KRC4_SafeOperation

KUKA System Technology

KUKA.SafeOperation 3.1 For KUKA System Software 8.2 For VW System Software 8.2 Assembly and Operating Instructions

Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

KUKA Roboter GmbH

KUKA.SafeOperation 3.1

© Copyright 2011 KUKA Roboter GmbH Zugspitzstraße 140 D-86165 Augsburg Germany This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Roboter GmbH. Other functions not described in this documentat ion may be operable in the controller. Th e user has no claims to these functions, however, in the case of a replacement or service work. We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition. Subject to technical alterations without an effect on the function. Translation of the original documentation KIM-PS5-DOC

Publication: Bookstructure: Label:

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Pub KST SafeOperation 3.1 en KST SafeOperation 3.1 V1 V1.1 KST SafeOperation 3.1 V1 en


Contents

Contents 1

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

7

1.1 1.2 1.2 1.3 1.3 1.4

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

7 7 7 8

2

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

11

2.1 2.1 Ov Over ervi view ew of Safe SafeOp Oper erat atio ion n .... ...... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... 2.2 Monitori oring spaces ...... ......... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ..... 2.2.1 Coordinate systems .... ...... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... 2.2. 2.2.1. 1.1 1 Spec pecial ial case casess ...... ......... ....... ....... ...... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ..... .. 2.2.2 Cell area ....... .......... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ... 2.2.3 Cartesian wo workspaces .... ...... ..... ...... ..... .... .... ..... ..... ..... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... 2.2.4 Carte rtesian pro prottect ected sp spaces .... ...... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... 2.2.5 Axis-specific fic wor workspaces .... ...... .... ..... ...... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... 2.2. 2.2.6 6 Axis Axis-s -spe peci cifi ficc pro prote tect cted ed spac spaces es ..... ....... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... .... 2.2.7 Space-specific ve velocity ..... ....... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... 2.2.8 Reference stop ...... .......... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ....... ....... ...... ...... ..... .. 2.3 Safe tools ...... ......... ....... ....... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ... 2.4 2.4 Velo Veloci city ty mon monititor orin ing g func functition onss .... ...... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... 2.5 2.5 Safe afe oper operat atio iona nall stop stop ..... ....... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... 2.6 Overrid ride re reduction ...... .......... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ....... ....... ...... ...... ..... .. 2.7 2.7 CRR CRR mod mode e (saf (safe e rob robot ot retr retrac actition on)) .... ....... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... .... .... ..... ..... .... .. 2.8 Start-up mode ....... .......... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ... 2.9 Mastering test ....... .......... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ... 2.9.1 Reference position .... ...... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... ..... ..... .... .... .. 2.9.2 Refer ference switch mod module .... ...... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... 2.9.3 Connecting ca cables .... ...... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... ..... ..... .... .... ..

11 12 14 15 16 17 18 19 20 22 22 23 23 24 24 25 26 26 27 28 28

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

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3.1 3.2 3.3 3.3 3.4 3.4

Service life ....... .......... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ...... .. Refe eference switch ...... .......... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ...... ....... ....... ...... ...... ...... ... Refe Refere renc nce e swi switc tch h hol hole e pat patte tern rn ..... ........ ...... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... Hole Hole patt patter ern n for for act actua uatiting ng plat plate e .... ...... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... ..... ..... .... .... ....

31 31 32 32

4

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

35

4.1 4.1.1 4.1. 4.1.2 2 4.1. 4.1.3 3 4.1.4 4.2 4.3 4.3 4.4 4.4 4.5 4.5. 4.5.1 1 4.5.2

General ...... ......... ...... ....... ....... ....... ....... ...... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ...... ...... ... Liability ...... .......... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ... Inte Intend nded ed use use of the the indu indust stri rial al robo robott .... ...... .... ..... ...... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .. EC dec decla larat ratio ion n of con confor formi mity ty and and dec decla lara ratio tion n of inco incorp rpora oratition on ............................... Terms used ...... .......... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ...... ...... ... Personnel ...... ......... ....... ....... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ........ ....... ...... ...... ....... ....... ...... ...... ... Work Worksp spac ace, e, safe safety ty zone zone and and dan dange gerr zone zone .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... Trig Trigge gers rs for for stop stop reac reactition onss ..... ....... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... Safe afety functions ...... ......... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ....... ........ ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ..... Over Ov ervi view ew of the the saf safet etyy fun funct ctio ions ns ..... ....... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ...... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .. Safety co controller ... r ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ...... ...

35 35 35 36 36 38 39 40 41 41 41


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4.5.3 Mode selection ..................................................................................................... 4.5.4 Operator safety ..................................................................................................... 4.5.5 EMERGENCY STOP device ................................................................................ 4.5.6 Logging off the higher-level safety controller ........................................................ 4.5.7 External EMERGENCY STOP device .................................................................. 4.5.8 Enabling device .................................................................................................... 4.5.9 External enabling device ...................................................................................... 4.5.10 External safe operational stop .............................................................................. 4.5.11 External safety stop 1 and external safety stop 2 ................................................. 4.5.12 Velocity monitoring in T1 ...................................................................................... 4.6 Additional protective equipment ................................................................................ 4.6.1 Jog mode .............................................................................................................. 4.6.2 Software limit switches ......................................................................................... 4.6.3 Mechanical end stops ........................................................................................... 4.6.4 Mechanical axis range limitation (optional) ........................................................... 4.6.5 Axis range monitoring (optional) ........................................................................... 4.6.6 Release device (optional) ..................................................................................... 4.6.7 Labeling on the industrial robot ............................................................................ 4.6.8 External safeguards ............................................................................................. 4.7 Overview of operating modes and safety functions ................................................... 4.8 Safety measures ........................................................................................................ 4.8.1 General safety measures ..................................................................................... 4.8.2 Transportation ...................................................................................................... 4.8.3 Start-up and recommissioning .............................................................................. 4.8.3.1 Start-up mode ....................................................................................................... 4.8.4 Manual mode ........................................................................................................ 4.8.5 Simulation ............................................................................................................. 4.8.6 Automatic mode ................................................................................................... 4.8.7 Maintenance and repair ........................................................................................ 4.8.8 Decommissioning, storage and disposal .............................................................. 4.8.9 Safety measures for “single point of control” ........................................................ 4.9 Applied norms and regulations ..................................................................................

42 42 43 43 44 44 45 45 45 45 45 45 45 46 46 46 46 47 47 48 48 48 50 50 52 52 53 53 54 55 55 57

5

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

59

5.1 5.2 5.3

System requirements ................................................................................................. Installing or updating SafeOperation ......................................................................... Uninstalling SafeOperation ........................................................................................

59 59 59

6

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

61

6.1 6.2 6.3 6.4 6.4.1 6.4.2 6.4.3

User groups ............................................................................................................... Opening the safety configuration ............................................................................... Overview of buttons ................................................................................................... Monitor functions ....................................................................................................... Displaying information about the safety configuration .......................................... Displaying the change log .................................................................................... Displaying machine data ......................................................................................

61 61 61 62 62 63 63

7

Start-up and recommissioning ...................................................................

65

7.1

Start-up overview .......................................................................................................

65


Contents

7.2 Safety warnings ......................................................................................................... 7.3 Installing the reference switch and actuating plate .................................................... 7.4 Connecting a reference switch ................................................................................... 7.5 Activating safe monitoring .......................................................................................... 7.6 Defining global parameters ........................................................................................ 7.7 Defining a cell area .................................................................................................... 7.8 Defining Cartesian monitoring spaces ....................................................................... 7.9 Defining axis-specific monitoring spaces ................................................................... 7.10 Defining axis-specific velocity monitoring .................................................................. 7.11 Defining the safe operational stop ............................................................................. 7.12 Defining safe tools ..................................................................................................... 7.13 Defining the reference position .................................................................................. 7.14 Checking the reference position (actuation with tool) ................................................ 7.15 Saving the safety configuration .................................................................................. 7.16 Performing a mastering test manually ....................................................................... 7.17 Testing safety parameters ......................................................................................... 7.17.1 Testing Cartesian velocity ..................................................................................... 7.17.2 Testing maximum axis velocity ............................................................................. 7.17.3 Testing Cartesian monitoring spaces ................................................................... 7.17.4 Testing axis-specific monitoring spaces ............................................................... 7.17.5 Testing safe operational stop for an axis group .................................................... 7.18 Safety acceptance overview ...................................................................................... 7.19 Activating a new safety configuration ......................................................................... 7.20 Deactivating safe monitoring ......................................................................................

66 67 67 68 68 70 72 75 79 82 84 87 89 90 91 91 91 92 93 94 94 94 95 96

8

Programming ...............................................................................................

97

8.1 8.2

Programs for the mastering test ................................................................................. Programming a mastering test ...................................................................................

97 97

9

System variables .........................................................................................

99

9.1 9.2 9.3

Variables for override reduction in $CUSTOM.DAT .................................................. Variables for the mastering test ................................................................................. Variables for diagnosis ...............................................................................................

99 99 100

10

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

101

10.1 SafeOperation via PROFIsafe (optional) ................................................................... 10.1.1 Diagnostic signals via PROFINET ........................................................................ 10.2 SafeOperation via interface X13 (optional) ................................................................

101 103 107

11

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

109

11.1 Displaying safe I/Os ...................................................................................................

109

12

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

111

12.1 Messages during operation ........................................................................................

111

13

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

115

13.1 Checklists ................................................................................................................... 13.1.1 Precondition for safety acceptance based on the checklists ................................ 13.1.2 Checklist for robot and system ............................................................................. 13.1.3 Checklist for safe functions ...................................................................................

115 115 115 115


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13.1.4 Checklist for velocity limits .................................................................................... 13.1.5 Checklist for configuration of the safe operational stop ........................................ 13.1.6 Checklist for configuration of the cell area ............................................................ 13.1.7 Checklist for configuration of Cartesian monitoring spaces .................................. 13.1.8 Checklist for configuration of axis-specific monitoring spaces ............................. 13.1.9 Checklist for configuration of the safe tools .......................................................... 13.2 Applied norms and directives ....................................................................................

118 121 122 123 125 127 130

14

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

131

14.1 Requesting support ................................................................................................... 14.2 KUKA Customer Support ...........................................................................................

131 131

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

139


1 Introduction

1

Introduction

1.1

Target group This documentation is aimed at users with the following knowledge and skills:  

Advanced knowledge of the robot controller system Advanced KRL programming skills

For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training program can be found at www.kuka.com or can be obtained 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 These warnings are relevant to safety and must be observed. These warnings mean that it is certain or highly probable that death or severe physical injury will occur, if no precautions are taken. These warnings mean that death or severe physical injury may occur, if no precautions are taken. These warnings mean that minor physical injuries may occur, if no precautions are taken. These warnings mean that damage to property may occur, if no precautions are taken. These warnings contain references to safety-relevant information or general safety measures. These warnings do not refer to individual hazards or individual precautionary measures.

Hints

These hints serve to make your work easier or contain references to further information. Tip to make your work easier or reference to further information.


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1.4

Terms used Term

Description

Axis range

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

Axis limit Stopping distance

Workspace

The stopping distance is part of the danger zone. Monitoring space that the defined axes or the safe tool must not leave. The axes or the safe tool must always move within the limits of the workspace. (>>> 2.2.5 "Axis-specific workspaces" Page 19)

Danger zone Mastering test

KL CRR

Alarm space

Monitoring time Polygon, convex

PROFIsafe

Reference group Reference position

(>>> 2.2.3 "Cartesian workspaces" Page 17) The danger zone consists of the workspace and the stopping distances. The mastering test is used to check whether the current position of the robot and the external axes corresponds to a reference position. (>>> 2.9 "Mastering test" Page 26) KUKA linear unit Controlled robot retraction Operating mode for retracting the robot in the case of a workspace violation. An alarm space signals a workspace violation by setting an output. The alarm spaces are permanently assigned to the configurable outputs of the interface options PROFIsafe and X13 (SIB Extended). During the monitoring time, the user is prompted to perform a mastering test. A convex polygon is a polygon consisting of at least 3 different corners. Triangles and squares are examples of convex polygons. (>>> 2.2.2 "Cell area" Page 16) PROFIsafe is a PROFINET-based safe interface for connecting a safety PLC to the robot controller. (PLC = master, robot controller = slave) (>>> 10.1 "SafeOperation via PROFIsafe (optional)" Page 101) A reference group contains the axes of a kinematic system that are required for moving to a reference position and are to be subjected to safe monitoring. The reference position is a Cartesian position to which the robot moves during the mastering test. (>>> 2.9.1 "Reference position" Page 27)

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1 Introduction

Term

Description

Reference stop

Safety stop that is triggered if the mastering test has not been carried out. The reference stop can be activated for monitoring spaces.

Reference switch

Protected space

(>>> 2.2.8 "Reference stop" Page 22) A reference switch is necessary for carrying out the mastering test. The reference switch confirms the reference position. (>>> 3.2 "Reference switch" Page 31) Monitoring space that the defined axes or the safe tool must not enter. The axes or the safe tool must always move outside the limits of the protected space. (>>> 2.2.6 "Axis-specific protected spaces" Page 20)

SIB Safety STOP 0

(>>> 2.2.4 "Cartesian protected spaces" Page 18) Safety Interface Board A stop that is triggered and executed by the safety controller. The safety controller immediately switches off the drives and the power supply to the brakes. Note: This stop is called safety STOP 0 in this docu-

Safety STOP 1

ment. A stop that is triggered and monitored by the safety controller. The braking process is performed by the non-safety-oriented part of the robot controller and monitored by the safety controller. As soon as the manipulator is at a standstill, the safety controller switches off the drives and the power supply to the brakes. Note: This stop is called safety STOP 1 in this docu-

Safety STOP 2

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

Safe operational stop

Safe tool

ment. In the case of a safe operational stop, the standstill of the axes for which it has been configured is monitored. When the axes are at a monitored standstill, they may move within the configured axis angle or distance tolerances. (>>> 2.5 "Safe operational stop" Page 24) Tool with up to 6 spheres modeled around it. These spheres are monitored against the limits of the Cartesian monitoring spaces. Each safe tool has a safe TCP which is monitored against the configured velocity limits. (>>> 2.3 "Safe tools" Page 23)


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Term

Description

Monitoring space

A monitoring space can be Cartesian or axis-specific and can be defined as a workspace or protected space.

Cell area

(>>> 2.2 "Monitoring spaces" Page 12) Cartesian workspace with 3 to 10 corners forming a convex polygon and limited in the ±Z direction. The cell area is the maximum permissible workspace of the robot. (>>> 2.2.2 "Cell area" Page 16)

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2 Product description

2

Product description

2.1

Overview of SafeOperation

Functions

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

          

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

Components

These software components are included in the SafeOperation package: 

KUKA.SafeOperation

These hardware components are included in the SafeOperation package: 

Areas of application

  

Reference switch module Human-robot cooperation Direct loading of workpieces without an intermediate support Replacement of conventional axis range monitoring systems


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

1 2 3 4 Functional principle

Reference switch Robot Loading station Safety mat

5 6 7

System control panel Robot controller Bending machine

The components of the industrial robot move within the limits that have been configured and activated. The actual positions are continuously calculated and monitored against the safety parameters that have been set. The safety controller monitors the industrial robot by means of the safety parameters that have been set. If a component of the industrial robot violates a monitoring limit or a safety parameter, the robot and external axes (optional) are stopped. Decouplable external axes are not supported by SafeOperation. In the case of decouplable external axes, safe position sensing is not possible, as the machine data change while the controller is running.

Interfaces

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

2.2

PROFINET/PROFIsafe Interface X13 via SIB Extended

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

Monitoring space

A monitoring space can be defined as a Cartesian cuboid or by means of individual axis ranges. Each monitoring space can be set as a workspace or protected space. (>>> 2.2.3 "Cartesian workspaces" Page 17)

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(>>> 2.2.4 "Cartesian protected spaces" Page 18) (>>> 2.2.5 "Axis-specific workspaces" Page 19) (>>> 2.2.6 "Axis-specific protected spaces" Page 20) For every monitoring space, a space-specific Cartesian velocity can be defined inside or outside the monitoring space. (>>> 2.2.7 "Space-specific velocity" Page 22) For each monitoring space, a reference stop can be set t hat stops the robot if no mastering test has been carried out. (>>> 2.2.8 "Reference stop" Page 22) Monitoring can be activated and deactivated for each individual monitoring space, or activated by means of safe inputs. Safe outputs are permanently assigned to the monitoring spaces. The safe outputs are set if a monitoring space is violated. Whether or not a stop is triggered at the space limit is a function that can be activated. Cell area

The cell area is a Cartesian workspace in the form of a convex polygon with 3 to 10 corners and is limited in the ±Z direction. (>>> 2.2.2 "Cell area" Page 16) The cell area is permanently monitored and always active. The corners can be configured, activated and deactivated individually. A safety stop 0 is always triggered at the space limit.

Stopping distance

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

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

EN ISO 10218-1, Annex B, specifies the need for information about the stopping time and distance. These have not yet been determined in full for all robot types in conjunction with the KR C4 robot controller. In this respect, the industrial robot does not conform to the requirements of EN ISO 10218-1. Stop reactions

Stop reaction

Description

Example

Safety stop 0

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

Safety stop 1

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

Robot exceeds the limit of an activated workspace in Automatic mode. Robot exceeds the limit of an activated workspace in T1 mode. A protected space in which the robot is currently situated is activated by a safety mat.


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2.2.1

Coordinate systems

Overview

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

WORLD ROBROOT BASE TOOL

Fig. 2-2: Overview of coordinate systems Description

WORLD

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

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

The BASE coordinate system is a Cartesian coordinate system that defines the position of the workpiece. It is relative to the WORLD coordinate system. By default, the BASE coordinate system is identical to the WORLD coordinate system. It is offset to the workpiece by the user. TOOL 14 / 143



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

2.2.1.1

Angle

Rotation about axis

Angle A Angle B Angle C

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

Special cases

Fig. 2-3: ROBROOT coordinate system Jet

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


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Fig. 2-4: ROBROOT coordinate system KL

In the case of a KL, the relationship between the ROBROOT coordinate system and the WORLD coordinate system changes. The ROBROOT coordinate system moves with the robot on the KL. 2.2.2

Cell area

Description

The cell area is a Cartesian monitoring space that is limited in the ±Z direction. Up to 6 user-configured spheres are modeled around the safe tool on the mounting flange of the robot; when the robot moves, these spheres move with it. These spheres are monitored against the cell area and must only move within this cell area. If a sphere violates the limits of the cell area, the robot stops with a safety stop 0. When configuring and programming, it must be remembered that the Cartesian monitoring spaces are only monitored against the modeled spheres on the mounting flange of the robot. If robot components are situated outside the modeled spheres, they are not monitored and a violation of the limit is not detected. Failure to observe this precaution may result in severe physical injuries and considerable damage to property. The cell area is configured in the WORLD coordinate system as a convex polygon with 3 to 10 corners. A convex polygon is a polygon consisting of at least 3 different corners. The individual line segments of the vertices must not be outside the polygon. Triangles and squares are examples of convex polygons.

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Fig. 2-5

1 2

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

The diagram shows an example of a configured cell area.

Example

Fig. 2-6: Example of a cell area

1 2 3 2.2.3

Cell area Spheres on safe tool Robot

Cartesian workspaces

Description

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



A safe output is set (alarm space). If interface X13 is used, safe outputs are only available for monitoring spaces 1 … 6. The robot is stopped (configurable).


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KUKA.SafeOperation 3.1 

Cartesian velocity monitoring is activated (configurable).

When configuring and programming, it must be remembered that the Cartesian monitoring spaces are only monitored against the modeled spheres on the mounting flange of the robot. If robot components are situated outside the modeled spheres, they are not monitored and a violation of the limit is not detected. Failure to observe this precaution may result in severe physical injuries and considerable damage to property. Only KUKA linear units are supported as ROBROOT kinematic systems. The diagram shows an example of a configured Cartesian workspace.

Example

Fig. 2-7: Example of a Cartesian workspace

1 2 3 2.2.4

Workspace Spheres on safe tool Robot

Cartesian protected spaces

Description

Up to 6 user-configured spheres are modeled around the safe tool on the mounting flange of the robot; when the robot moves, these spheres move with it. These spheres are simultaneously monitored against the activated Cartesian protected spaces and must move outside the protected spaces. If a sphere violates the limit of a protected space, the following reactions can occur: 



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A safe output is set (alarm space). If interface X13 is used, safe outputs are only available for monitoring spaces 1 … 6. The robot is stopped (configurable). Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

2 Product description 


When configuring and programming, it must be remembered that the Cartesian monitoring spaces are only monitored against the modeled spheres on the mounting flange of the robot. If robot components are situated outside the modeled spheres, they are not monitored and a violation of the limit is not detected. Failure to observe this precaution may result in severe physical injuries and considerable damage to property. Only KUKA linear units are supported as ROBROOT kinematic systems. The diagram shows an example of a Cartesian protected space.

Example

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

1 2 3 2.2.5

Protected space Spheres on safe tool Robot

Axis-specific workspaces

Description

The axis limits can be set and monitored individually for each axis via the software. The resulting axis range is the permissible range of an a xis within which the robot may move. The individual axis ranges together make up the overall workspace, which may consist of up to 8 axis ranges. 6 robot axes and 2 external axes can be defined in a workspace. If the robot violates an axis limit, the following reactions can occur: 



A safe output is set (alarm space). If interface X13 is used, safe outputs are only available for monitoring spaces 1 … 6. The robot is stopped (configurable).


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

Example

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

1 2 2.2.6

Workspace Robot

3 4

Stopping distance Protected space

Axis-specific protected spaces

Description

The axis limits can be set and monitored individually for each axis via the software. The resulting axis range is the protected range of an axis within which the robot may not move. The individual axis ranges together make up the overall protected space, which may consist of up to 8 axes ranges. 6 robot axes and 2 external axes can be defined in a protected space. If the robot violates an axis limit, the following reactions can occur: 

 

A safe output is set (alarm space). If interface X13 is used, safe outputs are only available for monitoring spaces 1 … 6. The robot is stopped (configurable). Cartesian velocity monitoring is activated (configurable).

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

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

1 2

Example

Workspace Robot

3 4

Protected space Protected space through which the robot can move

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

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

1 2 3

Permissible range 1 Robot Stoppi pping di distance


4 5

Protected space Permissible range 2

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2.2. 2.2.7 7

Spac Spacee-sp spec ecif ific ic velo veloci city ty

Description

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

Example

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

Fig. 2-12: Space-specific velocity example

1 2 3 2 . 2 .8

Workspace Spher pheres es on safe safe tool tool Robot

Reference stop

Description

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

Monitoring space is activated. Mastering test is requested internally.

If the reference stop is activated and the following preconditions are met, the robot stops with a safety stop 2:   

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



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

2.3

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

Safe tools

Description

Up to 16 safe tools can be defined. Up to 6 user-configured sphere s are modeled around each safe tool; these are monitored against the limits of the Cartesian monitoring spaces. A safe TCP is defined for each safe tool and monitored against the configured velocity limits. The safe tools are activated using safe inputs. Only one safe tool may be active at any time. The safe TCP for the velocity monitoring can be freely configured in the safety configuration. It is independent of the current TCP that is set in the KUKA System Software with the variable $TOOL. When configuring and programming, it must be remembered that the Cartesian monitoring spaces are only monitored against the modeled spheres on the mounting flange of the robot. If robot components are situated outside the modeled spheres, they are not monitored and a violation of the limit is not detected. Failure to observe this precaution may result in severe physical injuries and considerable damage to property.

Example

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

Fig. 2-13: Safe tool

2.4

Velocity mo monitoring fu functions Axis-specific and Cartesian velocities can be monitored.


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Axis velocity

The velocity of every axis can be monitored against a limit value.   

Cartesian velocity

Axis velocity limit value Reduced axis velocity limit value for T1 mode Maximum axis velocity limit value (not axis-dependent)

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



Limit value for the reduced velocity at the safe TCP Limit value for the reduced velocity at the safe TCP for T1 mode Limit value for the maximum velocity at the safe TCP and at the sphere center points of the safe tool (not space-dependent) Space-specific velocity (>>> 2.2.7 "Space-specific velocity" Page 22)

Stop reactions

Stop reaction

Description

Example

Safety stop 0

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

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

Safety stop 1

2.5

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

Safe operational stop

Description

Safe operational stop can be configured for up to 6 axis groups. The axes for which a safe operational stop is to be activated are grouped together in an a xis group. A standstill window can be configured in which an axis can still move with the safe operational stop activated. The axis angle or distance tolerance can be configured individually for axes 1 to 8. The axes activated for safe operational stop are not dependent on the activated axes for axis-specific workspace monitoring. If safe operational stop is activated, the standstill of the axes for which it has been configured is monitored. The axes that are at a monitored standstill may move within the configured axis angle or distance tolerances. If the safe operational stop is violated, i.e. if the tolerance is exceeded or the velocity is minimally increased, a safety stop 0 is trigge red. The safety stop 0 affects all axes, not just those for which the operational stop is configured.

2.6

Override reduction

Description

Override reduction is not subjected to safe monitoring. The variables for override reduction can be modified in the $CUSTOM.DAT file, in a KRL program or via the variable correction function. If a variable is modified, an advance run stop is triggered. (>>> 9.1 "Variables for override reduction in $CUSTOM.DAT" Page 99)

$SR_VEL_RED

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The variable $SR_VEL_RED is used to activate override reduction for the velocity. The Cartesian velocity at the safe TCP of the active tool is automatically reduced if the programmed velocity is greater than the value of the lowest veIssued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en


locity limit that is activated and currently monitored by the safety controller. This prevents the robot from being stopped when the Cartesian velocity limit is exceeded. $SR_OV_RED

The variable $SR_OV_RED specifies the percentage of the lowest velocity limit that is activated and currently monitored by the safe ty controller. The Cartesian velocity of the safe TCP of the active tool is reduced to this value.

$SR_WORKSPAC E_RED

If the function Stop at boundaries is activated for a monitoring space, the robot stops before it reaches the limit of the workspace. The stopping distance of the robot and the permissible distance between the robot and the workspace limits depend on the velocity of the robot. The variable $SR_WORKSPACE_RED can be used to activate over ride reduction for these monitoring spaces ($SR_WORKSPACE_RED = TRUE). If override reduction is active and the robot approaches the limit of a workspace, the override is continuously reduced to allow the robot to get as close as possible to the workspace limit without being stopped by the safety controller. If override reduction is active and the robot has violated the limit of a protected space, the robot reduces its velocity. As soon as it has reached a certain minimum distance from the workspace limit, the robot moves at its programmed velocity once again. The lowest velocity limit active on the safety controller is 1,000 mm/s. If $SR_VEL_RED = TRUE and $SR_OV_RED = 95 are set, the Cartesian velocity of the safe TCP of the active tool is reduced to 950 mm/s.

Example

Fig. 2-14: Example: Override reduction with $SR_VEL_RED

v3 v2 v1 t1 t2

2.7

Maximum Cartesian velocity; v3 = 1,200 mm/s Space-specific velocity; v2 = 1,000 mm/s 95% of velocity v2; v1 = 950 mm/s Override reduction is automatically activated because the programmed velocity exceeds velocity limit v1. Override reduction is automatically deactivated because the programmed velocity is lower than the velocity limit v1.

CRR mode (safe robot retraction)

Description

If the robot has violated a monitoring function and been stopped by the safety controller, it can only be moved out of the violated area in CRR mode. The motion velocity in CRR mode corresponds to that in T1 mode. In CRR mode, the robot can be moved to any position. No stop is triggered if it passes through other monitoring limits. The velocity monitoring functions remain active in CRR mode.


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2.8

Start-up mode External safeguards are disabled in Start-up mode. Observe the safety instructions relating to Start-up mode. (>>> 4.8.3.1 "Start-up mode" Page 52)

Description

Tool 1 is always active in Start-up mode. In Start-up mode, all monitor ing functions of the safety configuration that can be activated via safe inputs are deactivated. (>>> 10.1 "SafeOperation via PROFIsafe (optional)" Page 101) (>>> 10.2 "SafeOperation via interface X13 (optional)" Page 107) The following monitoring functions remain active:     



2.9

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

Mastering test

Overview

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



After the robot controller has booted Once the robot controller has booted, the robot can be moved for 2 hours without a mastering test. Once the monitoring time has elapsed, the robot stops with a safety stop 1. After mastering

The mastering test can be called in the following ways: 





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External request via a signal and automatic call of the program MasRef_Main.SRC Internal request caused by remastering or booting of the robot controller and automatic call of the program MasRef_Main.SRC Manual selection of the program MasRef_Main.SRC Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en


If, during operation, the mastering test is requested via the external signal, the mastering test is performed next time the program MasRef_Main.SRC is automatically called. If the reference switch is activated via PROFIsafe, the PLC input Mastering test must only be reset if the reference switch is actuated on both channels. This prevents a single-channel mastering test. 2.9.1

Reference position

Description

The reference position must be taught in the program MasRef_USER.SRC and in the safety configuration. (>>> 8.2 "Programming a mastering test" Page 97) The reference position can be approached with the actuating plate or with a ferromagnetic part of the tool. The reference run must be selected in accordance with the following criteria: 







The position of the reference switch and actuating plate must not interfere with the work sequence of the robot. The reference position must not be a position in which the axes are in a singularity. In the reference position, both proximity switch surfaces of the reference switch must be actuated by the switching surface (actuating plate or tool). In the reference position, the robot axes must be at least ±5° away from the mastering position.

Fig. 2-15: Example: position of the actuating plate on the reference switch

1 2 3 4 5

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


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2.9.2

Reference switch module

Description

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

Inductive reference switch XS Ref Actuating plate Reference cable X42 - XS Ref Reference connector X42

Fig. 2-16: Reference group hardware components

1 2.9.3

Inductive reference switch

2

Actuating plate

Connecting cables

Overview

The diagram shows an example of the connecting cables of the industrial robot with connected reference switch. The reference switch is connected via the reference cable to the robot controller. The maximum hose length is 50 m. Only 1 reference switch can be connected to the robot controller. If multiple reference groups are required, the reference switches can be connected to the safety PLC and activated via PROFIsafe. The safety PLC must evaluate the reference switches and set the inp ut Mastering test accordingly.

Fig. 2-17: Overview of connecting cables

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Item

1 2 3 4 5

Description

Robot controller Robot Reference switch XS Ref Reference cable X42 - XS Ref (maximum cable length 50 m) Data cable X21

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

Bending radius

Fixed installation Installation in cable carrier

Min. 5xØ of cable Min. 10xØ of cable


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3 Technical data

3

Technical data

3.1

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

3.2

Reference switch Designation

Values

Ambient temperature Switching function DC operating voltage or HIGH level in th e case of pulsed operating voltage of the reference switch Permissible range for the DC operating voltage or HIGH level for pulsed voltage Required pulse duty factor T(HIGH):T(LOW) for pulsed voltage Supported pulse duration T(LOW) for pulsed voltage Operating current (power consumption) without load Permissible load current Permissible switching frequency Permissible switching distance at the proximity switch surfaces Short circuit and overload protection, pulsed Outputs

-25 °C to +70 °C Break contact 24 V

20 to 33 V Min. 4:1 0.1 to 20 ms 5 mA max. 250 mA max. 500 Hz 0 to 4 mm Yes   

LED function indicator Hysteresis when installed EMC conformity


PNP LOW-active Dual-channel

Yes 0.2 to 1 mm IEC 60947-5-2

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3.3

Reference switch hole pattern

Description

Fig. 3-1

1 2

3.4

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

Hole pattern for actuating plate

Description

Fig. 3-2

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3 Technical data

1 2

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


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4 Safety

4

Safety

4.1

General

4.1.1

Liability

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

 

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

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

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

4.1.2

Intended use of the industrial robot

The industrial robot is intended exclusively for the use designated in the “Purpose” chapter of the operating instructions or assembly instructions. Further information is contained in the “Purpose” cha pter of the operating instructions or assembly instructions of the industrial robot. Using the industrial robot for any other or additional purpose is considered impermissible misuse. The manufacturer cannot be held liable for any damage resulting from such use. The risk lies entirely with the user. Operating the industrial robot and its options within the limits of its intended use also involves observance of the operating and assembly instructions for


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the individual components, with particular reference to the maintenance specifications. Any use or application deviating from the intended use is deemed to be impermissible misuse. This includes e.g.:

Misuse

     

4.1.3

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

EC declaration of conformity and declaration of incorporation

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



Declaration of conformity

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

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

Declaration of incorporation

The industrial robot as partly completed machinery is supplied with a declaration of incorporation in accordance with Annex II B of the EC Machinery Directive 2006/42/EC. The assembly instructions and a list of essential requirements complied with in accordance with Annex I are integral parts of this declaration of incorporation. The declaration of incorporation declares that the start-up of the partly completed machinery remains impermissible until the partly completed machinery has been incorporated into machinery, or has been assembled with other parts to form machinery, and this machinery complies with the terms of the EC Machinery Directive, and the EC declaration of conformity is present in accordance with Annex II A. The declaration of incorporation, together with its annexes, remains with the system integrator as an integral part of the technical documentation of the complete machinery.

4.1.4

Terms used

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

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4 Safety

Term

Description

Axis range

Range of each axis, in degrees or millimeters, within which it may move. The axis range must be defined for each axis. Stopp toppin ing g dist distan ance ce = rea react ctio ion n dist distan ance ce + bra braki king ng dis dista tanc nce e

Stopp toppin ing g dist distan ance ce Workspace Operator (User) Danger zon zone e KCP

Manipulator Safety zone Safe operational operational stop

The stopping distance is part of the danger zone. The manipulator is allowed to move within its workspace. The workspace is derived from the individual axis ranges. The user of the industrial robot can be the management, employer or delegated person responsible for use of the industrial robot. The danger zo zone con conssists of of th the wo workspace an and th the st stopping di distances. The KCP (KUKA Control Panel) teach pendant has all the operator control and display functions required for operating and programming the industrial robot. The KCP variant for the KR C4 is called KUKA smartPAD. The general term “KCP”, however, is generally used in this documentation. The robot arm and the associated electrical installations The safety zone is situated outside the danger zone. The safe safe operational operational stop is a standstill standstill monitoring monitoring function. function. ItIt does does not not stop the robot motion, but monitors whether the robot axes are stationary. If these are moved during the safe operational stop, a safety stop STOP 0 is triggered. The safe operational stop can also be triggered e xternally. xternally.

Safe Safety ty STOP STOP 0

When a safe operational stop is triggered, the robot controller sets an output to the field bus. The output is set even if not all the axes were stationary at the time of triggering, thereby causing a safety stop STOP 0 to be triggered. A stop stop that that is trig trigge gere red d and and exec execut uted ed by the the safe safety ty cont contro rollller er.. The The safe safety ty controller immediately switches off the drives and the power supply to the brakes. Note: This stop is called safety STOP 0 in this document.

Safe Safety ty STOP 1

A sto stop p tha thatt is is tri trigg gger ered ed and and mon monit itor ored ed by the the saf safet etyy con contr trol olle lerr. The The brak brak-ing process is performed by the non-safety-oriented part of the robot controller and monitored by the t he safety controller. As soon as the manipulator is at a standstill, the safety controller switches off the drives and the power supply to the brakes. When a safety STOP 1 is triggered, the robot controller sets an outpu t to the field bus. The safety STOP 1 can also be triggered externally. Note: This stop is called safety STOP 1 in this document.

Safe Safety ty STOP 2

A sto stop p tha thatt is is tri trigg gger ered ed and and mon monit itor ored ed by the the saf safet etyy con contr trol olle lerr. The The brak brak-ing process is performed by the non-safety-oriented part of the robot controller and monitored by the safety controller. The drives remain activated and the brakes released. As soon as the manipulator is at a standstill, a safe operational stop is triggered. When a safety STOP 2 is triggered, the robot controller sets an outpu t to the field bus. The safety STOP 2 can also be triggered externally. Note: This stop is called safety STOP 2 in this document.


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Term

Description

Stop top cat categ egor oryy 0

The The dri drive vess are are deac deactitiva vate ted d imm immed edia iate tely ly and and the the bra brake kess are are appl applie ied. d. The The manipulator and any external axes (optional) perform path-oriented braking. Note: This stop category is called STOP 0 in this document.

Stop top cate catego gory ry 1

The The mani manipu pula lato torr and and any any exte extern rnal al axes axes (opt (optio iona nal) l) perf perfor orm m path path-m -mai ainntaining braking. The drives are deactivated after 1 s and the brakes are applied. Note: This stop category is called STOP 1 in this document.

Stop top cat categ egor oryy 2

The The dri drive vess are are not not dea deact ctiv ivat ated ed and and th the bra brake kess are are not not app applilied ed.. The The manipulator and any external axes (optional) are braked with a pathmaintaining braking ramp. Note: This stop category is called STOP 2 in this document.

System integrator (plant integrator) T1 T2 Exter ternal axi axiss

4 .2

System integrators are people who safely integrate the industrial robot into a complete system and commission it. Test mode, Manual Reduced Velocity (<= 250 mm/s) Test mode, Manual High Velocity (> 250 mm/s permissible) Motion ax axis wh which is is no not pa part of of th the ma manipulator bu but wh which is is co contr ntrolled using the robot controller, e.g. KUKA linear unit, tu rn-tilt table, Posiflex.

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

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

User

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

Personnel

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

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

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

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

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The industrial robot is safely integrated into a complete system by the system integrator.


4 Safety

The system integrator is responsible for the following tasks:       

Operator

The operator must meet the following preconditions:  

Example

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

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

The tasks can be distributed as shown in the following table. Tasks

Operator

Programmer

System integrator

Switch robot controller on/off

x

x

x

Start program

x

x

x

Select program

x

x

x

Select operating mode

x

x

x

Calibration (tool, base)

x

x

Master the manipulator

x

x

Configuration

x

x

Programming

x

x

Start-up

x

Maintenance

x

Repair

x

Decommissioning

x

Transportation

x

Work on the electrical and mechanical equipment of the industrial robot may only be carried out by specially trained personnel.

4.3

Wor Workspa kspac ce, safe safety ty zon one e and and dang danger er zone zone Workspaces are to be restricted to the necessary minimum size. A workspace must be safeguarded using appropriate safeguards. The safeguards (e.g. safety gate) must be situated inside the safety zone. In the case of a stop, the manipulator and external axes (optional) are braked and come to a stop within the danger zone.


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The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). It must b e safeguarded by means of physical safeguards to prevent danger to persons or the risk of material damage.

Fig. 4-1: Example of axis range A1

1 2

4.4

Workspace Manipulator

3 4

Stopping distance Safety zone

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

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

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T1, T2

AUT, AUT EXT

STOP 2

STOP 2 STOP 1 STOP 2 STOP 0

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

Safety stop 1

Safety stop 2 Safety stop 1

-


4 Safety

Trigger

T1, T2

E-STOP pressed Error in safety controller or periphery of the safety controller

4.5

Safety functions

4.5.1

Overview of the safety functions

AUT, AUT EXT

Safety stop 1 Safety stop 0

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

Mode selection Operator safety (= connection for the guard interlock) EMERGENCY STOP device Enabling device External safe operational stop External safety stop 1 External safety stop 2 Velocity monitoring in T1

The safety functions of the industrial robot have the following performance: Category 3 and Performance Level d in accordance with EN ISO 138491:2008. This corresponds to SIL 2 and HFT 1 in accordance with EN 62061. This performance only applies under the following conditions, however: 

The EMERGENCY STOP button is pressed at least once every 6 months.

The following components are involved in the safety functions:       

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

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

Safety controller

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


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Safety controller tasks:      

4.5.3

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

Mode selection

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

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

Use

Velocities 

T1

For test operation, programming and teaching





T2

For test operation 

AUT

AUT EXT

4.5.4

For industrial robots without higher-level controllers



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







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

Operator safety

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

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4 Safety

Following a loss of signal, automatic operation must not be resumed merely by closing the safeguard; it must first additionally be acknowledged. It is the responsibility of the system integrator to ensure this. This is to prevent automatic operation from being resumed inadvertently while there are still persons in the danger zone, e.g. due to the safety gate closing accidentally. The acknowledgement must be designed in such a way that an actual  check of the danger zone can be carried out first. Acknowledgement functions that do not allow this (e.g. because they are automatically triggered by closure of the safeguard) are not permissible. Failure to observe this may result in death to persons, severe physical in juries or considerable damage to property. 4.5.5

EMERGENCY STOP device

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

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

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

Logging off the higher-level safety controller

If the robot controller is connected to a higher-level safety controller, switching off the robot controller inevitably terminates this connection . The KUKA safety controller generates a signal that prevents the higher-level contr oller from triggering an EMERGENCY STOP for the overall system. In his risk assessment, the system integrator must take into consideration whether the fact that switching off the robot controller does not trigger an EMERGENCY STOP of the overall system could constitute a hazard and, if so, how this hazard can be countered. Failure to take this into consideration may result in death to persons, severe physical injuries or considerable damage to property.


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If a robot controller is switched off, the E-STOP button on the KCP is no longer functional. The user is responsible for ensuring that the KCP is either covered or removed from the system. This serves to prevent operational and non-operational EMERGENCY STOP facilities from becoming interchanged. Failure to observe this precaution may result in death to persons, severe physical injuries or considerable damage to property. 4.5.7

External EMERGENCY STOP device

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

Enabling device

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

Not pressed Center position Panic position

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



Releasing the enabling switch triggers a safety stop 2. Pressing the enabling switch down fully (panic position) triggers a safety stop 1. It is possible, for a short time, to hold 2 enabling switches in the center position simultaneously. This makes it possible to adjust grip from one enabling switch to another one. If 2 enabling switches are held simultaneously in the center position for a longer period of time, this triggers a safety stop after several seconds.

If an enabling switch malfunctions (jams), the industrial robot can be stopped using the following methods:   

Press the enabling switch down fully Actuate the EMERGENCY STOP system Release the Start key The enabling switches must not be held down by adhesive tape or other means or manipulated in any other

way. Death, serious physical injuries or major damage to property may result.

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4 Safety

4.5.9

External enabling device

External enabling devices are required if it is necessary for mor e than one person to be in the danger zone of the industrial robot. They are connected to the robot controller via the customer interface. External enabling devices are not included in the scope of supply of the industrial robot. 4.5.10

External safe operational stop

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

External safety stop 1 and external safety stop 2

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

Velocity monitoring in T1

The velocity at the TCP is monitored in T1 mode. If, due to an error, the velocity exceeds 250 mm/s, a safety stop 0 is triggered.

4.6

Additional protective equipment

4.6.1

Jog mode

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



4.6.2

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

Software limit switches

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


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4.6.3

Mechanical end stops

The axis ranges of main axes A1 to A3 and wrist axis A5 of the manipulator are limited by means of mechanical end stops with buffers. Additional mechanical end stops can be installed on the external axes. If the manipulator or an external axis hits an obstruction or a buffer on the mechanical end stop or axis range limitation, this can result in material damage to the industrial robot. KUKA Roboter GmbH must be consulted before the industrial robot is put back into operation. (>>> 14 "KUKA Service" Page 131) The affected buffer must be replaced with a new one before operation of the industrial robot is resumed. If a manipulator (or external axis) collides with a buffer at more than 250 mm/s, the manipulator ( or external axis) must be exchanged or recommissioning must be carried out by KUKA Roboter GmbH. 4.6.4

Mechanical axis range limitation (optional)

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

4.6.5

Axis range monitoring (optional)

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

4.6.6

Release device (optional)

Description

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The release device can be used to move the manipulator manually after an accident or malfunction. The release device can be used for the main axis drive motors and, depending on the robot variant, also for the wrist axis drive motors. It is only for use in exceptional circumstances and emergencies (e.g. for freeing people).


4 Safety

The motors reach temperatures during operation which can cause burns to the skin. Contact must be avoided. Appropriate safety precautions must be taken, e.g. protective gloves must be worn. Procedure

1. Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. 2. Remove the protective cap from the motor. 3. Push the release device onto the corresponding motor and move the axis in the desired direction. The directions are indicated with arrows on the motors. It is necessary to overcome the resistance of the mechanical motor brake and any other loads acting on the axis. Moving an axis with the release device can damage the motor brake. This can result in personal injury and material damage. After using the release device, the affected motor must be exchanged.

4.6.7

Labeling on the industrial robot

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

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

4.6.8

External safeguards

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



 

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

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

They are reduced to an absolute minimum.


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





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

Other safety equipment

4.7

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

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

T1

T2

AUT

AUT EXT

Operator safety

-

-

active

active

EMERGENCY STOP device

active

active

active

active

Enabling device

active

active

-

-

Reduced velocity during program verification

active

-

-

-

Jog mode

active

active

-

-

Software limit switches

active

active

active

active

4.8

Safety measures

4.8.1

General safety measures

The industrial robot may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons. Operator errors can result in personal injury and damage to property. It is important to be prepared for possible movements of the industrial robot even after the robot controller has been switched off and locked. Incorrect installation (e.g. overload) or mechanical defects (e.g. brake defect) can cause the manipulator or external axes to sag. If work is to be carried out on a switched-off industrial robot, the manipulator and external axes must first be moved into a position in which they are unable to move on their own, whether the payload is mounted or not. If this is not possible, the manipulator and external axes must be secured by appropriate means.

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4 Safety

In the absence of operational safety functions and safeguards, the industrial robot can cause personal injury or material damage. If safety functions or safeguards are dismantled or deactivated, the industrial robot may not be operated. Standing underneath the robot arm can cause death or serious physical injuries. For this reason, standing underneath the robot arm is prohibited! The motors reach temperatures during operation which can cause burns to the skin. Contact must be avoided. Appropriate safety precautions must be taken, e.g. protective gloves must be worn. KCP

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

External keyboard, external mouse

An external keyboard and/or external mouse may only be used if the following conditions are met:   

Start-up or maintenance work is being carried out. The drives are switched off. There are no persons in the danger zone.

The KCP must not be used as long as an external keyboard and/or external mouse are connected. The external keyboard and/or external mouse must be removed as soon as the start-up or maintenance work is completed or the KCP is connected. Faults

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



 

Modifications

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

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


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After modifications to the industrial robot, existing programs must always be tested first in Manual Reduced Velocity mode (T1). This applies to all components of the industrial robot and includes modifications to the software and configuration settings. 4.8.2

Transportation

Manipulator

The prescribed transport position of the manipulator must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the manipulator.

Robot controller

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

External axis (optional)

4.8.3

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

Start-up and recommissioning

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

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

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4 Safety

It must be ensured that: 

  





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

Test of the safety functions:

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

    

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

Test of reduced velocity control:

This test is to be carried out as follows: 1. Program a straight path with the maximum possible velocity. 2. Calculate the length of the path. 3. Execute the path in T1 mode with the override set to 100% and time the motion with a stopwatch. It must be ensured that no persons are present within the danger zone during path execution. Death or severe physical injuries may result. 4. Calculate the velocity from the length of the path and the time measured for execution of the motion. Control of reduced velocity is functioning correctly if the following results are achieved:  

Machine data

The calculated velocity does not exceed 250 mm/s. The manipulator executes the path as programmed (i.e. in a straight line, without deviations).

It must be ensured that the rating plate on the robot controller has the same machine data as those entered in the declaration of incorporation. The machine data on the rating plate of the manipulator an d the external axes (optional) must be entered during start-up. The industrial robot must not be moved if incorrect machine data are loaded. Death, severe physical injuries or considerable damage to property may otherwise result. The correct machine data must be loaded. Following modifications to the machine data, the safety configuration must be checked.


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Further information is contained in the Operating and Programming Instructions for System Integrators. Following modifications to the machine data, control of the reduced velocity must be checked. 4.8.3.1

Start-up mode

Description

The industrial robot can be set to Start-up mode via the smartHMI user interface. In this mode, the manipulator can be moved in T1 in the absence of the safety periphery. If a connection to a higher-level safety system exists or is established, the robot controller prevents or terminates Start-up mode.

Hazards

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

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

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





Use

Cover disabled EMERGENCY STOP devices or attach a warning sign indicating that the EMERGENCY STOP device is out of operation. If there is no safety fence, other measures must be taken to prevent persons from entering the manipulator’s danger zone, e.g. use of warning tape. Use of Start-up mode must be minimized – and avoided where possible – by means of organizational measures.

Intended use of Start-up mode: 





Only service personnel who have received safety instruction may use Start-up mode. Start-up in T1 mode when the external safeguards have not yet been installed or put into operation. The danger zone must be delimited at least by means of warning tape. Fault localization (periphery fault).

Use of Start-up mode disables all external safeguards. The service personnel are responsible for ensuring that there is no-one in or near the danger zone of the manipulator. Misuse

Any use or application deviating from the designated use is deemed to be impermissible misuse. This includes, for example, use by any other personnel. KUKA Roboter GmbH accepts no liability for damage or injury caused thereby. The risk lies entirely with the user.

4.8.4

Manual mode

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

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Jog mode Teaching Programming Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

4 Safety 

Program verification

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







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

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



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

In Manual High Velocity mode (T2) : 

 

 

4.8.5

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

Simulation

Simulation programs do not correspond exactly to reality. Robot programs created in simulation programs must be tested in the system in Manual Reduced Velocity mode (T1). It may be necessary to modify the program. 4.8.6

Automatic mode

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

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

If the manipulator or an external axis ( optional) comes to a standstill for no apparent reason, the danger zone must not be entered until an EMERGENCY STOP has been triggered. Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

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4.8.7

Maintenance and repair

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









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

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

Even when the robot controller is switched off, parts connected to peripheral devices may still carry voltage. The external power sources must therefore be switched off if work is to be carried out on the robot controller. The ESD regulations must be adhered to when working on components in the robot controller. Voltages in excess of 50 V (up to 780 V) can be present in various components for several minutes after the robot controller has been switched off! To prevent life-threatening injuries, no work may be carried out on the industrial robot in this time. Water and dust must be prevented from entering the robot controller.

Counterbalancing system

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Some robot variants are equipped with a hydropneumatic, spring or g as cylinder counterbalancing system.


4 Safety

The hydropneumatic and gas cylinder counterbalancing systems are pressure equipment and, as such, are subject to obligatory equipment monitoring. Depending on the robot variant, the counterbalancing systems correspond to category 0, II or III, fluid group 2, of the Pressure Equipment Directive. The user must comply with the applicable national laws, regulations and st andards pertaining to pressure equipment. Inspection intervals in Germany in accordance with Industrial Safety Order, Sections 14 and 15. Inspection by the user before commissioning a t the installation site. The following safety measures must be carried out when working on the counterbalancing system: 



Hazardous substances

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

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

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

4.8.8

Decommissioning, storage and disposal

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

Safety measures for “single point of control”

Overview

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

Submit interpreter PLC OPC Server Remote control tools Tools for configuration of bus systems with online functionality KUKA.RobotSensorInterface External keyboard/mouse The implementation of additional safety measures may be required. This must be clarified for each specific application; this is the responsibility of the system integrator, programmer or user of the system.

Since only the system integrator knows the safe states of actuators in the periphery of the robot controller, it is his task to set these actuators to a safe state, e.g. in the event of an EMERGENCY STOP.


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T1, T2

Submit interpreter, PLC

In the test modes, the components referred to above (with the exception of the external keyboard/mouse) may only access the industrial robot if the following signals have the following states: Signal

State required for SPOC

$USER_SAF $SPOC_MOTION_ENABLE

TRUE TRUE

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



OPC server, remote control tools

In the test modes, the system variable $OV_PRO must not be written to by the Submit interpreter or the PLC. Do not modify safety-relevant signals and variables (e.g. operating mode, EMERGENCY STOP, safety gate contact) via the Submit interpreter or PLC. If modifications are nonetheless required, all safety-relevant signals and variables must be linked in such a way that they cannot be set to a dangerous state by the Submit interpreter or PLC.

These components can be used with write access to modify programs, outputs or other parameters of the robot controller, without this being noticed by any persons located inside the system. Safety measures: 



Tools for configuration of bus systems

KUKA stipulates that these components are to be used exclusively for diagnosis and visualization. Programs, outputs or other parameters of the robot controller must not be modified using these components. If these components are used, outputs that could cause a hazard must be determined in a risk assessment. These outputs must be designed in such a way that they cannot be set without being enabled. This can be done using an external enabling device, for example.

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

WorkVisual from KUKA Tools from other manufacturers

Safety measures: 

External keyboard/mouse

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

These components can be used to modify programs, outputs or other parameters of the robot controller, without this being noticed by any persons located inside the system. Safety measures:  

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Only use one operator console at each robot controller. If the KCP is being used for work inside the system, rem ove any keyboard and mouse from the robot controller beforehand. Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

4 Safety

4.9

Applied norms and regulations

Name

Definition

Edition

2006/42/EC

Machinery Directive:

2006

2004/108/EC

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

2004

97/23/EC

Directive 2004/108/EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC Pressure Equipment Directive:

1997

Directive 97/23/EC of the European Parliament and of the Council of 29 May 1997 on the approximation of the laws of the Member States concerning pressure equipment

EN ISO 13850

(Only applicable for robots with hydropneumatic counterbalancing system.) Safety of machinery:

2008

EN ISO 13849-1

Emergency stop - Principles for design Safety of machinery:

2008

EN ISO 13849-2

Safety-related parts of control systems - Part 1: General principles of design Safety of machinery:

2008

EN ISO 12100-1

Safety-related parts of control systems - Part 2: Validation Safety of machinery:

2003

EN ISO 12100-2

Basic concepts, general principles for design - Part 1: Basic terminology, methodology Safety of machinery:

2003

EN ISO 10218-1

Basic concepts, general principles for design - Part 2: Technical principles Industrial robots:

2008

EN 614-1

Safety Safety of machinery:

2006

EN 61000-6-2

Ergonomic design principles - Part 1: Terms and general principles Electromagnetic compatibility (EMC):

2005

EN 61000-6-4

Part 6-2: Generic standards; Immunity for industrial environments Electromagnetic compatibility (EMC):

2007

EN 60204-1

Part 6-4: Generic standards; Emission standard for industrial environments Safety of machinery:

2006

Electrical equipment of machines - Part 1: General requirements


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EN ISO 10218-1, Annex B, specifies the need for information about the stopping time and distance. These have not yet been determined in full for all robot types in conjunction with the KR C4 robot controller. In this respect, the industrial robot does not conform to the requirements of EN ISO 10218-1.

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5 Installation

5

Installation

5.1

System requirements

Hardware



Software

 

Compatibility

5.2



KR C4 KUKA System Software 8.2 Or VW System Software 8.2 KUKA.SafeOperation must not be installed on a robot controller together with the following technology packages:  KUKA.SafeRangeMonitoring

Installing or updating SafeOperation It is advisable to archive all relevant data before updating a software package.

Precondition

 

Expert user group Software on KUKA.USB data stick Only the KUKA.USB data stick may be used. Data may be lost or modified if any other USB stick is used.

Procedure

1. Plug in USB stick. 2. Select Start-up > Install additional software in the main menu. 3. Press New software. If a software package that is on the USB stick is not displayed, press Refresh. 4. Select the entry SafeOperation and press Install. Reply to the request for confirmation with Yes. The files are copied onto the hard drive. 5. Repeat step 4 if another software package is to be installed from this stick. 6. Remove USB stick. 7. It may be necessary to reboot the controller, depending on the additional software. In this case, a corresponding prompt is displayed. Confirm with OK and reboot the robot controller. Installation is resumed and completed.

LOG file

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

5.3

Uninstalling SafeOperation It is advisable to archive all relevant data before uninstalling a software package. Before uninstalling the software, the safety maintenance technician must deactivate the safe monitoring. If the safe monitoring is not deactivated before uninstallation, the safety configuration remains active.

Precondition Procedure



Expert user group

1. Select Start-up > Install additional software in the main menu. All additional programs installed are displayed.


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2. Select the entry SafeOperation and press Uninstall. Reply to the request for confirmation with Yes. Uninstallation is prepared. 3. Reboot the robot controller. Uninstallation is resumed and completed. LOG file

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


6 Operation

6

Operation

6.1

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

Safety recovery

This user can activate an existing safety configuration of the robot using an activation code. If no safe option, e.g. KUKA.SafeOperation or KUKA.SafeRangeMonitoring, is being used, the safety recovery technician has more extensive rights. In this case he is authorized, for example, to configure the standard safety functions. This user group is protected by means of a password. 

Safety maintenance

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

6.2

Opening the safety configuration

Procedure

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

6.3

Overview of buttons The following buttons are available: Button

Description

Reset all to default values

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

Reset changes Change log View Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

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Button

Description

Properties

The properties of a monitoring space or safe tool can be defined. The safety ID of the PROFINET device can be changed.

Device management

Note: Further information is contained in the

Global parameters Hardware options

Operating and Programming Instructions for System Integrators. The global parameters of the safety configuration can be defined. The hardware settings can be defined. Note: Further information is contained in the

Check machine data Safe operational stop Save Touch-up

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

Touch-up reference position for group Cell configuration Back

6.4

Monitor functions

6.4.1

Displaying information about the safety configuration

Select Configuration > Safety configuration in the main menu. The safety configuration opens with the General tab.

Procedure



Description

The General tab contains the following information: Parameter

Description

Robot Safety controller

Serial number of the robot  Version of SafeOperation  Safety controller version (internal) Checksum of the safety configuration   Time stamp of the safety configuration (date and time last saved)  Safety configuration version Activation code of the safety configuration 

Parameter data set

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


6 Operation

Parameter

Description

Machine data

Time stamp of the safety-relevant machine data (date and time last saved)  State of the safe monitoring (activated or deactivated) Name of the active bus system   Checksum of the brake test configuration  Number of velocity-monitored axes Number of monitoring spaces   Number of protected spaces  Number of safe tools

Current configuration

6.4.2

Displaying the change log

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

 

6.4.3

Select Configuration > Safety configuration in the main menu. Press Change log.

Displaying machine data

The safety-relevant machine data can be displayed. Procedure

1. Select Configuration > Safety configuration in the main menu. 2. Press View.


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7 Start-up and recommissioning

7

Start-up and recommissioning

7.1

Start-up overview Step

Description

1

Set up brake test. Installing SafeOperation activates the brake test for the robot controller. The brake test serves as a diagnostic measure for the robot axis and external axis brakes. The brakes are activated for the stop reactions safety stop 0 and safety stop 1. Note: Detailed information is contained in the Operating and

2

Programming Instructions for System Integrators. Install reference switch and actuating plate.

3

(>>> 7.3 "Installing the reference switch and actuating plate" Page 67) Connect the reference switch.

4

5

(>>> 7.4 "Connecting a reference switch" Page 67) Only if a safety PLC is being used: configure communication via the interface. (>>> 10 "Interfaces to the higher-level controller" Page 101) Master the robot. Note: Detailed information is contained in the operating and

6

programming instructions. Activate safe monitoring.

7

(>>> 7.5 "Activating safe monitoring" Page 68) Define global parameters.  

8

Mastering test input Cartesian velocity monitoring functions

(>>> 7.6 "Defining global parameters" Page 68) Define monitoring spaces. (>>> 7.7 "Defining a cell area" Page 70) (>>> 7.8 "Defining Cartesian monitoring spaces" Page 72)

9

(>>> 7.9 "Defining axis-specific monitoring spaces" Page 75) Define axis-specific velocity monitoring. (>>> 7.10 "Defining axis-specific velocity monitoring" Page 79)

10

(>>> 7.11 "Defining the safe operational stop" Page 82) Define safe tools.

11

(>>> 7.12 "Defining safe tools" Page 84) Program mastering test.

12

(>>> 8.2 "Programming a mastering test" Page 97) Define reference position.

13

(>>> 7.13 "Defining the reference position" Page 87) Only if the reference switch is actuated by the tool: Check reference position. (>>> 7.14 "Checking the reference position (actuation with tool)" Page 89)


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Step

Description

14

Save safety configuration.

15

(>>> 7.15 "Saving the safety configuration" Page 90) Perform mastering test.

16

(>>> 7.16 "Performing a mastering test manually" Page 91) Carry out safety acceptance. (>>> 7.18 "Safety acceptance overview" Page 94) (>>> 7.17 "Testing safety parameters" Page 91) Archive safety configuration.

17

Note: Detailed information is contained in the operating and

programming instructions. Only if a new safety configuration is being activated: compare the displayed checksum with the expected checksum in the checklist for safe functions.

18

(>>> 7.19 "Activating a new safety configuration" Page 95)

7.2

Safety warnings During system planning, the safety functions must be planned. Required safety functions that are not implemente d with SafeOperation must be implemented using different safety measures. Serious system errors, severe damage to the robot and injury or death can result from not carrying out the risk analysis. Risk analysis must be carried out before start-up and after any safety-relevant modification.  Define axes that must be tested in the brake test.  Determine brake test cycle time. Determine axis-specific and Cartesian limit values for the reduced veloc ity.  Define axis-specific and Cartesian monitoring spaces.  Define axes that must be configured for a safe operational stop. Serious damage and injury or death can result from incorrect configuration. Consequently, SafeOperation may not be operated until after safety acceptance has been carried out in accordance with the checklists. The checklists must be completed fully and confirmed in writing. (>>> 13.1 "Checklists" Page 115) Safe monitoring with SafeOperation is deactivated by default. The safety monitoring functions can only be configured or modified if safe monitoring is activated. If safe monitoring is deactivated, the configured safety monitoring functions are inactive. Serious injury and severe damage to the robot can be caused by changing the machine data. Modifying the machine data may deactivate monitoring functions. Machine data may only be modified by authorized personnel.

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7.3

Installing the reference switch and actuating plate

Precondition



 

Procedure

The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. The position of the reference switch is within the motion range of the robot. The position of the reference switch and actuating plate does not interfere with the work sequence of the robot.

1. Prepare a mechanical mounting fixture for mounting the reference switch. (>>> 3.3 "Reference switch hole pattern" Page 32) 2. Attach the reference switch to the mounting fixture. 3. If the actuating plate is being used, fasten the actuating plate to the robot flange or tool.

Example

Fig. 7-1: Example of an actuating plate on the tool

1 2 3 4

7.4

Robot Actuating plate on tool Tool Reference switch on mounting fixture

Connecting a reference switch The robot controller is preconfigured for the specific industrial robot. If cables are interchanged, the manipulator and the external axes (optional) may re ceive incorrect data and can thus cause personal injury or material damage. If a system consists of more than one manipulator, always connect the connecting cables to the manipulators and their corresponding robot controllers.


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Only 1 reference switch can be connected to the robot controller. If multiple reference groups are required, the reference switches can be connected to the safety PLC and activated via PROFIsafe. The safety PLC must evaluate the reference switches and set the inp ut Mastering test accordingly. Precondition



 

Procedure

7.5

The robot controller is switched off and secured to prevent unauthorized persons from switching it on again. Reference switch is installed. Reference cable X42 - XS Ref (maximum cable length 50 m)

1. Connect and route reference cable X42 - XS Ref. 2. Connect X42 to the robot controller and XS Ref to the reference switch.

Activating safe monitoring Configuration of the safety monitoring functions is only pos sible if safe monitoring has been activated.

Precondition

Procedure

7.6



User group “Safety maintenance” Operating mode T1 or T2

1. 2. 3. 4.

Open safety configuration. Press Global parameters. Activate the Safe monitoring check box (set the check mark). Save the safety configuration or continue configuration.



Defining global parameters

Precondition

   

Procedure

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

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



Description

Fig. 7-2: Defining global parameters

Defining global parameters: Parameter

Description

Safe monitoring

Check box activated = safe monitoring is acti-

vated. Check box deactivated = safe monitoring is

deactivated. Mastering test input

Default: Check box deactivated at cabinet = reference switch is connected to the robot controller. via ProfiSafe = reference switch is connected

via PROFIsafe. Cartesian maximum velocity

Default: at cabinet Limit value for maximum Cartesian velocity (not space-dependent) 

0.5 … 30,000 mm/s

Default: 10,000 mm/s


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Parameter

Description

Reduced Cartesian velocity

Limit value for safely reduced Cartesian velocity

Reduced Cartesian velocity T1



0.5 … 30,000 mm/s

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

0.5 … 250 mm/s

Default: 250 mm/s

7.7

Defining a cell area

Precondition

   

Procedure

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

1. Select the Monitoring spaces tab and press Cell area configuration. The Cell area configuration window is opened. 2. Enter the upper and lower bounds of the cell area. 3. Select a corner from the list. The parameters of the corner are displayed. 4. If required, activate the corner by means of the check box (set the check mark). Corners 1 to 4 are activated by default.

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

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Description

Fig. 7-3: Defining a cell area

Defining a cell area: Parameter

Description

Reference system

Reference coordinate system 

Z min

Lower limit of the cell area 

Z max

$WORLD -30,000 mm … +30,000 mm

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

-30,000 mm … +30,000 mm

Default: 30,000 mm


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Parameter

Description

Activated

Check box activated = corner of cell area is

(corner)

activated. Check box deactivated = corner of cell area is

deactivated. Default corner 1 to 4: Check box active X, Y (corner)

Default corner 5 to 10: Check box deactivated X, Y coordinate of corner 1 to 10 relative to the WORLD coordinate system 

-30,000 mm … +30,000 mm

Default corner 1 or 4: +30,000 mm Default corner 2 or 3: -30,000 mm Default corner 5 to 10: 0 mm

7.8

Defining Cartesian monitoring spaces

Precondition

   

Procedure


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

Monitoring space

Fig. 7-4: Defining a Cartesian monitoring space

Defining a monitoring space:

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Parameter

Description

Type

Type of monitoring space Working space = monitoring space is a work-

space. Protected space = monitoring space is a pro-

tected space. Activation

Default: Workspace Activation of monitoring space Inactive = monitoring space is not active. Always active = monitoring space is always

active. by input = monitoring space is activated by a

safe input. If interface X13 is used, safe inputs are only available for monitoring spaces 12 … 16. (>>> 10.2 "SafeOperation via interface X13 (optional)" Page 107) Space type

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

Stop at boundaries

Default: Cartesian space A stop is triggered if the space is violated. Check box activated = robot stops if the moni-

toring space limits are exceeded. Check box deactivated = robot does not stop if

the monitoring space limits are exceeded. V max

Default: Check box activated Limit value of the space-specific velocity 

Vmax valid if

0.5 … 30,000 mm/s

Default: 30,000 mm/s Validity of the space-specific velocity Deactivated = space-specific velocity is not

monitored. Space not violated = space-specific velocity is

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

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

Default: Deactivated Activation of reference stop Check box activated = reference stop is acti-

vated for the monitoring space. Check box deactivated = reference stop is

deactivated for the monitoring space. Default: Check box deactivated


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Properties

Fig. 7-5: Defining Cartesian properties

Defining properties: Parameter

Description

Reference system

Reference coordinate system

Origin X, Y, Z



$WORLD



$ROBROOT

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

-30,000 mm … +30,000 mm

Default: 0 mm

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Parameter

Description

Origin A, B, C

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

-180° … +180°

Origin B: 

Distance to origin XMin, YMin, ZMin

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

Distance to origin XMax, YMax, ZMax

-90° … +90°

-30,000 mm … +30,000 mm

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

-30,000 mm … +30,000 mm

Default: 0 mm The example shows a Cartesian monitoring space whose origin is offset in the X, Y and Z directions (yellow arrow) relative to the $ROBROOT system. The orientation A, B, C at the origin of the Cartesian monitoring space is identical to the orientation at the origin of $ROBROOT.

Example

Fig. 7-6: Example of a Cartesian monitoring space

7.9

Defining axis-specific monitoring spaces

Precondition

  

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


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Procedure

Safe monitoring is active.

1. Select the Monitoring spaces tab and select the monitoring space from the list. The parameters of the monitoring space are displayed. 2. Enter the name of the monitoring space (max. 24 characters). 3. Select the space type Axis space and set the parameters of the monitoring space. 4. Press Properties. The Axis-specific properties of [NameMonitoringSpace] window is opened. 5. Select axis from the list. The axis-specific properties are displayed. 6. Activate monitoring by means of the check box (set the check mark). 7. Move the axis to the upper axis limit in axis-specific mode. 8. Press Touch-up to save the current axis position. 9. Move the axis to the lower axis limit in axis-specific mode. 10. Press Touch-up to save the current axis position. 11. Repeat steps 5 to 10 to define the axis limits for additional axis ranges.

Monitoring space

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

Defining a monitoring space:

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Parameter

Description

Type

Type of monitoring space Working space = monitoring space is a work-

space. Protected space = monitoring space is a pro-

tected space. Activation

Default: Workspace Activation of monitoring space Inactive = monitoring space is not active. Always active = monitoring space is always

active. by input = monitoring space is activated by a

safe input. If interface X13 is used, safe inputs are only available for monitoring spaces 12 … 16. (>>> 10.2 "SafeOperation via interface X13 (optional)" Page 107) Space type

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

Stop at boundaries

Default: Cartesian space A stop is triggered if the space is violated. Check box activated = robot stops if the moni-

toring space limits are exceeded. Check box deactivated = robot does not stop if

the monitoring space limits are exceeded. V max

Default: Check box activated Limit value of the space-specific velocity 

Vmax valid if

0.5 … 30,000 mm/s

Default: 30,000 mm/s Validity of the space-specific velocity Deactivated = space-specific velocity is not

monitored. Space not violated = space-specific velocity is

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

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

Default: Deactivated Activation of reference stop Check box activated = reference stop is acti-

vated for the monitoring space. Check box deactivated = reference stop is

deactivated for the monitoring space. Default: Check box deactivated


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Properties

Fig. 7-8: Defining axis-specific properties Icon

Description

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

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Parameter

Description

Monitoring

Check box activated = axis limits are activated

for the monitoring space. Check box deactivated = axis limits are deacti-

vated for the monitoring space. Lower limit (lower axis limit)

Default: Check box deactivated The lower limit of an axis-specific workspace must be at least 0.5° or 1.5 mm less than the upper limit. The axis-specific protected space is dependent on the maximum axis velocity. A defined minimum size for the axis-specific protected space is derived from the maximum axis velocity; the size must not fall below this value. If this minimum value is violated, a message is displayed. Rotational axes: 

-360° … +360°

Linear axes: 

-30,000 mm … +30,000 mm

Default value for rotational axes: -360° Current position

Default value for linear axes: -30,000 mm Axis-specific actual position (display only) 

Upper limit (upper axis limit)

Red: axis position not allowed, as monitoring

space is violated  Green: axis position allowed The upper limit of an axis-specific workspace must be at least 0.5° or 1.5 mm greater than the lower limit. The axis-specific protected space is dependent on the maximum axis velocity. A defined minimum size for the axis-specific protected space is derived from the maximum axis velocity; the size must not fall below this value. If this minimum value is violated, a message is displayed. Rotational axes: 

-360° … +360°

Linear axes: 

-30,000 mm … +30,000 mm

Default value for rotational axes: 360° Default value for linear axes: 30,000 mm

7.10

Defining axis-specific velocity monitoring

Precondition

   

Procedure


1. Select the Axis monitoring tab.


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2. Select an axis from the list. The axis-specific parameters are displayed. 3. Activate monitoring by means of the check box (set the check mark). 4. Enter reduced axis velocities. 5. Repeat steps 2 to 4 to define further monitoring functions. 6. Enter maximum axis velocities. Description

Fig. 7-9: Defining axis velocities

Defining axis velocities:

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Parameter

Description

Monitoring

Check box activated = axis is monitored. Check box deactivated = axis is not monitored.

Reduced velocity

Default: Check box deactivated Limit value for safely reduced axis velocity Rotational axes: 

0.5 … 5,000°/s

Linear axes: 

1.5 … 10,000 mm/s

Default value for rotational axes: 5,000°/s Reduced velocity T1

Default value for linear axes: 10,000 mm/s Limit value for safely reduced axis velocity in T1 mode Rotational axes: 

0.5 … 100°/s

Linear axes: 

1.5 … 250 mm/s

Default value for rotational axes: 100°/s Safe operational stop

Default value for linear axes: 250 mm/s Check box activated = safe operational stop is activated. Check box deactivated = safe operational stop

is not activated. Default: Check box deactivated The safe operational stop cannot be activated here. The check box is automatically activated if safe operational stop has been defined for an axis.


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Parameter

Description

Maximum velocity rotational axis

Limit value for maximum velocity for rotational axes 

0.5 … 5,000°/s

Default: 1,000°/s

Maximum velocity translational axis

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

0.5 … 30,000 mm/s

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

7.11 7.11

Defi Defini ning ng the the saf safe e ope opera rati tion onal al stop stop

Precondition

   

Procedure

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1. Select the the Axis monitoring tab and press Safety stop. The Safety stop window is opened. 2. Sele Select ct axi axiss from from the the list list.. 3. Activate Activate one or or more axis axis groups groups in which which the axis axis is to to be monitored monitored by activating the corresponding check box (set the check mark). 4. Enter Enter the the axis angl angle e or dista distance nce toler toleranc ance. e. 5. Repeat steps 2 to 4 to define further monitoring monitoring functions. functions.



Description

Fig. 7-10: Defining the safe operational stop

Defining the safe operational stop:


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Parameter

Description

Monitoring in axis groups 1-6

Safe operational stop for axis group 1 … 6 Check box activated = safe operational stop is

activated for the axis. Check box deactivated = safe operational stop

is not activated for the axis. Default: Check box deactivated If interface X13 is used, safe inputs are only available for axis group 1 … 2.

Axis angle tolerance

(>>> (>>> 10.2 "SafeOperation via interface X13 (optional)" Page 107) 107) Limit value for the axis angle or distance tolerance for standstill monitoring Rotational axes: 

0.001° … 1°

Linear axes: 

0.003 … 3 mm

Default value for rotational axes: 0.01° Default value for linear axes: 0.01 mm

7 .1 2

Defining safe tools

Precondition

   

Procedure

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1. Select the the Tools tab and select a tool from the list. The parameters of the safe tool are displayed. 2. Activate Activate the safe safe tool via the check box box (set the the check check mark) and and enter a name for the tool (max. 24 characters). 3. Define Define the safe safe TCP TCP of the tool. tool. 4. Press Properties. The Properties of [NameTool] window window is opened. 5. Select Select a sphere sphere from the list and and activate activate monitoring monitoring via via the check check box (set (set the check mark). 6. Enter the the coordinates coordinates of of the center center of the the sphere sphere and the radius of the sphere. 7. Repeat steps 5 to 6 to define define additional additional spheres spheres for the the safe tool.



Tool

Fig. 7-11: Defining a safe tool

Defining a safe tool: Parameter

Description

Activation

Check box activated = safe tool is activated. Check box deactivated = safe tool is deacti-

vated. Default tool 1: check box activated Default tool 2 to 16: check box deactivated If interface X13 is used, tool 1 is always active. A tool change is not possible.

TCP X, Y, Z

(>>> 10.2 "SafeOperation via interface X13 (optional)" Page 107) X, Y and Z coordinates of the safe TCP relative to the velocity monitoring 

-10,000 mm … +10,000 mm

Default: 0 mm


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Properties

Fig. 7-12: Defining the properties of the safe tool

Defining properties: Parameter

Description

Monitoring

Check box activated = sphere is monitored. Check box deactivated = sphere is not moni-

tored. Default sphere 1: Check box activated Default spheres 2 to 6: Check box deactivated

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Parameter

Description

X, Y, Z

X, Y and Z coordinates of the sphere center point at the safe tool relative to the FLANGE coordinate system 

Radius

-10,000 mm … +10,000 mm

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

0 … 10,000 mm

Default: 250 mm The radius is dependent on the maximum Cartesian velocity. A defined minimum value for the radius is derived from the maximum Cartesian velocity; the radius must not be less than this value. If this minimum value is violated, a message is displayed.

7.13

Defining the reference position

Precondition

   

Procedure


1. 2. 3. 4. 5.

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


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Description

Fig. 7-13: Defining the reference position

Defining the reference position:

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Parameter

Description

Reference group

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

Reference position



1: robot axes



1 … 3: external axes

Default: 1 Axis-specific coordinates of the reference position To monitor the mastering, the axis angles of the robot axes are defined for a specific Cartesian reference position. During the mastering test, the robot moves to the Cartesian reference position and the actual position of the axes is compared with the command position. Rotational axes: 

-360° … +360°

Linear axes: 

-30,000 mm … +30,000 mm

Default value for rotational axes: 45° Current position

Default value for linear axes: 1,000 mm Axis-specific actual position (display only) 

Mastering position Cartesian reference position X, Y, Z

Red: reference position not allowed, as too

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

-30,000 mm … +30,000 mm

Default: 0 mm

7.14

Checking the reference position (actuation with tool) The robot can move beyond the configured limits if the reference switch is actuated by a ferromagnetic part of the tool and the accuracy at the reference position is exceeded. Severe physical injuries or damage to property may result. The accuracy of the reference position must be checked.


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If the tool is exchanged, the reference position and the accuracy of the reference position must be checked. If required, the reference position must be adapted to the new tool. Failure to observe this precaution may result in severe physical injuries or con siderable damage to property. Precondition

 

 

Procedure

7.15

Reference switch is installed and connected. The reference position has been taught in the program MasRef_USER.SRC and in the safety configuration. (>>> 8.2 "Programming a mastering test" Page 97) (>>> 7.13 "Defining the reference position" Page 87) User group “Safety maintenance” T1 or T2 operating mode

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

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

Precondition

  

Procedure

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

1. Press Save and answer the request for confirmation with Yes. The safety configuration is saved on the hard drive and the checksum of the safety configuration is saved to the RDC. The robot controller is automatically reinitialized. 2. The checksum and activation code of the safety configuration are displayed on the General tab. Note the checksum and activation code in the checklist for safe functions. (>>> 13.1.3 "Checklist for safe functions" Page 115)



7.16

Performing a mastering test manually

Precondition

 



Reference switch is installed and connected. The reference position has been taught in the program MasRef_USER.SRC and in the safety configuration. (>>> 8.2 "Programming a mastering test" Page 97) (>>> 7.13 "Defining the reference position" Page 87) T1 or T2 operating mode

The robot moves in T2 mode at the programmed velocity and can cause personal injury or material damage. M ake sure that the robot cannot collide and that no persons are in the motion range of the robot. Procedure

7.17



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

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

$SR_VEL_RED $WORKSPACE_RED

To check the configured limits, the space and velocity limits are deliberately exceeded by means of test programs. If the safety configuration stops the robot, the limits are correctly configured. If the robot is stopped by the safety controller, a message with message number 15 xxx is displayed. If no message is displayed, or if a message from a different number range is displayed, the safety controller must be checked. 7.17.1

Testing Cartesian velocity

(>>> 13.1.4 "Checklist for velocity limits" Page 118) Precondition Procedure



Override reduction is deactivated.

1. Configure reduced Cartesian velocity for T1, reduced Cartesian velocity and maximum Cartesian velocity. (>>> 7.6 "Defining global parameters" Page 68) 2. Create a test program in which the Cartesian velocity is to be exceeded deliberately, e.g. configured with 1000 mm/s, moved at 1100 mm/s. When testing the Cartesian velocity on a KL, the linear unit must also be moved. 3. Execute the test program in T1 mode for “Reduced Cartesian velocity in T1” and in T2 mode for reduced Cartesian velocity and maximum Cartesian velocity. Death, serious physical injuries or major damage to property may occur. If a program is executed in test mode T2, the operator must be in a position outside the danger zone.


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7.17.2

Testing maximum axis velocity

(>>> 13.1.4 "Checklist for velocity limits" Page 118) It is only necessary to test the maximum axis velocity if an axis must not exceed a defined velocity. If the maximum axis velocity is only to limit the minimum axis-specific protected space, no test is required. Override reduction is deactivated.

Precondition



Procedure

Testing linear axes:

1. Configure reduced axis velocity for T1, reduced axis velocity and maximum axis velocity. (>>> 7.10 "Defining axis-specific velocity monitoring" Page 79) 2. Create a test program in which the axis velocity is exceeded deliberately, e.g. KL configured with 1000 mm/s, moved at 1100 mm/s. 3. Execute the test program in T1 mode for “Reduced axis velocity in T1” and in T2 mode for reduced axis velocity and maximum axis velocity. Death, serious physical injuries or major damage to property may occur. If a program is executed in test mode T2, the operator must be in a position outside the danger zone. Testing rotational axes:

1. Configure reduced axis velocity for T1, reduced axis velocity and maximum axis velocity. (>>> 7.10 "Defining axis-specific velocity monitoring" Page 79) 2. Look up the maximum axis velocity Vmax in the data sheet of the robot used. 3. Create a test program in which the axis velocity is to be exceeded deliberately, e.g. axis A1 configured with 190°/s, moved at 200°/s. 4. Calculate axis velocity $VEL_AXIS[x]. (>>> "Calculation of $VEL_AXIS" Page 92) 5. Enter the axis velocity $VEL_AXIS[x] in the test program. 6. Execute the test program in T1 mode for “Reduced axis velocity in T1” and in T2 mode for reduced axis velocity and maximum axis velocity. Death, serious physical injuries or major damage to property may occur. If a program is executed in test mode T2, the operator must be in a position outside the danger zone. Calculation of $VEL_AXIS

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

Description

x Vtest

Number of the axis Test velocity

Vmax

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

The calculated axis velocity $VEL_AXIS[x] is entered in the test program:

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7 Start-up and recommissioning ... PTP {A1 -30} HALT $VEL_AXIS[1] = 56 PTP {A1 30} ...

7.17.3

Testing Cartesian monitoring spaces

(>>> 13.1.7 "Checklist for configuration of Cartesian monitoring spaces" Page 123) Description

The configuration of the boundaries and the space-specific velocity must be checked. If “Stop at boundaries” is not configured, an alarm space is used for this. The space surfaces can have any orientation. The robot must be moved to each of the 6 space surfaces of a Cartesian monitoring space in three different positions to check whether the limits have been pr ogrammed correctly. An exception is made here for space surfaces that cannot be addressed due to circumstances in the system. The cell area is a Cartesian monitoring space and is tested in the same way. Depending on the configuration, the cell area consists of 5, 6 or more space surfaces. Here, once again, each accessible space surface must be addressed in 3 different positions.

Fig. 7-14: Moving to space surfaces Precondition Procedure




1. Configure a Cartesian monitoring space. (>>> 7.7 "Defining a cell area" Page 70) (>>> 7.8 "Defining Cartesian monitoring spaces" Page 72) 2. Create a test program in which all positions addressed for checking the space surfaces are taught. 3. Execute test program in T1 mode. When testing a Cartesian monitoring space on a KL, the linear unit must also be moved. It must be ensured that the monitoring space moves with the linear unit and comes to a standstill. 4. Create a test program in which the space-specific velocity is deliberately exceeded, either inside or outside the monitoring space, e.g. 180 mm/s configured, moved at 200 mm/s. 5. Execute test program in T2 mode. Death, serious physical injuries or major damage to property may occur. If a program is executed in test mode T2, the operator must be in a position outside the danger zone.


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7.17.4

Testing axis-specific monitoring spaces

(>>> 13.1.8 "Checklist for configuration of axis-specific monitoring spaces" Page 125) Description


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


1. Configure an axis-specific monitoring space. (>>> 7.9 "Defining axis-specific monitoring spaces" Page 75) 2. Jog each axis once to the upper and lower boundaries of the monitoring space in T1 mode using the jog keys or Space Mouse. 3. Create a test program in which the space-specific velocity is deliberately exceeded, either inside or outside the monitoring space, e.g. 180 mm/s configured, moved at 200 mm/s. 4. Execute test program in T2 mode. Death, serious physical injuries or major damage to property may occur. If a program is executed in test mode T2, the operator must be in a position outside the danger zone.

7.17.5

Testing safe operational stop for an axis group

(>>> 13.1.5 "Checklist for configuration of the safe operational stop" Page 121) Forces acting on the robot in the production process may result in a violation of the safe operational stop, e.g. when loading a workpiece into a gripper. To remedy this, the ax is angle or distance tolerance for the affected axis must be increased. Precondition Procedure

7.18



Operating mode T1

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

Safety acceptance overview SafeOperation must not be put into operation until the safety acceptance procedure has been completed successfully. For successful safety acceptance, the points in the checklists must be completed fully and confirmed in writing. The completed checklists, confirmed in writing, must be kept as documentary evidence. Safety acceptance must be carried out in the following cases:   

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Following initial start-up or recommissioning of the industrial robot After a change to the industrial robot After a change to the safety configuration Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

7 Start-up and recommissioning 

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

The following checklists can be found in the Appendix: 















7.19

Checklist for robot and system (>>> 13.1.2 "Checklist for robot and system" Page 115) Checklist for safe functions (>>> 13.1.3 "Checklist for safe functions" Page 115) Checklist for velocity limits (>>> 13.1.4 "Checklist for velocity limits" Page 118) Checklist for configuration of the safe operational stop (>>> 13.1.5 "Checklist for configuration of the safe operational stop" Page 121) Checklist for configuration of the cell area (>>> 13.1.6 "Checklist for configuration of the cell area" Page 122) Checklist for configuration of Cartesian monitoring spaces (>>> 13.1.7 "Checklist for configuration of Cartesian monitoring spaces" Page 123) Checklist for configuration of axis-specific monitoring spaces (>>> 13.1.8 "Checklist for configuration of axis-specific monitoring spaces" Page 125) Checklist for configuration of the safe tools (>>> 13.1.9 "Checklist for configuration of the safe tools" Page 127)

Activating a new safety configuration

Description

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




User group “Safety recovery” or “Safety maintenance”

1. Select Configuration > Safety configuration in the main menu. The safety configuration checks whether there are any relevant deviations between the robot controller and the safety controller. The Troubleshooting wizard window is opened. 2. A description of the problem and a list of possible causes is displayed. Select the cause from the list, e.g. restoration of an archive. 3. Press Activate to activate the updated safety configuration on the robot controller.


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4. Only in the user group “Safety Recovery”: enter the activation code and press Activate again.

7.20

Deactivating safe monitoring If safe monitoring is deactivated, the configured safety monitoring functions are inactive. An exception is made here for the configured velocity limits for T1 mode. These remain active.

Precondition

 

Procedure

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1. 2. 3. 4.

User group “Safety maintenance” Operating mode T1 or T2 Open safety configuration. Press Global parameters. Deactivate the Safe monitoring check box. Press Save and answer the request for confirmation with Yes. The robot controller is automatically reinitialized.


8 Programming

8

Programming

8.1

Programs for the mastering test The following programs are used for the mastering test:

Program

Directory

Description

MasRef_Main.SRC

R1\System

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

MasRef_USER.SRC

R1\Program

The program calls the program MasRef_USER.SRC that is used to address the reference position. The program contains 3 subprograms for moving to reference positions 1 to 3 and 3 subprograms for the motion away from reference positions 1 to 3 after the mastering test has been performed. If the motion away from the reference position is not taught, the robot and external axes remain stationary after the mastering test. The robot controller generates an error message.

8.2

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

Precondition

  

Procedure

Reference switch is installed and connected. User group “Safety maintenance” T1 or T2 operating mode

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


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9. Teach the reference position. 10. Do not move the robot. 11. Teach the reference position in the safety configuration. (>>> 7.13 "Defining the reference position" Page 87) 12. Return to the subprogram MASREFSTARTG X () and perform a block selection to the END line. 13. Press the Start key. The subprogram MASREFBACKG X () of the program MasRef_USER.SRC is called. 14. In the subprogram MASREFBACKG X (), program the motion away from the reference position and teach the required points. 15. Deselect the program and save the changes. 16. For automatic operation, delete all HALT statements from the program MasRef_USER.SRC once again. 17. Cyclically call the program MasRef_Main.SRC at a suitable point and enable execution of the mastering test after an internal request. Program

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

GLOBAL DEF MASREFSTARTG1() Teach path and reference position for group 1 END GLOBAL DEF MASREFSTARTG2() Teach path and reference position for group 2 END GLOBAL DEF MASREFSTARTG3() Teach path and reference position for group 3 END GLOBAL DEF MASREFBACKG1() Teach path back for group 1 END GLOBAL DEF MASREFBACKG2() Teach path back for group 2 END GLOBAL DEF MASREFBACKG3() Teach path back for group 3 END

Line

Description

5

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

10 15 20 25 30

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DEF MasRef_USER() END


9 System variables

9

System variables

9.1

Variables for override reduction in $CUSTOM.DAT

Description

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

Variable

Description

$SR_OV_RED

Maximum velocity limit with override reduction activated for the velocity. The percentage value refers to the lowest activated velocity limit. 

$SR_VEL_RED

10 … 95 %

Default: 95 % Override reduction for the velocity TRUE = override reduction is activated. FALSE = override reduction is not activated.

$SR_WORKSPACE_RED

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

Default: FALSE

9.2

Variables for the mastering test

Variable

Description

$MASTERINGTEST_REQ_INT

Internal request of the mastering test from the safety controller TRUE = mastering test is requested. FALSE = mastering test is not requested.

$MASTERINGTEST_REQ_EXT

Default: FALSE External request for mastering test, e.g. from the safety PLC TRUE = mastering test is requested. FALSE = mastering test is not requested.

Default: FALSE Note: This signal is declared in the file KRC:\ROBOTER\

$MASTERINGTESTSWITCH_O K

KRC\STEU\MADA\$MACHINE.DAT and must be assigned to a suitable input. Check of the function of the reference switch TRUE = reference switch is OK. FALSE = reference switch is defective.

Default: TRUE


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9.3

Variables for diagnosis

Variable

Description

$SR_ACTIVETOOL

Number of the active safe tool

$SR_AXISSPEED_OK



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



1 … 16: safe tool 1 … 16 is active.

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

$SR_CARTSPEED_OK

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

$SR_DRIVES_ENABLE

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

$SR_MOVE_ENABLE

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

$SR_SAFEMON_ACTIVE

Status of the safe monitoring TRUE = monitoring is activated. FALSE = monitoring is not activated.

$SR_SAFEOPSTOP_ACTIVE[In dex ]

Status of the safe operational stop TRUE = safe operational stop is activated. FALSE = safe operational stop is not activated.

Index: 

$SR_SAFEOPSTOP_OK

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

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

$SR_SAFEREDSPEED_ACTIVE

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

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10 Interfaces to the higher-level controller

10

Interfaces to the higher-level controller The robot controller can communicate via the PROFIsafe protocol or interface X13 (SIB Extended) with the higher-level controller, e.g. a PLC. The safe I/Os of PROFIsafe are permanently assigned to the safety monitoring functions of SafeOperation: input and output bytes 2 to 7. (Input and output bytes 0 to 1 are assigned to the standard safety functions.) The safe I/Os of interface X13 only offer a reduced range of signals. Further information about SIB Extended and interface X13 can be found in the operating or assembly instructions for the robot controller and in the assembly and operating instructions for the optional interfaces of the robot controller.

10.1

SafeOperation via PROFIsafe (optional)

Reserved bits

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

Input byte 2

Bit

Signal

Description

0

JR

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

1

VRED

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

2…7

SBH1 … 6

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

Input byte 3

Bit

Signal

Description

0…7

RES

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


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Input byte 4

Bit

Signal

Description

0…7

UER1 … 8

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

Input byte 5

Bit

Signal

Description

0…7

UER9 … 16

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

Input byte 6

Bit

Signal

Description

0…7

WZ1 … 8

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

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

Bit

Signal

Description

0…7

WZ9 … 16

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

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

Bit

Signal

Description

0

SO

SafeOperation active SafeOperation activation status 0 = SafeOperation is not active. 1 = SafeOperation is active.

1

RR

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

2

JF

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

deactivated. 1 = no error.

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Bit

Signal

Description

3

VRED

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

4…5

SBH1 … 2

Activation status of safe operational stop for axis group 1 ... 2 Assignment: Bit 4 = axis group 1 … bit 5 = axis group 2 0 = safe operational stop is not active. 1 = safe operational stop is active.

Output byte 3

Output byte 4

6…7

RES

Reserved 23 ... 24

Bit

Signal

Description

0…7

RES

Reserved 25 ... 32

Bit

Signal

Description

0…7

MR1 … 8

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

Output byte 5

Bit

Signal

Description

0…7

MR9 … 16

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

Output byte 6

Output byte 7

10.1.1

Bit

Signal

Description

0…7

RES

Reserved 48 ... 55

Bit

Signal

Description

0…7

RES

Reserved 56 ... 63

Diagnostic signals via PROFINET

Description

Some signal states are extended to ensure that they can be detected reliably. In the case of extended signal states, the minimum duration of the extension is specified in square brackets. Values are specified in milliseconds, e.g. [200].


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Output byte 0

Bit

0

Signal

DG

Description

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

1

IFS

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

2

FF

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

3

AF

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

4

IBN

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

5

US2

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

6…7 Output byte 1

RES

Bit

0

Reserved

Signal

SO

Description

SafeOperation (optional) 0 = SafeOperation is not active. 1 = SafeOperation is active.

1

JF

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

2

VRED

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

3

VKUE

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

4

VAUE

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

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Bit

5

Signal

ZBUE

Description

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

6…7 Output byte 2

RES

Bit

0

Reserved

Signal

SHS1

Description

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

1

ESV

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

2

SHS2

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

3

SBH1

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

4

SBH2

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

5

WFK

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

6

WFME

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

7 Output byte 3

RES

Bit

0

Signal

JR

Reserved Description

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

1

RSF

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

2

JRA

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


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Bit

3

Signal

JRF

Description

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

4

RS

Reference stop (optional) Reference run only possible in operating modes T1 and KRR. 0 = no error 1 = reference stop due to impermissible operat-

5

RIA

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

6…7 Output byte 4

Bit

0…7

RES

Reserved

Signal

WZNR

Description

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

Output byte 5

Bit

0…7

Signal

Description

UER1 … 8

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

Output byte 6

Bit

Signal

Description

0…7

UER9 … 16

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

Output byte 7

Bit

Signal

Description

0 …7

UERV1 … 8

Violation of monitoring spaces 1 … 8 (optional) Assignment: Bit 0 = monitoring space 1 … bit 7 = monitoring space 8 0 = monitoring space not violated 1 = monitoring space violated [200]

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Output byte 8

Bit

Signal

Description

0 …7

UERV9 … 16

Violation of monitoring spaces 9 … 16 (optional) Assignment: Bit 0 = monitoring space 9 … bit 7 = monitoring space 16 0 = monitoring space not violated 1 = monitoring space violated [200]

10.2

SafeOperation via interface X13 (optional) Further information about connection to interface X13 and the required safety measures can be found in the assembly and operating instructions for the optional interfaces of the robot controller.

Inputs

Signal

Description

VRED

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

SBH1 … 2

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

UER12 … 16

Monitoring spaces 12 … 16 0 = monitoring space is active. 1 = monitoring space is not active.

Outputs

Signal

Description

SO

SafeOperation active SafeOperation activation status 0 = SafeOperation is not active. 1 = SafeOperation is active.

RR

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

MR1 … 6

Alarm space 1 … 6 Alarm space 1 (associated monitoring space 1) … alarm space 6 (associated monitoring space 8) 0 = space is violated. 1 = space is not violated.


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11 Diagnosis

11

Diagnosis

11.1

Displaying safe I/Os

Procedure

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


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12 Messages

12

Messages

12.1

Messages during operation Configuration or operator errors may result in error messages in an application.

No.

Message

15016

Ackn.: Stop due to stand- At least one of the axes monitored for standstill has still monitoring violation

15017

Ackn.: The braking ramp of the robot has been violated.

15018

Ackn.: Maximum Cartesian speed limit in T1 mode exceeded

15019

Ackn.: Maximum axisspecific speed limit in T1 mode exceeded

15020

Start-up mode active, EMERGENCY STOP has LOCAL effect ONLY

15021

Safety stop 2 violated (SHS2)

15022

Ackn.: Safety stop 2 violated (SHS2)

15031

Ackn.: Cartesian velocity in Cartesian monitoring space no. Number of monitoring space exceeded

15032

Ackn.: Cartesian velocity in axis-specific monitoring space no. Number of monitoring space exceeded

Cause

moved outside the configured axis angle or distance tolerances. The robot controller has not triggered sufficient braking in the case of a STOP 1 or a safe operational stop. The maximum permissible Cartesian velocity in operating mode T1 has been exceeded. At least one axis has exceeded the configured limit value for reduced axis velocity in operating mode T1. Start-up mode of the safety controller is activated. The brake ramp has not been maintained. The configured axis angles or distance tolerances have been violated during a monitored standstill. The space-specific velocity for the Cartesian monitoring space has been exceeded.

The space-specific velocity for the axis-specific monitoring space has been exceeded.


Remedy

Acknowledge the message.

Acknowledge the message.

Check override reduction and modify as required. (>>> 9.1 "Variables for override reduction in $CUSTOM.DAT" Page 99) Reduce jog override.

Deactivate Start-up mode.

Deactivate safe operational stop.

Check the programmed motion and modify as required. Check the active tool in the safety controller and $TOOL in the system software and modify as required. Check the safety configuration and modify as required. Check the programmed motion and modify as required. Check the safety configuration and modify as required.

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No.

Message

Cause

Remedy

15033

More then one tool activated in the safety controller

More than one tool is active in the safety controller. Only one tool may be active.

Deactivate invalid tools and activate the correct tool.

No tool is active in the safety controller. One tool must be active.

Activate the correct tool.

The active tool has exceeded the cell area.

Move robot out of the violated area in CRR mode.

15034

Ackn.: More then one tool activated in the safety controller

15035 15036

No tool activated in safety controller Ackn.: No tool activated in safety controller

15037

Cell area exceeded

15038

Ackn.: Cell area exceeded

15039

Ackn.: Maximum global Cartesian speed limit exceeded

15040

Ackn.: Maximum global axis speed exceeded

15041

Ackn.: Maximum safe reduced Cartesian speed exceeded

15042

Ackn.: Safe reduced axis speed exceeded

15043

Safe operational stop violated (axis group Number of axis group)

15044

Ackn.: Safe operational stop violated (axis group Number of axis group)

15045 15046

Error at mastering reference switch

The limit value for maxi Acknowledge the mesmum Cartesian velocity sage. (not space-dependent) has been exceeded. The limit value for maxiCheck the programmed mum axis velocity has motion and modify as been exceeded. required. Check the safety configuration and modify as required. The limit value for safely Check the programmed reduced Cartesian velocity motion and modify as has been exceeded. required. Check the safety configuration and modify as required. The limit value for safely Check the programmed reduced axis velocity has motion and modify as been exceeded. required. Check the safety configuration and modify as required. Check whether the velocity monitoring is activated and activate if required. Following activation of the Deactivate operational safe operational stop, at stop. least one axis from the axis Stop the axes in the axis group was not braked or group before activating the exceeded the configured operational stop. axis angles or distance tolCheck the configuration of erances during a monithe axis group and modify tored standstill. as required. The CIB signals an error at Check the reference switch the reference switch input. connection and CIB.

Ackn.: Error at mastering reference switch

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12 Messages

No.

Message

Cause

Remedy

15047

Mastering test required (internal)

Perform mastering test.

15048

Ackn.: Mastering test time interval expired

15049

Mastering test failed

15050

Reference stop

The mastering test is requested internally after the robot controller has booted or after mastering. The monitoring time has elapsed. The mastering test has failed. The cause of the error is indicated in a separate message. See messages no. 15051 to 15066. Reference stop is activated. (= function Stop if

Perform mastering test. Eliminate error and carry out mastering test.

Perform mastering test.

mastering test not yet done)

15051

Ackn.: Mastering test position not reached

It was not possible to move to the reference position.

15052

Ackn.: Mastering reference switch not actuated

Robot is in mastering position and the reference switch is not actuated: Reference switch is defective. The distance between  the reference switch and the reference position is too great. The mastering test for one or more reference groups could not be carried out because of a missing reference position or because of a missing motion away from the reference position. Loss of mastering of one or more axes: the workspace monitoring functions are deactivated. The reference switch is actuated although no mastering test is currently being carried out. 

15053

Ackn.: Not all mastering reference groups referenced

15054

Workspace monitoring functions deactivated (mastering error)

15065

Ackn.: Level at mastering reference switch is unexpectedly "low"

15066

Level at mastering reference switch is unexpectedly "low"

15079 15080

Monitoring space no. Number of monitoring space violated Ackn.: Monitoring space no. Number of monitoring space violated

One or more axes are situated outside the monitoring space. The monitoring was only activated after the space limit was violated.


Check the reference position in the program MasRef_USER.SRC and in the safety configuration and teach again if required. Check mastering. Exchange the reference switch. Check the reference position in the program MasRef_USER.SRC and in the safety configuration and teach again if required. Check mastering. Teach the missing reference positions or missing motion away from the reference position in the program MasRef_USER.SRC.

Master unmastered axes.

Check the reference switch and exchange if defective.

Move robot out of the violated area in CRR mode. Deactivate the monitoring space using the safe input.

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No.

Message

Cause

Remedy

15081

Monitoring space no. Number of monitoring space exceeded

One or more axes have left the monitoring space. The monitoring was already active when the space limit was violated.

Move robot out of the violated area in CRR mode. Deactivate the monitoring space using the safe input.

15082

Ackn.: Monitoring space no. Number of monitoring space exceeded

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13 Appendix

13

Appendix

13.1

Checklists

13.1.1

Precondition for safety acceptance based on the checklists 



13.1.2

Mechanical and electrical installation of the industrial robot have been completed. Safety configuration is completed.

Checklist for robot and system

The checklist must be completed and confirme d in writing by the system builder. Checklist

No.



Serial number of the robot: ____________________

Activity

1

Yes

The industrial robot is in flawless mechanical condition and correctly installed and fastened in accordance with the specifications in the documentation. The permissible rated payload of the robot has not been exceeded. There are no foreign bodies or loose parts on the industrial robot. All required safety equipment is correctly installed and operational. The power supply ratings of the industrial robot correspond to the local supply voltage and mains type. The connecting cables are correctly connected and the connectors are locked. The ground conductor and the equipotential bonding cable are sufficiently rated and correctly connected. The system meets all the relevant laws, regulations and norms valid for the installation site.

2 3 4 5 6 7 8

Place, date Signature By signing, the signatory confirms the correct and complete performance of the safety acceptance test.

Remarks:

13.1.3

Checklist for safe functions

Checklist

  

Serial number of the robot: ____________________ Time stamp of the safety configuration: ____________________ Checksum of the safety configuration: ____________________


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No.

1 2 3

4

5

Activation code of the safety configuration: ____________________

Activity

Yes

Not relevant

Safe monitoring has been activated. Robot is mastered. The machine data are consistent with the machine data in the safety configuration. Inconsistent machine data are indicated when the safety configuration is activated. The machine data have been checked and are appropriate for the robot used. The machine data loaded must match the machine data on the identification plate of the robot. The machine data of the external axes have been correctly entered and checked. Move each external axis a defined distance by means of a PTP_REL motion, e.g. 90°. Carry out a visual inspection and check whether this distance is covered.

6

7

8 9 10 11

12

In the case of a KL, move the external axis a defined distance by means of a PTP_REL motion, e.g. 500 mm. Carry out a visual inspection and additionally monitor the display of the Cartesian actual position to check whether this distance is covered. Control of the reduced velocity has been checked and is functioning correctly. (>>> 4.8.3 "Start-up and recommissioning" Page 50) The local and external safety functions have been checked and are functioning correctly. (>>> 4.8.3 "Start-up and recommissioning" Page 50) The reference position has been taught in the program MasRef_USER.SRC and in the safety configuration. Was the mastering test successful? Was the brake test successful? Operator safety acknowledgement has been checked and is functioning correctly. (>>> 4.5.4 "Operator safety" Page 42) Peripheral contactor (US2) has been checked and switches at the right time. Note: Further information is contained in the Operating and

13

Programming Instructions for System Integrators. The Cartesian and axis-specific velocities have been configured correctly. The checklist must be completed and confirmed in writing for the Cartesian and axis-specific velocities. (>>> 13.1.4 "Checklist for velocity limits" Page 118)

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13 Appendix

No.

Activity

14

The correct configuration of the safe operational stop has been checked by moving all axes.

Yes

Not relevant

Each axis in an axis group must be tested individually. The checklist must be completed and confirmed in writing for every axis group.

15

(>>> 13.1.5 "Checklist for configuration of the safe operational stop" Page 121) The correct configuration of the cell area has been checked by moving to all reachable limits. The checklist must be completed and confirmed in writing for the cell area.

16

(>>> 13.1.6 "Checklist for configuration of the cell area" Page 122) The correct configuration of the monitoring spaces used has been checked by moving to all reachable limits. Each space surface of a Cartesian monitoring space must be addressed in 3 different positions. The axis of an axis-specific monitoring space must be moved to the upper and lower limits of the space. The checklist must be completed and confirmed in writing for each monitoring space used. (>>> 13.1.7 "Checklist for configuration of Cartesian monitoring spaces" Page 123) (>>> 13.1.8 "Checklist for configuration of axis-specific monitoring spaces" Page 125) Monitoring space 1 Monitoring space 2 Monitoring space 3 Monitoring space 4 Monitoring space 5 Monitoring space 6 Monitoring space 7 Monitoring space 8 Monitoring space 9 Monitoring space 10 Monitoring space 11 Monitoring space 12 Monitoring space 13 Monitoring space 14 Monitoring space 15 Monitoring space 16


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No.

Activity

17

Yes

Not relevant

The safe tools used have been configured correctly. At least one monitoring space and one velocity must be checked with each safe tool. The checklist must be completed and confirmed in writing for each safe tool used. (>>> 13.1.9 "Checklist for configuration of the safe tools" Page 127) The safety configuration has been archived and the change log has been checked.

18

Place, date Signature By signing, the signatory confirms the correct and complete performance of the safety acceptance test. 13.1.4

Checklist for velocity limits

Checklist

  

Serial number of the robot: ____________________ Time stamp of the safety configuration: ____________________ Safe tool used (in test): ____________________

Specified value: 

Value specified by cell planner, design engineer

Configured value: 

Value entered in the safety configuration

Test value: 

No.

1

Value with which the test was carried out

Activity

Yes

Not relevant

The maximum Cartesian velocity has been correctly configured and checked. Specified value: __________ mm/s Configured value: __________ mm/s

2

Test value: __________ mm/s The safe reduced Cartesian velocity has been correctly configured and checked. Specified value: __________ mm/s Configured value: __________ mm/s

3

Test value: __________ mm/s The safe reduced Cartesian velocity for T1 has been correctly configured and checked. Specified value: __________ mm/s Configured value: __________ mm/s Test value: __________ mm/s

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13 Appendix

No.

4

Activity

Yes

Not relevant

The maximum axis velocity has been correctly configured and checked. Specified value for axis 1: __________ °/s or mm/s Configured value for axis 1: __________ °/s or mm/s Test value for axis 1: __________ °/s or mm/s Specified value for axis 2: __________ °/s Configured value for axis 2: __________ °/s Test value for axis 2: __________ °/s Specified value for axis 3: __________ °/s Configured value for axis 3: __________ °/s Test value for axis 3: __________ °/s Specified value for axis 4: __________ °/s Configured value for axis 4: __________ °/s Test value for axis 4: __________ °/s Specified value for axis 5: __________ °/s Configured value for axis 5: __________ °/s Test value for axis 5: __________ °/s Specified value for axis 6: __________ °/s Configured value for axis 6: __________ °/s Test value for axis 6: __________ °/s Specified value for axis 7: __________ °/s or mm/s Configured value for axis 7: __________ °/s or mm/s Test value for axis 7: __________ °/s or mm/s Specified value for axis 8: __________ °/s or mm/s Configured value for axis 8: __________ °/s or mm/s Test value for axis 8: __________ °/s or mm/s


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No.

5

Activity

Yes

Not relevant

The reduced axis velocity has been correctly configured and checked. Specified value for axis 1: __________ °/s or mm/s Configured value for axis 1: __________ °/s or mm/s Test value for axis 1: __________ °/s or mm/s Specified value for axis 2: __________ °/s Configured value for axis 2: __________ °/s Test value for axis 2: __________ °/s Specified value for axis 3: __________ °/s Configured value for axis 3: __________ °/s Test value for axis 3: __________ °/s Specified value for axis 4: __________ °/s Configured value for axis 4: __________ °/s Test value for axis 4: __________ °/s Specified value for axis 5: __________ °/s Configured value for axis 5: __________ °/s Test value for axis 5: __________ °/s Specified value for axis 6: __________ °/s Configured value for axis 6: __________ °/s Test value for axis 6: __________ °/s Specified value for axis 7: __________ °/s or mm/s Configured value for axis 7: __________ °/s or mm/s Test value for axis 7: __________ °/s or mm/s Specified value for axis 8: __________ °/s or mm/s Configured value for axis 8: __________ °/s or mm/s Test value for axis 8: __________ °/s or mm/s

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13 Appendix

No.

Activity

6

Yes

Not relevant

The reduced axis velocity for T1 has been correctly configured and checked. Specified value for axis 1: __________ °/s or mm/s Configured value for axis 1: __________ °/s or mm/s Test value for axis 1: __________ °/s or mm/s Specified value for axis 2: __________ °/s Configured value for axis 2: __________ °/s Test value for axis 2: __________ °/s Specified value for axis 3: __________ °/s Configured value for axis 3: __________ °/s Test value for axis 3: __________ °/s Specified value for axis 4: __________ °/s Configured value for axis 4: __________ °/s Test value for axis 4: __________ °/s Specified value for axis 5: __________ °/s Configured value for axis 5: __________ °/s Test value for axis 5: __________ °/s Specified value for axis 6: __________ °/s Configured value for axis 6: __________ °/s Test value for axis 6: __________ °/s Specified value for axis 7: __________ °/s or mm/s Configured value for axis 7: __________ °/s or mm/s Test value for axis 7: __________ °/s or mm/s Specified value for axis 8: __________ °/s or mm/s Configured value for axis 8: __________ °/s or mm/s Test value for axis 8: __________ °/s or mm/s


Checklist for configuration of the safe operational stop

A separate checklist must be completed for each axis group.

Precondition



Checklist

  

Operating mode T1 Serial number of the robot: ____________________ Time stamp of the safety configuration: ____________________ Axis group number: ____________________


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No.

Activity

1

Yes

Not relevant

Axis 1 has been correctly configured and checked. Specified axis angle tolerance: ______ ° or m m

2

Configured axis angle tolerance: ______ ° or mm Axis 2 has been correctly configured and checked. Specified axis angle tolerance: __________ °

3

Configured axis angle tolerance: __________ ° Axis 3 has been correctly configured and checked. Specified axis angle tolerance: __________ °

4


5


6


7

Configured axis angle tolerance: __________ ° Axis 7 has been correctly configured and checked. Specified axis angle tolerance: _______ ° or mm

8

Configured axis angle tolerance: ______ ° or mm Axis 8 has been correctly configured and checked. Specified axis angle tolerance: ______ ° or m m Configured axis angle tolerance: ______ ° or mm


Checklist for configuration of the cell area

Precondition



Checklist

  

The monitoring spaces that can be activated by means of safe inputs have been deactivated. Serial number of the robot: ________________ Time stamp of the safety configuration: ________________ Safe tool used in test: ________________

The surfaces arising from the configuration must be violated one after the other to demonstrate the correct configuration of the cell area. No.

1

Activity

Yes

Not relevant

Has the limit in the Z direction been configured correctly? Z min: ____________mm Z max: ____________mm

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13 Appendix

No.

2

Activity

Yes

Not relevant

Corner 1 has been correctly configured? X coordinate: __________ mm

3

Y coordinate: __________ mm Corner 2 has been correctly configured? X coordinate: __________ mm

4

Y coordinate: __________ mm Corner 3 has been correctly configured? Y coordinate: __________ mm

5

X coordinate: __________ mm Corner 4 has been correctly configured? Y coordinate: __________ mm

6

X coordinate: __________ mm Corner 5 has been correctly configured? X coordinate: __________ mm

7


8


9


10


11

Y coordinate: __________ mm Corner 10 has been correctly configured? X coordinate: __________ mm Y coordinate: __________ mm


Checklist for configuration of Cartesian monitoring spaces

A separate checklist must be completed for each monitoring space.

Precondition

 

The monitoring space to be checked is activated. The monitoring spaces that can be activated by means of safe inputs have been deactivated.


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Checklist

        

 

Serial number of the robot: ____________________ Time stamp of the safety configuration: ____________________ Monitoring space checked (name, number): __________ Type of space (protected space or workspace): ____________________ Stop at boundaries (TRUE|FALSE): __________ Reference stop (TRUE|FALSE): __________ Space-specific velocity __________mm/s Space-specific velocity valid in: __________ Safe tool used in test of velocity or space limit: _________________ Always active (TRUE|FALSE): __________ Reference coordinate system: _____________

The configured limit values must successively be violated to demonstrate the correct functioning of the monitoring space. No.

1

Activity

Yes

Not relevant

The coordinates of the monitoring space have been correctly configured and checked? Origin X: __________ mm Origin Y: __________ mm Origin Z: __________ mm Origin A: __________ ° Origin B: __________ ° Origin C: __________ ° Distance to origin XMin: __________ mm Distance to origin YMin: __________ mm Distance to origin ZMin: __________ mm Distance to origin XMax: __________ mm Distance to origin YMax: __________ mm Distance to origin ZMax: __________ mm

The following preconditions must be met to demonstrate the correct functioning of the reference stop:   

No.

2

Reference stop is active. Mastering test is requested. Monitored monitoring space is activated.

Activity

Yes

Not relevant

The correct functioning of the reference stop has been checked?

The following preconditions must be met to demonstrate the correct functioning of the space-specific velocity:  

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Space-specific velocity is active. The configured limit value of the space-specific velocity is less than the limit value of the maximum Cartesian velocity. Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

13 Appendix  

No.

Monitored monitoring space is activated. Robot exceeds the configured space-specific velocity.

Activity

3

Yes

Not relevant

The space-specific velocity has been correctly configured and checked? Specified value: __________ mm/s Configured value: __________ mm/s Test value: __________ mm/s


Checklist for configuration of axis-specific monitoring spaces

A separate checklist must be completed for each monitoring space.

Precondition

 

Checklist

        



The monitoring space to be checked is activated. The monitoring spaces that can be activated by means of safe inputs have been deactivated. Serial number of the robot: ____________________ Time stamp of the safety configuration: ____________________ Monitoring space checked (name, number): __________ Type of space (protected space or workspace): ____________________ Stop at boundaries (TRUE|FALSE): __________ Reference stop (TRUE|FALSE): __________ Space-specific velocity __________mm/s Space-specific velocity valid in: __________ Safe tool used in test of velocity or space limit: _________________ Always active (TRUE|FALSE): __________

The configured limit values must successively be violated to demonstrate the correct functioning of the monitoring space. No.

1

Activity

Yes

Not relevant

Axis 1 has been correctly configured and checked. Specified lower axis limit: __________ ° or m m Configured lower axis limit: __________ ° or mm Determined lower axis limit: __________ ° or mm Specified upper axis limit: __________ ° or mm Configured upper axis limit: __________ ° or mm Determined upper axis limit: __________ ° or mm


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No.

2

Activity

Yes

Not relevant

Axis 2 has been correctly configured and checked. Specified lower axis limit: __________ ° Configured lower axis limit: __________ ° Determined lower axis limit: __________ ° Specified upper axis limit: __________ ° Configured upper axis limit: __________ °

3

Determined upper axis limit: __________ ° Axis 3 has been correctly configured and checked. Specified lower axis limit: __________ ° Configured lower axis limit: __________ ° Determined lower axis limit: __________ ° Specified upper axis limit: __________ ° Configured upper axis limit: __________ °

4


5


6


7

Determined upper axis limit: __________ ° Axis 7 has been correctly configured and checked. Specified lower axis limit: __________ ° or mm Configured lower axis limit: __________ ° or mm Determined lower axis limit: __________ ° or mm Specified upper axis limit: __________ ° or mm Configured upper axis limit: __________ ° or mm Determined upper axis limit: __________ ° or mm

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13 Appendix

No.

8

Activity

Yes

Not relevant

Axis 8 has been correctly configured and checked. Specified lower axis limit: __________ ° or mm Configured lower axis limit: __________ ° or mm Determined lower axis limit: __________ ° or mm Specified upper axis limit: __________ ° or mm Configured upper axis limit: __________ ° or mm Determined upper axis limit: __________ ° or mm

The following preconditions must be met to demonstrate the correct functioning of the reference stop:   

No.

9

Reference stop is active. Mastering test is requested. Monitored monitoring space is activated.

Activity

Yes

Not relevant

The correct functioning of the reference stop has been checked?

The following preconditions must be met to demonstrate the correct functioning of the space-specific velocity:  

 

Space-specific velocity is active. The configured limit value of the space-specific velocity is less than the limit value of the maximum Cartesian velocity. Monitored monitoring space is activated. Robot exceeds the configured space-specific velocity.

No.

Activity

Yes

10

The space-specific velocity has been correctly configured and checked? Specified value: __________ mm/s

Not relevant

Configured value: __________ mm/s Test value: __________ mm/s


Checklist for configuration of the safe tools

A separate checklist must be completed for each safe tool.


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Checklist

    

Serial number of the robot: _________________ Time stamp of the safety configuration: _________________ Safe tool checked (name, number): _______________ Velocity limit during TCP test: ____________ mm/s Monitoring space used in sphere test (name, number): ________________

A monitoring space must be violated by each configured sphere to demonstrate the correct functioning of the safe tool. No.

1

Activity

Yes

Not relevant

Safe TCP of the tool The coordinates have been correctly configured and checked (velocity check)? Specified value for the X coordinate: __________ mm Configured value for the X coordinate: __________ mm Specified value for the Y coordinate: __________ mm Configured value for the Y coordinate: __________ mm Specified value for the Z coordinate: __________ mm

2

Configured value for the Z coordinate: __________ mm 1st sphere on tool The coordinates have been correctly configured and checked? Specified value for the X coordinate: __________ mm Configured value for the X coordinate: __________ mm Specified value for the Y coordinate: __________ mm Configured value for the Y coordinate: __________ mm Specified value for the Z coordinate: __________ mm Configured value for the Z coordinate: __________ mm Specified radius: __________ mm

3

Configured radius: __________ mm 2nd sphere on tool The coordinates have been correctly configured and checked? Specified value for the X coordinate: __________ mm Configured value for the X coordinate: __________ mm Specified value for the Y coordinate: __________ mm Configured value for the Y coordinate: __________ mm Specified value for the Z coordinate: __________ mm Configured value for the Z coordinate: __________ mm Specified radius: __________ mm Configured radius: __________ mm

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13 Appendix

No.

4

Activity

Yes

Not relevant

3rd sphere on tool The coordinates have been correctly configured and checked? Specified value for the X coordinate: __________ mm Configured value for the X coordinate: __________ mm Specified value for the Y coordinate: __________ mm Configured value for the Y coordinate: __________ mm Specified value for the Z coordinate: __________ mm Configured value for the Z coordinate: __________ mm Specified radius: __________ mm

5

Configured radius: __________ mm 4th sphere on tool The coordinates have been correctly configured and checked? Specified value for the X coordinate: __________ mm Configured value for the X coordinate: __________ mm Specified value for the Y coordinate: __________ mm Configured value for the Y coordinate: __________ mm Specified value for the Z coordinate: __________ mm Configured value for the Z coordinate: __________ mm Specified radius: __________ mm

6

Configured radius: __________ mm 5th sphere on tool The coordinates have been correctly configured and checked? Specified value for the X coordinate: __________ mm Configured value for the X coordinate: __________ mm Specified value for the Y coordinate: __________ mm Configured value for the Y coordinate: __________ mm Specified value for the Z coordinate: __________ mm Configured value for the Z coordinate: __________ mm Specified radius: __________ mm

7

Configured radius: __________ mm 6th sphere on tool The coordinates have been correctly configured and checked? Specified value for the X coordinate: __________ mm Configured value for the X coordinate: __________ mm Specified value for the Y coordinate: __________ mm Configured value for the Y coordinate: __________ mm Specified value for the Z coordinate: __________ mm Configured value for the Z coordinate: __________ mm Specified radius: __________ mm Configured radius: __________ mm


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Place, date Signature By signing, the signatory confirms the correct and complete performance of the safety acceptance test.

13.2

Applied norms and directives The safety functions of KUKA.SafeOperation meet the requirements of Category 3 and Performance Level d in accordance with EN ISO 13849-1:2007. This corresponds to SIL 2 in accordance with EN 62061.

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14 KUKA Service

14

KUKA Service

14.1

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.

Information

The following information is required for processing a support request:         

14.2

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 co untries. Please do not hesitate to contact us if you have any questions.

Argentina

Ruben Costantini S.A. (Agency) Luis Angel Huergo 13 20 Parque Industrial 2400 San Francisco (CBA) Argentina Tel. +54 3564 421033 Fax +54 3564 428877 [email protected]

Australia

Headland Machinery Pty. Ltd. Victoria (Head Office & Showroom) 95 Highbury Road Burwood Victoria 31 25 Australia Tel. +61 3 9244-3500 Fax +61 3 9244-3501 [email protected] www.headland.com.au


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Belgium

KUKA Automatisering + Robots N.V. Centrum Zuid 1031 3530 Houthalen Belgium Tel. +32 11 516160 Fax +32 11 526794 [email protected] www.kuka.be

Brazil

KUKA Roboter do Brasil Ltda. Avenida Franz Liszt, 80 Parque Novo Mundo Jd. Guançã CEP 02151 900 São Paulo SP Brazil Tel. +55 11 69844900 Fax +55 11 62017883 [email protected]

Chile

Robotec S.A. (Agency) Santiago de Chile Chile Tel. +56 2 331-5951 Fax +56 2 331-5952 [email protected] www.robotec.cl

China

KUKA Automation Equipment (Shanghai) Co., Ltd. Songjiang Industrial Zone No. 388 Minshen Road 201612 Shanghai China Tel. +86 21 6787-1808 Fax +86 21 6787-1805 [email protected] www.kuka.cn

Germany

KUKA Roboter GmbH Zugspitzstr. 140 86165 Augsburg Germany Tel. +49 821 797-4000 Fax +49 821 797-1616 [email protected] www.kuka-roboter.de


14 KUKA Service

France

KUKA Automatisme + Robotique SAS Techvallée 6, Avenue du Parc 91140 Villebon S/Yvette France Tel. +33 1 6931660-0 Fax +33 1 6931660-1 [email protected] www.kuka.fr

India

KUKA Robotics, Private Limited 621 Galleria Towers DLF Phase IV 122 002 Gurgaon Haryana Indien Tel. +91 124 4148574 [email protected] www.kuka.in

Italy

KUKA Roboter Italia S.p.A. Via Pavia 9/a - int.6 10098 Rivoli (TO) Italy Tel. +39 011 959-5013 Fax +39 011 959-5141 [email protected] www.kuka.it

Japan

KUKA Robotics Japan K.K. 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 [email protected]

Korea

KUKA Robotics Korea Co. Ltd. RIT Center 306, Gyeonggi Technopark 1271-11 Sa 3-dong, Sangnok-gu Ansan City, Gyeonggi Do 426-901 Korea Tel. +82 31 501-1451 Fax +82 31 501-1461 [email protected]


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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 [email protected]

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 [email protected]

Norway

KUKA Sveiseanlegg + Roboter Bryggeveien 9 2821 Gjövik Norway Tel. +47 61 133422 Fax +47 61 186200 [email protected]

Austria

KUKA Roboter Austria GmbH Vertriebsbüro Österreich Regensburger Strasse 9/1 4020 Linz Austria Tel. +43 732 784752 Fax +43 732 793880 [email protected] www.kuka-roboter.at

Poland

KUKA Roboter Austria GmbH Spółka z ograniczoną odpowiedzialnością Oddział w Polsce Ul. Porcelanowa 10 40-246 Katowice Poland Tel. +48 327 30 32 13 or -14 Fax +48 327 30 32 26 [email protected]


14 KUKA Service

Portugal

KUKA Sistemas de Automatización S.A. Rua do Alto da Guerra n° 50 Armazém 04 2910 011 Setúbal Portugal Tel. +351 265 729780 Fax +351 265 729782 [email protected]

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 Svetsanläggningar + Robotar AB A. Odhners gata 15 421 30 Västra Frölunda Sweden Tel. +46 31 7266-200 Fax +46 31 7266-201 [email protected]

Switzerland

KUKA Roboter Schweiz AG Industriestr. 9 5432 Neuenhof Switzerland Tel. +41 44 74490-90 Fax +41 44 74490-91 [email protected] www.kuka-roboter.ch

Spain

KUKA Robots IBÉRICA, S.A. Pol. Industrial Torrent de la Pastera Carrer del Bages s/n 08800 Vilanova i la Geltrú (Barcelona) Spain Tel. +34 93 8142-353 Fax +34 93 8142-950 [email protected] www.kuka-e.com


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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. No. 249 Pujong Road Jungli City, Taoyuan County 320 Taiwan, R. O. C. Tel. +886 3 4331988 Fax +886 3 4331948 [email protected] www.kuka.com.tw

Thailand

KUKA Robot Automation (M)SdnBhd Thailand Office c/o Maccall System Co. Ltd. 49/9-10 Soi Kingkaew 30 Kingkaew Road Tt. Rachatheva, A. Bangpli Samutprakarn 10540 Thailand Tel. +66 2 7502737 Fax +66 2 6612355 [email protected] www.kuka-roboter.de

Czech Republic

KUKA Roboter Austria GmbH Organisation Tschechien und Slowakei Sezemická 2757/2 193 00 Praha Horní Počernice Czech Republic Tel. +420 22 62 12 27 2 Fax +420 22 62 12 27 0 [email protected]

Hungary

KUKA Robotics Hungaria Kft. Fö út 140 2335 Taksony Hungary Tel. +36 24 501609 Fax +36 24 477031 [email protected]


14 KUKA Service

USA

KUKA Robotics Corp. 22500 Key Drive Clinton Township 48036 Michigan USA Tel. +1 866 8735852 Fax +1 586 5692087 [email protected] www.kukarobotics.com

UK

KUKA Automation + Robotics Hereward Rise Halesowen B62 8AN UK Tel. +44 121 585-0800 Fax +44 121 585-0900 [email protected]


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Index

Index Symbols

$MASTERINGTEST_REQ_EXT 99 $MASTERINGTEST_REQ_INT 99 $MASTERINGTESTSWITCH_OK 99 $ROBROOT, special cases 15 $SR_ACTIVETOOL 100 $SR_AXISSPEED_OK 100 $SR_CARTSPEED_OK 100 $SR_DRIVES_ENABLE 100 $SR_MOVE_ENABLE 100 $SR_OV_RED 25, 99 $SR_SAFEMON_ACTIVE 100 $SR_SAFEOPSTOP_ACTIVE 100 $SR_SAFEOPSTOP_OK 100 $SR_SAFEREDSPEED_ACTIVE 100 $SR_VEL_RED 24, 99 $SR_WORKSPACE_RED 25, 99 Numbers

2004/108/EC 57 2006/42/EC 57 89/336/EEC 57 95/16/EC 57 97/23/EC 57 A

Accessories 35 Activating a new safety configuration 95 Activation code, safety configuration 62 Activation, monitoring space 73, 77 Activation, reference stop 73, 77 Actuating plate, hole pattern 32 Actuating plate, installation 67 Alarm space 8 Ambient temperature, reference switch 31 Appendix 115 Applied norms and regulations 57 Areas of application 11 Automatic mode 53 Axis angle tolerance 84 Axis angle, lower limit 79 Axis angle, upper limit 79 Axis limit 8, 19, 20 Axis range 8, 19, 20, 37 Axis range limitation 46 Axis range monitoring 46 Axis velocity, maximum 82, 92 Axis velocity, reduced 24, 81, 92 Axis velocity, reduced for T1 81, 92 Axis velocity, testing 92 Axis-specific monitoring spaces, defining 75 Axis-specific monitoring spaces, testing 94 Axis-specific protected spaces 20 Axis-specific velocity monitoring, defining 79 Axis-specific workspaces 19 B

BASE coordinate system 14 Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

Brake defect 48 Braking distance 8, 37 Buttons, overview 61 C

Cartesian monitoring spaces, defining 72 Cartesian monitoring spaces, testing 93 Cartesian protected spaces 18 Cartesian velocity, maximum 69, 91 Cartesian velocity, reduced 70, 91 Cartesian velocity, reduced for T1 70, 91 Cartesian velocity, testing 91 Cartesian workspaces 17 CE mark 36 Cell area 10, 13, 16, 17 Cell area, defining 70 Change log 63 Checking the reference position 89 Checklist, Cartesian monitoring spaces 123 Checklist, configuration of axis-specific monitoring spaces 125 Checklist, configuration of safe tools 127 Checklist, configuration of the cell area 122 Checklist, configuration of the safe operational stop 121 Checklist, robot and system 115 Checklist, safe functions 115 Checklist, velocity limits 118 Checklists 115 Checksum, brake test configuration 63 Checksum, safety configuration 62 Cleaning work 54 Components 11 Connecting cables 35 Connecting cables, overview 28 Connecting, reference switch 67 Coordinate systems 14 Coordinate systems, angles 15 Coordinate systems, orientation 15 Counterbalancing system 54 Criteria, reference position 27 CRR 8, 25 D

Danger zone 8, 37 Declaration of conformity 36 Declaration of incorporation 35, 36 Decommissioning 55 Diagnosis 109 Diagnosis, variables 100 Diagnostic monitor (menu item) 109 Diagnostic signals via PROFINET 103 Directives 130 Displaying information, safety configuration 62 Displaying machine data 63 Displaying, change log 63 Disposal 55 Documentation, industrial robot 7 139 / 143


E

EC declaration of conformity 36 EMC conformity, reference switch 31 EMC Directive 36, 57 EMERGENCY STOP button 43, 51 EMERGENCY STOP device 43, 44, 48 EMERGENCY STOP, external 44, 51 EMERGENCY STOP, local 51 EN 60204-1 57 EN 61000-6-2 57 EN 61000-6-4 57 EN 614-1 57 EN ISO 10218-1 57 EN ISO 12100-1 57 EN ISO 12100-2 57 EN ISO 13849-1 57, 130 EN ISO 13849-2 57 EN ISO 13850 57 Enabling device 44, 48 Enabling device, external 45 Enabling switches 44 Error messages 111 External axes 35, 38 F

Faults 49 FLANGE coordinate system 15 Function test 50 Functional principle 12 Functions, SafeOperation 11 G

General safety measures 48 Global parameters, defining 68 Guard interlock 42

Knowledge, required 7 KUKA Customer Support 131 KUKA smartPAD 37 L

Labeling 47 Liability 35 Linear unit 35 Low Voltage Directive 36 M

Machine data 51, 63 Machinery Directive 36, 57 Maintenance 54 Manipulator 35, 37, 40 Manual mode 52 Mastering position, reference position 89 Mastering test 8 Mastering test input 69 Mastering test, overview 26 Mastering test, performing manually 91 Mastering test, programming 97 Mastering test, variables 99 Mechanical axis range limitation 46 Mechanical end stops 46 Messages 111 Mode selection 41, 42 Monitoring space 10 Monitoring space, axis-specific 75 Monitoring space, Cartesian 72 Monitoring spaces 12 Monitoring time 8 Monitoring, velocity 45 Mouse, external 49 N

H

Hardware components, scope of supply 11 Hazardous substances 55 Hole pattern, actuating plate 32 Hole pattern, reference switch 32 Hysteresis, reference switch 31

O

I/Os, interface X13 107 Industrial robot 35 Installation 59 Installation, SafeOperation 59 Intended use 35 Interface, X13 107 Interface, X13 12 Interfaces 101 Introduction 7

Operating current, reference switch 31 Operating voltage, reference switch 31 Operation 61 Operator 37, 39 Operator safety 41, 42, 48 Options 35 Outputs, reference switch 31 Overload 48 Override reduction 24 Override reduction, variables 99 Overview, buttons 61 Overview, SafeOperation 11 Overview, safety acceptance 94 Overview, start-up 65

J

P

Jog mode 45, 48

Panic position 44 Performance Level 41 Permissible load current, reference switch 31 Permissible switching distance, reference switch 31 Permissible switching frequency, reference swit-

I

K

KCP 37, 49 Keyboard, external 49 KL 8 140 / 143

Norms 130


Index

ch 31 Personnel 38 Plant integrator 38 Polygon, convex 8, 13, 16 Positioner 35 Pressure Equipment Directive 55, 57 Preventive maintenance work 54 Product description 11 PROFINET 12 PROFIsafe 8, 12 Programming 97 Programs, mastering test 97 Protected space 9, 12, 18, 20 Protective equipment 45 Pulse duration, reference switch 31 Pulse duty factor, reference switch 31 R

Reaction distance 8, 37 Recommissioning 50, 65 Reference group 8, 89 Reference position 8, 27 Reference position, axis angle 89 Reference position, Cartesian 89 Reference position, defining 87 Reference stop 9, 22 Reference switch 9 Reference switch module 28 Reference switch, connecting 67 Reference switch, hole pattern 32 Reference switch, installation 67 Reference switch, technical data 31 Reference system 71, 74 Release device 46 Repair 54 Robot controller 35 ROBROOT coordinate system 14 S

Safe I/Os, displaying 109 Safe monitoring 69 Safe monitoring, activating 68 Safe monitoring, deactivating 96 Safe operational stop 9, 24, 37, 45, 81 Safe operational stop, axis group 1 to 6 84 Safe operational stop, defining 82 Safe operational stop, testing 94 Safe robot retraction 25 Safe TCP 9 Safe tool 9 Safe tools 23 Safe tools, defining 84 Safeguards, external 47 SafeOperation via PROFIsafe 101 SafeOperation, overview 11 Safety 35 Safety acceptance, overview 94 Safety acceptance, precondition 115 Safety configuration, displaying information 62 Safety configuration, new, activating 95 Safety configuration, opening 61 Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en

Safety configuration, saving 90 Safety controller 41 Safety functions 48 Safety functions, overview 41 Safety instructions 7 Safety parameters, testing 91 Safety STOP 0 9, 37 Safety STOP 1 9, 37 Safety STOP 2 9, 37 Safety STOP 0 37 Safety STOP 1 37 Safety STOP 2 37 Safety stop, external 45 Safety warnings 66 Safety zone 37, 39, 40 Safety, general 35 Serial number, robot 62 Service life 31 Service, KUKA Roboter 131 SIB 9 SIB Extended 12 Simulation 53 Single point of control 55 smartPAD 37 Software 35 Software components, scope of supply 11 Software limit switches 45, 48 Space type 73, 77 Space-specific velocity 22, 73, 77 Special cases, $ROBROOT 15 SPOC 55 Standstill monitoring 24, 84 Start-up 50, 65 Start-up mode 26, 52 Start-up, overview 65 STOP 0 36, 38 STOP 1 36, 38 STOP 2 36, 38 Stop at boundaries 73, 77 Stop category 0 38 Stop category 1 38 Stop category 2 38 Stop reactions 13, 24, 40 Stopping distance 8, 37, 40 Storage 55 Support request 131 Switching function, reference switch 31 System integrator 36, 38 System requirements 59 System variables 99 T

T1 38 T2 38 Target group 7 Teach pendant 35 Technical data 31 Technical data, reference switch 31 Terms used 8 Terms used, safety 36 Time stamp, machine data 63 141 / 143


Time stamp, safety configuration 62 TOOL coordinate system 14 Training 7 Transport position 50 Transportation 50 Turn-tilt table 35 Type of monitoring space 73, 77 U

Uninstallation, SafeOperation 59 Update, SafeOperation 59 Use, contrary to intended use 35 Use, improper 35 User 37, 38 User groups 61 V

Velocity monitoring 45 Velocity monitoring functions 23 Velocity monitoring, axis-specific 79 Velocity, space-specific 22 Version, SafeOperation 62 Version, safety configuration 62 W

Warnings 7 Working range limitation 46 Workspace 8, 12, 17, 19, 37, 39, 40 WORLD coordinate system 14

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KRC4_SafeOperation

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