17-09-2021

Kuka Advanced Programming Manual

Take your chance and become a certified DKR Robotics Practitioner.
We offer courses for different skill levels to help you to unleash your potential!

We offer the benefits of world leading German industrial robotics and automation expertise for international student groups for a fraction of the price. We offer a unique program where you can learn industrial robotics and automation programming and operation while developing crucial enterprise skills, making you highly employable.

Advanced

Now check out the Advanced Tutorials for more details regarding each of the above steps and in-depth information about the used commands if you like, or move on to the various How-to Guides. 2.2Advanced Tutorials The advanced tutorial slides give a more in-depth introduction to grl and its use including in-depth information. WORKING AND PROGRAMMING OF KUKA ROBOT 1. I WORKING AND PROGRAMMING OF KUKA ROBOT A project work report submitted to MANIPAL UNIVERSITY For partial fulfillment of the requirement for the Award of the Degree of BACHELOR OF ENGINEERING in MECHANICAL AND MANUFACTURING ENGINEERING by SHAHID FAIZEE SAMRAT SUR Under the Guidance of Dr. Yagnesh Sharma Professor, Department of Mechanical. KUKA ROBOT Programming -Basic PalletizingLearn about Variable and Declaration apply to Simple Palletizing Programnote: I will not provide any document or sof. RoboDK supports all KUKA robot controllers since KRC2, including KUKA KRC3 and KRC4 controllers. This documentation is based on a KRC4 controller. The KRC4 robot controller runs the Microsoft Embedded Windows 7 operating system. Previous controllers, such as KRC2, run Windows 95. The robot teach pendant shows an “HMI” which is a program that KUKA developed to run on Windows and it is. Describes how to run the robot with the teach pendant in manual mode, how to create a simple program with the teach pendant, and how to teach the robot. Part 2 Creating a Program on a PC in WINCAPSII Provides instructions for setting up WINCAPSII on a PC, creating and compiling a program, and uploading the compiled program to the robot controller.

In addition, the training offers opportunities to see and feel breathtaking nature and get to known the friendly people and welcoming culture of the people in Bosina and Herzegovina. Mingle with automotive industry experts, and listen to their success stories. Experience firsthand industry 4.0 and learn how to utilize it to create a brighter future.

Course - Robot programming Basic KUKA/ABB/FANUC
Description:

You will learn the basic knowledge of robot programming and will be able to create, save and change simple programs on your own. You will get an overview of the use of industrial robots. You could be taught on KUKA, FANUC or ABB robots.

You will then deepen your programming knowledge and apply complex program structures and communication with PLCs, sensors and actuators. You can train on KUKA, FANUC or ABB robots.

Duration: 16h

Content:
  1. Safety instructions
  2. System Description
  3. Activation and shutdown of the program
  4. Jogging a robot with a joystick
  5. Routine & Modules
  6. Basic instructions
  7. Error codes
  8. Basic theory of programming RAPID
  9. Tool calibration
  10. Calibration of working objects
  11. Program Editing
Course - Robot programming ABB ADVANCED
Description:

The aim of the PRO course is to update the upskilling of knowledge in handling the robot cell, to modify the program, to work in the programming language KRL, to understand the extended instructions and critical programming elements and for the picking intended for the management and maintenance of the robot system.

Duration: 32h

Content:
  1. Safety instructions
  2. Data (Rob Target, Joint Target)
  3. Routine & Modules
  4. Sequences
  5. External TCP
  6. World zones
  7. Advanced functions
  8. Dispatch
  9. Trigger statements
  10. Trap routines
  11. Work facilities
  12. Malfunctions
  13. Definition of TCP & orientation via routines
  14. Use logical functions in the robot program
  15. Flex Pendant Communication
  16. Robot Studio
Course - Robot programming KUKA Advanced
Description:

The aim of the PRO course is to update the upskilling of knowledge in handling the robot cell, to modify the program, to work in the programming language KRL, to understand the extended instructions and critical programming elements and for the picking intended for the management and maintenance of the robot system.

Duration: 32h

Content:
  1. Safety instructions
  2. Data
  3. Basics of successful programming
  4. Checking the execution of the program
  5. External TCP
  6. Data types
  7. Overview
  8. Types of Structures
  9. Sequences
  10. Logical statements
  11. Movement programming
  12. Geometric operators
  13. Trigger statements
  14. Subroutines and Functions
  15. Switching commands
Course - Transfer course
Description:

Transfer courses are designed for professionals who already have experience in programming industrial robots and want to acquire skills in programming and handling another control system.

Duration: 24h

Content:
  1. Safety instructions
  2. System Description
  3. Starting and stopping the program
  4. Jogging a robot with a joystick
  5. Tool calibration
  6. Program editing
  7. Error codes

KUKA:

  1. The basic theory of KRL programming
  2. Calibration of the base
  3. Checking the execution of the program
  4. Calibration
  5. Fundamentals of the KRL programming language
  6. Subroutines and functions

ABB:

  1. The basic theory of RAPID programming
  2. Robot Studio
  3. Working with U / I signals
  4. Additional instructions and functions
Course - Welding with robots
Description:

Special course for the use of industrial robots for the MIG / MAG welding process. The training takes place on the robot ABB IRB 2400, with the help of Robot Studio and with the EWM alpha Q 352 welding source.

Duration: 40h

Content:
  1. Safety instructions
  2. Description of the system
  3. Starting and stopping the program
  4. Routines & Modules
  5. Basic instructions
  6. Definition of the system parameters of the ABB industrial robot integrated in the welding cell
  7. Error codes
  8. Basic theory of programming RAPID
  9. Tool Calibration
  10. Calibration of working objects
  11. Programming of the welding control code according to the guidelines for the generation of programs
Robot ProfiNet - configuration with Fieldbus
Description:

The course is designed for candidates who have some knowledge of robotics and related fields, and candidates who want to build their knowledge of digital communication. The course includes theoretical and practical lessons where you can learn the basics of managing complex industrial systems and using PLCs to manage management components.

You will get to know the interaction of robots and fieldbus participants and apply it in practice. You will apply the integration of components using specific project software such as Works Visual, Robot Studio and Robo Guide.

Duration: 40h

Content:
  1. Safety instructions
  2. Description of the system
  3. Starting and stopping the program
  4. Customize and change the program
  5. Adjustment
  6. Inline forms of the KRL movement
  7. Tool Calibration
  8. Base calibration
  9. Program Editing
  10. Creating a KRC4 project
  11. Structure of the PROFINET driver KRC4
  12. Working in TIA PORTAL V13
  13. Programming self-adjusting KUKA CELL.SRC
Course - TIA Basic
Description:

Future PLC programmers who have little or no previous knowledge of PLC programming in the TIA Portal will learn the basics of TIA Portal programming. You will learn the process of developing simple projects, from the hardware level to the creation of user interfaces on HMI screens using example macros.

This lays the foundation for your future career as a PLC programmer.

Duration: 120 hours (96 hours Leadtec)

Content:
  1. introduction to the basics of the TIA portal
    • navigation through the TIA portal
    • Automation pyramid
    • Data Types
    • programming languages
    • Program modules
    • Simple functions in the TIA Portal
  2. project engineering of PLC programs
    • Project Creation
    • Use of the “Siemens Proneta” software tool
    • Hardware creation
    • Software development
  3. project engineering of HMI panels
    • Integration HMI – SPS
    • use of basic image building blocks
    • Use of visualization effects
  4. further functions of the TIA portal
    • Program simulation with PLC SIM
    • observation and forcetables
    • Traces
Course - TIA Advanced - HMI
Description:

As a PLC programmer in the industry, you are expected not only to have sufficient knowledge of PLC programming, but also to have no difficulty in developing more complex HMI systems. To further develop your skills as an HMI programmer, we offer the course TIA Advanced – HMI. The focus here is on the creation and generation of error messages and warnings, programming of user-defined image blocks and a brief introduction to Visual Basic programming.

Duration: 60 hours

Content:
  1. extended HMI functions
    • User administration
    • error messages and warnings
    • User-defined screen modules
  2. 2nd Introduction to Visual Basic
Course - TIA Safety
Description:

In this course we will teach you the project planning, programming, commissioning, diagnosis and troubleshooting of the fail-safe SIMATIC controllers and the fail-safe, decentralized ET 200 systems. Using practical exercises on a training device, you will learn to put your theoretical knowledge into practice with the STEP 7 Safety software in the TIA Portal.

Duration: 24 hours

Content:
  1. safety in automation technology
  2. basics of fail-safe programming
    • Fail-safe CPUs
    • Fail-safe peripherals Parameters
    • Components for fail-safe programming
  3. F-IO Device
  4. programming of fail-safe objects
    • Safety doors
    • Compressed air feeds
Course - TIA Advanced
Description:

You can deepen your theoretical knowledge with numerous practical exercises on a TIA system model. This consists of a SIMATIC S7-1500 automation system, ET 200SP distributed I/O, Touchpanel TP700, drive SINAMICS G120 and a belt model.

Duration: 40 hours

Content:
  1. IO-Link
    • Introduction to the world of IO-Links
    • Interface setting with S7-PCT Tool
    • RF200 RFID Sample Project
  2. Sinamics
  3. identity systems
    • Technology Objects
    • Ident Blocks
    • Ident Profiles
    • MV540 sample project
Course - CNC operating
Description:

Computer Numerical Control (CNC) courses teach students how to set-up, maintain, operate and dismantle machining tools that are controlled by computers. The candidates will be taught on Fanuc ROBODRILL α-DiB5 series, high-performance vertical machining center.

Duration: 120 hours

Content:
  1. Basic principles of serving CNC machine
  2. Introduction in cutting tools, setting them and their offset up in CNC machine
  3. Standard G, M, T code functions in CNC programming
  4. Fundamentals of standard CNC program
  5. Manual programming of CNC machines
  6. Simulation of CNC program’s for parts on machine or using CAM software
  7. Practical excercise of programming and making part’s on CNC machine
Customer-specific qualification measures
Description:

We adapt all offered courses specifically to the concrete needs. Together with our customers we work out wishes and needs in a project-oriented way.

Content:
  1. Qualification within the scope of major projects or production start-ups
  2. Individual customer-specific employee qualification
Special Courses – Mechatronic Workshop
Description:

DKR is providing a project “Mechatronic Workshop” where the aim is to train young people, students and high school students, as well as employed and unemployed persons to diagnose, maintain, and service industrial robots.

– that’s our motto.

Our participants are keeping up with the rapid development in robotics and gain a higher level of professionalism.

Participants become certified robot commissioning engineers, programmers and PLC programmers.

We train international professionals, students and employees of emerging companies. Our participants know that education and training are the best investments in the future. Our Programs have been developed step by step based on concrete needs and have real relevance to the modern working world.

RoboDK supports all KUKA robot controllers since KRC2, including KUKA KRC3 and KRC4 controllers. This documentation is based on a KRC4 controller. The KRC4 robot controller runs the Microsoft Embedded Windows 7 operating system. Previous controllers, such as KRC2, run Windows 95. The robot teach pendant shows an “HMI” which is a program that KUKA developed to run on Windows and it is the interface that the robot user must use manipulate the robot.

The following sections demonstrate typical operations using a KUKA robot teach pendant to prepare a new program in RoboDK and transfer it to the robot.

Transfer a robot program

Follow these steps to load a program form a USB disk to your KUKA KRC4 robot controller.

1.Insert the USB disk on the robot controller (it is much faster than using the teach pendant connection)

2.If we don’t see the USB disk we must enter in Administrator mode

3.Select the file from the USB disk

4.Select Edit➔Copy

5.Select a folder in the KRC unit

6.Select Edit➔Paste

Start a robot program

Follow these steps to start a robot program on your KUKA KRC4 controller.

1.Select a program from the KRC memory unit

2.Select Select on the screen

3.Select the button “R” (top) and Reset program

4.Start the program by selecting green “Play” button on the teach pendant

Retrieving the TCP

The following steps allow you to create or modify robot tools (TCP) from your robot controller, also known as $TOOL in KUKA KRC robot programming):

Kuka Advanced Programming Manual Software

1.Select MENU➔Start-up➔Calibrate➔Tool

2.Select a tool and edit or retrieve the X,Y,Z position of the TCP.


Retrieving the robot joints

The following steps allow you to retrieve the robot joints from your robot:

1.Select MENU➔Display➔Actual position

2.Select Joints mode and use the left column to take the robot joints

Tip: It is possible to retrieve the robot joints more accurately (5 decimal precision) by monitoring the $AXIS_ACT variable or simply using the RoboDK robot driver for KUKA and selecting the Get robot joints button

Administrator mode

Some menu sections require “Administrator” rights. The following steps allow entering in “Administrator” mode:

Kuka Krc2 Controller Manual

1.Select MENU➔Configuration➔User group

2.Select Administrator (or other).

3.Enter the password if required (default password is “kuka”)


RoboDK driver for KUKA

Robot drivers provide an alternative to Offline Programming (where a program is generated, then, transferred to the robot and executed). With robot drivers, it is possible to run a simulation directly on the robot (Online Programming). More information available in the Robot Drivers section.

A connection between RoboDK and the KUKA robot can be established to move the robot automatically from a connected PC using RoboDK. This allows using the RoboDK Run on robot option for online programming and debugging. The connection can be established through a standard Ethernet connection (TCP/IP).

Follow these steps to set up the RoboDK driver for KUKA:

1.Connect a mouse (optional, but strongly recommended).
It is possible to plug USB devices to the teach pendant or the controller (reboot is not required).
Alternatively, it is possible to establish a remote desktop connection.
These steps can also be accomplished using the teach pendant’s touch screen and the virtual keyboard.

2.Using the KUKA HMI application it is possible to open the main menu using the KUKA button , at the top left of the screen:

a.KUKA➔Configuration➔User group➔ choose Administrator (password: kuka)

b.KUKA➔Start-up➔Service➔Minimize HMI (the windows screen will appear)

3.Copy the KUKAVARPROXY folder on the Desktop (or somewhere in the controller PC)

4.Allow port 7000 for TCP/UDP communication (this step is not required on KUKA KRC2 controllers):

a.Select the HMI.

b.KUKA➔Start-up➔Network configuration➔Advanced

c.NAT➔Add port➔Port number 7000

d.Set permitted protocols: tcp/udp

5.Start the KUKAVARPROXY.EXE program on the robot controller (running on Windows).

6.These steps allow starting the driver automatically on the controller on reboot (recommended):

a.Create a shortcut of the KUKAVARPROXY.EXE file

Kuka Robot Manuals

b.Select Windows START➔All programs➔Right click startup➔Open

c.Paste the shortcut in the startup folder

The KUKAVARPROXY server is now ready. You can leave this program running. This server allows exchanging global variables from the KUKA controller to the remote PC.

The next steps are to set up the main program that will handle the robot movements:

1.Add the declaration of the following global variables:
To do so, locate and modify the file “KRCR1STEU$config.dat” (or in “KRCR1System$config.dat” for KRC2 controllers). The folder “KRCR1” can also be accessed from the C: drive at the following Windows path: “C:KRCROBOTERKRC”.

INT COM_ACTION=0

INT COM_ACTCNT=0

Kuka Robot Maintenance Manual

REAL COM_ROUNDM=0

REAL COM_VALUE1=0

REAL COM_VALUE2=0

REAL COM_VALUE3=0

REAL COM_VALUE4=0

DECL E6AXIS COM_E6AXIS

DECL FRAME COM_FRAME

DECL POS COM_POS

2.Copy the SRC program provided (RoboDKsynch.src) to the folder KRCR1.

Kuka Krc2 Manual

3.Manually start the RoboDKsynch.src program to make the robot behave like a server that responds to move commands coming from the PC.

If the RoboDKsynch.src program is not running, RoboDK will still be able to read the robot joints anytime if the KUKAVARPROXY program is running in the robot controller.