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1 Introduction .................................................................................................. 7
1.1 Target group .............................................................................................................. 7
1.2 Industrial robot documentation ................................................................................... 7
1.3 Representation of warnings and notes ...................................................................... 7
1.4 Terms used ................................................................................................................ 8
2 Fundamentals .............................................................................................. 9
2.1 Distinction between external axis and kinematic system ........................................... 9
2.2 Kinematic system types ............................................................................................. 9
2.3 Motion types ............................................................................................................... 11
2.4 Master/slave operation ............................................................................................... 13
3 Hardware ...................................................................................................... 15
3.1 Maximum values for external axis systems ............................................................... 15
4 Safety ............................................................................................................ 17
5 Operation ...................................................................................................... 19
5.1 Coordinate systems ................................................................................................... 19
5.1.1 Kinematic chain with BASE kinematic system ...................................................... 19
5.1.2 Kinematic chain of a ROBROOT kinematic system .............................................. 20
5.2 Jogging external axes ................................................................................................ 22
5.3 Mathematical coupling ............................................................................................... 22
5.3.1 Manually activating a mathematical coupling ....................................................... 23

5.3.2 Activating a mathematical coupling via a program ............................................... 23

6 System planning .......................................................................................... 25
6.1 Planning external axis systems .................................................................................. 25
7 Configuration ............................................................................................... 27
7.1 WorkVisual Catalog Editor ......................................................................................... 27
7.1.1 Button bar ............................................................................................................. 28
7.1.2 Starting WorkVisual Catalog Editor ...................................................................... 28
7.1.3 Displaying/hiding windows .................................................................................... 28
7.1.4 Creating a new catalog ......................................................................................... 28
7.1.5 Adding a catalog ................................................................................................... 29
7.1.6 Setting access rights ............................................................................................. 29
7.1.7 Saving a catalog ................................................................................................... 30
7.1.8 Closing a catalog .................................................................................................. 30
7.1.9 Closing the WorkVisual Catalog Editor ................................................................. 30
7.2 Configuring kinematic systems – overview ................................................................ 30
7.2.1 Configuring a KUKA linear unit ............................................................................. 31
7.2.2 Configuring a kinematic system with KUKA MGU or KUKA motor ....................... 32
7.2.3 Configuring a kinematic system with master/slave motors ................................... 32
7.2.3.1 Master / slave parameters .................................................................................... 33
7.2.4 Configuring a CK .................................................................................................. 34
7.3 Transformation ........................................................................................................... 34
7.3.1 Transformation of BASE kinematic system .......................................................... 34
7.3.2 Transformation of ROBROOT kinematic system .................................................. 36
7.4 Optimizing machine data with the oscilloscope ......................................................... 36
7.4.1 Optimization sequence ......................................................................................... 37
7.4.2 Optimizing controller parameters .......................................................................... 37
7.4.2.1 Optimizing the proportional component of the speed controller ........................... 37
7.4.2.2 Optimizing the integral component of the speed controller .................................. 39
7.4.2.3 Optimizing the proportional component of the position controller ......................... 40
7.4.3 Optimizing acceleration parameters ..................................................................... 42
7.4.3.1 Optimizing axis ramp-up time ............................................................................... 42
7.4.3.2 Optimizing the reduction factor for the Emergency Stop ramp ............................. 43
7.4.3.3 Optimizing the braking ramp for dynamic braking ................................................ 44
7.4.3.4 Configuration examples ........................................................................................ 45
7.4.4 Checking the optimization results ......................................................................... 47
7.5 Simulating axes ......................................................................................................... 47
8 Start-up and recommissioning ................................................................... 49
8.1 Start-up of kinematic systems ................................................................................... 49
8.1.1 Starting up a KUKA linear unit .............................................................................. 49
8.1.2 Starting up a KUKA kinematic system .................................................................. 49
8.1.3 Starting up a kinematic system with KUKA MGU ................................................. 50
9 System variables ......................................................................................... 51
9.1 System variables for configuring external axes ......................................................... 51
9.2 Asynchronous, uncoordinated external axes ............................................................. 51
9.2.1 $ZUST_ASYNC .................................................................................................... 51
9.2.2 $ASYNC_AX… ..................................................................................................... 51
9.3 Asynchronous, coordinated external axes (ASYPTP) ............................................... 52
9.3.1 $ASYNC_T1_FAST .............................................................................................. 52
9.3.2 $ASYNC_MODE .................................................................................................. 53
9.4 Permanently asynchronous external axes ................................................................. 54
9.4.1 $EX_AX_ASYNC ................................................................................................. 54
10 Programming ............................................................................................... 57
10.1 Programming motions for external axes .................................................................... 57
10.2 Programming synchronous external axes ................................................................. 57
10.2.1 Programming a mathematically coupled motion ................................................... 58
10.3 Programming asynchronous external axes ............................................................... 58
10.3.1 $ASYNC_AXIS ..................................................................................................... 58
10.3.2 ASYPTP ............................................................................................................... 59
10.3.3 $OV_ASYNC ........................................................................................................ 60
10.3.4 $ASYNC_FLT ....................................................................................................... 61
10.3.5 ASYSTOP ........................................................................................................... 61
10.3.6 ASYCONT ............................................................................................................ 61
10.3.7 ASYCANCEL ........................................................................................................ 62
10.3.8 $ASYNC_STATE .................................................................................................. 62
11 Examples ...................................................................................................... 65
11.1 Transformation for DKP 400 ...................................................................................... 65
11.2 Transformation for KL 1500-3 .................................................................................... 68
12 Appendix ...................................................................................................... 71
12.1 Machine data for configuring the transformation ........................................................ 71
12.1.1 $ET1_TA1KR ........................................................................................................ 71
12.1.2 $ET1_TA2A1 ........................................................................................................ 71
12.1.3 $ET1_TA3A2 ........................................................................................................ 72
12.1.4 $ET1_TFLA3 ........................................................................................................ 72
12.1.5 $ET1_TPINFL ....................................................................................................... 72
12.2 Machine data for configuring axes ............................................................................. 73
12.2.1 $AXIS_TYPE ........................................................................................................ 73
12.2.2 $RED_VEL_AXC .................................................................................................. 74
12.2.3 $VEL_AX_JUS ..................................................................................................... 74
12.2.4 $L_EMT_MAX ...................................................................................................... 74
12.2.5 $APO_DIS_PTP ................................................................................................... 75
12.2.6 $IN_POS_MA ....................................................................................................... 75
12.2.7 $RED_ACC_OV ................................................................................................... 76
12.2.8 $VEL_AXIS_MA ................................................................................................... 77
12.2.9 $RED_ACC_AXC ................................................................................................. 77
12.2.10 $INC_AXIS ........................................................................................................... 77
12.2.11 $INC_EXTAX ........................................................................................................ 78
12.2.12 $ST_TOL_VEL ..................................................................................................... 78
12.2.13 $TIME_POS .......................................................................................................... 78
12.2.14 $AXIS_JERK ........................................................................................................ 79
12.2.15 $VEL_CPT1_MA .................................................................................................. 79
12.2.16 $JERK_MA ........................................................................................................... 79
12.2.17 $EX_AX_ASYNC .................................................................................................. 80
12.2.18 $SOFTN_END ...................................................................................................... 80
12.2.19 $SOFTP_END ...................................................................................................... 81
12.2.20 $RAT_MOT_AX .................................................................................................... 81
12.3 Machine data for configuring motors .......................................................................... 82
12.3.1 $IN_POS_MA ....................................................................................................... 82
12.3.2 $VEL_AXIS_MA ................................................................................................... 83
12.4 Machine data for configuring a CK ............................................................................. 83
12.4.1 $MAIN_AXIS ......................................................................................................... 83
12.4.2 $WRIST_AXIS ...................................................................................................... 87
12.4.3 $TIRORO .............................................................................................................. 88
12.4.4 $LENGTH_A ......................................................................................................... 89
12.4.5 $LENGTH_B ......................................................................................................... 89
12.4.6 $A4PAR ................................................................................................................ 90
12.4.7 $TRAFONAME ..................................................................................................... 90
12.4.8 $ROBROOT .......................................................................................................... 90
12.4.9 $ACTIVE_KAR_MASK ......................................................................................... 91
12.4.10 $RED_VEL_CPC .................................................................................................. 92
12.4.11 $TECH_MAX ........................................................................................................ 92
12.4.12 $VEL_CP_T1 ........................................................................................................ 92
12.4.13 $RED_ACC_DYN ................................................................................................. 92
12.4.14 $INDIVIDUAL_MAMES ........................................................................................ 93
12.4.15 $KINCLASS .......................................................................................................... 93
12.4.16 $RED_ACC_CPC ................................................................................................. 94
12.4.17 $WARMUP_TIME ................................................................................................. 94
12.4.18 $WARMUP_RED_VEL ......................................................................................... 94
12.4.19 $COOLDOWN_TIME ........................................................................................... 95
12.4.20 $WARMUP_SLEW_RATE ................................................................................... 95
12.4.21 $WARMUP_CURR_LIMIT .................................................................................... 95
12.4.22 $WARMUP_MIN_FAC ......................................................................................... 95
12.4.23 $JERK_MA ........................................................................................................... 96
12.4.24 $RED_T1 .............................................................................................................. 96
12.4.25 $DEF_FLT_PTP ................................................................................................... 96
12.4.26 $DEF_FLT_CP ..................................................................................................... 97
12.4.27 $DEF_OV_JOG .................................................................................................... 97
12.4.28 $BRK_MODE ....................................................................................................... 98
12.4.29 $BRK_DEL_COM ................................................................................................. 99
12.4.30 $BRK_DEL_PRO ................................................................................................. 99
12.4.31 $BRK_DEL_EX .................................................................................................... 99
12.4.32 $GEARTORQ_MON ............................................................................................. 99
12.4.33 $ACC_ACT_MA ................................................................................................... 100
12.4.34 $VEL_ACT_MA .................................................................................................... 100
12.4.35 $IN_POS_CAR ..................................................................................................... 101
12.4.36 $IN_POS_ORI ...................................................................................................... 101
12.4.37 $DIS_WRP1 ......................................................................................................... 102
12.4.38 $DIS_WRP2 ......................................................................................................... 102
12.4.39 $TFLWP ............................................................................................................... 102
12.4.40 $TX3P3 ................................................................................................................ 103
12.4.41 $ACC_MA ............................................................................................................ 103
12.4.42 $VEL_MA ............................................................................................................. 104
12.5 Machine data for kinematic systems without a dynamic model ................................. 104
13 KUKA Service ............................................................................................... 105
13.1 Requesting support ................................................................................................... 105
13.2 KUKA Customer Support ........................................................................................... 105
Index ............................................................................................................. 113