SOFTWARE
KR C...
KUKA.Gripper-- and SpotTech 2.2
for KUKA.KR C 5.2, 5.3, 5.4
Issued: 09 Nov 2004 Version: 00
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Installation / uninstallation / update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 GripperTech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Basic gripper functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.1 Type 1 2 outputs, 4 inputs, 2 switching states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.2 Type 2 2 outputs, 2 inputs, 3 switching states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.3 Type 3 2 outputs, 2 inputs, 3 switching states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.4 Type 4 3 outputs, 2 inputs, 3 switching states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.5 Type 5 2 outputs, 4 inputs, 2 switching states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.6 Freely programmable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.6.1 Programming example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.7 Initialization and configuration examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Manually operating a gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Programming gripper functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3.1 Gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3.2 Check Gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 SpotTech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1 Basic SpotTech user functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.1 Range of commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.2 The functions SPOT and RETRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Programming and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.1 General information on programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.1.1 Variables in input boxes of the inline forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.1.2 Overview of the inline forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.2 Spot welding (SPOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.3 Types of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.3.1 Point--to--point (PTP) motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.3.2 Motion along a straight line (LIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.3.3 Motion along a circular path (CIRC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.4 Programming a weld spot (SPOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.4.1 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.4.2 The inline form and the parameter lists for the welding command  SPOT . . . . . . . . . . . . . 23
4.2.4.3 Selecting the welding gun (Gun = n) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2.4.4 Retract stroke after the welding process (RETR OPN / CLO) . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2.4.5 Weld parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2.5 Opening/closing the welding gun retract stroke (RETRACT) . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.5.1 Types of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2.5.2 Programming the retract stroke (RETRACT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2.6 Motion commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.7 Reorientation of the welding gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3 Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3.1 Creating a new program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3.1.1 Welding the first spot sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3.1.2 Welding the second spot sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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4.3.1.3 Moving from the end of the spot seam to the home position . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.4 Altering existing programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.4.1 Altering command lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.4.2 Deleting command lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.4.3 Adding commands to an existing program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.4.3.1 Description of the alteration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4.3.2 Changing the position of the welding gun (point in space P10) . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4.3.3 Reorientation of the welding gun -- inserting the command  Motion (P11) . . . . . . . . . . . . . . 39
4.4.3.4 Moving to the point in space P12 -- inserting the command  Motion . . . . . . . . . . . . . . . . . . . 40
4.4.3.5 Welding spot P13 -- inserting the command  SPOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.3.6 Moving to the weld spot P16 and welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.3.7 Moving to the home position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.5 SpotTech configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5.1 Program sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5.2 Retract stroke (RETRACT) and working stroke (SPOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5.3 Early closing of the gun (PRESPOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.6 Components of the SpotTech package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.6.1 Program structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.6.2 SPOT Tech--specific files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.7 Adaptation to the periphery, configurable options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.7.1 FOLD  SPOT in the file  $CONFIG.DAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.7.2 The user--specific program  USERSPOT.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.7.2.1 Schematic sequence diagram for SPOT (without RETRACT) . . . . . . . . . . . . . . . . . . . . . . . . 47
4.7.2.2 Schematic sequence diagram for SPOT (with RETRACT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.7.2.3 Robot controller -- welding controller interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.7.2.4 Program example for the file  USERSPOT.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.8 Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.9 Manual operation of the welding gun using the status keys . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.9.1 Separate control of RETRACT and SPOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.9.1.1 Definition of function type and assignment of physical outputs . . . . . . . . . . . . . . . . . . . . . . . . 53
4.9.2 Manual control of RETRACT and SPOT in series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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KUKA.Gripper-- and SpotTech 2.2
1 General
The software packages GripperTech and SpotTech are supplied together on a Setup CD and
expand the scope of the basic KRC software.
-- The functions of the GripperTech technology package (gripper programming) enable the
robot system to control and monitor tools and devices in its work environment.
-- The SpotTech technology package is used for the convenient programming of spot welding
applications.
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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 .
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KUKA.Gripper-- and SpotTech 2.2
3 GripperTech
3.1 Basic gripper functions
The GripperTech technology package includes five basic types of gripper control, with whose
logic functions the majority of applications that occur are covered. If these basic types prove
to be insufficient at any time, any additional gripper functions can be freely programmed.
Each gripper must be assigned a function type. If a gripper is to be temporarily or
permanently excluded from use, it must be assigned gripper type  0 .
3.1.1 Type 1 2 outputs, 4 inputs, 2 switching states
e.g. a simple gripper with the functions OPEN and CLOSE;
State OUT1 OUT2 IN1 IN2 IN3 IN4
A TRUE FALSE TRUE FALSE TRUE FALSE
B FALSE TRUE FALSE TRUE FALSE TRUE
3.1.2 Type 2 2 outputs, 2 inputs, 3 switching states
e.g. a slide with a center position;
State OUT1 OUT2 IN1 IN2
A TRUE FALSE TRUE FALSE
B FALSE TRUE FALSE TRUE
C FALSE FALSE FALSE FALSE
3.1.3 Type 3 2 outputs, 2 inputs, 3 switching states
e.g. a vacuum gripper with the functions VACUUM, BLOW and OFF;
State OUT1 OUT2 IN1 IN2
A TRUE FALSE TRUE FALSE
B FALSE TRUE FALSE TRUE
C FALSE FALSE FALSE FALSE
3.1.4 Type 4 3 outputs, 2 inputs, 3 switching states
The same as type 3 but with three control outputs (type 3 has two outputs);
State OUT1 OUT2 OUT3 IN1 IN2
A TRUE FALSE FALSE TRUE FALSE
B FALSE TRUE TRUE FALSE TRUE
C FALSE TRUE FALSE FALSE FALSE
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3.1.5 Type 5 2 outputs, 4 inputs, 2 switching states
The same as type 1 but with a pulse signal instead of a continuous signal.
State OUT1 OUT2 IN1 IN2 IN3 IN4
A TRUE FALSE TRUE FALSE TRUE FALSE
B FALSE TRUE FALSE TRUE FALSE TRUE
In contrast to gripper type 1, a continuous signal is not applied here, but a pulse of variable
duration is transmitted whenever the signal level changes. It is set by modifying the variable
GRP_PULSE_TI.
During controller operation, this variable can be altered by means of the  Modify --  Variable
options in the  Monitor menu.
More detailed information on how to modify the values of system variables during controller
operation can be found in the chapter  Monitor Functions , section  Variables .
3.1.6 Freely programmable type
A freely programmable gripper type has been integrated in order to cover all user require-
ments. Any number of completely freely definable grippers can be configured by means of
entries in the files $CONFIG.DAT, USERGRP.DAT and USER_GRP.SRC.
3.1.6.1 Programming example
Requirement
A welding gun is to switch between the positions OPEN -- RETRACT -- WORKING STROKE
-- RETRACT -- OPEN when the status key  Manual gripper operation is pressed.
OPEN RETRACT WORKING STROKE RETRACT OPEN
Position  A Position  B Position  C Position  B Position  A
This task requires the use of two double--acting pneumatic cylinders controlled via electro-
magnetically operated 4/2--way valves.
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KUKA.Gripper-- and SpotTech 2.2
Retract cylinder Working stroke cylinder
Output 1 Output 2 Output 3 Output 4
State Control
Out- Out- Out- Out-
put1 put2 put3 put4
A FALSE TRUE FALSE TRUE
B TRUE FALSE FALSE TRUE
C TRUE FALSE TRUE FALSE
Programming
In order to implement the example described, make the following changes or additions to the
data shown below.
Entries in the file  $CONFIG.DAT
The freely programmable gripper is defined with the identification number  100 .
;==================================
; Definition of grippers
;==================================
DECL GRP_TYPES GRIPPER[8]
GRIPPER[1]={TYPE 100}
Entries in the file  $USER_GRP.DAT :
&ACCESS RP
&COMMENT USER GRIPPER package
DEFDAT USER_GRP
...
ENUM GUN_STAT RET_OPN,RET_CLS,WRK_CLS,WRK_OPN
Data type, enumeration of gun states:
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STRUC MY_GUN INT RET_OPN,RET_CLS,WRK_OPN,WRK_CLS,GUN_STAT
STAT
Structure of the user--defined data type  MY_GUN :
DECL MY_GUN MY_GUN1={RET_OPN 100,RET_CLS 101,WRK_OPN
102,WRK_CLS 103,STAT #RET_OPN}
Assignment of outputs for the welding gun  MY_GUN1 of type  MY_GUN :
...
ENDDAT
Entries in the file  USER_GRP.SRC
DEF GRP_MANUAL ( ) ;=================
;part for manual functions
;=====================================
SWITCH GRIPPER[G_NO].TYPE ;switch type of gripper
;end of example for new gripper
CASE 100
$OUT[MY_GUN1.RET_OPN]=FALSE Reset output
$OUT[MY_GUN1.RET_CLS]=FALSE Reset output
$OUT[MY_GUN1.WRK_OPN]=FALSE Reset output
$OUT[MY_GUN1.WRK_CLS]=FALSE Reset output
SWITCH MY_GUN1.STAT Start of the control structure
CASE #RET_OPN If the state of the gun
MY_GUN1.STAT has the value
#RET_OPN (retract stroke
open)
PULSE($OUT[MY_GUN1.RET_CLS],TRUE,0.3) send a 0.3 second
pulse to the output
RET_CLS (retract stroke
closes)
MY_GUN1.STAT=#RET_CLS set the state of the gun
MY_GUN1.STAT to
#RET_CLS (retract
stroke closed)
CASE #RET_CLS If the state of the gun
MY_GUN1.STAT has the value
#RET_CLS (retract stroke
closed)
PULSE($OUT[MY_GUN1.WRK_CLS],TRUE,0.3) send a 0.3 second
pulse to the output
WRK_CLS (working
stroke closes)
MY_GUN1.STAT=#WRK_CLS set the state of the gun
MY_GUN1.STAT
to #WRK_CLS (working
stroke closed)
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KUKA.Gripper-- and SpotTech 2.2
CASE #WRK_CLS If the state of the gun
MY_GUN1.STAT has the value
WRK_CLS (working stroke
closed)
PULSE($OUT[MY_GUN1.WRK_OPN],TRUE,0.3) send a 0.3 second
pulse to the output
WRK_OPN (working
stroke opens)
MY_GUN1.STAT=#WRK_OPN set the state of the gun
MY_GUN1.STAT to
#WRK_OPN (working
stroke open)
CASE #WRK_OPN If the state of the gun
MY_GUN1.STAT has the value
#WRK_OPN (working stroke
open)
PULSE($OUT[MY_GUN1.RET_OPN],TRUE,0.3) send a 0.3 second
pulse to the output
RET_OPN (retract stroke
opens)
MY_GUN1.STAT=#RET_OPN set the state of the gun
MY_GUN1.STAT to
#RET_OPN (retract
stroke open)
DEFAULT If none of the states listed so
far appears, execute the
following instructions
ENDSWITCH End of the control structure
...
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3.1.7 Initialization and configuration examples
On switching to state  A
Example_1
(Open), output 17 will be set
to TRUE and output 18
(inverted) also to TRUE.
Not defined
When scanned, input 22
must have the state TRUE
and input 23 the state FALSE
17
so that the motion program
can continue.
--18
0
On switching to state  B
0
(Closed), output 17 will be
set to FALSE and output 18
(inverted) also to FALSE.
22
When scanned, input 22
must have the state FALSE
23
and input 23 the state TRUE
0
so that the motion program
can continue.
0
On switching to state  A
Example_2
(Open), output 19 will be set
to TRUE and output 21 to
FALSE. When scanned,
Not defined
input 22 must have the state
TRUE, input 23 (inverted)
the state TRUE, input 24 the
19
state TRUE and input 25
21 (inverted) also the state
TRUE so that the motion
0
program can continue.
0
On switching to state  B
(Closed), output 19 will be
22
set to FALSE and output 21
to TRUE. When scanned,
--23
input 22 must have the state
24
FALSE, input 23 (inverted)
also the state FALSE, input
--25
24 the state FALSE and input
25 (inverted) also the state
FALSE so that the motion
program can continue.
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KUKA.Gripper-- and SpotTech 2.2
3.2 Manually operating a gripper
A configured gripper can only be operated in the modes:
G TEST1 (reduced velocity) or
G TEST2 (programmed velocity),
with an enabling switch being held down.
Use the top status key shown on the left to select from the configured grippers the one that
you would like to operate.
You can then switch between the gripper functions using the bottom status key shown on the
left.
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3.3 Programming gripper functions
Pay attention to the position of the edit
cursor. The next program line created
by you will be inserted as a new line
after the cursor.
3.3.1 Gripper
Open the menu using the menu key  Technology . Then select  GRIPPERTech . The follow-
ing submenu is displayed:
As a gripper function is to be programmed, confirm the offered selection  Gripper .
An inline form for entering the parameters that are required for executing a gripper function
is opened in the programming window.
The assignment of the softkey bar changes at the same time:
It is possible to abort programming of the gripper function at any time by pressing the softkey
 Cmd Abort or the ESC key. The command will not be saved in this case.
If the programming window is in focus, the various input windows can be selected using the
  and   arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The programming window can be activated by repeatedly pressing the  Window selection
key until the entire window is highlighted in color.
Move the cursor to the input box  SET . The status key (at the bottom right of the display)
changes its assignment.
You can choose between the configured grippers using this status key.
Move the cursor to the input box  State . The status key (at the bottom right of the display)
changes its assignment.
You can use this status key to choose between the functions that have been defined for the
selected gripper.
Move the cursor to the next input box on the right. The status key (at the bottom right of the
display) changes its assignment.
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KUKA.Gripper-- and SpotTech 2.2
The approximate positioning function can be switched on or off using this status key.
If you switch the approximation function off, a further input box,  GDATn , appears on
the right, in this case GDAT1.
If the cursor is moved to this box with the   arrow key, a status window is opened.
Data that more precisely characterize the gripper function must be entered here.
Activate this status window using the  Window selection key.
Decide at this point whether any sensors that may be fitted on the gripper are to be
interrogated or whether a wait time is to be used to ensure that the functions that have been
programmed are fully executed.
Wait Time:
If  Check Gripper is switched off because, for example, it is not possible to interrogate the
sensors, a wait time of up to ten seconds can be defined here.
Check Gripper:
Here you can specify whether the sensors on the gripper are to be interrogated before the
robot starts moving again (it is only possible to interrogate the sensors if approximate
positioning is switched off in this block). If the sensors do not return a status message, the
controller allows you to set the inputs so that execution of the program can continue
unhindered.
Only use this simulation if you are sure that it cannot result in any unexpected
situations!
If you switch the approximation function on, two further input boxes,  at and  Delay , appear
on the right.
Other than in the case of the gripper function without approximation, the robot does
not stop here after reaching the end point in order to activate the gripper.
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Motion block
1
Motion block
End point
1
The gripper function
End point
is executed along
Execute gripper
this line
function
End point
Motion block
Motion block
2
2
End point
With approximate
Without approximate
positioning
positioning
The parameters START, END and Delay are used to define the point at which the
gripper function is executed.
START
Delay
positive
Delay
END
negative
The reference point for activation of the gripper is determined using the status key (at
the bottom, to the right of the display).
Then move the cursor to the box  Delay . You can enter a value here, using the
numeric keypad, or change the default value by increments of 1 ms using the status
key (at the bottom, to the right of the display).
Then press the softkey  Cmd Ok . The gripper function is now fully programmed and saved.
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KUKA.Gripper-- and SpotTech 2.2
3.3.2 Check Gripper
This command is only executed if it is located before a motion instruction.
Any sensors fitted on the gripper can be interrogated using this command. If the conditions
defined by the function type and configuration of the gripper are not satisfied, the robot stops
moving. It does not continue the motion program until the conditions are met.
Now open the menu by means of the menu key  Technology . Then select  GRIPPERTech .
(The menu items contained in this menu depend on the specific software configuration.)
As a gripper sensor interrogation is to be programmed, select the option  Check Gripper .
The inline form for entering the parameters that are required for executing a gripper sensor
interrogation is opened in the programming window.
The assignment of the softkey bar changes at the same time:
It is possible to abort programming of the gripper sensor interrogation at any time by pressing
the softkey  Cmd Abort or the ESC key. The command will not be saved in this case.
If the programming window is in focus, the various input windows can be selected using the
  and   arrow keys. The window that is currently selected is highlighted by a color back-
ground.
The programming window can be activated by repeatedly pressing the  Window selection
key until the entire window is highlighted in color.
Move the cursor to the input box  CHECK . The status key (at the bottom right of the display)
changes its assignment.
You can choose between the configured grippers using this status key.
Move the cursor to the input box  State . The status key (at the bottom right of the display)
changes its assignment.
You can use this status key to choose between the functions that have been defined for the
selected gripper.
Move the cursor to the input box  at . The status key (at the bottom right of the display)
changes its assignment.
The reference point for the gripper interrogation is determined using this status key.
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Motion block
1
The gripper function
End point
is executed along
this line
End point
Motion block
2
The parameters START, END and Delay are used to define the point at which the gripper
function is executed.
START
Delay
positive
Delay
END
negative
Then move the cursor to the box  Delay . You can enter a value here, using the numeric
keypad, or change the default value by increments of 1 ms using the status key (at the
bottom, to the right of the display).
Then press the softkey  Cmd Ok . The gripper interrogation function is now fully programmed
and saved.
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KUKA.Gripper-- and SpotTech 2.2
4 SpotTech
4.1 Basic SpotTech user functions
Once the technology package has been correctly installed, additional commands are
available in the SpotTech package for spot welding applications.
4.1.1 Range of commands
An initialization command and two program commands, which are used to control the
welding equipment, are basically available for spot welding. These are:
G INI
This initialization command is automatically entered at the beginning of each new
program that is to be created (skeleton program). This sets the basic parameters for the
robot and the application program and initializes the welding and motion commands and
approximate positioning.
G SPOT
The command  SPOT controls the robot motion to a weld spot, and the welding process.
The opening and closing of the welding gun retract stroke after the welding process can
also be programmed by means of this command.
G RETRACT
The command  RETRACT controls the robot motion to any point, and the opening and
closing of the welding gun retract stroke after reaching the end point. This function is
required, for example, if access to weld spots or auxiliary points with the retract stroke
of the welding gun fully open or closed is impeded by obstructing contours.
Motions that do not include a welding operation and do not change the state of the welding
gun retract stroke or which are used for reorientating the welding gun are programmed by
means of a command belonging to the group  Motion .
4.1.2 The functions SPOT and RETRACT
The SpotTech basic functions  SPOT and  RETRACT are shown in the following sketch.
Welding gun
Component
Retract stroke open Welding process
Retract stroke closed
 RETR OPN  RETR CLO  SPOT
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Retract stroke
Working stroke
4.2 Programming and operation
This section describes how to create spot welding programs and how to program welding
and motion commands. It also contains information on everything that has to be taken into
account when setting individual parameters.
SpotTech has a universal basic structure and each of the programming possibilities given
here is dependent on the welding equipment and user--specific subprograms that are used.
4.2.1 General information on programming
4.2.1.1 Variables in input boxes of the inline forms
The inline forms contain a series of input boxes, whose designations are freely selectable.
This applies to the boxes
P1 ... Designation of the end point
PDAT1 ..., CPDAT1 ... Designation of the  Movement parameters data set
SDAT1 ... Designation of the  Weld parameters data set
The following must always be observed:
-- The designation can consist of letters and numbers. Special characters apart from the
underscore  _ cannot be used.
-- The first character of a designation must always be a letter.
-- The designation is entered unchanged as a pure character string into all of the
subsequent program lines.
-- If the last character is a number, the value of this number is automatically incremented
(n+1), e.g.  SDAT1 ,  SDAT2 ...  SDATn or  SEAM_FRONT1 ,  SEAM_FRONT2
...  SEAM_FRONT99 , in the subsequent commands.
If a number is entered at the end of the designation -- this number being incremented (n+1)
in each subsequent command -- please remember that the number of characters increases
by 1 when going from 9 to 10.
4.2.1.2 Overview of the inline forms
The following sections contain screenshots of the inline forms assigned to each of the
 SpotTech commands, showing both the input boxes and the parameter lists that can be
opened in the status window if the cursor is moved to the appropriate box in the inline form.
The operator control elements and symbols that are used here are explained below:
If the inline form is active, the desired input box can be selected by means of the arrow keys.
The selected box is displayed in white lettering on a blue background.
The operator control elements shown below the inline form are intended to be an additional
aid to familiarize you with the possibilities of making entries in inline forms and parameter
lists. These have the meanings described below:
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KUKA.Gripper-- and SpotTech 2.2
If the cursor is positioned in the appropriate box of the inline form, the bottom right status key
can be used to alter the parameters or to select data sets that have already been defined.
It is possible to both enter and alter commands and parameters by means of the keypad (by
pressing the initial letter of the command/parameter).
This symbol indicates that a parameter list (movement or weld parameters) is assigned to
the input box in the inline form. The status window together with the appropriate parameter
list is activated when the  Window selection key on the graphical user interface is pressed.
This softkey (which is only available when a parameter list is active in the status window) is
used to exit the status window and activate the corresponding input box in the inline form.
4.2.2 Spot welding (SPOT)
The command  SPOT controls the robot motion to a weld spot, and the welding process.
It can also be used to control the opening and closing of the welding gun retract stroke
(RETRACT) after the welding process.
This command primarily contains the type of motion (PTP, LIN, CIRC), the designation of the
weld spot (Pn), the movement parameters (PDATn or CDATn), the weld parameters
(SDATn) and the designation of the welding gun (Gun= n).
4.2.3 Types of motion
Three types of motion can be selected for the command  SPOT :  PTP ,  LIN and  CIRC .
Since the robot must be exactly positioned to each weld spot, the  approximate positioning
function is not included.
4.2.3.1 Point--to--point (PTP) motion
PTP (point--to--point) motion allows the robot to be moved to the end position at the highest
possible velocity. This motion is the most efficient. For spot welding seams, most robot
motions between the individual weld spots are generally executed as PTP motions.
However, it must be remembered that:
The path cannot be predicted exactly for PTP motions! The motion characteristics
of the robot with greater distances between points and near obstacles should
therefore be checked in a test run.
4.2.3.2 Motion along a straight line (LIN)
LIN (linear) motions are used whenever the robot has to follow an exact path to the end point.
4.2.3.3 Motion along a circular path (CIRC)
In the case of CIRC motions, the welding gun is moved along a circular path. This type of
motion is selected whenever the gun cannot be positioned to the end point using a linear
motion.
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4.2.4 Programming a weld spot (SPOT)
4.2.4.1 Menu
After selecting the relevant option ( SPOT Tech -- SPOT -- PTP in this example) by means
of the menu key  Technology , the inline form described in the next section is opened.
4.2.4.2 The inline form and the parameter lists for the welding command  SPOT
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KUKA.Gripper-- and SpotTech 2.2
Frames
Example of a
weld parameter list
Tool coordinate Early closing of
system the welding gun
Base coordinate
system
Ext. TCP
Timer program for
 True or  False
the 1st gun pair
Pressure for
the 1st gun pair
LIN/CIRC PTP
LIN/CIRC
PTP motion
motion
Velocity Velocity
(0.001 to 2 m/s) (1 to 100 %)
Acceleration
Acceleration
(1 to 100 %)
(1 to 100 %)
Softkey bar when the inline form is active
Softkey bar when a parameter list is active
You can switch to the commands  RETRACT or  Motion and change the motion type
(PTP, LIN or CIRC) at any time during programming, until this is concluded using  Cmd Ok .
Brief description of the input boxes of the inline form (from left to right), their functions and
their range of values where applicable:
Box Function Range of values, Comments
PTP, LIN, CIRC
PTP Type of motion
Change using bottom right status
key, softkey or keypad.
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Freely selectable
Designation of the end point;
with CIRC motions, a further
Change the designation Pn by
P2
input box is available for the
using the keypad or the bottom
auxiliary point.
right status key.
Designation of the movement Freely selectable (see Section
PDAT2
parameters 4.2.1.1).
SPOT Gun= 1 Designation of the welding gun Select from up to 5 guns.
Retract stroke after the welding CLO=retract stroke closed
RETR OPN
process (RETRACT) OPN = retract stroke open
Designation of the weld parame- Freely selectable (see Section
SDAT1
ters 4.2.1.1).
4.2.4.3 Selecting the welding gun (Gun = n)
It is possible to select from up to 5 welding guns. This is dependent on the welding equipment
that is used.
4.2.4.4 Retract stroke after the welding process (RETR OPN / CLO)
In this input box, you define whether the welding gun retract stroke is to be open or closed
after the welding process.
Welding gun
Component
Retract
Retract stroke closed
stroke open
 RETR OPN  RETR CLO
You can switch between  Retract stroke open (RETR OPN) and  Retract stroke closed
(RETR CLO) by pressing the bottom right status key. This status key has a toggle function
in this instance. The pulldown menu will be opened and closed automatically after a short
time. Alternatively, the respective initial letter ( O = OPN = open;  C = CLO = closed) can
be entered by means of the keypad. The cursor must be positioned in the input box next to
 RETR in this case.
4.2.4.5 Weld parameter list
Due to the universal basic structure of the spot welding technology, the parameters for the
welding data can be adapted individually to the requirements of both the user and the welding
equipment that is used.
The option of closing the welding gun early is described below on the basis of a spot welding
application.
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Retract stroke
Working stroke
KUKA.Gripper-- and SpotTech 2.2
Early closing of the welding gun
(early closing time)
-- 1000 to 0 milliseconds
Working stroke
Start of early
closing of gun
Weld spot
position Pn
reached
Early closing
distance
Pn
Gun closed
The point of closing the gun early (early closing time) is to optimize the time taken to execute
the spot welding process. Whilst the welding gun is still moving to the weld spot, the closing
operation is already starting. In this instance, it must be ensured that the gun is not closed
completely until just after the end position Pn is reached.
Variations in air pressure, the position of the gun and other factors may produce different
opening and closing times for the gun. The closing time of the welding gun must therefore
be checked in a test run. Closing the gun too early while the robot is still moving results in
the weld spot being incorrectly positioned and may cause the component and the tool to
be damaged!
4.2.5 Opening/closing the welding gun retract stroke (RETRACT)
The command  RETRACT controls the robot motion to any point, and the opening and
closing of the welding gun retract stroke. This function is required, for example, if access to
weld spots or auxiliary points with the gun fully open or closed as far as the working stroke,
is impeded by obstructing contours.
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Early closing time
In addition to the type of motion (PTP, LIN, CIRC), the name of the end point (Pn), the
movement parameters (PDATn or CDATn) and the designation of the welding gun (Gun= n),
this command also contains an instruction specifying whether the gun retract stroke is to be
open (OPN) or closed (CLO) after the end point has been reached.
4.2.5.1 Types of motion
Three types of motion can be selected for the command  RETRACT :  PTP ,  LIN and
 CIRC . Approximate positioning is not possible; the robot is exactly positioned to each point.
Further details on this are given in Section 4.2.3.
4.2.5.2 Programming the retract stroke (RETRACT)
Menu (The menu items contained depend on the specific software configuration.)
After selecting the relevant option by means of the menu key  Technology ( SPOT Tech --
RETRACT -- PTP in this example), the inline form described in the next section is opened.
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KUKA.Gripper-- and SpotTech 2.2
The inline form and the parameter lists for the command  RETRACT
Frames
Tool coordinate
system
Base coordinate
system
Ext. TCP
 True or  False
LIN/CIRC
PTP
LIN/CIRC
PTP motion
motion
Velocity
Velocity
(0.001 to 2 m/s)
(1 to 100 %)
Acceleration
Acceleration
(1 to 100 %)
(1 to 100 %)
Softkey bar when the inline form is active
Softkey bar when a parameter list is active
You can switch to the commands  SPOT or  Motion and change the motion type (PTP,
LIN or CIRC) at any time during programming, until this is concluded using  Cmd Ok .
Brief description of the input boxes of the inline form (from left to right), their functions and
their range of values where applicable:
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Box Function Range of values, Comments
PTP, LIN, CIRC
PTP Type of motion
Change using bottom right status
key, softkey or keypad
Freely selectable
Designation of the end point;
with CIRC motions, a further
Change the designation Pn by
P1
input box is included for the
using the keypad or the bottom
auxiliary point.
right status key.
Designation of the movement
PDAT1 Freely selectable
parameters.
OPN = retract stroke open
Retract stroke after reaching the
RETR OPN
end point.
CLO=retract stroke closed
SPOT Gun= 1 Designation of the welding gun Select from up to 5 guns.
Retract stroke after reaching the end point (RETR OPN / CLO)
In this box, you define whether the welding gun retract stroke is to be open or closed after
the end point has been reached.
Welding gun
Component
Retract
Retract stroke closed
stroke open
 RETR OPN  RETR CLO
You can switch between  Retract stroke open (RETR OPN) and  Retract stroke closed
(RETR CLO) by pressing the bottom right status key. This status key has a toggle function
in this instance. The pulldown menu will be opened and closed automatically after a short
time. Alternatively, the respective initial letter ( O = OPN = open;  C = CLO = closed) can
be entered by means of the keypad. The cursor must be positioned in the input box next to
 RETR in this case.
4.2.6 Motion commands
Motions of the tool which do not feature a welding operation and which do not change the
welding gun retract stroke can be programmed by means of the command  Motion from the
 Commands menu.
A corresponding inline form is opened by means of the softkey  Motion , with the motion type
(PTP, LIN or CIRC) that was predefined with the last command being displayed; this must
be changed, if necessary.
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Retract stroke
Working stroke
KUKA.Gripper-- and SpotTech 2.2
4.2.7 Reorientation of the welding gun
Pn
(P2)
Pn
(P3)
P4
P1
P3
P2
Reorientation of the
welding gun by 90
If the spot welding plane changes -- as shown in the sketch above -- the welding gun must
be reorientated. To do so, the gun must first be moved into a position (P2) where there is no
risk of it colliding with the component or with other obstructing contours during reorientation.
The reorientation (point in space P2 to P3) is carried out using the command  Motion -- LIN
or -- if the gun retract stroke (RETRACT) is to be changed during the same operation --  SPOT
Tech --  RETRACT --  LIN (see Section 4.2.5). The gun can subsequently be positioned
to the next weld spot (P4).
Depending on the position of the robot axes, it may also be possible to select a PTP motion.
As PTP motions cannot be predicted exactly, a test run should be carried out.
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4.3 Program example
In this section, the use of the basic commands of the spot welding technology will be
described step by step on the basis of a simple program example. The assembly shown
below, consisting of three individual parts, is to be fabricated by means of spot welding.
Home
position
4.3.1 Creating a new program
To create a new program, press the softkey  New and enter a program name (e.g.  Test )
in the input box.
Now press the softkey  Select . The following skeleton program is displayed in the program-
ming window:
Pay attention to the position of the edit cursor. The following program line created by you will
be inserted as a new line after the cursor.
Alternatively, you can program in edit mode by means of the softkey  Edit . The syntax will
not be checked, however.
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KUKA.Gripper-- and SpotTech 2.2
The first weld spot
Home
position
When moving the welding gun from the home position to the first weld spot, it must be
ensured that no obstructing contours (e.g. those of the component) can cause a collision.
For example, the path of the PTP motion cannot be exactly predicted! The motion
characteristics of the robot near obstacles should therefore always be checked in a test
run.
The diagram given below shows a collision situation on the left. As can be seen in the
situation on the right, you can ensure that the welding gun is positioned safely to the first weld
spot (P2) by inserting an additional point in space (P1).
1st weld
End
Risk of a colli-
Point in space P1
spot P2
position
sion with the
Component
component! Component
Home Home
position position
PTP
motion
Inserting an additional point
Positioning the welding gun
in space
directly to the end point
If the motion between the point in space P1 and the first weld spot (P2) is executed as a
PTP motion, the distance between these two points should not be too great. The robot can
use approximate positioning for moving from the home position to P2 via P1 because exact
positioning is not required until the welding gun moves to the position of the weld spot.
Moving from the home position to the point in space P1 --  RETRACT
The welding gun is moved from the home position to the point in space P1 by means of a
PTP motion. During the same operation, you ensure that the retract stroke is open after the
point has been reached.
Press the menu key  Technology and select the options shown below (menu items in white
lettering on a blue background):
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After selecting the command  SPOT Tech -- RETRACT -- PTP , the following inline form is
opened on the screen:
If the programming window is active, the input boxes can be selected by means of the arrow
keys. The selected box appears in white lettering on a blue background.
At the same time that the inline form given above is opened, the assignment of the softkey
bar changes to that shown below:
You can also correct your original selection ( SPOT ,  Motion and type of motion) by means
of this softkey. The inline form changes accordingly when a selection is made. The command
can be aborted by means of the softkey  Cmd Abort or the ESC key. This will close the inline
form.
The welding gun retract stroke must be open after the point in space P1 has been reached.
This is set in the input box  RETR . In the example given above,  OPN (open) is already
entered; otherwise,  CLO (closed) appears here.
To change the setting, move the cursor to the input box  RETR . You can
switch between  RETR CLO and  RETR OPN by means of the bottom right
status key. This status key has a toggle function. Alternatively, the letter  C
(=closed) or  O (=open) can be entered by means of the keypad. In this case,
enter  O .
For the purpose of positioning the welding gun, move it to the position P1 by means of the
Space Mouse or the traversing keys. Information on controlling motions of the robot manually
can be found in the chapter [Manual traversing of the robot].
You can now press the softkey  Touch Up . In this case, press the softkey  Yes to confirm
the query  Touchup (Y/N)? that is displayed in the message window. Alternatively, press the
softkey  Cmd Ok or the Enter key. The current robot coordinates are automatically saved.
The command is ended by pressing the softkey  Cmd Ok or the Enter key. If the point P1
has not yet been touched up, the current robot coordinates are now automatically saved. The
information message  Point P1 created automatically is displayed in the message window.
The inline form is closed and the generated program line is inserted into the program form
afterwards. The numbers of the following program lines are automatically updated.
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KUKA.Gripper-- and SpotTech 2.2
Setting the first weld spot (SPOT)
A PTP motion is used to move the welding gun from the point in space P1 to the weld spot
P2. The gun is exactly positioned to point P2 where the welding process will then be
executed. Since a sequence of further spot welds follows P2, the retract stroke can remain
closed.
Press the menu key  Technology and select the options shown below (menu items in white
lettering on a blue background):
After selecting the command  SPOT Tech --  SPOT --  PTP , the following inline form
appears on the display.
Alternatively, you can also press the softkey  Last Cmd . If you had last entered a
 RETRACT command, an inline form for the command  RETRACT is displayed.  SPOT
can then be called by means of the softkey  SPOT . The same inline form is thus available.
As can be seen, the names for the end point (P2) and the data set (PDAT2) have been
adapted. A further box is also displayed: the designation of the weld parameter set (SDAT1).
The welding gun retract stroke can be left closed ( RETR CLO ) in this program example.
If the first command to be entered was  RETR OPN (retract stroke open), this has been used
as a default setting in the input box of the new inline form.
To change the setting, move the cursor to the input box  RETR . Press the bottom right status
key or enter the letter  C by means of the keypad.  CLO (=closed) subsequently appears
in the input box of the inline form.
Enter the movement and weld parameters into both the inline form and the parameter lists
and move the welding gun to the desired position P2.
If your welding system has been configured appropriately, the functioning of the gun can be
checked at this point by means of the gun status keys. For information on this, see Section
4.9 and the chapter [SPOT Tech -- Expert Programming].
After entering all of the parameters, press the softkey  Cmd Ok . The current robot
coordinates are saved and the program form is updated accordingly.
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4.3.1.1 Welding the first spot sequence
P5
P4 P3 P2
RETR OPN RETR CLO
The further points (P3 to P5) can be programmed using the procedure described in the last
section. In this case, leave the welding gun retract stroke closed (RETR CLO) for P3 and P4.
As the welding gun is to be positioned to the first weld spot (P6) of the second welding
sequence (see the sketch at the beginning of Section 4) after P5, the retract stroke must be
opened at P5. To do so, select the option  RETR OPN when programming P5.
After all of the entries for the first spot sequence have been made, the program form appears
as follows:
As can be seen, the numeric values for the designation of the movement parameters
(PDATn) have each been increased by 1 in command lines 4 to 7. The numeric values for
the designation of the weld parameters (SDATn) have likewise been increased. The parame-
ters entered in  SDAT1 have automatically been entered in  SDAT2 ....  SDAT4 .
For spot sequences that are to be welded with the same welding tool and the same weld
parameters, programming can be simplified if each weld spot is not programmed
individually but by using the procedure described below:
G Program the first weld spot of the sequence.
G Determine the number of spots that are to be welded after the first spot.
G Press the softkey  Last Cmd and then the softkey  Cmd Ok .
Repeat this according to the number of weld spots.
G To save the robot coordinates, subsequently move the edit cursor (vertical line) to the
appropriate line of the program form in sequence. Position the robot manually to the
respective point, press the softkey  Touch Up and confirm the request for confirmation
to save the coordinates. The current robot coordinates are saved for the point that is
currently selected.
With the motion type  CIRC , the coordinates for the required auxiliary point must always
be touched up manually.
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KUKA.Gripper-- and SpotTech 2.2
4.3.1.2 Welding the second spot sequence
The second spot sequence begins at P6. A PTP motion can be used between the weld spots
P5 and P6 as the distance between them is small and the welding gun retract stroke is open.
The weld spot P6 can be programmed in the program example given above.
Now program the weld spots P7 to P9 following the description given in the previous section.
Select the option  RETR OPN again for the last weld spot (P9) to open the welding gun
retract stroke after P9 has been welded.
4.3.1.3 Moving from the end of the spot seam to the home position
To move the welding gun back to the home position, a further point in space outside the
component is required so that a collision is safely avoided. This is P10 in this program
example, where it is assumed that there are no obstacles between P10 and the home
position.
The path between the weld spot P9 and the point in space P10 is executed as a  PTP motion.
Press the softkey  Motion . An inline form is opened:
After entering the parameters, press the key  Cmd Ok .
Alternatively, this motion can also be programmed by means of the command  SPOT Tech
--  RETRACT --  PTP .
The motion from P10 to the home position ( PTP -- HOME ) is already included in the
skeleton program. Programming of this program example is thus completed.
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4.4 Altering existing programs
It is possible to alter commands and/or parameters and to delete command lines in an
existing program at any time. Two examples are given below.
4.4.1 Altering command lines
The procedure for altering command lines is demonstrated below by using a different type
of motion for the command  SPOT -- RETRACT to the point in space P1 to that used in the
above program example. The parameter  PTP for P1 is to be changed to  LIN .
Move the edit cursor to line 3 by means of the arrow keys.
Press the softkey  Change . The inline form for this command line is opened. Move the cursor
to the first input box on the left.
Press the bottom right status key until  LIN appears in the input box.
Then press the softkey  Cmd Ok . The inline form is closed and the program form is updated
accordingly.
4.4.2 Deleting command lines
The motion command that appears in line 13 of the program form given below (P11) is to be
deleted. To do so, move the edit cursor to line 13.
Press the menu key  Program
and select  Delete by means of the arrow key. Then press the Enter key. The key  1 in the
numeric keypad can also be pressed (do not press Enter).
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KUKA.Gripper-- and SpotTech 2.2
Line 13 has been deleted and the original line 14 is now line 13.
4.4.3 Adding commands to an existing program
The procedure for adding commands to an existing program is given below. A further part
is added to the welded assembly described in Section 4.3:
Home
position
Reorientation of
the welding gun
by 90
The new part is welded to the two brackets by means of two spots (P13 and P16 in the
diagram). As the welding gun has to be reorientated by 90 to weld these two spots in relation
to welding the spot sequences P2 to P5 and P6 to P9, it is advisable to weld them before
welding spot sequences P2 to P9.
In this example, these two spots are to be welded after weld spot P9. This requires the follow-
ing changes to be made to the program:
-- Alter the command  Motion (P10)
-- Insert the command  Motion (P11) to reorientate the welding gun
-- Insert the command  Motion (P12)
-- Insert the command  SPOT -- SPOT (P13)
-- Insert the command  Motion (P14)
-- Insert the command  Motion (P15)
-- Insert the command  SPOT -- SPOT (P16)
-- Insert the command  RETRACT (P17)
-- Insert the command  Motion (P18)
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4.4.3.1 Description of the alteration
Open the program form from the previous section.
4.4.3.2 Changing the position of the welding gun (point in space P10)
Move the edit cursor to line 12. Position the welding gun to the point in space P10. When
doing so, ensure that it cannot collide with the component or with other obstructing contours
during the following reorientation to P11. Press the softkey  Touch Up to save the new robot
coordinates.
4.4.3.3 Reorientation of the welding gun -- inserting the command  Motion (P11)
P10
P11
Ensure that the edit cursor is positioned in line 12 (P10). An inline form is opened by pressing
the softkey  Motion .
Select themotiontype LIN . UsethetraversingkeysortheSpaceMousetoalignthewelding
gun accordingly (rotate by 90 ). Save the current robot coordinates (Touch Up) and press
the softkey  Cmd Ok after entering all the parameters.
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KUKA.Gripper-- and SpotTech 2.2
4.4.3.4 Moving to the point in space P12 -- inserting the command  Motion
Now insert the command  Motion -- PTP to move the welding gun to the point in space P12,
which is located above the weld spot P13.
4.4.3.5 Welding spot P13 -- inserting the command  SPOT
Select  SPOT Tech --  SPOT --  PTP . Select the option  RETR OPN in the inline form,
enter the required parameters and close the inline form with  Cmd Ok .
4.4.3.6 Moving to the weld spot P16 and welding
The welding gun is moved to the weld spot P16 via the points in space P14 and P15. Two
PTP motions are programmed from P13 to P14 and from P14 to P15. The appropriate inline
forms are shown below:
This is followed by the welding command  SPOT Tech --  SPOT --  PTP :
4.4.3.7 Moving to the home position
The welding gun is moved to the home position via the points in space P17 and P18. The
motions from P16 to P17 and from P17 to P18 are to be programmed. The motion to  PTP
-- HOME is already included in the skeleton program.
Alteration of the program is now completed.
The altered line 12 (P10) and the new lines 13 to 20 (P11 to P18) are indicated by the white
line on the left in the diagram.
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4.5 SpotTech configuration
Configuration of the SpotTech software package is only possible in expert mode.
4.5.1 Program sequence
The following diagram shows the basic sequence of a spot welding program between two
weld spots.
Trigger Trigger
Weld spot P
(n--1)
PRESPOT SPOT
or starting point Weld spot
Pn
RETRACT Retract open
(if programmed)
Working
stroke open
ADVSPOT
Robot
motion
Time t t
Communication with the
welding controller (e.g.
ADVSPOT
setting program parameters)
t
Gun closing time
PRESPOT
t
SPOT
t
Weld
Weld start
Weld complete
duration
WLD_CMP WLD_STRT (weld start --
weld complete)
The usable functions depend on the type of welding gun used as well as its controller. The
individual functions:
Name Description
Retract stroke Retract stroke of the welding gun. Completely opens the gun, for
RETRACT example, to approach weld spots over component edges.
Working stroke of the welding gun. The working stroke is generally
Working stroke
sufficient for spot sequences along even surfaces.
Advance communication with the welding controller (during gun
ADVSPOT movement) so that all required weld data are available when the end
point is reached.
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Early closing of the gun; programmable in the parameter list  Selec-
PRESPOT tion . The closing operation already starts while the welding gun is
still moving to the weld spot.
The actual welding process, initiated with the  Weld start command
SPOT (WLD_STRT) to the welding periphery until the arrival of the  Weld
complete signal (WLD_CMP).
4.5.2 Retract stroke (RETRACT) and working stroke (SPOT)
The basic SpotTech functions  SPOT and  RETRACT are shown schematically in the
following sketch.
Welding gun
Component
Retract stroke open Retract stroke closed Workingstrokeclosed
 RETR OPN  RETR CLO  SPOT
4.5.3 Early closing of the gun (PRESPOT)
The  PRESPOT function allows the gun to close while the welding gun is moving to the end
point.
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Retract stroke
Working stroke
Trigger for early gun
Working stroke
closing (PRESPOT)
TRIGGER WHEN DISTANCE=1
DELAY=SSDAT1.CLO_TM DO
USERSPOT(#PRESPOT,S_ACT)
PRIO= -1
Weld spot
position Pn
reached
Early closing
distance
Welding gun
closed
Pn
Trigger for weld start
TRIGGER WHEN DISTANCE=1
DELAY=0.0 DO USERSPOT
(#SPOT,S_ACT) PRIO= -1
The point of closing the gun early (PRESPOT) is to optimize the time taken to execute the
spot welding process. The closing operation already starts while the welding gun is still
moving towards the weld spot. In this instance, it must be ensured that the gun is not closed
completely until just after the end position Pn is reached.
Variations in air pressure, the orientation of the gun and other factors may produce different
gun opening and closing times. The closing time of the welding gun must therefore be
checked in a test run. Closing the gun too early while the robot is still moving results in the
weld spot being incorrectly positioned and may cause the component and the tool to be
damaged!
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Early closing time
KUKA.Gripper-- and SpotTech 2.2
4.6 Components of the SpotTech package
4.6.1 Program structure
The interface to the welding controller is implemented in the form of a configurable
 handshake . The settings and assignments of the physical inputs and outputs are defined
in the file  $CONFIG.DAT .
In the following block diagram the program structure of the KR C1 robot controller is shown
in the  Spot welding robot configuration.
SPS.SUB
$CONFIG.DAT CELL.SRC
DEF SPS()
CWRITE (.. .RUN
Technology--
/R1/CELL() )
USERSPOT
specific
organization
PACKAGE LOOP
program
...
ENDLOOP
. . .
Part 1 Part 2 Part n
*.SRC *.SRC *.SRC
*.DAT *.DAT *.DAT
BAS(...) BAS(...) BAS(...)
H50(...) H50(...) H50(...)
USERSPOT USERSPOT USERSPOT
H50.SRC BAS.SRC USERSPOT.SRC P00.SRC IR_STOPM.SRC
Functions
Functions Functions Functions Routines for
for
for gripper for robot for spot handling
Automatic
control motion welding faults
External
KR C1 program structure
4.6.2 SPOT Tech--specific files
The following files, which are included in the  SPOT Tech package, are required for
executing spot welding applications. You will always see the symbols shown on the left with
the file names throughout this document whenever the corresponding file or parts of it are
described.
$CONFIG.DAT Contains data specific to SPOT Tech within the Fold
 USERSPOT .
USERSPOT.SRC This file is supplied as a skeleton program. This is where you enter
data for your own spot welding programs, e.g. for initializing, for
RETRACT, ADVSPOT, SPOT, etc.
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4.7 Adaptation to the periphery, configurable options
This section describes the SpotTech peripheral interfaces with an example illustrating the
assignment of the digital outputs and inputs. The Fold  USERSPOT contained in the file
 $CONFIG.DAT as well as the file  USERSPOT.SRC are described.
4.7.1 FOLD  SPOT in the file  $CONFIG.DAT
The Fold  SPOT from the file  $CONFIG.DAT is shown below.
;FOLD SPOT GLOBALS;
;==================================
; Structures:
;==================================
ENUM S_COMMAND SPOT,RETR,PRESPOT,INIT,ADVSPOT Branch
 SWITCH CMD
in file
 USERSPOT.SRC C
ENUM S_PAIR_SLCT FIRST,SECOND,BOTH Gun--specific
parameters
STRUC SPOT_SUGG_T CHAR GUN[24],RETR_CMD[24],CHOISE[24],CLO_TM[24],
PGNO1[24],PRESS1[24],PGNO2[24],PRESS2[24],SPOT_PARAMS[24]
STRUC SPOT_TYPE INT GUN,S_PAIR_SLCT PAIR,COMMAND RETR,INT CLO_TM,
INT PGNO1,REAL PRESS1,INT PGNO2,REAL PRESS2
;==============================
; External declarations:
;==============================
EXT USERSPOT (S_COMMAND :IN,SPOT_TYPE :IN )
;==============================
; Variables:
;==============================
DECL SPOT_TYPE SDEFAULT={GUN 1,PAIR Default data set
#FIRST,RETR #OPN,CLO_TM 0,PGNO1 1, for SPOT
PRESS1 0.0,PGNO2 0,PRESS2 0.0}
DECL SPOT_TYPE S_ACT Global variables
DECL INT S_ACT_DELAY that are used in
DECL BOOL S_READY the robot program.
INT BOSCHCMD_OK=534
INT BOSCHSTAT_OK=528
;==============================
; all for Bosch-Serial-Interface
;==============================
EXT BOSCH (INT :IN,INT :IN,INT :OUT )
; BOSCH-OUTWORD 1 (513-528) param
SIGNAL BOSCHPAR $OUT[513] TO $OUT[528]
; BOSCH-OUTWORD 2 (529-544) command
SIGNAL BOSCHCMD $OUT[529] TO $OUT[533]
; BOSCH-INWORD 1 (513-528) status+validbit
SIGNAL BOSCHSTAT $IN[513] TO $IN[527]
;ENDFOLD
If adaptation to the peripheral hardware used is required, please consult the corresponding
documentation.
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KUKA.Gripper-- and SpotTech 2.2
4.7.2 The user--specific program  USERSPOT.SRC
The skeleton program  USERSPOT.SRC provided in the SpotTech technology package
serves as the framework for applications individually tailored to the welding equipment being
used. In the following sections, you will find examples of the configuration options available.
&COMMENT USERSPOT package
DEF USERSPOT (CMD :IN,S :IN )
;********************************
; USERSPOT - Package KR C1
; R2.2.x
; Date: 23.03.98
;
;********************************
DECL S_COMMAND CMD
DECL SPOT_TYPE S
SWITCH CMD
CASE #INIT Initialization (contained in INI FOLD)
INIT ( )
CASE #ADVSPOT Call during advance run
ADVSPOT (CMD,S )
CASE #PRESPOT Triggering of early closing of
PRESPOT (CMD,S ) the welding gun
CASE #SPOT Triggering  Weld start at
SPOT (CMD,S ) weld spot position
S_READY=TRUE Enable for further program execution
CASE #RETR Gun retract stroke (RETRACT)
RETRACT (CMD,S )
S_READY=TRUE
ENDSWITCH
END ; END OF MAIN
;*****************************
DEF ADVSPOT (CMD :IN,S :IN ) User data for  ADVSPOT
DECL S_COMMAND CMD
DECL SPOT_TYPE S
END ;(ADVSPOT)
;*****************************
DEF PRESPOT (CMD :IN,S :IN ) User data for  PRESPOT
DECL S_COMMAND CMD
DECL SPOT_TYPE S
END ;(PRESPOT)
;*****************************
DEF SPOT (CMD :IN,S :IN ) User data for  SPOT
DECL S_COMMAND CMD
DECL SPOT_TYPE S
END ;(SPOT)
;*****************************
DEF RETRACT (CMD :IN,S :IN ) User data for  RETRACT
DECL S_COMMAND CMD
DECL SPOT_TYPE S
END ;(RETR)
;*****************************
DEF INIT ( ) User data for  INIT
END ;(INIT)
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4.7.2.1 Schematic sequence diagram for SPOT (without RETRACT)
The following diagram shows the basic program sequence of the command  SPOT . The
options  PRESPOT (early closing of the gun) and  RETRACT (open/close retract stroke
of the gun) are not shown.
Weld parameter S01
S02
(Auxiliary point)
designation
Robot
motion
t
GUN_WRK
Working stroke
OPEN
activation
(output)
t
CLOSE
WRK_STAT
Working stroke OPEN
status
(input)
t
CLOSE
WLD_STRT
TRUE
Weld start
(output)
t
FALSE
WLD_CMP
Weld TRUE
complete
(input)
t
FALSE
ADVSPOT
PNUM
S.PGN01
Program
number
(output)
t
0
After welding the spot  S01 the weld complete signal (WLD_CMP=TRUE) triggers, with its
falling edge (WLD_CMP=FALSE), the instruction for opening the working stroke of the
welding gun (GUN_WRK=G_OPN). At the same time the weld start signal
 WLD_STRT=FALSE as well as the program number  PNUM=0 are set.
The robot controller now waits for the status message  WRK_STAT==G_OPN indicating
that the working stroke of the gun is open. This signal enables robot movement to the next
weld spot.
To ensure that all the data required for welding are available at the end point (in this example
point  S02 ), the welding program number, for example  PNUM=S.PGN01 , is already output
during the actual movement, provided this has been configured in the section  ADVSPOT
of the file  USERSPOT.SRC .
At the end point (in this example point  S02 ), the control instruction is given to close the
working stroke (GUN_WRK=W_CLO). The status message from the welding controller that
the working stroke is closed (WRK_STAT=W_CLO) triggers the weld start
(WLD_STRT=TRUE).
At the conclusion of the welding process, the instruction is given once again, by means of
the falling edge of the weld complete signal (WLD_CMP=FALSE), to open the working stroke
of the gun (GUN_WRK=G_OPN) as well as to set the weld start signal  WLD_STRT to
FALSE and the program number  PNUM to ZERO.
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KUKA.Gripper-- and SpotTech 2.2
4.7.2.2 Schematic sequence diagram for SPOT (with RETRACT)
S01 S02
(Auxiliary point)
Robot
t
t
motion
With PRESPOT
GUN_RET
Retract stroke OPEN
activation
(output)
t
t
CLOSE
If  RETR OPN
RET_STAT
selected
OPEN
Retract stroke
status
(input)
t
t
CLOSE
If  RETR CLO
GUN_WRK
selected
OPEN
Working stroke
activation
(output)
t
CLOSE
WRK_STAT
Working stroke OPEN
status
(input)
t
CLOSE
WLD_STRT
TRUE
Weld start
(output)
t
FALSE
WLD_CMP
TRUE
Weld
complete
(input)
t
FALSE
ADVSPOT
PNUM
TRUE S.PGN01
Program
number
(output)
t
FALSE
0
After welding the spot  S01 the weld complete signal (WLD_CMP=TRUE) triggers, with its
falling edge (WLD_CMP=FALSE), the instruction for opening the working stroke of the
welding gun (GUN_WRK=G_OPN). At the same time the weld start signal
 WLD_STRT=FALSE as well as the program number  PNUM=0 are set.
When the status message  WRK_STAT==G_OPN is given, indicating that the working
stroke of the gun is open, movement is initiated to the next weld spot, provided the option
 RETR CLO (gun retract stroke remains closed) has been programmed with the SPOT
command.
If the option  RETR OPN has been programmed (the gun retract stroke is opened after the
spot has been welded), the command  GUN_RET=G_OPN is executed. In this case,
movement to the next weld spot is not enabled until the status signal  RET_STAT=OPEN
is set. During this movement, the welding program number (PNUM) is output if this has been
configured in the section  ADVSPOT of the file  USERSPOT.SRC .
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At the end point (in this example point  S02 ), the control instruction is given to close the
working stroke (GUN_WRK=CLOSE). The welding program number (PNUM) is output at the
same time. If the retract stroke at point  S02 is open (RET_STAT=OPEN), the
corresponding close instruction (GUN_RET=CLOSE) is given first of course.
The status message from the welding controller that the working stroke is closed
(WRK_STAT=W_CLO) triggers the weld start (WLD_STRT=TRUE). At the conclusion of the
welding process, an instruction is given once again by means of the weld complete signal
(WLD_CMP) to open the working stroke of the gun (GUN_WRK=G_OPN).
4.7.2.3 Robot controller -- welding controller interface
The following table provides an overview of the configurable physical inputs and outputs. The
addresses refer to the extension of the file  USERSPOT.SRC shown in Section 4.7.2.4.
Output / Input
Name Description, signal states
(example)
PNUM Welding program no. (max. 255 characters) Output 1 ... 8
WLD_STRT Weld start Output 15
WLD_CMP Weld complete signal (from welding controller) Input 15
Working stroke control (SPOT)
Close stroke Open stroke
GUN WRK
GUN_WRK
TRUE FALSE Output 10
FALSE TRUE Output 11
Working stroke status message (SPOT)
Stroke closed Stroke open
WRK STAT
WRK_STAT
TRUE FALSE Input 10
FALSE TRUE Input 11
Retract stroke control (RETRACT)
Close stroke Open stroke
GUN RET
GUN_RET
TRUE FALSE Output 12
FALSE TRUE Output 13
Retract stroke status message (RETRACT)
Stroke closed Stroke open
RET STAT
RET_STAT
TRUE FALSE Input 12
FALSE TRUE Input 13
4.7.2.4 Program example for the file  USERSPOT.SRC
&COMMENT USERSPOT package
DEF USERSPOT (CMD :IN,S :IN )
;********************************
; USERSPOT - Package KR C1
; R2.2.x
; Date: 23.03.98
; Example No 1
; SPOT / RETRACT
;********************************
DECL S_COMMAND CMD
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KUKA.Gripper-- and SpotTech 2.2
DECL SPOT_TYPE S
Assignment of inputs/outputs
;Program No.
SIGNAL PNUM $OUT[1] TO $OUT[8] Program number, outputs 1...8
;GUN-RETRACT
SIGNAL GUN_RET $OUT[10] TO $OUT[11] Retract stroke (RETRACT),
outputs 10, 11
;State RETRACT
SIGNAL RET_STAT $IN[10] TO $IN[11] Retract stroke status, inputs 10, 11
;GUN work (SPOT)
SIGNAL GUN_WRK $OUT[12] TO $OUT[13] Workingstroke(SPOT),
outputs 12, 13
;State SPOT
SIGNAL WRK_STAT $IN[12] TO $IN[13] Working stroke status, inputs 12, 13
;Weld Start
SIGNAL WLD_STRT $OUT[15] Weld start, output 15
;Weld done
SIGNAL WLD_CMP $IN[15] Weld complete signal, input 15
;=================================
;GROUP Definitions
INT R_CLO,R_OPN,W_CLO,W_OPN Retract stroke / working stroke states
R_CLO= B0001
R_OPN= B0010
W_CLO= B0001
W_OPN= B0010
;=================================
SWITCH CMD
CASE #INIT
INIT ( )
CASE #ADVSPOT
ADVSPOT (CMD,S )
CASE #PRESPOT
PRESPOT (CMD,S )
CASE #SPOT
SPOT (CMD,S )
S_READY=TRUE
CASE #RETR
RETRACT (CMD,S )
S_READY=TRUE
ENDSWITCH
END ; END OF MAIN
;*********************************
DEF ADVSPOT (CMD :IN,S :IN )
WLD_STRT=FALSE Reset weld start
PNUM=S.PGNO1 Issue program number
END ;(ADVSPOT)
;*****************************
DEF PRESPOT (CMD :IN,S :IN )
GUN_RET=R_CLO Close retract stroke (RETRACT)
WAIT FOR RET_STAT==R_CLO Waiting for  Retract closed
GUN_WRK=W_CLO Close working stroke
END ;(PRESPOT)
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;*****************************
DEF SPOT ( )
WAIT FOR WRK_STAT==W_CLO Waiting for  Working stroke closed
WLD_STRT=TRUE Set weld start
WAIT FOR WLD_CMP Waiting for weld complete
signal (TRUE)
PNUM=0 Set program number to ZERO
WAIT FOR NOT (WLD_CMP) Waiting for weld complete
signal (FALSE)
WLD_STRT=FALSE Reset weld start (FALSE)
GUN_WRK=W_OPN Open working stroke
WAIT FOR WRK_STAT==W_OPN Waiting for  Working stroke open
SWITCH S.RETR If  RETR OPN programmed
CASE #OPN after weld spot:
GUN_RET=R_OPN open retract stroke (RETRACT)
WAIT FOR RET_STAT==R_OPN Waiting for  Retract stroke open
ENDSWITCH
END ;(SPOT)
;*****************************
DEF RETRACT ( )
SWITCH S.RETR Retract stroke (RETRACT)
CASE #OPN If  RETR OPN programmed:
GUN_RET=R_OPN open retract stroke (RETRACT)
WAIT FOR RET_STAT==R_OPN Waiting for  Retract stroke open
CASE #CLO If  RETR CLO programmed:
GUN_RET=R_CLO close retract stroke
WAIT FOR RET_STAT==R_CLO Waiting for  Retract stroke closed
ENDSWITCH
END ;(RETR)
;*****************************
DEF INIT ( )
PNUM=0 Set program number to ZERO
WLD_STRT=FALSE Reset weld start
GUN_WRK=W_OPN Open working stroke (SPOT)
WAIT FOR WRK_STAT==W_OPN Waiting for  Working stroke open
GUN_RET=R_OPN Open retract stroke (RETRACT)
WAIT FOR RET_STAT==R_OPN Waiting for  Retract stroke open
S_READY=TRUE Enable for further program execution
END ;(INIT)
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KUKA.Gripper-- and SpotTech 2.2
4.8 Program example
A simple demonstration program (for example, DEMO01.SRC) for welding a single spot is
described in the following. Add the command  SPOT Tech -- SPOT -- PTP to a skeleton
program as shown in program line 4 below.
Now move the edit cursor to line 4 and select  FOLD --  Act FOLD op/cl with the menu
function  Program (to do so you must be within the user group  Expert ). You will now see
the complete program listing for the entered command.
File  DEMO01.SRC
PTP P1 PDAT1 SPOT Gun= 1 RETR OPN SDAT
PDAT_ACT=PPDAT1
BAS (#PTP_DAT )
FDAT_ACT=FP1 Motion parameters
BAS (#FRAMES )
BAS (#VEL_PTP,PPDAT1.VEL ) Ref. to data set (for
precalculation)
S_ACT.GUN=1 Selection of welding gun (1...5)
S_ACT.PAIR=SDEFAULT.PAIR Selection of gun pair
S_ACT.RETR=#OPN Retract stroke open
S_ACT.CLO_TM=SSDAT1.CLO_TM
S_ACT.PGNO1=SSDAT1.PGNO1 Welding program number
S_ACT.PGNO2=SDEFAULT.PGNO2
S_ACT.PRESS1=SSDAT1.PRESS1
S_ACT.PRESS2=SDEFAULT.PRESS2
S_READY=FALSE
USERSPOT (#ADVSPOT,S_ACT )
TRIGGER WHEN DISTANCE=1 Trigger for gun closing
DELAY=SSDAT1.CLO_TM DO USERSPOT (working stroke)
(#PRESPOT,S_ACT ) PRIO= -1 Trigger for early gun closing
(PRESPOT)
TRIGGER WHEN DISTANCE=1 Trigger for weld start (SS)
DELAY=0.0 DO USERSPOT
(#SPOT,S_ACT) PRIO= -1
PTP XP1
WAIT FOR S_READY
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4.9 Manual operation of the welding gun using the status keys
When carrying out tests, it is useful to be able to test the retract stroke (RETRACT) and
working stroke (SPOT) functions of the gun in addition to the gun movement, without actually
welding.
4.9.1 Separate control of RETRACT and SPOT
The configuration described below allows separate manual control of the gun retract stroke
(RETRACT) and working stroke (SPOT).
Using the  Gripper selection status key, you can choose from the following:
-- Retract stroke (RETRACT) -- ( Gripper ) no. 1 and
-- Working stroke (SPOT) -- ( Gripper ) no. 2
The retract stroke (1) or the working stroke (2) can be controlled corresponding to the
selection you make with the status key for manual gripper operation.
Retract/working stroke selection
Working stroke (SPOT)
Retract stroke (RETRACT)
GUN_RET GUN_WRK
OPEN CLOSE OPEN OPEN CLOSE OPEN
Operation of working stroke
Operation of retract stroke
4.9.1.1 Definition of function type and assignment of physical outputs
The  GRIPPER Tech package provides a number of gripper function types. Two function
types are available for implementing the above configuration:
Function type 1 static outputs (for static valves)
Function type 5 pulse outputs (for pulse valves)
Logic table for function types 1 and 5:
State OUT1 OUT2
A TRUE FALSE
B FALSE TRUE
The changes required in the file  $CONFIG.DAT for manual gun operation are described
below.
Static outputs
Entries in the file  $CONFIG.DAT when using gripper function type 1:
; Definition of grippers
;==================================
INT MAXGRIPPER=8
DECL GRP_TYPES GRIPPER[8]
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KUKA.Gripper-- and SpotTech 2.2
GRIPPER[1]={TYPE 1,OUT1 10,OUT2 11, Retract stroke (RETRACT)
OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, Definition of function type (1) and
IN4 0,GRP_OLD 1} assignment of the physical outputs
(in this example 10 and 11)
GRIPPER[2]={TYPE 1,OUT1 12,OUT2 13, Workingstroke(SPOT)
OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, Definition of function type (1) and
IN4 0,GRP_OLD 1} assignment of the physical outputs
(in this example 12 and 13)
Pulse outputs
Entries in the file  $CONFIG.DAT when using gripper function type 5:
; Definition of grippers
;==================================
INT MAXGRIPPER=8
DECL GRP_TYPES GRIPPER[8]
GRIPPER[1]={TYPE 5,OUT1 10,OUT2 11, Retract stroke (RETRACT)
OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, Definition of function type (5) and
IN4 0,GRP_OLD 1} assignment of the physical outputs
(in this example 10 and 11)
GRIPPER[2]={TYPE 5,OUT1 12,OUT2 13, Workingstroke(SPOT)
OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, Definition of function type (5) and
IN4 0,GRP_OLD 1} assignment of the physical outputs
(in this example 12 and 13)
The pulse duration for function type 5 is preset to 0.5 seconds. It is possible to make a change
at the end of the block  Definition of grippers in the file  $CONFIG.DAT .
REAL GRP_PULSE_TI=0.5 ; pulse time for gripper type 5
Corresponding entry using the menu function  Monitor -- Variable -- Modify :
Variable Default (sec.)
GRP_PULSE_TI 0.500
The inputs (IN1 ... IN4) are not polled in these examples because the mechanical gun
function can be checked visually. For this reason the configuration and addressing of the
physical inputs are irrelevant for the manual gun control function.
In the examples above, the retract stroke control for gripper no. 1 and working stroke
control for gripper no. 2 were assigned. You can also assign other numbers if these
numbers are reserved for other applications, for example.
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The assignment of gripper no. 8, for example, requires the following entry in the file
 $CONFIG.DAT :
GRIPPER[8]={TYPE 1,OUT1 10,OUT2 11, ...
Note that the value of the variable  MAXGRIPPER must be at least as high as the
configured gripper number.  MAXGRIPPER=8 is the default setting.
4.9.2 Manual control of RETRACT and SPOT in series
The following example describes how the retract stroke and working stroke of guns with
4--way valves can be manually controlled. Switching between the following states should be
possible using the status key for manual gripper control:
-- Retract stroke (RETRACT) open, working stroke (SPOT) open
-- Retract stroke closed, working stroke closed
-- Retract stroke closed, working stroke open
Selection of welding gun 1 / 2
GUN_RET OPEN CLOSE CLOSE OPEN
GUN_WRK OPEN CLOSE OPEN OPEN
Operation
Definition of function type and assignment of physical outputs
For implementation of the above configuration, the  GRIPPER Tech H50 package provides
function type 4, with only the outputs 2 and 3 being used.
Logic table of function type 4, outputs 2 and 3:
State OUT2 OUT3
A FALSE FALSE
B TRUE TRUE
C TRUE FALSE
The changes required in the file  $CONFIG.DAT for manual gun operation are described
below.
; Definition of grippers
;==================================
INT MAXGRIPPER=8
DECL GRP_TYPES GRIPPER[8]
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KUKA.Gripper-- and SpotTech 2.2
GRIPPER[1]={TYPE 4,OUT1 10,OUT2 12, Retract (OUT 10) and working stroke
OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, (OUT 12), definition of the function
IN4 0,GRP_OLD 1} type (4) and assignment of the
physical outputs (e.g. 10 and 11)
1
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Index
Zeichen F
$CONFIG.DAT, 9, 10, 44, 45, 53 FOLD, 52
Function type, 8
Zahlen
G
4/2--way valves, 9
GDAT, 16
Gripper sensor interrogation, 18
A
GRIPPERTech, 15, 18
Adding commands, 38
GRP_PULSE_TI, 9
ADVSPOT, 41, 47, 48
Gun, 22
Altering existing programs, 37
Gun opening and closing times, 43
Approximation function, 16
Arrow keys, 15
I
Assignment of inputs/outputs, 50
Identification number, 10
at, 16, 18
INI, 20
Initialization command, 20
B
Initialization and configuration examples, 13
Basic functions, 42
Inline form, 15, 18, 21, 23
BLOW, 8
Inline form RETRACT, 28
Inline form SPOT, 23
Inputs, 45
C
Issue program number, 50
Call during advance run, 46
CASE #ADVSPOT, 46
L
CASE #INIT, 46
CASE #PRESPOT, 46
LIN, 22
CASE #SPOT, 46
CHECK, 18
M
Check Gripper, 16, 18
Manual control of RETRACT and SPOT in se-
CIRC, 22
ries, 55
Cmd Ok, 17
Manual gripper operation, 9
Continuous signal, 9
Manual operation of the welding gun, 53
Creating a new program, 31
Manually operating a gripper, 14
Monitor, 9
D
Default data set, 45 O
Delay, 16, 17, 19
OFF, 8
Deleting command lines, 37
Outputs, 45
Designation of the welding gun, 22
P
E
P1, 21
Early closing of the welding gun, 26
Parameter lists RETRACT, 28
Early closing time, 26 Parameter lists SPOT, 23
Early gun closing, 42 PDAT, 21, 25
Enabling switch, 14 Peripheral interfaces, 45
END, 17, 19 Pneumatic cylinders, 9
Exclusion from use, 8 PRESPOT, 42
Index -- i
Index
Program example, 31, 49, 52 TEST1, 14
Program number output, 50
TEST2, 14
Program sequence, 41
Time optimization, 43
Program structure, 44
Programmed velocity, 14 Trigger for early gun closing, 43, 52
Programming a weld spot, 23
Trigger for weld start, 43, 52
Programming gripper functions, 15
Types of motion, 22, 27
Programming the retract stroke, 27
PTP, 22
Pulse, 9
Pulse outputs, 54
U
R
USER_GRP.DAT, 10
Reduced velocity, 14
Reorientation of the welding gun, 20, 30, 38,
USER_GRP.SRC, 9, 11
39
USERGRP.DAT, 9
Reset weld start, 50
USERSPOT, 45
RETR CLO, 20, 25, 29, 48
RETR OPN, 20, 25, 29, 48
USERSPOT.SRC, 44, 45, 46, 47, 49
RETRACT, 9, 20, 26, 41
Retract stroke, 20, 41, 42, 50
Retract stroke after the welding process, 25
Robot motion to a weld spot, 22
V
S
VACUUM, 8
S_READY, 46, 52
Vacuum gripper, 8
SDAT, 21, 25
Selecting the welding gun, 25 Variables, 9, 45
Sensor interrogation, 16
Sensors, 16
Sequence diagram for SPOT (with RETRACT),
48
W
Sequence diagram for SPOT (without RE-
TRACT), 47
Wait Time, 16
SET, 15
Set program number to ZERO, 51
Weld complete signal, 47, 48, 49, 50
Simulation, 16
Weld parameters, 22, 25
Softkey bar, 15
Weld start, 49, 50
SPOT, 20, 22, 23, 42, 47
SPOT Gun=, 25
Welding gun, 9
Spot welding, 22
Welding gun retract stroke, 22
START, 17, 19
State, 15, 18 Welding process, 20
Static outputs, 53
Welding program number, 47, 49
Status key, 14
WORKING STROKE, 9
System variables, 9
Working stroke, 26, 41, 42, 50
T Working stroke status, 50
Index -- ii