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1、 Guide for the programming of Robots with KUKA VKR-C 2 ed05-PV01 Controller in the Body Shop Guide for the programming of robots with KUKA VKR-C ED05 Controller Project:VW361 CN Date 16.04.2010,PKP-E/E VOLKSWAGEN AG File name:Robot_programming_guide_VW361_CN_V7.6.doc Page 2 of 42 1 Preface:This guid
2、e for the inputting of robot cycles is used for representing the standard,which is valid in the project VW361CN.It is kept generally since some applications show their own different standard.This guide does not raise any claim of completeness.Changes are at any time possible.If it should be necessar
3、y to deviate from this guide,this may occur only in agreement and with permission of the responsible department.Contacts:Issuer:PKP-E Planning Department Department:PKP-E/E Robotics Editor:Renee Smolka Phone:+49(0)5361-9-99 16 98 Mobile:+49(0)160-90 43 22 38 Fax:+49(0)5361-9-2 58 05 e-Fax:+49(0)5361
4、-9-5 77 80 65 e-Mail:renee.smolkavolkswagen.de Editor:Thomas Lenzi Phone:+49(0)5361-9-92 82 1 Mobile:+49(0)170-78 32 60 1 Fax:+49(0)5361-9-2 58 05 e-Fax:+49(0)5361-9-5 72 02 0 1 e-Mail:thomas.lenzivolkswagen.de Guide for the programming of robots with KUKA VKR-C ED05 Controller Project:VW361 CN Date
5、 16.04.2010,PKP-E/E VOLKSWAGEN AG File name:Robot_programming_guide_VW361_CN_V7.6.doc Page 3 of 42 1 Preface:.2 2 General.5 2.1 Programming in the vehicle Coordinate system.5 2.2 Macros.5 2.3 Cycle time measurement.5 2.4 Blocking tasks and/or sub program.5 2.5 Keypad,teach Pendant(KCP).5 3 Commissio
6、ning.5 3.1 Initial Startup.5 3.2 Software-Version.5 3.3 Commissioning Program.6 3.4 Adjustment with EMT.7 3.5 Configuration In-/Outputs.7 3.6 Interbus.7 3.7 Programming in the Vehicle Coordinate system.8 3.8 TCP Measuring.8 3.9 Load data acceptance protocol.8 4 Programming.9 4.1 Coordinates.9 4.2 Pr
7、ogram cycle.9 4.3 Program-and Point comment.9 4.4 Tool number.9 4.5 Sub programs.9 4.6 Function test(Dry run).9 4.7 Interpolation types.9 4.8 Overshoot.9 4.9 Path switching function.9 4.10 Guns and Grippers.9 4.11 Final speed.10 4.12 Drag points.10 4.13 FB online.10 4.14 Reduced speed.10 In the case
8、 of movements that require a reduced speed the value of VB is reduced.10 4.15 Programming of the Motion parameters.10 5 Robot PLC.10 5.1 Multiple use of PLC sequences.10 5.2 Macro interlacing.10 5.3 Position releasing gun positions.10 5.4 Docking.11 5.5 Standard Binary outputs.12 6 Standard Gun-/Too
9、l-Configuration.14 7 Before hand over to the Production.14 7.1 Moving area.14 7.2 Documentation file.15 7.3 Robot Data backup.15 7.4 Final acceptance.15 8 Application Examples.16 8.1 Programming(Tasks)Point 1.16 8.2 Programming(Tasks)Point 2.16 8.3 Programming Tasks Last Point.16 8.4 Programming Mai
10、ntenance Position(Task8),.17 SP 8 Maintenance Position.17 SP 9 Reference Position.17 SP 10 Tool changing position.18 8.5 Robot Interlocks.18 Example one Interlock:.18 Example:multiple Interlock:.18 Example:combines Interlocks with Release Jig:.19 Guide for the programming of robots with KUKA VKR-C E
11、D05 Controller Project:VW361 CN Date 16.04.2010,PKP-E/E VOLKSWAGEN AG File name:Robot_programming_guide_VW361_CN_V7.6.doc Page 4 of 42 Example:Interlocks in Point 2 of the working Task:.19 8.6 Spot welding with Index numbers using Bosch Welding timers.20 8.7 Spot welding with servo pneumatic Gun and
12、 Bosch Controller.21 8.8 Spot welding with servo pneumatic Gun and MEDAR welding timer.23 8.9 Handling.26 Example:Part Take.27 Example:Part drop.28 8.10 MIG/MAG Welding Example Fronius TPS 4000.28 8.11 Sealer Bead application in the Body shop.31 8.12 References for the speed controlled sealer applic
13、ation.35 8.13 Stud welding Tucker DCE.39 8.14 Pressure joining with TOX ElectricDrive.41 8.15 Pressure joining with TOX pneumatically with Gun compensation.41 8.16 Pressure joining with TOX pneumatically without Gun compensation.41 8.17 Inline-Measuring.42 8.18 Plasma cutting.42 9 Modification Index
14、:.42 Guide for the programming of robots with KUKA VKR-C ED05 Controller Project:VW361 CN Date 16.04.2010,PKP-E/E VOLKSWAGEN AG File name:Robot_programming_guide_VW361_CN_V7.6.doc Page 5 of 42 2 General 2.1 Programming in the vehicle Coordinate system The programming in the vehicle coordinate system
15、 under point 3.8 is to be considered.2.2 Macros The macros to be used in the project are provided fundamentally from Volkswagen Dept:PKP-E.If additional macros should be necessary,their function and/or necessity are to be clarified with the planning department.In order to use the provided robots mac
16、ro-masks,the use of the additional program“Makmaker”is compellingly necessary.For the use of the additional program please consult the KUKA Documentation.IMPORTANT!Following macros are to parameterize after search and replace:Macro 40,macro 60,macro 95,macro PLC.2.3 Cycle time measurement In the poi
17、nt 2 of the respective task the total cycle time measurement is to be started,and to be stopped in the last point.In the case of use of subprograms also timers for the cycle time acquisition are to be programmed(in the point 1 start,in the last point stop).The timers that must be used are to be take
18、n from timer reference list.2.4 Blocking tasks and/or sub program Tasks,sub programs for test purposes must be blocked with FB ONL=OFF and VB=0%.In CELL.PROJ.Are only tasks,which are able to run in automatic mode.2.5 Keypad,teach Pendant(KCP)Suitable supports for the keypads are to be created.(To pr
19、event falling down of the key pads can be used e.g.a hook)3 Commissioning 3.1 Initial Startup The initial startup is carried out by Co.KUKA or by the local maintenance department.3.2 Software-Version The robot system is to be checked for the valid version and the connected robot type(Kinematics)unde
20、r the Menu“Help”Version.Valid is the version R 5.4.10 and higher.In the Menu Commissioning“-Robot Name“is to be set the Robot name(e.g.A20R2A)Max.8 digits.In the same menu point is to be checked if the machine data is valid.Guide for the programming of robots with KUKA VKR-C ED05 Controller Project:
21、VW361 CN Date 16.04.2010,PKP-E/E VOLKSWAGEN AG File name:Robot_programming_guide_VW361_CN_V7.6.doc Page 6 of 42 3.3 Commissioning Program The“COMMISSIONING Program“supplied by Volkswagen helps shortening the commissioning time and has to be installed as follows:NOTE!The commissioning Program overwri
22、tes all System settings.Robot is powered on,select in the Menu“Configur.Settings Extras force cold boot“.Power off the robot controller.(Important,disconnect the Interbus card from the external power supply for approx.10 sec.)Boot the Robot-Controller with external Keyboard.Keep the left CTRL-STRG-K
23、ey pressed to avoid Auto start.Connect the USB Stick.Launch the file VKRC_SETSP_V7.5 XP.EXE”on the USB Stick.NOTE:The commissioning program overwrites all system settings in the files:INTERBUS.INI(5 Words Slave),IOSYS.INI(Interbus configuration),MASCHINE.DAT(System messages Interface PLC),CONFIG.DAT
24、(Automatic-External-interface,binary outputs).All project relevant data relevant is being updated.Robot specifically data will not be changed.(Robot type etc.)After call in the AUTO START CROSS 3 and boot the controller.The commissioning program changes following standard files:CONFIG.DAT:Settings R
25、obot interface,Gun texts,binary values IOSYS.INI:Master/Slave I/Os,Interbus Status word,Analogical outputs IBSPCI.INI:Interbus Slave(5 Words,ID 232)INTERBUS.INI:Interbus Slave(5 Words,ID 232)MASCHINE.DAT:(System outputs)VW _USR_S:()Name Value Type Description R_FBIT 1 Output First Output of the task
26、 mirroring P_OLD X Variable Last selected Task number READY 9 Output Robot ready(no Internal Failure condition)RK23 10 Output Programming mode RK8 11 Output Function mode Single Step RK9 12 Output Function mode Automatic mode RK100 13 Output FRG Actuators Start(E-Stop and Safety area o.k.)WPROZ 17 O
27、utput Wait for Process(Wait condition of the Master circuit)WSLAV 18 Output Wait for Slave(Wait condition of the Slave circuit)LPKT 14 Output Robot reached Last Point PF0 15 Output Home position SAK 16 Output Robot on track IntNotAus 1002 Output Internal E-Stop ANTEIN 12 Input Drives ON in EXT of PL
28、C SRB 9 Input Start Task P_TYPE 1 Variable Format for Task selection:(0=binary coded,1=1 of N)P_FBIT 1 Input First Input Task numbers P_LEN 8 Input Length of the Task number Guide for the programming of robots with KUKA VKR-C ED05 Controller Project:VW361 CN Date 16.04.2010,PKP-E/E VOLKSWAGEN AG Fil
29、e name:Robot_programming_guide_VW361_CN_V7.6.doc Page 7 of 42 3.4 Adjustment with EMT After the initial Start up the line supplier must execute the adjustment first with EMT and after without Offset for each Tool(Gun,Gripper with Part etc.).For stationary Guns the Tool-load data of the gripper with
30、part must be input.During the EMT adjustment has to be paid attention that the PVC cap on axis 4 is removed(only KR2000).Before each programming or correction the Robot must be checked with the EMT Check run and eventually.It is not possible to move the Robot with all axis ate the same time in the p
31、re-adjustment position therefore the deviating axis,usually axis 2 and 3,and their position must be documented,marking the degrees of deviation and a color mark.Also must be created an adjustment manual.3.5 Configuration In-/Outputs The number of the Guns and the gun assignment must be input in text
32、 form according to the prescription.Binary output formats are to input and/or controlled under the menu“Configuration I/Os according to the installation configuration.The assignment list/Long text of the used Outputs,inputs,Merker,Timer and must be created.The updated assignment list must be always
33、stored as TXT-file in the Task folder:C:KRCROBOTINIT 3.6 Interbus The data transfer rate is to set at 2Mbit/s.The Interbus-Configuration must be created with the Software IBS CMD.As Project name must be input the Robot-Name,e.g.Das Project must be stored as bg4-File and svc-File in INIT-folder under
34、 C:KRCROBOTINIT.Additionally must be described the parameter memory with the Project.Later must be input the name of the correct CMD file in the respective INI-File,in case of the use of IBS-ISA-card the INTERBUS.INI and/or the use of an IBS-PCI-card the IBSPCI1.INI and disable the comments.Example:
35、CMD_FILE=initAFO20R2A The start up behavior without pre-evaluation must be expanded with the service“reactivate optical control”depending on the Firmware version of the PCI-Card(4.61 or 12 the connection is to considerate faulty and must be fixed.Mark the Function Force cold start“.If the Interbus c
36、ard IBS-ISA SC/RI is used,it must be disconnected from the 24V-Slave-power supply.After the system must be restarted!Guide for the programming of robots with KUKA VKR-C ED05 Controller Project:VW361 CN Date 16.04.2010,PKP-E/E VOLKSWAGEN AG File name:Robot_programming_guide_VW361_CN_V7.6.doc Page 8 o
37、f 42 3.7 Programming in the Vehicle Coordinate system The programming of applications occurs according to following table in the vehicle coordinate system.Not used tool data sets can be used.Application Sample Application Coordinate systems BASE TCP Remark Head tool with/without docking Spot welding
38、,rivets,press-joining(Toxing,Clinching)Stud welding(without LMR),Arc welding,laser welding/soldering,Sealer application,roof brushing,roller hemming Vehicle-CS Tool Programming occurs in the Vehicle-CS Head tool with/without docking Handling without processing,Tucker LMR Default Tool Programming doe
39、s not occur in the Fzg-KS Handling Only Handling Default Tool Programming does not occur in the Fzg-KS The program sections in that no tool processing is carried on,load and drop part.Handling with external tool Spot welding,rivets,Toxing Clinching,stud welding(without LMR),arc welding,laser welding
40、/soldering,sealer application,roof brushing,roller hemming Tool Vehicle-CS Programming occurs in the Vehicle-CS External linear axes Use of head tools Use of external tool Now Default Now Default Now Tool Now Tool Programming does not occur in the Fzg-KS Turn table locator Mathematically coupled Not
41、 coupled mathematically Default Tool Programming does not occur in the Fzg-KS It must be considered for all applications that VKRC robot systems cannot exceed16 tool data(Base and TCP are together).3.8 TCP Measuring All tools contained in the system(TCP)are o measure with the aid of the robot contro
42、ller with the 4-Point-method or other suitable aids with accuracy smaller than 2mm.TCPs that are created by Offline systems or similar must be controlled using the Robot controller and deviations must be corrected.Die turning angles A,B,C are to measure with the 2-Point Method.It must paid attention
43、 that the tool punching direction(direction of motion)in the tool coordinate system is in direction of the part at X+.In case of external TCPs created with off-line systems a tool punch direction X-is permissible.3.9 Load data acceptance protocol The load data acceptance protocol is completely fille
44、d and signed to hand over to the customer(Construction site management)after commissioning.A copy of the protocols is to be stored in the documentation file of the robot.Without load data acceptance protocol no acceptance is given for the single step and/or automatic mode of the robot.(Note!Violatio
45、n can lead to right of recourse)Guide for the programming of robots with KUKA VKR-C ED05 Controller Project:VW361 CN Date 16.04.2010,PKP-E/E VOLKSWAGEN AG File name:Robot_programming_guide_VW361_CN_V7.6.doc Page 9 of 42 4 Programming Before every programming and/or before every correction the robot
46、must be checked and where appropriate adjusted with the EMT check run.4.1 Coordinates The first,second and last point of all main programs(Tasks)must be programmed at the same coordinate.In case of using subprograms the start-and endpoints can have different coordinates.If the sub programming is use
47、d,attention is to be paid to the respective main program can run forward as well as backwards also without subroutine call 4.2 Program cycle The programs are to be created so,that a flawless run of the program is automatic mode with 100%speed is guaranteed(no hitting onto the part,no error messages
48、as e.g.dragging not possible,no shunts during welding,no deformation of the robot when closing or opening of the gripper,manipulator).4.3 Program-and Point comment For the used tasks,subprograms and important program sections,as e.g.to welding spots,tool releases or dock positions,must be entered th
49、e corresponding comments.The comments for an open point plc must be placed before the upcoming event.Comments for a point(e.g.part drop)must be placed one point before.Generally important program steps must be commented(welding spots,docking,tool releases,part drops etc.).The comments must be writte
50、n in a way that to avoid text scrolling.4.4 Tool number Before learning of a new task attention is to be paid to the correct tool number.(In the Point-Related Data:Tool=tool number,see determination of the gun configuration)4.5 Sub programs Sub programs bust be used compellingly at:-Identical progra