KUKA System Technology KUKA Roboter GmbH

KUKA.ForceTorqueControl 3.0

For KUKA System Software 8.2

Issued: 07.02.2013

Version: KST ForceTorqueControl 3.0 V2 en (PDF)

 KUKA.ForceTorqueControl 3.0

© Copyright 2013
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
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, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC

Publication: Pub KST ForceTorqueControl 3.0 (PDF) en

Bookstructure: KST ForceTorqueControl 3.0 V2.1
Version: KST ForceTorqueControl 3.0 V2 en (PDF)

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 Contents

Contents
1 Introduction .................................................................................................. 7
1.1 Target group .............................................................................................................. 7
1.2 Industrial robot documentation ................................................................................... 7
1.3 Representation of warnings and notes ...................................................................... 7
1.4 Terms used ................................................................................................................ 8
1.5 Trademarks ................................................................................................................ 8

2 Product description ..................................................................................... 9

2.1 Overview of ForceTorqueControl ............................................................................... 9
2.2 Overview of connecting cables .................................................................................. 11
2.3 Motion types ............................................................................................................... 11
2.3.1 Sensor-guided motion ........................................................................................... 12
2.3.2 Superposed force/torque control .......................................................................... 12
2.4 Reference coordinate system: RCS ........................................................................... 13
2.4.1 RCS orientation: BASE ......................................................................................... 14
2.4.2 RCS orientation: TOOL ......................................................................................... 15
2.4.3 RCS orientation: TTS ............................................................................................ 15
2.4.4 RCS origin TCP, exemplified by RCS orientation BASE or TOOL ....................... 17
2.5 Monitoring of force/torque control .............................................................................. 18
2.5.1 Maximum load exceeded ...................................................................................... 18
2.5.2 Maximum sensor correction exceeded ................................................................. 19
2.5.3 Break condition met and hold time expired ........................................................... 20
2.5.4 Maximum time expired .......................................................................................... 20

3 Safety ............................................................................................................ 23
4 Planning ....................................................................................................... 25
4.1 Geometry of the tool .................................................................................................. 25
4.2 Selecting the sensor system ...................................................................................... 25
4.3 ATI DAQ F/T sensor system ...................................................................................... 27
4.4 ATI NET F/T sensor system ....................................................................................... 27
4.4.1 KUKA FT-NET controller box ................................................................................ 28
4.5 Intermediate flange between robot mounting flange and sensor ............................... 29

5 Installation ................................................................................................... 31
5.1 System requirements ................................................................................................. 31
5.2 Installing or updating ForceTorqueControl ................................................................. 31
5.3 Licensing ForceTorqueControl ................................................................................... 31
5.3.1 Requesting a license key ...................................................................................... 32
5.3.2 Activating ForceTorqueControl ............................................................................. 32
5.4 Uninstalling ForceTorqueControl ............................................................................... 32

6 Operation ...................................................................................................... 35
6.1 Menus ........................................................................................................................ 35
6.2 Navigation bar ............................................................................................................ 35

7 Start-up and configuration ......................................................................... 37

7.1 Start-up and configuration – NET F/T sensor system ................................................ 37
7.1.1 Network connection via the KLI of the robot controller ......................................... 37

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7.1.2 Configuring the Ethernet sensor network – IP address of the robot controller ..... 38
7.1.3 Configuring the ATI NET F/T sensor system ........................................................ 38
7.2 Start-up and configuration – DAQ F/T sensor system ............................................... 39
7.2.1 Configuring the KUKA Extension Bus (SYS-X44) in WorkVisual ......................... 40
7.2.2 Configuring the ATI DAQ F/T sensor system ....................................................... 40
7.3 Start-up and configuration – user-specific sensor system ......................................... 41
7.3.1 Configuring the user-specific sensor system ........................................................ 42
7.4 Determining sensor load data .................................................................................... 43

8 Programming ............................................................................................... 45
8.1 Creating a configuration and defining a task ............................................................. 45
8.2 Configuration parameters .......................................................................................... 46
8.2.1 “Sensor load data” page ..................................................................................... 46
8.2.2 “RCS” page .......................................................................................................... 47
8.2.3 “FT controller” page (make contact, velocity change) ......................................... 47
8.2.4 “FT controller” page (tracking motion during contact) ......................................... 48
8.2.5 “Approach motion” page (make contact, velocity change) ................................. 49
8.2.6 “Break condition” page (sensor-guided motions) ............................................... 50
8.2.7 “Correction limit” page ........................................................................................ 51
8.2.8 “Monitoring functions” page .............................................................................. 52
8.2.9 “Miscellaneous” page (sensor-guided motion) .................................................... 52
8.2.10 “Correction monitoring” page ............................................................................ 52
8.2.11 “Velocity change” page (velocity change) ........................................................... 52
8.3 Configuration examples ............................................................................................. 53
8.3.1 Force control with gain ......................................................................................... 53
8.3.2 Pressing a cube onto an inclined plane ................................................................ 53
8.3.3 Pressing a cube onto an inclined plane, orientation compensation ...................... 54
8.3.4 Pressing a cube against a beveled edge .............................................................. 55
8.3.5 Pressing a cube against a beveled edge, orientation compensation ................... 55
8.4 Instructions – Sensor-guided motion ......................................................................... 56
8.4.1 Programming sensor-guided motion .................................................................... 56
8.4.1.1 Inline form OnBreak_Init ....................................................................................... 57
8.4.1.2 Inline form OnBreak_On ....................................................................................... 57
8.5 Instructions – Superposed force/torque control ......................................................... 58
8.5.1 Programming superposed force/torque control .................................................... 58
8.5.1.1 Inline form OnPath_Init ......................................................................................... 58
8.5.1.2 Inline form OnPath_On ......................................................................................... 59
8.5.1.3 Inline form OnPath_Off ......................................................................................... 59

9 Diagnosis ...................................................................................................... 61
9.1 Signal display with the RSI monitor ........................................................................... 61
9.1.1 Setting signal properties ....................................................................................... 62
9.1.2 Displaying a signal diagram .................................................................................. 62
9.1.3 Saving a signal trace ............................................................................................ 63
9.1.4 Loading a signal trace into the monitor ................................................................. 63
9.2 Displaying diagnostic data about ForceTorqueControl .............................................. 63
9.3 Error protocol (logbook) ............................................................................................. 64
9.4 Return values of the variables FT_NIFBREAK .......................................................... 64

10 KUKA Service ............................................................................................... 65

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10.1 Requesting support .................................................................................................... 65

10.2 KUKA Customer Support ........................................................................................... 65

Index ............................................................................................................. 73

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 1 Introduction

1 Introduction

1.1 Target group

This documentation is aimed at users with the following knowledge and skills:
 Advanced KRL programming skills
 Advanced knowledge of the robot controller system
 Advanced knowledge of field bus interfaces

For optimal use of our products, we recommend that our customers

take part in a course of training at KUKA College. Information about
the training program can be found at www.kuka.com or can be ob-
tained directly from our subsidiaries.

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

 Documentation for the manipulator
 Documentation for the robot controller
 Operating and programming instructions for the KUKA System Software
 Documentation relating to options and accessories
 Parts catalog on storage medium
Each of these sets of instructions is a separate document.

1.3 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable

that death or severe injuries will occur, if no precautions
are taken.

These warnings mean that death or severe injuries may

occur, if no precautions are taken.

These warnings mean that minor injuries may occur, if

no precautions are taken.

These warnings mean that damage to property may oc-

cur, if no precautions are taken.

These warnings contain references to safety-relevant information or

general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.

This warning draws attention to procedures which serve to prevent or remedy

emergencies or malfunctions:

Procedures marked with this warning must be followed

exactly.

Notes These hints serve to make your work easier or contain references to further
information.

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Tip to make your work easier or reference to further information.

1.4 Terms used

Term Description
KLI Line bus for the integration of the system in the cus-
tomer network (KUKA Line Interface)
The KLI is the Ethernet interface of the robot controller
for external communication.
KUKA smartHMI KUKA smart human-machine interface
User interface of the KUKA System Software
RCS Reference coordinate system
The reference coordinate system is the reference sys-
tem for force/torque control.
(>>> 2.4 "Reference coordinate system: RCS"
Page 13)
RSI Robot Sensor Interface
Interface for communication between the industrial
robot and a sensor system.
RSI monitor Monitor for online visualization of RSI signals.
The RSI monitor can display and record defined sig-
nals of the force/torque control.
Sensor coordi- The sensor coordinate system depends on the sensor
nate system system used. The position and orientation of the sen-
sor coordinate system can be found on the sensor and
is described in the sensor system documentation.
Sensor override The sensor override refers to the program override
$OV_PRO programmed for the start of motion. In the
case of a velocity adaptation (“velocity change”) due to
ForceTorqueControl, the start value for $OV_PRO is
reduced by a specified percentage.
TCP Tool Center Point and origin of the TOOL coordinate
system
TTS Tool-based technological system
The TTS is a coordinate system that moves along the
path with the robot. It is calculated for every LIN, CIRC,
SLIN and SCIRC motion.

1.5 Trademarks

 Windows is a trademark of Microsoft Corporation.

 is a trademark of Beckhoff Automation

GmbH.

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 2 Product description

2 Product description

2.1 Overview of ForceTorqueControl

Functions ForceTorqueControl is an add-on technology package with the following func-

tions:
 Execution of motions as a function of measured process forces and
torques
 Compliance with process forces and torques irrespective of the position
and size of the workpiece
 Compliance with complex process force characteristics during the machin-
ing of workpieces
 Velocity adaptation along the programmed path as a function of the mea-
sured process forces.
 Compensation for deviations in workpiece size and position by program-
ming a degree of compliance for the robot
 Distortion-free positioning: motion until contact is made
 Monitoring of the sensor load limits
 Monitoring of the sensor correction limits

Functional ForceTorqueControl gives the robot a sense of touch, as it were, enabling it to

principle react sensitively to external forces and torques and to exert programmable
forces and torques on a workpiece.
Servo-control is possible in up to 6 degrees of freedom (Fx, Fy, Fz, Tx, Ty, Tz).
When force/torque control is active, the robot moves until the sensor detects
the defined force or torque. In the case of superposed force/torque control, the
robot also moves on a programmed path. A reference coordinate system is de-
fined as a reference system.

Fig. 2-1: Degrees of freedom of force/torque control

Areas of appli-  Handling

cation  Joining, e.g. bonding, riveting, assembly
 Forming, e.g. roll hemming
 Cutting, e.g. grinding, deburring, polishing

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Fig. 2-2: Areas of application, ForceTorqueControl

1 Handling 3 Roll hemming

2 Riveting 4 Grinding

Components These software components are included in the ForceTorqueControl package:

 KUKA.RobotSensorInterface 3.1
 KUKA.UserTech 3.1
 Program for determining the load data of the sensor

Sensor systems ForceTorqueControl supports the following sensor systems:

 ATI DAQ F/T sensor system
 ATI NET F/T sensor system

These sensor systems are not included in the scope of supply for
ForceTorqueControl. Information about the available sensor systems
and selection of the right sensor system for the planned application
can be obtained from KUKA Roboter GmbH. (>>> 10 "KUKA Service"
Page 65)

 User-specific sensor systems

It is possible to connect sensors via the I/O system of the robot. A field bus
can be used to integrate sensors that supply the measured value as an an-
alog output or as a digital output.

Communication The robot controller can communicate with the sensor system via the I/O sys-
tem or via Ethernet. This depends on the sensor used:
 ATI DAQ F/T sensor system:
Communication via a bus system. We recommend using the EtherCAT
bus coupler from Beckhoff.
 ATI NET F/T sensor system:
Communication via the Ethernet interface of the robot controller (KLI)

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 User-specific sensor systems:

Communication via a bus system

WorkVisual To configure the sensor system ATI DAQ F/T or a user-specific sensor sys-
tem, the following software is required:
 WorkVisual 2.3 or higher

2.2 Overview of connecting cables

The connection between the robot, the sensor and the robot controller de-
pends on the sensor system used. The figure gives an overview of the con-
necting cables for the NET F/T sensor system.

Fig. 2-3: Overview of connecting cables (example)

1 Robot controller
2 KUKA FT-NET controller box
3 Ethernet cable to the KLI
4 Sensor cable
5 Energy supply system with sensor cable
6 NET F/T sensor

The KUKA FT-NET controller box is a compact control cabinet with its
own power supply, which comprises all the necessary components
for operating the NET F/T sensor system.
(>>> 4.4.1 "KUKA FT-NET controller box" Page 28)

2.3 Motion types

Overview The following motion types can be configured with ForceTorqueControl:

 Sensor-guided motion
(>>> 2.3.1 "Sensor-guided motion" Page 12)

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 Superposed force/torque control

(>>> 2.3.2 "Superposed force/torque control" Page 12)

2.3.1 Sensor-guided motion

Description When the robot executes a sensor-guided motion, the robot does not move to
a programmed end point, but is moved from a start point on the basis of the
measured sensor data. The robot moves until a defined break condition is sat-
isfied. In order to move the robot, force and torque setpoints can be set for up
to 6 degrees of freedom (Fx, Fy, Fz, Tx, Ty, Tz). A reference coordinate sys-
tem is selected as a reference system.

Example The robot moves in the Z direction in the TOOL coordinate system until the de-
fined force setpoint of 100 N is reached.

Fig. 2-4: Sensor-guided motion

2.3.2 Superposed force/torque control

Description The robot moves along a programmed path. While moving along this path, the
robot exerts the defined force and torque setpoints. Force and torque setpoints
can be set for up to 6 degrees of freedom (Fx, Fy, Fz, Tx, Ty, Tz). A reference
coordinate system is selected as a reference system.
The following motion types can be executed with superposed force/torque
control:
 PTP, LIN, CIRC
 SLIN, SCIRC

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Fig. 2-5: Superposed force/torque control

In the case of a PTP motion, note that the robot guides the TCP along
the fastest path to the end point. This is generally a curved path.

Example The robot executes a programmed path in the XY plane in the BASE coordi-
nate system. Additionally, the robot exerts a defined force setpoint of 100 N in
the Z direction along the programmed path.

2.4 Reference coordinate system: RCS

Overview The reference coordinate system RCS is the reference system for force/torque
control. The origin of the reference coordinate system is always the current
TCP.
(>>> 2.4.4 "RCS origin TCP, exemplified by RCS orientation BASE or TOOL"
Page 17)
The orientation of the reference coordinate system can be defined using the
following coordinate systems:

RCS orientation Description

BASE Reference coordinate systems with the orienta-
WORLD tion of the BASE, WORLD or ROBROOT coordi-
nate system are independent of the orientation
ROBROOT
of the tool.
(>>> 2.4.1 "RCS orientation: BASE" Page 14)

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RCS orientation Description

TOOL Reference coordinate systems with the orienta-
tion of the TOOL coordinate system are depen-
dent on the orientation of the tool.
(>>> 2.4.2 "RCS orientation: TOOL" Page 15)
TTS Reference coordinate systems with the orienta-
tion of the TTS are only relevant for superposed
force/torque control.
(>>> 2.4.3 "RCS orientation: TTS" Page 15)

2.4.1 RCS orientation: BASE

Description The orientation of the reference coordinate system corresponds to the orien-
tation of the current BASE coordinate system. It is independent of the orienta-
tion of the tool.
The origin of the reference coordinate system is the current TCP.

Fig. 2-6: RCS orientation: BASE

Example  Grinding at a stationary abrasive belt

Irrespective of the orientation of the TOOL coordinate system, the work-
piece is pressed perpendicularly against the abrasive belt.

Fig. 2-7: Example – stationary abrasive belt

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2.4.2 RCS orientation: TOOL

Description The orientation of the reference coordinate system corresponds to the orien-
tation of the current TOOL coordinate system. It is dependent on the orienta-
tion of the tool.
The origin of the reference coordinate system is the current TCP.

Fig. 2-8: RCS orientation: TOOL

Examples  Handling
 Assembly
 Force/torque control in the tool direction

2.4.3 RCS orientation: TTS

Description The orientation of the reference coordinate system corresponds to the direc-
tion of motion of the TCP of the current tool.
The origin of the reference coordinate system is the current TCP.

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Fig. 2-9: RCS orientation: TTS

TTS The TTS is a coordinate system that moves along the path with the robot. It is
calculated for each CP motion. The TTS is derived from the path tangent, the
+X axis of the TOOL coordinate system (+XTOOL = tool direction ) and the re-
sulting normal vector.
 XTTS: path tangent
 YTTS: normal vector to the plane derived from the path tangent and
+XTOOL
 ZTTS: normal vector of the right-angled system derived from XTTS and
YTTS (= negative tool direction)

The path tangent and the tool direction must not be parallel, otherwise
the TTS cannot be calculated and the robot controller displays an er-
ror message.

Example  Force-controlled roll hemming

The roll is pressed against the metal sheet perpendicularly to the direction
of motion of the TCP.

Fig. 2-10: Example – force-controlled roll hemming

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2.4.4 RCS origin TCP, exemplified by RCS orientation BASE or TOOL

Description The origin of the reference coordinate system is always the current TCP.

Example The following parameters are configured for force/torque control.

Fx [N] Fy [N] Fz [N] Tx [Nm] Ty [Nm] Tz [Nm]

--- --- 50 --- 0 ---

In the following figure, the workpiece moves from top to bottom. When one
point of the workpiece has reached force FZ = 50 N on the surface, the work-
piece rotates until torque TY = 0 is reached. The direction of rotation of the
workpiece depends on the orientation of the TCP.

Fig. 2-11: RCS origin: TCP

Item Description
1 RCS orientation: BASE, TCP below perpendicular
When the workpiece rotates about the TCP, the orientation of the
reference coordinate system does not change.
Because the TCP is below the perpendicular to the surface, the
workpiece rotates.
2 RCS orientation: BASE, TCP above perpendicular
When the workpiece rotates about the TCP, the orientation of the
reference coordinate system does not change.
Because the TCP is above the perpendicular to the surface, the
workpiece rotates upwards until torque TY = 0 is reached.
3 RCS orientation: TOOL, TCP at bottom
When the workpiece rotates about the TCP, the orientation of the
reference coordinate system changes.
Because the TCP is below the perpendicular to the surface, the
workpiece rotates downwards until torque TY = 0 is reached.
4 RCS orientation: TOOL, TCP at top
When the workpiece rotates about the TCP, the orientation of the
reference coordinate system changes.
Because the TCP is above the perpendicular to the surface, the
workpiece rotates upwards until torque TY = 0 is reached.

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2.5 Monitoring of force/torque control

Overview The monitoring of force/torque control can be configured. ForceTorqueControl

ends force/torque control if the configured load or sensor correction limits are
exceeded.
 Exceeding of the maximum sensor load that may be exerted on the sensor
in the sensor coordinate system. This may be due to external process forc-
es and/or the weight of the tool.
Configuration: Load range page (configuration of the sensor system)
 Exceeding of the maximum load that may be exerted externally on the tool
in the reference coordinate system RCS.
Configuration: (>>> 8.2.8 "“Monitoring functions” page" Page 52)
 Exceeding of the maximum sensor correction.
Configuration: (>>> 8.2.7 "“Correction limit” page" Page 51)
For a sensor-guided motion, a break condition is always defined together with
a break mode. As the break condition, one or more ranges can be defined
which the measured sensor value must enter.
ForceTorqueControl ends sensor-guided motion when the break condition is
satisfied, or on expiry of a defined maximum time if the break condition is not
satisfied within this time.
 The break mode defines the time at which sensor-guided motion is termi-
nated:
 In the target range: Termination as soon as the measured sensor val-
ue lies within the defined range.
 Hold time once within target range: A timer starts once the mea-
sured sensor value lies within the defined range. Termination once the
hold time has expired, irrespective of whether the measured value
leaves a range again during this time.
 Hold time entirely within target range: The timer is reset each time
the measured value leaves a range. Termination when the measured
value lies within the defined range for the entire hold time.
 Hold time entirely within target range and signal: Termination
when the measured value lies within the defined range for the entire
hold time and a defined input is additionally set to TRUE.
Configuration: (>>> 8.2.6 "“Break condition” page (sensor-guided mo-
tions)" Page 50)
 Maximum time expired.
Configuration: (>>> 8.2.9 "“Miscellaneous” page (sensor-guided motion)"
Page 52)

The cause of termination of a sensor-guided motion can be evaluated

using the variable FT_NIFBREAK.
(>>> 9.4 "Return values of the variables FT_NIFBREAK" Page 64)

2.5.1 Maximum load exceeded

Description Force/torque control is terminated if a maximum force or a maximum torque is

exceeded. The reference coordinate system is the RCS.

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Fig. 2-12: Maximum load exceeded

Item Description
1 Maximum force FMax or torque TMax
Maximum force FMax or torque TMax is exceeded.
2
Force/torque control is terminated.

2.5.2 Maximum sensor correction exceeded

Description The maximum sensor correction can be defined in a positive and negative di-
rection for each activated component. The reference coordinate system is the
RCS.
If the maximum sensor correction is exceeded during a sensor-guided motion,
force/torque control is terminated.
If the maximum sensor correction is reached during a motion with superposed
force/torque control, no further sensor corrections are carried out in this direc-
tion.

Fig. 2-13: Maximum sensor correction exceeded

Item Description
1 Maximum sensor correction dMax in the positive direction
2 Maximum sensor correction dMin in the negative direction
Maximum sensor correction dMax has been exceeded.
3 A sensor-guided motion is terminated, and superposed force/
torque control is limited to the upper correction limit.

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2.5.3 Break condition met and hold time expired

Description Sensor-guided motion is terminated if the break condition is met and the timer
for the hold time has expired.

Fig. 2-14: Break condition met and hold time expired

Item Description
1 Positive limit of the range
2 Specified force FNom or torque TNom
3 Negative limit of the range
Break condition is met.
4
Timer for the hold time is started.
Timer for the hold time has expired.
5
Sensor-guided motion is terminated.

2.5.4 Maximum time expired

Description Sensor-guided motion is terminated if the timer for the maximum time has ex-
pired. The timer is started when sensor-guided motion is started.

Fig. 2-15: Maximum time expired

Item Description
1 Specified force FNom or torque TNom

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Item Description
Sensor-guided motion is started.
2
Start is started.
Timer has expired.
3
Sensor-guided motion is terminated.

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 3 Safety

3 Safety
This documentation contains safety instructions which refer specifically to the
software described here.
The fundamental safety information for the industrial robot can be found in the
“Safety” chapter of the Operating and Programming Instructions for System In-
tegrators or the Operating and Programming Instructions for End Users.

The “Safety” chapter in the operating and programming instructions

must be observed. Death to persons, severe injuries or considerable
damage to property may otherwise result.

Sensor-assisted  If used incorrectly, KUKA.ForceTorqueControl can cause personal injury

operation and material damage.
 In sensor-assisted operation, the robot may move unexpectedly in the fol-
lowing cases:
 Incorrectly configured force/torque control
 Hardware fault (e.g. incorrect cabling, break in the sensor cable or
sensor malfunction)
 Unexpected movements may cause serious injuries and substantial mate-
rial damage. The system integrator is obliged to minimize the risk of injury
to himself/herself and other people, as well as the risk of material damage,
by adopting suitable safety measures, e.g. by means of workspace limita-
tion.
 At the start of force/torque control, the safety controller generates the fol-
lowing acknowledgement message in T1 or T2 mode:
!!! Caution - sensor correction is activated!!!

Workspace  The axis ranges of all robot axes are limited by means of adjustable soft-
limitation ware limit switches. These software limit switches must be set in such a
way that the workspace of the robot is limited to the minimum range re-
quired for the process.
 The System Software allows the configuration of a maximum of 8 Carte-
sian and 8 axis-specific workspaces. The system integrator must configure
the workspaces in such a way that they are limited to the minimum range
required for the process. This reduces the risk of damage caused by un-
expected movements in sensor-assisted operation to a minimum.

Sensor correction  By default, KUKA.ForceTorqueControl limits the maximum sensor correc-

tion in the reference coordinate system to +/- 5 mm for translational direc-
tion corrections and 5° for axis angle corrections (= maximum rotational
offset across all axis angles).
If the preset range for sensor correction in the reference coordinate sys-
tem is not sufficient, the maximum permissible correction range can be in-
creased. The permissible range for sensor correction must always be
limited to the minimum required range.
(>>> 8.2.7 "“Correction limit” page" Page 51)

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 4 Planning

4 Planning

4.1 Geometry of the tool

Description The torque load of the sensor is determined by the geometry of the tool. The
following geometry must thus be observed when designing the tool in order to
reduce the sensor load:
 Minimize distance from center of mass of tool to sensor system.
 Minimize length of lever arm of external process forces acting on the sen-
sor system.

4.2 Selecting the sensor system

Description The following criteria must be met:

1. Sensor load in normal operation is within the permissible measurement
range of the sensor system.
2. Safety factor for peak loads is taken into consideration.
The required measurement range of the sensor system is derived from the fol-
lowing resulting forces:
 Weight of mounted tool at sensor system
 Maximum process force
 Maximum acceleration force
Simplified formula for dimensioning of the sensor system:
Mmax = FGw * dMs + FPmax * dKPmax

Element Description
Mmax Maximum torque in Nm
FGw Weight of tool in N
dMs Distance from center of mass to sensor origin in m
FPmax Maximum process force in N
dKPmax Maximum distance contact point to sensor origin in m

Selection of the wrong sensor system can result in dam-

age to the sensor system and other material damage.
The correct sensor system can only be selected with detailed knowledge of
the real process.
Consultation with KUKA Roboter GmbH is required here. (>>> 10 "KUKA
Service" Page 65)

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 KUKA.ForceTorqueControl 3.0

Example

Fig. 4-1: Example of sensor system selection

Item Description
1 Sensor
2 Mount
3 Spindle
FG1 Weight of spindle, e.g. 50 N
FG2 Weight of holder, e.g. 10 N
FP Process force, e.g. 100 N
s Center of gravity of holder, e.g. 0.15 m
d Center of gravity of spindle, e.g. 0.40 m
l Lever arm, e.g. 0.25 m

The required measurement range of the sensor system is derived from the
sum of the following torques acting on the sensor:
 Torque resulting from the weight of mounted tool at sensor system:
M1 = FG1 * d + FG2 * s = 50 N * 0.40 m + 10N * 0.15 m = 21.5 Nm
 Torque resulting from the maximum process force:
M2 = FP * l = 100 N * 0.25 m = 25.0 Nm
Sensor load in normal operation:
M1 + M2 = 46.5 Nm
Permissible torque from nominal load of the KR 16 robot and geometry of the
tool:
M3 = 160 N * 0.4 m = 64 Nm
Sensor selection: ATI DAQ F/T Delta: Measurement range ±60 Nm, maximum
load ±220 Nm
The following criteria are met:
1. Sensor load in normal operation is within the permissible measurement
range of the sensor system.
(-60 Nm < 46.5 Nm > +60 Nm)
2. Safety factor for peak loads is taken into consideration.
Safety factor = 220 Nm/64 Nm = 3.5
Disadvantage of this choice of sensor:

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 4 Planning

 Although the sensor load during normal operation is within the permissible
measuring range of the sensor system, the measuring range to be used
for the planned application could be too small.
M4 = 60 Nm - (M1 + M2) = 60 Nm - 46.5 Nm = 13.5 Nm

Recommendation: Select the sensor system so that its measuring

range is at least twice as large as the sensor load during normal op-
eration.

4.3 ATI DAQ F/T sensor system

Overview These hardware components are required for operating the sensor system
with ForceTorqueControl:
 ATI F/T-DAQ sensor
 Intermediate flange between robot mounting flange and sensor
 Power supply box
 For sensors of type Gamma or larger:
 3-piece cable set, sensor - power supply box (5 m, 6 m, 15 m)
 EtherCAT bus system

Fig. 4-2: ATI DAQ F/T sensor system (example with mini-sensor)

1 F/T-DAQ sensor 3 Power supply box

2 Sensor cable 4 EtherCAT bus system

EtherCAT bus We recommend using the EtherCAT bus coupler from Beckhoff. The following
system components are required:
 EL9505 power supply terminal 24 V —» 5 V
 EK1100 EtherCAT bus coupler
 2 EL3104 4-channel analog input terminals, -10 V to 10 V

4.4 ATI NET F/T sensor system

Overview These hardware components are required for operating the sensor system
with ForceTorqueControl:
 ATI F/T-NET sensor

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 Intermediate flange between robot mounting flange and sensor

 Sensor cable
 Ethernet cable
 ATI NET box or KUKA FT-NET controller box

The ATI NET box must be grounded and supplied with power in ac-
cordance with the sensor system documentation. The required ca-
bles must be assembled by the user.

The KUKA FT-NET controller box is a compact control cabinet with its
own power supply, which comprises all the necessary components
for operating the NET F/T sensor system.
(>>> 4.4.1 "KUKA FT-NET controller box" Page 28)

Fig. 4-3: ATI NET F/T sensor system (example)

1 F/T-NET sensor
2 Sensor cable, F/T-NET sensor – NET box
3 NET box
4 Ethernet cable, NET box – robot controller KLI

4.4.1 KUKA FT-NET controller box

The KUKA FT-NET controller box comprises all the necessary components for
operating the ATI NET F/T sensor system:
 Power supply unit
 Evaluation electronics for the sensor for conditioning the measured values
and making them available for Ethernet
 Power connection and connections for sensor and Ethernet cables

The KUKA FT-NET controller box is not included in the scope of sup-
ply for ForceTorqueControl and can be ordered.

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 4 Planning

Fig. 4-4: KUKA FT-NET controller box

1 F/T-NET sensor
2 Sensor cable, F/T-NET sensor – controller box
3 Main switch for switching the controller box on and off
4 Connection for 230 V power supply
5 Connection for Ethernet cable
6 Connection for sensor cable
7 Ethernet cable, controller box – robot controller KLI

4.5 Intermediate flange between robot mounting flange and sensor

Description The sensor cannot be mounted directly on the robot flange. An intermediate
flange is required between the mounting flange of the robot and the sensor.
Depending on the sensor type, the intermediate flange may consist of one or
two plates.

Example Intermediate flange with 2 plates

Fig. 4-5: Sensor with intermediate flange – flange plates separated

1 Plate 1 3 Sensor
2 Plate 2 with sensor

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Fig. 4-6: Sensor mounted with intermediate flange

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 5 Installation

5 Installation

5.1 System requirements

Hardware  KR C4

Software  KUKA System Software 8.2

5.2 Installing or updating ForceTorqueControl

It is advisable to archive all relevant data before updating a software

package.

Preparation  Copy software from CD to KUKA USB stick.

The software must be copied onto the stick with the file Setup.exe at the
highest level (i.e. not in a folder).

Recommendation: Always use KUKA sticks. Data may

be lost if sticks from other manufacturers are used.

Precondition  “Expert” user group

Procedure 1. Connect the USB stick to the robot controller or smartPAD.

2. In the main menu, select Start-up > Additional software.
3. Press New software. The entry Force Torque Control must be displayed
in the Name column and drive E:\ or K:\ in the Path column.
If not, press Refresh.
4. If the specified entries are now displayed, continue with step 5.
If not, the drive from which the software is being installed must be config-
ured first:
 Press the Configuration button. A new window opens.
 Select a line in the Installation paths for options area.
Note: If the line already contains a path, this path will be overwritten.
 Press Path selection. The available drives are displayed.
 Select E:\. (If stick connected to the robot controller.)
Or select K:\. (If stick connected to the smartPAD.)
 Press Save. The window closes again.
The drive only needs to be configured once and then remains saved for
further installations.
5. Select the entry Force Torque Control and press Install. Answer the re-
quest for confirmation with Yes.
6. Several reboot prompts are displayed consecutively. Confirm each prompt
by pressing OK.
7. Remove the stick.
8. Reboot the robot controller.

LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.

5.3 Licensing ForceTorqueControl

ForceTorqueControl must be activated using a license key.

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 KUKA.ForceTorqueControl 3.0

5.3.1 Requesting a license key

Precondition  “Expert” user group

Procedure 1. In the main menu, select Configuration > FTCtrl > Sensor. The configu-
ration window is opened.
2. Select the License page.
3. Press Request.
4. In the Navigator, select the storage location, e.g. USB stick or network
drive, and confirm with OK. The license request FTCtrl.ROB is created.
5. Send the license request FTCtrl.ROB together with the additional informa-
tion to the following address: [email protected]
The following additional information is required for processing the request:
 Serial number of the robot
 Version of the installed ForceTorqueControl software
 Order number of the installed ForceTorqueControl software
The license key is requested and KUKA Roboter returns the license file FTC-
trl.LIC.

5.3.2 Activating ForceTorqueControl

Precondition  “Expert” user group

 The license file FTCtrl.LIC is available, e.g. on a USB stick or network
drive.

Procedure 1. In the main menu, select Configuration > FTCtrl > Sensor. The configu-
ration window is opened.
2. Select the License page.
3. Press Import.
4. In the Navigator, navigate to the license file FTCtrl.LIC, select the file and
load it with Open.
ForceTorqueControl is now licensed and can be started.

5.4 Uninstalling ForceTorqueControl

It is advisable to archive all relevant data before uninstalling a soft-

ware package.

Description To uninstall the ForceTorqueControl technology package completely, the fol-

lowing components must be uninstalled:
 ForceTorqueControl
 RobotSensorInterface
 UserTech

Only uninstall components if it has been ascertained that they are not
being used by another technology package!

Precondition  “Expert” user group

Procedure 1. In the main menu, select Start-up > Additional software. All additional
programs installed are displayed.

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 5 Installation

2. Select the entry FTCtrl and press Uninstall. Reply to the request for con-
firmation with Yes. Uninstallation is prepared.
3. Repeat step 2 to prepare further software components for uninstallation.
4. Reboot the robot controller. Uninstallation is resumed and completed.

LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.

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 6 Operation

6 Operation

6.1 Menus

The following menus and commands are specific to this technology package:
Main menu:
 Configuration > FTCtrl
 Sensor
 Application
Menu sequence:
 Commands > FTCtrl
 Sensor-guided
 Init
 On
 Superposed
 Init
 On
 Off

6.2 Navigation bar

The navigation bar can be used to switch to the individual configuration pages.

Fig. 6-1: Navigation bar – Configuration

Item Description
1 Name of the configuration page currently being displayed.
Pressing the display opens a menu. In this menu, the user can se-
lect the pages individually. Precondition: “Expert” user group
2 Name of the task that is currently open (only displayed when con-
figuring force/torque control)

The following buttons are available:

Button Description
Next Switches to the next page.
Back Switches to the previous page.
Save Saves the configuration.

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 7 Start-up and configuration

7 Start-up and configuration

This chapter contains overviews of the most important steps for the
start-up of sensor systems supported by ForceTorqueControl. The
precise sequence depends on the application, the manipulator type,
the sensor type, the technology packages used and other customer-specific
circumstances.
For this reason, the overview does not claim to be comprehensive.

7.1 Start-up and configuration – NET F/T sensor system

Step Description
1 Mount the sensor on the robot.
The sensor cannot be mounted directly on the robot flange. An intermediate
flange is required between the mounting flange of the robot and the sensor.
Depending on the sensor type, the intermediate flange may consist of one or
two plates.
2 Mount the tool on the sensor.
Note: Tighten the fastening screws to the defined tightening torque in diago-
nally opposite sequence in accordance with the sensor system documenta-
tion. The maximum tightening torque and the maximum penetration depth of
the fastening screws must not be exceeded, otherwise the sensor could be
damaged.
3 Mount the KUKA FT-NET controller box externally. (The box is powered inde-
pendently from the robot controller.)
Alternatively: Mount the ATI NET box on the mounting plate for customer
components in the robot controller and install it in accordance with the sensor
system documentation.
4 Connect the connecting cables. Attention must be paid to the following:
 The sensor cable from the sensor to the FT-NET controller box must be cor-
rectly routed using an energy supply system. The energy supply system en-
sures that the cables are guided with minimum stress despite the high load
on the sensor cable caused by the robot motion.
 The Ethernet cable must be connected to the robot controller KLI.
(>>> 7.1.1 "Network connection via the KLI of the robot controller"
Page 37)
5 Configure the Ethernet sensor network.
(>>> 7.1.2 "Configuring the Ethernet sensor network – IP address of the robot
controller" Page 38)
6 Configure the sensor system.
(>>> 7.1.3 "Configuring the ATI NET F/T sensor system" Page 38)
7 Determine the sensor load data.
(>>> 7.4 "Determining sensor load data" Page 43)

7.1.1 Network connection via the KLI of the robot controller

Description A network connection must be established via the KLI of the robot controller in
order to exchange data via Ethernet.
The following Ethernet interfaces are available as options at the customer in-
terface of the robot controller, depending on the specification:
 Interface X66 (1 slot)

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 Interface X67.1-3 (3 slots)

Further information on the Ethernet interfaces can be found in the op-

erating or assembly instructions for the robot controller.

7.1.2 Configuring the Ethernet sensor network – IP address of the robot controller

Precondition  “Expert” user group

 Network connection via the KLI of the robot controller

Procedure 1. In the main menu, select Start-up > Service > Minimize HMI.
2. Select All Programs > RSI-Network in the Windows Start menu.
The Network Setup window appears. The network connections already
set up are displayed in the tree structure under Other Installed Interfac-
es.
3. Select the entry New under RSI Ethernet in the tree structure and press
Edit.
4. Enter the IP address of the robot controller and confirm with OK.

The IP addresses of the sensor (default: 192.168.1.1) and the robot

controller must be in the same network segment, i.e. the addresses
must differ only in the last of the 4 ranges.

The IP address range 192.168.0.x is blocked for the configuration of

the network connection.

5. Reboot the robot controller with a cold restart.

7.1.3 Configuring the ATI NET F/T sensor system

Precondition  The sensor system is installed and connected.

 The Ethernet sensor network is configured.

Procedure 1. In the main menu, select Configuration > FTCtrl > Sensor. The configu-
ration window is opened.
2. On the Sensor type page, select the sensor ATI NET/FT sensor.
3. Press Next to switch to the Connection page and enter the IP address of
the connected sensor.

The IP addresses of the sensor (default: 192.168.1.1) and the robot

controller must be in the same network segment, i.e. the addresses
must differ only in the last of the 4 ranges.

If the preset IP address of the sensor cannot be used, it must be mod-

ified in accordance with the sensor system documentation.

4. Modification only by the administrator and after consultation with KUKA

Roboter GmbH:
 Sampling time
 Low-pass cut-off frequency
5. Press Next to switch to the Mounting page. Enter the Offset X, Y, Z and
the Rotational offset A, B, C of the sensor coordinate system relative to
the reference coordinate system.

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 7 Start-up and configuration

The sensor is installed by default on the mounting flange. The reference

coordinate system for the sensor coordinate system is the FLANGE coor-
dinate system.
6. Press Next to switch to the Load range page and enter the permissible
sensor load. ForceTorqueControl terminates control if the permissible
sensor load is exceeded.

The permissible sensor load must lie within the measuring range of
the sensor. Information on the measuring range can be found in the
sensor system documentation.

If the values entered for the permissible sensor load are

too high, this can damage the sensor system, resulting in
damage to property.
The system integrator is responsible for analyzing the real processes and the
conditions of the sensor application and determining the values for the per-
missible sensor load on the basis of this analysis. It is generally advisable to
allow an additional safety factor when using the measured range specified by
the sensor manufacturer.

7. Press Next to switch to the License page and license KUKA.Force-

TorqueControl.
(>>> 5.3 "Licensing ForceTorqueControl" Page 31)
8. Save the configuration with Save.

7.2 Start-up and configuration – DAQ F/T sensor system

Step Description
1 Mount the sensor on the robot.
The sensor cannot be mounted directly on the robot flange. An intermediate
flange is required between the mounting flange of the robot and the sensor.
Depending on the sensor type, the intermediate flange may consist of one or
two plates.
2 Mount the tool on the sensor.
Note: Tighten the fastening screws to the defined tightening torque in diago-
nally opposite sequence in accordance with the sensor system documenta-
tion. The maximum tightening torque and the maximum penetration depth of
the fastening screws must not be exceeded, otherwise the sensor could be
damaged.
3 Mount the power supply box of the sensor on the mounting plate for customer
components in the robot controller or externally.
The precise mounting position of the power supply box depends on the config-
uration variant of the robot controller and the specific requirements of the over-
all system.
4 Connect the EtherCAT bus module directly to the CIB (connector X44) or via a
switch on the robot controller.
Note: Information about the EtherCAT connection on the CIB can be found in
the assembly and operating instructions of the robot controller and in the
assembly and operating instructions Optional Interfaces for KR C4.
5 Connect the cables between the power supply box and the EtherCAT bus
module in accordance with the sensor system documentation.

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Step Description
6 Connect the connecting cables. Attention must be paid to the following:
 The sensor cable from the sensor to the power supply box must be correctly
routed using an energy supply system. The energy supply system ensures
that the cables are guided with minimum stress despite the high load on the
sensor cable caused by the robot motion.
7 Configuration in WorkVisual
1. Transfer the project to WorkVisual
2. Connect the analog input terminals of the EtherCAT bus coupler to X44.
(>>> 7.2.1 "Configuring the KUKA Extension Bus (SYS-X44) in WorkVisu-
al" Page 40)
3. Then transfer the project from WorkVisual back to the robot controller.
Note: Information about bus configuration and project deployment can be
found in the WorkVisual documentation.
8 Configure the sensor system.
(>>> 7.2.2 "Configuring the ATI DAQ F/T sensor system" Page 40)
9 Determine the sensor load data.
(>>> 7.4 "Determining sensor load data" Page 43)

7.2.1 Configuring the KUKA Extension Bus (SYS-X44) in WorkVisual

Precondition  The robot controller has been set as the active controller.

Procedure 1. Insert the KUKA Extension Bus (SYS-X44) in the controller bus (window
Project structure > tab Hardware > Bus structure).
2. Add the EK1100 EtherCAT coupler under SYS-X44.
3. Add the EL9505 5V power supply terminal under EK1100.
4. Add 2 EL3104 4-channel analog inputs under EK1100.
5. Connect the analog inputs to the field buses EL3104 1 and EL3104 2.
 $ANIN[1] to Al Standard Channel 1.Value / terminal 1
 …
 $ANIN[4] to Al Standard Channel 4.Value / terminal 1
 $ANIN[5] to Al Standard Channel 1.Value / terminal 2
 …
 $ANIN[8] to Al Standard Channel 4.Value / terminal 2

7.2.2 Configuring the ATI DAQ F/T sensor system

Precondition  The sensor system is installed and connected.

 The EtherCAT bus system has been configured in WorkVisual and the
configuration has been transferred from WorkVisual to the robot controller.
 The file FT<XXXX>.CAL with the sensor calibration data is available, e.g.
on a USB stick or network drive.

Procedure 1. In the main menu, select Configuration > FTCtrl > Sensor. The configu-
ration window is opened.
2. On the Sensor type page, select the sensor ATI-DAQ system.
3. Press Next to switch to the Connection page and, under $ANIN[], specify
the inputs of the robot controller via which the EtherCAT bus system reads
in the sensor values Fx, Fy, Fz and Tx, Ty, Tz.

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 7 Start-up and configuration

4. Press Import and navigate in the Navigator to the CAL file with the sensor
calibration data. Select the file and load it with Open.
5. Press Next to switch to the Mounting page. Enter the Offset X, Y, Z and
the Rotational offset A, B, C of the sensor coordinate system relative to
the reference coordinate system.
The sensor is installed by default on the mounting flange. The reference
coordinate system for the sensor coordinate system is the FLANGE coor-
dinate system.
6. Press Next to switch to the Load range page and enter the permissible
sensor load. ForceTorqueControl terminates control if the permissible
sensor load is exceeded.

The permissible sensor load must lie within the measuring range of
the sensor. Information on the measuring range can be found in the
sensor system documentation.

If the values entered for the permissible sensor load are

too high, this can damage the sensor system, resulting in
damage to property.
The system integrator is responsible for analyzing the real processes and the
conditions of the sensor application and determining the values for the per-
missible sensor load on the basis of this analysis. It is generally advisable to
allow an additional safety factor when using the measured range specified by
the sensor manufacturer.

7. Press Next to switch to the License page and license KUKA.Force-

TorqueControl.
(>>> 5.3 "Licensing ForceTorqueControl" Page 31)
8. Save the configuration with Save.

7.3 Start-up and configuration – user-specific sensor system

Step Description
1 Mount the sensor on the robot.
The sensor cannot be mounted directly on the robot flange. An intermediate
flange is required between the mounting flange of the robot and the sensor.
Depending on the sensor type, the intermediate flange may consist of one or
two plates.
2 Mount the tool on the sensor.
Note: Tighten the fastening screws to the defined tightening torque in diago-
nally opposite sequence in accordance with the sensor system documenta-
tion. The maximum tightening torque and the maximum penetration depth of
the fastening screws must not be exceeded, otherwise the sensor could be
damaged.
3 Connect the connecting cables.
4 Configuration in WorkVisual
1. Transfer the project to WorkVisual
2. Configure the field bus in WorkVisual.
3. Then transfer the project from WorkVisual back to the robot controller.
Note: Information about bus configuration and project deployment can be
found in the WorkVisual documentation.

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Step Description
5 Configure the sensor system.
(>>> 7.3.1 "Configuring the user-specific sensor system" Page 42)
6 Determine the sensor load data.
(>>> 7.4 "Determining sensor load data" Page 43)

7.3.1 Configuring the user-specific sensor system

Precondition  The sensor system is installed and connected.

 The field bus has been configured in WorkVisual and the configuration has
been transferred from WorkVisual to the robot controller.

Procedure 1. In the main menu, select Configuration > FTCtrl > Sensor. The configu-
ration window is opened.
2. On the Sensor type page, select the sensor used:
 Sensor on analog input: For sensors which supply the measured val-
ue as an analog output
 Sensor on digital input: For sensors which supply the measured val-
ue as a digital output
3. Press Next to switch to the Connection page and set the following param-
eters:
 Specify the inputs of the robot controller via which the field bus reads
in the sensor values Fx, Fy, Fz and Tx, Ty, Tz. Depending on the sen-
sor used, either specify analog inputs under $ANIN[], or digital inputs
under Index.
 If required, the input signal can be adapted with the aid of Offset and
Scaling. This produces the measured values actually supplied by the
sensor. The adaptation is made using the following formula:
Measured value = (Input signal + Offset) x Scaling
Example: A sensor delivers a signal between 4 mA and 20 mA. This
is to correspond to measured values between -400 N and +400 N.
Consequently, the following values for Offset and Scaling are to be
selected:
Offset = -12 mA
Scaling = 50 N/mA
If, for example, the sensor delivers an input value of 15 mA, according
to the above formula the following measured value results:
(15 mA - 12 mA) x 50 N/mA = 150 N
 Only for sensors which supply the measured value as a digital output:
Specify the Data width of the sensor value for each digital input.
4. Press Next to switch to the Mounting page. Enter the Offset X, Y, Z and
the Rotational offset A, B, C of the sensor coordinate system relative to
the reference coordinate system.
The sensor is installed by default on the mounting flange. The reference
coordinate system for the sensor coordinate system is the FLANGE coor-
dinate system.
5. Press Next to switch to the Load range page and enter the permissible
sensor load. ForceTorqueControl terminates control if the permissible
sensor load is exceeded.

The permissible sensor load must lie within the measuring range of
the sensor. Information on the measuring range can be found in the
sensor system documentation.

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 7 Start-up and configuration

If the values entered for the permissible sensor load are

too high, this can damage the sensor system, resulting in
damage to property.
The system integrator is responsible for analyzing the real processes and the
conditions of the sensor application and determining the values for the per-
missible sensor load on the basis of this analysis. It is generally advisable to
allow an additional safety factor when using the measured range specified by
the sensor manufacturer.

6. Press Next to switch to the License page and license KUKA.Force-

TorqueControl.
(>>> 5.3 "Licensing ForceTorqueControl" Page 31)
7. Save the configuration with Save.

7.4 Determining sensor load data

Description The sensor load data can be determined automatically using the program
R1\Program\FTCtrl\FTCtrl_LDD.SRC.
The program FTCtrl_LDD.SRC contains 6 predefined measurement poses
with different robot orientations. During load data determination, the robot
moves to these measurement poses. From the measurements, a calculation
is made of the total load on the sensor and the center of gravity of the sensor
load relative to the origin of the sensor coordinate system.

The sensor load data are not the same as the payload data (= load
data of the sensor and tool relative to the FLANGE coordinate sys-
tem) which must be entered in the robot controller and assigned to the
correct tool.

To determine the sensor load data, the robot needs to move to at least 2 mea-
surement poses. It is recommended to move to all of the measurement poses,
if possible, as this produces a more accurate measurement result.

Preparation 1. Check whether there is enough workspace to be able to move to the indi-
vidual measurement poses.
2. If it is not possible to move to a measurement pose, change the measure-
ment position in the program or deactivate the measurement. To do this,
comment out the relevant lines in the program.

Precondition  Operating mode T1

Procedure  Select and execute the program FTCtrl_LDD.SRC to the end of the pro-
gram.
The measurement result and the sensor load and sensor load center of
gravity are displayed in a message.

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8 Programming
Overview Step Description
1 Create the configuration for the force/torque control and
define the task that is to be executed.
(>>> 8.1 "Creating a configuration and defining a task"
Page 45)
2 Call, start and terminate the configuration (task) in a KRL pro-
gram via inline forms.
(>>> 8.4 "Instructions – Sensor-guided motion" Page 56)
(>>> 8.5 "Instructions – Superposed force/torque control"
Page 58)

8.1 Creating a configuration and defining a task

Procedure 1. In the main menu, select Configuration > FTCtrl > Application. The con-
figuration window is opened.
2. On the Configuration page, enter a name for the configuration.
3. Press Create and then select the task that is to be defined from the Task
selection menu.
(>>> "Task selection" Page 46)
The next configuration page opens automatically.
4. Work through this page and all the subsequent pages, configuring the pa-
rameters as required.
(>>> 8.2 "Configuration parameters" Page 46)
5. Press Save. The configuration is saved.
6. Close the configuration window using the Close symbol.

Description

Fig. 8-1: “Configuration” page – Task selection

1 Configuration list

Buttons The following buttons are available on the Configuration page:

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Button Description
Create Opens the Task selection menu.
After task selection, a new configuration is created with
default values. This configuration is not yet saved.
Open Opens the configuration selected in the configuration
list.
The name of an opened configuration can be re-entered
and the configuration can be saved under this new
name.
Delete Deletes the configuration selected in the configuration
list.

Task selection The following tasks can be defined for a sensor-guided motion:
 Sensor-guided
 Sensor-guided: make contact
The robot has no contact with the environment. It is possible to define
in which direction and at what velocity the robot moves until contact is
made.
 Sensor-guided: tracking motion during contact
The robot is in contact. New setpoint values can be defined.
The following tasks can be defined for superposed force/torque control:
 Superposed
 Superposed: make contact
The robot has no contact with the environment. Control is performed
in parallel with the robot motion. Contact is made via control.
 Superposed: tracking motion during contact
The robot is in contact. Control is performed in parallel with the robot
motion. New setpoint values can be defined.
 Superposed: velocity change
The robot has no contact with the environment. Control is performed
in parallel with the robot motion. Contact is made via control. In addi-
tion, the velocity on the programmed path can be adapted as a func-
tion of the measured process force.

8.2 Configuration parameters

8.2.1 “Sensor load data” page

The sensor load data are not the same as the payload data (= load
data of the sensor and tool relative to the FLANGE coordinate sys-
tem) which must be entered in the robot controller and assigned to the
correct tool.

Parameter Description
Sensor load [N] Enter the sum of the loads mounted on the sensor.
Cent. of grav. [mm] Enter the position of the sensor load center of gravity relative to the ori-
gin of the sensor coordinate system in the boxes X, Y, Z.

Buttons The following buttons are available on the Sensor load data page:

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Button Description
Import mes- Automatically reads in the load data determined using
sages the program FTCtrl_LDD.SRC.
(>>> 7.4 "Determining sensor load data" Page 43)

8.2.2 “RCS” page

Parameter Description
Reference coordi- Select the Cartesian coordinate system to which the force/torque control
nate system refers.
 World
 Base
 RobRoot
 Tool
 TTS
Default: Tool
It is advisable to select a reference coordinate system that requires the
activation of as few components as possible.
(>>> 2.4 "Reference coordinate system: RCS" Page 13)

8.2.3 “FT controller” page (make contact, velocity change)

The difference between the setpoint and actual values of

the force/torque control influences the sensor correction
and thus the velocity of the robot. Incorrect entries can result in unexpectedly
fast robot motions and cause personal injury or material damage. The safety
regulations must be observed.

Here a main direction is defined in which motion is performed in the reference

coordinate system until contact is made, and a setpoint force or torque for this
direction:
 In the case of sensor-guided motion, control is maintained in the selected
main direction after contact is made, until the defined setpoint is reached.
The robot then stops.
 In the case of superposed force/torque control, the robot moves on a pro-
grammed path. In parallel with this motion, the robot moves in the selected
main direction until contact is made. Once the defined setpoint is reached,
control is maintained in the main direction and the robot attempts to main-
tain the established force or torque along the programmed path.

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Fig. 8-2: “FT controller” page (make contact, velocity change)

Check boxes Via the check boxes, further directions can be activated for force/torque con-
trol in addition to the main direction. The main direction is activated automati-
cally.
The setpoint force or torque for the additionally activated directions are set by
default to zero. If the sensor detects any contact in the additionally activated
direction, the controller deviates in the opposite direction. This makes it possi-
ble to compensate for distortion.

Parameter Description
Main direction (RCS) Select the direction in which motion to contact is performed in the refer-
ence coordinate system specified on the RCS page.
 Fx, Fy, Fz: Motion in X, Y or Z direction of the RCS
 Tx, Ty, Tz: Rotation about the X, Y or Z axis of the RCS
Default: Fz
Note: In the case of superposed velocity adaptation, a force controller
must be selected here.
Setpoint force [N] If a force controller is activated for the main direction in the Fx, Fy or Fz
direction, enter the desired setpoint force.
Setpoint torque If a torque controller is activated for the main direction in the Tx, Ty or Tz
[Nm] direction, enter the desired setpoint torque.
KR Here a gain factor can be entered for the activated directions for force/
torque control. The force/torque controller operates with these gain fac-
tors:
Default values:
 Gain factor for force controller: 0.01 (mm/s)/N
 Gain factor for torque controller: 0.1 (°/s)/Nm

Example (>>> 8.3.1 "Force control with gain" Page 53)

8.2.4 “FT controller” page (tracking motion during contact)

The difference between the setpoint and actual values of

the force/torque control influences the sensor correction
and thus the velocity of the robot. Incorrect entries can result in unexpectedly
fast robot motions and cause personal injury or material damage. The safety
regulations must be observed.

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Fig. 8-3: “FT controller” page (tracking motion during contact)

Check boxes Via the check boxes, activate the directions for force/torque control. By default,
the force controller is active in the Fz direction.

Parameter Description
Setpoint Enter here for each activated force controller Fx, Fy or Fz the corre-
sponding setpoint force and for each activated torque controller Tx, Ty
or Tz the corresponding setpoint torque.
The robot attempts to reach these setpoint values while it maintains con-
tact with the workpiece.
KR Here a gain factor can be entered for the activated directions. The force/
torque controller operates with these gain factors:
Default values:
 Gain factor for force controller: 0.01 (mm/s)/N
 Gain factor for torque controller: 0.1 (°/s)/Nm

Example (>>> 8.3.1 "Force control with gain" Page 53)

8.2.5 “Approach motion” page (make contact, velocity change)

Here the maximum velocity is defined at which motion to contact is performed

in the main direction of force or torque control. After this, the contact controller
takes over control and attempts to reach the setpoint force or torque defined
on the FT controller page.

If the robot moves to contact at too fast a velocity, the

controller will not be able to brake the robot quickly
enough, which may result in damage to property. For this reason, an ap-
proach velocity is suggested, depending on the setpoint value to be reached
during contact that is specified on the FT controller page.
To avoid damage to property, it is advisable to accept the suggested velocity
initially and adjust it later if necessary.

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Fig. 8-4: “Approach motion” page (make contact, velocity change)

Parameter Description
Approach velocity Enter the maximum approach velocity or accept the suggested velocity
as the approach velocity using the Apply button.
 Translational motion [mm/s]: This velocity is used for motion to
contact in the X, Y or Z direction of the RCS.
 Rotational motion [°/s]: This velocity is used for rotation about the
X, Y or Z axis of the RCS until contact is made.
Note: The reference coordinate system selected on the RCS page and
the main control direction set on the FT controller page are displayed
automatically, here Tool Z.
Switching condition Enter the minimum values which the sensor must measure on contact in
for contact control- order to switch to contact control.
ler
 Force |F| [N] >: Minimum force that must be measured
 Torque |T| [Nm] >: Minimum torque that must be measured

Buttons The following buttons are available on the Approach motion page:

Button Description
Apply Copies the suggested maximum approach velocity
Depending on the specified setpoint force or torque,
the velocity is estimated for the selected controller. This
suggestion can be accepted as the approach velocity
using the Apply button.

8.2.6 “Break condition” page (sensor-guided motions)

For each controller component activated on the FT controller page, a break

condition can be defined which terminates the sensor-guided motion. For this,
the setpoint force or torque that the robot attempts to reach is monitored within
a defined range.

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Fig. 8-5: “Break condition” page (sensor-guided motion)

Check boxes Via the check boxes, activate the controller components which are to be mon-
itored and enter the appropriate range.

Parameter Description
Break mode Select the break mode.
 In the target range: When the range is entered for the first time, the
task is considered as completed and the sensor-guided motion is ter-
minated.
 Hold time once within target range: When the range is entered for
the first time, a timer is started. When the defined hold time has
elapsed, the timer stops and the sensor-guided motion is terminated.
 Hold time entirely within target range: When the range is entered
for the first time, a timer is started. If the range is left again before the
hold time has elapsed, the timer is reset and restarted the next time
the range is entered. The sensor-guided motion is only terminated
when the sensor values lie within the range throughout the hold time.
 Hold time entirely within target range and signal: Behavior as for
Hold time entirely within target range. In addition, the Signal
$IN[x] must be set to TRUE in order to terminate the sensor-guided
motion.
Default: In the target range
Hold time [s] Hold time for the timer. The timer is stopped when the hold time has
elapsed.
Default: 5 s
This box is not displayed for the break mode In the target range.
Signal $IN[x] Number of the input which must be set to TRUE in order to terminate the
sensor-guided motion
Default: 1026
This box is only displayed for the break mode Hold time entirely within
target range and signal.

8.2.7 “Correction limit” page

The maximum permissible sensor correction in the reference coordinate sys-

tem is defined here. ForceTorqueControl monitors the correction limits from
the start of control, and terminates control immediately if one of the limits is ex-
ceeded.

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The maximum sensor correction in the RCS must lie within the global
correction limits that are defined on the Correction monitoring page.

Parameter Description
X, Y, Z [mm] Enter the maximum permissible Cartesian correction.
 Min: Maximum Cartesian correction in the negative X, Y or Z direc-
tion
Default: -5 mm
 Max: Maximum Cartesian correction in the positive X, Y or Z direction
Default: 5 mm
Angle of rotation [°] Enter the maximum permissible axis angle correction (= maximum rota-
tional offset across all axis angles).
Default: 5°

8.2.8 “Monitoring functions” page

Here the maximum load is defined that may be exerted externally on the tool
in the reference coordinate system. ForceTorqueControl monitors the load
limits from the start of control onwards, and terminates control immediately if
one of the limits is exceeded.

The maximum load must lie within the measuring range of the sensor.
Information on the measuring range can be found in the sensor sys-
tem documentation.

Parameter Description
Fx, Fy, Fz [N] Enter the maximum permissible load that may be exerted externally on
the tool in the X, Y, Z directions of the RCS.
Tx, Ty, Tz [Nm] Enter the maximum torque that may be exerted externally on the tool
about the X, Y, Z axes of the RCS.

8.2.9 “Miscellaneous” page (sensor-guided motion)

Sensor-guided motion is always terminated after the time specified here, if

none of the conditions defined on the Break condition page have been safis-
fied by that time.

8.2.10 “Correction monitoring” page

The global limits for sensor correction are defined here:

 Maximum permissible translational offset from the start point of sensor
correction (unit: mm)
 Maximum permissible rotational offset from the start point of sensor cor-
rection (unit: °)
The global limits refer to the overall correction system of the sensor, and must
limit the sensor correction in such a way that the workpiece and other cell com-
ponents are not damaged.

8.2.11 “Velocity change” page (velocity change)

Superposed velocity change can only be used if a setpoint force for contact is
defined in the main direction selected on the FT controller page. For this set-

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point force, 2 ranges can be defined to control the sensor override on the pro-
grammed path.

Parameter Description
Force range around  F in: If the sensor measured value enters this range, the motion is ex-
the setpoint force ecuted with a sensor override of 100%.
[N]  F out: If the sensor measured value leaves this range, the motion is
executed with the set sensor override.
Note: The force range F out must be larger than the force range F in.
Sensor override [%] The sensor override can only be set for the force range F out. In the
force range F in, the sensor override is always 100%.
The sensor override refers to the program override $OV_PRO pro-
grammed for the start of motion. In the case of a velocity change via
ForceTorqueControl, the start value for $OV_PRO is reduced by a spec-
ified percentage.
Example: The program override is 50% at the start of motion. With a
sensor override of 100%, the robot moves with an override of 50%. With
a sensor override of 50%, the robot moves with an override of 25%.

When superposed velocity change is active, ForceTorqueControl

takes control of the program override $OV_PRO. Changes to the pro-
gram override via the smartPAD or the KRL program are overwritten
by ForceTorqueControl and have no effect.

8.3 Configuration examples

8.3.1 Force control with gain

The following values have been defined for force control on the FT controller
page:
 Setpoint force: FDef = 50 N
 Gain factor: KR = 0.02 (mm/s)/N
The sensor measures the following force in the RCS:
FRCS = 125 N
Resulting control difference between measured force and setpoint force:
FDiff = FRCS - FDef = 125 N - 50 N = 75 N
The controller reacts to the control difference with the following velocity set-
point for the robot:
Vel = FDiff * KR = 75 N * 0.02 (mm/s)/N = 1.5 mm/s
The robot deviates from the control difference with a motion of 1.5 mm per
second, i.e. at a velocity of 1.5 mm/s.

8.3.2 Pressing a cube onto an inclined plane

Description  Sensor-guided motion (make contact)

 Reference coordinate system TOOL
The cube moves in the negative Z direction until the lower right-hand side
touches the inclined plane and a force setpoint FZ of 50 N has been reached.

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Fig. 8-6: Pressing a cube onto an inclined plane

The following parameters are configured for force/torque control.

Fx [N] Fy [N] Fz [N] Tx [Nm] Ty [Nm] Tz [Nm]

--- --- 50 --- --- ---

8.3.3 Pressing a cube onto an inclined plane, orientation compensation

Description  Sensor-guided motion (make contact)

 Reference coordinate system TOOL
The cube moves in the negative Z direction until the lower right-hand side
touches the inclined plane and a force setpoint FZ of 50 N has been reached.
With constant force setpoint FZ, the cube rotates about the Y axis until its sur-
face is lying on the inclined plane and a torque setpoint TY of 0 Nm has been
reached.

Fig. 8-7: Pressing a cube onto an inclined plane, orientation compensa-

tion

The following parameters are configured for force/torque control.

Fx [N] Fy [N] Fz [N] Tx [Nm] Ty [Nm] Tz [Nm]

--- --- 50 --- 0 ---

The orientation of the force/torque control is dependent on the defined refer-

ence coordinate system.

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 If the TOOL coordinate system is set, the orientation of the force/torque

control changes with that of the mounted tool. The cube rotates until a
force setpoint of 50 N is reached. The TCP moves along an arc-shaped
path.
 If the BASE, WORLD or ROBROOT coordinate system is set, the orienta-
tion of the force/torque control does not change. The cube rotates until a
force setpoint of 50 N * sinα is reached. The TCP moves along a straight
path.

8.3.4 Pressing a cube against a beveled edge

Description  Sensor-guided motion (make contact)

 Reference coordinate system TOOL
The cube moves in the negative Z direction until the lower right-hand side
touches the inclined plane and a force setpoint FZ of 50 N has been reached.
With constant force setpoint FZ, the cube moves in the negative XY direction
until its surface is lying on the inclined plane and a force setpoint FX of 0 N has
been reached.

Fig. 8-8: Pressing a cube against a beveled edge

The following parameters are configured for force/torque control.

Fx [N] Fy [N] Fz [N] Tx [Nm] Ty [Nm] Tz [Nm]

0 --- 50 --- --- ---

8.3.5 Pressing a cube against a beveled edge, orientation compensation

Description  Sensor-guided motion (make contact)

 Reference coordinate system TOOL
The cube moves in the negative Z direction until the lower right-hand side
touches the inclined plane and a force setpoint FZ of 50 N has been reached.
With constant force setpoint FZ, the following motions are executed simultane-
ously:
 The cube moves in the negative X direction until its surface is lying on the
inclined plane and a force setpoint FX of 0 N has been reached.
 The cube rotates about the Y axis until its surface is lying on the inclined
plane and a torque setpoint TY of 0 Nm has been reached.

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How far the cube moves on the inclined plane depends on the config-
uration of the individual controllers. The cube stops when both force/
torque control conditions are met.

Fig. 8-9: Pressing a cube against a beveled edge, orientation compensa-

tion

The following parameters are configured for force/torque control.

Fx [N] Fy [N] Fz [N] Tx [Nm] Ty [Nm] Tz [Nm]

0 --- 50 --- 0 ---

8.4 Instructions – Sensor-guided motion

Call  Select the menu sequence Commands > FTCtrl > Sensor-guided and
select the desired inline form.

Overview Inline form Description

Init Initialize sensor-guided motion with the data of the
desired task.
(>>> 8.4.1.1 "Inline form OnBreak_Init" Page 57)
On Start sensor-guided motion.
(>>> 8.4.1.2 "Inline form OnBreak_On" Page 57)

8.4.1 Programming sensor-guided motion

Precondition  The task is defined.

Procedure 1. Only with “Make contact”: Program the start point of the sensor-guided
motion.

There must not yet be any contact forces and torques acting on the
sensor at the start point of the motion. The tool on the robot must have
clearance on all sides.

2. Initialize sensor-guided motion.

3. Start sensor-guided motion.
The sensor-guided motion is terminated automatically when the break
condition defined in the configuration (task) is met or the defined maximum
time has elapsed. The cause of termination of the sensor-guided motion
can be evaluated using the variable FT_NIFBREAK.

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Example Sensor-guided motion: Make contact

1 DEF Sensorguided_Approach( )
2 INI
3
4 PTP HOME Vel= 100 % DEFAULT
5 FTCtrl.OnBreak_Init Config=Approach_1
6 FTCtrl.OnBreak_On Message=Quit
7 IF (FT_NIFBREAK <> FT_STOPSOLFZ) THEN
8 HALT
9 ENDIF
10 GRIPPER OPEN

Line Description
4 Start point of the sensor-guided motion
5 The sensor-guided motion is initialized.
6 The sensor-guided motion is started.
An acknowledgement message stating the cause of termina-
tion is generated when the sensor-generated motion is termi-
nated.
7…9 Evaluation of the cause of termination with FT_NIFBREAK

8.4.1.1 Inline form OnBreak_Init

The instruction initializes the sensor-guided motion with the data from the con-
figuration (task) selected in the inline form.

Fig. 8-10: Inline form OnBreak_Init

Item Description
1 Name of the configuration (task)

8.4.1.2 Inline form OnBreak_On

The instruction starts a sensor-guided motion. When the break condition de-
fined in the configuration (task) is met, the sensor-guided motion is terminated.
A message giving the cause of termination can be generated.

Fig. 8-11: Inline form OnBreak_On

Item Description
1 Message type
 No: No message
 Info: Notification message
 Quit: Acknowledgement message

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8.5 Instructions – Superposed force/torque control

Call  Select the menu sequence Commands > FTCtrl > Superposed and se-
lect the desired inline form.

Overview Inline form Description

Init Initialize superposed force/torque control with the data
of the desired task.
(>>> 8.5.1.1 "Inline form OnPath_Init" Page 58)
On Start superposed force/torque control.
(>>> 8.5.1.2 "Inline form OnPath_On" Page 59)
Off Terminate superposed force/torque control.
(>>> 8.5.1.3 "Inline form OnPath_Off" Page 59)

8.5.1 Programming superposed force/torque control

Precondition  The task is defined.

Procedure 1. Only with “Make contact” or “Velocity change”: Teach the start point for su-
perposed force/torque control.

There must not yet be any contact forces and torques acting on the
sensor at the start point of the motion. The tool on the robot must have
clearance on all sides.

2. Initialize superposed force/torque control.

3. Start superposed force/torque control.
4. Teach CP motions with superposed force/torque control.
5. Terminate superposed force/torque control.

Example Superposed force/torque control: Make contact

1 DEF Sensorimposed_Approach( )
2 INI
3
4 PTP HOME Vel= 100 % DEFAULT
5 PTP P1 Vel 100 % PDAT1 Tool[1] Base[1]
6 FTCtrl.OnPath_Init Config=Approach_2
7 FTCtrl.OnPath_On
8 LIN P2 Vel= 0.8 m/s CPDAT1 Tool[1] Base[1]
9 LIN P3 Vel= 0.8 m/s CPDAT1 Tool[1] Base[1]
10 LIN P4 Vel= 0.8 m/s CPDAT1 Tool[1] Base[1]
11 FTCtrl.OnPath_Off
12 ENDIF

Line Description
5 Start point for superposed force/torque control
6 Superposed force/torque control is initialized.
7 Superposed force/torque control is started.
8 … 10 Motion with superposed force/torque control
11 Superposed force/torque control is terminated.

8.5.1.1 Inline form OnPath_Init

The instruction initializes superposed force/torque control with the data from
the configuration (task) selected in the inline form.

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Fig. 8-12: Inline form OnPath_Init

Item Description
1 Name of the configuration (task)

8.5.1.2 Inline form OnPath_On

The instruction starts superposed force/torque control. All subsequent motions

are executed with superposed force/torque control.

Fig. 8-13: Inline form OnPath_On

8.5.1.3 Inline form OnPath_Off

The instruction terminates superposed force/torque control.

Fig. 8-14: Inline form OnPath_Off

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9 Diagnosis

9.1 Signal display with the RSI monitor

Call  In the main menu, select Configuration > FTCtrl > Application and se-
lect the Signal display page.

Overview

Fig. 9-1: RSI monitor

The following buttons are available:

Button Description
Setup The signal properties for the signal recording can be de-
fined.
(>>> 9.1.1 "Setting signal properties" Page 62)
File The recorded signal diagram can be saved in a file or a
file can be loaded.
Config To display the force/torque control signals, the default
RSI channel 1 must be used.
This button is only available to the user group “Expert”
or higher.
Zoom The displayed time frame can be increased or de-
creased in size using a slide controller.
The visible time frame can be shifted by dragging it hor-
izontally in the monitor display window.

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9.1.1 Setting signal properties

Description

Fig. 9-2: RSI monitor – signal properties

Item Description
1 List box with the signals 1 … 24
2 Line thickness of the signal
 Line thickness1 … 4
Default: Line thickness 1
3 Signal color of the signal
4 Ordinate along which the signal is scaled
 Left: Scaling on the left-hand ordinate
 Right: Scaling on the right-hand ordinate
Default: Left
5 The check box must be activated to display a signal in the moni-
tor.
Default: Check box for Signal 1 … 6 activated.

The following buttons are available:

Button Description
Activate all Activates all signals.
Deactivate all Deactivates all signals.
Reset thickness Resets the line thicknesses of the signals to the default line thickness 1.
Reset colors Resets the signal colors to the default colors.
Reset monitor Resets the time window to the default size (cancel zoom).
Reset all? Resets all signal properties to the default properties.

9.1.2 Displaying a signal diagram

Procedure 1. Press Setup and open the list box with the signals.
2. Activate the desired signals for the recording and change the signal prop-
erties if required.
3. Select and execute the program.

Description The following signals can be displayed and recorded using the RSI monitor:

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 9 Diagnosis

Signal Description
1…6 Process forces and torques in the RCS (transformed sensor
values)
 Signal 1: Fx
 Signal 2: Fy
 Signal 3: Fz
 Signal 4: Tx
 Signal 5: Ty
 Signal 6: Tz
7 … 12 Corrections in the RCS (distance traveled)
 Signal 7: Correction in the X direction
 Signal 8: Correction in the Y direction
 Signal 9: Correction in the Z direction
 Signal 10: Correction of angle A (rotation about the Z axis)
 Signal 11: Correction of angle B (rotation about the Y axis)
 Signal 12: Correction of angle C (rotation about the X axis)
13 … 18 Process forces and torques in the sensor coordinate system
(raw sensor values)
 Signal 13: Fx
 Signal 14: Fy
 Signal 15: Fz
 Signal 16: Tx
 Signal 17: Ty
 Signal 18: Tz
19 Correction status
 0: No correction possible
 1: Correction active
 >1: Correction in limitation

9.1.3 Saving a signal trace

Procedure 1. Activate the File check box.

2. Enter a file name for the trace in the Save file box and press Save.
The trace is saved as a DAT file in the directory C:\KRC\ROBOT-
ER\LOG\SensorInterface\MONITOR.

9.1.4 Loading a signal trace into the monitor

Procedure 1. Activate the File check box.

2. Select the desired file in the Load file box and press Load.
All traces saved in the directory C:\KRC\ROBOTER\LOG\SensorInter-
face\MONITOR are available for selection.

9.2 Displaying diagnostic data about ForceTorqueControl

Procedure 1. In the main menu, select Diagnosis > Diagnostic monitor.

2. Select the Force Torque Control (FTCtrl) module in the Module box.

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9.3 Error protocol (logbook)

The error messages of the RSI interface are logged by default in a LOG file
under C:\KRC\ROBOTER\LOG\SensorInterface.

9.4 Return values of the variables FT_NIFBREAK

The cause of termination of a sensor-guided motion can be evaluated using

the global KRL variable FT_NIFBREAK (type: INT).

Return value Constant Description

1 FT_STOPBREAKOK Break condition met
10 FT_STOPSOLFX Maximum force that the sensor can measure in the
X direction has been exceeded
11 FT_STOPSOLFY Maximum force that the sensor can measure in the
Y direction has been exceeded
12 FT_STOPSOLFZ Maximum force that the sensor can measure in the
Z direction has been exceeded
13 FT_STOPSOLTX Maximum torque that the sensor can measure in
the X direction has been exceeded
14 FT_STOPSOLTY Maximum torque that the sensor can measure in
the Y direction has been exceeded
15 FT_STOPSOLTZ Maximum torque that the sensor can measure in
the Z direction has been exceeded
16 FT_STOPROLFX Maximum permissible force in the X direction of the
RCS exceeded
17 FT_STOPROLFY Maximum permissible force in the Y direction of the
RCS exceeded
18 FT_STOPROLFZ Maximum permissible force in the Z direction of the
RCS exceeded
19 FT_STOPROLTX Maximum permissible torque about the X axis of
the RCS exceeded
20 FT_STOPROLTY Maximum permissible torque about the Y axis of
the RCS exceeded
21 FT_STOPROLTZ Maximum permissible torque about the Z axis of the
RCS exceeded
22 FT_STOPMAXTIME Time limit for the force/torque control exceeded
23 FT_STOPMAXCORR Maximum permissible overall Cartesian correction
exceeded

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 10 KUKA Service

10 KUKA Service

10.1 Requesting support

Introduction The KUKA Roboter GmbH documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.

Information The following information is required for processing a support request:

 Model and serial number of the robot
 Model and serial number of the controller
 Model and serial number of the linear unit (if applicable)
 Model and serial number of the energy supply system (if applicable)
 Version of the KUKA System Software
 Optional software or modifications
 Archive of the software
For KUKA System Software V8: instead of a conventional archive, gener-
ate the special data package for fault analysis (via KrcDiag).
 Application used
 Any external axes used
 Description of the problem, duration and frequency of the fault

10.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
[email protected]

Australia Headland Machinery Pty. Ltd.

Victoria (Head Office & Showroom)
95 Highbury Road
Burwood
Victoria 31 25
Australia
Tel. +61 3 9244-3500
Fax +61 3 9244-3501
[email protected]
www.headland.com.au

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Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
[email protected]
www.kuka.be

Brazil KUKA Roboter do Brasil Ltda.

Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
[email protected]
www.kuka-roboter.com.br

Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
[email protected]
www.robotec.cl

China KUKA Robotics China Co.,Ltd.

Songjiang Industrial Zone
No. 388 Minshen Road
201612 Shanghai
China
Tel. +86 21 6787-1888
Fax +86 21 6787-1803
www.kuka-robotics.cn

Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
[email protected]
www.kuka-roboter.de

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 10 KUKA Service

France KUKA Automatisme + Robotique SAS

Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
[email protected]
www.kuka.fr

India KUKA Robotics India Pvt. Ltd.

Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
[email protected]
www.kuka.in

Italy KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
[email protected]
www.kuka.it

Japan KUKA Robotics Japan K.K.

YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7691
Fax +81 45 744 7696
[email protected]

Canada KUKA Robotics Canada Ltd.

6710 Maritz Drive - Unit 4
Mississauga
L5W 0A1
Ontario
Canada
Tel. +1 905 670-8600
Fax +1 905 670-8604
[email protected]
www.kuka-robotics.com/canada

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Korea KUKA Robotics Korea Co. Ltd.

RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
[email protected]

Malaysia KUKA Robot Automation Sdn Bhd

South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
[email protected]

Mexico KUKA de México S. de R.L. de C.V.

Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de México
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
[email protected]
www.kuka-robotics.com/mexico

Norway KUKA Sveiseanlegg + Roboter

Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
[email protected]

Austria KUKA Roboter Austria GmbH

Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
[email protected]
www.kuka-roboter.at

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 10 KUKA Service

Poland KUKA Roboter Austria GmbH

Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
[email protected]

Portugal KUKA Sistemas de Automatización S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
[email protected]

Russia OOO KUKA Robotics Rus

Webnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
kuka-robotics.ru

Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
[email protected]

Switzerland KUKA Roboter Schweiz AG

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
[email protected]
www.kuka-roboter.ch

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Spain KUKA Robots IBÉRICA, S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
Fax +34 93 8142-950
[email protected]
www.kuka-e.com

South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

Taiwan KUKA Robot Automation Taiwan Co., Ltd.

No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
[email protected]
www.kuka.com.tw

Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
[email protected]
www.kuka-roboter.de

Czech Republic KUKA Roboter Austria GmbH

Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Počernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
[email protected]

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 10 KUKA Service

Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
[email protected]

USA KUKA Robotics Corporation

51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
[email protected]
www.kukarobotics.com

UK KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
[email protected]

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 Index

Index
A M
Approach motion 49 Maximum load 18, 52
Areas of application 9 Maximum time, sensor-guided motion 18, 20, 52
Availability, sensor system 10 Menus 35
Monitoring, force/torque control 18
B Motion types 11
BASE 14
Break condition, sensor-guided motion 18, 20, N
50 Navigation 35
Navigation bar 35
C NET F/T sensor system, start-up 37
Communication 10 Network connection 37
Components 10 Network connection, configuring 38
Configuration 37
Configuration examples 53 O
Configuration, creating 45 Operation 35
Connecting cables 11 Overview, ForceTorqueControl 9
Controller bus 40
P
D Pressing a cube, beveled edge 55
DAQ F/T sensor system, start-up 39 Pressing a cube, beveled edge, orientation com-
Diagnosis 61 pensation 55
Diagnostic monitor (menu item) 63 Pressing a cube, inclined plane 53
Documentation, industrial robot 7 Pressing a cube, inclined plane, orientation com-
pensation 54
E Product description 9
Error protocol 64 Programming 45
Ethernet, interfaces 37
Ethernet, sensor network 38 R
RCS 8, 13, 47
F RCS orientation BASE 14
ForceTorqueControl, activation 32 RCS orientation TOOL 15
FT_NIFBREAK, return values 64 RCS orientation TTS 15
Functional principle 9 RCS, origin TCP 17
Functions 9 Reference coordinate system 13, 47
RSI 8
H RSI monitor 8
Hardware 31
Hold time 18, 20, 51 S
Safety 23
I Safety instructions 7
Installation 31 Sensor coordinate system 8
Installation, ForceTorqueControl 31 Sensor correction, global limits 52
Introduction 7 Sensor correction, maximum 18, 19, 51
Sensor correction, safety 23
K Sensor load data, determining 43
KLI 8, 37 Sensor load, maximum 18
Knowledge, required 7 Sensor override 8, 53
KUKA Customer Support 65 Sensor system, ATI DAQ F/T 27
KUKA FT-NET controller box 28 Sensor system, ATI DAQ F/T, configuring 40
Sensor system, ATI NET F/T 27
L Sensor system, ATI NET F/T, configuring 38
License key, requesting 32 Sensor system, selecting 25
Licensing ForceTorqueControl 31 Sensor system, user-specific 42
Load data, sensor 46 Sensor systems 10
Logbook 64 Sensor-assisted operation, safety 23
Sensor-guided motion 12
Sensor-guided motion, programming 56

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Sensor, load data 46

Service, KUKA Roboter 65
Signal diagram, displaying 62
Signal properties, RSI monitor 62
Signal trace, loading into the RSI monitor 63
Signal trace, saving 63
smartHMI 8
Software 31
Software components, scope of supply 10
Software limit switches 23
Start-up 37
Superposed force/torque control 12
Superposed force/torque control, programming
58
Superposed velocity adaptation 48, 52
Support request 65
System requirements 31

T
Target group 7
Task, defining 45
TCP 8
Terms used 8
Terms, used 8
TOOL 15
Tool Center Point 8
Tool, geometry 25
Trademarks 8
Training 7
TTS 8, 14, 15

U
Uninstallation, ForceTorqueControl 32
Update, ForceTorqueControl 31
User-specific sensor system, start-up 41

W
Warnings 7
WorkVisual 11

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