FORCE TORQUE CONTROL / SENSOR COMMUNICATION

The choice from a range of signal processing software from KUKA is just a small expansion for your robot – but a great opportunity for your production. Because your robots no longer blindly follow the programmed commands, but can respond flexibly to changing situations around them thanks to the input from the sensors. You can select the type of sensor freely according to requirements. Whether from a camera, laser scanner or force/torque sensor, the KUKA software processes the incoming signals and reliably derives the necessary commands in accordance with the defined objectives. This allows a precise and flexible process sequence with substantial time and cost savings.

• KUKA.ForceTorqueControl
  With the technology package KUKA.ForceTorqueControl, it is possible to influence process forces and torques in order to increase the quality and process reliability of robotic applications. Together with a force/torque sensor, the software gives the robot a sense of touch, enabling it to react sensitively to external forces and torques and to exert corresponding programmable forces and torques on a workpiece.

• KUKA.RobotSensorInterface
  The software KUKA.RobotSensorInterface makes it possible to influence the robot motion or program execution via sensor data. The sensor data and signals can be read by a field bus, processed in the RSI context and forwarded to the robot controller. Optionally, the data can also be exchanged via Ethernet as XML strings.

• KUKA.Ethernet KRL XML
  KUKA.Ethernet KRL XML makes it possible to set up under KUKA.RobotSensorInterface an anticyclic Ethernet link between a robot controller and up to nine external systems, e.g. sensors. The data are transmitted via the Ethernet TCP/IP protocol as XML strings. The received data are saved in a buffer so that no information can be lost.

ROBOTEAM

The RoboTeam application package enables precisely coordinated teamwork between up to 15 robots through fast synchronization of the path motions. This allows the robots to work faster, and with greater precision and versatility than before. Cooperating robots allow totally new plant and cell layouts – with shorter production lines and simpler installations. In this way, load sharing makes it possible to flexibly multiply the payload capacity of standard robots. Or workpieces can be processed during transfer to the next assembly station, thereby reducing the non-productive transfer time. A further advantage of the KUKA.RoboTeam function: each robot keeps its standard controller. This is connected to a high-speed local network (Ethernet) via which the controllers communicate with one another and synchronize themselves. RoboTeam groups are programmed conveniently and transparently using inline forms that contain all the command parameters and exclude the possibility of incorrect entries.

• KUKA.CR.ProgramCooperation
  The software option KUKA.CR.ProgramCooperation supports the program synchronization and monitoring of shared workspaces. KUKA.CR.ProgramCooperation enables classic, central PLC functionalities such as workspace interlocks, program step and program sequence synchronization, to be transferred directly to be robot group. In this way, all tasks that directly affect the robot group are also carried out autonomously by the group. By setting shared synchronization markers, it is possible to synchronize the program sequences of several robots. The distributed sequence control of complete manufacturing programs is carried out decentrally within the networked robot group. Each robot in the group can start a manufacturing program on another robot or wait for the end of a manufacturing program. This means that it is possible to dispense with an external PLC in many cases, leading to significant cost reductions for the production cell.

• KUKA.CR.MotionCooperation
  The software option KUKA.CR.MotionCooperation supports the geometric path and transfer coupling of multiple robots. This enables state-of-the-art assembly line production and ensures significantly shorter cycle times. Geometrically coupled robots provide an extremely flexible solution for all handling tasks in which heavy loads need to be transferred and ensures process-optimized positioning even of pliant workpieces. This function can also be used for the application of parallel processes alongside the transfer of materials. Cooperation is dynamic and the composition of the group can be modified flexibly while the system is running. Depending on the production task, the synchronized motion can be led by different robots in the RoboTeam group. Modifications to the path or velocity of each robot in the group have an immediate effect on all other robots in the group. Communication of all safety-relevant signals such as Emergency Stop and Operator Safety is also carried out immediately within the group via the internal safety bus system. The synchronization of the robots is so fast that even Emergency Stop ramps can be coordinated without affecting production.

SAFE ROBOT TECHNOLOGY

KUKA Safe Robot Technology prevents the robot from breaking out of its defined workspace – without the use of mechanical axis range monitoring systems or cost-intensive, specially reinforced safety fencing. This is made possible by transferring safety-relevant control tasks directly to the robot controller, thereby eliminating the need for an external safety PLC. This also increases the safety of the overall system. With conventional, centralized safety systems, the reaction times, and thus also the stopping distances, are determined by the communication and cycle times of the PLC and are therefore often relatively long. With use of Safe Robot Technology, by contrast, the reaction time is reduced, as every safety-relevant reaction is controlled directly by the safety module of the robot. This means that the robot braking distances can be significantly reduced, thus making it possible to place safeguards closer to the robot. The module responsible for monitoring the safety functions is designed using failsafe technology with built-in redundancy. Extensive test routines while the module is running up and during operation ensure that it is functioning correctly.

• KUKA.SafeOperation
  The KUKA.SafeOperation function is used together with Safe Robot Technology and offers safety-relevant software and hardware components for the limitation and monitoring of the robot’s workspaces and safety zones. This makes mechanical axis range monitoring systems superfluous. The safe functions conform to the requirements of ISO 13849-1 (Performance Level d, Category 3). KUKA.SafeOperation monitors the axis velocities and accelerations of robot and external axes. For spatial monitoring of the robot, there are up to seven Cartesian spaces available, each of which can be configured either as a protected space or a workspace. For each workspace, a safely monitored velocity can additionally be specified. A further Cartesian space models the position of the safety fence. The monitoring of the Cartesian spaces is defined relative to the robot’s tools; up to three different tools can be configured here. Safe operational stop with the drives activated, global velocity monitoring independent of the individual workspaces, and safe signaling of the current robot position round out the available functions. The monitoring functions are activated and deactivated as required during the production process via dual-channel inputs or safe bus systems. KUKA.SafeOperation opens up new, cost-effective methods for cell configuration and human-machine cooperation. The space requirement of a system is significantly reduced, and safeguards are only required for this reduced area.
  The “Safe operational stop” function allows the drives to remain under servo-control when the robot is in the “Stop” state. The restarting of the robot is safely monitored. This enables time-optimized cooperation between humans and machines: during manual loading in manual loading stations, for example, workpieces can be loaded directly into the robot gripper, with the distance from the worker reduced.