KUKA Setup Instructions

This guide shows you how to set up Master-Control communication with a KUKA robot.

Check Controller and Software Compatibility

  • Controller model: KUKA KR C4, C5

  • Controller system software version: KSS 8.2, 8.3, 8.5 or 8.6

  • Add-on software package: Ethernet KRL (V 2.2.8, 3.0.3 or 3.1.2.29)

The correspondence between KSS and Ethernet KRL versions is as follows:

KSS version Ethernet KRL version

8.2 or 8.3

2.2.8

8.5

3.0.3

8.6

3.1.2.29

All teach pendant actions in this chapter are performed on KSS 8.6.

Set up the Network Connection

Connect the Hardware

  • KR C4 Compact: X66 port

    port1
  • Other KR C4 controllers: KLI port

    port2
  • KR C5: XF5 port

    port3

Set the IP Address

  • Switch to expert mode:

    1. Click robot icon, and then select Configuration  User group to enter the log-on interface.

      change mode
    2. Select Expert, enter the password (the default password is kuka), and click Log on.

      login
  • Set the IP address:

    1. Click robot icon, and then select Start-up  Network configuration to enter the network configuration interface.

      ip setting1
    2. Input an IP address in the same subnet as that of the IPC, and then click Save. In the next two pop-up windows, click Yes and OK, respectively.

      ip setting2
      ip setting4
  • Restart the robot to finish setting the IP address:

    1. Click robot icon, and select Shutdown to enter the shutdown interface.

      reboot1
    2. Click Reboot control PC in the shutdown interface.

    reboot2

Load the Program Files to the Robot

Switch to the Expert Mode

Refer to the above subject.

Back up the Robot Program

Make sure you have switched to the expert mode. Otherwise, the flash drive will not show up on the teach pendant.
  1. Plug the flash drive for storing the backup file to the controller, and make sure that the flash drive shows up on the teach pendant.

    backup1
  2. Click robot icon, then select File  Archive  USB (cabinet)  All, and click Yes in the pop-up window.

    backup2
    backup3
    backup4
  3. The following message is displayed when backup is in process. Once the backup is completed, this message disappears, and a ZIP file is created in the flash drive. Lastly, remove the flash drive.

    backup5

Prepare the Files

The program files are stored in the installation directory of Mech-Center.
  1. Navigate to Mech-Center/Robot_Server/Robot_FullControl/kuka/kuka_new from the installation directory of Mech-Mind Software Suite, and copy and paste all the program files to your flash drive.

    copy file
    Make sure you have switched to the expert mode. Otherwise, the flash drive will not show up on the teach pendant.
  2. Plug the flash drive to the controller. Click the flash drive on the left side, and locate the folder which contains the program files.

    copy file1
  3. Select the mm_motion file, click Edit, and then click Copy in the pop-up menu bar.

    copy file2
  4. Navigate to C:\\KRC\\ROBOTER\\Config\\User\\Common\\EthernetKRL,click Edit, and then select Paste in the pop-up menu bar. Repeat the above operation to copy the mm_status file to the target folder.

    copy file3
  5. Refer to the above procedures to copy and paste the other five files to the mechmind folder in the R1 folder (Create one if there is no mechmind folder).

    Long-press and drag to select multiple adjacent files.

    Create the mechmind folder:

    Click the R1 folder, and then click New.

    copy file4

    Input mechmind for the folder name, and click OK.

    copy file5
    copy file6

Select Program

Set Autostart for Background Program

Switch to the expert mode referring to the above subject.

  1. Click S on the teach pendant and then click Display/Assign.

    select program1
  2. Click Cold start configuration to jump to the Cold start configuration interface.

    select program2
  3. Click the blank in the drop-down menu on the right of SYS.

    select program3 1
  4. Then, clear the Autostart checkbox on the right of SYS.

    select program3 2
  5. Similarly, select mm_server in the drop-down menu for EX1, and make sure Autostart is checked.

    select program4
  6. Click Current display/assignment to jump to the current display/assignment interface. Click the text box to the right of SYS, and then click Deselect.

    select program5
  7. Click the text box to the right of SYS again, and select the blank in the drop-down menu.

    select program5 1
  8. Similarly, select mm_server from the drop-down menu for EX1, and click Select/Start.

    select program6

Select Foreground Program

Open the mechmind folder, select mainmodule.src, and then click Select.

select program7
select program8

Run Program in the AUT Mode

  1. How to switch the mode: Turn the key switch to horizontal, select T1 or AUT in the pop-up dialog box on the screen, and then turn the switch back to vertical.

    change aut1
  2. Switch to the T1 mode following the above step. Click O, and click I in the pop-up window to switch the status of Drives. If the status of Drives is I at the start, ignore this step.

    change aut3
  3. Set an appropriate velocity for the robot before moving it, and observe its motion carefully to avoid accidents. Press the enabling switch (either one of three) on the back of the pendant and the green start button on the front at the same time to move the robot back to the Home position. When the screen displays a message saying Programmed path reached (BCO), release the enabling switch and the green start button.

    change aut4
    change aut5
  4. Switch to AUT mode as described in the above step, and press the start button to run the master-control program (the R icon should turn green).

    change aut6
    If you failed to master control the robot but can successfully ping the robot IP on the IPC, please restart Mech-Center.

Test Robot Connection

Please refer to Test Robot Connection.

Fix Disconnection

The robot will automatically try to reconnect with Mech-Center if the connection is lost. If the reconnection fails, you can try the following steps to restart the program:

Click S, select mm_server from the drop-down menu, click Deselect, and click Select/Start. If an error message pops up, click Confirm all. After restarting the program, repeat the “Run Program in the AUT Mode” steps.

connect fail

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