KUKA系统软件8.2操作手册：集成商指南

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KUKA System Software 8.2 是一份针对系统集成商的详细操作和编程指南，由 KUKA Roboter GmbH 发布，日期为 2011 年 11 月 2 日。这份文档版本为 KSS8.2 SIV3 en，包含了关于 KUKA 机器人系统的最新软件配置，旨在帮助用户理解和操控 KUKA 机器人控制器。该软件覆盖了核心功能的描述，但也可能包含一些未在文档中详述的可操作功能，用户在替换或进行服务工作时应予以注意。版权信息表明，未经 KUKA Roboter GmbH 明确许可，不得复制或向第三方披露此文档或其部分。尽管文档内容经过了与所述硬件和软件的一致性检查，但仍然可能存在差异，因此不能完全保证完全符合，KUKA 方会定期更新文档以修正任何错误，并确保技术更新不影响功能。翻译自原始文档，这份资料可能是 KUKA Intelligent Motion Programming (KIM-PS5) 的一部分，它强调了用户在使用过程中应遵循的官方指导，以确保机器人操作的稳定性和安全性。对于系统集成工程师来说，理解并遵守这些指示至关重要，因为它们涉及到编程、调试、维护和优化 KUKA 机器人的高效运行流程。 KUKA System Software 8.2 提供的功能包括但不限于运动控制、编程接口、安全措施、通信协议以及故障诊断工具。通过学习和应用这份文档，集成商能够更好地集成 KUKA 机器人到生产线中，实现自动化任务的精准执行和灵活性。值得注意的是，这份文档可能会涉及高级编程概念，如CNC编程、FANUC或西门子PLC接口，以及KUKA Robot Language (KRL)的使用。用户在操作之前，应确保对这些技术有基本的理解，或者至少能参考配套的培训材料和在线支持资源。 KUKA System Software 8.2 是一个关键资源，对于提升KUKA机器人系统的性能和安全性，以及避免潜在问题的出现，具有重要的指导价值。阅读和遵循其中的规则是进行有效系统集成和维护的关键步骤。

16 / 391 Issued: 02.11.2011 Version: KSS 8.2 SI V3 en

KUKA System Software 8.2

Additional technology packages, containing application-specific instructions

and configurations, can be installed.

smartHMI The user interface of the KUKA System Software is called KUKA smartHMI

(smart Human-Machine Interface).

Features:

 User administration

 Program editor

 KRL (KUKA Robot Language)

 Inline forms for programming

 Message display

 Configuration window

 etc.

(>>> 4.2 "KUKA smartHMI user interface" Page 45)

Depending on customer-specific settings, the user interface may vary

from the standard interface.

17 / 391Issued: 02.11.2011 Version: KSS 8.2 SI V3 en

3 Safety

3.1 General

3.1.1 Liability

The device described in this document is either an industrial robot or a com-

ponent thereof.

Components of the industrial robot:

 Manipulator

 Robot controller

 Teach pendant

 Connecting cables

 External axes (optional)

e.g. linear unit, turn-tilt table, positioner

 Software

 Options, accessories

The industrial robot is built using state-of-the-art technology and in accor-

dance with the recognized safety rules. Nevertheless, misuse of the industrial

robot may constitute a risk to life and limb or cause damage to the industrial

robot and to other material property.

The industrial robot may only be used in perfect technical condition in accor-

dance with its intended use and only by safety-conscious persons who are ful-

ly aware of the risks involved in its operation. Use of the industrial robot is

subject to compliance with this document and with the declaration of incorpo-

ration supplied together with the industrial robot. Any functional disorders af-

fecting the safety of the industrial robot must be rectified immediately.

Safety infor-

mation

Safety information cannot be held against KUKA Roboter GmbH. Even if all

safety instructions are followed, this is not a guarantee that the industrial robot

will not cause personal injuries or material damage.

No modifications may be carried out to the industrial robot without the autho-

rization of KUKA Roboter GmbH. Additional components (tools, software,

etc.), not supplied by KUKA Roboter GmbH, may be integrated into the indus-

trial robot. The user is liable for any damage these components may cause to

the industrial robot or to other material property.

In addition to the Safety chapter, this document contains further safety instruc-

tions. These must also be observed.

3.1.2 Intended use of the industrial robot

The industrial robot is intended exclusively for the use designated in the “Pur-

pose” chapter of the operating instructions or assembly instructions.

Using the industrial robot for any other or additional purpose is considered im-

permissible misuse. The manufacturer cannot be held liable for any damage

resulting from such use. The risk lies entirely with the user.

Operating the industrial robot and its options within the limits of its intended

use also involves observance of the operating and assembly instructions for

Further information is contained in the “Purpose” chapter of the oper-

ating instructions or assembly instructions of the industrial robot.

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KUKA System Software 8.2

the individual components, with particular reference to the maintenance spec-

ifications.

Misuse Any use or application deviating from the intended use is deemed to be imper-

missible misuse. This includes e.g.:

 Transportation of persons and animals

 Use as a climbing aid

 Operation outside the permissible operating parameters

 Use in potentially explosive environments

 Operation without additional safeguards

 Outdoor operation

3.1.3 EC declaration of conformity and declaration of incorporation

This industrial robot constitutes partly completed machinery as defined by the

EC Machinery Directive. The industrial robot may only be put into operation if

the following preconditions are met:

 The industrial robot is integrated into a complete system.

Or: The industrial robot, together with other machinery, constitutes a com-

plete system.

Or: All safety functions and safeguards required for operation in the com-

plete machine as defined by the EC Machinery Directive have been added

to the industrial robot.

 The complete system complies with the EC Machinery Directive. This has

been confirmed by means of an assessment of conformity.

Declaration of

conformity

The system integrator must issue a declaration of conformity for the complete

system in accordance with the Machinery Directive. The declaration of confor-

mity forms the basis for the CE mark for the system. The industrial robot must

be operated in accordance with the applicable national laws, regulations and

standards.

The robot controller is CE certified under the EMC Directive and the Low Volt-

age Directive.

Declaration of

incorporation

The industrial robot as partly completed machinery is supplied with a declara-

tion of incorporation in accordance with Annex II B of the EC Machinery Direc-

tive 2006/42/EC. The assembly instructions and a list of essential

requirements complied with in accordance with Annex I are integral parts of

this declaration of incorporation.

The declaration of incorporation declares that the start-up of the partly com-

pleted machinery remains impermissible until the partly completed machinery

has been incorporated into machinery, or has been assembled with other parts

to form machinery, and this machinery complies with the terms of the EC Ma-

chinery Directive, and the EC declaration of conformity is present in accor-

dance with Annex II A.

The declaration of incorporation, together with its annexes, remains with the

system integrator as an integral part of the technical documentation of the

complete machinery.

3.1.4 Terms used

STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 60204-

1:2006.

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3 Safety

Term Description

Axis range Range of each axis, in degrees or millimeters, within which it may move.

The axis range must be defined for each axis.

Stopping distance Stopping distance = reaction distance + braking distance

The stopping distance is part of the danger zone.

Workspace The manipulator is allowed to move within its workspace. The work-

space is derived from the individual axis ranges.

Operator

(User)

The user of the industrial robot can be the management, employer or

delegated person responsible for use of the industrial robot.

Danger zone The danger zone consists of the workspace and the stopping distances.

KCP The KCP (KUKA Control Panel) teach pendant has all the operator con-

trol and display functions required for operating and programming the

industrial robot.

The KCP variant for the KR C4 is called KUKA smartPAD. The general

term “KCP”, however, is generally used in this documentation.

Manipulator The robot arm and the associated electrical installations

Safety zone The safety zone is situated outside the danger zone.

Safe operational stop The safe operational stop is a standstill monitoring function. It does not

stop the robot motion, but monitors whether the robot axes are station-

ary. If these are moved during the safe operational stop, a safety stop

STOP 0 is triggered.

The safe operational stop can also be triggered externally.

When a safe operational stop is triggered, the robot controller sets an

output to the field bus. The output is set even if not all the axes were sta-

tionary at the time of triggering, thereby causing a safety stop STOP 0 to

be triggered.

Safety STOP 0 A stop that is triggered and executed by the safety controller. The safety

controller immediately switches off the drives and the power supply to

the brakes.

Note: This stop is called safety STOP 0 in this document.

Safety STOP 1 A stop that is triggered and monitored by the safety controller. The brak-

ing process is performed by the non-safety-oriented part of the robot

controller and monitored by the safety controller. As soon as the manip-

ulator is at a standstill, the safety controller switches off the drives and

the power supply to the brakes.

When a safety STOP 1 is triggered, the robot controller sets an output to

the field bus.

The safety STOP 1 can also be triggered externally.

Note: This stop is called safety STOP 1 in this document.

Safety STOP 2 A stop that is triggered and monitored by the safety controller. The brak-

ing process is performed by the non-safety-oriented part of the robot

controller and monitored by the safety controller. The drives remain acti-

vated and the brakes released. As soon as the manipulator is at a stand-

still, a safe operational stop is triggered.

When a safety STOP 2 is triggered, the robot controller sets an output to

the field bus.

The safety STOP 2 can also be triggered externally.

Note: This stop is called safety STOP 2 in this document.

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KUKA System Software 8.2

3.2 Personnel

The following persons or groups of persons are defined for the industrial robot:

 User

 Personnel

User The user must observe the labor laws and regulations. This includes e.g.:

 The user must comply with his monitoring obligations.

 The user must carry out instructions at defined intervals.

Personnel Personnel must be instructed, before any work is commenced, in the type of

work involved and what exactly it entails as well as any hazards which may ex-

ist. Instruction must be carried out regularly. Instruction is also required after

particular incidents or technical modifications.

Personnel includes:

 System integrator

 Operators, subdivided into:

 Start-up, maintenance and service personnel

 Operating personnel

 Cleaning personnel

System integrator The industrial robot is safely integrated into a complete system by the system

integrator.

Stop category 0 The drives are deactivated immediately and the brakes are applied. The

manipulator and any external axes (optional) perform path-oriented

braking.

Note: This stop category is called STOP 0 in this document.

Stop category 1 The manipulator and any external axes (optional) perform path-main-

taining braking. The drives are deactivated after 1 s and the brakes are

applied.

Note: This stop category is called STOP 1 in this document.

Stop category 2 The drives are not deactivated and the brakes are not applied. The

manipulator and any external axes (optional) are braked with a path-

maintaining braking ramp.

Note: This stop category is called STOP 2 in this document.

System integrator

(plant integrator)

System integrators are people who safely integrate the industrial robot

into a complete system and commission it.

T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)

T2 Test mode, Manual High Velocity (> 250 mm/s permissible)

External axis Motion axis which is not part of the manipulator but which is controlled

using the robot controller, e.g. KUKA linear unit, turn-tilt table, Posiflex.

Term Description

All persons working with the industrial robot must have read and un-

derstood the industrial robot documentation, including the safety

chapter.

Installation, exchange, adjustment, operation, maintenance and re-

pair must be performed only as specified in the operating or assembly

instructions for the relevant component of the industrial robot and only

by personnel specially trained for this purpose.

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