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SOFTWARE

KR C...

Serial Sensor Interface

KUKA System Software (KSS) 5.1

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e

Copyright

KUKA Roboter GmbH

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.

Other functions not described in this documentation may be operable in the controller. The user has no claim 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 subsequent editions.

Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

1

General

5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Installation / uninstallation / update

6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Configuration

7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

HW_INF.INI

7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

PERCEPT.INI

7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

IOSYS.INI

8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

$CONFIG.DAT

8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5

PERCEPT.SRC

9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Functions of the Perceptron

â

â

â

â

laser measurement system

10

. . . . . . . . . .

4.1

Triggering a measuring procedure

10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2

Wait for end of measuring procedure

11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Read measurement data

12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4

Calculate measurement result

13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5

Measurement start

13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6

Start individual point measurement

14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7

Measurement end

14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8

Send sensor angle

15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Example programs

16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial Sensor Interface

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1

General

In this documentation, the configuration and use of the serial sensor interface add--on
module is described using the example of the Perceptron

â

laser measurement system.

This measurement system is fitted with a standard RS232 or RS422 serial interface. Data

are transferred using the software “communication task 1176” in accordance with protocol

3964R.
It is connected by default to the COM3 serial port on the robot controller (different

configurations can be made in the file percept.ini). The system is controlled by setting outputs

in the KRL program which cause a “message” to be sent via the serial interface.

Serial Sensor Interface

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2

Installation / uninstallation / update

From system software version 5.1 onwards, technology packages are offered exclusively as

add--on software modules. These are available on CD--ROM. Should you be interested in

purchasing further modules, please contact KUKA Support.
The installation procedure is the same for all technology packages and is described in a

separate documentation module.

The installation, uninstallation, reinstallation and update of technology

packages are described in detail in the documentation

“Installation/Uninstallation/Update of Tech Packages”.

3

Configuration

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3

Configuration

3.1

HW_INF.INI

In the [SERIAL] section of this file, which is located in the directory
c:\KRC\roboter\init, the available serial interfaces are assigned to one of the two

operating systems, Windows95 or VxWorks.
In the following example, management of the third serial interface is assigned to the real--time

operating system VxWorks.

HW_INF.INI
...
;important information to use serial ports (COMx) with V5.1 and higher
;COM1

no longer useable

;COM2

only useable with special ENABLE

;COM3

DISABLE / ENABLE (default) / CONSOLE

[SERIAL]
;ENABLE:

COM is accessible by robot (vxWorks)

;DISABLE: COM is accessible by Win95
;CONSOLE: for developer only
COM3=ENABLE

;[ENABLE, DISABLE, CONSOLE]

3.2

PERCEPT.INI

This file in the directory c:\KRC\roboter\init provides information for initializing the

measurement system protocol driver (protocol 3964R). The parameters “number of data

bits” <8>, “number of stop bits” <1> and “parity declaration” <even> are fixed.

PERCEPT.INI
...
[VERSION]
VERSION=x.x.x

[PERCEPTRON]

;baudrate | valid rates: 9600, 19200
BAUD=9600
;BAUD=19200

;comport | valid ports: 1, 2, 3
COM=3

;timeout (wait seconds for measurement complete)
TIMEOUT=10

;testprint on telnet if value > 0
TESTAUSGABE=0

[END SECTION]

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3.3

IOSYS.INI

This file is located in the directory c:\KRC\roboter\init. The PERCEPTRON driver

must also be loaded when initializing the system. For this, the file name and associated initial-

ization routine for the CALL--P interface must be named.
The driver is accessed via the controller’s internal I/O map. Output and input data words are

reserved for this purpose.

Make sure that the assignment of inputs and outputs to the measurement system

corresponds to the signal allocation in the PERCEPT.SRC file (see also Section 3.5).
If the driver is deactivated, e.g. the relevant file entries are turned into comments in the

[DRIVERS] section, the application program stops when a “PERCEPTRON” function is

called and waits in vain in the module PERCEPT.SRC for the measurement result.

[DRIVERS]

MFC=0,mfcEntry,mfcdrv.o

PERCEPTRON=4,percInit,percdrv.o

Detailed information on the file IOSYS.INI can be found in the chapter [I/O System].

3.4

$CONFIG.DAT

This file is located in the directory c:\KRC\roboter\KRC\R1\system. It contains, among

other things, the definitions of the globally valid variables which record the results of the

measurements and calculations of the measurement system. In addition to this, data words

are reserved here which are used by the measurement system as status registers.
The ranges of values are limited as follows:

Measurement result:

X, Y, Z

--99.999 mm ... 99.999 mm

A, B, C

--32.769 ° ... 32.767 °

Calculation:

--999.999 ... 999.999

DEFDAT $CONFIG
...
;FOLD PERCEPTRON GLOBALS
;==============================
; External declarations:
;==============================
EXT PERCEPT(INT:IN,INT:IN,INT:IN,INT:IN,INT:IN,INT:OUT)

;==============================
; Variables:
;==============================
INT PERCEPT_32
INT PERCEPT_33
INT PERCEPT_34
REAL PERCEPT_REL
FRAME PERCEPT_KOR
;ENDFOLD (PERCEPTRON GLOBALS)

3

Configuration (continued)

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3.5

PERCEPT.SRC

This KRL program file must be stored in the directory C:\KRC\roboter\R1\TP\percep-
tron. Communication between the application program and the measurement system is

carried out via the PERCEPT(...) function.

Make sure that the assignment of inputs and outputs to the measurement system

corresponds to the signal allocation in the $IOSYS.INI file (see also Section 3.3).

Serial Sensor Interface

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4

Functions of the Perceptronâ

â

â

â laser measurement system

The format for a measurement system function call reads as follows:

PERCEPT (CMD,PARA1,PARA2,PARA3,PARA4,STATUS)
(All components are integers)

If an unrecognized number is used for a command, the feedback parameter STATUS has

the value 1000.

4.1

Triggering a measuring procedure

This function sends the “start measuring procedure” message to the measurement system;

this is confirmed with the “start measuring procedure confirmation” message if the

connection and the measurement system are in order and ready for operation.

The system then waits for the “measuring procedure complete” message; once this is

received the “measuring procedure complete confirmation” message is sent back.

In the event of problems with the connection, you can increase the variable TIMEOUT

(cf. also Section 3.2).

CMD

1

Command number

PARA1

1...40

Space model number of measured object

PARA2

0...255

Number of sensors

PARA3

0...65535

Color

PARA4

1...9

Phase of the measurement

STATUS

0

=

OK

1

=

Measurement system switched
off

2

=

Measuring procedure in
progress

3

=

An error has occurred

1001 =

A parameter is outside
the permitted range

1002 =

The format of the message
is incorrect

4

Functions of the Perceptron) laser measurement system (continued)

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4.2

Wait for end of measuring procedure

This command is used if the measuring procedure is triggered by an external host computer

or PLC controller.

The function waits for the “measuring procedure complete” message and, once this is

received, sends back the “measuring procedure complete confirmation” message.

In the event of problems with the connection, you can increase the variable TIMEOUT

(cf. also Section 3.2).

CMD

2

Command number

PARA1

Not used here

PARA2

Not used here

PARA3

Not used here

PARA4

Not used here

STATUS

0

=

OK

1002 =

The format of the message
is incorrect

Any other value means that
an error has occurred

Serial Sensor Interface

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4.3

Read measurement data

This function sends the “communicate workpiece position” message to the measurement

system and then waits for the “communicate workpiece position confirmation” message.

CMD

3

Command number

PARA1

1...40

Space model number of measured object

PARA2

10...98

Visual location number

PARA3

Not used here

PARA4

Not used here

STATUS

0

=

Visual location of the
workpiece completed

1

=

Image information could
not be evaluated

2

=

Deviation of workpiece
position greater than
75% of the defined
tolerance value

3

=

Deviation of workpiece
position outside tolerance
range

4

=

Visual location was not
possible

5

=

Results of visual
location not known

6

=

Visual location sent
manually

7

=

Backup location
sent

9

=

Average location
sent

1001 =

A parameter is outside
the permitted range

1002 =

The format of the message
is incorrect

Once the confirmation message has been received, the global structure PERCEPT_KOR

contains in its components X, Y, Z, A, B and C the result of the measuring procedure.

PERCEPT_KOR.X; offset in x [-99.999...99.999 mm]

PERCEPT_KOR.Y; offset in y [-99.999...99.999 mm]

PERCEPT_KOR.Z; offset in z [-99.999...99.999 mm]

PERCEPT_KOR.A; rotation about z [-32.769...32.767 degrees]

PERCEPT_KOR.B; rotation about y [-32.769...32.767 degrees]

PERCEPT_KOR.C; rotation about x [-32.769...32.767 degrees]

4

Functions of the Perceptron) laser measurement system (continued)

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4.4

Calculate measurement result

This function sends the “calculate measurement result” message to the measurement

system and then waits for the “calculate measurement result confirmation” message.

CMD

4

Command number

PARA1

1...40

Space model number of measured object

PARA2

‘A’...‘L’

Zone

PARA3

1...9

Calculation formula

PARA4

Not used here

STATUS

0

=

OK

1

=

An error has occurred,
calculation could
not be carried out

999 =

Calculation formula not
selected or not available

1001 =

A parameter is outside
the permitted range

1002 =

The format of the message
is incorrect

The global variable PERCEPT_REL contains the result of the calculation.

4.5

Measurement start

This function sends the “measurement start” message to the measurement system and then

waits for the “measurement start confirmation” message, but not for the “measurement com-

plete” message. This is used to initialize the measurement system for measuring individual

points.

CMD

5

Command number

PARA1

1...40

Space model number of measured object

PARA2

0...255

Number of sensors

PARA3

0...65535

Color

PARA4

1...9

Phase of the measurement

STATUS

0

=

OK

1

=

Measurement system switched
off

2

=

Measurement system
currently in operation

3

=

An error has occurred

1001 =

A parameter is outside
the permitted range

1002 =

The format of the message
is incorrect

Serial Sensor Interface

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4.6

Start individual point measurement

This function sends the “start individual point measurement” message to the measurement

system. This begins with the measuring procedure and sends the “start individual point

measurement confirmation” message which is received by the function.

CMD

6

Command number

PARA1

1...999

Measurement point number

PARA2

Not used here

PARA3

Not used here

PARA4

Not used here

STATUS

0

=

OK

1-255=

An error has occurred

999 =

Sensor not switched
on or not present,
or point no. invalid

4.7

Measurement end

This function sends the “measurement end” message to the measurement system and then

waits for the “measurement complete” message. It then sends the “measurement complete

confirmation” message.
This message is sent when all individual point measurements have been completed.

CMD

7

Command number

PARA1

Not used here

PARA2

Not used here

PARA3

Not used here

PARA4

Not used here

STATUS

0

=

OK

1002 =

The format of the message
is incorrect

Any other value means that
an error has occurred

4

Functions of the Perceptron) laser measurement system (continued)

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4.8

Send sensor angle

This function sends a message to the measurement system communicating, by means of

the 3 rotational angles A, B and C, the orientation of a sensor mounted on the robot flange.

The system variable $POS_ACT is evaluated in this way. If $TOOL and $BASE are entered

or determined correctly, by means of tool calibration or manual entry of the values, there is

no need for the time--consuming determination of sensor angles and SWEEP area. The

desired values are determined by the kinematic chain.

CMD

8

Command number

PARA1

Not used here

PARA2

Not used here

PARA3

Not used here

PARA4

Not used here

STATUS

Not used here

Serial Sensor Interface

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5

Example programs

DEF

PERCPRO ( )

$BASE=$NULLFRAME
PTP

{A1 0,A2 -90,A3 90,A4 0,A5 0,A6 0}

LOOP

; Perceptron relation number
; model

39

zone ’B’

; relation number

5

PERCEPT(4,39,”B”,5,0,ERGEBNIS)

IF ERGEBNIS <> 0 THEN
HALT
ENDIF

; Perceptron measurement start with:
; model

39

partner 120

; color

41234

PHASE

8

PERCEPT(1,39,120,41234,8,ERGEBNIS)

IF ERGEBNIS <> 0 THEN
HALT
ENDIF

; Perceptron measurement start with:
; model

39

partner 120

; color

41234

PHASE

7

PERCEPT(1,39,120,41234,7,ERGEBNIS)

IF ERGEBNIS <> 0 THEN
HALT
ENDIF

; Perceptron get measurement data with:
; model

39

FIXTURE 87

PERCEPT(3,39,87,0,0,ERGEBNIS)

; only for test

$BASE=$NULLFRAME

; make base correction

$BASE=$BASE:PERCEPT_KOR

; fit in

PTP

{X 1025.0,Y 0.0,Z 1480.0,A 90.0,B 90.0,C 90.0}

; testhalt

HALT

ENDLOOP

END

5

Example programs (continued)

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This program demonstrates how a robot fitted with a Perceptron sensor follows a moving

measurement point.

DEF

FOLLOW ( )

INT ERG

POS P=$NULLFRAME

$BASE =$NULLFRAME

$TOOL=NULLFRAME

;move to start point
PTP

{A1 10,A2 -50,A3 120,A4 0,A5 13,A6 0}

;convert start point to Cartesian coordinates
P=$POS_ACT

LOOP

;start measurement cycle with model 3 and a partner
PERCEPT(5,3,1,0,0,ERG)

;start measurement, point 1
PERCEPT(6,1,0,0,0,ERG)

;end measurement cycle
PERCEPT(7,0,0,0,0,ERG)

;fetch measurement data for model 3 and coordinate direc-
tions 10
PERCEPT(3,3,10,0,0,ERG)

;check the vision system data

*)

IF (PERCEPT_KOR.X > 5.0) OR (PERCEPT_KOR.X < -5.0) THEN *)
;error reaction

*)

...
...
ENDIF

;correct start point by possible offset
P.X=P.X+PERCEPT_KOR.X
P.Y=P.Y+PERCEPT_KOR.Y
P.Z=P.Z+PERCEPT_KOR.Z

;follow measurement point

PTP P

ENDLOOP

END

*) The ranges of values for the vision system data (PERCEPT_KOR.X ...)

must undergo a plausibility test in the application program.

The limit values entered in the above program are given as an example.

1

Index

Index -- i

Symbols

$BASE, 15
$CONFIG.DAT, 8
$POS_ACT, 15
$TOOL, 15

Numbers

3964R, 5, 7

H

HW_INF.INI, 7

I

IOSYS.INI, 8

L

Laser measurement system, 10

M

MFC, 8

P

PERCEPT.INI, 7
PERCEPT.SRC, 9

R

Reinstallation, 6
RS232, 5
RS422, 5

T

TIMEOUT, 10, 11

U

Uninstallation, 6
Update, 6

V

VxWorks, 7