Kuka krc2

[Clano]

Hi guys,
I just have a few questions,

My kuka was part of a larger cell involving safety doors, conveyors etc all of which are gone, but my contoller is still looking for these parts (i get a "canbus system error") everytime its on. What i am wondering is can i just delete the files of these parts off the hard drive??? will this stop the pc trying to find them?

Also is it safe to delete all old programs that are stored on it? as there is many programs stored by its previous owners which incorporate all the obselete parts. I want to free up space on the hard drive but i dont want to effect the robot in anyway.

Thanks

[SkyeFire]

Getting rid of the Canbus errors will be simple, if you just want to turn the bus off.  If you want to use the bus for your own devices, it gets more complex.

Using CONFIGURE>I/O>EDIT, the file IOSYS.INI should come up in the KCP editor.  In the [DRIVERS] section, each line that does not have a semicolon for the first character is a communications driver that is active.  The one you're having trouble with is most likely DEVNET, but it could be PBMASL or even one of the Interbus drivers.  Try commenting out these drivers by adding a semicolon at the front of each line, then force the robot to cold-boot, or do an I/O RECONFIG under CONFIGURE>I/O.  If these drivers are the problem, your CanBus errors should go away.

As for programs, you can probably delete everything in the /R1/Programs directory, if there's nothing there you need to use.  Be careful about deleting things in other directories, though -- some of those files are system file, or part of whatever add-on option packages were purchased with the robot.

My advice is to make a complete backup (FILE>ARCHIVE>ARCHIVE ALL) of the robot before making any changes, and stick it someplace safe with a label that indicates that it is the "as received" setup of the robot, just in case you ever need to backtrack.

[Clano]

Hi skyefire thanks for the response, i already have a backup of the harddrive made thank god, so i can afford to be drastic with this one.

I tried using CONFIGURE>I/O>EDIT, but when i select configure - i/o edit is not an option??? I tried this in both expert and user mode. I also tried searching on the harddrive using widows explorer search option but this did not yield anything either.

Thanks fro the tips on the programs i got rid of most of the old users programs 

Also is it possible there is a proximity limits other than the normal ones as regards joints? as my robot was part of a cell and i think it had limits in it to stop it hitting any of the tables in the cell, i have since relocated the robot the top of an "open" table with no obstructions.
Also would it be possible to program in new proximity areas into it??

Also with regards to programmng the robot i am just about to begin programming it, i am sure enough of the different things i can make it do but i cannot find out how to "teach" it a point in space. anybody any tips??? i am sure it is something easy i am overlooking.

Thanks

[the leg]

To edit i/o config you need to make sure any program is canceled and you are in T1

If you still cant get it then in windows under Krc\init select the file iosys you can then rem out the devnet call driver 2 i think it is

Your robot may have Hard Stops installed on axis 1 or 2 these limit the range of the axis or some one will have setup software limits these are in the option.dat in the machine data at the R1

Depending on your robot type they look something like this standard

$SOFTN_END[1]=-185.0
$SOFTN_END[2]=-146.0
$SOFTN_END[3]=55.0
$SOFTN_END[4]=-350.0
$SOFTN_END[5]=-120.0
$SOFTN_END[6]=-350.0
$SOFTN_END[7]=0.0
$SOFTN_END[8]=0.0
$SOFTN_END[9]=0.0
$SOFTN_END[10]=0.0
$SOFTN_END[11]=0.0
$SOFTN_END[12]=0.0
REAL $SOFTP_END[12] ;SOFTWARE-ENDSCHALTER POSITIV ACHSE (I=1:A1,I=7:E1) [MM,GRAD]
$SOFTP_END[1]=185.0
$SOFTP_END[2]=0.0
$SOFTP_END[3]=155.0
$SOFTP_END[4]=350.0
$SOFTP_END[5]=125.0
$SOFTP_END[6]=350.0
$SOFTP_END[7]=0.0
$SOFTP_END[8]=0.0
$SOFTP_END[9]=0.0
$SOFTP_END[10]=0.0
$SOFTP_END[11]=0.0
$SOFTP_END[12]=0.0

[Clano]

Thanks the leg   I'm going to try that now.

I am just after mastering the robot and i even got the space mouse setting to work which i am sure hasnt worked in a long time.
BUT, when i try to run a program already saved on the robot( an example i used was the kuka to home position which i assume is a pre programmed preogram made by kuka??) the robot starts to move and then faults!!!

The error i get is no-1216 Ackn. DRIVES ERROR A5 No. TRIP

Any ideas why i am getting this???

Also various messages flash up like "belt grinder isolator is off" but they disapear!

This is so annoying as i feel i am very close to having it programmed!!!

Thanks guys

[SkyeFire]

The 1216 error sounds like you could have a problem with Axis 5, or with its servo amp.

Any messages referring to "belt sanders" and the like are probably coming from whatever program was written for this robot before, and are not relevant.  Try cancelling the SPS to get rid of these for the time being -- you'll probably have to edit the SPS later.

[Clano]

The 1216 error sounds like you could have a problem with Axis 5, or with its servo amp.

Is there anything i can do to remedy this??? It wont let me run any programs now

Also whenever we power the robot down and shut off power it needs to be mastered on start up!! i am presuming this is due to the two batterys in the controller???

[Daniel]

First,let controller energized for 24 hours,charging battery.
Replace battery.

[SkyeFire]

As Daniel said, leave the controller powered up for at least 24hrs straight.  If you still lose mastering when you cycle power after that, the batteries just aren't taking a charge anymore and need to be replaced.

As for the A5 error, the 1216 is an "Acknowledgment" message -- that means that the original error came and went.  These errors are the ones that have little flashing stop-signs for their icons.  They indicate an error whose root cause has already been cleared, but which is serious enough that the safety system requires an explicit user acknowledgment.  Most often seen with E-Stops.
In order to figure out your root error, we need to see the root cause error.  If it's not visible, look at MONITOR>DIAGNOSIS>LOGBOOK and look for logged error messages that occurred at the same time.

Other tests:  try jogging each joint by itself.  See which joints trigger the error.  See if the error is always for A5.  See if the error pops up for A5 even if it's a different axis that's moving.  See if A5 makes any strange noises when you try to move it.  See how far A5 moves before faulting when you try to move it.  Look at the servo amp for A5 in the cabinet (white module on the back wall, should be labeled N5 with a little yellow sticker) and see if the status LEDs look different than the others.

Other things that are pretty normal KUKA troubleshooting techniques, but require some care:  Try swapping the A5 motor cables with A4 or A6.  Those three motors are (almost) always the same, and have the same servo amp as well.  If you swap the A5 and A6 cables, and the error message moves to A6, then the problem is the motor or drivetrain.  If you swap cables and the error stays with A5, then the problem is in either the A5 cables, or the A5 servo amp.  You can swap the A4, A5, and A6 servo amps around with impunity -- just put A5's amp where A6's was, and plug A6's cables into it, and vice versa.  If the error message moves to another axis, then the problem is the amp.

[Clano]

Other tests:  try jogging each joint by itself.  See which joints trigger the error.  See if the error is always for A5.

Thanks for the replies lads!!!
As far as i can remember while jogging the a5 axis error only occurs when the a5 axis is the first axis moved, as in, if i move any other axis or a combination of a few first and then move a5 most of the time it works fine.
But i will verify this on friday when i am in the lab again.

Thanks for the reply skyefire that post will be a great as i said i will try all your suggestions friday and post my results thanks

[the leg]

Is this robot a KR6 krc2 that used to do Cone polishing for a well known american Company ??
If so then it may be a problem with the wrist unit on axis


" Also various messages flash up like "belt grinder isolator is off" but they disapear! "
These messages are called from the sps and are to with the job it used todo

You could take an origonal copy of the sps from the " D " Drive and overright the one you have if you have removed all
the other item (grinders, conveyor ect)

[Clano]

As for the A5 error, the 1216 is an "Acknowledgment" message -- that means that the original error came and went.  These errors are the ones that have little flashing stop-signs for their icons.  They indicate an error whose root cause has already been cleared, but which is serious enough that the safety system requires an explicit user acknowledgment.  Most often seen with E-Stops.
In order to figure out your root error, we need to see the root cause error.  If it's not visible, look at MONITOR>DIAGNOSIS>LOGBOOK and look for logged error messages that occurred at the same time.

Hi guys I am looking at the list now it is as follows:
139009 Ackn. DRIVES ERROR A5 No. TRIP
139008 Drives contactor off
139007 Drives contactor off, intermediate circuit loaded.
139006 COMMON DRIVES ERROR 1
139005 DRIVES ERROR A5 No. TRIP
139004 Ackn. regulator limit exceeded A5
139003 Dynamic breaking active.
139002 COMMON DRIVES ERROR 1
139001 Regulator limit exceeded A5
139000 Gear torque exceeded axis A5

[SkyeFire]

Hi guys I am looking at the list now it is as follows:
139009 Ackn. DRIVES ERROR A5 No. TRIP
139008 Drives contactor off
139007 Drives contactor off, intermediate circuit loaded.
139006 COMMON DRIVES ERROR 1
139005 DRIVES ERROR A5 No. TRIP
139004 Ackn. regulator limit exceeded A5
139003 Dynamic breaking active.
139002 COMMON DRIVES ERROR 1
139001 Regulator limit exceeded A5
139000 Gear torque exceeded axis A5

The "Drives Off" messages are nothing, just status.  "Dynamic Breaking" is just something that happens as a response to certain joint errors that trip the safety system to stop the robot.  The big ones we're interested in are the "Gear Torque" and "Regulator Limit" messages.

This pattern doesn't rule out an electrical or electronic error, but it makes my prime suspect something mechanically wrong with the motor or the joint.  I think the next thing you need to do is swap the A5 and A6/4 motor cables at the motors, as detailed above, and see what happens.  If that test is positive, you can try swapping the actual motors (this isn't hard to do, but it isn't easy, and requires reaching through the access port on the side of the arm between A3 and A4 to re-join the drive shafts).  If the problem stays with A5 after that, the problem is likely in the wrist.

[the leg]

Common drives error odd thats normally comms from the G1

Is this the robot i think it is (did cone polishing)

if so the wrist is Fooked sorry 

[Clano]

right guys

I swapped the 2 servo amps A5 and A6
When all was swapped (cables etc) the problem shifted onto A6!!!
So am i correct in saying its the servo amp?
Is there anything i can do to fix it?