Kuka VisionTech 2.1 Manual 

KUKA.VisionTech 2.1 For KUKA System Software 8.2 For VW System Software 8.2 KUKA Roboter GmbH Issued: 11.10.2013 Version: KST VisionTech 2.1 V1

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 © Copyright 2013 KUKA Roboter GmbH Zugspitzstraße 140 D-86165 Augsburg Germany This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Roboter GmbH. Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work. We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, how- ever, and necessary corrections will be incorporated in the subsequent edition. Subject to technical alterations without an effect on the function. Translation of the original documentation KIM-PS5-DOC Publication: Pub KST VisionTech 2.1 (PDF) en Book structure: KST VisionTech 2.1 V1.1 Version: KST VisionTech 2.1 V1

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 Contents 1 Introduction .................................................................................................. 7 1.1 Industrial robot documentation ................................................................................... 7 1.2 Representation of warnings and notes ...................................................................... 7 1.3 Trademarks ................................................................................................................ 7 1.4 Terms used ................................................................................................................ 8 2 Purpose ........................................................................................................ 9 2.1 Target group .............................................................................................................. 9 2.2 Intended use .............................................................................................................. 9 3 Product description ..................................................................................... 11 3.1 Overview of VisionTech ............................................................................................. 11 3.2 Hardware components ............................................................................................... 12 3.2.1 KUKA GigE switch ................................................................................................ 12 3.2.2 KUKA MXG20 camera .......................................................................................... 16 3.2.3 Connecting cables ................................................................................................ 17 3.2.4 Calibration plates .................................................................................................. 17 4 Technical data .............................................................................................. 19 4.1 KUKA MXG20 camera ............................................................................................... 19 4.2 KUKA GigE switch ..................................................................................................... 20 4.3 Connecting cables ..................................................................................................... 21 4.3.1 Connecting cables, KR C4 .................................................................................... 21 4.3.2 Connecting cables, KR C4 compact ..................................................................... 22 4.4 Dimensions of the camera ......................................................................................... 23 4.5 Dimensions of the extension ...................................................................................... 24 4.6 Plates and labels ........................................................................................................ 24 5 Safety ............................................................................................................ 27 5.1 General safety measures ........................................................................................... 27 5.2 Standards and regulations ......................................................................................... 27 6 Planning ....................................................................................................... 29 6.1 Connecting cables and interfaces .............................................................................. 29 7 Transportation ............................................................................................. 31 7.1 Transportation ............................................................................................................ 31 8 Installation and licensing ............................................................................ 33 8.1 System requirements ................................................................................................. 33 8.2 Installing or updating VisionTech ............................................................................... 33 8.3 Uninstalling VisionTech .............................................................................................. 34 8.4 Licensing VisionTech ................................................................................................. 34 8.4.1 Activating the license ............................................................................................ 34 8.4.2 Repairing the license ............................................................................................ 35 8.4.3 Activating an emergency license .......................................................................... 35 9 Start-up and recommissioning ................................................................... 37 9.1 Start-up for a stationary camera - overview ............................................................... 37 Contents

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 9.2 Start-up for moving cameras - overview .................................................................... 37 9.3 Connecting cameras to the robot controller ............................................................... 38 9.3.1 Networking KR C4 with interface X64, stationary ................................................. 38 9.3.2 Networking KR C4 with cable inlet, stationary ...................................................... 38 9.3.3 Networking KR C4 compact, stationary ................................................................ 39 9.3.4 Networking KR C4 with interface X64, robot-guided ............................................ 39 9.3.5 Networking KR C4 with cable inlet, robot-guided ................................................. 40 9.3.6 Description of the connecting cables .................................................................... 40 9.4 Configuring the Ethernet KRL interface ..................................................................... 43 9.5 Configuring the camera network ................................................................................ 43 9.6 Configuring cameras ................................................................................................. 44 9.7 Aligning camera (stationary) ...................................................................................... 45 9.8 Aligning cameras (moving) ........................................................................................ 45 9.9 Calibrating camera (stationary) ................................................................................. 46 9.9.1 Deleting a calibration plane .................................................................................. 48 9.10 Calibrating cameras (moving) .................................................................................... 48 10 Configuration ............................................................................................... 51 10.1 Configuring a 2D measurement task - overview ........................................................ 51 10.2 Configuring a 3D measurement task - overview ........................................................ 51 10.3 Creating a task and taking images (stationary) ......................................................... 51 10.4 Creating a task and taking images (moving) ............................................................. 52 10.5 Setting up an image processing task in WorkVisual .................................................. 52 10.5.1 Installing the image processing environment ....................................................... 53 10.5.2 Licensing the image processing environment in WorkVisual ............................... 53 10.5.2.1 Activating the license ....................................................................................... 53 10.5.2.2 Repairing the license ....................................................................................... 53 10.5.2.3 Activating an emergency license ..................................................................... 54 10.5.3 Creating a tool block file in WorkVisual ............................................................... 54 10.5.3.1 Templates ........................................................................................................ 55 10.6 Configuring a 2D task ................................................................................................ 56 10.7 Generating a 2D model ............................................................................................. 59 10.7.1 2D model with a stationary camera ...................................................................... 59 10.7.2 2D model with a moving camera .......................................................................... 60 10.8 Testing a 2D task ....................................................................................................... 61 10.9 Configuring a 3D task ................................................................................................ 62 10.10 Generating a 3D model ............................................................................................. 64 10.11 Testing a 3D task ....................................................................................................... 65 11 Programming ............................................................................................... 67 11.1 Note on programming ................................................................................................ 67 11.2 Subprogram VT_INIT ................................................................................................ 67 11.3 Subprogram VT_OPENCONNECTION ..................................................................... 67 11.4 Subprogram VT_TASKTRIGGER ............................................................................. 67 11.5 Subprogram VT_TASKTRIGGER_REFBASE ........................................................... 68 11.6 Subprogram GET_VTRESULT .................................................................................. 68 11.7 Subprogram GET_VTCORRECTIONFRAME ........................................................... 68 11.7.1 Structure of VTRESULT ....................................................................................... 69 11.8 Subprogram VTRESULT_CHECK ............................................................................ 69

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 Contents 11.9 Subprogram VT_RESULTCHECK2 ........................................................................... 70 11.10 Subprogram VT_WAIT ............................................................................................... 70 11.11 Subprogram VT_CLOSECONNECTION ................................................................... 71 11.12 Subprogram VT_CLEAR ............................................................................................ 71 11.13 Subprogram VT_CHECKPOSELIMIT ........................................................................ 71 11.14 Subprogram VT_CHECKPOSE ................................................................................. 72 11.14.1 Defining the points on the robot ............................................................................ 74 11.15 Subprogram GET_VTUSERDATA ............................................................................. 75 11.16 Subprogram DO_GETVTRESULT ............................................................................. 75 11.17 Subprogram DO_GETVTRESULTS .......................................................................... 76 11.18 Subprogram VT_DIRECT .......................................................................................... 77 12 Example programs ...................................................................................... 79 12.1 Example program ....................................................................................................... 79 13 Messages ..................................................................................................... 83 14 Maintenance ................................................................................................. 89 14.1 Maintenance symbols ................................................................................................ 89 15 Repair ........................................................................................................... 91 15.1 Exchanging the switch ............................................................................................... 91 15.2 Exchanging the camera ............................................................................................. 91 15.3 Exchanging the motherboard ..................................................................................... 91 16 Troubleshooting .......................................................................................... 93 17 Decommissioning, storage and disposal .................................................. 95 17.1 Decommissioning ....................................................................................................... 95 17.2 Storage ...................................................................................................................... 95 17.3 Disposal ..................................................................................................................... 95 18 Appendix ...................................................................................................... 97 18.1 Tightening torque ....................................................................................................... 97 19 KUKA Service .............................................................................................. 99 19.1 Requesting support .................................................................................................... 99 19.2 KUKA Customer Support ........................................................................................... 99 Index ............................................................................................................. 107

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 1 Introduction 1 Introduction 1.1 Industrial robot documentation The industrial robot documentation consists of the following parts:  Documentation for the manipulator  Documentation for the robot controller  Operating and programming instructions for the System Software  Instructions for options and accessories  Parts catalog on storage medium Each of these sets of instructions is a separate document. 1.2 Representation of warnings and notes Safety These warnings are relevant to safety and must be observed. This warning draws attention to procedures which serve to prevent or remedy emergencies or malfunctions: Notes These hints serve to make your work easier or contain references to further information. 1.3 Trademarks Windows is a trademark of Microsoft Corporation. VisionPro is a trademark of Cognex Corporation. These warnings mean that it is certain or highly probable that death or severe injuries will occur, if no precautions are taken. These warnings mean that death or severe injuries may occur, if no precautions are taken. These warnings mean that minor injuries may occur, if no precautions are taken. These warnings mean that damage to property may oc- cur, if no precautions are taken. These warnings contain references to safety-relevant information or general safety measures. These warnings do not refer to individual hazards or individual pre- cautionary measures. Procedures marked with this warning must be followed exactly. Tip to make your work easier or reference to further information.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 1.4 Terms used Term Description KUKA smartHMI User interface of the KUKA System Software (KUKA smart Human-Machine Interface) GigE Gigabit Ethernet GenICam Generic Interface for Cameras: generic pro- gramming interface for cameras used in industrial image processing. Reference pose Robot position for image acquisition Tool block Image processing task created using WorkVi- sual. EKI Ethernet KRL interface PoE Power over Ethernet Power supply via network KONI KUKA Option Network Interface KLI KUKA Line Interface Connection to Ethernet network

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 2 Purpose 2 Purpose 2.1 Target group This documentation is aimed at users with the following knowledge and skills:  Expert knowledge of KRL programming  Advanced knowledge of the robot controller system  Advanced knowledge of network connections  Knowledge of the VisionPro software from Cognex (training) 2.2 Intended use Use KUKA.VisionTech is used to determine and correct the position of a robot rel- ative to the position of a component with the aid of one or more cameras. Up to 3 cameras may be operated simultaneously with the system. Only hardware components approved by KUKA Roboter GmbH may be used. The hardware components must only be operated under the specified environmental condi- tions. Misuse Any use or application deviating from the intended use is deemed to be imper- missible misuse. This includes e.g.:  Operation outside the permissible operating parameters  Use in potentially explosive environments  Use in the vicinity of welding applications  Networking the camera network with a company network For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training program can be found at www.kuka.com or can be ob- tained directly from our subsidiaries.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 3 Product description 3 Product description 3.1 Overview of VisionTech Functions VisionTech is an add-on technology package and consists of an image pro- cessing package and a plug-in for the KUKA smartHMI. The acquisition and processing of images is used to calculate a base correction. The base correc- tion can be used to correct the position of the robot relative to the position of a component. Areas of appli- cation  Detecting the position of components  Deracking  Depalletizing Communication The robot controller communicates with one or more GigE cameras via the im- age processing system. The connection between the kernel system and the image processing system is established via the Ethernet KRL interface. Fig. 3-1: Communication, KR C4 1 Stationary camera 4 Robot 2 Connecting cable 5 Robot-guided cameras 3 KR C4 6 Service laptop Fig. 3-2: Communication, KR C4 compact

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 Image processing software An image processing environment is installed on the controller during installa- tion of VisionTech. This software performs the image processing tasks. This software must also be installed on the service laptop. 3.2 Hardware components The following hardware components are available in the form of a hardware package for KUKA.VisionTech:  KUKA GigE switch  KUKA MXG20 cameras  Calibration plate  Connecting cables There are different variants of the hardware package. The variants differ with regard to the interface, connecting cables and number of cameras: 3.2.1 KUKA GigE switch Overview There are 5 RJ45 connections on the KUKA GigE switch. Ports 1 to 4 are PoE- capable. KUKA MXG20 cameras can be connected to ports 1 to 3. Port 5 can be used to connect the KR C4 compact; this port is not PoE-capa- ble. The switch must be integrated into a housing with a protection rating of IP 54 and supplied with a direct voltage of 12-36 V. The switch can be mount- ed on a TS 35 top-hat rail. In the KR C4, the switch is installed and connected to the power supply of the KR C4. Up to 3 cameras can be connected to interfaces X64.1 to X64.3. Alter- natively, the cameras can be connected directly to the switch in the KR C4 via a cable inlet. 1 KR C4 compact 3 Switch 2 Connecting cable 4 Cameras Type Cameras Position Restriction 2D 1-3 Stationary None 1-3 Moving Only with KR C4 3D 2-3 Moving Only with KR C4

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 3 Product description DIP switches Fig. 3-3: KUKA GigE switch – overview 1 DIP switch for the function “Power Alarm Relay Output” 2 Changeover switch for port 6 (selection of SFP speed) 3 RJ45 PoE connection for the robot controller 4 3 RJ45 PoE connections for cameras Designation Description DIP switch for “Power Alarm Relay Output” DIP switch 1: P1 error message DIP switch 2: P2 error message On: Activated Off: Deactivated Changeover switch for port 6 (selection of SFP speed) DIP switches 1 and 2 on: 100 Mbps DIP switches 1 and 2 off: 1000 Mbps

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 LEDs Fig. 3-4: KUKA GigE switch – LEDs Item LED Description 1 P1 Green: Switch is on (if powered via V1) 2 P2 Green: Switch is on (if powered via V2) 3 Gigabit LAN port Green: GigE port is active, data being transferred to the connected device 4 Gigabit LAN port Yellow: 100 Mbps 5 Gigabit PoE port Green: Port is active 6 Gigabit PoE port Green: PoE is active 7 Fault Yellow: Fault at P1 or P2

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 3 Product description Power supply Interfaces Fig. 3-5: KUKA GigE switch – power supply 1 Power supply connection 12-36 V DC 2 Power supply connection 24 V DC 3 Output, alarm relay 4 Power supply connection 12-36 V DC 5 Housing ground Fig. 3-6: KUKA GigE switch – interfaces

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 3.2.2 KUKA MXG20 camera Overview The KUKA MXG20 camera conforms to the GigE standard and is PoE-capa- ble. The image resolution is 2 megapixels. The camera can be powered via PoE or from an external power supply. A protective lens hood is mounted on the camera. C-Mount lenses can be used (lenses are not included in the scope of supply). The following must be ensured when selecting the lens:  The lens fits on the camera  The lens fits into the protective lens hood (depth: 45 mm, can be enlarged using extension rings – 12 mm each)  The lens matches the sensor (size: 1 /1.8") A protective cap is mounted on the connection for the process interface / pow- er supply. This may only be removed if a cable is connected to the interface. Connector pin allocation It is recommended to use no more than 3 extension rings. Fig. 3-7: KUKA MXG20 camera – overview 1 LEDs 2 Data/PoE interface 3 Process interface / power supply The camera must not be powered simultaneously via PoE and from an external source, otherwise the camera may be damaged. Fig. 3-8: Contact diagram, data/PoE interface (view from contact side) 1 MX3- 5 MX2+ (pos./neg. Vport) 2 MX4+ 6 MX1+ (neg./pos. Vport) 3 MX4- 7 MX3+ 4 MX1- (neg./pos. Vport) 8 MX2- (pos./neg. Vport)

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 3 Product description LEDs 3.2.3 Connecting cables Different connecting cables are required for the operation of one or more cam- eras. The connecting cables used conform to the CAT6 standard for network cables. The network cables have different connectors depending on the inter- face. The cables are available in various lengths. 3.2.4 Calibration plates A calibration plate is required for the calibration of a camera. Calibration plates are available in the following sizes:  24 x 24 inch (60.9 x 60.9 cm), size of one square: 20 mm  12 x 12 inch (30.5 x 30.5 cm), size of one square: 10 mm  11.5 x 8 inch (29.2 x 20.3 cm), size of one square: 6.35 mm  5.75 x 4 inch (14.6 x 10.2 cm), size of one square: 3.175 mm  2.875 x 2 inch (7.3 x 5.1 cm), size of one square: 1.5875 mm Fig. 3-9: Contact diagram, process interface / power supply (view from contact side) 1 OUT 3 5 Uext OUT 2 Power VCC+ 6 OUT 1 3 IN1 7 Power GND 4 IO GND 8 OUT 2 Fig. 3-10: KUKA MXG20 camera – LEDs Item LED Description 1 Status  Green: Connection is active.  Flashing green: Data are being received  Flashing red: Data are being sent 2 Power Green: Camera is switched on

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 4 Technical data 4 Technical data 4.1 KUKA MXG20 camera Basic data Ambient condi- tions Connections Standards and guidelines Power supply (exter- nal) Control voltage: 12 … 24 V DC ± 10% Rated current: 176 … 252 mA Power supply (PoE) Control voltage: 36 … 57 V DC Rated current: 88 mA (with 48 V DC) Energy consumption approx. 4.2 W Digital input Voltage (min.): 0 … 4.5 V DC Voltage (max.): 11 … 30 V DC Rated current: 6.0 … 10 mA Pulse length: min. 2.0 µs Trigger delay outside of treadout: 1 µs Trigger delay during treadout: 14 µs Digital output Voltage: 5 … 30 V DC Rated current: max. 50 mA MTBF 335774 h @ 45°C Sensor size 1/1.8" Protection rating IP 67 Weight 185 g Conformity CE Storage and transpor- tation -25 °C to +70 °C (248 K to 343 K) Operation +5 °C to +50 °C (278 K to 323 K) Device temperature max. +50 °C (323 K) at the measurement point Air humidity 5 … 95% (no condensation) Data/PoE interface Transmission speed:  100 Mbit/s (Fast Ethernet)  1000 Mbit/s (Gigabit Ethernet) Connection: M12 male connector, 8-contact, A standard Process interface / power supply Connection: M12 female connector, 8-contact, A standard Name Definition 2004/108/EC EMC Directive: Directive 2004/108/EC of the European Parlia- ment and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 4.2 KUKA GigE switch Basic data Ethernet interface Ambient condi- tions Standards and guidelines EN 61000-6-2 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards – Immunity for industrial envi- ronments EN 61000-6-4 Electromagnetic compatibility (EMC) - Part 6-4: Generic standards – Emission standard for industrial environments Name Definition Housing Metal Protection classifica- tion IP 30 Dimensions 41 x 99.9 x 144.3 mm Weight 580 g Control voltage 12 … 36 V DC Energy consumption approx. 7.5 W MTBF > 450000 h @ 45° Conformity CE, FCC Part 15, RoHS Interface 1000base-T, 100base-TX, 10base-T Standard IEEE 802.3 for 10base-T IEEE 802.3u for 100base-TX and 100base-X IEEE 802.3z for 1000base-X IEEE 802.3ab for 1000base-T IEEE 802.3x for flow control IEEE 802.3at PoE specification (up to 30 watts per port for PoE) Ports 4x with PoE, 1x SFP, 1x without PoE Packet size Up to 9 kB, supports jumbo frames Auto-functions Auto-negotiation, auto-crossover PoE Conforms to IEEE 802.3at Protective function Against overload current Power infeed Up to 30 watts per port Storage -40 °C to +85 °C (233 K to 358 K) Operation -40 °C to +60 °C (233 K to 333 K) Air humidity 5 … 95% (no condensation) Name Definition 2004/108/EC EMC Directive: Directive 2004/108/EC of the European Parlia- ment and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC EN 55022 Information technology equipment – Radio dis- turbance characteristics – Limits and methods of measurement

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 4 Technical data 4.3 Connecting cables 4.3.1 Connecting cables, KR C4 Basic data Interfaces If a cable inlet on the KR C4 is used instead of interface X64, the following con- nectors are available: EN 55024 Information technology equipment – Immunity characteristics – Limits and methods of mea- surement EN 61000-3-2 Electromagnetic compatibility (EMC) - Part 3-2: Limits – Limits for harmonic current emissions EN 61000-3-3 Electromagnetic compatibility (EMC) - Part 3-3: Limits – Limitation of voltage changes, voltage fluctuations and flicker in public low-voltage sup- ply systems, for equipment with rated current Name Definition Type Suitable for use on robots Configuration 4x CAT6 elements acc. to DIN EN 50288-5-2 Conductor Bare copper strand 4x2xAWG26 Outside diameter 8.3 ± 0.2 mm Operating voltage ≤ 60 V Transmission charac- teristics, CAT6 ele- ment in accordance with DIN EN 50288-5-2 Transmission range 50 m (nominal) Bending radius (one- time) ≥ 3x cable diameter Bending radius (mov- ing) ≥ 10x cable diameter Certification UL AWM Style 20963 80 °C 30 V Connecting cable Connector des- ignation Connections KR C4 – linear unit X64.1 – X74.1.1 X64.2 – X74.2.1 PushPull V4 connector at both ends Linear unit – robot X74.1.1 – X74.1 X74.2.1 – X74.2 PushPull V4 coupling – PushPull V4 connector KR C4 – robot X64.1 – X74.1 X64.2 – X74.2 PushPull V4 connector at both ends KR C4 – camera X64.1 – B1 X64.2 – B2 X64.3 – B3 PushPull V4 connector – M12 male connector, 8- contact Connecting cable Cable lengths KR C4 – camera 5 m, 15 m, 25 m, 35 m KR C4 – linear unit 7 m, 15 m, 25 m Linear unit – robot 5 m KR C4 – robot 7 m, 15 m, 25 m

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 The RJ45 connectors that are connected to interfaces A13.1 to A13.3 have protection rating IP 20. For detailed specifications of the connecting cables, see (>>> 9.3.6 "De- scription of the connecting cables" Page 40). 4.3.2 Connecting cables, KR C4 compact Basic data Interfaces The RJ45 connectors that are connected to interfaces PoE 1 to PoE 3 have protection rating IP 20. For detailed specifications of the connecting cables, see (>>> 9.3.6 "De- scription of the connecting cables" Page 40). Connecting cable Connector des- ignation Connections Switch – linear unit A13.1 – X74.1.1 A13.2 – X74.2.1 RJ45 connector – Push- Pull V4 connector Linear unit – robot X74.1.1 – X74.1 X74.2.1 – X74.2 PushPull V4 coupling – PushPull V4 connector Switch – robot A13.1 – X74.1 A13.2 – X74.2 RJ45 connector – Push- Pull V4 connector Switch – camera A13.1 – B1 A13.2 – B2 A13.3 – B3 RJ45 connector – M12 male connector, 8-contact Type Not suitable for use on robots Configuration 4x CAT6 elements Conductor Bare copper AWG 26 Outside diameter 6.2 ± 0.15 mm Operating voltage 30 V Bending radius 4x cable diameter Certification UL 94 V0 Connecting cable Connector des- ignation Connections KR C4 compact – switch KONI – No PoE5 RJ45 connectors at both ends Switch – camera PoE 1 – B1 PoE 2 – B2 PoE 3 – B3 RJ45 connector – M12 male connector, 8-contact Connecting cable Cable lengths KR C4 compact – switch 1 m, 5 m Switch – camera 5 m, 15 m, 25 m, 35 m

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 4 Technical data 4.4 Dimensions of the camera Fig. 4-1: Dimensions of the camera (dimensions in mm) 1 Rear view 2 Side view 3 View from below 4 Front view 5 Side view with protective lens hood

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 4.5 Dimensions of the extension 4.6 Plates and labels Camera The identification plate is already mounted on the camera. The camera label must be selected and attached by the user; this depends on the interface to which the camera is connected:  Interface X64.1 / A13.1 / PoE 1: label B1  Interface X64.2 / A13.2 / PoE 2: label B2  Interface X64.3 / A13.3 / PoE 3: label B3 (for stationary cameras only) Switch The following plates and labels are attached to the switch. Fig. 4-2: Dimensions of the extension (dimensions in mm) 1 Front view 2 Side view Fig. 4-3: Plates and labels on the camera Plate no. Designation 1 Camera identification plate 2 Camera label

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 4 Technical data Fig. 4-4: Plates and labels on the switch Plate no. Designation 1 Switch identification plate

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 5 Safety 5 Safety This documentation contains safety instructions which refer specifically to the software and hardware described here. The fundamental safety information for the industrial robot can be found in the “Safety” chapter of the Operating and Programming Instructions for System In- tegrators or the Operating and Programming Instructions for End Users. 5.1 General safety measures Personnel The operator must meet the following preconditions:  The operator must be trained for the work to be carried out.  Start-up work may only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and experience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential hazards. 5.2 Standards and regulations The “Safety” chapter in the operating and programming instructions of the KUKA System Software (KSS) must be observed. Death to per- sons, severe injuries or considerable damage to property may other- wise result. If the position of the component is not correctly detected, this may result in a collision. Before operation, check the result of the base correction using the subprogram VT_CHECKPOSE. The Status and Turn of a target pose may be altered due to the base correction, thereby causing a collision. To avoid this, use the subprogram VT_DIRECT. (>>> 11.18 "Subprogram VT_DIRECT" Page 77) The protective lens hood must be mounted on the cam- era during operation. Otherwise, the lens can become loose and cause material damage. The user must carry out a risk analysis and is responsible for ensuring correctly adapted lighting. When fastening the cameras, the tightening torques must be ob- served; see (>>> 18.1 "Tightening torque" Page 97). Name Definition Edition EN 60204-1 + A1 Safety of machinery: Electrical equipment of machines - Part 1: General require- ments 2009

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 6 Planning 6 Planning 6.1 Connecting cables and interfaces Connecting cables The connecting cables comprise all the cables for transferring energy and sig- nals between the robot controller, linear unit, robot and cameras. The following connecting cables are available:  For the KR C4 with interface X64:  Connecting cable, KR C4 – linear unit  Connecting cable, linear unit – robot  Connecting cable, KR C4 – robot  Connecting cable, KR C4 – camera  For the KR C4 with cable inlet to interface A13 on the switch:  Connecting cable, switch – linear unit  Connecting cable, linear unit – robot  Connecting cable, switch – robot  Connecting cable, switch – camera  For the KR C4 compact:  Connecting cable, KR C4 compact – switch  Connecting cable, switch – camera All the connecting cables for the KR C4 are suitable for use on robots. The connecting cables for the KR C4 compact are not suitable for use on robots. Information about the energy supply system for axes 1 to 3 and axes 3 to 6 can be found in separate documentation. Depending on the specific system configuration, connecting cables are re- quired in different lengths. The following cable lengths are available: The maximum length of the connecting cables must not exceed 45 m with moving (robot-guided) cameras and 35 m with stationary cameras. Thus if the robot is operated on a linear unit which has its own energy supply chain these cables must also be taken into account. The following points must be observed when planning and routing the con- necting cables:  Protect cables against exposure to mechanical stress.  Route the cables without mechanical stress – no tensile forces on the con- nectors  Cables are only to be installed indoors.  Route cables in such a way that they cannot be damaged by sharp edges, tools or other materials.  Route cables in such a way that they are located outside of the camera’s field of vision.  Observe permissible temperature range (fixed installation) of 243 K (- 30 °C) to 363 K (+90 °C). Connecting cable Cable lengths KR C4 – camera 5 m, 15 m, 25 m, 35 m KR C4 – linear unit 7 m, 15 m, 25 m Linear unit – robot 5 m KR C4 – robot 7 m, 15 m, 25 m KR C4 compact – switch 1 m, 5 m Switch – camera 5 m, 15 m, 25 m, 35 m

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 For detailed specifications of the connecting cables, see (>>> 9.3.6 "De- scription of the connecting cables" Page 40). Interface X64 Interfaces X64.1 to X64.3 are situated on the connection panel of the KR C4. Fig. 6-1: Interfaces X64.1 to X64.3 1 Connection X64.1 3 Connection X64.3 2 Connection X64.2

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 7 Transportation 7 Transportation 7.1 Transportation Cameras Before transportation, the cameras must be removed. A protective cap must be mounted on the connection for the process interface / power supply. The cameras must be packaged for transportation in ESD protection foil. Care must be taken to ensure that the cameras do not come into contact with hu- midity. Switch The switch must be packaged for transportation in ESD protection foil. Care must be taken to ensure that the switch does not come into contact with hu- midity.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 8 Installation and licensing 8 Installation and licensing 8.1 System requirements Robot controller Hardware:  KR C4  Or KR C4 compact  Motherboard D3076-K Software:  KUKA System Software 8.2  Or VW System Software 8.2  KUKA.Ethernet KRL 2.2 Laptop/PC Software:  WorkVisual 3.0 The requirements for installation of WorkVisual are contained in the WorkVisual documentation. 8.2 Installing or updating VisionTech Precondition  “Expert” user group  Software on USB stick (unpacked) Procedure 1. Connect the USB stick to the robot controller or smartPAD. 2. In the main menu, select Start-up > Additional software. 3. Press New software. The entry VisionTech must be displayed in the Name column and drive E:\ or K:\ in the Path column. If not, press Refresh. 4. If the specified entries are now displayed, continue with step 5. If not, the drive from which the software is being installed must be config- ured first:  Press the Configuration button. A new window opens.  Select a line in the Installation paths for options area. Note: If the line already contains a path, this path will be overwritten.  Press Path selection. The available drives are displayed.  Select E:\. (If stick connected to the robot controller.) Or select K:\. (If stick connected to the smartPAD.) It is advisable to archive all relevant data before updating a software package. Recommendation: Use a KUKA stick. Data may be lost if any other stick is used. At least 1.5 GB of free space must be available on the USB stick. During the installation of the smartPAD, the installation may take up to 1 hour due to the size of the technology package.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1  Press Save. The window closes again. The drive only needs to be configured once and then remains saved for further installations. 5. Mark the entry VisionTech and click on Install. Answer the request for confirmation with Yes. 6. Confirm the reboot prompt with OK. 7. Remove the stick. 8. Reboot the robot controller. The robot controller is then automatically re- started once again. LOG file A LOG file is created under C:\KRC\ROBOTER\LOG. 8.3 Uninstalling VisionTech Precondition  “Expert” user group Procedure 1. In the main menu, select Start-up > Additional software. 2. Mark the entry VisionTech and click on Uninstall. Reply to the request for confirmation with Yes. Uninstallation is prepared. 3. Reboot the robot controller. Uninstallation is resumed and completed. LOG file A LOG file is created under C:\KRC\ROBOTER\LOG. 8.4 Licensing VisionTech 8.4.1 Activating the license Procedure 1. In the main menu, select VisionTech > Licensing. 2. Enter the license key in the License key box. The license key is either on a sticker in the robot controller or is enclosed with the software. 3. Press Create footprint and select a directory. A file is generated in the se- lected directory which links the control PC to the license. An encrypted sig- nature for this control PC is saved in the file. 4. Send the generated file to [email protected]. KUKA Service will use this to create a licensing file and send it to you. It is advisable to archive all relevant data before uninstalling a soft- ware package. If VisionTech is uninstalled, the image processing environment is not uninstalled automatically at the same time. If the image processing environment is to be uninstalled, it must be uninstalled separately via the Windows Control Panel. Fig. 8-1: Adhesive label in the robot controller (example) 1 License key

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 8 Installation and licensing 5. Press ..., select the received licensing file and confirm with OK. 6. Reboot the robot controller. 8.4.2 Repairing the license Description If hardware components are modified, added or exchanged, this may invali- date the license. A license becomes invalid if the current signature of the con- trol PC differs too greatly from the saved signature. In this case, the license can be repaired. Procedure 1. In the main menu, select VisionTech > Licensing. 2. In the list of currently installed licenses, select the license to be repaired. 3. Press Create repair request and select a directory. A file is generated in the selected directory. 4. Send the generated file to [email protected]. KUKA Service will use this to create a new licensing file and send it to you. 5. Press ..., select the received licensing file and confirm with OK. 6. Reboot the robot controller. 8.4.3 Activating an emergency license Description It is possible to activate an emergency license. A total of 5 emergency licenses are available. An emergency license is valid for 3 days. On expiry, emergency licenses cannot be reactivated. For this reason, they should only be used in an actual emergency. Procedure 1. In the main menu, select VisionTech > Licensing. 2. Select the Activate emergency license tab. 3. Press Activate next emergency license. 4. Reboot the robot controller.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 9 Start-up and recommissioning 9 Start-up and recommissioning 9.1 Start-up for a stationary camera - overview 9.2 Start-up for moving cameras - overview Step Description 1 Connect camera to the robot controller. (>>> 9.3.1 "Networking KR C4 with interface X64, stationary" Page 38) (>>> 9.3.2 "Networking KR C4 with cable inlet, stationary" Page 38) (>>> 9.3.3 "Networking KR C4 compact, stationary" Page 39) 2 Refresh the sensor overview. 1. In the main menu, select VisionTech > Sensor overview. 2. Press Refresh sensors. 3 Configure Ethernet KRL interface. (>>> 9.4 "Configuring the Ethernet KRL interface" Page 43) 4 Configure the camera network. (>>> 9.5 "Configuring the camera network" Page 43) 5 Configure the camera. (>>> 9.6 "Configuring cameras" Page 44) 6 Align the camera. (>>> 9.7 "Aligning camera (stationary)" Page 45) 7 Calibrate the camera. (>>> 9.9 "Calibrating camera (stationary)" Page 46) Step Description 1 Connect camera to the robot controller. (>>> 9.3.4 "Networking KR C4 with interface X64, robot- guided" Page 39) (>>> 9.3.5 "Networking KR C4 with cable inlet, robot-guided" Page 40) 2 Refresh the sensor overview. 1. In the main menu, select VisionTech > Sensor overview. 2. Press Refresh sensors. 3 Configure Ethernet KRL interface. (>>> 9.4 "Configuring the Ethernet KRL interface" Page 43) 4 Configure the camera network. (>>> 9.5 "Configuring the camera network" Page 43) 5 Configure the cameras. (>>> 9.6 "Configuring cameras" Page 44)

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 9.3 Connecting cameras to the robot controller Description The cameras are connected via Ethernet; the networking differs depending on the robot controller used and the mounting type of the cameras. 9.3.1 Networking KR C4 with interface X64, stationary Procedure  Carry out networking as illustrated below: 9.3.2 Networking KR C4 with cable inlet, stationary Procedure  Carry out networking as illustrated below: 6 Align the cameras. (>>> 9.8 "Aligning cameras (moving)" Page 45) 7 Calibrate the cameras. (>>> 9.10 "Calibrating cameras (moving)" Page 48) Step Description Variant Description KR C4 with interface X64, robot-guided (>>> 9.3.4 "Networking KR C4 with inter- face X64, robot-guided" Page 39) KR C4 with cable inlet, robot-guided (>>> 9.3.5 "Networking KR C4 with cable inlet, robot-guided" Page 40) KR C4 with interface X64, stationary (>>> 9.3.1 "Networking KR C4 with inter- face X64, stationary" Page 38) KR C4 with cable inlet, sta- tionary (>>> 9.3.2 "Networking KR C4 with cable inlet, stationary" Page 38) KR C4 compact, stationary (>>> 9.3.3 "Networking KR C4 compact, stationary" Page 39) Fig. 9-1: Networking KR C4 with interface X64, stationary (maximum number of cameras) 1 KR C4 2 KUKA MXG20 camera

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 9 Start-up and recommissioning 9.3.3 Networking KR C4 compact, stationary Procedure  Carry out networking as illustrated below: 9.3.4 Networking KR C4 with interface X64, robot-guided Procedure  Carry out networking as illustrated below: Fig. 9-2: Networking KR C4 with cable inlet, stationary (maximum num- ber of cameras) 1 KR C4 2 KUKA MXG20 camera Fig. 9-3: Networking KR C4 compact, stationary (maximum number of cameras) 1 KR C4 compact 3 KUKA MXG20 camera 2 KUKA GigE switch Fig. 9-4: Networking KR C4 with interface X64, robot-guided 1 KUKA MXG20 camera 3 Linear unit (optional) 2 Robot 4 KR C4

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 9.3.5 Networking KR C4 with cable inlet, robot-guided Procedure  Carry out networking as illustrated below: 9.3.6 Description of the connecting cables Configuration The connecting cables are used to transfer power and signals between the ro- bot controller, linear unit, robot and cameras. The following connecting cables are available:  For the KR C4 with interface X64:  Connecting cable, KR C4 – linear unit  Connecting cable, linear unit – robot  Connecting cable, KR C4 – robot  Connecting cable, KR C4 – camera  For the KR C4 with cable inlet to interface A13 on the switch:  Connecting cable, switch – linear unit  Connecting cable, linear unit – robot  Connecting cable, switch – robot  Connecting cable, switch – camera  For the KR C4 compact:  Connecting cable, KR C4 compact – switch  Connecting cable, switch – camera Interfaces, KR C4 For connection of the connecting cables between the KR C4, linear unit, robot and cameras, the following connectors are available at the interfaces: Fig. 9-5: Networking KR C4 with cable inlet, robot-guided 1 KUKA MXG20 camera 3 Linear unit (optional) 2 Robot 4 KR C4 Connecting cable Connector des- ignation Connections KR C4 – linear unit X64.1 – X74.1.1 X64.2 – X74.2.1 PushPull V4 connector at both ends Linear unit – robot X74.1.1 – X74.1 X74.2.1 – X74.2 PushPull V4 coupling – PushPull V4 connector KR C4 – robot X64.1 – X74.1 X64.2 – X74.2 PushPull V4 connector at both ends KR C4 – camera X64.1 – B1 X64.2 – B2 X64.3 – B3 PushPull V4 connector – M12 male connector, 8- contact

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 9 Start-up and recommissioning If a cable inlet on the KR C4 is used instead of interface X64, the following con- nectors are available: Connecting cables, KR C4 The following connecting cables are for a KR C4 with interface X64: The following connecting cables are for a KR C4 with a cable inlet: Connecting cable Connector des- ignation Connections Switch – linear unit A13.1 – X74.1.1 A13.2 – X74.2.1 RJ45 connector – Push- Pull V4 connector Switch – robot A13.1 – X74.1 A13.2 – X74.2 RJ45 connector – Push- Pull V4 connector Switch – camera A13.1 – B1 A13.2 – B2 A13.3 – B3 RJ45 connector – M12 male connector, 8-contact Fig. 9-6: Connecting cable, KR C4 – linear unit Fig. 9-7: Connecting cable, linear unit – robot Fig. 9-8: Connecting cable, KR C4 – robot Fig. 9-9: Connecting cable, KR C4 – camera

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 Interfaces, KR C4 compact For connection of the connecting cables between the KR C4 compact, switch and cameras, the following connectors are available at the interfaces: Connecting cables, KR C4 compact Fig. 9-10: Connecting cable, switch – linear unit Fig. 9-11: Connecting cable, switch – robot Fig. 9-12: Connecting cable, switch – camera Connecting cable Connector des- ignation Connections KR C4 compact – switch KONI – No PoE5 RJ45 connectors at both ends Switch – camera PoE 1 – B1 PoE 2 – B2 PoE 3 – B3 RJ45 connector – M12 male connector, 8-contact Fig. 9-13: Connecting cable, KR C4 compact – switch

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 9 Start-up and recommissioning 9.4 Configuring the Ethernet KRL interface Description To establish a connection between the kernel system and the image process- ing system, the number of the flag that is to trigger execution of the interrupt program must be entered in the configuration file for the Ethernet KRL inter- face. The interrupt program monitors the result of the image processing. It is triggered once the calculation of the image processing is completed. Precondition  User group "Expert".  Operating mode T1 or T2. Procedure 1. Open the configuration file VisionTechConfig.xml in the directory C:\KRC\ROBOTER\Config\User\Common\EthernetKRL. 2. In the line: replace the entry Choose Flag with the number of the flag that is to trig- ger execution of the interrupt program. 3. Save and close the file. 4. In the main menu, select Configuration > Inputs/outputs > I/O drivers and click on Reconfigure. The I/O driver is reconfigured. 9.5 Configuring the camera network Following installation of VisionTech, the network card is configured as follows:  IP address: 192.169.2.100  Subnet mask: 255.255.0.0 Precondition  The cameras are connected to the GigE switch.  A free address range is available for the camera network. Example address range Fig. 9-14: Connecting cable, switch – camera The camera network must not be connected to another network. During productive operation, the network configuration must not be changed. The address range of the camera network must not be in the address range of the KLI or the Windows network. This can cause severe errors in the robot controller. Device IP address Subnet mask 1st GigE camera 192.169.2.101 255.255.0.0 2nd GigE camera 192.169.2.102 255.255.0.0

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 Procedure 1. In the main menu, select VisionTech > Sensor overview. 2. Select the camera that is to be configured. 3. On the Network tab, enter the IP address of the camera and the subnet mask for the address range of the camera network. 4. Save the settings. 5. If necessary, repeat steps 2 to 4 for further cameras. 9.6 Configuring cameras VisionTech can be used with both stationary and moving cameras. A station- ary camera is fixed in its position, e.g. mounted on a stand or on the ceiling. A moving camera is mounted on the robot flange. Procedure 1. In the main menu, select VisionTech > Sensor overview. 2. Select the camera that is to be configured. 3. On the General tab, select the mounting type for the camera. 4. Optionally: Enter the name, e.g. “Camera on robot”, in the Description box. 5. Press Save. 6. Repeat steps 2 and 3 for the other cameras. Description 3rd GigE camera 192.169.2.103 255.255.0.0 GigE network card in the robot controller 192.169.2.100 255.255.0.0 Device IP address Subnet mask Fig. 9-15: Sensor overview

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 9 Start-up and recommissioning 9.7 Aligning camera (stationary) Precondition  The object to be measured (e.g. component or calibration plate) is mount- ed.  The camera is networked.  The network has been configured. Procedure 1. In the main menu, select VisionTech > Live picture. 2. Press Start. A live image is generated for the camera. 3. Position the camera over the measurement object so that the measure- ment object is visible in the live image of the camera. 4. Press on the live image of one camera. The live image is displayed in en- larged form. 5. Enter the default exposure time or set it using the plus/minus keys or the slider control. 6. Save the settings by selecting Set default exposure. 7. Use the arrow button to switch back to the overview and perform steps 4 to 6 for the other cameras. 8. Tighten and secure the camera fastening screws. 9. Focus the camera with the aid of the enlarged live image display until the measurement object is clearly visible. 10. Secure the lens of the camera with the fastening screws. 11. Screw on the protective lens hood. 12. Remove the protection foil from the protective lens hood. 9.8 Aligning cameras (moving) Precondition  The object to be measured (e.g. component or calibration plate) is mount- ed.  The cameras are networked.  The network has been configured.  The cameras are either mounted on the robot flange or on a tool that is mounted on the robot flange.  The cameras have the same orientation, i.e. the component is in the same position in all the images. Procedure 1. In the main menu, select VisionTech > Live picture. 2. Press Start. A live image is generated for each camera. 3. Position the robot over the measurement object so that the measurement object is visible in the live image of the cameras. If necessary, align the cameras again. 4. Press on the live image of one camera. The live image is displayed in en- larged form. 5. Enter the default exposure time or set it using the plus/minus keys or the slider control. Field Description Serial number Serial number of the cameras IP address IP address of the cameras Description Description of the cameras Status  Green: The camera is ready for operation.  Red: The camera is not ready for operation and can thus not be used.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 6. Save the settings by selecting Set default exposure. 7. Use the arrow button to switch back to the overview and perform steps 4 to 6 for the other cameras. 8. Tighten and secure the camera fastening screws. 9. Focus the cameras with the aid of the enlarged live image display until the measurement object is clearly visible. 10. Secure the lenses of the cameras with the fastening screws. 11. Screw on the protective lens hood. 12. Remove the protection foil from the protective lens hood. 9.9 Calibrating camera (stationary) Precondition  The camera is mounted in a fixed position and configured as stationary.  The camera is networked.  The network has been configured.  The camera is aligned.  A calibration plate is attached. This is in the workpiece plane and in the field of vision of the camera. Procedure 1. In the main menu, select VisionTech > Live picture. 2. Press on the live image of the camera. The live image is displayed in en- larged form. 3. Enter the calibration exposure time or set it using the plus/minus keys or the slider control. 4. Save the settings by selecting Set calibration exposure. 5. In the main menu, select VisionTech > Calibration. A freeze-frame image from the camera is displayed on the fixed sensors tab. If the camera is calibrated, the freeze-frame image has a green frame. If the camera is not calibrated, the freeze-frame image has a red frame. 6. Select the calibration plate used as the calibration body. All calibration plates from KUKA are available for selection. Each calibra- tion plate has a different size which is marked on the plate. The calibration plate used can be determined on the basis of size. 7. Select the camera by pressing on the freeze-frame image. 8. Press Calibration Wizard. 9. Press Take picture. The fiducial mark (cross at the center of the calibra- tion plate) must be visible. During calibration, the IP address of camera must not be changed.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 9 Start-up and recommissioning 10. Press Calibrate. 11. Once the calibration process has been completed, the result is displayed. For an adequate degree of accuracy, the result should be < 1 mm. 12. Select an existing calibration plane in the Calibration plane box or choose Create new calibration plane... to create a new calibration plane: a. Enter a name for the calibration plane in the Name box. b. Optionally: Enter a description of the calibration plane in the Descrip- tion box. c. Select an existing base in the Base ID box or choose Measure new base... to measure a new base. The base can, for example, be cali- brated using the 3-point method. Fig. 9-16: Calibration plate with fiducial mark 1 Fiducial mark 2 Origin Recommendations The camera should be directly above the calibration plate. The calibration plate should fill as much of the image of the camera as possible. Recommendation: The description of the calibration plane should contain the number of the base used. If an existing calibration plane is selected, the result is overwritten. The base used must be calibrated to the calibration plate (>>> Fig. 9- 16 ).

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 13. Press Save. The settings are saved. 14. Press Exit. The window closes. 9.9.1 Deleting a calibration plane Procedure 1. In the main menu, select VisionTech > Calibration management. 2. In the Serial number box, select the camera used to create the calibration plane. 3. In the Calibration result box, select the plane that was deleted. 4. Press Delete. The calibration plane is deleted. If the calibration plane was used in a task, the task can no longer be executed. 9.10 Calibrating cameras (moving) Precondition  The cameras are mounted on the robot flange and configured as moving.  The cameras are networked.  The network has been configured.  The cameras are aligned.  A calibration plate is mounted and is located in the field of vision of the cameras.  The NULLFRAME tool is selected. Procedure 1. In the main menu, select VisionTech > Calibration. Freeze-frame images from the cameras are displayed on the moving sen- sors tab. The freeze-frame images of the cameras that have already been calibrated have a green frame. In the case of cameras that have not yet been calibrated, the freeze-frame images have a red frame. 2. Select the cameras that are to be calibrated by pressing the freeze-frame images. 3. Press Calibration Wizard. Fig. 9-17: Base for a stationary camera 1 Stationary camera 2 Calibration plate If a palletizing robot is used, it is not possible to calibrate moving (ro- bot-guided) cameras. During calibration, the IP addresses of cameras must not be changed.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 9 Start-up and recommissioning 4. Move the robot to the first calibration pose and press Take picture. The fiducial mark (cross at the center of the calibration plate) must be visible in every pose. It is not possible to record the same pose twice. 5. Repeat step 4 for every pose. Record at least 6 poses. A maximum of 9 poses are possible. 6. Select the calibration plate used as the calibration body. All calibration plates from KUKA are available for selection. Each calibra- tion plate has a different size which is marked on the plate. The calibration plate used can be determined on the basis of size. 7. Press Calibrate. The calibration process takes approx. 5 to 10 minutes. 8. Once the calibration process has been completed, the result is displayed. For an adequate degree of accuracy, the result should be < 1 mm. 9. Press Save. The result is saved. 10. Press Exit. The window closes. Recommendation: For the first pose, the cameras should be directly above the calibration plate. In every pose, the cameras should be at a different angle relative to the calibration plate; for this, the robot must be moved.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 10 Configuration 10 Configuration 10.1 Configuring a 2D measurement task - overview 10.2 Configuring a 3D measurement task - overview 10.3 Creating a task and taking images (stationary) Precondition  The camera is networked and calibrated.  The network has been configured. Procedure 1. In the main menu, select VisionTech > Task configuration. 2. Press New and select the 2D fixed type. A new 2D task is created. The name of the task can be changed. Step Description 1 Teach reference position above the component. 2 Create task and take images. (>>> 10.3 "Creating a task and taking images (stationary)" Page 51) (>>> 10.4 "Creating a task and taking images (moving)" Page 52) 3 Set up an image processing task in WorkVisual. (>>> 10.5 "Setting up an image processing task in WorkVi- sual" Page 52) 4 Configure task. (>>> 10.6 "Configuring a 2D task" Page 56) 5 Generate model. (>>> 10.7 "Generating a 2D model" Page 59) 6 Test task. (>>> 10.8 "Testing a 2D task" Page 61) 7 Create KRL program. Step Description 1 Teach reference position above the component. 2 Create task and take images. (>>> 10.4 "Creating a task and taking images (moving)" Page 52) 3 Set up an image processing task in WorkVisual. (>>> 10.5 "Setting up an image processing task in WorkVi- sual" Page 52) 4 Configure task. (>>> 10.9 "Configuring a 3D task" Page 62) 5 Generate model. (>>> 10.10 "Generating a 3D model" Page 64) 6 Test task. (>>> 10.11 "Testing a 3D task" Page 65) 7 Create KRL program.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 3. Select the created task and activate the desired camera by means of the check box in the Configurations area. 4. Press the camera icon, select the calibration plane and press Save pic- ture. Or: In the Task area, press the Settings icon and select Save. The image is saved in the directory C:\KRC\TP\VisionTech\Snap- shots\Name of the task\Camera serial number\Name of the plane. The Snap- shots folder is a shared network resource. A maximum of 20 images can be saved per calibration plane; any further images overwrite the oldest ex- isting image. 10.4 Creating a task and taking images (moving) Precondition  The cameras are networked.  The network has been configured. Procedure 1. In the main menu, select VisionTech > Task configuration. 2. Press New and select the 2D moving or 3D moving type. A new task is created. The name of the task can be changed. 3. Select the created task and activate the camera that is to be used for tak- ing images by means of the check box in the Configurations area. 4. In the task, press the Settings icon and select Save. The images are saved in the directory C:\KRC\TP\VisionTech\Snap- shots\Name of the task\Camera serial number. The Snapshots folder is a shared network resource. A maximum of 20 images can be saved per camera; any further images overwrite the oldest existing image. 10.5 Setting up an image processing task in WorkVisual Step Description 1 Install the image processing environment on the service lap- top. (>>> 10.5.1 "Installing the image processing environment" Page 53) Note: It is advisable to archive all the data on the service lap- top before installation. 2 Install the VisionTech option package in WorkVisual. 3 License the image processing environment in WorkVisual. (>>> 10.5.2 "Licensing the image processing environment in WorkVisual" Page 53) 4 Save any perspective controlled images that were taken via the controller to a USB stick or make them available via the network. 5 Create a tool block file in WorkVisual. (>>> 10.5.3 " Creating a tool block file in WorkVisual" Page 54) 6 Transfer the tool block file to the controller on a USB stick or via the network. Information about installing and managing option packages can be found in the WorkVisual documentation.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 10 Configuration 10.5.1 Installing the image processing environment Precondition  The VisionTech software has been copied to a USB stick, or is accessible via the network. Procedure 1. Copy the software to the service laptop. 2. Execute the file VisionTech.exe in the directory ..\INTERNAT\KRCSET- UP\Vision. The image processing environment is installed. 10.5.2 Licensing the image processing environment in WorkVisual 10.5.2.1 Activating the license Procedure 1. Select the menu sequence Editors > Option packages > VisionTech > License configuration. The License configuration window is opened. 2. Click on Install license. 3. Enter the license key in the License key box. The license key is enclosed with the software. 4. Click on Create footprint and select a directory. A file is generated in the selected directory which links the image processing computer to the li- cense. An encrypted signature for this computer is saved in the file. 5. Send the generated file to [email protected]. KUKA Service will use this to create a licensing file and send it to you. 6. Click on ..., select the received licensing file and confirm with OK. 7. Restart WorkVisual. 10.5.2.2 Repairing the license Description If hardware components are modified, added or exchanged, this may invali- date the license. A license becomes invalid if the current signature of the im- age processing computer differs too greatly from the saved signature. In this case, the license can be repaired. Procedure 1. Select the menu sequence Editors > Option packages > VisionTech > License configuration. The License configuration window is opened. 2. Click on Repair license. 3. In the list of installed licenses, select the license to be repaired. 4. Click on Create repair request and select a directory. A file is generated in the selected directory. Fig. 10-1: Extract from the enclosed printout (example) 1 License key It is not possible to take images with the license for the service laptop.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 5. Send the generated file to [email protected]. KUKA Service will use this to create a new licensing file and send it to you. 6. Click ..., select the received licensing file and confirm with OK. 7. Restart WorkVisual. 10.5.2.3 Activating an emergency license Description It is possible to activate an emergency license. A total of 5 emergency licenses are available. An emergency license is valid for 3 days. On expiry, emergency licenses cannot be reactivated. For this reason, they should only be used in an actual emergency. Procedure 1. Select the menu sequence Editors > Option packages > VisionTech > License configuration. The License configuration window is opened. 2. Click on Install emergency license. 3. Click on Activate emergency license. 4. Restart WorkVisual. 10.5.3 Creating a tool block file in WorkVisual Procedure 1. Open the VisionTech plug-in:  Select the menu sequence Editors > Option packages > VisionTech > Image processing task.  Alternatively: Click on the button. 2. Select the menu sequence Toolblock > New > 2D or 3D. 3. Select the menu sequence Image source > File... or Directory... and se- lect the image(s) that were taken using the controller. 4. Click on the button. The image(s) are inserted next to the inputs under InputImage. 5. Click on the button. Tools and templates are displayed. (>>> 10.5.3.1 "Templates" Page 55) 6. Select the desired template or tool and drag it between the inputs and out- puts. 7. Link the inputs and outputs, e.g. InputImage under the inputs with InputIma- ge in the template. To do so, click on the input or output and drag it onto the other input or output. The link is displayed by an arrow. 8. Double-click on the template and configure the desired pattern. 9. Click on the button and choose whether the tool should be saved com- pletely or without images or results. 10. Select a directory and click on Save.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 10 Configuration Description 10.5.3.1 Templates Fig. 10-2: VisionTech plug-in: overview 1 Linking arrow Template Description LocatePartsOneStage Type: 2D Suitable for parts which are defined by relatively coarse structures, e.g. complete panels. The search area is the entire image. Further tools can be added; only the result of “PatMax” is transferred, however. LocatePartsKnown- Position Type: 2D With this template, a number of parts are searched for in the field of view. The rough position of these parts must be known, however. The search area is limited to the known rough position.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 10.6 Configuring a 2D task During configuration of a 2D task, a tool block is assigned to the camera. A tool block contains image processing tasks and has the file extension VPP. For 2D tasks, only 1 camera is needed; the calibration is carried out at the workpiece level. Precondition  A 2D task has been created.  The following inputs and outputs are preconfigured in the tool block: LocatePart3D Type: 3D With this template, the search procedure is subdivided into 2 steps (analogous to LocatePartTwoStages):  Coarse search The position of the parts in the picture is determined.  Fine search Individual features are located which are required for 3D position de- termination of the part. The features are identified by a consecutive index. The index is positioned at the start of the name of the feature tool block. The numbering starts at zero and must be consecutive. Numbering is largely automatic, however. The fine search is run once for each instance found in the coarse search. Templates for features:  PointFeaturePM Point feature which is located with a PatMax tool.  LineSegFeature Straight line feature; normally represents points on a straight edge of the part that is to be located. Has a start point and end point, which are defined by the search area of the FindLine tool.  LineFeature Line feature, without a start and end point.  CircleFeature Feature which describes a circle in 3D. Note: The PatMax tool and the FindLine tool must not be renamed. The features must be evenly distributed over the component. CrspCollector Collects the data from the FeatureCrsp outputs of 3D feature tool blocks and makes these available at the output as a list of Crsps. In addition, the result images of the Crsps are collected and forwarded in the Graphic output. StringCollector Collects the values at its inputs and returns these values as a string, separated by a vertical bar, at the UserData output. The inputs accept the data types INT32, DOUBLE, BOOL and STRING. These inputs must be created as required. PoseCreator Can be used if a 2D pose is not to be generated by a PatMax tool. The values from which the pose is to be created are provided by the inputs. PoseCollector Collects the individual poses from various tools and generates a list which is returned to the PartResults output. This list is expected at this output by the KUKA interface for 2D tasks. Template Description

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 10 Configuration  The following outputs can optionally be preconfigured: Procedure 1. In the main menu, select VisionTech > Task configuration. 2. Select the desired 2D task. 3. Press the Settings icon and select the number of components to be found. 4. Press Import tool block. 5. Select the directory in which the tool block file is located. 6. Select the tool block file and confirm with OK. The file is imported into Vi- sionTech and can then be used for all tasks. 7. In the line for the camera in the Toolblocks column, select the imported tool block file. 8. Press the camera icon. A window for setting the exposure time is dis- played and the selection of calibration planes is displayed. Input Type Description InputImage ICogImage Input image on which the image processing task is carried out NumberOf- Parts INT Number of components to be detected by means of the image processing Output Type Description PartResults List Positions of the found components in image coordinates Scores List Accuracy with which the compo- nents were detected Graphic CogGraphicCollec- tion Graphic showing the results of the image processing task Output Type Description Error Exception Exceptions or errors that occur dur- ing execution of the image process- ing task UserData Object User-specific data forwarded to KRL by VisionTech. Any type can be used that is derived from Object and overwrites the ToString() method. Note: Do not make strings with a semicolon since this is used as an internal separator. If the tool block is created with WorkVisual, the required inputs and outputs already exist. The directory INTERNAT\KRCSETUP\KRC\TP\VisionTech\Tem- plate on the VisionTech CD contains sample tool blocks which meet the following requirements:  Tool block for 2D tasks with a stationary camera  Tool block for 2D tasks with a moving camera  Tool block for 3D tasks If the selected is too low, this may lead to inconsistencies, e.g. if each camera detects different objects. It is advisable to enter the number of components that one expects to find.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 9. Select the calibration plane. 10. Optionally: Enter the exposure time or set it using the plus/minus keys or the slider control. 11. Press Save. The settings are saved. Configuration of the task has been successfully completed when the icon in the Status column changes to green. Description Fig. 10-3: Configuring a 2D task Item Description 1 Back to Overview 2 Name of the task The name is freely selectable. 3 State of the task  Green: Task has been successfully configured.  Red: Task is not configured. 4 Generate model.  Green frame: Model has been successfully generated.  Red frame: No model has yet been generated. 5 Test task  Activated: The task can be tested.  Deactivated: The task cannot be tested. No model has yet been generated, or the task is not configured. 6 Settings icon  Select the number of parts  Take images from all cameras

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 10 Configuration The following buttons are available: 10.7 Generating a 2D model 10.7.1 2D model with a stationary camera Precondition  The robot base is calibrated to the calibration base. (>>> 9.9 "Calibrating camera (stationary)" Page 46)  The task has been configured.  The icon in the Status column is green.  There is only 1 component in the field of vision of the camera. Procedure 1. In the main menu, select VisionTech > Task configuration. 2. In the Task area, press Model. A model is generated and a result window is displayed. 3. The images in the result window can be enlarged. To do so, press the de- sired image once. Generation of the model has been successfully completed when the Mod- el button has a green frame. The reference position of the component is now known; all deviations are relative to this position. Description Once the model has been generated, a result window with images and a table is displayed. The result is the position of the component in the calibration base. Areas detected by the cameras are indicated in green in the images. Areas that have not been detected are marked in red. 7 Camera icon  Set exposure time  0 … 200 ms  Select calibration plane  Take images from this camera 8 Exposure time that has been set 9 Select tool block file 10 Serial number of the camera 11  Activated: Camera is used.  Deactivated: Camera is not used. Button Description New Creates a new task. Delete Deletes the selected task from the list and from the file system. Refresh tasks Reloads all tasks and tool blocks in the directory C:\KRC\TP\VisionTech\Tasks. Import tool block Copies the selected file into the directory C:\KRC\TP\VisionTech\ToolBlocks. The file can then be selected in every task via the selection box in the Toolblocks column. Item Description

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 10.7.2 2D model with a moving camera Precondition  The XY plane of the workpiece base is located on the surface of the com- ponent.  The Z axis of the workpiece base points in the same direction as the cali- bration coordinate system.  The task has been configured.  The icon in the Status column is green.  There is only 1 component in the field of vision of the cameras.  The NULLFRAME tool is selected. Procedure 1. In the main menu, select VisionTech > Task configuration. 2. Move the robot to the reference pose. 3. In the Task area, press Model. Confirm the request with Yes. A model is generated and a result window is displayed. 4. The images in the result window can be enlarged. To do so, press the de- sired image once. Generation of the model has been successfully completed when the Mod- el button has a green frame. The reference position of the component is now known; all deviations are relative to this position. Description Once the model has been generated, a result window with images and a table is displayed. The result is the position of the component in the workpiece base. Areas detected by the cameras are indicated in green in the images. Areas that have not been detected are marked in red. Fig. 10-4: Result of 2D model generation with a stationary camera (exam- ple)

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 10 Configuration 10.8 Testing a 2D task Precondition  The task has been configured.  The model has been generated.  The base is the same as was used for model generation.  Only with use of a moving camera: the NULLFRAME tool is selected. Procedure 1. In the main menu, select VisionTech > Task configuration. 2. Only with use of a moving camera: move the robot to the reference pose. 3. In the Task area, press Test. The test is carried out and a result window is displayed. 4. The images in the result window can be enlarged. To do so, press the de- sired image once. If user data from the tool block have been transferred, they are displayed beneath the enlarged image. Description Once the test has been performed, a result window with images and a table is displayed. Areas detected by the cameras are indicated in green in the images. Areas that have not been detected are marked in red. The differences between the reference position used for model generation and the calculated position are displayed in the table. If multiple components have been detected, the tables are displayed on tabs. The value of Score is between 0.0 and 1.0. The better the match between the trained pattern and the pattern in the current search image, the higher the val- ue of Score. Fig. 10-5: Result of a 2D task test (example)

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 10.9 Configuring a 3D task During configuration of a 3D task, a tool block is assigned to the cameras. A tool block contains image processing tasks and has the file extension VPP. For 3D tasks, at least 2 cameras are required. Precondition  A 3D task has been created.  The following inputs and outputs are preconfigured in the tool block:  The following outputs can optionally be preconfigured: Procedure 1. In the main menu, select VisionTech > Task configuration. 2. Select the desired 3D task. 3. Press the Settings icon and select the number of components to be found. 4. Press Import tool block. 5. Select the directory in which the tool block file is located. Input Type Description InputImage ICogImage Input image on which the image processing task is carried out NumberOf- Parts INT Number of components to be detected by means of the image processing Output Type Description Graphic CogGraphicCollec- tion Graphic showing the results of the image processing task Features List List of features found by means of the image processing Output Type Description Error Exception Exceptions or errors that occur dur- ing execution of the image process- ing task UserData Object User-specific data forwarded to KRL by VisionTech. Any type can be used that is derived from Object and overwrites the ToString() method. Note: Do not make strings with a semicolon since this is used as an internal separator. If the tool block is created with WorkVisual, the required inputs and outputs already exist. The directory INTERNAT\KRCSETUP\KRC\TP\VisionTech\Tem- plate on the VisionTech CD contains sample tool blocks which meet the following requirements:  Tool block for 2D tasks with a stationary camera  Tool block for 2D tasks with a moving camera  Tool block for 3D tasks If the selected is too low, this may lead to inconsistencies, e.g. if each camera detects different objects. It is advisable to enter the number of components that one expects to find.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 10 Configuration 6. Select the tool block file and confirm with OK. The file is imported into Vi- sionTech and can then be used for all tasks. 7. Repeat steps 5 to 7 for further tool block files used. 8. In the line for the desired camera in the Toolblocks column, select the im- ported tool block file. 9. Press the camera icon. A window for setting the exposure time is dis- played and the taking of images is displayed. 10. Optionally: Enter the exposure time or set it using the plus/minus keys or the slider control. 11. Press Save picture. An image is made. 12. Press Save. The setting is saved. Configuration of the task has been successfully completed when the icon in the Status column changes to green. Description Fig. 10-6: Configuring a 3D task Item Description 1 Back to Overview 2 Name of the task The name is freely selectable. 3 State of the task  Green: Task has been successfully configured.  Red: Task is not configured. 4 Generate model  Green frame: Model has been successfully generated.  Red frame: No model has yet been generated.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 The following buttons are available: 10.10 Generating a 3D model Precondition  The task has been configured.  The state of the task is green.  There is only 1 component in the field of vision of the cameras.  The NULLFRAME tool is selected. Procedure 1. In the main menu, select VisionTech > Task configuration. 2. Move the robot to the reference pose. 3. In the Task area, press Model. Confirm the request with Yes. A model is generated and a result window is displayed. 4. The images in the result window can be enlarged. To do so, press the de- sired image once. Generation of the model has been successfully completed when the Mod- el button has a green frame. The reference position of the component is now known; all deviations are relative to this position. Description Once the model has been generated, a result window with images and a table is displayed. Areas detected by the cameras are indicated in green in the im- ages. Areas that have not been detected are marked in red. All configured 5 Test task  Activated: The task can be tested.  Deactivated: The task cannot be tested. No model has yet been generated, or the task is not configured. 6 Settings icon  Select the number of parts  Take images from all cameras 7 Camera icon  Set exposure time  0 … 200 ms  Take images from this camera 8 Exposure time that has been set 9 Select tool block file 10 Serial number of the camera 11  Activated: Camera is used.  Deactivated: Camera is not used. Button Description New Creates a new task. Delete Deletes the selected task from the list and from the file system. Refresh tasks Reloads all tasks and tool blocks in the directory C:\KRC\TP\VisionTech\Tasks. Import tool block Copies the selected file into the directory C:\KRC\TP\VisionTech\ToolBlocks. The file can then be selected in every task via the selection box in the Toolblocks column. Item Description

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 10 Configuration model points are listed in the table. For each model point, the model type is specified and whether or not it has been found. The maximum and mean error when finding the model point are also specified. For good results, the RMS er- ror should be < 1 mm. 10.11 Testing a 3D task Precondition  The task has been configured.  The model has been generated.  The base is the same as was used for model generation.  The NULLFRAME tool is selected. Procedure 1. In the main menu, select VisionTech > Task configuration. 2. Move the robot to the reference pose. 3. In the Task area, press Test. The test is carried out and a result window is displayed. 4. The images in the result window can be enlarged. To do so, press the de- sired image once. If user data from the tool block have been transferred, they are displayed beneath the enlarged image. Description Once the test has been performed, a result window with images and a table is displayed. Areas detected by the cameras are indicated in green in the images. Areas that have not been detected are marked in red. The differences between the reference position and the calculated position are displayed in the table. If mul- tiple components have been detected, the tables are displayed on tabs. Fig. 10-7: Result of 3D model generation (example)

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 The value of Score is the mean square residual error after calculation of the object position relative to the nominal position. If the position of the object can- not be calculated, Score has the value -1. Fig. 10-8: Result of a 3D task test (example)

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 11 Programming 11 Programming 11.1 Note on programming 11.2 Subprogram VT_INIT Description The subprogram VT_INIT initializes the EKI channel. The configuration file is transferred. VT_INIT is executed in the advance run. Syntax VT_INIT("Name of the configuration file") Explanation of the syntax Example 11.3 Subprogram VT_OPENCONNECTION Description The subprogram VT_OPENCONNECTION opens an EKI connection to the server. The configuration file is transferred. VT_OPENCONNECTION is exe- cuted in the advance run. Syntax VT_OPENCONNECTION("Configuration file") Explanation of the syntax Example 11.4 Subprogram VT_TASKTRIGGER Description The subprogram VT_TASKTRIGGER requests acquisition and processing of the images. The configuration file and the name of the image processing task are transferred. VT_TASKTRIGGER triggers an advance run stop. Syntax VT_TASKTRIGGER("Configuration file", "Image processing task") Explanation of the syntax VisionTech is programmed using not KRL commands, but subpro- grams. The default configuration file has the name “VisionTechConfig”. Element Description Configuration file Name of the configuration file Type: CHAR (IN) VT_INIT("VisionTechConfig") Element Description Configuration file Name of the configuration file Type: CHAR (IN) VT_OPENCONNECTION("VisionTechConfig") For this subprogram, the same base and the same tool files must be used as for model generation. The result is calculated relative to the base for model generation. Element Description Configuration file Name of the configuration file Type: CHAR (IN) Image processing task Name of the image processing task to be executed Type: CHAR (IN)

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 Example 11.5 Subprogram VT_TASKTRIGGER_REFBASE Description The subprogram VT_TASKTRIGGER_REFBASE requests acquisition and processing of the images. The configuration file and the name of the image processing task are transferred. Any base can be used for the execution of the subprogram. However, the same tool files must be used as for model generation. The result of the image processing is calculated relative to the reference base. VT_TASKTRIGGER_REFBASE triggers an advance run stop. Syntax VT_TASKTRIGGER_REFBASE("Configuration file", "Image processing task", Refe- rence base) Explanation of the syntax Example 11.6 Subprogram GET_VTRESULT Description The return value of GET_VTRESULT is the result of the previously executed image processing task in the form of a VTRESULT structure. The configura- tion file is transferred. The subprogram is executed in the advance run. Syntax RET = GET_VTRESULT("Configuration file") Explanation of the syntax Example 11.7 Subprogram GET_VTCORRECTIONFRAME Description The return value of GET_VTCORRECTIONFRAME is the correction frame ex- tracted from the image processing result. The image processing result is trans- ferred. GET_VTCORRECTIONFRAME is executed in the advance run. Syntax RET = GET_VTCORRECTIONFRAME(Image processing result) VT_TASKTRIGGER("VisionTechConfig", "TestTask") Element Description Configuration file Name of the configuration file Type: CHAR (IN) Image processing task Name of the image processing task to be executed Type: CHAR (IN) Reference base Base frame relative to which the result (= deviation in this base) is to be output Type: FRAME (IN) VT_TASKTRIGGER_REFBASE("VisionTechConfig", "TestTask", referenceFrame) Element Description RET Data structure containing the result of an image pro- cessing task Type: VTRESULT Configuration file Name of the configuration file Type: CHAR (IN) DECL VTRESULT RESULT RESULT = GET_VTRESULT("VisionTechConfig")

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 11 Programming Explanation of the syntax Example 11.7.1 Structure of VTRESULT 11.8 Subprogram VTRESULT_CHECK Description The subprogram VTRESULT_CHECK checks the result of an image process- ing task. If the result is faulty, a message is displayed. The result of the image Element Description RET Correction frame that can be offset against the compo- nent base Type: FRAME Image processing result Image processing result from which the correction frame is extracted Type: VTRESULT (IN) (>>> 11.7.1 "Structure of VTRESULT" Page 69) DECL VTRESULT RESULT RESULT = GET_VTRESULT("VisionTechConfig") CORRECTIONFRAME = GET_VTCORRECTIONFRAME(RESULT) BASE_DATA[3] = BASE_DATA[2]:CORRECTIONFRAME Name Unit Data type Description X mm REAL Translational deviation in the X direction relative to the nominal position. Y mm REAL Translational deviation in the Y direction relative to the nominal position. Z mm REAL Translational deviation in the Z direction relative to the nominal position. A degrees REAL Rotational deviation about the Z axis rela- tive to the nominal position. B degrees REAL Rotational deviation about the Y axis rela- tive to the nominal position. C degrees REAL Rotational deviation about the X axis rela- tive to the nominal position. SCORE REAL For a 2D task: Match between the trained pattern and the pattern on the current search image. Note: The value is normally between 0.0 and 1.0. The closer the value is to 1.0, the better the match. For a 3D task: Mean square residual error after calcula- tion of the object position relative to the nominal position. Note: If the position of the object cannot be calculated, the value -1 is displayed. SUCCEEDED BOOL  TRUE: The image processing task has been executed successfully.  FALSE: An error occurred during exe- cution of the image processing task. ERRORMESSAGE CHAR[100] Indicates errors that have occurred during execution of the image processing task.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 processing task is transferred. VTRESULT_CHECK is executed in the ad- vance run. Syntax VTRESULT_CHECK(Image processing result) Explanation of the syntax Example 11.9 Subprogram VT_RESULTCHECK2 Description The subprogram VT_RESULTCHECK2 checks the result of an image pro- cessing task. If the result is faulty, a message is displayed. The result of the image processing task is transferred. VT_RESULTCHECK2 is executed in the advance run. Syntax RET = VT_RESULTCHECK2(Image processing result) Explanation of the syntax Example 11.10 Subprogram VT_WAIT Description The subprogram VT_WAIT stops the program sequence until the flag is set to the value TRUE. Program execution is then resumed. VT_WAIT triggers an advance run stop. Syntax VT_WAIT("Flag") Explanation of the syntax Element Description Image processing result The image processing result that is to be checked Type: VTRESULT (IN) DECL VTRESULT RESULT RESULT = GET_VTRESULT("VisionTechConfig") VTRESULT_CHECK(RESULT,"VisionTechConfig") Element Description RET Return value Type: BOOL  TRUE: The image processing task has been exe- cuted successfully.  FALSE: An error occurred during execution of the image processing task. Image processing result The image processing result that is to be checked Type: VTRESULT (IN) DECL VTRESULT RESULT RESULT = GET_VTRESULT("VisionTechConfig") VT_RESULTCHECK2(RESULT,"VisionTechConfig") The flag for which the program is to wait is the same flag that is set to TRUE in the subprograms DO_GETVTRESULT and DO_GETVTRESULTS. Element Description Flag Number of the flag for which the program is to wait Type: INT (IN)

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 11 Programming 11.11 Subprogram VT_CLOSECONNECTION Description The subprogram VT_CLOSECONNECTION closes all existing connections to the server. The configuration file is transferred. VT_CLOSECONNECTION is executed in the advance run. Syntax VT_CLOSECONNECTION("Configuration file") Explanation of the syntax Example 11.12 Subprogram VT_CLEAR Description The subprogram VT_CLEAR ends the EKI channel. The configuration file is transferred. VT_CLEAR is executed in the advance run. Syntax VT_CLEAR("Configuration file") Explanation of the syntax Example 11.13 Subprogram VT_CHECKPOSELIMIT Description The subprogram VT_CHECKPOSELIMIT determines whether the target robot pose (here: P1') lies within the defined limit range. The defined limit value specifies a range about the original robot pose (here: P1). The range is repre- sented here by a circle. The defined limit value specifies the radius of the circle in which the target robot pose must lie. If e.g. a limit value of 100 mm is specified, the target robot pose must lie within a radius of 100 mm about the original robot pose. VT_CHECKPOSELIMIT is executed in the advance run. Element Description Configuration file Name of the configuration file Type: CHAR (IN) VT_CLOSECONNECTION("VisionTechConfig") Ensure that no data are called by a connection that has already been terminated by VT_CLEAR. Element Description Configuration file Name of the configuration file Type: CHAR (IN) VT_CLEAR("VisionTechConfig") This subprogram only remains supported for reasons of compatibility. It is recommended to use the subprogram VT_CHECKPOSE instead.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 Syntax RET = VT_CHECKPOSELIMIT("Robot pose", "Frame", "Offset") Explanation of the syntax 11.14 Subprogram VT_CHECKPOSE Description The subprogram VT_CHECKPOSE checks whether points on the robot de- fined by the user lie within an area defined by the user. The points on the robot defined by the user are defined relative to the robot flange. Up to 10 points can be defined. (>>> 11.14.1 "Defining the points on the robot" Page 74) It must be possible for all defined points to be addressed by the robot in the NULLFRAME base and with the NULLFRAME tool. If a point is located outside of the robot’s workspace, the robot stops. Fig. 11-1: Base correction with VT_CHECKPOSELIMIT 1 Base correction 2 Offset of point P1 due to the base correction 3 Radius (limit value) Element Description RET Return value Type: BOOL  TRUE: The target robot pose lies within the defined limit range.  FALSE: The limit value is exceeded. Robot pose The robot pose to be checked Type: FRAME (IN) Frame Frame returned by the function GET_VTCORRECTIONFRAME Type: FRAME (IN) Offset Maximum offset between the original robot pose and the robot pose in the new workpiece base in mm Type: REAL (IN)

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 11 Programming Syntax RET = VT_CHECKPOSE("Base of the area", "Limit value X", "Limit value Y", "Limit value Z", "Base of the gripping point", "Gripping point", "Tool") VT_CHECKPOSE can only be used once the gripping point of the component has been taught. Fig. 11-2: Example: Defined points and defined area 1 Defined point on the robot 2 Defined area (green) Fig. 11-3: Example: Defined points within and outside of the defined area 1 Defined point within the defined area 2 Defined point outside of the defined area

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 Explanation of the syntax Example All points (relative to the robot flange) in base 16 that lie within the following values are valid:  X value: max. 700 mm  Y value: max. 950 mm  Z value: max. 900 mm The gripping point is in base 11 and taught with tool 1. 11.14.1 Defining the points on the robot Preparation 1. Open the file ConfigMon.ini in the directory D:\KUKA_OPT\VisionTech\IN- TERNAT\KRCSETUP\UTIL. 2. Copy sections [Group1] and [Group2]. 3. Open the file ConfigMon.ini in the directory C:\KRC\USER. 4. Insert the copied sections under the existing group sections. 5. Adapt the index numbers. If, for example, the sections [Group1] to [Group3] already exist, rename the new sections as [Group4] and [Group5]. 6. Save and close the file. Element Description RET Return value Type: BOOL  TRUE: All points defined by the user lie within the defined limit values.  FALSE: The limit value of at least one point has been exceeded. Base of the area Number of the base within which the point to be checked must lie Type: INT (IN) Limit value X Maximum limit value of the base in X direction Type: INT (IN) Limit value Y Maximum limit value of the base in Y direction Type: INT (IN) Limit value Z Maximum limit value of the base in Z direction Type: INT (IN) Base of the grip- ping point Number of the base in which the component must be gripped Type: INT (IN) Gripping point Point at which the component is gripped Type: FRAME (IN) Tool Number of the tool with which the component must be gripped Type: INT (IN) RET = VT_CHECKPOSE(16,700,950,900,11,XGrippingPos,1) Preparation only needs to be carried out once after installation.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 11 Programming Procedure 1. In the main menu, select Variable > Overview > Display. 2. Mark a variable in the UserCheckPoints tab and press Edit. 3. Enter the X, Y and Z values and save with OK. 4. Repeat steps 2 to 3 for the further points used. Enter the points in an un- interrupted sequence from 1 to 10. If, for example, 5 points are desired, enter the values into the variables UserCheckPoint[1] to UserCheck- Point[5]. 11.15 Subprogram GET_VTUSERDATA Description The subprogram GET_VTUSERDATA calls up optional user data from all con- figured tool blocks and makes them available to the KRL. GET_VTUSERDATA is executed in the advance run. Syntax GET_VTUSERDATA("Configuration file", User data) Explanation of the syntax Example 11.16 Subprogram DO_GETVTRESULT Description The subprogram DO_GETVTRESULT is used for the detection of a compo- nent. DO_GETVTRESULT reads in the result of the image processing and creates a result structure. The result is written to the transfer parameter RESULT. The flags are then set to TRUE and FALSE. The subprogram is executed in the ad- vance run. DO_GETVTRESULT can also be used as an interrupt program. This is called after the image processing task has been executed. In this case, the subpro- gram is executed in the main run. Syntax DO_GETVTRESULT("Configuration file", RESULT, "Flag True", "Flag False") VT_CHECKPOSE ignores all variables in which all values are 0. For the execution of the subprogram, 1 entry with user data from the tool block is created for each camera. Element Description Configuration file Name of the configuration file Type: CHAR (IN) User data 2-dimensional array into which user data are written. The first dimension corresponds to the camera index, the second dimension contains the user data as a char- acter string. Type: CHAR (OUT) DECL CHAR USERDATA[2, 100] GET_VTUSERDATA("VisionTechConfig" USERDATA[ , ]) The flag that is to be set to TRUE is the same flag that is used in the subprogram VT_WAIT. The flag that is to be set to FALSE is defined in the configuration file.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 Explanation of the syntax Example 11.17 Subprogram DO_GETVTRESULTS Description The subprogram DO_GETVTRESULTS is used for the detection of multiple components. DO_GETVTRESULTS generates a result structure for all object instances found. This is written to the transfer parameter RESULTS. Once the subpro- gram has been executed, the parameter PARTCOUNTER contains the num- ber of components that have been found by the image processing system. The flags are then set to TRUE and FALSE. The subprogram is executed in the ad- vance run. DO_GETVTRESULT can also be used as an interrupt program. This is called after the image processing task has been executed. In this case, the subpro- gram is executed in the main run. Syntax Syntax: DO_GETVTRESULTS("Configuration file", RESULTS[], PART- COUNTER, "Flag True", "Flag False") Explanation of the syntax Example Element Description Configuration file Name of the configuration file Type: CHAR (IN) RESULT Result of image processing Type: VTRESULT (OUT) Flag True Number of the flag to be set to TRUE once the result has been read Type: INT (IN) Flag False Number of the flag to be set to FALSE once the result has been read Type: INT (IN) DECL VTRESULT RESULT DO_GETVTRESULT("VisionTechConfig", RESULT, 1, 998) Element Description Configuration file Name of the configuration file Type: CHAR (IN) RESULTS Results of image processing Type: VTRESULT (OUT) PART- COUNTER Contains the number of object instances found after execution of the subprogram Type: INT (OUT) Flag True Number of the flag to be set to TRUE once the result has been read Type: INT (IN) Flag False Number of the flag to be set to FALSE once the result has been read Type: INT (IN) DECL VTRESULT[100] RESULTS DECL INT PARTCOUNTER = 0 DO_GETVTRESULTS("VisionTechConfig", RESULTS, PARTCOUNTER, 1, 998)

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 11 Programming 11.18 Subprogram VT_DIRECT Description The subprogram VT_DIRECT calculates the status of axis 5 at the end point in such a way that axes 4 and 6 are moved as little as possible. The program requires the coordinates X, Y, Z, A, B and C of start and end points as well as the status of the start point. Start and end points can be taught with different tools and base coordinate systems. In order for these to be calculated for the axis angles, the tool and base must be transferred as a parameter for each start and end point. Syntax VT_DIRECT("Start point"), ("End point"), ("Base of the start point"), ("Base of the end point"), ("Tool of the start point"), ("Tool of the end point") Explanation of the syntax Example If the status for the basic area or for axes 2 and 3 changes from the start point to the end point, the program can no longer be used. Element Description Start point Type: E6POS (IN) End point Type: E6POS (IN) Base of the start point Number of the base of the start point Type: FRAME (IN) Base of the end point Number of the base of the end point Type: FRAME (IN) Tool of the start point Number of the tool of the start point Type: FRAME (IN) Tool of the end point Number of the tool of the end point Type: FRAME (IN) PTP VorPunkt Vel=100 % PDAT21 Tool[1]:Measuring Tip Base[1]:kalib VT_DIRECT(XVorPunkt,XGreifpunkt,base_data[1],base_data[11], tool_data[1],tool_data[10]) PTP Greifpunkt Vel=10 % PDAT12 Tool[10]:Measuring Tip Base[11]:greif

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 12 Example programs 12 Example programs 12.1 Example program Program 1 DEF Example( ) 2 3 DECL CHAR AppData[100,100] 4 DECL BOOL InGrippingZone, CheckPose_ok, Result_valid 5 DECL INT Part 6 DECL FRAME CorrFrame,GrippingPoint 7 8 INI 9 10 INTERRUPT DECL 98 WHEN $FLAG[998]==TRUE DO DO_GETVTRESULTS ("VisionTechConfig",RESULTS[],PARTCOUNTER,1,998) 11 INTERRUPT ON 98 12 13 PTP StartPos Vel=100 % PDAT1 Tool[0] Base[0] 14 15 BASE_DATA[11]=$NULLFRAME 16 $FLAG[1]=FALSE 17 InGrippingZone=False 18 Result_valid=False 19 PARTCOUNTER=0 20 21 VT_INIT("VisionTechConfig") 22 VT_OPENCONNECTION("VisionTechConfig") 23 VT_TASKTRIGGER_REFBASE("VisionTechConfig","Demo",BASE_DATA[16]) 24 VT_WAIT(1) 25 26 Get_vtuserdata("VisionTechConfig",appdata[,]) 27 28 FOR Part = 1 TO PARTCOUNTER STEP 1 29 30 Result_valid=VT_RESULTCHECK2(RESULTS[PART]) 31 32 CorrFrame=Get_VTCORRECTIONFRAME(RESULTS[PART]) 33 Base_Data[11]=BASE_DATA[16]:Corrframe 34 CheckPose_ok=VT_CHECKPOSE(12,700,950,950,11,xGrippingPos,1) 35 36 ;halt 37 38 IF(CheckPose_ok==True) then 39 40 IF(Part==1) then 41 VT_DIRECT(XStartPos,XProGrippingPos,$nullframe,base_data[11], $nullframe,tool_data[1]) 42 ELSE 43 VT_DIRECT(XPostGrippingPos,XProGrippingPos,base_data[11], base_data[11],tool_data[1],tool_data[1]) 44 ENDIF 45 PTP ProGrippingPos Vel=100 % PDAT2 Tool[1] Base[11] 46 47 VT_DIRECT(XProGrippingPos,XGrippingPos,base_data[11], base_data[11],tool_data[1],tool_data[1]) 48 PTP GrippingPos Vel=100 % PDAT3 Tool[1] Base[11] 49 50 VT_DIRECT(XGrippingPos,XPostGrippingPos,base_data[11], base_data[11],tool_data[1],tool_data[1]) 51 PTP PostGrippingPos Vel=100 % PDAT4 Tool[1] Base[11] 52 ENDIF 53 ENDFOR 54 55 VT_Closeconnection("VisionTechConfig") 56 VT_Clear("VisionTechConfig") 57 58 END

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 Description Line Description 3 … 6 Declaration of the variables required for the example pro- gram. 10 Defines the interrupt program that is to be executed when the result of the image processing is received. On successful execution, the program sets flag 1 to TRUE. This signals to the main program that execution can be resumed. The num- ber of workpiece instances found is saved in the PartCounter variable. Note: The variables PartCounter and RESULTS[] must be declared in the DAT file. 13 Start position of the robot  2D fixed: The robot is located outside of the camera’s field of vision. The component is located in the camera’s field of vision.  2D and 3D moving: The robot is located above the compo- nent. The component is located in the camera’s field of vi- sion. 15 Initializes the base in which the gripping point of the robot must be taught. 16 Flag 1 is set to FALSE. 17 … 19 Variables required for the further program sequence are ini- tialized. 21 Initializes the EKI channel with the data from the configuration file. 22 Opens an EKI connection to the server. 23 Requests execution of the task with the name “Demo”. The result is output in base 16. As an alternative, the subprogram VT_Tasktrigger() can be used.  2D fixed: The result is output in the calibration base.  2D and 3D moving: The result is output in the base of the image acquisition point or the model generation (the base of the image acquisition point and the base of the model generation must be identical). 24 Waits for flag 1. This is set by the interrupt program when the result of the image processing is received. Execution of the main program is then resumed. 26 Calls the user data of the executed task and saves them in the 2-dimensional array APPDATA[,]. Note: The program also functions without this call. 28 Executes the loop for each component instance found. 30 Checks the results of all components found. If a result is faulty, a message is displayed. Note: The program also functions without this call. 32 Takes the frame data required for the correction from the result. 33 Calculates the base in which the component must be gripped. 34 Checks whether points defined by the user lie within the area defined by the user. In this example, relative to base 12. Note: The program also functions without this call.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 12 Example programs 36 Stops the program. During the initial execution of the pro- gram, the points ProGrippingPos, GrippingPos and PostGrip- pingPos in the newly calculated coordinate system (here: base 11) must be taught here. 38 The query is TRUE if all defined points are located within the defined area. 40 … 45 Calculates the motion between 2 points in such a way that axis 4 and axis 6 are moved as little as possible. The query determines whether only 1 component (start point -> ProGrip- pingPos) or multiple components (PostGrippingPos -> Pro- GrippingPos) have been detected. Note: The program also functions without this call. 47 … 51 The point is addressed in the corrected component base. Note: The program also functions without lines 43, 47 and 50. 55 Terminates all existing connections to the server. 56 Terminates the EKI channel. Line Description

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 13 Messages 13 Messages Message Cause Remedy An error occurred when creat- ing the task {Task name}: {Error message} Insufficient access rights. Apply for the relevant access rights. The directory C:\KRC\TP\VisionTech\Tasks does not exist. Create the directory. An error occurred while acquiring an image from sen- sor {Serial number}: {Error message} The connection to the camera has been interrupted. Check and restore the con- nection. The camera is performing a different process. Terminate the process and restart the controller. Failed to save the calibration result Insufficient access rights. Apply for the relevant access rights. There is already a write-pro- tected calibration result avail- able. Turn to person who created the existing calibration result. The directory C:\KRC\TP\VisionTech\Sen- sorCalibration does not exist. Create the directory. Connection to sensor failed The camera is not connected. Connect the camera and restart the controller. The connecting cable is defec- tive. Exchange the connecting cable and restart the control- ler. Cannot establish a connection to the image processing mod- ule. VisionTech is not ready for operation The image processing module is not yet completely loaded. Wait until the image process- ing module is completely loaded. The image processing module is not correctly installed. Contact KUKA Service. An unknown exception occurred while acquiring a pic- ture from the sensor {Serial number}: {Error message} The camera is not connected. Connect the camera and restart the controller. The camera is performing a different process. Terminate the process and restart the controller. The connection to the camera has been interrupted. Check and restore the con- nection. The amount of captured pic- tures is not sufficient for per- forming a calibration Too few images were taken for performance of a calibration. Take at least 6 images. The following error occurred during calibration: {Error mes- sage} The fiducial mark is not detected in all the images. Move to the poses again and ensure that the fiducial mark is visible in every pose. The robot poses used are unsuitable for calculating the calibration. Move to the poses again and ensure that the poses differ to a greater extent. No sensor selected for the cal- ibration No camera is selected. Select a camera and restart calibration. An error occurred while saving the general sensor settings: {Error message} Insufficient access rights to the file system. Apply for the relevant access rights. The existing camera settings are write-protected. Contact the person who saved the existing camera settings.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 Model for task {Task name} could not be created: {Error message} It was not possible to detect features in the images because the lighting was too strong or too weak. Set the lighting lower or higher. Too few features were detected in the images because each camera detected different features. Align the cameras so that each camera can detect the same features. No object could be detected because the object was not in the field of vision of the cam- eras. Align the cameras so that the object is in the field of vision. The following error occurred while creating the reference model for task {Task name}: {Error message} It was not possible to detect features in the images because the lighting was too strong or too weak. Set the lighting lower or higher. Too few features were detected in the images because each camera detected different features. Align the cameras so that each camera can detect the same features. No object could be detected because the object was not in the field of vision of the cam- eras. Align the cameras so that the object is in the field of vision. The following error occurred while loading the task: {Error message} The task is not compatible with this version of Vision- Tech. Only use compatible tasks. The task does not have the TASK file format. Only use files with the TASK format. The sensor {Serial number} has no connection The camera is not connected to the robot controller. Establish the connection and restart the controller. The camera is performing a different process. Terminate the process and restart the controller. The maximum number of cap- tured images has been reached. It is not possible to add further images The maximum number of images has already been taken. Start calibration or terminate the calibration process. Failed to calculate the position of the object It was not possible to detect features in the images because the lighting was too strong or too weak. Set the lighting lower or higher. Too few features were detected in the images because each camera detected different features. Align the cameras so that each camera can detect the same features. No object could be detected because the object was not in the field of vision of the cam- eras. Align the cameras so that the object is in the field of vision. Message Cause Remedy

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 13 Messages Failed to calculate the position of the part It was not possible to detect features in the images because the lighting was too strong or too weak. Set the lighting lower or higher. Too few features were detected in the images because each camera detected different features. Align the cameras so that each camera can detect the same features. No component could be detected because the compo- nent was not in the field of vision of the cameras. Align the cameras so that the component is in the field of vision. Not enough features have been detected for calculating the object position It was not possible to detect features in the images because the lighting was too strong or too weak. Set the lighting lower or higher. Too few features were detected in the images because each camera detected different features. Align the cameras so that each camera can detect the same features. No object could be detected because the object was not in the field of vision of the cam- eras. Align the cameras so that the object is in the field of vision. Not enough features have been detected for calculating the position of the part It was not possible to detect features in the images because the lighting was too strong or too weak. Set the lighting lower or higher. Too few features were detected in the images because each camera detected different features. Align the cameras so that each camera can detect the same features. No component could be detected because the compo- nent was not in the field of vision of the cameras. Align the cameras so that the component is in the field of vision. The execution of a toolblock failed The tool block is faulty. Check the tool block in the image processing environ- ment or test the task in Vision- Tech. No toolblocks defined for the specified task The task has not been config- ured completely. Configure the task completely and generate a model. No toolblocks are set for the specified task. The task has not been config- ured completely. Configure the task completely and generate a model. Message Cause Remedy

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 An unknown error occurred while testing the task It was not possible to detect features in the images because the lighting was too strong or too weak. Set the lighting lower or higher. Too few features were detected in the images because each camera detected different features. Align the cameras so that each camera can detect the same features. No object could be detected because the object was not in the field of vision of the cam- eras. Align the cameras so that the object is in the field of vision. The following error occurred while saving the task: {Error message} Insufficient access rights. Apply for the relevant access rights. There is already a write-pro- tected task available with the same name. Contact the person who cre- ated the existing task. The directory C:\KRC\TP\VisionTech\Tasks does not exist. Create the directory. The task has no model. It is not possible to execute the task No model has been generated for this task. Generate a model. Failed to match the part instances found in the tool- blocks The features are incorrectly configured in the tool block: the order of the numbering of the features differs for 2 or more cameras. Check the tool block in the image processing environ- ment. The order of the num- bering of the features must be the same for all cameras. Different objects can be seen in the camera images. Align the cameras so that the same objects are in the field of vision of all cameras. The calibration contains errors. Recalibrate the cameras. Too few features have been detected. At least 3 features must be detected. Not enough features found for determining the part's position The tool block is faulty. Check the tool block in the image processing environ- ment. At least 3 features must be detected. The object is not fully in the field of vision of the camera. Align the cameras so that the same objects are in their field of vision. The lighting is too weak. Increase the lighting setting. The connection to one of the sensors could not be estab- lished The camera is not connected. Connect the camera and restart the controller. The connecting cable is defec- tive. Exchange the connecting cable and restart the control- ler. Image acquisition with one of the sensors failed The connection to the camera has been interrupted. Check and restore the con- nection. The camera is performing a different process. Terminate the process and restart the controller. Message Cause Remedy

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 13 Messages The specified task could not be found The task has not been loaded. Load the task with Refresh tasks. The task does not exist. Check the spelling. Unknown error during the exe- cution of a task It was not possible to detect features in the images because the lighting was too strong or too weak. Set the lighting lower or higher. Too few features were detected in the images because each camera detected different features. Align the cameras so that each camera can detect the same features. No object could be detected because the object was not in the field of vision of the cam- eras. Align the cameras so that the object is in the field of vision. Invalid calibration pose The following causes can be ruled out:  TOOL or BASE data differ from those of the previous pose.  Identical or similar coordi- nates to those of the previ- ous pose. Try a different calibration pose. Unable to create image buffer in memory: {Error message} Invalid image information. Only use valid image formats. Insufficient memory available. Contact KUKA Service. No image buffer available: {Error message} No image source has been ini- tialized. Contact KUKA Service. Unable to write the data to the image buffer: {Error message} Insufficient memory reserved for the image source. Only use valid image formats. An error occurred when changing the default exposure time The camera cannot be accessed. Check the connection to the camera. An error occurred when changing the calibration expo- sure time The camera cannot be accessed. Establish the connection to the camera. An error occurred when sav- ing the image from sensor {Serial number} The camera is performing a different process. Terminate the process and restart the controller. The camera is in an invalid connection state. Check the connection to the camera. The entered name {Task name} contains invalid char- acters. Please choose a differ- ent name The task name contains one or more of the following char- acters: \ / : * ? " < > | Delete the invalid characters from the name. An error occurred while saving the network settings of the sensor: {Error message} The network settings are faulty, see error description. Change the network settings. The task {Task name} cannot be deleted: {Error message} Another program or user is accessing the task. Exit the other programs. The task no longer exists. Update the task list. Message Cause Remedy

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 The calibration type of a sen- sor is not compatible with the task type A camera with the wrong cali- bration type has been assigned to the task, e.g. a stationary 2D camera has been assigned a 3D task. Assign a different camera to the task. An incorrectly calibrated cam- era has been assigned to a task. Recalibrate the camera. One of the configured sensors is not connected The camera is not connected. Connect the camera. Error in the subprogram DO_GETVTRESULTS. The transferred array is too small The size of the transferred array is too small. Declare an array of adequate size (at least the expected number of components). Unable to create the footprint The license key entered is not valid. Enter a valid license key. No license key has been entered. Enter a license key. Unable to save the request file to the selected path No write access is enabled for the selected directory. Request write access for the selected directory or select a different path. An error occurred while acti- vating the license The response file is not com- patible with the system that is to be licensed. Check whether the correct response file has been selected. There is no emergency license available All the emergency licenses have been used up. Contact KUKA Service. The following error occurred while activating the license: {Error message} See error description. Contact KUKA Service. The following error occurred while opening the selected response file: {Error message} The response file is invalid. Open a valid response file, or contact KUKA Service. An error occurred while acti- vating an emergency license The image processing module is not correctly installed. Contact KUKA Service. The following error occurred while creating the repair request file: {Error message} The image processing module is not correctly installed. Contact KUKA Service. Message Cause Remedy

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 14 Maintenance 14 Maintenance 14.1 Maintenance symbols Maintenance symbols Oil change Lubricate with grease gun Lubricate with brush Tighten screw/nut Check component, visual inspection Clean component Exchange battery Fig. 14-1: Maintenance points Interval Item Activity Depending on the degree of fouling 1 Depending on the degree of fouling, clean the lens and the protective lens hood with a dry, dust-free microfiber cloth. 1 year at the latest 1 Check the screw fastenings of the camera, the lens and the protective lens hood. Locking varnish can be used to secure the screw fastenings.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 15 Repair 15 Repair 15.1 Exchanging the switch Precondition  The robot controller is switched off and secured to prevent unauthorized persons from switching it on again.  The power cable is de-energized. Procedure 1. Disconnect the switch from the power supply. 2. Unplug the connecting cables. 3. Plug in the connecting cables on the new switch. 4. Connect the new switch to the power supply. 15.2 Exchanging the camera Precondition  The robot controller is switched off and secured to prevent unauthorized persons from switching it on again.  The power cable is de-energized. Procedure 1. Unplug the connecting cables. 2. Remove the camera. 3. Install the new camera. 4. Plug in the connecting cables on the new camera. 5. Switch on the new camera. 6. Calibrate the new camera. 7. Assign the new camera to the tasks. 15.3 Exchanging the motherboard Information about exchanging the motherboard is contained in the ro- bot controller documentation.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 16 Troubleshooting 16 Troubleshooting Fault Remedy “Power” LED on the camera does not light up  Check that the plugged and screwed connections along the connecting cable are fitted securely.  Check the connecting cable for dam- age. Neither LED “P1” nor LED “P2” lights up Check whether voltage is present at the power connection (V1 or V2). LED “P1” or LED “P2” lights up red on the switch Check that the DIP switches are set cor- rectly. Both switches must be in the “ON” position. LED “Gigabit PoE Port” does not light up on the switch The connected device does not support PoE.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 17 Decommissioning, storage and disposal 17 Decommissioning, storage and disposal 17.1 Decommissioning Procedure 1. Disconnect the cameras and switch from the power supply. 2. Unplug the connecting cables. 3. Prepare the cameras and switch for storage or transportation. 17.2 Storage Precondition If the cameras and switch are to be put into long-term storage, the following points must be observed:  The place of storage must be as dry and dust-free as possible.  Avoid temperature fluctuations.  Avoid condensation.  Observe and comply with the permissible temperature ranges for storage.  Select a storage location in which the packaging materials cannot be dam- aged.  Only store the cameras and switch indoors. Procedure  Cover the cameras and switch with ESD protection foil and seal it against dust. 17.3 Disposal When the cameras and switch reach the end of their useful life, dispose of them as electrical scrap without disassembling.

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 18 Appendix 18 Appendix 18.1 Tightening torque Tightening torque The following tightening torques are valid for screws and nuts where no other specifications are given. Tighten M5 domed cap nuts with a torque of 4.2 Nm. Strength class Screw size 8.8 10.9 12.9 M1.6 0.17 Nm 0.24 Nm 0.28 Nm M2 0.35 Nm 0.48 Nm 0.56 Nm M2.5 0.68 Nm 0.93 Nm 1.10 Nm M3 1.2 Nm 1.6 Nm 2.0 Nm M4 2.8 Nm 3.8 Nm 4.4 Nm M5 5.6 Nm 7.5 Nm 9.0 Nm M6 9.5 Nm 12.5 Nm 15.0 Nm M8 23.0 Nm 31.0 Nm 36.0 Nm M10 45.0 Nm 60.0 Nm 70.0 Nm M12 78.0 Nm 104.0 Nm 125.0 Nm M14 125.0 Nm 165.0 Nm 195.0 Nm M16 195.0 Nm 250.0 Nm 305.0 Nm M20 370.0 Nm 500.0 Nm 600.0 Nm M24 640.0 Nm 860.0 Nm 1030.0 Nm M30 1330.0 Nm 1700.0 Nm 2000.0 Nm

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 19 KUKA Service 19 KUKA Service 19.1 Requesting support Introduction This documentation provides information on operation and operator control, and provides assistance with troubleshooting. For further assistance, please contact your local KUKA subsidiary. Information The following information is required for processing a support request:  Model and serial number of the manipulator  Model and serial number of the controller  Model and serial number of the linear unit (if present)  Model and serial number of the energy supply system (if present)  Version of the system software  Optional software or modifications  Diagnostic package KrcDiag: Additionally for KUKA Sunrise: Existing projects including applications For versions of KUKA System Software older than V8: Archive of the soft- ware (KrcDiag is not yet available here.)  Application used  External axes used  Description of the problem, duration and frequency of the fault 19.2 KUKA Customer Support Availability KUKA Customer Support is available in many countries. Please do not hesi- tate to contact us if you have any questions. Argentina Ruben Costantini S.A. (Agency) Luis Angel Huergo 13 20 Parque Industrial 2400 San Francisco (CBA) Argentina Tel. +54 3564 421033 Fax +54 3564 428877 [email protected] Australia Headland Machinery Pty. Ltd. Victoria (Head Office & Showroom) 95 Highbury Road Burwood Victoria 31 25 Australia Tel. +61 3 9244-3500 Fax +61 3 9244-3501 [email protected] www.headland.com.au

Issued: 11.10.2013 Version: KST VisionTech 2.1 V1 KUKA.VisionTech 2.1 Belgium KUKA Automatisering + Robots N.V. Centrum Zuid 1031 3530 Houthalen Belgium Tel. +32 11 516160 Fax +32 11 526794 [email protected] www.kuka.be Brazil KUKA Roboter do Brasil Ltda. Travessa Claudio Armando, nº 171 Bloco 5 - Galpões 51/52 Bairro Assunção CEP 09861-7630 São Bernardo do Campo - SP Brazil Tel. +55 11 4942-8299 Fax +55 11 2201-7883 [email protected] www.kuka-roboter.com.br Chile Robotec S.A. (Agency) Santiago de Chile Chile Tel. +56 2 331-5951 Fax +56 2 331-5952 [email protected] www.robotec.cl China KUKA Robotics China Co.,Ltd. Songjiang Industrial Zone No. 388 Minshen Road 201612 Shanghai China Tel. +86 21 6787-1888 Fax +86 21 6787-1803 www.kuka-robotics.cn Germany KUKA Roboter GmbH Zugspitzstr. 140 86165 Augsburg Germany Tel. +49 821 797-4000 Fax +49 821 797-1616 [email protected] www.kuka-roboter.de