Kuka KUKA.PLC mxAutomation Logix 1.0 User manual

KUKA System Technology
KUKA.PLC mxAutomation Logix 1.0
For KUKA System Software 8.2
KUKA Roboter GmbH
Issued: 13.08.2012
Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)

KUKA.PLC mxAutomation Logix 1.0
2 / 123 Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
© Copyright 2012
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
Publication: Pub KST PLC mxAutomation Logix 1.0 (PDF) en
Bookstructure: KST PLC mxAutomation Logix 1.0 V1.1
Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)

3 / 123Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
Contents
1 Introduction .................................................................................................. 7
1.1 Target group .............................................................................................................. 7
1.2 Industrial robot documentation ................................................................................... 7
1.3 Representation of warnings and notes ...................................................................... 7
1.4 Terms used ................................................................................................................ 8
1.5 Trademarks ................................................................................................................ 8
2 Product description ..................................................................................... 9
2.1 KUKA.PLC mxAutomation Logix – overview ............................................................. 9
2.2 Intended use .............................................................................................................. 9
3 Safety ............................................................................................................ 11
4 Installation ................................................................................................... 13
4.1 System requirements ................................................................................................. 13
4.2 Installing or updating KUKA.PLC mxAutomation Logix ............................................. 13
4.3 Uninstalling KUKA.PLC mxAutomation Logix ............................................................ 14
5Operation...................................................................................................... 15
5.1 Menus ........................................................................................................................ 15
5.2 Status keys ................................................................................................................ 15
6 Start-up and configuration ......................................................................... 17
6.1 Start-up and configuration – overview ....................................................................... 17
6.2 Configuring message generation on an external system ........................................... 17
7 Programming ............................................................................................... 21
7.1 Overview of function blocks ....................................................................................... 21
7.2 Frequently used input/output signals in the function blocks ....................................... 23
7.2.1 Input/output signal KRC_AxisGroupRefArr (memory) .......................................... 23
7.2.2 Input signals .......................................................................................................... 23
7.2.3 Output signals ....................................................................................................... 23
7.2.4 Signal sequence for execution of ExecuteCmd .................................................... 24
7.3 Structures for motion programming (STRUCT) ......................................................... 25
7.4 Integer variables ........................................................................................................ 27
7.5 Programming tips for KUKA.PLC mxAutomation ....................................................... 28
7.5.1 Programming example (template MxA_Rockwell_Sample.ACD) ......................... 29
7.6 Administrative functions ............................................................................................. 30
7.6.1 Reading PLC-specific communication into a non-PLC-specific structure ............. 30
7.6.2 Writing a non-PLC-specific structure into PLC-specific communication ............... 31
7.6.3 Initializing the mxA interface ................................................................................. 32
7.6.4 Setting the program override (POV) ..................................................................... 33
7.6.5 Activating and reading Automatic External signals from the robot controller ........ 34
7.6.6 Reading the current robot position ........................................................................ 36
7.6.7 Reading the current axis position ......................................................................... 37
7.6.8 Reading the current path velocity ......................................................................... 37
7.6.9 Reading the current axis velocity .......................................................................... 38
7.6.10 Reading the current robot acceleration ................................................................. 39
7.6.11 Reading a digital input .......................................................................................... 40
Contents

4 / 123 Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
KUKA.PLC mxAutomation Logix 1.0
7.6.12 Reading a digital output ........................................................................................ 40
7.6.13 Writing a digital output .......................................................................................... 41
7.6.14 Reading an analog input ...................................................................................... 42
7.6.15 Reading an analog output .................................................................................... 43
7.6.16 Writing an analog output ...................................................................................... 44
7.6.17 Wait statement (read digital input) ........................................................................ 45
7.6.18 Selecting the tool, base and interpolation mode ................................................... 46
7.6.19 Reading TOOL data ............................................................................................. 47
7.6.20 Writing TOOL data ................................................................................................ 48
7.6.21 Reading BASE data ............................................................................................. 49
7.6.22 Writing BASE data ................................................................................................ 50
7.6.23 Reading the load data .......................................................................................... 51
7.6.24 Writing load data .................................................................................................. 52
7.6.25 Reading the software limit switches of the robot axes .......................................... 54
7.6.26 Reading the software limit switches of the external axes ..................................... 55
7.6.27 Writing the software limit switches of the robot axes ............................................ 56
7.6.28 Writing the software limit switches of the external axes ....................................... 57
7.6.29 Declaring interrupts .............................................................................................. 58
7.6.30 Activating interrupts .............................................................................................. 60
7.6.31 Deactivating interrupts .......................................................................................... 61
7.6.32 Reading the state of an interrupt .......................................................................... 62
7.6.33 Activating a path-related switching action (TRIGGER WHEN DISTANCE) ......... 63
7.6.34 Activating a path-related switching action (TRIGGER WHEN PATH) .................. 65
7.6.35 Canceling a program ............................................................................................ 67
7.6.36 Stopping the robot ................................................................................................ 68
7.6.37 Continuing a program ........................................................................................... 69
7.7 Functions for activating motions ................................................................................ 69
7.7.1 Moving to a Cartesian position with a LIN motion ................................................ 69
7.7.2 Moving to a Cartesian position with a LIN_REL motion ....................................... 71
7.7.3 Moving to a Cartesian position with a PTP motion ............................................... 73
7.7.4 Moving to a Cartesian position with a PTP_REL motion ...................................... 75
7.7.5 Moving to an axis-specific position with a PTP motion ......................................... 76
7.7.6 Moving to a Cartesian position with a CIRC motion ............................................. 77
7.7.7 Moving to a Cartesian position with a CIRC_REL motion .................................... 80
7.7.8 Jogging to a relative end position ......................................................................... 82
7.7.9 Jogging to a relative end position in the TOOL coordinate system ...................... 84
7.8 Diagnostic functions .................................................................................................. 86
7.8.1 Reading the current state of the mxA interface .................................................... 86
7.8.2 Reading error messages of the mxA interface ..................................................... 86
7.8.3 Resetting error messages of the mxA interface ................................................... 87
7.8.4 Reading error messages of the robot controller ................................................... 87
7.8.5 Reading diagnostic signals ................................................................................... 88
7.9 Special functions ....................................................................................................... 90
7.9.1 Reading system variables .................................................................................... 90
7.9.2 Writing system variables ....................................................................................... 91
7.9.3 Calling a brake test ............................................................................................... 92
7.9.4 Calling a mastering test ........................................................................................ 94
7.9.5 Reading the safety controller signals .................................................................... 96
7.9.6 Reading the state of the TouchUp status keys ..................................................... 97

5 / 123Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
Contents
7.9.7 Teaching points .................................................................................................... 97
8 Messages ..................................................................................................... 99
8.1 Error messages of the mxA interface in the robot interpreter .................................... 99
8.2 Error messages of the mxA interface in the Submit interpreter ................................. 103
8.3 Error in the function block .......................................................................................... 108
9 KUKA Service .............................................................................................. 111
9.1 Requesting support .................................................................................................... 111
9.2 KUKA Customer Support ........................................................................................... 111
Index ............................................................................................................. 119

6 / 123 Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
KUKA.PLC mxAutomation Logix 1.0

7 / 123Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
1 Introduction
1Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and skills:
Knowledge of the robot controller system
Advanced PLC programming skills
Advanced knowledge of field bus interfaces
1.2 Industrial robot documentation
The industrial robot documentation consists of the following parts:
Documentation for the manipulator
Documentation for the robot controller
Operating and programming instructions for the KUKA System Software
Documentation relating to options and accessories
Parts catalog on storage medium
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety These warnings are relevant to safety and must be observed.
Notes These hints serve to make your work easier or contain references to further
information.
For optimal use of our products, we recommend that our customers
take part in a course of training at KUKA College. Information about
the training program can be found at www.kuka.com or can be ob-
tained directly from our subsidiaries.
These warnings mean that it is certain or highly probable
that death or severe physical injury will occur, if no pre-
cautions are taken.
These warnings mean that death or severe physical inju-
ry may occur, if no precautions are taken.
These warnings mean that minor physical injuries may
occur, if no precautions are taken.
These warnings mean that damage to property may oc-
cur, if no precautions are taken.
These warnings contain references to safety-relevant information or
general safety measures. These warnings do not refer to individual
hazards or individual precautionary measures.
Tip to make your work easier or reference to further information.

8 / 123 Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
KUKA.PLC mxAutomation Logix 1.0
1.4 Terms used
1.5 Trademarks
RSLogix 5000 is a trademark of Rockwell Automation Inc.
Term Description
Axis group Depending on the machine data configuration, an axis group contains
the following axes:
Robot axes A1 to A6
External axes E1 to E6 (synchronous or asynchronous)
FIFO Method used to process a data memory
First In First Out: the elements saved first are taken first from the
memory.
KR C KUKA Robot Controller
KRL KUKA Robot Language
KUKA smartHMI User interface of the KUKA robot controller (KUKA smart Human-
Machine Interface)
KUKA smartPAD Hand-held operating and programming device for the KUKA industrial
robot
mxA interface KUKA.PLC mxAutomation Logix technology package on the robot con-
troller
Ethernet/IP Ethernet/IP is an Ethernet-based field bus.
Robot interpreter The robot interpreter is a process that works synchronously in which the
current robot program is executed.
BCO run The robot is moved to the coordinates of the motion block in which the
block pointer is situated. In this way, the robot position is made to match
the coordinates of the current point.
PLC Programmable Logic Controller
RSLogix 5000 Development environment for Rockwell controllers
Submit interpreter The Submit interpreter is a cyclical logic program that runs in parallel
with the motion program on the robot controller.
WorkVisual Engineering environment for KR C4-controlled robot cells

9 / 123Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
2 Product description
2 Product description
2.1 KUKA.PLC mxAutomation Logix – overview
KUKA.PLC mxAutomation Logix is an add-on technology package with which
a robot can be programmed and controlled via an external PLC (Rockwell con-
troller).
Functions KUKA.PLC mxAutomation Logix offers the following functionalities:
Function blocks for programming automation tasks with the RSLogix 5000
software
Teaching of points via status keys on the smartPAD and saving of the
taught points in the PLC
Sending of messages generated on the smartHMI to an external system
via UDP
Components The following software components are included in the scope of supply of the
software (USB stick):
KUKA.PLC mxAutomation Logix 1.0
Function blocks for RSLogix 5000 (Library folder)
Programming template MxA_Rockwell_Sample.ACD for RSLogix 5000
(Template folder)
Sample WorkVisual project MxA_Rockwell_Sample.wvs for EtherNet/IP
(Template folder)
Limitations KUKA.PLC mxAutomation can be used together with the KUKA.SafeOp-
eration technology package, but not with other technology packages, e.g.
KUKA.GlueTech, KUKA.ConveyorTech, etc.
Only a KUKA smartPAD may be used as teach pendant for the industrial
robot. External teach pendants are not permissible.
Only one robot can be controlled via the PLC.
KUKA.PLC mxAutomation is not approved for the following areas of appli-
cation:
Medical technology
Entertainment
Aerospace industry
Defense industry
Nuclear technology
Communication Data exchange between the PLC and the robot controller takes place via Eth-
erNet/IP.
WorkVisual The following software is required for configuring the EtherNet/IP adapter and
mapping the EtherNet/IP signals:
WorkVisual 2.4 or higher
2.2 Intended use
The online part of KUKA.PLC mxAutomation Logix may only be used on a
KR C4 robot controller with the following software:
KUKA System Software 8.2
KR C4 EtherNet/IP 1.1
The offline part of KUKA.PLC mxAutomation Logix is intended for use with
RSLogix 5000 V20 or higher.

10 / 123 Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
KUKA.PLC mxAutomation Logix 1.0
Using it for any other or additional purpose is considered impermissible mis-
use. The manufacturer cannot be held liable for any damage resulting from
such use. The risk lies entirely with the user.
Operation in accordance with the intended use also involves compliance with
the start-up and configuration instructions in this documentation.
Misuse Any use or application deviating from the intended use is deemed to be imper-
missible misuse; examples of such misuse include:
Incorrect configuration (not in compliance with this documentation). This
might result in the robot executing different actions from those planned by
the PLC programmer.
Use in a programming environment other than RSLogix 5000 V20 or high-
er.

11 / 123Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
3 Safety
3 Safety
This documentation contains safety instructions which refer specifically to the
software described here.
The fundamental safety information for the industrial robot can be found in the
“Safety” chapter of the Operating and Programming Instructions for System In-
tegrators or the Operating and Programming Instructions for End Users.
The “Safety” chapter in the operating and programming instructions
must be observed. Death to persons, severe injuries or considerable
damage to property may otherwise result.

12 / 123 Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
KUKA.PLC mxAutomation Logix 1.0

13 / 123Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
4 Installation
4 Installation
4.1 System requirements
Hardware Robot controller:
KR C4
External PLC:
Rockwell controller
Software Robot controller:
KUKA System Software 8.2
The following KRL resources must be free:
KR C4 EtherNet/IP 1.1
Standard laptop/PC:
WorkVisual 2.4 or higher
RSLogix 5000, version 20 or higher
4.2 Installing or updating KUKA.PLC mxAutomation Logix
Precondition “Expert” user group
Procedure 1. Connect the USB stick to the robot controller or smartPAD.
2. In the main menu, select Start-up > Install additional software.
3. Click on New software. The entry mxAutomation Logix must be dis-
played in the Name column and drive E:\ or K:\ in the Path column.
If not, press Refresh.
4. If the specified entries are now displayed, continue with step 5.
If not, the drive from which the software is being installed must be config-
ured first:
Press the Configuration button. A new window opens.
Select a line in the Installation paths for options area.
Note: If the line already contains a path, this path will be overwritten.
Press Browse. The available drives are displayed.
Select E:\. (If stick connected to the robot controller.)
Or select K:\. (If stick connected to the smartPAD.)
Press Save. The window closes again.
The drive only needs to be configured once and then remains saved for
further installations.
5. Mark the entry mxAutomation Logix and click on Install. Answer the re-
quest for confirmation with Yes.
6. Confirm the reboot prompt with OK.
7. Remove the stick.
8. Reboot the robot controller.
KRL resource Number
I/Os 2,049 … 4,080
It is advisable to archive all relevant data before updating a software
package.

14 / 123 Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
KUKA.PLC mxAutomation Logix 1.0
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.
4.3 Uninstalling KUKA.PLC mxAutomation Logix
Precondition “Expert” user group
Procedure 1. In the main menu, select Start-up > Install additional software. All addi-
tional programs installed are displayed.
2. Mark the entry mxAutomation Logix 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.
It is advisable to archive all relevant data before uninstalling a soft-
ware package.

15 / 123Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
5 Operation
5 Operation
5.1 Menus
The following menus and commands are specific to this technology package:
Main menu:
Configuration > Status keys > mxAutomation
Configuration > mxAutomation > Messages
5.2 Status keys
Procedure Displaying the status keys:
In the main menu, select Configuration > Status keys > mxAutomation.
Description For safety reasons, the status keys for teaching points are deactivated. To ac-
tivate them, the enabling switch on the smartPAD must be pressed.
The status keys are not available in Automatic External mode.
Status key Description
Inactive Active
Select the number with which a position is
to be taught and saved in the PLC using the
PLUS key (top) or the MINUS key (bottom).
Pos. 1 to Pos. 100
Press the status key to teach the position
with the selected number and save it in the
PLC.

16 / 123 Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
KUKA.PLC mxAutomation Logix 1.0

17 / 123Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
6 Start-up and configuration
6 Start-up and configuration
6.1 Start-up and configuration – overview
6.2 Configuring message generation on an external system
Messages generated on the smartHMI can be transferred to up to 5 external
systems, e.g. a cell visualization system, via the UDP/IP protocol. The mes-
sage text and the associated message elements are sent in the language that
is set on the smartHMI.
Procedure 1. In the main menu, select Configuration > mxAutomation > Messages.
The configuration window is opened.
2. Enter a name for the channel.
3. Enter the IP address and port number of the external system.
4. Configure the filter for the message type.
5. Press Save. The configuration is saved. At the same time, a ping is sent
to the external system to check whether the external system is accessible.
Step Description
1 Transfer a project from the robot controller to WorkVisual.
2 Configure EtherNet/IP in WorkVisual.
Note: The MxA_Rockwell_Sample.wvs template supplied on the USB stick
(Template folder) contains a sample WorkVisual project with the correct Ether-
Net/IP settings.
3 Map the I/Os of the robot controller to the EtherNet/IP signals in WorkVisual:
Map inputs 2,049 to 4,016 to the EtherNet/IP inputs from address 0.0 on-
wards.
Map outputs 2,049 to 4,016 to the EtherNet/IP outputs from address 0.0 on-
wards.
Note: The I/O range 4,017 to 4,080 must remain unused.
4 Transfer the project from WorkVisual to the robot controller and activate it.
5 Compare the project in WorkVisual with the project on the robot controller and
accept the differences in the WorkVisual project.
Information about the configuration of EtherNet/IP on the robot con-
troller can be found in the KR C4 EtherNet/IP documentation.
Information about configuring EtherNet/IP on the higher-level control-
ler can be found in the documentation for the RSLogix 5000 software.
Information about bus configuration and project deployment can be
found in the WorkVisual documentation.
During operation, a heartbeat signal is transmitted via all configured
channels at an interval of 5 minutes.

18 / 123 Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
KUKA.PLC mxAutomation Logix 1.0
Description
Message types The following message types can be transferred:
Fig. 6-1: Configuring message generation
Item Description
1 Name of the channel (up to 5 channels can be configured)
2 Here you will find an indication of whether the ping sent during
saving reached the external system.
Ping successful: The external system is accessible and can
receive data.
Ping failed: The external system is not accessible and cannot
receive data.
3 IP address of the external system
4 Port number of the external system
5 Filter for the message type
Check box active: Messages of this type are sent to the exter-
nal system.
Check box not active: Messages of this type are not sent to
the external system.
Name Description
Info Notification message
State Status message
Ackn. Acknowledgement message
Wait Wait message
Dialog Dialog message
Event System message

19 / 123Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
6 Start-up and configuration
Message
elements
The generated messages consist of the following elements:
Element Example
Network name of robot PCRC7190.ROBOTER.KUKA.DE
Name of robot ROB1
Time of message (date,
time)
---
Originator of the message KCP
Message text Value cannot be changed with pro-
gram selected
Message number 1172
Message type Info
Message status Add: Message displayed
Removed: Message deleted

20 / 123 Issued: 13.08.2012 Version: KST PLC mxAutomation Logix 1.0 V1 en (PDF)
KUKA.PLC mxAutomation Logix 1.0