KST ConveyorTech 71 en

KUKA System Technology
KUKA.ConveyorTech 7.1
For KUKA System Software 8.5
Issued: 04.05.2021
KST ConveyorTech 7.1 V2
KUKA Deutschland GmbH
© Copyright 2021
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 Deutschland 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 soft-
ware 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 regu-
lar basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Translation of the original documentation
Publication: Pub KST ConveyorTech 7.1 (PDF) en

PB10816
Book structure: KST ConveyorTech 7.1 V2.2

BS9986
Version: KST ConveyorTech 7.1 V2
2/108 | www.kuka.com KST ConveyorTech 7.1 V2 | Issued: 04.05.2021

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
1.6 Licenses................................................................................................................. 8
2 Product description................................................................................. 11
2.1 Overview of ConveyorTech................................................................................... 11
2.2 Intended use.......................................................................................................... 12
3 Safety......................................................................................................... 13
4 Planning.................................................................................................... 15
4.1 System with conveyor connection to RDC........................................................... 15
4.2 External conveyor.................................................................................................. 15
4.2.1 Communications interface to the higher-level controller...................................... 17
4.2.1.1 Reception structure from the perspective of the robot controller........................ 17
4.2.1.2 Transmission structure from the perspective of the robot controller................... 17
4.2.1.3 Communication sequence between robot controller and PLC............................. 19
4.2.2 Checksum calculation for external conveyor........................................................ 20
5 Start-up and recommissioning............................................................... 25

5.1 Overview................................................................................................................ 25
5.2 Connecting a resolver to the RDC....................................................................... 25
6 Installation................................................................................................ 29
6.1 System requirements............................................................................................. 29
6.2 Installation via WorkVisual.................................................................................... 29
6.2.1 Installing or updating ConveyorTech..................................................................... 29
6.2.2 Uninstalling ConveyorTech.................................................................................... 30
6.3 Installation via smartHMI....................................................................................... 31
6.3.1 Installing or updating ConveyorTech..................................................................... 31
6.3.2 Uninstalling ConveyorTech.................................................................................... 32
7 Configuration............................................................................................ 33
7.1 Overview: configuration in WorkVisual................................................................. 33
7.2 Inserting a conveyor in a project.......................................................................... 33
7.3 Inserting a resolver in a project............................................................................ 34
7.4 Modifying the connection between the synchronization switch and the CIB...... 35
7.5 Defining the conveyor as motion master.............................................................. 36
7.6 Configuring time synchronization.......................................................................... 37
7.7 Configuring conveyor parameters in the machine data....................................... 39
7.7.1 General I/O parameters........................................................................................ 39
7.7.2 Conveyor-specific expert parameters................................................................... 40
7.7.3 Alarm and stop distances..................................................................................... 41
7.7.4 Escape strategy..................................................................................................... 42
KST ConveyorTech 7.1 V2 | Issued: 04.05.2021 www.kuka.com | 3/108

7.7.4.1 Signal diagram for stop strategy CONV_STOPPABLE........................................ 43

7.8 Editing global conveyor settings........................................................................... 45
7.9 Configuring I/Os and adding long texts................................................................ 45
8 Operation.................................................................................................. 49
8.1 Displaying user rights............................................................................................ 49
8.2 Modifying global conveyor settings....................................................................... 49
8.3 Modifying conveyor-specific settings..................................................................... 50
8.4 Modifying alarm and stop distances..................................................................... 52
9 Calibration................................................................................................. 55
9.1 Calibrating a linear conveyor................................................................................ 55
9.2 Calibrating a circular conveyor............................................................................. 56
9.3 Checking the conveyor distance........................................................................... 57
9.4 Calibrating the workpiece on the conveyor.......................................................... 58
10 Programming............................................................................................ 61
10.1 Creating a conveyor application program............................................................. 61
10.2 Conveyor.INI_OFF: initializing a conveyor............................................................ 63
10.3 Conveyor.ON: activating a conveyor.................................................................... 64
10.4 Conveyor.FOLLOW: tracking a workpiece............................................................ 64
10.5 Conveyor.Skip: picking up a workpiece from the conveyor................................. 67
10.6 Conveyor.Quit: leaving the conveyor area........................................................... 70
10.7 Teaching synchronized motions............................................................................ 71
10.8 Programming a DLIN block................................................................................... 73
10.9 Programming a DLIN motion................................................................................ 74
10.9.1 Option window “Frames”....................................................................................... 75
10.9.2 Option window “Velocities”.................................................................................... 76
10.9.3 Option window “Accelerations”.............................................................................. 76
10.10 Creating an application program with DLIN template.......................................... 77
10.11 KRL functions........................................................................................................ 77
10.11.1 CONV_DELETE_ALL_WPS: delete all components............................................ 78
10.11.2 CONV_DELETE_WPS: Deleting components...................................................... 78
10.11.3 CONV_GET_SPEED: Requesting the conveyor speed....................................... 79
10.11.4 CONV_GET_WP_COUNT: Component counter................................................... 79
11 Troubleshooting....................................................................................... 81
11.1 Robot leaves the path in external mode EXT...................................................... 81
11.2 Modifying the program override............................................................................ 81
11.3 The decision to track a workpiece is made in the advance run......................... 82
11.4 Connection to position tracker broken.................................................................. 83
12 Messages.................................................................................................. 85
12.1 Information about the messages.......................................................................... 85
12.2 System messages from module: Conveyor.......................................................... 85
12.2.1 Conveyor 01002.................................................................................................... 85
12.2.2 Conveyor 01007.................................................................................................... 87
12.2.3 Conveyor 01008.................................................................................................... 89
12.2.4 Conveyor 01010.................................................................................................... 90
12.2.5 Conveyor 01011.................................................................................................... 91
12.2.6 Conveyor 01018.................................................................................................... 93

12.2.7 Conveyor 01211.................................................................................................... 95

12.2.8 Conveyor 01221.................................................................................................... 95
12.2.9 Conveyor 01250.................................................................................................... 96
12.2.10 Conveyor 01251.................................................................................................... 97
13 KUKA Service........................................................................................... 99
13.1 Requesting support............................................................................................... 99
13.2 KUKA Customer Support...................................................................................... 99
Index 107


Introduction
1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and

skills:
• Advanced knowledge of the robot controller system

• Advanced KRL programming skills
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 obtained di-
rectly from our subsidiaries.
1.2 Industrial robot documentation
The industrial robot documentation consists of the following parts:
• Documentation for the robot arm

• Documentation for the robot controller
• Documentation for the smartPAD-2
• Operating and programming instructions for the System Software
• Instructions for options and accessories
• Spare parts in KUKA.Xpert
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety
These warnings are provided for safety purposes and must be observed.
DANGER
These warnings mean that it is certain or highly probable that death or
severe injuries will occur, if no precautions are taken.
WARNING
These warnings mean that death or severe injuries may occur, if no
precautions are taken.
CAUTION
These warnings mean that minor injuries may occur, if no precautions
are taken.
NOTICE
These warnings mean that damage to property may occur, if no precau-
tions are taken.
These warnings contain references to safety-relevant information or gen-

eral safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.

This warning draws attention to procedures which serve to prevent or rem-

Introduction
edy emergencies or malfunctions:

SAFETY INSTRUCTION
The following procedure must be followed exactly!
Procedures marked with this warning must be followed exactly.
Notices
These notices serve to make your work easier or contain references to

further information.
Tip to make your work easier or reference to further information.
1.4 Terms used
Term Description
Conveyor Moving conveyor equipment, e.g. belt, chain, etc.
CRC Cyclic Redundancy Check
ESD ElectroStatic Discharge
On-the-fly synchro- Direct transition between robot motions that are
nization independent of the conveyor and motions that are
synchronized with the conveyor.
Tracking distance Distance over which the robot tracks the work-
piece on the conveyor
KLI KUKA Line Interface
The KLI is the Ethernet interface of the robot con-
troller for external communication. It is a physical
interface and can contain multiple virtual interfa-
ces.
KSB KUKA System Bus
KUKA bus for internal networking of the control-
lers with each other
PTP Precision Time Protocol
Network protocol for synchronization of clocks in
computer networks
RDC Resolver Digital Converter
Resolver Measurement system which calculates the dis-
tance that a conveyor has traveled
PLC Programmable Logic Controller
1.5 Trademarks
EtherCAT® is a registered trademark and patented technolo-

gy, licensed by Beckhoff Automation GmbH, Germany.
1.6 Licenses
The KUKA license conditions and the license conditions of the open-
source software used can be found in the following folders:

Introduction
• Under .\LICENSE on the data storage medium with the installation
files of the KUKA software
• Under D:\KUKA_OPT\Option package name\LICENSE after installation
on the robot controller
• In the license folder under the name of the option package in the Op-
tions catalog after installation in WorkVisual
Further information about open-source licenses can be requested from

the following address: [email protected]

Introduction KUKA.ConveyorTech 7.1

Product description
2 Product description
2.1 Overview of ConveyorTech
Functions
ConveyorTech is an add-on option package with the following functions:

• Programming of translational and rotational conveyor applications with-
in the robot controller.
• Coordination / synchronization of robot motions with linear or circular
motions of conveyor applications.
• Segmentation of conveyor operation
• Multiple conveyor tracking
Fig. 2-1: Overview of a conveyor system
1 Linear conveyor
2 Circular conveyor
3 Robot controller
4 Robot
Areas of application
Conveyor applications enable:

• Transfer
• Machining
• Unloading
• Positioning
of workpieces within a feed system.
Communication
The resolver transfers data from the conveyor to the robot controller. The
controller uses these data to calculate the transformations necessary to
synchronize the robot with the conveyor.

Product description KUKA.ConveyorTech 7.1
2.2 Intended use
Use
The ConveyorTech option package is used for gripping, processing or set-

ting down workpieces on a conveyor of any type. The precondition for this
is that the position of the workpiece at a defined point in time is known by
means of a synchronization signal (photo-electric barrier). In the case of a
sequence of multiple workpieces, a synchronization signal must be trig-
gered for each workpiece.
ConveyorTech is intended exclusively for use in an industrial environment.
Misuse
Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. The manufacturer cannot be held liable for any
resulting damage. The risk lies entirely with the user.
Examples of such misuse include:
• Gripping of workpieces located one on top of the other
• Gripping of workpieces without a synchronization signal
• Use in a non-industrial environment

Safety
3 Safety
This documentation contains safety instructions which refer specifically to
the option package 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 Integrators or the Operating and Programming Instructions for End
Users.
The “Safety” chapter in the operating and programming instructions of
the KUKA System Software (KSS) must be observed. Death to persons,
severe injuries or considerable damage to property may otherwise re-
sult.
NOTICE
The limit values for input and supply voltages must not be exceeded; in-
dividual components or complete modules may otherwise be damaged.
The corresponding ESD guidelines must be observed when handling
modules for use in the robot controller. These modules are fitted with
high-quality components and are very sensitive to electrostatic discharg-
es (e.s.d.).

Safety KUKA.ConveyorTech 7.1

Planning
4 Planning
4.1 System with conveyor connection to RDC
A total of 2 conveyors can be connected to the RDC in the base frame of

the robot with one resolver. With an additional RDC, one more conveyor
may be operated with the robot controller.
A synchronization switch (e.g. photo-electric barrier) is required for syn-
chronizing the robot with the workpiece. The synchronization switch is
mounted on the conveyor or on the robot and connected via the Fast
Measurement input. It can also be fitted on the robot tool (e.g. gripper),
for example, if different start positions are required. In this case, the appli-
cation must be specially programmed accordingly.
Fig. 4-1: System with conveyor connection to RDC
1 KR C4 robot controller
2 RDC
3 Robot
4 Resolver cable
5 Resolver
6 Conveyor
7 Synchronization switch
8 Cable for synchronization switch
9 “Fast measurement” option
4.2 External conveyor
Description
An external resolver can transfer position and workpiece information from

a linear conveyor to the robot controller via a higher-level controller, e.g. a
PLC.

Planning KUKA.ConveyorTech 7.1
The external position sensing system must be as accurate as possible

and must detect changes in velocity of the conveyor sufficiently quickly
and communicate them to the robot controller.
Precondition
• Higher-level controller is compatible with one of the following network

protocols according to IEEE standard 1588, e.g. with EtherCAT termi-
nal EL6688:
‒ PTPv1 in the case of time synchronization via the KSB
‒ PTPv2 in the case of time synchronization via the KLI
Time synchronization
The time synchronization can be implemented via one of the following in-
terfaces on the robot controller:
• RoboTeam interface X70 (KSB)
• KLI
If multiple robot controllers are to be synchronized with a higher-level con-
troller, the devices must be connected to a switch in a star configuration.
It must be ensured that the switch supports the PTP protocol. Hardware
support is recommended, as the synchronization accuracy is reduced in
the case of software support. The use of switches that do not support
PTP is not recommended, as the accuracy may be adversely affected by
a number of milliseconds depending on the load.
Fig. 4-2: System with external conveyors
1 Higher-level controller (PLC)

3 Conveyor
4 Resolver (conveyor position)
5 Robot
6 KR C4 robot controller
7 KSB or KLI interface

Planning
8 Time synchronization
9 Field bus for workpiece information
4.2.1 Communications interface to the higher-level controller
Communication between the higher-level controller and the conveyor driv-

er is carried out in a 12 ms cycle. Every 12 ms, the higher-level controller
increases the packet counter by one and the content of the remaining re-
ception structure is adapted as required.
New workpiece information must not be sent to the robot controller more
than once every 12 ms. Due to the handshake between the robot control-
ler and the higher-level controller using the workpiece ID, new workpieces
can only be transferred once every 24 ms at most.
4.2.1.1 Reception structure from the perspective of the robot controller
The reception structure has an overall size of 34 bytes.

Name Description Type Size Unit
CmdWord Control word to the robot controller unsigned 2 bytes -
short
Packet Packet counter for detecting packet unsigned 2 bytes -
Counter or reception errors short
ConvValue Conveyor position long long 8 bytes 10-6 mm
Piece Workpiece ID unsigned 2 bytes -
Identifier short
Time Time of workpiece detection long long 8 bytes 10-9 s
Position Conveyor position at which the work- long long 8 bytes 10-6 mm
piece is located
checkSum CRC32 checksum unsigned long 4 bytes -
Bits in the control word CmdWord:
Bit Name Description
0 IFC_BUS_CONV_IS_PRESENT Higher-level controller signals that it is
ready.
1 IFC_BUS_CONV_NEW_PIECE Higher-level controller signals new work-
piece.
4.2.1.2 Transmission structure from the perspective of the robot controller
The transmission structure has an overall size of 8 bytes.

Name Description Type Size Unit
StatusWord Status of the robot controller unsigned 2 bytes -
short
Piece Workpiece ID unsigned 2 bytes -
Identifier short
Mirroring of the workpiece ID of the
workpiece most recently received and
written to the workpiece memory
Checksum CRC32 checksum unsigned long 4 bytes -
Bits in the status word rc StatusWord:

Bit Name Description

0 IFC_CONV_BUS_READY_FOR Conveyor signals to the higher-level
_POSITIONS controller that the conveyor is ready to
receive position information.
1 IFC_CONV_BUS_READY_FOR Conveyor signals to the higher-level
_PIECES controller that the conveyor is ready to
receive workpiece information.

4.2.1.3 Communication sequence between robot controller and PLC
Planning
Fig. 4-3: Communication sequence

4.2.2 Checksum calculation for external conveyor
Description
In order to detect errors during the transfer of data from the PLC to the
robot controller, the data stream must be provided with a checksum. In
the robot controller, the evaluation of the checksum is implemented as fol-
lows in the programming language C++.
static void crc32Array(const char *value, unsigned long

*checksum, const int len)
{
*checksum = 0;
for (int idx = 0; idx < len; idx++)

{
*checksum = crc32Table[((*checksum) ^ value[idx]) & 0xFF]
^ ((*checksum)>>8);
}
}
PLC example program
The following example is a fragment and serves merely to illustrate how

the checksum is calculated.
TYPE ConveyorPLCtoKRC:
STRUCT
CmdWord : WORD;
PacketCounter : WORD;
ConvValue_1 : UDINT;
ConvValue_2 : UDINT;
PieceIdentifierOut : WORD;
Time_1 : UDINT;
Time_2 : UDINT;
Position_1 : UDINT;
Position_2 : UDINT;
CheckSumOut : UDINT;
END_STRUCT
END_TYPE
CrcTable : ARRAY [0..255] OF DWORD :=

16#00000000, 16#77073096, 16#EE0E612C, 16#990951BA,
16#076DC419,
16#706AF48F, 16#E963A535, 16#9E6495A3, 16#0EDB8832,
16#79DCB8A4,
16#e0d5e91e, 16#97d2d988, 16#09b64c2b, 16#7eb17cbd,
16#e7b82d07,
16#90BF1D91, 16#1DB71064, 16#6AB020F2, 16#F3B97148,
16#84BE41DE,
16#1adad47d, 16#6ddde4eb, 16#f4d4b551, 16#83d385c7,
16#136c9856,
16#646ba8c0, 16#fd62f97a, 16#8a65c9ec, 16#14015c4f,
16#63066cd9,
16#fa0f3d63, 16#8d080df5, 16#3b6e20c8, 16#4c69105e,
16#d56041e4,
16#a2677172, 16#3c03e4d1, 16#4b04d447, 16#d20d85fd,
16#a50ab56b,
16#35b5a8fa, 16#42b2986c, 16#dbbbc9d6, 16#acbcf940,
16#32d86ce3,
16#45df5c75, 16#dcd60dcf, 16#abd13d59, 16#26d930ac,
16#51de003a,

Planning
16#c8d75180, 16#bfd06116, 16#21b4f4b5, 16#56b3c423,
16#cfba9599,
16#b8bda50f, 16#2802b89e, 16#5f058808, 16#c60cd9b2,
16#b10be924,
16#2f6f7c87, 16#58684c11, 16#c1611dab, 16#b6662d3d,
16#76dc4190,
16#01db7106, 16#98d220bc, 16#efd5102a, 16#71b18589,
16#06b6b51f,
16#9fbfe4a5, 16#e8b8d433, 16#7807c9a2, 16#0f00f934,
16#9609a88e,
16#e10e9818, 16#7f6a0dbb, 16#086d3d2d, 16#91646c97,
16#e6635c01,
16#6B6B51F4, 16#1C6C6162, 16#856530D8, 16#F262004E,
16#6C0695ED,
16#1b01a57b, 16#8208f4c1, 16#f50fc457, 16#65b0d9c6,
16#12b7e950,
16#8bbeb8ea, 16#fcb9887c, 16#62dd1ddf, 16#15da2d49,
16#8cd37cf3,
16#fbd44c65, 16#4db26158, 16#3ab551ce, 16#a3bc0074,
16#d4bb30e2,
16#4adfa541, 16#3dd895d7, 16#a4d1c46d, 16#d3d6f4fb,
16#4369e96a,
16#346ed9fc, 16#ad678846, 16#da60b8d0, 16#44042d73,
16#33031de5,
16#aa0a4c5f, 16#dd0d7cc9, 16#5005713c, 16#270241aa,
16#be0b1010,
16#c90c2086, 16#5768b525, 16#206f85b3, 16#b966d409,
16#ce61e49f,
16#5edef90e, 16#29d9c998, 16#b0d09822, 16#c7d7a8b4,
16#59b33d17,
16#2eb40d81, 16#b7bd5c3b, 16#c0ba6cad, 16#edb88320,
16#9abfb3b6,
16#03b6e20c, 16#74b1d29a, 16#ead54739, 16#9dd277af,
16#04db2615,
16#73dc1683, 16#e3630b12, 16#94643b84, 16#0d6d6a3e,
16#7a6a5aa8,
16#e40ecf0b, 16#9309ff9d, 16#0a00ae27, 16#7d079eb1,
16#f00f9344,
16#8708a3d2, 16#1e01f268, 16#6906c2fe, 16#f762575d,
16#806567cb,
16#196c3671, 16#6e6b06e7, 16#fed41b76, 16#89d32be0,
16#10da7a5a,
16#67dd4acc, 16#f9b9df6f, 16#8ebeeff9, 16#17b7be43,
16#60b08ed5,
16#d6d6a3e8, 16#a1d1937e, 16#38d8c2c4, 16#4fdff252,
16#d1bb67f1,
16#a6bc5767, 16#3fb506dd, 16#48b2364b, 16#d80d2bda,
16#af0a1b4c,
16#36034af6, 16#41047a60, 16#df60efc3, 16#a867df55,
16#316e8eef,
16#4669be79, 16#cb61b38c, 16#bc66831a, 16#256fd2a0,
16#5268e236,
16#cc0c7795, 16#bb0b4703, 16#220216b9, 16#5505262f,
16#c5ba3bbe,
16#b2bd0b28, 16#2bb45a92, 16#5cb36a04, 16#c2d7ffa7,
16#b5d0cf31,
16#2cd99e8b, 16#5bdeae1d, 16#9b64c2b0, 16#ec63f226,
16#756aa39c,
16#026d930a, 16#9c0906a9, 16#eb0e363f, 16#72076785,
16#05005713,
16#95bf4a82, 16#e2b87a14, 16#7bb12bae, 16#0cb61b38,
16#92d28e9b,
16#E5D5BE0D, 16#7CDCEFB7, 16#0BDBDF21, 16#86D3D2D4,
16#F1D4E242,
16#68ddb3f8, 16#1fda836e, 16#81be16cd, 16#f6b9265b,
16#6fb077e1,

16#18b74777, 16#88085ae6, 16#ff0f6a70, 16#66063bca,

16#11010b5c,
16#8f659eff, 16#f862ae69, 16#616bffd3, 16#166ccf45,
16#a00ae278,
16#d70dd2ee, 16#4e048354, 16#3903b3c2, 16#a7672661,
16#d06016f7,
16#4969474d, 16#3e6e77db, 16#aed16a4a, 16#d9d65adc,
16#40df0b66,
16#37d83bf0, 16#a9bcae53, 16#debb9ec5, 16#47b2cf7f,
16#30b5ffe9,
16#bdbdf21c, 16#cabac28a, 16#53b39330, 16#24b4a3a6,
16#bad03605,
16#cdd70693, 16#54de5729, 16#23d967bf, 16#b3667a2e,
16#c4614ab8,
16#5d681b02, 16#2a6f2b94, 16#b40bbe37, 16#c30c8ea1,
16#5a05df1b,
16#2D02EF8D;
bytesForCRC : ARRAY[0..33] OF BYTE;

pos2temp : DWORD;
pos2 : DWORD;
crc2 : DWORD;
crc : DWORD;
i : INT;
arrayLen : INT;
DataToKRC : ConveyorPLCtoKRC;
------------------------------------------------
[...]
(*
The array bytesForCRC position 0 to 29 must contain the
data which should be sent to the KRC.
bytesForCRC is only used for the calculation of the
checksum,
not for sending the data, for sending DataToKRC is used.
*)
(* initialize the 4 bytes for checksum with 0 *)

bytesForCRC[30] := 16#00;
pos2temp := 16#00000000;
pos2 := 16#00000000;
crc2 := 16#00000000;
crc := 16#00000000
arrayLen := SIZEOF(bytesForCRC) - 1;
FOR i := 0 TO arrayLen BY 1 DO
crc := crc2;
pos2temp := crc XOR bytesForCRC[i];
pos2 := pos2temp AND 16#FF;
(*shift right by 8 bits*)
crc := SHR(crc, 8);
crc2:= crcTable[pos2] XOR crc;
END_FOR
(*

Planning
The variable crc2 contains the checksum for the data.
The value must be copied into the send structure to the
KRC.
*)
DataToKRC.CheckSumOut := crc2;


Start-up and recommissioning

5 Start-up and recommissioning
5.1 Overview
This is an overview of the most important steps during the start-up of

KUKA.ConveyorTech 7.1. The precise sequence depends on the appli-
cation and other system-specific circumstances.
For this reason, the overview does not claim to be comprehensive.
Step Description
1 Connect resolver to RDC (not for external conveyors).
(>>> 5.2 "Connecting a resolver to the RDC" Page 25)
2 Configure ConveyorTech in WorkVisual.
(>>> 7.1 "Overview: configuration in WorkVisual" Page 33)
3 Calibrate the conveyor.
(>>> 9.1 "Calibrating a linear conveyor" Page 55)
(>>> 9.2 "Calibrating a circular conveyor" Page 56)
4 Check the conveyor distance. (optional)
(>>> 9.3 "Checking the conveyor distance" Page 57)
5 Calibrate the workpiece on the conveyor. (optional)
(>>> 9.4 "Calibrating the workpiece on the conveyor"
Page 58)
5.2 Connecting a resolver to the RDC
Description
The following hardware is required:

• Resolver with cable (1 cable per conveyor)
• Synchronization switch (1 switch per conveyor)
• “Fast measurement” option
Only resolvers from KUKA Deutschland GmbH may be connected to the

robot’s RDC.
The hardware may only be connected by a skilled electrician in accord-

ance with the generally applicable electrical engineering rules.
When designing the mechanical coupling of the resolver (e.g. defining

the transmission ratio for a belt coupling), one should aim for the con-
veyor to cover a distance of approximately 1 mm per degree [°]. The
minimum acceptable degree of accuracy is provided by a distance of
3 mm per degree. Values greater than 3 mm per degree should be
avoided.
Procedure
1. Unscrew 4 fastening screws from the housing cover of the RDC and
remove the cover.

Start-up and recommissioning KUKA.ConveyorTech 7.1
Fig. 5-1: RDC housing
1 Fastening screw on the housing cover
2. Plug the flat connector of the connecting cable into one of the free
connections via the SKINTOP® cable gland. The cable gland is loca-
ted on the side of the RDC box. The connector locks itself in place.
Fig. 5-2: Connecting the resolver cable to the RDC
1 Free connections on the RDC
3. Connect the other end of the connecting cable to the resolver .

Start-up and recommissioning

Fig. 5-3: Connecting the resolver cable to the resolver
1 Connection for the connecting cable on the resolver
4. Remount the housing cover and secure it with 4 fastening screws.

Start-up and recommissioning KUKA.ConveyorTech 7.1

Installation
6 Installation
The option package can either be installed on the robot controller via the
smartHMI or via WorkVisual.
6.1 System requirements
Hardware
Robot controller:
• KR C4
Robot:
• Any robot that can be operated with a KR C4

Conveyor system:
• A maximum of 5 conveyors may be operated using one robot control-

ler.
The conveyors can either be connected to the RDC with a resolver or
to the robot controller via a higher-level controller. A combination of
both connection types is also possible.
Software
Robot controller:
• KUKA System Software 8.5.x

Laptop/PC:
• WorkVisual 5.0.x
The requirements for installation of WorkVisual are contained in the
WorkVisual documentation.
The numbers of the required releases must be taken from the file Relea-
seNotes_[…].txt. The file is located on the data storage medium contain-
ing KUKA.ConveyorTech 7.1.
6.2 Installation via WorkVisual
6.2.1 Installing or updating ConveyorTech
Description
The option package is installed in WorkVisual and added to the project.

During project deployment, the option package is automatically installed
on the robot controller.
In the case of an update, the previous version of the option package in
WorkVisual must first be uninstalled.
It is advisable to archive all relevant data before updating a software
package.
Precondition
• User group “Expert”

• T1 or T2 mode

Installation KUKA.ConveyorTech 7.1
• No program is selected.
• Network connection to the robot controller
• The option package is available as a KOP file.
Procedure
1. Only for an update: Uninstall the previous version of the Conveyor

option package in WorkVisual.
2. Install the Conveyor option package in WorkVisual.
3. Load the project from the robot controller.
4. Add the Conveyor option package to the project.
5. Configure the option package in WorkVisual.
(>>> 7.1 "Overview: configuration in WorkVisual" Page 33)
6. Deploy the project from WorkVisual to the robot controller and activate
it.
7. The request for confirmation Do you want to activate the project […]?
is displayed. The active project is overwritten during activation. If no
relevant project will be overwritten: Answer the query with Yes.
8. An overview with the changes and a request for confirmation are dis-
played on the smartHMI. Answer this with Yes. The option package is
installed and the robot controller carries out a reboot.
Information about procedures in WorkVisual is contained in the WorkVi-

sual documentation.
LOG file
A LOG file is created under C:\KRC\ROBOTER\LOG.
6.2.2 Uninstalling ConveyorTech
It is advisable to archive all relevant data before uninstalling a software

package.
Precondition

• T1 or T2 mode
Procedure

2. Remove the conveyor from the project.
3. Remove the Conveyor option package from the project. A window
with modifications is displayed.
it.
5. Answer the request for confirmation Do you want to activate the
project […]? with Yes.
uninstalled and the robot controller carries out a reboot.

Installation
sual documentation.
LOG file
6.3 Installation via smartHMI
6.3.1 Installing or updating ConveyorTech
It is advisable to archive all relevant data before updating a software

package.
Precondition
• User rights: Function group General configuration

But at least the user group “Expert”
• T1 or T2 mode
• USB stick with the option package (KOP file)
NOTICE
We recommend using a KUKA USB stick. Data may be lost if a stick
from a different manufacturer is used.
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 Conveyor 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.
Otherwise, the path from which the software is to be installed must be
configured first:
a. Press the Configure button.
b. Select a line in the Installation paths for options area.
Note: If the line already contains a path, this path will be overwrit-
ten.
c. Press Path selection. The available drives are displayed.
d. If the stick is connected to the robot controller: Select E:\.
If the stick is connected to the smartPAD: K:\ instead of E:\
e. Press Save. The Installation paths for options area is displayed
again. It now contains the new path.
f. Mark the line with the new path and press Save again.
5. Activate the check box next to Conveyor and press Install. Confirm
the installation query with OK.

Installation KUKA.ConveyorTech 7.1
7. An overview of the changes and a request for confirmation are dis-

played. Answer this with Yes. The option package is installed and the
robot controller carries out a reboot.
8. Remove the stick.
LOG file
6.3.2 Uninstalling ConveyorTech
It is advisable to archive all relevant data before uninstalling a software

package.
Precondition
• User rights: Function group General configuration

But at least the user group “Expert”
• T1 or T2 mode
Procedure

2. Activate the check box next to Conveyor and press Uninstall. Answer
the request for confirmation with Yes.
played. Answer this with Yes. The option package is uninstalled and
the robot controller carries out a reboot.
LOG file

Configuration
7 Configuration
7.1 Overview: configuration in WorkVisual
Step Description
1 Install the Conveyor option package in WorkVisual.
2 Load the project from the robot controller.
3 Insert the conveyor in the project.
(>>> 7.2 "Inserting a conveyor in a project" Page 33)
4 Insert the resolver into the project and modify the connec-
tion between the synchronization switch and the CIB if re-
quired (not for external conveyors).
(>>> 7.3 "Inserting a resolver in a project" Page 34)
(>>> 7.4 "Modifying the connection between the synchroni-
zation switch and the CIB" Page 35)
5 Define the conveyor as motion master.
(>>> 7.5 "Defining the conveyor as motion master"
Page 36)
6 Configure time synchronization (only for external convey-
ors).
(>>> 7.6 "Configuring time synchronization" Page 37)
7 Configure the conveyor parameters in the machine data.
(>>> 7.7 "Configuring conveyor parameters in the machine
data" Page 39)
8 Edit the global conveyor settings.
(>>> 7.8 "Editing global conveyor settings" Page 45)
9 Generate long texts for conveyor I/Os.
(>>> 7.9 "Configuring I/Os and adding long texts"
Page 45)
10 Transfer the project from WorkVisual to the robot controller.
Information about installing and managing option packages can be

found in the WorkVisual documentation.
Information about bus configuration and project deployment can be

found in the WorkVisual documentation.
7.2 Inserting a conveyor in a project
Description
A maximum of 5 conveyor systems can be inserted into a WorkVisual

project.
Precondition
• The project is open.

• The robot has been inserted into the project and configured.

Configuration KUKA.ConveyorTech 7.1
Procedure
1. Right-click on the robot controller in the Project structure (Hardware

tab) or in the Cell configurationand select Add... from the context
menu.
2. Select the Options tab and select the desired conveyor type in the
Conveyor catalog:
• LinearConveyor for a linear conveyor
• CircularConveyor for a circular conveyor
• LinearConveyorExt for an external linear conveyor
3. Click on Add.
If the option package Conveyor is not yet present in the project, a di-
alog opens. The files being added or modified are indicated there.
4. Click on OK. The dialog closes. The conveyor is inserted and as-
signed to the robot controller.
The conveyor can now be renamed. To do this, enter a new name
in the Properties window. This name is displayed in the inline forms
on the robot controller.
5. If required, repeat steps 1 to 4 to insert further conveyors.
7.3 Inserting a resolver in a project
Description
For every conveyor that is connected to the RDC of the robot via a re-
solver, a resolver must be inserted into the WorkVisual project. This is not
necessary for external conveyors.
Precondition

• The conveyor has been inserted into the project.
Procedure
1. Open the Drive configuration window: Menu sequence Editors >

Drive configuration
2. Select the catalog KukaControllers and open the Components folder.
3. Drag the element Position Tracker into the Drive configuration win-
dow. The resolver is inserted and automatically assigned.
4. The synchronization switch on the conveyor is automatically connected
to the next free input of interface X33 (Fast Measurement).
If the synchronization switch has been wired to a different input of the
interface, the connection must be modified in the Drive configuration
window.
(>>> 7.4 "Modifying the connection between the synchronization switch
and the CIB" Page 35)
5. Close the Drive configuration window.
As an alternative to this procedure, the correction proposal of the Work-

Visual project analysis can be accepted.

Configuration
Example
Fig. 7-1: Drive configuration for a circular conveyor
1 Cabinet Interface Board (CIB)

2 Inputs 1 … 4 of interface X33
3 Connection between the synchronization switch and the inputs of
interface X33
4 Circular conveyor
5 Resolver
7.4 Modifying the connection between the synchronization switch and the
CIB
Description
When the resolver is inserted into the WorkVisual project, the synchroniza-
tion switch on the conveyor is automatically connected to the next free in-
put of interface X33 (Fast Measurement). If the real synchronization switch
has been wired to a different input of the interface, the connection must
be changed in WorkVisual.
For external conveyors connected to the robot controller via a higher-
level controller, the following procedure is not relevant.
Precondition

• The resolver has been inserted into the project.
Procedure
1. Open the Drive configuration window: Menu sequence Editors >

Drive configuration
2. Select the connecting line between the synchronization switch and the
input of interface X33.
3. Right-click and select Do not keep selected connections from the
context menu.
4. Click on the synchronization switch and hold down the mouse button.
5. Drag the mouse pointer to the desired input and release the mouse
button. The synchronization switch is now connected to the desired in-
put.

6. Close the Drive configuration window.
Example
Fig. 7-2: Drive configuration: Connection to CIB
1 Cabinet Interface Board (CIB)

2 Inputs 1 … 4 of interface X33
3 Connecting line
5 Circular conveyor
7.5 Defining the conveyor as motion master
Precondition

• The resolver for the conveyor has been inserted into the project (not
for external conveyors).
Procedure
1. Open the Cell configuration window: Menu sequence Editors > Cell
configuration
2. Click on the robot in the cell configuration and hold down the mouse
button.
3. Drag the mouse pointer to the conveyor and release the mouse but-
ton. A selection menu is opened.
4. Click on Robot should follow conveyor.
The robot can now follow the conveyor. This is indicated by a dotted
arrow. The arrow is red if the root points have not yet been calibrated.
5. Open the Tool/base management editor and assign a number to the
BASE coordinate system of the workpiece. The motions are taught in
this BASE coordinate system.
6. Optional: Add further BASE coordinate systems to the conveyor.
a. Click on Reset filter. The Available tools and bases area is dis-
played.
b. In this area, add one or more BASE coordinate systems to the
conveyor. The names of the coordinate systems can be changed.

Configuration
c. Assign a number to each coordinate system.
7. Close the Cell configuration window.
As an alternative to this procedure, the correction proposal of the Work-

Visual project analysis can be accepted.
Example
Fig. 7-3: Robot following a circular conveyor
1 The circular conveyor is the motion master of the robot.
7.6 Configuring time synchronization
Description
For use of an external conveyor, it is necessary for the clocks of the con-
troller and the external system to be synchronized. For this, time synchro-
nization must be activated in the additional controller options in WorkVisu-
al and, depending on the system configuration, further settings must be
carried out:
• Define the interface for time synchronization (KSB or KLI).
• Optional: Activate VLAN tagging for KSB.
Precondition:
‒ The hardware and software used support VLAN tagging with

ID 10.
• If desired, define the selected controller as the master for the time
synchronization.
Within a single network, only one controller can function as the master
for the time synchronization. This can also be the higher-level control-
ler, e.g. the PLC.
Precondition
• The conveyor system is not part of a RoboTeam network.

If a RoboTeam network has been created, the settings for time syn-
chronization are not available. In this case, the time synchronization
is managed by the RoboTeam functionality.
• A project is open.

• An external conveyor has been inserted in the project.
Procedure
1. Select on the robot controller in the Project structure (Hardware tab)

or in the Cell configuration.
2. Select the menu sequence Editors > Additional controller settings.
The Additional controller settings window opens.
3. Activate the time synchronization and make the required settings.
4. Save the project.
Parameter
Name Description
Activate time syn- Activating/deactivating time synchronization
chronization
• Check box active: Time synchronization is
activated.
• Check box not active: Time synchronization
is deactivated.
Default: Check box not active
Time synchronization Interface for time synchronization via the net-
interface work
• KSB (PTPv1)
The KSB only supports PTPv1.
• KLI (PTPv2)
The KLI only supports PTPv2.
Default: KSB (PTPv1)
Activate VLAN tag- Activating/deactivating VLAN tagging for KSB
ging (KSB)
If VLAN tagging is activated, the data packets
are labeled and transferred with ID 10.
• Check box active: VLAN tagging is activa-

ted for KSB.
• Check box not active: VLAN tagging for
KSB is deactivated.
Set controller as Sets the selected controller as the master for
time master the time synchronization.
• Check box active: Controller is set as mas-

ter.
• Check box not active: Controller is not set
as master. A different controller in the net-
work functions as the master for the time
synchronization.

Configuration
7.7 Configuring conveyor parameters in the machine data
Description
In WorkVisual, various parameters in the machine data can be configured

for each conveyor:
• General I/O parameters (only for external conveyors)
• Alarm and stop distances
• Conveyor-specific expert parameters
• Escape strategy
Precondition

• The resolver for the conveyor has been inserted into the project (not
for external conveyors).
Procedure
1. Double-click on the conveyor in the Project structure (Hardware tab).

The machine data editor is opened.
2. Edit the machine data of the conveyor as required.
• (>>> 7.7.1 "General I/O parameters" Page 39)
• (>>> 7.7.2 "Conveyor-specific expert parameters" Page 40)
• (>>> 7.7.3 "Alarm and stop distances" Page 41)
• (>>> 7.7.4 "Escape strategy" Page 42)
7.7.1 General I/O parameters
Only available for external conveyors

Name Description
First input bit First bit for inputs of the I/O mapping for the
external conveyor
Arranged by bytes:
• 1
• 9
• 17
• …
Default: 1
First output bit First bit for outputs of the I/O mapping for the
external conveyor
Arranged by bytes:
• 1
• 9
• 17
• …
Default: 1

7.7.2 Conveyor-specific expert parameters
Name Description
Number of IPO cy- Number of interpolation cycles for calculating
cles the average conveyor velocity
If higher values are used, the robot motions
are smoother. This also has the effect, howev-
er, that the robot responds more slowly to
changes in the velocity of the conveyor.
Default: 10
Filter active Activating/deactivating filters
The filter compensates for small, jerky changes
to the velocity of the conveyor and thus en-
sures a smooth robot motion.
• Check box active: filter is active.

• Check box not active: filter is not active.
Default: check box not active
Note: It is generally not necessary to change
the default setting.
Delay [ms] Time (in ms) for compensation for the delay
and reaction times inherent in the motion con-
trol
Default: 24 ms
the default value.
Trace index Offset to KRCIpoTraceFeature-Channel Con-
veyorData
Default values per conveyor:
• 1st conveyor: 0
• 2nd conveyor: 10
• 3rd conveyor: 20
• 4th conveyor: -1
Note: A trace recording can be created for a
maximum of 1 conveyor at a time. A total of 32
channels are available for a recording and
each conveyor requires 19 channels. If a trace
recording is to be created for a conveyor, this
must be configured accordingly.
Resolver transmis- Transmission ratio between the translational or
sion ratio rotational distance traveled by the conveyor
and the number degrees supplied by the re-
solver
Default: 10
Note: This parameter is automatically calcula-
ted during calibration. No modification is
usually necessary.

Configuration
Name Description
Debouncing [ms] Cannot be configured for external conveyors
Minimum time (in ms) between 2 measurement
signals in order to be able to interpret them as
2 separate signals
Default: 12 ms
7.7.3 Alarm and stop distances
Name Description
Alarm distance Alarm distance
If the robot tracks a workpiece on the conveyor
over the alarm distance, a corresponding mes-
sage is generated and a configured output is
reset.
Default values:
• Linear conveyor: 2000 mm

• Circular conveyor: 2000 °
Maximum distance Maximum conveyor distance the robot can trav-
el as a synchronized motion.
As soon as the robot has reached the defined
value, the synchronized motion is canceled and
the robot executes the motion programmed in
the subprogram CONV_QUIT.
Default values:

Interrupt for alarm Interrupt number for the alarm distance
distance
The number determines the priority in which si-
multaneous interrupts are executed.
Default: 21 … 25
Interrupt for max. Interrupt number for the maximum conveyor
distance distance
Default: 26 … 30
Interrupt for stop Interrupt number for a $STOPMESS error dur-
signal ing the conveyor tracking motion
$STOPMESS is set in order to indicate the oc-
currence of a message requiring the robot to
be stopped (e.g. EMERGENCY STOP or oper-
ator safety violation).
Default: 31 … 35
Output for alarm dis- Output number for the alarm distance
tance
Default: 731 … 735

Name Description
Output for stop sig- Output number for $STOPMESS error
nal
Default: 701 … 705
7.7.4 Escape strategy
As standard, a stop request of the robot triggers a drive ramp stop; the
conveyor continues moving and the synchronization is lost.
Alternatively, a stop strategy can be configured in which the conveyor also
stops in the case of a stop request of the robot and the synchronization is
retained.
Name Description
Stop strategy Stop strategy
• GEN_STOP
A stop request of the robot leads to a drive
ramp stop. The conveyor continues moving
and the synchronization is lost.
• CONV_STOPPABLE
In the case of a stop request of the robot,
the robot controller sets an output that is
linked to a higher-level controller from
TRUE to FALSE. The higher-level controller
can then stop the conveyor synchronously
with the robot.
Default: GEN_STOP
Timeout for confir- Only relevant for the stop strategy
mation [ms] CONV_STOPPABLE
MON_TIME_ACKNOWLEDGE: Time within
which, at the latest, the higher-level controller
must have confirmed that it has received the
stop request
Default: 48 ms
Timeout for stop Only relevant for the stop strategy
[ms] CONV_STOPPABLE
MON_TIME_CONV_STOP: Time after receipt
of the stop request within which, at the latest,
the higher-level controller must have stopped
the conveyor
Default: 1500 ms
Input for Stop re- Only relevant for the stop strategy
quest confirmation CONV_STOPPABLE
IN_STOP_ACKNOWLEDGE: Index of the input
$IN[x] used by the higher-level controller to in-
form the robot controller that it has received
the stop request
Default: -1

Configuration
Name Description
Output for Stop re- Only relevant for the stop strategy
quest CONV_STOPPABLE
OUT_STOP_REQUEST: Index of the output
$OUT[x] used to transfer the stop request of
the robot to the higher-level controller
Default: -1
7.7.4.1 Signal diagram for stop strategy CONV_STOPPABLE
Description
If the stop strategy is configured for a conveyor, a stop request of the ro-
bot results in the following sequence:
1. A stop of the robot is requested during a synchronized motion, e.g. by
pressing the EMERGENCY STOP device on the smartPAD or the
STOP key.
2. The configured output OUT_STOP_REQUEST is set from TRUE to
FALSE.
3. The higher-level controller confirms the stop request via the configured
input IN_STOP_ACKNOWLEDGE (HIGH level expected).
Error case 1:
• Drive ramp stop if the confirmation is received after the configured

time MON_TIME_ACKNOWLEDGE has elapsed.
4. Conveyor and robot are stopped. The robot is stopped on the convey-
or base with path-maintaining braking (BCO is retained).
Error case 2:
• Drive ramp stop if the conveyor does not come to a standstill with-
in the configured time MON_TIME_CONV_STOP (BCO is lost.)
5. If the conveyor application is resumed after a reset or after a block se-
lection, the output OUT_STOP_REQUEST is reset to TRUE. The
robot continues tracking the conveyor base.
Good case
The figure shows the signal diagram for the good case: Conveyor applica-
tion can be resumed.
Fig. 7-4: Good case: resumption of conveyor application possible

Blue $OUT[OUT_STOP_REQUEST]
Red $IN[IN_STOP_ACKNOWLEDGE]
Green Conveyor progress
Error case 1
The figure shows the signal diagram for the following error case: Confir-
mation from higher-level controller is too late. This results in a drive ramp
stop.
• Configured maximum time for the confirmation: 1200 ms
• Time actually required for the confirmation: 1950 ms
Fig. 7-5: Fault: higher-level controller confirmation too late
Error case 2
The figure shows the signal diagram for the following error case: Convey-
or is stopped too late.
After the higher-level controller has confirmed the stop request, the con-
veyor continues moving and does not stop within the configured time. This
results in a drive ramp stop.
Fig. 7-6: Fault: conveyor is stopped too late

Configuration
7.8 Editing global conveyor settings
Description
The global conveyor settings are valid for all conveyors tracked by the ro-
bot and are carried out for each robot controller.
Precondition

• At least 1 conveyor has been inserted into the project.
Procedure
1. Open the Options folder in the Project structure (Hardware tab).

2. Right-click on the Conveyor option package and select Global con-
veyor settings. The editor is opened.
3. Edit the global conveyor settings as required.
Parameter
Name Description
Continue after Stop Resuming/stopping robot motion after
$STOPMESS error
• Check box active: Following a $STOPM-

ESS error, the robot motion on the convey-
or is resumed.
• Check box not active: Following a
$STOPMESS error, the robot motion on the
conveyor is stopped.
Timer index Timer index of the conveyor system
• 1 … 32
Default: 1
7.9 Configuring I/Os and adding long texts
Description
Long texts can be generated in WorkVisual for the I/O configured in the
machine data of a conveyor.
• The following outputs must be configured for every conveyor type:
‒ Output for alarm distance
‒ Output for stop signal
• The following parameters must additionally be configured for external
conveyors:
‒ First input bit
‒ First output bit
• The long texts for the I/Os are created in the long text editor accord-
ing to the following pattern:
‒ Conveyor name + Function

Example:
Configuration
‒ LinearConveyorExt2 Output for alarm distance
Precondition

• At least 1 conveyor has been inserted into the project.
• One resolver per conveyor has been inserted into the project (not for
external conveyors).
• The robot controller has been set as the active controller.
Procedure
1. Select the Hardware tab in the Project structure window.

2. Double-click on the conveyor that is to be configured. The machine
data editor is opened.
3. Configure the conveyor I/Os as required.
(>>> "Parameter" Page 46)
In the I/O configuration, it must be ensured that there are no over-
laps with other I/Os.

5. Right-click on the conveyor and select Add long texts for I/Os from
the context menu.
6. Repeat steps 2 to 5 for all further conveyors that are present in the
project.
7. If required, display and or edit the long texts for the configured I/Os in
the long text editor:
a. Select the menu sequence Editors > Symbol Table Editor.
b. The long texts are sorted thematically. In the left-hand column, se-
lect the long texts that are to be displayed:
• Digital inputs
• Digital outputs
Parameter
In the machine data of a conveyor under Distances:

Name Description
tance
Default: 731 … 735
nal
Default: 701 … 705
In the machine data of an external conveyor under General:

Configuration
Name Description
First input bit First bit for inputs of the I/O mapping for the
external conveyor
Arranged by bytes:
• 1
• 9
• 17
• …
Default: 1
First output bit First bit for outputs of the I/O mapping for the
external conveyor
Arranged by bytes:
• 1
• 9
• 17
• …
Default: 1


Operation
8 Operation
8.1 Displaying user rights
Description
The functions of a software package are assigned various function groups.

In the rights management, the minimum user group required to execute a
function is defined for each function group.
• The administrator can assign other user groups to the function groups.
• The assignment of the individual functions to the function groups can-
not be changed.
• Every user can display which user groups are currently assigned to
which function groups.
Further information about function groups and user rights is contained in

the operating and programming instructions for the KUKA System Soft-
ware (KSS).
If a function group is relevant for a procedure, this is indicated under Pre-

condition.
Procedure
The user groups assigned to the function groups can be displayed:

1. In the main menu, select Start-up > Rights management.
The Rights management window opens.
2. Select the Function groups tab.
8.2 Modifying global conveyor settings
Description
The global conveyor settings are configured in WorkVisual, but can be

modified subsequently on the smartHMI. They are valid for all conveyors
tracked by the robot and are carried out for each robot controller.
Precondition
• User group Expert
Procedure
1. In the main menu, select Configuration > Conveyor configuration >

Expert parameters. The configuration window is opened.
2. Modify the global settings as required.
3. Press Save.
4. Select Shutdown in the main menu and select the options Cold start
and Reload files. Reboot the robot controller; the changes are ap-
plied.

Operation KUKA.ConveyorTech 7.1
Parameter
Name Description
Continue after Stop Resuming/stopping robot motion after
$STOPMESS error
• Check box active: Following a $STOPM-

ESS error, the robot motion on the convey-
or is resumed.
• Check box not active: Following a
$STOPMESS error, the robot motion on the
conveyor is stopped.
Timer index Timer index of the conveyor system
• 1 … 32
Default: 1
8.3 Modifying conveyor-specific settings
Description
These settings are configured in WorkVisual for each conveyor in the sys-
tem, but can be modified subsequently on the smartHMI.
Precondition
Procedure

Expert parameters. The configuration window is opened.
2. Select the desired conveyor and modify the conveyor-specific settings
as required.
3. Press Save.
plied.

Operation
Parameters
Name Description
Number of IPO cy- Number of interpolation cycles for calculating
cles the average conveyor velocity
If higher values are used, the robot motions
are smoother. This also has the effect, howev-
er, that the robot responds more slowly to
changes in the velocity of the conveyor.
Default: 10
Filter active Activating/deactivating filters
The filter compensates for small, jerky changes
to the velocity of the conveyor and thus en-
sures a smooth robot motion.
• Check box active: filter is active.

• Check box not active: filter is not active.
Default: check box not active
the default setting.
Delay [ms] Time (in ms) for compensation for the delay
and reaction times inherent in the motion con-
trol
Default: 24 ms
the default value.
Debouncing [ms] Cannot be configured for external conveyors
Minimum time (in ms) between 2 measurement
signals in order to be able to interpret them as
2 separate signals
Default: 12 ms
Trace index Offset to KRCIpoTraceFeature-Channel Con-
veyorData
Default values per conveyor:
• 1st conveyor: 0
• 2nd conveyor: 10
• 3rd conveyor: 20
Note: A trace recording can be created for a
maximum of 1 conveyor at a time. A total of 32
channels are available for a recording and
each conveyor requires 19 channels. If a trace
recording is to be created for a conveyor, this
must be configured accordingly.

8.4 Modifying alarm and stop distances
Description
The alarm and stop distances are configured in WorkVisual for each con-
veyor in the system, but can be modified subsequently on the smartHMI.
Precondition
Procedure

Distances. The configuration window is opened.
2. Select the desired conveyor and modify the alarm and stop distances
as required.
3. Press Save.
plied.
Parameter
Name Description
Alarm distance Alarm distance
If the robot tracks a workpiece on the conveyor
over the alarm distance, a corresponding mes-
sage is generated and a configured output is
reset.
Default values:

Maximum distance Maximum conveyor distance the robot can trav-
el as a synchronized motion.
As soon as the robot has reached the defined
value, the synchronized motion is canceled and
the robot executes the motion programmed in
CONV_QUIT.
Default values:

Interrupt for alarm Interrupt number for the alarm distance
distance
Default: 21 … 25
Interrupt for max. Interrupt number for the maximum conveyor
distance distance
Default: 26 … 30

Operation
Name Description
Interrupt for stop Interrupt number for a $STOPMESS error dur-
signal ing the conveyor tracking motion
$STOPMESS is set in order to indicate the oc-
currence of a message requiring the robot to
be stopped (e.g. EMERGENCY STOP or oper-
ator safety violation).
Default: 31 … 35
tance
Default: 731 … 735
nal
Default: 701 … 705
Workpiece tracking with alarm and stop distances
Fig. 8-1: Alarm and stop distances
1 Wait distance
Distance traveled by the workpiece while the robot waits before
starting to track the workpiece on the conveyor
2 Maximum distance
Maximum distance traveled by the workpiece before the robot
starts to synchronize itself with the workpiece
3 Workpiece tracking
4 Alarm distance
5 Maximum conveyor distance
Wait distance and maximum distance are defined using the inline forms
Follow and Skip in the conveyor application program.


Calibration
9 Calibration
9.1 Calibrating a linear conveyor
Description
Calibration is carried out using 3 points. These points are labeled P1, P2
and P3 in the following diagram.
The accuracy of the conveyor applications created subsequently de-
pends on the accuracy with which these points are calibrated. Ensure
that the TCP points exactly to the point in question.
It is recommended to calibrate the conveyor with the direction of motion

that will also be used in subsequent operation.
Fig. 9-1: Calibration, linear
1 Conveyor 2 Direction of travel

The point P1 can be any point on the conveyor, but should be clearly
identifiable for further use. It is advisable to select a point in the start area
where the robot starts to track the workpiece. This reference point defines
the origin of the conveyor BASE. All conveyor programs will use this
BASE as a reference. In order to be able to repeat the calibration, it is im-
portant to define and mark this reference point in such a way that it can
be used again.
Point P2 is point P1, but offset by the distance traveled by the conveyor.
P2 defines the positive X axis of the conveyor BASE. It is advisable to se-
lect a position for P2 at the end of the area in which the robot can track
the workpiece on the conveyor. As large a distance as possible should be
selected between P1 and P2.
Point P3 must be in the positive XY plane of the conveyor BASE. This
point determines the orientation of the conveyor plane.
Precondition
• Operating mode T1
Procedure
1. In the main menu, select Start-up > Calibrate > Conveyor > Calibra-
tion. The Conveyor calibration window opens.
2. In the Calibration box, select the entry Calibrate conveyor.
3. In the Conveyor box, select the conveyor to be calibrated.
4. In the Measuring tool box, select the number of the tool (gauge pin)
used.
5. Press Execute. The calibration is started.
6. Place the workpiece on the conveyor and start the conveyor.

Calibration KUKA.ConveyorTech 7.1
7. Once the workpiece has passed the synchronization switch and the
synchronization signal has been detected, stop the conveyor and
press Next.
8. Move the TCP to the origin of the conveyor BASE (P1) and press
Continue.
9. Move the conveyor and then stop it again.
10. Position the TCP at the now offset origin (P2) and press Continue.
11. Move the TCP to any point in the positive XY plane of the conveyor
BASE (P3) and press Finish.
9.2 Calibrating a circular conveyor
Description

Fig. 9-2: Calibration, circular
1 Direction of travel of the con- 3 Robot

veyor
2 Conveyor
XR is the X axis and YR is the Y axis of the ROBROOT coordinate sys-
tem. XC is the X axis and YC is the Y axis of the conveyor BASE (MA-
CHINE_DEF[].ROOT).
where the robot starts to track the workpiece. This reference point is situ-

ated on the X axis of the conveyor BASE and defines the orientation of
Calibration
the conveyor BASE. The origin of the conveyor BASE is situated in the
(virtual) pivot point of the circular conveyor. All conveyor programs will use
this BASE as a reference. In order to be able to repeat the calibration, it
is important to define and mark this reference point in such a way that it
can be used again.
P2 should be in the middle of the area in which the robot can track the
workpiece on the conveyor.
Point P3 is also point P1, but offset by the distance traveled by the con-
veyor after P2. P3 should be as near as possible to the end of the area in
which the robot can track the workpiece on the conveyor.
Precondition
Procedure
used.
press Next.
8. Move the TCP to a point on the positive X axis of the conveyor BASE
(point P1) and press Continue.
9. Jog the conveyor.
10. Position the TCP at the now offset point P1 (P2) and press Continue.
The point should be near the middle of the tracking zone.
12. Position the TCP at the now even further offset point P1 (P3). The
point should be as near as possible to the end of the tracking zone.
13. Press Finish.
9.3 Checking the conveyor distance
Description
Once the conveyor has been calibrated it is possible to check the meas-
ured conveyor distance. This is saved in the variable CAL_DIG[x].
Precondition
Procedure
2. In the Calibration box, select the entry Check resolver ratio.

3. In the Conveyor box, select the conveyor for which the conveyor dis-
tance is to be checked.
used.
5. Press Execute. The check is started.
synchronization signal has been detected, allow the conveyor to run a
little further. Then stop it and press Next. The distance should be long
enough to be measured easily.
8. Measure the distance between the workpiece and the synchronization
point.
9. Compare the displayed value with the measured value.
10. If the value matches, press Cancel and answer the request for confir-
mation with Yes.
If the value does not match, calibrate the conveyor again or carry out
the following steps:
a. Press Modify.
b. Enter the manually measured value in the Distance or Angle box.
c. Press Finish.
9.4 Calibrating the workpiece on the conveyor
Description
Calibration of a workpiece on the conveyor is carried out using 3 points.

These points are labeled P4, P5 and P6 in the following diagram.
Fig. 9-3: Calibrating the workpiece on the conveyor
1 Conveyor 2 Workpiece
Point P4 is the coordinate origin of the workpiece BASE. The definition of
the workpiece BASE corresponds to the default definition of BASE in the
robot. It is important for the points on the workpiece to be defined unam-
biguously. The exact position at which the conveyor was stopped is insig-
nificant.
Point P5 is a point on the positive X axis of the workpiece BASE.
Point P6 is a point in the positive XY plane of the workpiece BASE.
Precondition
• The conveyor is calibrated.


Calibration
Procedure
2. In the Calibration box, select the entry Calibrate part base.
3. In the Conveyor box, select the conveyor on which the workpiece is
to be calibrated.
used.
5. Only if more than one BASE coordinate system has been configured
in WorkVisual: in the Part base box, select the BASE coordinate sys-
tem that is to be calibrated.
synchronization signal has been detected, allow the conveyor to run a
little further and stop it at a position in which the workpiece BASE can
be measured easily. Then press Next.
9. Move the TCP to the coordinate origin of the workpiece BASE (P4)
and press Continue.
10. Move the TCP to a point on the positive X axis (P5) and press Con-
tinue.
11. Move the TCP to a point in the positive XY plane of the workpiece
BASE (P6) and press Finish.


Programming
10 Programming
10.1 Creating a conveyor application program
Description
A special program structure must be used for all conveyor applications.

The conveyor commands will only function within this structure. This struc-
ture must not be altered.
Groups of synchronized motions are programmed in the subprogram
CONV_MOV. The motions are taught in a BASE that has been configured
in WorkVisual and calibrated on the smartHMI.
Motions to move the robot out of the conveyor area are programmed in
the subprogram CONV_QUIT. This is necessary if the maximum tracking
distance has been reached or in the case of an EMERGENCY STOP.
The motions in the subprogram CONV_QUIT cannot be synchronized
with the conveyor.
Precondition
• Not all folders allow the creation of new folders within them.
• User rights: Function group File operations
‒ Depending on the folder in which the program is to be created, the
“Expert” user group or higher may be required.
Procedure
1. In the directory structure of the Navigator, select the folder in which

the program is to be created, e.g. the folder KRC:\R1\Program.
2. Select the file list of the Navigator and press the New button.
The Template selection window opens.
3. Select the Conveyor template and confirm with OK.
4. Enter a name for the program and confirm it with OK.
Conveyor template
1 DEF Conveyor()
2
3 INI
4 CONV INI
5
6 PTP HOME Vel= 100 % DEFAULT
7
8 LOOP
9
10 ENDLOOP
11
12 END
13
14 DEF CONV_MOV(Z_CONV_NBR:IN,Z_MOV_NBR:IN)
15 INI CONV_MOV
16
17 CONVEYOR 1 MOVEMENT GROUP 1
18
20

Programming KUKA.ConveyorTech 7.1
22
24
26
28
29 END CONV_MOV
30 CONTINUE
31 END
32
33 DEF CONV_QUIT(Z_CONV_NBR:IN,B_STOP_AFTER_LEAVING:IN)
34 INT Z_CONV_NBR
35 BOOL B_STOP_AFTER_LEAVING
36 INT Z_ADVANCE_OLD
37
38 Z_ADVANCE_OLD=$ADVANCE
39 IF (B_QUIT_BECAUSE_EMS OR B_QUIT_BECAUSE_MAX_DIST) THEN
40 ;********************************************
41 ;Strategy for the robot to leave the conveyor
42 ;if there was an EMS or MAX_DIST reached
43 ;while synchronising.
44 ;********************************************
45 SWITCH Z_CONV_NBR
46 CASE 1
47 $BASE=$NULLFRAME
48 LIN_REL {Z 0.0}
49 CASE 2
50 $BASE=$NULLFRAME
51 LIN_REL {Z 0.0}
52 CASE 3
53 $BASE=$NULLFRAME
54 LIN_REL {Z 0.0}
55 ENDSWITCH
56 IF B_STOP_AFTER_LEAVING THEN
57 ;*****************************
58 ;* Robot Stopped because of *
59 ;* error while synchronising *
60 ;* EMS or MAX_DIST reached *
61 ;*****************************
62 LOOP
63 HALT
64 ENDLOOP
65 ENDIF
66 ENDIF
67 $ADVANCE=Z_ADVANCE_OLD
68 END

Programming
Line Description
5 … 7 The following conveyor instructions must be inserted before
the LOOP.
1. (>>> 10.2 "Conveyor.INI_OFF: initializing a conveyor"

Page 63)
2. (>>> 10.3 "Conveyor.ON: activating a conveyor"
Page 64)
8 … 10 The following conveyor instructions can be inserted in the
LOOP.
1. (>>> 10.4 "Conveyor.FOLLOW: tracking a workpiece"

Page 64)
2. (>>> 10.5 "Conveyor.Skip: picking up a workpiece from
the conveyor" Page 67)
3. (>>> 10.6 "Conveyor.Quit: leaving the conveyor area"
Page 70)
Note: If the instruction Conveyor.Skip is used, the instruc-
tion Conveyor.FOLLOW must be called at least once out-
side the LOOP.
14 … 29 Subprogram CONV_MOV
(>>> 10.7 "Teaching synchronized motions" Page 71)
33 … 68 Subprogram CONV_QUIT
For motions to move the robot out of the conveyor area.
The motions cannot be synchronized with the conveyor.
10.2 Conveyor.INI_OFF: initializing a conveyor
Description
The command IniOff can be used to initialize a conveyor. For this, the
conveyor distance is set to 0.
Precondition
• User rights: Function group General KRL program changes

• The conveyor application program has been selected.
• T1 mode
Procedure
1. Position the cursor in the line after which the instruction is to be inser-
ted.
2. Select the menu sequence Commands > Conveyor > IniOff.
3. In the inline form, select the conveyor to be initialized.
4. Press Cmd OK to save the instruction.
Inline form “IniOff”
Fig. 10-1: Inline form “IniOff”

Item Description
1 Conveyor
The available conveyors are configured in WorkVisual. The
names of the conveyors can be changed in WorkVisual.
10.3 Conveyor.ON: activating a conveyor
Description
The On command can be used to activate the conveyor driver. If the con-
veyor driver is activated, the synchronization signals at the input of inter-
face X33 (Fast Measurement) are evaluated.
The conveyor offset can be detected out in the background and the robot
controller can perform other tasks. This allows the robot to carry out on-
the-fly tracking of a part on the conveyor. The conveyor distance can be
monitored using the system variable $SEN_PREA_C[].
The instruction Conveyor.ON can only be executed if the conveyor has
been initialized using the instruction Conveyor.INI_OFF.
Precondition

• T1 mode
Procedure
ted.
2. Select the menu sequence Commands > Conveyor > On.
3. In the inline form, select the conveyor for which the driver is to be ac-
tivated.
Inline form “On”
Fig. 10-2: Inline form “On”
Item Description
1 Conveyor
10.4 Conveyor.FOLLOW: tracking a workpiece
Description
The Follow command enables programming of the tracking by the robot

of a workpiece on a conveyor. A range on the conveyor is defined in
which the robot starts to track the workpiece.

Programming
The instruction Conveyor.FOLLOW can only be executed if the conveyor
driver has been activated using the instruction Conveyor.ON.
Precondition

• T1 mode
Procedure
ted.
2. Select the menu sequence Commands > Conveyor > Follow.
3. In the inline form, select the desired conveyor and set the parameters
for the workpiece tracking on the conveyor.
Inline form “Follow”
Fig. 10-3: Inline form “Follow”
Item Description
1 Maximum wait time (in seconds)
It is possible to define the maximum time to wait for synchroni-
zation. Once the specified time has elapsed, execution of the
command is aborted.
2 Conveyor
3 Number of the digital input
Digital input via which execution of the command can be abor-
ted.
4 Number of the motion group
Two different motion groups can be programmed for each con-
veyor.
5 Logic level
• TRUE
• FALSE
When the specified value is set at the configured digital input
(item 3), execution of the command is aborted.

Item Description
6 Flag number
Flag via which execution of the command can be aborted.
7 Logic level
• TRUE
• FALSE
When the specified value is set on the configured flag (item 6),
execution of the command is aborted.
8 Distance traveled by the workpiece while the robot waits before
starting to track the workpiece on the conveyor.
• In the case of a linear conveyor: Specification in millimeters

• In the case of a circular conveyor: Specification in degrees
9 Maximum distance traveled by the workpiece before the robot
starts to synchronize itself with the workpiece.

Example with Conveyor.FOLLOW
1 DEF Conveyor()
2
3 INI
4 CONV INI
5
7 PTP P5 Vel=10 % PDAT2 Tool[1] Base[0]
8
9 Conveyor.INI_OFF LinearConveyor1
10 Conveyor.ON LinearConveyor1
11
12 LOOP
13
15
16 Conveyor.FOLLOW LinearConveyor1, Movement 1, Cancel on:
Max_time 240, Input 1, Input-Level TRUE, Flag 1, Flag-
Level TRUE, WaitDist 100, MaxDist 1500
17 Conveyor.Quit LinearConveyor1, Stop after error FALSE
18
19 ENDLOOP
20 END
21 __________________________________________________________
______
23 INI CONV_MOV
24
26 LIN P2 Vel=0.3 m/s CPDAT1 Tool[1] Base[1]:LinearConveyor1
28
30 ;...

Programming
Line Description
9 The instruction Conveyor.INI_OFF initializes the conveyor.
10 The instruction Conveyor.ON activates the conveyor driver.
14 The robot is moved to the conveyor wait position P7.
16 The robot waits a maximum of 240 seconds for a synchroniza-
tion signal.
17 The program jumps to this point if the wait time for a synchro-
nization signal has expired or if input 1 or flag 1 is set to the
level TRUE. The process is then terminated.
25 Once a synchronization signal has been received, program ex-
ecution is resumed from this point.
10.5 Conveyor.Skip: picking up a workpiece from the conveyor
Description
The Skip command can be used to program which workpieces are to be

picked up, e.g. every 2nd workpiece, every 3rd workpiece, etc. A total of
up to 1024 workpieces can be monitored in the background.
Precondition

• T1 mode
Procedure
ted.
2. Select the menu sequence Commands > Conveyor > Skip.
for the workpiece pickup on the conveyor.
Inline form “Skip”
Fig. 10-4: Inline form “Skip”

Item Description
1 Number of the motion group
Two different motion groups can be programmed for each con-
veyor.
2 Conveyor
3 Maximum wait time (in seconds)
It is possible to define the maximum time to wait for synchroni-
zation. Once the specified time has elapsed, execution of the
command is aborted.
4 Number of the digital input
Digital input via which execution of the command can be abor-
ted.
5 The number entered specifies which workpieces are to be
picked up.
Examples:
• 1: Every workpiece is picked up.

• 3: Every 3rd workpiece is picked up.
• 5: Every 5th workpiece is picked up.
6 Logic level
• TRUE
• FALSE
When the specified value is set at the configured digital input
(item 4), execution of the command is aborted.
7 Maximum distance traveled by the workpiece before the robot
starts to synchronize itself with the workpiece.

8 Flag number
Flag via which execution of the command can be aborted.
9 Logic level
• TRUE
• FALSE
When the specified value is set on the configured flag (item 8),
execution of the command is aborted.
10 Distance traveled by the workpiece while the robot waits before
starting to track the workpiece on the conveyor.

Example with Conveyor.Skip
1 DEF Conveyor()
2
3 INI
4 CONV INI

Programming
5
8
11 Conveyor.FOLLOW LinearConveyor1, Movement 1, Cancel on:
Max_time 240, Input 1, Input-Level TRUE, Flag 1, Flag-
12
13 LOOP
14
16
17 Conveyor.Skip LinearConveyor1, Skip to part index 2,
Movement 1, Cancel on: Max_time 240, Input 1, Input-
Level TRUE, Flag 1, Flag-Level TRUE, WaitDist 100,
MaxDist 1900
19
20 ENDLOOP
21 END
22 __________________________________________________________
______
24 INI CONV_MOV
25
29
31 ;...
Line Description
7 The robot is moved to the conveyor wait position P5.
Note: If the instruction Conveyor.Skip is used, the instruction
Conveyor.INI_OFF must always be located outside the LOOP.
Conveyor.ON must always be located outside the LOOP.
11 The instruction Conveyor.FOLLOW starts the workpiece track-
ing.
Conveyor.FOLLOW must be called at least once outside the
LOOP.
tion signal.

10.6 Conveyor.Quit: leaving the conveyor area
Description
The Quit command can be used to program whether the robot is to leave
the conveyor area in the following cases.
• EMERGENCY STOP in the case of a synchronous motion
• Reaching the maximum conveyor distance the robot can travel as a
synchronized motion
The motions to move the robot out of the conveyor area must be pro-
grammed in the subprogram CONV_QUIT. These motion cannot be
synchronized with the conveyor and are executed relative to the WORLD
coordinate system.
Precondition

• T1 mode
Procedure
ted.
2. Select the menu sequence Commands > Conveyor > Quit.
for the conveyor.
Inline form “Quit”
Fig. 10-5: Inline form “Quit”
Item Description
1 Conveyor
2 Stop after error
• TRUE: Program execution is stopped once the robot has

been moved out of the conveyor area.
• FALSE: Program execution is not stopped.

Programming
Item Description
3 Reset distance
• TRUE: The measured distance covered by the conveyor is

reset (system variable: $SEN_PREA_C[]).
• FALSE: The measured distance covered by the conveyor is
not reset.
Note: If multiple Conveyor.FOLLOW instructions are used for a
workpiece (e.g. for a tool change between the instructions), it is
advisable to set this parameter to TRUE after the last Convey-
or.FOLLOW instruction.
10.7 Teaching synchronized motions
Description
For teaching the synchronized motions, a basic conveyor program must

have been created beforehand. This basic conveyor program must contain
at least the following contain instructions:
• Conveyor.INI_OFF
• Conveyor.ON
• Conveyor.FOLLOW
(>>> "Example of a basic conveyor program" Page 73)
Precondition
• A basic conveyor program has been created.

• T1 mode
Procedure
1. Execute the basic conveyor program until the robot has reached the
position where it waits for synchronization.
2. Execute the instruction Conveyor.FOLLOW.
3. Answer the message with Yes. Teach mode is activated.
4. Start the conveyor.
5. As soon as the workpiece has passed the synchronization switch and
the signal has been received from the synchronization switch, stop the
conveyor.
6. The calculated conveyor distance is displayed. Check whether the
conveyor distance is correct.
• If the conveyor distance is correct, press Yes.
• If the conveyor distance is not correct, correct the conveyor dis-
tance.
(>>> 9.3 "Checking the conveyor distance" Page 57)
Then repeat steps 2 to 6.
7. Teach the points of the synchronized motions. In the following dia-
gram, these points are P2, P3 and P4.

Fig. 10-6: Teaching the points of a synchronized motion
1 Synchronization switch 3 Resolver

2 Workpiece 4 Conveyor
The following diagram illustrates the synchronized motions between
points P1 and P5.
Fig. 10-7: Synchronized motion between points P1 and P5
1 Conveyor 2 Workpiece
8. Once all points have been taught, the program can be tested in T2
mode.
NOTICE
Program execution must not be stopped while the robot is in the con-
veyor area! Damage to the robot, the workpiece and other equipment
may otherwise result.
NOTICE
Ensure that the last synchronized motion moves the robot out of the
conveyor area. There may otherwise be a collision between the robot
and the conveyor.
It is recommended that synchronized motions should always be execu-

ted in AUT or AUT EXT mode with 100% program override. The robot
may not otherwise be able to execute the synchronized motions com-
pletely with the specified conveyor distance.
For test purposes, the program override ($OV_PRO) in the conveyor

area can be increased to 100%. Once the robot has left the conveyor,
the program override is reset to its original value. This makes it possible
to conduct a test inside the conveyor area at full velocity while the re-
mainder of the application is executed with reduced program override.

Programming
Example of a basic conveyor program
1 DEF Conveyor()
2
3 INI
4 CONV INI
5
7 LIN P1 Vel= 2 m/s CPDAT6 Tool[1] Base[0]
8
11 Conveyor.FOLLOW LinearConveyor1, Movement 1, Cancel
on:Max_time 60, Input 1, Input-Level TRUE, Flag 1, Flag-
13
14 LIN P2 Vel=0.5 m/s CPDAT17 Tool[1] Base[0]
15 PTP HOME Vel=100 % DEFAULT
16 END
17 __________________________________________________________
______
19 INI CONV_MOV
20
22 LIN P10 Vel=0.5 m/s CPDAT1 Tool[1]
Base[1]:LinearConveyor1
26
28 ;...
Line Description
7 The robot is moved from the HOME position to the conveyor
wait position P1.
tion signal.
10.8 Programming a DLIN block
Description
LIN and DLIN motions that are programmed inside a DLIN block are exe-
cuted with maximum velocity and acceleration. A DLIN block triggers an
advance run stop.

Alternatively, the DLIN template can be used.

Programming
(>>> 10.10 "Creating an application program with DLIN template"

Page 77)
Approximate positioning is only possible within the DLIN block.
Precondition

• T1 mode
• A program is selected.
Procedure
1. Position the cursor in the line after which the DLIN block is to be in-
serted.
2. Select the menu sequence Commands > Motion > DLIN block.
3. Press Cmd OK to save the instruction. The DLIN block is inserted.
4. Program the desired motions in the opened fold of the DLIN block.
Inline form “DLIN block”
Fig. 10-8: Inline form “DLIN Block”
10.9 Programming a DLIN motion
Description
A dynamic LIN motion is executed with the instruction. In other words, an

attempt is made to achieve the specified velocity, acceleration and approx-
imation distance. If these values cannot be reached, they are gradually re-
duced in the path planning. This may be the case on account of physical
limitations (such as gear torque).
Precondition

• T1 mode
• A program is selected.
Procedure
ted.
2. Select the menu sequence Commands > Motion > DLIN Move.
3. Set the parameters in the inline form.
Inline form “DLIN Move”
Fig. 10-9: Inline form “DLIN Move”

Programming
Item Description
1 Name of the end point
The system automatically generates a name. The name can be
overwritten.
Touch the arrow to edit the point data. The corresponding op-
tion window is opened.
(>>> 10.9.1 "Option window “Frames”" Page 75)
The arrow can also be used to edit the Global point setting.
2 Name for the motion data set
The system automatically generates a name. The name can be
overwritten.
Touch the arrow to edit the point data. The corresponding op-
tion window is opened.
(>>> 10.9.2 "Option window “Velocities”" Page 76)
(>>> 10.9.3 "Option window “Accelerations”" Page 76)
Note: The orientation control type in the Motion parameters
option window corresponds to the orientation control of a LIN
motion.
3 • CONT: End point is approximated.
• [blank]: The motion stops exactly at the end point.
10.9.1 Option window “Frames”
Fig. 10-10: Option window “Frames”
Item Description
1 Tool selection.
Range of values: [1] … [16]
2 Base selection.
Range of values: [1] … [32]

10.9.2 Option window “Velocities”
Fig. 10-11: Option window “Velocities”
Item Description
1 Maximum path velocity. The value refers to the maximum value
specified in the machine data.
The maximum value depends on the robot type and the selec-
ted operating mode.
2 Maximum swivel velocity. The value refers to the maximum val-
ue specified in the machine data.
ted operating mode.
3 Maximum rotational velocity. The value refers to the maximum
value specified in the machine data.
ted operating mode.
10.9.3 Option window “Accelerations”
Fig. 10-12: Option window “Accelerations”

Programming
Item Description
1 Maximum path acceleration. The value refers to the maximum
ted operating mode.
2 Maximum swivel acceleration. The value refers to the maximum
ted operating mode.
3 Maximum rotational acceleration. The value refers to the maxi-
mum value specified in the machine data.
ted operating mode.
10.10 Creating an application program with DLIN template
Description
With the DLIN template, an entire program can be programmed with max-
imum velocity and maximum acceleration. LIN and DLIN motions that are
inserted into the template are executed with maximum velocity and accel-
eration.
A DLIN Block cannot be used in the template. It alters the functionality
of the template.
Precondition
• Not all folders allow the creation of new folders within them.
• User rights: Function group File operations
‒ Depending on the folder in which the program is to be created, the
“Expert” user group or higher may be required.
Procedure
1. In the directory structure of the Navigator, select the folder in which

the program is to be created, e.g. the folder KRC:\R1\Program.
2. Select the file list of the Navigator and press the New button.
The Template selection window opens.
3. Select the DynamicLin template and confirm with OK.
4. Enter a name for the program and confirm it with OK.
5. Select the program and program the desired instructions.
10.11 KRL functions
Using special KRL functions, workpieces can be deleted from the work-
piece list of the conveyor driver. Furthermore, the conveyor velocity can
be requested, as can the number of workpieces currently being tracked by
the conveyor.

10.11.1 CONV_DELETE_ALL_WPS: delete all components
Description
The function CONV_DELETE_ALL_WPS deletes all workpieces from the

workpiece list of the conveyor driver. If the function is called, the conveyor
driver no longer follows a workpiece with which the robot can synchronize
itself.
Syntax
DEL_COUNT = CONV_DELETE_ALL_WPS(Index, Error number)
Explanation of the syntax
Element Description
DEL_COUNT Number of deleted workpieces
Type: INT
Index Index of the conveyor
Type: INT
Error number Number of the error that occurred during execution of
the function
Type: INT
Example
DEL_COUNT = CONV_DELETE_ALL_WPS(1, ERRNBR)
10.11.2 CONV_DELETE_WPS: Deleting components
Description
The function CONV_DELETE_WPS deletes the specified number of work-

pieces from the workpiece list of the conveyor driver. Deletion starts with
the oldest workpiece in the list.
Syntax
DEL_COUNT = CONV_DELETE_WPS(Index, Number of workpieces, Error

number)
Element Description
DEL_COUNT Number of deleted workpieces
Type: INT
Type: INT
Number of Number of workpieces to be deleted
workpieces
Type: INT
the function
Type: INT

Programming
Example
DEL_COUNT = CONV_DELETE_WPS(1, 4, ERRNBR)
10.11.3 CONV_GET_SPEED: Requesting the conveyor speed
Description
The function CONV_GET_SPEED returns the current speed of the con-

veyor. For a linear conveyor, the speed is specified in millimeters per sec-
ond, while that of a circular conveyor is specified in degrees per second.
Syntax
SPEED = CONV_GET_SPEED(Index, Error number)
Element Description
SPEED Current speed of the conveyor
Type: REAL
Type: INT
the function
Type: INT
Example
SPEED = CONV_GET_SPEED(1, ERRNBR)
10.11.4 CONV_GET_WP_COUNT: Component counter
Description
The function CONV_GET_WP_COUNT returns the number of workpieces

currently being tracked by the conveyor
Syntax
WP_COUNT = CONV_GET_WP_COUNT(Index, Error number)
Element Description
WP_COUNT Number of workpieces currently being tracked by the
conveyor
Type: INT
Type: INT
the function
Type: INT

Example
WP_COUNT = CONV_GET_WP_COUNT(1, ERRNBR)
A total of 10 workpieces have been generated, for example. Synchroniza-

tion was most recently carried out on the fifth workpiece. The function
now returns the value 6, as 6 workpieces are currently still being tracked
by the conveyor. These are workpieces the inputs 5, 6, 7, 8, 9, 10.

Troubleshooting
11 Troubleshooting
WARNING
A robot that is synchronized with a conveyor is controlled not only by
the robot controller, but also partially by the conveyor.
When tracking a part on a conveyor, the robot executes Cartesian mo-
tions in a BASE coordinate system that moves with the conveyor.
In some cases, this can result in hazardous situations if the interface
between the robot controller and the conveyor controller has not been
designed correctly.
11.1 Robot leaves the path in external mode EXT
WARNING
If a robot that is tracking a part on a conveyor is stopped, the robot
leaves the path relative to the conveyor.
In most cases, this is due to the fact that a moving conveyor cannot
stop as quickly as a robot. In the external mode EXT, in particular, this
can lead to hazardous situations.
Example
1. A robot tracks a part on a conveyor.

2. An EMERGENCY STOP is triggered in the robot cell.
3. The robot stops.
4. Under normal circumstances, the conveyor also stops.
The robot has probably left the path because the conveyor has stop-
ped with a slight delay.
5. The EMERGENCY STOP is reset.
6. The conveyor starts up again and the part moves away from the ro-
bot.
7. An external start of the robot is triggered.
8. The robot attempts to track the part on the conveyor.
9. Range limits and workspaces are ineffective.
10. The robot collides with the conveyor.
Possible remedy
• Prevent restart of the robot following a synchronization error. It is pos-

sible to cancel the robot program in the submit interpreter SPS.SUB.
Never restart the conveyor if the robot has left the path
($ON_PATH) and has not been restarted ($PRO_ACT).
11.2 Modifying the program override
Description
Reducing the program override results in the robot spending more time
tracking a workpiece on a conveyor.
If the robot tracks the workpiece for a longer time, it also tracks it over a
greater distance. This may result in collisions when range limits are
reached.

Troubleshooting KUKA.ConveyorTech 7.1
Possible remedy
• Ensure that the program override is set to 100% before synchroniza-

tion is started.
Example:
$OV_PRO=100
Conveyor.FOLLOW...
• Ensure that robot and conveyor are stopped when range limits are
reached.
Range limits can be defined with the following parameters:
Parameter Description
Alarm distance As soon as the robot reaches this distance,
an output is set. This output can force the
conveyor controller (PLC) to stop the con-
veyor in order to prevent the robot from
moving too far.
Maximum distance As soon as the robot reaches this preset dis-
tance, tracking of the workpiece is aborted.
It is possible to move the robot out of the
conveyor area automatically (CONV_QUIT).
Note: These motions are not synchronized
with the conveyor. Ensure that there is no
collision with the conveyor.
• Set up workspaces. This enables the robot controller to respond as

soon as the robot enters a workspace (e.g. safety fence, machine).
11.3 The decision to track a workpiece is made in the advance run
Description
In the inline form “FOLLOW”, an area is defined which determines wheth-

er the robot is to track a workpiece on the conveyor. If the workpiece is
within both defined range limits, tracking of the workpiece is enabled.
Since the robot can be synchronized with and track the workpiece on the
conveyor on the fly, decisions are also made on the fly.
Example
1. A robot is working on side A and wants to track a workpiece on a

conveyor on side B of the robot cell.
For this, a 1 s motion towards the conveyor on side B is required.
2. The conveyor moves at a velocity of 1 m/s.
The range limits defined for part tracking are 0 mm and 500 mm.
3. The robot leaves side A and already evaluates whether it can track a
workpiece on conveyor B.
4. The robot decides to track the workpiece and moves to side B.
5. After 1 s, the robot is synchronized on the fly with the workpiece on
conveyor B, which has meanwhile moved forwards 1 m, and tracks it.
6. This means that the robot is tracking a workpiece that has already left
the workpiece tracking range.

Troubleshooting
Possible remedy
• No on-the-fly synchronization with workpieces on the conveyor. Ensure

that no advance run is defined ($ADVANCE=0) and that the wait posi-
tion before synchronization is programmed without approximate posi-
tioning.
• If on-the-fly synchronization is required, ensure that the advance run is
reduced to a minimum ($ADVANCE=1). Teach multiple positions at the
start of the conveyor. Since there is more than one position, the deci-
sion about workpiece tracking is delayed.
11.4 Connection to position tracker broken
Description
If the electrical connection to a position tracker (e.g. resolver on the con-

veyor) is broken, the robot receives no new position values of the convey-
or. The robot thus fails to detect that the conveyor is moving. This can re-
sult in the robot colliding with the workpiece.
If the connection is broken while the robot is tracking the workpiece on
the conveyor, the robot does not track the workpiece for the remaining
distance.
Possible remedy
• Respond to the signal SIGNAL $POS_TRACKER_ERROR FALSE in

the file $MACHINE.DAT.
Example: Set the signal at an output:
SIGNAL $POS_TRACKER_ERROR $OUT[120]

Troubleshooting KUKA.ConveyorTech 7.1

Messages
12 Messages
12.1 Information about the messages
The “Messages” chapter contains selected messages. It does not cover all
the messages displayed in the message window.
12.2 System messages from module: Conveyor
12.2.1 Conveyor 01002
Message code Conveyor 01002

Message text Unable to determine transmission ratio
Message type Acknowledgement message
Possible cause(s) Cause: Positions of the points not selected correctly (>>> Page 85)
Solution: Recalibrate the conveyor system (>>> Page 85)
Cause: Positions of the points not selected correctly
Description
During calibration of a circular conveyor system, the positions of the

points were not selected correctly.
Solution: Recalibrate the conveyor system
Description


Messages KUKA.ConveyorTech 7.1
Fig. 12-1: Calibration, circular
1 Direction of travel of the con- 3 Robot

veyor
2 Conveyor
XR is the X axis and YR is the Y axis of the ROBROOT coordinate sys-
tem. XC is the X axis and YC is the Y axis of the conveyor BASE (MA-
CHINE_DEF[].ROOT).
where the robot starts to track the workpiece. This reference point is situ-
ated on the X axis of the conveyor BASE and defines the orientation of
the conveyor BASE. The origin of the conveyor BASE is situated in the
(virtual) pivot point of the circular conveyor. All conveyor programs will use
this BASE as a reference. In order to be able to repeat the calibration, it
is important to define and mark this reference point in such a way that it
can be used again.
P2 should be in the middle of the area in which the robot can track the
workpiece on the conveyor.
Point P3 is also point P1, but offset by the distance traveled by the con-
veyor after P2. P3 should be as near as possible to the end of the area in
which the robot can track the workpiece on the conveyor.
Precondition
Procedure
used.

Messages
press Next.
8. Move the TCP to a point on the positive X axis of the conveyor BASE
(point P1) and press Continue.
10. Position the TCP at the now offset point P1 (P2) and press Continue.
The point should be near the middle of the tracking zone.
12. Position the TCP at the now even further offset point P1 (P3). The
point should be as near as possible to the end of the tracking zone.
13. Press Finish.
12.2.2 Conveyor 01007

Message text An error occurred on setting variable '{0}' to value '{1}': {2}
Possible cause(s) Cause: Faulty system files (>>> Page 87)

Solution: Uninstall and re-install ConveyorTech using smartHMI
(>>> Page 87)
Cause: Faulty system files (>>> Page 88)

Solution: Uninstall and re-install ConveyorTech using WorkVisual
(>>> Page 88)
Cause: Faulty system files
Description
One or more system files are faulty, not present and/or have been modi-
fied manually.
Description
Uninstall the existing version of ConveyorTech using the smartHMI and

then reinstall it. It is advisable to archive all relevant data before uninstal-
ling a software package.
Precondition
• User group "Expert".

• Operating mode T1 or T2.
Procedure

Description
fied manually.
Description
Uninstall the existing version of ConveyorTech using WorkVisual and then

reinstall it. It is advisable to archive all relevant data before uninstalling a
software package.
Precondition

• T1 or T2 mode
Procedure

it.

Messages
7. Reload the project from the robot controller.
it.
Information about configuring ConveyorTech is contained in the docu-

mentation concerning this option package.
12.2.3 Conveyor 01008

Message text Error reading current position. Please select a valid tool and base.
Error message: {0}
Possible cause(s) Cause: Tool and/or base not assigned (>>> Page 89)
Solution: Select tool and base (>>> Page 89)
Cause: Tool and/or base not assigned
Description
The base and tool have not yet been set after a reboot of the robot con-
troller. A program was started without selecting the base and tool.
The procedure for checking whether the tool and/or base have been
assigned is as follows:
Checking instructions
1. Touch the Tool/base status indicator. The Cur. Tool/Base window is

opened.
2. Check whether Unknown is shown next to the tool and/or base and a
question mark instead of the number.
Solution: Select tool and base
Description
One tool (TOOL coordinate system) and one base (BASE coordinate sys-
tem) must be selected for Cartesian jogging.
Procedure
1. Touch the status indicator Cur. tool/base. The Cur. tool/base window
opens.

2. Select the desired tool and base.

3. The window closes and the selection is applied.
12.2.4 Conveyor 01010

Message text Wrong conveyor configuration
Possible cause(s) Cause: ConveyorGlobals.dat contains errors (>>> Page 90)

Solution: Check the WorkVisual project and transfer it again
(>>> Page 90)
Cause: ConveyorGlobals.dat contains errors
Description
The file ConveyorGlobals.dat contains errors and/or has been modified

manually. The variable Cor_dir[] has the value #NONE, for example.
Configuration file
Directory C:\KRC\ROBOTER\KRC\R1\TP\Conveyor
File ConveyorGlobals.dat
Solution: Check the WorkVisual project and transfer it again
Description
The WorkVisual project must be checked and then transferred to the robot
controller again.
Precondition

• T1 or T2 mode
Procedure
1. Load the active project from the robot controller.

2. Check whether the configuration in the project matches the real sys-
tem configuration. If not, correct the configuration.
3. Transfer the project back from WorkVisual to the robot controller and
activate it.

sual documentation.

Messages
12.2.5 Conveyor 01011

Message text Error on setting a variable: {0}

(>>> Page 91)

(>>> Page 92)
Description
fied manually.
Description

Precondition

Procedure


Description
fied manually.
Description

software package.
Precondition

• T1 or T2 mode
Procedure

it.
it.


Messages
12.2.6 Conveyor 01018

Message text Error on polling a variable: {0}

(>>> Page 93)

(>>> Page 94)
Description
fied manually.
Description

Precondition

Procedure


Description
fied manually.
Description

software package.
Precondition

• T1 or T2 mode
Procedure

it.
it.


Messages
12.2.7 Conveyor 01211

Message text The conveyor driver is not in the state #ACTIVE.
Possible cause(s) Cause: Conveyor driver not activated (>>> Page 95)
Solution: Activating the conveyor driver at the start of the program
(>>> Page 95)
Cause: Conveyor driver not activated
Description
Certain functions and instructions can only be executed if the conveyor

driver has been activated, e.g. the function CONV_GET_SPEED.
Solution: Activating the conveyor driver at the start of the program
Description
At the start of the program, the conveyor must first be initialized, then the
conveyor driver must be activated.
Precondition

• T1 mode
Procedure
1. Move the cursor to the start of the program.

2. Select the menu sequence Commands > Conveyor > IniOff.
3. In the inline form, select the conveyor used.
5. Select the menu sequence Commands > Conveyor > On.
6. In the inline form, select the conveyor used.
12.2.8 Conveyor 01221

Message text An error occurred while ending conveyor tracking for {0}.

Possible cause(s) Cause: Error on ending the conveyor calibration (>>> Page 96)
Solution: Perform conveyor calibration again (>>> Page 96)
Cause: Error on ending the conveyor calibration
Description
An error occurred on ending the conveyor calibration. The conveyor posi-

tion could not be loaded.
Solution: Perform conveyor calibration again
Description
Calibration must be performed again.
12.2.9 Conveyor 01250

Message text The conveyor device is currently being used by the interpolation.
Possible cause(s) Cause: An attempt to delete workpieces from the workpiece list of a
synchronized conveyor (>>> Page 96)
Solution: Delete workpieces from the workpiece list before synchro-
nization (>>> Page 96)
Cause: An attempt to delete workpieces from the workpiece list of a synchron-

ized conveyor
Description
An impermissible attempt has been made to delete workpieces from the

workpiece list of a conveyor that is currently synchronized with the robot.
• Check programming.
Solution: Delete workpieces from the workpiece list before synchronization
Description
Workpieces can only be deleted from the workpiece list of a conveyor be-
fore the conveyor is synchronized. The programming must be modified ac-
cordingly.

Messages
12.2.10 Conveyor 01251

Message text The conveyor index is outside of the permissible range.
Possible cause(s) Cause: Conveyor index specified in KRL function >5

(>>> Page 97)
Solution: Correctly specify conveyor index in KRL function
(>>> Page 97)
Cause: Conveyor index specified in KRL function >5
Description
A maximum of 5 conveyors may be operated using one robot controller.

Each of these conveyors is assigned an index (1 … 5).
In a KRL function, a conveyor has been assigned an index >5.
• Check the index specifications (always parameter 1 of the function):

‒ CONV_DELETE_ALL_WPS(…)
‒ CONV_DELETE_WPS(…)
‒ CONV_GET_SPEED(…)
‒ CONV_GET_WP_COUNT(…)
Solution: Correctly specify conveyor index in KRL function
Description
The conveyor index in the KRL function must be specified correctly.
Precondition
• User rights: Function group Critical KRL program changes

• T1 mode
Procedure
1. Select the program in the Navigator and press Open. The program is
displayed in the editor.
2. Search for the corresponding position in the program and edit it.
3. Close the file and respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.


KUKA Service
13 KUKA Service
13.1 Requesting support
Introduction
This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further assistance,
please contact your local KUKA subsidiary.
Information
The following information is required for processing a support re-

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• As comprehensive information as possible about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ Model and serial number of the controller
‒ Model and serial number of the energy supply system
‒ Designation and version of the system software
‒ Designations and versions of other software components or modifi-
cations
‒ Diagnostic package KRCDiag
Additionally for KUKA Sunrise: existing projects including applica-
tions
For versions of KUKA System Software older than V8: archive of
the software (KRCDiag is not yet available here.)
‒ Application used
‒ External axes used
13.2 KUKA Customer Support
Availability
KUKA Customer Support is available in many countries. Please do not

hesitate to contact us if you have any questions.
Argentina
Ruben Costantini S.A. (Agentur)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
[email protected]

KUKA Service KUKA.ConveyorTech 7.1
Australia
KUKA Robotics Australia Pty Ltd
45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
[email protected]
www.kuka-robotics.com.au
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.
No. 889 Kungang Road
Xiaokunshan Town
Songjiang District
201614 Shanghai
P. R. China
Tel. +86 21 5707 2688
Fax +86 21 5707 2603
[email protected]
www.kuka-robotics.com

KUKA Service
Germany
Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
[email protected]
www.kuka.com
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 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 Japan K.K.
YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7531
Fax +81 45 744 7541
[email protected]
Canada
KUKA Robotics Canada Ltd.
2865 Argentia Road, Unit 4-5
Mississauga
Ontario L5N 8G6
Canada
Tel. +1 905 858‑5852
Fax +1 905 858-8581
[email protected]
www.kukarobotics.ca
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 (M) Sdn Bhd
South East Asia Regional Office
No. 7, Jalan TPP 6/6
Taman Perindustrian Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 (03) 8063-1792
Fax +60 (03) 8060-7386
[email protected]

KUKA Service
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 CEE GmbH
Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 732 784 752 0
Fax +43 732 793 880
[email protected]
www.kuka.at
Poland
KUKA CEE GmbH Poland
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 Robots IBÉRICA, S.A.
Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729 780
Fax +351 265 729 782
[email protected]
www.kuka.com

Russia
KUKA Russia OOO
1-y Nagatinskiy pr-d, 2
117105 Moskau
Russia
Tel. +7 495 665-6241
[email protected]
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 CEE GmbH
Linz, Zweigniederlassung Schweiz
Heinrich Wehrli-Strasse 27
5033 Buchs
Switzerland
Tel. +41 62 837 43 20
[email protected]
Slovakia
KUKA CEE GmbH
organizačná zložka
Bojnická 3
831 04 Bratislava
Slovakia
Tel. +420 226 212 273
[email protected]
Spain
KUKA Iberia, S.A.U.
Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
[email protected]

KUKA Service
South Africa
Jendamark Automation LTD (Agentur)
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 Automation Taiwan Co. Ltd.
1F, No. 298 Yangguang ST.,
Nei Hu Dist., Taipei City, Taiwan 114
Taiwan
Tel. +886 2 8978 1188
Fax +886 2 8797 5118
[email protected]
Thailand
KUKA (Thailand) Co. Ltd.
No 22/11-12 H-Cape Biz Sector Onnut
Sukhaphiban 2 road, Prawet
Bangkok 10250
Thailand
Tel. +66 (0) 90-940-8950
[email protected]
Czech Republic
KUKA Roboter CEE GmbH
organizační složka
Pražská 239
25066 Zdiby
Czech Republic
Tel. +420 226 212 273
[email protected]
Hungary
KUKA HUNGÁRIA 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.kuka.com
United Kingdom
KUKA Robotics UK Ltd
Great Western Street
Wednesbury West Midlands
WS10 7LL
United Kingdom
Tel. +44 121 505 9970
Fax +44 121 505 6589
[email protected]
www.kuka-robotics.co.uk

Index G
General I/O parameters................................. 39
Global conveyor settings, editing...................45
A Global conveyor settings, modifying..............49
Alarm distances.............................................. 41
Alarm distances, modifying............................ 52
H
Hardware........................................................ 29
C
Calibration.......................................................55
Calibration, circular conveyor.........................56 I
Calibration, linear conveyor............................55 I/Os, configuring............................................. 45
Communication............................................... 11 Installation.......................................................29
Configuration...................................................33 via smartHMI............................................. 31
Connection to position tracker broken...........83 via WorkVisual...........................................29
Connection to the CIB, modifying..................35 Installation, ConveyorTech............................. 29
CONV_DELETE_ALL_WPS........................... 78 Installing ConveyorTech................................. 31
CONV_DELETE_WPS................................... 78 Intended use...................................................12
CONV_GET_SPEED...................................... 79 Introduction....................................................... 7
CONV_GET_WP_COUNT..............................79
Conveyor...........................................................8
Conveyor-specific settings, modifying............50 K
Conveyor application program, creating........61 KLI.....................................................................8
Conveyor area, leaving.................................. 70 KRL functions................................................. 77
Conveyor distance, checking......................... 57 KSB...................................................................8
Conveyor driver, activating.............................64 KUKA Customer Support............................... 99
Conveyor parameters, editing........................ 39 KUKA Service.................................................99
Conveyor, initializing.......................................63
Conveyor, inserting in project........................ 33
Conveyor, motion master............................... 36
Conveyor.FOLLOW.........................................64
L
Licenses............................................................8
Conveyor.INI_OFF.......................................... 63
Long texts, adding..........................................45
Conveyor.ON.................................................. 64
Conveyor.Quit................................................. 70
Conveyor.Skip.................................................67
CRC.................................................................. 8 M
Messages........................................................85
D
Decision to track workpiece made in advance O
run...................................................................82 On-the-fly synchronization................................8
DLIN block, programming.............................. 73 Open source..................................................... 8
DLIN motion, programming............................ 74 Operation........................................................ 49
DLIN.MOVE.................................................... 74 Overview, ConveyorTech................................ 11
Documentation, industrial robot....................... 7 Overview, start-up...........................................25
E P
Escape strategy..............................................42 Planning.......................................................... 15
ESD...................................................................8 PLC................................................................... 8
Expert parameters.......................................... 40 Product description......................................... 11
External conveyor...........................................15 Program override, modifying.......................... 81
Programming.................................................. 61
PTP................................................................... 8
F
Function groups..............................................49
Functions.........................................................11 R
RDC.................................................................. 8
Recommissioning............................................25

Resolver............................................................8
Resolver, connecting to RDC........................ 25
Resolver, inserting in project......................... 34
Robot leaves path.......................................... 81
S
Safety..............................................................13
Safety instructions............................................ 7
Signal diagram, stop strategy
CONV_STOPPABLE...................................... 43
Start-up........................................................... 25
Stop distances................................................ 41
Stop distances, modifying.............................. 52
Stop strategy, CONV_STOPPABLE........ 42, 43
Stop strategy, GEN_STOP.............................42
Support request.............................................. 99
Synchronized motions, teaching.................... 71
System requirements......................................29
T
Target group..................................................... 7
Terms used....................................................... 8
Time synchronization, configuring..................37
Tracking distance............................................. 8
Trademarks....................................................... 8
Training............................................................. 7
Troubleshooting.............................................. 81
U
Uninstallation, ConveyorTech.................. 30, 32
Update, ConveyorTech................................... 29
Updating ConveyorTech................................. 31
Use, intended................................................. 12
User rights, displaying....................................49
W
Warnings........................................................... 7
Workpiece on conveyor, calibration............... 58
Workpiece tracking......................................... 64
Workpiece, picking up.................................... 67

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KUKA System Technology

Publication: Pub KST ConveyorTech 7.1 (PDF) en

Book structure: KST ConveyorTech 7.1 V2.2

Version: KST ConveyorTech 7.1 V2

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5 Start-up and recommissioning............................................................... 25

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7.7.4.1 Signal diagram for stop strategy CONV_STOPPABLE........................................ 43

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12.2.7 Conveyor 01211.................................................................................................... 95

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1.1 Target group

This documentation is aimed at users with the following knowledge and

• Advanced knowledge of the robot controller system

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

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

1.3 Representation of warnings and notes

These warnings contain references to safety-relevant information or gen-

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This warning draws attention to procedures which serve to prevent or rem-

edy emergencies or malfunctions:

Procedures marked with this warning must be followed exactly.

These notices serve to make your work easier or contain references to

1.4 Terms used

EtherCAT® is a registered trademark and patented technolo-

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Further information about open-source licenses can be requested from

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2.1 Overview of ConveyorTech

ConveyorTech is an add-on option package with the following functions:

Fig. 2-1: Overview of a conveyor system

Conveyor applications enable:

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2.2 Intended use

The ConveyorTech option package is used for gripping, processing or set-

Any use or application deviating from the intended use is deemed to be

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4.1 System with conveyor connection to RDC

A total of 2 conveyors can be connected to the RDC in the base frame of

Fig. 4-1: System with conveyor connection to RDC

4.2 External conveyor

An external resolver can transfer position and workpiece information from

KST ConveyorTech 7.1 V2 | Issued: 04.05.2021 www.kuka.com | 15/108

The external position sensing system must be as accurate as possible

• Higher-level controller is compatible with one of the following network

Fig. 4-2: System with external conveyors

1 Higher-level controller (PLC)

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4.2.1 Communications interface to the higher-level controller

Communication between the higher-level controller and the conveyor driv-

4.2.1.1 Reception structure from the perspective of the robot controller