System Software
KUKA Sunrise.OS 1.15
KUKA Sunrise.Workbench 1.15
Operating and Programming Instructions for System Integrators
KUKA Roboter GmbH
Issued: 24.01.2018
Version: KUKA Sunrise.OS 1.15 SI V1
KUKA Sun-
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© Copyright 2018
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.
KIM-PS5-DOC
Translation of the original documentation
Publication: Pub KUKA Sunrise.OS 1.15 SI (PDF) en
Book structure: KUKA Sunrise.OS 1.15 SI V1.2
Version: KUKA Sunrise.OS 1.15 SI V1
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Contents
1 Introduction .................................................................................................. 19
1.1 Target group .............................................................................................................. 19
1.2 Industrial robot documentation ................................................................................... 19
1.3 Representation of warnings and notes ...................................................................... 19
1.4 Trademarks ................................................................................................................ 20
1.5 Terms used ................................................................................................................ 20
1.6 Licenses ..................................................................................................................... 21
2 Product description ..................................................................................... 23
2.1 Overview of the robot system .................................................................................... 23
2.2 Overview of the software components ....................................................................... 23
2.3 Overview of KUKA Sunrise.OS .................................................................................. 24
2.4 Overview of KUKA Sunrise.Workbench ..................................................................... 25
2.5 Intended use of the system software ......................................................................... 26
3 Safety ............................................................................................................ 27
3.1 Legal framework ........................................................................................................ 27
3.1.1 Liability .................................................................................................................. 27
3.1.2 Intended use of the industrial robot ...................................................................... 27
3.1.3 EC declaration of conformity and declaration of incorporation ............................. 28
3.2 Safety functions ......................................................................................................... 28
3.2.1 Terms used ........................................................................................................... 29
3.2.2 Personnel .............................................................................................................. 31
3.2.3 Workspace, safety zone and danger zone ........................................................... 32
3.2.4 Safety-oriented functions ...................................................................................... 33
3.2.4.1 EMERGENCY STOP device ........................................................................... 33
3.2.4.2 Enabling device ............................................................................................... 34
3.2.4.3 “Operator safety” signal ................................................................................... 34
3.2.4.4 External EMERGENCY STOP device ............................................................. 35
3.2.4.5 External safety stop 1 (path-maintaining) ....................................................... 35
3.2.4.6 External enabling device .................................................................................. 35
3.2.4.7 External safe operational stop ......................................................................... 35
3.2.5 Triggers for safety-oriented stop reactions ........................................................... 36
3.2.6 Non-safety-oriented functions ............................................................................... 37
3.2.6.1 Mode selection ................................................................................................. 37
3.2.6.2 Software limit switches .................................................................................... 38
3.3 Additional protective equipment ................................................................................. 38
3.3.1 Jog mode .............................................................................................................. 38
3.3.2 Labeling on the industrial robot ............................................................................. 38
3.3.3 External safeguards .............................................................................................. 39
3.4 Safety measures ........................................................................................................ 39
3.4.1 General safety measures ...................................................................................... 39
3.4.2 Transportation ....................................................................................................... 41
3.4.3 Start-up and recommissioning .............................................................................. 41
3.4.4 Manual mode ........................................................................................................ 43
3.4.5 Automatic mode .................................................................................................... 44
3.4.6 Maintenance and repair ........................................................................................ 44
3.4.7 Decommissioning, storage and disposal .............................................................. 45
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3.4.8 Safety measures for “single point of control” ........................................................ 45
3.5 Applied norms and directives .................................................................................... 46
4 Installing KUKA Sunrise.Workbench ......................................................... 49
4.1 PC system requirements ........................................................................................... 49
4.2 Installing Sunrise.Workbench .................................................................................... 49
4.3 Uninstalling Sunrise.Workbench ................................................................................ 49
5 Operation of KUKA Sunrise.Workbench ................................................... 51
5.1 Starting Sunrise.Workbench ...................................................................................... 51
5.2 Overview of the user interface of Sunrise.Workbench .............................................. 51
5.2.1 Repositioning the views ........................................................................................ 53
5.2.2 Closing views and files ......................................................................................... 53
5.2.3 Displaying perspectives ........................................................................................ 53
5.2.4 Toolbar of the Programming perspective ............................................................ 54
5.3 Creating a Sunrise project with a template ................................................................ 55
5.4 Sunrise applications .................................................................................................. 58
5.4.1 Creating a new Java package .............................................................................. 58
5.4.2 Creating a robot application with a package ......................................................... 58
5.4.3 Creating a robot application for an existing package ............................................ 59
5.4.4 Creating a new background application ............................................................... 59
5.4.4.1 Creating a background application with a package ......................................... 59
5.4.4.2 Creating a background application for an existing package ............................ 60
5.4.5 Setting the robot application as the default application ........................................ 60
5.5 Workspace ................................................................................................................. 60
5.5.1 Creating a new workspace ................................................................................... 61
5.5.2 Switching to an existing workspace ...................................................................... 61
5.5.3 Switching between the most recently opened workspaces .................................. 61
5.5.4 Archiving projects ................................................................................................. 61
5.5.5 Loading projects from archive to the workspace .................................................. 61
5.5.6 Loading projects from the directory to the workspace .......................................... 62
5.6 Sunrise projects with referenced Java projects ......................................................... 62
5.6.1 Creating a new Java project ................................................................................. 62
5.6.1.1 Inserting robot-specific class libraries in a Java project .................................. 63
5.6.2 Referencing Java projects .................................................................................... 63
5.6.3 Canceling the reference to Java projects ............................................................. 64
5.7 Renaming an element in the Package Explorer ...................................................... 64
5.7.1 Renaming a project or Java package ................................................................... 64
5.7.2 Renaming a Java file ............................................................................................ 64
5.8 Removing an element from Package Explorer ........................................................ 64
5.8.1 Deleting an element from a project ....................................................................... 64
5.8.2 Removing a project from Package Explorer ....................................................... 64
5.8.3 Deleting a project from the workspace ................................................................. 65
5.9 Activating the automatic change recognition ............................................................. 65
5.10 Displaying release notes ........................................................................................... 65
6 Operating the KUKA smartPAD .................................................................. 67
6.1 KUKA smartPAD control panel .................................................................................. 67
6.1.1 Front view ............................................................................................................. 67
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6.1.2 Rear view .............................................................................................................. 69
6.2 Disconnecting and connecting the smartPAD ............................................................ 70
6.2.1 Disconnecting the smartPAD ................................................................................ 70
6.2.2 Connecting the smartPAD .................................................................................... 71
6.3 KUKA smartHMI user interface .................................................................................. 72
6.3.1 Navigation bar ....................................................................................................... 73
6.3.2 Status display ....................................................................................................... 74
6.3.3 Keypad .................................................................................................................. 75
6.3.4 Station level .......................................................................................................... 75
6.3.5 Robot level ............................................................................................................ 77
6.4 Calling the main menu ............................................................................................... 79
6.5 Setting the user interface language ........................................................................... 80
6.6 User groups ............................................................................................................... 81
6.6.1 Changing user group ............................................................................................ 82
6.7 CRR mode – controlled robot retraction .................................................................... 82
6.8 Changing the operating mode .................................................................................... 83
6.9 Activating the user keys ............................................................................................. 84
6.10 Resuming the safety controller .................................................................................. 85
6.11 Coordinate systems ................................................................................................... 85
6.12 “Override” window .................................................................................................... 87
6.13 “Jogging type” window ............................................................................................. 87
6.14 Jogging the robot ....................................................................................................... 89
6.14.1 “Jogging options” window .................................................................................. 89
6.14.2 Setting the jog override ......................................................................................... 91
6.14.3 Axis-specific jogging with the jog keys .................................................................. 92
6.14.4 Cartesian jogging with the jog keys ...................................................................... 92
6.14.4.1 Null space motion ............................................................................................ 93
6.15 Manually guiding the robot ......................................................................................... 94
6.16 Frame management ................................................................................................... 94
6.16.1 “Frames” view ...................................................................................................... 94
6.16.2 Creating a frame ................................................................................................... 96
6.16.3 Reteaching frames ................................................................................................ 97
6.16.4 Teaching a frame with the hand guiding device ................................................... 99
6.16.5 Manually addressing frames ................................................................................. 99
6.17 Program execution ..................................................................................................... 100
6.17.1 Selecting a robot application ................................................................................. 100
6.17.2 Setting the program run mode .............................................................................. 102
6.17.2.1 Program run modes ......................................................................................... 102
6.17.3 Setting the manual override .................................................................................. 103
6.17.4 Starting a robot application forwards (manually) .................................................. 103
6.17.5 Starting a robot application forwards (automatically) ............................................ 103
6.17.6 Resetting a robot application ................................................................................ 104
6.17.7 Repositioning the robot after leaving the path ...................................................... 104
6.17.8 Starting/stopping a background application manually .......................................... 105
6.17.8.1 Stopping a background application manually .................................................. 105
6.17.8.2 Starting a background application manually .................................................... 105
6.18 Display functions ........................................................................................................ 106
6.18.1 Displaying the end frame of the motion currently being executed ........................ 106
6.18.2 Displaying the axis-specific actual position ........................................................... 106
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