KST CRArcTech Digital 32 en

KUKA System Technology
CR.ArcTech Digital 3.2

For KUKA System Software 5.5 and 5.6
Issued: 30.09.2010
Version: KST CR.ArcTech Digital 3.2 V3 en
KUKA Roboter GmbH
Copyright 2010
KUKA Roboter GmbH
Zugspitzstrae 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, 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
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Publication:
Pub KST CR.ArcTech Digital 3.2 en
Bookstructure:
KST CR.ArcTech Digital 3.2 V3.1
Label:
KST CR.ArcTech Digital 3.2 V3 en
Issued: 30.09.2010 Version: KST CR.ArcTech Digital 3.2 V3 en
Contents
Contents
1
Introduction ..................................................................................................
1.1
Target group ..............................................................................................................
1.2
Industrial robot documentation ...................................................................................
1.3
Representation of warnings and notes ......................................................................
1.4
Trademarks ................................................................................................................
1.5
Terms used ................................................................................................................
Product description .....................................................................................
2.1
Overview of CR.ArcTech Digital ................................................................................
2.2
Program Generator: Structure in the Navigator .........................................................
10
Safety ............................................................................................................
13
Installation ...................................................................................................
15
4.1
System requirements .................................................................................................
15
4.2
Installing or updating CR.ArcTech Digital ..................................................................
15
4.3
Installing/updating CR.ArcTech Digital Power Sources separately ...........................
16
4.4
Uninstalling CR.ArcTech Digital Power Sources .......................................................
16
4.5
Uninstalling CR.ArcTech Digital .................................................................................
17
4.6
Check last installation/uninstallation ..........................................................................
17
Operation ......................................................................................................
19
5.1
Menus ........................................................................................................................
19
5.2
Status keys ................................................................................................................
19
Configuration ...............................................................................................
23
6.1
Configuration: General ...............................................................................................
23
6.1.1
Configuration user interface ..................................................................................
23
6.1.2
Configuring CR.ArcTech Digital ............................................................................
24
6.1.3
Archiving a configuration ......................................................................................
24
6.1.4
Loading a configuration ........................................................................................
24
6.1.5
Saving long text names of the configuration .........................................................
24
Configuration: Error strategies ...................................................................................
25
6.2.1
Error strategy configuration interface ....................................................................
25
6.2.2
Configuring error strategies ..................................................................................
26
6.2.3
Configuration parameters: Error strategies ...........................................................
26
6.2.3.1
Configuration parameters: Arc-strike error strategies ...........................................
26
6.2.3.2
Configuration parameters: Weld error handling strategy ......................................
28
6.2.3.3
Notes on configuring error strategies ....................................................................
29
6.2.3.4
Notes on configuring actions and service routines ...............................................
30
6.2.3.5
Overlap distance ...................................................................................................
31
Configuration: Dry run ................................................................................................
33
Configuring the dry run velocity ............................................................................
33
6.2
6.3
6.3.1
6.3.2
Activating/deactivating automatic dry run .............................................................
33
6.4
Configuration of VelUnitsConfig.xml ..........................................................................
34
Programming ...............................................................................................
37
7.1
Structure of a weld operation .....................................................................................
37
7.2
Standard program or Generator program? ................................................................
38
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7.3
Structure of a standard program ................................................................................
39
7.4
Structure of Generator programs ...............................................................................
39
Structure of a component program .......................................................................
39
7.4.1
7.4.2
Structure of a seam program ................................................................................
40
7.4.3
Structure of a subprogram for a service routine ...................................................
41
7.4.4
Structure of a subprogram for actions ..................................................................
42
Creating programs with the Program Generator .......................................................
43
7.5.1
Creating a new component program with seam programs ...................................
43
7.5.2
Program IDs .........................................................................................................
44
7.5.3
Changing the order of the seam programs ...........................................................
44
7.5.4
Changing the name of a component program ......................................................
44
7.5.5
Changing the name of a seam program ...............................................................
44
7.5.6
Duplicating a component program ........................................................................
45
7.5.7
Duplicating a seam program .................................................................................
45
7.5.8
Service routines ....................................................................................................
45
7.5
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7.5.8.1
Teaching a service routine ...................................................................................
46
7.5.8.2
Service routine: moving to points by means of block selection ............................
46
7.5.9
Actions ..................................................................................................................
47
7.5.9.1
Teaching an action ...............................................................................................
47
7.5.9.2
Action: moving to points by means of block selection ..........................................
48
7.6
Programming tips for CR.ArcTech Digital with RoboTeam .......................................
48
7.7
Weld instructions .......................................................................................................
48
Example programs ......................................................................................
49
8.1
Example programs for RoboTeam ............................................................................
49
8.1.1
Path with service routine for ignition errors example .........................................
49
8.1.2
Path with service routine for weld errors example .............................................
50
8.1.3
Example of a component program .......................................................................
51
8.1.4
Example of seam program 1 ................................................................................
52
8.1.5
Example of seam program 2 ................................................................................
53
8.1.6
Example of a service routine ................................................................................
53
KUKA Service ...............................................................................................
55
9.1
Requesting support ...................................................................................................
55
9.2
KUKA Customer Support ...........................................................................................
55
Index .............................................................................................................
63
1 Introduction
Introduction
1.1
Target group
This documentation is aimed at users with the following knowledge and skills:
Advanced KRL programming skills
Advanced knowledge of the robot controller system
Advanced knowledge of arc welding
Advanced knowledge of KUKA.RoboTeam (cooperating robots)
Advanced knowledge of external axes and external kinematic systems
Advanced knowledge of other peripheral controller systems (e.g. weld current controller)
Advanced knowledge of field bus and network connections
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 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
Safety
Representation of warnings and notes

Warnings marked with this pictogram are relevant to safety and must be observed.
Danger!
This warning means that death, severe physical injury or substantial material
damage will occur, if no precautions are taken.
Warning!
This warning means that death, severe physical injury or substantial material
damage may occur, if no precautions are taken.
Caution!
This warning means that minor physical injuries or minor material damage
may occur, if no precautions are taken.
Notes
Notes marked with this pictogram contain tips to make your work easier or references to further information.
Tips to make your work easier or references to further information.
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1.4
Trademarks
Windows is a trademark of Microsoft Corporation.
WordPad is a trademark of Microsoft Corporation.
1.5
Terms used
Term
Description
Action
User-defined reaction of the robot controller to

an ignition error
Asynchronous weld
seam
In the case of asynchronous weld seams, the

welding robots are not synchronized and weld
independent seams.
Component program
A component program contains the motions to

the weld seams and between the weld seams. It
contains the calls for the individual seam programs. It does not contain any weld instructions.
Seam program
A seam program contains the weld instructions

for 1 seam.
End crater position
The end crater position is the end of the weld

seam. It corresponds to the end point of the ARC
OFF instruction.
Remote device
In the cell configuration, a robot controller

regards all other devices in the RoboTeam as
remote devices.
On-the-fly activation
and deactivation of the
gas
Activation and deactivation of the gas without

exact positioning
On-the-fly ignition and

deactivation of the arc
Ignition and deactivation of the arc without exact

positioning
Local device
In the cell configuration, each robot controller

regards itself as a local device.
Weld error
A weld error occurs when the arc fails on the

weld seam, or in the case of a peripheral fault.
Service routine
Motion to a service position (e.g. to clean the

torch) and back to the path.
Synchronous weld
seam
Both welding robots commence a weld seam

simultaneously and terminate it simultaneously,
irrespective of the length of the seams.
In the case of seams of different lengths, it is the
welding robot that will take longer that determines the time. The velocity of the second welding robot is then reduced.
Without welding
The robot moves without welding.

This is not the same as a dry run, where the
velocity is additionally increased.
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1 Introduction
Term
Description
Dry run
In sections where no welding takes place, a dry

run can be carried out, i.e. the robot moves at
increased velocity.
The dry run function can be activated manually
(via status key) or automatically.
Ignition error
An ignition error (strike error) has occurred if

ignition is not successfully carried out in the weld
process.
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2 Product description
Product description
2.1
Overview of CR.ArcTech Digital

CR.ArcTech Digital is an add-on technology package with the following functions:
Functions
Welding with one robot
Welding in the RoboTeam (max. 4 welding robots and 1 handling robot)
Configurable error strategies

A dedicated configuration tool is available for the error strategies. It is also
possible to adapt the individual parameters in the inline form if this has
been enabled in the configuration.
Program Generator
The welding programs can be created using the standard procedure for
general robot programs, or alternatively using the Program Generator.
The Program Generator automatically generates a logical folder structure.
The programs contain, by default, the most important instructions and predefined subprograms for service routines and actions.
Areas of application
On-the-fly ignition and deactivation of the arc
On-the-fly activation and deactivation of the gas
Arc welding
Fig. 2-1: Application example: welding axles
9 / 65
Communication
The robot controller communicates with the weld controller via a field bus. The
robot controllers communicate with one another via a real-time capable network connection.
Further information about the field buses can be found in the corresponding
KUKA documentation.
Additional
software
The scope of supply of CR.ArcTech Digital includes the following additional

software packages:
CR.ArcTech Digital Power Sources

CR.ArcTech Digital contains general functions. Additionally, CR.ArcTech
Digital Power Sources contains power-source-specific functions. Together, these two parts allow arc welding.
Installation: CR.ArcTech Digital Power Sources is installed together with
KUKA.CR.ArcTech Digital. Alternatively, it can also be installed separately.
KUKA.ToolCorrManual
This software enables the TCP to be checked after a collision. If necessary, the TCP can be corrected. This means that the tool does not need to
be recalibrated.
Installation: KUKA.ToolCorrManual is automatically installed together with
CR.ArcTech Digital. It does not need to be installed separately.
KUKA.WeaveTech
This software enables mechanical weaving to be carried out.
Installation: To enable mechanical weaving, KUKA.WeaveTech must be
installed.
Separate documentation is available for the additional software.
2.2
Program Generator: Structure in the Navigator

When a component program is created using the Program Generator, the Arc
folder is automatically created in the directory \R1\Program (if it is not already present). Arc contains a folder with the name of the component program.
Fig. 2-2: Arc folder with program folders

The Arc folder also contains the program CADU_UserGlobal. In this program,
globally valid service routines and user-defined actions can be taught for use
in the event of an error.
The program folder contains the component program and the associated
seam programs.
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2 Product description
A component program contains the motions to the weld seams and between
the weld seams. It contains the calls for the individual seam programs. A seam
program contains the weld instructions for 1 seam.
Fig. 2-3: Program folder with component program and seam programs
The component program and the seam programs are created by the user in a
single operation. During this procedure, the user defines how many seam programs are to be created.
In the component and seam programs, service routines and user-defined actions can be taught for use in the event of an error.
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3 Safety
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 Integrators or the Operating and Programming Instructions for End Users.
Warning!
The Safety chapter in the operating and programming instructions must be
observed. Death to persons, severe physical injuries or considerable damage to property may otherwise result.
13 / 65
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4 Installation
Installation
It is advisable to archive all relevant data before updating or uninstalling a
software package.
4.1
System requirements
Hardware
Software
KR C2 edition2005
For welding in job mode: Welding controllers with job number control and
relevant welding accessories
For welding in the RoboTeam: Network components for KUKA.RoboTeam
KUKA System Software 5.5.x 5.5.8

or KUKA System Software 5.6
For welding in the RoboTeam:

KUKA.CR.MotionCooperation 2.2
The following KRL resources must be free:

KRL resource
Number
Interrupts
8 10
Timers
14 17
Cycflags
240 243
Recommended
robots
The welding robots should be of identical design.
Compatibility
CR.ArcTech Digital must not be installed on a robot controller together

with the following technology packages:
KUKA.ArcTech Analog
KUKA.ArcTech Digital
If KUKA.WeaveTech and KUKA.SeamTech are installed on the same robot controller, there may be conflicts in the assignment of the function generators. If this occurs, please contact KUKA Roboter GmbH.
(>>> 9 "KUKA Service" Page 55)
4.2
Installing or updating CR.ArcTech Digital
Precondition
If there is no CD-ROM drive on the robot controller: USB CD-ROM/DVD

drive
User group Expert
Additionally, if the robot controller is to form part of a RoboTeam:
Procedure
KUKA.CR.MotionCooperation is installed and configured.
1. Select the menu sequence Setup > Install Additional Software and
press the softkey New SW.
2. If the entry CR.ArcTechDigital is not displayed, press the Refresh softkey.
3. Select CR.ArcTechDigital and press the Install softkey. Answer the request for confirmation with Yes.
4. Confirm the reboot prompt with OK and reboot the robot controller.
5. Select a power source and confirm with Next. (Or abort with Cancel. In
this case, CR.ArcTech Digital Power Sources is not installed.)
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6. The following selection is only displayed if various models exist for the selected power source:
Select a power source model and confirm with Next. (Or abort with Cancel. In this case, CR.ArcTech Digital Power Sources is not installed.)
If CR.ArcTech Digital Power Sources has not been installed, it can be installed separately later.
KUKA.ToolCorrManual is automatically installed together with
CR.ArcTech Digital.
KUKA.WeaveTech must be installed separately if mechanical weaving is

required.
A LOG file is created under C:\KRC\ROBOTER\LOG.
LOG file
4.3
Installing/updating CR.ArcTech Digital Power Sources separately
Description
During an update, the power source that is already installed is updated. It is

not possible to select a different power source. If this is desired, CR.ArcTech
Digital Power Sources must first be uninstalled.
Precondition
If there is no CD-ROM drive on the robot controller: USB CD-ROM/DVD

drive
CR.ArcTech Digital is installed.
User group Expert
To install or update CR.ArcTech Digital Power Sources separately, the directory AddOn\CrArcTechPowersources on the CD must be accessed.
Preparation
To do so, select the menu sequence Setup > Install Additional Software. Configure the installation directory.
Information about configuring the installation directory is contained in the operating and programming instructions for the KUKA System Software (KSS).
Procedure
1. Select the menu sequence Setup > Install Additional Software and
press the softkey New SW.
2. If the entry CR.ArcTechPowersources is not displayed, press the Refresh softkey.
3. Select CR.ArcTechPowersources and press the Install softkey. Answer
the request for confirmation with Yes.
4. Select a power source and confirm with Next.
5. The following selection is only displayed if various models exist for the selected power source:
Select a power source model and confirm with Next.
6. Confirm the reboot prompt with OK and reboot the robot controller.
LOG file
4.4
Uninstalling CR.ArcTech Digital Power Sources

It is advisable to archive all relevant data before uninstalling a software package.
16 / 65
4 Installation
If CR.ArcTech Power Sources is uninstalled, the I/O ranges created in IOSYS.INI during installation are automatically deleted.
Example: If Profibus is used, the I/O ranges under [PBMASL] are deleted. If
DeviceNet is used, the I/O ranges under [DEVNET] are deleted.
(I/O ranges under [PBMASL], [DEVNET] etc., that are not from CR.ArcTech
Power Sources are not deleted.)
Expert user group
Precondition
Procedure
1. Select the menu sequence Setup > Install Additional Software. All installed additional programs are displayed.
2. Select the entry CRArcTechPowersources and press the Uninstall softkey.
3. Answer the request for confirmation with Yes. De-installation prepared is
displayed in the State column.
4. Reboot the robot controller. The uninstallation is completed.
LOG file
4.5
Uninstalling CR.ArcTech Digital
Description
To uninstall the CR.ArcTech Digital technology package completely, the following components must be uninstalled:
App-Library
CRArcTechDigital
TechConfigPlugIn
ToolCorrManual
Only uninstall components if it has been ascertained that they are not being
used by another technology package!
Precondition
Procedure
User group Expert
CR.ArcTech Digital Power Sources has been uninstalled/has not been installed.
1. Select the menu sequence Setup > Install Additional Software. All installed additional programs are displayed.
2. Select the software component to be uninstalled and press the softkey Uninstall. Answer the request for confirmation with Yes.
De-installation prepared is displayed in the State column.
3. Repeat step 2 to prepare further software components for uninstallation.
4. Reboot the robot controller. The uninstallation is completed.
LOG file
4.6
Check last installation/uninstallation
Description
The user can check which power source was most recently installed or uninstalled.
Procedure
1. Select the menu sequence Help > Info.

2. Select the Comments tab. Scroll down.
The last entry provides information about which power source was most
recently installed or uninstalled.
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18 / 65
Entry
Meaning
KUKA.CR.ArcTech Powersources
[No., Build] installed
The power source [No., Build] has

been installed.
KUKA.CR.ArcTech Powersources
[No., Build] removed
The power source [No., Build] has

been uninstalled.
No.
Power source
010101
Fronius TPS4000, job mode (with DeviceNet)
010201
Fronius TPS4000, job mode with RCU 5000 (with DeviceNet)
010301
Fronius TPS4000, program mode (with DeviceNet)
020102
SKS Q8PT/Q8PW (with Profibus)
020202
SKS Q8PT/Q8PW (with Profibus) (with increased bit

width for component selection)
5 Operation
Operation
5.1
Menus
The following menus and commands are specific to this technology package:
File
Standard programs
CR.ArcTech programs
Configuration
Statuskeys
CR.ArcTech
CR.ArcTech
Configuration
Error handling strategy
Technology
CR.ArcTech
Strike parameters
Welding
5.2
PTP
LIN
CIRC
Welding off
LIN
CIRC
Initializing
Special commands
Status keys
Procedure
Displaying status keys:
Select the menu sequence Configure > Status keys > CR.ArcTech.
Description
The status keys only refer to the local device, not to the other devices in
the RoboTeam.
Status key: Wire
This status key is only displayed when welding is deactivated.

State
Description
Wire feed
Wire retract
Status key: Power

source
This status key is displayed under the following conditions:
No program is selected.
No torch collision has been registered.
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State
Description
The power source is coupled to the robot. The control elements on the power source are disabled.
Pressing the status key decouples the power source.
The power source is decoupled from the robot. The control
elements on the power source can be operated.
Pressing the status key couples the power source.
Status key: Dry

run
This status key is displayed under the following conditions:
A program is selected.
No torch collision has been registered.
Welding has taken place, after which welding was deactivated using the
Welding status key.
State
Description
Dry run is deactivated: the robot moves at welding velocity.
Pressing the status key activates the dry run: the velocity is
increased to 0.15 m/s if it was previously lower than this.
Dry run is activated: the robot moves at 0.15 m/s (or welding velocity if this is higher).
Pressing the status key deactivates the dry run.
Only relevant if KUKA.WeaveTech is installed:
Dry run is deactivated: the robot moves at welding velocity.
Pressing the status key activates the dry run: the velocity is
increased to 0.15 m/s if it was previously lower than this.
Only relevant if KUKA.WeaveTech is installed:
Dry run is activated: the robot moves at 0.15 m/s (or welding velocity if this is higher). Weaving is deactivated.
Pressing the status key deactivates the dry run.
The dry run is executed from the advance run onward, i.e. for motions that
have not yet been planned.
Example: The advance run has a default value of 3 ($ADVANCE = 3). If a
seam consists of only 2 motions, the dry run will not be executed as the motions are already planned.
Status key:
Welding
The robot is welding or will weld because

State
Description
All conditions for welding are met (internal and external).
Pressing the status key deactivates welding.
The robot is on the weld path. Ignition was simulated with
ARC STRIKE OnFly and ARC.
The effect depends on the next weld command:
ARC SPECIAL ArcOn_OnFly: The robot begins to

weld.
ARC OFF: Ends the simulation state.
Only displayed in AUT EXT mode:

The external enabling signal for the weld operation is set.
(= Input weld enable - Extern is HIGH.)
20 / 65
5 Operation
The robot is not welding or will not weld because

State
Description
The configuration parameter Allow process in T1 is not
active and operating mode T1 is selected.
One or more simulation events are active. Examples:
An axis is simulated.
RoboTeam instructions are simulated.
Or in the BACKWARD.INI file, the following parameters are

not set as follows:
Set_To_False = TRUE
Restore = At_Fwd
Further possible cause:
The configuration parameter Allow process in T1 is active.

And operating mode T1 is selected.
And $RED_T1_OV_CP is set to TRUE in the file
STEU\MADA\$custom.DAT.
Remedy: Set $RED_T1_OV_CP to FALSE.
A block selection has been made.
The program run mode GO is not selected.
Welding has been deactivated via the status key. All other
conditions for welding are met.
Pressing the status key activates welding.
Welding has been deactivated via the status key.
The external enabling signal for the weld operation is not
set. (= Input weld enable - Extern is LOW.)
The external enabling signal for the weld operation is not
set. (= Input weld enable - Extern is LOW.)
By default, welding is disabled in every operating mode if
Input weld enable - Extern is LOW. Remedy:
Set the configuration parameter Input reaction to Automatic extern. Input weld enable - Extern then only
has an effect in AUT EXT mode.
Or do not configure Input weld enable - Extern. (= set

to zero.)
The program SPS.SUB has been stopped or deselected.

Pressing the status key has no effect.
This robot is used as a handling robot in the RoboTeam. (=
The configuration parameter Application as arc welding
robot is not active.)
Pressing the status key has no effect.
21 / 65
Status key: Clear

collision
This status key is displayed if a torch collision has been registered.

State
Description
The torch has had a collision. T1 mode must first be set
before the torch can be moved out of the collision zone.
The torch has had a collision.
Press the status key to move the torch a short distance.
If necessary, press the status key several times until the
torch is out of the collision zone.
The torch has had a collision. The robot can now be
moved.
22 / 65
6 Configuration
Configuration
6.1
Configuration: General
6.1.1
Configuration user interface
Overview
Fig. 6-1: Configuration user interface

Item
1
Description
Select
The various screens are selected here. Also possible via the
Screen status key.
Configuration parameters
The configuration parameters vary according to the power source
used. Descriptions of the individual screens and parameters can
be found in the CR.ArcTech Digital Power Sources documentation (separate documentation for each power source).
Info bar
The info bar displays a description of the selected parameter. In
the user group Expert it additionally displays the variable name of
the parameter.
Status keys
Status key
Description
Toggles between the different screens in the Select window.
Toggles between the items on a given screen.
Increases or decreases the value of the selected item.

With values of type BOOL: Toggles between TRUE and
FALSE.
Inputs/outputs
If an input or output is set, the LED icon next to the box is red (otherwise gray).
If an input or output is used more than once in the technology package, this is
indicated by an exclamation mark next to the box. All affected outputs or inputs
are displayed in the info line.
23 / 65
Fig. 6-2: Input/output used more than once
6.1.2
Configuring CR.ArcTech Digital
Precondition
Procedure
Expert user group
1. Select the menu sequence Configure > CR.ArcTech > Configuration.

2. In the Select list box, select the required screen, e.g. General.
3. Configure the parameters as required on the selected screen.
4. Repeat steps 2 and 3 for all screens.
5. Press the Close softkey. A request for confirmation is displayed, asking if
the changes should be saved.
6. Press the Yes softkey. The configuration is saved.
7. To apply the changes:
Deselect the Submit interpreter and reselect it. (It is not enough to stop
and restart the Submit interpreter.)
Or: Reboot the robot controller.
The configuration parameters vary according to the power source used. Descriptions of the individual screens and parameters can be found in the
CR.ArcTech Digital Power Sources documentation (separate documentation for each power source).
6.1.3
Archiving a configuration
Expert user group
Precondition
Procedure

2. Press the Save in file softkey.
3. Specify a path and name for the archive file and confirm with Save.
6.1.4
Loading a configuration
Precondition
Procedure
User group Expert
The configuration has been archived.

2. Press the Load file softkey.
3. Navigate to the archive file, select the archive file and confirm with OK.
4. A request for confirmation is displayed, asking if the old configuration
should be overwritten. Press Yes.
The configuration is loaded.
6.1.5
Saving long text names of the configuration
Description
24 / 65
The names of the inputs and outputs in the configuration can be transferred to
the Digital I/O window. If the names are displayed here, this aids orientation
in the window.
6 Configuration
If the names are changed in the Digital I/O window, these changes cannot
be transferred back to the configuration.
Expert user group
Precondition
Procedure

2. In the Select list box, select the screen from which the names are to be
transferred:
General
Weld control
Other inputs
Other outputs
PLC Interface
Roboteam
(The softkey Save Longtext is not enabled on the other screens.)

3. Press the Save Longtext softkey.
4. Reboot the robot controller. The names are displayed in the Digital I/O
window.
The window is called via the menu sequence Monitor > I/O > Digital Inputs.
6.2
Configuration: Error strategies
6.2.1
Error strategy configuration interface
Description
The parameters for ignition errors and weld errors are configured here.
It is possible to define whether a parameter is visible or not in the option windows for error strategies.
If a parameter is visible in the option windows, its value can be changed

there.
If a parameter is not visible in the option windows, the value defined here
in the configuration applies.
Overview
Fig. 6-3: Error strategy settings window
25 / 65
Item
Description
The configurable parameters, displayed in a tree structure
Values of the parameters. The values can be changed.
List boxes: Click on the arrow. A list opens from which a value
can be selected.
Boxes with numeric values: Click in the box. The value can be
changed.
Note: Changes must be confirmed using the Enter key.
The units cannot be changed.
Changeable: This parameter is visible in the option window for

the error strategies and its value can be changed there.
Invisible: This parameter is not visible in the option window.

The value set here in the configuration applies.
5
Softkeys
6.2.2
Information about the selected parameter is shown here.
Softkey
Description
Expand All
All elements in the tree structures for the strike error

and weld error strategies are expanded.
Collapse All
All elements in the tree structures are collapsed.
Expand
The selected element is expanded in the tree structure.
Collapse
The selected element is collapsed in the tree structure.
Save
Saves the changes.
Close
Closes the Error strategy settings window.
Configuring error strategies

Expert user group
Precondition
Procedure
1. Select the menu sequence Configure > CR.ArcTech > Error handling
strategy.
The Error strategy settings window is opened.
2. Select the entry Strike error strategies or Weld error strategies and
press the Expand softkey.
The tree structure is opened.
3. Open the desired elements and change the values as required. Confirm
the changes by pressing the Enter key.
4. Press the Save softkey.
5. Press the Close softkey. The Error strategy settings window is closed.
Description
Explanations of the parameters can be found here:

(>>> 6.2.3 "Configuration parameters: Error strategies" Page 26)
6.2.3
Configuration parameters: Error strategies
6.2.3.1
Configuration parameters: Arc-strike error strategies

Parameters set to Changeable can be changed later in the option window Error detection / Strike error strategy.
Some parameters can only be used in programs generated with the Program
Generator. These parameters are identified as such in the following overview.
26 / 65
6 Configuration
The tool direction must correspond to the direction in which the wire comes
out of the torch.
Parameter
Description
Error detection
Timeout
During this time, the robot controller waits for the input Arc established
from the weld controller. If this information is not available within this
time, the ignition process of the robot is deemed to have failed.
Roboteam
Only for welding in the RoboTeam:
Ignore: If an ignition error occurs in another robot, the robot continues its own seam.
Consider: If an ignition error occurs in another robot, the robot aborts

its own seam.
Strike error strategy 1

Number
Number of ignition retries, maximum setting 20.
Strategy
None: None. The robot carries out ignition again immediately.
(= Action)
Wire: Wire advanced and retracted, then ignition.
Retracting torch: The TCP is moved 20 mm in the negative X direction of the TOOL coordinate system and then back to the path. The
robot does not stop during this motion.
The default value 20 mm can be changed in the file
CADA_ActionsAndServices.dat.
Only for programs generated with the Program Generator:
Seam module action: User-defined action, programmed in the seam

program
Part module action: User-defined action, programmed in the component program
Global action routine: User-defined action, programmed in the program CADU_UserGlobal
Strike error strategy 2

Movement
This parameter defines where the service routine should be started from
in the event of an ignition error.
Error position: The service routine is executed from the error position. The robot then returns to the error position.
Seam end position: The robot moves from the error position to the
end of the seam without welding (ARC OFF). The service routine is
executed from here. The robot then moves to the start of the seam
(first ARC instruction in the program).
(>>> 6.2.3.3 "Notes on configuring error strategies" Page 29)

Message
Defines whether a message should be issued before the robot executes

the service routine.
None: No message is generated.
Note: A notification message is generated.
Ackn: An acknowledgement message is generated. Acknowledgement possible via KCP and PLC.
Ackn KCP: An acknowledgement message is generated. Acknowledgement only possible via KCP.
27 / 65
Parameter
Description
Service routine
None: No service routine, the robot carries out ignition again immediately.
Next seam: No service routine. The current seam is ignored. The robot moves to the next seam and resumes the program.
Waiting endless: Endless loop. The user must deselect and reselect
the program.
Retracting torch: The TCP is moved 20 mm in the negative X direction of the TOOL coordinate system. The robot stops and then moves
back to the path.

Seam service routine 1: Service routine 01, programmed in the
seam program

seam program
Part service routine 1: Service routine 01, programmed in the component program
Global service routine 01: Service routine 01, programmed in the

program CADU_UserGlobal

Number of repetitions of strike error strategy 1 and strike error strategy 2
Number
6.2.3.2
Configuration parameters: Weld error handling strategy

Parameters set to Changeable can be changed later in the option window Error detection / Weld error strategy.
Some parameters can only be used in programs generated with the Program
Generator. These parameters are identified as such in the following overview.
The tool direction must correspond to the direction in which the wire comes
out of the torch.
Parameter
Description
Error behaviour and overlap distance

Roboteam
Overlap distance
Only for welding in the RoboTeam:
Ignore: If a weld error occurs in another robot, the robot continues its
own seam.
Consider: If a weld error occurs in another robot, the robot aborts its
own seam.

(>>> 6.2.3.5 "Overlap distance" Page 31)
Weld error strategies
28 / 65
6 Configuration
Parameter
Description
Movement
This parameter defines where the service routine should be started from
in the event of a weld error.
Error position: The service routine is executed from the error position. The robot then returns to the error position.
Seam end position: The robot moves from the error position to the
end of the seam without welding (ARC OFF). The service routine is
executed from here. The robot then moves to the start of the seam
(first ARC instruction in the program). From the start of the seam, the
robot moves without welding as far as the position defined by the parameter Overlap distance.
(>>> 6.2.3.3 "Notes on configuring error strategies" Page 29)

Defines whether a message should be issued before the robot executes
the service routine.
Message
Service routine
None: No message is generated.
Note: A notification message is generated.
Ackn: An acknowledgement message is generated. Acknowledgement possible via KCP and PLC.
Ackn KCP: An acknowledgement message is generated. Acknowledgement only possible via KCP.
None: No service routine, the robot carries out ignition again immediately.
Next seam: No service routine. The current seam is ignored. The robot moves to the next seam and resumes the program.
Waiting endless: Endless loop. The user must deselect and reselect
the program.
Retracting torch: The TCP is moved 20 mm in the negative X direction of the TOOL coordinate system. The robot stops and then moves
back to the path.

seam program

seam program


Number of repetitions of the weld fault strategy.
Number
6.2.3.3
Notes on configuring error strategies
For all robots in the RoboTeam, the parameter Movement under Strike
error strategy 2 must have the same configuration.
(Either all on Error position or all on Seam end position.)
29 / 65
For all robots in the RoboTeam, the parameter Movement under Weld error strategy must have the same configuration.
(Either all on Error position or all on Seam end position.)
6.2.3.4
If the parameter Movement is set to Seam end position, then the parameter RoboTeam may be set to different values for the individual robots.
If the parameter Movement is set to Error position, then the parameter

RoboTeam must be set to Consider. This also applies in the case of
standalone robots.
Notes on configuring actions and service routines

Not every action or service routine that is available for selection in the configuration can be executed by the robot controller in all cases.
Some actions and service routines can only be used in programs generated with the Program Generator. These are specified in the description of
the configuration parameters.
(>>> 6.2.3.1 "Configuration parameters: Arc-strike error strategies"
Page 26)
(>>> 6.2.3.2 "Configuration parameters: Weld error handling strategy"
Page 28)
Which actions or service routines can be executed also depends on the

value set for the Movement parameter.
If a disallowed action or service routine is configured, the robot controller

generates an error message during program execution.
Weld errors
Movement
Possible values for Service routine
Error position
None
Next seam
Waiting endless
Only possible in the following cases:
Configuration parameter Number of connected robots within robo team = 1
Or: The parameter RoboTeam is set to

Consider for all robots.
Retracting torch
Only possible if the configuration parameter
Number of connected robots within robo
team = 1
All
Seam end position

Ignition errors
With ignition errors, the actions / service routines the robot controller can execute depends additionally on where the ignition error occurs. (Actions are configured via the parameter Strategy.)
Ignition error at the start of the seam:
Possible values for
Strategy
Possible values for

Service routine
Error position
All
All
Seam end position
None
Wire
Movement
30 / 65
All
6 Configuration
Ignition error on the path:

Movemen
t
Possible values for

Strategy
Possible values for Service

routine
Error position
None
Wire
The parameters Movement and

Service routine are ignored.
Retracting torch
Only possible if
the configuration
parameter Number of connected
robots within robo
team = 1
Seam end
position
None
Wire
For both parameters, the values

from the current weld error strategy
(last ARC instruction) are used.
If you wish to configure different actions / service routines for ignition errors
on the path from those configured for the start of the seam, insert a further
ARC STRIKE instruction in the program after the first ARC instruction and set
the parameters there as desired.
6.2.3.5
Overlap distance
Description
If a weld error occurs, the robot executes the defined service routine. When it
reaches the path again via the service routine, the robot moves to the position
defined by the parameter Overlap distance. There the robot stops and carries
out ignition again.
The parameter is defined in the configuration of the weld error strategy.
The parameter Overlap distance can only be used in programs generated
with the Program Generator.
Overlap distance
Ignition position after weld error
0 mm
The robot carries out ignition at the error position.
< 0 mm
A negative value defines a position after the error position. This is where
the robot carries out ignition.
(negative value)
The distance from the error position to the defined position remains
unwelded, i.e. a gap is left.
> 0 mm
(positive value)
A positive value defines a position before the error position. This is

where the robot carries out ignition.
The distance from the defined position to the error position is welded a
second time. (= The two parts of the weld seam overlap.)
Note: If the parameter Movement is set to Error position, the robot
controller cannot execute any positive values. Instead, it behaves as if
the value was 0.
Movement =
Seam end
position
Robots behavior when the parameter Movement is set to Seam end position:
31 / 65
Fig. 6-4: Movement = Seam end position

1
The robot welds. A weld error occurs.
The robot moves from the error position to the end of the seam without
welding (ARC OFF).
The robot executes the service routine and moves back to the start of
the seam (first ARC instruction in the program).
Fig. 6-5: Negative value results in gap
Fig. 6-6: Positive value results in overlap

4
From the start of the seam, the robot moves without welding as far as
the defined position.
Here the robot carries out ignition again and welds to the end of the
path.
Not every service routine allows both negative and positive values to be executed. If Movement = Seam end position:
Overlap distance
< 0 mm
All except:
(negative value)
Next seam
Waiting endless
> 0 mm
All except:
(positive value)
None
Next seam
Waiting endless
Retracting torch
(Only taught service routines are possible.)
32 / 65
6 Configuration
Movement = Error
position
Robots behavior when the parameter Movement is set to Error position:
Fig. 6-7: Negative value results in gap

1
The robot welds. A weld error occurs.
The robot executes the service routine and moves back to the error
position.
From the error position, the robot moves without welding as far as the
defined position.
Here the robot carries out ignition again and welds to the end of the
path.
Not every service routine allows a negative value to be executed. If Movement

= Error position:
Overlap distance
< 0 mm
None
(negative value)
Retracting torch
6.3
Configuration: Dry run
6.3.1
Configuring the dry run velocity
Description
The velocity applies to both automatic and manual dry runs. The default is
0.15 m/s. This is also the maximum value. If a higher value is defined, it is limited internally to 0.15 m/s.
The currently configured velocity is displayed in the configuration.
Procedure
The dry run velocity can be changed using one of the following functions. The
function must be inserted into the program. In place of Velocity, the desired velocity is set in m/s.
ROP_Init(,Velocity,)
ROP_Set_DryRun_Velocity(Velocity)
In both of the following examples, the dry run velocity is set to 0.1 m/s:
ROP_init(,0.1,)
ROP_Set_DryRun_Velocity(0.1)
6.3.2
Activating/deactivating automatic dry run
Description
The automatic dry run function is deactivated by default. When activated, a dry
run is automatically executed after weld errors at the dry run velocity (if this is
higher than the weld velocity). This comprises the following motions:
1. From the error position to the end of the seam
33 / 65
2. From the start of the seam to the beginning of the section where the arc is
struck again.
Precondition
Procedure
An automatic dry run is only executed under the following conditions:
A service routine and Seam end position are selected as the weld error
strategy.
The operating mode is not T1.
To activate automatic dry run:
Use the function ROP_SET_AutoDryRun(TRUE)
To deactivate automatic dry run:
Use the function ROP_SET_AutoDryRun(FALSE)
To determine the status (whether activated or deactivated):
Poll the status with Status = ROP_Get_AutoDryRun()

Status is a variable of the data type BOOL and must be declared.
Alternatively, look up the status in the configuration. (Screen: KUKA KRL

Library, Parameter: Velocity for dry run)
It is possible to prevent the increased velocity for the motion from the error position to the end of the seam. The automatic dry run then applies only to the
following motion:
From the start of the seam to the beginning of the section where the arc is
struck again.
For this, the call in the program BAS.SRC (in the folder R1\System) must be
modified as follows:
VEL_VALUE=ROP_Give_DryRun_Velocity(VEL_VALUE,FALSE)
6.4
Configuration of VelUnitsConfig.xml
Description
In the file VelUnitsConfig.xml, the units are selected which are to be available
for selection for the velocity in the inline forms ARC und ARC OFF. It is also
possible to create new units.
Precondition
Procedure
1. Open the file C:\KRC\HMI\Config\Save\VelUnitsConfig.xml using an editor

(e.g. WordPad).
Windows interface (CTRL+ESC)
2. For each unit, define whether it is to be displayed in the inline form using
the parameter IlfMode.
3. To create a new unit: Copy an existing line, insert it after the last line and
set the parameters as required.
4. Save and close the file.
5. On the KUKA.HMI, select the menu sequence Configure > Tools > Reinit
> BOF Reinitialization.
VelUnitsConfig.x
ml
34 / 65
Extract from the file VelUnitsConfig.xml

<TechParamReal Unit="m/s" FactorSI="1" IlfMode="Active"/>
<TechParamReal Unit="m/min" FactorSI="60" IlfMode="Active"/>
<TechParamReal Unit="inch/min" FactorSI="60000/25.4"
IlfMode="Hidden"/>
<TechParamReal Unit="inch/s" FactorSI="100/2.54" IlfMode="Active"/>
6 Configuration
Parameter
Description
Unit
Name of the unit. Displayed in the inline form if

IlfMode="Active".
FactorSI
The base unit for the velocity is 1 m/s. The FactorSI

specifies the relationship of the given unit to this base
unit.
Example for the unit m/min:
60 m/min is equivalent to 1 m/s. Therefore, FactorSI="60".
IlfMode
Active: The unit is available for selection in the inline

form.
Hidden: The unit is not available for selection in the
inline form.
35 / 65
36 / 65
7 Programming
Programming
7.1
Structure of a weld operation
Description
The weld operation will be explained using the example of a workpiece with 2
weld seams.
Seam 1 consists of 1 section.
Seam 2 consists of 3 sections.
A weld seam must consist of at least the following points:
Ignition position
End crater position
Further points are possible before the ignition position, after the end crater position and between these two points.
The following weld instructions are required for a weld seam:
ARC INIT
ARC STRIKE
ARC
ARC OFF
Fig. 7-1: Structure of a weld operation

Motions of a weld operation:
Item
Description
Instruction
Motion to the ignition position of seam 1
ARC STRIKE, then

ARC (LIN)
Seam 1 (1 motion)
ARC OFF (LIN)
Motion away from seam 1
LIN
Motion to next seam
PTP, LIN or CIRC
Motion to the ignition position of seam 2
ARC (LIN)
First section of seam 2
ARC (LIN)
Second section of seam 2
ARC (CIRC)
37 / 65
Item
Description
Instruction
Third and last section of seam 2
ARC OFF (LIN)
Motion away from seam 2
LIN
The instructions apply to Generator programs. With standard programs, each

seam must be preceded by an ARC INIT and an ARC STRIKE instruction.
Points of the weld operation:
P
Description
Allocation
P1,
P2
Points before seam 1 is called
Component program
P3
Point above ignition position of seam 1
Seam program 1
P4
Ignition position of seam 1
Seam program 1
P5
End crater position of seam 1
Seam program 1
P6
Point above end crater position of seam

1
Seam program 1
P7,
P8
Points between seam 1 and seam 2
Component program
P9
Point above ignition position of seam 2
Seam program 2
P10
Ignition position of seam 2
Seam program 2
P11
Start point of the second section of

seam 2
Seam program 2
P12
Start point of the third section of seam 2
Seam program 2
P13
End crater position of seam 2
Seam program 2
P14
Point above end crater position of seam

2
Seam program 2
P15,
P16
Points after seam 2
Component program
The allocation applies to Generator programs. With standard programs, the

entire weld operation can be contained in a single program.
Recommendation:
7.2
Always teach a point above the ignition position. This point makes it easier to move correctly to the ignition position.
Always teach a point above the end crater position. This point makes it
easier to lift off the torch correctly from the end crater position.
Standard program or Generator program?

The welding programs can be created using the standard procedure for general robot programs, or alternatively using the Program Generator.
Standard
program
Advantage:
A program can contain multiple seams. This makes it possible to switch

easily between the seams, for example.
Disadvantages:
Generator
program
38 / 65
Certain actions and service routines cannot be used.
Overlap distances cannot be used.
Advantages:
The Program Generator automatically generates a logical folder structure.
7 Programming
The programs contain, by default, the most important instructions and predefined subprograms for service routines and actions.
More actions and service routines are available.
Overlap distances can be used.
Disadvantages:
Procedure
It is not possible to program multiple seams in the same program.
To create a standard program:
Select the menu sequence File > New > Standard programs.
Or use the conventional procedure
To create a program with the Program Generator:
7.3
(>>> 7.5 "Creating programs with the Program Generator" Page 43)
Structure of a standard program

Each seam must be preceded by an ARC INIT and an ARC STRIKE instruction.
...
2 INI
3 ARC_Init
4
5 PTP HOME Vel=20 % DEFAULT
6 PTP P1 CONT Vel=20 % PDAT1 Tool[1] Base[0]
7
8 ARC_Strike_Param Job=1 Set=S ESet=SE
9 LIN P3 CONT Vel=0.5 m/s CPDAT3 ARC Job=1 Set=W1 ESet=EW
Tool[1] Base[0]
10 LIN P4 Vel=0.6 m/s CPDAT4 ARC_OFF Job=1 Set=C Tool[1] Base[0]
11
12
13 ARC_Init
15 LIN P7 CONT Vel=0.1 m/s CPDAT7 ARC Job=1 Set=W2 ESet=EW
Tool[1] Base[0]
16 LIN P8 Vel=0.6 m/s CPDAT8 ARC_OFF Job=1 Set=C Tool[1] Base[0]
17
18
19 LIN P5 CONT Vel=0.5 m/s CPDAT5 Tool[1] Base[0]
20 PTP HOME Vel=20 % DEFAULT
...
Line
Description
3 10
Seam 1
13 16
Seam 2
7.4
Structure of Generator programs
7.4.1
Structure of a component program

A component program contains the motions to the weld seams and between
the weld seams. It contains the calls for the individual seam programs. It does
not contain any weld instructions.
39 / 65
1 DEF MyProgram1( )
2 INI
3 PTP HOME Vel= 100 % DEFAULT
4 PTP P1 Vel= 100 % PDAT1 Tool[1] Base[0]
5
6 MyProgram1_Seam01()
7 MyProgram1_Seam02()
8
9
10 PTP P1000 Vel= 100 % PDAT1 Tool[1] Base[0]
11 PTP HOME Vel= 100 % DEFAULT
12 END
-----------------------------------------------------------------13 ...
Line
Description
Here the motions from the HOME position to the first seam are
inserted.
P1 is an example point and can be retaught or deleted.
6, 7
Calling the seam programs

The number of seam programs is defined when the component program is created. The seam programs are then generated automatically.
Between the seam programs, motions to the next seam can be
inserted.
10
Here the motions from the last seam to the HOME position are
inserted.
13
7.4.2
2 subprograms then follow:
Subprogram for the component-specific service routines
Subprogram for the component-specific actions
Structure of a seam program

A seam program contains the weld instructions for 1 weld seam.
1 DEF My_Program1_Seam01( )
2 INI
3
4 ============= Seam start ================>
6 LIN P1 Vel=0.6 m/min CPDAT1 ARC Job=1 Set=W1 ESet=EW1 Tool[1]
Base[0]
7 {H}
8 ------------ start insert movements -----9
10
11
12 ------------ end insert movements -------13 LIN P1000 Vel=0.6 m/min CPDAT ARC_OFF Job=1 Set=C Tool[1]
Base[0]
14 {H}
15 <============ Seam end ===================
16
17 END
-----------------------------------------------------------------18 ...
40 / 65
7 Programming
Recommendation:
Always teach a point above the ignition position. This point makes it easier to move correctly to the ignition position.
Always teach a point above the end crater position. This point makes it
easier to lift off the torch correctly from the end crater position.
Line
Description
By default, the INI line contains the instruction ARC INIT. ARC
INIT does not need to be programmed.
Here motions can be inserted before the first position on the

seam, e.g. a point above the ignition position.
From this line, it is possible to jump to subprograms for the service routines and actions. Only possible if set in the configuration.
(>>> 7.5.8.1 "Teaching a service routine" Page 46)
(>>> 7.5.9.1 "Teaching an action" Page 47)
The ignition parameters are set.

ARC STRIKE is present by default in every seam program.
The parameters must be adapted to the current seam program.
Ignition.
ARC is present by default in every seam program. The parameters must be adapted to the current seam program.
9 11
The weld motions must be inserted here.
13
End of seam.
ARC OFF is present by default in every seam program. The
parameters must be adapted to the current seam program.
7.4.3
15
From this line, it is possible to jump to subprograms for the service routines and actions. Only possible if set in the configuration.
16
Here motions can be inserted after the end crater position, e.g.
a point above the end crater position.
18
2 subprograms then follow:
Subprogram for the seam-specific service routines
Subprogram for the seam-specific actions
Structure of a subprogram for a service routine

All subprograms for service routines have the same structure.
The structure will be explained here using the example of a seam-specific service routine.
41 / 65
17
...
-----------------------------------------------------------------18 Service strategy on seam - to teach open fold
19 DEF
ServiceStrategy(ConsiderCRErr:IN,Motion:IN,Service:IN,MsgType:IN,Tea
chModeSender:IN)
20 {H}
21 HALT for TeachMode on seam
22 {H}
23
CASE #SeamServiceRoutine01
24
-- insert motion from pos. on seam to maintenance pos. -25
26 KL_MsgSendNotify("SeamServiceRoutine01NotTeached","CAD")
27 LIN P1001 Vel=0.2 m/s CPDAT Tool[1] Base[0]
28
29
HALT ;** maintenance position reached
30
-- insert motion from maintenance pos. back to seam -31
32
33
34
35
37 KL_MsgSendNotify("SeamServiceRoutine02NotTeached","CAD")
38 LIN P1002 Vel=0.2 m/s CPDAT Tool[1] Base[0]
39
40
41
43
44
{H}
45 {H}
46 END
-----------------------------------------------------------------47 ...
Line
Description
23 32
Section for service routine 1

(2 service routines can be taught in each subprogram.)
25
Insert the motions to the service position here.
26
This line must be deleted if a service routine 1 is being taught.

This line triggers a message during program execution, stating
that this service routing has not been taught.
27
29
The robot stops at the service position.
31
Teach the motions from the service position back to the path
here.
33 42
Section for service routine 2

The structure is the same as for service routine 1.
7.4.4
Structure of a subprogram for actions

All subprograms for actions have the same structure.
The structure will be explained here using the example of a seam-specific action.
42 / 65
7 Programming
20 DEF ActionStrategy(StrikeErrorSet:IN,TeachModeSender:IN)
21 {H}
22 HALT for TeachMode on seam
23 {H}
24
CASE #SeamActionRoutine
25
KL_MsgSendNotify("SeamActionRoutineNotDefined","CAD")
26
-- insert user defined actions -27 {H}
28 END
7.5
Line
Description
26
Insert the user-defined actions after this line.
Creating programs with the Program Generator

In the following procedures, the windows can also be called using the softkey
CR.Arc New.
(As an alternative to the menu sequence File > CR.ArcTech programs.)
7.5.1
Creating a new component program with seam programs
Precondition
Procedure
User group Expert
Operating mode T1 or T2
CR.ArcTech Digital has been configured (general configuration and configuration of error strategies).
1. Select the menu sequence File > CR.ArcTech programs. One of the following windows then opens:
New set of weld programs window: Continue with step 3.
Part program overview window: Continue with step 2.
2. Press the New softkey. The New set of weld programs window is
opened.
3. Enter the data for the new program.
4. Press the Create softkey. The program is created. The Seam program
overview window is displayed.
5. If required, assign IDs for the seam programs and confirm with the Enter
key.
(>>> 7.5.2 "Program IDs" Page 44)
6. Press the Back softkey. The Part program overview window is displayed.
7. If required, assign an ID for the component program and confirm with the
Enter key.
8. Press the Close softkey.
If the new folder is not displayed in the Arc folder in the Navigator, select
a higher-level folder and then return to the Arc folder. This refreshes the
display.
Description
Fig. 7-2: New set of weld programs window

43 / 65
Item
7.5.2
Description
Name for the component program and all seam programs. (The
seam programs are also assigned an additional name and number.)
Comment (optional)
Additional name added to the name of all seam programs
Number of seam programs. The seam programs are generated automatically and are assigned consecutive numbers as the last element in the name.
Program IDs
Program IDs enable called programs, for example, to be checked and released by a PLC before they are actually executed. Furthermore, they can also
be used for static evaluations, etc.
In the Part program overview window, IDs can be assigned to the component programs if required.
The ID is saved in the DAT file of the component program in the variable
PartNumber (data type: INT).
In the Seam program overview window, IDs can be assigned to the seam
programs if required.
The ID is saved in the DAT file of the seam program in the variable SeamNumber (data type: INT).
7.5.3
Changing the order of the seam programs
Precondition
Procedure
User group "Expert".
Operating mode T1 or T2.
1. Select the menu sequence File > CR.ArcTech programs. The Part program overview window is opened.
2. Select the component program and press the Details softkey. The seam
programs belonging to this component program are displayed.
3. Select a seam program and press the Move softkey.
4. Move the seam program to the desired position using the arrow keys and
confirm with the OK softkey.
7.5.4
Changing the name of a component program
Precondition
Procedure
2. Select a component program and press the Modify softkey.
3. Change the name and confirm with the Enter key.
If the new name is not displayed in the Arc folder in the Navigator, select
display.
7.5.5
Changing the name of a seam program
Precondition
44 / 65
7 Programming
Procedure
3. Select the seam program and press the Modify softkey.
4. Change the name and confirm with the Enter key.
If the new name is not displayed in the Arc folder in the Navigator, select
display.
7.5.6
Duplicating a component program
Precondition
Procedure
2. Select a component program and press the Duplicate softkey. The component program is duplicated.
3. Enter a program name and ID (optional).
4. Confirm by pressing the OK softkey.
7.5.7
Duplicating a seam program
Precondition
Procedure
3. Select the seam program and press the Duplicate softkey. The seam program is duplicated.
4. Enter a program name and ID (optional).
5. Confirm by pressing the OK softkey.
7.5.8
Service routines
The robot controller can execute a service routine in the event of an ignition or
weld error. A service routine is a motion to a service position (e.g. to clean the
torch) and back to the path. There are a number of service routines available
for selection. Which service routine is to be executed is selected during configuration of the error strategies or in the inline forms.
The service routines are already prepared as subprograms. They still need to
be taught, however.
Subprograms for service routines:
1 subprogram in each seam program
1 subprogram in each component program
1 subprogram in the global program CADU_UserGlobal
The subprograms are located at the end of each program in the form of folds.
Each subprogram contains 2 service routines:
45 / 65
Service routine 1 is used for ignition errors. Here the motions are taught
from the ignition position to the service position and back.
Service routine 2 is used for weld errors. Here the motions are taught from
the end of seam to the service position and back to the ignition position.
(>>> 7.4.3 "Structure of a subprogram for a service routine" Page 41)

In order to teach points in the subprogram, the fold in the relevant program can
be opened and edited. Block selection is not possible here.
(>>> 7.5.8.1 "Teaching a service routine" Page 46)
In order to move to points in the subprogram by means of block selection, it is
necessary to jump to the subprogram from the seam program. This is often
necessary for later adaptation of points.
(>>> 7.5.8.2 "Service routine: moving to points by means of block selection"
Page 46)
7.5.8.1
Teaching a service routine
Warning!
Teach service routines so that they can be executed by the robot without any
collisions. Severe physical injuries or considerable damage to property may
otherwise result.
Precondition
Procedure
Welding is deactivated (Welding OFF status key)
1. Open a program.
2. At the end of the program, select the following line: Service strategy
on seam - to teach open fold. This line is a fold.
3. Open the fold with the Fold open/cls softkey.
4. Place the cursor in the blank line after CASE #SeamServiceRoutine01.
5. Teach the motions to the service position here.
6. Delete the line
KL_MsgSendNotify("SeamServiceRoutine01NotTeached"
...). This line triggers a message during program execution, stating that
this service routing has not been taught.
7. The line after this contains an example point. Either change or delete this
point.
8. Place the cursor in the blank line after HALT ;** maintenance position reached.
9. Teach the motions from the service position back to the path.
10. If required, teach service routine 2:
Place the cursor in the blank line after CASE #SeamServiceRoutine02.
Carry out the remaining steps as for service routine 1.
11. Close the program.
7.5.8.2
Service routine: moving to points by means of block selection
Warning!
Teach service routines so that they can be executed by the robot without any
collisions. Severe physical injuries or considerable damage to property may
otherwise result.
Precondition
46 / 65
7 Programming
Procedure
The configuration parameter Teach mode for startup is set to one of the
following values:
Services
Or ActionsAndServices
1. Select and start the seam program.

The block pointer stops in the line Seam start. A message prompts the
user to select a subprogram.
2. Use the relevant softkey to select the desired subprogram:
Seam.Serv: Subprogram of this seam program
Piece.Serv: Subprogram of the component program
Glob.Serv: Subprogram of the global program CADU_UserGlobal.
3. Continue executing the seam program. The block pointer stops in this line:
Service strategy on seam - to teach open fold. This line is
a fold.
5. Carry out block selection to the desired point.
7.5.9
Actions
The robot controller can execute a user-defined action in the event of an ignition error. There are a number of actions available for selection. Which action
is to be executed is selected during configuration of the error strategies or in
the inline forms.
Subprograms are already prepared for the actions. They still need to be programmed, however.
Subprograms for actions:
1 subprogram in each seam program
1 subprogram in each component program
1 subprogram in the global program CADU_UserGlobal
The subprograms are located at the end of each program in the form of folds.
(>>> 7.4.4 "Structure of a subprogram for actions" Page 42)
In order to teach points in the subprogram, the fold in the relevant program can
be opened and edited. Block selection is not possible here.
(>>> 7.5.9.1 "Teaching an action" Page 47)
In order to move to points in the subprogram by means of block selection, it is
necessary to jump to the subprogram from the seam program. This is often
necessary for later adaptation of points.
(>>> 7.5.9.2 "Action: moving to points by means of block selection" Page 48)
7.5.9.1
Teaching an action
Precondition
Procedure
1. Open a program.
2. At the end of the program, select the following line: Action strategy
on seam - to teach open fold. This line is a fold.
47 / 65
4. Program the desired action after the line insert user defined actions.
5. Close the program.
7.5.9.2
Action: moving to points by means of block selection
Precondition
Procedure
The configuration parameter Teach mode for startup is set to one of the
following values:
Actions
Or ActionsAndServices
1. Select and execute the seam program. (Subprograms for actions can only
be accessed from seam programs.)
The block pointer stops in the line Seam start. A message prompts the
user to select a subprogram.
2. Use the relevant softkey to select the desired subprogram:
Seam.Act: Subprogram of this seam program
Part.Act: Subprogram of the component program
Global Act: Subprogram of the global program CADU_UserGlobal.
3. Continue executing the seam program. The block pointer stops in this line:
Action strategy on seam - to teach open fold. This line is a
fold.
5. Carry out block selection to the desired point.
7.6
Programming tips for CR.ArcTech Digital with RoboTeam
RoboTeam
7.7
Synchronous weld seams:
Synchronous weld seams must have the same motion points for all robots.
The number of ARC instructions for a weld seam does not need to be the
same for all robots. It is possible to change weld parameters for one robot
without changing these for the other robots.
The defined weld parameters may, in principle, differ from robot to robot.
In practice, however, it must always be ensured that the different weld parameters are compatible.
Weld instructions
The weld instructions vary according to the power source used. The descriptions can be found in the CR.ArcTech Digital Power Sources documentation (separate documentation for each power source).
48 / 65
8 Example programs
Example programs
8.1
Example programs for RoboTeam

This example illustrates the programming of a weld operation.
The weld operation has the following structure:
The weld operation consists of 2 weld seams.
Seam 1 consists of 1 section.
Seam 2 consists of 2 sections. (The weld parameters will be changed

once.)
2 service routines have been taught for seam 1.
Instructions from KUKA.CR.MotionCooperation are used in the programs. Information about these can be found in the documentation for KUKA.CR.MotionCooperation.
8.1.1
Path with service routine for ignition errors example
Description
In the event of an ignition error, the robot attempts to carry out ignition as many
times as are configured in the error strategy. If the ignition attempts fail, the
robot executes the service routine. A new ignition attempt is then carried out.
Fig. 8-1: Path with service routine for ignition errors

Element
Description
Seam 1
Seam 2
Service routine 01
P1 P3
Motions to seam 1 (component program)
S1P1
First point in seam program 1. Between S1P1 and

S1P2, the ignition parameters are set with ARC
STRIKE.
S1P2
ARC instruction. Ignition is triggered.
Ignition error. The robot attempts to carry out ignition

as many times as are configured in Strike error
strategy 1 If the ignition attempts fail, the robot executes service routine 01.
(Precondition: this service routine is configured for
this case under Strike error strategy 2.)
49 / 65
8.1.2
Element
Description
P101 P105
Motions in service routine 01. The robot moves to

service position P103 and then back to S1P2. Once
there, the robot carries out ignition again.
S1P3 S1P1000
Motions on seam 1.
S1P1000
ARC OFF instruction. End crater position. The seam

is completed.
S1P6
Motion to a point after the end crater position of

seam 1.
P4
Motion to seam 2 (component program)
S2P1
First point in seam program 2. The ARC STRIKE

instruction is executed between S2P1 and S2P2.
S2P2
ARC instruction. Ignition is triggered.
S2P3 S2P1000
Motions on seam 2.
S2P1000
ARC OFF instruction. End crater position. The seam

is completed.
S2P6
Motion to a point after the end crater position of

seam 2.
P5, P1000
Motion back to the HOME position.
Path with service routine for weld errors example
Description
If a weld error occurs, the robot completes the seam as a dry run and then executes the defined service routine. When it reaches the path again via the service routine, the robot moves to the position defined by the overlap distance.
There the robot stops and carries out ignition again. The weld operation is resumed.
Fig. 8-2: Path with service routine for weld errors

Element
Description
Weld error
The robot moves from the error position to the end

of the seam as a dry run (ARC OFF).
The robot executes service routine 02 and moves

back to the start of the seam (first ARC instruction in
the program).
(Precondition: this service routine is configured for
this case under Weld error strategy.)
50 / 65
8 Example programs
Element
Description
From the start of the seam, the robot executes a dry

run as far as the position defined by the overlap distance. Here the robot carries out ignition again and
welds to the end of the path.
Overlap distance (positive value)
P201...P204
Motions in service routine 02. The robot moves to

service position P202 and then back to S1P2. Once
there, the robot carries out ignition again.
A description of the remaining positions can be found here: (>>> 8.1.1 "Path
with service routine for ignition errors example" Page 49)
8.1.3
Example of a component program
Program
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DEF MyProgram_1( )
INI
PTP HOME Vel= 100 % DEFAULT
PTP P1 Vel=100 % PDAT1 Tool[1] Base[0]
PROGSYNC a1 -> R1_R2_R3 WAIT
LIN P3 Vel=1 m/s CPDAT3 Sync=a2 -> R1_R2_R3 Tool[1] Base[0]
MyProgram_Seam01()
MyProgram_Seam02()
PTP HOME Vel= 100 % DEFAULT
END
Line
Description
Motion from the HOME position towards the seam
Setting a synchronization flag (KUKA.CR.MotionCooperation)
6, 7
Further motions towards the seam
Call of the first seam program
Motion from the first to the second seam
10
Call of the second seam program
11 13
Motions from the second seam to the HOME position
(>>> 8.1.4 "Example of seam program 1" Page 52)
(>>> 8.1.5 "Example of seam program 2" Page 53)
51 / 65
8.1.4
Example of seam program 1
Program
1 DEF MyProgram_Seam01( )
2 INI
3
4 -> if needed add movements before first seam position
5
6 LIN S1P1 Vel=1 m/s CPDAT1 Sync=a3 -> R1_R2_R3 Tool[1] Base[0]
7 CALL strategys on Teachmode
8 == seam start ==>
9 = strike start =>
10 ARC_Strike_Param Job=10 Set=S1 ESet=ES Sync=s1 -> R1_R2_R3
11 -> this point must be the same as the ARC start point
12 LIN S1P2 Vel=0.6 m/min CPDAT2 Tool[1] Base[0]
13 -> this is the ARC start point
14 LIN S1P2 Vel=0.6 m/min CPDAT2 ARC Job=10 Set=W1 ESet=EW1
Sync=a4 -> R1_R2_R3 Tool[1] Base[0]
15 <= strike end =
16 = start insert movements =>
17 ;insert movements on seam with or without ARC only here
18
19 LIN S1P3 CONT Vel=0.6 m/min CPDAT3 Sync=a5 -> R1_R2_R3 Tool[1]
Base[0]
Base[0]
Base[0]
22
23 <= end insert movements =
24 this is the ARC_OFF point
25
26 LIN S1P1000 Vel=0.6 m/min CPDAT1000 ARC_OFF Job=10 Set=C
27 <== Seam End ==
29 -> if needed add additional movements after ARC_OFF below
30
31 LIN S1P6 CONT Vel=1 m/s CPDAT6 Sync=a10 -> R1_R2_R3 Tool[1]
Base[0]
32 END
-----------------------------------------------------------------33 ...
Description
Line
Description
Point in the seam program before the ignition position. (A

point is generally taught above the ignition position for this.)
10
12
This point must be identical to the point in the first ARC

instruction.
14
Ignition.
19 21
Motions on the seam.
26
Motion to the end crater position. The seam is completed.
31
Point in the seam program after the end of the seam. (A point
is generally taught above the end crater position for this.)
33
The subprogram for the seam-specific service routines follows.
The example point P1 from the template was renamed.
(>>> 8.1.6 "Example of a service routine" Page 53)
52 / 65
8 Example programs
8.1.5
Example of seam program 2
Program
1 DEF MyProgram_Seam02( )
2 INI
3
4 -> if needed add movements before first seam position
5
8 == seam start ==>
9 = strike start =>
10 ARC_Strike_Param Job=10 Set=S ESet=ES Sync=s2 -> R1_R2_R3
11 -> this point must be the same as the ARC start point
12 LIN S2P2 Vel=0.6 m/min CPDAT2 Tool[1] Base[0]
13 -> this is the ARC start point
15 <= strike end =
16 = start insert movements =>
17 ;insert movements on seam with or without ARC only here
18
19 LIN S2P3 CONT Vel=0.6 m/min CPDAT3 Sync=a14 -> R1_R2_R3
Tool[1] Base[0]
20 LIN S2P4 CONT Vel=0.6 m/min CPDAT4 Sync=a15 -> R1_R2_R3
Tool[1] Base[0]
23
24 <= end insert movements =
25 this is the ARC_OFF point
26 LIN S2P1000 Vel=0.6 m/min CPDAT1000 ARC_OFF Job=3 Set=C
27 <== Seam End ==
29 -> if needed add additional movements after ARC_OFF below
30
32 END
Description
Line
Description
Point in the seam program before the ignition position. (A

point is generally taught above the ignition position for this.)
10
12
This point must be identical to the point in the first ARC

instruction.
14
Ignition.
19, 20
Motions on the seam.
21
Modification of the weld parameters.
The example point P1 from the template was renamed.
8.1.6
26
Motion to the end crater position. The seam is completed.
31
Point in the seam program after the end of the seam. (A point
is generally taught above the end crater position for this.)
Example of a service routine

Seam-specific service routines for seam 1.
53 / 65
Program
Description
54 / 65
33 DEF
ServiceStrategy(ConsiderCRErr:IN,Motion:IN,Service:IN,MsgType:IN,Cal
lFrom[]:OUT,TeachModeSender:IN)
34 HALT for TeachMode
35
36
38 LIN P101 CONT Vel=1 m/s CPDAT101 Sync=b1 -> R1_R2_R3 Tool[1]
Base[0]
Base[0]
40 LIN P103 Vel=1 m/s CPDAT103 Sync=b3 -> R1_R2_R3 Tool[1]
Base[0]
41
42
Base[0]
Base[0]
46
47
48
49
Base[0]
Base[0]
53
54
-- insert motion from maintenance pos. back to seam -55 LIN P203 CONT Vel=1 m/s CPDAT203 Sync=b9 -> R1_R2_R3 Tool[1]
Base[0]
Base[0]
57
58 END
Line
Description
36 46
Service routine 01
38 40
Motions to the service position
41
44, 45
Motions from the service position back to the path
48 57
Service routine 02
51, 52
Motions to the service position
53
55, 56
Motions from the service position back to the path
9 KUKA Service
KUKA Service
9.1
Requesting support
Introduction
The KUKA Roboter GmbH documentation offers information on operation and

provides assistance with troubleshooting. For further assistance, please contact your local KUKA subsidiary.
Faults leading to production downtime should be reported to the local KUKA
subsidiary within one hour of their occurrence.
Information
9.2
The following information is required for processing a support request:
Model and serial number of the robot
Model and serial number of the controller
Model and serial number of the linear unit (if applicable)
Version of the KUKA System Software
Optional software or modifications
Archive of the software
Application used
Any external axes used
Description of the problem, duration and frequency of the fault
KUKA Customer Support
Availability
KUKA Customer Support is available in many countries. Please do not hesitate to contact us if you have any questions.
Argentina
Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com
Australia
Marand Precision Engineering Pty. Ltd. (Agency)

153 Keys Road
Moorabbin
Victoria 31 89
Australia
Tel. +61 3 8552-0600
Fax +61 3 8552-0605
robotics@marand.com.au
55 / 65
56 / 65
Belgium
KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be
Brazil
KUKA Roboter do Brasil Ltda.

Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guan
CEP 02151 900 So Paulo
SP Brazil
Tel. +55 11 69844900
Fax +55 11 62017883
info@kuka-roboter.com.br
Chile
Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl
China
KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd.

Shanghai Qingpu Industrial Zone
No. 502 Tianying Rd.
201712 Shanghai
P.R. China
Tel. +86 21 5922-8652
Fax +86 21 5922-8538
Franz.Poeckl@kuka-sha.com.cn
www.kuka.cn
Germany
KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-4000
Fax +49 821 797-1616
info@kuka-roboter.de
www.kuka-roboter.de
9 KUKA Service
France
KUKA Automatisme + Robotique SAS

Techvalle
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
commercial@kuka.fr
www.kuka.fr
India
KUKA Robotics, Private Limited

621 Galleria Towers
DLF Phase IV
122 002 Gurgaon
Haryana
India
Tel. +91 124 4148574
info@kuka.in
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
kuka@kuka.it
www.kuka.it
Japan
KUKA Robotics Japan K.K.

Daiba Garden City Building 1F
2-3-5 Daiba, Minato-ku
Tokyo
135-0091
Japan
Tel. +81 3 6380-7311
Fax +81 3 6380-7312
info@kuka.co.jp
Korea
KUKA Robot Automation Korea Co. Ltd.

4 Ba 806 Sihwa Ind. Complex
Sung-Gok Dong, Ansan City
Kyunggi Do
425-110
Korea
Tel. +82 31 496-9937 or -9938
Fax +82 31 496-9939
info@kukakorea.com
57 / 65
58 / 65
Malaysia
KUKA Robot Automation Sdn Bhd

South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 3 8061-0613 or -0614
Fax +60 3 8061-7386
info@kuka.com.my
Mexico
KUKA de Mexico S. de R.L. de C.V.

Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
Norway
KUKA Sveiseanlegg + Roboter

Bryggeveien 9
2821 Gjvik
Norway
Tel. +47 61 133422
Fax +47 61 186200
geir.ulsrud@kuka.no
Austria
KUKA Roboter Austria GmbH

Vertriebsbro sterreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. +43 732 784752
Fax +43 732 793880
office@kuka-roboter.at
www.kuka-roboter.at
Poland

Spka z ograniczon odpowiedzialnoci
Oddzia w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
ServicePL@kuka-roboter.de
9 KUKA Service
Portugal
KUKA Sistemas de Automatizacin S.A.

Rua do Alto da Guerra n 50
Armazm 04
2910 011 Setbal
Portugal
Tel. +351 265 729780
Fax +351 265 729782
kuka@mail.telepac.pt
Russia
OOO KUKA Robotics Rus

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

A. Odhners gata 15
421 30 Vstra Frlunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se
Switzerland
KUKA Roboter Schweiz AG

Riedstr. 7
8953 Dietikon
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch
Spain
KUKA Robots IBRICA, S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltr (Barcelona)
Spain
Tel. +34 93 8142-353
Fax +34 93 8142-950
Comercial@kuka-e.com
www.kuka-e.com
59 / 65
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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.

136, Section 2, Huanjung E. Road
Jungli City, Taoyuan
Taiwan 320
Tel. +886 3 4371902
Fax +886 3 2830023
info@kuka.com.tw
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
atika@ji-net.com
www.kuka-roboter.de
Czech Republic

Organisation Tschechien und Slowakei
Sezemick 2757/2
193 00 Praha
Horn Poernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
support@kuka.cz
Hungary
KUKA Robotics Hungaria Kft.

F t 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu
9 KUKA Service
USA
KUKA Robotics Corp.

22500 Key Drive
Clinton Township
48036
Michigan
USA
Tel. +1 866 8735852
Fax +1 586 5692087
info@kukarobotics.com
www.kukarobotics.com
UK
KUKA Automation + Robotics

Hereward Rise
Halesowen
B62 8AN
UK
Tel. +44 121 585-0800
Fax +44 121 585-0900
sales@kuka.co.uk
61 / 65
62 / 65
Index
Index
A
Action 6
Actions 47
Areas of application 9
C
CADU_UserGlobal 10
Checking, TCP 10
Collision 10
Communication 10
Component program 6
Component program, changing the name 44
Component program, creating 43
Component program, duplicating 45
Configuration 23
CR.ArcTech Digital Power Sources 10
Cycflags 15
D
Documentation, industrial robot 5
Dry run 7
Dry run velocity 33
Dry run, automatic 33
Dry run, configuration 33
Dry run, manual 20
Duplicating a component program 45
Duplicating a seam program 45
E
End crater position 6
Error strategies, configuration 26
Example programs 49
F
Function generators 15
Functions, CR.ArcTech Digital 9
I
Ignition error 7
Ignition errors 49
Installation 15
Interrupts 15
Introduction 5
K
Knowledge, required 5
KUKA Customer Support 55
KUKA.CR.MotionCooperation 49
KUKA.ToolCorrManual 10
KUKA.WeaveTech 10
L
Local device 6
M
Menus 19
O
On-the-fly, activation 6
On-the-fly, deactivation 6
On-the-fly, ignition 6
Operation 19
Overlap distance 28, 31
Overview of CR.ArcTech Digital 9
P
Product description 9
Program Generator 9, 10, 26, 28
Programming 37
Programs, creating 38, 43
R
Remote device 6
S
Safety 13
Safety instructions 5
Seam program 6
Seam program, changing the name 44
Seam program, creating 43
Seam program, duplicating 45
Seam programs, changing the order 44
Service routine 6
Service routines 45
Service, KUKA Roboter 55
Status keys 19, 23
Support request 55
System requirements 15
T
Target group 5
Terms 6
Terms used 6
Timers 15
Trademarks 6
Training 5
U
Uninstallation, CR.ArcTech Digital Power Sources 16
Uninstalling CR.ArcTech Digital 17
V
VelUnitsConfig.xml 34
W
Warnings 5
Weaving, mechanical 10
Weld error 6
Weld errors 50
Weld instructions 48
Weld operation, structure 37
Weld seam, asynchronous 6
Weld seam, synchronous 6
Without welding 6
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KST CRArcTech Digital 32 en

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KST CRArcTech Digital 32 en

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KUKA System Technology

CR.ArcTech Digital 3.2

Version: KST CR.ArcTech Digital 3.2 V3 en

KUKA Roboter GmbH

CR.ArcTech Digital 3.2

Pub KST CR.ArcTech Digital 3.2 en

KST CR.ArcTech Digital 3.2 V3.1

KST CR.ArcTech Digital 3.2 V3 en

Issued: 30.09.2010 Version: KST CR.ArcTech Digital 3.2 V3 en

Target group ..............................................................................................................

Industrial robot documentation ...................................................................................

Representation of warnings and notes ......................................................................

Terms used ................................................................................................................

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

Overview of CR.ArcTech Digital ................................................................................

Program Generator: Structure in the Navigator .........................................................

System requirements .................................................................................................

Installing or updating CR.ArcTech Digital ..................................................................

Installing/updating CR.ArcTech Digital Power Sources separately ...........................

Uninstalling CR.ArcTech Digital Power Sources .......................................................

Uninstalling CR.ArcTech Digital .................................................................................

Check last installation/uninstallation ..........................................................................

Status keys ................................................................................................................

Configuration: General ...............................................................................................

Configuration user interface ..................................................................................

Configuring CR.ArcTech Digital ............................................................................

Archiving a configuration ......................................................................................

Loading a configuration ........................................................................................

Saving long text names of the configuration .........................................................

Configuration: Error strategies ...................................................................................

Error strategy configuration interface ....................................................................

Configuring error strategies ..................................................................................

Configuration parameters: Error strategies ...........................................................

Configuration parameters: Arc-strike error strategies ...........................................

Configuration parameters: Weld error handling strategy ......................................

Notes on configuring error strategies ....................................................................

Notes on configuring actions and service routines ...............................................

Overlap distance ...................................................................................................

Configuration: Dry run ................................................................................................

Configuring the dry run velocity ............................................................................

Activating/deactivating automatic dry run .............................................................

Configuration of VelUnitsConfig.xml ..........................................................................

Structure of a weld operation .....................................................................................

Standard program or Generator program? ................................................................

Issued: 30.09.2010 Version: KST CR.ArcTech Digital 3.2 V3 en

CR.ArcTech Digital 3.2

Structure of a standard program ................................................................................

Structure of Generator programs ...............................................................................

Structure of a component program .......................................................................

Structure of a seam program ................................................................................

Structure of a subprogram for a service routine ...................................................

Structure of a subprogram for actions ..................................................................

Creating programs with the Program Generator .......................................................

Creating a new component program with seam programs ...................................

Program IDs .........................................................................................................

Changing the order of the seam programs ...........................................................

Changing the name of a component program ......................................................

Changing the name of a seam program ...............................................................

Duplicating a component program ........................................................................

Duplicating a seam program .................................................................................

Service routines ....................................................................................................

Teaching a service routine ...................................................................................

Service routine: moving to points by means of block selection ............................