KUKA Sunrise.OS 1.8

KUKA Sunrise.OS 1.8 KUKA Sunrise.Workbench 1.8
	1 Introduction
		1.1 Target group
		1.2 Industrial robot documentation
		1.3 Representation of warnings and notes
		1.4 Trademarks
		1.5 Terms used
	2 Product description
		2.1 Overview of the robot system
		2.2 Overview of the software components
		2.3 Overview of KUKA Sunrise.OS
		2.4 Overview of KUKA Sunrise.Workbench
		2.5 Intended use of the system software
	3 Safety
		3.1 Legal framework
			3.1.1 Liability
			3.1.2 Intended use of the industrial robot
			3.1.3 EC declaration of conformity and declaration of incorporation
		3.2 Safety functions
			3.2.1 Terms used
			3.2.2 Personnel
			3.2.3 Workspace, safety zone and danger zone
			3.2.4 Safety-oriented functions
				3.2.4.1 EMERGENCY STOP device
				3.2.4.2 Enabling device
				3.2.4.3 Operator safety
				3.2.4.4 External EMERGENCY STOP device
				3.2.4.5 External safety stop 1 (path-maintaining)
				3.2.4.6 External enabling device
				3.2.4.7 External safe operational stop
			3.2.5 Triggers for safety-oriented stop reactions
			3.2.6 Non-safety-oriented functions
				3.2.6.1 Mode selection
				3.2.6.2 Software limit switches
		3.3 Additional protective equipment
			3.3.1 Jog mode
			3.3.2 Labeling on the industrial robot
			3.3.3 External safeguards
		3.4 Safety measures
			3.4.1 General safety measures
			3.4.2 Transportation
			3.4.3 Start-up and recommissioning
			3.4.4 Manual mode
			3.4.5 Automatic mode
			3.4.6 Maintenance and repair
			3.4.7 Decommissioning, storage and disposal
			3.4.8 Safety measures for “single point of control”
		3.5 Applied norms and regulations
	4 Installing KUKA Sunrise.Workbench
		4.1 PC system requirements
		4.2 Installing Sunrise.Workbench
		4.3 Uninstalling Sunrise.Workbench
	5 Operation of KUKA Sunrise.Workbench
		5.1 Starting Sunrise.Workbench
		5.2 Overview of the user interface of Sunrise.Workbench
			5.2.1 Repositioning the views
			5.2.2 Displaying different perspectives on the user interface
			5.2.3 Toolbars
		5.3 Creating a Sunrise project with a template
		5.4 Creating a new robot application
			5.4.1 Creating a new Java package
			5.4.2 Creating a robot application with a package
			5.4.3 Creating a robot application for an existing package
		5.5 Creating a new background task
			5.5.1 Creating a background task with a package
			5.5.2 Creating a background task for an existing package
		5.6 Workspace
			5.6.1 Creating a new workspace
			5.6.2 Switching to an existing workspace
			5.6.3 Switching between the most recently opened workspaces
			5.6.4 Archiving projects
			5.6.5 Loading projects from archive to the workspace
			5.6.6 Loading projects from the directory to the workspace
		5.7 Sunrise projects with referenced Java projects
			5.7.1 Creating a new Java project
				5.7.1.1 Inserting robot-specific class libraries in a Java project
			5.7.2 Referencing Java projects
			5.7.3 Canceling the reference to Java projects
		5.8 Renaming an element in the Package Explorer
			5.8.1 Renaming a project or Java package
			5.8.2 Renaming a Java file
		5.9 Removing an element from Package Explorer
			5.9.1 Deleting an element from a project
			5.9.2 Removing a project from Package Explorer
			5.9.3 Deleting a project from the workspace
		5.10 Activating the automatic change recognition
	6 Operating the KUKA smartPAD
		6.1 KUKA smartPAD control panel
			6.1.1 Front view
			6.1.2 Rear view
		6.2 Switching the robot controller on/off
			6.2.1 Switching on the robot controller and starting the system software
			6.2.2 Switching off the robot controller
		6.3 Automatic update of the smartPAD software
		6.4 Performing a PDS firmware update
		6.5 KUKA smartHMI user interface
			6.5.1 Navigation bar
			6.5.2 Status display
			6.5.3 Keypad
			6.5.4 Station level
			6.5.5 Robot level
		6.6 Calling the main menu
		6.7 Changing the operating mode
		6.8 Coordinate systems
		6.9 Jogging the robot
			6.9.1 “Jogging options” window
			6.9.2 Setting the jog override (HOV)
			6.9.3 Axis-specific jogging with the jog keys
			6.9.4 Cartesian jogging with the jog keys
				6.9.4.1 Null space motion
		6.10 CRR mode – controlled robot retraction
		6.11 Manually guiding the robot
		6.12 Resuming the safety controller
		6.13 Opening the holding brakes
		6.14 Teaching and manually addressing frames
			6.14.1 Displaying frames
			6.14.2 Teaching frames
			6.14.3 Teaching frames with the hand guiding device
			6.14.4 “Jogging type” window
			6.14.5 Manually addressing frames
		6.15 Program execution
			6.15.1 Selecting a robot application
			6.15.2 Selecting the program run mode
			6.15.3 Setting the manual override
			6.15.4 Starting a program forwards (manually)
			6.15.5 Starting a program forwards (automatically)
			6.15.6 Repositioning the robot after leaving the path
		6.16 Activating the user keys
		6.17 Display functions
			6.17.1 Displaying the end frame of the motion currently being executed
			6.17.2 Displaying the axis-specific actual position
			6.17.3 Displaying the Cartesian actual position
			6.17.4 Displaying axis-specific torques
			6.17.5 Displaying an I/O group and changing the value of an output
			6.17.6 Displaying the IP address and software version
			6.17.7 Displaying the robot type and serial number
			6.17.8 Displaying messages of the virus scanner
	7 Start-up and recommissioning
		7.1 Position mastering
			7.1.1 Mastering axes
			7.1.2 Manually unmastering axes
		7.2 Calibration
			7.2.1 Tool calibration
				7.2.1.1 TCP calibration: XYZ 4-point method
				7.2.1.2 Defining the orientation: ABC 2-point method
				7.2.1.3 Defining the orientation: ABC World method
			7.2.2 Calibrating the base: 3-point method
		7.3 Determining tool load data
	8 Brake test
		8.1 Overview of the brake test
		8.2 Creating the brake test application from the template
			8.2.1 Adapting the brake test application for testing against the minimum brake holding torque
			8.2.2 Changing the motion sequence for torque value determination
			8.2.3 Changing the starting position for the brake test
		8.3 Programming interface for the brake test
			8.3.1 Evaluating the torques generated and determining the maximum absolute value
			8.3.2 Polling the evaluation results of the maximum absolute torques
			8.3.3 Creating an object for the brake test
			8.3.4 Starting the execution of the brake test
			8.3.5 Evaluating the brake test
				8.3.5.1 Polling the results of the brake test
		8.4 Performing a brake test
			8.4.1 Evaluation results of the maximum absolute torques (display)
			8.4.2 Results of the brake test (display)
	9 Project management
		9.1 Sunrise projects – overview
		9.2 Frame management
			9.2.1 Creating a new frame
			9.2.2 Designating a frame as a base
			9.2.3 Moving frames
			9.2.4 Deleting frames
			9.2.5 Displaying and modifying the properties of a frame
			9.2.6 Inserting a frame in a motion instruction
		9.3 Object management
			9.3.1 Geometric structure of tools
			9.3.2 Geometric structure of workpieces
			9.3.3 Creating a tool or workpiece
			9.3.4 Creating a frame for a tool or workpiece
			9.3.5 Defining a default motion frame
			9.3.6 Load data
				9.3.6.1 Entering load data
			9.3.7 Safety-oriented tools
				9.3.7.1 Defining a safety-oriented tool
			9.3.8 Safety-oriented workpieces
				9.3.8.1 Defining a safety-oriented workpiece
		9.4 Overview of project synchronization
			9.4.1 Transferring the project to the robot controller
			9.4.2 Updating the project on the robot controller or in Sunrise.Workbench
		9.5 Loading the project from the robot controller
	10 Station configuration and installation
		10.1 Opening the station configuration
			10.1.1 Configuring parameters for calibration
		10.2 Installing the system software
			10.2.1 Converting the safety configuration to a new software version
		10.3 Installing a language package
		10.4 Installing or updating the virus scanner
	11 Bus configuration
		11.1 Configuration and I/O mapping in WorkVisual – overview
		11.2 Overview of field buses
		11.3 Creating a new I/O configuration
		11.4 Opening an existing I/O configuration
		11.5 Creating Sunrise I/Os
			11.5.1 “Create I/O signals” window
			11.5.2 Creating an I/O group and inputs/outputs within the group
			11.5.3 Editing an I/O group
			11.5.4 Deleting an I/O group
			11.5.5 Changing an input/output of a group
			11.5.6 Deleting an input/output of a group
			11.5.7 Exporting an I/O group as a template
			11.5.8 Importing an I/O group from a template
		11.6 Mapping the bus I/Os
			11.6.1 I/O Mapping window
			11.6.2 Buttons in the “I/O Mapping” window
			11.6.3 Mapping Sunrise I/Os
		11.7 Exporting the I/O configuration to the Sunrise project
	12 External control
		12.1 Configuring external control
			12.1.1 External control inputs
			12.1.2 External control outputs
			12.1.3 Signal diagrams
			12.1.4 Configuring external control in the project properties
		12.2 Selecting a robot application as the default application
		12.3 Defining the signal outputs for a project that is not externally controlled
	13 Safety configuration
		13.1 Overview of safety configuration
		13.2 Safety concept
		13.3 Permanent Safety Monitoring
		13.4 Event-driven Safety Monitoring
		13.5 Overview of Atomic Monitoring Functions
			13.5.1 Standard Atomic Monitoring Functions
			13.5.2 Parameterizable Atomic Monitoring Functions
			13.5.3 Extended Atomic Monitoring Functions
			13.5.4 Availability of the AMFs depending on the kinematic system
		13.6 Safety configuration with KUKA Sunrise.Workbench
			13.6.1 Safety configuration and start-up
			13.6.2 Opening the safety configuration
				13.6.2.1 Evaluating the safety configuration
				13.6.2.2 Overview of the graphical user interface for the safety configuration
			13.6.3 Configuring the safety functions of the PSM mechanism
				13.6.3.1 Opening the Customer PSM table
				13.6.3.2 Creating safety functions for the PSM mechanism
				13.6.3.3 Deleting safety functions of the PSM mechanism
				13.6.3.4 Editing existing safety functions of the PSM mechanism
			13.6.4 Configuring the safe states of the ESM mechanism
				13.6.4.1 Adding a new ESM state
				13.6.4.2 Opening a table for an ESM state
				13.6.4.3 Deleting an ESM state
				13.6.4.4 Creating a safety function for the ESM state
				13.6.4.5 Deleting a safety function of an ESM state
				13.6.4.6 Editing an existing safety function of an ESM state
				13.6.4.7 Deactivating the ESM mechanism
				13.6.4.8 Switching between ESM states
			13.6.5 Mapping safety-oriented tools
		13.7 Activating the safety configuration on the robot controller
			13.7.1 Deactivating the safety configuration
			13.7.2 Restoring the safety configuration
			13.7.3 Changing the password for activating the safety configuration
		13.8 Use and parameterization of the Atomic Monitoring Functions
			13.8.1 Evaluating the safety equipment on the KUKA smartPAD
			13.8.2 Evaluating the operating mode
			13.8.3 Evaluating the motion enable
			13.8.4 Monitoring safe inputs
			13.8.5 Manual guidance with enabling device and velocity monitoring
				13.8.5.1 Monitoring of enabling switches on hand guiding devices
				13.8.5.2 Monitoring functions during manual guidance
				13.8.5.3 Velocity monitoring during manual guidance
			13.8.6 Evaluating the position referencing
			13.8.7 Evaluating the torque referencing
			13.8.8 Velocity monitoring functions
				13.8.8.1 Defining axis-specific velocity monitoring
				13.8.8.2 Defining Cartesian velocity monitoring
				13.8.8.3 Direction-specific monitoring of Cartesian velocity
			13.8.9 Monitoring spaces
				13.8.9.1 Defining Cartesian workspaces
				13.8.9.2 Defining Cartesian protected spaces
				13.8.9.3 Defining axis-specific monitoring spaces
			13.8.10 Monitoring the tool orientation
			13.8.11 Standstill monitoring (safe operational stop)
			13.8.12 Activation delay for safety functions
			13.8.13 Monitoring of forces and torques
				13.8.13.1 Axis torque monitoring
				13.8.13.2 Collision detection
				13.8.13.3 TCP force monitoring
				13.8.13.4 Direction-specific monitoring of the external force at the TCP
		13.9 Example of a safety configuration
			13.9.1 Task
			13.9.2 Requirement
			13.9.3 Suggested solution for the task
		13.10 Position and torque referencing
			13.10.1 Position referencing
			13.10.2 Torque referencing
			13.10.3 Creating an application for position and torque referencing
		13.11 Safety acceptance overview
			13.11.1 Checklist for general safety functions
			13.11.2 Checklist for tool selection table
			13.11.3 Checklists for safety-oriented tools
				13.11.3.1 Pickup frame for fixed tools
				13.11.3.2 Pickup frame for activatable tools
				13.11.3.3 Tool orientation
				13.11.3.4 Tool-specific velocity component
				13.11.3.5 Geometry data of the tool
				13.11.3.6 Load data of the tool
			13.11.4 Checklist for safety-oriented workpieces
			13.11.5 Checklist for rows used in the PSM tables
			13.11.6 Checklists for ESM states
				13.11.6.1 Used ESM states
				13.11.6.2 Non-used ESM states
			13.11.7 Checklists for AMFs used
				13.11.7.1 AMF smartPAD Emergency Stop
				13.11.7.2 AMF smartPAD enabling switch inactive
				13.11.7.3 AMF smartPAD enabling switch panic active
				13.11.7.4 AMF Hand guiding device enabling inactive
				13.11.7.5 AMF Hand guiding device enabling active
				13.11.7.6 AMF Test mode
				13.11.7.7 AMF Automatic mode
				13.11.7.8 AMF Reduced-velocity mode
				13.11.7.9 AMF High-velocity mode
				13.11.7.10 AMF Motion enable
				13.11.7.11 AMF Input signal
				13.11.7.12 AMF Standstill monitoring of all axes
				13.11.7.13 AMF Axis torque monitoring
				13.11.7.14 AMF Axis velocity monitoring
				13.11.7.15 AMF Position referencing
				13.11.7.16 AMF Torque referencing
				13.11.7.17 AMF Axis range monitoring
				13.11.7.18 AMF Cartesian velocity monitoring
				13.11.7.19 AMF Cartesian workspace monitoring / Cartesian protected space monitoring
				13.11.7.20 AMF Collision detection
				13.11.7.21 AMF TCP force monitoring
				13.11.7.22 Base-related TCP force component AMF
				13.11.7.23 AMF Time delay
				13.11.7.24 AMF Tool orientation
				13.11.7.25 AMF Tool-related velocity component
			13.11.8 Creating a safety configuration report
	14 Basic principles of motion programming
		14.1 Overview of motion types
		14.2 PTP motion type
		14.3 LIN motion type
		14.4 CIRC motion type
		14.5 SPL motion type
		14.6 Spline motion type
			14.6.1 Velocity profile for spline motions
			14.6.2 Modifications to spline blocks
			14.6.3 LIN-SPL-LIN transition
		14.7 Manual guidance motion type
		14.8 Approximate positioning
		14.9 Orientation control with LIN, CIRC, SPL
			14.9.1 CIRC – reference system for the orientation control
			14.9.2 CIRC – combinations of reference system and type for the orientation control
		14.10 Redundancy information
			14.10.1 Redundancy angle
			14.10.2 Status
			14.10.3 Turn
		14.11 Singularities
			14.11.1 Kinematic singularities
			14.11.2 System-dependent singularities
	15 Programming
		15.1 Java Editor
			15.1.1 Opening a robot application in the Java Editor
			15.1.2 Structure of a robot application
			15.1.3 Edit functions
				15.1.3.1 Renaming a variable
				15.1.3.2 Auto-complete
				15.1.3.3 Templates – Fast entry of Java statements
				15.1.3.4 Creating user-specific templates
				15.1.3.5 Extracting methods
			15.1.4 Displaying Javadoc information
				15.1.4.1 Configuration of the Javadoc browser
		15.2 Symbols and fonts
		15.3 Data types
		15.4 Variables
		15.5 Network communication via UDP and TCP/IP
		15.6 RoboticsAPI version information
			15.6.1 Displaying the RoboticsAPI version
			15.6.2 Structure of the RoboticsAPI version number:
		15.7 Motion programming: PTP, LIN, CIRC
			15.7.1 Structure of a motion command (move/moveAsync)
			15.7.2 PTP
			15.7.3 LIN
			15.7.4 CIRC
			15.7.5 LIN REL
			15.7.6 MotionBatch
		15.8 Motion programming: spline
			15.8.1 Programming tips for spline motions
			15.8.2 Creating a CP spline block
			15.8.3 Creating a JP spline block
			15.8.4 Using spline in a motion instruction
		15.9 Motion parameters
			15.9.1 Programming axis-specific motion parameters
		15.10 Programming manual guidance
			15.10.1 Axis-specific limits for manual guidance
		15.11 Using tools and workpieces in the program
			15.11.1 Declaring tools and workpieces
			15.11.2 Initializing tools and workpieces
			15.11.3 Attaching tools and workpieces to the robot
				15.11.3.1 Attaching a tool to the robot flange
				15.11.3.2 Attaching a workpiece to other objects
				15.11.3.3 Detaching objects
			15.11.4 Moving tools and workpieces
			15.11.5 Defining user-specific object classes
			15.11.6 Commanding load changes to the safety controller
		15.12 Inputs/outputs
			15.12.1 Creating a data array for an I/O group
			15.12.2 Initializing a data array for an I/O group
			15.12.3 Reading inputs/outputs
			15.12.4 Setting outputs
		15.13 Polling axis torques
		15.14 Reading Cartesian forces and torques
			15.14.1 Polling calculated force/torque data
			15.14.2 Polling individual force/torque values
			15.14.3 Checking the reliability of the calculated force/torque values
			15.14.4 Polling individual values of a vector
		15.15 Polling the robot position
			15.15.1 Polling the axis-specific actual or setpoint position
			15.15.2 Polling the Cartesian actual or setpoint position
			15.15.3 Polling the Cartesian setpoint/actual value difference
		15.16 HOME position
			15.16.1 Changing the HOME position
		15.17 Polling system states
			15.17.1 Polling the HOME position
			15.17.2 Polling the mastering state
			15.17.3 Polling “ready for motion”
				15.17.3.1 Reacting to changes in the “ready for motion” signal
			15.17.4 Polling the robot activity
			15.17.5 Polling and evaluating safety signals
				15.17.5.1 Polling the state of the safety signals
				15.17.5.2 Reacting to a change in state of safety signals
		15.18 Changing and polling the program run mode
		15.19 Changing and polling the override
			15.19.1 Reacting to an override change
		15.20 Conditions
			15.20.1 Conditions in the RoboticsAPI
			15.20.2 Complex conditions
			15.20.3 Axis torque condition
			15.20.4 Force condition
				15.20.4.1 Condition for Cartesian force from all directions
				15.20.4.2 Condition for normal force
				15.20.4.3 Condition for shear force
			15.20.5 Force component condition
			15.20.6 Condition for Cartesian torque
				15.20.6.1 Condition for Cartesian torque from all directions
				15.20.6.2 Condition for torque
				15.20.6.3 Condition for tilting torque
			15.20.7 Torque component condition
			15.20.8 Path-related condition
			15.20.9 Condition for Boolean signals
			15.20.10 Condition for the range of values of a signal
		15.21 Break conditions for motion commands
			15.21.1 Defining break conditions
			15.21.2 Evaluating the break conditions
				15.21.2.1 Polling a break condition
				15.21.2.2 Polling the robot position at the time of termination
				15.21.2.3 Polling a terminated motion (spline block, MotionBatch)
		15.22 Path-related switching actions (Trigger)
			15.22.1 Programming triggers
			15.22.2 Programming a path-related switching action
			15.22.3 Evaluating trigger information
		15.23 Monitoring processes (Monitoring)
			15.23.1 Listener for monitoring conditions
			15.23.2 Creating a listener object to monitor the condition
			15.23.3 Registering a listener for notification of change in state
			15.23.4 Activating or deactivating the notification service for listeners
			15.23.5 Programming example for monitoring
		15.24 Blocking wait for condition
		15.25 Recording and evaluating data
			15.25.1 Creating an object for data recording
			15.25.2 Specifying data to be recorded
			15.25.3 Starting data recording
			15.25.4 Ending data recording
			15.25.5 Polling states from the DataRecorder object
			15.25.6 Example program for data recording
		15.26 Defining user keys
			15.26.1 Creating a user key bar
			15.26.2 Adding user keys to the bar
			15.26.3 Defining the function of a user key
			15.26.4 Labeling and graphical assignment of the user key bar
				15.26.4.1 Assigning a text element
				15.26.4.2 Assigning an LED icon
			15.26.5 Identifying safety-critical user keys
			15.26.6 Publishing a user key bar
		15.27 Message programming
			15.27.1 Programming user messages
			15.27.2 Programming user dialogs
		15.28 Program execution control
			15.28.1 Pausing an application
			15.28.2 Pausing motion execution
			15.28.3 FOR loop
			15.28.4 WHILE loop
			15.28.5 DO WHILE loop
			15.28.6 IF ELSE branch
			15.28.7 SWITCH branch
			15.28.8 Examples of nested loops
		15.29 Continuing a paused application in Automatic mode (recovery)
		15.30 Error treatment
			15.30.1 Handling of failed motion commands
			15.30.2 Handling of failed synchronous motion commands
			15.30.3 Handling of failed asynchronous motion commands
	16 Background tasks
		16.1 Using background tasks
		16.2 Cyclical background task
		16.3 Non-cyclic background task
		16.4 Data exchange between tasks
			16.4.1 Declaring task functions
			16.4.2 Implementing task functions
			16.4.3 Creating the providing task
			16.4.4 Using task functions
	17 Programming with a compliant robot
		17.1 Sensors and control
		17.2 Available controllers – overview
		17.3 Using controllers in robot applications
			17.3.1 Creating a controller object
			17.3.2 Defining controller parameters
			17.3.3 Transferring the controller object as a motion parameter
		17.4 Position controller
		17.5 Cartesian impedance controller
			17.5.1 Calculation of the forces on the basis of Hooke’s law
			17.5.2 Parameterization of the Cartesian impedance controller
				17.5.2.1 Representation of Cartesian degrees of freedom
				17.5.2.2 Defining controller parameters for individual degrees of freedom
				17.5.2.3 Controller parameters specific to the degrees of freedom
				17.5.2.4 Controller parameters independent of the degrees of freedom
		17.6 Cartesian impedance controller with overlaid force oscillation
			17.6.1 Overlaying a simple force oscillation
			17.6.2 Overlaying superposed force oscillations (Lissajous curves)
			17.6.3 Parameterization of the impedance controller with overlaid force oscillation
				17.6.3.1 Controller parameters specific to the degrees of freedom
				17.6.3.2 Controller parameters independent of the degrees of freedom
		17.7 Static methods for impedance controller with superposed force oscillation
			17.7.1 Overlaying a constant force
			17.7.2 Overlaying a simple force oscillation
			17.7.3 Overlaying a Lissajous oscillation
			17.7.4 Overlaying a spiral-shaped force oscillation
		17.8 Axis-specific impedance controller
			17.8.1 Parameterization of the axis-specific impedance controller
			17.8.2 Methods of the axis-specific impedance controller
		17.9 Holding the position under servo control
	18 Diagnosis
		18.1 Field bus diagnosis
			18.1.1 Displaying general field bus errors
			18.1.2 Displaying the error state of I/Os and I/O groups
		18.2 Displaying the protocol
			18.2.1 “Protocol” view
			18.2.2 Filtering log entries
		18.3 Display of error messages (Applications view)
		18.4 Collecting diagnostic information for error analysis at KUKA
			18.4.1 Creating a diagnosis package with the smartHMI
			18.4.2 Creating a diagnosis package with the smartPAD
			18.4.3 Creating a diagnosis package with Sunrise.Workbench
			18.4.4 Loading existing diagnosis packages from the robot controller
	19 Appendix
		19.1 Compatibility and migration of projects
			19.1.1 Modified task functions – adapting the programming
	20 KUKA Service
		20.1 Requesting support
		20.2 KUKA Customer Support
	Index