Kuka VisionTech 2.1 User manual

KUKA System Technology
KUKA.VisionTech 2.1
For KUKA System Software 8.2
For VW System Software 8.2
KUKA Roboter GmbH
Issued: 11.10.2013
Version: KST VisionTech 2.1 V1

KUKA.VisionTech 2.1
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© Copyright 2013
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
Publication: Pub KST VisionTech 2.1 (PDF) en
Book structure: KST VisionTech 2.1 V1.1
Version: KST VisionTech 2.1 V1

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Contents
1 Introduction .................................................................................................. 7
1.1 Industrial robot documentation ................................................................................... 7
1.2 Representation of warnings and notes ...................................................................... 7
1.3 Trademarks ................................................................................................................ 7
1.4 Terms used ................................................................................................................ 8
2 Purpose ........................................................................................................ 9
2.1 Target group .............................................................................................................. 9
2.2 Intended use .............................................................................................................. 9
3 Product description ..................................................................................... 11
3.1 Overview of VisionTech ............................................................................................. 11
3.2 Hardware components ............................................................................................... 12
3.2.1 KUKA GigE switch ................................................................................................ 12
3.2.2 KUKA MXG20 camera .......................................................................................... 16
3.2.3 Connecting cables ................................................................................................ 17
3.2.4 Calibration plates .................................................................................................. 17
4 Technical data .............................................................................................. 19
4.1 KUKA MXG20 camera ............................................................................................... 19
4.2 KUKA GigE switch ..................................................................................................... 20
4.3 Connecting cables ..................................................................................................... 21
4.3.1 Connecting cables, KR C4 .................................................................................... 21
4.3.2 Connecting cables, KR C4 compact ..................................................................... 22
4.4 Dimensions of the camera ......................................................................................... 23
4.5 Dimensions of the extension ...................................................................................... 24
4.6 Plates and labels ........................................................................................................ 24
5 Safety ............................................................................................................ 27
5.1 General safety measures ........................................................................................... 27
5.2 Standards and regulations ......................................................................................... 27
6 Planning ....................................................................................................... 29
6.1 Connecting cables and interfaces .............................................................................. 29
7 Transportation ............................................................................................. 31
7.1 Transportation ............................................................................................................ 31
8 Installation and licensing ............................................................................ 33
8.1 System requirements ................................................................................................. 33
8.2 Installing or updating VisionTech ............................................................................... 33
8.3 Uninstalling VisionTech .............................................................................................. 34
8.4 Licensing VisionTech ................................................................................................. 34
8.4.1 Activating the license ............................................................................................ 34
8.4.2 Repairing the license ............................................................................................ 35
8.4.3 Activating an emergency license .......................................................................... 35
9 Start-up and recommissioning ................................................................... 37
9.1 Start-up for a stationary camera - overview ............................................................... 37
Contents

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9.2 Start-up for moving cameras - overview .................................................................... 37
9.3 Connecting cameras to the robot controller ............................................................... 38
9.3.1 Networking KR C4 with interface X64, stationary ................................................. 38
9.3.2 Networking KR C4 with cable inlet, stationary ...................................................... 38
9.3.3 Networking KR C4 compact, stationary ................................................................ 39
9.3.4 Networking KR C4 with interface X64, robot-guided ............................................ 39
9.3.5 Networking KR C4 with cable inlet, robot-guided ................................................. 40
9.3.6 Description of the connecting cables .................................................................... 40
9.4 Configuring the Ethernet KRL interface ..................................................................... 43
9.5 Configuring the camera network ................................................................................ 43
9.6 Configuring cameras ................................................................................................. 44
9.7 Aligning camera (stationary) ...................................................................................... 45
9.8 Aligning cameras (moving) ........................................................................................ 45
9.9 Calibrating camera (stationary) ................................................................................. 46
9.9.1 Deleting a calibration plane .................................................................................. 48
9.10 Calibrating cameras (moving) .................................................................................... 48
10 Configuration ............................................................................................... 51
10.1 Configuring a 2D measurement task - overview ........................................................ 51
10.2 Configuring a 3D measurement task - overview ........................................................ 51
10.3 Creating a task and taking images (stationary) ......................................................... 51
10.4 Creating a task and taking images (moving) ............................................................. 52
10.5 Setting up an image processing task in WorkVisual .................................................. 52
10.5.1 Installing the image processing environment ....................................................... 53
10.5.2 Licensing the image processing environment in WorkVisual ............................... 53
10.5.2.1 Activating the license ....................................................................................... 53
10.5.2.2 Repairing the license ....................................................................................... 53
10.5.2.3 Activating an emergency license ..................................................................... 54
10.5.3 Creating a tool block file in WorkVisual ............................................................... 54
10.5.3.1 Templates ........................................................................................................ 55
10.6 Configuring a 2D task ................................................................................................ 56
10.7 Generating a 2D model ............................................................................................. 59
10.7.1 2D model with a stationary camera ...................................................................... 59
10.7.2 2D model with a moving camera .......................................................................... 60
10.8 Testing a 2D task ....................................................................................................... 61
10.9 Configuring a 3D task ................................................................................................ 62
10.10 Generating a 3D model ............................................................................................. 64
10.11 Testing a 3D task ....................................................................................................... 65
11 Programming ............................................................................................... 67
11.1 Note on programming ................................................................................................ 67
11.2 Subprogram VT_INIT ................................................................................................ 67
11.3 Subprogram VT_OPENCONNECTION ..................................................................... 67
11.4 Subprogram VT_TASKTRIGGER ............................................................................. 67
11.5 Subprogram VT_TASKTRIGGER_REFBASE ........................................................... 68
11.6 Subprogram GET_VTRESULT .................................................................................. 68
11.7 Subprogram GET_VTCORRECTIONFRAME ........................................................... 68
11.7.1 Structure of VTRESULT ....................................................................................... 69
11.8 Subprogram VTRESULT_CHECK ............................................................................ 69

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11.9 Subprogram VT_RESULTCHECK2 ........................................................................... 70
11.10 Subprogram VT_WAIT ............................................................................................... 70
11.11 Subprogram VT_CLOSECONNECTION ................................................................... 71
11.12 Subprogram VT_CLEAR ............................................................................................ 71
11.13 Subprogram VT_CHECKPOSELIMIT ........................................................................ 71
11.14 Subprogram VT_CHECKPOSE ................................................................................. 72
11.14.1 Defining the points on the robot ............................................................................ 74
11.15 Subprogram GET_VTUSERDATA ............................................................................. 75
11.16 Subprogram DO_GETVTRESULT ............................................................................. 75
11.17 Subprogram DO_GETVTRESULTS .......................................................................... 76
11.18 Subprogram VT_DIRECT .......................................................................................... 77
12 Example programs ...................................................................................... 79
12.1 Example program ....................................................................................................... 79
13 Messages ..................................................................................................... 83
14 Maintenance ................................................................................................. 89
14.1 Maintenance symbols ................................................................................................ 89
15 Repair ........................................................................................................... 91
15.1 Exchanging the switch ............................................................................................... 91
15.2 Exchanging the camera ............................................................................................. 91
15.3 Exchanging the motherboard ..................................................................................... 91
16 Troubleshooting .......................................................................................... 93
17 Decommissioning, storage and disposal .................................................. 95
17.1 Decommissioning ....................................................................................................... 95
17.2 Storage ...................................................................................................................... 95
17.3 Disposal ..................................................................................................................... 95
18 Appendix ...................................................................................................... 97
18.1 Tightening torque ....................................................................................................... 97
19 KUKA Service .............................................................................................. 99
19.1 Requesting support .................................................................................................... 99
19.2 KUKA Customer Support ........................................................................................... 99
Index ............................................................................................................. 107

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KUKA.VisionTech 2.1

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1 Introduction
1Introduction
1.1 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.
1.2 Representation of warnings and notes
Safety These warnings are relevant to safety and must be observed.
This warning draws attention to procedures which serve to prevent or remedy
emergencies or malfunctions:
Notes These hints serve to make your work easier or contain references to further
information.
1.3 Trademarks
Windows is a trademark of Microsoft Corporation.
VisionPro is a trademark of Cognex Corporation.
These warnings mean that it is certain or highly probable
that death or severe injuries will occur, if no precautions
are taken.
These warnings mean that death or severe injuries may
occur, if no precautions are taken.
These warnings mean that minor injuries may occur, if
no precautions are taken.
These warnings mean that damage to property may oc-
cur, if no precautions are taken.
These warnings contain references to safety-relevant information or
general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.
Procedures marked with this warning must be followed
exactly.
Tip to make your work easier or reference to further information.

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1.4 Terms used
Term Description
KUKA smartHMI User interface of the KUKA System Software
(KUKA smart Human-Machine Interface)
GigE Gigabit Ethernet
GenICam Generic Interface for Cameras: generic pro-
gramming interface for cameras used in
industrial image processing.
Reference pose Robot position for image acquisition
Tool block Image processing task created using WorkVi-
sual.
EKI Ethernet KRL interface
PoE Power over Ethernet
Power supply via network
KONI KUKA Option Network Interface
KLI KUKA Line Interface
Connection to Ethernet network

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2 Purpose
2Purpose
2.1 Target group
This documentation is aimed at users with the following knowledge and skills:
Expert knowledge of KRL programming
Advanced knowledge of the robot controller system
Advanced knowledge of network connections
Knowledge of the VisionPro software from Cognex (training)
2.2 Intended use
Use KUKA.VisionTech is used to determine and correct the position of a robot rel-
ative to the position of a component with the aid of one or more cameras. Up
to 3 cameras may be operated simultaneously with the system. Only hardware
components approved by KUKA Roboter GmbH may be used. The hardware
components must only be operated under the specified environmental condi-
tions.
Misuse Any use or application deviating from the intended use is deemed to be imper-
missible misuse. This includes e.g.:
Operation outside the permissible operating parameters
Use in potentially explosive environments
Use in the vicinity of welding applications
Networking the camera network with a company network
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.

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3 Product description
3 Product description
3.1 Overview of VisionTech
Functions VisionTech is an add-on technology package and consists of an image pro-
cessing package and a plug-in for the KUKA smartHMI. The acquisition and
processing of images is used to calculate a base correction. The base correc-
tion can be used to correct the position of the robot relative to the position of
a component.
Areas of appli-
cation
Detecting the position of components
Deracking
Depalletizing
Communication The robot controller communicates with one or more GigE cameras via the im-
age processing system. The connection between the kernel system and the
image processing system is established via the Ethernet KRL interface.
Fig. 3-1: Communication, KR C4
1 Stationary camera 4 Robot
2 Connecting cable 5 Robot-guided cameras
3 KR C4 6 Service laptop
Fig. 3-2: Communication, KR C4 compact

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Imageprocessing
software
An image processing environment is installed on the controller during installa-
tion of VisionTech. This software performs the image processing tasks. This
software must also be installed on the service laptop.
3.2 Hardware components
The following hardware components are available in the form of a hardware
package for KUKA.VisionTech:
KUKA GigE switch
KUKA MXG20 cameras
Calibration plate
Connecting cables
There are different variants of the hardware package. The variants differ with
regard to the interface, connecting cables and number of cameras:
3.2.1 KUKA GigE switch
Overview There are 5 RJ45 connections on the KUKA GigE switch. Ports 1 to 4 are PoE-
capable. KUKA MXG20 cameras can be connected to ports 1 to 3.
Port 5 can be used to connect the KR C4 compact; this port is not PoE-capa-
ble. The switch must be integrated into a housing with a protection rating of
IP 54 and supplied with a direct voltage of 12-36 V. The switch can be mount-
ed on a TS 35 top-hat rail.
In the KR C4, the switch is installed and connected to the power supply of the
KR C4. Up to 3 cameras can be connected to interfaces X64.1 to X64.3. Alter-
natively, the cameras can be connected directly to the switch in the KR C4 via
a cable inlet.
1 KR C4 compact 3 Switch
2 Connecting cable 4 Cameras
Type Cameras Position Restriction
2D 1-3 Stationary None
1-3 Moving Only with KR C4
3D 2-3 Moving Only with KR C4

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3 Product description
DIP switches
Fig. 3-3: KUKA GigE switch – overview
1 DIP switch for the function “Power Alarm Relay Output”
2 Changeover switch for port 6 (selection of SFP speed)
3 RJ45 PoE connection for the robot controller
4 3 RJ45 PoE connections for cameras
Designation Description
DIP switch for “Power
Alarm Relay Output”
DIP switch 1: P1 error message
DIP switch 2: P2 error message
On: Activated
Off: Deactivated
Changeover switch for
port 6 (selection of
SFP speed)
DIP switches 1 and 2 on: 100 Mbps
DIP switches 1 and 2 off: 1000 Mbps

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KUKA.VisionTech 2.1
LEDs
Fig. 3-4: KUKA GigE switch – LEDs
Item LED Description
1 P1 Green: Switch is on (if powered via V1)
2 P2 Green: Switch is on (if powered via V2)
3 Gigabit LAN port Green: GigE port is active, data being
transferred to the connected device
4 Gigabit LAN port Yellow: 100 Mbps
5 Gigabit PoE port Green: Port is active
6 Gigabit PoE port Green: PoE is active
7 Fault Yellow: Fault at P1 or P2

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3 Product description
Power supply
Interfaces
Fig. 3-5: KUKA GigE switch – power supply
1 Power supply connection 12-36 V DC
2 Power supply connection 24 V DC
3 Output, alarm relay
4 Power supply connection 12-36 V DC
5 Housing ground
Fig. 3-6: KUKA GigE switch – interfaces

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3.2.2 KUKA MXG20 camera
Overview The KUKA MXG20 camera conforms to the GigE standard and is PoE-capa-
ble. The image resolution is 2 megapixels. The camera can be powered via
PoE or from an external power supply. A protective lens hood is mounted on
the camera. C-Mount lenses can be used (lenses are not included in the scope
of supply).
The following must be ensured when selecting the lens:
The lens fits on the camera
The lens fits into the protective lens hood (depth: 45 mm, can be enlarged
using extension rings – 12 mm each)
The lens matches the sensor (size: 1/1.8")
A protective cap is mounted on the connection for the process interface / pow-
er supply. This may only be removed if a cable is connected to the interface.
Connector pin
allocation
It is recommended to use no more than 3 extension rings.
Fig. 3-7: KUKA MXG20 camera – overview
1LEDs
2 Data/PoE interface
3 Process interface / power supply
The camera must not be powered simultaneously via
PoE and from an external source, otherwise the camera
may be damaged.
Fig. 3-8: Contact diagram, data/PoE interface (view from contact side)
1 MX3- 5 MX2+ (pos./neg. Vport)
2 MX4+ 6 MX1+ (neg./pos. Vport)
3MX4- 7MX3+
4 MX1- (neg./pos. Vport) 8 MX2- (pos./neg. Vport)

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3 Product description
LEDs
3.2.3 Connecting cables
Different connecting cables are required for the operation of one or more cam-
eras. The connecting cables used conform to the CAT6 standard for network
cables. The network cables have different connectors depending on the inter-
face. The cables are available in various lengths.
3.2.4 Calibration plates
A calibration plate is required for the calibration of a camera. Calibration plates
are available in the following sizes:
24 x 24 inch (60.9 x 60.9 cm), size of one square: 20 mm
12 x 12 inch (30.5 x 30.5 cm), size of one square: 10 mm
11.5 x 8 inch (29.2 x 20.3 cm), size of one square: 6.35 mm
5.75 x 4 inch (14.6 x 10.2 cm), size of one square: 3.175 mm
2.875 x 2 inch (7.3 x 5.1 cm), size of one square: 1.5875 mm
Fig. 3-9: Contact diagram, process interface / power supply (view from
contact side)
1OUT3 5U
ext OUT
2 Power VCC+ 6 OUT 1
3 IN1 7 Power GND
4 IO GND 8 OUT 2
Fig. 3-10: KUKA MXG20 camera – LEDs
Item LED Description
1 Status Green: Connection is active.
Flashing green: Data are being received
Flashing red: Data are being sent
2 Power Green: Camera is switched on

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4 Technical data
4 Technical data
4.1 KUKA MXG20 camera
Basic data
Ambient condi-
tions
Connections
Standards and
guidelines
Power supply (exter-
nal)
Control voltage: 12 … 24 V DC ± 10%
Rated current: 176 … 252 mA
Power supply (PoE) Control voltage: 36 … 57 V DC
Rated current: 88 mA (with 48 V DC)
Energy consumption approx. 4.2 W
Digital input Voltage (min.): 0 … 4.5 V DC
Voltage (max.): 11 … 30 V DC
Rated current: 6.0 … 10 mA
Pulse length: min. 2.0 µs
Trigger delay outside of treadout: 1 µs
Trigger delay during treadout: 14 µs
Digital output Voltage: 5 … 30 V DC
Rated current: max. 50 mA
MTBF 335774 h @ 45°C
Sensor size 1/1.8"
Protection rating IP 67
Weight 185 g
Conformity CE
Storage and transpor-
tation
-25 °C to +70 °C (248 K to 343 K)
Operation +5 °C to +50 °C (278 K to 323 K)
Device temperature max. +50 °C (323 K) at the measurement point
Air humidity 5 … 95% (no condensation)
Data/PoE interface Transmission speed:
100 Mbit/s (Fast Ethernet)
1000 Mbit/s (Gigabit Ethernet)
Connection: M12 male connector, 8-contact, A
standard
Process interface /
power supply
Connection: M12 female connector, 8-contact, A
standard
Name Definition
2004/108/EC EMC Directive:
Directive 2004/108/EC of the European Parlia-
ment and of the Council of 15 December 2004
on the approximation of the laws of the Member
States relating to electromagnetic compatibility
and repealing Directive 89/336/EEC

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4.2 KUKA GigE switch
Basic data
Ethernet interface
Ambient condi-
tions
Standards and
guidelines
EN 61000-6-2 Electromagnetic compatibility (EMC) - Part 6-2:
Generic standards – Immunity for industrial envi-
ronments
EN 61000-6-4 Electromagnetic compatibility (EMC) - Part 6-4:
Generic standards – Emission standard for
industrial environments
Name Definition
Housing Metal
Protection classifica-
tion
IP 30
Dimensions 41 x 99.9 x 144.3 mm
Weight 580 g
Control voltage 12 … 36 V DC
Energy consumption approx. 7.5 W
MTBF > 450000 h @ 45°
Conformity CE, FCC Part 15, RoHS
Interface 1000base-T, 100base-TX, 10base-T
Standard IEEE 802.3 for 10base-T
IEEE 802.3u for 100base-TX and 100base-X
IEEE 802.3z for 1000base-X
IEEE 802.3ab for 1000base-T
IEEE 802.3x for flow control
IEEE 802.3at PoE specification (up to 30 watts
per port for PoE)
Ports 4x with PoE, 1x SFP, 1x without PoE
Packet size Up to 9 kB, supports jumbo frames
Auto-functions Auto-negotiation, auto-crossover
PoE Conforms to IEEE 802.3at
Protective function Against overload current
Power infeed Up to 30 watts per port
Storage -40 °C to +85 °C (233 K to 358 K)
Operation -40 °C to +60 °C (233 K to 333 K)
Air humidity 5 … 95% (no condensation)
Name Definition
2004/108/EC EMC Directive:
Directive 2004/108/EC of the European Parlia-
ment and of the Council of 15 December 2004
on the approximation of the laws of the Member
States relating to electromagnetic compatibility
and repealing Directive 89/336/EEC
EN 55022 Information technology equipment – Radio dis-
turbance characteristics – Limits and methods of
measurement