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 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
2 / 143
Publication:
Pub KST SafeOperation 3.1 en
Bookstructure:
KST SafeOperation 3.1 V1.1
Label:
KST SafeOperation 3.1 V1 en
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
Contents
Contents 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
Product description .....................................................................................
11
2.1
Overview of SafeOperation ........................................................................................
11
2.2
Monitoring spaces ......................................................................................................
12
2.2.1
Coordinate systems ..............................................................................................
14
2.2.1.1
Special cases ........................................................................................................
15
2.2.2
Cell area ...............................................................................................................
16
2.2.3
Cartesian workspaces ..........................................................................................
17
2.2.4
Cartesian protected spaces ..................................................................................
18
2.2.5
Axis-specific workspaces ......................................................................................
19
2.2.6
Axis-specific protected spaces .............................................................................
20
2.2.7
Space-specific velocity .........................................................................................
22
2.2.8
Reference stop .....................................................................................................
22
2.3
Safe tools ...................................................................................................................
23
2.4
Velocity monitoring functions .....................................................................................
23
2.5
Safe operational stop .................................................................................................
24
2.6
Override reduction .....................................................................................................
24
2.7
CRR mode (safe robot retraction) ..............................................................................
25
2.8
Start-up mode ............................................................................................................
26
2.9
Mastering test ............................................................................................................
26
2.9.1
Reference position ................................................................................................
27
2.9.2
Reference switch module .....................................................................................
28
2.9.3
Connecting cables ................................................................................................
28
3
Technical data ..............................................................................................
31
3.1
Service life .................................................................................................................
31
3.2
Reference switch .......................................................................................................
31
3.3
Reference switch hole pattern ...................................................................................
32
3.4
Hole pattern for actuating plate ..................................................................................
32
4
Safety ............................................................................................................
35
4.1
General ......................................................................................................................
35
4.1.1
Liability ..................................................................................................................
35
4.1.2
Intended use of the industrial robot ......................................................................
35
4.1.3
EC declaration of conformity and declaration of incorporation .............................
36
4.1.4
Terms used ...........................................................................................................
36
4.2
Personnel ...................................................................................................................
38
4.3
Workspace, safety zone and danger zone .................................................................
39
4.4
Triggers for stop reactions .........................................................................................
40
4.5
Safety functions .........................................................................................................
41
4.5.1
Overview of the safety functions ...........................................................................
41
4.5.2
Safety controller ....................................................................................................
41
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
3 / 143
KUKA.SafeOperation 3.1
4.5.3
Mode selection .....................................................................................................
42
4.5.4
Operator safety .....................................................................................................
42
4.5.5
EMERGENCY STOP device ................................................................................
43
4.5.6
Logging off the higher-level safety controller ........................................................
43
4.5.7
External EMERGENCY STOP device ..................................................................
44
4.5.8
Enabling device ....................................................................................................
44
4.5.9
External enabling device ......................................................................................
45
4.5.10
External safe operational stop ..............................................................................
45
4.5.11
External safety stop 1 and external safety stop 2 .................................................
45
4.5.12
Velocity monitoring in T1 ......................................................................................
45
Additional protective equipment ................................................................................
45
4.6
4 / 143
4.6.1
Jog mode ..............................................................................................................
45
4.6.2
Software limit switches .........................................................................................
45
4.6.3
Mechanical end stops ...........................................................................................
46
4.6.4
Mechanical axis range limitation (optional) ...........................................................
46
4.6.5
Axis range monitoring (optional) ...........................................................................
46
4.6.6
Release device (optional) .....................................................................................
46
4.6.7
Labeling on the industrial robot ............................................................................
47
4.6.8
External safeguards .............................................................................................
47
4.7
Overview of operating modes and safety functions ...................................................
48
4.8
Safety measures ........................................................................................................
48
4.8.1
General safety measures .....................................................................................
48
4.8.2
Transportation ......................................................................................................
50
4.8.3
Start-up and recommissioning ..............................................................................
50
4.8.3.1
Start-up mode .......................................................................................................
52
4.8.4
Manual mode ........................................................................................................
52
4.8.5
Simulation .............................................................................................................
53
4.8.6
Automatic mode ...................................................................................................
53
4.8.7
Maintenance and repair ........................................................................................
54
4.8.8
Decommissioning, storage and disposal ..............................................................
55
4.8.9
Safety measures for “single point of control” ........................................................
55
4.9
Applied norms and regulations ..................................................................................
57
5
Installation ...................................................................................................
59
5.1
System requirements .................................................................................................
59
5.2
Installing or updating SafeOperation .........................................................................
59
5.3
Uninstalling SafeOperation ........................................................................................
59
6
Operation ......................................................................................................
61
6.1
User groups ...............................................................................................................
61
6.2
Opening the safety configuration ...............................................................................
61
6.3
Overview of buttons ...................................................................................................
61
6.4
Monitor functions .......................................................................................................
62
6.4.1
Displaying information about the safety configuration ..........................................
62
6.4.2
Displaying the change log ....................................................................................
63
6.4.3
Displaying machine data ......................................................................................
63
7
Start-up and recommissioning ...................................................................
65
7.1
Start-up overview .......................................................................................................
65
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
Contents
7.2
Safety warnings .........................................................................................................
66
7.3
Installing the reference switch and actuating plate ....................................................
67
7.4
Connecting a reference switch ...................................................................................
67
7.5
Activating safe monitoring ..........................................................................................
68
7.6
Defining global parameters ........................................................................................
68
7.7
Defining a cell area ....................................................................................................
70
7.8
Defining Cartesian monitoring spaces .......................................................................
72
7.9
Defining axis-specific monitoring spaces ...................................................................
75
7.10 Defining axis-specific velocity monitoring ..................................................................
79
7.11 Defining the safe operational stop .............................................................................
82
7.12 Defining safe tools .....................................................................................................
84
7.13 Defining the reference position ..................................................................................
87
7.14 Checking the reference position (actuation with tool) ................................................
89
7.15 Saving the safety configuration ..................................................................................
90
7.16 Performing a mastering test manually .......................................................................
91
7.17 Testing safety parameters .........................................................................................
91
7.17.1
Testing Cartesian velocity .....................................................................................
91
7.17.2
Testing maximum axis velocity .............................................................................
92
7.17.3
Testing Cartesian monitoring spaces ...................................................................
93
7.17.4
Testing axis-specific monitoring spaces ...............................................................
94
7.17.5
Testing safe operational stop for an axis group ....................................................
94
7.18 Safety acceptance overview ......................................................................................
94
7.19 Activating a new safety configuration .........................................................................
95
7.20 Deactivating safe monitoring ......................................................................................
96
8
Programming ...............................................................................................
97
8.1
Programs for the mastering test .................................................................................
97
8.2
Programming a mastering test ...................................................................................
97
9
System variables .........................................................................................
99
9.1
Variables for override reduction in $CUSTOM.DAT ..................................................
99
9.2
Variables for the mastering test .................................................................................
99
9.3
Variables for diagnosis ...............................................................................................
100
10
Interfaces to the higher-level controller ....................................................
101
10.1 SafeOperation via PROFIsafe (optional) ...................................................................
101
10.1.1
Diagnostic signals via PROFINET ........................................................................
103
10.2 SafeOperation via interface X13 (optional) ................................................................
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 ...................................................................................................................
115
13.1.1
Precondition for safety acceptance based on the checklists ................................
115
13.1.2
Checklist for robot and system .............................................................................
115
13.1.3
Checklist for safe functions ...................................................................................
115
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
5 / 143
KUKA.SafeOperation 3.1
6 / 143
13.1.4
Checklist for velocity limits ....................................................................................
118
13.1.5
Checklist for configuration of the safe operational stop ........................................
121
13.1.6
Checklist for configuration of the cell area ............................................................
122
13.1.7
Checklist for configuration of Cartesian monitoring spaces ..................................
123
13.1.8
Checklist for configuration of axis-specific monitoring spaces .............................
125
13.1.9
Checklist for configuration of the safe tools ..........................................................
127
13.2 Applied norms and directives ....................................................................................
130
14
KUKA Service ...............................................................................................
131
14.1 Requesting support ...................................................................................................
131
14.2 KUKA Customer Support ...........................................................................................
131
Index .............................................................................................................
139
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 / 143
KUKA.SafeOperation 3.1
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.
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
Stopping distance = reaction distance + braking distance The stopping distance is part of the danger zone.
Workspace
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) (>>> 2.2.3 "Cartesian workspaces" Page 17)
Danger zone
The danger zone consists of the workspace and the stopping distances.
Mastering test
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)
KL
KUKA linear unit
CRR
Controlled robot retraction Operating mode for retracting the robot in the case of a workspace violation.
Alarm space
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).
Monitoring time
During the monitoring time, the user is prompted to perform a mastering test.
Polygon, convex
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
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)
Reference group
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.
Reference position
The reference position is a Cartesian position to which the robot moves during the mastering test. (>>> 2.9.1 "Reference position" Page 27)
8 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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. (>>> 2.2.8 "Reference stop" Page 22)
Reference switch
A reference switch is necessary for carrying out the mastering test. The reference switch confirms the reference position.
Protected space
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.
(>>> 3.2 "Reference switch" Page 31)
(>>> 2.2.6 "Axis-specific protected spaces" Page 20) (>>> 2.2.4 "Cartesian protected spaces" Page 18) SIB
Safety Interface Board
Safety STOP 0
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 document.
Safety STOP 1
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 document.
Safety STOP 2
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 document.
Safe operational stop
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)
Safe tool
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)
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
9 / 143
KUKA.SafeOperation 3.1
Term
Description
Monitoring space
A monitoring space can be Cartesian or axis-specific and can be defined as a workspace or protected space. (>>> 2.2 "Monitoring spaces" Page 12)
Cell area
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)
10 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
11 / 143
KUKA.SafeOperation 3.1
Fig. 2-1: Example of a cell with SafeOperation
Functional principle
1
Reference switch
5
System control panel
2
Robot
6
Robot controller
3
Loading station
7
Bending machine
4
Safety mat
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
2.2
Various interfaces are available for connection to a higher-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.
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)
12 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
2 Product description
(>>> 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 that 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.
Robot exceeds the limit of an activated workspace in Automatic mode.
The stop is triggered if a monitoring function is just being activated and the robot has already exceeded the monitoring limit.
A protected space in which the robot is currently situated is activated by a safety mat.
Safety stop 1
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
Robot exceeds the limit of an activated workspace in T1 mode.
13 / 143
KUKA.SafeOperation 3.1
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 the 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
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
2 Product description
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
Rotation about the Z axis
Angle B
Rotation about the Y axis
Angle C
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
15 / 143
KUKA.SafeOperation 3.1
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.
16 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
2 Product description
Fig. 2-5 1
Example of a convex polygon with 6 corners
2
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
2.2.3
1
Cell area
2
Spheres on safe tool
3
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).
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
17 / 143
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
2.2.4
1
Workspace
2
Spheres on safe tool
3
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:
A safe output is set (alarm space). If interface X13 is used, safe outputs are only available for monitoring spaces 1 … 6.
18 / 143
The robot is stopped (configurable). Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
2 Product description
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 Cartesian protected space.
Example
Fig. 2-8: Example of a Cartesian protected space
2.2.5
1
Protected space
2
Spheres on safe tool
3
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 axis 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).
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
19 / 143
KUKA.SafeOperation 3.1
Cartesian velocity monitoring is activated (configurable).
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
2.2.6
1
Workspace
3
Stopping distance
2
Robot
4
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 protected space in the other direction from -90° to -185°. In this case, it is advisable to configure a workspace from -90° to +90°.
20 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
2 Product description
Fig. 2-10: Example of an axis-specific protected space through which the robot can move
Example
1
Workspace
3
Protected space
2
Robot
4
Protected space through which the robot can move
The diagram shows an example of an axis-specific protected 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
Permissible range 1
4
Protected space
2
Robot
5
Permissible range 2
3
Stopping distance
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
21 / 143
KUKA.SafeOperation 3.1
2.2.7
Space-specific velocity
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
2.2.8
1
Workspace
2
Spheres on safe tool
3
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:
22 / 143
Monitoring space is activated.
Mastering test is requested internally.
Operating mode T2, AUT or AUT EXT
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
2 Product description
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 spheres 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 monitoring functions Axis-specific and Cartesian velocities can be monitored.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
23 / 143
KUKA.SafeOperation 3.1
Axis velocity
Cartesian velocity
The velocity of every axis can be monitored against a limit value.
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.
In automatic operation, the robot exceeds the activated limit value for reduced axis velocity.
Safety stop 1
The stop is triggered if a monitoring function is just being activated and the robot has already exceeded the monitoring limit.
The safe reduced velocity, for which the limit value has already been exceeded by the robot, is activated by a safety mat.
2.5
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 axis 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 triggered. 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
24 / 143
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 ve-
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
2 Product description
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 safety 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 $SR_WORKSPACE_RED can be used to activate override reduction for these monitoring spaces ($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
2.7
v3
Maximum Cartesian velocity; v3 = 1,200 mm/s
v2
Space-specific velocity; v2 = 1,000 mm/s
v1
95% of velocity v2; v1 = 950 mm/s
t1
Override reduction is automatically activated because the programmed velocity exceeds velocity limit v1.
t2
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
25 / 143
KUKA.SafeOperation 3.1
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 monitoring 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 mastering 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:
26 / 143
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
2 Product description
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
Tool
2
Actuating plate
3
Reference switch
4
Mechanical mounting fixture for the reference switch
5
Actuated reference switch
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
27 / 143
KUKA.SafeOperation 3.1
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 input Mastering test accordingly.
Fig. 2-17: Overview of connecting cables
28 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
2 Product description
Item
Description
1
Robot controller
2
Robot
3
Reference switch XS Ref
4
Reference cable X42 - XS Ref (maximum cable length 50 m)
5
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
Min. 5xØ of cable
Installation in cable carrier
Min. 10xØ of cable
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
29 / 143
KUKA.SafeOperation 3.1
30 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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
-25 °C to +70 °C
Switching function
Break contact
DC operating voltage or HIGH level in the case of pulsed operating voltage of the reference switch
24 V
Permissible range for the DC operating voltage or HIGH level for pulsed voltage
20 to 33 V
Required pulse duty factor T(HIGH):T(LOW) for pulsed voltage
Min. 4:1
Supported pulse duration T(LOW) for pulsed voltage
0.1 to 20 ms
Operating current (power consumption) without load
5 mA
Permissible load current
max. 250 mA
Permissible switching frequency
max. 500 Hz
Permissible switching distance at the proximity switch surfaces
0 to 4 mm
Short circuit and overload protection, pulsed
Yes
Outputs
PNP
LOW-active
Dual-channel
LED function indicator
Yes
Hysteresis when installed
0.2 to 1 mm
EMC conformity
IEC 60947-5-2
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
31 / 143
KUKA.SafeOperation 3.1
3.3
Reference switch hole pattern
Description
Fig. 3-1
3.4
1
2 holes for fastening elements, Ø 6.6 mm
2
2 holes for roll pins, Ø 4 mm
Hole pattern for actuating plate
Description
Fig. 3-2
32 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
3 Technical data
1
2 M6 threaded holes for fastening elements
2
2 holes for fastening elements, Ø 9 mm
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
33 / 143
KUKA.SafeOperation 3.1
34 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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 guarantee 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 further 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” chapter 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
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
35 / 143
KUKA.SafeOperation 3.1
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:
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.
Declaration of conformity
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.
36 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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.
Stopping distance
Stopping distance = reaction distance + braking distance
Workspace
The manipulator is allowed to move within its workspace. The workspace is derived from the individual axis ranges.
Operator (User)
The user of the industrial robot can be the management, employer or delegated person responsible for use of the industrial robot.
Danger zone
The danger zone consists of the workspace and the stopping distances.
KCP
The KCP (KUKA Control Panel) teach pendant has all the operator control and display functions required for operating and programming the industrial robot.
The stopping distance is part of the danger zone.
The KCP variant for the KR C4 is called KUKA smartPAD. The general term “KCP”, however, is generally used in this documentation. Manipulator
The robot arm and the associated electrical installations
Safety zone
The safety zone is situated outside the danger zone.
Safe operational stop
The safe operational stop is a standstill monitoring function. It does 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 externally. 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.
Safety STOP 0
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.
Safety STOP 1
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 0 in this document.
When a safety STOP 1 is triggered, the robot controller sets an output to the field bus. The safety STOP 1 can also be triggered externally. Note: This stop is called safety STOP 1 in this document. Safety STOP 2
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. 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 output to the field bus. The safety STOP 2 can also be triggered externally. Note: This stop is called safety STOP 2 in this document.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
37 / 143
KUKA.SafeOperation 3.1
Term
Description
Stop category 0
The drives are deactivated immediately and the brakes are applied. The manipulator and any external axes (optional) perform path-oriented braking. Note: This stop category is called STOP 0 in this document.
Stop category 1
The manipulator and any external axes (optional) perform path-maintaining braking. The drives are deactivated after 1 s and the brakes are applied.
Stop category 2
The drives are not deactivated and the brakes are not applied. The manipulator and any external axes (optional) are braked with a pathmaintaining braking ramp.
Note: This stop category is called STOP 1 in this document.
Note: This stop category is called STOP 2 in this document. System integrator (plant integrator)
System integrators are people who safely integrate the industrial robot into a complete system and commission it.
T1
Test mode, Manual Reduced Velocity ( 250 mm/s permissible)
External axis
Motion axis which is not part of the manipulator but which is controlled using the robot controller, e.g. KUKA linear unit, turn-tilt table, Posiflex.
4.2
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
Personnel
The user must observe the labor laws and regulations. This includes e.g.:
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 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 the operating or assembly instructions for the relevant component of the industrial robot and only by personnel specially trained for this purpose. System integrator
38 / 143
The industrial robot is safely integrated into a complete system by the system integrator.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
4 Safety
The system integrator is responsible for the following tasks:
Operator
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 meet the following preconditions:
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
Workspace, safety zone and danger 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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
39 / 143
KUKA.SafeOperation 3.1
The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). It must be 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
4.4
1
Workspace
3
Stopping distance
2
Manipulator
4
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
T1, T2
AUT, AUT EXT
STOP 2
-
STOP key pressed
STOP 2
Drives OFF
STOP 1
“Motion enable” input drops out
STOP 2
Robot controller switched off (power failure)
STOP 0
Internal error in nonsafety-oriented part of the robot controller
STOP 0 or STOP 1 (dependent on the cause of the error)
Operating mode changed during operation
40 / 143
Safety stop 2
Safety gate opened (operator safety)
-
Safety stop 1
Enabling switch released
Safety stop 2
-
Enabling switch pressed fully down or error
Safety stop 1
-
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
4 Safety
Trigger
T1, T2
AUT, AUT EXT
E-STOP pressed
Safety stop 1
Error in safety controller or periphery of the safety controller
Safety stop 0
4.5
Safety functions
4.5.1
Overview of the safety functions 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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
41 / 143
KUKA.SafeOperation 3.1
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
Programmed velocity, maximum 250 mm/s
AUT
AUT EXT
4.5.4
Jog mode: Jog velocity, maximum 250 mm/ s
T2
Program verification:
For test operation
Program verification: Programmed velocity
Jog mode: Not possible
For industrial robots without higher-level controllers
Program mode:
Jog mode: Not possible
For industrial robots with higher-level controllers, e.g. PLC
Program mode:
Programmed velocity
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).
42 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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.
4.5.5
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 injuries or considerable damage to property.
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 controller 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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
43 / 143
KUKA.SafeOperation 3.1
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.
44 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
4 Safety
4.5.9
External enabling device External enabling devices are required if it is necessary for more 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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
45 / 143
KUKA.SafeOperation 3.1
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 personal 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 must 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-channel axis range monitoring systems in main axes A1 to A3. The positioner axes may 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
46 / 143
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).
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
47 / 143
KUKA.SafeOperation 3.1
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.
48 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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
Modifications
The following tasks must be carried out in the case of faults in the industrial robot:
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 safety 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).
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
49 / 143
KUKA.SafeOperation 3.1
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 must be carried out in accordance with the operating instructions or assembly instructions 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 that 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 to 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:
50 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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 and 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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
51 / 143
KUKA.SafeOperation 3.1
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:
52 / 143
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
53 / 143
KUKA.SafeOperation 3.1
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 return 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 the industrial robot:
Carry out work outside the danger zone. If work inside the danger zone is necessary, the user must define additional safety measures to 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 robot 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 carried 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
54 / 143
Some robot variants are equipped with a hydropneumatic, spring or gas cylinder counterbalancing system.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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 standards pertaining to pressure equipment. Inspection intervals in Germany in accordance with Industrial Safety Order, Sections 14 and 15. Inspection by the user before commissioning at 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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
55 / 143
KUKA.SafeOperation 3.1
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
TRUE
$SPOC_MOTION_ENABLE
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:
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.
OPC server, remote control tools
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:
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.
Tools for configuration of bus systems
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:
56 / 143
Only use one operator console at each robot controller.
If the KCP is being used for work inside the system, remove 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
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) 2004/108/EC
EMC Directive:
2004
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 97/23/EC
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 (Only applicable for robots with hydropneumatic counterbalancing system.) EN ISO 13850
Safety of machinery:
EN ISO 13849-1
Safety of machinery:
2008
Emergency stop - Principles for design 2008
Safety-related parts of control systems - Part 1: General principles of design EN ISO 13849-2
Safety of machinery:
2008
Safety-related parts of control systems - Part 2: Validation EN ISO 12100-1
Safety of machinery:
2003
Basic concepts, general principles for design - Part 1: Basic terminology, methodology EN ISO 12100-2
Safety of machinery:
2003
Basic concepts, general principles for design - Part 2: Technical principles EN ISO 10218-1
Industrial robots:
2008
Safety EN 614-1
Safety of machinery:
2006
Ergonomic design principles - Part 1: Terms and general principles EN 61000-6-2
Electromagnetic compatibility (EMC):
2005
Part 6-2: Generic standards; Immunity for industrial environments EN 61000-6-4
Electromagnetic compatibility (EMC):
2007
Part 6-4: Generic standards; Emission standard for industrial environments EN 60204-1
Safety of machinery:
2006
Electrical equipment of machines - Part 1: General requirements
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
57 / 143
KUKA.SafeOperation 3.1
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.
58 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
5 Installation
5
Installation
5.1
System requirements
Hardware
KR C4
Software
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:
Compatibility
5.2
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. A LOG file is created under C:\KRC\ROBOTER\LOG.
LOG file
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. Expert user group
Precondition
Procedure
1. Select Start-up > Install additional software in the main menu. All additional programs installed are displayed.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
59 / 143
KUKA.SafeOperation 3.1
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
60 / 143
A LOG file is created under C:\KRC\ROBOTER\LOG.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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.
Reset changes
Resets all changes since the last time the configuration was saved.
Change log
The log of changes to the safety configuration is displayed.
View
The safety-relevant machine data are displayed.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
61 / 143
KUKA.SafeOperation 3.1
Button
Description
Properties
The properties of a monitoring space or safe tool can be defined.
Device management
The safety ID of the PROFINET device can be changed. Note: Further information is contained in the Operating and Programming Instructions for System Integrators.
Global parameters
The global parameters of the safety configuration can be defined.
Hardware options
The hardware settings can be defined. Note: Further information is contained in the Operating and Programming Instructions for System Integrators.
Check machine data
It is possible to check whether the machine data of the safety configuration are up to date.
Safe operational stop
The safe operational stop can be defined.
Save
Saves and activates the safety configuration for the robot.
Touch-up
Saves the current robot position as a corner of a cell area. OR Saves the current axis angle as the lower limit or upper limit of the axis-specific monitoring space.
Touch-up reference position for group
Saves the current robot flange position or the position of the axes of a reference group as a reference position.
Cell configuration
The cell area can be defined.
Back
Back to the tab
6.4
Monitor functions
6.4.1
Displaying information about the safety configuration
Procedure
Select Configuration > Safety configuration in the main menu. The safety configuration opens with the General tab.
Description
The General tab contains the following information: Parameter
Description
Robot
Serial number of the robot
Safety controller
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
62 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
6 Operation
6.4.2
Parameter
Description
Machine data
Time stamp of the safety-relevant machine data (date and time last saved)
Current configuration
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
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
63 / 143
KUKA.SafeOperation 3.1
64 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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 Programming Instructions for System Integrators.
2
Install reference switch and actuating plate. (>>> 7.3 "Installing the reference switch and actuating plate" Page 67)
3
Connect the reference switch.
4
Only if a safety PLC is being used: configure communication via the interface.
(>>> 7.4 "Connecting a reference switch" Page 67)
(>>> 10 "Interfaces to the higher-level controller" Page 101) 5
Master the robot. Note: Detailed information is contained in the operating and programming instructions.
6
Activate safe monitoring. (>>> 7.5 "Activating safe monitoring" Page 68)
7
Define global parameters.
Mastering test input
Cartesian velocity monitoring functions
(>>> 7.6 "Defining global parameters" Page 68) 8
Define monitoring spaces. (>>> 7.7 "Defining a cell area" Page 70) (>>> 7.8 "Defining Cartesian monitoring spaces" Page 72) (>>> 7.9 "Defining axis-specific monitoring spaces" Page 75)
9
Define axis-specific velocity monitoring. (>>> 7.10 "Defining axis-specific velocity monitoring" Page 79) (>>> 7.11 "Defining the safe operational stop" Page 82)
10
Define safe tools. (>>> 7.12 "Defining safe tools" Page 84)
11
Program mastering test. (>>> 8.2 "Programming a mastering test" Page 97)
12
Define reference position.
13
Only if the reference switch is actuated by the tool: Check reference position.
(>>> 7.13 "Defining the reference position" Page 87)
(>>> 7.14 "Checking the reference position (actuation with tool)" Page 89)
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
65 / 143
KUKA.SafeOperation 3.1
Step
Description
14
Save safety configuration. (>>> 7.15 "Saving the safety configuration" Page 90)
15
Perform mastering test.
16
Carry out safety acceptance.
(>>> 7.16 "Performing a mastering test manually" Page 91) (>>> 7.18 "Safety acceptance overview" Page 94) (>>> 7.17 "Testing safety parameters" Page 91) 17
Archive safety configuration. Note: Detailed information is contained in the operating and programming instructions.
18
Only if a new safety configuration is being activated: compare the displayed checksum with the expected checksum in the checklist for safe functions. (>>> 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 implemented 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 velocity.
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.
66 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
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
7.4
1
Robot
2
Actuating plate on tool
3
Tool
4
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 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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
67 / 143
KUKA.SafeOperation 3.1
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 input Mastering test accordingly. Precondition
Procedure
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.
7.5
Connect X42 to the robot controller and XS Ref to the reference switch.
Activating safe monitoring Configuration of the safety monitoring functions is only possible if safe monitoring has been activated.
Precondition
Procedure
User group “Safety maintenance”
Operating mode T1 or T2
1. Open safety configuration. 2. Press Global parameters. 3. Activate the Safe monitoring check box (set the check mark). 4. Save the safety configuration or continue configuration.
7.6
Defining global parameters
Precondition
Procedure
68 / 143
User group “Safety maintenance”
Operating mode T1 or T2
A safety configuration is open.
Safe monitoring is active.
Press Global parameters and set parameters.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
Description
Fig. 7-2: Defining global parameters Defining global parameters: Parameter
Description
Safe monitoring
Check box activated = safe monitoring is activated. Check box deactivated = safe monitoring is deactivated. Default: Check box deactivated
Mastering test input
at cabinet = reference switch is connected to the robot controller. via ProfiSafe = reference switch is connected via PROFIsafe. Default: at cabinet
Cartesian maximum velocity
Limit value for maximum Cartesian velocity (not space-dependent)
0.5 … 30,000 mm/s
Default: 10,000 mm/s
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
69 / 143
KUKA.SafeOperation 3.1
Parameter
Description
Reduced Cartesian velocity
Limit value for safely reduced Cartesian velocity
0.5 … 30,000 mm/s
Default: 30,000 mm/s Reduced Cartesian velocity T1
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.
70 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
Description
Fig. 7-3: Defining a cell area Defining a cell area: Parameter
Description
Reference system
Reference coordinate system
Z min
$WORLD
Lower limit of the cell area
-30,000 mm … +30,000 mm
Default: -30,000 mm Z max
Upper limit of the cell area
-30,000 mm … +30,000 mm
Default: 30,000 mm
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
71 / 143
KUKA.SafeOperation 3.1
Parameter
Description
Activated
Check box activated = corner of cell area is activated.
(corner)
Check box deactivated = corner of cell area is deactivated. Default corner 1 to 4: Check box active Default corner 5 to 10: Check box deactivated X, Y (corner)
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
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 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:
72 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
Parameter
Description
Type
Type of monitoring space Working space = monitoring space is a workspace. Protected space = monitoring space is a protected space. Default: Workspace
Activation
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) Default: Inactive
Space type
Type of monitoring space Cartesian space = Cartesian monitoring space Axis space = axis-specific monitoring space Default: Cartesian space
Stop at boundaries
A stop is triggered if the space is violated. Check box activated = robot stops if the monitoring space limits are exceeded. Check box deactivated = robot does not stop if the monitoring space limits are exceeded. Default: Check box activated
V max
Limit value of the space-specific velocity
0.5 … 30,000 mm/s
Default: 30,000 mm/s Vmax valid if
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 monitored if the monitoring space is violated. Default: Deactivated
Stop if mastering test not yet done
Activation of reference stop Check box activated = reference stop is activated for the monitoring space. Check box deactivated = reference stop is deactivated for the monitoring space. Default: Check box deactivated
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
73 / 143
KUKA.SafeOperation 3.1
Properties
Fig. 7-5: Defining Cartesian properties Defining properties: Parameter
Description
Reference system
Reference coordinate system
$WORLD
$ROBROOT
Default: $WORLD Origin X, Y, Z
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
74 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
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:
-90° … +90°
Default: 0° Distance to origin XMin, YMin, ZMin
Minimum X, Y and Z coordinates of the Cartesian monitoring space relative to the origin
-30,000 mm … +30,000 mm
Default: 0 mm Distance to origin XMax, YMax, ZMax
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
75 / 143
KUKA.SafeOperation 3.1
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:
76 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
Parameter
Description
Type
Type of monitoring space Working space = monitoring space is a workspace. Protected space = monitoring space is a protected space. Default: Workspace
Activation
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) Default: Inactive
Space type
Type of monitoring space Cartesian space = Cartesian monitoring space Axis space = axis-specific monitoring space Default: Cartesian space
Stop at boundaries
A stop is triggered if the space is violated. Check box activated = robot stops if the monitoring space limits are exceeded. Check box deactivated = robot does not stop if the monitoring space limits are exceeded. Default: Check box activated
V max
Limit value of the space-specific velocity
0.5 … 30,000 mm/s
Default: 30,000 mm/s Vmax valid if
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 monitored if the monitoring space is violated. Default: Deactivated
Stop if mastering test not yet done
Activation of reference stop Check box activated = reference stop is activated for the monitoring space. Check box deactivated = reference stop is deactivated for the monitoring space. Default: Check box deactivated
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
77 / 143
KUKA.SafeOperation 3.1
Properties
Fig. 7-8: Defining axis-specific properties Icon
Description Icon for rotational and infinitely rotating axes Icon for linear axes
Defining properties:
78 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
Parameter
Description
Monitoring
Check box activated = axis limits are activated for the monitoring space. Check box deactivated = axis limits are deactivated for the monitoring space. Default: Check box deactivated
Lower limit (lower axis limit)
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° Default value for linear axes: -30,000 mm Current position
Upper limit (upper axis limit)
Axis-specific actual position (display only)
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
User group “Safety maintenance”
Operating mode T1 or T2
A safety configuration is open.
Safe monitoring is active.
1. Select the Axis monitoring tab.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
79 / 143
KUKA.SafeOperation 3.1
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:
80 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
Parameter
Description
Monitoring
Check box activated = axis is monitored. Check box deactivated = axis is not monitored. Default: Check box deactivated
Reduced velocity
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 Default value for linear axes: 10,000 mm/s Reduced velocity T1
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 Default value for linear axes: 250 mm/s Safe operational stop
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
81 / 143
KUKA.SafeOperation 3.1
Parameter
Description
Maximum velocity rotational axis
Limit value for maximum velocity for rotational axes
0.5 … 5,000°/s
Default: 1,000°/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. Maximum velocity translational axis
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
Defining the safe operational stop
Precondition
Procedure
User group “Safety maintenance”
Operating mode T1 or T2
A safety configuration is open.
Safe monitoring is active.
1. Select the Axis monitoring tab and press Safety stop. The Safety stop window is opened. 2. Select axis from the list. 3. Activate one or more axis groups in which the axis is to be monitored by activating the corresponding check box (set the check mark). 4. Enter the axis angle or distance tolerance. 5. Repeat steps 2 to 4 to define further monitoring functions.
82 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
Description
Fig. 7-10: Defining the safe operational stop Defining the safe operational stop:
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
83 / 143
KUKA.SafeOperation 3.1
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. (>>> 10.2 "SafeOperation via interface X13 (optional)" Page 107)
Axis angle tolerance
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
7.12
Defining safe tools
Precondition
Procedure
User group “Safety maintenance”
Operating mode T1 or T2
A safety configuration is open.
Safe monitoring is active.
1. Select the Tools tab and select a tool from the list. The parameters of the safe tool are displayed. 2. Activate the safe tool via the check box (set the check mark) and enter a name for the tool (max. 24 characters). 3. Define the safe TCP of the tool. 4. Press Properties. The Properties of [NameTool] window is opened. 5. Select a sphere from the list and activate monitoring via the check box (set the check mark). 6. Enter the coordinates of the center of the sphere and the radius of the sphere. 7. Repeat steps 5 to 6 to define additional spheres for the safe tool.
84 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
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 deactivated. 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. (>>> 10.2 "SafeOperation via interface X13 (optional)" Page 107)
TCP X, Y, Z
X, Y and Z coordinates of the safe TCP relative to the velocity monitoring
-10,000 mm … +10,000 mm
Default: 0 mm
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
85 / 143
KUKA.SafeOperation 3.1
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 monitored. Default sphere 1: Check box activated Default spheres 2 to 6: Check box deactivated
86 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
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
-10,000 mm … +10,000 mm
Default: 0 mm Radius
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
User group “Safety maintenance”
Operating mode T1 or T2
A safety configuration is open.
Safe monitoring is active.
1. Select the tool and base for Cartesian jogging. 2. Select the Reference position tab. 3. Move robot to the reference position. 4. Select one of the robot axes. 5. 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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
87 / 143
KUKA.SafeOperation 3.1
Description
Fig. 7-13: Defining the reference position Defining the reference position:
88 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
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.
1: robot axes
1 … 3: external axes
Default: 1 Reference position
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° Default value for linear axes: 1,000 mm Current position
Axis-specific actual position (display only)
Red: reference position not allowed, as too near mastering position
Green: reference position allowed
Mastering position
The axis angles at the mastering position are defined in the machine data. (display only)
Cartesian reference position X, Y, Z
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
89 / 143
KUKA.SafeOperation 3.1
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 considerable damage to property. 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)
Procedure
User group “Safety maintenance”
T1 or T2 operating mode
1. Open the program MasRef_USER.SRC. 2. In the subprogram MASREFSTARTGX(), 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 MASREFSTARTGX() 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 reference position if necessary. 9. For automatic operation, delete all HALT statements from the program MasRef_USER.SRC once again.
7.15
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
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)
90 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
7 Start-up and recommissioning
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. Make 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 15xxx 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) Override reduction is deactivated.
Precondition
Procedure
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
91 / 143
KUKA.SafeOperation 3.1
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] = (VTest / Vmax) * 100 = (200 °/s / 360 °/s) * 100 = 56 Element
Description
x
Number of the axis
Vtest
Test velocity Unit: °/s
Vmax
Maximum axis velocity Unit: °/s
The calculated axis velocity $VEL_AXIS[x] is entered in the test program:
92 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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 programmed 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 Override reduction is deactivated.
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
93 / 143
KUKA.SafeOperation 3.1
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.
Precondition
Procedure
1. Configure an axis-specific monitoring space.
Override reduction is deactivated.
(>>> 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 axis angle or distance tolerance for the affected axis must be increased. Operating mode T1
Precondition
Procedure
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.
7.18
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:
94 / 143
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:
Checklist for robot and system (>>> 13.1.2 "Checklist for robot and system" Page 115)
Checklist for safe functions
Checklist for velocity limits
(>>> 13.1.3 "Checklist for safe functions" Page 115) (>>> 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)
7.19
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”
Precondition
Procedure
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
95 / 143
KUKA.SafeOperation 3.1
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
User group “Safety maintenance”
Operating mode T1 or T2
1. Open safety configuration. 2. Press Global parameters. 3. Deactivate the Safe monitoring check box. 4. Press Save and answer the request for confirmation with Yes. The robot controller is automatically reinitialized.
96 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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. The program calls the program MasRef_USER.SRC that is used to address the reference position.
MasRef_USER.SRC
R1\Program
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 MASREFSTARTGX() and MASREFBACKGX(). 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 MASREFSTARTGX() of the program MasRef_USER.SRC is called. 7. In the subprogram MASREFSTARTGX(), 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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
97 / 143
KUKA.SafeOperation 3.1
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 MASREFSTARTGX() and perform a block selection to the END line. 13. Press the Start key. The subprogram MASREFBACKGX() of the program MasRef_USER.SRC is called. 14. In the subprogram MASREFBACKGX(), 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
98 / 143
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
DEF MasRef_USER() END 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.
10
Program the motion to the reference position of reference group 2 and teach the reference position.
15
Program the motion to the reference position of reference group 3 and teach the reference position.
20
Teach the motion away from the reference position of reference group 1.
25
Teach the motion away from the reference position of reference group 2.
30
Teach the motion away from the reference position of reference group 3. Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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.
10 … 95 %
Default: 95 % $SR_VEL_RED
Override reduction for the velocity TRUE = override reduction is activated. FALSE = override reduction is not activated. Default: TRUE
$SR_WORKSPACE_RED
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. Default: FALSE
$MASTERINGTEST_REQ_EXT
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\ KRC\STEU\MADA\$MACHINE.DAT and must be assigned to a suitable input.
$MASTERINGTESTSWITCH_O K
Check of the function of the reference switch TRUE = reference switch is OK. FALSE = reference switch is defective. Default: TRUE
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
99 / 143
KUKA.SafeOperation 3.1
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. The variable is set to FALSE when the excessive value is detected and then set immediately back to TRUE.
$SR_CARTSPEED_OK
Cartesian velocity exceeded TRUE = Cartesian velocity has not been exceeded. FALSE = Cartesian velocity has been exceeded. The variable is set to FALSE when the excessive value is detected and then set immediately back to TRUE.
$SR_DRIVES_ENABLE
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:
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)
$SR_SAFEOPSTOP_OK
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.
100 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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 actuated).
1
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.
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
101 / 143
KUKA.SafeOperation 3.1
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.
102 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
10 Interfaces to the higher-level controller
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].
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
103 / 143
KUKA.SafeOperation 3.1
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 deactivated.
2
VRED
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]
104 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
10 Interfaces to the higher-level controller
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
105 / 143
KUKA.SafeOperation 3.1
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 operating mode
5
RIA
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]
106 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
10 Interfaces to the higher-level controller
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
107 / 143
KUKA.SafeOperation 3.1
108 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
109 / 143
KUKA.SafeOperation 3.1
110 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
12 Messages
12
Messages
12.1
Messages during operation Configuration or operator errors may result in error messages in an application.
No.
Message
Cause
Remedy
15016
Ackn.: Stop due to standstill monitoring violation
At least one of the axes monitored for standstill has moved outside the configured axis angle or distance tolerances.
Acknowledge the message.
15017
Ackn.: The braking ramp of the robot has been violated.
The robot controller has not triggered sufficient braking in the case of a STOP 1 or a safe operational stop.
Acknowledge the message.
15018
Ackn.: Maximum Cartesian speed limit in T1 mode exceeded
The maximum permissible Cartesian velocity in operating mode T1 has been exceeded.
Check override reduction and modify as required.
15019
Ackn.: Maximum axisspecific speed limit in T1 mode exceeded
At least one axis has exceeded the configured limit value for reduced axis velocity in operating mode T1.
Reduce jog override.
15020
Start-up mode active, EMERGENCY STOP has LOCAL effect ONLY
Start-up mode of the safety controller is activated.
Deactivate Start-up mode.
15021
Safety stop 2 violated (SHS2)
The brake ramp has not been maintained.
Deactivate safe operational stop.
Ackn.: Safety stop 2 violated (SHS2)
The configured axis angles or distance tolerances have been violated during a monitored standstill.
Ackn.: Cartesian velocity in Cartesian monitoring space no. Number of monitoring space exceeded
The space-specific velocity for the Cartesian monitoring space has been exceeded.
15022
15031
(>>> 9.1 "Variables for override reduction in $CUSTOM.DAT" Page 99)
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.
15032
Ackn.: Cartesian velocity in axis-specific monitoring space no. Number of monitoring space exceeded
The space-specific velocity for the axis-specific monitoring space has been exceeded.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
Check the programmed motion and modify as required. Check the safety configuration and modify as required.
111 / 143
KUKA.SafeOperation 3.1
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
The limit value for maximum Cartesian velocity (not space-dependent) has been exceeded.
Acknowledge the message.
15040
Ackn.: Maximum global axis speed exceeded
The limit value for maximum axis velocity has been exceeded.
Check the programmed motion and modify as required. Check the safety configuration and modify as required.
15041
Ackn.: Maximum safe reduced Cartesian speed exceeded
The limit value for safely reduced Cartesian velocity has been exceeded.
Check the programmed motion and modify as required. Check the safety configuration and modify as required.
15042
Ackn.: Safe reduced axis speed exceeded
The limit value for safely reduced axis velocity has been exceeded.
Check the programmed motion and modify as required. Check the safety configuration and modify as required. Check whether the velocity monitoring is activated and activate if required.
15043 15044
Safe operational stop violated (axis group Number of axis group) Ackn.: Safe operational stop violated (axis group Number of axis group)
15045 15046
Error at mastering reference switch
Following activation of the safe operational stop, at least one axis from the axis group was not braked or exceeded the configured axis angles or distance tolerances during a monitored standstill.
Deactivate operational stop.
The CIB signals an error at the reference switch input.
Check the reference switch connection and CIB.
Stop the axes in the axis group before activating the operational stop. Check the configuration of the axis group and modify as required.
Ackn.: Error at mastering reference switch
112 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
12 Messages
No.
Message
Cause
Remedy
15047
Mastering test required (internal)
The mastering test is requested internally after the robot controller has booted or after mastering.
Perform mastering test.
15048
Ackn.: Mastering test time interval expired
The monitoring time has elapsed.
Perform mastering test.
15049
Mastering test failed
The mastering test has failed. The cause of the error is indicated in a separate message. See messages no. 15051 to 15066.
Eliminate error and carry out mastering test.
15050
Reference stop
Reference stop is activated. (= function Stop if mastering test not yet done)
Perform mastering test.
15051
Ackn.: Mastering test position not reached
It was not possible to move to the reference position.
Check the reference position in the program MasRef_USER.SRC and in the safety configuration and teach again if required.
15052
Ackn.: Mastering reference switch not actuated
Robot is in mastering position and the reference switch is not actuated:
Check mastering.
Reference switch is defective.
The distance between the reference switch and the reference position is too great.
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.
15053
Ackn.: Not all mastering reference groups referenced
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.
Teach the missing reference positions or missing motion away from the reference position in the program MasRef_USER.SRC.
15054
Workspace monitoring functions deactivated (mastering error)
Loss of mastering of one or more axes: the workspace monitoring functions are deactivated.
Master unmastered axes.
15065
Ackn.: Level at mastering reference switch is unexpectedly "low"
The reference switch is actuated although no mastering test is currently being carried out.
Check the reference switch and exchange if defective.
One or more axes are situated outside the monitoring space. The monitoring was only activated after the space limit was violated.
Move robot out of the violated area in CRR mode.
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
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
Deactivate the monitoring space using the safe input.
113 / 143
KUKA.SafeOperation 3.1
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.
15082
Ackn.: Monitoring space no. Number of monitoring space exceeded
114 / 143
Deactivate the monitoring space using the safe input.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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 confirmed in writing by the system builder.
Checklist
No.
Serial number of the robot: ____________________
Activity
Yes
1
The industrial robot is in flawless mechanical condition and correctly installed and fastened in accordance with the specifications in the documentation.
2
The permissible rated payload of the robot has not been exceeded.
3
There are no foreign bodies or loose parts on the industrial robot.
4
All required safety equipment is correctly installed and operational.
5
The power supply ratings of the industrial robot correspond to the local supply voltage and mains type.
6
The connecting cables are correctly connected and the connectors are locked.
7
The ground conductor and the equipotential bonding cable are sufficiently rated and correctly connected.
8
The system meets all the relevant laws, regulations and norms valid for the installation site.
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: ____________________
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
115 / 143
KUKA.SafeOperation 3.1
No.
Activation code of the safety configuration: ____________________
Activity
Yes
1
Safe monitoring has been activated.
2
Robot is mastered.
3
The machine data are consistent with the machine data in the safety configuration.
Not relevant
Inconsistent machine data are indicated when the safety configuration is activated. 4
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.
5
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. 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.
6
Control of the reduced velocity has been checked and is functioning correctly.
7
The local and external safety functions have been checked and are functioning correctly.
(>>> 4.8.3 "Start-up and recommissioning" Page 50)
(>>> 4.8.3 "Start-up and recommissioning" Page 50) 8
The reference position has been taught in the program MasRef_USER.SRC and in the safety configuration.
9
Was the mastering test successful?
10
Was the brake test successful?
11
Operator safety acknowledgement has been checked and is functioning correctly. (>>> 4.5.4 "Operator safety" Page 42)
12
Peripheral contactor (US2) has been checked and switches at the right time. Note: Further information is contained in the Operating and Programming Instructions for System Integrators.
13
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)
116 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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. (>>> 13.1.5 "Checklist for configuration of the safe operational stop" Page 121) 15
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. (>>> 13.1.6 "Checklist for configuration of the cell area" Page 122)
16
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
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
117 / 143
KUKA.SafeOperation 3.1
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)
18
The safety configuration has been archived and the change log has been checked.
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 Test value: __________ mm/s
2
The safe reduced Cartesian velocity has been correctly configured and checked. Specified value: __________ mm/s Configured value: __________ mm/s Test value: __________ mm/s
3
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
118 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
119 / 143
KUKA.SafeOperation 3.1
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
120 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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
Place, date Signature By signing, the signatory confirms the correct and complete performance of the safety acceptance test.
13.1.5
Checklist for configuration of the safe operational stop A separate checklist must be completed for each axis group.
Precondition
Operating mode T1
Checklist
Serial number of the robot: ____________________
Time stamp of the safety configuration: ____________________
Axis group number: ____________________
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
121 / 143
KUKA.SafeOperation 3.1
No.
Activity
1
Yes
Not relevant
Axis 1 has been correctly configured and checked. Specified axis angle tolerance: ______ ° or mm Configured axis angle tolerance: ______ ° or mm
2
Axis 2 has been correctly configured and checked. Specified axis angle tolerance: __________ ° Configured axis angle tolerance: __________ °
3
Axis 3 has been correctly configured and checked. Specified axis angle tolerance: __________ ° Configured axis angle tolerance: __________ °
4
Axis 4 has been correctly configured and checked. Specified axis angle tolerance: __________ ° Configured axis angle tolerance: __________ °
5
Axis 5 has been correctly configured and checked. Specified axis angle tolerance: __________ ° Configured axis angle tolerance: __________ °
6
Axis 6 has been correctly configured and checked. Specified axis angle tolerance: __________ ° Configured axis angle tolerance: __________ °
7
Axis 7 has been correctly configured and checked. Specified axis angle tolerance: _______ ° or mm Configured axis angle tolerance: ______ ° or mm
8
Axis 8 has been correctly configured and checked. Specified axis angle tolerance: ______ ° or mm Configured axis angle tolerance: ______ ° or mm
Place, date Signature By signing, the signatory confirms the correct and complete performance of the safety acceptance test.
13.1.6
Checklist for configuration of the cell area
Precondition
The monitoring spaces that can be activated by means of safe inputs have been deactivated.
Checklist
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
122 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
13 Appendix
No. 2
Activity
Yes
Not relevant
Corner 1 has been correctly configured? X coordinate: __________ mm Y coordinate: __________ mm
3
Corner 2 has been correctly configured? X coordinate: __________ mm Y coordinate: __________ mm
4
Corner 3 has been correctly configured? Y coordinate: __________ mm X coordinate: __________ mm
5
Corner 4 has been correctly configured? Y coordinate: __________ mm X coordinate: __________ mm
6
Corner 5 has been correctly configured? X coordinate: __________ mm Y coordinate: __________ mm
7
Corner 6 has been correctly configured? Y coordinate: __________ mm X coordinate: __________ mm
8
Corner 7 has been correctly configured? X coordinate: __________ mm Y coordinate: __________ mm
9
Corner 8 has been correctly configured? Y coordinate: __________ mm X coordinate: __________ mm
10
Corner 9 has been correctly configured? X coordinate: __________ mm Y coordinate: __________ mm
11
Corner 10 has been correctly configured? X coordinate: __________ mm Y coordinate: __________ mm
Place, date Signature By signing, the signatory confirms the correct and complete performance of the safety acceptance test.
13.1.7
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.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
123 / 143
KUKA.SafeOperation 3.1
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:
124 / 143
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
Place, date Signature By signing, the signatory confirms the correct and complete performance of the safety acceptance test.
13.1.8
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 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
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
125 / 143
KUKA.SafeOperation 3.1
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: __________ ° Determined upper axis limit: __________ °
3
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: __________ ° Determined upper axis limit: __________ °
4
Axis 4 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: __________ ° Determined upper axis limit: __________ °
5
Axis 5 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: __________ ° Determined upper axis limit: __________ °
6
Axis 6 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: __________ ° Determined upper axis limit: __________ °
7
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
126 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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?
Not relevant
Specified value: __________ mm/s Configured value: __________ mm/s Test value: __________ mm/s
Place, date Signature By signing, the signatory confirms the correct and complete performance of the safety acceptance test.
13.1.9
Checklist for configuration of the safe tools A separate checklist must be completed for each safe tool.
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
127 / 143
KUKA.SafeOperation 3.1
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 Configured value for the Z coordinate: __________ mm
2
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 Configured radius: __________ mm
3
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
128 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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 Configured radius: __________ mm
5
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 Configured radius: __________ mm
6
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 Configured radius: __________ mm
7
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
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
129 / 143
KUKA.SafeOperation 3.1
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.
130 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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 countries. Please do not hesitate to contact us if you have any questions.
Argentina
Ruben Costantini S.A. (Agency) Luis Angel Huergo 13 20 Parque Industrial 2400 San Francisco (CBA) Argentina Tel. +54 3564 421033 Fax +54 3564 428877
[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
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
131 / 143
KUKA.SafeOperation 3.1
132 / 143
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
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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]
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
133 / 143
KUKA.SafeOperation 3.1
134 / 143
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]
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
135 / 143
KUKA.SafeOperation 3.1
136 / 143
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]
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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]
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
137 / 143
KUKA.SafeOperation 3.1
138 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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
KUKA.SafeOperation 3.1
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 H Hardware components, scope of supply 11 Hazardous substances 55 Hole pattern, actuating plate 32 Hole pattern, reference switch 32 Hysteresis, reference switch 31 I 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 J Jog mode 45, 48 K KCP 37, 49 Keyboard, external 49 KL 8 140 / 143
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 Norms 130 O 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 P Panic position 44 Performance Level 41 Permissible load current, reference switch 31 Permissible switching distance, reference switch 31 Permissible switching frequency, reference switIssued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
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
KUKA.SafeOperation 3.1
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
142 / 143
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
KUKA.SafeOperation 3.1
Issued: 31.03.2011 Version: KST SafeOperation 3.1 V1 en
143 / 143
