 16 Arrow keys, 15 Assignment of inputs/outputs, 50 at, 16, 18
I
Identification number, 10 INI, 20 Initialization command, 20 Initialization and configuration examples, 13 Inline form, 15, 18, 21, 23 Inline form RETRACT, 28 Inline form SPOT, 23 Inputs, 45 Issue program number, 50
B
Basic functions, 42 BLOW, 8
C
Call during advance run, 46 CASE #ADVSPOT, 46 CASE #INIT, 46 CASE #PRESPOT, 46 CASE #SPOT, 46 CHECK, 18 Check Gripper, 16, 18 CIRC, 22 Cmd Ok, 17 Continuous signal, 9 Creating a new program, 31
L
LIN, 22
M
Manual control of RETRACT and SPOT in series, 55 Manual gripper operation, 9 Manual operation of the welding gun, 53 Manually operating a gripper, 14 Monitor, 9
D
Default data set, 45 Delay, 16, 17, 19 Deleting command lines, 37 Designation of the welding gun, 22
O
OFF, 8 Outputs, 45
E
Early closing of the welding gun, 26 Early closing time, 26 Early gun closing, 42 Enabling switch, 14 END, 17, 19 Exclusion from use, 8
P
P1, 21 Parameter lists RETRACT, 28 Parameter lists SPOT, 23 PDAT, 21, 25 Peripheral interfaces, 45 Pneumatic cylinders, 9 PRESPOT, 42 Index -- i
Index Program example, 31, 49, 52 Program number output, 50 Program sequence, 41 Program structure, 44 Programmed velocity, 14 Programming a weld spot, 23 Programming gripper functions, 15 Programming the retract stroke, 27 PTP, 22 Pulse, 9 Pulse outputs, 54 TEST1, 14 TEST2, 14 Time optimization, 43 Trigger for early gun closing, 43, 52 Trigger for weld start, 43, 52 Types of motion, 22, 27
R
Reduced velocity, 14 Reorientation of the welding gun, 20, 30, 38, 39 Reset weld start, 50 RETR CLO, 20, 25, 29, 48 RETR OPN, 20, 25, 29, 48 RETRACT, 9, 20, 26, 41 Retract stroke, 20, 41, 42, 50 Retract stroke after the welding process, 25 Robot motion to a weld spot, 22
U
USER_GRP.DAT, 10 USER_GRP.SRC, 9, 11 USERGRP.DAT, 9 USERSPOT, 45 USERSPOT.SRC, 44, 45, 46, 47, 49
V
VACUUM, 8 Vacuum gripper, 8 Variables, 9, 45
S
S_READY, 46, 52 SDAT, 21, 25 Selecting the welding gun, 25 Sensor interrogation, 16 Sensors, 16 Sequence diagram for SPOT (with RETRACT), 48 Sequence diagram for SPOT (without RETRACT), 47 SET, 15 Set program number to ZERO, 51 Simulation, 16 Softkey bar, 15 SPOT, 20, 22, 23, 42, 47 SPOT Gun=, 25 Spot welding, 22 START, 17, 19 State, 15, 18 Static outputs, 53 Status key, 14 System variables, 9
W
Wait Time, 16 Weld complete signal, 47, 48, 49, 50 Weld parameters, 22, 25 Weld start, 49, 50 Welding gun, 9 Welding gun retract stroke, 22 Welding process, 20 Welding program number, 47, 49 WORKING STROKE, 9 Working stroke, 26, 41, 42, 50
Working stroke status, 50 Index -- ii

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SOFTWARE

KUKA.Gripper- and SpotTech 2.2

for KUKA.KR C 5.2, 5.3, 5.4

Issued: 09 Nov 2004

KUKA Roboter GmbH

KUKA.Gripper- and SpotTech 2.2

Installation / uninstallation / update

KUKA.Gripper- and SpotTech 2.2

2 outputs, 4 inputs, 2 switching states

2 outputs, 2 inputs, 3 switching states

FALSE FALSE FALSE FALSE

2 outputs, 2 inputs, 3 switching states

FALSE FALSE FALSE FALSE

3 outputs, 2 inputs, 3 switching states

FALSE TRUE FALSE TRUE

FALSE FALSE FALSE

2 outputs, 4 inputs, 2 switching states

Freely programmable type

WORKING STROKE Position C

KUKA.Gripper- and SpotTech 2.2

Working stroke cylinder

State Output1 A B C TRUE TRUE

Control Output2 Output3 Output4

FALSE TRUE FALSE

FALSE TRUE TRUE FALSE

FALSE FALSE TRUE

KUKA.Gripper- and SpotTech 2.2

Initialization and configuration examples

Not defined 17 --18 0 0 22 23 0 0

Not defined 19 21 0 0 22 --23 24 --25

KUKA.Gripper- and SpotTech 2.2

Manually operating a gripper

Programming gripper functions

The assignment of the softkey bar changes at the same time:

Execute gripper function

The gripper function is executed along this line

Without approximate positioning

With approximate positioning

KUKA.Gripper- and SpotTech 2.2

The assignment of the softkey bar changes at the same time:

The gripper function is executed along this line

KUKA.Gripper- and SpotTech 2.2

The functions SPOT and RETRACT

Retract stroke open RETR OPN

Programming and operation

General information on programming

Variables in input boxes of the inline forms

Spot welding (SPOT)

Programming a weld spot (SPOT)

KUKA.Gripper- and SpotTech 2.2

Example of a weld parameter list Early closing of the welding gun

LIN/CIRC LIN/CIRC motion Velocity (0.001 to 2 m/s) Acceleration (1 to 100 %)

PTP PTP motion

Velocity (1 to 100 %) Acceleration (1 to 100 %)

Softkey bar when the inline form is active

Softkey bar when a parameter list is active

PDAT2 SPOT Gun= 1 RETR OPN SDAT1

Retract stroke open RETR OPN

Retract stroke closed RETR CLO

KUKA.Gripper- and SpotTech 2.2

Working stroke Start of early closing of gun

Weld spot position Pn reached

Early closing time

Part 1 .SRC .DAT BAS(...) H50(...) USERSPOT

Part 2 .SRC .DAT BAS(...) H50(...) USERSPOT

Part n .SRC .DAT BAS(...) H50(...) USERSPOT