KST SafeOperation 32 En

KUKA System Technology

KUKA.SafeOperation 3.2 For KUKA System Software 8.3 Assembly and Operating Instructions

KUKA.SafeOperation3.2

Issued: 08.06.2016 Version: KST SafeOperation 3.2 V7

KUKA Roboter GmbH

KUKA.SafeOperation 3.2

© Copyright 2016 KUKA Roboter GmbH Zugspitzstraße 140 D-86165 Augsburg Germany This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Roboter GmbH. Other functions not described in this documentat ion may be operable in the controller. Th e user has no claims to these functions, however, in the case of a replacement or service work. We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition. Subject to technical alterations without an effect on the function. Translation of the original documentation KIM-PS5-DOC

Publication: Book structure: Version:

2 / 205

Pub KST SafeOperation 3.2 (PDF) en KST SafeOperation 3.2 V6.2 KST SafeOperation 3.2 V7



© Copyright 2016 KUKA Roboter GmbH Zugspitzstraße 140 D-86165 Augsburg Germany This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Roboter GmbH. Other functions not described in this documentat ion may be operable in the controller. Th e user has no claims to these functions, however, in the case of a replacement or service work. We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition. Subject to technical alterations without an effect on the function. Translation of the original documentation KIM-PS5-DOC

Publication: Book structure: Version:

2 / 205

Pub KST SafeOperation 3.2 (PDF) en KST SafeOperation 3.2 V6.2 KST SafeOperation 3.2 V7


Contents

Contents 1

Introduction .... ...... ..... ..... ..... ..... .... ..... ..... ..... ..... .... ..... ...... ..... .... ..... ..... ..... ...... ..... ..... ...... ...... ..... ..... ..... .... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... ..... ..

9

1.1 1.2 1.2 1.3 1.3 1.4

Target gr group .... ...... ..... ...... ..... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... ..... ..... .... .... .... ..... ..... .... .... .... ..... ... Indu Indust stri rial al rob robot ot doc docum umen enta tatition on .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Repr Repres esen entat tatio ion n of of war warni ning ngss and and note notess .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Terms used ...... ......... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ....... ........ ....

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Product description ..... ........ ..... ..... ..... .... ..... ..... ..... ...... ...... ..... .... ..... ..... ..... ..... .... ..... ..... ..... ..... .... ..... ..... ..... ..... .... ..... ..... .... ..... ..... .... ..

13

2.1 2.1 Ov Over ervi view ew of Safe SafeOp Oper erat atio ion n .... ...... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... .... .. 2.2 Monitoring spaces ...... ......... ....... ....... ...... ...... ....... ....... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ..... 2.2.1 Coordinate systems ...... ........ .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... 2.2.1.1 Special cases .... ...... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ...... ..... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... .. 2.2.2 Cell area ....... .......... ...... ....... ........ ....... ...... ....... ........ ....... ....... ....... ...... ...... ....... ....... ...... ....... ........ ....... ...... ....... ........ ....... ...... ....... ....... ....... ........ ....... ...... ..... 2.2.3 Cartesian wo workspaces ..... ....... .... ..... ..... .... .... ..... ..... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ... 2.2. 2.2.4 4 Cart Cartes esia ian n prot protec ecte ted d spac spaces es .... ....... ..... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... 2.2.5 Axis-specific wor workspaces .... ...... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... .... .. 2.2. 2.2.6 6 Axisxis-sp spe ecifi cificc prot protec ecte ted d spac space es .... ...... ..... ..... .... .... ..... ..... .... .... .... ..... ...... ..... ..... ..... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... .. 2.2.7 Space-sp -specific ve velocity ..... ....... .... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .. 2.2.8 Reference stop ....... .......... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ...... ... 2.3 Safe tools ...... ......... ...... ....... ....... ...... ....... ....... ...... ...... ....... ....... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ..... 2.4 2.4 Velo Veloci city ty mon monititor orin ing g func functition onss .... ...... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ...... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... 2.5 2.5 Safe Safe oper operat atio iona nall sto stop p for for axis axis grou groups ps ..... ....... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... ..... ..... .... .. 2.6 2.6 Refe Refere renc nce e sw switch itch modu module le ..... ....... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .. 2.7 Connecting cables ...... ......... ....... ....... ...... ....... ....... ...... ....... ....... ...... ....... ....... ...... ....... ....... ...... ....... ........ ........ ....... ...... ...... ....... ....... ...... ....... ....... ...... .....

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....... ..... ..... .... ..... ..... ..... ..... .... ..... ..... ..... ..... .... ..... ...... ...... ..... ..... ..... .... ..... ..... ..... ..... .... ..... ...... ..... .... ..... ..... ..... ..... .... ..... ..... Technical data .....

31

3.1 3.2 3.3 3.4 3.4 3.5 3.5

Service life ...... ......... ....... ....... ...... ...... ....... ....... ...... ....... ........ ....... ...... ...... ....... ....... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ....... ........ ....... ...... ...... ...... ..... Referen rence switch ....... .......... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ....... ....... ...... ...... ....... ....... ...... ....... ....... ...... ...... ....... ....... ...... ....... ........ ....... ... Connec Connector tor pin assign assignmen mentt of refere reference nce cable cable X42-X X42-XS S Ref Ref .......... ............. ............ ............. ... Circ Circui uitt digr digram am of of refe referen rence ce swit switch ch XS XS Ref Ref .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Hole Hole patt patter ern n for for act actua uatiting ng plat plate e .... ...... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ...

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Safety ....... ........... ........ ....... ....... ....... ....... ....... ....... ....... ....... ........ ....... ....... ........ ....... ....... ........ ........ ........ ....... ....... ........ ....... ....... ........ ....... ....... ...... ..

4.1 4.1.1 4.1. 4.1.2 2 4.1.3 4.1.3 4.1.4 4.2 4.3 4.3 4.3. 4.3.1 1 4.4 4.4 4.5 4.5. 4.5.1 1 4.5.2 4.5. 4.5.3 3 4.5.4 4.5.5

General ........ ........... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ...... .. Liability ....... .......... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ...... ...... ... Inte Intend nded ed use use of the the indu indust stri rial al robo robott .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. EC dec decla lara ratio tion n of con confo form rmitityy and and decl declara aratition on of of inco incorp rpor orat atio ion n ............................. Terms used ....... .......... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ....... ....... ...... ...... ....... ...... Personnel ...... ......... ....... ....... ...... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ...... ....... ....... ...... ...... ....... ....... ....... ........ ....... ...... ..... Works Workspa pace, ce, safe safety ty zone zone and and dan dange gerr zon zone e .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Dete Determ rmiining ning stop stoppi ping ng dis distanc tances es .... ....... ..... .... .... .... ..... ..... .... .... ..... ...... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .. Trig Trigge gers rs for for sto stop p rea react ctio ions ns .... ...... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... ..... ..... ..... ..... .... .... .. Safety functions ....... .......... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ... Over Ov ervi view ew of the the saf safet etyy fun funct ctio ions ns .... ...... .... .... ..... ..... .... .... ..... ..... ..... ..... .... .... ..... ...... ..... .... .... ..... ..... ..... ..... .... .... ..... ..... .... .... .... .... ..... ... Safety co controller ... r ....... ........ ....... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ....... ........ ....... ...... ...... ....... ....... ...... ....... ........ ....... ...... ...... ....... ...... .. Selec electi ting ng the the oper operat atin ing g mode mode .... ....... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... “Op “Operat rator sa safet fety” si signal .... ....... ..... .... .... .... .... ..... ..... .... .... ..... ...... ..... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... EMERGENCY STOP device ..... ........ ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... ....


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4.5.6 4.5.6 Loggi Logging ng off off from from the the hig highe herr-le leve vell saf safet etyy con contr trol olle ler r .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 4.5. 4.5.7 7 Exte Extern rnal al EMERG MERGE ENCY NCY STO STOP P dev deviice .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 4.5.8 Enabling device ..... ....... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ...... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... 4.5.9 External en enabling de device ..... ....... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .. 4.5. 4.5.10 10 Exter Externa nall safe safe oper operat atio iona nall stop stop ..... ....... .... .... ..... ..... .... .... ..... ..... ..... ..... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... 4.5.11 4.5.11 Extern External al safety safety stop stop 1 and extern external al safety safety stop stop 2 .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 4.5. 4.5.12 12 Velo Veloci city ty moni monito tori ring ng in T1 T1 ..... ....... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... 4.6 4.6 Addi Additition onal al protec protectitive ve equi equipm pmen entt .... ...... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ...... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... .. 4.6.1 Jog mode ....... .......... ...... ....... ....... ...... ....... ....... ...... ...... ....... ....... ...... ....... ....... ...... ....... ....... ...... ....... ....... ...... ....... ....... ...... ....... ....... ....... ....... ...... ....... ....... ... 4.6.2 Software limit switches ..... ....... ..... ..... .... .... ..... ..... .... .... ..... ...... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... ..... ... 4.6.3 Mechanical end stops ..... ....... .... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .. 4.6. 4.6.4 4 Mech Mechan anic ical al axis axis rang range e limi limita tatition on (opt (optio iona nal) l) .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 4.6. 4.6.5 5 Axis Axis rang range e mon monit itor orin ing g (op (opti tion onal al)) ..... ....... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... .... 4.6. 4.6.6 6 Opti Option onss for for movi moving ng the the mani manipu pula lato torr with withou outt driv drive e ener energy gy ... .................................... 4.6. 4.6.7 7 Labe Labeliling ng on the the ind indus ustr tria iall rob robot ot ..... ....... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... ..... ...... ..... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... 4.6.8 External safeguards .... ....... ..... .... .... ..... ...... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .. 4.7 Overvi Overview ew of operat operating ing modes modes and and safety safety functi functions ons .... ...... .... .... .... .... .... .... ........ ...... .... .... .... .... .... .... .... .... ........ ...... .... .... 4.8 Safety me measures ....... .......... ...... ...... ....... ....... ...... ...... ....... ....... ...... ....... ........ ....... ...... ...... ....... ....... ...... ....... ........ ....... ...... ....... ....... ...... ...... ....... ....... ...... ..... 4.8.1 General safety measures .... ...... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... 4.8.2 Transportation ..... ....... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .. 4.8. 4.8.3 3 Start tart-u -up p and and reco recomm mmis issi sion onin ing g ..... ....... .... .... ..... ..... .... .... ..... ..... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... 4.8. 4.8.3. 3.1 1 Chec Checki king ng mach machin ine e dat data a and and safe safety ty conf config igur urat atio ion n .......... ............ ....... ............ ....... ........... 4.8.3.2 Start-up mode .... ...... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ...... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... 4.8.4 Manual mode ....... .......... ...... ...... ....... ....... ...... ...... ...... ....... ....... ...... ...... ...... ...... ....... ....... ...... ...... ...... ....... ....... ...... ...... ...... ....... ....... ...... ...... ....... ....... ..... 4.8.5 Simulation ....... .......... ....... ....... ...... ...... ....... ....... ...... ....... ....... ...... ...... ....... ....... ...... ....... ....... ....... ....... ...... ...... ....... ....... ...... ....... ....... ...... ....... ........ ....... ..... .. 4.8.6 Automatic mode .... ...... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .... .... .... 4.8.7 Maintenance and repair .. r ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ... 4.8. 4.8.8 8 Deco Decomm mmis issi sion onin ing, g, stor storag age e and and disp dispos osal al ... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 4.8. 4.8.9 9 Safe Safety ty mea measu sure ress for for “sin “singl gle e poin pointt of con contr trol ol”” .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 4.9 4.9 Appl Applie ied d norm normss and and regu regula latition onss ..... ....... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... .... ..

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5

Installation ..... ....... ..... ..... ..... ..... .... ..... ...... ..... .... ..... ..... .... ..... ..... ..... ..... .... ..... ..... ..... ..... .... ..... ..... ..... ..... .... ..... ..... .... ..... ...... ..... .... ..... ..... ..... ..... ....

61

5.1 5.1 5.2 5.2 5.3 5.3

Syste ystem m requ requir irem emen ents ts .... ....... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... .... ..... ... Inst Instal alliling ng or upda updatiting ng Safe SafeOp Oper erat atio ion n ..... ....... ..... ...... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... .. Unin Uninst stal alliling ng Safe SafeOp Oper erat atio ion n .... ...... ..... ..... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... ....

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Operation ....... ........... ....... ....... ........ ....... ....... ....... ....... ....... ....... ........ ....... ....... ........ ....... ....... ........ ....... ....... ........ ....... ....... ....... ....... ....... ....... ......

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6.1 6.2 6.2 6.3 6.4 6.4.1 6.4.1 6.4.2 6.4.3 6.5 6.5 6.6 6.6 6.7 6.7

User groups ...... ......... ...... ....... ....... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ....... ....... ...... ...... ....... ....... ....... ....... ...... ...... ....... ....... ...... ....... ........ ...... .. Open Openin ing g the the safe safety ty con confifigu gura ratition on ..... ........ ..... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ... Overview of of bu buttons .... ...... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... Display fu functions ...... .......... ....... ...... ...... ....... ....... ...... ....... ....... ...... ....... ........ ....... ...... ....... ....... ...... ...... ....... ....... ....... ....... ...... ....... ....... ...... ....... ........ ...... .. Disp Displa layi ying ng inf infor orma matition on abo about ut the the saf safet etyy conf config igur urat atio ion n ... ........ ............ .......... ............. ......... ..... Displaying th the ch change lo log ... ..... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ...... ..... ..... ..... ..... ..... ..... ...... ..... .... .... .... ..... ..... .. Displaying machine data ..... ....... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ..... .... .... .... ..... ..... .... .... ..... ..... .... .... ..... ... Impo Import rtin ing g the saf safet etyy confi configu gura ratio tion n (XML (XML import import)) .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Expo Exporti rting ng the the safet safetyy confi configu gura ratition on (XML (XML expo export) rt) .... ...... .... .... .... ........ ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. Safe Safe robo robott retr retract actio ion n in case case of of space space vio viola latition on .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

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Start-up and configuration .... ....... ..... .... ..... ..... ..... ..... .... ..... ...... ..... .... ..... ..... ..... ..... .... ..... ..... ..... ...... ...... ..... .... ..... ..... ..... ..... ....

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Contents

7.1 System safety instructions ......................................................................................... 7.2 Jogging the robot without a higher-level safety controller .......................................... 7.3 Start-up and configuration – overview ....................................................................... 7.4 Information about the safety configuration ................................................................. 7.4.1 Safe definition of Cartesian protected spaces ...................................................... 7.4.2 Unexpected protected space violation at space corners ...................................... 7.5 Configuring safety monitoring functions ..................................................................... 7.5.1 Activating safe monitoring ..................................................................................... 7.5.2 Defining global parameters ................................................................................... 7.5.3 Defining a cell area ............................................................................................... 7.5.4 Defining Cartesian monitoring spaces .................................................................. 7.5.5 Defining axis-specific monitoring spaces .............................................................. 7.5.6 Defining axis-specific velocity monitoring ............................................................. 7.5.6.1 Parameter Braking time ................................................................................. 7.5.7 Defining the safe operational stop for axis groups ................................................ 7.5.8 Defining safe tools ................................................................................................ 7.5.9 Defining the reference position ............................................................................. 7.5.10 Saving the safety configuration ............................................................................. 7.6 Mastering test ............................................................................................................ 7.6.1 Overview, mastering test ...................................................................................... 7.6.2 Programs for the mastering test ........................................................................... 7.6.3 Variables for the mastering test ............................................................................ 7.6.4 Selecting a reference position .............................................................................. 7.6.4.1 Installing the reference switch and actuating plate .......................................... 7.6.4.2 Connecting a reference switch ........................................................................ 7.6.5 Teaching positions for the mastering test ............................................................. 7.6.6 Checking the reference position (actuation with tool) ........................................... 7.6.7 Performing a mastering test manually .................................................................. 7.7 Brake test ................................................................................................................... 7.7.1 Overview of the brake test .................................................................................... 7.7.2 Activating the brake test ....................................................................................... 7.7.3 Programs for the brake test .................................................................................. 7.7.4 Configuring input and output signals for the brake test ........................................ 7.7.4.1 Signal diagram of the brake test – examples ................................................... 7.7.5 Teaching positions for the brake test .................................................................... 7.7.6 Performing a manual brake test ............................................................................ 7.7.7 Checking that the brake test is functioning correctly ............................................ 7.8 Override reduction for velocity and workspace limits ................................................. 7.8.1 Override reduction with spline .............................................................................. 7.8.2 Examples of override reduction with spline .......................................................... 7.8.3 Variables for override reduction in $CUSTOM.DAT ............................................. 7.9 Safety acceptance overview ...................................................................................... 7.10 Checking that the safety functions are functioning correctly ...................................... 7.10.1 Testing Cartesian velocity limits ........................................................................... 7.10.2 Testing axis-specific velocity limits ....................................................................... 7.10.3 Testing Cartesian monitoring spaces ................................................................... 7.10.4 Testing axis-specific monitoring spaces ............................................................... 7.10.5 Testing the safe operational stop for an axis group .............................................. 7.11 Activating a new safety configuration ......................................................................... Issued: 08.06.2016 Version: KST SafeOperation 3.2 V7

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7.12 Deactivating safe monitoring .....................................................................................

123

Interfaces to the higher-level controller ....................................................

125

8.1 Safety functions via Ethernet safety interface ........................................................... 8.1.1 SafeOperation via Ethernet safety interface (optional) ......................................... 8.1.2 Diagnostic signals via Ethernet interface .............................................................. 8.2 SafeOperation via interface X13 ................................................................................

125 129 133 136

8

9

Diagnosis ......................................................................................................

139

9.1 9.2 9.3

Displaying safe I/Os ................................................................................................... Variables for diagnosis .............................................................................................. Outputs for space monitoring ....................................................................................

139 139 140

10

Messages ......................................................................................................

141

10.1 Information about the messages ............................................................................... 10.2 System messages from module: CrossMeld (KSS) .................................................. 10.2.1 KSS15016 ............................................................................................................ 10.2.2 KSS15017 ............................................................................................................ 10.2.3 KSS15018 ............................................................................................................ 10.2.4 KSS15019 ............................................................................................................ 10.2.5 KSS15033 ............................................................................................................ 10.2.6 KSS15034 ............................................................................................................ 10.2.7 KSS15035 ............................................................................................................ 10.2.8 KSS15036 ............................................................................................................ 10.2.9 KSS15037 ............................................................................................................ 10.2.10 KSS15039 ............................................................................................................ 10.2.11 KSS15040 ............................................................................................................ 10.2.12 KSS15041 ............................................................................................................ 10.2.13 KSS15042 ............................................................................................................ 10.2.14 KSS15043 ............................................................................................................ 10.2.15 KSS15044 ............................................................................................................ 10.2.16 KSS15045 ............................................................................................................ 10.2.17 KSS15046 ............................................................................................................ 10.2.18 KSS15047 ............................................................................................................ 10.2.19 KSS15048 ............................................................................................................ 10.2.20 KSS15049 ............................................................................................................ 10.2.21 KSS15050 ............................................................................................................ 10.2.22 KSS15051 ............................................................................................................ 10.2.23 KSS15052 ............................................................................................................ 10.2.24 KSS15053 ............................................................................................................ 10.2.25 KSS15054 ............................................................................................................ 10.2.26 KSS15065 ............................................................................................................ 10.2.27 KSS15066 ............................................................................................................ 10.2.28 KSS15079 ............................................................................................................ 10.2.29 KSS15081 ............................................................................................................ 10.2.30 KSS15083 ............................................................................................................ 10.2.31 KSS15127 ............................................................................................................ 11

Appendix ......................................................................................................

11.1 Checklists .................................................................................................................. 6 / 205

141 141 141 141 142 143 144 144 145 145 146 146 148 149 151 152 154 155 158 159 159 159 160 160 161 163 164 165 165 168 169 170 170

171 171


Contents

11.1.1 Precondition for safety acceptance based on the checklists ................................ 11.1.2 Checklist for robot and system ............................................................................. 11.1.3 Checklist for safety functions ................................................................................ 11.1.4 Checklist for Cartesian velocity monitoring functions ........................................... 11.1.5 Checklist for axis-specific velocity monitoring functions ....................................... 11.1.6 Checklist for safe operational stop for axis groups ............................................... 11.1.7 Checklist for cell area ........................................................................................... 11.1.8 Checklist for Cartesian monitoring spaces ........................................................... 11.1.9 Checklist for axis-specific monitoring spaces ....................................................... 11.1.10 Checklist for safe tools .......................................................................................... 11.2 Applied norms and directives .....................................................................................

171 171 172 175 176 180 182 183 185 190 192

KUKA Service ..............................................................................................

193

12

12.1 Requesting support .................................................................................................... 12.2 KUKA Customer Support ...........................................................................................

193 193

Index .............................................................................................................

201


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1 Introduction

1

Introduction

t

1.1

Target group

t

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 directly from our subsidiaries. 1.2

Industrial robot documentation

The industrial robot documentation consists of the following parts:     

Documentation for the manipulator Documentation for the robot controller Operating and programming instructions for the System Software Instructions for options and accessories Parts catalog on storage medium

Each of these sets of instructions is a separate document. 1.3 Safety

Representation of warnings and notes

These warnings are relevant to safety and must be observed. These warnings mean that it is certain or highly probable that death or severe injuries will occur, if no precautions are taken. These warnings mean that death or severe injuries may occur, if no precautions are taken. These warnings mean that minor injuries may occur, if no precautions are taken. These warnings mean that damage to property may occur, if no precautions are taken. These warnings contain references to safety-relevant information or general safety measures. These warnings do not refer to individual hazards or individual precautionary measures. This warning draws attention to procedures which serve t o prevent or remedy emergencies or malfunctions: Procedures marked with this warning must be followed exactly.

Notices

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


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

1.4

Terms used Term

Description

Axis range

Range of an axis in degrees or millimeters within which the axis moves. The axis range is defined by a lower and an upper axis limit. An axis has 2 axis limits which define the axis range. There is an upper and a lower axis limit. Stopping distance = reaction distance + braking distance

Axis limit Stopping distance

Workspace

The stopping distance is part of the danger zone. Monitoring space that the defined axes or the safe tool are not allowed to leave. The axes or the safe tool must always move within the limits of the workspace. (>>> 2.2.3 "Cartesian workspaces" Page 20)

CIP Safety

CK EtherNet/IP

Danger zone Mastering test

KL Alarm space

Monitoring time Polygon, convex

(>>> 2.2.5 "Axis-specific workspaces" Page 22) CIP Safety is an Ethernet/IP-based safety interface for connecting a safety PLC to the robot controller. (PLC = master, robot controller = slave) (>>> 8.1.1 "SafeOperation via Ethernet safety interface (optional)" Page 129) Customer-built Kinematics EtherNet/IP is an Ethernet-based field bus (Ethernet interface). (>>> 8.1.2 "Diagnostic signals via Ethernet interface" Page 133) The danger zone consists of the workspace and the stopping distances. The mastering test verifies whether the current position of the robot and the additional axes matches a reference position. (>>> 7.6 "Mastering test" Page 98) KUKA linear unit An alarm space signals a workspace violation by setting an output. The alarm spaces are permanently assigned to the configurable outputs of the interface options PROFIsafe, CIP Safety or X13 (Extended SIB). During the monitoring time, the user is prompted to perform the mastering test. A convex polygon is a polygon consisting of at least 3 different corners. Triangles and squares are examples of convex polygons. (>>> 2.2.2 "Cell area" Page 19)

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1 Introduction

Term

Description

PROFINET

PROFINET is an Ethernet-based field bus (Ethernet interface).

PROFIsafe

Reference group

Reference position

(>>> 8.1.2 "Diagnostic signals via Ethernet interface" Page 133) PROFIsafe is a PROFINET-based safety interface for connecting a safety PLC to the robot controller. (PLC = master, robot controller = slave) (>>> 8.1.1 "SafeOperation via Ethernet safety interface (optional)" Page 129) A reference group contains the axes of a kinematic system that are required for moving to a reference position and are to be subjected to safe monitoring. The reference position is a Cartesian position to which the robot moves during the mastering test.

Reference stop

(>>> 7.6.4 "Selecting a reference position" Page 101) Safety stop that is triggered if the mastering test has not been performed. The reference stop can be activated for monitoring spaces.

Reference switch

(>>> 2.2.8 "Reference stop" Page 25) To perform the mastering test, a reference button is required. The reference position is confirmed using the reference button.

Protected space

(>>> 2.6 "Reference switch module" Page 28) Monitoring space into which the defined axes or the safe tool are not allowed to intrude. The axes or the safe tool must always move outside the limits of the protected space. (>>> 2.2.4 "Cartesian protected spaces" Page 21)

SIB Safety STOP 0

(>>> 2.2.6 "Axis-specific protected spaces" Page 23) Safety Interface Board A stop that is triggered and executed by the safety controller. The safety controller immediately switches off the drives and the power supply to the brakes. Note: This stop is called safety STOP 0 in this docu-

Safety STOP 1

ment. A stop that is triggered and monitored by the safety controller. The braking operation is carried out by the non-safety-oriented section of the robot controller and monitored by the safety controller. As soon as the manipulator is has stopped, the safety controller deactivates the drives and the power supply of the brakes. Note: This stop is called safety STOP 1 in this docu-

ment.


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Term

Description

Safety STOP 2

A stop that is triggered and monitored by the safety controller. The braking operation is carried out by the non-safety-oriented section of the robot controller and monitored by the safety controller. The drives remain activated and the brakes released. Note: This stop is called safety STOP 2 in this docu-

Safe operational stop

Safe tools

Monitoring space

Cell area

ment. In the event of a safe operational stop, the system monitors standstill of the axes for which the safe operational stop is configured. When the axes are at a monitored standstill, they may move within the configured axis angle or distance tolerances. (>>> 2.5 "Safe operational stop for axis groups" Page 28) A safe tool can be modeled using up to 6 configurable spheres. These spheres are monitored against the limits of the Cartesian monitoring spaces. Each safe tool has a safe TCP against which the configured velocity limits are monitored. (>>> 2.3 "Safe tools" Page 26) A monitoring space can be defined in Cartesian terms or axis-specifically and as a workspace or protected space. (>>> 2.2 "Monitoring spaces" Page 14) Cartesian workspace that forms a convex polygon with 3 … 10 vertices (corners) and is limited in ±Z direction. The cell area is the maximum permitted working range of the robot. (>>> 2.2.2 "Cell area" Page 19)

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2 Product description

2

Product description

2.1

Overview of SafeOperation

t

Functions

SafeOperation is a safety option with software and hardware components and the following functions: 

          

Safe monitoring of a maximum of 16 user-defined, axis-specific or Cartesian monitoring spaces Safe monitoring of a user-defined cell area Safe monitoring of axis-specific velocities Safe monitoring of space-specific velocities Safe monitoring of Cartesian velocities Modeling of up to 16 safe tools with safe TCP Safe stop via safety controller Safe operational stop for up to 6 axis groups Connection to a higher-level controller, e.g. to a safety PLC Safe inputs for activation of the monitoring functions Safe outputs for status messages of the monitoring functions Creation and editing of the safety configuration on the robot controller or in WorkVisual. Information about the safety configuration in WorkVisual is contained in the WorkVisual documentation.

Areas of application

  

Human-robot cooperation Direct loading of workpieces without an intermediate support Replacement of conventional axis range monitoring systems SafeOperation cannot and must not be used in conjunction with a CK.

Decouplable external axes are not supported by SafeOperation. In the case of decouplable external axes, safe position sensing is not possible, as the machine data change while the controller is running. Functional principle

The components of the industrial robot move within the limits that have been configured and activated. The actual positions are continuously calculated and monitored against the safety parameters that have been set. The safety controller monitors the industrial robot by means of the safety parameters that have been set. If a component of the industrial robot violates a monitoring limit or a safety parameter, the robot and external axes (optional) are stopped.


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Fig. 2-1: Example of a cell with SafeOperation

1 2 3 4 Components

Reference switch Robot Loading station Safety mat

5 6 7

System control panel Robot controller Bending machine

These software components are included in the SafeOperation package: 


These hardware components are included in the SafeOperation package: 

Brake test

Reference switch module

The brake test serves as a diagnostic measure for the robot axis and external axis brakes. The brakes are activated for the stop reactions safety stop 0 and safety stop 1. If a safety option is installed and the safe mo nitoring is active, the brake test is automatically active.

Interfaces

Various interfaces are available for connection to a h igher-level controller. The safe I/Os of these interfaces can be used, for example, to signal a violation of safety monitoring functions. 



2.2

Ethernet safety interfaces: PROFINET/PROFIsafe  EtherNet/IP/CIP Safety  Discrete safety interface for safety options:  X13 via Extended SIB

Monitoring spaces

A maximum of 16 monitoring spaces can be configured. A cell area must also be configured.

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Monitoring space

A monitoring space can be defined as a Cartesian cuboid or by means of individual axis ranges. Each monitoring space can be set as a workspace or protected space. (>>> 2.2.3 "Cartesian workspaces" Page 20) (>>> 2.2.4 "Cartesian protected spaces" Page 21) (>>> 2.2.5 "Axis-specific workspaces" Page 22) (>>> 2.2.6 "Axis-specific protected spaces" Page 23) For every monitoring space, a space-specific Cartesian velocity can be defined inside or outside the monitoring space. (>>> 2.2.7 "Space-specific velocity" Page 25) For each monitoring space, a reference stop can be set t hat stops the robot if no mastering test has been carried out. (>>> 2.2.8 "Reference stop" Page 25) Monitoring can be activated and deactivated for each individual monitoring space, or activated by means of safe inputs. Safe outputs are permanently assigned to the monitoring spaces. The safe outputs are set if a monitoring space is violated. Whether or not a stop is triggered at the space limit is a function that can be configured.

Cell area

The cell area is a Cartesian workspace in the form of a convex polygon with 3 to 10 corners and is limited in the ±Z direction. (>>> 2.2.2 "Cell area" Page 19) The cell area is permanently monitored and always active. The corners can be configured, activated and deactivated individually. A safety stop 0 is always triggered at the space limit.

Stopping distance

If the robot is stopped by a monitoring function, it requires a certain stopping distance before coming to a standstill. The stopping distance depends primarily on the following factors:    

Robot type Velocity of the robot Position of the robot axes Payload

The stopping distance when a monitoring function is trigger ed varies according to the specific robot type. This aspect must be taken into account by the system integrator during parameterization of the mon itoring functions as part of the safety assessment. Further information about the stopping distances and stopping times can be found in the assembly or operating instructions of the relevant robot.


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Stop reactions Stop reaction

Description

Example

Safety stop 0

The stop is triggered in T2, AUT or AUT EXT mode if a monitoring function is already activated and the robot then exceeds the monitoring space limit. The stop is triggered if the robot exceeds a monitoring space limit in T1 mode. The stop is triggered if a monitoring function is just being activated and the robot has already exceeded the monitoring space limit. The stop is triggered if a reference stop is activated for an activated monitoring space and the robot exceeds the monitoring space limit after an internal mastering test request in T2, AUT or AUT EXT mode.

Robot exceeds the limit of an activated workspace in Automatic mode.

Safety stop 1

2.2.1

Robot exceeds the limit of an activated workspace in T1 mode. A protected space in which the robot is currently situated is activated by a safety mat. After a restart of the robot controller, the safety controller requests a mastering test. The robot continues to move during the monitoring time and exceeds in T2 mode the limit of an activated protected space for which the reference stop is activated.

Coordinate systems

Overview

The following Cartesian coordinate systems are defined in the robot controller:    

WORLD ROBROOT BASE TOOL

Fig. 2-2: Overview of coordinate systems

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Description

WORLD

The WORLD coordinate system is a permanently defined Cartesian coordinate system. It is the root coordinate system for the ROBROOT and BASE coordinate systems. By default, the WORLD coordinate system is located at the robot base. ROBROOT

The ROBROOT coordinate system is a Cartesian coordinate system, which is always located at the robot base. It defines the position of the robot relative to the WORLD coordinate system. By default, the ROBROOT coordinate system is identical to the WORLD coordinate system. $ROBROOT allows the definition of an offset of the robot relative to the WORLD coordinate system. BASE

The BASE coordinate system is a Cartesian coordinate system that defines the position of the workpiece. It is relative to the WORLD coordinate system. By default, the BASE coordinate system is identical to the WORLD coordinate system. It is offset to the workpiece by the user. TOOL

The TOOL coordinate system is a Cartesian coordinate system which is located at the tool center point. By default, the origin of the TOOL coordinate system is located at the flange center point. (In this case it is called the FLANGE coordinate system.) The TOOL coordinate system is offset to the tool center point by the user. Angles of rotation of the robot coordinate systems Angle

Rotation about axis

Angle A Angle B Angle C

Rotation about the Z axis Rotation about the Y axis Rotation about the X axis


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2.2.1.1

Special cases

Fig. 2-3: ROBROOT coordinate system Jet

In the case of Jet robots, the ROBROOT coordinate system is fixed. They do not move with the robot.

Fig. 2-4: ROBROOT coordinate system KL

In the case of a KL, the relationship between the ROBROOT coordinate system and the WORLD coordinate system changes. The ROBROOT coordinate system moves with the robot on the KL.

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2.2.2

Cell area

Description

The cell area is a Cartesian monitoring space that is limited in the ±Z direction. The safe tool on the mounting flange of the robot is modeled using up to 6 configurable spheres; when the robot moves, these spheres move with it. These spheres are monitored against the cell area and must only move within this cell area. If a sphere violates the limits of the cell area, the robot stops with a safety stop 0. Cartesian monitoring spaces are only monitored against the spheres used to model the safe tool. Robot components situated outside the tool spheres are not monitored and a space violation by these components is not detected. Cartesian monitoring spaces and tool spheres must therefore be designed and configured in such a manner that the unmonitored robot components do not pose any threat. The cell area is configured in the WORLD coordinate system as a convex polygon with 3 to 10 corners. A convex polygon is a polygon consisting of at least 3 different corners. The line segments between any 2 corners must not be outside the polygon. Triangles and squares are examples of convex polygons.

Fig. 2-5

1 2 Example

Example of a convex polygon with 6 corners Example of a non-convex polygon with 6 corners

The diagram shows an example of a configured cell area.


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Fig. 2-6: Example of a cell area

1 2 3 2.2.3

Cell area Safely monitored tool spheres Robot

Cartesian workspaces

Description

The safe tool on the mounting flange of the robot is modeled using up to 6 configurable spheres; when the robot moves, these spheres move with it. These spheres are simultaneously monitored against the activated Cartesian workspaces and must move within the workspaces. If a sphere violates the limit of a workspace, the following reactions can occur: 

 

A safe output is reset (state: “logic 0”). The safe outputs are set if a monitoring space is not violated (state: “ logic 1”). If interface X13 is used, safe outputs are only available for monitoring spaces 1 … 6. The robot is stopped (configurable). Cartesian velocity monitoring is activated (configurable).

Cartesian monitoring spaces are only monitored against the spheres used to model the safe tool. Robot components situated outside the tool spheres are not monitored and a space violation by these components is not detected. Cartesian monitoring spaces and tool spheres must therefore be designed and configured in such a manner that the unmonitored robot components do not pose any threat. Only KUKA linear units are supported as ROBROOT kinematic systems. Example

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The diagram shows an example of a configured Cartesian workspace.



Fig. 2-7: Example of a Cartesian workspace

1 2 3 2.2.4

Working space Safely monitored tool spheres Robot

Cartesian protected spaces

Description

The safe tool on the mounting flange of the robot is modeled using up to 6 configurable spheres; when the robot moves, these spheres move with it. These spheres are simultaneously monitored against the activated Cartesian protected spaces and must move outside the protected spaces. The length, width and height of a protected space must not fall below the predefined minimum value. This value depends on the global maximum Cartesian velocity and the radius of the smallest sphere of the safe tool. (>>> "Minimum protected space dimensions" Page 72) If a sphere violates the limit of a protected space, the following reactions can occur: 

 

A safe output is reset (state: “logic 0”). The safe outputs are set if a monitoring space is not violated (state: “logic 1”). If interface X13 is used, safe outputs are only available for monitoring spaces 1 … 6. The robot is stopped (configurable). Cartesian velocity monitoring is activated (configurable).

Cartesian monitoring spaces are only monitored against the spheres used to model the safe tool. Robot components situated outside the tool spheres are not monitored and a space violation by these components is not detected. Cartesian monitoring spaces and tool spheres must therefore be designed and configured in such a manner that the unmonitored robot components do not pose any threat. Issued: 08.06.2016 Version: KST SafeOperation 3.2 V7

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Only KUKA linear units are supported as ROBROOT kinematic systems. The diagram shows an example of a Cartesian protected space.

Example

Fig. 2-8: Example of a Cartesian protected space

1 2 3 2.2.5

Protected space Safely monitored tool spheres Robot

Axis-specific workspaces

Description

The axis limits can be set and monitored individually for each axis via the software. The resulting axis range is the permissible range of an axis within which the robot may move. The individual axis ranges together make up the overall workspace, which may consist of up to 8 axis ranges. A maximum of 8 axes or, in the case of kinematic systems with master/slave axes, a maximum of 8 drives can be configured for each monitoring space. If the robot violates an axis limit, the following reactions can occur: 

 

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A safe output is reset (state: “logic 0”). The safe outputs are set if a monitoring space is not violated (state: “ logic 1”). If interface X13 is used, safe outputs are only available for monitoring spaces 1 … 6. The robot is stopped (configurable). Cartesian velocity monitoring is activated (configurable).



The diagram shows an example of an axis-specific workspace. The workspace of axis 1 is configured from -110° to +130° and corresponds to the permissible motion range of the robot.

Example

Fig. 2-9: Example of an axis-specific workspace

1 2 2.2.6

Workspace Robot

3 4

Stopping distance Protected space

Axis-specific protected spaces

Description

The axis limits can be set and monitored individually for each axis via the software. The resulting axis range is the protected range of an axis within which the robot may not move. The individual axis ranges together make up the protected space, which may consist of up to 8 axis ranges. A maximum of 8 axes or, in the case of kinematic systems with master/slave axes, a maximum of 8 drives can be configured for each monitoring space. If the robot violates an axis limit, the following reactions can occur: 

 

A safe output is reset (state: “logic 0”). The safe outputs are set if a monitoring space is not violated (state: “logic 1”). If interface X13 is used, safe outputs are only available for monitoring spaces 1 … 6. The robot is stopped (configurable). Cartesian velocity monitoring is activated (configurable).

In the case of axes that can rotate more than 360°, e.g. axis 1, the configured axis ranges refer to the position of the axis (including sign) and not to the sector of a circle. Serious injury and severe damage to the robot can be caused. If, for example, a protected space of +90° to +270° is configured, the robot can move through the protect ed space in the other direction from -90° to -185°. In this case, it is advisable to configure a workspace from -90° to +90°.


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Fig. 2-10: Example of an axis-specific protected space through which the robot can move

1 2

Example

Workspace Robot

3 4

Protected space Protected space through which the robot can move

The diagram shows an example of an axis-specific prote cted space. The safeguarded space and the stopping distances correspond to the configured protected space. The motion range of axis 1 is limited to -185° to +185° by means of software limit switches. The protected space is configured from -110° to -10°. This results in 2 permissible motion ranges for the robot, separated by the configured protected space.

Fig. 2-11: Example of an axis-specific protected space

1 2 3 24 / 205

Permissible range 1 Robot Stopping distance

4 5

Protected space Permissible range 2



2.2.7

Space-specific velocity

Description

For Cartesian and axis-specific monitoring spaces, a Cartesian velocity can be defined which is monitored if the space is violated or not violated. A safe TCP is defined for every safe tool. This safe TCP is monitored against a configured velocity limit. If the safe TCP exceeds the velocity limit, the robot is stopped safely.

Example

The diagram shows an example of a Cartesian workspace. If the safe TCP on the safe tool exceeds the velocity limit inside the workspace, the robot is stopped with a safety stop 0.

Fig. 2-12: Space-specific velocity example

1 2 3 2.2.8

Working space Safely monitored tool spheres Robot

Reference stop

Description

A reference stop can be activated for monitoring spaces. (= function Stop if mastering test not yet done) If the reference stop is activated and the following conditions are met, the robot can only be moved in T1 mode:  

Monitoring space is activated. Mastering test is requested internally.

If the reference stop is activated and the following preconditions are met, the robot stops with a safety stop 1:   

Monitoring space is activated. Mastering test is requested internally. Operating mode T2, AUT or AUT EXT


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To be able to move the robot again in the stop-triggering operating modes, the following possibilities are available:   

2.3

Perform mastering test in T1 mode. Deactivate monitoring spaces. Deactivate reference stop.

Safe tools

Description

Up to 16 safe tools can be defined. A safe TCP is defined for each safe tool and monitored against the configured velocity limits. A safe tool can be modeled using up to 6 configurable spheres. These spheres are monitored against the limits of the Cartesian monitoring spaces. The sphere radius must not fall below the predefined minimum value. This radius is dependent on the global maximum Cartesian velocity. (>>> "Minimum sphere radius" Page 72) The safe tools are activated using safe inputs. Only one safe tool may be active at any time. If interface X13 is used, tool 1 is always active. The tool cannot be activated via a safe input. An automated, safely monitored tool change is thus not possible. The safe TCP for the velocity monitoring can be freely configured in the safety configuration. It is independent of the current TCP that is set in the KUKA System Software with the variable $TOOL. Cartesian monitoring spaces are only monitored against the spheres used to model the safe tool. Robot components situated outside the tool spheres are not monitored and a space violation by these components is not detected. Cartesian monitoring spaces and tool spheres must therefore be designed and configured in such a manner that the unmonitored robot components do not pose any threat.

Example

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The diagram shows an example of a safe tool. 2 spheres and a safe TCP are defined on the safe tool of the robot by means of the FLANGE coordinate system.



Fig. 2-13: Safe tool

2.4

Velocity monitoring functions

Axis-specific and Cartesian velocities can be monitored. Axis velocity

The velocity of every axis is monitored against a limit value:  

Limit value for reduced axis velocity (optional) Limit value for maximum axis velocity for T1 mode Monitoring of the maximum axis velocity in T1 mode is part of the standard safety configuration and always active.



Cartesian velocity

Limit value for maximum axis velocity (valid globally for every axis)

The Cartesian velocity at the safe TCP of the active safe tool is monitored. The velocity monitoring is always relative to $WORLD:   



Limit value for the reduced velocity at the safe TCP (optional) Limit value for the reduced velocity at the safe TCP for T1 mode Limit value for the global maximum velocity at the safe TCP and at the sphere center points of the safe tool (not space-dependent) Space-specific velocity (>>> 2.2.7 "Space-specific velocity" Page 25)

Stop reactions Stop reaction

Description

Example

Safety stop 0

The stop is triggered if a monitoring function is already activated and the robot then exceeds the monitoring limit. The stop is triggered if a monitoring function is just being activated and the robot has already exceeded the monitoring limit.

In automatic operation, the robot exceeds the activated limit value for reduced axis velocity.

Safety stop 1


The safe reduced velocity, for which the limit value has already been exceeded by the robot, is activated by a safety mat.

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2.5

Safe operational stop for axis groups

Description

The global safe operational stop is one of the standard safety functions. If it is activated via the safety interface, the standstill of all axes of the kinematic system is monitored. The axes may still move within the conf igured axis angle or distance tolerances. These can be configured individually for each axis. With SafeOperation, the safe operational stop can additionally be configured for up to 6 axis groups. An axis group comprises the axes that are to be monitored when the safe operational stop is activated for this axis group. Before monitoring is activated, the corresponding axes must be stopped under program control. A maximum of 8 axes or, in the case of kinematic systems with master/slave axes, a maximum of 8 drives can be configured for each axis group. If the safe operational stop is activated for an axis group, the standstill of the axes for which it has been configured is monitored using failsafe technology. The axes may still move within the configured axis angle o r distance tolerances. If the safe operational stop is violated, i.e. if the position tolerance for an axis is exceeded or the velocity of an axis exceeds the maximum permitted level, a safety stop 0 is triggered in response. The safety stop 0 affects all axes, not just those for which the operational stop is configured. This means that an unintended motion of an axis relevant for the safe operational stop causes the machine to stop.

2.6

Reference switch module

Description

A reference switch module consists of the following components:    

Inductive reference switch XS Ref Straight or angled actuating plate Reference cable X42 - XS Ref Reference connector X42

Fig. 2-14: Reference group hardware components

1

Inductive reference switch

2

Straight actuating plate

In combination with a straight or angled actuating plate , reference switch modules are available with different cable lengths.

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2.7

Length

Actuating plate

7m 15 m 25 m 40 m

Straight or angled

Connecting cables

Overview

The diagram shows an example of the connecting cables of the industrial robot with connected reference switch. The reference switch is connected via the reference cable to the robot controller. The maximum hose length is 40 m. In the case of a KR C4, only 1 reference switch can be connected directly to the robot controller. If multiple reference groups are required, the reference switches can be connected to the safety PLC and activated via PROFIsafe or CIP Safety. The safety PLC must evaluate the ref erence switches and set the input Mastering test accordingly. A KR C4 compact is not equipped with a connection allowing a reference switch to be connected to the robot controller. Reference switches must be connected to the safety PLC and activated via PROFIsafe or CIP Safety. The safety PLC must evaluate the reference switches and set the input Mastering test accordingly.

Fig. 2-15: Overview of connecting cables Pos.

1 2 3 4 5

Description

Robot controller Robot Reference switch XS Ref Reference cable X42 - XS Ref (maximum cable length 40 m) Data cable X21


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Cables must not be connected and disconnected during operation. Only the reference cable X42 - XS Ref supplied by KUKA Roboter GmbH may be used. Reference cable X42 - XS Ref is suitable for use in a cable carrier. The minimum bending radii must be observed when routing cables.

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Type of routing

Bending radius

Fixed installation Installation in cable carrier

Min. 5xØ of cable Min. 10xØ of cable


3 Technical data

T

3

Technical data

3.1

Service life

The maximum permissible service life of safety-relevant hardware components is 20 years. Once this time has been reached, the safety-relevant hardware components must be exchanged.

t

3.2

Reference switch

Basic data

Designation

Values

Ambient temperature Switching function DC operating voltage or HIGH level in th e case of pulsed operating voltage of the reference switch Permissible range for the DC operating voltage or HIGH level U B(HIGH) for pulsed voltage

-25 °C to +70 °C Break contact 24 V

LOW level UB(LOW) for pulsed voltage

0…5V

Required pulse duty factor T(HIGH):T(LOW) for pulsed voltage Supported pulse duration T(LOW) for pulsed voltage Protection rating Operating current (power consumption) without load Permissible load current Permissible switching frequency Permissible switching distance at the proximity switch surfaces Short circuit and overload protection, pulsed Outputs

Min. 4:1

20 … 33 V

0.1 … 20 ms IP67 5 mA max. 250 mA max. 500 Hz 0 … 4 mm Yes   

LED function indicator Hysteresis when installed EMC conformity

PNP LOW-active Dual-channel

Yes 0.2 … 1 mm IEC 60947-5-2

Pulse duty factor

Fig. 3-1: Pulse duty factor for pulsed voltage


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Hole pattern

Fig. 3-2: Hole pattern for reference switch

1 2 3.3

2 holes for fastening elements, Ø 6.6 mm 2 holes for roll pins, Ø 4 mm

Connector pin assignment of reference cable X42-XS Ref

Fig. 3-3: Connector pin allocation for reference cable X42 - XS Ref

Fig. 3-4: Wiring diagram for reference cable X42 - XS Ref

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3 Technical data

3.4

Circuit digram of reference switch XS Ref

Fig. 3-5: Circuit diagram of reference switch XS Ref

1 3.5

Switching element, channel A

2

Switching element, channel B

Hole pattern for actuating plate

Fig. 3-6: Hole pattern for actuating plate

1 2

2 M6 threaded holes for fastening elements 2 holes for fastening elements, Ø 9 mm


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4 Safety

4

Safety

f

t

4.1

General

4.1.1

Liability

The device described in this document is either an industrial robot or a component thereof. Components of the industrial robot:     

 

Manipulator Robot controller Teach pendant Connecting cables External axes (optional) e.g. linear unit, turn-tilt table, positioner Software Options, accessories

The industrial robot is built using state-of-the-art technology and in accordance with the recognized safety rules. Nevertheless, misuse of the industrial robot may constitute a risk to life and limb or cause damage to the industrial robot and to other material property. The industrial robot may only be used in perfect technical condition in accordance with its designated use and only by safety-conscious persons who are fully aware of the risks involved in its operation. Use of the industrial robot is subject to compliance with this document and with the declaration of incorporation supplied together with the industrial robot. Any functional disorders affecting safety must be rectified immediately. Safety information

Safety information cannot be held against KUKA Roboter GmbH. Even if all safety instructions are followed, this is not a g uarantee that the industrial robot will not cause personal injuries or material damage. No modifications may be carried out to the industrial robot without the authorization of KUKA Roboter GmbH. Additional components (tools, software, etc.), not supplied by KUKA Roboter GmbH, may be integrated into the industrial robot. The user is liable for any damage these components may cause to the industrial robot or to other material property. In addition to the Safety chapter, this document contains f urther safety instructions. These must also be observed.

4.1.2

Intended use of the industrial robot

The industrial robot is intended exclusively for the use designated in the “Purpose” chapter of the operating instructions or assembly instructions. Any use or application deviating from the intended use is deemed to be misuse and is not allowed. The manufacturer is not liable for any damage resulting from such misuse. The risk lies entirely with the user. Operation of the industrial robot in accordance with its intended use also requires compliance with the operating and assembly instructions for the individual components, with particular reference to the maintenance specifications. Misuse

Any use or application deviating from the intended use is deemed to be misuse and is not allowed. This includes e.g.:


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KUKA.SafeOperation 3.2       

4.1.3

Transportation of persons and animals Use as a climbing aid Operation outside the specified operating parameters Use in potentially explosive environments Operation without additional safeguards Outdoor operation Underground operation

EC declaration of conformity and declaration of incorporation

The industrial robot constitutes partly completed machinery as defined by the EC Machinery Directive. The industrial robot may only be put into operation if the following preconditions are met: 



The industrial robot is integrated into a complete system. or: The industrial robot, together with other machinery, constitutes a complete system. or: All safety functions and safeguards required for operation in the complete machine as defined by the EC Machinery Directive have been added to the industrial robot. The complete system complies with the EC Machinery Directive. This has been confirmed by means of an assessment of conformity.

The system integrator must issue a declaration of conformity for the complete system in accordance with the Machinery Directive. The declaration of conformity forms the basis for the CE mark for the system. The industrial robot must always be operated in accordance with the applicable national laws, regulations and standards.

Declaration of conformity

The robot controller is CE certified under the EMC Directive and the Low Voltage Directive. The partly completed machinery is supplied with a declaration of incorporation in accordance with Annex II B of the EC M achinery Directive 2006/42/EC. The assembly instructions and a list of essential requirements complied with in accordance with Annex I are integral parts of this declaration of incorporation.

Declaration of incorporation

The declaration of incorporation declares that the start-up of the partly completed machinery is not allowed until the p artly completed machinery has been incorporated into machinery, or has been assembled with other parts to form machinery, and this machinery complies with the terms of the EC Machinery Directive, and the EC declaration of conformity is present in accordance with Annex II A. 4.1.4

Terms used

STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 602041:2006. Term

Description

Axis range

Range of each axis, in degrees or millimeters, within which it may move. The axis range must be defined for each axis. Stopping distance = reaction distance + braking distance

Stopping distance Workspace

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The stopping distance is part of the danger zone. Area within which the robot may move. The workspace is derived from the individual axis ranges.


4 Safety

Term

Description

User

The user of the industrial robot can be the management, employer or delegated person responsible for use of the industrial robot. The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). The service life of a safety-relevant component begins at the time of delivery of the component to the customer.

Danger zone Service life

KUKA smartPAD Manipulator Safety zone Safe operational stop

The service life is not affected by whether the component is used or not, as safety-relevant components are also subject to aging during storage. see “smartPAD” The robot arm and the associated electrical installations The safety zone is situated outside the danger zone. The safe operational stop is a standstill monitoring function. It does not stop the robot motion, but monitors whether the robot axes are stationary. If these are moved during the safe operational stop, a safety stop STOP 0 is triggered. The safe operational stop can also be triggered externally.

Safety STOP 0

When a safe operational stop is triggered, the robot controller sets an output to the field bus. The output is set even if not all the axes were stationary at the time of triggering, thereby causing a safety stop STOP 0 to be triggered. A stop that is triggered and executed by the safety controller. The safety controller immediately switches off the drives and the power supply to the brakes. Note: This stop is called safety STOP 0 in this document.

Safety STOP 1

A stop that is triggered and monitored by the safety controller. The braking operation is carried out by the non-safety-oriented section of the robot controller and monitored by the safety controller. As soon as the manipulator is has stopped, the safety controller deactivates the drives and the power supply of the brakes. When a safety STOP 1 is triggered, the robot controller sets an outpu t to the field bus. The safety STOP 1 can also be triggered externally. Note: This stop is called safety STOP 1 in this document.

Safety STOP 2

A stop that is triggered and monitored by the safety controller. The braking operation is carried out by the non-safety-oriented section of the robot controller and monitored by the safety controller. The drives remain activated and the brakes released. As soon as the manipulator is at a standstill, a safe operational stop is triggered. When a safety STOP 2 is triggered, the robot controller sets an outpu t to the field bus. The safety STOP 2 can also be triggered externally. Note: This stop is called safety STOP 2 in this document.

Safety options

smartPAD

Generic term for options which make it possible to configure additional safe monitoring functions in addition to the standard safety functions. Example: SafeOperation Programming device for the robot controller The smartPAD has all the operator control and display functions required for operating and programming the industrial robot.


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Term

Description

Stop category 0

The drives are deactivated immediately and the brakes are applied. The manipulator and any external axes (optional) perform path-oriented braking. Note: This stop category is called STOP 0 in this document.

Stop category 1

The manipulator and any external axes (optional) perform path-maintaining braking. 



Operating mode T1: The drives are deactivated as soon as the robot has stopped, but no later than after 680 ms. Operating mode T2, AUT (not available for VKR C4), AUT EXT: The drives are switched off after 1.5 s.

Note: This stop category is called STOP 1 in this document.

Stop category 2

The drives are not deactivated and the brakes are not applied. The manipulator and any external axes (optional) are braked with a pathmaintaining braking ramp. Note: This stop category is called STOP 2 in this document.

System integrator (plant integrator) T1 T2 External axis

4.2

The system integrator is responsible for safely integrating the industrial robot into a complete system and commissioning it. Test mode, Manual Reduced Velocity (<= 250 mm/s) Test mode, Manual High Velocity (> 250 mm/s permissible) Motion axis which is not part of the manipulator but which is controlled using the robot controller, e.g. KUKA linear unit, tu rn-tilt table, Posiflex.

Personnel

The following persons or groups of persons are defined for the industrial robot:  

User Personnel All persons working with the industrial robot must have read and understood the industrial robot documentation, including the safety chapter.

User

The user must observe the labor laws and regulations. This includes e.g.:  

Personnel

The user must comply with his monitoring obligations. The user must carry out briefing at defined intervals.

Personnel must be instructed, before any work is commenced, in the type of work involved and what exactly it entails as well as any hazards which may exist. Instruction must be carried out regularly. Instruction is also required after particular incidents or technical modifications. Personnel includes:  

System integrator Operators, subdivided into:  Start-up, maintenance and service personnel  Operating personnel Cleaning personnel 

Installation, exchange, adjustment, operation, maintenance and repair must be performed only as specified in th e operating or assembly instructions for the relevant component of the in dustrial robot and only by personnel specially trained for this purpose. 38 / 205


4 Safety

System integrator

The industrial robot is safely integrated into a complete system by the system integrator. The system integrator is responsible for the following tasks:       

Operator

Installing the industrial robot Connecting the industrial robot Performing risk assessment Implementing the required safety functions and safeguards Issuing the declaration of conformity Attaching the CE mark Creating the operating instructions for the complete system

The operator must meet the following preconditions:  

The operator must be trained for the work to be carried out. Work on the industrial robot must only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and experience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential hazards. Work on the electrical and mechanical equipment of the industrial robot may only be carried out by specially trained personnel.

4.3

Workspace, safety zone and danger zone

Workspaces are to be restricted to the necessary minimum size. A workspace must be safeguarded using appropriate safeguards. The safeguards (e.g. safety gate) must be situated inside the safety zone. In the case of a stop, the manipulator and external axes (optional) are braked and come to a stop within the danger zone. The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). It must be safeguarded by means of physical safeguards to prevent danger to persons or the risk of material damage. 4.3.1

Determining stopping distances

The system integrator’s risk assessment may indicate that the stopping distances must be determined for an application. In order to determine the stopping distances, the system integrator must identify the safety-relevant points on the programmed path. When determining the stopping distances, the robot must be moved with the tool and loads which are also used in the application. The robot must be at operating temperature. This is the case after approx. 1 h in normal operation. During execution of the application, the robot must be stopped at the point from which the stopping distance is to be calculated. This process must be repeated several times with a safety stop 0 and a safety stop 1. The least favorable stopping distance is decisive. A safety stop 0 can be triggered by a safe operational stop via the safety interface, for example. If a safety option is installed, it can be triggered, for instance, by a space violation (e.g. the robot exceeds the limit of an activated workspace in Automatic mode). A safety stop 1 can be triggered by pressing the EMERGENCY STOP device on the smartPAD, for example.


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4.4

Triggers for stop reactions

Stop reactions of the industrial robot are triggered in response to operator actions or as a reaction to monitoring functions and error messages. The following table shows the different stop reactions according to the operating mode that has been set. Trigger

Start key released STOP key pressed Drives OFF “Motion enable” input drops out Power switched off via main switch or power failure Internal error in nonsafety-oriented part of the robot controller Operating mode changed during operation Safety gate opened (operator safety) Enabling switch released Enabling switch pressed fully down or error E-STOP pressed Error in safety controller or periphery of the safety controller 4.5

Safety functions

4.5.1

Overview of the safety functions

T1, T2

AUT, AUT EXT

STOP 2

STOP 2 STOP 1 STOP 2 STOP 0

STOP 0 or STOP 1 (dependent on the cause of the error) Safety stop 2 -

Safety stop 1

Safety stop 2 Safety stop 1

-

Safety stop 1 Safety stop 0

The following safety functions are present in the industrial robot:        

Selecting the operating mode Operator safety (= connection for the monitoring of physical safeguards) EMERGENCY STOP device Enabling device External safe operational stop External safety stop 1 External safety stop 2 Velocity monitoring in T1

The safety functions of the industrial robot meet the following requirements: 

Category 3 and Performance Level d in accordance with EN ISO 13849-

1 The requirements are only met on the following condition, however: 

The EMERGENCY STOP device is pressed at least once every 12 months.

The following components are involved in the safety functions: 40 / 205


4 Safety       

Safety controller in the control PC KUKA smartPAD Cabinet Control Unit (CCU) Resolver Digital Converter (RDC) KUKA Power Pack (KPP) KUKA Servo Pack (KSP) Safety Interface Board (SIB) (if used)

There are also interfaces to components outside the industrial robot and to other robot controllers. In the absence of operational safety functions and safeguards, the industrial robot can cause personal injury or material damage. If safety functions or safeguards are dismantled or deactivated, the industrial robot may not be operated. During system planning, the safety functions of the overall system must also be planned and designed. The industrial robot must be integrated into this safety system of the overall system. 4.5.2

Safety co controller

The safety controller is a unit inside the control PC. It links safety-relevant signals and safety-relevant monitoring functions. Safety controller tasks:      

4.5. 4.5.3 3

Switching off the drives; applying the brakes Monitoring the braking ramp Standstill monitoring (after the stop) Velocity monitoring in T1 Evaluation of safety-relevant signals Setting of safety-oriented outputs

Sele Select ctin ing g the the oper peratin ating g mode

Operating modes

The industrial robot can be operated in the following modes:    

Manual Reduced Velocity (T1) Manual High Velocity (T2) Automatic (AUT) Automatic External (AUT EXT) Do not change the operating mode while a program is running. If the operating mode is changed during program execution, the industrial robot is stopped with a safety stop 2.


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Operating mode

Us e

Velocities 

T1

For test operation, programming and teaching





T2

For test operation 

AUT

AUT EXT

Mode selector switch

For industrial robots without higher-level controllers



For industrial robots with higher-level controllers, e.g. PLC







Program verification: Programmed velocity, maximum 250 mm/s Jog mode: Jog velocity, maximum 250 mm/s Program verification: Programmed velocity Jog mode: Not possible Program mode: Programmed velocity Jog mode: Not possible Program mode: Programmed velocity Jog mode: Not possible

The user can change the operating mode via the connection manager. The connection manager is a view that is called by means of the mode selector switch on the smartPAD. The mode selector switch may be one of the following variants: 



With key It is only possible to change operating mode if the key is inserted. Without key

If the smartPAD is fitted with a switch without a key: An additional device must be present to ensure that the relevant functions cannot be executed by all users, but only by a restricted group of people. The device itself must not trigger motions of the industrial robot or other hazards. If this device is missing, death or severe injuries may result. The system integrator is responsible for ensuring that such a device is implemented. 4.5. .5.4

“Operator sa safety fety” ” si signal

The “operator safety” signal is used for monitoring physical safeguards, e.g. safety gates. Automatic operation is not possible without this signal. In the event of a loss of signal during automatic operation (e.g. safety gate is opened), the manipulator stops with a safety stop 1. Operator safety is not active in modes T1 (Manual Reduced Velocity) and T2 (Manual High Velocity).

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4 Safety

Following a loss of signal, automatic operation may only be resumed when the safeguard has been closed and when the closing has been acknowledged. This acknowledgement is to prevent automatic operation from being resumed inadvertently while there are still persons in the danger zone, e.g. due to the safety gate closing accidentally. The acknowledgement must be designed in such a way that an actual check of the danger zone can be carried out first. Other acknowledgement functions (e.g. an acknowlegement which is automatically triggered by closure of the safeguard) are not permitted. The system integrator is responsible for ensuring that these criteria are met. Failure to met them may result in death, severe injuries or considerable damage to property. 4.5.5

EMERGENCY ST STOP de device

The EMERGENCY STOP device for the industrial robot is the EMERGENCY STOP device on the smartPAD. The device must be pressed in the event of a hazardous situation or emergency. Reactions of the industrial robot if the EMERGENCY STOP device is pressed: 

The manipulator and any external axes (optional) are stopped with a safety stop 1.

Before operation can be resumed, the EMERGENCY STOP device must be turned to release it. Tools and other equipment connected to the manipulator must be integrated into the EMERGENCY STOP circuit on the system side if they could constitute a potential hazard. Failure to observe this precaution may result in death, severe injuries or considerable damage to property. There must always be at least one external EMERGENCY STOP device installed. This ensures that an EMERGENCY STOP device is available even when the smartPAD is disconnected. (>>> (>>> 4.5.7 "External EMERGENCY STOP device" Page 44) 44 ) 4.5. 4.5.6 6

Logg Loggin ing g off off fro from m the the high higher er-l -lev evel el saf safety ety cont contro roll ller er

If the robot controller is connected to a higher-level safety controller, this connection will inevitably be terminated in the following cases: 

 

   

Switching off the voltage via the main switch of the robot Or power failure Shutdown of the robot controller via the smartHMI Activation of a WorkVisual project in WorkVisual or directly on the robot controller Changes to Start-up > Network configuration Changes to Configuration > Safety configuration I/O drivers > Reconfigure Restoration of an archive

Effect of the interruption: 

If a discrete safety interface is used, this triggers an EMERGENCY STOP for the overall system.


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KUKA.SafeOperation 3.2 

If the Ethernet interface is used, the KUKA safety controller generates a signal that prevents the higher-level controller from triggering an EMERGENCY STOP for the overall system.

If the Ethernet safety interface is used: In his risk assessment, the system integrator must take into consideration whether the fact that switching off the robot controller does not trigger an EMERGENCY STOP of the overall system could constitute a hazard and, if so, h ow this hazard can be countered. Failure to take this into consideration may res ult in death, injuries or damage to property. If a robot controller is switched off, the E-STOP device on the smartPAD is no longer functional. The user is responsible for ensuring that the smartPAD is either cove red or removed from the system. This serves to prevent operational and non-operational EMERGENCY STOP devices from becoming interchanged. Failure to observe this precaution may result in death, injuries or damage to property. 4.5. 4.5.7 7

Exte Extern rnal al EMER MERGEN GENCY STOP STOP devic evice e

Every operator station that can initiate a robot motion or other potentially hazardous situation must be equipped with an EMERGENCY STOP device. The system integrator is responsible for ensuring this. There must always be at least one external EMERGENCY STOP device installed. This ensures that an EMERGENCY STOP device is available even when the smartPAD is disconnected. External EMERGENCY STOP devices are connected via the customer interface. External EMERGENCY STOP devices are not included in the scope of supply of the industrial robot. 4.5.8

Enabling device

The enabling devices of the industrial robot are the enabling switches on the smartPAD. There are 3 enabling switches installed on the smartPAD. The enabling switches have 3 positions:   

Not pressed Center position Panic position

In the test modes, the manipulator can only be moved if one of the enabling switches is held in the central position.  



Releasing the enabling switch triggers a safety stop 2. Pressing the enabling switch down fully (panic position) triggers a safety stop 1. It is possible to hold 2 enabling switches in the center position simultaneously for up to 15 seconds. This makes it possible to adjust grip from one enabling switch to another one. If 2 enabling switches are held simultaneously in the center position for longer than 15 seconds, this trigger s a safety stop 1.

If an enabling switch malfunctions (e.g. jams in the central position), th e industrial robot can be stopped using the following methods: 

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Press the enabling switch down fully. Issued: 08.06.2016 Version: KST SafeOperation 3.2 V7

4 Safety  

Actuate the EMERGENCY STOP device. Release the Start key. The enabling switches must not be held down by adhesive tape or other means or tampered with in any other

way. Death, injuries or damage to property may result. 4.5.9

External enabling device

External enabling devices are required if it is necessary for mor e than one person to be in the danger zone of the industrial robot. External enabling devices are not included in the scope of supply of the industrial robot. Which interface can be used for connecting external enabling devices is described in the “Planning” chapter of the robot controller operating instructions and assembly instructions. 4.5.10

External safe operational stop

The safe operational stop can be triggered via an input on the customer interface. The state is maintained as long as the external signal is FALSE. If the external signal is TRUE, the manipulator can be moved again. No acknowledgement is required. 4.5.11

External safety stop 1 and external safety stop 2

Safety stop 1 and safety stop 2 can be triggered via an input on the customer interface. The state is maintained as long as the external signal is FALSE. If the external signal is TRUE, the manipulator can be moved again. No acknowledgement is required. If interface X11 is selected as the customer interface, only the signal Safety stop 2 is available. 4.5.12

Velocity monitoring in T1

The velocity at the mounting flange is monitored in T1 mode. If t he velocity exceeds 250 mm/s, a safety stop 0 is triggered. 4.6

Additional protective equipment

4.6.1

Jog mode

In the operating modes T1 (Manual Reduced Velocity) and T2 (Manual High Velocity), the robot controller can only execute programs in jog mode. This means that it is necessary to hold down an enabling switch and the Start key in order to execute a program.  



Releasing the enabling switch triggers a safety stop 2. Pressing the enabling switch down fully (panic position) triggers a safety stop 1. Releasing the Start key triggers a STOP 2.


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4.6.2

Software limit switches

The axis ranges of all manipulator and positioner axes are limited by means of adjustable software limit switches. These software limit switches only serve as machine protection and must be adjusted in such a way that the manipulator/positioner cannot hit the mechanical end stops. The software limit switches are set during commissioning of an industrial robot. Further information is contained in the operating and programming instructions.

4.6.3

Mechanical end stops

Depending on the robot variant, the axis ra nges of the main and wrist axes of the manipulator are partially limited by mechanical end stops. Additional mechanical end stops can be installed on the external axes. If the manipulator or an external axis hits an obstruction or a mechanical end stop or axis range limitation, the manipulator can no longer be operated safely. The manipulator must be taken out of operation and KUKA Roboter GmbH must be co nsulted before it is put back into operation . 4.6.4

Mechanical axis range limitation (optional)

Some manipulators can be fitted with mechanical axis range limitation in axes A1 to A3. The adjustable axis range limitation systems restrict the working range to the required minimum. This increases p ersonal safety and protection of the system. In the case of manipulators that are not designed to be fitted with mechanical axis range limitation, the workspace must be laid out in such a way that there is no danger to persons or material property, even in the absence of mechanical axis range limitation. If this is not possible, the workspace must be limited by means of photoelectric barriers, photoelectric curtains or obstacles on the system side. There mu st be no shearing or crushing hazards at the loading and transfer areas. This option is not available for all robot models. Information on specific robot models can be obtained from KUKA Roboter GmbH.

4.6.5

Axis range monitoring (optional)

Some manipulators can be fitted with dual-chan nel axis range monitoring systems in main axes A1 to A3. The positioner axes ma y be fitted with additional axis range monitoring systems. The safety zone for an axis can be adjusted and monitored using an axis range monitoring system. This increases personal safety and protection of the system. This option is not available for all robot models. Information on specific robot models can be obtained from KUKA Roboter GmbH.

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4 Safety

4.6.6

Options for moving the manipulator without drive energy

The system user is responsible for ensuring that the training of personnel with regard to the response to emergencies or exceptional situations also includes how the manipulator can be moved without drive energy. Description

The following options are available for moving the manipulator without drive energy after an accident or malfunction: 





Release device (optional) The release device can be used for the main axis drive motors and, depending on the robot variant, also for the wrist axis drive motors. Brake release device (option) The brake release device is designed for robot variants whose motors are not freely accessible. Moving the wrist axes directly by hand There is no release device available for the wrist axes of variants in the low payload category. This is not necessary because the wrist axes can be moved directly by hand. Information about the options available for the various robot models and about how to use them can be found in the assembly and operating instructions for the robot or requested from KUKA Roboter

GmbH. Moving the manipulator without drive energy can damage the motor brakes of the axes concerned. The motor must be replaced if the brake has been damaged. The manipulator may therefore be moved without drive energy only in emergencies, e.g. for rescuing persons. 4.6.7

Labeling on the industrial robot

All plates, labels, symbols and marks constitute safety-relevant parts of the industrial robot. They must not be modified or removed. Labeling on the industrial robot consists of:      

Identification plates Warning signs Safety symbols Designation labels Cable markings Rating plates Further information is contained in the technical data of the operating instructions or assembly instructions of the components of the industrial robot.

4.6.8

External safeguards

The access of persons to the danger zone of the industrial robot must be prevented by means of safeguards. It is the responsibility of the system integrator to ensure this.


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Physical safeguards must meet the following requirements:  



 

They meet the requirements of EN 953. They prevent access of persons to the danger zone and cannot be easily circumvented. They are sufficiently fastened and can withstand all forces that are likely to occur in the course of operation, whether from inside or outside the enclosure. They do not, themselves, represent a hazard or potential hazard. The prescribed minimum clearance from the danger zone is maintained.

Safety gates (maintenance gates) must meet the following requirements:  







They are reduced to an absolute minimum. The interlocks (e.g. safety gate switches) are linked to the operator safety input of the robot controller via safety gate switching devices or safety PLC. Switching devices, switches and the type of switching conform to the requirements of Performance Level d and category 3 according to EN ISO 13849-1. Depending on the risk situation: the safety gate is additionally safeguarded by means of a locking mechanism that only allows the gate to be opened if the manipulator is safely at a standstill. The button for acknowledging the safety gate is located outside the space limited by the safeguards. Further information is contained in the corresponding standards and regulations. These also include EN 953.

Other safety equipment

4.7

Other safety equipment must be integrated into the system in accordance with the corresponding standards and regulations.

Overview of operating modes and safety functions

The following table indicates the operating modes in which the safety functions are active. Safety functions

Operator safety EMERGENCY STOP device Enabling device Reduced velocity during program verification Jog mode Software limit switches 4.8

Safety measures

4.8.1

General safety measures

T1

T2

AUT

AUT EXT

Active Active

Active Active

Active Active -

Active Active -

Active

-

-

-

Active Active

Active Active

Active

Active

The industrial robot may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons. Operator errors can result in personal injury and damage to property. It is important to be prepared for possible movements of the industrial robot even after the robot controller has been switched off and locked out. Incorrect 48 / 205


4 Safety

installation (e.g. overload) or mechanical defects (e.g. brake defect) can cause the manipulator or external axes to sag. If work is to be carried out on a switched-off industrial robot, the manipulator and external axes must first be moved into a position in which they are unable to move on their own, whether the payload is mounted or not. If this is not possible, the manipulator and external axes must be secured by appropriate means. In the absence of operational safety functions and safeguards, the industrial robot can cause personal injury or material damage. If safety functions or safeguards are dismantled or deactivated, the industrial robot may not be operated. Standing underneath the robot arm can cause death or injuries. For this reason, standing underneath the robot arm is prohibited! The motors reach temperatures during operation which can cause burns to the skin. Contact must be avoided. Appropriate safety precautions must be taken, e.g. protective gloves must be worn. smartPAD

The user must ensure that the industrial robot is only ope rated with the smartPAD by authorized persons. If more than one smartPAD is used in the overall system, it must be ensured that each smartPAD is unambiguously assigned to the corresponding industrial robot. They must not be interchanged. The operator must ensure that decoupled smartPADs are immediately removed from the system and stored out of sight and reach of personnel working on the industrial robot. This serves to prevent operational and non-operational EMERGENCY STOP devices from becoming interchanged. Failure to observe this precaution may result in death, severe injuries or considerable damage to property.

Modifications

After modifications to the industrial robot, checks must be carried out to ensure the required safety level. The valid national or regional work safe ty regulations must be observed for this check. The correct functioning of all safety functions must also be tested. New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). After modifications to the industrial robot, existing programs must always be tested first in Manual Reduced Velocity mode (T1). This applies to all components of the industrial robot and includes modifications to the software and configuration settings.

Faults

The following tasks must be carried out in the case of faults in the industrial robot: 



 

Switch off the robot controller and secure it ( e.g. with a padlock) to prevent unauthorized persons from switching it on again. Indicate the fault by means of a label with a corresponding warning (tagout). Keep a record of the faults. Eliminate the fault and carry out a function test.


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4.8.2

Transportation

Manipulator

The prescribed transport position of the manipulator must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the robot. Avoid vibrations and impacts during transportation in order to prevent damage to the manipulator.

Robot controller

The prescribed transport position of the robot controller must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the robot controller. Avoid vibrations and impacts during transportation in order to prevent damage to the robot controller.

External axis (optional)

4.8.3

The prescribed transport position of the external axis (e.g. KUKA linear unit, turn-tilt table, positioner) must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the external axis.

Start-up and recommissioning

Before starting up systems and devices for the first time, a check must be carried out to ensure that the systems and devices are complete and operational, that they can be operated safely and that any damage is detected. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. The passwords for the user groups must be changed in the KUKA System Software before start-up. The passwords must only be communicated to authorized personnel. The robot controller is preconfigured for the specific industrial robot. If cables are interchanged, the manipulator and the external axes (optional) may receive incorrect data and can thus cause personal injury or material damage. If a system consists of more than one manipulator, always connect the connecting cables to the manipulators and their corresponding robot controllers. If additional components (e.g. cables), which are not part of the scope of supply of KUKA Roboter GmbH, are integrated into the industrial robot, the user is responsible for ensuring th at these components do not adversely affect or disable safety functions. If the internal cabinet temperature of the robot controller differs greatly from the ambient temperature, condensation can form, which may cause damage t o the electrical components. Do not put the robot controller into operation until the internal temperature of the cabinet has adjusted to the ambient temperature. Function test

The following tests must be carried out before start-up and recommissioning: General test:

It must be ensured that: 

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The industrial robot is correctly installed and fastened in accordance with the specifications in the documentation.


4 Safety 

There is no damage to the robot that could be attributed to external forces. Examples: Dents or abrasion that could be caused by an impact or collision.

In the case of such damage, the affected components must be exchanged. In particular, the motor and counterbalancing system must be checked carefully. External forces can cause non-visible damage. For example, it can lead to a gradual loss of drive power from the motor, resulting in unintended movements of the manipulator. Death, injuries or consider able damage to property may otherwise result.   





There are no foreign bodies or loose parts on the industrial robot. All required safety equipment is correctly installed and operational. The power supply ratings of the industrial robot correspond to the local supply voltage and mains type. The ground conductor and the equipotential bonding cable are sufficiently rated and correctly connected. The connecting cables are correctly connected and the connectors are locked.

Test of the safety functions:

A function test must be carried out for the following safety functions to ensure that they are functioning correctly:      

4.8.3.1

Local EMERGENCY STOP device External EMERGENCY STOP device (input and output) Enabling device (in the test modes) Operator safety All other safety-relevant inputs and outputs used Other external safety functions

Checking machine data and safety configuration

The industrial robot must not be moved if incorrect machine data or an incorrect controller configuration are loaded. Death, severe injuries or considerable damage to property may otherwise result. The correct data must be loaded. 











It must be ensured that the rating plate on the robot controller has the same machine data as those entered in the declaration of incorporation. The machine data on the rating plate of the manipulator and the external axes (optional) must be entered during start-up. The practical tests for the machine data must be carried out within the scope of the start-up procedure. Following modifications to the machine data, the safety configuration must be checked. After activation of a WorkVisual project on the robot controller, the safety configuration must be checked! If machine data are adopted when checking the safety configuration (regardless of the reason for the safety configuration check), the practical tests for the machine data must be carried out. System Software 8.3 or higher: If the checksum of the safety configuration has changed, the safe axis monitoring functions must be checked.


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Information about checking the safety configuration and the safe axis monitoring functions is contained in the Operating and Programming Instructions for System Integrators. If the practical tests are not successfully completed in the initial start-up, KUKA Roboter GmbH must be contacted. If the practical tests are not successfully completed during a different procedure, the machine data and the safety-relevant controller configuration must be checked and corrected. General practical test:

If practical tests are required for the machine data, this test must always be carried out. The following methods are available for performing the practical test: 

TCP calibration with the XYZ 4-point method The practical test is passed if the TCP has been successfully calibrated.

or: 1. Align the TCP with a freely selected point. The point serves as a reference point. It must be located so that reorientation is possible. 2. Move the TCP manually at least 45° once in each of the A, B and C directions. The movements do not have to be accumulative, i.e. after motion in one direction it is possible to return to the original position before moving in the next direction. The practical test is passed if the TCP does not deviat e from the reference point by more than 2 cm in total. Practical test for axes that are not mathematically coupled:

If practical tests are required for the machine data, this test must be carrie d out when axes are present that are not mathematically coupled. 1. Mark the starting position of the axis that is not mathematically coupled. 2. Move the axis manually by a freely selected path length. Determine the path length from the display Actual position on the smartHMI.  Move linear axes a specific distance.  Move rotational axes through a specific angle. 3. Measure the length of the path covered and compare it with the value displayed on the smartHMI. The practical test is passed if the values differ by no more than 10%. 4. Repeat the test for each axis that is not mathematically coupled. Practical test for couplable axes:

If practical tests are required for the machine data, this test must be carrie d out when axes are present that can be physically coupled and uncoupled, e.g. a servo gun. 1. Physically uncouple the couplable axis. 2. Move all the remaining axes individually. The practical test is passed if it has been possible to move all the remaining axes.

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4 Safety

4.8.3.2

Start-up mode

Description

The industrial robot can be set to Start-up mode via the smartHMI user interface. In this mode, the manipulator can be moved in T1 without the external safeguards being put into operation. When Start-up mode is possible depends on the safety interface that is used. Discrete safety interface 



System Software 8.2 or earlier: Start-up mode is always possible if all input signals at the discrete safety interface have the state “logic zero”. If this is not the case, the robot controller prevents or terminates Start-up mode. If an additional discrete safety interface for safety options is used, the inputs there must also have the state “logic zero”. System Software 8.3 or higher: Start-up mode is always possible. This also means that it is independent of the state of the inputs at the discrete safety interface. If an additional discrete safety interface is used for safety options: The states of these inputs are also irrelevant.

Ethernet safety interface

The robot controller prevents or terminates Start-up mode if a connection to a higher-level safety system exists or is established. Effect

When the Start-up mode is activated, all outputs are automatically set to the state “logic zero”. If the robot controller has a peripheral contactor (US2), and if the safety configuration specifies for this to switch in accordance with the motion enable, then the same also applies in Start-up mode. This means that if motion enable is present, the US2 voltage is switched on – even in Start-up mode.

Hazards

Possible hazards and risks involved in using Start-up mode:  

A person walks into the manipulator’s danger zone. In a hazardous situation, a disabled external EMERGENCY STOP device is actuated and the manipulator is not shut down.

Additional measures for avoiding risks in Start-up mode: 



Use

Cover disabled EMERGENCY STOP devices or attach a warning sign indicating that the EMERGENCY STOP device is out of operation. If there is no safety fence, other measures must be taken to prevent persons from entering the manipulator’s danger zone, e.g. use of warning tape.

Intended use of Start-up mode: 

 

Start-up in T1 mode when the external safeguards have not yet been installed or put into operation. The danger zone must be delimited at least by means of warning tape. Fault localization (periphery fault). Use of Start-up mode must be minimized as much as possible.

Use of Start-up mode disables all external safeguards. The service personnel are responsible for ensuring that there is no-one in or near the danger zone of the manipulator as long as the safeguards are disabled. Failure to observe this precaution may result in death, injuries or damage to property.


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Any use or application deviating from the intended use is deemed to be misuse and is not allowed. KUKA Roboter GmbH is not liable for any damage resulting from such misuse. The risk lies entirely with the user.

Misuse

4.8.4

Manual mode

Manual mode is the mode for setup work. Setup work is all the tasks that have to be carried out on the industrial robot to enable automatic operation. Setup work includes:    

Jog mode Teaching Programming Program verification

The following must be taken into consideration in manual mode: 







New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). The manipulator, tooling or external axes (optional) must never touch or project beyond the safety fence. Workpieces, tooling and other objects must not become jammed as a result of the industrial robot motion, nor must they lead to short-circuits or be liable to fall off. All setup work must be carried out, where possible, from outside the safeguarded area.

If the setup work has to be carried out inside the safeguarded area, the following must be taken into consideration: In Manual Reduced Velocity mode (T1): 



If it can be avoided, there must be no other persons inside the safeguarded area. If it is necessary for there to be several persons inside the safeguarded area, the following must be observed:  Each person must have an enabling device. All persons must have an unimpeded view of the industrial robot.   Eye-contact between all persons must be possible at all times. The operator must be so positioned that he can see into the danger area and get out of harm’s way.

In Manual High Velocity mode (T2): 

 

 

4.8.5

This mode may only be used if the application requires a test at a velocity higher than that possible in T1 mode. Teaching and programming are not permissible in this operating mode. Before commencing the test, the operator must ensure that the enabling devices are operational. The operator must be positioned outside the danger zone. There must be no other persons inside the safeguarded area. It is the responsibility of the operator to ensure this.

Simulation

Simulation programs do not correspond exactly to reality. Robot programs created in simulation programs must be tested in th e system in Manual Reduced Velocity mode (T1). It may be necessary to modify the program.

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4 Safety

4.8.6

Automatic mode

Automatic mode is only permissible in compliance with the following safety measures:   

All safety equipment and safeguards are present and operational. There are no persons in the system. The defined working procedures are adhered to.

If the manipulator or an external axis ( optional) comes to a standstill for no apparent reason, the danger zone must not be entered until an EMERGENCY STOP has been triggered. 4.8.7

Maintenance and repair

After maintenance and repair work, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. The purpose of maintenance and repair work is to ensure that the system is kept operational or, in the event of a fault, to retur n the system to an operational state. Repair work includes troubleshooting in addition to the actual repair itself. The following safety measures must be carried out when working on t he industrial robot: 









Carry out work outside the danger zone. If work inside the danger zone is necessary, the user must define additional safety measures to ensure the safe protection of personnel. Switch off the industrial robot and secure it (e.g. with a padlock) to prevent it from being switched on again. If it is necessary to carry out work with the robot controller switched on, the user must define additional safety measures to ensure the safe protection of personnel. If it is necessary to carry out work with the robot cont roller switched on, this may only be done in operating mode T1. Label the system with a sign indicating that work is in progress. This sign must remain in place, even during temporary interruptions to the work. The EMERGENCY STOP devices must remain active. If safety functions or safeguards are deactivated during maintenance or repair work, they must be reactivated immediately after the work is completed.

Before work is commenced on live parts of the robot system, the main switch must be turned off and secured against being switched on again. The system must then be checked to ensure that it is deenergized. It is not sufficient, before commencing work on live parts, to execute an EMERGENCY STOP or a safety stop, or to switch off the drives, as this does not disconnect the robot system from the mains power supply. Parts remain energized. Death or severe injuries may result. Faulty components must be replaced using new components with the same article numbers or equivalent components approved by KUKA Roboter GmbH for this purpose. Cleaning and preventive maintenance work is to be ca rried out in accordance with the operating instructions. Robot controller

Even when the robot controller is switched off, parts connected to peripheral devices may still carry voltage. The external power sources must therefore be switched off if work is to be carried out on the robot controller.


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The ESD regulations must be adhered to when working on components in the robot controller. Voltages in excess of 50 V (up to 780 V) can be present in various components for several minutes after the robot controller has been switched off! To prevent life-threatening injuries, no work may be carried out on the industrial robot in this time. Water and dust must be prevented from entering the robot controller. Counterbalancing system

Some robot variants are equipped with a hydropneumatic, spring or g as cylinder counterbalancing system. The hydropneumatic and gas cylinder counterbalancing systems are pressure equipment and, as such, are subject to obligatory equipment monitoring and the provisions of the Pressure Equipment Directive. The user must comply with the applicable national laws, regulations and standards pertaining to pressure equipment. Inspection intervals in Germany in accordance with Industrial Safety Order, Sections 14 and 15. Inspection by the user before comm issioning at the installation site. The following safety measures must be carried out when working on the counterbalancing system: 



Hazardous substances

The manipulator assemblies supported by the counterbalancing systems must be secured. Work on the counterbalancing systems must only be carried out by qualified personnel.

The following safety measures must be carried out when h andling hazardous substances:   

Avoid prolonged and repeated intensive contact with the skin. Avoid breathing in oil spray or vapors. Clean skin and apply skin cream. To ensure safe use of our products, we recommend regularly requesting up-to-date safety data sheets for hazardous substances.

4.8.8

Decommissioning, storage and disposal

The industrial robot must be decommissioned, stored and disposed of in accordance with the applicable national laws, regulations and standards. 4.8.9

Safety measures for “single point of control”

Overview

If certain components in the industrial robot are operated, safety measures must be taken to ensure complete implementation of the principle of “single point of control” (SPOC). The relevant components are:      

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Submit interpreter PLC OPC server Remote control tools Tools for configuration of bus systems with online functionality KUKA.RobotSensorInterface


4 Safety

The implementation of additional safety measures may be required. This must be clarified for each specific application; this is the responsibility of the system integrator, programmer or user of the system. Since only the system integrator knows the safe states of actuators in the periphery of the robot controller, it is his task to set these actuators to a safe state, e.g. in the event of an EMERGENCY STOP. In modes T1 and T2, the components referred to above may only access the industrial robot if the following signals have the following states:

T1, T2

Submit interpreter, PLC

Signal

State required for SPOC

$USER_SAF $SPOC_MOTION_ENABLE

TRUE TRUE

If motions, (e.g. drives or grippers) are controlled with the submit interpreter or the PLC via the I/O system, and if they are not safeguarded by other means, then this control will take effect even in T1 and T2 modes or while an EMERGENCY STOP is active. If variables that affect the robot motion (e.g. override) are modified with the submit interpreter or the PLC, this takes effect even in T1 and T2 modes or while an EMERGENCY STOP is active. Safety measures: 



OPC server, remote control tools

In T1 and T2, the system variable $OV_PRO must not be written to by the submit interpreter or the PLC. Do not modify safety-relevant signals and variables (e.g. oper ating mode, EMERGENCY STOP, safety gate contact) via the submit interpreter or PLC. If modifications are nonetheless required, all safety-relevant signals and variables must be linked in such a way that they cannot be set to a dangerous state by the submit interpreter or PLC. This is the responsibility of the system integrator.

These components can be used with write access to modify programs, outputs or other parameters of the robot controller, without this being noticed by any persons located inside the system. Safety measure: If these components are used, output s that could cause a hazard must be determined in a risk assessment. These outputs must be designed in such a way that they cannot be set without being enabled. This can be done using an external enabling device, for example.

Tools for configuration of bus systems

If these components have an online functionality, they can be used with write access to modify programs, outputs or other parameters of the robot controller, without this being noticed by any persons located inside the system.  

WorkVisual from KUKA Tools from other manufacturers

Safety measure: In the test modes, programs, outputs or other parameters of the robot controller must not be modified using these components. 4.9

Name

Applied norms and regulations

Definition


Edition 57 / 205


2006/42/EC

2006

Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast) 2014/30/EU

2014

EMC Directive:

Directive 2014/30/EC of the European Parliament and of the Council of 26 February 2014 on the approximation of the laws of the Member States concerning electromagnetic compatibility 2014/68/EC

Pressure Equipment Directive:

2014

Directive 2014/68/EC of the European Parliament and of the Council of 15 May 2014 on the approximation of the laws of the Member States concerning pressure equipment (Only applicable for robots with hydropneumatic counterbalancing system.) This directive is valid from the 19/07/2016 on. 97/23/EC

Pressure Equipment Directive:

1997

Directive 97/23/EC of the European Parliament and of the Council of 29 May 1997 on the approximation of the laws of the Member States concerning pressure equipment (Only applicable for robots with hydropneumatic counterbalancing system.) This directive is valid until 18/07/2016. EN ISO 13850

2008

Safety of machinery:

Emergency stop - Principles for design EN ISO 13849-1

2008


Safety-related parts of control systems - Part 1: General principles of design EN ISO 13849-2

2012


Safety-related parts of control systems - Part 2: Validation EN ISO 12100

2010


General principles of design, risk assessment and risk reduction EN ISO 10218-1

Industrial robots – Safety requirements

2011

Part 1: Robot Note: Content equivalent to ANSI/RIA R.15.06-2012, Part 1 EN 614-1 + A1

2009


Ergonomic design principles - Part 1: Terms and general principles

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4 Safety

EN 61000-6-2

Electromagnetic compatibility (EMC):

2005

Part 6-2: Generic standards; Immunity for industrial environments EN 61000-6-4 + A1

Electromagnetic compatibility (EMC):

2011

Part 6-4: Generic standards; Emission standard for industrial environments EN 60204-1 + A1


2009

Electrical equipment of machines - Part 1: General requirements


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5 Installation

5

Installation

t

5.1

System requirements

t

Hardware

Software



KR C4 or KR C4 compact Reference switch module



KUKA System Software 8.3



With a KR C4 compact, PROFIsafe or CIP Safety is always required for the purpose of connecting a reference switch.  

Compatibility

5.2



KR C4 PROFINET 3.0 for connection via PROFIsafe KR C4 EtherNet/IP 2.0 for connection via CIP Safety KUKA.SafeOperation must not be installed on a robot controller together with other safety options: KUKA.SafeRangeMonitoring   KUKA.SafeSingleBrake

Installing or updating SafeOperation

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

   

“Expert” user group T1 or T2 mode No program is selected. USB stick with the software to be installed ZIP files must be unzipped.   There must be no other files in the directory in which the individual files are located. 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 SafeOperation 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 overwritten. c. Press Path selection. The available drives are displayed. d. If the stick is connected to the robot controller: On E:\, select the directory in which the software is located. 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.


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5. 6. 7. 8.

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

LOG file

5.3

f. Mark the line with the new path and press Save again. Mark the entry SafeOperation and click on Install. Answer the request for confirmation with Yes. Confirm the reboot prompt with OK. Remove the stick. Reboot the robot controller.

Uninstalling SafeOperation

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

  

“Expert” user group T1 or T2 mode Safe monitoring has been deactivated.

If the safe monitoring is not deactivated before uninstallation, the safety configuration remains active after the software has been uninstalled. (>>> 7.12 "Deactivating safe monitoring" Page 123)

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Procedure

1. In the main menu, select Start-up > Additional software. 2. Mark the entry SafeOperation and click on Uninstall. Reply to the request for confirmation with Yes. Uninstallation is prepared. 3. Reboot the robot controller. Uninstallation is resumed and completed.

LOG file

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


6 Operation

6

Operation

6.1

User groups

t

Different functions are available in the KSS, depending on the user group. The following user groups are relevant for the safety configuration of the robot: 

Safety recovery

This user can activate an existing safety configuration of the robot using an activation code. If no safety option is installed, the safety recovery personnel have more extensive rights. In this case he is authorized, for example, to configure the standard safety functions. This user group is protected by means of a password. 

Safety maintenance

User group for the start-up technician. This user can edit the safety configuration and make safety-relevant changes. This user group is protected by means of a password. The safety maintenance technician must be specially trained in the configuration of safety functions. For this, we recommend training courses at KUKA College. Information about the training program can be found at www.kuka.com or can be obtained directly from our subsidiaries. The password for the “Safety Maintenance” and “Safety Recovery” user groups must be changed before start-up and must only be communicated to authorized personnel. 6.2

Opening the safety configuration

Procedure

1. Select Configuration > Safety configuration in the main menu. 2. The safety configuration checks whether there are any relevant deviations between the data in the robot controller and those in the safety controller.  If there are no deviations, the Safety configuration window is opened.  If there are deviations, the Troubleshooting wizard window is opened. A description of the problem and a list of possible causes is displayed. The user can select the applicable cause. The wizard then suggests a solution. Further information about checking the safety configuration is contained in the Operating and Programming Instructions for System Integrators.

6.3

Overview of buttons

The following buttons are available: Button

Description

Reset all to defaults

Resets all parameters of the safety configuration to the default values. Resets all changes since the last time the configuration was saved. The log of changes to the safety configuration is displayed. The safety-relevant machine data are displayed.

Revert changes Change log View


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Button

Description

Properties

The properties of a monitoring space or safe tool can be defined. Parts of the safety configuration can be exported into an XML file (XML export). Parts of the safety configuration can be imported as an XML file (XML export). The safety ID of the PROFINET device can be changed.

Export Import Communication parameters

Note: Further information is contained in the Operating and

Programming Instructions for System Integrators. The global parameters of the safety configuration can be defined. The hardware settings can be defined.

Global parameters Hardware options

Note: Further information is contained in the Operating and

Programming Instructions for System Integrators. It is possible to check whether the machine data of the safety configuration are up to date. The safe operational stop can be defined. Saves and activates the safety configuration for the robot. Saves the current robot position as a corner of a cell area.

Check machine data Safe operational stop Save Touch-up

OR

Touch-up reference position for group Cell configuration Back

6.4

Display functions

6.4.1

Displaying information about the safety configuration

In the main menu, select Configuration > Safety configuration. The safety configuration opens with the General tab.

Procedure



Description

The General tab contains the following information:

Parameter

Description

Robot

Serial number of the robot  Installed safety option version Safety controller version (internal)   Checksum of the safety configuration  Time stamp of the safety configuration (date and time last saved) Safety configuration version   Activation code of the safety configuration Time stamp of the safety-relevant machine data ( date and time last saved)

Safety controller Parameter data set

Machine data

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Saves the current axis angle as the lower limit or upper limit of the axis-specific monitoring space. Saves the current robot flange position or the position of the axes of a reference group as a reference position. The cell area can be defined. Back to the tab


6 Operation

Parameter

Description

Brake test

 

Current configuration

 

    

6.4.2

State of brake test (activated, deactivated or forced) Checksum of the brake test configuration Name of the safety interface State of Cartesian monitoring (= velocity monitoring in T1) (activated or deactivated) State of safe monitoring (activated or deactivated) Number of velocity-monitored axes Number of monitoring spaces Number of protected spaces Number of safe tools

Displaying the change log

Every modification to the safety configuration and every saving operation is automatically logged. The log can be displayed. Procedure





6.4.3

In the main menu, select Configuration > Safety configuration. The Safety configuration window opens. Press Change log.

Displaying machine data

The safety-relevant machine data can be displayed. Procedure

6.5

1. In the main menu, select Configuration > Safety configuration. The Safety configuration window opens. 2. Press View.

Importing the safety configuration (XML import)

Description

Parts of the safety configuration can be imported as an XML file. The importable parameters depend on the installed safety option: SafeOperation

SafeRangeMonitoring

SafeSingleBrake

Cell configuration Cartesian monitoring spaces Axis-specific monitoring spaces Tools Global parameters In order to generate an XML file for importing, the user has the following options: 

Export the current safety configuration of the robot controller to an XML file and edit it. In this way it is possible to ensure that the format of the XML file is correct for a subsequent import. (>>> 6.6 "Exporting the safety configuration (XML export)" Page 67)


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Generate the XML file on the basis of the XML schema C:\KRC\SmartHMI\Schemes\SafetyConfigImport.xsd, e.g. using a script programmed by the user.

The following points must be observed when editing the XML files: 



The XML schema defines the structure of the XML file for the import. For individual parameters, the XML schema allows higher values than the installed version of the safety option. The XML file to be imported should only contain parameters and values which are supported by the current safety option. If this is not the case, it can prevent the XML import from occurring. It is also possible to import safety configurations in WorkVisual. Information about this can be found in the WorkVisual documentation.

Precondition

   

Procedure

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Safety option is installed. User group “Safety maintenance” T1 or T2 mode No program is selected.

1. In the main menu, select Configuration > Safety configuration. The Safety configuration window opens. 2. Press Import . The available drives are displayed. 3. Navigate to the directory where the XML file to be imported is located. 4. Select the XML file and press Next. The parameters configured in the XML file are compared with the current parameters of the safety configuration. 5. If notification, warning or error messages occur, these are displayed in the Safety configuration window. To continue with the XML import, press Next. The Next button is deactivated in the event of error messages. Analyze errors and cancel the XML import.  Rectify the error in the XML file and repeat the XML import. OR: Select the correct XML file and repeat the XML import.  6. A tree view provides an overview of the parameters to be imported. By default, only those nodes which contain changes to the current safety configuration are expanded in the tree view. The parameters which are changed by the XML import are displayed in blue text. 7. Check the parameters. If not all of the required safety functions are configured correctly, or if the wrong XML file was selected, cancel the XML import.  Rectify the error in the XML file and repeat the XML import. OR: Select the correct XML file and repeat the XML import.  8. Press Import . The safety configuration is imported. 9. Save the safety configuration. (>>> 7.5.10 "Saving the safety configuration" Page 97) 10. If plausibility errors are detected while saving, the user is informed of this by a dialog. Close the dialog with OK. 11. Rectify errors directly in the safety configuration and save the safety configuration. OR Rectify the error in the XML file, repeat the XML import and save the safety configuration. Issued: 08.06.2016 Version: KST SafeOperation 3.2 V7

6 Operation

Following a change to the safety configuration, safety acceptance must be carried out. (>>> 7.9 "Safety acceptance overview" Page 117) Overview

The display with the overview of the parameters to be imported has the following columns: Column

Description

Parameter name

Name of the parameter in the Safety configuration window Value of the parameter following import of the safety configuration Value of the parameter in the current safety configuration Value of the parameter in the XML file to be imported

Result Current Imported

The column is hidden when the display opens. The following buttons are available for changing the display: Button

Description

Display import column

Displays or hides the Imported column.

Collapse all Expand all Expand changes

6.6

Check box active: Column is displayed. Check box not active: Column is hidden. All nodes in the tree view are collapsed. All nodes in the tree view are expanded. Only those nodes which contain changes to the current safety configuration are expanded in the tree view.

Exporting the safety configuration (XML export)

Description

Parts of the safety configuration can be exported into an XML file:    

Cell configuration Monitoring spaces Tools Global parameters

The XML file always contains all the parameter s which are contained in the exported parts of the safety configuration. Exporting is always possible, irrespective of whether a safety option is installed or not. However, an export only makes sense if a safety option is installed. The current safety configuration of the robot controller is exported. If the safety configuration contains unsaved changes, these are also exported. If invalid values are entered in the safety configuration, the export is aborted with an error message (plausibility error). It is also possible to export safety configurations in WorkVisual. Information about this can be found in the WorkVisual documentation. Procedure

1. In the main menu, select Configuration > Safety configuration.


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The Safety configuration window opens. 2. Press Export . The available drives are displayed. 3. Select the desired file path and press Export . The safety configuration is saved in an XML file. The file name is generated automatically. 6.7

Safe robot retraction in case of space violation

Description

If the robot has violated a monitoring space, it is stopped by the safety controller (precondition: function Stop at boundaries is active). The robot must be moved out of the violated space in T1 mode. After a “Stop at boundaries”, the robot can only be moved in T1 mode. No other operating mode can be set until the robot has left the violated space. If the space is violated in T2 or Automatic mode, only a status message is displayed. The status message indicates which space has been violated. If the space is violated in T1 mode, the acknowledgement message Ackn.: Stop because workspace exceeded is additionally displayed.

Precondition Procedure



Operating mode T1

1. When the acknowledgement message is displayed, confirm it with OK. 2. Press and hold down the enabling switch. 3. Move the robot out of the violated space:  Using the jog keys (manual mode)  Using the Start and Start backwards keys (program mode) The status message is cleared when the robot has left the violated space.

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7 Start-up and configuration

7

Start-up and configuration

t

t

7.1

System safety instructions

During system planning, the safety functions must be planned. Required safety functions that are not implemented with the SafeOperation safety option must be implemented using different safety measures. The stopping distance when a monitoring function is trigger ed varies according to the specific robot type. This aspect must be taken into account by the system integrator during parameterization of the mon itoring functions as part of the safety assessment. Further information about the stopping distances and stopping times can be found in the assembly or operating instructions of the relevant robot. Serious system errors, severe damage to the robot and injury or death can result from not carrying out the risk analysis. Risk analysis must be carried out before start-up and after any safety-relevant modification.  Define axes that must be tested in the brake test.  Determine brake test cycle time.  Determine axis-specific and Cartesian limit values for the reduced velocity.  Define axis-specific and Cartesian monitoring spaces.  Define axes that must be configured for a safe operational stop. Incorrect configuration of the safe monitoring functions may result in death or severe injuries and major damage to property. Consequently, safety options may not be operated until after safety acceptance has been carried out in accordance with the checklists. The checklists must be completed fully and confirmed in writing. (>>> 11.1 "Checklists" Page 171) If safe monitoring is deactivated, the configured safety monitoring functions are inactive. Serious injury and severe damage to the robot can be caused by changing the machine data. Modifying the machine data may deactivate monitoring functions. Machine data may only be modified by authorized personnel. 7.2

Jogging the robot without a higher-level safety controller

Description

To jog the robot without a higher-level safety controller, Start-up mode must first be activated. The robot can then be jogged in T1 mode. Tool 1 is always active in Start-up mode. In Start-up mode, all monitoring functions of the safety configuration that can be activated via safe inpu ts are deactivated. (>>> 8.1.1 "SafeOperation via Ethernet safety interface (optional)" Page 129) (>>> 8.2 "SafeOperation via interface X13" Page 136)


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The following monitoring functions remain active:     



Monitoring of the cell area Monitoring of global maximum Cartesian velocity Monitoring of global maximum axis velocity Workspace monitoring functions that are configured as always active Monitoring of the workspace-specific velocity in workspaces that are configured as always active Velocity monitoring in T1

External safeguards are disabled in Start-up mode. Observe the safety instructions relating to Start-up mode. (>>> 4.8.3.2 "Start-up mode" Page 53) Precondition

 

Procedure



Operating mode T1 If the Ethernet safety interface is used: No connection to a higher-level safety controller In the main menu, select Start-up > Service > Start-up mode. Menu

Description

Start-up mode is active. Touching the menu item deactivates the mode. Start-up mode is not active. Touching the menu item activates the mode. 7.3

Start-up and configuration – overview Step

Description

1

Set up brake test.

2

(>>> 7.7 "Brake test" Page 106) Install reference switch and actuating plate.

3

(>>> 7.6.4.1 "Installing the reference switch and actuating plate" Page 101) Connect the reference switch.

4

5

(>>> 7.6.4.2 "Connecting a reference switch" Page 102) Only if a safety PLC is being used: Configure the communication via the interface. (>>> 8 "Interfaces to the higher-level controller" Page 125) Master the robot. Note: Further information on mastering is contained in the oper-

6

ating and programming instructions for the System Software. Activate safe monitoring.

7

(>>> 7.5.1 "Activating safe monitoring" Page 75) Define global parameters.  

Mastering test input Cartesian velocity monitoring functions

(>>> 7.5.2 "Defining global parameters" Page 75)

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Step

8

Description

Define monitoring spaces. (>>> (>>> 7.5.3 "Defining a cell area" Page 77) 77) (>>> (>>> 7.5.4 "Defining Cartesian monitoring spaces" Page 79) 79)

9

(>>> (>>> 7.5.5 "Defining axis-specific monitoring spaces" Page 84) 84) Defi efine axi axis-specific vel velocity mon monitoring. (>>> (>>> 7.5.6 "Defining axis-specific velocity monitoring" Page 87) 87)

10

(>>> (>>> 7.5.7 "Defining the safe operational stop for axis groups" Page 91) 91) Define safe tools.

11

(>>> (>>> 7.5.8 "Defining safe tools" Page 93) 93) Program ma mastering te test.

12

(>>> (>>> 7.6.5 "Teaching "Teaching positions for the mastering m astering test" Page 103) 103) Define re reference po position.

13

(>>> (>>> 7.5.9 "Defining the reference position" Page 95) 95) Only Only if the the ref refer eren ence ce swit switch ch is actua actuate ted d by by a fer ferro roma magn gneti eticc par partt of the tool or following a tool change: Check the accuracy of the reference position.

14

(>>> (>>> 7.6.6 "Checking the reference position (actuation with tool)" Page 105) 105) Save sa safety co configuration.

15

(>>> (>>> 7.5.10 "Saving the safety configuration" Page 97) 97) Perform ma mastering te test.

16

(>>> (>>> 7.6.7 "Performing a mastering test manually" Page 105) 105) Carry out safety acceptance. (>>> (>>> 7.9 "Safety acceptance overview" Page 117) 117)

17

(>>> (>>> 7.10 "Checking that the safety functions are functioning correctly" Page 118) 118) Archive sa safety co configuration. Note: Further information on archiving is contained in the oper-

18

ating and programming instructions for the System Software. Only Only ifif a new new safe safety ty con confifigu gura ratition on is is acti activa vate ted: d: Com Compa pare re the the checksum displayed when the safety configuration is archived with the checksum documented in the checklist for safety functions. (>>> (>>> 7.11 "Activating a new safety configuration" Page 122) 122 )

7.4 7.4

Info Inform rmat atio ion n abou aboutt the safe safety ty conf config igur urat atio ion n

Cartesian monitoring spaces are only monitored against the spheres used to model the safe tool. Robot components situated outside the tool spheres are not monitored and a space violation by these components is not detected. Cartesian monitoring spaces and tool spheres must therefore be designed and configured in such a manner that the unmonitored robot components do not pose any threat.


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Minimum sphere radius

The sphere radius must not fall below the predefined minimum value. This radius is dependent on the global maximum Cartesian velocity. The minimum sphere radius is calculated as follows: 

r min [mm] >= 0.5 * (maximum Cartesian velocity [mm/s] * 0.012 s)

The smallest possible radius is 10 mm. A radius smaller than 10 mm cannot be configured, even if the calculation gives a smaller value. If values that are too small are configured, a message is displayed when saving and the configuration is prevented from being saved. Minimum protected space dimensions

The length, width and height of a protected space must not fall below the predefined minimum value. This value depends on the global maximum Cartesian velocity and the radius of the smallest sphere of the safe tool. The minimum space dimensions (= minimum length, width and height) are calculated as follows: 

amin [mm] ≥ 0.018 s * maximum Cartesian velocity [mm/s] − 2 * r sphere

[mm] A precondition for a correct result is that the sphere radius has been configured correctly. (>>> (>>> "Minimum sphere radius" Page 72) 72) The smallest permissible length, width and height is 10 mm. Values smaller than 10 mm cannot be configured, even if the calculation gives a smaller value. If values that are too small are configured, a message is displayed when saving and the configuration is prevented from being saved. 7.4.1 7.4.1

Safe Safe defi defini niti tion on of Cart Cartes esian ian prot protec ecte ted d spac spaces es

Here, different constellations are covered which can ca use a protected space violation to not be detected:  

Narrow protected spaces

Narrow protected spaces Motion across corners

With narrow protected spaces, there is a risk that the robot may be able to move through the protected space without the space v iolation being detected. The risk is partially reduced by the specified minimum value f or the sphere radius and space dimensions. To further reduce the risk, the following rules must be observed in the configuration of protected spaces: 





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An area to be protected must always lie completely within a protected space, i.e. be enclosed by the protected space. Shielding an area to be protected using a narrow protected space (e.g. by replicating a light curtain) is not permitted. The stopping distances of the robot must also be taken into account when defining a protected space. The protected space must overlap with the area to be protected on all sides so that the robot can under no circumstances enter the area to be protected.



Fig. 7-1: Definition of protected space

1 2 3 Motion across corners

Area rea to be prot protec ecte ted d Protect Protected ed space space shield shieldss the area area to be prot protecte ected d (not (not allowe allowed) d) Protec Protected ted spac space e enclos encloses es the the entire entire area area to be be protec protected ted

If a sphere is moved across the corner of a prote cted space at a high velocity, there is a risk of the space violation not being detected. To ensure that a signal is always reliably triggered on violation of an alarm space, this space must be made large enough to ensure that its full width, length or height is passed through.

Fig. 7-2: Protected space as an alarm space

1 2 3

Target area Sphere Sphere moves moves acros acrosss corner corner of protec protected ted space space (sign (signal al not trigg triggere ered) d) Protec Protected ted space space is passed passed throug through h complet completely ely (sign (signal al reliab reliably ly trigtriggered)


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7.4.2 7.4.2

Unex Unexpe pecte cted d pro prote tecte cted d spa space ce vio viola lati tion on at spa space ce cor corne ners rs

At the corners of a Cartesian protected space, unexpected space violations can occur even though the tool sphere is clearly outside the space boundary. The following figure depicts the closest path along which a tool sphere can theoretically move about a Cartesian protected space. It can be moved along this closest path and reoriented without violating the protected space.

Fig. 7-3: Path of a tool sphere along the space surface

1 2

Protected space Tool spheres

3

Tool spheres reoriented

The monitoring responds earlier than expected at the corners because of the virtually expanded space boundaries. Depending on the radius of the tool sphere, the protected space is expanded virtually on all sides (X, Y, Z) by precisely this radius. As long as the tool sphere infringes the expanded space boundaries in only one direction, the protected space is not violated. If, however, the expanded protected space is infringed in 2 planes simultaneously, this is evaluated as a space violation.

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Fig. 7-4: Protected space violation at space corners

1 2 3 4

Protected space Protected space expanded by the radius of the tool sphere Space violation in the X direction Space violation in the Y direction

In the figure, a simplified depiction is used. Only the space expansion in the directions X and Y is shown. 7.5

Configuring safety monitoring functions

7.5.1

Activating safe monitoring

Configuration of the safety monitoring functions is only possible if safe monitoring has been activated. Precondition

Procedure

7.5.2



User group “Safety maintenance” Operating mode T1 or T2

1. 2. 3. 4.

Open the safety configuration. Press Global parameters. Set the check mark at Safe monitoring. Save the safety configuration or continue configuration.



Defining global parameters

Precondition

   

Procedure



User group “Safety maintenance” Operating mode T1 or T2 A safety configuration is open. Safe monitoring is active. Press Global parameters and set parameters.


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Description

Fig. 7-5: Defining global parameters

Defining global parameters: Parameter

Description

Safe monitoring

Activation of safe monitoring Check box active: Safe monitoring is activated. Check box not active: Safe monitoring is not activated.

Mastering test input

Default: Safe monitoring not activated. at cabinet = reference switch is connected to the robot controller. via bus interface = reference switch is connected via Ethernet

interface. Maximum Cartesian velocity

Default: to control cabinet Limit value for global maximum Cartesian velocity (not spacedependent) 

0.5 … 30,000 mm/s

Default: 10,000 mm/s

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Parameter

Description

Reduced Cartesian velocity

Limit value for safely reduced Cartesian velocity 

Reduced Cartesian velocity T1

0.5 … 30,000 mm/s

Default: 30,000 mm/s Limit value for safely reduced Cartesian velocity in T1 mode 

0.5 … 250 mm/s

Default: 250 mm/s 7.5.3

Defining a cell area

Precondition

   

Procedure

User group “Safety maintenance” Operating mode T1 or T2 A safety configuration is open. Safe monitoring is active.

1. Select the Monitoring spaces tab and press Cell configuration. The Cell configuration window opens. 2. Enter the upper and lower bounds of the cell area. 3. Select a corner from the list. The parameters of the corner are displayed. 4. Activate the corner of the cell area if necessary. Set the check mark for the corner to do so. Corners 1 to 4 are activated by default.

5. Move the robot to one corner of the cell area. 6. Press Touch-up. The X and Y coordinates of the corner are saved. The taught point refers to $WORLD and the tool $TOOL that is being used. 7. Repeat steps 3 to 6 to define further corners. There must be at least 3 corners activated.


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Description

Fig. 7-6: Defining a cell area

Defining a cell area: Parameter

Description

Reference system

Reference coordinate system 

Z min

Lower limit of the cell area 

Z max

$WORLD -100,000 mm … +100,000 mm

Default: -30,000 mm Upper limit of the cell area 

-100,000 mm … +100,000 mm

Default: 30,000 mm

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Parameter

Description

Activated

Check box active: Corner of cell area is activated.

(corner)

Check box not active: Corner of cell area is not activated. Default corner 1 to 4: Activated X, Y (corner)

Default corner 5 to 10: Not activated X, Y coordinate of corner 1 to 10 relative to the WORLD coordinate system 

-100,000 mm … +100,000 mm

Default corner 1 or 4: +100,000 mm Default corner 2 or 3: -100,000 mm Default corner 5 to 10: 0 mm 7.5.4

Defining Cartesian monitoring spaces

Precondition

   

Procedure


1. Select the Monitoring spaces tab and select the monitoring space from the list. The parameters of the monitoring space are displayed. 2. Enter the name of the monitoring space (max. 24 characters). 3. Select the space type Cartesian space and set the parameters of the monitoring space. 4. Press Properties. The Cartesian properties of {0} window is opened. 5. Select the reference coordinate system and enter Cartesian positions.

Monitoring space

Fig. 7-7: Defining a Cartesian monitoring space

Defining a Cartesian monitoring space:


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Parameter

Description

Type

Type of monitoring space working space = The safe tool must move

within the configured limits of the monitoring space. (Space violation if the safe tool leaves the monitoring space.) protected space = The safe tool must move

outside the configured limits of the monitoring space. (Space violation if the safe tool enters the monitoring space.) Activation

Default: working space Activation of monitoring space always off = monitoring space is not active. always active = monitoring space is always

active. by input = monitoring space is activated by a

safe input. If interface X13 is used, safe inputs are only available for monitoring spaces 12 … 16. (>>> 8.2 "SafeOperation via interface X13" Page 136) Space type

Default: always off Type of monitoring space Cartesian space = Cartesian monitoring space Axis space = axis-specific monitoring space

Stop at boundaries

Default: Cartesian space A stop is triggered if the space is violated. Check box active: Robot stops if the monitoring space limits are exceeded. Check box not active: Robot does not stop if the monitoring space limits are exceeded.

V max

Default: Robot stops at boundaries. Limit value of the space-specific velocity 

0.5 … 30,000 mm/s


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Parameter

Description

Vmax valid if

Validity of the space-specific velocity not used = space-specific velocity is not moni-

tored. Space not violated = space-specific velocity is

monitored if the monitoring space is not violated. Space violated = space-specific velocity is mon-

itored if the monitoring space is violated. Stop if mastering test not yet done

Default: Deactivated Activation of reference stop Check box active: Reference stop is activated for the monitoring space. Check box not active: Reference stop is not activated for the monitoring space. Default: Reference stop activated.


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Properties

Fig. 7-8: Defining Cartesian properties

Defining properties: Parameter

Description

Reference system

Reference coordinate system

Space dimensions



$WORLD



$ROBROOT

Default: $WORLD Length, width and height of the monitoring space (display only) The length, width and height of a protected space must not fall below the predefined minimum value. This value depends on the global maximum Cartesian velocity and the radius of the smallest sphere of the safe tool. (>>> "Minimum protected space dimensions" Page 72)

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Parameter

Description

Origin X, Y, Z

Offset of the origin of the Cartesian monitoring space in X, Y and Z relative to the selected reference coordinate system. 

Origin A, B, C

-100,000 mm … +100,000 mm

Default: 0 mm Orientation in A, B and C at the origin of the Cartesian monitoring space relative to the selected reference coordinate system. Origin A, C: 

-180° … +180°

Origin B: 

Distance to origin XMin, YMin, ZMin

Default: 0° Minimum X, Y and Z coordinates of the Cartesian monitoring space relative to the origin 

Distance to origin XMax, YMax, ZMax

-90° … +90°

-100,000 mm … +100,000 mm

Default: 0 mm Maximum X, Y and Z coordinates of the Cartesian monitoring space relative to the origin 

-100,000 mm … +100,000 mm

Default: 0 mm Example

The example shows a Cartesian monitoring space whose origin is offset in the X, Y and Z directions (yellow arrow) relative to the $ROBROOT system. The orientation A, B, C at the origin of the Cartesian monitoring space is identical to the orientation at the origin of $ROBROOT.

Fig. 7-9: Example of a Cartesian monitoring space


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7.5.5

Defining axis-specific monitoring spaces

Precondition

   

Procedure


1. Select the Monitoring spaces tab and select the monitoring space from the list. The parameters of the monitoring space are displayed. 2. Enter the name of the monitoring space (max. 24 characters). 3. Select the space type Axis space and set the parameters of the monitoring space. 4. Press Properties. The Axis-specific properties of {0} window opens. 5. Select axis from the list. The axis-specific properties are displayed. 6. Activate the monitoring of axis limits by setting the check mark at Monitoring. 7. Move the axis to the upper axis limit in axis-specific mode. 8. Press Touch-up to save the current axis position. 9. Move the axis to the lower axis limit in axis-specific mode. 10. Press Touch-up to save the current axis position. 11. Repeat steps 5 to 10 to define the axis limits for additional axis ranges. A maximum of 8 axes or, in the case of kinematic systems with master/slave axes, a maximum of 8 drives can be configured for each monitoring space.

Monitoring space

Fig. 7-10: Defining an axis-specific monitoring space

Defining an axis-specific monitoring space:

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Parameter

Description

Type

Type of monitoring space working space = The axes must move within

the configured limits of the monitoring space. (Space violation if the axes leave the monitoring space.) protected space = The axes must move outside

the configured limits of the monitoring space. (Space violation if the axes enter the monitoring space.) Activation

Default: working space Activation of monitoring space always off = monitoring space is not active. always active = monitoring space is always

active. by input = monitoring space is activated by a

safe input. If interface X13 is used, safe inputs are only available for monitoring spaces 12 … 16. (>>> 8.2 "SafeOperation via interface X13" Page 136) Space type

Default: always off Type of monitoring space Cartesian space = Cartesian monitoring space Axis space = axis-specific monitoring space

Stop at boundaries

Default: Cartesian space A stop is triggered if the space is violated. Check box active: Robot stops if the monitoring space limits are exceeded. Check box not active: Robot does not stop if the monitoring space limits are exceeded.

V max

Default: Robot stops at boundaries. Limit value of the space-specific velocity 

0.5 … 30,000 mm/s



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Parameter

Description

Vmax valid if

Validity of the space-specific velocity not used = space-specific velocity is not moni-

tored. Space not violated = space-specific velocity is

monitored if the monitoring space is not violated. Space violated = space-specific velocity is mon-

itored if the monitoring space is violated. Stop if mastering test not yet done

Default: not used Activation of reference stop Check box active: Reference stop is activated for the monitoring space. Check box not active: Reference stop is not activated for the monitoring space. Default: Reference stop activated.

Properties

Fig. 7-11: Defining axis-specific properties

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Icon

Description

Icon for rotational and infinitely rotating axes Icon for linear axes Defining properties: Parameter

Description

Monitoring

Activation of monitoring Check box active: Monitoring is activated. Check box not active: Monitoring is not activated.

Lower limit

Default: Monitoring is not activated. Lower limit of the axis-specific monitoring space

(lower axis limit)





Rotational axes: -360° … +360° Default: -360° Linear axes: -30,000 mm … +30,000 mm Default: -30,000 mm

The lower limit of an axis-specific workspace must be at least 0.5° or 1.5 mm less than the upper limit. The axis-specific protected space is dependent on the maximum axis velocity. The minimum size for the axis-specific protected space is equal to the distance that the relevant axis can travel at maximum axis velocity in an interval of 18 ms. If this minimum value is violated, a message is displayed. Axis-specific actual position (display only)

Current position



Red: axis position not allowed, as monitoring space is violat-

ed 

Green: axis position allowed

Upper limit

Upper limit of the axis-specific monitoring space

(upper axis limit)





Rotational axes: -360° … +360° Default: 360° Linear axes: -30,000 mm … +30,000 mm Default: 30,000 mm

The upper limit of an axis-specific workspace must be at least 0.5° or 1.5 mm greater than the lower limit. The axis-specific protected space is dependent on the maximum axis velocity. The minimum size for the axis-specific protected space is equal to the distance that the relevant axis can travel at maximum axis velocity in an interval of 18 ms. If this minimum value is violated, a message is displayed. 7.5.6

Defining axis-specific velocity monitoring

Precondition

   

User group “Safety maintenance” T1 or T2 mode A safety configuration is open. To modify option-specific monitoring functions: Safe monitoring is active.


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Monitoring of the braking time and the maximum axis velocity in T1 is part of the standard safety configuration and always active. The corresponding parameters can also be modified if safe monitoring is deactivated. Procedure

1. Select the Axis monitoring tab. 2. Edit the parameters of the standard safety configuration as required. 3. If necessary, activate monitoring of the safely reduced axis velocity for one axis. To do so, select the desired axis and set the check mark at Monitoring. 4. Change the limit value for the safely reduced axis velocity if necessary. 5. Modify the maximum velocity for rotational axes and linear axes (valid globally for every axis).

Description

Fig. 7-12: Defining axis velocities

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Icon

Description

Icon for rotational and infinitely rotating axes Icon for linear axes Defining axis velocities: Parameter

Description

Monitoring

Activation of monitoring Check box active: Axis is monitored. Check box not active: Axis is not monitored.

Braking time

Default: Axis is not monitored. Duration of the monitored axis-specific braking ramp for safety stop 1 and safety stop 2 

500 … 15,000 ms

Default: 1,500 ms Maximum velocity T1

(>>> 7.5.6.1 "Parameter Braking time" Page 90) Maximum axis velocity in T1 



Rotational axes: 1.0 … 100.00 °/s Default: 30 °/s Linear axes: 1.0 … 1,500 mm/s Default: 250 mm/s

This parameter enables a servo gun, for example, to be calibrated in T1 with a higher velocity than 250 mm/s. Note: The Cartesian velocities at the flange and at the TCP are

Reduced velocity

monitored independently of this parameter and cannot exceed 250 mm/s. Limit value for safely reduced axis velocity Rotational axes: 0.5 … 5,000 °/s Default: 5,000°/s  Linear axes: 1.5 … 10,000 mm/s Default: 10,000 mm/s Limit value for global maximum velocity for rotational axes 

Maximum velocity rotational axis



0.5 … 5,000 °/s

Default: 1,000°/s

Maximum velocity translational axis

The axis-specific protected space is dependent on the global maximum axis velocity. A defined minimum size for the axisspecific protected space is derived from the global maximum axis velocity; the size must not fall below this value. If this minimum value is violated, a message is displayed. Limit value for global maximum velocity for translational axes 

0.5 … 30,000 mm/s

Default: 5,000 mm/s The axis-specific protected space is dependent on the global maximum axis velocity. A defined minimum size for the axisspecific protected space is derived from the global maximum axis velocity; the size must not fall below this value. If this minimum value is violated, a message is displayed.


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7.5.6.1

Parameter Braking time

Description

If a safety stop 1 or 2 occurs, the safety controller monitors the braking process. Among other things, it monitors whether the axis-specific velocity remains below its monitoring ramp. If the velocity is too high, i.e. if the ramp is violated, then the safety controller triggers a safety stop 0. The monitoring ramp can be specified using the parameter Braking time. The parameter Braking time modifies the monitoring ramp. It does not modify the actual time required by the kinematic system for braking. Only alter the default time if it is necessary to do so. This might be required, for example, in the case of very heavy machines and/or very heavy loads as these cannot stop within the default time. The safety recovery technician must check whether and to what extent the Braking time value needs to be modified in each specific application. He must also check whether the modification makes additional safety measures necessary, e.g. installation of a gate lock. The monitoring ramp is determined as follows: 



The robot controller subtracts 200 ms from the value of the parameter Braking time (taking into account the brake closing time). Th e result is the monitoring time. For example, the default value of 1 500 ms results in a monitoring time of 1 300 ms. When this time has elapsed, another monitoring function begins: The ramp has plateaus of 300 ms at the start and end. The plateau at the start is always 106% of the rated speed of the axis. The plateau at the end is always 10.6 %.

Fig. 7-13: Monitoring ramp

1 2 3 vrs t

Velocity profile during braking (example) Monitoring ramp (default value Braking time 1 500 ms) From this moment on, standstill monitoring begins. Rated speed of the axis (rs = "rated speed") Time The value “0” on the time axis is the moment at which the safety stop 1 or 2 begins.

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Limitations





Value increased

Braking time can be configured separately for each axis; at the moment

of braking, however, the value used for all axes is always the highest value entered. Recommendation: for greater transparency, enter the same value for all axes. The parameter Braking time usually has no effect in T1, since it refers to the axis-specific monitoring. In T1, however, there is another (non-configurable) monitoring function for the Cartesian velocity o n the flange. This is usually stricter.

If the value Braking time is increased, this has the following effect:

The monitoring ramp becomes longer and flatter, i.e. monitoring is now less strict. There is now a lower probability that a braking process will violate the ramp.

Fig. 7-14: Example: value is increased

1 2 3 Value reduced

Velocity profile during braking (example) Monitoring (lower Braking time value) Monitoring (higher Braking time value)

If the value “Braking time” is reduced, this has the following effect:

The monitoring ramp becomes shorter and steeper, i.e. monitoring is now stricter. There is now a higher probability that a braking process will violate the ramp. 7.5.7

Defining the safe operational stop for axis groups

Precondition

   

Procedure


1. Select the Axis monitoring tab and press Safe operational stop. The Safe operational stop window opens. 2. Select axis from the list. 3. Enter the position tolerance for this axis. The position tolerance configured here also applies to the global safe operational stop, with which all axes are monitored.


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The global safe operational stop is one of the standard safety functions. The position tolerances can also be modified if safe monitoring is deactivated. 4. Activate one or more axis groups in which the axis is to be monitored by activating the corresponding check box (set the check mark). 5. Repeat steps 2 to 4 to define further monitoring functions. A maximum of 8 axes or, in the case of kinematic systems with master/slave axes, a maximum of 8 drives can be configured for each axis group. Description

Fig. 7-15: Defining a safe operational stop Icon

Description

Icon for rotational and infinitely rotating axes Icon for linear axes Defining the safe operational stop:

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Parameter

Description

Monitoring in axis groups 1-6

Safe operational stop for axis group 1 … 6 Check box active: Axis is monitored in axis group. Check box not active: Axis is not monitored in axis group. Default: No monitoring Tolerance for standstill monitoring in the case of safe operational stop. The axis may still move within th is tolerance when a safe operational stop is active.

Position tolerance





7.5.8

Rotational axes: 0.001° … 1° Default: 0.01° Linear axes: 0.003 … 3 mm Default: 0.1 mm

Defining safe tools

Precondition

   

Procedure


1. Select the Tools tab and select a tool from the list. The parameters of the safe tool are displayed. 2. Activate safe tool. To do so, set the check mark at Activation. 3. Enter a name for the tool (max. 24 characters). 4. Define the safe TCP of the tool. 5. Press Properties. The Properties of {0} window opens. 6. Select a sphere from the list and activate monitoring of the sphere. To do so, set the check mark at Monitoring. 7. Enter the coordinates of the center of the sphere and the radius of the sphere. 8. Repeat steps 6 to 7 to define additional spheres for the safe tool.

Tool

Fig. 7-16: Defining a safe tool

Defining a safe tool:


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Parameter

Description

Activation

Activation of the safe tool Check box active: Safe tool is activated. Check box not active: Safe tool is not activated. Default tool 1: Activated Default tool 2 … 16: Not activated Note: If interface X13 is used, tool 1 is always

TCP X, Y, Z

active. The tool cannot be activated via a safe input. An automated, safely monitored tool change is thus not possible. X, Y and Z coordinates of the safe TCP for velocity monitoring 

-10,000 mm … +10,000 mm

Default: 0 mm Properties

Fig. 7-17: Defining the properties of the safe tool

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Defining properties: Parameter

Description

Monitoring

Activation of monitoring of the sphere Check box active: Sphere is monitored. Check box not active: Sphere is not monitored. Default sphere 1: Monitoring active

X, Y, Z

Default spheres 2 to 6: Monitoring deactivated X, Y and Z coordinates of the sphere center point relative to the FLANGE coordinate system 

Radius

-10,000 mm … +10,000 mm

Default: 0 mm Radius of the sphere at the safe tool 

10 … 10,000 mm

Default: 250 mm The sphere radius must not fall below the predefined minimum value. This radius is dependent on the global maximum Cartesian velocity. (>>> "Minimum sphere radius" Page 72) 7.5.9

Defining the reference position

Precondition

   

Procedure


1. 2. 3. 4. 5.

Select the tool and base for Cartesian jogging. Select the Reference position tab. Move robot to the reference position. Select one of the robot axes. Press Touch-up reference position for group to accept the current flange position of the robot as the reference position for the axes in reference group 1. The coordinates of the Cartesian reference position are displayed in the configuration window. 6. If external axes are configured, enter the number of the corresponding reference group for each external axis. 7. If present, move external axes in reference group 2 to the reference position and save with Touch-up reference position for group. 8. If present, move external axes in reference group 3 to the reference position and save with Touch-up reference position for group.


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Description

Fig. 7-18: Defining the reference position Icon

Description

Icon for rotational and infinitely rotating axes Icon for linear axes Defining the reference position:

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Parameter

Description

Reference group

Each axis that is to be subjected to safe monitoring must be assigned to a reference group. Robot axes are always assigned to reference group 1. External axes can be assigned to other reference groups, but also to reference group 1, e.g. in the case of a KL. 

1: Robot axes



1 … 3: External axes

Default: 1 Axis-specific coordinates of the reference position

Reference position

To monitor the mastering, the axis angles of the robot axes are defined for a specific Cartesian reference position. During the mastering test, the robot moves to the Cartesian reference position and the actual position of the axes is compared with the command position. Rotational axes: -360° … +360° Default: 45°  Linear axes: -30,000 mm … +30,000 mm Default: 1,000 mm Axis-specific actual position (display only) 

Current position



Mastering position Cartesian reference position X, Y, Z

Red: reference position not allowed, as too near mastering

position  Green: reference position allowed The axis angles at the mastering position are defined in the machine data. (display only) X, Y and Z coordinates of the Cartesian reference position relative to the WORLD coordinate system (display for reference group 1) The coordinates of the Cartesian reference position refer to the center point of the mounting flange. 

-30,000 mm … +30,000 mm

Default: 0 mm 7.5.10

Saving the safety configuration

Serious injury and severe damage to the robot can be caused by an error during saving or a failed reinitialization. If an error message is displayed after saving, the safety configuration must be checked and saved again. Precondition

  

Procedure

User group “Safety maintenance” A safety configuration is open. Safety configuration is completed.

1. Press Save and answer the request for confirmation with Yes. The safety configuration is saved on the hard drive and the checksum of the safety configuration is saved to the RDC. The robot controller is automatically reinitialized. 2. The checksum and activation code of the safety configuration are displayed on the General tab.


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Note the checksum and activation code in the checklist for safety functions. (>>> 11.1.3 "Checklist for safety functions" Page 172) 7.6

Mastering test

7.6.1

Overview, mastering test

Description

The mastering test is used to check whether the current position of the robot and the external axes corresponds to a reference position. Infinitely rotating axes are taken into consideration in the mastering test with modulo 360°, i.e. the reference position is always relative to the circle. If the deviation between the current position and the reference position is too great, the mastering test has failed. The robot stops with a safety stop 1 and can only be moved in T1 mode. If the mastering test run was successful, the robot can be safely monitored using the safety controller. The position to be monitored is not verified until a mastering test has been carried out. It is advisable to perform the mastering test as quickly as possible. The safety maintenance personnel must determine, by means of a risk assessment, whether additional system-specific safety measures are required, e.g. reference stop if the mastering test has not been carried out.

Reference group

Each axis that is to be subjected to safe monitoring must be assigned to a reference group. Robot axes are always assigned to reference group 1. External axes can be assigned to other reference groups, but also to reference group 1, e.g. in the case of a KL. 

1: Robot axes



1 … 3: External axes

All axes of a reference group are mastered together. During the mastering test, all axes of a reference group must be in the reference position in order to actuate the reference switch. If not all the axes of a reference group are involved in actuating the reference switch, the position of the axes cannot be checked. Requirement

The following events cause a mastering test to be requested:    

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Robot controller is rebooted (internal request) Robot is remastered (internal request) I/O driver is reconfigured (internal request) Input $MASTERINGTEST_REQ_EXT is set externally, e.g. by a safety PLC (external request)

Monitoring time

Once the robot controller has booted, the robot can be moved for 2 hours without a mastering test. Once the monitoring time has elapsed, the robot stops with a safety stop 1 and the safety controller generates the following message: Ackn.: Mastering test time interval expired .

Execution

The mastering test is carried out using the program MasRef_Main.SRC. It can be started in the following ways:


7 Start-up and configuration 

Automatic

Integrate MasRef_Main.SRC into the application program in such a way that it is cyclically called as a subprogram. If a mastering test is requested, the robot detects this and starts the mastering test. 

Manual

For this, start the program MasRef_Main.SRC manually. If the reference switch is activated via PROFIsafe or CIP Safety, the PLC input Mastering test must only be reset if the reference switch is actuated on both channels. This prevents a single-channel mastering test. Overview

Step

Description

1

Select reference position.

2

(>>> 7.6.4 "Selecting a reference position" Page 101) Install reference switch and actuating plate.

3

(>>> 7.6.4.1 "Installing the reference switch and actuating plate" Page 101) Connect the reference switch.

4

5

(>>> 7.6.4.2 "Connecting a reference switch" Page 102) Configure the input signal $MASTERINGTEST_REQ_EXT for the external mastering test request. This signal is declared in the file $machine.dat in the directory KRC:\ROBOTER\KRC\STEU\MADA and must be assigned to a suitable input. By default, the signal is routed to $IN[1026]. Teach positions for the mastering test in the program MasRef_USER.SRC. The reference position must be taught in the program MasRef_USER.SRC and in the safety configuration. (>>> 7.6.5 "Teaching positions for the mastering test" Page 103)

6

(>>> 7.5.9 "Defining the reference position" Page 95) Only if the reference switch is actuated by a ferromagnetic part of the tool or following a tool change:

7

Check the accuracy of the reference position. (>>> 7.6.6 "Checking the reference position (actuation with tool)" Page 105) If the mastering test is to be executed automatically:

8

Integrate MasRef_Main.SRC into the application program in such a way that it is cyclically called as a subprogram. If the mastering test is to be executed manually:



Start the program MasRef_Main.SRC manually. (>>> 7.6.7 "Performing a mastering test manually" Page 105) 7.6.2

Programs for the mastering test

The following programs are used for the mastering test:


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Program

Directory

Description

MasRef_Main.SRC

R1\System

The program checks whether a mastering test is required and must be executed as soon as possible after an internal request. If the program is not executed within 2 hours, the robot stops and the robot controller generates a message. If a mastering test is required, the robot performs it immediately.

MasRef_USER.SRC

The program calls the program MasRef_USER.SRC that is used to address the reference position. The program contains 3 subprograms for moving to reference positions 1 to 3 and 3 subprograms for the motion away from reference positions 1 to 3 after the mastering test has been performed.

R1\Program

If the motion away from the reference position is not taught, the robot and external axes remain stationary after the mastering test. The robot controller generates an error message. 7.6.3

Variables for the mastering test

Variable

Description

$MASTERINGTEST_ACTIVE

State of the mastering test TRUE = mastering test is active.

$MASTERINGTEST_GROUP

$MASTERINGTEST_REQ_INT

FALSE = no mastering test is active. Number of the reference group that is currently in the reference position 

0: No reference group in reference position



1 … 3: Reference group with this number in reference

position Internal mastering test request from the safety controller TRUE = mastering test is requested.

$MASTERINGTEST_REQ_EXT

FALSE = mastering test is not requested. Input for the external request for mastering test, e.g. from the safety PLC TRUE = mastering test is requested. FALSE = mastering test is not requested. Note: This signal is declared in the file $machine.dat in the

$MASTERINGTEST_SWITCH_ OK

directory KRC:\ROBOTER\KRC\STEU\MADA and must be assigned to a suitable input. By default, the signal is routed to $IN[1026]. Check of the function of the reference switch TRUE = reference switch is OK. FALSE = reference switch is defective.

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7.6.4

Selecting a reference position

Description

The reference position can be approached with the actuating plate or with a ferromagnetic part of the tool as follows:

Fig. 7-19: Example: position of the actuating plate on the reference switch

1 2 3 4 5 Selection criteria

The reference run must be selected in accordance with the following criteria: 











7.6.4.1

Tool Actuating plate Reference switch Mechanical mounting fixture for the reference switch Actuated reference switch

The position of the reference switch and actuating plate does not interfere with the work sequence of the robot. The reference position is not a position in which the axes are in a singularity. In the reference position, both proximity switch surfaces of the reference switch are actuated by the switching surface (actuating plate or tool). All axes of a reference group are in the reference position in order to actuate the reference switch. In the reference position, the robot axes are at least ±5° (rotational axes) or ±15 mm (linear axes) away from the mastering position. The position of the reference switch is within the motion range of the robot.

Installing the reference switch and actuating plate

Precondition





The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. The reference run has been selected in accordance with the required criteria. (>>> "Selection criteria" Page 101)


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Procedure

1. Prepare a mechanical mounting fixture for mounting the reference switch. 2. Attach the reference switch to the mounting fixture. 3. If the actuating plate is being used, fasten the actuating plate to the robot flange or tool.

Example

Fig. 7-20: Example of an actuating plate on the tool

1 2 3 4 7.6.4.2

Robot Actuating plate on tool Tool Reference switch on mounting fixture

Connecting a reference switch

The robot controller is preconfigured for the specific industrial robot. If cables are interchanged, the manipulator and the external axes (optional) may receive incorrect data and can thus cause personal injury or material damage. If a system consists of more than one manipulator, always connect the connecting cables to the manipulators and their corresponding robot controllers. In the case of a KR C4, only 1 reference switch can be connected directly to the robot controller. If multiple reference groups are required, the reference switches can be connected to the safety PLC and activated via PROFIsafe or CIP Safety. The safety PLC must evaluate the reference switches and set the input Mastering test accordingly. A KR C4 compact is not equipped with a connection allowing a reference switch to be connected to the robot controller. Reference switches must be connected to the safety PLC and activated via PROFIsafe or CIP Safety. The safety PLC must evaluate the reference switches and set the input Mastering test accordingly.

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Precondition



 

The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. Reference switch is installed. Reference cable X42 - XS Ref (maximum cable length 40 m) The following procedure applies only to connection of the reference switch to a KR C4.

Procedure

1. Route the reference cable X42 - XS Ref correctly (in a fixed installation or cable carrier). When routing the cable, avoid mechanical damage and observe the minimum bending radii. The following bending radii serve as guide values: Type of routing

Bending radius



2. Connect the reference cable: Connect X42 to the robot controller and XS Ref to the reference switch. 7.6.5

Teaching positions for the mastering test

Description

The following points must be taught for each reference group:  

Motion to the reference switch Reference position The reference position must additionally be taught in the safety configuration.



Precondition

  

Procedure

Motion away from the reference switch Reference switch is installed and connected. User group “Safety maintenance” T1 or T2 operating mode

1. Open the program MasRef_USER.SRC. 2. Insert a HALT statement in the subprograms MASREFSTARTG X () and MASREFBACKG X (). 3. Close the program MasRef_USER.SRC. 4. Select the program MasRef_Main.SRC. 5. Perform block selection to the subprogram RunTest_Group( X ). 6. Press the Start key. The subprogram MASREFSTARTG X () of the program MasRef_USER.SRC is called. 7. In the subprogram MASREFSTARTG X (), program a motion to a point approx. 10 cm before the reference switch and teach the required points. 8. Program a LIN motion to the reference switch so that it is actuated. This position is the reference position. The distance from the reference switch must not exceed 2 mm in the reference position. If the distance is greater, the refer ence switch will not be actuated. 9. Teach the reference position. 10. Do not move the robot.


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11. Teach the reference position in the safety configuration. (>>> 7.5.9 "Defining the reference position" Page 95) 12. Return to the subprogram MASREFSTARTG X () and perform a block selection to the END line. 13. Press the Start key. The subprogram MASREFBACKG X () of the program MasRef_USER.SRC is called. 14. In the subprogram MASREFBACKG X (), program the motion away from the reference position and teach the required points. 15. Deselect the program and save the changes. 16. For automatic operation, delete all HALT statements from the program MasRef_USER.SRC once again. 17. Cyclically call the program MasRef_Main.SRC at a suitable point and enable execution of the mastering test after an internal request. Program

1 DEF MasRef_USER() 2 END 3 4 GLOBAL DEF MASREFSTARTG1() 5 Teach path and reference position for group 1 6 7 END 8 9 GLOBAL DEF MASREFSTARTG2() 10 Teach path and reference position for group 2 11 12 END 13 14 GLOBAL DEF MASREFSTARTG3() 15 Teach path and reference position for group 3 16 17 END 18 19 GLOBAL DEF MASREFBACKG1() 20 Teach path back for group 1 21 22 END 23 24 GLOBAL DEF MASREFBACKG2() 25 Teach path back for group 2 26 27 END 28 29 GLOBAL DEF MASREFBACKG3() 30 Teach path back for group 3 31 32 END

Line

Description

5

Program the motion to the reference position of reference group 1 and teach the reference position. Program the motion to the reference position of reference group 2 and teach the reference position. Program the motion to the reference position of reference group 3 and teach the reference position. Teach the motion away from the reference position of reference group 1.

10 15 20

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Line

Description

25

Teach the motion away from the reference position of reference group 2. Teach the motion away from the reference position of reference group 3.

30

7.6.6

Checking the reference position (actuation with tool)

The robot can move beyond the configured limits if the reference switch is actuated by a ferromagnetic part of the tool and the accuracy at the reference position is exceeded. Severe physical injuries or damage to property may result. The accuracy of the reference position must be checked. If the tool is exchanged, the reference position and the accuracy of the reference position must be checked. If required, the reference position must be adapted to the new tool. Failure to observe this precaution may result in severe physical injuries or considerable damage to property. Precondition

 

 

Procedure

7.6.7

Reference switch is installed and connected. The reference position has been taught in the program MasRef_USER.SRC and in the safety configuration. User group “Safety maintenance” Operating mode T1 or T2

1. Open the program MasRef_USER.SRC. 2. In the subprogram MASREFSTARTG X (), insert a HALT statement immediately before the END line. 3. Close the program MasRef_USER.SRC. 4. Select the program MasRef_Main.SRC. 5. Perform block selection to the subprogram RunTest_Group( X ). 6. Press the Start key. The subprogram MASREFSTARTG X () of the program MasRef_USER.SRC is called and the robot moves to the reference position. 7. Jog each axis individually in the positive and negative directions using the jog keys and observe when the reference switch is no longer actuated. 8. Analyze the axis-specific tolerances determined in this way for the mastering test relative to the application and select a different reference position if necessary. 9. For automatic operation, delete all HALT statements from the program MasRef_USER.SRC once again.

Performing a mastering test manually

Precondition



Reference switch is installed and connected. If the reference switch is connected to the robot controller via interface X42, the mastering test can be executed in Start-up mode.





The reference position has been taught in the program MasRef_USER.SRC and in the safety configuration. T1 or T2 mode


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The robot moves in T2 mode at the program med velocity and can cause personal injury or material damage. Make sure that the robot cannot collide and that no persons are in the motion r ange of the robot. Procedure



Select and execute the program MasRef_Main.SRC to the end of the program.

7.7

Brake test

7.7.1

Overview of the brake test

Description

Each robot axis has a holding brake integrated into the motor. The brake test checks every axis at low speed and at the current temperature to see if the braking torque is sufficiently high, i.e. whether it exceeds a certain minimum value. The minimum value for the individual axes is stored in the machine data. (The brake test does not calculate the absolute value of the braking torque.)

Request

If the brake test is active, the following events cause a brake test to be requested: 

  

Input $BRAKETEST_REQ_EX is set externally, e.g. by a PLC (external request) Robot controller boots with a cold start (internal request) Function test of the brake test (internal request) Brake test cycle time has elapsed (internal request)

Cycle time

The cycle time is 46 h. It is deemed to have elapsed when the drives have been under servo-control for a total of 46 h. The robot controller then requests a brake test and generates the following message: Brake test required . The robot can be moved for another 2 hours. It then stops and the robot controller generates the following acknowledgement message: Cyclical check for brake test request not made. Once the message has been acknowledged, the robo t can be moved for another 2 hours.

Execution

A precondition for the brake test is that the robot is at operating temperature. This is the case after approx. 1 h in normal operation. The brake test is carried out using the program BrakeTestReq.SRC. It can be started in the following ways: 

Automatically

Integrate BrakeTestReq.SRC into the application program in such a way that it is cyclically called as a subprogram. If a brake test is requested, the robot detects this and starts the brake test. 

Manually

Start the program BrakeTestReq.SRC manually. Sequence

The brake test checks all brakes one after the other. 1. The robot accelerates to a defined velocity. (The velocity cannot be influenced by the user.) 2. Once the robot has reached the velocity, the brake is applied and the result for this braking operation is displayed in the message window. 3. If a brake has been identified as being defective, the brake test can be repeated for confirmation or the robot can be moved to the parking position. If a brake has reached the wear limit, the robot controller indicate s this by means of a message. A worn brake will soon be identified as defective. Until then, the robot can be moved without restrictions.

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If a brake has been identified as being defective, the drives remain under servo-control for 2 hours following the start of the brake test (= monitoring time). The robot controller then switches the drives off. Overview

Step

Description

In WorkVisual:

1

If required: Activate the brake test in WorkVisual. (>>> 7.7.2 "Activating the brake test" Page 107)

On the robot controller:

2

Configure input and output signals for the brake test.

3

(>>> 7.7.4 "Configuring input and output signals for the brake test" Page 108) Teach positions for the brake test. The parking position must be taught. The start position and end position can be taught.

4

(>>> 7.7.5 "Teaching positions for the brake test" Page 111) If the brake test is to be carried out automatically:

5

Integrate BrakeTestReq.SRC into the application progra m in such a way that it is cyclically called as a subprogram. If the brake test is to be carried out manually: Start the program BrakeTestReq.SRC manually.

6

(>>> 7.7.6 "Performing a manual brake test" Page 112) If required: Test the function of the brake test. (>>> 7.7.7 "Checking that the brake test is functioning correctly" Page 113)

7.7.2

Activating the brake test 



If a safety option is installed and the safe monitoring is active, the brake test is automatically active. If the brake test is not automatically active, the user has the option of manually activating it. This must be carried out in WorkVisual. If the brake test is not automatically active, the user must carry out a risk assessment to determine whether it is necessary to activate the brake test for the specific application. Further information about activating the brake test is contained in the WorkVisual documentation.

7.7.3

Programs for the brake test

The programs are located in the directory C:\KRC\ROBOTER\KRC\R1\TP\BrakeTest.


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Program

Description

BrakeTestReq.SRC

This program performs the brake test. It can be performed in the following ways: Integrate the program into the application program in such a way that it is cyclically called as a subprogram. If a brake test is requested, the robot detects this and performs the brake test immediately.  Execute the program manually.  Test the function of the brake test. The robot controller executes BrakeTestReq.SRC with special parameterization. The parking position of the robot must be taught in this program. 

BrakeTestPark.SRC

The robot can be moved to the parking position if a brake has been identified as being defective. Alternatively, the brake test can be repeated for confirmation. The start position of the brake test can be taught in this program. The robot starts the brake test from this position.

BrakeTestStart.SRC

If the start position is not taught, the robot performs the brake test at the actual position. The end position of the brake test can be taught in this program. The robot moves to this position after the brake test.

BrakeTestBack.SRC

If the end position is not taught, the robot remains at the actual position after the brake test. The program checks whether the brake test has correctly detected a defective brake. For this purpose, the robot controller executes BrakeTestReq.SRC with special parameterization.

BrakeTestSelfTest.SRC

7.7.4

Configuring input and output signals for the brake test

Description

All signals for the brake test are declared in the file $machine.dat in the directory KRC:\STEU\MADA. These signals are not redundant in design and can supply incorrect information. Do not use these signals for safety-relevant applications.

Precondition



“Expert” user group

Procedure

1. Open the file $machine.dat in the directory KRC:\STEU\MADA in the Navigator. 2. Assign inputs and outputs. 3. Save and close the file.

$machine.dat

Extract from the file $machine.dat (with default settings, without comments): ... SIGNAL $BRAKETEST_REQ_EX $IN[1026] SIGNAL $BRAKETEST_MONTIME FALSE ... SIGNAL $BRAKETEST_REQ_INT FALSE SIGNAL $BRAKETEST_WORK FALSE SIGNAL $BRAKES_OK FALSE SIGNAL $BRAKETEST_WARN FALSE ...

Signals

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There is 1 input signal. By default, it is routed to $IN[1026].



The output signals are preset to FALSE. There is no compelling need to assign output numbers to them. It is only necessary to assign numbers if there is a need to be able to read the signals (e.g. via the variable correction function or program execution.) Signal

Description

$BRAKETEST_REQ_EX

Input 

TRUE = brake test is being requested externally (e.g. by PLC).

$BRAKETEST_MONTIME

The robot controller confirms the signal with $BRAKETEST_REQ_INT = TRUE and generates message 27004.  FALSE = brake test is not being requested externally. Output

$BRAKETEST_REQ_INT

TRUE = robot was stopped due to elapsed monitoring time. Acknowledgement message 27002 is generated.  FALSE = acknowledgement message 27002 is not active. (Not generated, or has been acknowledged.) Output 



$BRAKETEST_WORK

TRUE = message 27004 is active.

The signal is not set to FALSE again until a brake test is carried out with a positive result, i.e. with message 27012.  FALSE = brake test is not requested (either internally or externally). Output 

TRUE = brake test is currently being performed.



FALSE = brake test is not being performed.

If no defective brakes have been detected, message 27012 is generated. Edge TRUE → FALSE:

$BRAKES_OK

Test was successfully completed. No brake is defective. Message 27012 is generated.  Or at least 1 defective brake was detected and the robot has moved to the parking position.  Or the program was canceled during execution of the brake test. Output

$BRAKETEST_WARN

Edge FALSE → TRUE: Output was set to FALSE by the previous brake test. The brake test was carried out again and no defective brake was detected. Edge TRUE → FALSE: A brake has just been detected as de fective. Message 27007 is generated. Output









Edge FALSE → TRUE: At least 1 brake has been detected as having reached the wear limit. Message 27001 is generated at the same time. Edge TRUE → FALSE: Output was set to TRUE by the previous brake test. The brake test was carried out again and no worn brake was detected.


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Messages

7.7.4.1

No.

Message

27001 27002 27004 27007 27012

Brake {Brake no.}{Axis no.} has reached the wear limit Cyclical check for brake test request not made Brake test required Insufficient holding torque of brake {Brake no.}{Axis no.} Brake test successful

Signal diagram of the brake test – examples

Example 1

The signal diagram for the brake test applies in the following case:  

No brake has reached the wear limit. No brake is defective.

Fig. 7-21: Signal diagram: brakes OK Item

Example 2

Description

1 2

The brake test is requested. Automatic call of the program BrakeTestReq.SRC

3

Start of the brake test The brake test is completed.

The signal diagram for the brake test applies in the following case:  

Brake A2 is worn. Brake A4 is defective.

Fig. 7-22: Signal diagram: brakes not OK

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Item

1

The brake test is requested.

2

$BRAKETEST_REQ_INT is not set to FALSE again until a brake test is carried out with a positive result. Automatic call of the program BrakeTestReq.SRC

3 4 5

7.7.5

Description

Start of the brake test Brake A2 is tested: brake is worn. Brake A4 is tested: brake is defective. The robot has been moved to the parking position or the program has been canceled.

Teaching positions for the brake test

Description

The parking position must be taught. The start position and end position can be taught. 



Parking position

If the start position is not taught, the robot performs the brake test at the actual position. If the end position is not taught, the robot remains at t he actual position after the brake test.

If a brake is identified as being defective, the robot can be moved to the parking position. Alternatively, the brake test can be repeated for confirmation. The parking position must be selected in a position where no persons are endangered if the robot sags because of the defective brake. The transport positio n, for example, can be selected as the parking position. Further information about the transport position is contained in the robot operating or assembly instructions.

Precondition

  

Procedure

All output signals are assigned to outputs. “Expert” user group Operating mode T1

1. Open the program BrakeTestStart.SRC in the directory R1\TP\BrakeTest. 2. Teach the motions to the start position of the brake test. The motions must be taught in such a way that the robot cannot cause  a collision on the way to the start position.  In the start position, every robot axis must have an available motion range of ±10°. 3. Save and close the program. 4. Open the program BrakeTestBack.SRC in the directory R1\TP\BrakeTest. 5. Teach the motions from the start position to the end position of the brake test. The start and end position may be identical. 6. Save and close the program. 7. Open the program BrakeTestPark.SRC in the directory R1\TP\BrakeTest. 8. Program the motions from the end position to the parking position of the robot. 9. Save and close the program.


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7.7.6

Performing a manual brake test

If a brake is identified as being defective and the drives are deactivated, the robot may sag. For this reason, no stop may be triggered during the motion to the parking position. The monitoring functions that can trigger a stop in this range (e.g. monitoring spaces) must be deactivated beforehand. No safety functions may be executed that would trigger a stop (e.g. E-STOP, opening the safety gate, change of operating mode, etc.). If a brake has been identified as being defective, the parking position must be approached no faster than at 10% of maximum velocity. Program override for the test is automatically set to 100%. The robot moves at high velocity. Make sure that the robot cannot collide and that no persons are in the motion range of the robot. Precondition

 

    

Procedure

No persons or objects are present within the motion range of the robot. In the start position, every robot axis has an available motion range of ±10°. (Or, if no start position has been taught, in the actual position.) The parking position has been taught in the program BrakeTestPark.SRC. “Expert” user group Program run mode GO AUT mode The robot is at operating temperature (= after approx. 1 h in normal operation).

1. Select the program BrakeTestReq.SRC in the directory R1\TP\BrakeTest and press the Start key. 2. The following message is displayed: Performing manual brake test please acknowledge. Acknowledge the message. 3. Press the Start key. The message Programmed path reached (BCO) is displayed. 4. Press the Start key. The brakes are tested, starting with A1. 5. Possible results:  If a brake is OK, this is indicated by the following message: Brake {Brake no.}{Axis no.} OK . If all brakes are OK, this is indicated after the brake test by the following message: Brake test successful . (It is possible that one or more brakes may have reached the wear limit. This is also indicated by a message.) Deselect the program BrakeTestReq.SRC.  If a brake is defective, this is indicated by the following message: Insufficient holding torque of brake {Brake no.}{Axis no.} . Once all brakes have been tested, either press Repeat to repeat the brake test for checking purposes or press Park pos. to move the robot to the parking position. If a brake has been identified as being defective, the drives remain under servo-control for 2 hours following the start of the brake test (= monitoring time). The robot controller then switches the drives off.

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7.7.7

Checking that the brake test is functioning correctly

Description

It is possible to check whether the brake test has correctly detected a defective brake: the program BrakeTestSelfTest.SRC simulates a fault in the brakes and triggers a brake test. If the brake test detects the simulated fault, it is functioning correctly. Program override for the test is automatically set to 100%. The robot moves at high velocity. Make sure that the robot cannot collide and that no persons are in the motion range of the robot.

Precondition

 

    

Procedure

1. Select the program BrakeTestSelfTest.SRC in the directory R1\TP\BrakeTest and press the Start key. 2. The following message is displayed: Performing self-test for brake test - please acknowledge. Confirm the message by pressing Ackn.. 3. Press the Start key. 4. Result of the function test: Message Insufficient holding torque of brake 3: The brake test has correct ly detected the simulated fault. The brake test is functioning correctly. Deselect the program BrakeTestSelfTest.SRC. Perform a manual brake test. This ensures that the simulated fault does not remain active. Any other message, or no message, means: The brake test has not  detected the simulated fault. The brake test is not functioning correctly.

 

7.8

No persons or objects are present within the motion range of the robot. In the start position, every robot axis has an available motion range of ±10°. (Or, if no start position has been taught, in the actual position.) The parking position has been taught in the program BrakeTestPark.SRC. “Expert” user group Program run mode GO AUT mode The robot is at operating temperature (= after approx. 1 h in normal operation).

If the function test establishes that the brake test is not functioning correctly: The robot must no longer be moved. KUKA Roboter GmbH must be contacted.

Override reduction for velocity and workspace limits

Override reduction for velocity and workspace limits is not a safety function. Description

Override reduction can be activated for the velocities and workspaces monitored by the safety controller:


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

Override reduction for the velocity ($SR_VEL_RED = TRUE) If override reduction is active, the velocity is automatically reduced so that the lowest currently monitored velocity limit is not exceeded. The variable $SR_OV_RED specifies the reduction factor for the ove rride reduction as a percentage. The velocity is reduced to the following value: lowest velocity limit * reduction factor (>>> "Example" Page 114) Override reduction for monitoring spaces ($SR_WORKSPACE_RED = TRUE) Override reduction is only relevant for monitoring spaces for which the function Stop at boundaries is active, and the robot is stopped with a safety stop if it violates the space limit. The override reduction for monitoring spaces is only effective in modes T2, AUT and AUT EXT. In T1 mode, the override reduction for monitoring spaces is generally deactivated, i.e. it is also deactivated if $SR_WORKSPACE_RED = TRUE. If override reduction is active and the robot approaches the workspace limit, the velocity is continuously reduced. When the robot moves over the workspace limit and is stopped, the velocity has already been greatly reduced. The stopping distance is short and the robot quickly comes to a standstill. If override reduction is not active and the robot approaches the workspace limit, the velocity is not reduced. The robot is still moving at full velocity when it is stopped at the workspace limit. The robot does not come to a standstill as quickly as with override reduction active, as the stopping distance is greater due to the higher velocity.

The variables for override reduction can be modified in the $CUSTOM.DAT file, in a KRL program or via the variable correction function. If a variable is modified, an advance run stop is triggered. (>>> 7.8.3 "Variables for override reduction in $CUSTOM.DAT" Page 117) Example

Override reduction for the velocity:  

$SR_VEL_RED = TRUE $SR_OV_RED = 95

The lowest Cartesian velocity limit active on the safety controller is a spacespecific velocity of 1,000 mm/s. The override reduction function reduces the Cartesian velocity at the safe TCP of the active tool to 950 mm/s. The override reduction function is only triggered if it is foreseeable that the limit of 950 mm/s would be exceeded without velocity reduction.

Fig. 7-23: Example: Override reduction with $SR_VEL_RED

v3 v2 v1

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Maximum Cartesian velocity; v3 = 1,200 mm/s Space-specific velocity; v2 = 1,000 mm/s Velocity v2 * reduction factor; v1 = 1,000 mm/s * 95% = 950 mm/s Issued: 08.06.2016 Version: KST SafeOperation 3.2 V7


t1 t2 7.8.1

Override reduction is triggered: without velocity reduction, the limit v1 would be exceeded. Override reduction is no longer triggered.

Override reduction with spline

Overview

If motion is carried out without spline, override reduction takes effect before workspace limits and at Cartesian velocity limits. If motion is carried out with spline, override reduction also affects axis-specific velocity limits.

Override reduction has an effect …

before workspace limits (in T2, AUT and AUT EXT modes) on space-specific velocity

Without spline

With spline

Cartesian Axis-specific Cartesian space Axis-specific space

on velocity limits

Cartesian velocity Maximum velocity (not space-dependent)  Reduced velocity  Reduced velocity for T1 Axis velocity 



 

Maximum velocity (valid globally for every axis) Reduced velocity Maximum velocity for T1

Spline is a motion type that is suitable for particularly complex, curved paths. Such paths can also be generated using approximated LIN and CIRC motions, but splines have advantages, however. The advantages of spline include: 



The path always remains the same, irrespective of the override setting, velocity or acceleration. Circles and tight radii are executed with great precision.

It is advisable to use spline for optimal override reduction, e.g. in the case of frequent motion along the workspace limits. Information about motion programming with spline is contained in the “Operating and Programming Instructions for System Integrators”.

7.8.2

Examples of override reduction with spline

Changing workspace

A change of workspace is carried out from one Cartesian workspace to another Cartesian workspace with a lower space-specific velocity vmax. The following preconditions are met: System variables: 

$SR_VEL_RED = TRUE


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$SR_OV_RED = 80

Safety configuration:   



Safe monitoring is active. At least one tool sphere on the active tool is monitored. The workspace with the lower space-specific velocity vmax is switched to active (permanently for preference). The space-specific velocity vmax is valid if the workspace is not violated.

With spline (red line), override reduction r educes the Cartesian velocity at the safe TCP of the active tool in good time in the old workspace and moves into the new workspace with the lower space-specific velocity. Without spline (blue line), the Cartesian velocity is reduced in the old workspace, but the override reduction function is not usually triggered early enough. The lower space-specific velocity of the new workspace has not yet been reached at the workspace limit and the robot stops with a safety stop 0.

Fig. 7-24: Changing to a workspace with a lower v max

1 2

Cartesian workspace with vmax = 1,000 mm/s, reduced to 800 mm/s Cartesian workspace with vmax = 500 mm/s, reduced to 400 mm/s Due to override reduction with $SR_OV_RED = 80, a maximum of 80 percent of the configured space-specific velocity vmax is reached in the workspaces.

Moving into a protected space

A Cartesian protected space is configured into which the robot may not move. If the robot approaches the protected space, override reduction is triggered and reduces the velocity. If the robot wishes to enter the protected space, a safety stop 0 is triggered at the workspace limit. The following preconditions are met: System variables: 

$SR_WORKSPACE_RED = TRUE

Safety configuration:    

Safe monitoring is active. The function Stop at boundaries is active. At least one tool sphere on the active tool is monitored. The protected space is switched to active.

With spline (red line), override reduction r educes the Cartesian velocity at the safe TCP of the active tool to a value that roughly corresponds to a program 116 / 205



override of 1% while it is still in the permissible range. The robot enters the Cartesian protected space with this velocity and is stopped with a safety stop 0. Without spline (blue line), the Cartesian velocity is reduced while in the permissible range, but the override reduction function is not usually triggered ea rly enough. The robot enters the Cartesian protected space at a higher velocity than with spline. Here, once again, the robot stops with a safety stop 0, but the braking reaction is more abrupt and the stopping distance greater.

Fig. 7-25: Moving into a protected space

1 7.8.3

Permissible range

2

Cartesian protected space

Variables for override reduction in $CUSTOM.DAT

The variables for override reduction can be modified in the $CUSTOM.DAT file, in a KRL program or via the variable correction function. If a variable is modified, an advance run stop is triggered. Variable

Description

$SR_VEL_RED

Override reduction for the velocity TRUE = override reduction is activated. FALSE = override reduction is not activated.

Default: TRUE Reduction factor for override reduction as a percentage

$SR_OV_RED

The currently monitored velocity limit is reduced to this percentage value. 

$SR_WORKSPACE_RED

10 … 95 %

Default: 75 % Override reduction for monitoring spaces TRUE = override reduction is activated. FALSE = override reduction is not activated.

Default: TRUE 7.9

Safety acceptance overview

SafeOperation must not be put into operation until the safety acceptance procedure has been completed successfully. For successful safety acceptance, the points in the checklists must be completed fully and confirmed in writing.


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The completed checklists, confirmed in writing, must be kept as documentary evidence. Safety acceptance must be carried out in the following cases:    

Following initial start-up or recommissioning of the industrial robot After a change to the industrial robot After a change to the safety configuration After a software update, e.g. of the system software Safety acceptance after a software update is only necessary if the checksum of the safety configuration changes as a result of the update. The safety configuration must be archived and the change log checked after every modification. It is also advisable to print out the data set containing the safety parameters using WorkVisual.

The following checklists can be found in the Appendix: 

















7.10

Checklist for robot and system (>>> 11.1.2 "Checklist for robot and system" Page 171) Checklist for safety functions (>>> 11.1.3 "Checklist for safety functions" Page 172) Checklist for Cartesian velocity monitoring functions (>>> 11.1.4 "Checklist for Cartesian velocity monitoring functions" Page 175) Checklist for axis-specific velocity monitoring functions (>>> 11.1.5 "Checklist for axis-specific velocity monitoring functions" Page 176) Checklist for safe operational stop for axis groups (>>> 11.1.6 "Checklist for safe operational stop for axis groups" Page 180) Checklist for cell area (>>> 11.1.7 "Checklist for cell area" Page 182) Checklist for Cartesian monitoring spaces (>>> 11.1.8 "Checklist for Cartesian monitoring spaces" Page 183) Checklist for axis-specific monitoring spaces (>>> 11.1.9 "Checklist for axis-specific monitoring spaces" Page 185) Checklist for safe tools (>>> 11.1.10 "Checklist for safe tools" Page 190)

Checking that the safety functions are functioning correctly

The configured velocity limits, the limits of the monitoring spaces and the space-specific velocities must be checked with override reduction deactivated. For this, the following variables must be set to FALSE in $CUSTOM.DAT:  

$SR_VEL_RED $SR_WORKSPACE_RED

To check the configured limits, the space and velocity limits are deliberately exceeded by means of test programs. If the safety configuration stops the robot, the limits are correctly configured. If the robot is stopped by the safety controller, a message with message number 15 xxx is displayed. If no message is displayed, or if a message from a different number range is displayed, the safety controller must be checked.

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7.10.1

Testing Cartesian velocity limits

(>>> 11.1.4 "Checklist for Cartesian velocity monitoring functions" Page 175) Description

The following Cartesian velocities must be tested:



Reduced Cartesian velocity for T1 Reduced Cartesian velocity Global maximum Cartesian velocity



Override reduction is deactivated.

 

Precondition

The following procedure must be followed exactly! Procedure

1. Create a test program in which the Cartesian velocity is to be exceeded deliberately, e.g. configured with 1000 mm/s, moved at 1100 mm/s. When testing the Cartesian velocity on a KL, the linear unit must also be moved. 2. To test the reduced Cartesian velocity for T1, execute the test program in operating mode T1. 3. To test the reduced Cartesian velocity and the maximum Cartesian velocity, execute the test program in operating mode T2. Death, serious injuries or major damage to property may occur. If a program is executed in test mode T2, the operator must be in a position outside the danger zone.

7.10.2

Testing axis-specific velocity limits

(>>> 11.1.5 "Checklist for axis-specific velocity monitoring functions" Page 176) Description

The following axis-specific velocity limits must be tested:   

Maximum axis velocity for T1 Reduced axis velocity Maximum axis velocity (valid globally for every axis)

It is only necessary to test the global maximum axis velocity if an axis must not exceed a defined velocity. If the global maximum axis velocity is only to limit the minimum axis-specific protected space, no test is required. Override reduction is deactivated.

Precondition



Procedure

Testing linear axes:

The following procedure must be followed exactly! 1. Create a test program in which the axis velocity is exceeded deliberately, e.g. KL configured with 1000 mm/s, moved at 1100 mm/s. 2. To test the maximum axis velocity for T1, execute the test program in operating mode T1. 3. To test the reduced axis velocity and the global maximum axis velocity, execute the test program in operating mode T2.


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Death, serious injuries or major damage to property may occur. If a program is executed in test mode T2, the operator must be in a position outside the danger zone. Testing rotational axes:

The following procedure must be followed exactly! 1. Look up the maximum axis velocity Vmax in the data sheet of the robot used. 2. Create a test program in which the axis velocity is to be exceeded deliberately, e.g. axis A1 configured with 190°/s, moved at 200°/s. 3. Calculate axis velocity $VEL_AXIS[x]. (>>> "Calculation of $VEL_AXIS" Page 120) 4. Enter the axis velocity $VEL_AXIS[x] in the test program. 5. To test the maximum axis velocity for T1, execute the test program in operating mode T1. 6. To test the reduced axis velocity and the maximum axis velocity, execute the test program in operating mode T2. Death, serious injuries or major damage to property may occur. If a program is executed in test mode T2, the operator must be in a position outside the danger zone. Calculation of $VEL_AXIS

The axis velocity $VEL_AXIS[x] is calculated using the following formula: $VEL_AXIS[x] = (V Test / Vmax) * 100 = (200 °/s / 360 °/s) * 100 = 56 Element

Description

x Vtest

Number of the axis Test velocity

Vmax

Unit: °/s Maximum axis velocity Unit: °/s

The calculated axis velocity $VEL_AXIS[x] is entered in the test program: ... PTP {A1 -30} HALT $VEL_AXIS[1] = 56 PTP {A1 30} ...

7.10.3

Testing Cartesian monitoring spaces

(>>> 11.1.8 "Checklist for Cartesian monitoring spaces" Page 183) (>>> 11.1.7 "Checklist for cell area" Page 182) Description

The configuration of the boundaries and the space-specific velocity must be checked. If “Stop at boundaries” is not configured, an alarm space is used for this. The space surfaces can have any orientation. The robot must be moved to each of the 6 space surfaces of a Cartesian monitoring space at 3 different points to check whether the limits have been programmed corr ectly. An excep-

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tion is made here for space surfaces that cannot be addressed due to circumstances in the system. The cell area is a Cartesian monitoring space and is tested in the same way. Depending on the configuration, the cell area consists of 5, 6 or more space surfaces. Each addressable space surface must be addressed at 2 different points to check whether the limits have been programmed correctly.

Fig. 7-26: Moving to space surfaces

Override reduction is deactivated.

Precondition



Procedure

Testing space limits:

The following procedure must be followed exactly! 1. Create a test program in which all positions addressed for checking the space surfaces are taught. 2. Execute test program in T1 mode. When testing a Cartesian monitoring space on a KL, the linear unit must also be moved. It must be ensured that the monitoring space moves with the linear unit and comes to a standstill. Testing the space-specific velocity:

The following procedure must be followed exactly! 1. Create a test program in which the space-specific velocity is deliberately exceeded, either inside or outside the monitoring space, e.g. 180 mm/s configured, moved at 200 mm/s. 2. Execute test program in T2 mode. Death, serious injuries or major damage to property may occur. If a program is executed in test mode T2, the operator must be in a position outside the danger zone. 7.10.4

Testing axis-specific monitoring spaces

(>>> 11.1.9 "Checklist for axis-specific monitoring spaces" Page 185) Description

The configuration of the boundaries and the space-specific velocity must be checked. If “Stop at boundaries” is not configured, an alarm space is used for this. Override reduction is deactivated.

Precondition



Procedure

Testing space limits:

The following procedure must be followed exactly!


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Jog each axis (that is to be monitored) on ce to the upper and lower boundaries of the monitoring space in T1 mode using the jog keys or Space Mouse.

Testing the space-specific velocity:

The following procedure must be followed exactly! 1. Create a test program in which the space-specific velocity is deliberately exceeded, either inside or outside the monitoring space, e.g. 180 mm/s configured, moved at 200 mm/s. 2. Execute test program in T2 mode. Death, serious injuries or major damage to property may occur. If a program is executed in test mode T2, the operator must be in a position outside the danger zone. 7.10.5

Testing the safe operational stop for an axis group

(>>> 11.1.6 "Checklist for safe operational stop for axis groups" Page 180) Forces acting on the robot in the production process may result in a violation of the safe operational stop, e.g. when loading a workpiece into a gripper. To remedy this, the position tolerance for the affected axis must be increased. Precondition



Operating mode T1 The following procedure must be followed exactly!

Procedure

7.11

1. Activate safe operational stop for the axis group. 2. Jog the first axis in the axis group in the positive or negative direction using the jog keys and with a jog override of 1%. A robot stop must be triggered (safety stop 0). 3. Deactivate safe operational stop for the axis group and reactivate it. 4. Repeat steps 2 to 3 to test additional axes of the axis group.

Activating a new safety configuration

Description

If the safety configuration is update d by transferring a project from WorkVisual to the robot controller or by restoring an archive, the safety controller signals that the checksum of the safety configuration is incorrect. The safety maintenance technician must check the new safety configuration on the robot controller and is responsible for ensuring that the correct safety configuration is activated. The displayed checksum must match the expected checksum from the checklist for safety functions. (>>> 11.1.3 "Checklist for safety functions" Page 172) A new safety configuration can also be activated by the safety recovery technician. The safety recovery technician requires the 8-digit activation code of the safety configuration for this. The correct activation code must be communicated by the safety maintenance technician.

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User group “Safety recovery” or “Safety maintenance”

Precondition



Procedure

1. Select Configuration > Safety configuration in the main menu.



The safety configuration checks whether there are any relevant deviations between the robot controller and the safety controller. The Troubleshooting wizard window is opened. 2. A description of the problem and a list of possible causes is displayed. Select the cause from the list, e.g. restoration of an archive. 3. Press Activate to activate the updated safety configuration on the robot controller. 4. Only in the user group “Safety Recovery”: enter the activation code and press Activate again. 7.12

Deactivating safe monitoring

If safe monitoring is deactivated, the configured safety monitoring functions are inactive. Description

The following monitoring functions are part of the standard safety configuration and always active. This means that these monitoring functions remain active when safe monitoring is deactivated:   

Precondition

 

Procedure

1. 2. 3. 4.

Monitoring of the braking time Monitoring of the maximum axis velocity in T1 Monitoring of the axis positions during a global safe operational stop (all axes) User group “Safety maintenance” Operating mode T1 or T2 Open the safety configuration. Press Global parameters. Remove the check mark from Safe monitoring. Click on Save and answer the request for confirmation with Yes. The robot controller is automatically reinitialized.


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8 Interfaces to the higher-level contr...

8

Interfaces to the higher-level controller

t

The robot controller can communicate with the higher-level controller, e.g. a PLC, via the Ethernet safety interface (PROFIsafe or CIP Safety) or via the discrete safety interface for safety options (X13 via Extended SIB).

f

t

The safe I/Os of the Ethernet safety interface are permanently assigned to the safety monitoring functions of SafeOperation: input and output bytes 2 to 7. (Input and output bytes 0 to 1 are assigned to the standard safety functions.) The safe I/Os of the discrete safety interface only offe r a reduced range of signals. If the interface X13 (Extended SIB) is used, the relay outputs of the Standard SIB and Extended SIB must be checked cyclically. The checking instructions are contained in the robot controller operating instructions. Further information about Extended SIB and interface X13 can be found in the operating or assembly instructions for the robot controller and in the Optional Interfaces assembly and operating instructions for the robot controller. 8.1

Safety functions via Ethernet safety interface

Description

The exchange of safety-relevant signals between the controller and the system is carried out via the Ethernet safety interface (e.g. PROFIsafe or CIP Safety). The assignment of the input and output states within the Ethernet safety interface protocol are listed below. In addition, non-safety-oriented information from the safety controller is sent to the non-safe section of the higher-level controller for the purpose of diagnosis and control.

Reserved bits

Reserved safe inputs can be pre-assigned by a PLC with the values 0 or 1. In both cases, the manipulator will move. If a safety function is assigned to a reserved input (e.g. in the case of a software update) and if this input is preset with the value 0, then the manipulator either does not move or comes unexpectedly to a standstill. KUKA recommends pre-assignment of the reserved inputs with 1. If a reserved input has a new safety function assigned to it, and the input is not used by the customer’s PLC, the safety function is not activated. This prevents the safety controller from unexpectedly stopping the manipulator.

Input byte 0

Bit

0 1

Signal

Description

RES

Reserved 1

NHE

The value 1 must be assigned to the input. Input for external Emergency Stop 0 = external E-STOP is active 1 = external E-STOP is not active

2

BS

Operator safety 0 = operator safety is not active, e.g. safety gate o pen 1 = operator safety is active


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Bit

3

Signal

Description

QBS

Acknowledgement of operator safety Precondition for acknowledgment of operator safety is the signal "Operator safety active" set in the BS bit. Note: If the “BS” signal is acknowledged by the system, this must be specified under Hardware options

in the safety configuration. Information is contained in the Operating and Programming Instructions for System Integrators. 0 = operator safety has not been acknowledged

4

SHS1

Edge 0 ->1 = operator safety has been acknowledged Safety STOP 1 (all axes)   

FF (motion enable) is set to 0. Voltage US2 is switched off. AF (drives enable) is set to 0 after 1.5 s.

Cancelation of this function does not require acknowledgement. This function is not permissible for the EMERGENCY STOP function. 0 = safety stop is active 1 = safety stop is not active

5

SHS2

Safety STOP 2 (all axes)  

FF (motion enable) is set to 0. Voltage US2 is switched off.

Cancelation of this function does not require acknowledgement. This function is not permissible for the EMERGENCY STOP function. 0 = safety stop is active 1 = safety stop is not active

6 7

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RES RES

-



Input byte 1

Bit

0

Signal

Description

US2

Supply voltage US2 (signal for switching the second supply voltage, US2, without battery backup) If this output is not used, it should be set to 0. 0 = switch off US2 1 = Switch on US2 Note: Whether and how input US2 is used must be specified under Hardware options in the safety con-

1

SBH

figuration. Information is contained in the Operating and Programming Instructions for System Integrators. Safe operational stop (all axes) Prerequisite: All axes are stationary Cancelation of this function does not require acknowledgement. This function is not permissible for the EMERGENCY STOP function. 0 = safe operational stop is active. 1 = safe operational stop is not active.

2 3 4 5 6 7

RES

Reserved 11

RES

The value 1 must be assigned to the input. Reserved 12

RES


RES


RES


SPA

The value 1 must be assigned to the input. System Powerdown Acknowledge The system confirms that it has received the powerdown signal. A second after the “SP” (System Powerdown) signal has been set by the controller, the requested action is executed, without the need for confirmation from the PLC, and the controller shuts down. 0 = confirmation is not active 1 = confirmation is active


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Output byte 0

Bit

0

Signal

Description

NHL

Local E-STOP (local E-STOP triggered) 0 = local E-STOP is active 1 = local E-STOP is not active

1

AF

Drives enable (the internal safety controller in the KRC has enabled the drives so that they can be switched on) 0 = drives enable is not active (the robot controller

must switch the drives off) 1 = drives enable is active (the robot controller must

2

FF

switch the drives to servo-control) Motion enable (the internal safety controller in the KRC has enabled robot motions) 0 = motion enable is not active (the robot controller

must stop the current motion) 1 = motion enable is active (the robot controller may

3

ZS

trigger a motion) One of the enabling switches is in the center position (enabling in test mode) 0 = enabling is not active 1 = enabling is active

4

PE

The signal “Peri enabled” is set to 1 (active) if the following conditions are met:   

5

AUT

Drives are switched on. Safety controller motion enable signal present. The message “Operator safety open” must not be active.

The manipulator is in AUT or AUT EXT mode. 0 = AUT or AUT EXT mode is not active 1 = AUT or AUT EXT mode is active

6

T1

The manipulator is in Manual Reduced Velocity mode. 0 = T1 mode is not active 1 = T1 mode is active

7

T2

The manipulator is in Manual High Velocity mode. 0 = T2 mode is not active 1 = T2 mode is active

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Output byte 1

Bit

0

Signal

Description

NHE

External E-STOP has been triggered. 0 = external E-STOP is active 1 = external E-STOP is not active

1

BSQ

Operator safety acknowledged 0 = operator safety is not assured 1 = operator safety is assured (input BS = 1 and, if

2

SHS1

configured, input QBS acknowledged) Safety stop 1 (all axes) 0 = Safety stop 1 is not active 1 = Safety stop 1 is active (safe state reached)

3

SHS2

Safety stop 2 (all axes) 0 = Safety stop 2 is not active 1 = Safety stop 2 is active (safe state reached)

4 5 6

RES RES PSA

Reserved 13 Reserved 14 Safety interface active Precondition: An Ethernet interface must be installed on the controller, e.g. PROFINET or Ethernet/IP 0 = safety interface is not active 1 = safety interface is active

7

SP

System Powerdown (controller will be shut down) One second after the SP signal has been set, the PSA output is reset by the robot controller, without confirmation from the PLC, and the controller is shut down. 0 = controller on safety interface is active. 1 = controller will be shut down

8.1.1

SafeOperation via Ethernet safety interface (optional)

Description

The components of the industrial robot move within the limits that have been configured and activated. The actual positions are continuously calculated and monitored against the safety parameters that have been set. The safety controller monitors the industrial robot by means of the safety parameters that have been set. If a component of the industrial robot violates a monitoring limit or a safety parameter, the manipulator and external axes (optional) are stopped. The Ethernet safety interface can be used, for example, to signal a violation of safety monitoring functions. In the case of the KR C4 compact robot controller, safety options such as SafeOperation are only available via the Ethernet safety interface from KSS/VSS 8.3 onwards.

Reserved bits

Reserved safe inputs can be pre-assigned by a PLC with the values 0 or 1. In both cases, the manipulator will move. If a safety function is assigned to a reserved input (e.g. in the case of a software update) and if this input is preset with the value 0, then the manipulator either does not move or comes unexpectedly to a standstill.


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KUKA recommends pre-assignment of the reserved inputs with 1. If a reserved input has a new safety function assigned to it, and the input is not used by the customer’s PLC, the safety function is not activated. This prevents the safety controller from unexpectedly stopping the manipulator. Input byte 2

Bit

Signal

Description

0

JR

Mastering test (input for the reference switch of the mastering test) 0 = reference switch is active (actuated). 1 = reference switch is not active (not actu-

1

VRED

ated). Reduced axis-specific and Cartesian velocity (activation of reduced velocity monitoring) 0 = reduced velocity monitoring is active. 1 = reduced velocity monitoring is not active.

2…7

SBH1 … 6

Safe operational stop for axis group 1 ... 6 Assignment: Bit 2 = axis group 1 … bit 7 = axis group 6 Signal for safe operational stop. The function does not trigger a stop, it only activates the safe standstill monitoring. Cancelation of this function does not require acknowledgement. 0 = safe operational stop is active. 1 = safe operational stop is not active.

Input byte 3

Bit

Signal

Description

0…7

RES

Reserved 25 ... 32 The value 1 must be assigned to the inputs.

Input byte 4

Bit

Signal

Description

0…7

UER1 … 8

Monitoring spaces 1 … 8 Assignment: Bit 0 = monitoring space 1 … bit 7 = monitoring space 8 0 = monitoring space is active. 1 = monitoring space is not active.

Input byte 5

Bit

Signal

Description

0…7

UER9 … 16

Monitoring spaces 9 … 16 Assignment: Bit 0 = monitoring space 9 … bit 7 = monitoring space 16 0 = monitoring space is active. 1 = monitoring space is not active.

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Input byte 6

Bit

Signal

Description

0…7

WZ1 … 8

Tool selection 1 … 8 Assignment: Bit 0 = tool 1 … bit 7 = tool 8 0 = tool is not active. 1 = tool is active.

Exactly one tool must be selected at all times. Input byte 7

Bit

Signal

Description

0…7

WZ9 … 16

Tool selection 9 … 16 Assignment: Bit 0 = tool 9 … bit 7 = tool 16 0 = tool is not active. 1 = tool is active.

Exactly one tool must be selected at all times. Output byte 2

Bit

Signal

Description

0

SO

Safety option active Activation status of the safety option 0 = safety option is not active 1 = safety option is active

1

RR

Manipulator referenced Mastering test display 0 = mastering test required. 1 = mastering test performed successfully.

2

JF

Mastering error Space monitoring is deactivated because at least one axis is not mastered. 0 = mastering error. Space monitoring has been

deactivated. 1 = no error.

3

VRED

Reduced axis-specific and Cartesian velocity (activation status of reduced velocity monitoring) 0 = reduced velocity monitoring is not active. 1 = reduced velocity monitoring is active.

4…7

SBH1 … 4

Activation status of safe operational stop for axis group 1 ... 4 Assignment: Bit 4 = axis group 1 … bit 7 = axis group 4 0 = safe operational stop is not active. 1 = safe operational stop is active.


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Output byte 3

Bit

Signal

Description

0…1

SBH5 … 6

Activation status of safe operational stop for axis group 5 ... 6 Assignment: Bit 0 = axis group 5 … bit 1 = axis group 6 0 = safe operational stop is not active. 1 = safe operational stop is active.

2

SOS

Safe Operation Stop 0 = a safety function has triggered a stop. The

output remains in the “0” state for at least 200 ms. 1 = none of the safety functions has triggered a

stop. Note: The output SOS is available in System

Output byte 4

3…7

RES

Software 8.3 or higher. In System Software 8.2 or lower, bit 2 is a spare bit. Reserved 28 ... 32

Bit

Signal

Description

0…7

MR1 … 8

Alarm space 1 … 8 Assignment: Bit 0 = alarm space 1 (associated monitoring space 1) … bit 7 = alarm space 8 (associated monitoring space 8) 0 = monitoring space is violated. 1 = monitoring space is not violated. Note: An inactive monitoring space is consid-

ered to be violated by default, i.e. in this case the associated safe output MR x has the state “0”. Output byte 5

Bit

Signal

Description

0…7

MR9 … 16

Alarm space 9 … 16 Assignment: Bit 0 = alarm space 9 (associated monitoring space 9) … bit 7 = alarm space 16 (associated monitoring space 16) 0 = monitoring space is violated. 1 = monitoring space is not violated. Note: An inactive monitoring space is consid-

ered to be violated by default, i.e. in this case the associated safe output MR x has the state “0”. Output byte 6

Output byte 7

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Bit

Signal

Description

0…7

RES

Reserved 49 ... 56

Bit

Signal

Description

0…7

RES

Reserved 57 ... 64



8.1.2

Diagnostic signals via Ethernet interface

Description

Some signal states are extended to ensure that they can be detected reliably. In the case of extended signal states, the minimum duration of the extension is specified in square brackets. Values are specified in milliseconds, e.g. [200]. The diagnostic signals available via the Ethernet interface are not safe signals and may only be used for diagnostic purposes.

Output byte 0

Bit

Signal

Description

0

DG

Validity for non-safety-oriented signals and data on this interface 0 = data are not valid 1 = data are valid

1

IFS

Internal error in safety controller 0 = no error 1 = error [200]

2

FF

Motion enable 0 = motion enable not active [200] 1 = motion enable active

3

AF

Drives enable 0 = drives enable not active [200] 1 = drives enable active

4

IBN

Start-up mode Start-up mode enables jogging of the manipulator without a higher-level controller. 0 = Start-up mode is not active. 1 = Start-up mode is active.

5

US2

Peripheral voltage 0 = US2 switched off 1 = US2 switched on

Output byte 1

6…7

RES

Reserved

Bit

Signal

Description

0

SO

Activation status of the safety option 0 = safety option is not active 1 = safety option is active

1

JF

Mastering error (optional) 0 = no error 1 = mastering error, space monitoring deacti-

2

VRED

vated. Reduced velocity (optional) 0 = reduced velocity monitoring is not active. 1 = reduced velocity monitoring is active.


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Bit

Signal

Description

3

VKUE

At least one Cartesian velocity limit exceeded (optional) 0 = no error 1 = velocity exceeded [200]

4

VAUE

At least one axis velocity limit exceeded (optional) 0 = no error 1 = velocity exceeded [200]

5

ZBUE

Cell area exceeded (optional) 0 = no error 1 = cell area exceeded [200]

Output byte 2

6…7

RES

Reserved

Bit

Signal

Description

0

SHS1

Safety stop (all axes) STOP 0 or STOP 1 0 = safety stop is not active. 1 = safety stop is active.

1

ESV

External stop request violated Safe operational stop SBH1, SBH2 or safety stop SHS1, SHS2 violated Braking ramp was not maintained or a monitored axis has moved. 0 = no error 1 = violated

2

SHS2

Safety stop 2 0 = safety stop is not active. 1 = safety stop is active.

3

SBH1

Safe operational stop (axis group 1) (optional) 0 = safe operational stop is not active. 1 = safe operational stop is active.

4

SBH2

Safe operational stop (axis group 2) (optional) 0 = safe operational stop is not active. 1 = safe operational stop is active.

5

WFK

Tool error (no tool) (optional) 0 = no error 1 = no tool selected.

6

WFME

Tool error (more than one tool) (optional) 0 = no error 1 = more than one tool selected.

7

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RES

Reserved



Output byte 3

Bit

Signal

Description

0

JR

Mastering test (optional) 0 = mastering test is not active. 1 = mastering test is active.

1

RSF

Reference switch error (optional) 0 = reference switch OK 1 = reference switch defective [200]

2

JRA

Mastering test request (optional) 0 = mastering test not requested. 1 = mastering test requested.

3

JRF

Mastering test failed (optional) 0 = mastering test OK. 1 = mastering test failed.

4

RS

Reference stop (optional) Reference run is only possible in T1 mode. 0 = no error 1 = reference stop due to impermissible operat-

5

RIA

ing mode Referencing interval (optional) 0 = no reminder 1 = reminder interval expired [200]

Output byte 4

6…7

RES

Reserved

Bit

Signal

Description

0…7

WZNR

Tool number (8-bit word) (optional) 0 = error (see WFK and WFME) 1 = tool 1 2 = tool 2, etc.

Output byte 5

Bit

Signal

Description

0…7

UER1 … 8

Monitoring spaces 1 … 8 (optional) Assignment: Bit 0 = monitoring space 1 … bit 7 = monitoring space 8 0 = monitoring space is not active. 1 = monitoring space is active.

Output byte 6

Bit

Signal

Description

0…7

UER9 … 16

Monitoring spaces 9 … 16 (optional) Assignment: Bit 0 = monitoring space 9 … bit 7 = monitoring space 16 0 = monitoring space is not active. 1 = monitoring space is active.


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Output byte 7

Bit

Signal

Description

0 …7

UERV1 … 8

Stop in the event of a violation of monitoring spaces 1 … 8 (optional) Assignment: Bit 0 = monitoring space 1 … bit 7 = monitoring space 8 0 = monitoring space is not violated, or monitor-

ing space is violated but “Stop at boundaries” has not been configured. 1 = monitoring space is violated and robot stops

with a safety stop [200]. Precondition: “Stop at boundaries” has been configured. Output byte 8

Bit

Signal

Description

0 …7

UERV9 … 16

Stop in the event of a violation of monitoring spaces 9 … 16 (optional) Assignment: Bit 0 = monitoring space 9 … bit 7 = monitoring space 16 0 = monitoring space is not violated, or monitor-

ing space is violated but “Stop at boundaries” has not been configured. 1 = monitoring space is violated and robot stops

with a safety stop [200]. Precondition: “Stop at boundaries” has been configured. 8.2

SafeOperation via interface X13

If interface X13 is used, tool 1 is always active. The tool cannot be activated via a safe input. An automated, safely monitored tool change is thus not possible. Further information about connection to interface X13 and the required safety measures can be found in the Optional Interfaces assembly and operating instructions for the robot controller. Inputs

Some of the inputs can be configured in WorkVisual. By default, the configurable inputs are used to activate the monitoring space UER13 … UER16. Alternatively, these inputs can be configured to activat e the safe operational stop SBH3 … SBH6. It is not permissible to assign an input twice, i.e. to use it simultaneously for activating a monitoring space and a safe operational stop.

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X13 Pin

Signal

Description

1, 2 (A)

VRED

Reduced axis-specific and Cartesian velocity (activation of reduced velocity monitoring)

19, 20 (B)

0 = reduced velocity monitoring is active. 1 = reduced velocity monitoring is not

3, 4 (A)

UER12

21, 22 (B)

active. Monitoring space 12 0 = monitoring space is active. 1 = monitoring space is not active.

5, 6 (A)

UER13

23, 24 (B)

Monitoring space 13 (default) 0 = monitoring space is active. 1 = monitoring space is not active.

SBH3

Safe operational stop (axis group 3) 0 = safe operational stop is active. 1 = safe operational stop is not active.

7, 8 (A)

UER14

25, 26 (B)


SBH4


9, 10 (A)

UER15

27, 28 (B)


SBH5


11, 12 (A)

UER16

29, 30 (B)


SBH6


13, 14 (A)

SBH1

31, 32 (B)


15, 16 (A)

SBH2

33, 34 (B)


The signal for the safe operational stop does not trigger a stop, it o nly activates the safe standstill monitoring. Cancelation of this function does not require acknowledgement.


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Outputs

An inactive monitoring space is considered to be violated by default, i.e. in this case the associated safe output MR x has the state “0”. X13 Pin

Signal

Description

37, 38 (A)

MR1

Alarm space 1 (associated monitoring space 1)

55, 56 (B)

0 = space is violated. 1 = space is not violated.

39, 40 (A)

MR2

57, 58 (B)

Alarm space 2 (associated monitoring space 2) 0 = space is violated. 1 = space is not violated.

41, 42 (A)

MR3

59, 60 (B)


43, 44 (A)

MR4

61, 62 (B)


45, 46 (A)

MR5

63, 64 (B)


47, 48 (A)

MR6

65, 66 (B)


49, 50 (A)

SO

67, 68 (B)

Activation status of the safety option 0 = safety option is not active 1 = safety option is active

51, 52 (A) 69, 70 (B)

RR

Manipulator referenced Mastering test display 0 = mastering test required. 1 = mastering test performed successfully.

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9 Diagnosis

9

Diagnosis

9.1

Displaying safe I/Os

Procedure

9.2

1. Select Diagnosis > Diagnostic monitor in the main menu. 2. Select the Bus process data image [Name of bus/interface] module in the Module box.

Variables for diagnosis

Variable

Description

$SR_ACTIVETOOL

Number of the active safe tool

$SR_AXISSPEED_OK



0: no safe tool or multiple safe tools are selected.



1 … 16: Safe tool 1 … 16 is active.

Reduced axis acceleration exceeded TRUE = axis velocity has not been exceeded. FALSE = axis velocity has been exceeded.

$SR_CARTSPEED_OK

The variable is set to FALSE when the excessive value is detected and then set immediately back to TRUE. Cartesian velocity exceeded TRUE = Cartesian velocity has not been exceeded. FALSE = Cartesian velocity has been exceeded.

$SR_DRIVES_ENABLE

The variable is set to FALSE when the excessive value is detected and then set immediately back to TRUE. Enabling of the drives by the safety controller TRUE = drives are enabled. FALSE = drives are not enabled.

$SR_MOVE_ENABLE

Enabling by the safety controller TRUE = motion enable FALSE = no motion enable

$SR_RANGE_ACTIVE[1]

Activation status of monitoring spaces 1...16

…

TRUE = monitoring space is active.

$SR_RANGE_ACTIVE[16] $SR_RANGE_OK[1]

FALSE = monitoring space is not active.

…

TRUE = monitoring space is not violated.

$SR_RANGE_OK[16]

FALSE = monitoring space has been violated and the robot

Violation of monitoring spaces 1...16

has been stopped. Note: The variable depends on whether a stop has been

$SR_SAFEMON_ACTIVE

configured for the monitoring space in the event of a violation. If no stop is configured, the variable is always TRUE. State of safe monitoring TRUE = monitoring is activated. FALSE = monitoring is not activated.


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Variable

Description

$SR_SAFEOPSTOP_ACTIVE[Ind State of the safe operational stop ex ] TRUE = safe operational stop is activated. FALSE = safe operational stop is not activated.

Index: 

$SR_SAFEOPSTOP_OK

1: state of the global safe operational stop (all axes)

The global operational stop is a standard safety function of the Ethernet safety interface. (Input byte 1, bit 1, safe operational stop)  2 … 7: state of the safe operational stop in relation to axis group 1 … 6 (safe operational stop 1 …safe operational stop 6) Violation of an externally activated operational stop TRUE = no violation FALSE = safe operational stop has been violated.

$SR_SAFEREDSPEED_ACTIVE

State of the monitoring of the reduced velocity TRUE = monitoring is activated. FALSE = monitoring is not activated.

9.3

Outputs for space monitoring

In the following error situations, outputs that signal a space violation likewise switch to the “violated” state (precondition: monitoring space is active.): 





In the case of a Cartesian monitoring space, the Cartesian position is invalid. The Cartesian position is invalid if one of the robot axes has an invalid position. This applies in the following cases:  An axis is unmastered.  An encoder error has occurred. A communication error has occurred.  In the case of an axis-specific monitoring space, the position of one of the monitored axes is invalid. This applies in the following cases:  An axis is unmastered. An encoder error has occurred.   A communication error has occurred. In the case of a Cartesian monitoring space, no tool is selected or several tools are selected simultaneously.

Signal states in error situations:

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Output / variable

Logic state

MR x (safe outputs) UERV x $SR_RANGE_OK[ x ]

0 1 0 (FALSE)


10 Messages

10

Messages

10.1

Information about the messages

The “Messages” chapter contains selected messages. It does not cover all the messages displayed in the message window. 10.2

System messages from module: CrossMeld (KSS)

10.2.1

KSS15016

Message code Message text Message type

  

Effect



Ramp stop Input of active commands (robot motions, program start) is blocked.



Cause: Safe operational stop violated (>>> Page 141)



Possible cause(s)

KSS15016 Ackn.: Stop due to standstill monitoring violation Acknowledgement message

Solution: Acknowledge message (>>> Page 141)

Cause: Safe operational stop violated Description

At least one of the axes monitored for standstill has moved outside the configured position tolerance.

Solution: Acknowledge message Description

The program can be resumed once the message has been acknowledged.

Procedure



An acknowledgeable message can be acknowledged with OK. All acknowledgeable messages can be acknowledged at once with All OK.



10.2.2

KSS15017


Effect

Possible cause(s)

  

KSS15017 Ackn.: The braking ramp of the robot has been violated. Acknowledgement message



Short-circuit braking Input of active commands (robot motions, program start) is blocked.



Cause: Braking ramp for STOP 1 or safe operational stop not main-



tained (>>> Page 142) Solution: Acknowledge message (>>> Page 142)


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Cause: Braking ramp for STOP 1 or safe operational stop not maintained Description

The robot controller has not triggered strong enough braking in the case of a STOP 1 or a safe operational stop.



Procedure






10.2.3

KSS15018


  

Effect






Cause: $SR_VEL_RED is FALSE (>>> Page 142)



Possible cause(s)

KSS15018 Ackn.: Maximum Cartesian velocity in T1 mode exceeded Acknowledgement message

Solution: Change value of the variable (>>> Page 142) 

Cause: $SR_OV_RED set too high (>>> Page 143) Solution: Change value of the variable (>>> Page 143)

Cause: $SR_VEL_RED is FALSE Description

The variable $SR_VEL_RED is used to activate the override reduction for monitored velocities. If override reduction is active, the velocity is automatically reduced so that the lowest currently monitored velocity limit is not exceeded. This override reduction is deactivated if the variable is FALSE. Further information on override reduction is contained in the assembly and operating instructions of the safety option. The procedure for checking the current value of the variable is as follows:

Checking instructions

1. In the main menu, select Display > Variable > Single. The Variable display – Single window opens. 2. Enter the variable name in the Name box and confirm with the Enter key. The current value of the variable is displayed.

Solution: Change value of the variable Precondition Procedure

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


1. In the main menu, select Display > Variable > Single. The Variable display – Single window opens. Issued: 08.06.2016 Version: KST SafeOperation 3.2 V7

10 Messages

2. Enter the variable name in the Name box and confirm with the Enter key. The current value of the variable is displayed. 3. Enter the new value in the New value box. 4. Press the Set value button. The new value is displayed in the Current value box.

Cause: $SR_OV_RED set too high Description

The override reduction for monitored v elocities is activated ($SR_VEL_RED = TRUE), but the value of the variable $SR_OV_RED is set too high. The lower the value of $SR_OV_RED, the more a monitored velocity limit is reduced by the override reduction. Further information on override reduction is contained in the assembly and operating instructions of the safety option. The procedure for checking the value of the variable is as follows:


1. In the main menu, select Display > Variable > Single. The Variable display – Single window opens. 2. Enter the variable name in the Name box and confirm with the Enter key. The current value of the variable is displayed.

Solution: Change value of the variable Precondition Procedure

10.2.4




1. In the main menu, select Display > Variable > Single. The Variable display – Single window opens. 2. Enter the variable name in the Name box and confirm with the Enter key. The current value of the variable is displayed. 3. Enter the new value in the New value box. 4. Press the Set value button. The new value is displayed in the Current value box.

KSS15019


Effect

Possible cause(s)

  

KSS15019 Ackn.: Maximum axis-specific velocity in T1 mode exceeded Acknowledgement message






Cause: Override for T1 too high (>>> Page 143)



Solution: Reduce jog or program override. (>>> Page 144)

Cause: Override for T1 too high Description

The jog override (HOV) was too high for jogging or the program override (POV) was too high for program motion in T1 mode.


143 / 205


Solution: Reduce jog or program override. Procedure 10.2.5

Reduce the jog override or the program override for jogging in T1.



KSS15033


  

Effect

KSS15033 More then one tool activated in the safety controller Status message

Follow-up message



Ramp stop Input of active commands (robot motions, program start) is blocked. KSS15034 (>>> Page 144)

Possible cause(s)



Cause: More then one tool activated in the safety controller

 

(>>> Page 144) Solution: Deactivate invalid tools (>>> Page 144)

Cause: More then one tool activated in the safety controller Description

There is more than one tool activated in the safety controller. Only one safe tool may be active.

Solution: Deactivate invalid tools Procedure

10.2.6

Deactivate invalid tools and activate only the safe tool that is currently being used.



KSS15034


Effect

  

KSS15034 Ackn.: More than one tool activated in the safety controller Acknowledgement message

Original message




Possible cause(s)



Cause: Error cause of the original message has been eliminated.

 

(>>> Page 144) Solution: Acknowledge message (>>> Page 145)

Cause: Error cause of the original message has been eliminated. Description

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This follow-up message is displayed if the error cause of the original message has been eliminated.


10 Messages



Procedure






10.2.7

KSS15035


  

Effect

KSS15035 No tool activated in safety controller Status message

Follow-up message




Possible cause(s)



Cause: No tool activated in safety controller (>>> Page 145)

 

Solution: Activate safe tool (>>> Page 145)

Cause: No tool activated in safety controller Description

There is no tool activated in the safety controller.

Solution: Activate safe tool Procedure

Activate the safe tool that is currently being used.



If KUKA.SafeRangeMonitoring is used, tool 1 must always be activated.

10.2.8

KSS15036


Effect

  

KSS15036 Ackn.: No tool activated in safety controller Acknowledgement message

Original message




Possible cause(s)




 



145 / 205






Procedure






10.2.9

KSS15037


  

Effect



No braking reaction No interlock of motions or commands



Cause: Cell area exceeded (>>> Page 146)



Possible cause(s)

KSS15037 Cell area exceeded Status message

Solution: Move the robot out of the violated space: (>>> Page 146)

Cause: Cell area exceeded Description

The active safe tool has left the cell area. There is a space violation.

Solution: Move the robot out of the violated space: Description

The robot must be moved out of the violated space in T1 mode. No other operating mode can be set until the robot has left the violated space. If the space is violated in T1 mode, the acknowledgement message Ackn.: Stop because workspace exceeded is additionally displayed.


Operating mode T1



1. When the acknowledgement message is displayed, confirm it with OK. 2. Press and hold down the enabling switch. 3. Move the robot out of the violated space:  Using the jog keys (manual mode)  Using the Start and Start backwards keys (program mode)

10.2.10 KSS15039


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  

KSS15039 Ackn.: Maximum global Cartesian velocity exceeded Acknowledgement message


10 Messages

Effect






Cause: Limit value for global maximum Cartesian velocity exceeded



Possible cause(s)

(>>> Page 147) Solution: Change the safety configuration (>>> Page 147) 

Cause: Limit value for global maximum Cartesian velocity exceeded

(>>> Page 147) Solution: Adapt the program in such a way that limit value is not reached (>>> Page 148)

Cause: Limit value for global maximum Cartesian velocity exceeded Description

The limit value defined in the safety configuration for the global maximum Cartesian velocity was exceeded. Possible reasons: 



An incorrect limit value is entered in the safety configuration, e.g. a value other than that specified by the system integrator. The programmed path or programming method causes the limit value to be exceeded.

The procedure for checking which value is configured for the parameter Cartesian maximum velocity is as follows: Checking instructions

1. In the main menu, select Configuration > Safety configuration. The safety configuration opens with the General tab. 2. Press Global parameters. The global parameters are displayed. 3. Search for the parameter and check the value.

Solution: Change the safety configuration Precondition

 

Procedure


1. In the main menu, select Configuration > Safety configuration. The safety configuration opens with the General tab. 2. Select the corresponding tab and modify the configuration as required. 3. Save safety configuration. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Further information on safety acceptance is contained in the assembly and operating instructions of the safety option.

Cause: Limit value for global maximum Cartesian velocity exceeded Description

The limit value defined in the safety configuration for the global maximum Cartesian velocity was exceeded. Possible reasons:


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



The procedure for checking which value is configured for the parameter Cartesian maximum velocity is as follows: Checking instructions


Solution: Adapt the program in such a way that limit value is not reached 10.2.11 KSS15040


  

Effect

KSS15040 Ackn.: Maximum global axis velocity exceeded Acknowledgement message






Cause: Limit value for maximum global axis velocity exceeded



Possible cause(s)

(>>> Page 148) Solution: Change the safety configuration (>>> Page 149) Cause: Limit value for maximum global axis velocity exceeded




Cause: Limit value for maximum global axis velocity exceeded Description

The limit value for the maximum global velocity for rotational axes or the limit value for the maximum global velocity for linear axes defined in the safety configuration was exceeded. Possible reasons: 




The procedure for checking which values are configured for the maximum global axis velocities is as follows: Checking instructions

1. In the main menu, select Configuration > Safety configuration. The safety configuration opens with the General tab. 2. Select the Axis monitoring tab. 3. Check the values of the following parameters: 

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Maximum velocity rotational axis Issued: 08.06.2016 Version: KST SafeOperation 3.2 V7

10 Messages 




 

Procedure


Cause: Limit value for maximum global axis velocity exceeded Description

The limit value for the maximum global velocity for rotational axes or the limit value for the maximum global velocity for linear axes defined in the saf ety configuration was exceeded. Possible reasons: An incorrect limit value is entered in the safety configuration, e.g. a value other than that specified by the system integrator. The programmed path or programming method causes the limit value to be exceeded.





The procedure for checking which values are configured for the maximum global axis velocities is as follows: Checking instructions

1. In the main menu, select Configuration > Safety configuration. The safety configuration opens with the General tab. 2. Select the Axis monitoring tab. 3. Check the values of the following parameters: 

Maximum velocity rotational axis






Effect

  

 

KSS15041 Ackn.: Maximum safe reduced Cartesian velocity exceeded Acknowledgement message



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Possible cause(s)



Cause: Limit value for safe reduced Cartesian velocity exceeded


Cause: Limit value for safe reduced Cartesian velocity exceeded


Cause: Limit value for safe reduced Cartesian velocity exceeded Description

The limit value defined in the global parameters of the safety configuration for the safe reduced Cartesian velocity was exceeded. Possible reasons: 




The procedure for checking which value is configured for the parameter Reduced Cartesian velocity is as follows: Checking instructions



 

Procedure



Cause: Limit value for safe reduced Cartesian velocity exceeded Description

The limit value defined in the global parameters of the safety configuration for the safe reduced Cartesian velocity was exceeded. Possible reasons: 

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An incorrect limit value is entered in the safety configuration, e.g. a value other than that specified by the system integrator.


10 Messages

The programmed path or programming method causes the limit value to be exceeded.



The procedure for checking which value is configured for the parameter Reduced Cartesian velocity is as follows: Checking instructions




  

Effect






Cause: Limit value for safe reduced axis velocity incorrectly configure d



Possible cause(s)

KSS15042 Ackn.: Safe reduced axis velocity exceeded Acknowledgement message


Cause: Limit value for safe reduced axis velocity exceeded by pro-

gramming (>>> Page 152) Solution: Correcting the programming in the SRC file (>>> Page 152)

Cause: Limit value for safe reduced axis velocity incorrectly configured Description

The limit value defined in the safety configuration for the safe reduced Cartesian velocity was exceeded. An incorrect limit value is entered in the safety configuration, e.g. a value other than that specified by the system integrator. The procedure for checking which value is configur ed for the safe reduced velocity is as follows:


1. In the main menu, select Configuration > Safety configuration. The safety configuration opens with the General tab. 2. Select the Axis monitoring tab. 3. Check the value entered for the parameter Reduced velocity.


 

Procedure


1. In the main menu, select Configuration > Safety configuration. The safety configuration opens with the General tab.


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2. Select the corresponding tab and modify the configuration as required. 3. Save safety configuration. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Further information on safety acceptance is contained in the assembly and operating instructions of the safety option.

Cause: Limit value for safe reduced axis velocity exce eded by programming Description

The programmed path or programming method causes the limit value defined in the safety configuration for the safe reduced axis velocity to be exceeded. If an override reduction is activated by $SR_VEL_RED=TRUE, but the robot moves without spline, the axis velocities are not reduced. The override reduction then only has an effect on axis velocities if spline motions are programmed.

Example

Axis 5 is moved into a singularity position. Axes 4 and 6 are therefore considerably accelerated and the safe reduced axis velocity is exceeded.

Fig. 10-1: Wrist axis singularity (α5 position) Solution: Correcting the programming in the SRC file Procedure

Correct the programming in the SRC file



Further information is contained in the documentation for the relevant software.

10.2.14 KSS15043


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 



KSS15043 External safe operational stop violated (axis group {Number of axis group}) Status message


10 Messages

Effect Follow-up message



Short-circuit braking Input of active commands (robot motions, program start) is blocked. KSS15044 (>>> (>>> Page 154) 154)

Possible cause(s)



Cause: Value configured for position tolerance too low (>>> (>>> Page 153) 153)

 

Solution: Change the safety configuration (>>> (>>> Page 153) 153) 

Cause: Axis group incorrectly configured (>>> (>>> Page 153) 153) Solution: Change the safety configuration (>>> (>>> Page 154) 154)

Cause: Value configured for position tolerance too low Description

The value configured in the safety configuration for the position tolerance of at least one axis in the axis group is too low. The values specified by the system builder must be configured. The procedure for checking what values are configured is as follows:


1. In the the mai main n men menu, u, sel selec ectt Configuration > Safety configuration. The safety configuration opens with the General tab. 2. Select the Axis monitoring tab and press Safe operational stop. The Safe operational stop window opens. 3. For each each axis axis in the the axis group, check whether whether the value value entered entered for Position tolerance matches the specified value.


 

Procedure


1. In the the mai main n men menu, u, sel selec ectt Configuration > Safety configuration. The safety configuration opens with the General tab. 2. Select Select the correspon corresponding ding tab and modify modify the configu configuration ration as as required. required. 3. Save Save safet safetyy confi configu gurat ratio ion. n. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Further information on safety acceptance is contained in the assembly and operating instructions of the safety option.

Cause: Axis group incorrectly configured Description

The axis group is incorrectly configured in the safety configuration, i.e. the group contains axes which are not to be monitored here. The axes specified by the system builder must be monitored. The procedure for checking whether an axis is monitored in the correct axis group is as follows:


1. In the the mai main n men menu, u, sel selec ectt Configuration > Safety configuration. The safety configuration opens with the General tab.


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2. Select the the Axis monitoring tab and press Safe operational stop. The Safe operational stop window opens. 3. Select Select the the axis axis that is is to be checke checked d from the the list. list. The check mark must be activated in the check box with the number of the axis group in which the axis is to be monitored. Solution: Change the safety configuration Precondition


 

Procedure

1. In the the main main menu, menu, sele select ct Configuration > Safety configuration. The safety configuration opens with the General tab. 2. Select the correspondi corresponding ng tab and and modify modify the configura configuration tion as required. required. 3. Save Save safe safety ty conf configu igurat ratio ion. n. Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Further information on safety acceptance is contained in the assembly and operating instructions of the safety option.

10.2 10.2.1 .15 5 KSS15 SS1504 044 4

Message code Message text

 

Message type



Effect



KSS15044 Ackn.: External safe operational stop violated (axis group {Number of axis group}) Acknowledgement message

Original message



Short-circuit braking Input of active commands (robot motions, program start) is blocked. KSS15043 (>>> (>>> Page 152) 152)

Possible cause(s)






(>>> Page 154) 154) (>>> Page 154) 154) Solution: Acknowledge message (>>>





Procedure

 

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10 Messages

10.2 10.2.1 .16 6 KSS KSS1504 15045 5


  

Effect

KSS15045 Error at mastering reference switch Status message

Follow-up message



No braking reaction No interlock of motions or commands KSS15046 (>>> (>>> Page 158) 158)

Possible cause(s)



Cause: Reference cable X42 - XS Ref not correctly connected

 

(>>> Page 155) 155) (>>> Page 155) 155) Solution: Connect cable correctly (>>> 

Cause: Reference position taught incorrectly (>>> (>>> Page 156) 156) Solution: Reteach reference position and check accuracy

(>>> Page 156) 156) 

Cause: Reference switch installed incorrectly or moved

(>>> Page 156) 156) Solution: Reinstall or realign reference switch (>>> (>>> Page 156) 156) 

Cause: Reference cable X42 - XS Ref defective (>>> (>>> Page 157) 157) Solution: Exchange reference cable X42 - XS Ref (>>> (>>> Page 158) 158)

Cause: Reference cable X42 - XS Ref not correctly connected Description

The reference switch is connected to interf ace X42 on the robot controller via the reference cable. The procedure for checking whether the reference cable is correctly connected is as follows:

Precondition



 


The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. The power cable is de-energized. Observe the ESD guidelines.

1. Check whether whether the connector connectorss of the cable cable are connected connected firmly firmly enough. enough. 2. Check Check whethe whetherr pins pins are bent bent when when conne connected cted..

Solution: Connect cable correctly Precondition






Connect cable correctly.





Procedure


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Cause: Reference position taught incorrectly Description

The reference position to which the robot moves in the mastering test has been taught incorrectly. This results in single-channel referencing.


1. Move Move to ref refere erence nce pos posititio ion. n. 2. Check whether both proximity proximity switch surfaces surfaces of the reference reference switch switch are actuated by the switching surface (actuating plate or tool).

Solution: Reteach reference position and check accuracy Description

The reference position must be taught in the subprogram that is executed during the mastering test and in the safety configuration. If the reference switch is actuated by the ferromagnetic part of a tool, the accuracy of the newly taught reference position must be checked. The reference position must be taught and checked in accordance with the procedure described in the operating and assembly instructions.

Cause: Reference switch installed incorrectly or moved Description

The taught reference position has been addressed correctly. Single-channel mastering occurs because the reference switch has been installed in an incorrect position or has been moved.


1. Move Move to ref refere erence nce pos posititio ion. n. 2. Check whether both proximity proximity switch surfaces surfaces of the reference reference switch switch are actuated by the switching surface (actuating plate or tool).

Solution: Reinstall or realign reference switch Description

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The reference switch must installed or aligned in such a way that both proximity switch surfaces of the reference switch are actuated simultaneously when the robot is in the reference position.


10 Messages

Fig. 10-2: Installation position of reference switch on external axis

Cause: Reference cable X42 - XS Ref defectiv e Description

The reference switch is connected to interf ace X42 on the robot controller via the reference cable. The procedure for checking whether the reference cable is defective is as follows:

Precondition



 

Inspection instructions


1. Check whether the connectors are correctly connected. Particular attention must be paid to:  Pins pushed in Corrosion   Scorched contacts  Connector insert pushed back Connector on correct slot  2. Check whether the cable is mechanically damaged. Causes of squashed cables or wires can include the following:  Cable straps too tight  Clips too tight Trapped when closing a cover   Bend radius too tight 3. Check whether the cable still conducts electricity. Particular attention must be paid to: Cross-connection of individual wires   Short-circuit of individual wires with the ground conductor  Correct wiring in accordance with circuit diagram


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Solution: Exchange reference cable X42 - XS Ref Description

The reference cable must be exchanged. When routing the cable, avoid mechanical damage and observe the minimum bending radii. The following bending radii serve as guide values:

Precondition

Type of routing

Bending radius






 

Procedure

1. Disconnect and remove the defective reference cable. 2. Route the new reference cable correctly (in a fixed installation or cable carrier). 3. Connect the reference cable. Connect connector X42 to interface X42 on the robot controller and connector XS Ref to the reference switch.

10.2.17 KSS15046


  

Effect

KSS15046 Ackn.: Error at mastering reference switch Acknowledgement message

Original message



No braking reaction No interlock of motions or commands KSS15045 (>>> Page 155)

Possible cause(s)




 






Procedure

 

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10 Messages

10.2.18 KSS15047


Effect

  

 

KSS15047 Mastering test required (internal) Status message


10.2.19 KSS15048


Effect

Possible cause(s)

  

KSS15048 Ackn.: Mastering test time interval expired Acknowledgement message






Cause: Monitoring time elapsed (>>> Page 159)



Solution: Perform mastering test and acknowledge message

(>>> Page 159)

Cause: Monitoring time elapsed Description

Following an internal mastering test request, the robot can be moved for another 2 hours. This time has elapsed. It is possible to acknowledge the message without p erforming a mastering test beforehand. The robot can then be moved for another 2 hours without referenced axes (not recommended). The safety integrity of the safety functions based upon safe axis positions is limited until the mastering test has been performed and confirmed. The safety functions may behave differently from how they were configured, creating additional hazards in the system.

Solution: Perform mastering test and acknowledge message Description

Following a successful mastering test, the message can be acknowledged.

Procedure

1. Perform mastering test. 2. Acknowledge the message with OK.

10.2.20 KSS15049


  

KSS15049 Mastering test failed Status message


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Effect

Possible cause(s)






Cause: Mastering test failed (>>> Page 160)



Solution: Eliminate cause of error and carry out mastering test

(>>> Page 160)

Cause: Mastering test failed Description

The mastering test has failed. The cause of the error is indicated in an additional message.

Solution: Eliminate cause of error and carry out mastering test Description

The error cause specified in the additional message must be eliminated and the mastering test must then be performed again.

10.2.21 KSS15050


Effect

Possible cause(s)

  

KSS15050 Reference stop Status message






Cause: Mastering test not yet performed successfully (>>> Page 160)



Solution: Perform mastering test in T1 mode (>>> Page 160)

Cause: Mastering test not yet performed successfully Description

The mastering test has not yet been performed successfully. The reference stop is triggered by an activated monitoring space for which the option Stop if mastering test not yet done is configured.

Solution: Perform mastering test in T1 mode Description

The mastering test must be performed in T1 mode.

10.2.22 KSS15051


Effect

  

 

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KSS15051 Ackn.: Mastering test position not reached Acknowledgement message



10 Messages

Possible cause(s)



Cause: Mastering test interrupted (>>> Page 161) Solution: Acknowledge message and resume program

(>>> Page 161)

Cause: Mastering test interrupted Description

The mastering test was interrupted before the reference position was reached: Operating mode T1 or T2: The operator released the Start key. AUT EXT mode: The Start signal from the higher-level controller was cancelled.

 

Solution: Acknowledge message and resume program Description


Procedure

1. Acknowledge the message with OK. 2. Operating mode T1 or T2: Press and hold down the Start key to resume the program. AUT EXT mode: Send the Start signal from the higher-level controller to resume the program.

10.2.23 KSS15052


Effect

Possible cause(s)

  

KSS15052 Ackn.: Mastering reference switch not actuated Acknowledgement message






Cause: Reference switch fouled (>>> Page 162)



Solution: Clean the reference switch (>>> Page 162) 

Cause: Reference switch moved (>>> Page 162) Solution: Realign the reference switch (>>> Page 162)



Cause: Actuating plate bent (>>> Page 162) Solution: Realign the actuating plate (>>> Page 162)



Cause: Referencing with incorrectly mastered robot (>>> Page 162) Solution: Restore the mastering or remaster (>>> Page 162)



Cause: Reference switch defective (>>> Page 163) Solution: Exchange the reference switch (>>> Page 163)


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Cause: Reference switch fouled Description

The reference switch was not actuated at the reference position because the proximity switch surfaces of the reference switch are fouled.

Solution: Clean the reference switch Procedure



Clean the proximity switch surfaces of the reference switch. Do not use aggressive cleaning agents.

Cause: Reference switch moved Description

The taught reference position has been addressed correctly, but the reference switch not actuated. The reference switch or the device on which the reference switch is installed has been moved.


1. Move to reference position. 2. Check whether both proximity switch surfaces of the reference switch are actuated by the switching surface (actuating plate or tool).

Solution: Realign the reference switch Description

The reference switch must aligned in such a way that both proximity switch surfaces of the reference switch are actuated simultaneously when the robot is in the reference position.

Cause: Actuating plate bent Description

The taught reference position has been addressed correctly, but the reference switch not actuated. The actuating plate fastened to the robot flange or robot tool was bent.


1. Move to reference position. 2. Check whether both proximity switch surfaces of the reference switch are actuated by the actuating plate.

Solution: Realign the actuating plate Description

The actuating plate must be aligned so that both proximity switch surfaces of the reference switch are actuated simultaneously when the robot is in the reference position.

Cause: Referencing with incorrectly mastered robot Description

The reference switch was not actuated in the reference position. The reference position was not reached because the current mastering deviates from the one used to teach the reference run.

Solution: Restore the mastering or remaster Description

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Restore the mastering with which the reference run was taught or remaster the robot.


10 Messages

Cause: Reference switch defective Description

The taught reference position has been addressed correctly, but the reference switch is defective.

Solution: Exchange the reference switch Description

The reference switch must be exchanged.

Precondition




 

Procedure

1. 2. 3. 4. 5.

Unplug the reference cable. Unscrew the reference switch. Screw on the new reference switch. Plug the reference cable into the new reference switch. Perform a mastering test in order to check whether all reference groups are referenced by the new switch.

10.2.24 KSS15053


  

Effect






Cause: Reference group not taught (>>> Page 163)



Possible cause(s)

KSS15053 Ackn.: Not all mastering reference groups referenced Acknowledgement message

Solution: Teach reference group (>>> Page 164)

Cause: Reference group not taught Description

One of the configured reference groups has not been taught. The following points must be taught for each reference group:  

Motion to the reference switch Reference position The reference position must additionally be taught in the safety configuration.



Motion away from the reference switch

With KSS, the points are taught in the following file: File

Directory

C:\KRC\Roboter\KRC\R1\Program


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File

MasRef_USER.src The file contains 2 subprograms each for reference groups 1 … 3. MASREFSTARTG1() … MASREFSTARTG3() The motion to the reference switch and the reference position are taught here. MASREFBACKG1() … MASREFBACKG3() The motion away from the reference switch is taught here.

With VSS, the points are taught in the following file: File

Directory File

C:\KRC\Roboter\KRC\R1\UPs User-specific subprogram

The procedure for checking which reference groups are configured is as follows: Checking instructions

1. Open the safety configuration: For this, select Configuration > Safety configuration in the main menu. 2. Select the Reference position tab. For each axis, the reference group to which it is assigned is indicated in the Reference group column. It is then possible to check whether the configured reference groups have been taught:


1. Select the file in the Navigator and press Open. The file is displayed in the editor. 2. Check whether the points required for addressing a reference group have been taught.

Solution: Teach reference group Description

The points required for addressing the reference group must be taught. This activity must be carried out in accordance with the procedure de scribed in the assembly and operating instructions.

10.2.25 KSS15054


Effect

Possible cause(s)

  

KSS15054 Workspace monitoring functions deactivated (mastering error) Status message






Cause: Axes unmastered (>>> Page 165)



Solution: Master unmastered axes (>>> Page 165)

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10 Messages

Cause: Axes unmastered Description

At least one axis is unmastered.

Solution: Master unmastered axes Procedure

Remaster all unmastered axes.



10.2.26 KSS15065


  

Effect

KSS15065 Ackn.: Level at mastering reference switch is unexpectedly "low" Acknowledgement message

Original message




Possible cause(s)




 



This follow-up message is displayed if the error cause of t he original message has been eliminated.



Procedure






10.2.27 KSS15066


Effect

  

KSS15066 Level at mastering reference switch is unexpectedly "low" Status message

Follow-up message




Possible cause(s)



Cause: Reference switch fouled (>>> Page 166)

 

Solution: Clean the reference switch (>>> Page 166)


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

Cause: Mastering test input incorrectly configured (>>> Page 166) Solution: Change the safety configuration (>>> Page 166)



Cause: Reference switch installed incorrectly or moved

(>>> Page 167) Solution: Reinstall or realign reference switch (>>> Page 167) 

Cause: Reference switch defective (>>> Page 167) Solution: Exchange the reference switch (>>> Page 167)

Cause: Reference switch fouled Description

The reference switch was actuated for at least 5 minutes outside the mastering test because the proximity switch surfaces of the reference switch are fouled, e.g. with metal dust or weld spatter.

Solution: Clean the reference switch Procedure



Clean the proximity switch surfaces of the reference switch. Do not use aggressive cleaning agents.

Cause: Mastering test input incorrectly configured Description

The reference switch for the mastering test can be connected either to the robot controller via interface X42, or to a higher level safety PLC that is linked to the robot controller using an Ethernet safety interface. The mastering test input must be configured accordingly in the safety configuration. The procedure for checking how the mastering test input is configured is as follows:


1. Open the safety configuration: For this, select Configuration > Safety configuration in the main menu. 2. On the General tab, press Global parameters. 3. Check the parameter Mastering test input:  at cabinet = reference switch is connected to the robot controller.  via bus interface = reference switch is connected via Ethernet interface.


 

Procedure

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1. In the main menu, select Configuration > Safety configuration. The safety configuration opens with the General tab. 2. Select the corresponding tab and modify the configuration as required. 3. Save safety configuration.


10 Messages

Following a change to the safety configuration, safety acceptance must be carried out and documented by means of checklists. Further information on safety acceptance is contained in the assembly and operating instructions of the safety option.

Cause: Reference switch installed incorrectly or moved Description

The reference switch was actuated outside of the mastering test for at least 5 minutes. The reference switch is installed in the wrong position or has been moved.


1. Move to reference position. 2. Check whether both proximity switch surfaces of the reference switch are actuated by the switching surface (actuating plate or tool).

Solution: Reinstall or realign reference switch Description

The reference switch must installed or aligned in such a way that both proximity switch surfaces of the reference switch are actuated simultaneously when the robot is in the reference position.

Fig. 10-3: Installation position of reference switch on external axis

Cause: Reference switch defective Description

The reference switch was actuated outside of the mastering test for at least 5 minutes. The reference switch is defective.

Solution: Exchange the reference switch Description

The reference switch must be exchanged.


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Precondition




 

Procedure

1. 2. 3. 4. 5.

Unplug the reference cable. Unscrew the reference switch. Screw on the new reference switch. Plug the reference cable into the new reference switch. Perform a mastering test in order to check whether all reference groups are referenced by the new switch.

10.2.28 KSS15079


Effect

Possible cause(s)

  

KSS15079 Monitoring space no. {Number of monitoring space} violated Status message






Cause: Monitoring space violated in T1 or T2 (>>> Page 168)




Cause: Monitoring space violated in T1 or T2 Description

The monitoring space has been violated in T1 or T2 mode. The active safe tool, or at least one of the robot axes, is no longer situated in the permissible range of the monitoring space. The monitoring space is considered to have been violated if the monitoring was only activated after the robot had moved over the space limit. The permissible range depends on the type of monitoring space:

Space type

Workspace

Protected space

Cartesian space

The active safe tool must move within the limits of the monitoring space.

The active safe tool must move outside the limits of the monitoring space.

The space is violated if the safe tool leaves the monitoring space. The axes must move within the limits of the monitoring space.

The space is violated if the safe tool enters the monitoring space. The axes must move outside the limits of the monitoring space.

The space is violated if the axes leave the monitoring space.

The space is violated if the axes enter the monitoring space.

Axis space



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10 Messages


Operating mode T1



1. When the acknowledgement message is displayed, confirm it with OK. 2. Press and hold down the enabling switch. 3. Move the robot out of the violated space:  Using the jog keys (manual mode)  Using the Start and Start backwards keys (program mode)

10.2.29 KSS15081


  

Effect






Cause: Monitoring space exceeded in T1 or T2 (>>> Page 169)



Possible cause(s)

KSS15081 Monitoring space no. {Number of monitoring space} exceeded Status message


Cause: Monitoring space exceeded in T1 or T2 Description

The monitoring space has been exceeded in T1 or T2 mode. The active safe tool, or at least one of the robot axes, is no longer situated in the permissible range of the monitoring space. The monitoring space is considered to have been exceeded if the monitoring was already activated when the robot moved over the space limit. The permissible range depends on the type of monitoring space:

Space type

Workspace

Protected space

Cartesian space

The active safe tool must move within the limits of the monitoring space.

The active safe tool must move outside the limits of the monitoring space.

The space is exceeded if the safe tool leaves the monitoring space. The axes must move within the limits of the monitoring space.

The space is exceeded if the safe tool enters the monitoring space. The axes must move outside the limits of the monitoring space.

The space is exceeded if the axes leave the monitoring space.

The space is exceeded if the axes enter the monitoring space.

Axis space






Operating mode T1

1. When the acknowledgement message is displayed, confirm it with OK. 2. Press and hold down the enabling switch.


169 / 205


3. Move the robot out of the violated space: Using the jog keys (manual mode)   Using the Start and Start backwards keys (program mode) 10.2.30 KSS15083

Message code Message text

 

Message type



Effect

 

KSS15083 Ackn.: Cartesian velocity in monitoring space no. {Number of monitoring space} exceeded Acknowledgement message


10.2.31 KSS15127


  

Effect






Cause: Monitoring space violated or exceeded in T1 (>>> Page 170)



Possible cause(s)

KSS15127 Ackn.: Stop because workspace exceeded Acknowledgement message

Solution: Acknowledge the message and move the robot out of the vi-

olated space (>>> Page 170)

Cause: Monitoring space violated or exceeded in T1 Description

The robot has violated or exceeded a monitoring space in T1 mode. A status message additionally indicates the affected space.

Solution: Acknowledge the message and move the robot out of the violated space Description Precondition Procedure

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The robot must be moved out of the violated space in T1 mode. This is only possible once the message has been acknowledged. 

Operating mode T1

1. Acknowledge the message with OK. 2. Press and hold down the enabling switch. 3. Move the robot out of the violated space:  Using the jog keys (manual mode) Using the Start and Start backwards keys (program mode) 


11 Appendix

11

Appendix

11.1

Checklists

The checklists here serve merely as examples of checklists for safety acceptance. It is permissible to carry out and document safety acceptance using user-specific checklists. 11.1.1

Precondition for safety acceptance based on the checklists 

 

Mechanical and electrical installation of the industrial robot have been completed. Safety configuration is completed. Safety maintenance technician is trained (training at KUKA Roboter GmbH)

The system integrator is responsible for the design of the cell. The safety maintenance technician uses the values and configurations supplied by the system integrator to configure the robot and tests whether the safety functions work as specified. The safet y maintenance technician does not perform a safety assessment of the system. 11.1.2

Checklist for robot and system

The inspection points of this checklist must be completed and confirmed in writing by the system builder. Checklist

  

No.

1

2 3 4 5 6 7 8

Serial number of the robot: ____________________ Serial number of the robot controller: ____________________ Name of system builder: ____________________

Inspection point

OK

The industrial robot is in flawless mechanical condition and correctly installed and fastened in accordance with the assembly or operating instructions of the robot. The permissible rated payload of the robot has not been exceeded. There are no foreign bodies or loose parts on the industrial robot. All safety equipment required for the system and robot is correctly installed and operational. The power supply ratings of the industrial robot correspond to the local supply voltage and mains type, and the machine data correspond to these. The connecting cables are correctly connected and the connectors are locked. The ground conductor and the equipotential bonding cable are sufficiently rated and correctly connected. The system meets all the relevant laws, regulations and norms valid for the installation site.


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Remarks / deviations

Place, date Signature By signing, the signatory confirms the correct and complete performance of the safety acceptance test. 11.1.3

Checklist for safety functions

The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. Checklist

     

No.

1 2 3

Serial number of the robot: ____________________ Serial number of the robot controller: ____________________ Time stamp of the safety configuration: ____________________ Checksum of the safety configuration: ____________________ Activation code of the safety configuration: ____________________ Name of safety maintenance technician: ____________________

Inspection item

OK

Not relevant

Safe monitoring is activated. Robot is mastered. The machine data have been checked and are appropriate for the robot used. (>>> 4.8.3.1 "Checking machine data and safety configuration" Page 51)

4

The machine data loaded must match the machine data on the identification plate of the robot. The machine data of the external axes have been correctly entered and checked. Checking instructions: Move each external axis a defined distance by means of a PTP_REL motion, e.g. 90°. Carry out a visual inspection and check whether this distance is covered. In the case of a KL, move the external axis a defined dis tance by means of a PTP_REL motion, e.g. 500 mm. Carry out a visual inspection and additionally monitor the display of the Cartesian actual position to check whether this distance is covered. The local and external safety functions have been checked and are functioning correctly. 

5

(>>> 4.8.3 "Start-up and recommissioning" Page 50)

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11 Appendix

No.

6 7 8

9

10

Inspection item

OK

Not relevant

The reference position has been taught in the mastering test program and in the safety configuration. Was the mastering test successful? Was the brake test successful? Axis A1 Axis A2 Axis A3 Axis A4 Axis A5 Axis A6 External axes Operator safety acknowledgement has been checked and is functioning correctly. (>>> 4.5.4 "“Operator safety” signal" Page 42) Peripheral contactor (US2) has been checked and switches at the right time. Note: Further information about checking the peripheral con-

11

tactor is contained in the “Operating and Programming Instructions for System Integrators”. Have the Cartesian and axis-specific velocities been configured correctly and checked? The corresponding checklists must be completed and confirmed in writing for the Cartesian and axis-specific velocity monitoring functions. (>>> 11.1.4 "Checklist for Cartesian velocity monitoring functions" Page 175)

12

(>>> 11.1.5 "Checklist for axis-specific velocity monitoring functions" Page 176) Has the correct configuration of the safe operational stop been checked by moving all axes? Each axis in an axis group must be tested individually. The corresponding checklist must be completed and confirmed in writing for every axis group.

13

(>>> 11.1.6 "Checklist for safe operational stop for axis groups" Page 180) Has the correct configuration of the cell area been checked by moving to all reachable limits? The corresponding checklist must be completed and confirmed in writing for the cell area. (>>> 11.1.7 "Checklist for cell area" Page 182)


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No.

Inspection item

OK

14

Has the correct configuration of the monitoring spaces used been checked by moving to all reachable limits?

Not relevant

Each space surface of a Cartesian monitoring space must be addressed at 3 different points. The axis of an axis-specific monitoring space must be moved to the upper and lower limits of the space. The corresponding checklist must be completed and confirmed in writing for each monitoring space used. (>>> 11.1.8 "Checklist for Cartesian monitoring spaces" Page 183) (>>> 11.1.9 "Checklist for axis-specific monitoring spaces" Page 185) Monitoring space 1 Monitoring space 2 Monitoring space 3 Monitoring space 4 Monitoring space 5 Monitoring space 6 Monitoring space 7 Monitoring space 8 Monitoring space 9 Monitoring space 10 Monitoring space 11 Monitoring space 12 Monitoring space 13 Monitoring space 14 Monitoring space 15 Monitoring space 16

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11 Appendix

No.

15

Inspection item

OK

Not relevant

Have the safe tools used been configured correctly and checked? At least one monitoring space and one velocity must be checked with each safe tool. The corresponding checklist must be completed and confirmed in writing for each safe tool used.

16 17

(>>> 11.1.10 "Checklist for safe tools" Page 190) Tool 1 Tool 2 Tool 3 Tool 4 Tool 5 Tool 6 Tool 7 Tool 8 Tool 9 Tool 10 Tool 11 Tool 12 Tool 13 Tool 14 Tool 15 Tool 16 The safety configuration has been archived. If an existing safety configuration has been changed: A change log has been created and checked.


: Must be checked by system integrator Place, date Signature By signing, the signatory confirms the correct and complete performance of the safety acceptance test. 11.1.4

Checklist for Cartesian velocity monitoring functions

The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician.


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The Cartesian velocity monitoring functions cannot be tested against a discrete value. It is possible to carry out a test using an exaggerated value in order to check whether velocity monitoring is triggered. Precondition



Checklist

    

Override reduction for the velocity is deactivated: $SR_VEL_RED = FALSE Serial number of the robot: ____________________ Serial number of the robot controller: ____________________ Time stamp of the safety configuration: ____________________ Safe tool used in test: ____________________ Name of safety maintenance technician: ____________________

Specified value: 

Value specified by cell planner, design engineer

Configured value: 

No.

1

2

3

Value entered in the safety configuration

Inspection item

OK

Not relevant

The global maximum Cartesian velocity has been correctly configured and checked. Specified value: __________ mm/s Configured value: __________ mm/s The safe reduced Cartesian velocity has been correctly configured and checked. Specified value: __________ mm/s Configured value: __________ mm/s The safe reduced Cartesian velocity for T1 has been correctly configured and checked. Specified value: __________ mm/s Configured value: __________ mm/s



Checklist for axis-specific velocity monitoring functions

The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician.

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11 Appendix

The trace function (oscilloscope) can be used to determine the axis velocities. Precondition



Checklist

   

Override reduction for the velocity is deactivated: $SR_VEL_RED = FALSE Serial number of the robot: ____________________ Serial number of the robot controller: ____________________ Time stamp of the safety configuration: ____________________ Name of safety maintenance technician: ____________________





Test value: 

Value with which the test was carried out

1. Checking the global maximum axis velocity

It is only necessary to test the global maximum axis velocity if an axis must not exceed a defined velocity. If the global maximum axis velocity is only to limit the minimum axis-specific protected space, no test is required. No.

Axis name

Inspection item

OK

Not relevant

OK

Not relevant

The global maximum axis velocity has been correctly entered and checked using at least one axis. 1 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 2. Checking the reduced axis velocity No.

Axis name

Inspection item

The reduced axis velocity has been correctly configured and checked for each axis. 2.1 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s 2.2

Test value: __________ °/s or mm/s Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s

2.3


2.4

Test value: __________ °/s or mm/s Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s


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No.

2.5

Axis name

Inspection item

OK

Not relevant

Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s

2.6


2.7

Test value: _________ °/s or mm/s Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s

2.8


2.9

Test value: ________ °/s or mm/s Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s

2.10


2.11


2.12


2.13


2.14


2.15


2.16

Test value: __________ °/s or mm/s Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s 3. Checking the maximum axis velocity for T1

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11 Appendix

No.

Axis name

Inspection item

OK

Not relevant

The maximum axis velocity for T1 has been correctly configured and checked for each axis. 3.1 Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s 3.2


3.3


3.4


3.5


3.6


3.7

Test value: _________ °/s or mm/s Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s

3.8


3.9


3.10


3.11


3.12


3.13

Test value: __________ °/s or mm/s Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: ________ °/s or mm/s


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No.

Axis name

Inspection item

3.14

OK

Not relevant

Specified value: ________ °/s or mm/s Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s Specified value: ________ °/s or mm/s

3.15

Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s Specified value: ________ °/s or mm/s

3.16

Configured value: ________ °/s or mm/s Test value: __________ °/s or mm/s Remarks / deviations


Checklist for safe operational stop for axis groups

The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. A separate checklist must be completed for each axis group.

Precondition



Checklist

    

Operating mode T1 Serial number of the robot: ____________________ Serial number of the robot controller: ____________________ Time stamp of the safety configuration: ____________________ Axis group number: ____________________ Name of safety maintenance technician: ____________________




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11 Appendix

No.

1

2

3

4

5

6

7

8

Axis name

Inspection item

OK

Not relevant

1st axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 2nd axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 3rd axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 4th axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 5th axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 6th axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 7th axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm 8th axis of the axis group has been correctly configured and checked. Position tolerance (specified value): __________ ° or mm Position tolerance (configured value): __________ ° or mm


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Checklist for cell area

The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. The accessible surfaces resulting from the configuration must be violated one after the other, each at 2 different points, to demonstrate the correct configuration of the cell area. Precondition





Checklist

    

No.

1

The monitoring spaces that can be activated by means of safe inputs have been deactivated. Override reduction for monitoring spaces is deactivated: $SR_WORKSPACE_RED = FALSE Serial number of the robot: ________________ Serial number of the robot controller: ____________________ Time stamp of the safety configuration: ________________ Safe tool used in test: ________________ Name of safety maintenance technician: ____________________

Inspection item

OK

Not relevant

The limit in the Z direction has been configured correctly and checked. Z min: ____________mm

2

Z max: ____________mm Corner 1 has been correctly configured and checked. X coordinate: __________ mm

3

Y coordinate: __________ mm Corner 2 has been correctly configured and checked. X coordinate: __________ mm

4

Y coordinate: __________ mm Corner 3 has been correctly configured and checked. Y coordinate: __________ mm X coordinate: __________ mm

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11 Appendix

No.

5

Inspection item

OK

Not relevant

Corner 4 has been correctly configured and checked. Y coordinate: __________ mm

6

X coordinate: __________ mm Corner 5 has been correctly configured. X coordinate: __________ mm

7

Y coordinate: __________ mm Corner 6 has been correctly configured and checked. Y coordinate: __________ mm

8

X coordinate: __________ mm Corner 7 has been correctly configured and checked. X coordinate: __________ mm

9

Y coordinate: __________ mm Corner 8 has been correctly configured and checked. Y coordinate: __________ mm

10

X coordinate: __________ mm Corner 9 has been correctly configured and checked. X coordinate: __________ mm

11

Y coordinate: __________ mm Corner 10 has been correctly configured and checked. X coordinate: __________ mm Y coordinate: __________ mm



Checklist for Cartesian monitoring spaces

The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. A separate checklist must be completed for each monitoring space.


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The accessible surfaces resulting from the configuration must be violated one after the other, each at 3 different points, to demonstrate the correct configuration of the monitoring space. Precondition

 



Checklist

         

  

No.

1

The monitoring space to be checked is activated. The monitoring spaces that can be activated by means of safe inputs have been deactivated. Override reduction is deactivated:  $SR_WORKSPACE_RED = FALSE  $SR_VEL_RED = FALSE Serial number of the robot: ____________________ Serial number of the robot controller: ____________________ Time stamp of the safety configuration: ____________________ Monitoring space checked (name, number): __________ Type of space (protected space or workspace): ____________________ Stop at boundaries (TRUE|FALSE): __________ Reference stop (TRUE|FALSE): __________ Space-specific velocity __________mm/s Space-specific velocity valid in: __________ Safe tool used in test of velocity or space limit: _________________ Always active (TRUE|FALSE): __________ Reference coordinate system: _____________ Name of safety maintenance technician: ____________________

Inspection item

OK

Not relevant

The coordinates of the monitoring space have been correctly configured and checked. Origin X: __________ mm Origin Y: __________ mm Origin Z: __________ mm Origin A: __________ ° Origin B: __________ ° Origin C: __________ ° Distance to origin XMin: __________ mm Distance to origin YMin: __________ mm Distance to origin ZMin: __________ mm Distance to origin XMax: __________ mm Distance to origin YMax: __________ mm Distance to origin ZMax: __________ mm The following preconditions must be met to demonstrate the correct functioning of the reference stop:   

No.

2

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Reference stop is active. Mastering test is requested. Monitored monitoring space is activated.

Inspection item

OK

Not relevant

The correct functioning of the reference stop has been checked. Issued: 08.06.2016 Version: KST SafeOperation 3.2 V7

11 Appendix

The following preconditions must be met to demonstrate the correct functioning of the space-specific velocity:  

  

Space-specific velocity is active. The configured limit value of the space-specific velocity is less than the limit value of the maximum Cartesian velocity. Checked monitoring space is activated. Robot exceeds the configured space-specific velocity. Override reduction for the velocity is deactivated: $SR_VEL_RED = FALSE




No.

3


Inspection item

OK

Not relevant

The space-specific velocity has been correctly configured and checked. Specified value: __________ mm/s Configured value: __________ mm/s



Checklist for axis-specific monitoring spaces

The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. A separate checklist must be completed for each monitoring space.

The configured limit values must successively be violated to demonstrate the correct functioning of the monitoring space. Precondition

 



The monitoring space to be checked is activated. The monitoring spaces that can be activated by means of safe inputs have been deactivated. Override reduction is deactivated: $SR_WORKSPACE_RED = FALSE 


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Checklist

         

 

$SR_VEL_RED = FALSE

Serial number of the robot: ____________________ Serial number of the robot controller: ____________________ Time stamp of the safety configuration: ____________________ Monitoring space checked (name, number): _________________ Type of space (protected space or workspace): ____________________ Stop at boundaries (TRUE|FALSE):_________________ Reference stop (TRUE|FALSE): _________________ Space-specific velocity _________________ mm/s Space-specific velocity valid in: _________________ Safe tool used in test of velocity or space limit: _________________ Always active (TRUE|FALSE): _________________ Name of safety maintenance technician: ____________________





Determined value: 

No.

1

Axis name

Value determined during the test Inspection item

OK

Not relevant

1st axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm Upper limit (determined value): __________ ° or mm

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11 Appendix

No.

2

Axis name

Inspection item

OK

Not relevant

2nd axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm

3

Upper limit (determined value): __________ ° or mm 3rd axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm

4

Upper limit (determined value): __________ ° or mm 4th axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm Upper limit (determined value): __________ ° or mm


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No.

5

Axis name

Inspection item

OK

Not relevant

5th axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm

6

Upper limit (determined value): __________ ° or mm 6th axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm

7

Upper limit (determined value): __________ ° or mm 7th axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm Upper limit (determined value): __________ ° or mm

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11 Appendix

No.

Axis name

Inspection item

8

OK

Not relevant

8th axis of the monitoring space has been correctly configured and checked. Lower limit (specified value): __________ ° or mm Lower limit (configured value): __________ ° or mm Lower limit (determined value): __________ ° or mm Upper limit (specified value): __________ ° or mm Upper limit (configured value): __________ ° or mm Upper limit (determined value): __________ ° or mm The following preconditions must be met to demonstrate the correct functioning of the reference stop:   

No.

9

Reference stop is active. Mastering test is requested. Monitored monitoring space is activated.

Inspection item

OK

Not relevant

The The cor corre rect ct func functition onin ing g of of the the refe refere renc nce e sto stop p has has been been checked. The following preconditions must be met to demonstrate the correct functioning of the space-specific velocity:  

  

Space-specific velocity is active. The configured limit value of the space-specific velocity is less than the limit value of the maximum Cartesian velocity. Checked monitoring space is activated. Robot exceeds the configured space-specific velocity. Override reduction for the velocity is deactivated: $SR_VEL_RED = FALSE

No.

Inspection item

10

The The spac spacee-sp spec ecifific ic veloci velocity ty has has bee been n corre correct ctly ly confi configu gured red and checked. Specified value: __________ mm/s

OK

Not relevant

Configured value: __________ mm/s Remarks / deviations

: Must be checked by system integrator


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Place, date Signature By signing, the signatory confirms the correct and complete performance of the safety acceptance test. 11.1. 11.1.10 10 Chec Checkl klis istt for saf safe e tool tools s

The inspection items of this checklist must be completed and confirmed in writing by the safety maintenance technician. A separate checklist must be completed for each safe tool.

A monitoring space must be violated by each configured sphere to demonstrate the correct functioning of the safe tool. Checklist

    



Serial number of the robot: _________________ Serial number of the robot controller: ____________________ Time stamp of the safety configuration: _________________ Safe tool checked (name, number): _______________ Monitoring space used in sphere test (name, number): ________________ Name of safety maintenance technician: ____________________




No.

1


Inspection item

OK

Not relevant

Safe TCP of the tool The X, Y and Z coordinates of the safe TCP are correctly configured and checked. TCP X (specified value): __________ mm TCP X (configured value): __________ mm TCP Y (specified value): __________ mm TCP Y (configured value): __________ mm TCP Z (specified value): __________ mm TCP Z (configured value): __________ mm

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11 Appendix

No.

2

Inspection item

OK

Not relevant

1st sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm

3

Radius (configured value): __________ mm 2nd sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm

4

Radius (configured value): __________ mm 3rd sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm

5

Radius (configured value): __________ mm 4th sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm


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No.

6

Inspection item

OK

Not relevant

5th sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm

7

Radius (configured value): __________ mm 6th sphere on tool The X, Y and Z coordinates of the sphere center point and the sphere radius are correctly configured and checked. X (specified value): __________ mm X (configured value): __________ mm Y (specified value): __________ mm Y (configured value): __________ mm Z (specified value): __________ mm Z (configured value): __________ mm Radius (specified value): __________ mm Radius (configured value): __________ mm


: Must be checked by system integrator Place, date Signature By signing, the signatory confirms the correct and complete performance of the safety acceptance test. 11. 11.2

Applied ied no norms rms an and dir direc ecttives

The safety functions of KUKA.SafeOperation meet the requirements of Category 3 and Performance Level d in accordance with EN ISO 13849-1:2008.

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12 KUKA Service

12

KUKA Service

12.1

Requesting support

Introduction

This documentation provides information on operation and operator control, and provides assistance with troubleshooting. For further assistance, please contact your local KUKA subsidiary.

Information

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



12.2

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 relevant in many cases:  Model and serial number of the kinematic system, e.g. the manipulator  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 modifications Diagnostic package KRCDiag  Additionally for KUKA Sunrise: Existing projects including applications For versions of KUKA System Software older than V8: Archive of the software (KRCDiag is not yet available here.) Application used   External axes used

KUKA Customer Support

Availability

KUKA Customer Support is available in many co untries. Please do not hesitate to contact us if you have any questions.

Argentina

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

Australia

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


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Belgium

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

Brazil

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

Chile

Robotec S.A. (Agency) Santiago de Chile Chile Tel. +56 2 331-5951 Fax +56 2 331-5952 [email protected] www.robotec.cl

China

KUKA Robotics China Co., Ltd. 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

Germany

KUKA Roboter GmbH Zugspitzstr. 140 86165 Augsburg Germany Tel. +49 821 797-1926 Fax +49 821 797-41 1926 [email protected] www.kuka-roboter.de


12 KUKA Service

France

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

India

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

Italy

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

Japan

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

Canada

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


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Korea

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

Malaysia

KUKA Robot Automation (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]

Mexico

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

Norway

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

Austria

KUKA Roboter CEE GmbH Gruberstraße 2-4 4020 Linz Austria Tel. +43 7 32 78 47 52 Fax +43 7 32 79 38 80 [email protected] www.kuka.at


12 KUKA Service

Poland

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

Portugal

KUKA 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 Robotics RUS Werbnaja ul. 8A 107143 Moskau Russia Tel. +7 495 781-31-20 Fax +7 495 781-31-19 [email protected] www.kuka-robotics.ru

Sweden

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

Switzerland

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


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Spain

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

South Africa

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

Taiwan

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

Thailand

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

Czech Republic

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


12 KUKA Service

Hungary

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

USA

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

UK

KUKA Robotics UK Ltd Great Western Street Wednesbury West Midlands WS10 7LL UK Tel. +44 121 505 9970 Fax +44 121 505 6589 [email protected] www.kuka-robotics.co.uk


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Index

Index Symbols

$BRAKES_OK 109 $BRAKETEST_MONTIME 109 $BRAKETEST_REQ_EX 109 $BRAKETEST_REQ_INT 109 $BRAKETEST_WARN 109 $BRAKETEST_WORK 109 $MASTERINGTEST_ACTIVE 100 $MASTERINGTEST_GROUP 100 $MASTERINGTEST_REQ_EXT 100 $MASTERINGTEST_REQ_INT 100 $MASTERINGTEST_SWITCH_OK 100 $ROBROOT, special cases 18 $SR_ACTIVETOOL 139 $SR_AXISSPEED_OK 139 $SR_CARTSPEED_OK 139 $SR_DRIVES_ENABLE 139 $SR_MOVE_ENABLE 139 $SR_OV_RED 114, 117 $SR_RANGE_ACTIVE 139 $SR_RANGE_OK 139 $SR_SAFEMON_ACTIVE 139 $SR_SAFEOPSTOP_ACTIVE 140 $SR_SAFEOPSTOP_OK 140 $SR_SAFEREDSPEED_ACTIVE 140 $SR_VEL_RED 114, 117, 118 $SR_WORKSPACE_RED 114, 117, 118

Axis velocity, maximum in T1 27, 89, 119 Axis velocity, reduced 27, 89, 119 Axis-specific monitoring spaces, defining 84 Axis-specific monitoring spaces, testing 121 Axis-specific protected spaces 23 Axis-specific velocity limits, testing 119 Axis-specific velocity monitoring, defining 87 Axis-specific workspaces 22 B

BASE coordinate system 16 Brake defect 49 Brake release device 47 Brake test 14, 65, 106 Brake test cycle time 106 Brake test, function test 113 Brake test, programs 107 Brake test, signals 108, 110 Brake test, teaching positions 111 Brake, defective 112 BrakeTestBack.SRC 108, 111 BrakeTestPark.SRC 108, 111 BrakeTestReq.SRC 108, 112 BrakeTestSelfTest.SRC 108, 113 BrakeTestStart.SRC 108, 111 Braking distance 10, 36 Braking time 89 Buttons, overview 63

Numbers

2006/42/EC 58 2014/30/EU 58 2014/68/EC 58 95/16/EC 58 97/23/EC 58 A

Accessories 35 Activating a new safety configuration 122 Activation code, safety configuration 64 Activation, monitoring space 80, 85 Activation, reference stop 81, 86 Actuating plate, hole pattern 33 Actuating plate, installation 101 Alarm space 10 Ambient temperature, reference switch 31 ANSI/RIA R.15.06-2012 58 Appendix 171 Applied norms and regulations 57 Areas of application 13 Automatic mode 55 Axis angle, lower limit 87 Axis angle, upper limit 87 Axis limit 10, 22, 23 Axis range 10, 22, 23, 36 Axis range limitation 46 Axis range monitoring 46 Axis velocity, maximum 27, 89 Axis velocity, maximum global 119 Issued: 08.06.2016 Version: KST SafeOperation 3.2 V7

C

Cable lengths, reference switch module 28 Cartesian monitoring spaces, defining 79 Cartesian monitoring spaces, testing 120 Cartesian protected spaces 21 Cartesian velocity limits, testing 119 Cartesian velocity, maximum 76, 119 Cartesian velocity, reduced 77, 119 Cartesian velocity, reduced for T1 77, 119 Cartesian workspaces 20 CE mark 36 Cell area 12, 15, 19, 20 Cell area, defining 77 Change log 65 Checking the reference position 105 Checklists 171 Checksum, brake test configuration 65 Checksum, safety configuration 64 CIP Safety 10, 14, 61 Circuit diagram, reference switch 33 CK 10, 13 Cleaning work 55 Compatibility 61 Components 14 Configuration 69 Configuration, overview 70 Connecting cables 35 Connecting cables, overview 29 Connecting, reference switch 102 201 / 205


Connector pin assignment, reference cable X42XS Ref 32 Coordinate systems 16 Coordinate systems, angles 17 Coordinate systems, orientation 17 Counterbalancing system 56 D

Danger zone 10, 37 Declaration of conformity 36 Declaration of incorporation 35, 36 Decommissioning 56 Diagnosis 139 Diagnostic monitor (menu item) 139 Diagnostic signals via Ethernet interface 133 Directives 192 Discrete safety interface, for safety options 14 Displaying machine data 65 Displaying, change log 65 Disposal 56 Documentation, industrial robot 9

Hole pattern, actuating plate 33 Hole pattern, reference switch 32 Hysteresis, reference switch 31 I

I/Os, interface X13 136 Industrial robot 35 Installation 61 Intended use 35 Interface, X13 136 Interface, X13 14 Interfaces 125 Introduction 9 J

Jog mode 45, 48 K

KL 10 Knowledge, required 9 KUKA Customer Support 193 KUKA smartPAD 37

E

EC declaration of conformity 36 Electromagnetic compatibility (EMC) 59 EMC conformity, reference switch 31 EMC Directive 36, 58 EMERGENCY STOP device 43, 44, 48 EMERGENCY STOP, external 44, 51 EMERGENCY STOP, local 51 EN 60204-1 + A1 59 EN 61000-6-2 59 EN 61000-6-4 + A1 59 EN 614-1 + A1 58 EN ISO 10218-1 58 EN ISO 12100 58 EN ISO 13849-1 58 EN ISO 13849-2 58 EN ISO 13850 58 Enabling device 44, 48 Enabling device, external 45 Enabling switches 44 Ethernet interface 10, 11, 133 EtherNet/IP 10, 14, 61 Extended SIB 14 External axes 35, 38 F

Faults 49 FLANGE coordinate system 17 Function test 50 Functional principle 13 Functions, SafeOperation 13

L

Labeling 47 Liability 35 Linear unit 35 Low Voltage Directive 36 M

Machine data 51, 64, 65 Machinery Directive 36, 58 Maintenance 55 Manipulator 35, 37 Manual mode 54 Mastering position, reference position 97 Mastering test 10, 98 Mastering test input 76 Mastering test, performing manually 105 Mastering test, programs 99 Mastering test, teaching positions 103 Mastering test, variables 100 Mechanical axis range limitation 46 Mechanical end stops 46 Messages 141 Monitoring space 12 Monitoring space, axis-specific 84 Monitoring space, Cartesian 79 Monitoring spaces 14 Monitoring time 10, 98 Monitoring, physical safeguards 42 Monitoring, velocity 45 N

G

Norms 192

General safety measures 48 Global parameters, defining 75

O

H

Hardware 14, 61 Hazardous substances 56 202 / 205

Operating current, reference switch 31 Operating voltage, reference switch 31 Operation 63 Operator 39 Issued: 08.06.2016 Version: KST SafeOperation 3.2 V7

Index

Operator safety 40, 42, 48 Options 35 Outputs, reference switch 31 Overload 49 Override reduction 113 Override reduction, spline 115 Override reduction, variables 117 Overview, buttons 63 Overview, SafeOperation 13 Overview, safety acceptance 117 P

Panic position 44 Performance Level 40 Performing a manual brake test 112 Peripheral contactor 53 Permissible load current, reference switch 31 Permissible switching distance, reference switch 31 Permissible switching frequency, reference switch 31 Personnel 38 Plant integrator 38 Polygon, convex 10, 15, 19 Position tolerance 93 Positioner 35 Pressure Equipment Directive 56, 58 Preventive maintenance work 55 Product description 13 PROFINET 11, 14, 61 PROFIsafe 11, 14, 61 Protected space 11, 15, 21, 23 Protection rating 31 Protective equipment 45 Pulse duration, reference switch 31 Pulse duty factor, reference switch 31 R

Radius, tool sphere 72 Reaction distance 10, 36 Recommissioning 50 Reference cable X42-XS Ref, connector pin assignment 32 Reference group 11, 97, 98 Reference position 11, 98 Reference position, axis angle 97 Reference position, Cartesian 97 Reference position, defining 95 Reference position, selecting 101 Reference stop 11, 25 Reference switch 11 Reference switch module 28 Reference switch, connecting 102 Reference switch, installation 101 Reference switch, technical data 31 Reference system 78, 82 Release device 47 Repair 55 Robot controller 35 ROBROOT coordinate system 16


S

Safe I/Os, displaying 139 Safe monitoring 76 Safe monitoring, activating 75 Safe monitoring, deactivating 123 Safe operational stop 12, 28, 37, 45 Safe operational stop, axis group 1 to 6 93 Safe operational stop, defining 91 Safe operational stop, testing 122 Safe robot retraction 68 Safe TCP 26 Safe tools 12, 26 Safe tools, defining 93 Safeguards, external 47 SafeOperation via Ethernet safety interface 129 SafeOperation, overview 13 Safety 35 Safety acceptance, overview 117 Safety acceptance, precondition 171 Safety configuration, displaying information 64 Safety configuration, export 67 Safety configuration, import 65 Safety configuration, new, activating 122 Safety configuration, opening 63 Safety configuration, saving 97 Safety controller 41 Safety functions 40, 48 Safety functions, Ethernet safety interface 125 Safety functions, overview 40 Safety functions, test 118 Safety instructions 9, 69 Safety of machinery 58, 59 Safety options 37 Safety STOP 0 11, 37 Safety STOP 1 11, 37 Safety STOP 2 12, 37 Safety STOP 0 37 Safety STOP 1 37 Safety STOP 2 37 Safety stop, external 45 Safety zone 37, 39 Safety, general 35 Selecting the operating mode 40, 41 Serial number, robot 64 Service life 31, 37 Service, KUKA Roboter GmbH 193 SIB 11 Signals, brake test 108 Signals,brake test 110 Simulation 54 Single point of control 56 smartPAD 37, 49 Software 14, 35, 61 Software limit switches 46, 48 Space dimensions 82 Space type 80, 85 Space-specific velocity 25, 80, 81, 85, 86 Special cases, $ROBROOT 18 Sphere, radius 72 Spline, override reduction 115 SPOC 56 203 / 205


Standstill monitoring 28, 93 Start-up 50, 69 Start-up mode 53, 69 Start-up, overview 70 STOP 0 36, 38 STOP 1 36, 38 STOP 2 36, 38 Stop at boundaries 80, 85 Stop category 0 38 Stop category 1 38 Stop category 2 38 Stop reactions 16, 27, 40 Stopping distance 10, 15, 36, 39 Storage 56 Support request 193 Switching function, reference switch 31 System integrator 36, 38, 39 System requirements 61 System variables 100, 117, 139

X

XML export 67 XML import 65

T

T1 38 T2 38 Target group 9 Teach pendant 35 Technical data 31 Technical data, reference switch 31 Terms used 10 Terms used, safety 36 Time stamp, machine data 64 Time stamp, safety configuration 64 TOOL coordinate system 16 Tool sphere, radius 72 Training 9 Transportation 50 Turn-tilt table 35 Type of monitoring space 80, 85 U

Uninstallation, SafeOperation 62 Update, SafeOperation 61 US2 53 Use, contrary to intended use 35 Use, improper 35 User 37, 38 User groups 63 V

Velocity monitoring 45 Velocity monitoring functions 27 Velocity monitoring, axis-specific 87 Velocity, space-specific 25 Version, safety configuration 64 Version, safety option 64 W

Warnings 9 Working range limitation 46 Workspace 10, 15, 20, 22, 36, 39 WORLD coordinate system 16

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KST SafeOperation 32 En

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