SOFTWARE

KR C2

BendTech V 2.0

KUKA System Tech (KST)

Issued: 08 Jul 2004 Version: 00

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e Copyright KUKA Roboter GmbH
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.

PD Interleaf

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Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Diagram of plate handling sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Installing the hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.1 Configuration example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.3 Installation of linear encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.4 Connection X33 to the robot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Installing the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Uninstalling the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 BendTech configurator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1.1 Using the configurator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1.1.1 Modifying variable values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.1.2 Save data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.1.3 Load data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.1.4 Closing the configurator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 I/O interface assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.1 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.2 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.3 Sensor for checking whether two blanks are stuck together . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.4 Fast Measurement for option “Bending machine with resolver” . . . . . . . . . . . . . . . . . . . . . . . 19
3.2.5 Overview of the signal assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.6 Example of an exchange of signals between the robot and the press . . . . . . . . . . . . . . . . . . 21
3.3 Routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.1 BeamDownToMutePoint.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.2 BeamDownToClampPoint.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.3 BeamDownToBendEnd.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.4 BeamUp.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.5 CloseFoldTool.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.6 OpenFoldTool.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.7 StartBackGauges.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3.8 Example of an interface routine: robot to press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.4 Setting up the double plate measurement sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5 Base calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.6 TCP calibration for vacuum gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.7 User–defined grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.8 Plate parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.9 “Get stack” station parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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3.10 “Put stack” station parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.11 Palletizing pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.12 Synchronous robot/press motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.1 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.1.1 INIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1.2 GET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1.3 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1.4 CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.1.4.1 Parameter list for setdown offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1.4.2 Parameter list for pick–up offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1.5 APPROACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.1.5.1 Bending point parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1.5.2 Parameter list APDAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1.6 BEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1.6.1 Bending without additional parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1.6.2 Normal bending with parameter “Sensor” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.1.6.3 Complex bending processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.1.6.4 Bending with parameter “FOLD” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.1.6.5 Parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1.7 LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.1.8 REPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1.8.1 Bending point parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1.8.2 Parameter list for repositioning in the press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.1.9 PUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.2 Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3 Example program Palletize.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.3.1 Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.3.2 Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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 1 Introduction

1 Introduction
“BendTech” enables you to process metal sheets and plates in press brakes and seam
bending machines. The module provides additional inline forms for programming by the user.

1.1 Diagram of plate handling sequence

This illustration shows an example. The robot takes an unworked blank from a “get stack”
station, checks that no further blank is stuck to it, aligns the plate in a centering station and
loads it into the press. Once forming has been completed, the robot removes the plate from
the press and palletizes it on a “put stack” station.

5
2
3 4

8
1

Sequence diagram
1. Take blank from pallet (GET)
2. Measurement to check whether two blanks are stuck together (CHECK)
3. Align blank in centering station (CENTER)
4. Load into press (APPROACH)
5. Bend (BEND)
6. Optional repositioning (REPOSITION)
7. Repeat steps 4 to 6 for further bending sequences
8. Remove from press (LIFT)
9. Palletization of finished part on a stack (PUT)

4
PTP P4 PTP P5

3 CENTER APPROACH 5
PUT
BEND
PTP P3
REPOSITION
LIFT INIT
CHECK
2
PTP HOME

PTP P2

1 GET
PTP P1

1 “Get stack” station 2 Double plate check 3 Centering station

4 Press 5 “Put stack” station

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Motions in the press

The press mechanism consists of a lower formed part – the die – and the upper part – the
beam – which clamps the blank down onto the die. The robot moves the blank sideways into
the press until the back gauges (backstops) are detected by means of suitable switches. The
“top dead–center position” of the beam represents the starting position of the press motion.
From here, the beam moves downwards to the “mute point” where the robot can safely move
the blank in the press. The mute point is thus the wait position for the beam while the robot
moves the blank. Once the blank has reached the desired position, the beam moves
downwards to the clamp point. The robot can then bend the plate in the desired direction.
The beam then moves upwards releasing the plate. The “bottom dead–center position” is the
lowest point of the beam in the die. This is the lowest permissible point for bending motions.

3
4 5 9
8
6

8
7
10

11

1 Direction of motion of beam 7 Base of press

2 Top dead–center position of beam (TDC) 8 Robot suction gripper (from below or
above)
3 Opening angle γ of die 9 Direction of motion of gripper
4 Safety point (mute point) 10 Clamp point of beam
5 Bending motion of robot (circular) 11 Bottom dead–center position of beam
(BDC)
6 Back gauges with switches

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 1 Introduction (continued)

1.2 Safety instructions

The system may only be operated, maintained and repaired by personnel specially
trained for work on this system.

When operating or working on this system, the safety instructions in the chapter
[Safety] of the robot documentation and the safety instructions issued by the
bending press manufacturer must be observed!
Any injury to persons or damage to equipment resulting from the non–observance
of general safety instructions or instructions contained within this documentation
releases the manufacturer from his warranty obligations.

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2 Installation

2.1 Installation requirements

The “BendTech” software can be run on KR C2 controllers (KSS version 5.2). The option
“Bending machine with resolver” requires an RDC2 module.

2.2 Installing the hardware

2.2.1 Configuration example

1 KR C2 controller with software 5.2 and digital servo–electronics type C33

2 KUKA robot with Resolver Digital Converter type 2
3 RLC–FM cover (FM = fast measurement)
4 Sensor cable for synchronization (fast measurement cable)
5 Resolver cable
6 RLC unit (RDC – Linear Encoder Coupler)
7 Connecting cable from linear encoder to RLC unit
8 Linear encoder and coupling rod
9 Press beam

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 2 Installation (continued)

2.2.2 Components

Linear encoder and coupling rod

Example technical data for Heidenhain LS 629 1 Vptp

Output level Sinusoidal incremental signals 1 Vptp

Signal length 20 µm
(signal period)
Max. transversal velocity 1 m/s
Max. transversal velocity during bending 5.5 mm/s
process
Operating temperature 10 to 50 _C
Length measurements in mm 420, 620

Recommended technical data

Output level Sinusoidal incremental signals 1 Vptp +/– 5 % over the entire
measured distance
Signal length 20 µm to 1 mm
(signal period)
Max. transversal velocity during bending 5.5 mm/s
process
Operating temperature 10 to 50 _C

If the signal length differs from 20 µm, the following declaration in $Config.dat must be
modified:
DECL REAL BT_ENC_PERIOD=0.02
20 µm corresponds to 0.02 mm.

Connecting cable from linear encoder to RLC unit

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Resolver cable

Top of RLC–FM cover Underside of RLC–FM cover

Open RLC unit, top view

2.2.3 Installation of linear encoder

The linear encoder is to be installed vertically on a moving surface of the press using four
screws. One end of the coupling rod is connected to the linear encoder, the other end to a
fixed part of the press.

Ensure that both connections are parallel to the direction of motion of the press.

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 2 Installation (continued)

2.2.4 Connection X33 to the robot controller

The 24 V DC output O_RDC_MEAS_PULSE from the RDC is connected to the first five “fast
measurement” inputs.

X33, pin 1 0V
X33, pin 2 24 V DC
X33, pin 3 Fast measurement, input 1
X33, pin 4 Fast measurement, input 2
X33, pin 5 Fast measurement, input 3
X33, pin 6 Fast measurement, input 4
X33, pin 7 Fast measurement, input 5

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2.3 Installing the software

“BendTech” is installed from an installation CD. Start the program d:\Setup.exe. All the
necessary steps for installing “BendTech” are carried out automatically.
A resolver or a robot with an external axis can be included in the installation.

Option “Bending machine with resolver”

The current position of the press beam is communicated to the robot by a resolver. The robot
synchronizes its motion with that of the press. Activate this option if there is a resolver
connected to the main axis of the bending machine.

In addition to the resolver, a Resolver Digital Converter (RDC2) and a digital

servo–electronics module (DSE type 33) must also be installed.

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 2 Installation (continued)

Option “Robot with external axis”

A robot with a linear traversing motion increases the number of axes. Activate this option if,
for example, the robot is mounted on a linear unit (see below).

Once the software has been installed successfully, the KCP menu Technology contains the
new menu item BENDTech and the BendTech commands.

2.4 Uninstalling the software

The program C:\KRC_OPTION\Bendtech\Uninst\uninstall.exe is used to uninstall
the BendTech software.

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3 Configuration
The smooth, safe operation of BendTech is dependent on the correct setting of the
parameters.

3.1 BendTech configurator

The entries are made in the configurator (Configuration Editor), which is started via the
“Setup” menu.

When the configurator is started, the corresponding tab cards are displayed.

3.1.1 Using the configurator

The configurator allows you to view and edit the variables subdivided into:
– Inputs/Outputs (I/O interface)*
– Sensor (sensors for double plate measurement)*
– Base–Conf. (base calibration)*
– Gripper (TCP calibration for vacuum gripper)*
– Plate param. (dimensions of blanks)
– Stations (“Put stack”/“Get stack” stations)*
– Pal. pattern (palletizing pattern)*
– MADA (machine data)*

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 3 Configuration (continued)

3.1.1.1 Modifying variable values

The tab cards can only be edited in Expert mode! In User mode, the tab cards
marked * can only be viewed. An exception is made here for the plate parameters.
Corresponding comments are displayed in the message window.

Activate the relevant tab card if you wish to modify a variable. Move the yellow insertion mark
to the desired position using the arrow keys, then press the softkey “Change”. Enter a new
value and confirm the entry by pressing “Enter”.

If the insertion mark is positioned on a variable, the variable is displayed in the message
window along with all the possible input options. This comment is not displayed during
editing.

3.1.1.2 Save data set

Once all the variables have been modified, they must be saved.

Saves data in Opens a selection

$config.dat window and exports
data to any storage
medium

3.1.1.3 Load data set

Variables from external storage media are loaded by means of the status key “LOAD”.

3.1.1.4 Closing the configurator

To close the configurator, press the softkey “Exit” and confirm the subsequent dialog in the
message window.

BendTech will not work with the modified values until the variables have been saved
and the configurator has been closed.

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3.2 I/O interface assignment

The tab card “Inputs/Outputs” can be used to configure the digital interface.

3.2.1 Inputs

Inputs from gripper to robot

The robot gripper must be equipped with at least one part detection sensor (vacuum or
proximity switch) and one sensor for locating parts (proximity switch, ultrasound switch, laser
switch). Coding is also possible for each gripper for detecting incorrect grippers.
The gripper can work with up to four part detection sensors and up to two sensors for locating
parts. The number of sensors is set in the gripper structure. If only one sensor is used for
locating parts, the variables I_NO_PART_DETECTED1 and I_NO_PART_DETECTED2 must
be assigned to the same input.
I_VACUUM1: vacuum circuit 1: first vacuum circuit or proximity switch actuated
I_VACUUM2: vacuum circuit 2: second vacuum circuit or proximity switch actuated
I_VACUUM3: vacuum circuit 3: third vacuum circuit or proximity switch actuated
I_VACUUM4: vacuum circuit 4: fourth vacuum circuit or proximity switch actuated
I_GRIPPER_CODE: enables the system to check that the correct gripper is connected
I_NO_PART_DETECTED1: sensor 1 for search function on the gripper
I_NO_PART_DETECTED2: sensor 2 for search function on the gripper

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Inputs from press to robot

The inputs indicate the status of the press. The robot uses the switch inputs to detect the
position of the plate. Up to four switch inputs can be assigned to the switches I_SWITCH_1
to I_SWITCH_4. The first switch on the far left of the press must be assigned to the input
for switch 1.
I_SWITCH_1: switch 1, plate against back gauge (far left–hand side of press)
I_SWITCH_2: switch 2, plate against back gauge (second switch from left)
I_SWITCH_3: switch 3, plate against back gauge (third switch from left)
I_SWITCH_4: switch 4, plate against back gauge (fourth switch from left)
I_PUT_PLATE: press ready: press requests a plate
I_PRESS_CLAMP_POINT: press has reached clamp point
I_PRESS_MUTE_POINT: press has reached mute point
I_PRESS_TDC: press at top dead–center position
I_PRESS_BDC: press at bottom dead–center position

3.2.2 Outputs

Outputs from robot to gripper

O_NO_VACUUM1: deactivation of vacuum circuit 1
O_NO_VACUUM2: deactivation of vacuum circuit 2
O_NO_VACUUM3: deactivation of vacuum circuit 3
O_NO_VACUUM4: deactivation of vacuum circuit 4
O_BLOW: blow to release part or open gripper
O_SEPARATE_BLOW (BLOW To SEPARATE PART: ROBOT –> GET STACK)
is set if the robot is coming from the “get stack” station and the option “Separate” is selected
in the inline form “GET”. A compressed–air separator is activated for separating the blanks.

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Outputs from robot to press

The robot uses the outputs to control the press.
O_PRESS_DOWN: move the press beam down
O_PRESS_UP: move the press beam up
O_RELEASE_MUTE_POINT: release mute point
O_RELEASE_CLAMP_POINT: release clamp point
O_OUT_OF_PRESS: robot out of press area, motion enable from robot to press
O_NO_ALARM_STOP: no robot fault during bending motion

3.2.3 Sensor for checking whether two blanks are stuck together
Double plate measurement, or measurement for checking whether two blanks are stuck
together, can be carried out with an analog or digital sensor. The result of the measurement
is converted to a value in mm. The sensor settings are carried out in the tab card “Sensor”.
Analog sensor

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Digital sensor

I_THICK_SENSOR_MEASURED signals that a valid measured value is present at the sensor.

I_THICK_SENSOR_VALUE: analog or digital input for double plate measurement.

Outputs (from robot to sensor)

The output O_START_MEASUREMENT is used to start a double plate measurement.

Selection of the sensor type

Selection “analog” The number of the configured analog input (iosys.ini)
is entered under “TAddress”.
Selection “digital” The input number of the first bit of the input range occupied
by the sensor is entered under “Start” and the input number
of the last bit is entered under “End”.

3.2.4 Fast Measurement for option “Bending machine with resolver”

Outputs (from robot to RDC)
O_RDC_MEAS_PULSE Robot–internal signal for sensor operation,
resets the “external base” counter.

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3.2.5 Overview of the signal assignments

Digital input Signal declaration

1 SIGNAL I_VACUUM1 $IN[1]
2 SIGNAL I_VACUUM2 $IN[2]
3 SIGNAL I_VACUUM3 $IN[3]
4 SIGNAL I_VACUUM4 $IN[4]
5 SIGNAL I_NO_PART_DETECTED1 $IN[5]
6 SIGNAL I_NO_PART_DETECTED2 $IN[6]
7 SIGNAL I_THICK_SENSOR_CLOSED $IN[7]
8 SIGNAL I_SWITCH_1 $IN[8]
9 SIGNAL I_SWITCH_2 $IN[9]
10 SIGNAL I_SWITCH_3 $IN[10]
11 SIGNAL I_SWITCH_4 $IN[11]
12 SIGNAL I_PUT_PLATE $IN[12]
13 SIGNAL I_PRESS_CLAMP_POINT $IN[13]
14 SIGNAL I_PRESS_MUTE_POINT $IN[14]
15 SIGNAL I_PRESS_TDC $IN[15]
16 SIGNAL I_PRESS_BDC $IN[16]
17 – 24 SIGNAL I_GRIPPER_CODE $IN[17] TO $IN[24]

Analog input Signal declaration

1 SIGNAL I_THICK_SENSOR_VALUE $ANIN[1]

Digital output Signal declaration

1 SIGNAL O_NO_VACUUM1 $OUT[1]
2 SIGNAL O_NO_VACUUM2 $OUT[2]
3 SIGNAL O_NO_VACUUM3 $OUT[3]
4 SIGNAL O_NO_VACUUM4 $OUT[4]
5 SIGNAL O_OUT_OF_PRESS $OUT[5]
6 SIGNAL O_PRESS_DOWN $OUT[6]
7 SIGNAL O_RELEASE_MUTE_POINT $OUT[7]
8 SIGNAL O_PRESS_UP $OUT[8]
9 SIGNAL O_RDC_MEAS_PULSE $OUT[17]
10
11 SIGNAL O_RELEASE_CLAMP_POINT $OUT[11]
12
13 SIGNAL O_SEPARATE_BLOW $OUT[13]
14 SIGNAL O_BLOW $OUT[14]
15 SIGNAL O_CLOSE_THICK_SENSOR $OUT[15]
16 SIGNAL O_NO_ALARM_STOP $OUT[16]

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3.2.6 Example of an exchange of signals between the robot and the press
The press is at the top dead–center position TDC (I_PRESS_TDC=TRUE) and prompts the
robot to load a blank (I_PUT_PLATE=TRUE). The robot now loads the blank into the press,
using the “APPROACH” command, and sets the output O_OUT_OF_PRESS=FALSE. When
the plate is several centimeters away from the backstops, a one second pulse is generated
at the output O_PRESS_DOWN and the outputs O_RELEASE_MUTE_POINT=FALSE and
O_RELEASE_CLAMP_POINT=FALSE are set at the same time. The press then moves to the
mute point.

With the “BEND” command, a check is made to see if the back gauges (backstops) have
been reached. If the selected back gauges have not been actuated, the robot searches for
the back gauges using relative motions. If the back gauges are not found, an error message
is generated. If the back gauges have been actuated, the outputs
O_RELEASE_MUTE_POINT=TRUE and O_RELEASE_CLAMP_POINT=TRUE are set. The
press is then lowered to the clamp point. At the clamp point, the robot sets the output
O_PRESS_DOWN=FALSE in order to stop the press. The robot enables the press to pass the
clamp point by means of O_RELEASE_CLAMP_POINT=TRUE and starts the press motion by
means of O_PRESS_DOWN=TRUE. Using I_PRESS_BDC=TRUE, the press signals that it has
reached the end point of the bending motion. The robot stops the press with O_PRESS_DOWN
=FALSE. The outputs for the mute point O_RELEASE_MUTE_POINT=FALSE and the clamp
point O_RELEASE_CLAMP_POINT=FALSE are reset and the press is moved upwards by
means of the output O_PRESS_UP=TRUE (one second pulse). The robot now removes the
plate from the press and sets the output O_OUT_OF_PRESS=TRUE. The next bending
operation is carried out.

The exchange of signals can be freely programmed. Modules for the exchange of
signals are located in .../R1/TP/BENDTECH/

Example: robot with Weinbrenner press and Cybelec controller

O_NO_ALARM_STOP

I_PUT_PLATE
I_PRESS_TDC

O_PRESS_DOWN

I_PRESS_MUTE_POINT

O_RELEASE_MUTE_POINT

I_PRESS_CLAMP_POINT

O_RDC_MEAS_PULSE

O_RELEASE_CLAMP_POINT

I_PRESS_BDC

O_PRESS_UP

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3.3 Routines
3.3.1 BeamDownToMutePoint.SRC
The routine controls the motion of the press beam to the mute point. If no mute point has been
defined, no signals are exchanged in this routine. Programs with a defined mute point have
an advantage in terms of cycle times.

3.3.2 BeamDownToClampPoint.SRC
The routine controls the motion of the press beam to the clamp point. This is the position of
the beam where contact is just made with the blank. Make sure that the press communicates
with the robot at the end of this routine (I_PRESS_CLAMP_POINT=TRUE).

3.3.3 BeamDownToBendEnd.SRC
The routine controls the motion of the press beam to the end point of the bending motion.
The end point of the bending motion is the point at which the beam begins to move upwards
again. Make sure that the press communicates with the robot at the end of this routine
(I_PRESS_BDC=TRUE).

3.3.4 BeamUp.SRC
The routine controls the motion of the press beam to the top dead–center position. Make sure
that the press communicates with the robot at the end of this routine
(I_PRESS_TDC=TRUE).

3.3.5 CloseFoldTool.SRC
The routine closes the gripper and is executed if the option “FOLD” is selected in the inline
form “BEND”. Make sure that the press communicates with the robot at the bottom
dead–center position (I_PRESS_BDC=TRUE).

3.3.6 OpenFoldTool.SRC
The routine opens the gripper and is executed if the option “FOLD” is selected in the inline
form “BEND”. Make sure that the press communicates with the robot at the top dead–center
position (I_PRESS_TDC=TRUE).

3.3.7 StartBackGauges.SRC
The routine moves the back gauge of the press forwards and is executed if a negative value
(–1 to –100) has been selected for the parameter “Distance to backstops” in the inline form
“APPROACH”.

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3.3.8 Example of an interface routine: robot to press

Beam at top dead–center

position (TDC)

Back gauge with

switches

Def BeamDownTo MutePoint()

O_RELEASE_CLAMP_POINT=FALSE
O_RELEASE_MUTE_POINT=FALSE
O_PRESS_DOWN=TRUE
END

Result:

Beam at
safety point
(mute point)

Back gauge with

switches

Def BeamDownTo MutePoint()

O_RELEASE_MUTE_POINT=TRUE
O_RELEASE_CLAMP_POINT=FALSE
O_PRESS_DOWN=TRUE
END

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Result:

Beam at
clamp point

Back gauge with

switches

Def BeamDownTo MutePoint()

O_RELEASE_MUTE_POINT=TRUE
O_RELEASE_CLAMP_POINT=TRUE
O_PRESS_DOWN=TRUE
END

Result:

Beam at bottom
dead–center
position (BDC)

Back gauge with

switches

Def BeamDownTo MutePoint()

O_RELEASE_MUTE_POINT=FALSE
O_RELEASE_CLAMP_POINT=FALSE
PULSE (O_PRESS_UP,TRUE,0.3)
WAIT FOR NOT I_PRESS_BDC
O_PRESS_DOWN=FALSE
END

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3.4 Setting up the double plate measurement sensor

If two blanks are stuck together, this is detected by measuring the plate thickness. If the value
is too high, this means that two blanks were stuck together and have been measured
together. Calculation of the plate thickness dependent on the sensor values is carried out
using the following formula:
PLATE_THICKNESS[MM]=(BT_CHECK_FACTOR* ANALOG_SENSOR_VALUE)– BT_CHECK_OFFSET

Given that sensors have manufacturing tolerances and can thus measure incorrect values,
additional variables are included to compensate for these manufacturing tolerances.
Signal declaration for the analog sensor input
SIGNAL I_THICK_SENSOR_VALUE $ANIN[1]

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Signal declaration for the digital sensor input

SIGNAL I_THICK_SENSOR_VALUE $IN[37] TO $IN[53]

Variables for sensor parameters

BT_CHECK_OFFSET contains a tolerance value, or offset, which is output by the sensor, even
though the plate thickness should be zero.
REAL BT_CHECK_OFFSET=0.4682768
Calculation of BT_CHECK_OFFSET
Measurement is carried out without a plate and the value is entered in BT_CHECK_OFFSET.
BT_CHECK_FACTOR contains the tolerance value output by the sensor for a known reference
thickness.
REAL BT_CHECK_FACTOR = 0.7741751
Calculation of BT_CHECK_FACTOR
The sensor is calibrated using a reference plate. In order to determine the factor as
accurately as possible, it is advisable to carry out several measurements and calculate their
arithmetic mean. The calculated mean value is to be entered under BT_CHECK_FACTOR.

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Variables for program execution

BT_CHECK_NIO_HALT generates a stop if the measured value is too high, i.e. two blanks
are stuck together.
BT_CHECK_NIO_HALT=True stops the robot if the measured value is too high.
If the variable BT_CHECK_NIO_HALT=FALSE is set, the robot continues its motion and the
variable BT_CHECK_IO is polled. If the variable BT_CHECK_IO=False is set, the robot can
set the blank down at a defined point, for example, and resume the operation with the next
blank.

Example:

IF NOT BT_CHECK_IO THEN

PTP EM_SETDOWN
;release part

ENDIF

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3.5 Base calibrations

Essentially, the general rules for base calibration apply.

Information about this can be found in the Operating Handbook!

Before the program is put into operation, the bases of the following positions must be
calibrated using the 3–point method:
– “Get stack” station
– Centering station
– Press
– “Put stack” station
For this purpose, the tab card “Base–Conf.” is available in the configurator:

The following rules are to be observed here:

– The origin of the base is always situated in a corner
– The positive Z direction of the base always points upwards, perpendicular to the plate
– The positive X or Y directions are configured
by means of BT_Base_X_DIRECTION[x]

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 3 Configuration (continued)

Example #LENGTH
“Get stack” station
X of BASE_DATA[1] is aligned with the long side of the plate:
BT_BASE_X_DIRECTION[1] = #LENGTH

Example #WIDTH
“Get stack” station
X of BASE_DATA[1] is aligned with the short side of the plate:
BT_BASE_X_DIRECTION[1]=#WIDTH

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Example
Centering station
X of BASE_DATA[1] is aligned with the long side of the plate:
BT_BASE_X_DIRECTION[1]=#LENGTH

Example
Centering station
X of BASE_DATA[1] is aligned with the short side of the plate:
BT_BASE_X_DIRECTION[1]=#WIDTH

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Example
Calibration of the base at the bending press must always be carried out in the following
manner:
– Origin of the base is situated on the bending line
– Positive X direction points from right to left, along the bending line
– Positive Y direction points out from the bending press
– Positive Z direction points upwards
BT_BASE_X_DIRECTION=#NONE
BT_BASE_X_DIRECTION has no effect on the base of the bending press!

Example
Definition of the setdown points within a ”put stack” station: BT_BASE_X_DIRECTION
has no effect on the bases of the “put stacks”!
BT_BASE_X_DIRECTION[x]=#NONE

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3.6 TCP calibration for vacuum gripper

The general rules for robot tool calibration apply here. Information about this can
be found in the Operating Handbook!

Coordinate system and calibration of the vacuum gripper:

If you are using the calibration methods XYZ – 4 Point and XYZ – Reference:
–The TCP is situated exactly in the center of the suction gripper or plate.
If you are using the calibration methods ABC – 2 Point and ABC – WORLD:
–The positive Z axis points to the robot wrist (upwards).
–The positive Y axis is calibrated along the short side of the plate.
–The positive X axis is calibrated along the long side of the plate.

The load data for the calibrated suction grippers must be determined under load.

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3.7 User–defined grippers

There is no limit to the number of user–defined grippers that can be used.

This technology package uses exclusively user–defined grippers for the entire
program sequence. When the command “INIT” is executed, the selected user–
defined gripper is always written to TOOL_DATA[1] internally in the system.

The user–defined grippers BT_GRIPPER_DATA[..] are also configured in the tab card
“Gripper”.

The softkey “New” is used to insert a new user–defined gripper at the end of the table.

Variable Meaning
NAME Name of the user–defined gripper (max. 24 characters)
GRP_TOOL Tool data of the gripper
GRP_LOAD Load data of the gripper:
–M –1 – weight The mass of the gripper with a
plate is to be entered for M. If this value is set to –1, the
default values for the mass, center of gravity and
inertia for the corresponding robot type are used.
–CM{X 0.0, Y 0.0, Z 0.0, a 0.0, b 0.0, c 0.0} – center of
gravity. The center of gravity of the gripper with a plate
is to be entered for CM.
–J{X 0.0, Y 0.0, Z 0.0} – moments of inertia. The
moment of inertia with a plate is to be entered for J. The
moments of inertia can be calculated mathematically or
dynamically using the load data determination functions.

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VAC_CIRCUIT Vacuum circuit to be controlled:

#C1 Vacuum circuit 1
#C2 Vacuum circuit 2
#C3 Vacuum circuit 3
#C4 Vacuum circuit 4
#C12 Vacuum circuits 1 and 2
#C13 Vacuum circuits 1 and 3
#C14 Vacuum circuits 1 and 4
#C123 Vacuum circuits 1 to 3
#C234 Vacuum circuits 2 to 4
#C134 Vacuum circuits 1, 3 and 4
#C124 Vacuum circuits 1, 2 and 4
#C1234 Vacuum circuits 1, 2, 3 and 4
GRP_CODE Gripper code of the gripper used
(range of values: 0...255)
GRP_CODE=0 Gripper has no hardware code

Configuration procedure:
The gripper must first be calibrated using the tool calibration functions integrated into the
KR C... software. The required load data must have been determined under load.
– Select the gripper
– Select the tool
(These data are saved under GRP_TOOL and GRP_LOAD)
– Set the vacuum circuit to be controlled (VAC_CIRCUIT)
– Set the gripper code (GRP_CODE)

Example
BT_GRIPPER_DATA[1]={NAME[ ] “DEMO_GRIPPER ”, GRP_TOOL {x 0.0,y
0.0,z 190.0, a 0.0, b 180.0, c 0.0}, GRP_LOAD {M –1.0,CM {x 0.0,
y 0.0, z 0.0, a 0.0, b 0.0, c 0.0}, J {X 0.0,Y 0.0,z 0.0}},
VAC_CIRCUIT #C12,GRP_CODE 0}

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3.8 Plate parameters

The parameters for the plates used and for the finished parts are configured in the tab card
“Plate param.”:

The softkey “New” is used to insert a new data set for the plate parameters at the end
of the table.

Variable Meaning
NAME Name of plate, e.g. article number (max. 24 characters)
Raw plate Length Length of plate (mm)
Raw plate Width Width of plate (mm)
Raw plate Thickness Thickness of plate (mm)
Finished part Length Length of the finished part (mm)
Finished part Width Width of the finished part (mm)
Finished part Height Height of the finished part (mm)

Example: Data set for BT_PLATE_DATA[...]

BT_PLATE_DATA[1]={NAME[]“Blank_Floor_Tray ”,LENGTH 549,WIDTH
465,THICKNESS 0.9,BENT_LENGTH 470,BENT_WIDTH 397,BENT_HEIGHT
35.0}

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3.9 “Get stack” station parameters

The structure variable BT_GET_STACK_DATA[..] describes the properties for a “get stack”
station. The structure variable BT_GET_STACK_DATA[..] is an array which can be
expanded as required up to the maximum array size defined in MAXGETSTACK. By default,
the value for the array size MAXGETSTACK is set to 10.
The parameters for the “get stack” station BT_GET_STACK_DATA[..] are configured in the
tab card “Stations” (page “Get stack”):

The softkey “New” is used to insert a new data set for the “get stacks/put stacks” at
the end of the table.

Variable Meaning
NAME Name of the “get stack” station (max. 24 characters)
BASE No. Base index for the “get stack” station
(e.g. 1 –> BASE_DATA[1] )
(range of values: 1...16)
Stack Height Height of stack in [mm]
Offset Offset frame when fetching from the “get stack” station

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 3 Configuration (continued)

GET_STACK_OFFSET.X=0
GET_STACK_OFFSET.Y=0

GET_STACK_OFFSET.X

GET_STACK_OFFSET.X>0
GET_STACK_OFFSET.Y>0

GET_STACK_OFFSET.Y

Example: Data set for BT_GET_STACK_DATA[...]

BT_GET_STACK_DATA[1]={NAME[]“Pickup_position1 ”,BASE_NO
1,STACK_HEIGHT 230,SEARCH_COUNTER 2,ACT_STACK_HEIGHT
230,LAST_PICKUP_FRAME {x 273.9766,y 232.0035,z 3.739464,a
–0.00319786,b 0.0003579359,c –0.0008765379},GET_STACK_OFFSET {x
0.0,y 0.0,z 0.0,a 0.0,b 0.0,c 0.0},STATE_KNOWN FALSE}

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3.10 “Put stack” station parameters

The parameters for the “put stack” station are configured in the structure variable
BT_PUT_STACK_DATA[..]. The structure variable BT_PUT_STACK_DATA[..] is an
array which can be expanded as required up to the maximum array size defined in
MAXPUTSTACK. By default, the value for the array size MAXPUTSTACK is set to 10.
The parameters for the “put stack” station BT_PUT_STACK_DATA[..] are configured in the
tab card “Stations” (page “Put stack”):

The softkey “New” is used to insert a new data set for the “get stacks/put stacks” at
the end of the table.

Variable Meaning
NAME Name of the “put stack” station (max. 24 characters)
BASE No. Base index for the “put stack” station
(e.g. 1 –> BASE_DATA[1] )
(range of values: 1...16)
Stack Height Height of stack in [mm]
Offset Offset frame when setting down the bent parts

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 3 Configuration (continued)

Example: Data set for BT_PUT_STACK_DATA[...]

BT_PUT_STACK_DATA[1]={NAME[ ] “Setdown_station1 ”,BASE_NO 4,
STACK_HEIGHT 100, ACT_LAYER 1,ACT_CNT_PER_LAYER 1,PUT_STACK_OFF-
SET {x 0.0, y 0.0, z 0.0, a 0.0, b 0.0, c 0.0},STATE_KNOWN
FALSE, PUT_STACK_FULL FALSE}

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3.11 Palletizing pattern

The parameters for the palletizing pattern are configured in the structure variable
BT_PUT_METHOD_DATA[..]. The structure variable BT_PUT_METHOD_DATA[..] is an
array which can be expanded as required up to the maximum array size defined in
MAXPUTMETHOD. By default, the value for the array size MAXPUTMETHOD is set to 10.
The palletizing patterns BT_PUT_METHOD_DATA[..] are configured in the tab card “Pal.
pattern”:

The softkey “New” is used to insert a new palletizing pattern at the end of the table.

The setdown positions (max. 6) for the parts are programmed not in this data set,
but in the inline form “PUT”!

Variable Meaning
NAME Name of the palletizing pattern (max. 24 characters)
CNT_PER_LAYER Number of parts per layer (max. 6)
LAYER_RESET_COUNTER Number of parts after which offset palletizing is restarted
DEL_X_P1...6 Stack 1...6
Offset in X direction in [mm] relative to BASE of the
“put stack” station
DEL_Y_P1...6 Stack 1...6
Offset in Y direction in [mm] relative to BASE of the
“put stack” station
DEL_A_P1...6 Stack 1...6
Rotation relative to previously set down part [degrees]

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 3 Configuration (continued)

* The descriptions are also valid for DEL_X_P2 / DEL_Y_P2 / DEL_A_P2, i.e. the offset or
the rotations of the max. 6 stacks can be explicitly configured in a “put stack” station.
Y offset X offset
DEL_Y_P1 DEL_X_P1

Stack 1

Angle offset
DL_A_P2

Stack 2

Example: Palletizing pattern

BT_PUT_METHOD_DATA[1]={NAME[ ] “Demo PUT_METHOD 1 “,
CNT_PER_LAYER 2, LAYER_RESET_COUNTER 2, DEL_X 0, DEL_Y 0, DEL_A
90}

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3.12 Synchronous robot/press motion

The variables for the synchronous motion of the robot and press can be configured using the
tab card “MADA”.

In the case of synchronous motions with plate thicknesses in excess of 2.5 mm,
large forces may be generated with a risk of damage to the robot. The robot must
be programmed to move more slowly than the press and the vacuum must be
deactivated.

ROB_RAISE_TIME determines the time in seconds required by the robot to start the motion.
The value of ROB_RAISE_TIME depends on the robot type and controller. Experience shows
that this value is close to the value of $DEF_FLT_PTP [ms] (R1/Mada/$machine.dat).
WAIT_HYDRAULIC_ON determines the time in seconds after the start signal from the robot
before the press moves. This delay time is specific to the individual press and is caused by
the hydraulic system. The press is positioned, for example, at the clamp point and is started
by the robot. The value of WAIT_HYDRAULIC_ON depends on the press type and controller.
BEND_VEL_FACTOR The velocity at which the robot follows the plate is calculated internally
in the system. This factor can be used to reduce or increase the actual velocity. If
BEND_VEL_FACTOR is greater than 1, the robot follows the plate at a higher velocity. If the
factor is equal to 1, the motion is carried out at the calculated velocity. If the factor is less than
1, the bending motion is carried out at a lower velocity.
BT_RATIO influences the velocity and position of the robot during sensor–assisted motion.
A value is calculated internally in the system and determines what distance traveled by the
press beam corresponds to what angular rotation of the robot. BT_RATIO can be used to
influence this value. If a low value is selected for BT_RATIO, the robot moves faster and the
distance traveled is longer. If a higher value is selected, the robot moves more slowly and
the distance traveled is shorter. The factor can be programmed by calling the BEND SENSOR
command. Example: bending angle 90 degrees, press travel 3.6 mm; when the plate is bent
by 90 degrees, the robot is to follow the plate through 45 degrees. Robot angle = (180 –
bending angle) / 2 = 45 degrees. BT_RATIO = beam travel / robot angle = 3.6 mm / 45
degrees = 0.08 mm / degree.

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 3 Configuration (continued)

Example
BT_RATIO = 0.08
BEND SENSOR Matrix Width= 12 mm, KL= 400 mm, Probe= S12, Follow=
With vacuum BENDDATA23

BT_MATRIX_DATA[ ] / BT_STAMP_RADIUS In order to calculate the factor BT_RATIO,

the robot uses information from the die and the beam. These data are used when the BEND
SENSOR command is executed and are entered in the array BT_MATRIX_DATA[] and
BT_STAMP_RADIUS.
BT_MATRIX_DATA.W= tangential die width [mm]
BT_MATRIX_DATA.M_ANGEL= die angle [degrees]
BT_MATRIX_DATA.M_RADIUS= die opening radius [mm]
BT_STAMP_RADIUS= beam radius [mm]

Beam radius
Die width

Die
opening
radius Die angle

It is advisable to adapt the acceleration of the robot to that of the press in order to
optimize the synchronized motion. If the motion starts too quickly, the robot may
stop because the permissible acceleration is exceeded. If the motion stops too
abruptly, the robot may leave the path.

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4 Programming
4.1 Commands
The “BendTech” menu is available under “Technology”.

“Technology” can only be selected if a program has been opened or selected. The
keyswitch must not be in the “EXTERNAL” position.

INIT Initialize the basic parameters

GET Remove a plate from the “get stack” station
CHECK Measure the plate thickness
CENTER Align the plate in a centering station
APPROACH Move the plate into the press
BEND Bend, fold
LIFT Move the plate out of the press
REPOSITION Reposition the plate in the press
PUT Set down the finished part in a “put stack” station (palletizing function)

Collisions and resulting damage can be avoided by teaching mute points

(safety points) between the work stations.

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 4 Programming (continued)

Schematic representation of a processing sequence cycle

Initialize, get, center
INIT→ GET→ CHECK → CENTER
First bend
APPROACH→BEND
if next bend on same side of plate
→ REPOSITION → BEND
if next bend on other side of plate
LIFT → APPROACH →BEND
Set down plate
→PUT

4.1.1 INIT
“INIT” sets the basic parameters for all BENDTech commands and carries out the following
tasks:
– Reset all robot outputs
– Plate selection and plate parameter check
– Gripper selection and parameter check
– Check whether or not there is still a plate in the gripper. A message appears in the message
window. If desired, suction to the plate is released.
– Plate processing sequence
– Selection of the simulation mode

All BENDTech programs commence with the INIT command. “INIT” must be
inserted into the program manually.

Checking the basic parameters:

– The gripper selected in the selection box “Gripper=” must be configured.
– If a gripper with a coding connector is used, the code must match the gripper code of the
selected gripper. In the case of a gripper without coding, the gripper code is 0.
– The values for the plate length/width/thickness may not be less than 0.01.
If an error is detected when checks are carried out, program execution is aborted and a
program RESET is required.

Inline form for “INIT” command

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Parameter Meaning
Plate Selection: name of the plate
Gripper Selection: name of the gripper
First bend side First side to be bent (1...4)
Last bend side Last side to be bent (1...4)
DryRun TRUE Dry run without plate
FALSE Normal run with plate
Press signals Press signals are displayed if “dry run” = TRUE is set.
ON Simulation with press signals
OFF Simulation without press signals

Parameter “First bend side” (1...4)

The side specified in “First bend side” determines in vorgabe.src the orientation of the
blank relative to the centering table and the motion from the centering table to the press. The
value is saved in the global variable BT_FIRST_BEND_SIDE.

Example
PTP BEFORE_CENTERING_TABLE
SWITCH BT_FIRST_SIDE
CASE 1
PTP BEFORE_PRESS_SIDE_1
CASE 2
PTP BEFORE_PRESS_SIDE_2
CASE 3
PTP BEFORE_PRESS_SIDE_3
CASE 4
PTP BEFORE_PRESS_SIDE_4
ENDSWITCH

Parameter “Last bend side” (1...4)

The side specified in “Last bend side” determines in vorgabe.src the motion from the press
to the “put stack” station. The value is saved in the global variable BT_LAST_SIDE.

Example

SWITCH BT_LAST_SIDE
CASE 1
PTP BEFORE_PRESS_SIDE_1
CASE 2
PTP BEFORE_PRESS_SIDE_2
CASE 3
PTP BEFORE_PRESS_SIDE_3
CASE 4
PTP BEFORE_PRESS_SIDE_4
ENDSWITCH
PTP BEFORE_PUT_STACK_TABLE

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 4 Programming (continued)

4.1.2 GET
The “GET” command is used to fetch a blank from the “get stack” station. Various “get stack”
positions can be defined for the “get stack” station and “GET” can also be used to separate
a second stuck blank from the fetched blank. For the first blank, a search run is carried out
at reduced velocity to check whether the fetch operation functions as required. All
subsequent plates are fetched at increased velocity.

The search run is repeated after an E–STOP or opening of a safety gate.

Inline form for “GET”

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Overview of the “GET” parameters

Parameter Meaning
from Stack Selection of name of “get stack” position
Vel [m/s] Velocity at which plates are fetched (range of values: 0...2 m/s)
Acc [%] Acceleration for GET procedure (range of values: 0...100%)
Pal. Mode Palletizing mode:
TRUE Palletizing ON
FALSE Palletizing OFF
In the case of Pal.Mode=TRUE, axes 4 and 5 are moved to a defined
position before the GET sequence; in this position, the robot flange is
moved parallel to the plane of the robot base.
Separate Separation of second plate stuck to blank fetched
TRUE ON
FALSE OFF
GETDAT Name of parameter data set (only visible if Separate=TRUE)

“SEPARATE” parameter (optional)

If two plates are stuck together, they can be separated during execution of the “GET”
command at the “get stack” station by means of separating brushes, magnets or compressed
air. In the case of separating brushes, the gripper first moves the plate against these brushes
(X and Y offset) and then swivels about the defined “spin angle” to remove any additional
plate stuck to the plate. A dialog is opened for the required settings.

Parameter Meaning
X–Offset Offset value X (range of values: 0...20 mm)
Y–Offset Offset value Y (range of values: 0...20 mm)
Spin Angle [°] Specification of “spin angle” (range of values: 0...45 degrees)

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 4 Programming (continued)

Example of a motion with “SEPARATE”

4.1.3 CHECK
After the “GET” command, an external sensor is used to measure the plate thickness. If the
plate thickness is greater than that of a single plate, this indicates that a second plate is still
attached to the first.

Inline form for double plate check

Parameter Meaning
Tolerance + [mm] Positive tolerance for plate thickness
(permissible range of values: 0...10 mm)
Tolerance – [mm] Negative tolerance for plate thickness
(permissible range of values: 0...10 mm)

Example
Thickness of plate = 1 mm
Tolerance + = 0.2 mm
Tolerance – = 0.2 mm
Plate thickness in the tolerance range = 0.8 to 1.2 mm

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4.1.4 CENTER
The robot places the blank in the centering station and releases it. The plate drops into a
defined position and is then picked up again by the robot. Offset values can be configured
for both the setting down and the picking up of the plate.

Centering station coordinate system

Inline form for the centering function

Parameter Meaning
on BASE Centering station base selection (1...16)
Vel [0...2 m/s] Centering velocity (range of values: 0...2 m/s)
Acc [0...100%] Centering acceleration (range of values: 0...100%)
CTDAT Name of parameter data set

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4.1.4.1 Parameter list for setdown offset

Parameter Meaning
X–Offset X offset for setdown (0...100 mm)
Y–Offset Y offset for setdown (0...100 mm)

X offset Y offset

Example
X offset = 40 mm
Y offset = 40 mm
When the plate is set down, it is dropped onto the centering table with an offset of
40 mm in the X and Y directions relative to the origin of the base.

4.1.4.2 Parameter list for pick–up offset

Parameter Meaning
X–Offset X offset for pick–up (0...100 mm)
Y–Offset Y offset for pick–up (0...100 mm)

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Gripper

X offset Y offset

Example
X offset = 0 mm
Y offset = 0 mm
The blank is picked up with the gripper positioned centrally.

Example
X offset = 20 mm
Y offset = 40 mm
The plate is gripped with an offset of 20 mm in the X direction and 40 mm in the Y
direction relative to the BASE of the centering table.

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 4 Programming (continued)

4.1.5 APPROACH

“APPROACH” is used to prepare for the “BEND” command. “APPROACH” moves the blank
to the press. Coordinates defined in the parameters are approached singly, because it is not
possible to teach the individual motions. Subsequent points must be measured and entered
in the parameter list of the “BEND” command.

1
2
3

5
4

6
7

1 Distance to backstops 2 Distance to press 3 Bending point

4 Height before hard end 5 Height in press 6 Base of press
7 Backstops position

Parameter Meaning
Distance to press Range of values: 100 to 1000 mm
Height in press Range of values: 10 to 100 mm
Height before hard end Range of values: 0 to 400 mm
Distance to backstops Range of values: 0 to 100 mm
Backstops position Range of values: 0 to 100 mm
Press down Delay Advance time delay* for the “Press down” signal
(range of values: –2000 to 0 ms)
* If no value is specified, the press moves from the top dead–center position to the mute point
when the plate has reached the back gauges (backstops). If the press is to move sooner,
then a value must be entered.
Inline form for “APPROACH” command

Bending point; this name is freely selectable

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The bending point must be the first point programmed.

Parameter Meaning
Bending point Name of the taught position at the stops in the press
Vel [m/s] Velocity at which the press is approached
(range of values: 0 to 2 m/s)
Acc [%] Acceleration when approaching the press
(range of values: 0 to 100%)
APDAT Name of parameter data set

4.1.5.1 Bending point parameter list

Parameter Meaning
Base Base coordinate system of the press (1...16)

4.1.5.2 Parameter list APDAT

The remaining defined distances are entered in the parameter list. The values are either
known or must be measured.

Height in press [mm] Range of values 10 to 1000 mm (see diagram)

Height before hard end [mm] Range of values 10 to 1000 mm (see diagram)
Distance to backstops [mm] Range of values –100 to 100 mm (see diagram)
Backstops position [mm] Range of values 0 to 100 mm (see diagram)
Press down Delay Advance time delay for “Press down” (range of values: –2000 to 0 ms)

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 4 Programming (continued)

With the specified parameters, the programmed sequence runs as follows:

Position 1: plate has reached “Distance to press” with “Height in press” and moves down

Position 2: with “Distance to press”, the plate reaches “Height before hard end” and moves
toward the back gauges

Position 3: plate has reached “Distance to backstops” and moves down to rest on the die

Position 4: “Distance to backstops”, plate is positioned on die and moves to the bending point

Position 5: plate against back gauges and on die

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4.1.6 BEND

4.1.6.1 Bending without additional parameters

“BEND” allows two further parameters for the bending operation. In the case of bending
without parameters, a simple bend is formed in the plate. The robot synchronously tracks
the resulting motions of the plate. At the end of the operation the press returns to the starting
position.

The plate is loaded and the beam moves down.

The plate bends under the pressure of the beam.

Inline form for the function “BEND”

Parameter Meaning
Bend Selection box without entry: Bend
Matrix Width [mm] Opening of die (range of values: 0.0 to 100.0 mm)
Bend Angle [deg] Bend angle [degrees] (range of values: 30.0 to 180.0 degrees)
Press Vel [mm/s] Velocity at which the press moves down (range of values: 0.0 to
10.0 mm/s)
KL [mm] Distance to be covered by the robot on the linear unit during the
bending motion (range of values –6000 to 6000 mm)
Probe Switches to be monitored during positioning:
NONE All switches are ignored
S1 Monitoring: switch 1
S2 Monitoring: switch 2
S3 Monitoring: switch 2
S4 Monitoring: switch 4
S12 Monitoring: switches 1 & 2
S23 Monitoring: switches 2 & 3
S34 Monitoring: switches 3 & 4
S123 Monitoring: switches 1 to 3
S234 Monitoring: switches 2 to 4
S1234 Monitoring: switches 1 to 4

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Parameter Meaning
Follow OFF Robot does not move during the bending
motion. Pick–up position of the plate must be
programmed.

With vacuum Robot moves synchronously along a circular

path with the vacuum switched on during the
bending motion.

Without vacuum Robot moves synchronously along a circular

path with the vacuum switched off during the
bending motion. On completion of bending,
the vacuum is switched back on.
BENDDAT Name of parameter data set

BEND MatrixWidth= 6 mm, Bend Angle= 90 [deg], Press Vel= 7 mm/s,

Probe= S12
Follow= With vacuum BENDDAT1
BT_PUT_METHOD_DATA[1].LAYER_RESET_COUNTER=3
BT_PUT_METHOD_DATA[1].DEL_X_P1=0 mm
BT_PUT_METHOD_DATA[1].DEL_Y_P1=0 mm
BT_PUT_METHOD_DATA[1].DEL_A_P1=10 degrees

4.1.6.2 Normal bending with parameter “Sensor”

Bending with sensor corresponds to “Bending without additional parameters” with the
difference that the parameters “Bend Angle” and “Press Vel” no longer need be entered.
These parameters are calculated from the data that are read from the resolver on the press
in real time. The robot performs the motion with the calculated parameters.
Inline form for the function “BEND”

Parameter Meaning
Bend Selection box: normal bending (no entry) / folding (FOLD) / normal
bending with sensor (SENSOR)
Matrix Width [mm] Opening of die (range of values: 0.0 to 100.0 mm)
KL [mm] Distance to be covered by the robot on the linear unit during the
bending motion (range of values –6000 to 6000 mm)
Probe Switches to be monitored during positioning:
NONE All switches are ignored
S1 Monitoring: switch 1
S2 Monitoring: switch 2
S3 Monitoring: switch 2
S4 Monitoring: switch 4
S12 Monitoring: switches 1 & 2
S23 Monitoring: switches 2 & 3
S34 Monitoring: switches 3 & 4
S123 Monitoring: switches 1 to 3
S234 Monitoring: switches 2 to 4
S1234 Monitoring: switches 1 to 4

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Follow OFF Robot does not move during the bending

motion. Pick–up position of the plate must be
programmed.

With vacuum Robot moves synchronously along a circular

path with the vacuum switched on during the
bending motion.

Without vacuum Robot moves synchronously along a circular

path with the vacuum switched off during the
bending motion. On completion of bending, the
vacuum is switched back on.
BENDDAT Name of parameter data set

If the distance KL is traveled in sensor mode, the velocity can be adapted using the
parameter KL_TIME.
Example:
KL_TIME = 0.5 ; auxiliary motion is to be executed within 0.5 s.

4.1.6.3 Complex bending processes

In the case of complex bends, it is advisable to break the bending process down
into several steps.

A 60 degree bend, for example, can be broken down into two bends: bend 1: 180 degrees
to 90 degrees; bend 2: 90 degrees to 60 degrees. The angle to be programmed must be
calculated:
Example, bend 1: 180 degrees to 90 degrees
BEND MatrixWidth= 6 mm, Bend Angle= 90 [deg], Press Vel= 7 mm/s,
Probe= S12
Follow= With vacuum BENDDAT1
Example, bend 2: 90 degrees to 60 degrees
BEND MatrixWidth= 6 mm, Bend Angle= 150 [deg], Press Vel=
3 mm/s, Probe= none
Follow= With vacuum BENDDAT1

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 4 Programming (continued)

Folding with the BEND command

“BEND” can also be used, for example, to press flat a 30 degree bend. To do this, the
press base must be rotated.
Example, bend 1: 180 degrees to 30 degrees
BEND with base_data[1]
BEND MatrixWidth= 6 mm, Bend Angle= 30 [deg], Press Vel= 7 mm/s, Probe= S12
Follow= With vacuum BENDDAT1

BASE_DATA[x] for the folding motion is calculated from the press base.
BASE_DATA[2]=BASE_DATA[1]:{X 0,Y 0,Z 0, A 180,B 0,C 0}
BASE_DATA[2]=BASE_DATA[2]:{X 0,Y 0 5,Z 2.5, A 0,B 0,C 0}
Press flat 30 degrees to 0 degrees; BEND with BASE_DATA[2]
BEND MatrixWidth= 6 mm, Bend Angle= 120 [deg], Press Vel 3 mm/s, Probe= NONE
Follow vacuum BENDDAT2

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BASE_DATA[x] for the folding motion is calculated from the press base.
BASE_DATA[2]=BASE_DATA[1]:{X 0,Y 0,Z 0, A 180,B 0,C 0}
Press flat 30 degrees to 0 degrees; BEND with BASE_DATA[2]
BEND MatrixWidth= 6 mm, Bend Angle= 120 [deg], Press Vel 3 mm/s, Probe= NONE
Follow vacuum BENDDAT2
4.1.6.4 Bending with parameter “FOLD”
The “BEND” command with the parameter “FOLD” is used to press a fold flat.

Inline form for the function “BEND” with the parameter “FOLD” selected

Parameter Meaning
Bend Selection: no entry selected (normal bending) / FOLD (folding)

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 4 Programming (continued)

Parameter Meaning
Probe Back gauge switches to be monitored during positioning:
NONE All switches are ignored
S1 Monitoring: switch 1
S2 Monitoring: switch 2
S3 Monitoring: switch 3
S4 Monitoring: switch 4
S12 Monitoring: switches 1 & 2
S23 Monitoring: switches 2 & 3
S34 Monitoring: switches 3 & 4
S123 Monitoring: switches 1 to 3
S234 Monitoring: switches 2 to 4
S1234 Monitoring: switches 1 to 4
Follow With vacuum During the folding procedure, the robot holds the
plate firmly in place. Vacuum is active.

Without vacuum Robot releases vacuum on the plate when the press
reaches the clamp point. Vacuum off.
BENDDAT Name of parameter data set

4.1.6.5 Parameter list

Parameter Meaning
Base Matrix BASE of die (1...16)
Regrip Regrip function*:
TRUE The press stops at the end of the bending
procedure and does not move back up. Vacuum is
switched off and motion to new gripping position
must be programmed by operator.
FALSE Press moves up after bending procedure. Robot
keeps hold of the plate in the gripper, vacuum
stays on.

*With the regrip function it is possible for the robot to grip the plate in a new position
following a bending procedure.

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4.1.7 LIFT
On completion of the press procedure, the robot lifts the plate a configured distance out of
the press die. The plate is then removed completely from the die and can be transported
further.

Inline form for the LIFT command

Parameter Meaning
Up [mm] Distance the robot moves upwards (Z direction relative to the BASE of
the press); range of values: 0 to 150 mm
Out [mm] Distance the robot moves out of the press (Y direction relative to the
BASE of the press); range of values: –50 to 500 mm
Vel [m/s] Velocity when moving out of the press; range of values: 0 to 2 m/s
Acc [%] Acceleration when moving out of the press; range of values: 0 to 100%
Wait for Wait option
TDC Wait for the press TDC (top dead–center position)
signal as trigger for starting the robot motion
TIME Motion is started after the delay time specified in
“sec”.
SENSOR Wait for signal from press beam; upward motion with
linear sensor
sec Delay time for the start of the motion when the press beam moves
upwards; range of values: 0 to 10 s
The input box is only displayed if WAIT for TIME is selected.
Matrix BASE No. Selection list for the base of the press (1...16)

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Up
Out Press procedure complete,
plate can be removed

Plate moves up out of the die

Out by the distance specified in the
Up
parameter “Up”

Out Plate moves out of the press

Up
by the distance specified in
the parameter “Out”

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4.1.8 REPOSITION
“REPOSITION” makes it possible to reposition the robot following the bending procedure.
Repositioning is necessary if more than one bend must be carried out on the same side of
the plate.

Bending
point

Parameter Meaning
Bending point Selection of the name of the bending point at the stops in the press
Vel [m/s] Velocity when moving to the bending point
(range of values: 0 to 2 m/s)
Acc [%] Acceleration when moving to the bending point
(range of values: 0 to 100%)
REPOSDAT Name of parameter data set

4.1.8.1 Bending point parameter list

If the focus in the inline form is placed on the input box for the bending point name, the
parameter list for the selection of the BASE on the press is displayed. The bending point is
programmed using the “TouchUp” function.

Parameter Meaning
Base Base of the press (1...16)

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4.1.8.2 Parameter list for repositioning in the press

ÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇ
ÇÇ
ÇÇÇÇÇÇÇÇÇ
ÇÇ
Distance to backstops
ÇÇÇÇÇÇÇÇÇ
ÇÇ
Back gauges (backstops) ÇÇÇÇÇÇÇÇÇ
Ç Ç
Height before hard end

Bending point Backstops

position

Parameter Meaning
Height before hard end [mm] Vertical distance between the top of the die and the
underside of the plate, represents the intermediate
position in the press (range of values: 0 to 400 mm)
Distance to backstops [mm] Distance between the back gauges and the forward
edge of the plate, represents the intermediate position
in the press (range of values: 0 to 100 mm)
Backstops position [mm] Distance between the back gauges and the center of
the die (range of values: 0 to 1000 mm)
Press down Delay [ms] The delay time for the “Press down” signal can be
used to specify the advance time for the signal. The
beam starts to move from the top dead–center
position (TDC) before the plate has been positioned
against the back gauges (range of values: –2000 to
0 ms)

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First press sequence

complete, beam moves
up

Plate is lifted to
“Height before hard
end”

Circular motion of
gripper until plate
horizontal on die

Part moved in as far

as “Distance to
backstops”.

Part is lowered onto the

die again

Move to back gauges,

second press sequence
started

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4.1.9 PUT
“PUT” transports the finished parts to the “put stack” station and sets them down there. It is
possible to use more than one “put stack” station. For each “put stack” station, a maximum
of six setdown positions can be defined and a palletizing method can be selected (in
$config.dat).

At the same time, a corresponding softkey bar appears at the bottom of the screen:

The robot must be moved manually to the relevant position and the point taught.

Pressing one of the softkeys offered causes a name to be assigned to the setdown position.
In the following example, Position 2 is selected:

A request for confirmation is then generated:

If this is answered by pressing the softkey “Yes”, the position is saved as a setdown point
(in this example “P2”).

Parameter Meaning
on Stack Selection of name of “get stack” station
using put method Selection of the name of the palletizing pattern to be used for
stacking the plates in the station
Pal.Mode Palletizing mode:
TRUE ON
FALSE OFF
In the case of Pal.Mode=TRUE, axes 4 and 5 are moved to a
defined position before the GET sequence; in this position, the robot
flange is moved parallel to the plane of the robot base.
Positions Point name for the programmed setdown position. The number of
input boxes displayed depends on the number of parts in the
palletizing pattern (max. 6).
(Variable: BBT_PUT_METHOD_DATA.CNT_PER_LAYER)
Vel [m/s] Velocity when moving to the setdown point (values: 0 to 2 m/s)
Acc [%] Acceleration when moving to the setdown point (values: 0 to 100%)

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Coordinate system for a “put stack” station with four setdown positions:

Stacking examples
Several different setdown variants are illustrated below. Offset values only ever apply
within a stack. If several stacks are to be created, a corresponding number of setdown
positions must be programmed.

One setdown position / stacking with offset A

BT_PUT_METHOD_DATA[1].CNT_PER_LAYER=1
BT_PUT_METHOD_DATA[1].LAYER_RESET_COUNTER=3
BT_PUT_METHOD_DATA[1].DEL_X_P1=0 mm
BT_PUT_METHOD_DATA[1].DEL_Y_P1=0 mm
BT_PUT_METHOD_DATA[1].DEL_A_P1=10 degrees

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One setdown position / stacking with offset X and offset Y

BT_PUT_METHOD_DATA[1].CNT_PER_LAYER=1
BT_PUT_METHOD_DATA[1].LAYER_RESET_COUNTER=3
BT_PUT_METHOD_DATA[1].DEL_X_P1= –10 mm
BT_PUT_METHOD_DATA[1].DEL_Y_P1= +10 mm
BT_PUT_METHOD_DATA[1].DEL_A_P1=0 degrees

Two setdown positions / stacking with offset X

BT_PUT_METHOD_DATA[1].CNT_PER_LAYER= 2
BT_PUT_METHOD_DATA[1].LAYER_RESET_COUNTER= 3
BT_PUT_METHOD_DATA[1].DEL_X_P1= –20 mm
BT_PUT_METHOD_DATA[1].DEL_Y_P1= 0 mm
BT_PUT_METHOD_DATA[1].DEL_A_P1= 0 degrees
BT_PUT_METHOD_DATA[1].DEL_X_P2= 0 mm
BT_PUT_METHOD_DATA[1].DEL_Y_P2= 0 mm
BT_PUT_METHOD_DATA[1].DEL_A_P2= –5 degrees

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Three setdown positions / stacking without offset

BT_PUT_METHOD_DATA[1].CNT_PER_LAYER= 3
BT_PUT_METHOD_DATA[1].LAYER_RESET_COUNTER= 1
BT_PUT_METHOD_DATA[1].DEL_X_P1=0 mm
BT_PUT_METHOD_DATA[1].DEL_Y_P1=0 mm
BT_PUT_METHOD_DATA[1].DEL_A_P1=0 degrees
BT_PUT_METHOD_DATA[1].DEL_X_P2=0 mm
BT_PUT_METHOD_DATA[1].DEL_Y_P2=0 mm
BT_PUT_METHOD_DATA[1].DEL_A_P2=0 degrees
BT_PUT_METHOD_DATA[1].DEL_X_P3=0 mm
BT_PUT_METHOD_DATA[1].DEL_Y_P3=0 mm
BT_PUT_METHOD_DATA[1].DEL_A_P3=0 degrees

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 4 Programming (continued)

4.2 Program example

The following program example illustrates step by step the sequence for a complete bending
cycle.
INI

; Initialization for the bending cycle

INIT Plate= Blank_Floor_Tray Gripper= Demo_Gripper First bend side= 1 Last bend
side= 4 Dry run= TRUE Press signals= OFF

; Move to intermediate position above “get stack” station

PTP TO_GET_STACK1 CONT Vel=100 % PDAT1 Tool[1]:Tooldata Demo_Gripper
Base[1] Get_Stack

; Fetch blank from the support at Position 1

GET from Stack= Support Position 1 Vel=1.5 m/s, Acc=10 % Pal. Mode= FALSE
Separate= FALSE

; Intermediate positions for the motion into the double plate check station
LIN TO_CHECK1 CONT Vel=2 m/s CPDAT9 Tool[1]:Tooldata Demo_Gripper
Base[1]Get_Stack
LIN TO_CHECK2 CONT Vel=2 m/s CPDAT9 Tool[1]:Tooldata Demo_Gripper
Base[1]Get_Stack

; Double plate check

CHECK Tolerance + = 0.1 mm, Tolerance – = 0.1 mm

; Intermediate position before the centering station

PTP TO_CENTER1 CONT Vel=100 % PDAT5 Tool[1]:Tooldata Demo_Gripper Base[2]
Centering Base

; Centering of the plate

CENTER on BASE= [2] Centering Base Vel= 1.5 m/s, Acc=100 % CTDAT

; Intermediate position for the motion to the press

PTP TO_PRESS1 CONT Vel=100 % PDAT9 Tool[1]:Tooldata Demo_Gripper Base[2]
Centering Base

; First bend
APPROACH P_BEND1 Vel=1.5 m/s, Acc= 100 % APDAT1
BEND Matrix Width= 6 mm, Bend Angle= 90 [deg], Press Vel= 7 mm/s, Probe= S12
Follow= With vacuum BENDDAT
LIFT Up 10 mm, Out= 100 mm, Vel=1.5 m/s, Acc= 100 % Wait for TDC Matrix BASE
No. = [3] Press Base

PTP TO_BEND21 CONT Vel=100 % PDAT10 Tool[1]:Tooldata Demo_Gripper Base[3]

Press Base

; Second bend
APPROACH P_BEND2 Vel=1.5 m/s, Acc= 100 % APDAT1
BEND Matrix Width= 6 mm, Bend Angle= 90 [deg], Press Vel= 7 mm/s, Probe= S12
Follow= With vacuum BENDDAT
LIFT Up 10 mm, Out= 100 mm, Vel=1.5 m/s, Acc= 100 % Wait for TDC Matrix BASE
No. = [3] Press Base

PTP TO_BEND31 CONT Vel=100 % PDAT10 Tool[1]:Tooldata Demo_Gripper Base[3]

Press Base

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; Third bend
APPROACH P_BEND3 Vel=1.5 m/s, Acc= 100 % APDAT1
BEND Matrix Width= 6 mm, Bend Angle= 90 [deg], Press Vel= 7 mm/s, Probe= S12
Follow= With vacuum BENDDAT
LIFT Up 10 mm, Out= 100 mm, Vel=1.5 m/s, Acc= 100 % Wait for TDC Matrix BASE
No. = [3] Press Base

PTP TO_BEND41 CONT Vel=100 % PDAT10 Tool[1]:Tooldata Demo_Gripper Base[3]

Press Base

; Fourth bend
APPROACH P_BEND4 Vel=1.5 m/s, Acc= 100 % APDAT1
BEND Matrix Width= 6 mm, Bend Angle= 90 [deg], Press Vel= 7 mm/s, Probe= S12
Follow= With vacuum BENDDAT
LIFT Up 10 mm, Out= 100 mm, Vel=1.5 m/s, Acc= 100 % Wait for TDC Matrix BASE
No. = [3] Press Base

; Intermediate position above “put stack” station

PTP TO_PUTSTACK1 CONT Vel=100 % PDAT25 Tool[1]:Tooldata Demo_Gripper
Base[4] Put_Base

; Deposit finished part in “put stack” station

PUT on Stack= Put stack station 1 using put method= Palletizing pattern 1 Pal.
Mode= FALSE Positions=( P_PUT11 ) Vel= 2 m/s, Acc= 100 %

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 4 Programming (continued)

4.3 Example program Palletize.SRC

The PUT command is used to set parts down on one or more “put stacks”.
NO_OFF_PUT_STACK=2 Number of stacks you wish to use
PUT_STACK_ORDER[1]=1 The stack you wish to use first
(index of BT_PUT_STACK_DATA)
PUT_STACK_ORDER[2]=2 The stack you wish to use second
(index of BT_PUT_STACK_DATA)
METHOD_FOR_STACK_ORDER[1]=1 Put method to be used for the first “put stack”
(index of BT_PUT_METHOD_DATA)
METHOD_FOR_STACK_ORDER[2]=1 Put method to be used for the second stack
(index of BT_PUT_METHOD_DATA)

4.3.1 Example 1
NO_OFF_PUT_STACK=3
PUT_STACK_ORDER[1]=1
PUT_STACK_ORDER[2]=2
PUT_STACK_ORDER[3]=3
METHOD_FOR_STACK_ORDER[1]=1
METHOD_FOR_STACK_ORDER[2]=1
METHOD_FOR_STACK_ORDER[3]=1

4.3.2 Example 2
NO_OFF_PUT_STACK=3
PUT_STACK_ORDER[1]=1
PUT_STACK_ORDER[2]=2
PUT_STACK_ORDER[3]=3
METHOD_FOR_STACK_ORDER[1]=1
METHOD_FOR_STACK_ORDER[2]=2
METHOD_FOR_STACK_ORDER[3]=2

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Options
OPT_PALLETIZE_TWICE=FALSE The robot sets two parts down opposite ways round,
one on top of the other, in order to nest the parts
inside one another.

OPT_PALLETIZE_SYNCHRON=FALSE The stacks are loaded simultaneously, rather than

consecutively.

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 5 Troubleshooting

5 Troubleshooting
The following is a list of possible error messages and how to eliminate them:

Message: Release part on gripper?

Cause: There is still a plate in the gripper at the start of the program.
Monitoring: When the inline form “INIT” is executed.
Effect: Robot waits for response from operator.
Remedy: Answer using the “Yes” or “No” softkey and then restart the program.

Message: Wrong gripper code

Cause: The wrong gripper is mounted on the robot or the gripper code has
been entered incorrectly in the inline form INIT.
Monitoring: When the inline form “INIT” is executed.
Effect: The robot stops.
Remedy: Mount the correct gripper or set the value of the variable:
BT_GRIPPER_DATA[x].GRP_CODE to “0”, resume program.

Message: Program reset required

Cause: A higher–priority error has occurred. The KRL program must therefore
be reset.
Monitoring: When the inline form “INIT” is executed.
Effect: The robot stops.
Remedy: Mount the correct gripper or set the value of the variable:
BT_GRIPPER_DATA[x].GRP_CODE to “0”. Then restart program.

Message: Measured plate < 1 mm is too thin

Cause: Sensor has measured a plate that is too thin.
Monitoring: When the inline form “CHECK” is executed.
Effect: Robot stops (depending on BT_CHECK_NIO_HALT) after 3
consecutive faulty measurements.
Remedy: Remove plate from gripper and restart system.

Message: Measured plate > 1 mm is too thick

Cause: Sensor has measured a plate that is too thick.
Monitoring: When the inline form “CHECK” is executed.
Effect: Robot stops (depending on BT_CHECK_NIO_HALT) after 3
consecutive faulty measurements.
Remedy: Remove plate from gripper and restart system.

Message: Double plate check not correct

Cause: Sensor has registered 3 consecutive incorrect plate thickness
measurements.
Monitoring: When the inline form “CHECK” is executed.
Effect: Robot stops (depending on BT_CHECK_NIO_HALT).
Remedy: Remove plate from robot gripper and restart system.

Message: BT_PLATE_DATA[ ].THICKNESS not entered correctly

Cause: Plate Thickness[ ] not entered correctly in the current plate data set.
Monitoring: When “Plate Thickness” value is read during the sequence.
Effect: The robot stops.
Remedy: Open configuration window and adapt the value “Thickness” to the
current plate structure.

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Message: BT_PLATE_DATA[ ].LENGTH not entered correctly

Cause: Plate Length[ ] not entered correctly in the current plate data set.
Monitoring: When “Plate Length” value is read during the sequence.
Effect: The robot stops.
Remedy: Open configuration window and adapt the value “Length” to the
current plate structure.

Message: BT_PLATE_DATA[ ].WIDTH not entered correctly

Cause: Plate Width[ ] not entered correctly in the current plate data set.
Monitoring: When “Plate Width” value is read during the sequence.
Effect: The robot stops.
Remedy: Open configuration window and adapt the value “Width” to the current
plate structure.

Message: BT_GRIPPER_DATA[ ].GRP_TOOL not entered correctly

Cause: Tooldata[ ] for the selected tool in the gripper data set not calibrated.
Monitoring: When “Tooldata” value is read during the sequence.
Effect: The robot stops.
Remedy: Open configuration window and select the correct tool number or
recalibrate the tool.

Message: Base_Data[ ] not measured correctly

Cause: Basedata[ ] for the selected base not calibrated, X and Y value of
base are 0 mm.
Monitoring: When Base[ ] is read.
Effect: The robot stops.
Remedy: Recalibrate the base data for the selected base or select a base that
has already been calibrated.

Message: Stamp velocity too high

Cause: Press velocity too high (inline form: BEND)
Monitoring: Before the start of the bending motion in the inline form “BEND”.
Effect: Notification message
Remedy: Set a lower press velocity in the current “BEND” inline form.

Message: Wait time hydraulic too short

Cause: The value of the variable WAIT_HYDRAULIC_ON is too low.
Monitoring: Before execution of the bending motion in the inline form “BEND”.
Effect: Notification message
Remedy: Increase the value of the variable WAIT_HYDRAULIC_ON using the
variable modification function.

Message: Maximum robot velocity not achieved

Cause: The robot was not able to reach the calculated velocity during the
bending motion.
Monitoring: After execution of the bending motion in the inline form “BEND”.
Effect: Notification message
Remedy: If this message is displayed frequently, correct the value of
ROB_RAISE_TIME.
If the robot was not stopped by the operator, the press velocity in the
current “BEND” inline form must be set to a lower value.

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 5 Troubleshooting (continued)

Message: BT_BASE_X_DIRECTION[ ] not entered correctly

Cause: The X direction (value assignment as #LENGTH or #WIDTH) was not
entered in BT_BASE_X_DIRECTION[x] in the $Config.dat file
when the base currently used was calibrated.
Monitoring: When Base[ ] is read.
Effect: The robot stops.
Remedy: Set the value of the variable BT_BASE_X_DIRECTION[x] to
#LENGTH or #WIDTH.

Message: Switch X on press not found

Cause: Before the start of the bending motion, a search was made for the
defined switch X on the press, but the switch was not found.
Monitoring: Before the start of the bending procedure.
Effect: The robot stops.
Remedy: Check the switch on the press and, if necessary, correct the position
of the previous Approach motion.

Message: Set robot in operation mode “T2”

Cause: The robot cannot synchronize with the press in operating mode T1.
Monitoring: Before the start of the bending motion.
Effect: The robot stops.
Remedy: Switch the mode selector switch to “T2” or simulate this state.

Message: Warning press runs

Cause: Notification message warning the operator that the press is moving
upwards.
Monitoring: At the end of the bending motion.
Effect: Notification message
Remedy: Restart program.

Message: No plate found

Cause: When searching for a blank in the “GET STACK” process, the vacuum
sensors have not found anything.
Monitoring: At the end of the “GET STACK” process.
Effect: The robot stops.
Remedy: Check blank pallet.

Message: Search sensor on gripper not OK

Cause: Search sensors on the robot gripper incorrectly activated.
Monitoring: Before the “Get Stack” or “Put Stack” processes.
Effect: The robot stops.
Remedy: Check the search sensors on the gripper.

Message: Vacuum sensor on gripper not OK

Cause: Vacuum sensors on the gripper incorrectly activated.
Monitoring: Before the “Get Stack” process.
Effect: The robot stops.
Remedy: Check vacuum sensors on the gripper.

Message: No drop–off point found

Cause: The search sensors did not respond during drop–off of processed
plates in the “put stack”.
Monitoring: Before the search motion in the “put stack”.
Effect: The robot stops.
Remedy: Check the search sensors on the gripper.

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Message: PUT_STACK[ ] is full.

Cause: The last plate has been set down on the “put stack” and the stack is
now full.
Monitoring: After “PUT” process has been executed.
Effect: None, notification only.
Remedy: Empty “put stack” station and restart robot.

Message: Vacuum lost on gripper

Cause: Loss of vacuum during robot motion monitored by interrupt 2.
Monitoring: During motion with plate held in suction gripper.
Effect: The robot stops.
Remedy: Remove plate from gripper and restart system. If you wish to
deactivate this monitoring, set the variable BT_WATCH_PART=FALSE
in the “INIT” inline form.

Message: Palletizing mode not active; position A4 not correct

Cause: A4 is not in the range +10 to –10 degrees
Monitoring: During execution of the GET or PUT command if Pal.Mode=TRUE is
set
Effect: Notification message
Remedy: A4 must be taught in a position between –10 and +10 degrees before
the GET/PUT command.

Message: Linear Resolver on Press Brake not OK

Cause: Linear sensor has not signaled motion of the beam although the press
has been started.
Effect: The robot stops.
Remedy: Check whether linear sensor is correctly connected.

Message: Robot followed Resolver too long (>60 degrees)

Cause: Robot is supposed to track the plate in sensor mode with an angle of
more than 60 degrees.
Effect: The robot stops.
Remedy: Correct the bending angle or the value assignment for BT_RATIO.

Message: Robot followed Sensor too long (>30 seconds)

Cause: Robot in sensor mode for longer than 30 s. Press does not reach the
end position of the bending process.
Effect: The robot stops.
Remedy: Check why the signal I_BEND_END is not received from the press
controller.

Message: No valid Resolver calibration value (BT_RATIO)

Cause: Value for BT_RATIO greater than 0.5
Effect: The robot stops.
Remedy: Check the parameters BT_RATIO, BT_MATRIXDATA[ ] and
BT_STAMP_RADIUS.
1

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 Index

A Plate separation, 48
Analog input, 20 Plate thickness, 25
Program reset, 75
B ”Put stack” station, 38
BEND_VEL_FACTOR, 42
BT_CHECK_FACTOR, 26
BT_CHECK_IO, 27
BT_CHECK_NIO_HALT, 27 R
BT_CHECK_OFFSET, 26
BT_MATRIX_DATA[] / BT_STAMP_RADIUS, Regrip function, 61
43
ROB_RAISE_TIME, 42
BT_RATIO, 42

C
Change – Modifying the BendTech configurator, S
15
Configuration Editor, 14 Save, 15
Sequence cycle, 45
D
Setup.exe, 12
Delay, 53
Simulation mode, 45
Digital input, 20
Digital output, 20 Spin angle for plate separation, 48
Double plate check, 18 Synchronous motion, 42

E
Error messages, 75
External sensor, 49 T

TDC, 62, 65
G
”Get stack” station, 36
Gripper code, 75
U
I
uninstall.exe, 13
I/O interface, 16

K
KSS 5.2, 8 V

L Vacuum circuit, 34

LOAD, 15

P
W
Palletizing pattern, 40
Part detection, 16 WAIT_HYDRAULIC_ON, 42

Index – i