Copyright

_________________________
SEMINAR WORKBOOK OF

ADVANCED ROBOT PROGRAMMING

for KUKA System Software V5.x

PROGRAMMER

Workbook MP3 01.06.03

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Copyright

Copyright

Copyright 2006

KUKA Roboter GmbH

Zugspitzstrae 140
D-86165 Augsburg

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 claims 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.
KUKA Roboter GmbH accepts no liability whatsoever for any errors in technical information communicated orally or in writing in the
training courses or contained in the documentation. Nor will liability be accepted for any resultant damage or consequential damage.

Responsible for this training documentation: College Development (WSC-IC)

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 Contents

Contents
1. Structured programming 5
1.1. Programming methodology - conceptualization 5
1.2. Program flowchart 13
1.3. Programming methodology - realization 23
2. General information about expert level 37
2.1. Navigator 37
2.2. Fold - concept 41
3. Variables and declarations 45
3.1. Simple data types 45
3.2. Monitoring of variables 51
3.3. Arrays 55
3.4. Structures 61
3.5. Enumeration data types 65
4. Subprograms and functions 68
4.1. Definition of subprograms 68
4.2. Transfer of parameter 71
4.3. Function 75
5. Data lists 79
6. Data manipulation 83
7. Motion programming 89
7.1. Coordinate systems 89
7.2. Axis motion - PTP 93
7.3. Continuous path motion - LIN und CIRC 99
7.4. Orientation control 103
7.5. Advance run 109
7.6. Approximate positioning 113
7.7. Status and Turn 119
8. System variables 123

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Contents

9. Program execution control 127

9.1. Jump instruction and branches 127
9.2. Loops 131
9.3. Wait und Halt function 137
10. Automatic external function 141
10.1. Definition and sequence 141
10.2. Configuration inputs 149
10.3. Configuration Outputs 159
11. Submit - Interpreter 165
12. Exercises 169

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 Structured programming

1. Structured programming

1.1. Programming methodology - conceptualization

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Structured programming

Programming methodology Objectives

Objectives for consistent programming methodology:

Structured programming makes it easier to solve complex

problems by imposing a rigidly structured, hierarchical
program layout.

Structured programming is a method of creating programs

in which the underlying process is comprehensible and
transparent.

The aim of structured programming is not to restrict the

programmer, but to increase efficiency during program
maintenance (modification and expansion).

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Demands on programs

Programs must be:

Efficient

Free from errors

Easy to understand

Maintenance-friendly

Clearly structured

Economical

Each of these features describes a specific aspect of

the utility value of the program.

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 Structured programming

Design and planning

Necessity:

Before planning how to proceed, it is necessary first

to define what is to be achieved.

This does not increase the overall amount of

programming work, since the extra work at the
planning stage is more than offset by the amount of
work saved in the test phase.

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Conceptualization and planning - Requirements specification

User expectations as basis for program planning:

Tender specification or
requirements specification

What does the program do?

What inputs does the program require?

What outputs does the program supply?

How must the program be operated?

How does the program react to a fault/malfunction?

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Structured programming

Conceptualization and planning - Requirements specification

Definition:

Requirements specification

A requirements specification is the

organizational and technical specification
for program creation.

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Conceptualization and planning - Requirements specification

Advantages of a requirements specification:

Description of the application

Definitions of inputs/outputs/parameters and program sequences

Transparent breakdown

Project familiarization significantly easier

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 Structured programming

Design and planning

An exact functional description must exist first before programming

can begin. It must be clear and simple, but nonetheless exhaustive. The
functional description must correspond exactly to the task requirements.
It forms the basis for the planning.

This is because:

Uncertainties increase the probability of user and/or operator

errors.

Wherever possible, the program must do what the user expects it

to do what seems natural and understandable.

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Program planning methodology

1. Break down task into modules:

The overall task is broken down into

subtasks.

Individual components can safely be

developed separately.

Components that do the same job can be exchanged simply

without affecting other functions.

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Structured programming

Program planning methodology

2. Component independence:

Starting from the user expectations, the problem is

gradually refined until the resulting components are
manageable enough to be converted into KRL.

The drafts made at successive stages of development

become steadily more detailed.

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Program planning representation

Graphic representation of the procedure:

Using a program flowchart (DIN 66001)

START

No No

Yes Yes

No

Yes

END

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 Structured programming

Program planning representation - advantages

This has the following advantages:

The graphic representation of a program algorithm is

significantly more legible than the same program
algorithm in a sequential programming language as
the structure is much easier to recognize.

Structure errors (e.g. if, while, for) will be much

easier to avoid when translating the program into
program code as a direct translation into program
code is possible in most cases.

The program can be documented clearly.

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Structured programming

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 Structured programming

1.2. Program flowchart

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Structured programming

Program flowchart

Graphic representation of the procedure:

Program flowcharts (DIN 66001)

Program flowcharts are one way of formulating abstract

descriptions of programs and processes. The sequence is
represented using standardized symbols that are not dependent on
the program code used.

START

No No

Yes Yes

No

Yes

END

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Program flowchart comparison with programming language

Example of a program flowchart:

An algorithm is required for calculating the highest common factor of two numbers a
and b. This is embedded in a function hcf with two transfer parameters (a and b).

Program flowchart KRL Pascal

function hcf (a,b:integer);

function

while a<>b do

while
If a>b

if then a:=a-b else b:=b-a;

a-b b-a hcf:=a;

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 Structured programming

Program flowchart - symbols

Symbols Statement Description

General statements The statements are executed in the sequence
in the program code Statement 1, Statement 2, ..., Statement n.

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Program flowchart - symbols

Symbols Statement Description

Input / output This statement is used for input/output and is
statement treated as a normal statement.

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Structured programming

Program flowchart - symbols

Symbols Statement Description

IF statement (without If the logic condition is met (true), statements
Condition
ELSE) A are executed, otherwise program execution
Yes No
is resumed at the next statement.

Statement A

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Program flowchart - symbols

Symbols Statement Description

IF statement (with If the logic condition is met (true), statements
Condition
ELSE) or branch A are executed, otherwise statements B are
Yes
No executed.

Statement A Statement B

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 Structured programming

Program flowchart - symbols

Symbols Statement Description

Branch A branch / transfer without conditions

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Program flowchart - symbols

Symbols Statement Description

Terminal Start or end of a process or program
START

END

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Structured programming

Program flowchart - symbols

Symbols Statement Description

Flow lines Link statements and operations

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Program flowchart - symbols

Symbols Statement Description

WHILE-loop The statements are executed while the
WHILE condition is fulfilled. As soon as the condition
Condition ? is no longer met when execution of the loop is
started again, program execution is resumed
No
Yes at the first statement after the loop.

Statement

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 Structured programming

Program flowchart - symbols

Symbols Statement Description

REPEAT-loop The statements are executed until the
condition is fulfilled. As soon as the condition
is met, program execution is resumed at the
No
Statement first statement after the loop.
The statements are always executed at least
once.
Repeat
Condition ?

Yes

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Program flowchart - symbols

Symbols Statement Description

FOR-loop The statements are executed a known
For i = number of times. The run variable i runs from
the initial value (from) to the final value (to)
with the specified increment (step). A FOR
Statement loop counts until a counting variable either
exceeds or falls below a certain end value.

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Structured programming

Program flowchart - symbols

Symbols Statement Description

Subprogram calls A certain sequence of statements is
segregated from a certain position in the
program and implemented as a separate
subprogram that can then be called from the
Fetch ( )
program.

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Program flowchart example - main program

START

Boss No
Employee No
present tiered
Program
flowchart Yes Yes

example: Set alarm for Kill time

day in the 1 hour
life of an No Answer
question
employee
Sleep until
Is it alarm rings
5 oclock?

Yes

Go home

END
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 Structured programming

Program flowchart example - subprogram

START

Program
flowchart Set alarm for next
whole hour
example:
day in the
life of an No Read book
employee until alarm Go and eat
rings

Is it Yes
12 o'clock?

No

Is it
5 o'clock?

END

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Structured programming

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 Structured programming

1.3. Programming methodology - realization

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Structured programming

Program planning representation

This rough program flowchart serves as program

specification on the one hand, and as program
documentation on the other.

The author of the rough flowchart should therefore

always bear in mind that the documentation is
primarily being created for others (end customers)
rather than for his/her own use.

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Program legibility

Transparency:

Legibility makes it much easier to locate errors

and to avoid them in the first place.

Legibility makes it easier to understand and

therefore also to modify programs.

It is not sufficient to add comments to the text later. The following

points must be considered during the programming itself.

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 Structured programming

Program legibility

Identification of data names:

Only meaningful names should be used as data names.

For the purposes of unambiguous identification, a prefix should be

used (where appropriate), e.g. IN_IMM_READY.

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Program legibility Data name configuration

Identification of data names in the system:

1. Long texts

Outputs

SYS Ausgnge

18 Output
19 Gripper open
20 Gripper close
21 Output

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Structured programming

Program legibility Data name configuration

Identification of data names in the system:

2. Designation of BASE and TOOL

BASE designation TOOL designation

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Program legibility Data name configuration

Identification of data names in the system:

2. Designation of BASE and TOOL

DEF AIR ( )
...
PTP HOME Vel= 100% DEFAULT

PTP P3 CONT Vel= 100% Tool[2]:Gripper Base[2]: table

PTP P4 CONT Vel= 100% Tool[2]:Gripper Base[2]: table
PTP xP5
...
END

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 Structured programming

Program legibility Data name programming

Identification of data names in KRL:

3. Using of signal-declaration

DEF PART_1 ( )
; Inputs / Outputs
SIGNAL machine_OK $IN[32]
SIGNAL Programnumber $IN[33] to $IN[40]
SIGNAL cycle_start $OUT[88]

IF machine_OK==TRUE THEN
cycle_start = TRUE

ENDIF

END

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Program legibility

Indenting command sequences:

In order to make explicit the structures within program

modules, it is advisable to indent nested command
sequences in the program text and write instructions
at the same nesting depth directly below one another.

The effect obtained is purely optical and serves merely

to make the program more comprehensible to other
people.

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Structured programming

Program legibility

Indentation of command sequences in KRL

DEF INDENTION ( )
INT part, counter
INI
PTP HOME Vel= 100% DEFAULT
LOOP
FOR counter = 1 TO 20
part = part + 1
; Inlineforms are not able to indent !!!
PTP P3 CONT Vel= 100% Tool[2]:Greifer Base[2]: Tisch
PTP P4 CONT Vel= 100% Tool[2]:Greifer Base[2]: Tisch
PTP xP5
ENDFOR

ENDLOOP
END

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Program legibility

Use of comments:

Comments on their own cannot render a program

legible; they can, however, significantly increase the
legibility of a well-structured program.

It is the responsibility of the programmer to ensure that

the contents of the comments are up to date and
correspond to the actual program instructions. If
programs are modified, the comments must also be
checked.

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 Structured programming

Program legibility

Use of comments in KRL:

The following comment commands can be selected:

File Program Configure Monitor Setup Commands Technology Help

0 Normal
1 Stamp

Any text line

Expanded text line

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Program legibility Comment: NORMAL

Text can be freely entered after selection of the command NORMAL:

; Any text

Text box
Example:

...
INI
PTP HOME Vel= 100% DEFAULT
; Any text
PTP P1 CONT Vel= 100% Tool[2]:Gripper Base[2]: Table
...

When the command is selected again, the previously entered

string will already be offered as a default text in the inline form.
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Structured programming

Program legibility Comment: STAMP

The name and a text can be freely entered after selection of the
command STAMP:

; 01.01.05 10:15 NAME USER CHANGES: Any text

Name Text box

Example:

...
INI
PTP HOME Vel= 100% DEFAULT
; 01.01.05 10:15 NAME: User CHANGES: Any text
PTP P1 CONT Vel= 100% Tool[2]:Gripper Base[2]: Table
...

With the Softkeys New time, New name and new text the
respective box can be selected or updated.
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Program legibility Comment: NORMAL EXPERT

After switching to Expert mode, the programmer can turn any line into a
comment by writing a ; as the first character (exception: inline forms).

DEF CLEANING ( )
; **************************************
; *** AUTOR Peter PAN ***
; *** Last changing 05/05/05 ***
; **************************************
INI
PTP HOME Vel= 100% DEFAULT

part = part + 1; part-counter increase
; move to purge
PTP P4 CONT Vel= 100% Tool[2]:Gripper Base[2]: Table
PTP xP5 ; Endposition cleaning
It is also possible to tag a comment onto the end of a command line using ;.

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 Structured programming

Program legibility

Use of FOLDs:

Unlike normal editors, the KRC Editor allows a requirement-

specific display of the program contents. The user only sees the
important contents of a program, while at expert level the whole
program is visible.

The KUKA user interface uses so-called FOLDs to display a

program clearly. This is done by enclosing the relevant
declarations or instructions within the designations ;FOLD and
;ENDFOLD. FOLDs are closed by default with their contents
hidden. FOLDs can be opened or closed using a menu.

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Program legibility

Use of FOLDs closed:

DEF CLEANING ( )
USER
INI FOLD
IO_SETUP
PTP HOME Vel= 100% DEFAULT
KUKA
PTP P21 CONT Vel= 100% Tool[2]:Gripper Base[2]: Table FOLD
PTP HOME Vel= 100% DEFAULT
END

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Structured programming

Program legibility

Use of FOLDs KUKA FOLD open

DEF CLEANING ( )

INI
IO_SETUP
PTP HOME Vel= 100% DEFAULT
$BWDSTART = FALSE KUKA
PDAT_ACT=PDEFAULT FOLD
BAS(#PTP_DAT) open
FDAT_ACT=FHOME
BAS(#FRAMES)
BAS(#VEL_PTP,100)
$H_POS=XHOME
PTP XHOME

PTP P21 CONT Vel= 100% Tool[2]:Gripper Base[2]: Table
PTP HOME Vel= 100% DEFAULT
END

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Program legibility

Use of FOLDs USER FOLD open

DEF CLEANING ( )
USER
INI FOLD
IO_SETUP open
$OUT[12]=TRUE ;cell OK
part = 0 ; counter reset
glue = FALSE ; glueing off
position = 0 ; position-counter reset
PTP HOME Vel= 100% DEFAULT

PTP P21 CONT Vel= 100% Tool[2]:Gripper Base[2]: Table
PTP HOME Vel= 100% DEFAULT
END

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 Structured programming

Conversion into program structures

As we have seen, not much is actually

required for structured solutions to
problems. The problem must simply be
identified and broken down into steps. The
individual steps can in turn be broken
down into smaller steps.

Depending on the nature of the problem, one of the following basic

routines is required: conditional statements (branches), loops and
data.

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Conversion into program structures Conditional statement, choice

With [ if (condition) ....; else; ...endif ] statements, it is possible to

recognize the one specific state that is important for continued
program execution. These conditional statements are also called
choices, branches or IF statements.

Syntax: Syntax:
IF ... THEN SWITCH
ELSE CASE
ENDIF ENDSWITCH

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Structured programming

Conversion into program structures Loops

Loops can be used as a simple means of repeating part of a

program. The number of repetitions can be specified in a counting
loop or linked to a conditional statement.

Syntax:
FOR ENDFOR (counting loop)
WHILE ENDWHILE (rejecting loop)
REPEAT UNTIL (non-rejecting loop)
LOOP ENDLOOP (endless loop)

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Conversion into program structures General data

Data are electronic saved, process able values or information

There are simple data types, which have already a predefined
valuation, like integer, floating-point number or logic state
(true/false).
Complex data types are e.g. structures (robot position)

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 Structured programming

Conversion into program structures Programming

An algorithm is a method for a schematic solution of a

requirement. Therefore a robot programmer has the following
routines:

Syntax :
SUBPROG ( ) Local or global subprogram
DEFFCT Function
INTERRUPT Process execution parallel to the robot program
TRIGGER Path-related switching actions

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Structured programming

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 General information about expert level

2. General information about expert level

2.1. Navigator

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General information about expert level

Changing user group

When the softkey Expert is pressed, the user is prompted to

enter a password. The preset password is kuka.

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Symbols in the Navigator

Symbol Meaning Symbol Meaning

Folder closed Module containing errors

SRC file containing

Folder open
errors

Module Dat file containing errors

SUB file

SRC file

Dat file

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 General information about expert level

Creating a new module

A KRL program can be made up of SRC and DAT files:

SRC - contains program code
DAT - contains specific program data

Cell Skeleton program for control via a PLC

Expert SRC and DAT file without a skeleton program

Expert
SUB file without a skeleton program
Submit
Function SRC file without a skeleton program

Module SRC and DAT file with a skeleton program

Submit SUB file with a skeleton program

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Program run modes (1)

Run mode Description

GO GO mode

All instructions in the progam are executed up to the end of the

program without a STOP.

MSTEP Motion Step (motion block)

The program is executed one motion instruction at a time, i.e. with a

STOP before each motion instruction. The program is executed
without advance processing.

ISTEP Incremental Step (single block)

The program is executed step by step, i.e. with a STOP after each
instruction (including blank lines). The program is executed without
advance processing.

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General information about expert level

Program run modes (2)

Run mode Description

PSTEP Program Step

The program is executed step by step without advance

processing.
Subprograms are executed completely

CSTEP Continuous Step (motion instruction)

Approximate positioning points are executed with advance

processing, i.e. they are approximated. Exact positioning
points are executed without advance processing and without a
STOP after the motion instruction

The program run modes #PSTEP and #CSTEP can only

be activated via the variable correction function
($PRO_MODE) and not using the status key.

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Displaying machine data and version number

You can access further windows using the softkey TAB

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 General information about expert level

2.2. Fold - concept

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General information about expert level

Hiding program sections - FOLDS

Program sections can be hidden in FOLDS.

These program sections are processed during program execution.
FOLDS are closed by default.
The contents of FOLDS are not visible to the user.
FOLDS can be nested.
Sub-FOLDS are color-coded.

Color-coding of FOLDS:
Closed FOLD
Open FOLD
Closed sub-FOLD
Open sub-FOLD
Contents of the FOLD

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Hiding program sections - FOLDS

Syntax for creation of FOLD:

;FOLD Name
Program line
Program line
;ENDFOLD

int x int x
INI INI
;fold Home_position Home_position
$out[1]=true
counter=0
advance=35.0
;endfold

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 General information about expert level

Hiding program sections - FOLDS

int x int x
INI INI
Outputs Outputs
$out[1]=true
$out[2]=true
$out[3]=true

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Hiding program sections - FOLDS

int x int x
INI INI
Outputs ;fold Outputs
$out[1]=true $out[1]=true
$out[2]=true $out[2]=true
$out[3]=true $out[3]=true
;endfold

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General information about expert level

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 Variables and declarations

3. Variables and declarations

3.1. Simple data types

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Variables and declarations

Definition of variables

In addition to the use of constants (digits, characters, etc.),

memory locations are also defined in the robot controller in
which these values can be stored.

This stored information can thus be retrieved at various points in the

program for evaluation and further processing.

A variable is a fixed memory area, whose contents can be

addressed via the variable name.

Example:
Variable name
...
...
Part_counter
Part_counter==37
37 Content of the
...
... variable

01/2006 1
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Declaration of variables

Variable declarations always have the following syntax:

DECL Data_Type Variable_Name

Example:

Def
DefMain(
Main())
DECL
DECLINT
INTpart_counter
part_counter
INI
INI
...
...
End
End

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 Variables and declarations

Variables and names

Variable names in KRL

can have a maximum length of 24 characters.

can consist of letters (A-Z), numbers (0-9) and the signs _
and $.
must not begin with a number.
must not be a keyword.

01/2006 3
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Simple data types

Data type Integer Real Boolean Character

Keyword INT REAL BOOL CHAR

Floating-point
Meaning Integer
number
Logic state 1 character

-231 +/-1.1E-38
Range of ASCII character
... ... TRUE, FALSE
values 1-255
(231-1) +/-3.4E+38

Example 32 1.43 TRUE A

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Workbook MP3 01.06.03 47 / 198

Variables and declarations

Basic structure of a robot program

DEF
DEFNAME(
NAME() )

;--- Declaration section ---

...

;--- Initialization section ---

...

;--- Instruction section ---

...

END
END

01/2006 5
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Activating the DEF line

Variables must be declared before the INI line

In order to set syntax before the INI line, the DEF line must be
activated

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 Variables and declarations

Declaration and value assignment

DEF
DEFMAIN_PROGRAM(
MAIN_PROGRAM() )
;---
;--- Declaration
Declarationsection
section ---
---
DECL
DECLINT
INTPART
PART
;---
;--- Initialization
Initializationsection
section ---
---
INI
INI ;Initialization
;Initializationofofacceleration
accelerationand
andvelocity
velocity
;--- Instruction section
;--- Instruction section ------
PART=58
PART=58 ;Value
;Valueassignment,
assignment,decimal
decimal
PART='B111010'
PART='B111010' Value assignment, binary
Value assignment, binary
PART='H3A'
PART='H3A' ;Value
;Valueassignment,
assignment,hexadecimal
hexadecimal
......
END
END

Value assignments are made in the program advance run!

01/2006 7
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Lifetime of variables

Variables declared ...

DEF
DEFHP1(
HP1())
in the SRC file DECL
DECLINT
INTCUBE
CUBE
... are only recognized in their own program. INI
INI
... are not recognized in local subprograms. CUBE=0
CUBE=0
END
END

in the corresponding DAT file DEFDAT

DEFDATHP1(
HP1())
... are only recognized in their own program, DECL
DECL INTCUBE=0
INT CUBE=0
i.e. in the main program and in local ...
...
subprograms. ENDDAT
ENDDAT

in the $CONFIG.DAT file DEFDAT

DEFDAT$CONFIG
$CONFIG
... are recognized in every program. DECL
DECLINT
INTCUBE=0
CUBE=0
... can be called during program execution. ...
...
ENDDAT
ENDDAT

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Workbook MP3 01.06.03 49 / 198

Variables and declarations

Declaration of constants

Constant declarations always have the following syntax and they could
only declared in a data list:

DECL CONST Datentyp Variable_Name

Example :

Defdat
Defdat Main(
Main())
Decl
DeclCONST
CONSTREAL
REALPI
PI==3.14159
3.14159
...
...
End
End

You can not manipulate Constants in the SRC-file. It causes

a error message.

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 Variables and declarations

3.2. Monitoring of variables

Workbook MP3 01.06.03 51 / 198

Variables and declarations

Variable display Single

Current variable name; reachable

over softkey NAME
$PRO_MODE

Current value of the variable of

#GO
the field Name

New value of the variable of the

field Name #ISTEP

Folder of the program /R1/CELL.SRC

01/2006 1
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Variable display Single

Current value of the variable will

only updated, when you pressed PART
in the field Name the Return-
Key. 51

Current value of the variable will

automatically be updated, when
you pressed in the field Name
the Shift+Return-Keys together.
/R1/HAUPT.SRC

Attention: Limited functionality with runtime variables

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 Variables and declarations

Variable display Configure

To use the variable in variable display it

have to be:
Declared in the $config.dat
KUKA-System variable

01/2006 3
monitor_variable_en.ppt
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Variable display Configure

Continually Description of Variable name

refreshed the variable used

Softkeys Meaning
Display Switch to the display modes
Tab Next group/worksheet
Jump Jump to the group parameters
(e.g. column width)
Insert Open Insert menu (insert
before/after group/line)
Delete Delete a group/line
OK Confirm, save and close
configuration
Cancel Close window without saving

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Variables and declarations

Variable display Display

Continually Description of Current value

refreshed the variable of the variable

Softkeys Meaning
Configure Switch to the configuration modes
Tab Next group/worksheet
Refresh all Static update
Start info / Activate/deactivate continual update
Cancel info
Edit Change the name or value of the
variable (writing access)
OK Confirm, save and close
configuration
Cancel Close window without saving

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 Variables and declarations

3.3. Arrays

Workbook MP3 01.06.03 55 / 198

Variables and declarations

Arrays (one-dimensional)

Syntax: Creation:
DECL Data_Type Variable_Name[Number of array elements]
Work:
Variable_Name[Index] = Value_Assignment

Example: DEF
DEFMAIN_PROGRAM(
MAIN_PROGRAM() )
DECL
DECLREAL
REALmeasurement[3]
measurement[3]

INI
INI

measurement
measurement[1]
[1]==17.5
17.5
measurement
measurement[2]==35.7
[2] 35.7
measurement
measurement[3]
[3]==67.2
67.2
......
END
END

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Simple counting loop

Syntax: FOR Counter = Start TO End

Statement
ENDFOR

Example: DEF
DEFINIT_OUTPUTS
INIT_OUTPUTS(())
DECL
DECLINT
INTCOUNTER
COUNTER
INI
INI
$OUT[X]

FOR
FORCOUNTER=1
COUNTER=1TO TO10
10 no
;Set
;Set output 1-10 toFALSE
output 1-10 to FALSE
X>10 ?

$OUT[counter]=FALSE
$OUT[counter]=FALSE
ENDFOR
ENDFOR yes
...
...
END
END

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 Variables and declarations

Example: Simple counting loop (1)

DEF
DEFMAIN_PROGRAM(
MAIN_PROGRAM() )
DECL
DECLINT
INTCELL[4]
CELL[4]
DECL
DECL INTFI
INT FI ;Array
;Arrayindex
index
INI
INI

FOR
FORFI FI==11TO
TO44
CELL[FI]
CELL[FI] =FI
= FI**55
ENDFOR
ENDFOR
......
END
END

1*5=5

CELL 5

[1] [2] [3] [4]

01/2006 3
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Example: Simple counting loop (2)

DEF
DEFMAIN_PROGRAM(
MAIN_PROGRAM() )
DECL
DECLINT
INTCELL[4]
CELL[4]
DECL
DECLINT
INTFI
FI ;Array
;Arrayindex
index
INI
INI

FOR
FORFI FI==11TO
TO44
CELL[FI]
CELL[FI] =FI
= FI**55
ENDFOR
ENDFOR
......
END
END

2 * 5 = 10

CELL 5 10

[1] [2] [3] [4]

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Workbook MP3 01.06.03 57 / 198

Variables and declarations

Example: Simple counting loop (3)

DEF
DEFMAIN_PROGRAM(
MAIN_PROGRAM() )
DECL
DECLINT
INTCELL[4]
CELL[4]
DECL
DECL INTFI
INT FI ;Array
;Arrayindex
index
INI
INI

FOR
FORFI FI==11TO
TO44
CELL[FI]
CELL[FI] =FI
= FI**55
ENDFOR
ENDFOR
......
END
END

3 * 5 = 15

CELL 5 10 15

[1] [2] [3] [4]

01/2006 5
arrays_en.ppt
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Example: Simple counting loop (4)

DEF
DEFMAIN_PROGRAM(
MAIN_PROGRAM() )
DECL
DECLINT
INTCELL[4]
CELL[4]
DECL
DECLINT
INTFI
FI ;Array
;Arrayindex
index
INI
INI

FOR
FORFI FI==11TO
TO44
CELL[FI]
CELL[FI] =FI
= FI**55
ENDFOR
ENDFOR
......
END
END

FI = 5 4 * 5 = 20

CELL 5 10 15 20

[1] [2] [3] [4]

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 Variables and declarations

Two-dimensional array

DEF
DEFMAIN_PROGRAM(
MAIN_PROGRAM() )
DECL
DECLINT INTMEAS_VALUE
MEAS_VALUE[2,4] [2,4]
DECL INT ROW,COLUMN
DECL INT ROW,COLUMN
INI
INI
; ;---
---Pre-assignment
Pre-assignmentofofan
anarray
array---
---
FOR
FORROW ROW==11TO TO22
FOR
FORCOLUMN COLUMN==11TO TO44
MEAS_VALUE
MEAS_VALUE [ROW,COLUMN]==00
[ROW,COLUMN]
ENDFOR
ENDFOR
ENDFOR
ENDFOR
......
END
END

Column 1 2 3 4

Row 1
0 0 0 0
Row 2
0 0 0 0

01/2006 7
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Example: Three-dimensional array

BOOL MATRIX [3, 3, 3]

Column
Row Level
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Workbook MP3 01.06.03 59 / 198

Variables and declarations

Three-dimensional array

DEF
DEFMAIN_PROGRAM(
MAIN_PROGRAM() )
BOOL
BOOLMATRIX
MATRIX[3,3,3]
[3,3,3]
INT
INTROW,
ROW,COLUMN,
COLUMN,LEVEL
LEVEL
INI
INI

FOR
FORLEVEL LEVEL==11TO
TO33
FOR
FOR COLUMN==11TO
COLUMN TO33
FOR
FOR ROW = 1 TO33
ROW = 1 TO
MATRIX
MATRIX[ROW,
[ROW,COLUMN,
COLUMN,LEVEL]
LEVEL]==FALSE
FALSE
ENDFOR
ENDFOR
ENDFOR
ENDFOR
ENDFOR
ENDFOR
......

END
END

The keyword DECL may also be omitted when

declaring simple data types.

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 Variables and declarations

3.4. Structures

Workbook MP3 01.06.03 61 / 198

Variables and declarations

Structures

Example: Exact definition of a car

Color Motor

Manufacturer Air conditioning

01/2006 1
structure_en.ppt
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Structures

A structure is a combination of different data types,

witch creates a group.
A structure is initialized with an aggregate.
Not all the parameters have to be specified in an
aggregate.
The order of the parameters is insignificant.

User-defined structures should end in ...TYPE!

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 Variables and declarations

User-defined structure

Name of the structure Data type Variable name

DEF
DEFWELD
WELD( () )
STRUC
STRUCWELDTYPE
WELDTYPEREAL
REALV_WIRE,
V_WIRE,INT
INTCHARAC,
CHARAC,BOOL
BOOLPULSE
PULSE
DECL
DECLWELDTYPE
WELDTYPESEAM1
SEAM1
INI
INI
SEAM1={V_WIRE
SEAM1={V_WIRE0.7,
0.7,CHARAC
CHARAC5,5,PULSE
PULSEFALSE}
FALSE}
......
SEAM1.PULSE=TRUE
SEAM1.PULSE=TRUE
......
END
END

Modification of a value in an
aggregate using a point separator

01/2006 3
structure_en.ppt
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Predefined structures

The following structures are predefined in the KUKA robot system:

STRUC AXIS REAL A1,A2,A3,A4,A5,A6

STRUC E6AXIS REAL A1,A2,A3,A4,A5,A6,E1,E2,E3,E4,E5,E6

STRUC FRAME REAL X,Y,Z,A,B,C

STRUC POS REAL X,Y,Z,A,B,C INT S,T

STRUC E6POS REAL X,Y,Z,A,B,C,E1,E2,E3,E4,E5,E6, INT S,T

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Variables and declarations

64 / 198 Workbook MP3 01.06.03

 Variables and declarations

3.5. Enumeration data types

Workbook MP3 01.06.03 65 / 198

Variables and declarations

Enumeration data type - ENUM

Ball Car Spade Pebble

01/2006 1
enum_en.ppt
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Enumeration data type

An enumeration data type consists of a limited number of

constants
The constants are freely definable names
The constants are defined by the programmer
A variable can only take on the value of one of these
constants

User-defined ENUM variables should end in ...TYPE!

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 Variables and declarations

Enumeration data type

The following ENUM variable is predefined in the KUKA robot system:

ENUM MODE_OP T1, T2, AUT, EX, INVALID

DEF
DEFSEARCH
SEARCH()()
ENUM
ENUMCOUNTRY_TYPE
COUNTRY_TYPE German,
German,English,
English,French
French
DECL
DECLCOUNTRY_TYPE
COUNTRY_TYPE LANGUAGE
LANGUAGE
INI Generate enumerating variable
INI
......
LANGUAGE Declare enumerating variable
LANGUAGE==#German
#German
......
LANGUAGE Value assignment
LANGUAGE==#English
#English
Value assignment
END
END

01/2006 3
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Overview of the data types

Data types

Simple Complex
data types data types
- INT - BOOL
- REAL - CHAR

Enumeration
Arrays Structures
data type

All array elements All structure elements A ENUM variable

have the same data type could have different data can have only one
have the same name types of the previously
differentiation only in their have different terms defined constants
own index number

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Workbook MP3 01.06.03 67 / 198

Subprograms and functions

4. Subprograms and functions

4.1. Definition of subprograms

68 / 198 Workbook MP3 01.06.03

 Subprograms and functions

Local subprograms

A KRL file can consist of up to 255 local subprograms.

The maximum nesting depth for subprograms is 20.
Local subprograms are located after the main program and are identified by
means of DEF and END.
Local subprograms can be called repeatedly.
Point coordinates are saved in the corresponding DAT list and are available
for the entire file.
Once a local subprogram has been executed, the program jumps back to the
next command after the subprogram call.

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Local subprograms

DEF
DEFMain_Program
Main_Program( () )
INI
INI
......
Subprogram1
Subprogram1( () )
......
Subprogram2
Subprogram2( () )
......
END
END
DEF
DEFSubprogram1
Subprogram1( () )
......
Subprogram2
Subprogram2( () )
......
END
END
DEF
DEFSubprogram2
Subprogram2( () )
......
END
END

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Subprograms and functions

Global subprograms

Global subprograms consist of a separate SRC file.

Variables declared in global subprograms are not
recognized in the main program.
Variables declared in the main program are not
recognized in the global subprogram.

DEF
DEFMAINPROG
MAINPROG(()) DEF
DEFGLOBAL_SP1
GLOBAL_SP1(())
INI
INI INI
INI
...
...
...
...
GLOBAL_SP1()
GLOBAL_SP1() ...
...

...
...

END
END END
END

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Return from the subprogram

RETURN

The RETURN function ends the execution of the

subprogram and causes the system to return to the calling
module.

DEF
DEFMAINPROG
MAINPROG(()) DEF
DEFGLOBAL_SP1
GLOBAL_SP1(())
INI
INI INI
INI
...
...
...
...
GLOBAL_SP1()
GLOBAL_SP1() IF
IFvalue
value>15
>15THEN
THEN
RETURN
RETURN
...
... ENDIF
ENDIF

END
END END
END

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70 / 198 Workbook MP3 01.06.03

 Subprograms and functions

4.2. Transfer of parameter

Workbook MP3 01.06.03 71 / 198

Subprograms and functions

Variable parameter transfer

Main_program ( )

X=21.0
Y=TRUE
Calc (X,Y) Calc ()

01/2006 1
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Variable parameter transfer

There are two different transfer options:

IN parameter OUT parameter

(call by value) (call by reference)

The value of the variable The value of the variable is

remains unchanged in the changed in the main program,
main program, i.e. it continues i.e. the value is taken from the
to be processed with the old subprogram
value from the main program

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 Subprograms and functions

Variable transfer to local subprograms

Syntax: Program call:

Subprogram_Name (Transfer_Variable)
Subprogram header:
DEF Subprogram_Name (Variable_Name: Call by)

Example: DEF
DEFMAIN
MAIN( () )
REAL
REALAMOUNT
AMOUNT
INI
INI
......
CALC
CALC(AMOUNT)
(AMOUNT)
END
END

DEF
DEFCALC
CALC(SUM:OUT)
(SUM:OUT)
REAL
REALSUMSUM
......
END
END

01/2006 3
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Variable transfer to global subprograms

Syntax: Program call:

Subprogram_Name (Transfer_Variable)
Subprogram header:
DEF Subprogram_Name (Variable_Name: Call by)

Example: DEF
DEFMAIN
MAIN( () )
REAL
REALAMOUNT
AMOUNT
INI
INI
......
CALC
CALC(AMOUNT)
(AMOUNT)
END
END

DEF
DEFCALC
CALC(SUM:OUT
(SUM:OUT) )
REAL SUM
REAL SUM
INI
INI
......
END
END

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Subprograms and functions

Example of variable transfer

DEF
DEFPROG_1
PROG_1( () )
INT
INT A,BB
A,
REAL
REALCC
AA==11
BB==22
Two types of parameter list
CC==3.0
3.0
Call by value: IN
Sequence Call by reference: OUT
CALC is important!
CALC(A,
(A,B,
B,C)
C)

HALT;
HALT;AAisisnownow11
11
The use of parameter lists is
; ;BBisisnow
now22 necessary in both
; ;CCisisnow
now3.0
3.0 LOCAL
END
END and
DEF GLOBAL
DEFCALC
CALC(X1:
(X1:OUT,
OUT,X2:X2:IN,
IN,X3:
X3:IN)
IN)
INT X1, X2
INT X1, X2 subprograms.
REAL
REALX3X3
X1
X1==X1+10
X1+10 ; ;X1
X1isisnow
now11
11
X2
X2 = X2+10 ; X2 is now12
= X2+10 ; X2 is now 12
X3
X3==X3+10
X3+10 ; ;X3
X3isisnow
now13.0
13.0
END
END

01/2006 5
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Array parameter transfer

Arrays may only be transferred with parameter OUT

(Call by reference)
Arrays may only be transferred with the dimension
specified, e.g. ARRAY_1D[ ] , ARRAY_2D[,] ,
ARRAY_3D[,,]

Example: DEF
DEFMAIN
MAIN(())
CHAR
CHARNAME[8]
NAME[8]
INI
INI
...
...
SP1
SP1(NAME[
(NAME[])])
END
END
DEF
DEFSP1
SP1(FIRST_NAME[
(FIRST_NAME[]:OUT)
]:OUT)
CHAR
CHAR FIRST_NAME[]]
FIRST_NAME[
...
...
END
END

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 Subprograms and functions

4.3. Function

Workbook MP3 01.06.03 75 / 198

Subprograms and functions

Functions

Function

Arithmetical
Input values algorithm Output value

Return
statement

Example: using camera correction position calculate pickup position

Copyright by KUKA Roboter GmbH College

Functions

A function is a subprogram that returns a certain value to

the main program.
The program name is also the variable name of a certain
data type.
The value to be transferred must be returned by means of
the RETURN(x) statement before the ENDFCT statement.

Syntax: DEFFCT Data_Type NAME_FUNCTION ( )

...
RETURN(x)
ENDFCT

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76 / 198 Workbook MP3 01.06.03

 Subprograms and functions

Function with IN and OUT parameters

X=15
Call by value

15 DEFFCT
DEFFCTINTINTSQUARE(NUMBER:IN)
SQUARE(NUMBER:IN)
NUMBER
INT
INTNUMBER
NUMBER
......
225 NUMBER=NUMBER*NUMBER
NUMBER=NUMBER*NUMBER X = 15
DEF
DEFPROG()
PROG() RETURN(NUMBER)
RETURN(NUMBER) Y = 225
INT
INTX,Y,E ......
X,Y,E E = 15
...... ENDFCT
ENDFCT
X=5*3
X=5*3
Y=SQUARE(X)
Y=SQUARE(X) ;Y=225
;Y=225
E=Y/X
E=Y/X
...... Call by reference
END
END DEFFCT
DEFFCTINTINTSQUARE(NUMBER:OUT)
SQUARE(NUMBER:OUT)
15 INT
INTNUMBER
NUMBER
......
X , NUMBER NUMBER=NUMBER*NUMBER
NUMBER=NUMBER*NUMBER X = 225
RETURN(NUMBER)
RETURN(NUMBER) Y = 225
225 ......
E=1
ENDFCT
ENDFCT

Copyright by KUKA Roboter GmbH College

Workbook MP3 01.06.03 77 / 198

Subprograms and functions

78 / 198 Workbook MP3 01.06.03

 Data lists

5. Data lists

Workbook MP3 01.06.03 79 / 198

Data lists

Data lists - local

Data lists are used for preparing program-specific and higher-level

declarations (variables, coordinates, etc.)

Source file (SRC file) Data list (DAT file)

DEF
DEFPROG_1
PROG_1(()) DEFDAT
DEFDATPROG_1
PROG_1
...
... INT
INTOTTO
OTTO==00
HALT
HALT Value assignment ENDDAT
... ENDDAT
...
OTTO
OTTO==25
25
... Declarationand initialization
...
HALT
HALT
END
END
DEFDAT
DEFDATPROG_1
PROG_1
INT
INTOTTO
OTTO==25
25
ENDDAT
ENDDAT
The value remains unchanged
after program execution

01/2006 1
data_files_en.ppt
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Data lists - global

Certain system files are global data lists, i.e. variables, signals and
declarations are valid for all programs.

$MACHINE.DAT
DEFDAT $MACHINE
$CONFIG.DAT .. DEFDAT
..
$MACHINE
..
DEFDAT $CONFIG
.. DEFDAT $CONFIG $SOFTP_END[1] ==185.0
. ... . $SOFTP_END[1]
.
185.0
E6AXIS HOME ..
.. E6AXIS
.. HOME{A1
{A10.0,A2
0.0,A2-90.0,...}
-90.0,...} ..
.. $SOFTP_END[6] ==350.0
.. $SOFTP_END[6]
.
350.0
ENDDAT
ENDDAT . ..
ENDDAT
ENDDAT

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 Data lists

Importing variables

Variables defined in a data list can be imported into a foreign main

program.

PROG_1.SRC PROG_1.DAT
DEF
DEFPROG_1
PROG_1( () ) DEFDAT
DEFDATPROG_1
PROG_1PUBLIC
PUBLIC
...... DECL INT OTTO = 0
HALT DECL INT OTTO = 0
...HALT
...
......
OTTO ==25 ENDDAT
ENDDAT
...OTTO
...
25
END
END
PROG_2.SRC

DEF
The contents of the variable
DEFPROG_2
PROG_2( () ) cannot be modified
IMPORT
IMPORTINTINTOTTO_2
OTTO_2IS
IS/R1/PROG_1
/R1/PROG_1....OTTO
OTTO
...... Make sure that the path is
...... spelled correctly
END
END

01/2006 3
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Copyright by KUKA Roboter GmbH College

Global variables

Variables defined in a data list can be made globally accessible to a

foreign main program.

PROG_1.SRC PROG_1.DAT
DEF
DEFPROG_1
PROG_1( () ) DEFDAT
DEFDATPROG_1
PROG_1PUBLIC
PUBLIC
...... DECL
HALT DECL GLOBALINT
GLOBAL INTOTTO
OTTO==00
...HALT
...
......
OTTO ==25 ENDDAT
ENDDAT
...OTTO
...
25
END
END
PROG_2.SRC

DEF
DEFPROG_2
PROG_2( () )
...... The contents of the variable
OTTO
OTTO==100
100
...... can be modified
END
END

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Data lists

82 / 198 Workbook MP3 01.06.03

 Data manipulation

6. Data manipulation

Workbook MP3 01.06.03 83 / 198

Data manipulation

Arithmetic operators

Basic arithmetic operations for the data types INTEGER and REAL:

Operator Description
+ Addition or positive sign
- Subtraction or negative sign
* Multiplication
/ Division

Result of an arithmetic operation:

Operands INT REAL

INT INT REAL
REAL REAL REAL

01/2006 1
manipulation_en.ppt
Copyright by KUKA Roboter GmbH College

Program example

DEF
DEFARITH()
ARITH()
;-------
;-------Declaration
Declarationsection
section--------
--------
INT
INTA,B,C
A,B,C
REAL
REALK,L,MK,L,M
;--------
;--------Initialization
Initializationsection
section-------
------- ;All
;Allvariables
variablesare
areinvalid
invalidprior
priortotoinitialization!
initialization!
AA== 22 ;A=2
;A=2
BB== 9.89.8 ;B=10
;B=10
CC== 7/47/4 ;C=1
;C=1
KK== 3.53.5 ;K=3.5
;K=3.5
LL == 0.1E01
0.1E01 ;L=1.0
;L=1.0* *EEhave
havetotobebeaacapital
capitalletter
letter
MM== 33 ;M=3.0
;M=3.0
;-------------
;-------------Main
Mainsection------------
section------------
AA== AA* *CC ;A=2
;A=2
BB== BB- -'HB
'HB ;B=-1
;B=-1
CC== CC++KK ;C=5
;C=5
KK== KK* *10 10 ;K=35.0
;K=35.0
LL == 1010/ /44 ;L=2.0
;L=2.0
LL == 1010/ /4.0
4.0 ;L=2.5
;L=2.5
LL == 1010/ /4.4. ;L=2.5
;L=2.5
LL == 10./
10./44 ;L=2.5
;L=2.5
CC== 10./
10./4.4. ;C=3
;C=3
MM== (10/3)
(10/3)* *MM ;M=9.0
;M=9.0
END
END

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 Data manipulation

Relational operators

Using relational operators, it is possible to form logic expressions. The result of

a comparison is always of data type BOOL.

Operator Description Permissible data types

== equal to INT, REAL, CHAR, ENUM, BOOL
<> not equal to INT, REAL, CHAR, ENUM, BOOL
> greater than INT, REAL, CHAR, ENUM
< less than INT, REAL, CHAR, ENUM
>= greater than/equal to INT, REAL, CHAR, ENUM
<= less than/equal to INT, REAL, CHAR, ENUM

Example: BOOL A,B

...
B = 10 < 3 ;B=FALSE
A = 10/3 == 3 ;A=TRUE
B = ((B == A) <> (10.00001 >= 10)) == TRUE ;B=TRUE

01/2006 3
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Logic operators

Logic operators are used for logic operations with Boolean variables, constants
and simple logic expressions.

Operator Operand number Description

NOT 1 Inversion
AND 2 Logic AND
OR 2 Logic OR
EXOR 2 Exclusive OR

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Data manipulation

Truth table

Truth table for logic operations:

NOT A A AND B A OR B A EXOR B

1 & >1 =1
Operation
A=TRUE B=TRUE FALSE TRUE TRUE FALSE
A=TRUE B=FALSE FALSE FALSE TRUE TRUE
A=FALSE B=TRUE TRUE FALSE TRUE TRUE
A=FALSE B=FALSE TRUE FALSE FALSE FALSE

Example: ...
BOOL A,B,C
...
A = TRUE ;A=TRUE
B = NOT A ;B=FALSE
C = (A AND B) OR NOT (B EXOR NOT A) ;C=TRUE
A = NOT NOT C ;A=TRUE
...

01/2006 5
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Bit operators

Bit operators are used to perform logic operations on the individual bits of whole
numbers.

Operator Operand number Description

B_NOT 1 Bit-by-bit inversion
B_AND 2 Bit-by-bit AND operation
B_OR 2 Bit-by-bit OR operation
B_EXOR 2 Bit-by-bit exclusive OR operation

As ASCII characters can also be addressed via the integer ASCII code, the data
type of the operands may also be CHAR besides INT. The result is always of type
INT.

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 Data manipulation

Bit operators

23 22 21 20
Values
8 4 2 1

Example: 1st number 0 1 0 1 =5

2nd number 1 1 0 0 =12

B_AND 0 1 0 0 =4

B_OR 1 1 0 1 =13

B_EXOR 1 0 0 1 =9

Bit-by-bit inversion does not simply involve all the bits being inverted.
Instead, 1 is added to the operand and the sign is changed, e.g.:
B_NOT 10 = -11 or B_NOT -10 = 9

01/2006 7
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Priority of operators

Operators will be executed in order of priority.

Priority Operator
1 NOT B_NOT
2 * /
3 + -
4 AND B_AND
5 EXOR B_EXOR
6 OR B_OR
7 == <> < > >= <=

Example: INT A,B

BOOL E,F
A=4
B=7
E = TRUE
F = FALSE
E = NOT E OR F AND NOT (-3 + A * 2 > B) ;E=FALSE

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Data manipulation

Standard functions

Standard functions for calculating mathematical problems:

Description Function
Absolute value ABS (X)
Square root SQRT (X)
Sine SIN (X)
Cosine COS (X)
Tangent TAN (X)
Arc cosine ACOS (X)
Arc tangent ATAN2 (Y, X)
X=COS ()
X=SIN ()

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 Motion programming

7. Motion programming

7.1. Coordinate systems

Workbook MP3 01.06.03 89 / 198

Motion programming

Coordinate transformation at interpolation cycle rate (12 ms)

Forward transformation

X,Y,Z,A,B,C(,S,T) A1,A2,A3,A4,A5,A6

Z
Y
X

Reverse transformation

01/2006 1
motion_koordinate_systems_en.ppt
Copyright by KUKA Roboter GmbH College

Cartesian coordinate systems

X
Y Tool coordinate
Z system $TOOL

Z
Y

Z X

Y Z
Y Base coordinate
X system $BASE
Robot coordinate X
system World coordinate
$ROBROOT system $WORLD
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 Motion programming

Kinematic sequence with base-related interpolation

$IPO_MODE=#BASE

X
Y $TOOL
Z
$POS_ACT
Z
Y

X
Z
Z
Y
Y $BASE

X X
$ROBROOT $WORLD

01/2006 3
motion_koordinate_systems_en.ppt
Copyright by KUKA Roboter GmbH College

Kinematic sequence with tool-related interpolation

$IPO_MODE=#TCP

X
Y $TOOL
Z
$POS_ACT
Z

X
Z
Z
Y
Y

X X $BASE
$ROBROOT $WORLD

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Workbook MP3 01.06.03 91 / 198

Motion programming

92 / 198 Workbook MP3 01.06.03

 Motion programming

7.2. Axis motion - PTP

Workbook MP3 01.06.03 93 / 198

Motion programming

Overview of motion types

KUKA robot motion types (interpolation types)

PTP LIN CIRC

Axis motion CP motion

Quickest motion between The TCP of the currently The TCP of the currently
two points. active tool is moved along active tool is moved along
a straight line from the a defined circular path.
The controller calculates
start point to the end
the required angle
point.
differences.
P2
P2

P1 P2

P1
P1

01/2006 1
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Copyright by KUKA Roboter GmbH College

BCO run

Before a program can be executed, block coincidence (BCO)

must first be established.
This is done by holding down the Start key after selecting the
program.
The robot moves automatically at reduced velocity
Once the robot has reached the programmed path, the
program can be continued by pressing the Start key again

A HOME run is recommended for both the first and

final motions as this represents an unambiguously
defined uncritical position.

No BCO run is carried out in Automatic External

mode!

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 Motion programming

PTP motion - simplified

Acceleration Constant phase Deceleration phase

phase
Vmax
Axis 3

Axis 4

Axis 2

01/2006 3
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PTP motion higher motion profile

The higher motion profile is used as standard for PTP motions.

V

Vmax
Constant phase
velocity because
Constant
Acceleration

Deceleration
torque too high
phase

Reduction in
phase

phase

t
01/2006 4
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Copyright by KUKA Roboter GmbH College

Workbook MP3 01.06.03 95 / 198

Motion programming

PTP motions - axis-specific

The axis velocities and accelerations must be initialized

before a PTP motion can be executed. Values are specified
in %.

DEF
DEFPTP_AXIS
PTP_AXIS(())
INT
INTXX
INI
INI ;Initialization
;Initialization
...
...
FOR
FORX=1X=1TO
TO66
$ACC_AXIS[X]=70
$ACC_AXIS[X]=70 ;Modification
;Modificationofofthe
theaxis
axisaccelerations
accelerations
$VEL_AXIS[X]=70
$VEL_AXIS[X]=70 ;Modification
;Modification of the axisvelocities
of the axis velocities
ENDFOR
ENDFOR
...
...
PTP
PTP{AXIS:
{AXIS:A1
A10,
0,A2
A290,
90,A3
A390,90,A4
A40,0,A5
A50,0,A6
A60} 0}
...
...
END
END

01/2006 5
motion_ptp_en.ppt
Copyright by KUKA Roboter GmbH College

PTP motions - Cartesian

The base and tool coordinate systems must also be defined

when entering the end point using Cartesian coordinates.

DEF
DEFPTP_AXIS
PTP_AXIS(())
INT
INT XX
INI
INI
$BASE=BASE_DATA[1]
$BASE=BASE_DATA[1] ;Setting;Settingthe
thebase
basecoordinate
coordinatesystem
system
$TOOL=TOOL_DATA[3]
$TOOL=TOOL_DATA[3] ;Setting the tool coordinatesystem
;Setting the tool coordinate system
FOR
FORX=1 X=1TO
TO66
$ACC_AXIS[X]=70
$ACC_AXIS[X]=70 ;Modification
;Modificationofofthe
theaxis
axisaccelerations
accelerations
$VEL_AXIS[X]=70
$VEL_AXIS[X]=70 ;Modification
;Modificationof
ofthe
theaxis
axisvelocities
velocities
ENDFOR
ENDFOR
...
...
PTP
PTP{POS:X
{POS:X1025,
1025,YY0,
0,ZZ1480,
1480,AA0,0,BB0,
0,CC0}0}
...
...
END
END

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 Motion programming

Axis-specific absolute and relative motion

Absolute motion

PTP {A3 45}

A3 = 90 Actual position

Relative motion

PTP_REL {A3 45}

01/2006 7
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Copyright by KUKA Roboter GmbH College

Cartesian absolute and relative motion

Z PTP_REL {X 50, Y 50}

PTP {X 50, Y 50}

Y in [mm]

200

150

100

50

50 100 150 200 X in [mm]

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Workbook MP3 01.06.03 97 / 198

Motion programming

98 / 198 Workbook MP3 01.06.03

 Motion programming

7.3. Continuous path motion - LIN und CIRC

Workbook MP3 01.06.03 99 / 198

Motion programming

Overview of motion types

KUKA robot motion types (interpolation types)

PTP LIN CIRC

Axis motion CP motion

Quickest motion between The TCP of the currently The TCP of the currently
two points. active tool is moved along active tool is moved along
a straight line from the a defined circular path.
The controller calculates
start point to the end
the required angle
point.
differences.
P2
P2

P1 P2

P1
P1

01/2006 1
motion_lin_circ_en.ppt
Copyright by KUKA Roboter GmbH College

CP motions (CP = Continuous Path)

The path, swivel and rotational velocities and accelerations

must be initialized before a CP motion can be executed.

Variable name Data type Unit Function

$VEL.CP REAL m/s Path velocity

Velocity
$VEL.ORI1 REAL /s Swivel velocity
$VEL.ORI2 REAL /s Rotational velocity
$ACC.CP REAL m/s Path acceleration
Acceleration $ACC.ORI1 REAL /s Swivel acceleration
$ACC.ORI2 REAL /s Rotational acceleration

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 Motion programming

Path-related absolute and relative motion

When the initialization sequence of the basic package is called,

the default settings for the velocities and rates of acceleration of
CP motions are also preset to the maximum values defined in
the machine data or $CONFIG.DAT.

DEFDAT
DEFDAT$CONFIG
$CONFIG
...
...
; ;CPCP- -MOVEMENTS
MOVEMENTS
;----------------------------------
;----------------------------------
DECL
DECLCIRC_TYPE
CIRC_TYPEDEF_CIRC_TYP=#BASE
DEF_CIRC_TYP=#BASE
REAL DEF_VEL_CP=2.00
REAL DEF_VEL_CP=2.00
REAL
REALDEF_VEL_ORI1=200.0
DEF_VEL_ORI1=200.0
REAL
REALDEF_VEL_ORI2=200.0
DEF_VEL_ORI2=200.0
REAL
REALDEF_ACC_CP=2.3
DEF_ACC_CP=2.3
REAL
REALDEF_ACC_ORI1=100.0
DEF_ACC_ORI1=100.0
REAL
REALDEF_ACC_ORI2=100.0
DEF_ACC_ORI2=100.0
......
ENDDAT
ENDDAT

01/2006 3
motion_lin_circ_en.ppt
Copyright by KUKA Roboter GmbH College

Path-related absolute and relative motion

The first motion in a program must be a PTP motion.

DEF
DEFCPMOTION
CPMOTION( () )
INI
INI
$BASE=BASE_DATA[1]
$BASE=BASE_DATA[1] ;Setting
;Settingthe
thebase
basecoordinate
coordinatesystem
system
$TOOL=TOOL_DATA[3]
$TOOL=TOOL_DATA[3] ;Setting
;Settingthe
thetool
toolcoordinate
coordinatesystem
system
$VEL.CP=1.0
$VEL.CP=1.0 ;Modification
;Modificationofofvelocities
velocities
$VEL.ORI1=150
$VEL.ORI1=150
$VEL.ORI2=100
$VEL.ORI2=100
$ACC.CP=1.7
$ACC.CP=1.7 ;Modification
;Modificationofofaccelerations
accelerations
$ACC.ORI1=80
$ACC.ORI1=80
$ACC.ORI2=80
$ACC.ORI2=80
......
PTP
PTPHOMEHOME
LIN
LIN{X {X1050,
1050,ZZ900}
900} ;Absolute
;Absolutecoordinate
coordinatespecification
specification
LIN_REL {X 100, Y 250, Z 125} ;Relative distancespecification
LIN_REL {X 100, Y 250, Z 125} ;Relative distance specification
......
END
END

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Copyright by KUKA Roboter GmbH College

Workbook MP3 01.06.03 101 / 198

Motion programming

Circular motion

CIRC Aux_Point , End_Point , CA Circular_Angle

Argument Explanation
Auxiliary point coordinate specified by means of an aggregate or the point
Aux_Point
name of a point in the data list

End point coordinate specified by means of an aggregate or the point name

End_Point of a point in the data list

Circular_ CA = Circular Angle

Angle Circular angle in degrees

When specifiying the auxiliary point or end point using an

aggregate, make sure the tool and base coordinate systems
are assigned correctly!

01/2006 5
motion_lin_circ_en.ppt
Copyright by KUKA Roboter GmbH College

Circular motion

CA > 0 Circle is executed in the direction programmed:

start point auxiliary point end point

CA < 0 Circle is executed in the opposite direction from that programmed:

start point end point auxiliary point

The orientation angles at the calculated destination point are identical with the
orientation angles at the destination point, that was touched up.

CA = 290 Programmed CA = -290 Actual end

end point point

Auxiliary point Programmed

Auxiliary point Actual end end point
point

Start point

Start point

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 Motion programming

7.4. Orientation control

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Motion programming

Orientation control with LIN motions

Variable Value Description

The orientation remains constant
during the CP motion. The
$ORI_TYPE #CONSTANT
programmed orientation is
disregarded for the end point

$ORI_
TYPE
= #CO
NST ANT

01/2006 1
motion_orientation_en.ppt
Copyright by KUKA Roboter GmbH College

Orientation control with LIN motions

Variable Value Description

During the CP motion the orientation
$ORI_TYPE #VAR changes continuously to the
orientation of the end point

$ORI_
TYPE
= #VA
R

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Copyright by KUKA Roboter GmbH College

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 Motion programming

Orientation control with LIN motions

Variable Value Description

During the path motion, the

orientation of the tool changes
continuously from the start position to
the end position. This is done by
linear transformation of the wrist axis
$ORI_TYPE #JOINT
angles. The problem of the wrist
singularity can be avoided using this
option as there is no orientation
control by rotating and pivoting the
tool direction.

01/2006 3
motion_orientation_en.ppt
Copyright by KUKA Roboter GmbH College

Variables for orientation control with circular motions

Variable Value Description

The orientation remains constant
during the circular motion. The
$ORI_TYPE #CONSTANT
programmed orientation is
disregarded for the end point
During the circular motion the
$ORI_TYPE #VAR orientation changes continuously to
the orientation of the end point

Space-related orientation control

$CIRC_TYPE #BASE
during the circular motion

Path-related orientation control

$CIRC_TYPE #PATH
during the circular motion

The variable $CIRC_TYPE is meaningless in the case of a linear

transformation of the wrist axis angles with $ORI_TYPE = #JOINT.

01/2006 4
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Workbook MP3 01.06.03 105 / 198

Motion programming

Orientation control with circular motions

$ORI_TYPE = #CONSTANT
$CIRC_TYPE = #PATH

01/2006 5
motion_orientation_en.ppt
Copyright by KUKA Roboter GmbH College

Orientation control with circular motions

$ORI_TYPE = #VAR
$CIRC_TYPE = #PATH

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 Motion programming

Orientation control with circular motions

$ORI_TYPE = #CONSTANT
$CIRC_TYPE = #BASE

01/2006 7
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Copyright by KUKA Roboter GmbH College

Orientation control with circular motions

$ORI_TYPE = #VAR
$CIRC_TYPE = #BASE

01/2006 8
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Motion programming

108 / 198 Workbook MP3 01.06.03

 Motion programming

7.5. Advance run

Workbook MP3 01.06.03 109 / 198

Motion programming

Computer advance run

What is the computer advance run?

The main run pointer (white bar), which can be seen on the graphical user interface
when the program is running, always indicates the block that is currently being
processed. The advance run pointer, on the other hand, is not visible and precedes
the main run pointer by three motion blocks (default setting).

What is the function of the advance run pointer?

In order to be able to calculate the path, e.g. of an approximation motion, it is
necessary to read the path planning data using the advance run pointer. It is not only
motion data that are processed, however, but also arithmetical data and commands
for controlling the periphery.

How is the advance run pointer influenced?

Instructions and data that influence the periphery (e.g. input/output instructions)
trigger an advance run stop. If the advance run pointer is stopped, approximate
positioning cannot be carried out.

01/2006 1
continue_en.ppt
Copyright by KUKA Roboter GmbH College

Advance run pointer

The variable $ADVANCE specifies the maximum number of motion blocks the
advance run may process ahead of the program pointer. The actual advance
run is dependent, however, on the capacity of the computer.

Syntax:

$ADVANCE = Value

Value Explanation
0 Approximation not possible, every point is positioned exactly
1 Minimum value permitting approximation
3 Default
5 Maximum value

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 Motion programming

Position of the advance run pointer

Main run pointer

Advance run pointer

01/2006 3
continue_en.ppt
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Automatic advance run stop

Instructions and data which affect the peripheral equipment (e.g. I/O
instructions), or which are based on the current state of the robot, trigger an
advance run stop. This is necessary in order to guarantee the correct sequence
of statements and robot motions.

Statements HALT WAIT PULSE

ANIN ON/OFF ANOUT ON/OFF
Customary system $IN[x] $OUT[x]
variables $ANIN[x] $ANOUT[x]

Imported variables All, when accessed

A complete table of commands that trigger an automatic advance run

stop can be found in the documentation (see Documentation CD)

01/2006 4
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Copyright by KUKA Roboter GmbH College

Workbook MP3 01.06.03 111 / 198

Motion programming

CONTINUE

Syntax: CONTINUE

In applications where this advance run stop should be

prevented, the command CONTINUE must be
programmed immediately before the relevant
instruction. The controller then allows the advance run
to continue. The effect of this command is limited to the
next program line (even if this line is empty!!).

01/2006 5
continue_en.ppt
Copyright by KUKA Roboter GmbH College

Approximate positioning using CONTINUE

Syntax: CONTINUE

The condition or value assignment is polled by the

advance run pointer, but it is still possible to
approximate the preceding point

DEF EXIT_PRO ( )
...
PTP XP9 C_PTP
CONTINUE
WAIT FOR $IN[14] == TRUE
...
END

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 Motion programming

7.6. Approximate positioning

Workbook MP3 01.06.03 113 / 198

Motion programming

Approximate positioning with PTP commands

PTP Point_Name (or coordinate) C_PTP

The size of the approximate positioning range is set using the

variable $APO.CPTP (in %)
The maximum approximation distance is limited in the machine data
to 90 for all axes

DEF
DEFPTP_AXIS_CPTP
PTP_AXIS_CPTP(())
...
...
$APO.CPTP
$APO.CPTP==5050
...
...
PTP
PTPXHOME
XHOME
PTP
PTP {AXIS:A1
{AXIS: A180,
80,A2
A240,
40,A3
A30,0,A4
A40,0,A5
A50,
0,A6
A6-90}
-90}C_PTP
C_PTP
PTP XPOINT1 C_PTP
PTP XPOINT1 C_PTP
...
...
END
END

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Example of PTP-PTP approximate positioning

PTP {POS:X 1159.08,Y -232.06,Z 716.38,A 171.85,B 67.32,C 162.65,S 2,T 10}
PTP {POS:X 1246.93,Y -98.86,Z 715,A 125.1,B 56.75,C 111.66,S 2,T 10} C_PTP
PTP {POS:X 1109.41,Y -0.51,Z 715,A 95.44,B 73.45,C 70.95,S 2,T 10}
$APO.CPTP=20
PTP {POS:X 1296.61,Y 133.41,Z 715,A 150.32,B 55.07,C 130.23,S 2,T 11} C_PTP
PTP {POS:X 988.45,Y 238.53,Z 715,A 114.65,B 50.46,C 84.62,S 2,T 11} C_PTP
PTP {POS:X 1209.5,Y 381.09,Z 715,A -141.91,B 82.41,C -159.41,S 2,T 11}

End point M
di otio
re
cti n
on

Start point

$APO.CPTP=20

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 Motion programming

Approximate positioning with CP motions

Unit /
Variable Description Keyword
Data type

$APO.CDIS mm The distance from the end

point must be less than the C_DIS
(Distance) REAL value $APO.CDIS

$APO.CORI The dominant orientation

angle must be less than the C_ORI
(Orientation) REAL value $APO.CORI

The velocity in the

$APO.CVEL % deceleration phase to the
C_VEL
(Velocity) INT end point must be less than
the value $APO.CVEL

01/2006 3
motion_approximation_en.ppt
Copyright by KUKA Roboter GmbH College

Approximate positioning with CP motions

LIN Point_Name (or coordinate) Approximate_Positioning_Criterion

The size of the approximate positioning range is set using the variables
$APO.CDIS, $APO.CVEL and $APO.CORI

DEF
DEFLIN_CIRC_CONT
LIN_CIRC_CONT( () )
......
$APO.CVEL
$APO.CVEL==50 50
$APO.CDIS
$APO.CDIS==20 20
$APO.CORI
$APO.CORI==20 20
......
PTP
PTPXHOME
XHOME
LIN_REL
LIN_REL{X {X-500,
-500,ZZ250,
250,AA50,
50,CC90}
90}C_VEL
C_VEL
CIRC XHP, XZP, CA 270 C_ORI
CIRC XHP, XZP, CA 270 C_ORI
LIN
LIN{X {X1050,
1050,YY120,
120,ZZ1000,
1000,AA0,0,BB0,0,CC0}
0}C_DIS
C_DIS
......
END
END

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Motion programming

Example of LIN-LIN approximate positioning

PTP {POS: X 1159.08,Y -232.06,Z 716.38,A 171.85,B 67.32,C 162.65,S 2,T 10}
$APO.CDIS=20
LIN {X 1246.93,Y -98.86,Z 715,A 125.1,B 56.75,C 111.66} C_DIS
LIN {X 1109.41,Y -0.51,Z 715,A 95.44,B 73.45,C 70.95}
LIN {X 1296.61,Y 133.41,Z 714.99,A 150.32,B 55.07,C 130.23} C_ORI
LIN {X 988.45,Y 238.53,Z 714.99,A 114.65,B 50.46,C 84.62} C_VEL
LIN {X 1209.5,Y 381.09,Z 715,A -141.91,B 82.41,C -159.41}

End point M
di otio
re
cti n
on

$APO.CDIS=20
Start point

01/2006 5
motion_approximation_en.ppt
Copyright by KUKA Roboter GmbH College

PTP-CP approximate positioning

CP motion (CP = Continuous Path) = LIN or CIRC

Program:
Program:

......
LIN
LINP1 P1
LIN
LINP2 P2C_DIS
C_DIS
PTP
PTPP3 P3
......

Table

The problem here is that the approximate positioning motion is

unpredictable. There is the possibility of a collision with the table.

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 Motion programming

PTP-CP approximate positioning

In order to counter the above problem, while avoiding exact positioning,

an additional CP motion (P2_AUX) must be inserted.

Program:
Program:

......
P2_AUX LIN
LINP1 P1
LIN
LINP2 P2C_DIS
C_DIS
LIN
LINP2_AUX
P2_AUXC_DIS
C_DIS
PTP
PTPP3 P3
......

Table

01/2006 7
motion_approximation_en.ppt
Copyright by KUKA Roboter GmbH College

Example of CIRC-CIRC approximate positioning

PTP {POS: X 980,Y -238,Z 718,A 133,B 66,C 146,S 6,T 50}
$APO.CDIS=20
CIRC {X 925,Y -285,Z 718},{X 867,Y -192,Z 718,A 155,B 75,C 160} C_DIS
$ORI_TYPE=#CONST
CIRC {X 982,Y -221,Z 718,A 50,B 60,C 0},{X 1061,Y -118,Z 718,A -162,B 60,C 177}, CA 150 C_ORI

CIRC {X 963.08,Y -85.39,Z 718},{X 892.05,Y 67.25,Z 718.01,A 97.34,B 57.07,C 151.11} C_ORI
$APO.CVEL=50
CIRC_REL {X -50,Y 50},{X 0,Y 100} C_VEL
$APO.CDIS=40
CIRC_REL {X -50,Y 50},{X 0,Y 100} C_DIS Start point
CIRC_REL {X -50,Y 50},{X 0,Y 100}

End point

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Motion programming

Approximate positioning contour with LIN-CIRC blocks

The approximate positioning path consists of two parabolic segments,

which have a tangential transition between each other and also to the
individual blocks.

End of approximate positioning

Start of approximate positioning

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 Motion programming

7.7. Status and Turn

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Motion programming

Status and Turn

The entries S and T in a POS structure serve to select a specific,

unambiguously defined robot position where several different axis
positions are possible for the same point in space.

The specification of Status and Turn is only evaluated for

PTP motions. For this reason, the first motion in a
program must be a PTP motion.

DEFDAT
DEFDATMAIN_PROGRAM
MAIN_PROGRAM(())

DECL
DECLPOS
POSXPOINT1={X
XPOINT1={X900,
900,YY0,
0,ZZ800,
800,AA0,
0,BB0,
0,CC0,
0,SS6,6,TT27}
27}
DECL FDAT FPOINT1...
DECL FDAT FPOINT1...
...
...

STATUS TURN
ENDDAT
ENDDAT

01/2006 1
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Status and Turn

Status = 1 Status = 2
Turn = 46 Turn = 43

Status = 6 Status = 4
Turn = 59 Turn = 63

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 Motion programming

Turn

With rotational axes, the individual bits determine the sign before the
axis value in the following way:
Bit x = 0: angle of axis x 0
Bit x = 1: angle of axis x < 0

Value Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

0 A6 0 A5 0 A4 0 A3 0 A2 0 A1 0

1 A6 < 0 A5 < 0 A4 < 0 A3 < 0 A2 < 0 A1 < 0

Example:
Specification T 19 TB010011
Axes A1, A2 and A5 negative; axes A3, A4 and A6 positive

01/2006 3
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Status BIT 0: Position of the wrist root point

Wrist root point

BA = Basic area Bit 0 = 0

OHA = Overhead area Bit 0 = 1

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Motion programming

Status BIT 1: Arm configuration

Axis 5

Axis 3
Axis 2

Offset
Bit 1 specifies the position of the arm. The
setting of the bit is dependent on the robot model
in use. For robots whose axes 3 and 4 intersect,
the following applies:
Bit 1 has the value 0, if axis 3 < 0, otherwise
bit 1 = 1.
For robots with an offset between axis 3 and axis
4 (e.g. KR 30), the angle at which the value of bit KR 30
1 changes depends on the size of this offset.

01/2006 5
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Copyright by KUKA Roboter GmbH College

Status BIT 2: Wrist configuration

Bit 2 specifies the configuration of the wrist. This is dependent on the

position of axis 5.

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 System variables

8. System variables

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System variables

System variables and system files

The KRC supports the concept of predefined system variables and

system files.
System variables can be read and written in the same way as any other
variable (with limitations due to the type of data).
It is possible to write separate data lists with data definitions and
initializations if required.
The system contains predefined data lists which cannot be generated or
deleted, e.g.:
$MACHINE.DAT Adapt controller to robot
$CUSTOM.DAT Configure control functions
$CONFIG.DAT Predefined data list
$ROBCOR.DAT Robot-specific data

01/2006 1
systemvariables_en.ppt
Copyright by KUKA Roboter GmbH College

Starting and stopping timers

The system variables $TIMER[1]$TIMER[32] serve the purpose of measuring

time sequences (20 on the display). A timing process is started and stopped by
means of the system variables $TIMER_STOP[1]$TIMER_STOP[16]:

Syntax:

$TIMER_STOP[No] = Value

Argument Type Explanation

Value BOOL FALSE: Start timer
TRUE: Stop timer

Example:
$TIMER[5] = 0 ;Reset timer 5 by assigning a value
$TIMER_STOP[5] = FALSE ;Start timer 5
...
$TIMER_STOP[5] = TRUE ;Stop timer 5
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 System variables

Timer flag

1
$TIMER_STOP[No]
0
1
$TIMER_FLAG[No]
0

10000
$TIMER[No] in ms

0 Time

Zero position

-10000

01/2006 3
systemvariables_en.ppt
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Flags

Flags are 1-bit memories and are used as global markers. Flags are static.

Syntax:

$FLAG[No] = Value

Argument Type Explanation

No. INT Flag number,
range of values: 11024 (999 on the display)
Value BOOL FALSE: Reset flag
TRUE: Set flag

Example:
$FLAG[1] = FALSE ;Reset flag 1

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System variables

Cyclical flags

Cyclical flags are also 1-bit memories, but are cyclically active at the robot level
only.

Syntax:

$CYCFLAG[No] = Value

Argument Type Explanation

No. INT Cyclical flag number,
range of values: 1256 (32 on the display)
Value BOOL FALSE: Reset cyclical flag
TRUE: Set cyclical flag

Example:
$CYCFLAG[1] = $IN[2] AND $IN[13] ;Boolean expression is cyclically
evaluated and updated.

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 Program execution control

9. Program execution control

9.1. Jump instruction and branches

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Program execution control

Program execution control - Overview

Jump instruction GOTO

Branches Conditional branch IF - THEN - ELSE

Switch SWITCH - CASE

The controller does not detect logic errors!

01/2006 1
program_control_branches_en.ppt
Copyright by KUKA Roboter GmbH College

Jump instruction

Syntax:
GOTO Marker

GOTO statements can very quickly lead to a loss of structural clarity

within a program and should therefore be used as little as possible

DEF
DEFPRG
PRG(())

...
...
GOTO
GOTOMark1
Mark1
...
...
...
...
Mark1:
Mark1:
...
...
END
END
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 Program execution control

Conditional branch

Syntax: IF Execution_Condition THEN

Statement
ELSE
Statement
ENDIF

...
...
Condition
IF
IF$IN[22]==TRUE
$IN[22]==TRUETHEN
THEN
OK ?

PTP HOME
PTP HOME Yes
No

ELSE
ELSE
$OUT[17]=TRUE
$OUT[17]=TRUE Statement A Statement B

$OUT[18]=FALSE
$OUT[18]=FALSE
PTP
PTPHOME
HOME
ENDIF
ENDIF
...
...

01/2006 3
program_control_branches_en.ppt
Copyright by KUKA Roboter GmbH College

Verteiler

Syntax: SWITCH Variable (INT or ENUM)

CASE 1
Statement
CASE 2
Statement Selection
DEFAULT
ENDSWITCH 1 2 3 n

Statement A Statement B Statement C Statement n

...
...
SWITCH
SWITCHPROG_NO
PROG_NO
CASE
CASE11
Part1
Part1(()) ; ;ififProg_No
Prog_No==11
CASE 2
CASE 2
Part2
Part2()() ; ;ififProg_No
Prog_No==22
DEFAULT
DEFAULT
ERROR_SP(
ERROR_SP()); ;all allother
othervalues
values
ENDSWITCH
ENDSWITCH
...
...
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Program execution control

130 / 198 Workbook MP3 01.06.03

 Program execution control

9.2. Loops

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Program execution control

Program execution control - Overview

Loops Endless loop LOOP

Counting loop FOR - TO - STEP

WHILE
Conditional loops
REPEAT - UNTIL

The controller does not detect logic errors!

01/2006 1
program_control_loops_en.ppt
Copyright by KUKA Roboter GmbH College

Loops - general

1. Loops are required for repeating program instructions.

2. A distinction is made between counting loops and conditional
loops.
3. A jump into the loop from outside is not allowed and is refused by
the controller (error messages).
4. The nesting of loops is a further programming technique.

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 Program execution control

Counting loop

Syntax:
FOR Counter = Start TO End STEP Increment
Statement
ENDFOR

E6POS
E6POSPOSITION[4,4]
POSITION[4,4]
INT
INTX, X,YY For i = 1 to 4
...
...
FOR
FORX=1 X=1TOTO44STEP
STEP11
FOR
FOR Y=4 TO11STEP
Y=4 TO STEP-1-1 Statement

POSITION[X,Y]=P1
POSITION[X,Y]=P1
POSITION[X,Y].X=P1.X+50
POSITION[X,Y].X=P1.X+50
POSITION[X,Y].Y=P1.Y+50
POSITION[X,Y].Y=P1.Y+50
ENDFOR
ENDFOR
ENDFOR
ENDFOR

01/2006 3
program_control_loops_en.ppt
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Rejecting loop

Syntax: WHILE Condition

Statement

ENDWHILE

...
...
WHILE
WHILE$IN[22]==TRUE
$IN[22]==TRUE
WHILE
condition ?

$OUT[17]=TRUE
$OUT[17]=TRUE Yes
$OUT[18]=FALSE
$OUT[18]=FALSE No
PTP
PTPHOME
HOME
Statement

ENDWHILE
ENDWHILE
...
...

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Program execution control

Non-rejecting loop

Syntax: REPEAT

Statement

UNTIL Condition

...
...
REPEAT
REPEAT No
Statement

$OUT[17]=TRUE
$OUT[17]=TRUE
$OUT[18]=FALSE
$OUT[18]=FALSE
PTP
PTPHOME
HOME Repeat
condition ?

UNTIL
UNTIL$IN[22]==TRUE
$IN[22]==TRUE Yes
...
...

01/2006 5
program_control_loops_en.ppt
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Endless loop

Syntax: LOOP
Statement 1
...
Statement n
ENDLOOP

Statement A
...
...
PTP
PTPHOME
HOME
LOOP
LOOP Statement B
LIN
LINXP1
XP1
LIN
LINXP2
XP2
LIN
LINXP4
XP4 Statement C
ENDLOOP
ENDLOOP
PTP
PTPHOME
HOME
...
...

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 Program execution control

Premature termination of loop execution

Syntax: EXIT

Any loop can be terminated prematurely by using the EXIT statement.

DEF
DEFEXIT_PRO
EXIT_PRO(())
PTP
PTPXHOME
XHOME
LOOP
LOOP ;Start
;Startof
ofendless
endlessloop
loop
LIN XP1
LIN XP1
IF
IF$IN[1]
$IN[1]==
==TRUE
TRUETHEN
THEN ;Terminate
;Terminatewhen when
EXIT
EXIT ;input
;input11set
set
ENDIF
ENDIF
LIN
LINXP2
XP2
ENDLOOP
ENDLOOP ; ;End
Endofofendless
endlessloop
loop
PTP
PTPXHOME
XHOME
END
END
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Program execution control

136 / 198 Workbook MP3 01.06.03

 Program execution control

9.3. Wait und Halt function

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Program execution control

Wait statements

Syntax: WAIT FOR Condition

DEF EXIT_PRO ( )
...
WAIT FOR $IN[14] == TRUE ;waits until input 14 is set
...
END

If the logical expression Condition is already TRUE when

WAIT is called, program execution is not stopped
(an advance run stop is triggered, however).
If Condition is FALSE, program execution is stopped until
the expression takes the value TRUE.

01/2006 1
program_control_add_en.ppt
Copyright by KUKA Roboter GmbH College

Wait statements

Syntax: WAIT FOR Time

DEF EXIT_PRO ( )
...
WAIT SEC 5 ;waits 5 seconds
...
WAIT SEC Time*0.5+0.25 ;waits calculated time

END

Time is an arithmetic REAL expression which can be used to

specify the number of seconds for which program execution is
to be interrupted. If the value is negative, the program does
not wait.

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 Program execution control

Stopping the program

Syntax: HALT

HALT statements are used to stop programs. The last motion

instruction to be executed will, however, be completed.

The program can be resumed by pressing the START key.

Special case: In the case of interrupt programs, the routine is

processed completely (advance run pointer).

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Program execution control

140 / 198 Workbook MP3 01.06.03

 Automatic external function

10. Automatic external function

10.1. Definition and sequence

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Automatic external function

System structure

Controls the entire

system and saves Host computer
data

Control system
PLCs components
(robots and periphery)

Robots

Execute application programs

01/2006 1
automatic_external_en.ppt
Copyright by KUKA Roboter GmbH College

System structure: KRC - PLC

Organization program for selecting the motion programs

Automatic External:
Operating mode in which a
host computer or PLC
CELL.SRC assumes control of the robot
system.
PLC

Signal exchange

T T

Information about operating and The entire robot process,

fault states are transmitted to the e.g. motion enable, fault
PLC acknowledgement, program start,
is controlled by the PLC

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 Automatic external function

Configuring the interface

The signals of the Automatic External interface must be assigned physical inputs
and outputs of the robot controller.

01/2006 3
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Automatic External inputs

Functional
Variable name
description

Var Variable Input number or

I/O Input variable value

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Automatic external function

Automatic External outputs - Start condition

Functional
Function name
description

Output number

01/2006 5
automatic_external_en.ppt
Copyright by KUKA Roboter GmbH College

$NEAR_POSRET

The signal $NEAR_POSRET can be used to determine whether or not the robot is
situated within a sphere about the position saved in $POS_RET*). The radius of the
sphere can be set in the file $CUSTOM.DAT using the system variable $NEARPATHTOL.

$NEAR_POSRET=FALSE

$NEAR_POSRET=TRUE

Deviation from
path caused,
th for example, by
Pa dynamic braking
$NEARPATHTOL

*) $POS_RET: Position at which the robot left the path ( )

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 Automatic external function

Organization program: CELL.SRC

INIT
BASISTECH INI
Position check CHECK HOME
PTP HOME Vel= 100 % DEFAULT
AUTOEXT INI
LOOP
Function for program P00 (#EXT_PGNO,#PGNO_GET,DMY[],0 )
number transfer
SWITCH PGNO

CASE 1
Delete semicolon P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )
;EXAMPLE1 ( )
CASE 2
Substitute program P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )
name for ;EXAMPLE2 ( )
EXAMPLEx CASE 3
P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )
;EXAMPLE3 ( )
If program number
invalid, restart program DEFAULT
P00 (#EXT_PGNO,#PGNO_FAULT,DMY[],0 )
with $EXT_START
ENDSWITCH
ENDLOOP

01/2006 7
automatic_external_en.ppt
Copyright by KUKA Roboter GmbH College

Expanding CELL.SRC

LOOP

P00 (#EXT_PGNO,#PGNO_GET,DMY[],0 )
SWITCH PGNO
CASE 1
Select CASE branch with P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )
SHIFT + cursor key and insert PROG1 ( )
as new copied branch CASE 2
Proceed in the same way for P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )
PROG2 ( )
each subsequent program CASE 3
Modify program number and P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )
corresponding program name PROG3 ( )
CASE 4
P00 (#EXT_PGNO,#PGNO_ACKN,DMY[],0 )
PROG4 ( )
DEFAULT
P00 (#EXT_PGNO,#PGNO_FAULT,DMY[],0 )
ENDSWITCH

ENDLOOP

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Automatic external function

Automatic External interface example (not complete)

$STOPMESS
PGNO_REQ
APPL_RUN
$PERI_RDY

INPUTS
OUTPUTS
$ALARM_STOP
$USER_SAF
$I_O_ACTCONF(EXT)
$ON_PATH
$PRO_ACT
$IN_HOME
PGNO / PGNO_PARITY
KRC PGNO_VALID PLC

OUTPUTS
$EXT_START
INPUTS

$MOVE_ENABLE
$CONF_MESS
$DRIVES_ON
$DRIVES_OFF

01/2006 9
automatic_external_en.ppt
Copyright by KUKA Roboter GmbH College

Signal diagram example: Precondition

$STOPMESS (stop message)

$PERI_RDY (drives are on)

INPUTS
OUTPUTS

$ALARM_STOP (no E-STOP)

$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)

$IN_HOME (robot in HOME position)

KRC PLC
OUTPUTS
INPUTS

$MOVE_ENABLE (motion enable)

$DRIVES_ON (activate drives)

$DRIVES_OFF (drives not deactivated)

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 Automatic external function

Signal diagram example: Acknowledge messages

$STOPMESS (stop message)

$PERI_RDY (drives are on)

INPUTS
OUTPUTS
$ALARM_STOP (no E-STOP)
$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)

$IN_HOME (robot in HOME position)

KRC PLC

OUTPUTS
INPUTS

$MOVE_ENABLE (motion enable)

$CONF_MESS (ackn. messages)

$DRIVES_OFF (drives not deactivated)

01/2006 11
automatic_external_en.ppt
Copyright by KUKA Roboter GmbH College

Signal diagram example: Start program

$PERI_RDY (drives are on)

INPUTS
OUTPUTS

$ALARM_STOP (no E-STOP)

$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)
$ON_PATH (robot is on path)
$PRO_ACT (program is active)
$IN_HOME (robot in HOME position)

KRC PLC
OUTPUTS

$EXT_START (start program)

INPUTS

$MOVE_ENABLE (motion enable)

$DRIVES_OFF (drives not deactivated)

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Automatic external function

Signal diagram example: Transfer program number

PGNO_REQ (request)

$PERI_RDY (drives are on)

INPUTS
OUTPUTS
$ALARM_STOP (no E-STOP)
$USER_SAF (safety gate closed)
$I_O_ACTCONF(EXT)
$ON_PATH (robot is on path)
$PRO_ACT (program is active)
$IN_HOME (robot in HOME position)
PGNO (number + parity)
KRC PGNO_VALID (read command) PLC

OUTPUTS
INPUTS

$MOVE_ENABLE (motion enable)

$DRIVES_OFF (drives not deactivated)

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 Automatic external function

10.2. Configuration inputs

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Automatic external function

Program number format: PGNO_TYPE

PGNO_TYPE Program number type

This value determines the format in which the program number sent by the host
computer is read.

PGNO_TYPE Read as ... Meaning Example

1 Binary number Sent as binary coded integer Click

Click
2 BCD value Sent as binary coded decimal Click
Click
3 1 of n *1 Sent as 1 of n coded value Click
Click
*1 When using this transmission format, the values of PGNO_REQ, PGNO_PARITY and
PGNO_VALID are not evaluated and are thus of no significance.

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Display format of the program number: BINARY

Binary coded integer: PGNO_TYPE=1

Input: ... E8 E7 E6 E5 E4 E3 E2 E1

Values: 27= 26= 25= 24= 23= 22= 21= 20=

128 64 32 16 8 4 2 1

Example: 0 1 1 0 0 0 0 1
Prog. no.: 97 =0 + 64 + 32 + 0 + 0 + 0 + 0 + 1

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 Automatic external function

Display format of the program number: BCD

Binary coded decimal: PGNO_TYPE=2

2nd decimal place 1st decimal place

Input: ... E8 E7 E6 E5 E4 E3 E2 E1
Values: 8 4 2 1 8 4 2 1

Example: 0 0 1 0 0 1 1 1

Result: 2 7

Prog. no.: 27
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Display format of the program number: 1 of n

1 of n coded integer: PGNO_TYPE=3

Input (max. 16): ... E8 E7 E6 E5 E4 E3 E2 E1

Prog. no. 1 : 0 0 0 0 0 0 0 1

Prog. no. 2 : 0 0 0 0 0 0 1 0

Prog. no. 3 : 0 0 0 0 0 1 0 0

Prog. no. 4 : 0 0 0 0 1 0 0 0

Prog. no. 5 : 0 0 0 1 0 0 0 0

Prog. no. 6 : 0 0 1 0 0 0 0 0

Prog. no. 7 : 0 1 0 0 0 0 0 0

Prog. no. 8 : 1 0 0 0 0 0 0 0

Only one input may be TRUE at any time.

All other input combinations result in an invalid program number.
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Automatic external function

Mirroring the program number: REFLECT_PROG_NR

REFLECT_PROG_NR REFLECT_PROG_NR

This option allows you to decide whether or not the program number
should be mirrored in a definable output area.

REFLECT_PROG_NR Function
0 Deactivated
1 Activated

The output of the signal starts with the output defined using
PGNO_FBIT_REFL.

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Program number length in bits: PGNO_LENGTH

PGNO_LENGTH Program number length in bits

Its value determines the number of bits defining the program number sent by the
host computer.

Range of values: PGNO_LENGTH = 1...16

Example: PGNO_LENGTH = 4

the external program number is four bits long

While PGNO_TYPE has the value 2 (program number read as BCD

value), only 4, 8, 12 and 16 are permissible values for the number of bits.

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 Automatic external function

First bit in the program number: PGNO_FBIT

PGNO_FBIT First bit in program number

Input representing the first bit of the program number.

Range of values: PGNO_FBIT = 1...4096

Example: PGNO_FBIT = 5

the external program number begins with the input $IN[5]

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Parity bit: PGNO_PARITY

PGNO_PARITY Parity bit

Input to which the parity bit is transferred from the host computer.

Input Function

Negative value Odd parity

0 No evaluation
Positive value Even parity

While PGNO_TYPE has the value 3 (program number read as 1

of n value), PGNO_PARITY is NOT evaluated.

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Automatic external function

Program number valid: PGNO_VALID

PGNO_VALID Program number valid

Input to which the command to read the program number is transferred from the
host computer. If the variable PGNO_TYPE has the value 3, PGNO_VALID is
not evaluated.

Input Function
Number is transferred at the falling edge of the signal
Negative value

Number is transferred at the rising edge of the signal on the

0
EXT_START line
Number is transferred at the rising edge of the signal
Positive value

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Program start: $EXT_START

$EXT_START Program start

If the I/O interface is active, this input can be set to start or continue a program.

Only the rising edge of the signal is evaluated.

There is no BCO run in Automatic External mode, so there is no

program stop at the first programmed position.

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 Automatic external function

Motion enable: $MOVE_ENABLE

$MOVE_ENABLE Motion enable

This input is used by the host computer to check the robot drives.

Signal Function
TRUE Jogging and program execution are possible
All drives are stopped and all active commands inhibited
FALSE

If the drives have been switched off by the host computer, the message
GENERAL MOTION ENABLE appears in the message window of the
KCP. It is only possible to move the robot again once this message has
been reset and another external start signal has been given.
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MOVE_ENABLE monitoring: $CHCK_MOVENA

$MOVE_ENABLE Motion enable

If the variable $CHCK_MOVENA has the value FALSE, MOVE_ENABLE can be

bypassed. The value of the variable can only be changed in the file
C:\KRC\Roboter\KRC\Steu\MaDa\OPTION.DAT.

Signal Function

TRUE MOVE_ENABLE monitoring is activated

FALSE MOVE_ENABLE monitoring is deactivated

In order to be able to use MOVE_ENABLE monitoring, $MOVE_ENABLE

must have been configured with the input $IN[1025].
Otherwise, $CHCK_MOVENA has no effect whatsoever.

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Automatic external function

Error acknowledgement: $CONF_MESS

$CONF_MESS Error acknowledgement

Setting this input enables the host computer to reset (acknowledge) error
messages automatically.

Only the rising edge of the signal is evaluated.

Acknowledgement of the error messages is only possible once the cause of the
error has been eliminated.

1 1

0 0
Rising edge Falling edge
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Drives on/off: $DRIVES_ON / $DRIVES_OFF

DRIVES_OFF (inverse)

With a low-level pulse of at least 20 ms duration at this input, the host

computer can switch off the robot drives.

DRIVES_ON

With a high-level pulse of at least 20 ms duration at this input, the host

computer can switch on the robot drives.

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 Automatic external function

Drives on/off: $DRIVES_ON / $DRIVES_OFF

$I_O_ACT Interface

The I/O interface can be activated by setting this system variable to TRUE
($IN[1025])

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Automatic external function

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 Automatic external function

10.3. Configuration Outputs

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Automatic external function

Output RC_RDY1 & ALARM_STOP

Start condition

RC_RDY1 Controller ready

Ready for program start

ALARM_STOP E-Stop circuit closed

This output is reset in the event of an EMERGENCY STOP event.

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Output USER_SAF & PERI_RDY

Start condition

USER_SAF Operator safety device closed

This output is reset if the safety fence monitoring switch is opened (in AUTO
mode) or an enabling switch is released (in TEST mode).

PERI_RDY Drives ready

By setting this output, the robot controller communicates to the host computer
the fact that the robot drives are switched on.

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 Automatic external function

Output ROB_CAL & I_O_ACTCONF

Start condition

ROB_CAL Robot mastered

Signal is FALSE as soon as an axis has been unmastered

I_O_ACTCONF Interface active

The Automatic External interface is active. This signal is set to TRUE as soon as
the operating mode is switched to EXT.

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Output STOPMESS & PGNO_FBIT_REFL

Start condition

STOPMESS Collective fault

This output is set by the robot controller in order to communicate to the host
computer any message occurring which requires the robot to be stopped.
(e.g. EMERGENCY STOP, Motion enable, Operator safety, Command velocity,
etc.)

PGNO_FBIT_REFL
Mirrored output representing the first bit of the program number. If a program
selected by the PLC is deselected by the user, the output area starting with
PGNO_FBIT_REFL is set to FALSE. In this way, the PLC can prevent a
program from being restarted manually.

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Automatic external function

Output PRO_ACT & PGNO_REQ

Program status

PRO_ACT Program active

This output is always set if a process or the program execution is active at robot
level. The process is therefore active as long as a program or an interrupt is
being processed. Program processing is set to the inactive state at the end of the
program only after all pulse outputs and all triggers have been processed.

PGNO_REQ Program number request

A change of signal at this output requests the host computer to send a program
number. If the variable PGNO_TYPE has the value 3, PGNO_REQ is not
evaluated.

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Output APPL_RUN & PRO_MOVE

Program status

APPL_RUN Application running

By setting this output, the robot controller communicates to the host computer
the fact that a program is currently being executed.

PRO_MOVE Program motion active

Means that a synchronous axis is moving, including in jog mode. The signal is
thus the inverse of $ROB_STOPPED.

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 Automatic external function

Output IN_HOME & ON_PATH

Robot position

IN_HOME In HOME position

This output communicates to the host computer whether or not the robot is in its
HOME position.

ON_PATH Robot on the path

This output remains set as long as the robot stays on its programmed path. The
output ON_PATH is set after the BCO run. This output remains set until the robot
leaves the path, the program is reset or block selection is carried out. The
ON_PATH signal has no tolerance window, however; as soon as the robot
leaves the path the signal is reset.

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Output NEAR_POSRET & ROB_STOPPED

Robot position

NEAR_POSRET Robot near the path

This signal, NEAR_POSRET, allows the host computer to determine whether or
not the robot is situated within a sphere about the position saved in $POS_RET.
The host computer can use this information to decide whether or not the program
may be restarted.

ROB_STOPPED Robot not in motion

This signal is set if all the axes are in position, i.e. the robot is stationary. In the
event of a WAIT command, this output is set during the wait.

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Automatic external function

Operating mode output

Operating mode

Operating modes: T1 T2 AUT EXT

These outputs are set when the corresponding operating mode is selected.

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 Submit - Interpreter

11. Submit - Interpreter

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Submit - Interpreter

SPS.SUB - Meaning and purpose

The KRC has two internal tasks that run in parallel:

- Robot interpreter

- Controller interpreter

Robot operator and control tasks

Runs independently of the selected robot program

Cannot be used with time-critical applications

Examples: monitoring a cooling circuit or safeguard

This renders the use of an additional PLC unnecessary for smaller

applications as these tasks can be accommodated by the KRC.

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SPS.SUB - Programming

DEF
DEFSPS
SPS(()) Declaration section
for SUBMIT
DECLARATIONS
DECLARATIONS
Initialization section
INI
INI for SUBMIT

LOOP
LOOP
GRIPPERKEYS
GRIPPERKEYS
STATUSKEYS Submit interpreter
STATUSKEYS
programs that run
USER continuously in the
USER
background
ENDLOOP
ENDLOOP

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 Submit - Interpreter

SPS.SUB - Programming

Controller Robot

DEF
DEFSPS
SPS(())
...RUN
...RUN/R1/CELL(
/R1/CELL()) DEF
DEFCELL
CELL(())
LOOP
LOOP LOOP
LOOP
GRIPPERKEYS
GRIPPERKEYS CASE1 EXAMPLE1.SRC
CASE1
STATUSKEYS
STATUSKEYS
CASE2
CASE2 EXAMPLE2.SRC
USER
USER CASE3
CASE3 EXAMPLE3.SRC
ENDLOOP
ENDLOOP
ENDLOOP
ENDLOOP
SUBMIT 0 START SELECT
1 STOP

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SPS.SUB - Features

Only controller commands (e.g. $OUT[x]) can be used in SPS.SUB,

no motion commands.
Commands which are only to be executed once after running up the
system can be inserted before the LOOP.
Within the LOOP, calculations, monitoring or other actions can be
executed parallel to the robot process.
The LOOP is run cyclically (PLC philosophy) and should not be held
up by wait commands.

Caution: SPS.SUB must be stopped before it is edited.

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Submit - Interpreter

Frequently-used system variables in the Submit interpreter (1)

$MODE_OP

Value Explanation
#T1 Robot controller is in T1 mode

#T2 Robot controller is in T2 mode

#AUT Robot controller is in Automatic mode

#EX Robot controller is in Automatic External mode

#INVALID Robot controller has no defined state

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Frequently-used system variables in the Submit interpreter (2)

$OV_PRO = Value

Argument Data type Explanation

Value (%) INT Program override value

Programming example:
If the programmed velocity cannot be reached, output 2 remains set to
FALSE:

...
...
IF
IF(($MODE_OP
(($MODE_OP====#T1)
#T1)OR
OR($OV_PRO
($OV_PRO<<100))
100))THEN
THEN
$OUT[2] = FALSE
$OUT[2] = FALSE
ENDIF
ENDIF
...
...

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 Exercises

12. Exercises
Exercise: Creating a program sequence 170
Exercise: Recapitulation of TOOL/BASE calibration 173
Exercise: Navigator (Expert) and endless loop 175
Exercise: Simple data types 177
Exercise: Arrays with simple data types and counting loop 179
Exercise: Creating a structure Box 181
Exercise: Creating an enumeration type - ENUM color 183
Exercise: Subprograms with parameter transfer 184
Exercise: Data manipulation - Position calculation 186
Exercise: Motion programming Palletizing / Depalletizing 189
Exercise: System variable Timer Cycle time measurement 191
Exercise: Use of loops 193
Exercise: Program optimization / Program intelligence 195
Exercise: Automatic External 197

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Exercise: Creating a program sequence101

Exercise: Creating a program sequence101

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Break down the overall task into subtasks
Refine a rough breakdown
Create a program flowchart

Prerequisites:
Theoretical knowledge of the chapter Programming methodology

Necessary equipment:
Office PC with VISIO

Reading materials:
Training documentation:
Workbook Advanced Robot Programming Release 5.x Chapter Programming methodology
Task:
System description
The robots task is to remove plastic components from an injection molding machine. The components
are gripped using suction cups and stacked up on an indexing conveyor next to the injection molding
machine.

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 Exercise: Creating a program sequence101

Gate Injection molding machine

Gate 1

KUKA robot

Cell
Indexing conveyor

Procedure
Once the injection molding machine (IMM) has manufactured a part, gate 1 is opened. After checking
the limit switch, the robot moves to the unloading position and grips the part. The ejector pushes the part
out of the mold. The robot now moves out of the machine and the ejector is retracted. As soon as the
robot has moved safely out of the machine, gate 1 can be closed and a new part can be manufactured.

The finished part is now set down in the free space on the indexing conveyor. The indexing conveyor is
then moved until the setdown position is free again.

Input/output configuration

;+++++++++++ OUTPUTS ++++++++++++++

CLOSE TOOL GATE 1 $OUT[1]
RETRACT EJECTOR $OUT[2]
ADVANCE EJECTOR $OUT[3]
VACUUM ON $OUT[18]
VACUUM OFF $OUT[19]
INDEXING CONVEYOR ON $OUT[20]

;+++++++++++++ INPUTS +++++++++++++

TOOL GATE 1 OPEN $IN[1]
TOOL GATE 1 CLOSED $IN[2]
EJECTOR IS RETRACTED $IN[3]
EJECTOR FORWARD POSITION $IN[4]
MACHINE IN AUTOMATIC $IN[5]
VACUUM ACHIEVED $IN[9]
INDEXING CONVEYOR FREE $IN[10]

Tasks
Break the task down into appropriate program modules
Refine your preliminary task break-down
Create a program flowchart

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Exercise: Creating a program sequence101

What you should now know:

1. What demands are placed on a program?


2. What is meant by requirements specification?


3. What are the advantages of good legibility/structuring of a program?


4. What types of loop are available in the KUKA controller?


5. What must be taken into consideration when using comments?

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 Exercise: Recapitulation of TOOL/BASE calibration102

Exercise: Recapitulation of TOOL/BASE calibration102

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Tool calibration using the XYZ 4-Point and World 5D methods
Tool calibration by entering numerical values
Base calibration using the 3-point method

Prerequisites:
Theoretical knowledge of tool calibration
Theoretical knowledge of base calibration

Necessary equipment:
Pen 1 from the pen magazine

Reading materials:
Standard documentation:
Operating Handbook, chapter Start-up

Task:
Calibrating the gripper
Calibrate the TCP of the gripper using numeric input. Assign the tool number 3 and the name
gripper. The calibration data are: X=132.05, Y=171.3, Z=173.0, A=45, B=0, C=0
Payload gripper : M=6,68kg; X=23mm; Y=11mm; Z=41mm; A=25; B=87; C=123; JX=0 kgm;
JY=0,4 kgm; JZ=0,46 kgm

TCP of gripper
y

z x

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Exercise: Recapitulation of TOOL/BASE calibration102

Calibration of pen 1
Use the uppermost pen from the pen magazine and clamp it manually in the gripper. Calibrate the
pen using the XYZ 4-Point and ABC World 5D methods. Use the tool number 2 and the name
pen 1.
Calibration of the blue BASE
BASE number 2 is calibrated using pen 1 and the 3-point method. The name blue base is used.

What you should now know:

1. What are the advantages of using a work base on the table?


2. Where is the reference point for the calibration of a tool?


3. How many different BASE systems can KUKA software V5.x manage?


4. What is the difference between the ABC-World 5D and 6D methods?


5. Where is there an uncalibrated base (on delivery)?

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 Exercise: Navigator (Expert) and endless loop103

Exercise: Navigator (Expert) and endless loop103

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Creation of modules at Expert level
Linking of individual modules in a main program
Use of an endless loop

Prerequisites:
Theoretical knowledge of the Navigator at Expert level
Theoretical knowledge of the use of global subprograms
Theoretical knowledge of an endless loop

Fetch cube Set down cube

Necessary equipment:
Training cell

Reading materials:
Standard documentation:
Operating Handbook, chapter Start-up

Training documentation:
Workbook, chapter Navigator
Workbook, chapter Subprograms and functions Definition
Workbook, chapter Program execution control Loops

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Exercise: Navigator (Expert) and endless loop103

Task:
Procedure
Remove a cube from the cube magazine. The start and end position is the HOME position. Next,
place the cube back into the magazine. Both processes are then to be linked and left to run
continuously. Optimize the HOME position if necessary.
Task
Create two appropriate modules (Setdown_cube/Fetch_cube).
These are to be linked in the module MAGAZINE.
Before commencing programming, create a program flowchart
Test your program in the modes T1, T2 and Automatic. Observe the relevant safety instructions.

What you should now know:

1. What is the difference between selecting MODULE and EXPERT when creating a program?


2. What is meant by the program run mode ISTEP?


3. What is the difference between SELECTING a program and OPENING it?


4. What does the syntax for a Fold look like?


5. What are the consequences of subsequently changing the HOME position?

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 Exercise: Simple data types104

Exercise: Simple data types104

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Using simple data types
Declaration, initialization and use of variables
Correct use of variables with regard to their lifetime

Prerequisites:
Theoretical knowledge of simple data types and how they are handled

INT -4, -3, -2, -1, 0, +1, +2, +3

REAL -1.5, -1.0, 0, +1.02, +2.96

BOOL TRUE --- FALSE

CHAR A, b, C, X, 8, +

Necessary equipment:
Training cell

Reading materials:
Standard documentation:
Programming Handbook, chapter Expert Programming

Training documentation:
Workbook, chapter Variables and declarations Simple data types

Task:
Description
Expand the programs you have created to include the following:
A variable that counts the number of cubes transported since the last program selection.
A variable that saves the absolute number of all cubes transported so far.
A variable that adds up the combined weight (in kg) of all cubes transported. A cube weighs 0.329
kg.
A variable that is set to TRUE while the cube is being fetched and is otherwise set to FALSE.
A variable that contains the letter O when the gripper is open and the letter C when the gripper is
closed. In the undefined state, the variable is assigned the value X.

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Exercise: Simple data types104

Use appropriate variable names and data types. It is also important to declare the variable in the
correct place.

Task
Define where your variables are declared.
Expand your existing program flowchart to include these new variables.
Observe the different initializations of the variables.
Test your program in the modes T1, T2 and Automatic. Observe the relevant safety instructions.

What you should now know:

1. What is the maximum length of a variable name?


2. What simple data types are there?


3. Where are variables declared in the SRC file?


What is the lifetime of a variable declared in $CONFIG.DAT?


4. How do you declare a floating-point number with the name PAUL in the DAT file with the value
138.74?

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 Exercise: Arrays with simple data types and counting loop105

Exercise: Arrays with simple data types and counting loop105

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Declare and initialize arrays with simple data types
Process individual array elements
Work with the variable display (Configure/Show)

Prerequisites:
Knowledge of simple data types
Theoretical knowledge of arrays
Theoretical knowledge of the FOR loop
Theoretical knowledge of the variable display

Pre-initialization:
1 2 3 4 5 6 7 8 9 10 11 12

O O O O O O O O O O O O

Program execution:
1 2 3 4 5 6 7 8 9 10 11 12

X X X X X X O O O O O O

6 cubes set down

Necessary equipment:
Training robot cell

Reading materials:
Standard documentation:
Programming Handbook, chapter Expert Programming
Operating Handbook, chapter Operator control

Training documentation:
Workbook, chapter Variables and declarations Arrays

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Exercise: Arrays with simple data types and counting loop105

Task:
Description
Expand the program you have created to include the following:
Create a one-dimensional array of size 12. The contents of the individual boxes should be the
letters O and X.
Before the program is executed, the pre-defined content for all boxes should be the letter O
Once the first cube has been set down, the first box should receive the letter X. The same
procedure is to apply for each subsequent setdown operation.
Check the current array index and the contents of the array.

Task
Define where your variables are declared.
Expand your existing program flowchart to include this array.
Create a new group to display your required array variables.
Test your program in the modes T1, T2 and Automatic. Observe the relevant safety instructions.

What you should now know:

1. How is the size of an array defined?


2. What is the difference between declaring an array in the SRC file and declaring it in the DAT file?


3. What error message is generated if the array index is exceeded?


4. Declare a 3-dimensional array with the name Cabinet_price. The cabinet price is calculated from the
components length, width and depth. The range includes 5 different lengths, 3 different widths and 2
different depths.


5. What can be activated in the variable display by means of the softkey Start info?

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 Exercise: Creating a structure BOX_Type106

Exercise: Creating a structure BOX_Type106

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Create your own structures (declaration, initialization)
Work with the point separator

Prerequisites:
Theoretical knowledge of simple data types and structures

Necessary equipment:
Training robot cell

Reading materials:
Standard documentation:
Programming Handbook, chapter Expert Programming

Training documentation:
Workbook, chapter Variables and declarations Structures

Task:
Task
Create a program with the name Structure.
Generate a structure with the name BOX_Type. This structure is to be able to store the following
variables:
o Length
o Width
o Height
o Painted (yes/no)
o Number of bottles
Assign the structure BOX_Type to the variable CRATE and initialize it with the following start values:
o Length 25.2
o Width 18.5
o Height 5.0
o Contents: 4 bottles
o Not painted
In the first operation, a further 8 bottles are added to the crate. In the second step, the CRATE is
painted. Plan a wait time of 3 seconds between steps one and two.
Display the contents of the variable CRATE during program execution.

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Exercise: Creating a structure BOX_Type106

What you should now know:

1. What is a structure?


2. What predefined KUKA structures are there?


3. What is the difference between a POS structure and an E6POS structure?


4. Name a FRAME structure you already know.


5. What is a point separator?

182 / 198 Workbook MP3 01.06.03

 Exercise: Creating an enumeration type - ENUM color107

Exercise: Creating an enumeration type - ENUM color107

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Create your own ENUM variables (declaration)
Work with ENUM variables

Prerequisites:
Theoretical knowledge of simple data types and structures
Theoretical knowledge of simple ENUM variables

Necessary equipment:
Training robot cell

Reading materials:
Standard documentation:
Programming Handbook, chapter Expert Programming

Training documentation:
Workbook, chapter Variables and declarations ENUM

Task:
Task
Expand your program Structure to include the following:
Generate an ENUM variable containing the colors red, yellow, green and blue.
Create a variable with the name Lamp and assign it the color blue.
In the second step, assign the lamp the color yellow.
Expand your BOX_Type structure to include the aggregate Color and assign the following colors
to the CRATE: first red, then yellow, and finally green.
Display the contents of the variable CRATE during program execution.

What you should now know:

1. Who defines the number of constants and their names in the enumeration type ENUM?


2. When is the symbol # used?


3. What is wrong in the following declaration?
ENUM Day_type mo, di, mi, do, fr, sa, so

Workbook MP3 01.06.03 183 / 198

Exercise: Subprograms with parameter transfer108

Exercise: Subprograms with parameter transfer108

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Subprograms with transfer of parameters

Prerequisites:
Knowledge of working with subprograms
Theoretical knowledge of parameter transfer
Theoretical knowledge of functions

Necessary equipment:
Training robot cell

Reading materials:
Standard documentation:
Programming Handbook, chapter Expert Programming

Training documentation:
Workbook, chapter Subprograms and functions

Task:
Please complete the results following program execution.
Main program:
DEF var_transf( )
INT A, B, C, D, E, F
A=50
B=48
C=200
D=300
E=8
F=5
CALC (C, D, A, F, B, E)
;A = B = C =
;D = E = F =

END

Subprogram:
DEF CALC (X1:OUT, X2:IN, X3:OUT, X4:IN, X6:IN, X5:OUT)
INT X1, X2, X3, X4, X5, X6
; Calculation
X1 = X1+211 ; X1 =
X2 = X2-312 ; X2 =
X3 = X2 +X3 ; X3 =
X4 = X4 * X5 ; X4 =
X5 = X5 * 8 ; X5 =
X6 = X6 40 ; X6 =

END

184 / 198 Workbook MP3 01.06.03

 Exercise: Subprograms with parameter transfer108

What you should now know:

1. What is the maximum nesting depth for subprograms?


2. What DAT file is accessed by a local subprogram?


3. Where a variable is declared if it is to be recognized both in the global subprogram and in the main
program?


4. What command is used to transfer a return value from a function to the main program?


5. What is the difference, in parameter transfer, between IN parameter and OUT parameter?

Workbook MP3 01.06.03 185 / 198

Exercise: Data manipulation - Position calculation109

Exercise: Data manipulation - Position calculation109

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Work with arrays
Work with structures and the point separator
Calculate position coordinates
Use nested FOR loops

Prerequisites:
Knowledge of arrays, structures and the FOR loop
Theoretical knowledge of data manipulation

Necessary equipment:
Training robot cell

Reading materials:
Standard documentation:
Programming Handbook, chapter Expert Programming

Training documentation:
Workbook, chapter Variables and subprograms
Workbook, chapter Data manipulation

Task:

80 mm

80 mm START position

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 Exercise: Data manipulation - Position calculation109

1. Subtask: Calculation of setdown position

a. Description
Starting from the START position indicated in gray, calculate all the other positions on the table.
Cubes will later be set down in the calculated positions. The distances between the individual
setdown positions are 80 mm on all sides. Teach the START position by moving the robot, with the
cube clamped in place, to the position indicated in gray.
b. Tasks
Create a program flowchart for the task described.
Create suitable variables for the program CALCULATION. Use a module for program creation.
Initialize your variables with appropriate start values.
Calculate the 16 setdown positions on the worktable.

2. Subtask: Calculation of pre-position

a. Description
Additional positions are required for subsequent setdown operations. In addition to the setdown
positions, a pre-position is required for each cube. This position is 100 mm above the actual position
of the cube on the table.

Pre-position

Setdown position

b. Tasks
Expand your existing program flowchart to include this new function.
Expand your program CALCULATION to include this pre-position (declaration, initialization,
calculation).

Workbook MP3 01.06.03 187 / 198

Exercise: Data manipulation - Position calculation109

What you should now know:

1. Calculate the values for A, B, C, X, Y, Z:
INT X, Y, Z
REAL A, B, C
A= 4.5
B= -2
C= 4.1
X= 2.5
Y= 4
Z= 0.1
A= A * B + Y ;A=
B= B * Z + X ;B=
C= C + 4/3 ;C=
X= X + 2.5 * 4 ;X=
Y= Y 10.0/4 ;Y=
Z= 14 Z * C + A ;Z=

2. Calculate the values for O, P, Q:

INT O, P, Q
O= 11 B_OR 44 ;O=
P= 21 B_AND 18 ;P=
Q= 53 B_EXOR 35 ;Q=

3. Calculate the values for H, I, J, K:

BOOL T, F, H, I, J, K
T= TRUE
F= FALSE
H= (7/3 >2) AND T ;H=
I= (17-4*3>10) EXOR NOT T ;I=
J=NOT (T OR F) AND (F OR T) ;J=
K=NOT T OR F AND F OR T ;K=

188 / 198 Workbook MP3 01.06.03

 Exercise: Motion programming Palletizing / Depalletizing110

Exercise: Motion programming Palletizing / Depalletizing110

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Program motions without using inline forms.
Move the robot to calculated target coordinates.

Prerequisites:
Theoretical knowledge of motion programming without inline forms

Necessary equipment:
Training robot cell

Reading materials:
Standard documentation:
Programming Handbook, chapter Expert Programming

Training documentation:
Workbook, chapter Motion programming

Task:
Description
Duplicate your program CALCULATION with the new name Pallet.
Now that you have calculated the 16 setdown positions, it only remains to fetch the cube from the
magazine and set it down in the corresponding position on the table. Once all 16 cubes have been set
down, they should automatically be cleared away from the table. The cube that was set down first is also
to be cleared away first.

1st cube

16th cube

Workbook MP3 01.06.03 189 / 198

Exercise: Motion programming Palletizing / Depalletizing110

Tasks
Create a program flowchart for palletizing/depalletizing. A block with calculation is sufficient for
calculation of the coordinates.
Create a program for the entire operation.
Pack your calculation in suitable Folds.
Make appropriate use of existing modules.
Check the different variables in the variable display.
Test your program in the modes T1, T2 and Automatic. Observe the relevant safety instructions.

What you should now know:

1. What is set using the system variable $IPO_MODE?


2. What is specified as CA in circular motion?


3. What can be done using the command CONTINUE?


4. What must be taken into consideration when using the CONTINUE command?


5. What information is conveyed by Turn T22?

190 / 198 Workbook MP3 01.06.03

 Exercise: System variable Timer Cycle time measurement111

Exercise: System variable Timer Cycle time

measurement111
Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Work with a timer (initialize, start, stop).
Optimize cycle times.

Prerequisites:
Knowledge of the system variable $TIMER[x].

Necessary equipment:
Training cell

Reading materials:
Standard documentation:
Programming Handbook, chapter Expert Programming

Training documentation:
Workbook, chapter System variables

Task:
Description
Duplicate your program Pallet and rename it Time_measurement. You should record three times.
Timer 1 is to time the palletization and timer 2 is to time the clearing operation. Timer 3 calculates the
overall time of the two operations. Make sure that you do not start and stop the timer with the advance
run.

Task
Use $TIMER[1] for timer 1 and also save the final value in $TIMER[4]. Assign the description of
timer 1 the name Current palletization and assign the saved value the name OLD palletization.
$TIMER[2] is used for timer 2 and the value is saved in $TIMER[5]. Here, once again, appropriate
names are to be assigned in the display.
$TIMER[3] is used for timer 3 and the value is saved in $TIMER[6]. Here, once again, appropriate
names are to be assigned in the display.
Try to optimize your program.

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Exercise: System variable Timer Cycle time measurement111

Test your program in the modes T1, T2 and Automatic. Observe the relevant safety instructions.

What you should now know:

1. How many timers does the KUKA controller have and how are they started?


2. Give an example of a variable in $CONFIG.DAT.


3. Where are the variables for the software limit switches located?


4. What advantages does a CYCFLAG have over a FLAG?


5. How many CYCFLAGs are available in the KUKA controller?

192 / 198 Workbook MP3 01.06.03

 Exercise: Use of loops112

Exercise: Use of loops112

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Substitute FOR loops with other loops
Use WHILE or REPEAT/UNTIL loops

Prerequisites:
Theoretical knowledge of the functionality of the different loop techniques in programming

Necessary equipment:
Training robot cell

Reading materials:
Standard documentation:
Programming Handbook, chapter Expert Programming

Training documentation:
Workbook, chapter Program execution control

Task:
Description
In the program section Palletization, change the double FOR loop into two WHILE loops. During
depalletization, the existing loops are to be converted into REPEAT/UNTIL loops.

Task
Duplicate your program Pallet with the new name Pal_loop.
Update your existing program flowchart for the new loops.
Create new counting variables for your loops. Make sure that your variables are correctly initialized
or suitably reset.
Modify the way the cubes are cleared from the table so that the last cube cleared is the first one to
be picked up and set back down again.
Test your program in the modes T1, T2 and Automatic. Observe the relevant safety instructions.

Workbook MP3 01.06.03 193 / 198

Exercise: Use of loops112

What you should now know:

1. In connection with SWITCH/CASE, there is also a DEFAULT statement. What is the purpose of the
DEFAULT statement?


2. What command can you use with the FOR loop to set the increment?


3. What loops can be left using the EXIT command?


4. Which component can be omitted when using a branch?
a. IF
b. THEN
c. ELSE
d. ENDIF
5. What is wrong in the following example program?
IF $IN[14]==FALSE THEN
$OUT[12]=TRUE
GOTO MARK1
ELSE
$OUT[12]=FALSE
GOTO MARK2
WHILE $IN[17]==TRUE
PTP P1
MARK1:
...
ENDWHILE
MARK2:

PTP HOME

194 / 198 Workbook MP3 01.06.03

 Exercise: Program optimization / Program intelligence113

Exercise: Program optimization / Program intelligence113

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Program subprogram calls
Program an endless loop

Prerequisites:
Knowledge of the Navigator at Expert level
Knowledge of subprogram and loop programming

Necessary equipment:
Training robot cell

Reading materials:
Standard documentation:
Programming Handbook, chapter Expert Programming

Training documentation:
Workbook, chapter Variables and declarations
Workbook, chapter Program execution control

Task:
Description
Optimize your program Pal_loop by expanding it so that you can deselect it at any time and resume
program execution on restarting the program from the point at which it was stopped.

Task
Define in your program sequence whether you are palletizing or depalletizing.
Evaluate the state of the gripper (e.g: open $IN[26] / closed with cube $IN[29]) and resume the
program accordingly.
Check during initialization of the basic values whether this is necessary, or whether you wish to
continue working with the saved values.
Update your existing program flowchart for this new function.
Test your program in the modes T1, T2 and Automatic. Observe the relevant safety instructions.

Workbook MP3 01.06.03 195 / 198

Exercise: Program optimization / Program intelligence113

What you should now know:

1. Which variable is responsible for the advance run pointer?


2. How is a one-dimensional array transferred?
a. SUBPRG(VALUE(( ))
b. SUBPRG(VALUE[255])
c. SUBPRG(VALUE[ ])
d. SUBPRG(VALUE[x])
3. In which structure can you save the position of a robot with a two-axis positioner (2 external axes)?
a. POS
b. E6POS
c. AXIS
d. E6AXIS
e. FRAME
4. What is the correct syntax for a non-rejecting loop?

196 / 198 Workbook MP3 01.06.03

 Exercise: Automatic External114

Exercise: Automatic External114

Aim of the exercise:
On successful completion of this exercise, you will be able to carry out the following activities:
Targeted integration of a robot program into Automatic External operation
Adaptation of the Cell program
Configuration of the Automatic External interface
Recognition of sequence in Automatic External mode

Prerequisites:
Knowledge of how to edit the Cell program
Knowledge of how to configure the Automatic External interface
Theoretical knowledge of the signal sequence in Automatic External

Necessary equipment:
Training robot cell

Reading materials:
Standard documentation:
Programming Handbook, chapter Configuration

Training documentation:
Workbook, chapter Automatic External interface

Task:
Description:
You have individual functioning modules and these are to be made available to the Automatic External
interface.
Task
Configure the Automatic External interface to the requirements of your control panel.
Expand your Cell program by any three modules, the functions of which you have verified
beforehand.
Use buttons to simulate the functionality of the PLC.
Test your program in the modes T1, T2 and Automatic. Observe the relevant safety instructions.

Input 17

Photograph: Control panel at KUKA College for controlling Automatic External

Workbook MP3 01.06.03 197 / 198

Exercise: Automatic External114

What you should now know:

1. What is the precondition for PGNO_REQ not to be evaluated?


2. What signal is used to activate the drives and what must be taken into consideration?


3. Which Automatic External interface variable also influences jogging?


4. Which Fold in the CELL program checks the HOME position?


5. What are the preconditions for Automatic External mode?

198 / 198 Workbook MP3 01.06.03