KUKA ROBOT WELDING AND MILLING

A PROJECT REPORT

Submitted by

MOHD. SHADAB

In partial fulfilment for the award of the degree of

B.Tech

IN

MECHANICAL ENGINEERING

Department of Mechanical Engineering

Rawal Institute of Engineering and Technology
Sohna Road, Near Zakopur, Faridabad
www.rawalinstitutions.com

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INDUSTRIAL ROBOTS WELDING PROGRAMMING
& MILLING OPERATION

A PROJECT REPORT

Submitted by

MOHD. SHADAB

15-ME-6062

in partial fulfilment for the award of the degree of

BACHELOR OF TECHNOLOGY

In

Mechanical Engineering

Department of Mechanical engineering

Rawal Institute of Engineering and Technology
Sohna Road, Near Zakopur, Faridabad
www.rawalinstitutions.com

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Certificate

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 ACKNOWLEDGEMENTS

Written word has an unfortunate tendency to degenerate Genuine gratitude into a formality
however it is the only way to record one’s feeling permanently.

I was bestowed with the golden opportunity to undergo my internship training at AKGEC
Skills foundation, Ghaziabad and hence took this opportunity to express my heartfelt thanks
to all those who have been a mentor and trainer with my training.

I express my special thanks to MR. VIKASH KUMAR, the Assistant General Manager of
AKGEC Skills Foundation. I gained knowledge about robot programming along with
welding operation, simulation of individual task of different aspects and project integrated
with different types of tools.

I got experience with Kuka based articulated robot and had exposure to:

 Basic robot programming with KR16

 Welding with KR16 HW ARC (WELDING APPLICATION)
 Milling Project with Kuka KR120

Mohd. Shadab
15-ME-6062

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 ABSTRACT

This report introduces the robotic welding and milling application on different robot with
integration of technologies and control process for Kuka robot.

In the project task I used KUKA KR 16 HW ARC robot with FRONIOUS CMT welding
set, special jig and figure are also used to hold the application. I did welding on the material
with minimum thickness. Welding on Aluminium having a thickness of 0.5 mm to 1 mm is
very critical job to do in industries by manual welding sets. Hence I used Kuka robot for
welding thin Aluminium sheets. And for my final year research I performed experiments to
find difference between manual and robot welding and also found out different parameters
which will manipulate the quality and strength of weld.

The another task I performed is of milling application. I used KUKA KR 120 Milling robot
where we have seven axes, 6 robot axes and 1 external axes. Robot coordinates with PLC
drive system of Siemens from where it gets data to move all axes in collaboration with each
other. I performed a task where I used milling robot for making “Shaghai” from a block of
Styrofoam for “RoboCon 2019” held at “IIT DELHI” here I completed this task within two
weeks of time and the complete program has more than 4 lakh lines to execute.

For the purpose of programming robots for fulfilling these two task, instead of using normal
conventional teaching programming method. I used various advance software like Siemens
NX, RoboDK, Grasshopper and Rhino 6 for programming duties which reduces chances of
error in program and also reduces time and workforce required for programming.

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 TABLE OF CONTANT
CERTIFICATE …………………………………………………………………… 3
ACKNOWLEDGEMENTS ………………………………………………………. 4
ABSTRACT ………………………………………………………………………. 5
TABLE OF CONTANT ………………………………………………………… 6-7
LIST OF TABLE …………………………………………………………………. 8
LIST OF FIGURES ……………………………………………………………… 9
CHAPTER 1 ………………………………………………………………………. 10-12
Robot System Basic ………………………………………………………. 10
I. Component Of Complete Kuka Robot System ……………………. 10
II. Kuka Control Panel ………………………………………………... 10
III. Axis Designation Of Kuka Robot ………………………………… 10
IV. System Overview …………………………………………………. 11
V. User group …………………………………………………………. 12
VI. Energy supply ……………………………………………………... 12
VII. Kuka Robot Control (KRC) ……………………………………….. 12

CHAPTER 2 ……………………………………………………………………….. 13-17

Robot safety feature ………………………………………………………. 13

I. Some of specify feature …………………………………………. 13
II. Operating mode ………………………………………………….. 13
III. Basic of structure programming ……………………………….. 15
IV. Advantage of requirement specification ………………………. 15
V. Program flow chart …………………………………………….. 16
VI. Sequence flow chart ……………………………………………. 16
VII. General information about expert level ………………………… 16
VIII. Navigator ………………………………………………………. 17
IX. Program run mode ……………………………………………... 17
X. Variable and declaration ………………………………………... 17

CHAPTER 3 …………………………………………………………………….. 18-19

Basic structure of robot programming ……………………………………... 18
Life time variable ……………………………………………………...…... 18
I. src file …………………………………………………………… 18
II. dat file …………………………………………………………... 18
III. config.dat file …………………………………………………… 18
Structure ………………………………………………………………… 18
Coordinate system of robots ……………………………………………. 19
I. Axis specific motion ……………………...……………………… 19
II. World coordinate system …………………...…………………… 19
III. Tool coordinate system ……………………...………………… 19
IV. Base coordinate system ……………………….……………… 19

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CHAPTER 4 …………………………………………………………………….. 20-22

Application of Kuka robot ………………………………………………… 20

I. KUKA.Lasercut ……………………………………….………… 20
II. KUKA.Arctech …………………………………….…………. 20
III. KUKA.Milling 8KW …………………………….…………….. 21
Scope Of Supply ………………………………………………………… 22

CHAPTER 5 ……………………………………………………………………. 23

Programming of kuka robot …………………………………………… 23

Motion programming …………………………………………….. 23
I. Axis specific motion …………………………………….. 23
II. Path related motion ……………………………………. 23
BCO run ………………………………………..……..…………… 23
i. Part 1 …………………………………………………….. 23
ii. Part 2 ………………………………………….…………. 23
II. LIN ( linear ) ………………………………….……..… 23

CHAPTER 6 ………………………………………………………………….. 24-26

Robotic welding project ………………………………………… 24

Programming ………………………………………………… 25-26

CHAPTER 7 ………………………………………………………………….. 27-28

Robotic milling project ……………………………………………… 27

I. Feature ………………………………………………… 27
II. Options ………………………………………………… 27
III. Applications ……………………………………… 27-28

CHAPTER 8 …………………………………………………………………… 29-30

Robotic Simulation ………………………………………………... 29

I. parametric robot simulation ...………………………… 29-30

CHAPTER 9 …………………………………………………………………… 31-35

Introduction to PLC ………………………………………………... 31

I. History of PLC ...……………………………………… 31-32
II. Architecture of PLC…………………...………………… 32-33
III. Steps for Indra control Bosch Rexroth Software L20 ….. 33
IV. Firmware………………………………………………… 33-34
V. Latching…………………………………………………. 34-35
VI. Simple Timers…………………………………………… 35

REFERENCE …………………………………………………………………… 36
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 LIST OF TABLE

TABLE 1 Operating Mode Table ………………13

TABLE 2 Variable & Declaration……………...17

TABLE 3 Structure Keywords……………….... 19

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 LIST OF FIGURES

Figure: 1 Parts of KUKA robot ………...….…………………11

Figure: 2 Operating mode………………………………….…14
Figure: 3 Advantage of requirement specification…………..15
Figure: 4 Kuka laser…………………………………....……..20
Figure: 5 Kuka laser ……………………………………….…21
Figure: 6 Kuka milling………………………………….…..…21
Figure: 7 Welding table and welding torch…………………..22
Figure: 8 Types of program …………………………….….…25
Figure: 9 Types of program …………………………….….…25
Figure: 10 Types of weld…………………………………..…...26
Figure: 11 Manual welding ……………...……………………26
Figure: 12 Milling robot ……………………..………………..28
Figure: 13 Milling work piece…………………………………28
Figure: 14 Grasshopper………………………………….…….29
Figure: 15 Grasshopper software……………………….…….30
Figure: 16 Sample of programing of robot…………………...30

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 CHAPTER 1
THE ROBOT SYSTEM
ROBOT SYSTEM BASIC

I. Components of a complete KUKA robot system:

 Kuka robot (KR 16)

 Kuka control panel
 KR C4 robot controller

II. KUKA Control panel (KCP):

Following are the various parts of Kuka Control panel and their function

 Key switch for mode selection

 Drive on/off switch
 Emergency stop button
 6D mouse
 Numeric keypad
 Alphabetic keypad
 Cursor block
 Soft key
 Base frame
 Rotating column

III. Axis designation of KUKA robot:

It consists of following axis:

 AXIS 1
 AXIS 2
 AXIS 3
 AXIS 4
 AXIS 5
 AXIS 6

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IV. System overview
KR C4 Controller for maximum 9 axis

CONTROL OF 6 AXIS
ROBOT + 3 EXTERNAL AXIS

Figure: 1

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 V. User group
 Configuration of robot controller (External axis, Technology package)
 Configuration of robot system (field buses, vision system etc.)
 User defined technology commands with UserTech.
 Start-up task (mastering, tool calibration)
 Simple application programs
 Motion commands, technology command, limit value checking
 Advance programming with using a KRL language
 Complete application programme (subprograms, interrupt
programming)
 Loops programming
 Numerical motion programming

VI. Energy supply

KUKA energy supply system

VII. Energy supply system – adjusting the protectors

 There is protector for protecting the robot

 These protectors cannot be adjusting

VIII. KUKA robot controller (KRC)

 Performance feature of Kuka robot control

 Open network capable pc technology
 free slot for external axis
 compact control cabinet
 Ergonomic KUKA control panel
 USB drive for data backup.

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 CHAPTER 2
ROBOTS SAFETY FEATURE
The safety system consists of external and internal safeguards. The external
safeguards are installation specific, like fences, gates, pressure mats, etc. Internal
safeguards consist of axis monitoring, workspace monitoring, operating modes, etc.
Electronic Safety Circuit (ESC) is responsible for monitoring all safety related
hardware. The KRC has four operating modes, different safety features are available
depending on the active mode. The KCP is outfitted with a local emergency stop. In
addition to this, there is an input for external emergency stop. To move the robot in
T1 or T2, one of the enable switches on the KCP must be pressed down.

I. SOME OF THE SAFETY FEATURES ARE:

 Emergency stop
 Start key released
 Enabling switch

II. OPERATING MODE:

Safety feature T1 T2 AUT AUT EXT

Emergency stop STOP0 STOP0 STOP1 STOP1

Enabling switch Active Active Not active Not active

Operator safety Not active Not active Active Active

Max 250mm/s Active Not active Not active Not active

Jog mode Active Active Not active Not active

Table: 1

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Figure: 2

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III. BASIC OF STRUCTURE PROGRAMMING:

Basic of structure programing is beginning with some requirement which full the task and
easy to coordinate with the robots and programmer, organisational and technical specification
for programme creation is necessary for all aspect.

IV. ADVANTAGE OF REQUIREMENT SPECIFICATION:

 Description of the application

 Definitions of inputs/outputs/parameters and program sequences
 Transparent breakdown
 Project formalization significantly easier

Figure: 3
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 V. PROGRAM FLOW CHART:
Program flowchart are one way of formulating abstract description of programs and
processes. The sequence is represented using standardized symbols that are not
dependent on the program code used.

VI. SEQUENCE OF FLOW CHART

 General statement
 Input/output statement
 If and else
 Branch
 Terminal
 Flow lines
 While loop
 Repeat loop
 For loop
 Subprogram call

VII. GENERAL INFORMATION ABOUT EXPERT LEVEL:

Navigator is describing with the specify symbol with their meaning which are indicate
in the panel usually for user and expert level of understanding.

 Module
 SUB file
 SRC file
 DAT file
 Folder closed
 Folder open

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VIII. PROGRAM RUN MODE:

 GO mode: All instructions in the program are executed up to the end of the
program without a STOP.
 MSTEP: The program is executed one motion instruction at a time with a stop
before each motion instruction.
 ISTEP: The program is executed step by step with a stop after each instruction
(including blank line).
 PSTEP: The program is executed step by step without advance processing.
subprograms are executed completely.
 CSTEP: Approximate positioning points are executed with advance processing
they are approximated. Exact positioning points are executed without advance
processing and with a stop after the motion instruction.

IX. VARIABLE AND DECLARATIONS:

Simple data type:

 INT.
 REAL.
 BOOL.
 CHAR.

Keyword Data type Range Example

INT Integer −2 31 ..2 31 − 1 32

REAL Floating point ±1.1x10−38 ± 3.4x1038 1.43

BOOL Boolean TRUE, FALSE TRUE

CHAR 1 Character ASCII character 1-255 “A”

Table: 2

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 CHAPTER 3
BASIC STRUCTURE OF ROBOT PROGRAMMING
 Declaration section
 Initialization section
 Instruction section

Basic structure of robot programming is describing in three section which the pillar of
the programming in which the programme are call These structure is mainly use for
the KRL language.

LIFE TIME VARIABLE:

I. SRC FILE.
 SRC file are only recognized in their own program
 SRC file are not recognized in local subprograms

II. DAT FILE.

 DAT file are only recognized in their own program in the main
program and in local subprograms.

III. $CONFIG.DAT FILE.

 CONFIG.DAT file is recognized in every program
 CONFIG.DAT file can be called during program execution

STRUCTURES:

 Struc axis
 Struc E6axis
 Struc frame
 Struc pos
 Struc E6pos

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Keyword Data type Range
AXIS Struct REAL A1,A2,A3,A4,A5,A6
E6AXIS Struct REAL A1,A2,A3,A4,A5,A6,E1,E2,E3,E4,E5,E6
FRAME Struct REAL X,Y,Z,A,B,C
POS Struct REAL X,Y,Z,A,B,C, INT S,T
E6POS Struct REAL X,Y,Z,A,B,C,E1,E2,E3,E4,E5,E6, INT S,T

Table: 3

COORDINATE SYSTEM OF ROBOTS:

I. Axis specific motion

Each robotic axis will move individually in a positive and negative direction.

II. World coordinate system

Fixed rectangular coordinate system whose origin is located at the base of

robot.

III. Tool coordinate system

Rectangular coordinate system whose origin located at the tool.

IV. Base coordinate system

Rectangular coordinate system which has its origin in the work piece that is to
be processed.

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 CHAPTER 4
APPLICATION OF KUKA ROBOT

I. KUKA Laser Cut

Technologies for laser cutting once Kuka.lasercut has been set up, additional
commands are available these command supports the programmer in the creation of
robots programme switch use laser function commands for switching the laser on &
off, control of a distance sensor system , the setting of the gas pressure and the
programming of sample geometric figure are .

Figure: 4

II. KUKA Arc Tech

Kuka.Arctech is a welding technology package for controlling power source with
program number control. This package has been specially developed for use with
cooperating robots and enable the simultaneous operation of up to three robots that
are in communication with one another. The package is further characterized by its
high degree of operating convenience the setup procedures are simplified by means of
a configuration tool. safe operation with shared pendant is supported by the wide
range of available operating & simulation made for convenient teaching & detailed
cause specific message including indication of the originator.

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 Figure: 5

III. KUKA Milling 8kw

Kuka with milling 8 KW application module, Kuka offers application specific
components and tool for deployment of a robot as a machine tool for milling tasks.
Milling 8 KW is specially designed for machining tasks using an electrically driven
spindle with a rated power of 8kw. It is used particularly with light weight material
such as plastic, wood or rigid foamed material from the HSC spindle and its
controller to the special milling software the application module has everything you
need for the quick & easy setup of a robot as a milling unit.

Figure: 6

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SCOPE OF SUPPLY
 Technology cabinet with integrated spindle controller frequency inverter, pneumatic
air supply and safety PLC
 Air & water supply for the spindle
 HSC electrically driven spindle, high speed cutting spindle with rated supply
 Mounting kit for the spindle on the robot flange
 HMI milling robot software

Figure: 7

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 CHAPTER 5

PROGRAMMING OF KUKA ROBOT

MOTION PROGRAMMING

I. Axis specific motion

 PTP (point to point) the tool is moved along the quickest path to an
end point
II. Path related motion
 Lin (linear) The tool is guided at a defined velocity along straight
line
 Circ (circular) The tool is guided at a defined velocity along a
circular path

BCO RUN
I. Part 1
 For the purpose of ensuring that the robot position corresponds
to the coordinates
 of the current program point, a so called BCO run is executed
II. Part 2
 This is done after a program reset by means of BCO run to the
home position
 After block selection to the coordinates of the point at which
the block pointer is situated
 After selection of a CELL program before the automatic
external mode can be started
 After new program has been selected
 After jogging in programming mode
 After modifying a command
III. LIN (Linear)
 The TCP is moved along a straight line to the end point

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 CHAPTER 6

ROBOTIC WELDING PROJECT

Robotic welding application is a wide usage in industrial fabrication industries, different type
model in Kuka for welding having a payload capacity of 16 kg work with KR C4 controller
and teach panel. The special software which we use in the application I detail about that in
chapter 5 for ArcTtech this software will command the robot to start and stop the welding.
before programming we are learn about teaching of robotic by taking basic robot
programming than we move to advance in advance programming we start learn the hidden
feature in Kuka . of welding according to their task the robot and their software will being
change I start my project with Kuka welding module of Kuka KR1 HW ARC this is a
standard new introduce.

PROGRAMING
Robot welding programming is as simple as mobile operation this is like to place with
technology, the programming starts to connect the gas supply to the welding
application than we use argon and carbon dioxide for welding. after this we start
programming to the home location of robot to the safe point and give command of arc
on and off according to the programming section. As we see in the image the robot
will programme to work and its will show two type of bed in the image first bed with
gas and second without gas option so their such application error also shown by robot.
we manage this error before programming like an axis limit reach and safety error for
the sensor command.

Before start the welding we are work on manual welding cell of SMAW, GMAW,
GTAW to finding the parameter of voltage, ampere, federate, angle, speed of the
torch, meanly we have a task to decide the best parameter for welding this parameter
we apply with the robotic welding and analyse the difference of welding with manual
and robot. as see this difference also in the second image which is totally depend on
the manual weld with forward parameter.

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Figure: 8

Figure: 9
25
 Welding Without Gas

Welding With
Gas

Figure: 10

Figure: 11

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 CHAPTER 7
ROBOTIC MILLING PROJECT
Robotic Milling project is a done with KUKA KR120 robot in India it is a first robot which is
integrated with grind master milling tool and cell this cell will be design by Siemens and the
project will ready by NX software to design a project and programming of four lakhs above
line there, this robot will have use a special application in industries for die, models,
industrial project. This robot will complete their task by performing layer to layer movement.

This task will be taken time to complete and having a smooth movement. lots of complete
task are their like, monument.

Grind Master is a Global Technology Leader in Robotic Machining Systems with launch of
RMC1000 in IMTEX 2015. Robots are used with machining spindles for realizing flexible,
modular machining systems for a range of applications including sculpting, blade polishing
and educational applications. Grind Master developed this state-of the-art technology to bring
complete solution to customers.
Robotic Machining System gets the input 3D model and carves out physical component from
solid block of the material

I. FEATURES

 Rugged Reliable High Performance System

 Robotic CAM Programming Software
II. OPTIONS

 These Machines Are Customized to meet specific Customer Needs of

Automation, Load/Unload, Size, Cycle Time and much more
III. APPLICATIONS

 Sculpture making in various materials

 Machining cum Finishing of Heavy Engineering components like Marine
Propeller blades
 Educational Purpose

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Figure: 12

Figure: 13

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 CHAPTER 8
ROBOTIC SIMULATION
I. Parametric robotic simulation
Robotic simulation is a part of robot programming on the project I do parametric
simulation with grasshopper and rhino 6 software with integration of Kuka prc this
software will make the programming easy and progressive with learning and working
environment of robotics we do number of integrated task like sketching which is main
concern with parametric as well as pick and place, milling etc. it is connected version
of all the industrial task every.

Figure: 14

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Figure: 15

Figure: 16

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 CHAPTER 9
INTRODUCTION TO PLC

PLC is the industrial computer. It is capable of storing instructions to implement control

functions such as sequencing, timing, counting, arithmetic, data manipulating and
communication. The PLC receives information from connected sensors or input devices,
processes the data, and triggers outputs based on pre-programmed parameters.

I. History of PLC

Before the PLC, control, sequencing and safety system interlock logic for
manufacturing automobiles was accomplished using hundreds or thousands of relay
was cam timers, and drum sequencers and dedicated closed loop controllers. The
process for updating such facilities for the yearly model change-over was very time
consuming and expensive, as electrical needed to individual rewire each and every
relay. Dickey Morley invented PLC in 1964.

II. Architecture of PLC

The basic architecture of a PLC consists of main components-the processor module,

the power supply, and the I/O modules. The processor module consists of the central
processing unit (CPU) and memory. In addition to a microprocessor, the CPU also
contains at least an interface to a programming device and may contain interfaces to
remote I/O and other communication networks. The power supply is usually a
separate module, and the I/O modules are separate from the processor. The types of
I/O modules include discrete (on/off), analog (continuous variable), and special
modules like motion control or high-speed counters. The field devices are connected
to the I/O modules.

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 Depending on the amount of I/O and the particular PLC processor, the I/O modules
may be in the same chassis as the processor and/or in one or more other chassis. Up
until the late 1980s, the I/O modules in a typical PLC system were in chassis separate
from the PLC processor. In the more typical present-day PLC, some of the I/O
modules are present in the chassis that contains the processor. Some PLC systems
allow more than one processor in the same chassis. Smaller PLCs are often mounted
on a DIN rail. The smallest PLCs (often called micro-PLCs or nano-PLCs) include the
power supply, processor, and all of the I/Os in one package. Some micro-PLCs
contain a built-in operator interface panel. For many micro-PLCs, the amount of I/O
is limited and not expandable.

III. Steps for Indra control Bosch Rexroth Software L20

New project-> Library-> Choose PLC acc. to hardware -> Choose next-> By default
profibus /M-> Choose target from the firmware-> Open communication parameters
and add local->Add module according to input and output, analog and digital-
>program PLC_PRG->Project (rebuild all)->Convert object (LD)->Then
programming……….

8 bit = 1 byte
syntax for input : %ix0.0 x= bite
syntax for output : %qx0.0 w= word
1 word =2 byte

IV. Firmware
Firmware is the combination of read-only memory and program code and data stored
in it. Typical examples of devices containing firmware are embedded systems,
computers, computer peripherals, mobile phones, and digital cameras . The firmware
contained in these devices provides the control program for the device. Firmware is
held in non-volatile memory devices such as ROM, EPROM, or flash memory.
Changing the firmware of a device may rarely or never be done during its economic
lifetime; some firmware memory devices are permanently installed and cannot be
changed after manufacture. Common reasons for updating firmware include fixing
bugs or adding features to the device. This may require physically changing ROM
integrated circuits, or reprogramming flash memory with a special procedure.

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 Firmware such as the ROM BIOS of a personal computer may contain only
elementary basic functions of a device and may only provide services to higher-level
software. Firmware such as the program of an embedded system may be the only
program that will run on the system and provide all of its functions.

V. Latching
The latching is used where the output must be activated even after the entry ceases.
There are often situations where it is necessary to hold an output energized, even
when the input ceases.

A simple example of such a situation is a motor, which is started by pressing a push

button switch. Though the switch contacts do not remain closed, the motor is required
to continue running until a stop push button switch is pressed.

The term latch circuit is used for the circuit used to carry out such an operation. It is a
self-maintaining circuit in that, after being energized, it maintains that state until
another input is received.

VI. Simple Timers

A Timer is simply a control block that takes an input and changes an output based on
time. There are two basic timer types we will deal with initially (there are other
advanced timers, but we will start with the basics first) – On-Delay Timer and the
Off-Delay Timer.

On-Delay Timer - this timer takes an input, waits a specific amount of time, then turns ON
an output (or allows logic to flow after the delay).

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 Off-Delay Timer - this timer takes turns ON an output (or allows logic to flow) and
keeps that output ON until the set amount of time has passed, then turns it OFF
(hence off-delay).

 Pulse Timer - Pulse timers are used to produce a fixed-duration output from some
initiating input.

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VII. Simple Counter

A counter simply counts the number of events that occur on an input. There are two basic
types of counters – Up counter and a Down counter.

 Up Counter – as its name implies, whenever a triggering event occurs, an up counter

increments the counter.

 Down Counter - whenever a triggering event occurs, a down counter decrements the
counter.

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 REFERENCES

 https://www.kuka.com/

 Introduction to robotics by Prof. Dr.- Ing. Eberhard Roos, Dipl.- Ing. Miklos lorinczi

 Kuka Advanced robot programming for KUKA system Software V5.x

 Kuka arc.tech lecture handouts by Augsberg University of applied sciences

 https://www.kuka.com/en-in/products/robotics-systems/software/application-

software/kuka_arctech

 http://grindmaster.co.in/

 https://www.rhino3d.com/6

 Bosch Rexroth PLC for beginner’s 2011

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