KUKA.Load 5.0
KUKA.Load Pro 5.0
Valid for KSS 5.5, 5.6, 8 and VSS 8
Issued: 24.10.2012
Copyright 2012
KUKA Roboter GmbH
Zugspitzstrae 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
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Publication:
Bookstructure:
Version:
Contents
Contents
1
Introduction ..................................................................................................
1.1
1.2
1.3
Trademarks ................................................................................................................
1.4
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
10
2.4
10
Installation ...................................................................................................
11
3.1
11
3.2
11
3.3
11
13
4.1
13
4.1.1
15
4.1.2
16
4.1.3
Tabs ......................................................................................................................
17
18
20
20
22
Operation ......................................................................................................
25
5.1
25
5.2
25
5.3
25
5.4
25
5.5
25
5.6
26
5.7
26
5.8
27
5.9
4.2
4.2.1
4.3
4.3.1
28
29
30
30
30
31
31
32
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34
37
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6.1
37
6.2
37
Index .............................................................................................................
45
1 Introduction
Introduction
1.1
Target group
This documentation is aimed at users with the following knowledge and skills:
Knowledge of robotics
1.2
Safety
Notes
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.
1.3
Trademarks
Windows is a trademark of Microsoft Corporation.
.NET Framework is a trademark of Microsoft Corporation.
Office 2003 is a trademark of Microsoft Corporation.
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1.4
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Terms used
Term
Description
Dynamic loading
Dynamic overloading
Total load
Load case
A load case consists of the load data of the payload on the flange and the supplementary loads
on axes A1 to A3.
Metric measurement
system
Station
At a given plant there may be one or more stations. A number of robots (e.g. welding robots)
may be used in a given station.
2 Product description
Product description
2.1
2.2
Overview of KUKA.Load
Functions
Calculating the load for several tools mounted simultaneously on the robot
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2.3
Load data
The load data must be entered in the robot controller. The load data are factored into the calculation of the paths and accelerations and help to optimize
the cycle times.
The robot must not be operated with incorrect load data
or unsuitable loads. Failure to observe this precaution
may result in severe injuries or considerable damage to property.
2.3.1
Description
Parameters
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Payload
2 Product description
Parameter
Unit
Mass
kg
Lx, Ly, Lz
mm
Ix, Iy, Iz
kg m2
Supplementary load
A3
Supplementary load
A2
Supplementary load
A1
A4 = 0, A5 = 0, A6 = 0
A2 = -90
A1 = 0
Sources
2.3.2
Reference system
Payload
Manufacturer information
Manual calculation
CAD programs
Description
If the maximum permissible motor holding torques and gear torques are exceeded, this is referred to as static overloading of the robot. This overloading
can be prevented by means of the following measures:
Shifting the position of the center of gravity towards the flange center point
2.3.3
Description
If the load data are out of specification, this is referred to as dynamic overloading of the robot. This overloading can be prevented by means of the following
measures:
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2.3.4
Description
100% corresponds to the attainable velocity at nominal load. If the axis is the
leading axis, this may cause the velocity to be reduced or the energy monitoring to be triggered.
2.4
Description
In KUKA.Load Pro, when Palletizer is set under Preselection, the list of robot
types displayed also includes robots with 6 axes. The static and dynamic loading of these robots is analyzed on the basis of the higher loads permitted in
palletizing mode. The analysis is therefore only valid if the robot is operated in
palletizing mode. If the robot receives a release for the analysis, a corresponding message will be displayed.
When using robots in palletizing mode, it must be ensured that the
safety instructions and the specified operation of the robot in palletizing mode are observed.
Further information about operating robots in palletizing mode is contained in the operating and programming instructions of the KUKA
System Software (KSS) in the chapter Start-up and recommissioning in the section Activating palletizing mode.
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3 Installation
Installation
3.1
System requirements
Hardware
Minimum requirements
512 MB RAM
Recommended equipment
Software
3.2
2 GB RAM
Precondition
Procedure
Follow the instructions in the installation wizard. Visual C++ Runtime Libraries is installed.
4. The installation wizard for KUKA.Load opens. Confirm with Next >.
5. For KUKA.Load Pro only: Accept the license agreement and click on
Next >.
6. Select the directory and confirm with Next >.
7. Confirm installation with Next >. Installation is carried out.
8. When the installation wizard reports that KUKA.Load has been installed,
close the installation wizard with Close.
3.3
Uninstalling KUKA.Load
Precondition
Procedure
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4.1
Overview
Preselection area
Status bar
Toolbar
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Areas
Area
Description
Preselection
Controller
Supply voltage
Configuration
Reach [mm]
In the Robot type area, all the robots are shown that
correspond to the current preselection. These robots
are particularly suitable for the selected controller and
supply voltage.
The general conditions for operation of the controller
with the corresponding mains power supply can be
found in the robot controller documentation.
The specified supply voltage refers to the input supply
voltage to the controller and can if necessary be generated by a transformer connected upstream of the controller.
Note: In KUKA.Load Pro, when Palletizer is set under
Preselection, the list of robot types displayed also
includes robots with 6 axes. When using these robots,
it must be ensured that the safety instructions and the
specified operation of the robot in palletizing mode are
observed.
Load
analysis
Load data
Tabs
Payload diagram
Coordinate systems
Static
Dynamic
Velocity
Info
Button
Description
Robot search
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Toolbar
Button
Description
Load
analysis
Robot comparison
Icon
Description
Add robot with load case to a project.
Precondition: A project file is loaded.
Update the load case of a robot in a project.
Precondition: A link is established between the open project
file and the graphical user interface.
Status bar
Fig. 4-2
4.1.1
Preselection area
Description
The Preselection area features a tab for the controller and a tab for the manipulator configuration.
On the tab for the controller, you can select between the controllers KR C2,
KR C4 and KR C4 compact.
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Description
In this area the payload and supplementary loads are entered. These values
can be entered manually in the boxes, or automatically using the buttons Set
all nominal values, Nom. values or Nom. values of all suppl. loads.
Buttons
Selection of axes A1 to A3
Button
Description
Nom. values
Nom. values of
all suppl. loads
Energy supply
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4.1.3
Tabs
Description
Description
Payload
diagram
Coordinate
systems
Static
Dynamic
Velocity
Info
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4.2
Description
When a project file is created, a project window opens with the name of the
created project file. The project file can contain several projects and individual
stations. Each station can be assigned a number of robots with different load
cases.
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Description
In the Analysis area, a load analysis can be carried out for a load
case, and a sign-off sheet can be created.
Item
4
Description
In the Load data area, the selected robot and its load case are
shown. The payload and supplementary loads are displayed separately.
Mass
In the Robot types area, robots and load cases can be added. A
link can be established between the project window and the
graphical user interface. Information is displayed about the project; this can be changed.
(>>> 4.2.1 "Robot types area" Page 20)
Buttons
Button
Description
Create project
Delete project
Create station
Delete station
Load analysis
Save
Close
Exit
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4.2.1
Description
In this box, the robots are shown with their load cases in a tree
structure. Each load case is assigned an originator and a result.
With the exception of the result, all the elements can be renamed
by double-clicking. Robots and load cases can be deleted by
right-clicking on the robot or load case and selecting Delete. If a
robot is assigned only one load case, the robot is also deleted
together with the load case.
In this area, information about the project, such as the robot serial
number, is displayed here. The information can be changed.
Element
Description
Link is active.
Link is not active.
4.3
Description
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When a project file is created, a project window opens with the name of the
created project file. The project file can contain several projects and individual
stations. Each station can be assigned a number of robots with different load
cases.
Description
In the Analysis area, a load analysis can be carried out for one or
more load cases, and sign-off sheets can be created.
In the Load data area, the selected robot and its load case are
shown. The payload and supplementary loads are displayed separately.
Mass
In the Robot types area, robots and load cases can be added. A
link can be established between the project window and the
graphical user interface. Information is displayed about the project; some of this can be changed.
(>>> 4.3.1 "Robot types area (KUKA.Load Pro)" Page 22)
Buttons
Button
Description
Add
project file
Create project
Delete project
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Button
Description
Delete station
Create sign-off
sheet(s)
Note: The result is displayed in the project information in the Robot types area.
Load analysis for all
robots
Advanced
Save
Close
Exit
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Item
1
Description
In this box, the robots are shown with their load cases in a tree
structure. Each load case is assigned an originator, determination
and result. Right-clicking on Determination allows selection of
the method of determination for the load data.
With the exception of determination and result, all the elements
can be renamed by double-clicking. Robots and load cases can
be deleted by right-clicking on the robot or load case and selecting
Delete. If a robot is assigned only one load case, the robot is also
deleted together with the load case.
Element
Description
Link is active.
Link is not active.
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5 Operation
Operation
5.1
Starting KUKA.Load
Procedure
Under Programs, select Kuka Roboter GmbH > Kuka.Load 5.0 or Kuka.Load Pro 5.0 in the Windows Start menu.
KUKA.Load is opened.
5.2
Description
Procedure
5.3
Metric
Imperial
Select the menu sequence Extras > Units and choose the desired measurement system.
Procedure
5.4
Select the menu sequence Extras > Language and select the desired language.
Description
A project file is used to manage and verify the load data for a number of robots.
The project file is an XML file.
Procedure
5.5
Precondition
Procedure
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5.6
Precondition
Procedure
Alternative
5.7
Precondition
Procedure
Display
Description
Green
Green
Yellow
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5 Operation
Result message
Display
Description
Yellow
Robot is statically
OK
Red
The selected robot type is not suitable for the specified load case.
Red
Robot is statically
overloaded
Robot is statically
overloaded
Red
5.8
Description
The Add tool data button allows several loads to be added together to make
a total load. For this, the load data for each component are entered separately.
Procedure
Load components
1. In the Load data area, click on the Add tool data button.
The Summation Tool window is opened.
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2. In the Load distribution area, specify where the load is located on the robot using the Add to box.
3. Enter the load data of the components.
4. To specify values for further components, click on the Add individual
load button and enter the load data.
The sum of the currently specified loads is displayed in the Sum of individual tools area.
5. To select an energy supply system, click on the Energy supply button.
The Energy supply system window is opened. Select the application and
configuration of the energy supply system.
6. Confirm the entries made by pressing OK.
Transfer the payload and supplementary loads to the KukaLoadGUI window.
To delete a supplementary load, select the relevant line and click on
the Delete selection button.
5.9
Description
Potentially suitable robots for the specified load case are displayed and 2 robots are recommended.
The robots are recommended on the basis of their suitability for the
specified load data. Additional requirements arising from the application cannot be taken into account here. More detailed guidance is offered by KUKA Service.
Procedure
1. Enter the payload and supplementary loads in the Load data area.
The range of robot types can be restricted in the Preselection area.
2. Click on the Robot search button.
3. After the search, the Load analysis area changes into the Robot search
area.
Only robots which are relevant for this load case are now displayed in the
Robot type area.
in the Robot search area, 2 recommended robots and their static evaluations are displayed for the specified load case.
4. The recommended robots are displayed simultaneously on the following
tabs, where they can be compared:
Payload diagram
Static
Dynamic
The tabs are locked if a load case is changed after the search. Clicking on the Robot search button makes the tabs accessible again.
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5 Operation
5.10
Comparing robots
Procedure
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5.11
Precondition
Procedure
5.12
Precondition
Procedure
1. In the project window, select a load case in the Robot types display.
2. Activate the Project link check box in the Transfer load case to KukaLoadGUI area.
The robot with its load case is transferred to the graphical user interface
and displayed there.
3. On the graphical user interface, change the load case in the Load data area.
4. Optionally, click on the Load analysis button.
5. In the project window, click on the Update load case button.
The changed load case is transferred to the selected project.
6. Save the project in the project window by pressing the Save button.
5.13
Precondition
Procedure
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5 Operation
5. Drag the desired projects, robots, stations or load cases from the tree
structure in the New project file box into the tree structure in the Current
project file box.
Possible positions for insertion are highlighted in blue when the object is
moved over it with the left-hand mouse button pressed. Robots which differ in type or name but have the same serial number are highlighted in red
and cannot be merged.
Names and serial numbers can be changed in the tree structures.
5.14
Description
During automatic merging, the load cases of identical robots are merged irrespective of their project and station. Identical robots are robots whose serial
numbers, names and types match. All other robots and their load cases are
merged within their project and station. If a project or station of the same name
is not yet present, the project or station is added; otherwise it is inserted.
If the projects contain robots with the same serial number, but a different type
or name, automatic merging is not possible. An error message is generated
and the operation is aborted.
A project file is loaded and opened.
Precondition
Procedure
5.15
Description
With automatic merging of multiple project files, the specified directory and all
subdirectories are searched for KUKA.Load project files. These are merged
one after the other with the open project file in the same way as with automatic
merging of 2 project files. Project files that cannot be added automatically are
omitted and listed in a message.
Precondition
Procedure
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5.16
Precondition
Procedure
Customer
Station
Created by
Robot name
Robot type
Application
Tool name
3. The orientation of the coordinate system for the principal moments of inertia at the center of gravity can be entered in the Tool orientation [] area.
4. Fill out the following box in the Customer confirmation area:
CAD
Manually
5. Click on the Create sign-off sheet button to create and open the sign-off
sheet.
The customer confirms via the sign-off sheet that the load data have been
correctly assigned to the controller.
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5 Operation
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5.17
Precondition
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5 Operation
Procedure
Select the load cases for which sign-off sheets are to be created and confirm with Start.
A Sign-Off Sheet window is opened for each load case.
3. To save the sign-off sheets, select the relevant directory in the File path
area via ..., and confirm with OK. Confirm the selection with Start.
If all the necessary information for a load case has already been entered
in the project window, the sign-off sheet is automatically saved to the specified directory. The Sign-Off Sheet window is not displayed in this case.
The necessary information includes the creator and the KSS release.
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6 KUKA Service
KUKA Service
6.1
Requesting support
Introduction
Information
Model and serial number of the energy supply system (if applicable)
6.2
Application used
Availability
KUKA Customer Support is available in many countries. Please do not hesitate to contact us if you have any questions.
Argentina
Australia
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Belgium
Brazil
Chile
China
Germany
6 KUKA Service
France
India
Italy
Japan
Canada
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Korea
Malaysia
Mexico
Norway
Austria
6 KUKA Service
Poland
Portugal
Russia
Sweden
Switzerland
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Spain
South Africa
Taiwan
Thailand
Czech Republic
6 KUKA Service
Hungary
USA
UK
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Index
Index
A
Add load case to robot (button) 19, 22
Add project file (button) 21
Add robot with load case (button) 19, 22
Add tool data (button) 16, 27
Advanced (button) 22
Analysis (area) 18, 21
B
Button, Add tool data 27
Buttons 14, 16
C
Center of gravity 9
Close (button) 22
Create project (button) 19, 21
Create sign-off sheet (button) 19
Create sign-off sheet(s) (button) 22
Create station (button) 19, 21
Creating a project file 25
D
Delete project (button) 19, 21
Delete station (button) 19, 22
Dynamic loading 6
Dynamic overloading 6
Dynamic overloading of the robot 9
E
Energy supply (button) 16
Exit (button) 19, 22
G
Graphical user interface 13
Graphical user interface KukaLoadGUI 13
Graphics card 11
I
Imperial measurement system 6
Installation 11
Installing KUKA.Load 11
Introduction 5
K
KUKA Customer Support 37
L
Language, changing 25
Load analysis (area) 14
Load analysis (button) 15, 19
Load analysis for all robots (button) 22
Load analysis for one load case (button) 22
Load analysis, performing 26
Load case 6
Load data (area) 14, 19, 21
Load project file (button) 21
Loads on the robot 8
M
Mass 9
Mass moments of inertia 9
Merging multiple project files (KUKA.Load Pro)
31
Merging project files automatically (KUKA.Load
Pro) 31
Merging project files manually (KUKA.Load Pro)
30
Metric measurement system 6
N
Nom. values (button) 16
Nom. values of all suppl. loads (button) 16
O
Operation 25
Overall load 8
P
Payloads 8
Preselection (area) 14
Processor 11
Product description 7
Project file, loading 25
Project information (area) 18, 21
Project window 18
Project window (KUKA.Load Pro) 20
R
RAM 11
Robot comparison 29
Robot comparison (button) 15
Robot search 28
Robot search (button) 14
Robot type (area) 14
Robot types (area) 19, 21
Robots in palletizing mode (KUKA.Load Pro) 10
S
Safety instructions 5
Save (button) 19, 22
Saved robot load case, changing 30
Saving the robot in the project 30
Service, KUKA Roboter 37
Set all nominal values (button) 16
Sign-off sheet, creating 32
Sign-off sheets, creating multiple sheets simultaneously (KUKA.Load Pro) 34
Starting, KUKA.Load 25
Static overloading of the robot 9
Station 6
Station (area) 18, 21
Status bar 15
Support request 37
System requirements, KUKA.Load 5.0 11
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T
Tabs 17
Target group 5
Terms used 6
Toolbar 15
Trademarks 5
Training 5
Transfer load case to KukaLoadGUI (area) 20,
23
U
Uninstallation, KUKA.Load 11
Unit of measurement, changing 25
Update load case (button) 19, 22
Updating KUKA.Load 11
W
Warnings 5
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