K-ROSET

How to make paint package

cell project

90210-1437DEB

Kawasaki Heavy Industries, Ltd.

Introduction 1

Safety 2

1 Summary 3
Summary of table synchronous 3

2 Procedure to Create Project 5

Objective system 5

Activation 6

Plug-in Setting 7

Creating projects 8

Adding robot and pedestal 9

Adding painting spray gun 14

Adding workpieces 19

Adding obstacles 27

Teaching 31

Creating teaching points 38

Creating teaching programs 51

Simulation 60

3 Various setting 73
Interface panel 73

4 FAQ and Troubleshooting 75

FAQ and troubleshooting upon operation 75

i
ii
Introduction
This manual describes frequently used operating instructions for explosion-proof painting of K-ROSET. This manual
should be read with careful review of the related manuals such as Kawasaki robot, Controller and Controller options.
Once the contents of all the manuals are thoroughly read and understood, the robot can be used.

 Safety Manual
 Installation and Connection Manual for Arm
 Installation and Connection Manual for Controller
 External I/O Manual (for connecting with peripheral devices)
 Inspection and Maintenance Manual
 AS Language Manual
 Servo Tombow Manual

Should any unexplained questions or problems arise during robot operation, please contact Kawasaki Robot Service
(former Kawasaki Machine Systems). Refer to the contact information listed on the rear cover of this manual for
the nearest Kawasaki Robot Service office.
The explanations in this manual include information on optional functions, but depending on the specification of each
unit, not every optional function detailed here may be included with the robot. Also, note that figures given here
may differ partially from actual screens.

1 This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damage, and/or problems
relating to industrial property rights as a result of using the system.

2 It is recommended that all personnel assigned for activation of operation, teaching,

maintenance or inspection of the robot attend the necessary education/training course(s)
prepared by Kawasaki, before assuming their responsibilities.
3 Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4 This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.

5 Store this manual with care and keep it available for use at any time. If the robot is
reinstalled or moved to a different side or sold off to a different use, attach this manual to the
robot without fail. In the event the manual is lost or damaged severely, contact Kawasaki.
Copyright © 2021 Kawasaki Heavy Industries, Ltd. All rights reserved.

1
Safety
The items that require special attention in this manual are designated with the following symbols.

Ensure proper and safe operation of the robot and prevent physical injury or property damage by complying with the
safety matters given in the boxes with these symbols.

WARNING

Failure to comply with indicated matters may possibly lead to injury or death.

[ NOTE ]
Denotes precautions regarding robot specification, handling,
teaching, operation and maintenance.

WARNING

1. The accuracy and effectiveness of the diagrams, procedures, and detail explanations
given in this manual cannot be confirmed with absolute certainty. Should any
unexplained questions or problems arise, please contact Kawasaki Robot Service.
2. Safety related contents described in this manual apply to each individual work and not
to all robot work. In order to perform every work in safety, read and fully
understand the safety manual, all pertinent laws, regulations and related materials as
well as all the safety explanations described in each chapter, and prepare safety
measures suitable for actual work.

2
1 Summary
This manual shows servo tombow of K-ROSET explosion-proof painting robot as an example, and explains how to
use paint package cell and operating precaution. There are four systems which combined robot and servo tombow.
Among them, this manual is to describe operations with table synchronous-interlocking mode.
For functions of robot itself or servo tombow, please refer to the robot operating manual.

1.1 Summary of table synchronous

Robot teaching is operated in stationary condition of workpieces even when turning arm or turning table while
painting workpieces are loaded on the table.

When playing back, robot automatically follows up with painting workpieces on the table and paints. This function is
called synchronous function.

For teaching, following instructions need to be added unlike lines (such as tact line) painting in stationary condition
of workpieces.

Start synchronous[TBL_TRACK ON]

After this instruction, teaching points follow up the table of paint package cell and replay.
After start synchronous instruction, robot follows up table and keeps positions of workpieces and the spray gun from
workpieces viewpoint same as teaching points.

Stop synchronous[TBL_TRACK OFF]

After this instruction, teaching points replay asynchronous (not follow up) to the table.

Rotation[(example) TBL_SLFTRN 20rpm,60sec,POSITIVE]

With this instruction, table rotates with setup conditions. Table position that stored in teaching program is ignored
while rotating. Also, rotation instruction is invalid with teaching mode, and table rotates to match position that stored
in teaching program.

End rotation[TBL_SLFTRN OFF]

With this instruction, table rotation terminates. After this instruction, table rotates to match position that stored in
teaching program.

Wait rotation[TBL_WAIT]
With this instruction, robot waits until appointed time by rotation instruction.

Rotation number[(example) TBL_ROTCNT 0]

With this instruction, rotation numbers can be changed. Only table direction can be changed without table axis
rotation.

3
Memo

4
2 Procedure to Create Project
This chapter explains how to simulate table synchronous of explosion-proof painting robot in K-ROSET.

2.1 Objective system

Drawing 2.1 indicates specification of creating project.

Drawing 2.1 paint package cell simulation objective system

Summary of drawing 2.1

★ Use robot KF121 with servo tombow function and install wall-mounted.
★ Attach to J8 and layout to let hanger and workpieces rotate.
★ Use spray gun as tool.

5
 2.2 Activation
This chapter explains how to activate K-ROSET.

1 Double-click shortcut icon on the Desktop.

Example of shortcut icon

K-ROSET starts.

 When the shortcut icon is not on the desktop,

click K-ROSET of Start Menu. (Start Menu - Apps lists or All Apps - Kawasaki Robot Solutions -
K-ROSET)

6
 2.3 Plug-in Setting
This chapter explains how to appoint required plug-in for explosion-proof painting servo tombow

1 Select [setting menu] - [Plug-in setting].

Plug-in activates.

2 Fill check marks as follows in function cell on plug-in dialogue box.

Each Plug-in will be loaded to K-ROSET.
When marks are already filled in, no action is required here.
For details of each function, please refer to K-ROSET instruction manual.

7
 2.4 Creating projects
This chapter explains how to create projects

2.4.1 New creation

 Projects should be saved before this operation.

1 Right-click project icon [ ] on layout.

Menu related to projects is displayed.

2 Click [Project]-[New ] menu.

View is cleared and project setting dialogue box is displayed.

 Default project name is set as new_project.

 Click OK and if project is already existing, message is displayed to confirm overwrite.

3 Type project name. Type project explanation in comment section and click [OK] button.
New project with appointed name is created.

8
 2.5 Adding robot and pedestal
This chapter explains how to add robot and obstacle (Pedestal).

2.5.1 Adding robot

1 Right-click project icon [ ] on layout and select [Add]-[Robot] from menu.

Robot loading dialogue box is displayed.

2 Select each item as follows and click [OK] button.

R01 [001] will be added to the layout and the robot R01 will appear in the view.

Items to be selected
Application Painting
Controller E controller
Series KF series
Product Code KF121-A001-
Specification Tombow 1000mm 20kg
AS version 8000001E

 For details of each item, please refer to K-ROSET manual.

 KF121-A001-Tombow1000_20 is a robot with servo tombow which has 1000mm distance between
tables of tombow and weight capacity of 20kg.

3 Double-click robot icon [ ] on layout.

9
 Position dialogue box is displayed.

4 Set following values as each coordinate value and click [OK] button.

Robot is allocated to the appointed position.

5 Allocate table base. Double-click table base(obstacle icon[ ]) on layout.

Position dialogue box is displayed.

6 Set reference frame as WORLD and set following values as each coordinate value. Click [OK] button.

Table base is allocated to the appointed position.

 When reference frame is local, coordinates will be based on robot base.

10
 2.5.2 Adding robot pedestal

1 Right-click project icon [ ] on layout.

Menu related to project is displayed.

2 Click [Add]-[Environment]-[Obstacle] menu.

Dialogue box to select configuration file is displayed.

3 Click [KHIlibraries] folder icon on left side of dialogue box.

KHIlibraties is opened.

4 Select KHlibraries¥ Envs¥Equipment¥Pedestals folder.

The model folder for robot pedestal is opened

11
5 Select [Pedestal_1000_1000_3010.stl] file and click [OPEN] button.
Obstacle 1 is added in layout. Robot pedestal of height 3010mm is added.

6 To rename the item, left-click on the obstacle in the layout tree.

The name of the item will be editable.

7 Type “PEDESTAL” and fix with Enter key.

12
 The name will be set.

8 Allocate pedestal. Double-click Pedestal (obstacle icon[ ])on layout.

Position dialogue box is displayed.

9 Set following values as each coordinate value and click [OK] button.

Pedestal is allocated to the appointed position.

13
 2.6 Adding painting spray gun
This chapter explains how to add painting spray gun. This explanation is the way to read painting spray gun already
registered.

1 Right-click robot icon [ ] on layout.

Menu related to robot is displayed.

2 Click [Tool]-[Load].
File selection dialogue box is displayed.

3 Click [KHIlibraries] folder on left side of dialogue box and select

[Tools¥Paint¥T-AGPV_GUN_57201-4099_Alpha_90_200] folder.

14
  When select files that registered as tools, thumbnail is displayed and “T” is displayed on the thumbnail.

4 Select [T-AGPV_GUN_57201-4099_Alpha_90_200.krprj] and click [Open] button.

Tool file is read and spray gun is loaded on robot wrist flange.

Paint pattern

 When tool is already stored, that stored tool will be cancelled and the read tool will be loaded.
 This paint spray gun originally has a paint pattern of gun distance 200mm.

5 Change position. Left-double-click T-AGPV_GUN_57201-4099[ ] on layout.

Position dialogue box is displayed.

6 Set following values as each coordinate value and click [OK] button.

Tool is allocated to the appointed position.

7 Change tool transformation values. Left-double-click tool arrow under T-AGPV_GUN_57201-4099[ ]

on layout.
Position dialogue box is displayed.

15
8 Set following values as each coordinate value and click [OK] but-90ton.

Tool arrow is allocated to the appointed position.

 Make sure to operate synchronous right after adding paint spray gun to layout or after changing tool
transformation values. Implement synchronous of layout <- controller on synchronous dialogue box.

9 Click Robot R01 [C01] tab on controller tab and click Synchronize button on R01 [C01] tab.
Synchronous operation dialogue box is displayed.

10 Place a checkmark in the check box for “Controller Settings” and select [K-ROSET-> Controller] then
click on “Start”.
A confirmation dialog will appear.

16
17
11 Click “Yes”.
The settings will be synchronized to controller.

Synchronous operation of tool transformation values

When linear interpolation steps or converted values variable are added to a program, they are stored based on
tool transformation values of loaded tool as of adding moment. In order to forward this program to controller
and run, tool transformation values of loaded tool need to be set in controller.

The tool transformed

value of the attached tool
is synchronized.

In case several tools are stored, please be careful enough to run the program with reloaded tool.
Therefore, we recommend operating synchronous of K-ROSET-> controller on synchronous dialogue box after
loading tool or after changing tool transformation values.

18
 2.7 Adding workpieces
This chapter explains how to add workpieces.

1 Expand robot tree on layout and right-click [J8].

Menu related to movable axis is displayed.

2 Click [Add]-[Environment]-[Work].
Selection dialogue box of configuration file is displayed.

3 Click the KHlibraries folder icon on the left of the screen and select
KHIlibraries¥Envs¥Equipment¥Others folder.
The selected folder is opened.

19
4 Select HangerServoJig.stl file and click [Open] button.
Model is read on J8 HOME. Work1 icon [ ] is added under J8 on layout.

5 Change name. Left-click workpiece 1 icon [ ] under J8.

The item can be renamed.

6 Type “Hanger” and fix by Enter key.

The name will be set.

7 Change position. Left-double-click hanger icon [ ] under J8.

Position dialogue box is displayed.

8 Set following values as each coordinate value and click [OK] button.

20
 Hanger is allocated to the appointed position.

9 Add workpiece to be painted to the hanger. Right-click hanger icon then click
[Add]-[Environment]-[Work]
Selection dialogue box of configuration file is displayed.

10 Click [KHIlibraries] folder icon on left side of dialogue box.

Select [KHIlibraries¥Envs¥CarParts] folder.

21
11 Select [Grille.stl] file and click [Open] button.
Model is loaded on hanger home. Work1 icon [ ] is added under hanger.

12 Change position. Left-double click Work1 icon [ ] under hanger.

Position dialogue box is displayed.

13 Set following values as each coordinate value and click [OK] button.

It is allocated as following drawing.

22
  Instead of left-double click workpiece icon, position dialogue box can be displayed by double-click
workpiece model on the view, or select [Position]-[Change] from workpiece menu.

2.7.1 Add workpiece to the opposite axis of Tombow and Twister

This chapter describes how to add workpiece to the opposite side of the axis.

1 Right-click on the robot in the layout and select [Show Axis on Group Status].
Display of the axis will change to group.

2 Expand the Robot tree in the layout and right-click on the “Shaft” then select [Add]-[Environment]
-[Workpiece].

23
 Shape file chooser dialog will appear.

3 Choose the jig to use. Click on the KHIlibraries folder icon on the left side of the screen.
The selected jig will move to the KHIlibraries folder.
This section describes how to add obstacles from the KHI library to the project. To add your own parts, specify the
location of the file.
Select KHIlibraries¥Envs¥Equipment¥Others folder.
*Select C:¥Program Files¥Kawasaki¥Hisui¥KHIlibraries folder using chooser dialog when you do not have
KHIlibraries icon.

4 Select “HangerServoJig.stl” and click [Open].

The selected model will be loaded to the Shaft origin and appear as [ ] underneath the Shaft in the layout.

5 To rename the item, left-click on the [ ] icon in the layout.

Item name will be editable.

24
6 Enter “Hanger” and press “Enter”.
The item is renamed.

7 To edit the layout, left-double-click on the “Hanger” icon [ ].

Layout edit dialog will appear.

8 Input the value and click “OK”.

The model in the view will move.

9 Add workpiece for paint to the hanger. Right-click on the “Hanger” icon and select
[Add]-[Environment]-[Workpiece].
Shape file chooser dialog will appear.

10 Click the KHIlibraries folder icon on the left side of the screen and select KHIlibraries¥Envs¥CarParts
folder.
The item will move to the selected folder.

11 Select “Grille.stl” and click [Open].

25
 The selected model will be loaded to the hanger origin. Icon [ ] will appear as “workpiece” underneath the “Hanger”
icon in the layout.

12 Edit layout. Left-double-click on the “Workpiece” icon [ ] in the layout.

Layout edit dialog will appear.

13 Input value and click on “OK”.

Layout will change as shown below.

26
 2.8 Adding obstacles
This chapter explains how to add obstacles.

1 Right-click project icon [ ] on layout.

Menu related to project is displayed.

2 Click [Add]-[Environment]-[Obstacle].
Selection dialogue box of configuration file is displayed.

3 Click [KHIlibraries] folder on left side of dialogue box.

Select [KHIlibraries¥Envs¥Equipment¥Others] folder.

4 Select [Booth.stl] file and click [Open] button.

Model is loaded on world home. Obstacle 1 is added on layout.

27
5 Change name. Left-click Obstacle1 on layout.
It enables you to rename the item.

6 Type “Paint Booth” and fix by Enter key.

The item is renamed.

7 Appoint transparency from obstacle menu.

8 Allocation. Double-click paint booth(obstacle icon[ ])on layout.

Position dialogue box is displayed.

9 Set following values as each coordinate value and click [OK] button.

Painting booth is allocated to the appointed position.

10 Add remaining obstacles. Right-click project icon 【 ] then click [Add]-[Environment]-[Obstacle].

Selection dialogue box of configuration file is displayed.

11 Click [KHIlibraries] folder icon on left side of dialogue box.

28
 Select [KHIlibraries¥Envs¥Equipment¥Controllers] folder.

12 Select [E-con_explosion-proof.stl] file and click [Open] button.

Model is loaded on world home. Obstacle1 is added on layout.

13 Change name. Left-click [Obstacle1] on layout.

It enables you to rename the item.

14 Type “Controller” and fix by Enter key.

The item is renamed.

15 Right-click project icon [ ] then click [Add]-[Environment]-[Obstacle].

Selection dialogue box of configuration file is displayed.

16 Click [KHIlibraries] folder icon on left side of dialogue box.

Select [KHIlibraries¥Envs¥Equipment¥Fences] folder.

17 Select [Safetyfence_2440_1565.stl] file and click [Open] button.

Model is loaded on world home. Obstacle 1 is added on layout.

18 Change name. Left-click [Obstacle 1] on layout.

It enables you to rename the item.

19 Type “Safety fence 1” and fix by Enter key.

The item is renamed.
Appoint transparency from obstacle menu.

20 Right-click Safety fence (obstacle icon[ ]) and click [Edit]-[Copy].

21 Right-click project icon [ ] and click [Edit]-[Paste].

Model of safety fence is copied as obstacle 1 in layout.

22 Change name. Left-click [Obstacle 1] on layout.

Type “Safety fence 2” and fix by Enter key.
Appoint transparency from obstacle menu.

23 Allocation. Double-click Controller, Safety fence(obstacle icon[ ]) on layout.

Position dialogue box is displayed.
Allocate as follows.
X Y Z O A T
Controller 2500 0 0 0 0 -90
Safety fence 1 -2000 1200 0 0 0 90
Safety fence 2 2000 1200 0 0 0 90

29
30
 2.9 Teaching
This chapter explains how to teach with teaching panel. Preliminary operation is required.

2.9.1 Float teaching panel

By floating teaching panel, it is deviated from right task panel. It allows easier operation since you can check
program dialogue box and teaching panel at the same time. Please skip this chapter in case this function is not
necessary.

 Restart of K-ROSET is required to validate floating setting. When project is open, make sure to save
project before this operation.

1 Click [Setting] - [Plug-in setting] on main menu.

Plug-in setting menu is displayed.

2 Fill check mark in floating section of teaching panel and click [OK] button.
Confirmation dialogue box is displayed. Click [OK] button.

3 Restart K-ROSET.
Teaching panel is displayed in floating condition from right task panel. Since it is separated from the program,
program step can be created while changing robot postures.

31
 2.9.2 Setting collision pairs

In teaching operation, models can be displayed in different colors in case robot and workpiece/ obstacle collide.
This operation needs setting of collision pairs between models. Please skip this chapter in case this function is not
necessary.

1 Click [Plug-in] main menu and [Collision check] menu

 Performance of K-ROSET improves by limiting models as required.

32
 Create necessary collision pairs
Here, set following collision pairs that is likely to collide with this system.
J2-J6 Hanger/Workpiece 1
Pedestal
Tool Hanger/Workpiece 1
Pedestal

2 Expand left robot tree and select [J2]. Click [Hanger] on right tree. Click [Add] button.
Pairs are added to the collision pair list. When appointed parent, all following children are added to pairs list.

3 Repeat procedure 3 and add a pair of J3 to J6 and hanger.

J3-Hanger, J4-Hanger, J5-Hanger and J6-Hanger and J3-Workpiece 1, J4-Workpiece 1, J5-Workpiece 1 and
J6-Workpiece 1 will be added to the Collision pair list.

4 Add a pair of tool (T-AGPV_GUN_57201-4099) and hanger.

Selected tool and hanger will be added to the Collision pair list as a pair.

33
5 Select J2 to J6, pedestal and add a pair. Also add tool and pedestal.
J2 through J6 and pedestal will be added to the Interference pair list.

 When create tool pairs, pattern of tool children are also registered as collision pair as per below
dialogue box. Since pattern is for painting, please basically eliminate it from collision objective.

6 Eliminate tool pattern from collision pair. Select pattern on left tree. Select project on right tree. Object
pair is blue-inverted

7 Click [Delete] button.

Blue-inverted list is deleted.

8 Pairs list is completed then fix by [Apply] button.

Boldface is disappeared from pairs list. Also, check marks are shown on registered pair items.

34
 2.9.3 Setting motion range

Set robot motion range of each axis. Actual system requires mechanical stopper and user limit of fluctuate motion in
order to prevent collision to wall when robot JT1 rotates.
With K-ROSET, user limit of fluctuate motion can be set. Please skip this chapter if this function is not necessary.

1 Right-click robot icon on layout.

Robot menu is displayed.

2 Click arm setting menu.

Arm setting menu is displayed.

3 Left-click [R01] icon on left tree.

4 Select [UP-LIM] from dropdown list of extension setting section

35
5 After selecting [UP-LIM], left-click …icon on right edge of value input section.
Dialogue box for setting motion upper/lower limit is displayed. Set upper and lower limit.

6 Set user setting of each axis as follows.

Input upper/lower limit of JT5 as 115 degree.
Changed and unconfirmed value section is green-highlighted.

36
7 Click [OK] button, then return to dialogue box for setting upper/lower limit.

8 Click [Apply] button, then confirmation message for restart controller is displayed.
Click [YES] button, and then set values of layout is reflected on the controller.

 Robot system data can be set with Arm setting. In order to reflect changes with this dialogue box to
virtual controller, reflection to controller after restart is required.

9 Click [Controller each axis limit value] button on option dialogue box of teaching panel.
Button is faded and description becomes ON.

 When operate robot by teaching panel with this option ON, robot does not move beyond each axis
fluctuation limit.

37
2.10 Creating teaching points
This chapter explains how to teach by creating teaching points on workpieces.
First of all, please note about sites to be painted this time. Please refer to below drawing 2.10.1.
Blue line roughly indicates robot motion. Red dots are painted tracks. Arrows in red or green are teaching points.
Create points to be nearly in a straight line toward longer direction of workpiece. This time, create teaching points 1-6
as route 1 (painting path) and regard it as basis to create subsequent teaching programs.
(Besides, create TP7 in order to copy teaching point.)
Spray painting basically teach gun to be vertically toward to painting surface. Thus, K-ROSET regards creating
teaching points vertically on clicked sites as default.

2.10.1 Front

2.10.1 Back

38
 2.10.1 Top

 Drawing shows created teaching points with dots but they can be shown with lines.

2.10.1 Adding with current value posture

Create teaching points with teaching panel. Create home and save position.

Register home position

1 Move robot to home position with teaching panel.

Home position is posture that servo arm does not collide by rotation when robot is not in operation.

2 Click [Add Point] button on teaching panel.

TP1 is created at robot hand (tool arrow) position.

Teaching point is added under robot node.

39
3 Change name. Left-click TP 1[ ] on layout.
Type “Home” and fix by Enter key.

Register Home position

1 Move robot to home position with teaching panel.

Home position is posture that servo arm does not collide by rotation when robot is not in operation and that easy to
start painting operation.
Example
X Y Z O A T
280 900 -650 90 90 -90

2 Click [Add Point] button on teaching panel.

TP1 is created on robot hand (tool arrow) position.

3 Change name. Left-click TP 1 [ ] on layout.

Type “Save” and fix by Enter key.

2.10.2 Adding teaching points by click

Create teaching points with teaching panel.

1 Set the joint value of J7 at -180 using the teach panel.

Workpiece will moved to the robot working area.

40
2 Click [Click Teach] button on option dialogue box of teaching panel.
Button is faded and description becomes ON. Click teaching becomes valid.
Subsequent left clicks on the view model add teaching points.

3 Add teaching points on workpieces.

Change viewpoint to the site to be created. Left-click workpiece then teaching point arrows are added on workpiece
surface. Teaching point is added under workpiece on layout. Drawing below shows example that created TP1.

 Pedestal can be hidden in case it encumbers operation.

 Right-click pedestal on layout then click Show menu. Mark is removed then pedestal is hidden.
 If teaching points are already stored, the name of TP1 might be invalid. The number gets increased
consecutively by each creation.

41
4 Move robot to TP1. Left-click created [TP1] icon on layout.
Move robot and tool arrows to be same coordinates with TP1. This is called as JUMP. If it does not move, robot
cannot take that teaching point posture.
In order to let robot take that posture, move direction of teaching point adequately or put workpiece closer to robot.

5 In case robot cannot take posture, change direction of teaching point. Double-click [TP1] on layout.
Position dialogue box is displayed.
Let reference frame to be local then increase and decrease T value. X and Y axis rotate on Z axis (blue arrow
rotation) of teaching point. By increasing T value, rotate clockwise toward workpiece surface as per below blue
arrow.

Increase and decrease several 0. Fix by Apply button on position dialogue box.
Once again, click TP1 on layout and check whether robot jumps.
If not, try to repeat procedure 7 until it moves.

 Letting Y axis of teaching point (green arrow) head to robot enables robot to take posture easily but it is
not versatile.

6 Create 6 teaching points on each surface referring to front, back and top drawing in chapter 2.10.1 and
also below drawing.
Create 6 points roughly by clicking workpiece. Create teaching points 1-6 to be nearly on the same path.

7 If robot cannot take posture, change direction of teaching point. Select [TP2] and then select [TP6] while
pressing Shift key. Double-click [TP6] while pressing Shift key.
Position dialogue is displayed. Change T value in order to let robot jump to added teaching point position.
Please refer to the drawing below that shows only teaching points.

42
 Front

Back

Top

 Eventually teach to move in ascending order from TP1.

 Posture of adjacent points should not be drastically varied. In order to keep painting quality, it is
important to move gun on surface with as stable posture as possible.

2.10.3 Edit teaching points

TP1 and 6 need to be fixed on little bit beyond workpiece, not on workpiece. Otherwise, coating material is not
painted evenly on workpiece edge.
After that, let robot jump between points one by one and check whether robot moves properly.

43
 Point 1 and point 6 are points little bit beyond workpiece

1 Move the mouse cursor to meet either the TP1 point or one of the arrows and then right-double-click on
it.
Context menu will popup.
Zoom in the view if the view is too small to be the mouse cursor to meet the TP1 point or either of the arrows.

2 Select [Position]-[Change] on menu.

Position dialogue box is displayed.

 Position dialogue box can be displayed by left-double-click TP1 on layout. However, in case robot can
jump, gun tip moves to TP1 and it encumber edit of teaching point position.
 With above example way, edit position is easier since robot does not move.

3 Reference frame to be local. Move approximately 100mm toward X axis positive direction (red arrow)
and click [Apply] button.
Move 100mm along with teaching point arrow.

4 In the same way, create point 6 beyond workpiece. Expand view size to click TP6 ball or coordinate
arrow.

44
5 Right-double-click ball or arrow of TP6.
Menu is displayed.

6 Select [Position]-[Change] on menu.

Position dialogue box is displayed.

7 Set coordinate system to be local. Move approximately 100mm toward X axis negative direction (reverse
direction of red arrow) and click [Apply] button.
Position moved 100mm along with teaching point arrows.

8 Repeat 2 - 7 procedures and move teaching points on back side to be beyond workpieces.

Create teaching points for direction of automatic program creation (copy)

Using Create Painting Program (Copy) function, copy teaching points 1 - 6 and register them as direction to create
second path.

1 Right-double-click [TP6] on view.

Menu is displayed.

2 Click [Edit]-[Copy] from menu.

45
3 Right-double-click [Workpiece 1] on view and display menu.

4 Select [Edit]-[Paste]. Copy teaching points

5 Right-click teaching point copied on layout and select [Position]-[Change] from menu.
Position dialogue box is displayed.

 Position dialogue box can be displayed by left-double-click on layout. However, robot jumps and it
encumber operation. It is recommended to open from menu.

6 Select [World] in reference frame. Move 100mm toward Y positive direction and press Enter key.
Confirm position moved 100mm to point and fix by [Apply] button.

7 Click each teaching point on layout and confirm robot jumps to click teaching points.
In case it does not move, robot cannot take posture of that teaching point. Edit position and direction of teaching
point adequately in order to take that posture.

 When robot jumps, confirming wrist direction with gage display of teaching panel is useful to make sure
wrist not to rotate too much.

8 Repeat 1 - 7 procedures and create teaching points for direction of automatic program creation on back.

46
 2.10.4 Copy teaching points

So far teaching points for 1 path are created. Next step is to copy these teaching points.
Use Create Painting Program (Copy) function. Please refer to the operation manual for details.

1 Add groups under Work1 to use copy function. Right-click [Workpiece 1].
Menu is displayed.

2 Click [Add] - [Group] from menu.

Group 1 is created under workpiece 1.

3 Select TP1 then select TP7 while pushing shift key. Left-click TP7 while pushing shift key, drag and drop
on group 1.

4 Select copy function from right task panel. Click [ ] icon.

Copy function is displayed.

47
 Input as follows in setting section of teaching point automatic creation.
The name of currently selected robot on layout is displayed.
When group is selected, default program name is automatically input as “group name_copy.”
With group reference, select group 1 from list box.
The name “group1_copy” is automatically input as program name.
Pitch is 80mm
Repeat 4 times
Select reverse direction. (With reverse direction, teaching points are created by return in second and subsequent path.)

 This function creates not only teaching points but also programs. Please utilize the function.

5 Click [Creation] button.

Group 1 copy will be created underneath the project in the layout.

6 Left-double-click [Group 1_copy] and display position dialogue box.

48
 Move toward world Z positive direction and adjust painting position.

7 Drag created [Group 1_copy] and drop under workpiece 1.

When workpiece moves, teaching points also move.

8 Click teaching points 8 - 31 and confirm that robot can take postures.

 In case robot cannot take postures, move teaching points as follows in order to take postures.

49
 Move teaching points 20 and 31 100mm toward X negative direction. Move teaching points 25 and 26 100mm
toward X positive direction.

9 Repeat 1 - 8 procedure and create teaching points on back by automatic program creation.

50
 2.11 Creating teaching programs
This chapter explains how to create teaching programs.
Teaching program is divided into two main groups: move instruction and subsidiary instruction. Move instruction is
created based on previously created teaching positions.

2.11.1 Creating move instructions

Create new programs on program dialogue box.

1 Right-click [Controller node] and click [Add] - [Program].

Program node is created under controller and named Pg001.

2 Click program name. Edit it to Pg1 ().

 Use interface panel to operate paint package cell. Program names are Pg1 -Pg999 that can use in
program selection of interface. Please be careful since Pg001 is invalid.

3 Drag and drop all teaching points in group 1_copy and create linear interpolation move instruction.
Confirm following things in advance.

★ Whether linear interpolation move instruction is possible by drag and drop.

★ J7, J8 axis value as of drop is reflected. J7 is -180deg, J8 is surface 0deg, back and top is 180deg.
★ Program node on program dialogue box of drop destination is visible.

4 Right-click [Root node] of program. Click [Setting].

Setting dialogue box is displayed.

51
5 Select motion instruction from D&D additional setting and select “LMOVE”
Fix by [Apply] button.

6 Click on “Cancel”.
Settings dialog will close.

7 Left click TP8 of group 1_copy and select TP31 while pushing shift key.
All teaching points are selected.

8 Drag TP31 while pushing shift key, and drop on program node on program dialogue box.
+mark is displayed by putting mouse cursor on program name, then get off of mouse button there.

52
 Linear move instruction of explosion-proof painting instruction is created. Make sure that J7 and J8 axis values are
filled in after 6 axis instruction.

9 Left-click move instruction.

Robot jumps to that posture.

10 Push down arrow key of keyboard from selected move instruction(also called as STEP).
By transferring to the next move instruction, it jumps to that move destination. By moving lines with up and down
key, robot takes appointed posture.

11 Repeat 5 - 9 procedures and add linear move instruction from teaching points on back and top.
Set J8 axis value to be 180deg with teaching panel.

Create save point

Here, register postures with following converted values. Set J8 to rotate when move to save point.
X Y Z O A T Jt7 Jt8
280 500 -650 90 90 -90 -180 180

1 Select Program instruction tab from task panel on K-ROSET dialogue box.

53
 Click initial step of move instruction for back painting on program.
Move instruction tab is automatically selected as Program instruction tab. Position and posture of selected move
instruction are displayed.

2 Click [Save teaching point] on layout.

Robot posture moves to save position.

3 Click [Current value] button on Program instruction tab.

Converted value is set as current robot posture.

4 Confirm converted value and click [Insert] button.

Instruction is inserted in previous line.

Create home position.

Here, record following each axis posture. Make sure that J7,J8 axis value to be 0.
Jt1 Jt2 Jt3 Jt4 Jt5 Jt6 Jt7 Jt8
0 0 -90 0 -90 0 0 0

1 Select Program instruction tab from task panel on K-ROSET dialogue box.
Click initial move instruction in program.
Move instruction tab is automatically selected as Program instruction tab. Position and posture of selected move
instruction is displayed.

54
2 Make move instruction of Program instruction tab to be axis interpolation motion.
Each axis posture of that position is displayed.

3 Click [Home teaching point] on layout.

Robot posture moves to Home position.

4 Click [Current value] button on Program instruction tab.

Each axis value is set as current robot posture.

5 Confirm each axis value and click [Insert] button.

Instruction is inserted in previous line.

6 Add instruction also to the end of move program.

Add in condition of table rotating once.

7 Select initial each axis instruction and right-click. Click [Edit] then [Copy] from menu.
Instruction is copied.

8 Right-click the bottom line of move instruction of this program. Click [Edit] then [Paste] on menu.
Each axis instruction is copied on the bottom line.

55
 Creation of move instruction is completed.

2.11.2 Creating motion instructions

This chapter explains how to add instructions concerning speed and table motion.

Input table instructions

With Program instruction tab, add table instruction after each axis instruction of program.

1 Click second line of Pg 1 on program dialogue box.

Move instruction tab is automatically selected on painting instruction dialogue box.

2 Select table instruction tab on painting instruction dialogue box.

3 Select table synchronous start and click [Insert] button.

Table synchronous start instruction is inserted.

4 Click each axis move instruction at the bottom line.

Move instruction tab is selected as painting instruction.

5 Select table instruction tab and select table synchronous stop instruction. Click [insert] button.
Table synchronous stop instruction is inserted in previous line of each axis move instruction.

Input speed, smooth instructions

1 Click each axis move instruction of the top line.

Move instruction tab is selected as painting instruction.

2 Select speed instruction tab and select air cut tip speed. Input 800 and click [insert] button.
Air cut tip speed instruction is inserted.

56
3 Select speed instruction tab and select painting tip speed. Input 900 and click [Insert] button.
Painting tip speed instruction is inserted.

4 Select speed instruction tab and select air cut each axis speed Input 100 and click [Insert] button.
Air cut each axis speed instruction is inserted.

5 Select smooth/time instruction tab on painting instruction dialogue box and select smooth range. Input
30 and click [Insert] button.
Smooth range instruction is inserted.

Inputting motion instruction is completed.

2.11.3 Adding painting instruction

After creating move instructions, add painting relative instructions.

Input spray instruction

1 Click move step where start painting on program dialogue box Pg1.
Move instruction tab is automatically selected on painting instruction dialogue box.

2 Select spray instruction tab on painting instruction dialogue box.

3 Select spray and input 1 in spray number section. Select ON in signal section. Click [Insert] button.
Spray ON instruction is inserted in previous line of move instruction where start spraying.

57
 Spray instruction needs to be inserted after move instruction to be performed.

4 Drag line of spray number 1 ON instruction and move mouse cursor to after move instruction where
start spraying, and then drop.
When move mouse cursor while dragging, black line is displayed between the lines. This shows line space of drop.

After drag and drop

5 On Pg 1 of program dialogue box, click move instruction followed by painting stop move instruction.
Move instruction tab is automatically selected on painting instruction dialogue box.

6 Select spray instruction tab on painting instruction dialogue box.

7 Select spray and input 1 in spray number section. Select OFF in signal section. Click [Insert] button.
Spray OFF instruction is inserted after move instruction line where stop spraying.

58
  With this operation, spray instruction is inserted after move instruction line to stop. There is no need to
transfer instruction line.

Input painting condition instruction

Input flow rate, high voltage instruction

1 Click initial Pg 1 on program dialogue box.

2 Select spray precedence/delay instruction tab on painting instruction dialogue box.

3 Select flow rate and input 1. Click [Insert] button.

Flow rate 1 instruction is inserted at the top.

4 Select high voltage and input 1. Click [Insert] button.

High voltage 1 instruction is inserted at the top.

Instruction insert of painting condition is completed.

Simulate program and display painting track.

59
 2.12 Simulation
This chapter explains how to run project while displaying painting track with virtual teach pendant.

2.12.1 Setting action functions

This chapter explains how to attach painting track that displays accordingly spray ON/OFF instruction to workpiece.
By attaching, workpiece rotates with table move.

1 Confirm mark is filled in action on plug-in setting dialogue box.

OK if this function is valid.

2 Start action. Click plug-in action on main menu.

Action dialogue box is displayed.

3 Select painting line (workpiece) drawing from function list. Click [Add] button.

60
 Painting line setting dialogue box is displayed.

4 Select object robot and object workpiece to be painted and click [OK] button.

Item set in painting line setting is added. Painting line is created under object workpiece on layout.

61
5 Click [Cancel] button.
Action dialog will close.

2.12.2 Registration of robot home position

This chapter explains how to register reply starting position when rewound at simulation.

1 Click each axis move instruction on the top of Pg1 on program dialogue box.
Robot jumps to posture of appointed step position.

2 Right-click [1HOME] on teaching panel and click [Menu setting].

Home setting dialogue box is displayed.

3 Select robot on home setting dialogue box and select 1HOME and click [Current Joint] button then click
[Apply] button.
Each axis value of robot is loaded and this position is registered.

62
 Click [close] button to close dialogue box.

2.12.3 Forwarding program

This chapter explains how to forward created program to controller.

1 Display program dialogue.

Program dialog will appear.

2 Right-click object program name then click [Load].

The selected program will be transferred to the virtual robot controller.

2.12.4 Various setting of playback

So far, preparation for playback is completed. K-ROSET has several animation effects when playing back. Confirm
setting of each effect here.
Effects are setting of playback speed, painting path display, painting pattern ON/OFF, cycle time and collision check.

63
 2.12.4.1 Playback speed

Confirm playback speed.

1 Click pendant display on controller dialogue box.

Display virtual teaching pendant.

Make sure repeat speed to be 100%

To make it 100%, click gauge of repeat speed and set on speed designation dialogue box.

2.12.4.2 Painting path display

Path can be displayed at tool tip while playing back.

1 Confirm mark is filled in painting simulation on plug-in setting dialogue box.

OK if this function is valid.

2.12.4.3 Display painting pattern ON/OFF

While playing back, added painting pattern can be displayed/non-displayed at tool tip in conjunction with spray
ON/OFF signal.

1 Confirm mark is filled in painting simulation on plug-in setting dialogue box.

64
2 Confirm pattern is attached to loaded tool.

2.12.4.4 Cycle time display

Display cycle time when complete playback.

1 Confirm mark is filled in cycle time on plug-in setting dialogue box.

2 Confirm check mark is filled in [Show Cycle Time when Simulation stops] on quick setting on controller
dialogue box.

Cycle time is not displayed with blank check box.

2.12.4.5 Collision check display

Collision result is displayed in case set collision pair model collides when playing back.

65
 Also, it is possible to stop playback at collision point.

1 Confirm check mark is filled in [collision check] on plug-in setting dialogue box.
Check mark in collision log if you would like to display collision log.

2 Confirm check mark is filled in [Enable collision detection] on quick setting on controller dialogue box.

Collision is not checked with blank check box.

 Every time change and reflect check mark status, click apply button at right side of that dialogue box.

3 In order to stop robot at the time of collision, confirm check mark is filled in [Stop the robot when
collision is detected] on quick setting on controller dialogue box.

 With this setting valid and if robot stops due to collision, it cannot be resumed.

66
 2.12.5 Playback

Operate program using virtual teaching pendant.

1 Click pendant display on controller dialogue box.

Virtual teaching pendant is displayed.

2 Confirm primed program of teaching pendant is zmain.

In case of conjunction, robot starts operation with selected program after arm rotates 180deg. Use simulation dialogue
box to pause or resume.

Set as follows if program is not zmain.

67
 Click program box and select [List Select zmain by and on panel.
display].

3 Click [MTR] button.

Motor power turns ON.

4 Click [CYC] button.

Cycle lamp turns ON.

5 Click operation dialogue box on pendant then click [I/F panel] from menu.
Change it to I/F panel.

->

6 Click program number.

Input program number to be operated with keyboard.
Example) Pg1

->

7 Click [DUET/SOLO].

68
 Set whether rotate arm when operating.

 Default is set as single-acting mode that arm does not rotate.

8 Click [Work Set]

With interlocking mode, robot starts operation of selected program after arm rotates 180deg. Use simulation dialogue
box to pause or resume.

 Internal signal 2505 is allocated for Work Set completed signal. It is possible to start playback with other
signal ON.

Play Pause
Rewind Sto

 Play button cannot be used.

Stop playback temporary with pause button. Resume with replay button.
Terminate with stop button. It is same condition as emergency stop and cannot be resumed. Bring back to default
position with rewind button and click Work Set button of teach pendant.

69
 After playing back, painted sites are displayed with dots. They are painting line that set in action.
By right-click painting line, menu related to painting path is displayed. It is possible to change track dots into lines or
change track color and dot size.
Yellow dots are teaching point group [Pg1] on layout and shows program step positions. As well as painting path,
color and dot size can be changed.

9 Click [emergency stop] button.

Cycle lamp turns off and stops playback.

 Cycle time is not displayed until cycle lamp turns OFF with emergency stop.

Cycle time includes time from turning cycle lamp ON to clicking Work Set, and time from ending program to turning
cycle lamp OFF.
Operation time needs to be calculated as follows.
26.08(Total time till last operation step) - 4.864(Total time till start step) = 21.216[s]

70
71
Memo

72
3 Various setting
This chapter explains frequently used various setting.
For details of robot functions, please refer to robot operation manual.

3.1 Interface panel

This chapter explains about interface panel used in paint package cell.

3.1.1 Manual operation

Take servo tombow controller as an example and operate manually by interface panel of virtual teach pendant.

1 Click [pendant display] on controller dialogue box.

Virtual teach pendant is displayed.

2 Make sure that primed program of teaching pendant is zmain

3 Click [MTR] button

Motor power turns ON.

4 Click [CYC] button

Cycle lamp turns ON.

5 Click operation dialogue box of pendant. Click [I/F panel] on menu.

Change to I/F panel.

6 Click [DUET/SOLO] button.

Select Single-acting mode

7 Click [PANEL OPERATION].

Approve.

8 Operate clicking each button.

73
Arm indexing
Click [ARM INDEXING] then arm is inverted. Arm can be moved only when table indexing lamp is ON.

Table indexing
Every click [TABLE INDEXING] let table rotate from current position and stop by 90degunit.
It can be operated only when arm indexing lamp is ON.

Table consecutive rotation

Table keep rotating with click on [CONT.ROTATION].

Stop rotation
Above three rotations are stop by click [STOP ROTATION].

74
4 FAQ and Troubleshooting

4.1 FAQ and troubleshooting upon operation

This chapter describes FAQ and troubleshooting about user operations.

Q1. Executing simulation of the program with table synchronize instruction does not cause an error, however, model
does not move.
A1. Currently we do not support this trouble. Please note that Kawasaki is not responsible for this operation.

75