BendTechV1.1 en

SOFTWARE
KR C...
BendTech V1.1
KUKA System Tech (KST)
Issued: 16 May 2003
Version: 00
BendTechV1.1KST 05.03.00 en
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e Copyright
KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.
PD Interleaf
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Contents
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
Basic plate handling sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Installing the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
Uninstalling the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
3.1.1
3.1.1.1
3.1.1.2
3.1.1.3
3.1.1.4
BendTech Configuration Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the configurator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modifying variable values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Save data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closing the configurator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
10
10
11
11
3.2
I/O interface assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
3.3
Setting up the double plate measurement sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
3.4
Base calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
3.5
TCP calibration for vacuum gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
3.6
User--defined grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
3.7
Plate parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
3.8
Get stack station parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
3.9
Put stack station parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
3.10
Palletizing pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
3.11
Synchronous robot/press motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.4.1
4.1.4.2
4.1.5
4.1.5.1
4.1.5.2
4.1.6
4.1.6.1
4.1.6.2
4.1.6.3
Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter list for setdown offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter list for pick--up offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
APPROACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bending point parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter list APDAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
38
40
43
44
45
45
47
47
48
50
50
52
53
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BendTech V1.1
4.1.7
4.1.8
4.1.8.1
4.1.8.2
4.1.9
LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bending point parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter list for repositioning in the press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
56
56
57
60
4.2
Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
4.3
4.3.1
4.3.2
Example program Palletize.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
67
68
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
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Introduction
Introduction
The (add--on) software module BendTech enables you to control the robot to load and
unload metal sheets or plates in press brakes and seam bending machines.
The computer link between the robot and the bending machine is implemented using an
electrical interface. The module provides a large range of additional inline forms for
convenient programming by the user.
1.1
Basic plate handling sequence

The basic layout of a complete system for the automatic forming of metal plates is illustrated
in the following diagram. The robot takes the unworked blanks directly from a pallet, places
them first in a centering station and then loads them directly into the press. Once forming
has been completed, the robot removes the plates from the press and palletizes them directly
onto a put stack.
The blanks are always handled according to the same basic sequence:
1. Take plate from get stack (GET)
2. Double plate check (CHECK)
3. Center blank plate on centering table (CENTER)
4. Load into press (APPROACH)
5. Bend (BEND)
6. Optional repositioning, only if next bend on same side of plate. Steps 7 and 4 are then no
longer carried out. (REPOSITION)
7. Remove from press (LIFT)
8. Repeat steps 4 to 7 for further bending sequences
9. Palletization of finished part on a stack (PUT)
The commands required for each step are available in BENDTech as prepared inline forms:
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BendTech V1.1
1. 2. 3.
LIFT
REPOSITION
Bend
Schematic representation of the press mechanism:
Press
Press at top
dead--center
position (TDC)
Safety point
(mute point)
Angle
Circular robot
motion
Stop with switches

Base of press
Gripper
Press at clamp point
Press at bottom dead-center position (BDC)
Die opening
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1.2
Introduction (continued)
Safety instructions
The system may only be operated, maintained and repaired by personnel qualified
to do so and specially trained for work on this system.
When operating or working on this system, the safety instructions in the chapter
[Safety] of the robot documentation and the safety instructions issued by the
bending press manufacturer must be observed!
Any injury to persons or damage to equipment resulting from the non--observance
of general safety instructions and/or instructions contained within this
documentation releases the manufacturer from his warranty obligations.
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BendTech V1.1
Installation
2.1
Installation requirements
The BendTech software can be run on KR C1/C2 robot controllers (KUKA System
Software KSS 4.1).
2.2
Installing the software

This software is installed from an installation CD. Place the CD in the CD--ROM drive of the
KRC controller and start the program d:\Setup.exe. All the necessary steps for installing
BENDTech are carried out automatically.
Once the software has been installed successfully, the KCP menu Technology contains
the new menu item BENDTech and its associated commands.
2.3
Uninstalling the software

To uninstall the technology package, run the program uninstall.exe which has the
following path C:\KRC_OPTION\Bendtech\Uninst.
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Configuration
Configuration
Correct configuration of all the relevant parameters is a precondition for the correct and safe
operation of BendTech.
3.1
BendTech Configuration Editor

All the required entries are made using the supplied Configuration Editor (configurator),
which is started via the Setup menu.
When the configurator is started, a startup screen appears briefly, followed by the input
masks.
3.1.1
Operating the configurator

The configurator provides a convenient interface for viewing/editing all the variables, which
are grouped together on eight tab cards:
-- Inputs/Outputs (I/O interface)*
-- Sensor (sensors for double plate measurement)*
-- Base--Conf. (base calibration)*
-- Gripper (TCP calibration for vacuum gripper)*
-- Plate param. (blank parameters)
-- Stations (Put stack/Get stack stations)*
-- Pal. pattern (palletizing pattern)*
-- MADA (machine data)*
(* These variables can only be edited in Expert mode)
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BendTech V1.1
Comment area
3.1.1.1
Modifying variable values

The configuration screens are only fully available in Expert mode on the KRC level.
In User mode, the tab cards marked * can only be viewed and not edited. The only
exception here is made for the plate parameters. Any associated comments,
however, will still be displayed in the comment line.
To modify a variable, activate the relevant tab card, move the yellow insertion mark to the
desired position using the arrow keys, then press the softkey Change. You can now enter
a new value and terminate the entry by pressing Enter.
If the insertion mark is positioned on a variable, the variable is displayed in the comment area
along with all the possible input options. This comment is not displayed during editing.
3.1.1.2
Save data set

Once all the variables have been modified accordingly, they must be saved. This is done by
pressing the softkey Save:
Saves data in
$config.dat
Opens a selection
window and exports
data to any storage
medium
Modifications to data carried out in the configurator do not take effect until they have been
saved to the $config.dat file by pressing the softkey SAVE.
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3
3.1.1.3
Configuration (continued)
Load data set

Variable data sets that have previously been exported can be loaded from various storage
media. This is done by pressing the softkey LOAD and selecting the relevant file path.
3.1.1.4
Closing the configurator

To close the configurator, press the softkey Exit. The program window is closed following
an affirmative response to a request for confirmation.
BendTech will not work with the new variable values until the changes have been
saved and the configurator has been closed.
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BendTech V1.1
3.2
I/O interface assignment

The KRC robot controller communicates with the other system components via the digital
interface. For this purpose, the configurator contains the tab card Inputs/Outputs, which
consists of the two forms Inputs and Outputs:
Configuration of the inputs:
Configuration of the outputs:
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Gripper:
Inputs (gripper --> robot)
The robot gripper must be equipped with at least one part detection sensor (vacuum
or proximity switch) and one sensor for locating parts (proximity switch, ultrasound
switch, laser switch). The robot gripper can additionally be assigned a hardware code
to prevent the wrong gripper being used for the program.
Up to four vacuum or proximity switches for part detection and a maximum of two
sensors for locating parts can be monitored on the robot gripper. The number of part
detection sensors used can be selected in the gripper structure (see also Section 3.5).
If only one sensor is used for locating parts, the signal declarations for
I_NO_PART_DETECTED1 and I_NO_PART_DETECTED2 must be configured to the
same input.
I_VACUUM1: vacuum circuit 1: first vacuum circuit or proximity switch actuated
I_VACUUM2: vacuum circuit 2: second vacuum circuit or proximity switch actuated
I_VACUUM3: vacuum circuit 3: third vacuum circuit or proximity switch actuated
I_VACUUM4: vacuum circuit 4: fourth vacuum circuit or proximity switch actuated
I_GRIPPER_CODE: enables the system to check for certain that the correct gripper
is connected
I_NO_PART_DETECTED1: sensor 1 for search function on the gripper
I_NO_PART_DETECTED2: sensor 2 for search function on the gripper
Outputs (robot --> gripper)
Outputs from the robot to the gripper for controlling grippers with vacuum suction cups
or mechanical clamps.
O_NO_VACUUM1: deactivation of vacuum circuit 1
O_BLOW: blow to release part or open gripper
O_SEPARATE_BLOW (BLOW To SEPARATE PART: ROBOT -> GET STACK)
This output is set if the robot moves out of the get stack station and the option
Separate with robot is selected in the inline form GET. This output can be used to
control a compressed--air separator mounted on the get stack station for separating
the blanks.
Press
Inputs (press --> robot)
The inputs from the press to the robot inform the robot of the status of the press, thus
enabling the robot to react accordingly. The robot uses the switch inputs to search for
the correct position to which to move when positioning the plate against the stops. Up
to four switch inputs can be configured with the signal declarations I_SWITCH_1 to
I_SWITCH_4. The first switch on the left--hand side of the press must be assigned to
the input for switch 1.
I_SWITCH_1: switch 1, plate against stop (far left--hand side of press)
I_SWITCH_2: switch 2, plate against stop (second switch from left)
I_SWITCH_3: switch 3, plate against stop (third switch from left)
I_SWITCH_4: switch 4, plate against stop (fourth switch from left)
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BendTech V1.1
I_PUT_PLATE: press ready: press requests a plate
I_PRESS_CLAMP_POINT: press has reached clamp point
I_PRESS_MUTE_POINT: press has reached mute point
I_PRESS_TDC: press at top dead--center position
I_PRESS_BDC: press at bottom dead--center position
Outputs (robot --> press)
The robot uses the outputs from the robot to the press to control the press.
O_PRESS_DOWN: move the press down
O_PRESS_UP: move the press up
O_RELEASE_MUTE_POINT: release mute point
O_RELEASE_CLAMP_POINT: release clamp point
O_OUT_OF_PRESS: move robot away from press, motion enable from robot to press
(must be implemented manually in the program)
O_NO_ALARM_STOP: no robot fault during bending motion
Sensor for double plate measurement
Double plate measurement can be carried out using a sensor with an analog or digital
output. The analog or digital value measured at the robot input is converted to a plate
thickness in millimeters (see also Section 3.2). Sensor settings are made in the tab
card Sensor, which consists of the two screens analog and digital:
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I_THICK_SENSOR_MEASURED signals to the robot that a valid measured value is

present at the sensor.
I_THICK_SENSOR_VALUE:
analog or digital input for double plate measurement

sensor
Outputs (robot --> sensor)

The output O_START_MEASUREMENT is used to start a double plate measurement.
Selection of the sensor type
Selection analog
The number of the configured analog input channel

(iosys.ini) is entered under TAddress.
Selection digital
The input number of the first bit of the input range

occupied by the sensor is entered under Start and
the input number of the last bit is entered under
End.
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The following table lists all the signals used.
Digital input
Signal declaration
SIGNAL I_VACUUM1 $IN[1]
SIGNAL I_NO_PART_DETECTED1 $IN[5]
SIGNAL I_NO_PART_DETECTED2 $IN[6]
SIGNAL I_THICK_SENSOR_CLOSED $IN[7]
SIGNAL I_SWITCH_1 $IN[8]
10
11
12
SIGNAL I_PUT_PLATE $IN[12]
13
SIGNAL I_PRESS_CLAMP_POINT $IN[13]
14
SIGNAL I_PRESS_MUTE_POINT $IN[14]
15
SIGNAL I_PRESS_TDC $IN[15]
16
SIGNAL I_PRESS_BDC $IN[16]
17 -- 24
SIGNAL I_GRIPPER_CODE $IN[17] TO $IN[24]
Analog input
Signal declaration
SIGNAL I_THICK_SENSOR_VALUE $ANIN[1]
Digital output
Signal declaration
SIGNAL O_NO_VACUUM1 $OUT[1]
SIGNAL O_OUT_OF_PRESS $OUT[5]
SIGNAL O_PRESS_DOWN $OUT[6]
SIGNAL O_RELEASE_MUTE_POINT $OUT[7]
SIGNAL O_PRESS_UP $OUT[8]
9
10
11
SIGNAL O_RELEASE_CLAMP_POINT $OUT[11]
12
13
SIGNAL O_SEPARATE_BLOW $OUT[13]
14
SIGNAL O_BLOW $OUT[14]
15
SIGNAL O_CLOSE_THICK_SENSOR $OUT[15]
16
SIGNAL O_NO_ALARM_STOP $OUT[16]
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Description of the exchange of signals between the robot and the press:
The press is at the top dead--center position TDC (I_PRESS_TDC=TRUE) and prompts the
robot to load a blank (I_PUT_PLATE=TRUE). The robot now loads the blank into the press,
using the APPROACH command, and sets the output O_OUT_OF_PRESS=FALSE. When the
plate is several centimeters away from the backstops, a one second pulse is generated at
the output O_PRESS_DOWN and the outputs O_RELEASE_MUTE_POINT=FALSE and
O_RELEASE_CLAMP_POINT=FALSE are set at the same time. The press may then be
lowered to the mute point.
With the BEND command, a check is made to see if the backstops have been reached. If
the selected backstops have not been actuated, the robot searches for the backstops using
relative motions. If the backstops are not found, an error message is generated. If the
backstops have been actuated, the robot sets the outputs O_RELEASE_MUTE_POINT=TRUE
and O_RELEASE_CLAMP_POINT=TRUE. The press may then be lowered to the clamp point.
At the clamp point, the robot withdraws the motion enable from the press by setting the output
O_PRESS_DOWN=FALSE. The robot enables the press to pass the clamp point by means of
O_RELEASE_CLAMP_POINT=TRUE and starts the press motion by means of
O_PRESS_DOWN=TRUE. Using the input I_PRESS_BDC=TRUE, the press signals that it has
reached the bottom dead--center position. The robot stops the downward motion of the press
using the output O_PRESS_DOWN=FALSE. The motion enable for the mute point
O_RELEASE_MUTE_POINT=FALSE and the clamp point O_RELEASE_CLAMP_POINT=FALSE
are reset and the press is moved upwards by means of the output O_PRESS_UP=TRUE (one
second pulse). The robot now removes the plate from the press and sets the output
O_OUT_OF_PRESS=TRUE. This signals to the press controller that the next bending
operation can be carried out.
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BendTech V1.1
3.3
Setting up the double plate measurement sensor

Calculation of the plate thickness dependent on the sensor parameters is carried out
internally in the system using the following formula:
PLATE_THICKNESS[MM]=(BT_CHECK_FACTOR * ANALOG_SENSOR_VALUE) - BT_CHECK_OFFSET
Analog or digital sensors can be used for double plate measurement!
See also Section 3.2!
--Signal declaration for the analog sensor input:

SIGNAL I_THICK_SENSOR_VALUE $ANIN[1]
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--Signal declaration for the digital sensor input:

SIGNAL I_THICK_SENSOR_VALUE $IN[37] TO $IN[53]
--Variables for sensor parameters:

BT_CHECK_OFFSET contains the value for the sensor--specific offset which describes the
linear relationship between the sensor value and the actual plate thickness when the plate
thickness is measured.
REAL BT_CHECK_OFFSET=0.4682768
Calculation of BT_CHECK_OFFSET:
To calculate the sensor--specific offset, the sensor carries out a measurement without a
plate. The measured value displayed corresponds to the sensor offset and must be entered
under BT_CHECK_OFFSET.
BT_CHECK_FACTOR contains the value for the sensor--specific factor which describes the
linear relationship between the sensor value and the actual plate thickness when the plate
thickness is measured.
REAL BT_CHECK_FACTOR = 0.7741751
Calculation of BT_CHECK_FACTOR:
To calculate the sensor--specific factor, a reference plate of known thickness is measured
in the sensor. In order to determine the sensor--specific factor as accurately as possible, it
is advisable to carry out several measurements and calculate their mean value. The
calculated mean value is to be entered under BT_CHECK_FACTOR.
--Variables for program execution:

BT_CHECK_NIO_HALT: The variable BT_CHECK_NIO_HALT is used to define whether or not
the robot program is to be stopped if the sensor signals a fault.
BT_CHECK_NIO_HALT=TRUE: The robot is stopped if the plate thickness measurement is
incorrect.
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BendTech V1.1
If the variable BT_CHECK_NIO_HALT is set to FALSE, the robot is not stopped even in the
event of an incorrect plate thickness measurement. It is possible to react to this in the
application program by polling the variable BT_CHECK_IO. If the variable is set to
BT_CHECK_IO=FALSE, the robot can be programmed, for example, to set the plate down
at an emergency setdown point.
BOOL BT_CHECK_NIO_HALT
BOOL BT_CHECK_IO
Example:
IF NOT BT_CHECK_IO THEN
PTP EM_SETDOWN
;release part
ENDIF
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3.4
Base calibrations
Essentially, the general rules for robot base calibration apply here. Information
about this can be found in the Operating Handbook!
Before the program is put into operation, the bases of the following positions must be
calibrated using the 3--point method:
-- Get stack station
-- Centering station
-- Press
-- Put stack station
For this purpose, the tab card Base--Conf. is available in the configurator:
The following rules are to be observed here:

-- The origin of the base is always situated in a corner
-- The positive Z direction of the base always points upwards, perpendicular to the plate
-- The positive X or Y directions are configured by means of BT_BASE_X_DIRECTION[x]
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BendTech V1.1
Example #LENGTH
Get stack station
X of BASE_DATA[1] is aligned with the long side of the plate:
BT_BASE_X_DIRECTION[1]=#LENGTH
Example #WIDTH
Get stack station
X of BASE_DATA[1] is aligned with the short side of the plate:
BT_BASE_X_DIRECTION[1]=#WIDTH
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Example
Centering station
X of BASE_DATA[1] is aligned with the long side of the plate:
BT_BASE_X_DIRECTION[1]=#LENGTH
Example
Centering station
X of BASE_DATA[1] is aligned with the short side of the plate:
BT_BASE_X_DIRECTION[1]=#WIDTH
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BendTech V1.1
Example
Calibration of the base at the bending press must always be carried out in the following
manner:
-- Origin of the base is situated on the bending line
-- Positive X direction points from right to left, along the bending line
-- Positive Y direction points out from the bending press
-- Positive Z direction points upwards
BT_BASE_X_DIRECTION=#NONE
BT_BASE_X_DIRECTION has no effect on the base of the bending press!
Example
Definition of the setdown points within a put stack station: BT_BASE_X_DIRECTION
has no effect on the bases of the put stacks!
BT_BASE_X_DIRECTION[x]=#NONE
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3.5
TCP calibration for vacuum gripper

Essentially, the general rules for robot tool calibration apply here. Information
about this can be found in the Operating Handbook!
Coordinate system and calibration of the vacuum gripper:
When setting up BendTech, the TCP of the vacuum gripper is to be calibrated as follows:
If you are using the calibration methods XYZ 4 Point and XYZ Reference:
--The TCP is situated exactly in the center of the suction gripper or plate.
If you are using the calibration methods ABC 2 Point and ABC WORLD:
--The positive Z axis points to the robot wrist (upwards).
--The positive Y axis is calibrated along the short side of the plate.
--The positive X axis is calibrated along the long side of the plate.
The load data for the calibrated suction grippers must be determined under load.
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BendTech V1.1
3.6
User--defined grippers
There is no limit to the number of user--defined grippers that can be used.
This technology package uses exclusively user--defined grippers for the entire
program sequence. When the command INIT is executed, the selected user-defined gripper is always written to TOOL_DATA[1] internally in the system.
The user--defined grippers BT_GRIPPER_DATA[..] are also configured in the tab card
Gripper.
The softkey New is used to insert a new user--defined gripper at the end of the table.
Variable
Meaning
NAME
Name of the user--defined gripper (max. 24 characters)
GRP_TOOL
Tool data of the gripper
GRP_LOAD
Load data of the gripper:

--M --1 weight
The mass of the gripper with a
plate is to be entered for M. If this value is set to --1, the
default values for the mass, center of gravity and
inertia for the corresponding robot type are used.
--CM{X 0.0, Y 0.0, Z 0.0, a 0.0, b 0.0, c 0.0} -- center of
gravity. The center of gravity of the gripper with a plate
is to be entered for CM.
--J{X 0.0, Y 0.0, Z 0.0} -- moments of inertia. The
moment of inertia with a plate is to be entered for J. The
moments of inertia can be calculated mathematically or
dynamically using the load data determination functions.
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VAC_CIRCUIT
Vacuum circuit to be controlled:

#C1
Vacuum circuit 1
#C2
Vacuum circuit 2
#C3
Vacuum circuit 3
#C4
Vacuum circuit 4
#C12
Vacuum circuits 1 and 2
#C13
#C14
#C123
Vacuum circuits 1 to 3
#C234
Vacuum circuits 2 to 4
#C134
Vacuum circuits 1, 3 and 4
#C124
Vacuum circuits 1, 2 and 4
#C1234
Vacuum circuits 1, 2, 3 and 4
GRP_CODE
Gripper code of the gripper used

(range of values: 0...255)
GRP_CODE=0 Gripper has no hardware code
Configuration procedure:
--The gripper must first be calibrated using the tool calibration functions integrated into the
KR C... software. The required load data must have been determined under load.
-- Select the gripper
-- Select the tool
(These data are saved under GRP_TOOL and GRP_LOAD)
-- Set the vacuum circuit to be controlled (VAC_CIRCUIT)
-- Set the gripper code (GRP_CODE)
Example
BT_GRIPPER_DATA[1]={NAME[ ] DEMO_GRIPPER
, GRP_TOOL {x 0.0,y
0.0,z 190.0, a 0.0, b 180.0, c 0.0}, GRP_LOAD {M -1.0,CM {x 0.0,
y 0.0, z 0.0, a 0.0, b 0.0, c 0.0}, J {X 0.0,Y 0.0,z 0.0}},
VAC_CIRCUIT #C12,GRP_CODE 0}
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BendTech V1.1
3.7
Plate parameters
The parameters for the plates used in production and for the finished parts are configured
in the tab card Plate param.:
The softkey New is used to insert a new data set for the plate parameters at the end
of the table.
Variable
Meaning
NAME
Name of plate, e.g. article number (max. 24 characters)
Raw plate Length
Length of plate (mm)
Raw plate Width
Width of plate (mm)
Raw plate Thickness
Thickness of plate (mm)
Finished part Length
Length of the finished part (mm)
Finished part Width
Width of the finished part (mm)
Finished part Height
Height of the finished part (mm)
Example: Data set for BT_PLATE_DATA[...]

BT_PLATE_DATA[1]={NAME[]Blank_Floor_Tray ,LENGTH 549,WIDTH
465,THICKNESS 0.9,BENT_LENGTH 470,BENT_WIDTH 397,BENT_HEIGHT
35.0}
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3.8
Get stack station parameters

The structure variable BT_GET_STACK_DATA[..] describes the data set properties for a
get stack station. The structure variable BT_GET_STACK_DATA[..] is an array which can
be expanded as required up to the maximum array size defined in MAXGETSTACK. By
default, the value for the array size MAXGETSTACK is set to 10.
The get stack station parameters BT_GET_STACK_DATA[..] are configured in the tab
card Stations (page Get stack):
The softkey New is used to insert a new data set for the get stacks/put stacks at
the end of the table.
Variable
Meaning
NAME
Name of the get stack station (max. 24 characters)
BASE No.
Base index for the get stack station

(e.g. 1 --> BASE_DATA[1] )
Stack Height
Stack height in [mm]
Offset
Offset frame when fetching from the get stack station
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BendTech V1.1
GET_STACK_OFFSET.X=0
GET_STACK_OFFSET.Y=0
GET_STACK_OFFSET.X
GET_STACK_OFFSET.X>0
GET_STACK_OFFSET.Y>0
GET_STACK_OFFSET.Y
Example: Data set for BT_GET_STACK_DATA[...]

BT_GET_STACK_DATA[1]={NAME[]Pickup_position1 ,BASE_NO
1,STACK_HEIGHT 230,SEARCH_COUNTER 2,ACT_STACK_HEIGHT
230,LAST_PICKUP_FRAME {x 273.9766,y 232.0035,z 3.739464,a
-0.00319786,b 0.0003579359,c -0.0008765379},GET_STACK_OFFSET
{x 0.0,y 0.0,z 0.0,a 0.0,b 0.0,c 0.0},STATE_KNOWN FALSE}
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3.9
Put stack station parameters

The parameters for the put stack station are configured in the structure variable
BT_PUT_STACK_DATA[..]. The structure variable BT_PUT_STACK_DATA[..] is an
array which can be expanded as required up to the maximum array size defined in
MAXPUTSTACK. By default, the value for the array size MAXPUTSTACK is set to 10.
The put stack station parameters BT_PUT_STACK_DATA[..] are configured in the tab
card Stations (page Put stack):
The softkey New is used to insert a new data set for the get stacks/put stacks at
the end of the table.
Variable
Meaning
NAME
Name of the put stack station (max. 24 characters)
BASE No.
Base index for the put stack station

(e.g. 1 --> BASE_DATA[1] )
Stack Height
Stack height in [mm]
Offset
Offset frame when setting down the bent parts
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BendTech V1.1
Example: Data set for BT_PUT_STACK_DATA[...]

BT_PUT_STACK_DATA[1]={NAME[ ] Setdown_station1 ,BASE_NO 4,
STACK_HEIGHT 100, ACT_LAYER 1,ACT_CNT_PER_LAYER 1,PUT_STACK_OFFSET {x 0.0, y 0.0, z 0.0, a 0.0, b 0.0, c 0.0},STATE_KNOWN FALSE,
PUT_STACK_FULL FALSE}
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3.10
Palletizing pattern
The parameters for the palletizing pattern are configured in the structure variable
BT_PUT_METHOD_DATA[..]. The structure variable BT_PUT_METHOD_DATA[..] is an
array which can be expanded as required up to the maximum array size defined in MAXPUTMETHOD. By default, the value for the array size MAXPUTMETHOD is set to 10.
The palletizing patterns BT_PUT_METHOD_DATA[..] are configured in the tab card
Pal. pattern:
The softkey New is used to insert a new palletizing pattern at the end of the table.
The setdown positions (max. 6) for the parts are programmed not in this data set,
but in the inline form PUT!
Variable
Meaning
NAME
Name of the palletizing pattern (max. 24 characters)
CNT_PER_LAYER
Number of parts per layer (max. 6)
LAYER_RESET_COUNTER
Number of parts after which offset palletizing is restarted
DEL_X_P1...6
Stack 1...6
Offset in X direction in [mm] relative to BASE of the
put stack station
DEL_Y_P1...6
Stack 1...6
Offset in Y direction in [mm] relative to BASE of the
put stack station
DEL_A_P1...6
Stack 1...6
Rotation relative to previously set down part [degrees]
* The descriptions are also valid for DEL_X_P2 / DEL_Y_P2 / DEL_A_P2, i.e. the offset or
the rotations of the max. 6 stacks can be explicitly configured in a put stack station.
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BendTech V1.1
Y offset
DEL_Y_P1
X offset
DEL_X_P1
Stack 1
Angle offset
DEL_A_P2
Stack 2
Example: Palletizing pattern

BT_PUT_METHOD_DATA[1]={NAME[ ] Demo PUT_METHOD 1 ,
CNT_PER_LAYER 2, LAYER_RESET_COUNTER 2, DEL_X 0, DEL_Y 0, DEL_A
90}
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3.11
Synchronous robot/press motion

The synchronous motion of the robot and press can be influenced using the following
variables. These are configured in the tab card MADA:
In the case of synchronous motions with plate thicknesses in excess of 2.5 mm,
large forces may be generated with a risk of damage to the robot system. In such
cases, the robot must be programmed to move more slowly than the press and the
vacuum must be deactivated.
ROB_RAISE_TIME determines the time in seconds required by the robot to start the motion.
The value of ROB_RAISE_TIME depends on the robot type and controller.
WAIT_HYDRAULIC_ON determines the time in seconds after the start signal from the robot
before the press moves. This delay time is specific to the individual press and is caused by
the hydraulic system. The press is positioned, for example, at the clamp point and is started
by the robot with the signal O_PRESS_DOWN=TRUE. The press does not start its downward
motion, however, until the end of the delay time WAIT_HYDRAULIC_ON. The value of
WAIT_HYDRAULIC_ON depends on the press type and controller.
FACTOR[A,B]
This variable can be used to influence the velocity of the robot during the bending motion.
The velocity at which the robot follows the plate in the bending motion is calculated internally
in the system. If this factor is greater than 1, the robot follows the plate at a lower velocity.
If the factor is equal to 1, the bending motion is carried out at the calculated velocity. If the
factor is less than 1, the bending motion is carried out at a higher velocity. The factor depends
on the width of the die and the bending angle.
Parameter A determines the bending angle range:
A=1 :
A=2 :
0
<
37.5 <
bending angle
bending angle
<
<
37.5
52.5
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BendTech V1.1
A=3
A=4
A=5
A=6
:
:
:
:
52.5
75
105
130
<
<
<
<
bending angle
bending angle
bending angle
bending angle
<
<
<
<
75
105
130
180
Parameter B is calculated from the width of the die according to the following formula:
B = (width of die/2)-2
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Programming
4.1
Commands
Programming
Once the software module has been installed, the Technology menu contains the new
menu item BendTech.
The Technology menu is only available if a program has been opened or selected.
The mode selector switch on the KCP must not be set to EXTERNAL.
The following commands are available:

INIT
Initialize the basic parameters for program execution
GET
Remove a plate from a get stack station
CHECK
Check plate thickness
CENTER
Center a plate in a centering station
APPROACH
Move the plate into the press
BEND
Bend with/without following motion of robot, folding
LIFT
Move the plate out of the press on completion of bending
REPOSITION
Reposition the plate in the press
PUT
Set down the finished part in a put stack station using the palletizing
function
Depending on the individual system, it may be necessary to program safe

positions between the individual working positions. Otherwise, there is a
risk of collisions and serious damage to system components.
Open pulldown menu with all the BENDTech commands:
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BendTech V1.1
Sequence cycle:
The following command cycle is usually used for the complete processing of a plate:
Initialize, get, center
INIT GET CHECK CENTER
First bend
APPROACH BEND
if next bend on same side of plate
REPOSITION* BEND
if next bend on same side of plate
LIFT APPROACH BEND
Set down plate
PUT
(* optional)
4.1.1
INIT
This command sets the basic parameters for subsequent BENDTech commands.
The INIT command carries out the following tasks:
--Reset all outputs to the periphery
--Plate selection and plate parameter check
--Gripper selection and parameter check
--Check whether or not there is still a plate in the gripper at the start of the program (if there
is still a plate in the gripper, this is indicated in the message window. If desired, suction to
the plate is released)
--Plate processing sequence
--Selection of the simulation mode
All BENDTech application programs commence with the INIT command. It is not set
automatically and must be inserted into the KRL program manually.
Checking the basic parameters:

--The gripper selected in the selection box Gripper= must be configured; the configuration
must include tool and load data.
--If a gripper with a coding connector is used, the hardware coding must match the gripper
code of the selected gripper. In the case of a gripper without hardware coding, the gripper
code must be set to 0.
--The values for the plate length/width/thickness may not be less than 0.01.
If an error is detected when checks are carried out, program execution is aborted and a
program RESET is required.
38 of 74
Programming (continued)
Inline form for initialization:
Parameter
Meaning
Plate
Selection: name of the plate (see Section

3.6)
Gripper
Selection: name of the gripper (see Section

3.5)
First bend side
First side to be bent (1...4)
Last bend side
Last side to be bent (1...4)
DryRun
Simulation mode:
TRUE Dry run (without plate pick--up),
selection list for Press signals is
displayed
FALSE Normal run
Press signals
Press signals:
ON
Dry run with press signals
OFF
Dry run without press signals
(selection list is only visible if dry run =
TRUE is set)
Parameter First bend side (1...4)

This parameter is necessary for preprogramming the robot path from the centering table to
the press in vorgabe.src. The side specified in First bend side determines the orientation
of the blank on the centering table and the motion from the centering table to the press. The
value is saved in the global variable BT_FIRST_BEND_SIDE.
Example
PTP BEFORE_CENTERING_TABLE
SWITCH BT_FIRST_SIDE
CASE 1
PTP BEFORE_PRESS_SIDE_1
CASE 2
CASE 3
CASE 4
ENDSWITCH
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BendTech V1.1
Parameter Last bend side (1...4)
This parameter is necessary for preprogramming the robot path from the press to the get
stack station in vorgabe.src. The side specified in Last bend side determines the motion
from the press to the put stack station. The value is saved in the global variable
BT_LAST_SIDE.
Example
SWITCH BT_CASE_SIDE
CASE 1
CASE 2
CASE 3
CASE 4
ENDSWITCH
PTP BEFORE_PUT_STACK_TABLE
4.1.2
GET
The GET command is used to fetch a blank from the get stack station. In the case of the
first blank, a search run is carried out first at reduced velocity. Subsequent plates are fetched
at increased velocity.
This search run is repeated in the event of a system restart (e.g. after an E--STOP
or opening of a safety gate).
--Separator function (optional)
The purpose of this function is to ensure that only one blank at a time is taken from the stack.
As the plates may stick together as a result of suction, the robot is equipped to be able to
40 of 74
separate the plates. Separation of the blanks can be supported by means of separating
brushes, magnets or compressed air at the get stack station. In the case of separating
brushes, the gripper first moves the plate against these brushes (X and Y offset) and then
swivels about the defined spin angle. This releases any plates that may be stuck
underneath.
Parameter
Meaning
from Stack
Selection of name of get stack station

(see Chapter 3)
Vel [m/s]
Velocity at which plates are fetched

(range of values: 0...2 m/s)
Acc [%]
Acceleration for GET procedure

(range of values: 0...100%)
Pal. Mode
Palletizing mode:
TRUE
Palletizing ON
FALSE
Palletizing OFF
In the case of Pal.Mode=TRUE, robot axes
4 and 5 are moved to a defined position
before the GET sequence; in this position,
the robot flange is moved parallel to the
plane of the robot base.
Separate
Separator function, plate separation with

robot
TRUE
ON; input box for GETDAT
is displayed
FALSE
OFF
GETDAT
Name for parameter data set (only visible

with Separate=TRUE)
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BendTech V1.1
This parameter list only appears if the separator function has been activated:
Parameter
Meaning
X--Offset
Offset value X
Range of values: 0...20 mm
Y--Offset
Offset value Y
Range of values: 0...20 mm
Spin Angle []
Specification of spin angle

Range of values: 0...45 degrees
Blank stack coordinate system:
42 of 74
4.1.3
CHECK
In order to ensure that there really is only one blank (and not several!) in the gripper, an
external sensor is used to check the plate thickness (see Section 3.2). The calculated values
are communicated to the robot controller via the configured interface. Permissible deviations
from the setpoint value may be specified in the corresponding inline form.
Inline form for double plate check:
Parameter
Meaning
Tolerance + [mm]
Positive tolerance for plate thickness

(permissible range of values: 0...10 mm)
Tolerance -- [mm]
Negative tolerance for plate thickness

(permissible range of values: 0...10 mm)
Example
Thickness of plate = 1 mm
Tolerance + = 0.2 mm
Tolerance -- = 0.2 mm
Plate thickness in the tolerance range = 0.8 to 1.2 mm
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BendTech V1.1
4.1.4
CENTER
Command and parameters for centering the plate.
To center the blank, the robot places it in the centering station and releases it. The plate drops
into a defined position in the centering station and is then picked up again by the robot. Offset
values can be configured in a parameter list for both the setting down and the subsequent
picking up of the plate.
Centering station coordinate system:
Inline form for the centering function:
Parameter
Meaning
on BASE
Centering station base selection (1...16)
Vel [0...2 m/s]
Centering velocity
(range of values: 0...2 m/s)
Acc [0...100%]
Centering acceleration
(range of values: 0...100 %)
CTDAT
Name of parameter data set
44 of 74
4
4.1.4.1
Parameter list for setdown offset

Parameter
Meaning
X--Offset
X offset for setdown (0...100 mm)
Y--Offset
Y offset for setdown (0...100 mm)
X offset
Y offset
Example
X--Offset = 40 mm
Y--Offset = 40 mm
When the blank is set down, it is dropped onto the centering table with an offset of
40 mm in the X and Y directions relative to the origin of the base.
4.1.4.2
Parameter list for pick--up offset

Parameter
Meaning
X--Offset
X offset for pick--up (0...100 mm)
Y--Offset
Y offset for pick--up (0...100 mm)
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BendTech V1.1
Gripper
X offset
Y offset
Example
X--Offset = 0 mm
Y--Offset = 0 mm
The blank is picked up with the gripper positioned centrally.
Example
X--Offset = 20 mm
Y--Offset = 40 mm
The blank is gripped with a center offset of 20 mm in the X direction and 40 mm in the
Y direction relative to the BASE of the centering table.
46 of 74
4.1.5
APPROACH
This command is used for moving to the press with the parameters defined. The robot loads
the blank into the press.
The bending point at the stops in the press must be programmed first as the starting
position for loading the plate (TouchUp).
Inline form for the approach function:
Bending point
4.1.5.1
Parameter
Meaning
Bending point
Name of the taught position at the stops in

the press
Vel [m/s]
Velocity at which the press is approached

(range of values: 0 to 2 m/s)
Acc [%]
Acceleration when approaching the press

(range of values: 0 to 100%)
APDAT
Bending point parameter list
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BendTech V1.1
4.1.5.2
Parameter
Meaning
Base
BASE of press (1...16)
Parameter list APDAT
Parameter
Meaning
Distance to press [mm]
see diagram
(range of values: 100 to 1000 mm)
Height in press [mm]
see diagram
Height before hard end [mm]
see diagram
Distance to backstops [mm]
see diagram
Backstops position [mm]
see diagram
Press down Delay
Advance time delay* for the Press down

signal
(range of values: --2000 to 0 ms)
* The delay time for the Press down signal can be used to specify the advance time of the
press. The press does not wait until the plate has reached the stops before moving (from the
top dead--center position to the mute point), but a definable length of time earlier.
48 of 74
Distance to
backstops
Distance to press
Bending point
Height before hard end
Backstops position
Height in press
Base of press
Position 1, distance to
press, height in press
press, height before
hard end
backstops, height before
hard end
Position 4, distance
to backstops, plate
positioned on die
Position 5, plate against

stop and on die (bending
point position)
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BendTech V1.1
4.1.6
BEND
4.1.6.1
Normal bending
In the case of normal bending, the plate is bent by the press. Once the corresponding
parameters have been configured, the robot can track the resulting movements of the plate
synchronously. Following the forming operation, the press returns to its starting position and
the press sequence is completed.
Plate is loaded, press

moves down
Under the pressure of the

press, the plate bends
upwards
Parameter
Meaning
Bend
Selection: Normal / FOLD
Matrix Width [mm]
Opening of die
(range of values: 0,0 to 100,0 mm)
Bend Angle [deg]
Bend angle [degrees]

(range of values: 30.0 to 180.0 degrees)
Press Vel [mm/s]
Velocity at which the press moves down

(range of values: 0.0 to 10.0 mm/s)
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Probe
Sensors to be monitored during positioning:

NONE All sensors are ignored
S1
Monitoring: sensor 1
S2
S3
S4
S12
Monitoring: sensors 1 & 2
S23
S34
S123 Monitoring: sensors 1 to 3
Follow
OFF = Robot does not move during the

bending motion. Pick--up position of
the plate must be programmed by
the operator.
With vacuum = Robot moves synchronously
along a circular path with the
vacuum switched on during the
bending motion.
Without vacuum = Robot moves synchro-nously along a circular path with the
vacuum switched off during the
bending motion. On completion of
bending, the vacuum is switched
back on.
BENDDAT
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BendTech V1.1
4.1.6.2
Fold
In folding, a hem that has already been bent is pressed flat.
Parameter
Meaning
Bend
Selection: Normal / FOLD
Probe
Sensors to be monitored during positioning:

NONE All sensors are ignored
S1
S2
S3
S4
S12
S23
S34
Follow
With vacuum = During the folding pro-cedure, the robot holds the
plate in the gripper.
Vacuum is active.
Without vacuum = Robot releases vacuum
on the plate when the press
reaches the clamp point.
Vacuum off.
BENDDAT
52 of 74
4
4.1.6.3
Parameter list
Parameter
Meaning
Base Matrix
BASE of die (1...16)
Regrip
Regrip function*:
TRUE The press stops at the end of the
bending procedure and does not
move back up. Vacuum is switched
off and motion to new gripping
position must be programmed by
operator.
FALSE Press moves up after bending
procedure. Robot keeps hold of the
plate in the gripper, vacuum stays
on.
*Regrip function: With this function it is possible for the robot to grip the plate in a new
position following a bending procedure.
4.1.7
LIFT
On completion of the press procedure, the robot lifts the plate a configured distance out of
the press die. The plate is then removed completely from the die and can be transported
further.
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BendTech V1.1
Parameter
Meaning
Up [mm]
Distance the robot moves upwards

(Z direction relative to the BASE of the
press)
Out [mm]
Distance the robot moves out of the press

(Y direction relative to the BASE of the
press)
(range of values: --50 to 500 mm)
Vel [m/s]
Velocity when moving out of the press

Acc [%]
Acceleration when moving out of the press

Wait for TDC
Wait for the press TDC (top dead--center

position) signal as trigger for starting the
robot motion:
TRUE Motion is started when TDC is
reached.
FALSE Motion is started after the delay
time specified in Wait=. The input
box Wait= is displayed.
Wait
Delay time for the start of the motion when

the press moves upwards.
(range of values: 0 to 10 s)
(input box only visible if
WAIT for TDC=FALSE)
Matrix BASE No.
Selection list for the base of the press

(1...16)
54 of 74
Press procedure complete,

plate can be removed
Out
Up
Out
Up
Out
Up
Plate moves up out of the die

by the distance specified in the
parameter Up
Plate moves out of the press

by the distance specified in
the parameter Out
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BendTech V1.1
4.1.8
REPOSITION
The REPOSITION process makes it possible for the robot to be repositioned according to
defined parameters following the bending procedure. Repositioning is necessary if more
than one bend must be carried out on the same side of the plate.
Bending
point
4.1.8.1
Parameter
Meaning
Bending point
Selection of the name of the bending point

at the stops in the press
Vel [m/s]
Velocity when moving to the bending point

Acc [%]
Acceleration when moving to the bending

point (range of values: 0 to 100%)
REPOSDAT
Bending point parameter list

If the focus in the inline form is placed on the input box for the bending point name, the
parameter list for the selection of the BASE on the press is displayed. The bending point is
programmed using the TouchUp function.
56 of 74
4.1.8.2
Parameter
Meaning
Base
Base of the press (1...16)
Parameter list for repositioning in the press
Bending point
Distance to
backstops
Height before hard end
Stop
Backstops
position
Parameter
Meaning
Height before hard end [mm]
Vertical distance between the top of the die

and the underside of the plate, represents
the intermediate position in the press.
Distance to backstops [mm]
Distance between the stop and the forward

edge of the plate, represents the
intermediate position in the press.
57 of 74
BendTech V1.1
Backstops position [mm]
Distance between the stop and the center

of the die
Press down Delay
The delay time for the Press down signal

can be used to specify the advance time for
the signal. The press starts to move from the
top dead--center position (TDC) before the
plate has been positioned against the stops.
(range of values: --2000 to 0 ms)
58 of 74
First press sequence complete,

press moves up
Plate moves up to Height

before hard end
Circular motion of gripper until

plate horizontal on die
Part moved in as far as

Distance to backstops
Part is lowered onto the die

again
Move to stop, second

press sequence started
59 of 74
BendTech V1.1
4.1.9
PUT
The PUT process transports the finished parts to the put stack station and deposits them
there. Finished parts can be set down in several different put stack stations. For each
individual put stack station, a maximum of six setdown positions can be defined and a
palletizing method (predefined in $config.dat) can be selected.
At the same time, a corresponding softkey bar appears at the bottom of the screen:
The robot is now moved manually to the relevant position where the softkey TouchUp must
be pressed.
Pressing one of the softkeys offered causes a name to be assigned to the setdown position.
In the following example, Position 2 is selected:
A request for confirmation is then generated:
If this is answered by pressing the softkey Yes, the position is saved as a setdown point
(in this example P2).
Parameter
Meaning
on Stack
Selection of name of put stack station

(see Section 3.8)
using put method
Selection of the name of the palletizing

pattern to be used for stacking the finished
parts in the selected palletizing station
(see Section 3.9)
60 of 74
Pal.Mode
Palletizing mode:
TRUE
ON
FALSE
OFF
In the case of Pal.Mode=TRUE, axes 4 and
5 are moved to a defined position before the
GET sequence; in this position, the robot
flange is moved parallel to the plane of the
robot base.
Positions
Point name for the programmed setdown

position. The number of input boxes
displayed depends on the number of parts in
the palletizing pattern (max. 6).
(Variable:
BBT_PUT_METHOD_DATA.CNT_PER_LAYER)
Vel [m/s]
Velocity at which the setdown position is

approached
Acc [%]
Acceleration with which the setdown

position is approached
Coordinate system for a put stack station with four setdown positions:
61 of 74
BendTech V1.1
Stacking examples
Several different setdown variants are illustrated below. Offset values only ever apply
within a stack. If several stacks are to be created, a corresponding number of setdown
positions must be programmed.
--One setdown position / stacking with offset A:
BT_PUT_METHOD_DATA[1].CNT_PER_LAYER=1
BT_PUT_METHOD_DATA[1].LAYER_RESET_COUNTER=3
BT_PUT_METHOD_DATA[1].DEL_X_P1=0 mm
BT_PUT_METHOD_DATA[1].DEL_Y_P1=0 mm
BT_PUT_METHOD_DATA[1].DEL_A_P1=10 degrees
--One setdown position / stacking with offset X and offset Y:
62 of 74
BT_PUT_METHOD_DATA[1].CNT_PER_LAYER=1
BT_PUT_METHOD_DATA[1].LAYER_RESET_COUNTER=3
BT_PUT_METHOD_DATA[1].DEL_X_P1= -10 mm
BT_PUT_METHOD_DATA[1].DEL_Y_P1= +10 mm
--Two setdown positions / stacking with offset X:
BT_PUT_METHOD_DATA[1].CNT_PER_LAYER= 2
BT_PUT_METHOD_DATA[1].LAYER_RESET_COUNTER= 3
BT_PUT_METHOD_DATA[1].DEL_X_P1= -20 mm
BT_PUT_METHOD_DATA[1].DEL_Y_P1= 0 mm
BT_PUT_METHOD_DATA[1].DEL_A_P1= 0 degrees
BT_PUT_METHOD_DATA[1].DEL_X_P2= 0 mm
BT_PUT_METHOD_DATA[1].DEL_Y_P2= 0 mm
BT_PUT_METHOD_DATA[1].DEL_A_P2= -5 degrees
63 of 74
BendTech V1.1
--Three setdown positions / stacking without offset:
BT_PUT_METHOD_DATA[1].CNT_PER_LAYER= 3
BT_PUT_METHOD_DATA[1].LAYER_RESET_COUNTER= 1
64 of 74
4.2
Program example
The following program example illustrates step by step the sequence for a complete bending
cycle.
INI
; Initialization for the bending cycle
INIT Plate= Blank_Floor_Tray Gripper= Demo_Gripper First bend side= 1 Last bend
side= 4 Dry run= TRUE Press signals= OFF
; Move to intermediate position above get stack station
PTP TO_GET_STACK1 CONT Vel=100 % PDAT1 Tool[1]:Tooldata Demo_Gripper
Base[1] Get_Stack
; Fetch blank from the support at Position 1
GET from Stack= Support Position 1 Vel=1.5 m/s, Acc=10 % Pal. Mode= FALSE
Separate= FALSE
; Intermediate positions for the motion into the double plate check station
LIN TO_CHECK1 CONT Vel=2 m/s CPDAT9 Tool[1]:Tooldata Demo_Gripper
Base[1]Get_Stack
LIN TO_CHECK2 CONT Vel=2 m/s CPDAT9 Tool[1]:Tooldata Demo_Gripper
Base[1]Get_Stack
; Double plate check
CHECK Tolerance + = 0.1 mm, Tolerance -- = 0.1 mm
; Intermediate position before the centering station
PTP TO_CENTER1 CONT Vel=100 % PDAT5 Tool[1]:Tooldata Demo_Gripper Base[2]
Centering Base
; Centering of the plate
CENTER on BASE= [2] Centering Base Vel= 1.5 m/s, Acc=100 % CTDAT
; Intermediate position for the motion to the press
PTP TO_PRESS1 CONT Vel=100 % PDAT9 Tool[1]:Tooldata Demo_Gripper Base[2]
Centering Base
; First bend
APPROACH P_BEND1 Vel=1.5 m/s, Acc= 100 % APDAT1
BEND Matrix Width= 6 mm, Bend Angle= 90 [deg], Press Vel= 7 mm/s, Probe= S12
Follow= With vacuum BENDDAT
LIFT Up 10 mm, Out= 100 mm, Vel=1.5 m/s, Acc= 100 % Wait for TDC= TRUE Matrix
BASE No.= [3] Press Base
PTP TO_BEND21 CONT Vel=100 % PDAT10 Tool[1]:Tooldata Demo_Gripper Base[3]
Press Base
; Second bend
Press Base
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BendTech V1.1
; Third bend
Press Base
; Fourth bend
; Intermediate position above put stack station
PTP TO_PUTSTACK1 CONT Vel=100 % PDAT25 Tool[1]:Tooldata Demo_Gripper
Base[4] Put_Base
; Deposit finished part in put stack station
PUT on Stack= Put stack station 1 using put method= Palletizing pattern 1 Pal.
Mode= FALSE Positions=( P_PUT11 ) Vel= 2 m/s, Acc= 100 %
66 of 74
4.3
Example program Palletize.SRC

The PUT command is used to set parts down on a put stack. In order to operate with several
stacks, a command sequence is required.
The following example illustrates the necessary parameters:
NO_OFF_PUT_STACK=2
Number of put stacks you wish to use
PUT_STACK_ORDER[1]=1
The put stack you wish to use first (index of

BT_PUT_STACK_DATA)
The put stack you wish to use second (index of

BT_PUT_STACK_DATA)
METHOD_FOR_STACK_ORDER[1]=1 put method to be used for the first put stack (index
of BT_PUT_METHOD_DATA)
METHOD_FOR_STACK_ORDER[2]=1 put method to be used for the second put stack
(index of BT_PUT_METHOD_DATA)
4.3.1
Example 1
NO_OFF_PUT_STACK=3
METHOD_FOR_STACK_ORDER[1]=1
67 of 74
BendTech V1.1
4.3.2
Example 2
NO_OFF_PUT_STACK=3
68 of 74
;OPTIONS
OPT_PALLETIZE_TWICE=FALSE
The robot sets two parts down, one on top of the

other, opposite ways round. The purpose of this is to
nest the parts inside one another. See the illustration
below:
69 of 74
BendTech V1.1
OPT_PALLETIZE_SYNCHRON=FALSE This option is used to load the stacks simultaneously,
rather than consecutively. See the illustration below:
70 of 74
Troubleshooting
Troubleshooting
The following is a list of possible error messages and how to eliminate them:
Message:
Cause:
Monitoring:
Effect:
Remedy:
Release part on gripper?

There is still a plate in the gripper at the start of the program.
When the inline form INIT is executed.
Robot waits for response from operator.
Answer using the Yes or No softkey and then restart the program.
Message:
Cause:
Wrong gripper code

The wrong gripper is mounted on the robot or the gripper code has been
entered incorrectly in the inline form INIT.
The robot stops.
Mount the correct gripper or set the value of the variable:
BT_GRIPPER_DATA[x].GRP_CODE to 0. Restart program.
Monitoring:
Effect:
Remedy:
Message:
Cause:
Monitoring:
Effect:
Remedy:
Message:
Cause:
Monitoring:
Effect:
Remedy:
Message:
Cause:
Monitoring:
Effect:
Remedy:
Message:
Cause:
Monitoring:
Effect:
Remedy:
Message:
Cause:
Monitoring:
Effect:
Remedy:
Program reset required

A higher--priority error has occurred. The KRL program must therefore
be reset.
The robot stops.
Mount the correct gripper or set the value of the variable:
BT_GRIPPER_DATA[x].GRP_CODE to 0. Then restart program.
Measured plate < 1 mm is too thin
Plate thickness sensor has measured a plate that is too thin.
When the inline form CHECK is executed.
Robot stops (depending on BT_CHECK_NIO_HALT) after
consecutive faulty measurements.
Remove plate from gripper and restart system.
Measured plate > 1 mm is too thick

Plate thickness sensor has measured a plate that is too thick.
Robot stops (depending on BT_CHECK_NIO_HALT) after 3 faulty
measurements.
Remove plate from gripper and restart system.
Double plate check not correct
Plate thickness sensor has registered 3 consecutive
measurements.
Robot stops (depending on BT_CHECK_NIO_HALT).
Remove plate from robot gripper and restart system.
faulty
BT_PLATE_DATA[ ].THICKNESS not entered correctly

Plate Thickness[ ] not entered correctly in the current plate data set.
When Plate Thickness value is read during the sequence.
The robot stops.
Open configuration window and adapt the value Thickness to the
current plate structure.
71 of 74
BendTech V1.1
Message:
Cause:
Monitoring:
Effect:
Remedy:
BT_PLATE_DATA[ ].LENGTH not entered correctly

Plate Length[ ] not entered correctly in the current plate data set.
When Plate Length value is read during the sequence.
The robot stops.
Open configuration window and adapt the value Length to the current
plate structure.
Message:
Cause:
Monitoring:
Effect:
Remedy:
BT_PLATE_DATA[ ].WIDTH not entered correctly

Plate Width[ ] not entered correctly in the current plate data set.
When Plate Width value is read during the sequence.
The robot stops.
Open configuration window and adapt the value Width to the current
plate structure.
Message:
Cause:
Monitoring:
Effect:
Remedy:
BT_GRIPPER_DATA[ ].GRP_TOOL not entered correctly

Tooldata[ ] for the selected tool in the gripper data set not calibrated.
When Tooldata value is read during the sequence.
The robot stops.
Open configuration window and select the correct tool number or
recalibrate the tool.
Message:
Cause:
Base_Data[ ] not measured correctly

Basedata[ ] for the selected base not calibrated, X and Y value of base
are 0 mm.
When Base[ ] is read.
The robot stops.
Recalibrate the base data for the selected base or select a base that has
already been calibrated.
Monitoring:
Effect:
Remedy:
Message:
Cause:
Monitoring:
Effect:
Remedy:
Stamp velocity too high

Press velocity too high (inline form: BEND)
Before the start of the bending motion in the inline form BEND.
Notification message.
Set a lower press velocity in the current BEND inline form.
Message:
Cause:
Monitoring:
Effect:
Remedy:
Wait time hydraulic too short

The value of the variable WAIT_HYDRAULIC_ON is too low.
Before execution of the bending motion in the inline form BEND.
Increase the value of the variable WAIT_HYDRAULIC_ON using the
variable modification function.
Message:
Cause:
Maximum robot velocity not achieved

The robot was not able to reach the calculated velocity during the
bending motion. If this message is displayed frequently, correct the value
of ROB_RAISE_TIME.
After execution of the bending motion in the inline form BEND.
If the robot was not stopped by the operator, the press velocity in the
current BEND inline form must be set to a lower value.
Monitoring:
Effect:
Remedy:
Message:
Cause:
Monitoring:
Effect:
Remedy :
BT_BASE_X_DIRECTION[ ] not entered correctly

The X direction (#LENGTH or #WIDTH) was not entered in
BT_BASE_X_DIRECTION[x] in the $Config.dat file when the base
currently used was calibrated.
When Base[ ] is read.
The robot stops.
Set the value of the variable BT_BASE_X_DIRECTION[x] to #LENGTH
or #WIDTH.
72 of 74
Message:
Cause:
Monitoring:
Effect:
Remedy:
Troubleshooting (continued)
Switch X on press not found

Before the start of the bending motion, a search was made for the defined
switch X on the press, but the switch was not found.
Before the start of the bending procedure.
The robot stops.
Check the switch on the press and, if necessary, correct the position of
the previous Approach motion.
Message:
Cause:
Monitoring:
Effect:
Remedy:
Set robot in operation mode T2

The robot cannot synchronize with the press in operating mode T1.
Before the start of the bending motion.
The robot stops.
Switch the mode selector switch to T2 or simulate this state.
Message:
Cause:
Warning press runs

Notification message warning the operator that the press is moving
upwards.
At the end of the bending motion.
Restart program.
Monitoring:
Effect:
Remedy:
Message:
Cause:
Monitoring:
Effect:
Remedy:
No plate found
When searching for a blank in the GET STACK process, the vacuum
sensors have not found anything.
At the end of the GET STACK process.
The robot stops.
Check blank pallet.
Message:
Cause:
Monitoring:
Effect:
Remedy:
Search sensor on gripper not OK

Search sensors on the robot gripper incorrectly activated.
Before the Get Stack or Put Stack processes.
The robot stops.
Check the search sensors on the gripper.
Message:
Cause:
Monitoring:
Effect:
Remedy:
Vacuum sensor on gripper not OK

Vacuum sensors on the gripper incorrectly activated.
Before the Get Stack process.
The robot stops.
Check the vacuum sensors on the gripper.
Message:
Cause:
No drop--off point found

The search sensors did not respond during drop--off of processed plates
in the put stack.
Before the search motion in the put stack.
The robot stops.
Check the search sensors on the gripper.
Monitoring:
Effect:
Remedy:
Message:
Cause:
Monitoring:
Effect:
Remedy:
PUT_STACK[ ] is full.
The last plate has been set down on the put stack and the stack is now
full.
After PUT process has been executed.
None, notification only.
Empty put stack station and restart robot.
73 of 74
BendTech V1.1
Message:
Cause:
Monitoring:
Effect:
Remedy:
Vacuum lost on gripper

Loss of vacuum during robot motion monitored by interrupt 2.
During motion with plate held in suction gripper.
The robot stops.
Remove plate from gripper and restart system. If you wich to deactivate
this monitoring, set the variable BT_WATCH_PART=FALSE in the INIT
inline form.
Message:
Cause:
Monitoring:
Palletizing mode not active; position A4 not correct

A4 is not in the range +10 to --10 degrees.
During execution of the GET or PUT command if Pal.Mode=TRUE is
set.
A4 must be taught in a position between --10 and +10 degrees before the
GET/PUT command.
Effect:
Remedy:
1
74 of 74
Index
P
Analog input, 16
Palletizing pattern, 33
Part detection, 13
Plate thickness, 18
BT_CHECK_FACTOR, 19
BT_CHECK_IO, 20
BT_CHECK_NIO_HALT, 19
BT_CHECK_OFFSET, 19
Program reset, 71
Put stack, 31
Regrip function, 53
Change, 10
Configuration Editor, 9
Configurator, 9
ROB_RAISE_TIME, 35
Save, 10
Delay, 48
Digital input, 16
Digital output, 16
Double plate measurement, 14
Separator function, 40
Sequence cycle, 38
Setup.exe, 8
Simulation mode, 38
Spin angle, 41
Synchronous motion, 35
Error messages, 71
External sensor, 43
F
FACTOR[A,B], 35
G
Get stack, 29
Gripper code, 71
I
I/O interface, 12
TDC, 54, 58
U
uninstall.exe, 8
V
Vacuum circuit, 27
Vacuum suction cups, 13

KSS 4.1, 8
L
LOAD, 11
WAIT_HYDRAULIC_ON, 35
Index -- i

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SOFTWARE

KUKA System Tech (KST)

Issued: 16 May 2003

KUKA Roboter GmbH

Basic plate handling sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Uninstalling the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BendTech Configuration Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I/O interface assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting up the double plate measurement sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TCP calibration for vacuum gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Get stack station parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Put stack station parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Synchronous robot/press motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Example program Palletize.SRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic plate handling sequence

Schematic representation of the press mechanism:

Stop with switches

Installing the software

Uninstalling the software

BendTech Configuration Editor

Operating the configurator

Modifying variable values

Save data set

Load data set

Closing the configurator

I/O interface assignment

Configuration of the outputs:

I_THICK_SENSOR_MEASURED signals to the robot that a valid measured value is

analog or digital input for double plate measurement

Outputs (robot --> sensor)

The number of the configured analog input channel

The input number of the first bit of the input range

SIGNAL I_VACUUM1 $IN[1]

SIGNAL I_VACUUM2 $IN[2]

SIGNAL I_VACUUM3 $IN[3]

SIGNAL I_VACUUM4 $IN[4]

SIGNAL I_NO_PART_DETECTED1 $IN[5]

SIGNAL I_NO_PART_DETECTED2 $IN[6]

SIGNAL I_THICK_SENSOR_CLOSED $IN[7]

SIGNAL I_SWITCH_1 $IN[8]

SIGNAL I_SWITCH_2 $IN[9]

SIGNAL I_SWITCH_3 $IN[10]

SIGNAL I_SWITCH_4 $IN[11]

SIGNAL I_PUT_PLATE $IN[12]

SIGNAL I_PRESS_CLAMP_POINT $IN[13]

SIGNAL I_PRESS_MUTE_POINT $IN[14]

SIGNAL I_PRESS_TDC $IN[15]

SIGNAL I_PRESS_BDC $IN[16]

SIGNAL I_GRIPPER_CODE $IN[17] TO $IN[24]

SIGNAL I_THICK_SENSOR_VALUE $ANIN[1]

SIGNAL O_NO_VACUUM1 $OUT[1]

SIGNAL O_NO_VACUUM2 $OUT[2]

SIGNAL O_NO_VACUUM3 $OUT[3]

SIGNAL O_NO_VACUUM4 $OUT[4]

SIGNAL O_OUT_OF_PRESS $OUT[5]

SIGNAL O_PRESS_DOWN $OUT[6]

SIGNAL O_RELEASE_MUTE_POINT $OUT[7]

SIGNAL O_PRESS_UP $OUT[8]

SIGNAL O_RELEASE_CLAMP_POINT $OUT[11]

SIGNAL O_SEPARATE_BLOW $OUT[13]

SIGNAL O_BLOW $OUT[14]

SIGNAL O_CLOSE_THICK_SENSOR $OUT[15]