KST ConveyorTech 80 en NT

KUKA System Technology
KUKA.ConveyorTech 8.0
For KUKA System Software 8.6
Issued: 08.07.2021
KST ConveyorTech 8.0 V2
KUKA Deutschland GmbH
© Copyright 2021
KUKA Deutschland 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 Deutschland 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 soft-
ware 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 regu-
lar basis, however, 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 KST ConveyorTech 8.0 (PDF) en

PB12854
Book structure: KST ConveyorTech 8.0 V2.1

BS11913
Version: KST ConveyorTech 8.0 V2
2/132 | www.kuka.com KST ConveyorTech 8.0 V2 | Issued: 08.07.2021

Contents
1 Introduction.............................................................................................. 7
1.1 Target group.......................................................................................................... 7
1.2 Industrial robot documentation.............................................................................. 7
1.3 Representation of warnings and notes................................................................. 7
1.4 Terms used............................................................................................................ 8
1.5 Trademarks............................................................................................................ 9
1.6 Licenses................................................................................................................. 9
2 Product description................................................................................. 11
2.1 Product description................................................................................................ 11
2.2 Application example.............................................................................................. 11
2.3 Intended use and misuse...................................................................................... 12
3 Safety......................................................................................................... 15
4 Planning.................................................................................................... 17
4.1 Conveyor with resolver.......................................................................................... 17
4.2 Client conveyor...................................................................................................... 17
4.3 External conveyor.................................................................................................. 18
4.3.1 Communications interface to the higher-level controller...................................... 20
4.3.1.1 Reception structure from robot controller’s point of view (1D conveyor)............ 20
4.3.1.2 Reception structure from robot controller’s point of view (6D conveyor)............ 20
4.3.1.3 Transmission structure from the perspective of the robot controller................... 21
4.3.1.4 Communication sequence between robot controller and PLC............................. 22
4.3.2 Checksum calculation for external conveyor........................................................ 23
5 Start-up and recommissioning............................................................... 27

5.1 Overview................................................................................................................ 27
5.2 Connecting a resolver to the RDC....................................................................... 27
6 Installation................................................................................................ 31
6.1 System requirements............................................................................................. 31
6.2 Installation via WorkVisual.................................................................................... 31
6.2.1 Installing or updating ConveyorTech..................................................................... 31
6.2.2 Uninstalling ConveyorTech.................................................................................... 32
6.3 Installation via smartHMI....................................................................................... 33
6.3.1 Installing or updating ConveyorTech..................................................................... 33
6.3.2 Uninstalling ConveyorTech.................................................................................... 34
7 Configuration............................................................................................ 35
7.1 Overview: configuration in WorkVisual................................................................. 35
7.2 Inserting a conveyor in a project.......................................................................... 36
7.3 Changing the dimension of the conveyor............................................................. 36
7.4 Modifying the connection between the synchronization switch and the CIB...... 37
7.5 Defining the conveyor as motion master.............................................................. 38
7.6 Adding robot controllers to a RoboTeam network................................................ 39
7.7 Assigning a source conveyor................................................................................ 39
7.8 Configuring cycle synchronization......................................................................... 40
KST ConveyorTech 8.0 V2 | Issued: 08.07.2021 www.kuka.com | 3/132

7.9 Configuring conveyor parameters in the machine data....................................... 42

7.9.1 General I/O parameters........................................................................................ 42
7.9.2 Conveyor-specific expert parameters................................................................... 43
7.9.3 Alarm and stop distances..................................................................................... 45
7.9.4 Escape strategy..................................................................................................... 46
7.9.4.1 Signal diagram for stop strategy CONV_STOPPABLE........................................ 48
7.10 Editing controller-specific conveyor settings......................................................... 49
7.11 Configuring I/Os and adding long texts................................................................ 50
8 Operation.................................................................................................. 53
8.1 Displaying user rights............................................................................................ 53
8.2 Status keys............................................................................................................ 53
8.3 Modifying controller-specific conveyor settings.................................................... 54
8.4 Modifying conveyor-specific settings..................................................................... 54
8.5 Modifying alarm and stop distances..................................................................... 56
9 Calibration................................................................................................. 59
9.1 Calibrating a linear conveyor................................................................................ 59
9.2 Calibrating a circular conveyor............................................................................. 60
9.3 Checking the conveyor distance........................................................................... 62
9.4 Calibrating a workpiece on the 1D conveyor....................................................... 63
9.5 Calibrating a 6D conveyor.................................................................................... 65
9.6 Calibrating a workpiece on the 6D conveyor....................................................... 67
10 Programming............................................................................................ 69
10.1 Creating a conveyor application program............................................................. 69
10.2 Conveyor.INI_OFF: Initializing a conveyor........................................................... 71
10.3 Conveyor.ON: activating a conveyor driver.......................................................... 72
10.4 Conveyor.FOLLOW: tracking the current workpiece............................................ 72
10.5 Conveyor.Skip: tracking a specific workpiece...................................................... 75
10.6 Conveyor.Quit: leaving the conveyor area........................................................... 78
10.7 Programming inline forms with WorkVisual.......................................................... 80
10.8 Teaching synchronized motions............................................................................ 81
10.9 Programming a DLIN block................................................................................... 84
10.10 Programming a DLIN motion................................................................................ 85
10.10.1 Option window “Frames”....................................................................................... 86
10.10.2 Option window “Velocities”.................................................................................... 87
10.10.3 Option window “Accelerations”.............................................................................. 87
10.11 Creating an application program with DLIN template.......................................... 88
10.12 KRL functions........................................................................................................ 88
10.12.1 CONV_DELETE_ALL_WPS: delete all components............................................ 89
10.12.2 CONV_DELETE_WPS: Deleting components...................................................... 89
10.12.3 CONV_GET_SPEED: Requesting the conveyor speed....................................... 90
10.12.4 CONV_GET_WP_COUNT: Component counter................................................... 90
11 Troubleshooting....................................................................................... 93
11.1 Robot leaves the path in external mode EXT...................................................... 93
11.2 Modifying the program override............................................................................ 93
11.3 The decision to track a workpiece is made in the advance run......................... 94
12 Messages.................................................................................................. 97

12.1 Information about the messages.......................................................................... 97

12.2 System messages from module: Conveyor.......................................................... 97
12.2.1 Conveyor 01000.................................................................................................... 97
12.2.2 Conveyor 01001.................................................................................................... 97
12.2.3 Conveyor 01002.................................................................................................... 98
12.2.4 Conveyor 01006.................................................................................................... 98
12.2.5 Conveyor 01007.................................................................................................... 100
12.2.6 Conveyor 01009.................................................................................................... 103
12.2.7 Conveyor 01010.................................................................................................... 103
12.2.8 Conveyor 01011.................................................................................................... 105
12.2.9 Conveyor 01013.................................................................................................... 107
12.2.10 Conveyor 01019.................................................................................................... 109
12.2.11 Conveyor 01020.................................................................................................... 110
12.2.12 Conveyor 01210.................................................................................................... 111
12.2.13 Conveyor 01211.................................................................................................... 114
12.2.14 Conveyor 01212.................................................................................................... 116
12.2.15 Conveyor 01213.................................................................................................... 116
12.2.16 Conveyor 01215.................................................................................................... 117
12.2.17 Conveyor 01216.................................................................................................... 121
12.2.18 Conveyor 01217.................................................................................................... 121
12.2.19 Conveyor 01221.................................................................................................... 122
12.2.20 Conveyor 01222.................................................................................................... 122
12.2.21 Conveyor 01223.................................................................................................... 123
12.2.22 Conveyor 01224.................................................................................................... 123
12.2.23 Conveyor 01250.................................................................................................... 124
12.2.24 Conveyor 01251.................................................................................................... 125
12.2.25 Conveyor 09999.................................................................................................... 126
13 KUKA Service........................................................................................... 129

13.1 Requesting support............................................................................................... 129
13.2 KUKA Customer Support...................................................................................... 129
Index 131


Introduction
1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and

skills:
• Advanced knowledge of the robot controller system

• Advanced KRL programming skills
For optimal use of KUKA products, we recommend the training courses

offered by KUKA College. Information about the training program can be
found at www.kuka.com or can be obtained directly from our subsidia-
ries.
1.2 Industrial robot documentation
The industrial robot documentation consists of the following parts:
• Documentation for the robot arm

• Documentation for the robot controller
• Documentation for the smartPAD-2 (if used)
• Operating and programming instructions for the System Software
• Instructions for options and accessories
• Spare parts overview in KUKA Xpert
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety
These warnings are provided for safety purposes and must be observed.
DANGER
These warnings mean that it is certain or highly probable that death or
severe injuries will occur, if no precautions are taken.
WARNING
These warnings mean that death or severe injuries may occur, if no
precautions are taken.
CAUTION
These warnings mean that minor injuries may occur, if no precautions
are taken.
NOTICE
These warnings mean that damage to property may occur, if no precau-
tions are taken.
These warnings contain references to safety-relevant information or gen-

eral safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.

This warning draws attention to procedures which serve to prevent or rem-

Introduction
edy emergencies or malfunctions:

SAFETY INSTRUCTION
The following procedure must be followed exactly!
Procedures marked with this warning must be followed exactly.
Notices
These notices serve to make your work easier or contain references to

further information.
Tip to make your work easier or reference to further information.
1.4 Terms used
Term Description
Client conveyor Conveyor to which no resolver is connected and which draws data
from the resolver of the source conveyor
Conveyor Moving conveyor system, e.g. belt, chain, etc.
CRC Cyclic Redundancy Check

Cyclic Redundancy Check
ESD Electrostatic Discharge

Electrostatic discharge
On-the-fly synchronization Direct transition between robot motions that are independent of the
conveyor and motions that are synchronized with the conveyor.
Tracking distance Distance over which the robot tracks the workpiece on the conveyor
KLI KUKA Line Interface

Ethernet interface of the robot controller for external communication
KSB KUKA System Bus

Field bus for internal networking of the controllers
PTP Precision Time Protocol

Network protocol for synchronization of clocks in computer networks
RDC Resolver Digital Converter

The resolver digital converter is used to acquire motor data (e.g.
position data, motor temperatures).
Resolver Measurement system which calculates the distance that a conveyor

has traveled
Source conveyor Conveyor to which a resolver is connected. The client conveyors

draw the required data from this resolver.
PLC Programmable Logic Controller

Introduction
1.5 Trademarks
EtherCAT® is a registered trademark and patented technolo-

gy, licensed by Beckhoff Automation GmbH, Germany.
1.6 Licenses
The KUKA license conditions and the license conditions of the open-
source software used can be found in the following folders:
• Under .\LICENSE on the data storage medium with the installation
files of the KUKA software
• On the KUKA smartHMI, in the main menu under Help > Info, tab Li-
censes
• Under D:\KUKA_OPT\Option package name\LICENSE on the robot
controller
• In the license folder under the name of the option package in the Op-
tions catalog in WorkVisual
Further information about open-source licenses can be requested from

the following address: opensource@kuka.com

Introduction KUKA.ConveyorTech 8.0

Product description
2 Product description
2.1 Product description
Description
The KUKA.ConveyorTech 8.0 option package is designed as a solution for

applications that require synchronization between the robot motion and the
motion of workpieces through a conveyor system (conveyor). Through
synchronization, the robot can process, grip or set workpieces down on
the conveyor system. The position of the workpiece on the conveyor sys-
tem and the motion of the conveyor system must be clearly known for this
purpose.
Conveyor belts of various designs or mobile platforms can be used as
conveyor systems.
Functions
• Synchronization of robot motions with the motion of conveyor systems

of different designs
• Configuration of up to 5 conveyor systems per robot controller for
synchronized workpiece tracking
‒ Linear conveyor
‒ Acquisition of the conveyor motion via:
‒ Resolver
‒ Resolver signal of a source conveyor (client conveyor)
‒ 1D position data transmitted via the I/O interface for exter-
nal conveyors (external conveyor)
‒ Monitoring of multiple workpieces simultaneously; the robot mo-
tion can be synchronized with the motion of these workpieces
‒ Circular conveyor
‒ Acquisition of the conveyor motion via resolver
‒ Monitoring of multiple workpieces simultaneously; the robot mo-
tion can be synchronized with the motion of these workpieces
‒ 6D conveyor
‒ Acquisition of the conveyor motion via 6D position data, which
are transmitted via the I/O interface for external conveyors (ex-
ternal conveyor)
‒ Monitoring of a single workpiece – the robot motion can be
synchronized with the motion of this workpiece
2.2 Application example
Description
In this application example, a robot removes workpieces from a linear con-

veyor and places them on a circular conveyor. The workpieces are then
transported on from there.
At the beginning of the linear conveyor, there is a photo-electric barrier
which is used to detect the position of the workpiece. The resolver at the
linear conveyor transmits the conveyor motion to the robot controller. The
robot controller uses these data to calculate the transformations necessary
to synchronize the robot with the conveyor. During synchronization, the ro-

bot removes the workpiece from the linear conveyor and places it on the
Product description
circular conveyor.
The following figure shows the configuration of the system:
Fig. 2-1: Layout of the conveyor system in the application example
1 Linear conveyor 3 Robot controller

2 Circular conveyor 4 Robot
2.3 Intended use and misuse
Use
The KUKA.ConveyorTech 8.0 option package is intended exclusively for

industrial operation for implementing applications in an industrial robot cell.
It is designed as a solution for applications that require synchronization
between the robot motion and the motion of workpieces through a convey-
or system within this cell. The position of the workpiece on the conveyor
system and the motion of the conveyor system must be clearly known for
this purpose.
Conveyor belts of various designs or mobile platforms can be used as
conveyor systems.
The cell must conform to the applicable safety standards. The system in-
tegrator must ensure that the robot system is installed and operated in an
environment that is suitable for this. In particular, it is important to consid-
er the hazards which could arise from incorrect user programming.
The option package must only be operated in compliance with the speci-
fied system requirements.
Operation in accordance with the intended use also requires compliance
with the configuration instructions in this documentation and constant ob-
servance of the assembly and operating instructions for the cell compo-
nents used.
Misuse
Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. The manufacturer cannot be held liable for any
resulting damage. The risk lies entirely with the user.

Examples of such misuse include, for example, use in a non-industrial en-
Product description
vironment. The following sources of error can lead to undesired robot mo-
tions and result in damage to property:
• Errors in user programming
• Overlapping workpieces
• Errors in determining and transmitting the position of the workpiece
(especially in 6D conveyor applications)

Product description KUKA.ConveyorTech 8.0

Safety
3 Safety
This documentation contains safety instructions which refer specifically to
the option package 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 Integrators or the Operating and Programming Instructions for End
Users.
Comply with safety-relevant information
The safe use of this product requires knowledge of and compliance with
fundamental safety measures. Death, severe injuries or damage to prop-
erty may otherwise result.
• The “Safety” chapter in the operating and programming instructions
of the KUKA System Software (KSS) must be observed.
NOTICE
Damage to property due to electrostatic discharge (ESD)
The modules used in the robot controller are equipped with high-quality
components and are very sensitive to electrostatic discharges. If the
ESD guidelines are not observed, individual components or complete
modules may be damaged.
• Follow the appropriate ESD guidelines while handling all modules
used in the robot controller.
NOTICE
Damage to property due to excessive input and supply voltages
If the limit values for input voltages (inputs) and supply voltages are ex-
ceeded, individual components or complete modules may be damaged.
• During the handling of all modules used in the robot controller, ob-
serve the limits for input voltages (inputs) and supply voltages.

Safety KUKA.ConveyorTech 8.0

Planning
4 Planning
4.1 Conveyor with resolver
Description
The motion of the conveyor can be detected with a resolver. The resolver
is connected to a free channel of the RDC in the base frame of the robot.
Depending on the type, different numbers of free channels are available
on the RDC for the connection of resolvers. If required, additional chan-
nels can be made available by another RDC. A maximum of 5 conveyors
can be configured for one robot controller.
A synchronization switch (e.g. photo-electric barrier) can be used for work-
piece detection. For this purpose, the synchronization switch is connected
to one of the available fast measurement inputs of the robot controller.
Fig. 4-1: System with conveyor connection to RDC
1 Robot controller
2 RDC
3 Robot
4 Resolver cable
5 Resolver
6 Conveyor
7 Synchronization switch
8 Cable for synchronization switch
9 “Fast measurement” option
4.2 Client conveyor
Description
If multiple robots are to work at a single conveyor, this can be implemen-

ted in linear conveyor applications using the client conveyor functionality.
Only one resolver (source conveyor) is required here. The conveyor mo-

tion of the source conveyor can be transmitted via the system bus to ro-
Planning
bot controllers that have been configured as client conveyors.

To enable communication, the participating robot controllers must be in a
RoboTeam network. The synchronization signal for workpiece detection is
required separately for each robot controller and must be wired to the re-
spective fast measurement input.
Only linear conveyors can be used as source conveyors. External con-
veyors cannot be used for this.
4.3 External conveyor
Description
The interface for external conveyors enables the connection of external

position acquisition systems (e.g. a PLC). These systems detect the posi-
tion and motion of a workpiece independently of the robot controller. The
motion of the workpiece is transmitted by the external position acquisition
system to the robot controller by means of a field bus and a special pro-
tocol via the I/O interface of the robot controller. In addition to the motion
of the workpiece, the data also contain information on workpiece detec-
tion. The fast measurement inputs are not used here.
Using an external conveyor, it is possible to track workpieces in 1D (1D
conveyor) or 6D (6D conveyor). With a 1D conveyor, multiple workpieces
can be monitored and tracked; with a 6D conveyor, only 1 workpiece can
be monitored and tracked.
The external position acquisition system must be as accurate as possi-
ble. It must detect changes in velocity sufficiently quickly and transmit
them to the robot controller.
Precondition
• Cycle synchronization of the higher-level controller with the robot con-

troller
• Only for cycle synchronization via KSB or KLI:
The higher-level controller is compatible with the following network pro-
tocols according to IEEE standard 1588, e.g. with EtherCAT terminal
EL6688 from Beckhoff:
‒ PTPv1 for cycle synchronization via KSB
‒ PTPv2 for cycle synchronization via KLI
Cycle synchronization
The cycle synchronization can be carried out via one of the following inter-
faces to the robot controller:
• RoboTeam interface X70 (KSB)
• KLI
• Fast Measurement inputs
Cycle synchronization via Fast Measurement inputs is intended for high-

er-level controllers which are not compatible with the network protocol
PTPv1 or PTPv2 (e.g. Siemens).
For cycle synchronization via KSB or KLI, the time is also synchronized.
This is not the case with Fast Measurement inputs. It is therefore rec-
ommended to only use Fast Measurement inputs if cycle synchroniza-
tion via KSB or KLI is not possible.

If multiple robot controllers are to be synchronized with a higher-level con-
Planning
troller, the devices must be connected to a switch in a star configuration.
Here, it must be ensured that the switch supports the PTP protocol. Hard-
ware support is recommended since the synchronization accuracy
declines with software support. Using switches which do not support PTP
is not advisable since, depending on the load, the accuracy can be ad-
versely affected by milliseconds.
Fig. 4-2: System with external conveyors
1 Higher-level controller (PLC)

3 Conveyor
4 Resolver (conveyor position)
5 Robot
6 Robot controller
7 Interface for KSB, KLI or fast measurement inputs
8 Cycle synchronization
9 Field bus for workpiece information
6D conveyor
Workpiece tracking with 6 degrees of freedom represents a special case

in the application of ConveyorTech. There are thus the following limitations
with a 6D conveyor:
• It is only possible to transmit the position of one workpiece to the ro-
bot controller for each 6D conveyor. It is also only possible to have
the position of one workpiece on the conveyor tracked by the robot.
• The parameters Alarm distance and End of work area only work in
the conveyor’s main direction of motion. The main direction of motion
is the direction in which the conveyor travels – for example, a work-
piece is transported to the robot – so that the workpiece can be pro-
cessed. The conveyor’s main direction of motion must be calibrated.
Both parameters can also have negative values with the 6D conveyor.

As a rule, however, the value of the parameter Alarm distance must

Planning
be smaller than the value of the parameter End of work area.

• The position of workpiece is based on the calibrated position of the
conveyor and is transmitted to the robot controller as an absolute val-
ue.
4.3.1 Communications interface to the higher-level controller
Communication between the higher-level controller and the conveyor driv-

er is carried out in a 12 ms cycle. Every 12 ms, the higher-level controller
increases the packet counter by one and the content of the remaining re-
ception structure is adapted as required.
New workpiece information must not be sent to the robot controller more
than once every 12 ms. Due to the handshake between the robot control-
ler and the higher-level controller using the workpiece ID, new workpieces
can only be transferred once every 24 ms at most.
4.3.1.1 Reception structure from robot controller’s point of view (1D conveyor)
The reception structure has a total size of 34 bytes.

Name Description Type Size Unit
CmdWord Command word to the robot controller unsigned 2 bytes -
short
Packet Packet counter for detecting packet unsigned 2 bytes -
Counter and reception errors short
ConvValue Conveyor position long long 8 bytes 10-6 mm
Piece Workpiece ID unsigned 2 bytes -
Identifier short
Time Time of component detection long long 8 bytes 10-9 s
Position Conveyor position where the work- long long 8 bytes 10-6 mm
piece is located
checkSum CRC32 checksum unsigned long 4 bytes -
Bits in the command word (“CmdWord”):
Bit Name Description
0 IFC_BUS_CONV_IS_PRESENT Higher-level controller reports itself
ready.
1 IFC_BUS_CONV_NEW_PIECE Higher-level controller reports new work-
piece.
4.3.1.2 Reception structure from robot controller’s point of view (6D conveyor)
The reception structure has a total size of 42 bytes.

CmdWord Command word to the robot controller unsigned 2 bytes -
short
Packet Packet counter for detecting packet unsigned 2 bytes -
Counter and reception errors short
ConvValue Conveyor position in the form of a float 24 bytes [1-3] mm
BASE coordinate system (X, Y, Z, A,
[4-6] °
B, C)

Planning
Identifier short
Time Time of component detection long long 8 bytes 10-9 s
checkSum CRC32 checksum unsigned long 4 bytes -
Bits in the command word (“CmdWord”):
0 IFC_BUS_CONV_IS_PRESENT Higher-level controller reports itself
ready.
1 IFC_BUS_CONV_NEW_PIECE Higher-level controller reports new work-
piece.
2 IFC_BUS_CONV_BASE_VALID Higher-level controller delivers valid data
for an external BASE coordinate system
4.3.1.3 Transmission structure from the perspective of the robot controller
The transmission structure has an overall size of 8 bytes.

StatusWord Status of the robot controller unsigned 2 bytes -
short
Identifier short
Mirroring of the workpiece ID of the
workpiece most recently received and
written to the workpiece memory
Checksum CRC32 checksum unsigned long 4 bytes -
Bits in the status word rc StatusWord:
0 IFC_CONV_BUS_READY_FOR Conveyor signals to the higher-level
_POSITIONS controller that the conveyor is ready to
receive position information.
1 IFC_CONV_BUS_READY_FOR Conveyor signals to the higher-level
_PIECES controller that the conveyor is ready to
receive workpiece information.

4.3.1.4 Communication sequence between robot controller and PLC

Planning
Fig. 4-3: Communication sequence

Planning
4.3.2 Checksum calculation for external conveyor
Description
In order to detect errors during the transfer of data from the PLC to the
robot controller, the data stream must be provided with a checksum. In
the robot controller, the evaluation of the checksum is implemented as fol-
lows in the programming language C++.
static void crc32Array(const char *value, unsigned long

*checksum, const int len)
{
*checksum = 0;
for (int idx = 0; idx < len; idx++)

{
*checksum = crc32Table[((*checksum) ^ value[idx]) & 0xFF]
^ ((*checksum)>>8);
}
}
PLC example program
The following example is a fragment and serves merely to illustrate how

the checksum is calculated.
TYPE ConveyorPLCtoKRC:
STRUCT
CmdWord : WORD;
PacketCounter : WORD;
ConvValue_1 : UDINT;
ConvValue_2 : UDINT;
PieceIdentifierOut : WORD;
Time_1 : UDINT;
Time_2 : UDINT;
Position_1 : UDINT;
Position_2 : UDINT;
CheckSumOut : UDINT;
END_STRUCT
END_TYPE
CrcTable : ARRAY [0..255] OF DWORD :=

16#00000000, 16#77073096, 16#EE0E612C, 16#990951BA,
16#076DC419,
16#706AF48F, 16#E963A535, 16#9E6495A3, 16#0EDB8832,
16#79DCB8A4,
16#e0d5e91e, 16#97d2d988, 16#09b64c2b, 16#7eb17cbd,
16#e7b82d07,
16#90BF1D91, 16#1DB71064, 16#6AB020F2, 16#F3B97148,
16#84BE41DE,
16#1adad47d, 16#6ddde4eb, 16#f4d4b551, 16#83d385c7,
16#136c9856,
16#646ba8c0, 16#fd62f97a, 16#8a65c9ec, 16#14015c4f,
16#63066cd9,
16#fa0f3d63, 16#8d080df5, 16#3b6e20c8, 16#4c69105e,
16#d56041e4,
16#a2677172, 16#3c03e4d1, 16#4b04d447, 16#d20d85fd,
16#a50ab56b,
16#35b5a8fa, 16#42b2986c, 16#dbbbc9d6, 16#acbcf940,
16#32d86ce3,
16#45df5c75, 16#dcd60dcf, 16#abd13d59, 16#26d930ac,
16#51de003a,

Planning KUKA.ConveyorTech 8.0
16#c8d75180, 16#bfd06116, 16#21b4f4b5, 16#56b3c423,

16#cfba9599,
16#b8bda50f, 16#2802b89e, 16#5f058808, 16#c60cd9b2,
16#b10be924,
16#2f6f7c87, 16#58684c11, 16#c1611dab, 16#b6662d3d,
16#76dc4190,
16#01db7106, 16#98d220bc, 16#efd5102a, 16#71b18589,
16#06b6b51f,
16#9fbfe4a5, 16#e8b8d433, 16#7807c9a2, 16#0f00f934,
16#9609a88e,
16#e10e9818, 16#7f6a0dbb, 16#086d3d2d, 16#91646c97,
16#e6635c01,
16#6B6B51F4, 16#1C6C6162, 16#856530D8, 16#F262004E,
16#6C0695ED,
16#1b01a57b, 16#8208f4c1, 16#f50fc457, 16#65b0d9c6,
16#12b7e950,
16#8bbeb8ea, 16#fcb9887c, 16#62dd1ddf, 16#15da2d49,
16#8cd37cf3,
16#fbd44c65, 16#4db26158, 16#3ab551ce, 16#a3bc0074,
16#d4bb30e2,
16#4adfa541, 16#3dd895d7, 16#a4d1c46d, 16#d3d6f4fb,
16#4369e96a,
16#346ed9fc, 16#ad678846, 16#da60b8d0, 16#44042d73,
16#33031de5,
16#aa0a4c5f, 16#dd0d7cc9, 16#5005713c, 16#270241aa,
16#be0b1010,
16#c90c2086, 16#5768b525, 16#206f85b3, 16#b966d409,
16#ce61e49f,
16#5edef90e, 16#29d9c998, 16#b0d09822, 16#c7d7a8b4,
16#59b33d17,
16#2eb40d81, 16#b7bd5c3b, 16#c0ba6cad, 16#edb88320,
16#9abfb3b6,
16#03b6e20c, 16#74b1d29a, 16#ead54739, 16#9dd277af,
16#04db2615,
16#73dc1683, 16#e3630b12, 16#94643b84, 16#0d6d6a3e,
16#7a6a5aa8,
16#e40ecf0b, 16#9309ff9d, 16#0a00ae27, 16#7d079eb1,
16#f00f9344,
16#8708a3d2, 16#1e01f268, 16#6906c2fe, 16#f762575d,
16#806567cb,
16#196c3671, 16#6e6b06e7, 16#fed41b76, 16#89d32be0,
16#10da7a5a,
16#67dd4acc, 16#f9b9df6f, 16#8ebeeff9, 16#17b7be43,
16#60b08ed5,
16#d6d6a3e8, 16#a1d1937e, 16#38d8c2c4, 16#4fdff252,
16#d1bb67f1,
16#a6bc5767, 16#3fb506dd, 16#48b2364b, 16#d80d2bda,
16#af0a1b4c,
16#36034af6, 16#41047a60, 16#df60efc3, 16#a867df55,
16#316e8eef,
16#4669be79, 16#cb61b38c, 16#bc66831a, 16#256fd2a0,
16#5268e236,
16#cc0c7795, 16#bb0b4703, 16#220216b9, 16#5505262f,
16#c5ba3bbe,
16#b2bd0b28, 16#2bb45a92, 16#5cb36a04, 16#c2d7ffa7,
16#b5d0cf31,
16#2cd99e8b, 16#5bdeae1d, 16#9b64c2b0, 16#ec63f226,
16#756aa39c,
16#026d930a, 16#9c0906a9, 16#eb0e363f, 16#72076785,
16#05005713,
16#95bf4a82, 16#e2b87a14, 16#7bb12bae, 16#0cb61b38,
16#92d28e9b,
16#E5D5BE0D, 16#7CDCEFB7, 16#0BDBDF21, 16#86D3D2D4,
16#F1D4E242,
16#68ddb3f8, 16#1fda836e, 16#81be16cd, 16#f6b9265b,
16#6fb077e1,

Planning
16#18b74777, 16#88085ae6, 16#ff0f6a70, 16#66063bca,
16#11010b5c,
16#8f659eff, 16#f862ae69, 16#616bffd3, 16#166ccf45,
16#a00ae278,
16#d70dd2ee, 16#4e048354, 16#3903b3c2, 16#a7672661,
16#d06016f7,
16#4969474d, 16#3e6e77db, 16#aed16a4a, 16#d9d65adc,
16#40df0b66,
16#37d83bf0, 16#a9bcae53, 16#debb9ec5, 16#47b2cf7f,
16#30b5ffe9,
16#bdbdf21c, 16#cabac28a, 16#53b39330, 16#24b4a3a6,
16#bad03605,
16#cdd70693, 16#54de5729, 16#23d967bf, 16#b3667a2e,
16#c4614ab8,
16#5d681b02, 16#2a6f2b94, 16#b40bbe37, 16#c30c8ea1,
16#5a05df1b,
16#2D02EF8D;
bytesForCRC : ARRAY[0..33] OF BYTE;

pos2temp : DWORD;
pos2 : DWORD;
crc2 : DWORD;
crc : DWORD;
i : INT;
arrayLen : INT;
DataToKRC : ConveyorPLCtoKRC;
------------------------------------------------
[...]
(*
The array bytesForCRC position 0 to 29 must contain the
data which should be sent to the KRC.
bytesForCRC is only used for the calculation of the
checksum,
not for sending the data, for sending DataToKRC is used.
*)
(* initialize the 4 bytes for checksum with 0 *)

bytesForCRC[30] := 16#00;
pos2temp := 16#00000000;
pos2 := 16#00000000;
crc2 := 16#00000000;
crc := 16#00000000
arrayLen := SIZEOF(bytesForCRC) - 1;
FOR i := 0 TO arrayLen BY 1 DO
crc := crc2;
pos2temp := crc XOR bytesForCRC[i];
pos2 := pos2temp AND 16#FF;
(*shift right by 8 bits*)
crc := SHR(crc, 8);
crc2:= crcTable[pos2] XOR crc;
END_FOR
(*

Planning KUKA.ConveyorTech 8.0
The variable crc2 contains the checksum for the data.

The value must be copied into the send structure to the
KRC.
*)
DataToKRC.CheckSumOut := crc2;

Start-up and recommissioning

5 Start-up and recommissioning
5.1 Overview
This is an overview of the most important steps during the start-up of

KUKA.ConveyorTech 8.0. The precise sequence depends on the appli-
cation and other system-specific circumstances.
For this reason, the overview does not claim to be comprehensive.
Step Description
1 Connect resolver to RDC (not for external conveyors).
(>>> 5.2 "Connecting a resolver to the RDC" Page 27)
2 Configure ConveyorTech in WorkVisual.
(>>> 7.1 "Overview: configuration in WorkVisual" Page 35)
3 Calibrate the conveyor.
(>>> 9.1 "Calibrating a linear conveyor" Page 59)
(>>> 9.2 "Calibrating a circular conveyor" Page 60)
(>>> 9.5 "Calibrating a 6D conveyor" Page 65)
4 Optional: Check conveyor (not for 6D conveyor).
(>>> 9.3 "Checking the conveyor distance" Page 62)
5 Optional: Calibrate the workpiece on the conveyor.
(>>> 9.4 "Calibrating a workpiece on the 1D conveyor"
Page 63)
(>>> 9.6 "Calibrating a workpiece on the 6D conveyor"
Page 67)
5.2 Connecting a resolver to the RDC
Description
The following hardware is required:

• Resolver with cable (1 cable per conveyor)
• Synchronization switch (1 switch per conveyor)
• “Fast measurement” option
Only resolvers from KUKA Deutschland GmbH may be connected to the

robot’s RDC.
The hardware may only be connected by a skilled electrician in accord-

ance with the generally applicable electrical engineering rules.
When designing the mechanical coupling of the resolver (e.g. defining

the transmission ratio for a belt coupling), one should aim for the con-
veyor to cover a distance of approximately 1 mm per degree [°]. The
minimum acceptable degree of accuracy is provided by a distance of
3 mm per degree. Values greater than 3 mm per degree should be
avoided.

Start-up and recommissioning KUKA.ConveyorTech 8.0
Procedure
1. Unscrew 4 fastening screws from the housing cover of the RDC and
remove the cover.
Fig. 5-1: RDC housing
1 Fastening screw on the housing cover
2. Plug the flat connector of the connecting cable into one of the free
connections via the SKINTOP® cable gland. The cable gland is loca-
ted on the side of the RDC box. The connector locks itself in place.
Fig. 5-2: Connecting the resolver cable to the RDC
1 Free connections on the RDC
3. Connect the other end of the connecting cable to the resolver .

Start-up and recommissioning

Fig. 5-3: Connecting the resolver cable to the resolver
1 Connection for the connecting cable on the resolver
4. Remount the housing cover and secure it with 4 fastening screws.

Start-up and recommissioning KUKA.ConveyorTech 8.0

Installation
6 Installation
The option package can either be installed on the robot controller via the
smartHMI or via WorkVisual.
6.1 System requirements
Hardware
Robot controller:
• KR C4
Robot:
• Any robot that can be operated with a KR C4
Conveyor system:
• A maximum of 5 conveyors may be operated using one robot control-
ler.
The conveyors can either be connected to the RDC with a resolver or
to the robot controller via a higher-level controller. A combination of
both connection types is also possible.
Software
Robot controller:
• KUKA System Software 8.6
Laptop/PC:
• WorkVisual 6.0
6.2 Installation via WorkVisual
6.2.1 Installing or updating ConveyorTech
Description
The option package is installed in WorkVisual and added to the project.

When the project is transferred to the robot controller, the option package
is automatically installed there.
In the case of an update, the previous version of the option package in
WorkVisual must first be uninstalled.
It is advisable to archive all relevant data before updating a software
package.
Precondition
• User group “Expert”

• T1 or T2 mode
• No program is selected.
• Network connection to the robot controller
• The option package is available as a KOP file.

Installation KUKA.ConveyorTech 8.0
Procedure
1. Only for an update: uninstall the previous version of the Conveyor op-
tion package in WorkVisual.
2. Install the Conveyor option package in WorkVisual.
3. Load the project from the robot controller.
4. Add the Conveyor option package to the project.
5. Configure the option package in WorkVisual.
(>>> 7.1 "Overview: configuration in WorkVisual" Page 35)
6. Deploy the project from WorkVisual to the robot controller and activate
it.
7. The request for confirmation Do you want to activate the project […]?
is displayed on the smartHMI. The active project is overwritten during
activation. If no relevant project will be overwritten: answer the query
with Yes.
8. An overview with the changes and a request for confirmation are dis-
played on the smartHMI. Answer this with Yes. The option package is
installed and the robot controller carries out a reboot.
Information about procedures in WorkVisual is contained in the WorkVi-

sual documentation.
LOG file
A LOG file is created under C:\KRC\ROBOTER\LOG.
6.2.2 Uninstalling ConveyorTech
It is advisable to archive all relevant data before uninstalling a software

package.
Precondition
• User group “Expert”

• T1 or T2 mode
Procedure

2. Remove the conveyor from the project.
3. Remove the Conveyor option package from the project. A window
with modifications is displayed.
it.
is displayed on the smartHMI. Answer the query with Yes.
uninstalled and the robot controller carries out a reboot.

sual documentation.

Installation
LOG file
6.3 Installation via smartHMI
After initial installation, it is not yet possible to use the inline forms and
the tabs for configuration on the smartHMI. To complete the installation
of ConveyorTech, a WorkVisual project containing at least one config-
ured conveyor must be transferred to the robot controller
(>>> 7.1 "Overview: configuration in WorkVisual" Page 35).
If ConveyorTech is updated, the Conveyor option package must also be
updated in WorkVisual. The previously used WorkVisual project must be
updated with this version and then transferred to the robot controller.
6.3.1 Installing or updating ConveyorTech
It is advisable to archive all relevant data before updating a software

package.
Precondition
• User rights: Function group General configuration

But at least the user group “Expert”
• T1 or T2 mode
• USB stick with the option package (KOP file)
NOTICE
Data loss due to USB sticks from third-party manufacturers
Data may be lost if USB sticks from manufacturers other than KUKA
are used for activities on the robot controller.
• For activities on the robot controller requiring a USB stick, use a
KUKA stick.
The KUKA sticks are validated for use with the robot controller.
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 Conveyor 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.
Otherwise, the path from which the software is to be installed must be
configured first:
a. Press the Configure button.
b. Select a line in the Installation paths for options area.
Note: If the line already contains a path, this path will be overwrit-
ten.
c. Press Path selection. The available drives are displayed.
d. If the stick is connected to the robot controller: Select E:\.
If the stick is connected to the smartPAD: K:\ instead of E:\

Installation KUKA.ConveyorTech 8.0
e. Press Save. The Installation paths for options area is displayed

again. It now contains the new path.
f. Mark the line with the new path and press Save again.
5. Activate the check box next to Conveyor and press Install. Confirm
the installation query with OK.
is displayed. The active project is overwritten during activation. If no
relevant project will be overwritten: Answer the query with Yes.
7. An overview of the changes and a request for confirmation are dis-
played. Answer this with Yes. The option package is installed and the
robot controller carries out a reboot.
8. Remove the stick.
LOG file
6.3.2 Uninstalling ConveyorTech
It is advisable to archive all relevant data before uninstalling a software

package.
Precondition
• User rights: Function group General configuration

But at least the user group “Expert”
• T1 or T2 mode
Procedure

2. Activate the check box next to Conveyor and press Uninstall. Answer
the request for confirmation with Yes.
3. Answer the request for confirmation Do you want to activate the
project […]? with Yes.
played. Answer this with Yes. The option package is uninstalled and
the robot controller carries out a reboot.
LOG file

Configuration
7 Configuration
7.1 Overview: configuration in WorkVisual
Step Description
All conveyor types:
1 Install the Conveyor option package in WorkVisual.
2 Load the project from the robot controller.
3 Insert the conveyor in the project.
(>>> 7.2 "Inserting a conveyor in a project" Page 36)
Only for external conveyors:
4 Change the dimensions of the conveyor.
(>>> 7.3 "Changing the dimension of the conveyor"
Page 36)
Not for external conveyors:
5 Modify the connection between the synchronization switch
and the CIB if required.
(>>> 7.4 "Modifying the connection between the synchroni-
zation switch and the CIB" Page 37)
All conveyor types:
6 Define the conveyor as motion master.
(>>> 7.5 "Defining the conveyor as motion master"
Page 38)
Not for source and client conveyors:
7 Add robot controllers to a RoboTeam network.
(>>> 7.6 "Adding robot controllers to a RoboTeam network"
Page 39)
8 Assign source conveyor.
(>>> 7.7 "Assigning a source conveyor" Page 39)
Only for external conveyors:
9 Configure cycle synchronization.
(>>> 7.8 "Configuring cycle synchronization" Page 40)
All conveyor types:
10 Configure the conveyor parameters in the machine data.
(>>> 7.9 "Configuring conveyor parameters in the machine
data" Page 42)
11 Edit the controller-specific conveyor settings.
(>>> 7.10 "Editing controller-specific conveyor settings"
Page 49)
12 Generate long texts for conveyor I/Os.
(>>> 7.11 "Configuring I/Os and adding long texts"
Page 50)
13 Transfer the project from WorkVisual to the robot controller.
Information about installing and managing option packages can be

found in the WorkVisual documentation.

Configuration KUKA.ConveyorTech 8.0
Information about bus configuration and project deployment can be

found in the WorkVisual documentation.
7.2 Inserting a conveyor in a project
Description
A maximum of 5 conveyor systems can be inserted into a WorkVisual

project.
Precondition
• The project is open.

• The robot has been inserted into the project and configured.
Procedure
1. Right-click on the robot controller in the Project structure (Hardware

tab) or in the Cell configuration and select Add... from the context
menu.
2. Select the Options tab and select the desired conveyor type in the
Conveyor catalog:
• LinConveyor for a linear conveyor
• CircConveyor for a circular conveyor
• LinConveyorExt for an external conveyor
• LinConveyorClient for a linear client conveyor
3. Click on Add.
If the option package Conveyor is not yet present in the project, a di-
alog opens. The files being added or modified are indicated there.
4. Click on OK. The dialog closes. The conveyor is inserted and as-
signed to the robot controller.
The conveyor can now be renamed. To do this, enter a new name
in the Properties window. This name is displayed in the inline forms
on the robot controller.
5. If required, repeat steps 1 to 4 to insert further conveyors.
7.3 Changing the dimension of the conveyor
Description
Conveyors that are added to the WorkVisual project are 1-dimensional

conveyors by default. However, if the conveyor is a 6D conveyor or a mo-
bile platform, the dimension must be changed in WorkVisual.
Precondition

• The conveyor has been inserted into the project.
Procedure
1. Double-click on the catalog element of type LinConveyorExt in the

Project structure (Hardware tab). The machine data editor is opened.

Configuration
2. Select 6D in the selection box at the parameter Conveyor dimen-
sions.
3. Save the change and close the window.
7.4 Modifying the connection between the synchronization switch and the
CIB
Description
When a conveyor is inserted into the WorkVisual project, the synchroniza-

tion switch on the conveyor is automatically connected to the next free in-
put of interface X33 (Fast Measurement). If the real synchronization switch
has been wired to a different input of the interface, the connection must
be changed in WorkVisual.
For external conveyors connected to the robot controller via a higher-
level controller, the following procedure is not relevant.
Precondition

Procedure
1. Open the Drive configuration window: Menu sequence Editors >

Drive configuration
2. Select the connecting line between the synchronization switch and the
input of interface X33.
3. Right-click and select Do not keep selected connections from the
context menu.
4. Click on the synchronization switch and hold down the mouse button.
5. Drag the mouse pointer to the desired input and release the mouse
button. The synchronization switch is now connected to the desired in-
put.
6. Close the Drive configuration window.
Example
Fig. 7-1: Drive configuration: Connection to CIB
1 Cabinet Interface Board (CIB)

2 Inputs 1 … 4 of interface X33

3 Connecting line
5 Circular conveyor
7.5 Defining the conveyor as motion master
Precondition

Procedure
1. Open the Cell configuration window: Menu sequence Editors > Cell
configuration
2. Click on the robot in the cell configuration and hold down the mouse
button.
3. Drag the mouse pointer to the conveyor and release the mouse but-
ton. A selection menu is opened.
4. Click on Robot should follow conveyor.
The robot can now follow the conveyor. This is indicated by a dotted
arrow. The arrow is red if the root points have not yet been calibrated.
5. Open the Tool/base management editor and assign a number to the
BASE coordinate system of the workpiece. The motions are taught in
this BASE coordinate system.
6. Optional: Add further BASE coordinate systems to the conveyor.
a. Click on Reset filter. The Available tools and bases area is dis-
played.
b. In this area, add one or more BASE coordinate systems to the
conveyor. The names of the coordinate systems can be changed.
c. Assign a number to each coordinate system.
7. Close the Cell configuration window.
As an alternative to this procedure, the correction proposal of the Work-

Visual project analysis can be accepted.

Configuration
Example
Fig. 7-2: Robot following a circular conveyor
1 The circular conveyor is the motion master of the robot.
7.6 Adding robot controllers to a RoboTeam network
Description
The robot controllers of the source and client conveyors must be located
in a RoboTeam network to enable the client conveyor to use the resolver
of the source conveyor.
For this purpose, the robot controllers of the source and client conveyors
must be added to a RoboTeam network in WorkVisual.
The following procedure is only relevant if source and client conveyors
are being used in the project.
Precondition
• A project is open.
• The project contains at least 2 robot controllers.
• The robots have been added to the project and configured.
• The source and client conveyors have been added to the project.
Procedure
1. In the cell configuration, select the robot controllers that are to be add-
ed to the RoboTeam network.
2. Right-click and select RoboTeam > Generate RoboTeam from selec-
ted controllers from the context menu.
The RoboTeam network is created and the selected robot controllers
are added to the network.
7.7 Assigning a source conveyor
Description
A client conveyor must be assigned a source conveyor in WorkVisual.

This assignment enables the client conveyor to use the resolver of the
source conveyor.

The following procedure is only relevant if source and client conveyors

are being used in the project.
Precondition
• The project contains at least 2 robot controllers.
• The robots have been added to the project and configured.
• The source and client conveyors have been added to the project.
• The robot controllers of the source and client conveyors are located in
a RoboTeam network.
Procedure

tab).
2. Select Conveyor settings in the context menu. The editor is opened.
3. Select the source conveyor at Client/Source conveyor connection.
4. Repeat steps 1 to 3 for additional client conveyors.
5. Save the project.
7.8 Configuring cycle synchronization
Description
When using an external conveyor, cycle synchronization must exist be-

tween the robot controller and the external system. This is ensured by
time synchronization. For this, time synchronization must be activated in
the additional controller options in WorkVisual and, depending on the sys-
tem configuration, further settings must be carried out:
• Define the interface for time synchronization (KSB, KLI or fast meas-
urement inputs).
• Optionally: Activate VLAN tagging for KSB.
Precondition:
‒ The hardware and software used support VLAN tagging with

ID 10.
• If desired, define the selected controller as the master for the time
synchronization.
Within a single network, only one controller can function as the master
for the time synchronization. This can also be the higher-level control-
ler, e.g. the PLC.
If the fast measurement inputs are selected as the interface, the selec-
ted controller cannot be the master for time synchronization. In this
case, a higher-level controller must perform this task.
Precondition
• The conveyor system is not part of a RoboTeam network.

If a RoboTeam network has been created, the settings for time syn-
chronization are not available. In this case, synchronization is man-
aged by the RoboTeam functionality.

Configuration
• An external conveyor has been inserted in the project.
Procedure
1. Select the robot controller in the Project structure (Hardware tab) or

in the Cell configuration.
2. Select the menu sequence Editors > Additional controller settings.
The Additional controller settings window opens.
3. Activate the time synchronization and make the required settings.
Parameter
Name Description
Activate time syn- Activating/deactivating time synchronization
chronization
• Check box active: Cycle synchronization is
activated.
• Check box not active: Cycle synchroniza-
tion is deactivated.
Default: Check box not active
Time synchronization Interface for time synchronization via the net-
interface work
• KSB (PTPv1)
The KSB only supports Precision Time Pro-
tocol version 1.
• KLI (PTPv2)
The KLI only supports Precision Time Pro-
tocol version 2.
• Fast Measurement inputs
Note: A Fast Measurement input must be set
every 1.2 s for a duration of at least 500 ms.
Default: KSB (PTPv1)
Fast Measurement Defining the fast measurement input
input
• 1 … 8
Note: There are always 8 fast measurement in-
puts to choose from here. However, some con-
troller variants have fewer than 8 fast measure-
ment inputs. When making a selection, ensure
that the selected input exists on the robot con-
troller.
Default: 7
Activate VLAN tag- Activating/deactivating VLAN tagging for KSB
ging (KSB)
If VLAN tagging is activated, the data packets
are labeled and transferred with ID 10.
• Check box active: VLAN tagging is activa-

ted for KSB.
• Check box not active: VLAN tagging for
KSB is deactivated.

Name Description
Set controller as Sets the selected controller as the master for
time master the time synchronization.
• Check box active: Controller is set as mas-

ter.
• Check box not active: Controller is not set
as master. A different controller in the net-
work functions as the master for the time
synchronization.
7.9 Configuring conveyor parameters in the machine data
Description
In WorkVisual, various parameters in the machine data can be configured

for each conveyor:
• General I/O parameters (only for external conveyors)
• Alarm and stop distances
• Conveyor-specific expert parameters
• Escape strategy
Precondition

Procedure
1. Double-click on the conveyor in the Project structure (Hardware tab).

The machine data editor is opened.
2. Edit the machine data of the conveyor as required.
• (>>> 7.9.1 "General I/O parameters" Page 42)
• (>>> 7.9.2 "Conveyor-specific expert parameters" Page 43)
• (>>> 7.9.3 "Alarm and stop distances" Page 45)
• (>>> 7.9.4 "Escape strategy" Page 46)
7.9.1 General I/O parameters
Only available for external conveyors

Configuration
Name Description
First input bit First bit for inputs of the I/O mapping for the
external conveyor
Arranged by bytes:
• 1
• 9
• 17
• …
Default: 1
First output bit First bit for outputs of the I/O mapping for the
external conveyor
Arranged by bytes:
• 1
• 9
• 17
• …
Default: 1
Conveyor dimen- Type of conveyor
sions
• 1D: 1D conveyor
• 6D: 6D conveyor
7.9.2 Conveyor-specific expert parameters
Name Description
Number of IPO cy- Number of interpolation cycles for calculating the average conveyor
cles velocity
If higher values are used, the robot motions are smoother. This also
has the effect, however, that the robot responds more slowly to
changes in the velocity of the conveyor.
Default: 10
Filter active Activating/deactivating filters
The filter compensates for small, jerky changes to the velocity of the
conveyor and thus ensures a smooth robot motion.
• Check box active: Filter is active.

• Check box not active: Filter is not active.
Note: It is generally not necessary to change the default setting.
Delay [ms] Time (in ms) for compensation for the delay and reaction times inher-
ent in the motion control
Default: 24 ms
Note: It is generally not necessary to change the default value.

Name Description
Trace active Activating/deactivating trace recording
• Check box active: Trace recording is active for this conveyor.

• Check box not active: Trace recording is not active for this con-
veyor.
Note: Trace recording can only be activated for one conveyor at a
time.
Continuous convey- Cannot be configured for 6D conveyors
or advance
• Check box active: The distance traveled by the conveyor since in-
itialization of the conveyor is written to the system variable
$SEN_PREA_C[].
This value is independent of the synchronization with a workpiece
on the conveyor.
The index in the box $SEN_PREA_C[] is calculated by adding the
value 10 to the conveyor index. For a conveyor with the index 1,
the continuous conveyor advance is written to location 11
($SEN_PREA_C[11]).
• Check box not active: The distance traveled by the conveyor
since initialization of the conveyor is not written to the system var-
iable $SEN_PREA_C[] and thus cannot be polled.
Resolver transmis- Transmission ratio between the translational or rotational distance
sion ratio traveled by the conveyor and the number degrees supplied by the re-
solver
Default: 10
Note: This parameter is automatically calculated during calibration. No
modification is usually necessary.
Debouncing [ms] Cannot be configured for external conveyors
Minimum time (in ms) between 2 measurement signals in order to be
able to interpret them as 2 separate signals
Default: 12 ms

Configuration
7.9.3 Alarm and stop distances
Name Description
Alarm distance Alarm distance
If the robot tracks a workpiece on the conveyor over the alarm dis-
tance, a corresponding message is generated and a configured output
is reset.
Default values:
• Linear conveyor: 2000 mm

• Circular conveyor: 2000°
End of work area Maximum conveyor distance the robot can travel as a synchronized
motion.
As soon as the robot has reached the defined value, the synchron-
ized motion is canceled and the robot executes the motion program-
med in the subprogram CONV_QUIT.
Preconditions for this are:
• Programming of the inline form Quit

• Programming of a motion in the subprogram CONV_QUIT that is
not synchronized with the conveyor
Default values:

Cycflag for External Cycflag number for External Cancel
Cancel
The Cycflag is used in combination with the interrupt for External
Cancel in order to cancel the synchronized motion as a reaction to a
user-defined signal.
Default: 250 … 254
Note: It is advisable to carry out assignment of the Cycflag in the
conveyor application program before the Follow or Skip inline form.
The correct Cycflag can be accessed using the variable
Z_EXT_QUIT_CYCFLAG_NBR and the conveyor index.
Example: $CYCFLAG[Z_EXT_QUIT_CYCFLAG_NBR[1]] = $IN[100]
AND $IN[101]
Interrupt for alarm Interrupt number for the alarm distance
distance
The number determines the processing priority if several interrupts oc-
cur at the same time.
Default: 21 … 25
Interrupt at end of Interrupt number for the maximum conveyor distance
work area
Default: 26 … 30

Name Description
Interrupt for stop Interrupt number for a $STOPMESS error during the conveyor track-
signal ing motion
$STOPMESS is set in order to indicate the occurrence of a message
requiring the robot to be stopped (e.g. EMERGENCY STOP or opera-
tor safety violation).
Default: 31 … 35
Interrupt at External Interrupt number for External Cancel during the conveyor tracking mo-
Cancel tion.
An External Cancel can be used to react to a user-defined signal by
canceling the synchronized motion and executing the motion program-
med in the subprogram CONV_QUIT.

• Programming of a motion in the subprogram CONV_QUIT that is
not synchronized with the conveyor
Default: 36 … 40
Output for alarm Output number for the alarm distance
distance
Default: 731 … 735
Output for stop sig- Output number for $STOPMESS error
nal
Default: 701 … 705
7.9.4 Escape strategy
As standard, a stop request of the robot triggers a drive ramp stop; the
conveyor continues moving and the synchronization is lost.
Alternatively, a stop strategy can be configured in which the conveyor also
stops in the case of a stop request of the robot and the synchronization is
retained.

Configuration
Name Description
Stop strategy Stop strategy
• GEN_STOP
A stop request of the robot leads to a drive ramp stop. The con-
veyor continues moving and the synchronization is lost.
• CONV_STOPPABLE
In the case of a stop request of the robot, the robot controller sets
an output that is linked to a higher-level controller from TRUE to
FALSE. The higher-level controller can then stop the conveyor
synchronously with the robot.
Default: GEN_STOP
Timeout for confir- Only relevant for the stop strategy CONV_STOPPABLE
mation [ms]
MON_TIME_ACKNOWLEDGE: Timeframe in which the higher-level
controller must confirm that it has received the stop request
Default: 48 ms
Timeout for stop Only relevant for the stop strategy CONV_STOPPABLE
[ms]
MON_TIME_CONV_STOP: Timeframe after receiving the stop request
in which the higher-level controller must stop the conveyor
Default: 1500 ms
Note: The braking time of the axes is monitored independently of this
by the safety controller. Depending on the configuration, this can re-
sult in a stop of the robot already being triggered at an earlier point in
time by the safety controller. The braking time per axis can be set in
the safety configuration. Further information about the safety configu-
ration can be found in the operating and programming instructions for
the System Software.
(>>> "Example for Timeout for stop [ms]" Page 47)
Input for Stop re- Only relevant for the stop strategy CONV_STOPPABLE
quest confirmation
IN_STOP_ACKNOWLEDGE: Index of the input $IN[x] used by the
higher-level controller to inform the robot controller that it has
received the stop request
Default: -1
Output for Stop re- Only relevant for the stop strategy CONV_STOPPABLE
quest
OUT_STOP_REQUEST: Index of the output $OUT[x] used to transmit
the stop request of the robot to the higher-level controller
Default: -1
Example for Timeout for stop [ms]
In this example, the following settings have been made:

• Braking time of axis 1: 1000 ms
• Braking time of axes 2 to 6: 2000 ms
• Timeout for stop [ms]: 1500 ms
If the user now presses a button that triggers a stop request during the
synchronized motions of the robot and conveyor, the following situations
may arise:
• If the conveyor stops within 700 ms, then the robot also stops and the
synchronization is maintained.

• If the conveyor only stops after 1200 ms, it is possible that the robot
will stop before this because a braking time of 1000 ms has been set
for axis 1. This means that the synchronization is lost.
7.9.4.1 Signal diagram for stop strategy CONV_STOPPABLE
Description
If the stop strategy is configured for a conveyor, the stop request of the
robot results in the following sequence:
1. During a synchronized motion, a stop of the robot is requested, e.g.
by pressing the EMERGENCY STOP device on the smartPAD, the
STOP button
2. The configured output OUT_STOP_REQUEST is set from TRUE to
FALSE.
3. The higher-level controller confirms the stop request via the configured
input IN_STOP_ACKNOWLEDGE (HIGH level expected).
Error situation 1:
• Drive ramp stop if confirmation arrives after the configured time

MON_TIME_ACKNOWLEDGE has elapsed
4. Conveyor and robot are stopped. The robot comes to a path-maintain-
ing stop on the conveyor base (BCO is maintained).
Error situation 2:
• Drive ramp stop if the conveyor does not come to a standstill in

the configured time MON_TIME_CONV_STOP (BCO is lost)
5. If the conveyor application is resumed after the reset or after a block
selection, the output OUT_STOP_REQUEST is reset to TRUE. The ro-
bot continues to track the conveyor base.
Good case
The figure shows the signal diagram for the good case: conveyor applica-
tion can be resumed.
Fig. 7-3: Good case: resumption of conveyor application possible
Blue $OUT[OUT_STOP_REQUEST]
Red $IN[IN_STOP_ACKNOWLEDGE]
Green Conveyor advance
48 ms MON_TIME_ACKNOWLEDGE

Configuration
1500 ms MON_TIME_CONV_STOP
Error situation 1
The figure shows the signal diagram for the following error case: higher-
level controller confirmation too late. This results in a drive ramp stop.
• Configured maximum time for confirmation: 1200 ms
• Actual time required for confirmation: 1950 ms
Fig. 7-4: Fault: higher-level controller confirmation too late
Error situation 2
The figure shows the signal diagram for the following error case: conveyor
is stopped too late.
Once the higher-level controller has confirmed the stop request, the con-
veyor continues to run and does not come to a standstill within the config-
ured time. This results in a drive ramp stop.
Fig. 7-5: Fault: conveyor is stopped too late
7.10 Editing controller-specific conveyor settings
Description
The controller-specific conveyor settings are valid for all conveyors tracked
by the robot and are carried out for each robot controller.

Precondition

• At least 1 conveyor has been inserted into the project.
Procedure

tab).
2. Select Conveyor settings in the context menu. The editor is opened.
3. Edit the parameters as required.
Alternative procedure
1. Open the Options folder in the Project structure (Hardware tab).

2. Right-click on the Conveyor option package and select Conveyor set-
tings. The editor is opened.
3. Edit the parameters as required.
Parameters
Name Description
Continue after Stop Resuming/stopping robot motion after
$STOPMESS error
• Check box active: Following a $STOPM-

ESS error, the robot motion on the convey-
or is resumed.
• Check box not active: Following a
$STOPMESS error, the robot motion on the
conveyor is stopped.
Default: Check box active
Timer index Timer index of the conveyor system
• 1 … 32
Default: 1
7.11 Configuring I/Os and adding long texts
Description
Long texts can be generated in WorkVisual for the I/O configured in the
machine data of a conveyor.
• The following outputs must be configured for every conveyor type:
‒ Output for alarm distance
‒ Output for stop signal
• The following parameters must additionally be configured for external
conveyors:
‒ First input bit
‒ First output bit
• The long texts for the I/Os are created in the long text editor accord-
ing to the following pattern:

Configuration
‒ Conveyor name + Function
Example:
‒ LinearConveyorExt2 Output for alarm distance
Precondition
• At least 1 conveyor has been inserted into the project.
• The robot controller has been set as the active controller.
Procedure
1. Select the Hardware tab in the Project structure window.

2. Double-click on the conveyor that is to be configured. The machine
data editor is opened.
3. Configure the conveyor I/Os as required.
(>>> "Parameter" Page 51)
In the I/O configuration, it must be ensured that there are no over-
laps with other I/Os.

5. Right-click on the conveyor and select Add long texts for I/Os from
the context menu.
6. Repeat steps 2 to 5 for all further conveyors that are present in the
project.
7. If required, display and or edit the long texts for the configured I/Os in
the long text editor:
a. Select the menu sequence Editors > Symbol Table Editor.
b. The long texts are sorted thematically. In the left-hand column, se-
lect the long texts that are to be displayed:
• Digital inputs
• Digital outputs
Parameter
In the machine data of a conveyor under Distances:

Name Description
Output for alarm dis- Output number for the alarm distance
tance
Default: 731 … 735
Output for stop sig- Output number for $STOPMESS error
nal
Default: 701 … 705
In the machine data of an external conveyor under General:

Name Description
First input bit First bit for inputs of the I/O mapping for the
external conveyor
Arranged by bytes:
• 1
• 9
• 17
• …
Default: 1
First output bit First bit for outputs of the I/O mapping for the
external conveyor
Arranged by bytes:
• 1
• 9
• 17
• …
Default: 1

Operation
8 Operation
8.1 Displaying user rights
Description
The functions of a software package are assigned various function groups.

In the rights management, the minimum user group required to execute a
function is defined for each function group.
• The administrator can assign other user groups to the function groups.
• The assignment of the individual functions to the function groups can-
not be changed.
• Every user can display which user groups are currently assigned to
which function groups.
Further information about function groups and user rights is contained in

the operating and programming instructions for the KUKA System Soft-
ware (KSS).
If a function group is relevant for a procedure, this is indicated under Pre-

condition.
Procedure
The user groups assigned to the function groups can be displayed:

1. In the main menu, select Start-up > Rights management.
The Rights management window opens.
2. Select the Function groups tab.
8.2 Status keys
Precondition
• User rights: Function group Configuration of Tech packages
Procedure
Displaying the status keys:

• In the main menu, select Configuration > Status keys > Conveyor-
TeachMode.
Description
Status key Description

Teach mode is active
Pressing the status key deactivates Teach mode.
Teach mode is not active

Pressing the status key activates Teach mode.

Operation KUKA.ConveyorTech 8.0
8.3 Modifying controller-specific conveyor settings
Description
The controller-specific conveyor settings are configured in WorkVisual, but

can be modified subsequently on the smartHMI. They are valid for all con-
veyors tracked by the robot and are carried out for each robot controller.
Precondition
• User rights:
‒ For display: Function group Basic operation of Tech packages
‒ If changes are to be carried out: Function group Configuration of
Tech packages
• T1 or T2 mode
Procedure
1. In the main menu, select Configuration > Conveyor > Expert pa-
rameters. The configuration window is opened.
2. Modify the parameters as required.
3. Press Save.
4. Select Shutdown in the main menu and select the options Cold start
and Reload files. Reboot the robot controller; the changes are ap-
plied.
Parameters
Name Description
Continue after Stop Resuming/stopping robot motion after
$STOPMESS error
• Check box active: Following a $STOPM-

ESS error, the robot motion on the convey-
or is resumed.
• Check box not active: Following a
$STOPMESS error, the robot motion on the
conveyor is stopped.
Default: Check box active
Timer index Timer index of the conveyor system
• 1 … 32
Default: 1
8.4 Modifying conveyor-specific settings
Description
These settings are configured in WorkVisual for each conveyor in the sys-
tem, but can be modified subsequently on the smartHMI.
Precondition
• User rights:
Tech packages

Operation
• T1 or T2 mode
Procedure
1. In the main menu, select Configuration > Conveyor > Expert pa-
rameters. The configuration window is opened.
2. Select the desired conveyor and modify the conveyor-specific settings
as required.
3. Press Save.
4. Select Shutdown in the main menu and select the options Cold start
and Reload files. Reboot the robot controller; the changes are ap-
plied.
Parameters
Name Description
Number of IPO cy- Number of interpolation cycles for calculating
cles the average conveyor velocity
If higher values are used, the robot motions
are smoother. This also has the effect, howev-
er, that the robot responds more slowly to
changes in the velocity of the conveyor.
Default: 10
Filter active Activating/deactivating filters
The filter compensates for small, jerky changes
to the velocity of the conveyor and thus en-
sures a smooth robot motion.
• Check box active: Filter is active.

• Check box not active: Filter is not active.
Note: It is generally not necessary to change
the default setting.
Delay [ms] Time (in ms) for compensation for the delay
and reaction times inherent in the motion con-
trol
Default: 24 ms
Note: It is generally not necessary to change
the default value.
Debouncing [ms] Cannot be configured for external conveyors
Minimum time (in ms) between 2 measurement
signals in order to be able to interpret them as
2 separate signals
Default: 12 ms
Trace active Activating/deactivating trace recording
• Check box active: Trace recording is active

for this conveyor.
• Check box not active: Trace recording is
not active for this conveyor.
Note: Trace recording can only be activated for
one conveyor at a time.

8.5 Modifying alarm and stop distances
Description
The alarm and stop distances are configured in WorkVisual for each con-
veyor in the system, but can be modified subsequently on the smartHMI.
Precondition
• User rights:
Tech packages
• T1 or T2 mode
Procedure
1. In the main menu, select Configuration > Conveyor > Distances.

The configuration window is opened.
2. Select the desired conveyor and modify the alarm and stop distances
as required.
3. Press Save.
Parameters
Name Description
Alarm distance Alarm distance
If the robot tracks a workpiece on the conveyor over the
alarm distance, a corresponding message is generated and a
configured output is reset.
Default values:

End of work area Maximum conveyor distance the robot can travel as a
synchronized motion.
As soon as the robot has reached the defined value, the
synchronized motion is canceled and the robot executes the
motion programmed in CONV_QUIT.

• Programming of a motion in the subprogram CONV_QUIT
that is not synchronized with the conveyor
Default values:


Operation
Name Description
Cycflag for External Cancel Cycflag number for External Cancel
The Cycflag is used in combination with the interrupt for Ex-
ternal Cancel in order to cancel the synchronized motion as a
reaction to a user-defined signal.
Default: 250 … 254
Note: It is advisable to carry out assignment of the Cycflag in
the conveyor application program before the Follow or Skip
inline form. The correct Cycflag can be accessed using the
variable Z_EXT_QUIT_CYCFLAG_NBR and the conveyor in-
dex.
Example: $CYCFLAG[Z_EXT_QUIT_CYCFLAG_NBR[1]] =
$IN[100] AND $IN[101]
Interrupt for alarm distance Interrupt number for the alarm distance
The number determines the processing priority if several inter-
rupts occur at the same time.
Default: 21 … 25
Interrupt at end of work Interrupt number for the maximum conveyor distance
area
Default: 26 … 30
Interrupt for stop signal Interrupt number for a $STOPMESS error during the conveyor
tracking motion
$STOPMESS is set in order to indicate the occurrence of a
message requiring the robot to be stopped (e.g. EMERGEN-
CY STOP or operator safety violation).
Default: 31 … 35
Interrupt at External Cancel Interrupt number for External Cancel during the conveyor
tracking motion.
An External Cancel can be used to react to a user-defined
signal by canceling the synchronized motion and executing
the motion programmed in the subprogram CONV_QUIT.

Default: 36 … 40
Output for alarm distance Output number for the alarm distance
Default: 731 … 735
Output for stop signal Output number for $STOPMESS error
Default: 701 … 705

Workpiece tracking with alarm and stop distances
Fig. 8-1: Alarm and stop distances
Element Description
Conveyor advance Advance of the conveyor
($SEN_PREA[])
The advance of the conveyor is written to the system variable
$SEN_PREA[].
Waiting range Absolute distance a workpiece on the conveyor must have trav-
eled before the robot begins synchronization
Conveyor work area Range in which synchronized motion with the conveyor is possi-
ble
Synchronization area Range in which the robot can synchronize with the workpiece
Start of work area Absolute distance a workpiece on the conveyor must have trav-
eled before the robot begins processing the workpiece.
Note: This parameter is set in the Follow or Skip inline form.
End of synchronization Maximum absolute distance a workpiece on the conveyor is al-
area lowed to have traveled in order for the robot to begin processing
the workpiece.
Note: This parameter is set in the Follow or Skip inline form.
Alarm distance At this point, a defined output for the alarm distance is set and
a message is generated.
End of work area At this point, the synchronized motion is aborted and the motion
programmed in the subprogram CONV_QUIT is executed.


Calibration
9 Calibration
9.1 Calibrating a linear conveyor
Description
Calibration is carried out using 3 points. These points are labeled P1, P2
and P3 in the following diagram.
The accuracy of the conveyor applications created subsequently de-
pends on the accuracy with which these points are calibrated. Ensure
that the TCP points exactly to the point in question.
It is recommended to calibrate the conveyor with the direction of motion

that will also be used in subsequent operation.
Fig. 9-1: Calibration, linear
1 Conveyor 2 Direction of travel

The point P1 can be any point on the conveyor, but should be clearly
identifiable for further use. It is advisable to select a point in the start area
where the robot starts to track the workpiece. This reference point defines
the origin of the conveyor BASE. All conveyor programs will use this
BASE as a reference. In order to be able to repeat the calibration, it is im-
portant to define and mark this reference point in such a way that it can
be used again.
Point P2 is point P1, but offset by the distance traveled by the conveyor.
P2 defines the positive X axis of the conveyor BASE. It is advisable to se-
lect a position for P2 at the end of the range in which the robot can track
the workpiece on the conveyor. As large a distance as possible should be
selected between P1 and P2.
Point P3 must be in the positive XY plane of the conveyor BASE. This
point determines the orientation of the conveyor plane.
NOTICE
Incorrect calibration due to tool modification
If the current tool is changed manually or by a program during calibra-
tion, this can lead to errors in the calibration. Damage to property may
result.
• Ensure that the correct tool is set as the current tool for the respec-
tive position.
Precondition
• User rights:
‒ If the calibration is to be carried out: Function group Configura-
tion of Tech packages
• T1 mode

Calibration KUKA.ConveyorTech 8.0
Procedure
1. In the main menu, select Start-up > Calibrate > Conveyor. The Con-
veyor calibration window opens.
2. In the Calibration box, select the entry Calibrate conveyor.
3. In the Conveyor box, select the conveyor to be calibrated.
4. In the Measuring tool box, select the number of the tool (gauge pin)
used.
5. Press Execute. The calibration is started. The tool that was selected
for the calibration is set as the current tool.
6. Place the workpiece on the conveyor and start the conveyor.
7. Once the workpiece has passed the synchronization switch and the
synchronization signal has been detected, stop the conveyor.
8. Press the right arrow in the navigation bar.
9. Move the TCP to the origin of the conveyor BASE (P1) and press Ap-
ply position.
11. Move the conveyor and then stop it again.
12. Position the TCP at the now offset origin (P2) and press Apply posi-
tion.
14. Move the TCP to any point in the positive XY plane of the conveyor
BASE (P3) and press Apply position.
15. Press the right arrow in the navigation bar. The results of the calibra-
tion procedure are displayed for checking purposes.
16. Press Save. The results are saved.
17. Press Finish.
9.2 Calibrating a circular conveyor
Description
Calibration is carried out using 3 points. These points are labeled P1, P2
and P3 in the following diagram.
It is recommended to calibrate the conveyor with the direction of motion

that will also be used in subsequent operation.

Calibration
Fig. 9-2: Calibration, circular
1 Direction of travel of the con- 3 Robot

veyor
2 Conveyor
XR is the X axis and YR is the Y axis of the ROBROOT coordinate sys-
tem. XC is the X axis and YC is the Y axis of the conveyor BASE (MA-
CHINE_DEF[].ROOT).
where the robot starts to track the workpiece. This reference point is situ-
ated on the X axis of the conveyor BASE and defines the orientation of
the conveyor BASE. The origin of the conveyor BASE is situated in the
(virtual) pivot point of the circular conveyor. All conveyor programs will use
this BASE as a reference. In order to be able to repeat the calibration, it
is important to define and mark this reference point in such a way that it
can be used again.
P2 should be in the middle of the area in which the robot can track the
workpiece on the conveyor.
Point P3 is also point P1, but offset by the distance traveled by the con-
veyor after P2. P3 should be as near as possible to the end of the area in
which the robot can track the workpiece on the conveyor.
NOTICE
result.
tive position.
Precondition
• User rights:


• T1 mode
Procedure
used.
synchronization signal has been detected, stop the conveyor.
9. Move the TCP to a point on the positive X axis of the conveyor BASE
(point P1) and press Apply position.
12. Position the TCP at the now offset point P1 (P2) and press Apply po-
sition. The point should be near the middle of the tracking zone.
15. Position the TCP at point P1 (P3), which has now been offset even
further, and press Apply position. The point should be as near as
possible to the end of the tracking zone.
18. Press Finish.
9.3 Checking the conveyor distance
Description
Once the conveyor has been calibrated it is possible to check the meas-
ured conveyor distance. This is saved in the variable CAL_DIG[x].
The following sequence is not relevant for 6D conveyors.
Precondition
• User rights:
‒ If the check is to be carried out: Function group Configuration of
Tech packages
• T1 mode
Procedure

Calibration
2. In the Calibration box, select the entry Check resolver ratio.
3. In the Conveyor box, select the conveyor for which the conveyor dis-
tance is to be checked.
used.
5. Press Execute. The check is started.
synchronization signal has been detected, allow the conveyor to run a
little further and then stop it. The distance should be long enough to
be measured easily.
9. Measure the distance between the workpiece and the synchronization
point.
10. Compare the displayed value with the measured value.
11. If the value matches, press Finish.
If the value does not match, calibrate the conveyor again or carry out
the following steps:
a. Enter the manually measured value in the Distance or Angle box.
b. Press Save. The value entered is saved.
c. Press Finish.
9.4 Calibrating a workpiece on the 1D conveyor
Description
Calibration of a workpiece on the conveyor is carried out using 3 points.

These points are labeled P4, P5 and P6 in the following diagram.
Fig. 9-3: Calibrating the workpiece on the conveyor
1 Conveyor 2 Workpiece
Point P4 is the coordinate origin of the workpiece BASE. The definition of
the workpiece BASE corresponds to the default definition of BASE in the
robot. It is important for the points on the workpiece to be defined unam-
biguously. The exact position at which the conveyor was stopped is insig-
nificant.
Point P5 is a point on the positive X axis of the workpiece BASE.
Point P6 is a point in the positive XY plane of the workpiece BASE.

NOTICE
result.
tive position.
Precondition
• The conveyor is calibrated.

• User rights:
• T1 mode
Procedure
2. In the Calibration box, select the entry Calibrate part base.
3. In the Conveyor box, select the conveyor on which the workpiece is
to be calibrated.
used.
5. Only if more than 1 BASE coordinate system has been configured in
WorkVisual: In the Part base box, select the BASE coordinate system
that is to be calibrated.
synchronization signal has been detected, allow the conveyor to run a
little further and stop it at a position in which the workpiece BASE can
be measured easily.
10. Move the TCP to the coordinate origin of the workpiece BASE (P4)
and press Apply position.
12. Move the TCP to a point on the positive X axis (P5) and press Apply
position.
14. Move the TCP to a point in the positive XY plane of the workpiece
17. Press Finish.

Calibration
9.5 Calibrating a 6D conveyor
Description
Calibration is carried out using 4 points. The current position of the con-
veyor is calibrated using 3 points. The conveyor ROOT coordinate system
is calculated on the basis of the link between the current conveyor posi-
tion and the conveyor position from the PLC (variable ConvValue). The
4th point defines the main direction of motion of the conveyor.
These points are labeled P1, P2, P3 and P4 in the following diagram.
The main direction of motion is required to allow the parameters Alarm
distance and End of work area to be used correctly. The main direction
of motion is the direction in which the conveyor travels – for example, a
workpiece is transported to the robot – so that the workpiece can be pro-
cessed.
Fig. 9-4: Calibrating a 6D conveyor
1 Origin of the PLC coordinate system

2 Conveyor ROOT coordinate system (calculated)
3 Conveyor position from PLC (variable ConvValue)
4 Current conveyor position
5 Robot
6 6D conveyor
7 Main direction of motion
8 6D conveyor after travel
where the robot starts to track the workpiece. This reference point defines
the origin for calculation of the conveyor BASE. All conveyor programs will
use this BASE as a reference. In order to be able to repeat the calibra-
tion, it is important to define and mark this reference point in such a way
that it can be used again.
Point P2 defines the positive X axis for calculation of the conveyor BASE.
It is advisable to select a position for P2 at the end of the range in which
the robot can track the workpiece on the conveyor. As large a distance as
possible should be selected between P1 and P2.
Point P3 must be in the positive XY plane of the conveyor BASE to be
calculated. This point determines the orientation of the conveyor plane.

Fig. 9-5: After calibration
1 Conveyor ROOT coordinate system

2 Robot
3 6D conveyor
4 6D conveyor after travel
5 $SEN_PREA[1] = 0 (time t = 0)
6 $SEN_PREA[1] = 58 (time t = 1)
7 Main direction of motion
Once calibration is complete, the conveyor ROOT coordinate system is lo-
cated at the point where the PLC coordinate system was defined. The val-
ue of the variable $SEN_PREA[] is the distance between the origin of the
conveyor ROOT coordinate system and the current position of the convey-
or in relation to the main direction of motion. The variable does not refer
to the distance actually traveled by the conveyor. Therefore, the reference
point for the alarm and stop distances is also located at the origin of the
conveyor ROOT coordinate system. The variable $SEN_PREA[] has the
value 0 if the value of the ConvValue variable is equal to $NULLFRAME.
NOTICE
result.
tive position.
Precondition
• Valid data are present at the communication interface to the PLC.

• User rights:
• T1 mode

Calibration
Procedure
used.
6. Move the TCP to the origin of the conveyor BASE (P1) and press Ap-
ply position.
8. Move the TCP to a point on the positive X axis of the conveyor BASE
(point P2) and press Apply position.
10. Move the TCP to any point in the positive XY plane of the conveyor
12. Move the conveyor in the positive main direction of motion and stop
the conveyor.
13. Move the TCP to the origin of the conveyor BASE (P4) again and
press Apply position.
16. Press Finish.
9.6 Calibrating a workpiece on the 6D conveyor
Description
Calibration of a workpiece on the conveyor is carried out using 3 points.

These points are labeled P4, P5 and P6 in the following diagram.
Fig. 9-6: Calibrating the workpiece on the conveyor
Point P4 is the coordinate origin of the workpiece BASE. The definition of
the workpiece BASE corresponds to the default definition of BASE in the
robot. It is important for the points on the workpiece to be defined unam-
biguously. The exact position at which the conveyor was stopped is insig-
nificant.

Point P5 is a point on the positive X axis of the workpiece BASE.

Calibration
Point P6 is a point in the positive XY plane of the workpiece BASE.

NOTICE
result.
tive position.
Precondition
• The conveyor is calibrated.

• User rights:
• T1 mode
• The workpiece is located on the conveyor.
• The workpiece position is present at the interface to the PLC.
Procedure
2. In the Calibration box, select the entry Calibrate part base.
3. In the Conveyor box, select the conveyor on which the workpiece is
to be calibrated.
used.
5. Only if more than 1 BASE coordinate system has been configured in
WorkVisual: In the Part base box, select the BASE coordinate system
that is to be calibrated.
8. Move the TCP to the coordinate origin of the workpiece BASE (P4)
and press Apply position.
10. Move the TCP to a point on the positive X axis (P5) and press Apply
position.
12. Move the TCP to a point in the positive XY plane of the workpiece
15. Press Finish.

Programming
10 Programming
10.1 Creating a conveyor application program
Description
A special program structure must be used for all conveyor applications.

The conveyor commands will only function within this structure. This struc-
ture must not be altered.
Groups of synchronized motions are programmed in the subprogram
CONV_MOV. The motions are taught in a BASE that has been configured
in WorkVisual and calibrated on the smartHMI.
Motions to move the robot out of the conveyor area are programmed in
the subprogram CONV_QUIT. This is necessary if the end of the work
area has been reached or in the case of an EMERGENCY STOP.
Only the motion types LIN, CIRC and DLIN can be programmed in the
subprogram CONV_MOV. PTP and Spline motions are not possible.
The motions in the subprogram CONV_QUIT cannot be synchronized

with the conveyor.
Precondition
• The Navigator is displayed.

• User rights: Function group File operations
‒ Depending on the folders that are to be displayed, the “Expert”
user group or higher may be required.
Procedure
1. In the directory structure of the Navigator, select the folder in which

the program is to be created, e.g. the folder KRC:\R1\Program.
2. Select the file list of the Navigator and press the New button.
The Template selection window opens.
3. Select the Conveyor template and confirm with OK.
4. Enter a name for the program and confirm it with OK.
Conveyor template
1 DEF Conveyor()
2
3 INI
4 CONV INI
5
6 PTP HOME Vel= 100 % DEFAULT
7
8 LOOP
9
10 ENDLOOP
11
12 END
13
14 DEF CONV_MOV(Z_CONV_NBR:IN,Z_MOV_NBR:IN)
15 INI CONV_MOV
16
17 CONVEYOR 1 MOVEMENT GROUP 1

Programming KUKA.ConveyorTech 8.0
18
20
22
24
26
28
29 END CONV_MOV
30 CONTINUE
31 END
32
33 DEF CONV_QUIT(Z_CONV_NBR:IN,B_STOP_AFTER_LEAVING:IN)
34 INT Z_CONV_NBR
35 BOOL B_STOP_AFTER_LEAVING
36 INT Z_ADVANCE_OLD
37
38 Z_ADVANCE_OLD=$ADVANCE
39 IF (B_QUIT_BECAUSE_EMS OR B_QUIT_BECAUSE_MAX_DIST) THEN
40 ;********************************************
41 ;Strategy for the robot to leave the conveyor
42 ;if there was an EMS or MAX_DIST reached
43 ;while synchronising.
44 ;********************************************
45 SWITCH Z_CONV_NBR
46 CASE 1
47 $BASE=$NULLFRAME
48 LIN_REL {Z 0.0}
49 CASE 2
50 $BASE=$NULLFRAME
51 LIN_REL {Z 0.0}
52 CASE 3
53 $BASE=$NULLFRAME
54 LIN_REL {Z 0.0}
55 ENDSWITCH
56 IF B_STOP_AFTER_LEAVING THEN
57 ;*****************************
58 ;* Robot Stopped because of *
59 ;* error while synchronising *
60 ;* EMS or MAX_DIST reached *
61 ;*****************************
62 LOOP
63 HALT
64 ENDLOOP
65 ENDIF
66 ENDIF
67 $ADVANCE=Z_ADVANCE_OLD
68 END

Programming
Line Description
5 … 7 The following conveyor instructions must be inserted before
the LOOP.
1. (>>> 10.2 "Conveyor.INI_OFF: Initializing a conveyor"

Page 71)
2. (>>> 10.3 "Conveyor.ON: activating a conveyor driver"
Page 72)
8 … 10 The following conveyor instructions can be inserted in the
LOOP.
1. (>>> 10.4 "Conveyor.FOLLOW: tracking the current

workpiece" Page 72)
2. (>>> 10.5 "Conveyor.Skip: tracking a specific workpiece"
Page 75)
3. (>>> 10.6 "Conveyor.Quit: leaving the conveyor area"
Page 78)
Note: If the instruction Conveyor.Skip is used, the instruc-
tion Conveyor.FOLLOW must be called at least once out-
side the LOOP.
14 … 29 Subprogram CONV_MOV
(>>> 10.8 "Teaching synchronized motions" Page 81)
33 … 68 Subprogram CONV_QUIT
For motions to move the robot out of the conveyor area.
The motions cannot be synchronized with the conveyor.
10.2 Conveyor.INI_OFF: Initializing a conveyor
Description
The inline form IniOff can be used to initialize a conveyor. For this, the
conveyor distance is set to 0.
Precondition
• User rights: Function group General KRL program changes

• The conveyor application program has been selected.
• T1 mode
Procedure
1. Position the cursor in the line after which the instruction is to be inser-
ted.
2. Select the menu sequence Commands > Conveyor > IniOff.
3. In the inline form, select the conveyor to be initialized.
4. Press Cmd OK to save the instruction.
Inline form
Fig. 10-1: Inline form “IniOff”

Item Description
1 Conveyor
The available conveyors are configured in WorkVisual. The
names of the conveyors can be changed in WorkVisual.
10.3 Conveyor.ON: activating a conveyor driver
Description
The On inline form can be used to activate the conveyor driver. If the con-
veyor driver is activated, the synchronization signals at the input of inter-
face X33 (Fast Measurement) are evaluated.
The conveyor offset can be detected in the background and the robot con-
troller can execute other tasks. This allows the robot to carry out
on-the-fly tracking of a part on the conveyor. The conveyor distance can
be monitored using the system variable $SEN_PREA_C[].
The instruction Conveyor.ON can only be executed if the conveyor has
been initialized using the instruction Conveyor.INI_OFF.
Precondition

• T1 mode
Procedure
ted.
2. Select the menu sequence Commands > Conveyor > On.
3. In the inline form, select the conveyor for which the driver is to be ac-
tivated.
Inline form
Fig. 10-2: Inline form “On”
Item Description
1 Conveyor
10.4 Conveyor.FOLLOW: tracking the current workpiece
Description
The Follow inline form can be used to program tracking of the current
workpiece on a conveyor by the robot. A range on the conveyor is defined
in which the robot starts to track the workpiece.

Programming
The instruction Conveyor.FOLLOW can only be executed if the conveyor
driver has been activated using the instruction Conveyor.ON.
Precondition

• T1 mode
Procedure
ted.
2. Select the menu sequence Commands > Conveyor > Follow.
3. In the inline form, select the desired conveyor and set the parameters
for the workpiece tracking on the conveyor.
Inline form
Fig. 10-3: Inline form “Follow”
Item Description
1 Maximum wait time (in seconds)
It is possible to define the maximum time to wait for synchroni-
zation. Once the specified time has elapsed, execution of the
instruction is aborted.
2 Conveyor
3 Number of the digital input
Digital input used to abort execution of the instruction.
4 Number of the motion group
Two different motion groups can be programmed for each con-
veyor.
5 Logic level
• TRUE
• FALSE
When the entered value occurs at the configured digital input
(item 3), execution of the instruction is aborted.
6 Flag number
Flag used to abort execution of the instruction.

Item Description
7 Logic level
• TRUE
• FALSE
When the entered value occurs at the configured flag (item 6),
execution of the instruction is aborted.
8 End of synchronization area
Maximum absolute distance a workpiece on the conveyor is al-
lowed to have traveled in order for the robot to begin tracking
this workpiece
• In the case of a linear conveyor: specification in millimeters

• In the case of a circular conveyor: specification in degrees
9 Start of work area
Absolute distance a workpiece on the conveyor must have trav-
eled before the robot begins tracking the workpiece

Example with Conveyor.FOLLOW
1 DEF Conveyor()
2
3 INI
4 CONV INI
5
7 PTP P5 Vel=10 % PDAT2 Tool[1] Base[0]
8
9 LOOP
10
11 Conveyor.INI_OFF LinearConveyor1
12 Conveyor.ON LinearConveyor1
13
15
16 Conveyor.FOLLOW LinearConveyor1, Movement 1, Cancel on:
Max_time 240, Input 1, Input-Level TRUE, Flag 1, Flag-
Level TRUE, Start of work area 100, End of sync area
1500
17 Conveyor.Quit LinearConveyor1, Stop after error FALSE
18
19 ENDLOOP
20 END
21 __________________________________________________________
______
23 INI CONV_MOV
24
26 LIN P2 Vel=0.3 m/s CPDAT1 Tool[1] Base[1]:LinearConveyor1
28
30 ;...

Programming
Line Description
11 The instruction Conveyor.INI_OFF initializes the conveyor.
12 The instruction Conveyor.ON activates the conveyor driver.
14 The robot is moved to the conveyor wait position P7.
16 The robot waits a maximum of 240 seconds for a synchroniza-
tion signal.
17 The program jumps to this point if the wait time for a synchro-
nization signal has expired or if input 1 or flag 1 is set to the
level TRUE. The process is then terminated.
25 Once a synchronization signal has been received, program ex-
ecution is resumed from this point.
10.5 Conveyor.Skip: tracking a specific workpiece
Description
The Skip inline form can be used to program, by means of an index off-
set, which workpiece in the workpiece list is to be tracked, e.g. the 2nd
workpiece, the 3rd workpiece, etc. A total of up to 1024 workpieces can
be monitored in the background.
Precondition

• T1 mode
Procedure
ted.
2. Select the menu sequence Commands > Conveyor > Skip.
for the workpiece tracking on the conveyor.
Inline form
Fig. 10-4: Inline form “Skip”

Item Description
1 Maximum wait time (in seconds)
It is possible to define the maximum time to wait for synchroni-
zation. Once the specified time has elapsed, execution of the
instruction is aborted.
2 Conveyor
3 Number of the digital input
Digital input used to abort execution of the instruction.
4 Index offset in the workpiece list
The number entered indicates the difference between the index
of the workpiece to be tracked and the last workpiece tracked
in the workpiece list.
Examples:
• 1: Every workpiece in the workpiece list is tracked.

• 3: Every 3rd workpiece in the workpiece list is tracked.
• 5: Every 5th workpiece in the workpiece list is tracked.
(>>> "Examples of index offsets in the workpiece list"
Page 77)
5 Logic level
• TRUE
• FALSE
When the entered value occurs at the configured digital input
(item 3), execution of the instruction is aborted.
6 Flag number
Flag used to abort execution of the instruction.
7 Number of the motion group
Two different motion groups can be programmed for each con-
veyor.
8 Logic level
• TRUE
• FALSE
When the entered value occurs at the configured flag (item 6),
execution of the instruction is aborted.
9 End of synchronization area
Maximum absolute distance a workpiece on the conveyor is al-
lowed to have traveled in order for the robot to begin tracking
this workpiece


Programming
Item Description
10 Start of work area
Absolute distance a workpiece on the conveyor must have trav-
eled before the robot begins tracking the workpiece

Examples of index offsets in the workpiece list
The following examples show which workpiece is tracked in the workpiece

list (= index).
Fig. 10-5: Examples of index offsets in the workpiece list
Example with Conveyor.Skip
1 DEF Conveyor()
2
3 INI
4 CONV INI
5
8
11 Conveyor.FOLLOW LinearConveyor1, Movement 1, Cancel on:
Max_time 240, Input 1, Input-Level TRUE, Flag 1, Flag-
Level TRUE, Start of work area 100, End of sync area
1900
12
13 LOOP

14
16
17 Conveyor.Skip LinearConveyor1, Index offset part list 2,
Movement 1, Cancel on: Max_time 240, Input 1, Input-
Level TRUE, Flag 1, Flag-Level TRUE, Start of work area
100, End of sync area 1900
19
20 ENDLOOP
21 END
22 __________________________________________________________
______
24 INI CONV_MOV
25
29
31 ;...
Line Description
7 The robot is moved to the conveyor wait position P5.
Note: If the instruction Conveyor.Skip is used, the instruction
Conveyor.INI_OFF must always be located outside the LOOP.
Conveyor.ON must always be located outside the LOOP.
11 The instruction Conveyor.FOLLOW starts the workpiece track-
ing.
Conveyor.FOLLOW must be called at least once outside the
LOOP.
tion signal.
10.6 Conveyor.Quit: leaving the conveyor area
Description
The Quit inline form can be used to program whether the robot is to
leave the conveyor area in the following cases.
• EMERGENCY STOP in the case of a synchronous motion
• Robot has reached the end of the work area on the conveyor
The motions to move the robot out of the conveyor area must be pro-
grammed in the subprogram CONV_QUIT. These motion cannot be

synchronized with the conveyor and are executed relative to the WORLD
Programming
coordinate system.
Precondition

• T1 mode
Procedure
ted.
2. Select the menu sequence Commands > Conveyor > Quit.
for the conveyor.
Inline form
Fig. 10-6: Inline form Quit (1D conveyor)
Fig. 10-7: Inline form Quit (6D conveyor)
Item Description
1 Conveyor
2 Stop after error
• TRUE: Program execution is stopped once the robot has

been moved out of the conveyor area.
• FALSE: Program execution is not stopped.

Item Description
3 Reset distance (only displayed if a 1D conveyor is used)
• TRUE: The measured distance covered by the conveyor is

reset (system variable: $SEN_PREA_C[]).
• FALSE: The measured distance covered by the conveyor is
not reset.
Note: If multiple Conveyor.FOLLOW instructions are used for a
workpiece (e.g. for a tool change between the instructions), it is
advisable to set this parameter to TRUE after the last Convey-
or.FOLLOW instruction.
4 Deactivate distance monitoring (only displayed if a 6D con-
veyor is used)
• TRUE: The interrupts used for monitoring the values of the

parameters Alarm distance and End of work area are de-
activated.
• FALSE: The interrupts used for monitoring the values of the
parameters Alarm distance and End of work area remain
active.
Note: The interrupts are reactivated in the conveyor application
program at the next synchronization with the conveyor.
10.7 Programming inline forms with WorkVisual
Description
Inline forms can also be programmed with WorkVisual. If an option pack-

age is installed in WorkVisual, the associated inline forms are available in
the KRL editor.
The conveyor instructions are also programmed in the conveyor template
in WorkVisual. The template is included in the option package and must
be inserted into the project.
Precondition
• The Conveyor option package is installed in WorkVisual.

• Project is open in WorkVisual.
• Code has been generated.
• The KRL Templates catalog is available.
Procedure
1. Select the Files tab in the Project structure window.

2. In the KRL Templates catalog, open the Conveyor folder and select
the Conveyor template.
3. Drag and drop the template onto the Files tab and onto the desired
directory (example: KRC:\R1\Program). A window opens.
4. Enter a name for the program and confirm it with OK. An SRC file
and a DAT file are created in the directory.
5. Double-click on the SRC file. The file opens in the KRL editor.
6. Position the cursor in the line in which the inline form is to be
inserted. A button is displayed to the left of the line number.

Programming
7. Click on the button or press CTRL + Enter. A menu is displayed.
8. Select the desired inline form in the menu, e.g. the IniOff inline form:
Select the menu sequence Commands > Conveyor > IniOff. The in-
line form is opened.
9. Set the parameters in the inline form and save them with Cmd OK.
Further information about editing programs in the KRL editor is con-

tained in the WorkVisual documentation.
Programs can also be opened and inline forms programmed in the KRC
Explorer of WorkVisual. A precondition for this is that the WorkVisual
project on the robot controller contains a conveyor.
10.8 Teaching synchronized motions
Description
For teaching the synchronized motions, a basic conveyor program must

have been created beforehand. This basic conveyor program must contain
at least the following contain instructions:
• Conveyor.INI_OFF
• Conveyor.ON
• Conveyor.FOLLOW
(>>> "Example of a basic conveyor program" Page 83)
Precondition
• A basic conveyor program has been created.

• T1 mode
In operating mode T1, Teach mode is activated by default. To execute

the basic conveyor program in operating mode T1, Teach mode must
first be deactivated. This is possible using the status keys
(>>> 8.2 "Status keys" Page 53).
Basic conveyor programs created with an older version of
ConveyorTech cannot be executed in T1 mode.
Procedure
1. Execute the basic conveyor program until the robot has reached the
position where it waits for synchronization.
2. Execute the instruction Conveyor.FOLLOW.
3. Answer the message with Yes. Teach mode is activated.
4. Start the conveyor.
5. As soon as the workpiece has passed the synchronization switch and
the signal has been received from the synchronization switch, stop the
conveyor.
6. The calculated conveyor distance is displayed Check whether the con-
veyor distance is correct.
• If the conveyor distance is correct, press Yes.
• If the conveyor distance is not correct, correct the conveyor dis-
tance.
(>>> 9.3 "Checking the conveyor distance" Page 62)
Then repeat steps 2 to 6.

7. Teach the points of the synchronized motions. In the following dia-

gram, these points are P2, P3 and P4.
Fig. 10-8: Teaching the points of a synchronized motion
1 Synchronization switch 3 Resolver

2 Workpiece 4 Conveyor
The following diagram illustrates the synchronized motions between
points P1 and P5.
Fig. 10-9: Synchronized motion between points P1 and P5
8. Once all points have been taught, the program can be tested in T2
mode.
NOTICE
Risk of collision due to stopping program execution
If program execution is stopped while the robot is in the conveyor area,
there is a risk of collision. Damage to the robot, the workpiece and oth-
er equipment may otherwise result.
• Do not stop program execution until the robot is no longer in the
conveyor area.
NOTICE
Risk of collision due to the robot remaining in the conveyor area
If the robot is still in the conveyor area after the last synchronized mo-
tion, a collision may occur between the robot and the conveyor.
Damage to property may result.
• Ensure that the last synchronized motion moves the robot out of the
conveyor area.
It is recommended that synchronized motions should always be execu-

ted in AUT or AUT EXT mode with 100% program override. The robot
may not otherwise be able to execute the synchronized motions com-
pletely with the specified conveyor distance.

Programming
For test purposes, the program override ($OV_PRO) in the conveyor
area can be increased to 100%. Once the robot has left the conveyor,
the program override is reset to its original value. This makes it possible
to conduct a test inside the conveyor area at full velocity while the re-
mainder of the application is executed with reduced program override.
Example of a basic conveyor program
1 DEF Conveyor()
2
3 INI
4 CONV INI
5
7 LIN P1 Vel= 2 m/s CPDAT6 Tool[1] Base[0]
8
11 Conveyor.FOLLOW LinearConveyor1, Movement 1, Cancel
on:Max_time 60, Input 1, Input-Level TRUE, Flag 1, Flag-
Level TRUE, Start of work area 10, End of sync area 2000
13
14 LIN P2 Vel=0.5 m/s CPDAT17 Tool[1] Base[0]
15 PTP HOME Vel=100 % DEFAULT
16 END
17 __________________________________________________________
______
19 INI CONV_MOV
20
22 LIN P10 Vel=0.5 m/s CPDAT1 Tool[1]
Base[1]:LinearConveyor1
26
28 ;...
Line Description
7 The robot is moved from the HOME position to the conveyor
wait position P1.
tion signal.

10.9 Programming a DLIN block
Description
LIN and DLIN motions that are programmed inside a DLIN block are exe-
cuted with maximum velocity and acceleration. A DLIN block triggers an
advance run stop.
Approximate positioning is only possible within the DLIN block. To allow
approximate positioning within a conveyor application, the LOOP in the
conveyor application program can be moved to a DLIN block.
The following alternatives to the DLIN block are available:

• Use of the DLIN template
(>>> 10.11 "Creating an application program with DLIN template"
Page 88)
• Setting the variable $CP_VEL_MODE to the value 5 at a suitable po-
sition
In all subsequent CP motions, an attempt is made to address the pro-
grammed points with the maximum possible velocity and acceleration.
If this is not possible, the planned velocity will be gradually reduced.
The maximum possible velocities and accelerations depend on the
machine data and the programmed velocities and accelerations.
To reduce the velocities and accelerations, the following variables
must be programmed appropriately:
‒ $VEL.CP
‒ $VEL.ORI1
‒ $VEL.ORI2
‒ $ACC.CP
‒ $ACC.ORI1
‒ $ACC.ORI2
When resetting the variable to the value 0, the velocity and accelera-
tion must be set as follows:
‒ $VEL = $VEL_MA
‒ $ACC = $ACC_MA
Setting or resetting the variable $CP_VEL_MODE triggers an advance
run stop.
Precondition

• T1 mode
• A program is selected.
Procedure
1. Position the cursor in the line after which the DLIN block is to be in-
serted.
2. Select the menu sequence Commands > Motion > DLIN block.
3. Press Cmd OK to save the instruction. The DLIN block is inserted.
4. Program the desired motions in the opened fold of the DLIN block.

Programming
Inline form “DLIN block”
Fig. 10-10: Inline form “DLIN Block”
10.10 Programming a DLIN motion
Description
A dynamic LIN motion is executed with the instruction. In other words, an

attempt is made to achieve the specified velocity, acceleration and approx-
imation distance. If these values cannot be reached, they are gradually re-
duced in the path planning. This may be the case on account of physical
limitations (such as gear torque).
Precondition

• T1 mode
• A program is selected.
Procedure
ted.
2. Select the menu sequence Commands > Motion > DLIN Move.
3. Set the parameters in the inline form.
Inline form “DLIN Move”
Fig. 10-11: Inline form “DLIN Move”

Item Description
1 Name of the end point
The system automatically generates a name. The name can be
overwritten.
Touch the arrow to edit the point data. The corresponding op-
tion window is opened.
(>>> 10.10.1 "Option window “Frames”" Page 86)
The arrow can also be used to edit the Global point setting.
2 Name for the motion data set
The system automatically generates a name. The name can be
overwritten.
Touch the arrow to edit the point data. The corresponding op-
tion window is opened.
(>>> 10.10.2 "Option window “Velocities”" Page 87)
(>>> 10.10.3 "Option window “Accelerations”" Page 87)
Note: The orientation control type in the Motion parameters
option window corresponds to the orientation control of a LIN
motion.
3 • CONT: End point is approximated.
• [blank]: The motion stops exactly at the end point.
10.10.1 Option window “Frames”
Fig. 10-12: Option window “Frames”
Item Description
1 Tool selection.
Range of values: [1] … [16]
2 Base selection.
Range of values: [1] … [32]

Programming
10.10.2 Option window “Velocities”
Fig. 10-13: Option window “Velocities”
Item Description
1 Maximum path velocity. The value refers to the maximum value
specified in the machine data.
The maximum value depends on the robot type and the selec-
ted operating mode.
2 Maximum swivel velocity. The value refers to the maximum val-
ue specified in the machine data.
ted operating mode.
3 Maximum rotational velocity. The value refers to the maximum
value specified in the machine data.
ted operating mode.
10.10.3 Option window “Accelerations”
Fig. 10-14: Option window “Accelerations”

Item Description
1 Maximum path acceleration. The value refers to the maximum
ted operating mode.
2 Maximum swivel acceleration. The value refers to the maximum
ted operating mode.
3 Maximum rotational acceleration. The value refers to the maxi-
mum value specified in the machine data.
ted operating mode.
10.11 Creating an application program with DLIN template
Description
With the DLIN template, an entire program can be programmed with max-
imum velocity and maximum acceleration. LIN and DLIN motions that are
inserted into the template are executed with maximum velocity and accel-
eration.
A DLIN Block cannot be used in the template. It alters the functionality
of the template.
Precondition
• The Navigator is displayed.

• User rights: Function group File operations
‒ Depending on the folders that are to be displayed, the “Expert”
user group or higher may be required.
Procedure
1. In the directory structure of the Navigator, select the folder in which

the program is to be created, e.g. the folder KRC:\R1\Program.
2. Select the file list of the Navigator and press the New button.
The Template selection window opens.
3. Select the DynamicLin template and confirm with OK.
4. Enter a name for the program and confirm it with OK.
5. Select the program and program the desired instructions.
10.12 KRL functions
Using special KRL functions, workpieces can be deleted from the work-
piece list of the conveyor driver. Furthermore, the conveyor velocity can
be requested, as can the number of workpieces currently being tracked by
the conveyor.

Programming
10.12.1 CONV_DELETE_ALL_WPS: delete all components
Description
The function CONV_DELETE_ALL_WPS deletes all workpieces from the

workpiece list of the conveyor driver. If the function is called, the conveyor
driver no longer follows a workpiece with which the robot can synchronize
itself.
Syntax
DEL_COUNT = CONV_DELETE_ALL_WPS(Index, Error number)
Explanation of the syntax
Element Description
DEL_COUNT Number of deleted workpieces
Type: INT
Index Index of the conveyor
Type: INT
Error number Number of the error that occurred during execution of
the function
Type: INT
Example
DEL_COUNT = CONV_DELETE_ALL_WPS(1, ERRNBR)
10.12.2 CONV_DELETE_WPS: Deleting components
Description
The function CONV_DELETE_WPS deletes the specified number of work-

pieces from the workpiece list of the conveyor driver. Deletion starts with
the oldest workpiece in the list.
Syntax
DEL_COUNT = CONV_DELETE_WPS(Index, Number of workpieces, Error

number)
Element Description
DEL_COUNT Number of deleted workpieces
Type: INT
Type: INT
Number of Number of workpieces to be deleted
workpieces
Type: INT
the function
Type: INT

Example
DEL_COUNT = CONV_DELETE_WPS(1, 4, ERRNBR)
10.12.3 CONV_GET_SPEED: Requesting the conveyor speed
Description
The function CONV_GET_SPEED returns the current speed of the con-

veyor. For a linear conveyor, the speed is specified in millimeters per sec-
ond, while that of a circular conveyor is specified in degrees per second.
Syntax
SPEED = CONV_GET_SPEED(Index, Error number)
Element Description
SPEED Current speed of the conveyor
Type: REAL
Type: INT
the function
Type: INT
Example
SPEED = CONV_GET_SPEED(1, ERRNBR)
10.12.4 CONV_GET_WP_COUNT: Component counter
Description
The function CONV_GET_WP_COUNT returns the number of workpieces

currently being tracked by the conveyor
Syntax
WP_COUNT = CONV_GET_WP_COUNT(Index, Error number)
Element Description
WP_COUNT Number of workpieces currently being tracked by the
conveyor
Type: INT
Type: INT
the function
Type: INT

Programming
Example
WP_COUNT = CONV_GET_WP_COUNT(1, ERRNBR)
A total of 10 workpieces have been generated, for example. Synchroniza-

tion was most recently carried out on the fifth workpiece. The function
now returns the value 6, as 6 workpieces are currently still being tracked
by the conveyor. These are workpieces the inputs 5, 6, 7, 8, 9, 10.


Troubleshooting
11 Troubleshooting
11.1 Robot leaves the path in external mode EXT
Description
If a robot that is tracking a part on a conveyor is stopped, the robot

leaves the path relative to the conveyor.
In most cases, this is due to the fact that a moving conveyor cannot stop
as quickly as a robot. In the external mode EXT, in particular, this can
lead to hazardous situations.
Example
1. A robot tracks a part on a conveyor.

2. An EMERGENCY STOP is triggered in the robot cell.
3. The robot stops.
4. Under normal circumstances, the conveyor also stops.
The robot has probably left the path because the conveyor has stop-
ped with a slight delay.
5. The EMERGENCY STOP is reset.
6. The conveyor starts up again and the part moves away from the ro-
bot.
7. An external start of the robot is triggered.
8. The robot attempts to track the part on the conveyor.
9. Range limits and workspaces are ineffective.
10. The robot collides with the conveyor.
Possible remedy
• Prevent restart of the robot following a synchronization error. It is pos-

sible to cancel the robot program in the submit interpreter SPS.SUB.
Never restart the conveyor if the robot has left the path
($ON_PATH) and has not been restarted ($PRO_ACT).
11.2 Modifying the program override
Description
Reducing the program override results in the robot spending more time
tracking a workpiece on a conveyor.
If the robot tracks the workpiece for a longer time, it also tracks it over a
greater distance. This may result in collisions when range limits are
reached.
Possible remedy
• Ensure that the program override is set to 100% before synchroniza-

tion is started.
Example:
$OV_PRO=100
Conveyor.FOLLOW...

Troubleshooting KUKA.ConveyorTech 8.0
• Ensure that robot and conveyor are stopped when range limits are
reached.
Range limits can be defined with the following parameters:
Parameter Description
Alarm distance As soon as the robot reaches this distance,
an output is set. This output can force the
conveyor controller (PLC) to stop the con-
veyor in order to prevent the robot from
moving too far.
End of work area As soon as the robot reaches this preset dis-
tance, tracking of the workpiece is aborted.
It is possible to move the robot out of the
conveyor area automatically (CONV_QUIT).
Note: These motions are not synchronized
with the conveyor. Ensure that there is no
collision with the conveyor.
• Set up workspaces. This enables the robot controller to respond as

soon as the robot enters a workspace (e.g. safety fence, machine).
11.3 The decision to track a workpiece is made in the advance run
Description
In the inline form “FOLLOW”, an area is defined which determines wheth-

er the robot is to track a workpiece on the conveyor. If the workpiece is
within both defined range limits, tracking of the workpiece is enabled.
Since the robot can be synchronized with and track the workpiece on the
conveyor on the fly, decisions are also made on the fly.
Example
1. A robot is working on side A and wants to track a workpiece on a

conveyor on side B of the robot cell.
For this, a 1 s motion towards the conveyor on side B is required.
2. The conveyor moves at a velocity of 1 m/s.
The range limits defined for part tracking are 0 mm and 500 mm.
3. The robot leaves side A and already evaluates whether it can track a
workpiece on conveyor B.
4. The robot decides to track the workpiece and moves to side B.
5. After 1 s, the robot is synchronized on the fly with the workpiece on
conveyor B, which has meanwhile moved forwards 1 m, and tracks it.
6. This means that the robot is tracking a workpiece that has already left
the workpiece tracking range.
Possible remedy
• No on-the-fly synchronization with workpieces on the conveyor. Ensure

that no advance run is defined ($ADVANCE=0) and that the wait posi-
tion before synchronization is programmed without approximate posi-
tioning.
• If on-the-fly synchronization is required, ensure that the advance run is
reduced to a minimum ($ADVANCE=1). Teach multiple positions at the

start of the conveyor. Since there is more than one position, the deci-
Troubleshooting
sion about workpiece tracking is delayed.

Troubleshooting KUKA.ConveyorTech 8.0

Messages
12 Messages
12.1 Information about the messages
The “Messages” chapter contains selected messages. It does not cover all
the messages displayed in the message window.
12.2 System messages from module: Conveyor
12.2.1 Conveyor 01000
Message code Conveyor 01000

Message text The calibration points are too close to one another (minimum clear-
ance = {Minimum clearance}mm)
Message type Acknowledgement message
Possible cause(s) Cause: Points are too close to one another (>>> Page 97)
Solution: Recalibrate the conveyor system (>>> Page 97)
Cause: Points are too close to one another
Description
During calibration of a conveyor system, the positions of the points were

not selected correctly. The points are too close to one another. The mini-
mum distance between the points must be adhered to during calibration.
This is specified in the message.
Solution: Recalibrate the conveyor system
Description
Recalibrate the conveyor system.

This activity must be carried out in accordance with the procedure de-
scribed in the operating and programming instructions.
12.2.2 Conveyor 01001

Message text The points are almost in a straight line
Possible cause(s) Cause: Points are almost in a straight line (>>> Page 98)

Cause: Points are almost in a straight line

Messages
Description
During calibration of a conveyor system, the positions of the points were

not selected correctly. The points are almost in a straight line. The mini-
mum angle between the points must be adhered to during calibration.
Description

12.2.3 Conveyor 01002

Message text Unable to determine transmission ratio
Possible cause(s) Cause: Positions of the points not selected correctly (>>> Page 98)
Cause: Positions of the points not selected correctly
Description
During calibration of a circular conveyor system, the positions of the

points were not selected correctly.
Description

12.2.4 Conveyor 01006

Message text The robot is not in the correct operating mode for calibration.

Messages
Possible cause(s) Cause: Impermissible operating mode set (>>> Page 99)
Solution: Change operating mode (>>> Page 99)
Cause: Impermissible operating mode set
Description
The set operating mode is not permissible for the calibration process. Cal-
ibration must be started in mode T1 or T2.
The procedure for checking which operating mode is set is as fol-
lows:
Checking instructions
• In the status bar, check which operating mode is activated:
Fig. 12-1
Solution: Change operating mode
Do not change the operating mode while a program is running. If the

operating mode is changed during program execution, the industrial ro-
bot is stopped with a safety stop 2.
Precondition
• The robot controller is not executing a program.

• If the mode selector switch is the variant with a key: the key is inser-
ted in the switch.
Procedure
1. Turn the mode selector switch on the smartPAD. The connection man-
ager is displayed.
2. Select the operating mode.
3. Return the mode selector switch to its original position.
The selected operating mode is displayed in the status bar of the
smartPAD.

Messages KUKA.ConveyorTech 8.0
Operating modes with KUKA System Software (KSS)
Operating
Use Velocities
mode
• Program verification:
Programmed velocity, maxi-
For test operation,
mum 250 mm/s
T1 programming and
teaching • Jog mode:
Jog velocity, maximum
250 mm/s
T2 For test operation Programmed velocity
• Jog mode: Not possible
For industrial robots • Program operation:

AUT without higher-level Programmed velocity
controllers • Jog mode: Not possible

AUT EXT with higher-level con- Programmed velocity
trollers, e.g. PLC • Jog mode: Not possible
Operating modes with VW System Software (VSS)
Operating
Use Velocities
mode
Programmed velocity, maxi-
For test operation,
mum 250 mm/s
T1 programming and
teaching • Jog mode:
Jog velocity, maximum
250 mm/s
T2 For test operation Programmed velocity
• Jog mode: Not possible

EXT with higher-level con- Programmed velocity
trollers, e.g. PLC • Jog mode: Not possible
12.2.5 Conveyor 01007

Message text An error occurred on setting variable '{Variable name}' to value '{Val-
ue of variable}': {Additional error message.}

Messages
Possible cause(s) Cause: Faulty system files (>>> Page 101)
Solution: Uninstall and re-install ConveyorTech using smartHMI
(>>> Page 101)
Cause: Faulty system files (>>> Page 102)

Solution: Uninstall and re-install ConveyorTech using WorkVisual
(>>> Page 102)
Cause: Faulty system files
Description
One or more system files are faulty, not present and/or have been modi-
fied manually.
• KSS: Switch to the directory C:\KRC\ROBOTER\KRC\R1\TP\Convey-

or and check whether the file ConveyorGlobals.dat is present on the
controller.
• VSS: Switch to the directory C:\KRC\ROBOTER\KRC\R1\VW_User
\Applikation\CO_Conveyor and check whether the file
vw_conv_usr_r.dat is present on the controller.
Description
Uninstall the existing version of ConveyorTech using the smartHMI and

then reinstall it. It is advisable to archive all relevant data before uninstal-
ling a software package.
Precondition
• User rights:
‒ KSS: Function group General configuration
‒ VSS: User group “User”
• T1 or T2 mode
Procedure


Description
fied manually.

controller.
Description
Uninstall the existing version of ConveyorTech using WorkVisual and then

reinstall it. It is advisable to archive all relevant data before uninstalling a
software package.
Precondition
• User rights:
‒ KSS: user group “Expert”
‒ VSS: user group “User”
• T1 or T2 mode
Procedure

it.
7. Reload the project from the robot controller.

Messages
it.
activation. If no relevant project will be overwritten: Answer the query
with Yes.
Information about configuring ConveyorTech is contained in the docu-

mentation concerning this option package.
12.2.6 Conveyor 01009

Message text The conveyor did not move.
Possible cause(s) Cause: Conveyor not set in motion (>>> Page 103)
Solution: Set the conveyor in motion and resume the calibration
(>>> Page 103)
Cause: Conveyor not set in motion
Description
The conveyor was not set in motion when it was calibrated. The conveyor
must be set in motion for it to be calibrated correctly.
Solution: Set the conveyor in motion and resume the calibration
Description
Set the conveyor in motion and resume calibration of the conveyor.

12.2.7 Conveyor 01010

Message text Incorrect conveyor configuration
Possible cause(s) Cause: ConveyorGlobals.dat contains errors (>>> Page 104)

Solution: Check the WorkVisual project and transfer it again
(>>> Page 104)

Cause: vw_conv_usr_r.dat is faulty (>>> Page 104)

(>>> Page 105)
Cause: ConveyorGlobals.dat contains errors
Description
The file ConveyorGlobals.dat contains errors and/or has been modified

manually. The variable Cor_dir[] has the value #NONE, for example.
Configuration file
Directory C:\KRC\ROBOTER\KRC\R1\TP\Conveyor
File ConveyorGlobals.dat
Description
The WorkVisual project must be checked and then transferred to the robot
controller again.
Precondition
• User rights:
• T1 or T2 mode
Procedure
1. Load the active project from the robot controller.

2. Check whether the configuration in the project matches the real sys-
tem configuration. If not, correct the configuration.
3. Transfer the project back from WorkVisual to the robot controller and
activate it.

sual documentation.
Cause: vw_conv_usr_r.dat is faulty
Description
The file vw_conv_usr_r.dat is faulty and/or has been changed manually.

The variable Cor_dir[] has the value #NONE, for example.
Configuration file
Directory C:\KRC\ROBOTER\KRC\R1\VW_User\Applikation
\CO_Conveyor
File vw_conv_usr_r.dat

Messages
Description
The WorkVisual project must be checked and then transferred to the robot
controller again.
Precondition
• User rights:
• T1 or T2 mode
Procedure
1. Load the active project from the robot controller.

2. Check whether the configuration in the project matches the real sys-
tem configuration. If not, correct the configuration.
3. Transfer the project back from WorkVisual to the robot controller and
activate it.

sual documentation.
12.2.8 Conveyor 01011

Message text Error on setting a variable: {Variable name}
Possible cause(s) Cause: Faulty system files (>>> Page 105)

(>>> Page 106)
Cause: Faulty system files (>>> Page 106)

(>>> Page 107)
Description
fied manually.

controller.


Description

Precondition
• User rights:
• T1 or T2 mode
Procedure

Description
fied manually.

controller.

Messages
Description

software package.
Precondition
• User rights:
• T1 or T2 mode
Procedure

it.
it.
with Yes.

12.2.9 Conveyor 01013

Message text Parameters cannot be modified while conveyor '{Conveyor Device
Name}' is active.

Possible cause(s) Cause: Conveyor driver is active (>>> Page 108)

Solution: Deactivate conveyor driver (VSS) (>>> Page 108)
Cause: Conveyor driver is active (>>> Page 109)

Solution: Deactivate conveyor driver (KSS) (>>> Page 109)
Cause: Conveyor driver is active
Description
An attempt was made to modify parameters while the conveyor driver was
active. The conveyor in question is specified in the message. The convey-
or driver must be deactivated in order to modify parameters.
Solution: Deactivate conveyor driver (VSS)
Description
The conveyor driver must be deactivated with the aid of the Conv_InitOff
instruction. To do so, you can either use the current program or another
program.
Precondition
• User group “User”

• The conveyor application program (Folge) is selected.
• T1 mode
Procedure
1. Position the cursor in the line with the motion instruction and open the
Point PLC.
2. In the Point PLC, position the cursor in the line where the instruction
is to be inserted.
3. Select the menu sequence Commands > USER. The USER inline
form is opened.
4. Select Tech9_ in the 1st box from the left.
5. Select Conv_Basis_Fkt in the 2nd box from the left.
6. In the P1 box, select Conv_InitOff.
7. Select the number of the conveyor whose driver is to be deactivated
in the P2 box.
8. Save the instruction with Cmd OK.
9. Carry out a block selection to the Conv_InitOff instruction and then ex-
ecute it.

Cause: Conveyor driver is active
Messages
Description
An attempt was made to modify parameters while the conveyor driver was
active. The conveyor in question is specified in the message. The convey-
or driver must be deactivated in order to modify parameters.
Solution: Deactivate conveyor driver (KSS)
Description
The conveyor driver must be deactivated with the aid of the inline form
Conveyor.INI_OFF. To do so, you can either use the current program or
another program.
Precondition

• T1 mode
Procedure
ted.
3. In the inline form, select the conveyor in question.
5. Carry out a block selection using the instruction IniOff and then exe-
cute it.
12.2.10 Conveyor 01019

Message text No conveyors are configured.
Possible cause(s) Cause: The active project does not contain a conveyor
(>>> Page 109)
Solution: Add conveyor to project (>>> Page 110)
Cause: The active project does not contain a conveyor
Description
In order for KUKA.ConveyorTech Tracking to work correctly, a conveyor

must be assigned to the active project. The active project does not con-
tain a conveyor.
The procedure for checking whether the active project contains a
conveyor is as follows:

1. Open the project in WorkVisual.

2. Select the Hardware tab in the Project structure window and expand
the tree structure of the robot controller.
3. Check if the tree structure contains one of the following catalog ele-
ments:
• LinConveyor (linear conveyor)
• CircConveyor (circular conveyor)
• LinConveyorExt (external conveyor)
• LinConveyorClient (linear client conveyor)

sual documentation.
Solution: Add conveyor to project
Description
A maximum of 5 conveyor systems can be inserted into a WorkVisual

project.
Precondition

Procedure

tab) or in the Cell configuration and select Add... from the context
menu.
2. Select the Options tab and select the desired conveyor type in the
Conveyor catalog:
• LinConveyor for a linear conveyor
• CircConveyor for a circular conveyor
• LinConveyorExt for an external conveyor
• LinConveyorClient for a linear client conveyor
3. Click on Add.
If the option package Conveyor is not yet present in the project, a di-
alog opens. The files being added or modified are indicated there.
4. Click on OK. The dialog closes. The conveyor is inserted and as-
signed to the robot controller.
The conveyor can now be renamed. To do this, enter a new name
in the Properties window. This name is displayed in the inline forms
on the robot controller.
5. If required, repeat steps 1 to 4 to insert further conveyors.
12.2.11 Conveyor 01020

Message text The conveyor must not be set in motion during the component-base
calibration.

Messages
Possible cause(s) Cause: Conveyor was set in motion during calibration of a compo-
nent (>>> Page 111)
Solution: Recalibrate the workpiece on the conveyor
(>>> Page 111)
Cause: Conveyor was set in motion during calibration of a component
Description
The conveyor was set in motion during calibration of a component on the

conveyor. If the component is to be calibrated correctly, the conveyor must
not be set in motion.
Solution: Recalibrate the workpiece on the conveyor
Description
Recalibrate the workpiece on the conveyor. Make sure that the conveyor
is not set in motion.
12.2.12 Conveyor 01210

Message text Device or command unknown.
Possible cause(s) Cause: Conveyor driver called with invalid parameters

(>>> Page 112)
Solution: Transfer WorkVisual project again (>>> Page 112)
Cause: Conveyor driver called with invalid parameters

(>>> Page 112)
(>>> Page 112)

(>>> Page 113)
(>>> Page 113)

(>>> Page 114)
Solution: Contact KUKA Customer Support (>>> Page 114)


Messages
Description
The conveyor driver was called with invalid parameters.
Solution: Transfer WorkVisual project again
Description
Deploy the WorkVisual project on the robot controller again.
Precondition
• User rights:
• T1 or T2 mode
Procedure
1. Open project in WorkVisual.

2. Transfer the project to the robot controller.
3. Reboot the robot controller.
Description
Description

Precondition
• User rights:
• T1 or T2 mode
Procedure


Messages
Description
Description

software package.
Precondition
• User rights:
• T1 or T2 mode
Procedure

it.

it.
with Yes.

Description
Solution: Contact KUKA Customer Support
Description
Contact the relevant KUKA Customer Support department to rectify the er-
ror.
Procedure
• Send support request by e-mail to local subsidiary.
12.2.13 Conveyor 01211

Message text The conveyor driver is not active.
Possible cause(s) Cause: Conveyor driver not activated (KSS) (>>> Page 114)
Solution: Activate conveyor driver at start of program (KSS)
(>>> Page 115)
Cause: Conveyor driver not activated (VSS) (>>> Page 115)

Solution: Activate conveyor driver at start of program (VSS)
(>>> Page 115)
Cause: Conveyor driver not activated (KSS)
Description
Certain functions and instructions can only be executed if the conveyor

driver has been activated, e.g. the function CONV_GET_SPEED.

Solution: Activate conveyor driver at start of program (KSS)
Messages
Description
At the start of the program, the conveyor must first be initialized, then the
conveyor driver must be activated.
Precondition

• T1 mode
Procedure
1. Move the cursor to the start of the program.

3. In the inline form, select the conveyor used.
5. Select the menu sequence Commands > Conveyor > On.
6. In the inline form, select the conveyor used.
Cause: Conveyor driver not activated (VSS)
Description
Certain functions and instructions can only be executed if the conveyor

driver has been activated, e.g. The Conv_Sync instruction.
Solution: Activate conveyor driver at start of program (VSS)
Description
At the start of the program, the conveyor must first be initialized, then the
conveyor driver must be activated.
Precondition

• T1 mode
Procedure
1. Place the cursor in the line with the 1st motion instruction in the pro-
gram and open the Point PLC.
2. In the Point PLC, position the cursor in the line where the instruction
is to be inserted.
form is opened.
6. In the P1 box, select Conv_InitOff.
7. In the P2 box, select the number of the conveyor to be initialized.

9. Position the cursor in the following line in the Point PLC.

form is opened.
13. In the P1 box, select Conv_Ein.
14. In the P2 box, select the number of the conveyor whose drives is to
be activated.
12.2.14 Conveyor 01212

Message text The length of the integer array must not be smaller than 2.
Possible cause(s) Cause: Values cannot be displayed (>>> Page 116)

Cause: Values cannot be displayed
Description
Values read by the conveyor driver cannot be displayed.
Description
ror.
Procedure
12.2.15 Conveyor 01213

Message text The number of parts to be deleted must not be negative.
Possible cause(s) Cause: Parameters in KRL function CONV_DELETE_WPS incorrect-

ly specified (>>> Page 117)
Solution: Specify KRL function parameters correctly (>>> Page 117)

Messages
Cause: Values cannot be displayed (>>> Page 117)
Cause: Parameters in KRL function CONV_DELETE_WPS incorrectly specified
Description
A parameter has been specified incorrectly in the CONV_DELETE_WPS

KRL function. The number of components to be deleted was entered as a
negative value. The number of components must always be positive.
Solution: Specify KRL function parameters correctly
Description
The parameters in the KRL function must be specified correctly.
Precondition
• User rights: function group Critical KRL program changes

• T1 mode
Procedure
1. Select the program in the Navigator and press Open. The program is
displayed in the editor.
2. Search for the corresponding position in the program and edit it.
3. Close the file and respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.
Cause: Values cannot be displayed
Description
Values read by the conveyor driver cannot be displayed.
Description
ror.
Procedure
12.2.16 Conveyor 01215

Message text The MD command could not be executed.

Possible cause(s) Cause: Conveyor driver called with invalid parameters

(>>> Page 118)
Solution: Transfer WorkVisual project again (>>> Page 118)

(>>> Page 118)
(>>> Page 119)

(>>> Page 119)
(>>> Page 119)

(>>> Page 120)
Description
Solution: Transfer WorkVisual project again
Description
Deploy the WorkVisual project on the robot controller again.
Precondition
• User rights:
• T1 or T2 mode
Procedure
1. Open project in WorkVisual.

2. Transfer the project to the robot controller.
3. Reboot the robot controller.
Description

Messages
Description

Precondition
• User rights:
• T1 or T2 mode
Procedure

Description
Description

software package.
Precondition
• User rights:


• T1 or T2 mode
Procedure

it.
it.
with Yes.

Description
Description
ror.
Procedure

Messages
12.2.17 Conveyor 01216

Message text An error occurred when starting conveyor tracking for {Conveyor De-
vice Name}. Cause of error: '{Cause of error}'
Possible cause(s) Cause: Error when starting component tracking (>>> Page 121)
Cause: Error when starting component tracking
Description
An error occurred when starting component tracking. Further information

about the cause of the error is specified in the message.
Description
ror.
Procedure
12.2.18 Conveyor 01217

Message text An error occurred when resetting conveyor tracking for {Conveyor
Device Name}. Cause of error: '{Cause of error}'
Possible cause(s) Cause: Error when resetting component tracking (>>> Page 121)
Cause: Error when resetting component tracking
Description
An error occurred when resetting component tracking. Further information

about the cause of the error is specified in the message.
The message appears after the message An error occurred when starting
conveyor tracking for {Conveyor Device Name}. Cause of error: '{Cause of
error}'. This message is the actual cause.


Messages
Description
ror.
Procedure
12.2.19 Conveyor 01221

Message text An error occurred while ending conveyor tracking for {Conveyor De-
vice Name}. Cause of error: '{Cause of error}'
Possible cause(s) Cause: Error on ending the conveyor calibration (>>> Page 122)
Solution: Perform conveyor calibration again (>>> Page 122)
Cause: Error on ending the conveyor calibration
Description
An error occurred on ending the conveyor calibration. The conveyor posi-

tion could not be loaded.
Solution: Perform conveyor calibration again
Description
Calibration must be performed again.
12.2.20 Conveyor 01222

Message text The part BASE could not be calculated.
Possible cause(s) Cause: Error when calculating the part BASE (>>> Page 123)

Cause: Error when calculating the part BASE
Messages
Description
An error occurred during calibration of a component on the conveyor. The

part BASE could not be calculated.
Description
ror.
Procedure
12.2.21 Conveyor 01223

Message text The conveyor base could not be saved in full.
Possible cause(s) Cause: Error when saving the conveyor BASE (>>> Page 123)
Cause: Error when saving the conveyor BASE
Description
An error occurred during calibration of a conveyor. The conveyor BASE

could not be saved.
Description
ror.
Procedure
12.2.22 Conveyor 01224

Message text An error occurred while communicating with the conveyor driver.

Possible cause(s) Cause: Error in communication with the conveyor driver

(>>> Page 124)
Cause: Error in communication with the conveyor driver
Description
An error occurred while communicating with the conveyor driver. The in-
struction cannot be executed on account of this error.
Description
ror.
Procedure
12.2.23 Conveyor 01250

Message text The conveyor device is currently being used by the interpolation.
Possible cause(s) Cause: An attempt to delete workpieces from the workpiece list of a
synchronized conveyor (>>> Page 124)
Solution: Delete workpieces from the workpiece list before synchro-
nization (>>> Page 125)
Cause: An attempt to delete workpieces from the workpiece list of a synchron-

ized conveyor
Description
An impermissible attempt has been made to delete workpieces from the

workpiece list of a conveyor that is currently synchronized with the robot.
• Check programming.

Solution: Delete workpieces from the workpiece list before synchronization
Messages
Description
Workpieces can only be deleted from the workpiece list of a conveyor be-
fore the conveyor is synchronized. The programming must be modified ac-
cordingly.
12.2.24 Conveyor 01251

Message text The conveyor index is outside of the permissible range.
Possible cause(s) Cause: Conveyor index specified in KRL function > 5 (KSS)
(>>> Page 125)
Solution: Specify conveyor index in KRL function correctly (KSS)
(>>> Page 125)
Cause: Conveyor number is outside the permissible range (VSS)

(>>> Page 126)
Solution: Specify conveyor number in inline form correctly (VSS)
(>>> Page 126)
Cause: Conveyor index specified in KRL function > 5 (KSS)
Description
A maximum of 5 conveyors may be operated using one robot controller.

Each of these conveyors is assigned an index (1 … 5).
In a KRL function, a conveyor has been assigned an index > 5.
• Check the index specifications (always parameter 1 of the function):

‒ CONV_DELETE_ALL_WPS(…)
‒ CONV_DELETE_WPS(…)
‒ CONV_GET_SPEED(…)
‒ CONV_GET_WP_COUNT(…)
Solution: Specify conveyor index in KRL function correctly (KSS)
Description
The conveyor index in the KRL function must be specified correctly.
Precondition
• User rights: function group Critical KRL program changes

• T1 mode

Procedure
1. Select the program in the Navigator and press Open. The program is
displayed in the editor.
2. Search for the corresponding position in the program and edit it.
3. Close the file and respond to the request for confirmation asking
whether the changes should be saved by pressing Yes.
Cause: Conveyor number is outside the permissible range (VSS)
Description
A maximum of 5 conveyors may be operated using one robot controller. In

an inline form, a conveyor number has been specified which is greater
than or less than 5. The conveyor number, however, must be between 1
and 5.
Solution: Specify conveyor number in inline form correctly (VSS)
Description
The conveyor number in the inline form must be specified correctly.
Precondition

• T1 mode
Procedure
1. Position the cursor in the line with the motion instruction and open the
Point PLC.
2. Position the cursor in the line containing the instruction to be changed.
3. Press the Change button. The inline form for this instruction is
opened.
4. In the P2 box, change the number of the conveyor.
5. Save the change with Cmd OK.
12.2.25 Conveyor 09999

Message text Unexpected exceptional error: {0}
Possible cause(s) Cause: Unexpected exceptional error during execution of Conveyor-

Tech (>>> Page 127)

Cause: Unexpected exceptional error during execution of ConveyorTech
Messages
Description
An unexpected exceptional error occurred during execution of Conveyor-

Tech. Further information about the cause of the error is specified in the
message.
Description
ror.
Procedure


KUKA Service
13 KUKA Service
13.1 Requesting support
Introduction
This documentation provides information on operation and operator con-

trol, and provides assistance with troubleshooting. For further assistance,
please contact your local KUKA subsidiary.
Information
The following information is required for processing a support re-

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• As comprehensive information as possible about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ Model and serial number of the controller
‒ Model and serial number of the energy supply system
‒ Designation and version of the system software
‒ Designations and versions of other software components or modifi-
cations
‒ Diagnostic package KRCDiag
Additionally for KUKA Sunrise: existing projects including applica-
tions
For versions of KUKA System Software older than V8: archive of
the software (KRCDiag is not yet available here.)
‒ Application used
‒ External axes used
13.2 KUKA Customer Support
The contact details of the local subsidiaries can be found at:

www.kuka.com/customer-service-contacts

KUKA Service KUKA.ConveyorTech 8.0

Index F
Function groups..............................................53
A
Alarm distances.............................................. 45 G
Alarm distances, modifying............................ 56 General I/O parameters................................. 42
C I
Calibrating, 6D conveyor................................65 I/Os, configuring............................................. 50
Calibrating, circular conveyor.........................60 Inline forms, programming (WorkVisual)....... 80
Calibrating, linear conveyor............................59 Installation.......................................................31
Calibration.......................................................59 via smartHMI............................................. 33
Client conveyor.......................................... 8, 17 via WorkVisual...........................................31
Configuration...................................................35 Installation, ConveyorTech............................. 31
Connection to the CIB, modifying..................37 Installing ConveyorTech................................. 33
Controller-specific conveyor settings, editing 49 Intended use...................................................12
Controller-specific conveyor settings, Introduction....................................................... 7
modifying........................................................ 54
CONV_DELETE_ALL_WPS........................... 89
CONV_DELETE_WPS................................... 89 K
CONV_GET_SPEED...................................... 90 KLI.....................................................................8
CONV_GET_WP_COUNT..............................90 KRL functions................................................. 88
Conveyor...........................................................8 KSB...................................................................8
Conveyor-specific settings, modifying............54 KUKA Customer Support............................. 129
Conveyor application program, creating........69 KUKA Service...............................................129
Conveyor area, leaving.................................. 78
Conveyor distance, checking......................... 62
Conveyor driver, activating.............................72
Conveyor parameters, editing........................ 42
L
Licenses............................................................9
Conveyor, initializing.......................................71
Long texts, adding..........................................50
Conveyor, inserting in project........................ 36
Conveyor, motion master............................... 38
Conveyor.FOLLOW.........................................72
Conveyor.INI_OFF.......................................... 71 M
Conveyor.ON.................................................. 72 Messages........................................................97
Conveyor.Quit................................................. 78 Misuse.............................................................12
Conveyor.Skip.................................................75
CRC.................................................................. 8
Current workpiece, tracking........................... 72 O
Cycle synchronization, configuring.................40 On-the-fly synchronization................................8
Open source..................................................... 9
Operation........................................................ 53
D Overview, start-up...........................................27
Decision to track workpiece made in advance
run...................................................................94
Dimension of conveyor, changing..................36 P
DLIN block, programming.............................. 84 Planning.......................................................... 17
DLIN motion, programming............................ 85 PLC................................................................... 8
DLIN.MOVE.................................................... 85 Product description......................................... 11
Documentation, industrial robot....................... 7 Program override, modifying.......................... 93
Programming.................................................. 69
PTP................................................................... 8
E
Escape strategy..............................................46
ESD...................................................................8 R
Expert parameters.......................................... 43 RDC.................................................................. 8
EXT (operating mode)..................................100 Recommissioning............................................27
External conveyor...........................................18 Resolver............................................................8

Resolver, connecting to RDC........................ 27

Robot leaves path.......................................... 93
RoboTeam network, adding robot
controllers....................................................... 39
S
Safety..............................................................15
Safety instructions............................................ 7
Signal diagram, stop strategy
CONV_STOPPABLE...................................... 48
Source conveyor...............................................8
Source conveyor, assigning........................... 39
Specific workpiece, tracking...........................75
Start-up........................................................... 27
Status keys..................................................... 53
Stop distances................................................ 45
Stop distances, modifying.............................. 56
Stop strategy, CONV_STOPPABLE........ 47, 48
Stop strategy, GEN_STOP.............................47
Support request............................................ 129
Synchronized motions, teaching.................... 81
System requirements......................................31
Hardware................................................... 31
Software.....................................................31
T
T1 (operating mode).....................................100
T2 (operating mode).....................................100
Target group..................................................... 7
Terms used....................................................... 8
Tracking distance............................................. 8
Trademarks....................................................... 9
Training............................................................. 7
Troubleshooting.............................................. 93
U
Uninstallation, ConveyorTech.................. 32, 34
Update, ConveyorTech................................... 31
Updating ConveyorTech................................. 33
User rights, displaying....................................53
W
Warnings........................................................... 7
Workpiece on 1D conveyor, calibrating.........63
Workpiece on 6D conveyor, calibrating......... 67

KST ConveyorTech 80 en NT

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KUKA System Technology

Publication: Pub KST ConveyorTech 8.0 (PDF) en

Book structure: KST ConveyorTech 8.0 V2.1

Version: KST ConveyorTech 8.0 V2

2/132 | www.kuka.com KST ConveyorTech 8.0 V2 | Issued: 08.07.2021

5 Start-up and recommissioning............................................................... 27

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7.9 Configuring conveyor parameters in the machine data....................................... 42

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12.1 Information about the messages.......................................................................... 97

13 KUKA Service........................................................................................... 129

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1.1 Target group

This documentation is aimed at users with the following knowledge and

• Advanced knowledge of the robot controller system

For optimal use of KUKA products, we recommend the training courses

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

• Documentation for the robot arm

1.3 Representation of warnings and notes

These warnings contain references to safety-relevant information or gen-

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This warning draws attention to procedures which serve to prevent or rem-

edy emergencies or malfunctions:

Procedures marked with this warning must be followed exactly.

These notices serve to make your work easier or contain references to

1.4 Terms used

Conveyor Moving conveyor system, e.g. belt, chain, etc.

CRC Cyclic Redundancy Check

ESD Electrostatic Discharge

KLI KUKA Line Interface

KSB KUKA System Bus

PTP Precision Time Protocol

RDC Resolver Digital Converter

Resolver Measurement system which calculates the distance that a conveyor

Source conveyor Conveyor to which a resolver is connected. The client conveyors

PLC Programmable Logic Controller

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EtherCAT® is a registered trademark and patented technolo-

Further information about open-source licenses can be requested from

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2.1 Product description

The KUKA.ConveyorTech 8.0 option package is designed as a solution for

• Synchronization of robot motions with the motion of conveyor systems

2.2 Application example

In this application example, a robot removes workpieces from a linear con-

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Fig. 2-1: Layout of the conveyor system in the application example

1 Linear conveyor 3 Robot controller

2.3 Intended use and misuse

The KUKA.ConveyorTech 8.0 option package is intended exclusively for

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

12/132 | www.kuka.com KST ConveyorTech 8.0 V2 | Issued: 08.07.2021

Examples of such misuse include, for example, use in a non-industrial en-

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4.1 Conveyor with resolver

Fig. 4-1: System with conveyor connection to RDC

4.2 Client conveyor