resolved

What kind of 7th axis? Turntable carrying the workpiece? Linear rail carrying the robot?

KRC2ed05? So, I assume it's using KSS 5.something. Correct?

Have you completed the hardware integration of the 77th axis?

The spindle is almost irrelevant. It has no effect on the 7th axis integration. You will need to set up TCPs for each cutting tool the spindle uses.

I can't speak to PowerMill, having never used it. But for any OLP-generation software, ensuring that the virtual model matches the real-world robot in all respected (axes, Base frames, Tool frames, etc) is absolutely critical.

Start with the Axis Configurator tool.

Hi, I always use X12 connctor in KPS600 to 7th breake. Your drive power in +UG and -UG must come from X17 connector in KPS600, you will find it in wirinig diagram.

About configuration of 7th axis, the easiest way to configuing, is reinstall the KSS with KL, after you just chage parameters or you configure manually in menu: setup, service, axis configuration. You will find it in manual.

Every thing a said was considering you are not using SBM2 module.

brake circuit on KRC2 external axis that does not use SBM need to look like this.

basically it is a replica of robot axes but on a next channel of X12 (bottom side of KPS600).

Positive wire need have toroid (just like the positive wire on X12 pin1)

servo amplifier wiring for 600V (black wires) and 24V (blue wires):

above three posts show complete wiring modifications inside the KRC2.

next part is to connect E1 feedback cable to RDC (at the base of the robot).

With above, electrical integration of external axis is complete. Next step is software configuration

If you see better, in x17 connector you will find small numbers, you will find each pin function in wiring diagram.

To change the software you will find in external axis manual.

you could also use multimeter to verify polarity.

1FK7xxxx is a newer motor, normally used with KRC4/KRC5.

KUKA has motor data document that shows all relevant data.

so one option is to install WorkVisual, create project and add this axis, parametrize it and compile. then check MADA for all settings that apply to axis 7.

adding axis... there is no KSD1-16 but we can use KSP for 20A

parametrize as if you were to make it work with KRC4 and you will get most of the settings served on a silver platter. mark measurement point on the turn table with X (this is also called "pin") then use tape to measure distance from that point to center of the axis. enter the value in transform:

example measuring point distance:

then after all values are set in the KRC2 MADA you should be very close... and able to just master the axis, and measure root point.

WorkVisual is a free software from KUKA that need to be installed on own computer, not robot.

But... this is used for configuration of KRC4 and KRC5 (on KRC2 one still has to make changes manually). the only reason i mentioned the process is how to get most of the parameter values - by extracting them from WoV project. and since they are shown in above screenshots, you can skip getting and installing WorkVisual, and just use values posted.

Note: MADA is different between different KSS versions. So above is not a complete list of settings. it is just a list of (most) values that apply to your motor. there are few more that are in XML files (such as gains, current limit etc.). you can start by using some other motor that is already listed in axis configurator of your KRC2, then with the help of above screenshot you could modify values that are shown to match them to your motor.

personally i just edit mada files without bothering with axis configurator. but in doing that one need to know what to change (MADA has a lot of things but we only need to change few).

the other approach (which was mentioned in previous discussions on integration of external axis) is to determine what settings need to be changed. one can simply go to D: and find some robot (any robot) that has mada both with and without KL (linear rail). then compare those MADA files (using KDIF or WinMerge or whatever) and the difference is simply the list of all the settings (parameter names) that need to be changed. since we picked random robot and with linear rail rather than turn table, the values of course will be different ...but that is not important here. goal here was to just get clean list of settings that need to be checked and modified... then you just need to find the right values - and conveniently many of them are shown above ...extracted from WoV project.

I recommend you read the documents many times until you understand, if you really need one exclusive personality document or configured backup it will cost 1 work day, 2000 usd. Or you can contract a local kuka technician (expert).

forum is place to discuss things but it is not a replacement for formal training, anyone seeking help should be mindful of what they ask for, nobody is going to bend over and spend own time writing elaborate tutorials or work instructions - that is what KUKA training and workshops are for. the other way is to pay for turn-key service.

everything you need to know is already out there, you just need to read (a lot) and find it. this is why there is a pinned topic READ FIRST and forum search function. as you have noticed, there is more than one MADA. if you searched forum or simply looked inside MADA, it would be obvious that you are looking in the wrong one:

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RE: Transmission of system variables...STEU\Mada\$machine.dat

there are two MADA sets. "MADA" is short for "Machine Data"

manipulator MADA is set of files in KRC:\R1\MADA

controller MADA is set of files in KRC:\STEU\MADA

long time ago it was assumed that one controller would control several manipulators but that prediction was wrong so you will not see folders for R2, R3 etc.

panic mode

July 23, 2021 at 2:58 PM

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RE: Kuka robot project and difficulties

also there are two sets of machine data:

- robot MADA is in KRC:\R1\MADA

- controller MADA is in KRC:\R1\STEU

each MADA is a set of files. here we are focusing on robot MADA, which is following two files

- $machine.dat

- $robcor.dat

one thing to note about MADA is that one may not add or remove any lines,.... or you get message that MADA is corrupted.

to see if any line is added or removed compare robot MADA with factory MADA that is on D:

panic mode

February 21, 2021 at 11:00 PM

MADA you want to look at is in KRC:R1\

i suppose someone used to have an idea of having the robot mada split further - so that each "robot" (kinematic system) has own set of files. perhaps:

R1 = kinematics1 such as robot
R2 = kinematics2 such as linear rail
R3 = kinematics3 such as positionser or turn table.

that could make integrations neater but KUKA never got around to complete this. many MADA settings are arrays. and because of how KRL handles arrays in a DAT file, it was needed to keep all kinematics in the same MADA set.

check this too:

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RE: Kuka krc2 Linear axis configuration

On D: there are many examples of MADA for robots with and without KL.

nice thing about that is that one can do simple comparison and see what the differences are. Something like this:

robot-forum.com/attachment/32132/

panic mode

October 25, 2021 at 5:05 PM

Where did you get your KSS versions and DSE/RDC from? Every KRC2 comes with the fitting firmware version for the dse/rdc combimnation supported by a specific kss version. The message you see here points to a inconsistency in this direction. C33 is a version of the dse board.

Regarding mastering just use forum search with keyword mastering or dial gauge.

And? Do you have the necessary dse firmware? AFAIK it is called *_c33.bin or similar? What version is your dse board?

On the board of course and maybe also in service-> dse rdw. Not sure about the last one.

So you have c32 but need c33 according to the message. Also not sure about this because to long ago but maybe c32 only supported up to 6 axes. But at least it does not seem compatible to your use case. If you open up the menu items on the left hand side how many axes do you see? I think one could see the axis and axis status flags in there. But for this I am no specialist, so probably my help ends here.