Docu-83 KUKA ArcSense 20 en PDF

KUKA System Technology KUKA Roboter GmbH
KUKA.ArcSense 2.0
For KUKA System Software 8.3
KUKA.Arc-
Sense 2.0
Issued: 28.07.2017
Version: KST ArcSense 2.0 V3

KUKA.ArcSense 2.0
© Copyright 2017
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Roboter GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
Publication: Pub KST ArcSense 2.0 (PDF) en

Book structure: KST ArcSense 2.0 V2.1
Version: KST ArcSense 2.0 V3
2 / 81 Issued: 28.07.2017 Version: KST ArcSense 2.0 V3

Contents
Contents
1 Introduction .................................................................................................. 5
1.1 Target group .............................................................................................................. 5
1.2 Industrial robot documentation ................................................................................... 5
1.3 Representation of warnings and notes ...................................................................... 5
1.4 Terms used ................................................................................................................ 6
1.5 Licenses ..................................................................................................................... 6
2 Product description ..................................................................................... 7

2.1 Overview of ArcSense ............................................................................................... 7
2.2 General process conditions ....................................................................................... 10
2.3 Hardware components ............................................................................................... 11
2.3.1 KUKA ArcSense Shunt Box Basic ........................................................................ 12
2.4 Intended use .............................................................................................................. 13
3 Technical data .............................................................................................. 15

3.1 KUKA ArcSense Shunt Box Basic and the connecting cables .................................. 15
3.1.1 Hole pattern for shunt box .................................................................................... 16
3.1.2 Plates and labels .................................................................................................. 16
4 Safety ............................................................................................................ 19
4.1 Applied norms and directives ..................................................................................... 19
5 Planning ....................................................................................................... 21
5.1 Dimensioning of the welding cable to the robot ......................................................... 21
6 Start-up and recommissioning ................................................................... 23

6.1 Installing and connecting the shunt box ..................................................................... 23
7 Transportation ............................................................................................. 25
7.1 Transporting the shunt box ........................................................................................ 25
8 Installation .................................................................................................... 27
8.1 System requirements ................................................................................................. 27
8.2 Installing or updating ArcSense ................................................................................. 27
8.3 Uninstalling ArcSense ................................................................................................ 28
9 Operation ...................................................................................................... 29
9.1 Menus ........................................................................................................................ 29
9.2 Operator control options in the event of an envelope violation .................................. 29
9.2.1 Performing manual correction ............................................................................... 29
9.2.2 Status keys for manual correction ........................................................................ 30
9.2.3 Proceeding with welding after manual correction ................................................. 31
9.3 Deactivating sensor guidance via status key ............................................................. 31
10 Configuration ............................................................................................... 33
10.1 Overview: Configuration in WorkVisual ...................................................................... 33
10.2 Inserting the shunt box in a project ............................................................................ 34
10.3 Opening the ArcTech Editor ..................................................................................... 34
10.4 Configuring the inputs/outputs of the sensor ............................................................. 35
Issued: 28.07.2017 Version: KST ArcSense 2.0 V3 3 / 81

KUKA.ArcSense 2.0
10.4.1 “ArcSense” tab (I/O definition) ........................................................................... 35

10.5 Modifying global settings ........................................................................................... 36
10.5.1 Envelope monitoring ............................................................................................. 36
10.5.2 Reaction to seam guidance errors ........................................................................ 36
10.5.3 Tool direction ........................................................................................................ 37
10.5.4 Calibration options ................................................................................................ 38
10.6 Expert configuration ................................................................................................... 39
10.6.1 User-specific power sources ................................................................................ 39
10.6.2 Maximum correction per cycle .............................................................................. 39
11 Programming ............................................................................................... 41
11.1 Instructions on programming sensor guidance .......................................................... 41
11.2 Activating sensor guidance with ARC ON ................................................................. 41
11.2.1 Option window “Correction parameters” (ARC ON) .......................................... 42
11.2.2 Option window “Weaving” .................................................................................... 44
11.3 Modifying sensor guidance with ARC SWITCH ........................................................ 45
11.3.1 Option window “Correction parameters” (ARC SWITCH) .................................. 47
11.4 Deactivating sensor guidance with ARC OFF ........................................................... 50
11.5 Activating sensor guidance with ARC SPLINE ......................................................... 50
11.5.1 Option window “Correction parameters” (ARC SPLINE) ................................... 51
11.6 Modifying sensor guidance with ARC SWITCH in the ARC spline block .................. 54
11.6.1 Option window “Correction parameters” (ARC SWITCH) .................................. 56
12 Diagnosis ...................................................................................................... 59
12.1 Recording sensor signals with the RSI monitor ......................................................... 59
12.2 ArcTech diagnosis editor ........................................................................................... 59
12.2.1 Loading data from the robot controller into the editor ........................................... 59
12.2.2 Loading locally saved data into the editor ............................................................ 60
12.3 Configuring the display in the ArcTech diagnosis editor ............................................ 60
12.3.1 Changing the signal display options ..................................................................... 62
12.3.2 Overview of sensor signals ................................................................................... 63
13 Maintenance ................................................................................................. 65
13.1 Shunt box maintenance ............................................................................................. 65
14 Repair ............................................................................................................ 67
14.1 Exchanging the shunt box ......................................................................................... 67
15 Decommissioning, storage and disposal .................................................. 69

15.1 Decommissioning the shunt box ................................................................................ 69
15.2 Storing the shunt box ................................................................................................. 69
15.3 Disposal of the shunt box .......................................................................................... 69
16 KUKA Service ............................................................................................... 71

16.1 Requesting support ................................................................................................... 71
16.2 KUKA Customer Support ........................................................................................... 71
Index ............................................................................................................. 79

1 Introduction
1 Introduction
t
1.1 Target group

t
This documentation is aimed at users with the following knowledge and skills:
 KRL programming skills
 Knowledge of the robot controller system
 Knowledge of arc welding
 Knowledge of weld power sources
For optimal use of our products, we recommend that our customers

take part in a course of training at KUKA College. Information about
the training program can be found at www.kuka.com or can be ob-
tained directly from our subsidiaries.
1.2 Industrial robot documentation
The industrial robot documentation consists of the following parts:

 Documentation for the manipulator
 Documentation for the robot controller
 Operating and programming instructions for the System Software
 Instructions for options and accessories
 Parts catalog on storage medium
Each of these sets of instructions is a separate document.
1.3 Representation of warnings and notes
Safety These warnings are relevant to safety and must be observed.
These warnings mean that it is certain or highly probable

that death or severe injuries will occur, if no precautions
are taken.
These warnings mean that death or severe injuries may

occur, if no precautions are taken.
These warnings mean that minor injuries may occur, if

no precautions are taken.
These warnings mean that damage to property may oc-

cur, if no precautions are taken.
These warnings contain references to safety-relevant information or

general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.
This warning draws attention to procedures which serve to prevent or remedy

emergencies or malfunctions:
The following procedure must be followed exactly!
Procedures marked with this warning must be followed exactly.

KUKA.ArcSense 2.0
Notices These notices serve to make your work easier or contain references to further
information.
Tip to make your work easier or reference to further information.
1.4 Terms used
Term Description
KUKA ArcSense KUKA ArcSense Shunt Box Basic contains a measuring shunt that can
Shunt Box Basic be used to measure the weld current values (measurement signals) for
the arc sensor.
The short designation “shunt box” is usually used in this documentation.
Sensor error There is a sensor error if no sufficiently stable measurement signal can
be detected or if no control points can be determined when teaching the
sensor.
RS Revision level
RS number Number indicating the revision level of the shunt box
1.5 Licenses
The KUKA license conditions and the license conditions of the open-source
software used can be found in the following folders:
 Under .\LICENSE on the data storage medium with the installation files of
the KUKA software
 Under D:\KUKA_OPT\Option package name\LICENSE after installation on
the robot controller
Further information about open-source licenses can be requested

from the following address: opensource@kuka.com

2 Product description
2
2.1
t
Overview of ArcSense
Functionality ArcSense is an add-on option package for sensor-guided path correction. Arc-
s
Sense expands the ArcTech Advanced option package to include this func-
tion.
The position of the seam and its path are not always identical from one work-
piece to the next. Correction of the original path is often necessary in order to
compensate for deviations in the shape or position of workpieces.
Using ArcSense, the original path can be corrected in such a way that the ro-
bot finds the actual path of the seam. ArcSense enables both lateral correction
of the path in relation to the seam center and correction of the standoff dis-
tance between the welding torch and the workpiece.
Envelope In order to ensure that the corrected path cannot deviate more than desired
monitoring from the original path, a protective envelope can be defined around the original
path.
Fig. 2-1: Envelope monitoring
1 Weave amplitude (deflection to one side from the path center)

2 Weave length
3 Maximum correction of the path (radius of the protective envelope)
Functional The arc sensor uses the shunt box to determine the effective current during
principle welding. In combination with a weave motion, a deviation from the real path
center can be detected and corrected by ArcSense.
ArcSense regards each weld seam as a self-contained unit. As a result, spe-
cific and non-retain controller values must be taught for every weld seam.
Teaching the sensor (= calibration of the sensor) typically requires 5 complete
weave motions at the start of a weld seam. A weave motion consists of one
positive and one negative amplitude. The teaching phase is limited in the sys-
tem to a maximum of 15 weave motions. If required, the sensor can also be
retaught at the start of a new seam section.

KUKA.ArcSense 2.0
Fig. 2-2: Teaching the sensor
1 Minimum distance for teaching the sensor

2 Maximum distance for teaching the sensor
3 Active seam tracking
During teaching, the parameters are determined that will be used for control
over the further course of the weld seam. If no plausible parameters can be
determined for the sensor, a sensor error results and the fault strategy config-
ured in WorkVisual is carried out.
(>>> 10.5 "Modifying global settings" Page 36)
ArcSense supports the Triangle weave pattern.
ArcSense supports 2 correction methods:
 If the welding task merely requires a vertical correction (= correction along
the tool direction), no weave motion may be executed.
 If weave motion is active, both vertical and lateral correction are automat-
ically carried out.
Production-related contamination of the weld seam prep-

aration, such as rolling skin, lubricants and other foreign
matter, can have a disruptive effect on the quality of the sensor signal and
consequently on seam guidance.
The ArcSense system comes with the option of attenuating or filtering sensor
signal interference. This must be checked on a case-by-case basis, however,
and it may be necessary to ensure greater surface purity.
Lateral bias A lateral bias can be programmed for a seam or seam section in order to offset
the TCP sideways relative to the direction of travel:
 If the bias value is positive, the offset occurs to the right of the seam.
 If the bias value is negative, the offset occurs to the left of the seam.
The bias is relative to the located or calibrated seam center.

Fig. 2-3: Positive lateral bias
1 Lateral bias = 0
2 Lateral bias = positive value
3 Positive lateral bias = bias to the right in the direction of travel
Fig. 2-4: Negative lateral bias
1 Lateral bias = 0
2 Lateral bias = negative value
3 Negative lateral bias = bias to the left in the direction of travel
The lateral bias is set as a percentage value in the correction parameters. The
real lateral bias in mm resulting from the set value depends on several process
factors. The value that must be set in order to achieve the desired bias can
thus only be determined during optimization of the process.
(>>> 11.2.1 "Option window “Correction parameters” (ARC ON)" Page 42)
(>>> 11.3.1 "Option window “Correction parameters” (ARC SWITCH)"
Page 47)
(>>> 11.5.1 "Option window “Correction parameters” (ARC SPLINE)"
Page 51)
Restrictions Sensor guidance can be activated for individual seams and seam sections. If
sensor guidance is activated, the following functions of ArcTech Advanced are
deactivated:
 Sloping

KUKA.ArcSense 2.0
 On-the-fly activation/deactivation of the arc
Arc types ArcSense supports the following arc types for power sources with constant
voltage (CV) characteristics:
 Spray arc
Restriction:
 The functional capability of ArcSense may be restricted if regulation of
the welding current is active.
 Pulse arc
Restriction:
the welding current and pulse form is active.
 Short arc
If using a short arc, we recommend thoroughly testing the sensor guidance
function in advance under real conditions.
Restriction:
 The functional capability of ArcSense may be restricted in the case of
strong or irregular short-circuit formation.
the welding current is active.
 No modified arc types
ArcSense does not support all arc types available on the welding mar-
ket:
To receive information on the suitability of individual power sources
or arc types, please contact KUKA Roboter GmbH. (>>> 16 "KUKA Ser-
vice" Page 71)
 The general process conditions must also be taken into consideration.
(>>> 2.2 "General process conditions" Page 10)
Seam tracking depends, among other things, on the welding process

used and the characteristic curve. If necessary, a different welding
process or characteristic curve must be used.
WorkVisual The following software is required for configuring the sensor and the sensor
fault strategy:
 WorkVisual 4.0
2.2 General process conditions
Reliable and reproducible sensor guidance requires compliance with a num-

ber of general conditions:
 The material thickness should be at least 3 mm.
 Only the weave pattern “Triangle” can be used for sensor guidance.
 The minimum weave amplitude should not be less than 1.5 times the wire
diameter.
 The welding torch must be positioned close to the center of the weld seam
at the start point of the weld. It may additionally be necessary to use the
KUKA.TouchSense option package.
 The actual course of the weld seam should deviate by less than a 10 de-
gree rotation from the programmed weld seam, even if the sensor signal
is stable.

 A single-V butt weld should have a seam preparation with a constant in-
cluded angle. This should be in the range of 60 to 90 degrees. A larger in-
cluded angle may require a greater weave amplitude.
 A fillet weld should have a seam preparation with a constant included an-
gle of 90 degrees.
 During welding, the upper edge must not be melted; a residual depth of
penetration of 5 mm is recommended.
 Tack welds and depth of penetration should be less than or equal to half
the seam thickness and concave in profile.
 Tack welds must not be in the sensor calibration area.
 Sensor guidance requires a weld seam preparation without a root run and
with a constant gap.
 Sensor guidance is suitable in the welding positions PA (gravity position)
and PB (horizontal seam path).
 Base metals must be ferrous metals or have a greater resistance than
steel.
 We recommend using a shielding gas with only a low proportion of CO2
(up to 20%).
 If using a shielding gas with 100% CO2, we recommend thoroughly testing
the sensor guidance function in advance under real conditions. In this
case, the welding process tends to be susceptible to strong and irregular
short-circuit formation, which can have a negative influence on the stability
of seam tracking.
 If using filler wires, sensor guidance must be tested on a case-by-case ba-
sis.
 If using the KUKA Shunt Box Basic, a welding characteristic curve with a
constant voltage characteristic must be used.
 If using a digital checkback signal via a field bus interface from the power
source, a signal must be used that is specifically suitable for through-the-
arc sensors.
 During programming, care must be taken to ensure a constant welding
torch position. A forehand welding torch position is to be used for prefer-
ence.
 More stable seam tracking is achieved by setting an arc that is as free as
possible from short-circuits.
 The properties of the workpiece surface influence the stability of seam
tracking. It must be ensured that the surface characteristics are constant
along the weld seam.
 The component temperature should be as constant as possible through-
out the entire weld.
2.3 Hardware components
The following hardware components are optionally available:

 KUKA ArcSense Shunt Box Basic
 Lid for RDC box, cascadable
 Connecting cables:
 Welding cable 95 mm2 with reducer adapter (600 A –> 500 A)
 Data cable X21 - X31
 Shunt box ground conductor

KUKA.ArcSense 2.0
A 95 mm2 welding cable is permissible up to a maximum weld current

strength of 500 A. It can be connected via the reducer adapter (600 A
–> 500 A).
Alternatively, without a reducer adapter, a welding cable with a cross-section
of 120 mm2 can be used.
2.3.1 KUKA ArcSense Shunt Box Basic
Interfaces
Fig. 2-5: Shunt box interface
1 Data cable connection X31

2 Connection, ground conductor (M6)
3 Input for welding cable from power source (male connector)
4 Ouput for welding cable to robot (female connector)
Connecting How the shunt box is connected depends on the hardware configuration.
cables If the robot used has an RDC interface, the shunt box is connected to this RDC
interface.
Fig. 2-6: Shunt box connection to robot (example)
1 Weld power source

2 Welding cable from the power source to the shunt box (positive polar-
ity of the weld current circuit)
3 Shunt box
4 Welding cable to robot
5 Wire feeder
6 Robot
7 Cover for RDC box, cascadable (optional)
8 Data cable X21 - X31
9 Ground conductor

If the robot used has no RDC interface, the shunt box must be connected to a
control cabinet with an RDC interface.
Fig. 2-7: Shunt box connection to control cabinet (example)
1 Weld power source

2 Welding cable from the power source to the shunt box (positive polar-
ity of the weld current circuit)
3 Shunt box
4 Welding cable to robot
5 Wire feeder
6 Robot
7 Data cable X21 - X31
8 Cover for RDC box, cascadable (optional)
9 Interface X21.1, 2nd RDC
10 Control cabinet
11 Ground conductor
Equipotential bonding (ground conductor) between shunt box and

system PE must be established. The user of the system is responsi-
ble for ensuring that this is implemented correctly.
Further information about the installation of the lid for the cascadable
RDC box is contained in the assembly and operating instructions for
the External Cabling.
2.4 Intended use
Use KUKA.ArcSense is intended exclusively for arc welding in an industrial envi-

ronment. Using an arc sensor, the option package serves to correct the path
in accordance with the position and shape of a workpiece.
The option package must only be operated in compliance with the specified
system requirements.
(>>> 8.1 "System requirements" Page 27)
Operation in accordance with the intended use also requires compliance with
the start-up and configuration instructions in this documentation and constant
observance of the assembly and operating instructions for the cell compo-
nents used.
Misuse Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. KUKA Roboter GmbH is not liable for any damage resulting
from such misuse. The risk lies entirely with the user.

KUKA.ArcSense 2.0
Examples of such misuse include:

 Use in a cell which does not conform to the applicable safety regulations
for arc welding
 Use in a non-industrial environment

3 Technical data
3
T
Technical data
3.1 KUKA ArcSense Shunt Box Basic and the connecting cables
Basic data
t Housing Metal
Dimensions 160 x 260 x 91 mm
Weight 2300 g
Permissible load cur- max. 600 A (120 mm2) / max. 500 A (95 mm2)
rent
Protection rating IP 23
Energy consumption approx. 4.8 W
Conformity CE
Ambient condi- Operation +5 °C to +40 °C (278 K to 313 K)

tions Storage, transportation -20 °C to +55 °C (253 K to 328 K)
Air humidity max. 90% at +20 °C (293 K)
Connecting Cable designation Connector designa- Connection

cables tion
Data cable X21 - X31 Harting connectors at
both ends, HAN 3A
Welding cable 95 mm2 IN - customer-spe- Dinse DIX connec-
cific power source tors at both ends,
BKS 120 - SKK 95
Ground conductor, M6 ring cable lug at
10 mm2 both ends
Cable lengths
Data cable 3 m, 10 m, 20 m
Welding cable 1m
Ground conductor 10 m
Fig. 3-1: Connecting cable, data cable X21 - X31

KUKA.ArcSense 2.0
Fig. 3-2: Connecting cable, wiring diagram, data cable X21 - X31
3.1.1 Hole pattern for shunt box
Fig. 3-3: Hole pattern for shunt box (wall mounting)
1 Holes for fastening (4x)
3.1.2 Plates and labels
The following plates and labels are attached to the shunt box. They must not
be removed or rendered illegible. Illegible plates and labels must be replaced.

3 Technical data
Overview
Fig. 3-4: Plates and labels
Item Designation
1 Identification plate
The RS number with the revision level of the shunt box can be
found at the top left of the identification plate.
2 Interface labelling
3 Ground symbol
4 Warning: High voltage warning sign (housing cover)

KUKA.ArcSense 2.0

4 Safety
4 Safety
4
y This documentation contains safety instructions which refer specifically to the

option package described here.
The fundamental safety information for the industrial robot can be found in the
“Safety” chapter of the Operating and Programming Instructions for System In-
tegrators or the Operating and Programming Instructions for End Users.
The “Safety” chapter in the operating and programming instructions

of the KUKA System Software (KSS) must be observed. Death to per-
sons, severe injuries or considerable damage to property may other-
wise result.
4.1 Applied norms and directives
KUKA ArcSense Shunt Box Basic and the connecting cables fulfill the follow-
ing norms and directives.
Name/Edition Definition
2014/35/EU:2014 Low Voltage Directive:

Directive of the European Parliament and the Council of 26 February
2014 on the harmonization of the laws of Member States relating to
electrical equipment designed for use within certain voltage limits.
2014/30/EU:2014 EMC Directive:

Directive 2014/30/EC of the European Parliament and of the Council
dated 26 February 2014 on the approximation of the laws of the
Member States concerning electromagnetic compatibility
EN 61000-6-2:2005 Electromagnetic compatibility (EMC):

Part 6-2: Generic standards; Immunity for industrial environments
EN 61000-6-4:2007 + Electromagnetic compatibility (EMC):

A1:2011
Part 6-4: Generic standards; Emission standard for industrial envi-
ronments
EN 60974-12:2011 Arc welding equipment:

Part 12: Coupling devices for welding cables (IEC 60974-12:2011)

KUKA.ArcSense 2.0

5 Planning
5 Planning
5.1 Dimensioning of the welding cable to the robot
The cross-section and length of the welding cable from the shunt box to the
robot must be dimensioned in accordance with the following guide values.
Cable cross-
Cross-section 100% DC 60% DC
section
10 … 16 mm2 135 A 140 A
16 … 25 mm2 180 A 190 A
25 … 35 mm2 225 A 245 A
35 … 50 mm2 285 A 315 A
50 … 70 mm2 355 A 400 A
70 … 95 mm2 430 A 500 A
95 … 120 mm2 500 A 590 A
Cable length
Current
≤ 10 m > 10 m > 50 m > 100 m
strength
100 A 25 mm2 35 mm2 50 mm2 70 mm2
200 A 35 mm2 50 mm2 70 mm2 95 mm2
300 A 50 mm2 70 mm2 95 mm2 120 mm2
400 A 70 mm2 95 mm2 120 mm2 —
500 A 95 mm2 120 mm2 — —
600 A 120 mm2 — — —

KUKA.ArcSense 2.0

6 Start-up and recommissioning
6 Start-up and recommissioning

t
6.1 Installing and connecting the shunt box
Description The shunt box is connected to the data bus (KCB) of the system. Start-up is
thus not completed until configuration in WorkVisual has been finished. The
robot cannot be moved until the configuration has been carried out and the
project with the configuration has been activated on the robot controller.
Precondition  The robot controller has been shut down with the following settings:
 Cold start
 Reload files
 The robot controller is switched off and secured to prevent unauthorized
persons from switching it on again.
 The power cable is de-energized.
The shunt box must be installed in such a way that the

connecting cables do not become kinked when connect-
ed. The user of the system is responsible for ensuring that this is implement-
ed correctly. Recommendation: Wall mounting with connector outlet on the
bottom.
Procedure 1. Fasten the shunt box between the power source and the manipulator with
4 screws (M6 x 35/10). Hand-tighten the screws.
The precise positioning depends on customer-specific circumstances in
the system.
2. Connect the connecting cables.
(>>> "Connecting cables" Page 12)
3. Plug the ground conductor into the shunt box and connect it to the system
PE.
The ground conductor must be installed properly. An im-

properly installed ground conductor can lead to inductive
interference, which adversely affects the function of sensors.

KUKA.ArcSense 2.0

7 Transportation
7
T
Transportation
s
7.1 Transporting the shunt box

t
Before transportation, the shunt box must be removed. The shunt box must be
t
packaged in ESD protection foil for transportation. Care must be taken to en-
sure that the shunt box does not come into contact with humidity.

KUKA.ArcSense 2.0

8 Installation
8 Installation
s
8.1 System requirements

t
Robot Hardware:
controller  KR C4
Software:
 KUKA System Software 8.3
 KUKA.ArcTech Basic 1.5
 KUKA.ArcTech Advanced 1.5
 KUKA.RobotSensorInterface 3.3
Laptop/PC Software:
 WorkVisual 4.0
The requirements for installation of WorkVisual are contained in the
WorkVisual documentation.
Configuration Minimum requirements regarding configuration of the ArcTech Basic and

ArcTech Advanced option packages:
 The option packages have been installed in WorkVisual.
 The weld power source has been inserted into the WorkVisual project.
 The WorkVisual project has been deployed on the robot controller.
 The WorkVisual project is running on the robot controller without errors.
8.2 Installing or updating ArcSense
It is advisable to archive all relevant data before updating a software

package.
Precondition  User group “Expert”

 T1 or T2 mode
 No program is selected.
 USB stick with the option package
We recommend using a KUKA USB stick. Data may be

lost if a stick from a different manufacturer is used.
Procedure 1. Connect the USB stick to the robot controller or smartPAD.

2. In the main menu, select Start-up > Additional software.
3. Press New software: The entry ArcSense must be displayed in the Name
column and drive E:\ or K:\ in the Path column.
If not, press Refresh.
4. If the specified entries are now displayed, continue with step 5.
Otherwise, the path from which the software is to be installed must be con-
figured first:
a. Press the Configure button.
b. Select a line in the Installation paths for options area.
Note: If the line already contains a path, this path will be overwritten.
c. Press Path selection. The available drives are displayed.
d. If the stick is connected to the robot controller: Select E:\.

KUKA.ArcSense 2.0
If the stick is connected to the smartPAD: K:\ instead of E:\

e. Press Save. The Installation paths for options area is displayed
again. It now contains the new path.
f. Mark the line with the new path and press Save again.
5. Activate the check box next to ArcSense and press Install. Answer the
request for confirmation with Yes.
6. Confirm the installation message with OK and press Restart.
7. Answer the confirmation request for rebooting with Yes. The robot control-
ler carries out a reboot.
8. Remove the stick.
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.
8.3 Uninstalling ArcSense
It is advisable to archive all relevant data before uninstalling a soft-

ware package.
Precondition  User group “Expert”

 Operating mode T1 or T2.
 No program is selected.
Procedure 1. In the main menu, select Start-up > Additional software. All additional
programs installed are displayed.
2. Activate the check box next to ArcSense and press Uninstall. Answer the
request for confirmation with Yes.
3. Confirm the uninstallation message with OK and press Restart.
4. Answer the request for confirmation for rebooting with Yes. The robot con-
troller carries out a reboot.
LOG file A LOG file is created under C:\KRC\ROBOTER\LOG.

9 Operation
9 Operation
9.1 Menus
t
The following menus and commands are specific to this option package:
Main menu:
 Configuration > Status keys > ArcSense
 Deactivation
 Motion
9.2 Operator control options in the event of an envelope violation
If the envelope monitoring is active and the maximum permissible correction

is exceeded (envelope violation), the robot is stopped, the process switched
off and a dialog message displayed. Operators are asked how they would like
to proceed.
The following operator control options are available:
 Cancel
This option is to be selected if the program is to be canceled, e.g. in order
to start welding a new workpiece.
The operator must reset or deselect the program.
 Proceed
This option is to be selected if visual inspection of the workpiece reveals
that the executed sensor correction is OK and welding can proceed with-
out any loss of quality.
The configured weld fault strategy is automatically executed and the sen-
sor is retaught. The sensor offset is also retained.
 Manual correction
The operator has the option of manually moving and repositioning the
welding torch via the status keys in T1. Status keys for manual correction
are automatically displayed.
(>>> 9.2.1 "Performing manual correction" Page 29)
Once correction has ended, welding may proceed.
(>>> 9.2.3 "Proceeding with welding after manual correction" Page 31)
9.2.1 Performing manual correction
Precondition  The Manual correction option is activated.

 T1 mode
Procedure 1. Press and hold down the Start key.

2. Press and hold down the enabling switch.
3. Move the welding torch into the position where welding is to be resumed
using the status keys.
(>>> 9.2.2 "Status keys for manual correction" Page 30)
4. Once the welding torch is in the desired position, end manual correction
using the related status key.
The status keys for manual correction can no longer be activated. This is
only possible after the next envelope violation.

KUKA.ArcSense 2.0
Example
Fig. 9-1: Manual correction following envelope violation
1 Envelope violation 2 Manual correction
9.2.2 Status keys for manual correction
Description If the Manual correction option is activated following an envelope violation,

the status keys are automatically displayed.
Status key Description

Correction direction ±YTTS
The welding torch is moved in the weave plane (at right
angles to the weld path).
 Arrow pointing left = correction direction +YTTS
 Arrow pointing right = correction direction -YTTS
Switches to the correction direction ±ZTTS.
Correction direction ±ZTTS

The welding torch is moved at right angles to the weave
plane (vertically upwards/downwards).
 Arrow pointing upwards = correction direction +ZTTS
 Arrow pointing downwards = correction direction -ZTTS
Switches to the correction direction ±YTTS.
Terminates manual correction.

The status keys for manual correction can no longer be
activated. Welding can proceed.
If other status keys were displayed before the envelope
violation and the activation of manual correction, these
keys will automatically be displayed again.
Precondition The status keys are active if the following conditions are met:
 T1 mode
 Start key is pressed.
 Enabling switch is pressed.

9 Operation
 Submit interpreter is running.
Procedure Displaying the status keys:

 In the main menu, select Configuration > Status keys > ArcSense > Mo-
tion.
9.2.3 Proceeding with welding after manual correction
Precondition  Manual correction has been completed.

 T1, T2 or AUT mode
Welding proceeds immediately. Wear personal protec-

tive equipment (e.g. safety goggles, protective clothing)
during welding in T1.
Procedure  T1 or T2 mode: Press and hold down the Start key.

 AUT mode: Press the Start key.
9.3 Deactivating sensor guidance via status key
Description Sensor guidance is typically deactivated in order to create and optimize the
process without sensor guidance.
Status key Description

The status key is grayed out and inactive, e.g. because an
automatic mode is set.
Sensor guidance is activated.
Sensor guidance is deactivated.
Precondition The status key is active if the following conditions are met:
 T1 or T2 mode
 User group “Expert” or higher
Procedure Display status key:

 In the main menu, select Configuration > Status keys > ArcSense > De-
activation.

KUKA.ArcSense 2.0

10 Configuration
10 Configuration
f
10.1 Overview: Configuration in WorkVisual

t
Step Description
1 Install the ArcSense option package in WorkVisual.
Precondition:
 ArcTech Basic and ArcTech Advanced have been in-
stalled in WorkVisual.
 RobotSensorInterface has been installed in WorkVisual.
 The weld power source has been inserted into the WorkVi-
sual project.
 The WorkVisual project has been deployed on the robot
controller.
 The WorkVisual project is running on the robot controller
without errors.
2 Load the project from the robot controller.
Precondition:
 ArcSense is already installed on the robot controller.
Note: The loaded project must be used for configuration of
ArcSense. Otherwise, ArcTech package entries already
installed on the robot controller could be lost when the project
is redeployed.
3 Insert the ArcSense option package into the project.
3 If the shunt box is being used, insert the shunt box into the
project.
(>>> 10.2 "Inserting the shunt box in a project" Page 34)
4 Configure the inputs/outputs of the sensor in the ArcTech
Editor.
(>>> 10.4 "Configuring the inputs/outputs of the sensor"
Page 35)
5 Configure global settings in the ArcTech Editor:
 Envelope monitoring
 Reaction to seam guiding errors
 Tool direction
 Calibration options
(>>> 10.5 "Modifying global settings" Page 36)
6 Transfer the project from WorkVisual to the robot controller.
Note: During project deployment, the technology-specific files
are copied to the robot controller and activated. If an earlier
project has already been transferred, the files of this project
will be overwritten. It is therefore recommended to archive the
files of the earlier project before transferring the new project.
Information about installing and managing option packages can be

found in the WorkVisual documentation.
Information about bus configuration and project deployment can be

found in the WorkVisual documentation.

KUKA.ArcSense 2.0
10.2 Inserting the shunt box in a project
Description The ArcSense option offers different shunt box devices in WorkVisual, as
there may be different configurations depending on the control cabinet and the
revision level of the shunt box.
The RS number with the revision level of the shunt box can be found on the
identification plate of the shunt box. (>>> 3.1.2 "Plates and labels" Page 16)
Precondition  The project is open.

 The controller has not been set to active.
Procedure 1. Select the Hardware tab in the Project structure window.

2. Right-click on the robot controller and select Add… in the context menu.
3. Select the Options tab and mark the appropriate shunt box for this project.
The following must be taken into consideration when selecting the shunt
box:
 Is the shunt box (or will it be) physically connected to the control cabi-
net or robot base?
 What is the revision level RSx of the shunt box? (Observe the identifi-
cation plate.)
4. Add the shunt box to the project by means of Drag&Drop. A dialog indi-
cates that the ArcSense option must also be added.
5. Confirm the dialog with OK. The shunt box and option are added.
6. Configurations are already stored in the shunt box. Respond to the query
asking whether these configurations are to be imported with Yes.
7. The Adjust signal connections window opens.
If the sensor signal to which the shunt box is to be mapped in accordance
with its default settings is already mapped in the current project, this is
shown in the Current conflicts area.
8. If there is a conflict, enter the number of the input to which the sensor sig-
nal should be mapped in the Analog inputs box.
The input set here must also be configured in the ArcTech Editor.
(>>> 10.4 "Configuring the inputs/outputs of the sensor" Page 35)
9. If a conflict is no longer displayed in the Current conflicts area, click on
OK.
If several RDCs are being used, take care to ensure that the shunt
box is configured to the RDC of the robot. If the shunt box is located
in the topology of the drive bus on another RDC, the connection must
be corrected manually.
The shunt box is displayed with the name EK1100 EtherCAT cou-
pler (2A E-Bus) in the topology tree. The shunt box may have a dif-
ferent address from one project to another.
Information about the topology of the drive bus and editing the con-
nections is contained in the WorkVisual documentation.
10.3 Opening the ArcTech Editor
Precondition  The project is open.

 The power source is inserted in the project.
Procedure 1. Select the power source in the project (Hardware tab).

10 Configuration
2. Select the menu sequence Editors > Options packages > Open
ArcTech Editor.
Alternative
procedure  Click on the button in the menu bar, or double-click on the power
source in the project (Hardware tab).
10.4 Configuring the inputs/outputs of the sensor
Description An analog or digital input can be configured for the sensor signal. The signal
type to be configured depends on the power source.
Outputs can also be configured to send an error signal to the higher-level con-
troller in the event of a sensor error or an envelope violation.
Preparation WorkVisual does not indicate a double assignment of inputs/outputs or an

overlap of the configured signal ranges.
 For configuration of analog inputs/outputs: Check whether the desired in-
puts/outputs have already been assigned by ArcTech Basic.
 For configuration of a digital sensor signal: Check whether the desired sig-
nal range overlaps with a signal range that has already been configured
for ArcTech Basic.
Precondition  ArcTech Editor is open.
Procedure 1. Select the I/O definition tab.

2. Configure the inputs/outputs of the sensor on the ArcSense tab as re-
quired.
(>>> 10.4.1 "“ArcSense” tab (I/O definition)" Page 35)
3. Save the project to accept the changes made.
10.4.1 “ArcSense” tab (I/O definition)
Signal input The following signal types are available for inputs:
Parameter Description
Current sensor signal (ana- Use of the shunt box is intended for evaluation of an analog
log) sensor signal.
Enter the number of the analog input to which the sensor signal
is mapped.
 1 … 32
Default: 15
Note: If the default input is already assigned, a different analog
input can be configured. The number of the input that was previ-
ously specified when inserting the shunt box into the project
must be entered.
Current sensor signal (digi- The digital sensor signal is transferred directly from the power
tal) source by means of a field bus signal. The signal must meet the
specific requirements.
Enter the start and end values for the signal width of the sensor
signal.
Signal width: max. 32 bits
Note: The signal range configured for the sensor must not over-
lap with the signal ranges configured in ArcTech Basic. WorkVi-
sual does not indicate a range overlap.

KUKA.ArcSense 2.0
Signal outputs The following outputs can be configured:
Sensor error, ArcSense Enter the number of the output that is used to report errors that
automatically switches arise while teaching the sensor.
off(proceed).
Envelope monitoring Enter the number of the output that is used to report an enve-
lope violation.
10.5 Modifying global settings
Description The global settings for ArcSense can be modified:

 Envelope monitoring
 Reaction to seam guiding errors
 Tool direction
 Calibration options:
 Calibration type
 Activation delay for seam calibration
Precondition  ArcTech Editor is open.
Procedure 1. Select the Global settings tab.

2. Make the required settings on the ArcSense tab.
3. Save the project to accept the changes made.
10.5.1 Envelope monitoring
Without envelope monitoring there is a risk of the robot

colliding with the weldment, e.g. due to a sensor error. It
is advisable to always use envelope monitoring to reduce the risk of this oc-
curring. Using envelope monitoring can also detect if the parts to be welded
are in significantly faulty positions.
Envelope monitoring Envelope monitoring is activated as standard (= On).
Envelope monitoring can be deactivated (= Off), but this is not
recommended. No value can then be entered for the maximum
sensor correction in the programming.
10.5.2 Reaction to seam guidance errors
The following strategies are available for responding to seam guidance errors:

10 Configuration
Reaction to seam guiding Stop and execute the fault strategy (default)
errors
The weld fault strategy configured in ArcTech Basic is used.
The following fault strategies from ArcTech Basic are supported
by ArcSense:
 KeepOnPosition
 MoveBackward
The distance on the path over which a backward movement
is possible is limited to 100 mm when sensor guidance is ac-
tivated.
 MoveUpAndStop
 MoveForward
As soon as the fault strategy has been carried out and welding
can proceed, the sensor is retaught and welding resumes with
activated sensor guidance.
Continue without sensor
The robot continues to the next weld command, e.g. to the next
ARC SWITCH, without sensor guidance. Program execution
then proceeds as programmed.
In the Continue without sensor fault strategy, sensor

guidance is deactivated. This can lead to a collision with
components since the robot follows the taught path.
Further information about the fault strategies can be found in the

ArcTech Basic documentation.
10.5.3 Tool direction
If the tool direction is entered incorrectly, e.g. if the Neg-

ative setting has been selected even though the tool di-
rection actually lies in the positive X axis of the TOOL coordinate system, an
incorrect reaction for vertical control will result. This can lead to a collision
with the weldment.
Tool direction The tool direction configured for the tool used must be specified
here.
 Positive: This is the default setting.
Leave this setting if the tool direction lies in the positive X or
Z axis of the TOOL coordinate system (in the direction of the
free wire end).
 Negative: Select this setting if the tool direction lies in the
negative X or Z axis of the TOOL coordinate system (away
from the free wire end).
Tool direction The negative tool direction must be set in the following cases:
Negative  If using weld programs that have been taught with a negative tool direction
If the tool direction lies in the positive X or Z axis of the TOOL coordinate
system (in the direction of the free wire end), it is configured correctly. This

KUKA.ArcSense 2.0
is specified in the operating and programming instructions for the System

Software and for ArcTech Basic.
If the tool direction, contrary to this requirement, lies in the negative X or Z
axis of the TOOL coordinate system (away from the free wire end) and
welding programs have been taught with this tool, then these welding pro-
grams may not be used with ArcSense without taking further action. Risk
of collision!
In order to be able to use welding programs taught with the negative tool
direction, the negative tool direction must be set.
 Vertical control with voltage signal
If there is a signal (measured value) available whose value is exactly indi-
rectly proportional to the length of the arc, this signal can be used for ver-
tical control. The precondition here is that the weave function is not used.
Such a voltage measurement signal is generally available in the case of
TIG and plasma power sources.
In order for ArcSense to be able to work with this signal, the tool direction
must be exactly the opposite to the real programming.
The sensor signal expected by ArcSense is indirectly proportional to the
length of the arc (distance signal). If the distance gets smaller, the signal
value (measured value) increases and if the distance gets larger, the sig-
nal value (measured value) decreases. An example of a directly propor-
tional signal would be a voltage signal whose signal value (measured
value) increases with increasing distance and decreases with decreasing
distance (e.g. in the case of plasma cutting).
10.5.4 Calibration options
The following parameters are available:
Calibration type Method used for teaching the sensor signal at the start of the
welding process
 Seam center
During teaching, ArcSense attempts to detect and track the
center of the weld seam preparation.
 As taught (default)
The sensor signal is taught dependent on the current signal
that ArcSense finds in the programmed position at the start
of the welding process.
 Selection in ILF
The user can set the method for teaching the sensor signal
in the inline form ARC ON or ARC SPLINE.
Activation delay for seam Teaching of the sensor signal starts with the ignition of the arc.
calibration In this case, the system attempts to generate sufficient control
points from the outset.
Teaching can also be delayed, e.g. if the current signal after
ignition is unstable.
 None (default)
Teaching commences at the start of the ignition process.
 Selection in ILF
The user can set the teaching delay in the inline form ARC
ON or ARC SPLINE.

10 Configuration
10.6 Expert configuration
10.6.1 User-specific power sources
It is possible for the user to configure a power source with user-specific con-
troller parameters in order to optimize the welding process.
The file C:\KRC\ROBOTER\KRC\R1\TP\ArcSense\ArcSenseUniversal-
SQ.dat is available for this. Up to 5 different user-specific controller parameter
data sets can be configured for the power source used. The data sets are pre-
set with default values that have not yet been adapted to the power source.
The configuration of controller parameters requires expert knowledge

and should only be carried out in consultation with KUKA Customer
Support. (>>> 16 "KUKA Service" Page 71)
10.6.2 Maximum correction per cycle
The maximum correction per cycle can be limited using global REAL variables.
These variables can be set using the variable correction function:
Variable Description
ARSg_MaxCorrWeaveSide Limitation in mm for lateral correction
Even if the determined correction per amplitude exceeds this
value, the actual lateral correction that is executed will be lim-
ited to this value. Only change this value if the lateral correction
is no longer sufficient.
ARSg_MaxCorrWeaveHeight Limitation in mm for vertical correction (tool direction)
Even if the determined correction per amplitude exceeds this
value, the actual vertical correction that is executed will be lim-
ited to this value. Only change this value if the vertical correc-
tion is no longer sufficient.

KUKA.ArcSense 2.0

11 Programming
11 Programming
11.1 Instructions on programming sensor guidance
ArcSense data The weld instructions from ArcTech Basic are used for ArcSense.
set ArcSense provides an additional data set in the weld instructions for program-
ming the sensor guidance. This ArcSense data set can be inserted or deleted
using the ArcSense On/ArcSense Off button.
Without spline The following weld instructions are required for a single seam:
 ARC ON
 ARC OFF
The following weld instructions are required for a seam that is divided into sev-
eral seam sections:
 ARC ON
 ARC SWITCH
 ARC OFF
If sensor guidance is used for a seam, the ArcSense data

set must be used in all weld instructions used for the
seam. If this data set is missing in any of the inline forms, the robot may move
in a way other than expected and cause material damage.
ARC spline block The following weld instructions are required for a seam that is to be executed
as a spline motion:
 ARC SPLINE
 ARC ON
 ARC SWITCH
Only required if a seam is to be divided into several sections.
 ARC OFF
When using the ARC spline block, the ArcSense data set is only required in
ARC SPLINE and ARC SWITCH and is only available in these instructions.
General instruc-  It is advisable to optimize the weld parameters for the application first, and
tions then to program the sensor guidance. As long as the application is set
without ArcSense, sensor guidance must be deactivated by means of the
corresponding status key.
(>>> 9.3 "Deactivating sensor guidance via status key" Page 31)
 Slight deviations when teaching the sensor can strongly affect the sensor
signal and thus the position of the weld seam. The start of a seam and the
start of a seam section at which the sensor is retaught must therefore be
taught precisely.
11.2 Activating sensor guidance with ARC ON
Description Sensor guidance is activated with the ARC ON instruction. The correction pa-
rameters for the seam can be defined.
Precondition  Program has been opened.
Procedure 1. Select the menu sequence Commands > ArcTech > ARC ON.
2. Press ArcSense On to insert the ArcSense data set in the inline form.
3. Set the sensor guidance parameters as required in the inline form.

KUKA.ArcSense 2.0
4. Press Cmd OK to save the instruction.
Inline form
Fig. 11-1: Inline form “ARC ON” with ArcSense
Item Description
1 If sensor guidance is used, the configurable weave parameters
are modified.
Touch the arrow to edit the parameters. The corresponding option
window is opened.
(>>> 11.2.2 "Option window “Weaving”" Page 44)
2 ArcSense data set with correction parameters
window is opened.
(>>> 11.2.1 "Option window “Correction parameters” (ARC ON)"
Page 42)
3 If sensor guidance is used, this is indicated by TRACK in the pro-
gram code.
11.2.1 Option window “Correction parameters” (ARC ON)
Fig. 11-2: Option window “Correction parameters” (ARC ON)

11 Programming
Item Description
1 Lateral controller gain
 0 … 100%
The greater the value, the quicker the sensor responds to
detected lateral changes in position of the weld seam. The lower
the value, the slower the reaction.
If the value “0” is set, there is no lateral correction.
2 Vertical controller gain
 0 … 100%
detected changes in position of the weld seam in the tool direction
of the welding torch. The lower the value, the slower the reaction.
If the value “0” is set, there is no vertical correction.
3 Maximum correction (= radius of the protective envelope)
This box is only displayed if the envelope monitoring has been
activated in WorkVisual.
 1 … 300 mm
The maximum expected correction must be set.
4 Activation delay for seam calibration
This box is only displayed if the value Selection in ILF has been
set for the parameter Activation delay for seam calibration in
WorkVisual.
 0 … 10 s
As standard, teaching of the sensor signal starts with the ignition
of the arc (activation delay = 0 s). The start of teaching can be
delayed.

KUKA.ArcSense 2.0
Item Description
5 Check box Find seam center
This box is only displayed if the value Selection in ILF or Seam
center has been set for the parameter Calibration type in
WorkVisual.
 Check box active: During teaching, ArcSense attempts to de-
tect and track the center of the weld seam preparation.
The maximum correction of the seam center search depends
on the magnitude of the programmed weave width, as the con-
troller has to work with a minimal checkback signal from both
side walls of the seam.
 Check box not active: ArcSense tracks the position of the weld-
ing torch relative to the seam located at the start of the welding
process.
6 Lateral bias
WorkVisual.
The box is locked if the seam center search is deactivated (Find
seam center check box not activated).
 -100 … 100%
The parameter can be used to offset the TCP laterally relative to
the direction of travel. If the value is positive, the bias occurs to
the right of the seam. If the value is negative, the bias occurs to
the left of the seam.
The real lateral bias in mm resulting from the set value depends
on several process factors. The value that must be set in order to
achieve the desired bias can thus only be determined during opti-
mization of the process.
If the value for the controller gain is set too high, the sys-
tem may overreact, resulting in a wavy line. If, on the oth-
er hand, the value is too low, the system may, under certain circumstances,
not respond quickly enough to changes.
It is advisable to set a higher value for the controller gain initially and to re-
duce it gradually in order to determine the optimal value empirically.
The maximum correction of the taught path by ArcSense

is limited to 300 mm. It is advisable to set a value that is
as low as possible, i.e. the maximum expected correction. This reduces the
risk of the robot colliding with the weldment or other system parts in the event
of an error.
11.2.2 Option window “Weaving”
If sensor guidance is activated, the configurable weave parameters are modi-

fied.

11 Programming
Fig. 11-3: Option window “Weaving”
Item Description
1 If sensor guidance is activated, the following weave patterns are
available:
 ArcSense - Triangle
Triangle weave pattern
 None
No weaving is carried out. Suitable if the welding task only re-
quires a vertical correction and not a lateral correction.
Note: If sensor guidance is not activated, the weave patterns that
were configured for the selected data set in WorkVisual remain
available.
Note: If weave patterns are already preset when sensor guidance
is activated, the behavior is as follows:
 If the preset weave pattern is not supported by ArcSense,
weaving is automatically deactivated (= None).
 If the preset weave pattern is supported by ArcSense, the set-
ting is retained.
2 Only available if a weave pattern has been selected.
Weave length (= 1 oscillation: length of the path from the start
point to the end point of the pattern)
Lateral deflection (= height of the weave pattern)
4 Not available. It is not permissible to rotate the weave plane if
sensor guidance is activated.
If the weld or weave parameters are modified at the start

of a new seam section, the sensor is retaught automati-
cally. This applies even if it is defined in the correction parameters that the
sensor is not to be retaught at the start of the new seam section.
Page 47)
11.3 Modifying sensor guidance with ARC SWITCH
Description As standard, the correction parameters programmed with ARC ON are valid
for the entire seam. The ARC SWITCH instruction can be used to assign other

KUKA.ArcSense 2.0
correction parameters to individual seam sections. These values then apply

only to this seam section:
 The existing sensor offset can be retained in a new seam section or elim-
inated.
 The sensor can be retaught at the start of a new seam section.
 Sensor guidance can be deactivated for individual seam sections.
Procedure 1. Select the menu sequence Commands > ArcTech > ARC SWITCH.
Inline form
Fig. 11-4: Inline form “ARC SWITCH” with ArcSense
Item Description
are modified.
window is opened.
window is opened.
(>>> 11.3.1 "Option window “Correction parameters” (ARC
SWITCH)" Page 47)
gram code.

11 Programming
11.3.1 Option window “Correction parameters” (ARC SWITCH)
Fig. 11-5: Option window “Correction parameters” (ARC SWITCH)
Item Description
1 Check box Control activated
 Check box active: Sensor guidance is activated in the new
seam section.
 Check box not active: Sensor guidance is deactivated in the
new seam section.
If sensor guidance is deactivated, only the Keep offset check
box remains available in the option window. All other parame-
ters are hidden since they are no longer relevant.
2 Check box Keep offset
 Check box active: The existing sensor offset is retained in the
new seam section.
 Check box not active: The existing sensor offset is not retained
in the new seam section, but rather reduced to zero over a dis-
tance depending on the offset.
If the sensor offset has been eliminated, the sensor must be re-
taught at the start of the new seam section. For this reason, the
Teach new check box is automatically activated and locked for
the user.
3 Check box Teach new
 Check box active: The sensor is retaught at the start of the new
seam section.
 Check box not active: The sensor is not retaught at the start of
the new seam section.
 0 … 100%

KUKA.ArcSense 2.0
Item Description
 0 … 100%
 1 … 300 mm
7 Lateral bias
 -100 … 100%

of an error.
For each new seam section, it must be checked to see if

the sensor offset may be retained. Depending on the
system configuration, both proceeding with the sensor offset as well as pro-
ceeding without it and re-teaching the sensor can lead to a collision with the
weldment or other system parts.

Page 47)

11 Programming

fied.
Item Description
available:
 None
available.
ting is retained.

Page 56)

KUKA.ArcSense 2.0
11.4 Deactivating sensor guidance with ARC OFF
Description Sensor guidance is deactivated with the ARC OFF instruction.
Procedure 1. Select the menu sequence Commands > ArcTech > ARC OFF.
The inline form “ARC OFF” does not have any additional
parameters. It is nevertheless imperative to insert the
ArcSense data set into the inline form in order to terminate the sensor guid-
ance. Otherwise, unexpected reactions may result.
Inline form
Fig. 11-7: Inline form “ARC OFF” with ArcSense
Item Description
1 ArcSense data set without definable parameters
gram code.
11.5 Activating sensor guidance with ARC SPLINE
Description Sensor guidance is activated in the ARC spline block with the ARC SPLINE
instruction. The correction parameters for the seam can be defined.
Procedure 1. Select the menu sequence Commands > ArcTech > ARC SPLINE.

11 Programming
Inline form
Fig. 11-8: Inline form “ARC SPLINE” with ArcSense
Item Description
are modified.
window is opened.
window is opened.
SPLINE)" Page 51)
gram code.
11.5.1 Option window “Correction parameters” (ARC SPLINE)
Fig. 11-9: Option window “Correction parameters” (ARC SPLINE)

KUKA.ArcSense 2.0
Item Description
 0 … 100%
 0 … 100%
 1 … 300 mm
4 Activation delay for seam calibration
This box is only displayed if the value Selection in ILF has been
set for the parameter Activation delay for seam calibration in
WorkVisual.
 0 … 10 s
As standard, teaching of the sensor signal starts with the ignition
of the arc (activation delay = 0 s). The start of teaching can be
delayed.

11 Programming
Item Description
5 Check box Find seam center
WorkVisual.
 Check box active: During teaching, ArcSense attempts to de-
tect and track the center of the weld seam preparation.
The maximum correction of the seam center search depends
on the magnitude of the programmed weave width, as the con-
troller has to work with a minimal checkback signal from both
side walls of the seam.
 Check box not active: ArcSense tracks the position of the weld-
ing torch relative to the seam located at the start of the welding
process.
6 Lateral bias
WorkVisual.
The box is locked if the seam center search is deactivated (Find
seam center check box not activated).
 -100 … 100%

of an error.

fied.

KUKA.ArcSense 2.0
Item Description
available:
 None
available.
ting is retained.

Page 56)
11.6 Modifying sensor guidance with ARC SWITCH in the ARC spline block
Description As standard, the correction parameters programmed with ARC SPLINE are
valid for the entire seam (ARC spline block). The ARC SWITCH instruction
can be used to assign other correction parameters to individual seam sections

11 Programming
(spline segments). These values then apply only to this seam section (this
spline segment):
 The existing sensor offset can be retained in a new seam section or elim-
inated.
 The sensor can be retaught at the start of a new seam section.
 Sensor guidance can be deactivated for individual seam sections.

 Sensor guidance for ARC spline block is activated.
 ARC spline block fold is open.
Procedure  Select the menu sequence Commands > ArcTech > ARC SWITCH.
 Set the sensor guidance parameters as required in the inline form.
 Press Cmd OK to save the instruction.
Inline form
Fig. 11-11: Inline form “ARC SWITCH” in the ARC spline block with Arc-
Sense
Item Description
are modified.
window is opened.
window is opened.
SWITCH)" Page 56)
gram code.

KUKA.ArcSense 2.0
11.6.1 Option window “Correction parameters” (ARC SWITCH)
Fig. 11-12: Option window “Correction parameters” (ARC SWITCH)
Item Description
1 Check box Control activated
 Check box active: Sensor guidance is activated in the new
seam section.
 Check box not active: Sensor guidance is deactivated in the
new seam section.
If sensor guidance is deactivated, only the Keep offset check
box remains available in the option window. All other parame-
ters are hidden since they are no longer relevant.
2 Check box Keep offset
 Check box active: The existing sensor offset is retained in the
new seam section.
 Check box not active: The existing sensor offset is not retained
in the new seam section, but rather reduced to zero over a dis-
tance depending on the offset.
If the sensor offset has been eliminated, the sensor must be re-
taught at the start of the new seam section. For this reason, the
Teach new check box is automatically activated and locked for
the user.
3 Check box Teach new
 Check box active: The sensor is retaught at the start of the new
seam section.
 Check box not active: The sensor is not retaught at the start of
the new seam section.
 0 … 100%

11 Programming
Item Description
 0 … 100%
 1 … 300 mm
7 Lateral bias
 -100 … 100%

of an error.
For each new seam section, it must be checked to see if

the sensor offset may be retained. Depending on the
system configuration, both proceeding with the sensor offset as well as pro-
ceeding without it and re-teaching the sensor can lead to a collision with the
weldment or other system parts.

Page 56)

KUKA.ArcSense 2.0

fied.
Item Description
available:
 None
available.
ting is retained.

Page 47)

12 Diagnosis
12
2
Diagnosis
12.1
s
Recording sensor signals with the RSI monitor
s
If ArcSense does not function as intended, the sensor signals can be dis-
played, recorded and saved in a file using the RSI monitor. It is advisable to
compress the recorded data in the diagnosis package KRCDiag and send
them to KUKA for error analysis.
Additionally there is an ArcTech diagnosis editor available in WorkVisual that
can be used to display the sensor signals recorded with the RSI monitor.
(>>> 12.3.2 "Overview of sensor signals" Page 63)
Further information about the RSI monitor can be found in the

KUKA.RobotSensorInterface documentation.
Further information about the diagnosis package KRCDiag can be

found in the operating and programming instructions for the System
Software.
12.2 ArcTech diagnosis editor
There is an ArcTech diagnosis editor available in WorkVisual that can be used

to display the sensor signals recorded with the RSI monitor. The recorded data
can be loaded from the robot controller or locally from a data storage medium,
e.g. USB stick or network drive.
Fig. 12-1: ArcTech diagnosis editor
1 Legend for signals 2 Arrow button
The arrow button on the right-hand side of the editor can be used to open a
configuration window in which the display of the data can be customized.
12.2.1 Loading data from the robot controller into the editor
Precondition  Network connection to the robot controller

 Robot controller and KUKA smartHMI are running.

KUKA.ArcSense 2.0
 There is at least one RSI monitor file with recorded data present on the ro-
bot controller.
 The Programming and diagnosis workspace has been opened in
WorkVisual.
Procedure 1. Right-click on the robot controller of the desired cell in the Cell view win-
dow and select ArcTech diagnosis. The ArcTech package window
opens.
2. Select the desired file and click on OK. The editor opens and loads the
data from the selected file.
12.2.2 Loading locally saved data into the editor
Precondition  At least one RSI monitor file with recorded data has been saved locally.
 The Programming and diagnosis workspace has been opened in
WorkVisual.
Procedure 1. Select the menu sequence Editors > Options packages > ArcTech di-
agnosis.
Alternatively: Click on the Open ArcTech diagnosis editor button in the
button bar.
2. Navigate to the desired file, select it and click on Open. The editor opens
and loads the data from the selected file.
12.3 Configuring the display in the ArcTech diagnosis editor
Description The display in the ArcTech diagnosis editor can be configured:

 Signals that are to be displayed in the editor can be selected.
 Signals that are no longer to be displayed in the editor can be removed
again.
 For each signal, it is possible to set how it is to be displayed in the editor,
e.g. in which color.

12 Diagnosis
Fig. 12-2: Configuration window in the editor
1 Opens the display options

2 Closes the display options
3 Open display options
4 Adds a signal to the editor
5 Closes the configuration window
6 Removes signal from the editor
Save In order for the RSI monitor file to be loaded into the editor again with the con-
figured settings next time, the configuration must be saved before the editor is
closed. Otherwise, the settings will be lost.
Button Description
Save configuration Saves the configuration.
Restore default configuration Restores the default configuration.
Precondition  RSI monitor file is open in the editor.
Procedure 1. Move the mouse pointer to the arrow on the right-hand side of the editor.
If there is a circle enclosing the arrow, the button is active.
2. Click on the button. The configuration window with the available signals
opens.
3. Add or remove signals as required.

KUKA.ArcSense 2.0
(>>> 12.3.2 "Overview of sensor signals" Page 63)

4. Modify the display options as required and save the configuration.
(>>> 12.3.1 "Changing the signal display options" Page 62)
5. To close the configuration window, move the mouse pointer to the central
left-hand area of the window until a semicircle becomes visible (= button
for closing the window).
6. Click on the button. The configuration window closes.
12.3.1 Changing the signal display options
Description The following display options can be modified for each signal:
 Name: Name under which the signal is displayed in the editor
 Color: Color in which the signal is displayed in the editor
 Gain: Line thickness with which the signal is displayed in the editor
 Y offset: Offset in the Y axis with which the signal is displayed in the editor
Fig. 12-3: Display options for signals
1 Closes the display options

2 Buttons only visible after modification in display options
Button Description
Saves the changes in the display options
Rejects the changes in the display options and restores the

previous settings.

12 Diagnosis
Precondition  RSI monitor file is open in the editor.

 Configuration window is open in the editor.
Procedure 1. Move the mouse pointer to the signal for which the display options are to
be modified.
2. Click on the button with the arrow that is now displayed on the right-hand
side next to the signal. The display options are shown.
3. Make the desired settings and confirm the changes with the green button.
4. To close the display options, click on the arrow that is displayed on the
right-hand side next to the signal.
12.3.2 Overview of sensor signals
The sensor signals that can be recorded with the RSI monitor and displayed
in the ArcTech diagnosis editor are described here. Each sensor signal is as-
signed a number in the RSI monitor and a name in the diagnosis editor.
No. Name Description

1 TTS-PosAct-Y Position of the TCP relative to the taught path (X+) Y axis
2 TTS-PosAct-Z Position of the TCP relative to the taught path (X+) Z axis
3 InSignalFilter Filtered sensor signal
4 InSignalMulti Normalized sensor signal
5 SigQualReady Signal quality check has issued an enable signal (controller
start)
6 SigQualState Information about the status of the signal quality check
7 SigQualDebug Information about errors in the signal quality check
8 ControllerNGY Controller output, Y axis
9 ControllerNGZ Controller output, Z axis
10 ControllerNGY_Int Controller output, Y axis (integrated to controller cycle)
11 ControllerNGZ_Int Controller output, Z axis (integrated to controller cycle)
12 PosCalcSentOffsetInt Established sensor offset, Y axis
13 PosCorrZ Established sensor offset, Z axis
14 ControllerNGCleanPo- Corrected weave signal, Y axis
sIN
15 PosCorrY Overall correction frame, Y axis
16 ControllerNGUDZHeight Upper hysteresis barrier, vertical controller
17 ControllerNGLDZHeight Lower hysteresis barrier, vertical controller
18 ControllerNGState Internal states of the controller state machine
19 ControllerNGError Coded error output of the controller (type: INT, bit-coded)
20 ControllerNGTrigger Trigger window for measured value generation and refer-
ence value information
21 ControllerNGMid- Measured mean values of the controller
ValMeas
22 ControllerNGActSideR- Current measured value, lateral controller
atio
23 ControllerNGUDZSide Upper hysteresis barrier, lateral controller
24 ControllerNGLDZSide Lower hysteresis barrier, lateral controller

KUKA.ArcSense 2.0

13 Maintenance
13 Maintenance
13.1 Shunt box maintenance

t
If used correctly, the shunt box is maintenance-free. Visual inspections of the

cabling are recommended in order to be able to detect changes in good time.
If damaged, exchange the complete shunt box.

KUKA.ArcSense 2.0

14 Repair
14
4
Repair
14.1 Exchanging the shunt box
Description The new shunt box may have a different revision level from that of the existing
shunt box, e.g. RS1 instead of RS0. If this is the case, the existing shunt box
must be removed from the WorkVisual project and replaced with the new
shunt box.
Precondition  The robot controller is switched off and secured to prevent unauthorized
Procedure 1. Disconnect the shunt box from the power source.

2. Unplug the connecting cables.
3. Disconnect the ground conductor.
4. Unscrew the shunt box.
5. Screw on the new shunt box.
6. Plug in the connecting cables on the shunt box.
7. Plug in the ground conductor on the shunt box.
8. Connect the new shunt box to the power source.
9. If the exchanged shunt boxes have different revision levels:
 Remove the existing shunt box from the WorkVisual project and insert
the new shunt box into the project.
(>>> 10.2 "Inserting the shunt box in a project" Page 34)

KUKA.ArcSense 2.0

15 Decommissioning, storage and dispos...
15 Decommissioning, storage and disposal
15.1 Decommissioning the shunt box

s
Precondition  The robot controller is switched off and secured to prevent unauthorized
Procedure 1. Disconnect the shunt box from the power source.

2. Unplug the connecting cables.
3. Disconnect the ground conductor.
4. Unscrew the shunt box.
5. Prepare the shunt box for storage or transportation.
15.2 Storing the shunt box
Description If the shunt box is to be put into long-term storage, the following points must
be observed:
 The place of storage must be as dry and dust-free as possible.
 Avoid temperature fluctuations.
 Avoid condensation.
 Observe and comply with the permissible temperature ranges for storage.
 Select a storage location in which the packaging materials cannot be dam-
aged.
 Only store the shunt box indoors.
Procedure  Cover the shunt box with ESD protection foil and seal it against dust.
15.3 Disposal of the shunt box
When the shunt box reaches the end of its useful life, dispose of it as electrical
scrap without disassembling.

KUKA.ArcSense 2.0

16 KUKA Service
16 KUKA Service
A
16.1 Requesting support

v
Introduction This documentation provides information on operation and operator control,

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

 Description of the problem, including information about the duration and
frequency of the fault
 As comprehensive information as possible about the hardware and soft-
ware components of the overall system
The following list gives an indication of the information which is relevant in
many cases:
 Model and serial number of the kinematic system, e.g. the manipulator
 Model and serial number of the controller
 Model and serial number of the energy supply system
 Designation and version of the system software
 Designations and versions of other software components or modifica-
tions
 Diagnostic package KRCDiag
Additionally for KUKA Sunrise: Existing projects including applications
For versions of KUKA System Software older than V8: Archive of the
software (KRCDiag is not yet available here.)
 Application used
 External axes used
16.2 KUKA Customer Support
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Argentina Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
ventas@costantini-sa.com
Australia KUKA Robotics Australia Pty Ltd

45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
info@kuka-robotics.com.au
www.kuka-robotics.com.au

KUKA.ArcSense 2.0
Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
info@kuka.be
www.kuka.be
Brazil KUKA Roboter do Brasil Ltda.

Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
info@kuka-roboter.com.br
www.kuka-roboter.com.br
Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
robotec@robotec.cl
www.robotec.cl
China KUKA Robotics China Co., Ltd.

No. 889 Kungang Road
Xiaokunshan Town
Songjiang District
201614 Shanghai
P. R. China
Tel. +86 21 5707 2688
Fax +86 21 5707 2603
info@kuka-robotics.cn
www.kuka-robotics.com
Germany KUKA Roboter GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
Hotline.robotics.de@kuka.com
www.kuka-roboter.de

16 KUKA Service
France KUKA Automatisme + Robotique SAS

Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
commercial@kuka.fr
www.kuka.fr
India KUKA Robotics India Pvt. Ltd.

Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
info@kuka.in
www.kuka.in
Italy KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
kuka@kuka.it
www.kuka.it
Japan KUKA Robotics Japan K.K.

YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7691
Fax +81 45 744 7696
info@kuka.co.jp
Canada KUKA Robotics Canada Ltd.

6710 Maritz Drive - Unit 4
Mississauga
L5W 0A1
Ontario
Canada
Tel. +1 905 670-8600
Fax +1 905 670-8604
info@kukarobotics.com
www.kuka-robotics.com/canada

KUKA.ArcSense 2.0
Korea KUKA Robotics Korea Co. Ltd.

RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
info@kukakorea.com
Malaysia KUKA Robot Automation (M) Sdn Bhd

South East Asia Regional Office
No. 7, Jalan TPP 6/6
Taman Perindustrian Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 (03) 8063-1792
Fax +60 (03) 8060-7386
info@kuka.com.my
Mexico KUKA de México S. de R.L. de C.V.

Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de México
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
info@kuka.com.mx
www.kuka-robotics.com/mexico
Norway KUKA Sveiseanlegg + Roboter

Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
info@kuka.no
Austria KUKA Roboter CEE GmbH

Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 7 32 78 47 52
Fax +43 7 32 79 38 80
office@kuka-roboter.at
www.kuka.at

16 KUKA Service
Poland KUKA Roboter CEE GmbH Poland

Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
ServicePL@kuka-roboter.de
Portugal KUKA Robots IBÉRICA, S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729 780
Fax +351 265 729 782
info.portugal@kukapt.com
www.kuka.com
Russia KUKA Robotics RUS

Werbnaja ul. 8A
107143 Moskau
Russia
Tel. +7 495 781-31-20
Fax +7 495 781-31-19
info@kuka-robotics.ru
www.kuka-robotics.ru
Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
info@kuka.se
Switzerland KUKA Roboter Schweiz AG

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
info@kuka-roboter.ch
www.kuka-roboter.ch

KUKA.ArcSense 2.0
Spain KUKA Robots Ibérica, S.A.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
comercial@kukarob.es
South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za
Taiwan KUKA Robot Automation Taiwan Co., Ltd.

No. 249 Pujong Road
Jungli City, Taoyuan County 320
Taiwan, R. O. C.
Tel. +886 3 4331988
Fax +886 3 4331948
info@kuka.com.tw
www.kuka.com.tw
Thailand KUKA Robot Automation (M)SdnBhd

Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. +66 2 7502737
Fax +66 2 6612355
atika@ji-net.com
www.kuka-roboter.de
Czech Republic KUKA Roboter Austria GmbH

Organisation Tschechien und Slowakei
Sezemická 2757/2
193 00 Praha
Horní Počernice
Czech Republic
Tel. +420 22 62 12 27 2
Fax +420 22 62 12 27 0
support@kuka.cz

16 KUKA Service
Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
info@kuka-robotics.hu
USA KUKA Robotics Corporation

51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
info@kukarobotics.com
www.kukarobotics.com
UK KUKA Robotics UK Ltd

Great Western Street
Wednesbury West Midlands
WS10 7LL
UK
Tel. +44 121 505 9970
Fax +44 121 505 6589
service@kuka-robotics.co.uk
www.kuka-robotics.co.uk

KUKA.ArcSense 2.0

Index
Index
Numbers L
2014/30/EU2014 19 Licenses 6
2014/35/EU2014 19 Low Voltage Directive 19
A M
Amplitude 45, 49, 54, 58 Maintenance 65
Arc types 10 Manual correction, performance 29
Arc welding equipment 19 Manual correction, proceeding with welding 31
ArcTech diagnosis editor 59 Maximum correction per cycle 39
ArcTech Editor, opening 34 Menus 29
Misuse 13
C
Calibration options 38 N
Configuration 33 Norms 19
Connecting cables 15
Connecting cables, cable lengths 15 O
Open source 6
D Operation 29
Decommissioning 69 Overview, ArcSense 7
Diagnosis 59
Dimensioning, welding cable 21 P
Directives 19 Planning 21
Disposal 69 Plates and labels 16
Documentation, industrial robot 5 Process conditions, general 10
Product description 7
E Programming 41
Electromagnetic compatibility (EMC) 19 Programming instructions 41
EMC Directive 19
EN 60974-122011 19 R
EN 61000-6-22005 19 Reaction to seam guidance errors 36
EN 61000-6-42007 + A12011 19 Recommissioning 23
Envelope monitoring 7, 36 Repair 67
Envelope violation 29 Restrictions 9
Expert configuration 39 RS 6
RS number 6, 17, 34
F RSI monitor 59
Functional principle 7
Functionality 7 S
Safety 19
G Safety instructions 5
Global settings, modifying 36 Sensor error 6
Sensor guidance, activating (ARC ON) 41
H Sensor guidance, activating (ARC SPLINE) 50
Hardware components 11 Sensor guidance, deactivating (ARC OFF) 50
Hole pattern, shunt box 16 Sensor guidance, modifying (ARC SWITCH in
the ARC spline block) 54
I Sensor guidance, modifying (ARC SWITCH) 45
Identification plate 17 Service, KUKA Roboter GmbH 71
Inputs/outputs, configuration 35 Shunt box, exchanging 67
Installation 27 Shunt box, hole pattern 16
Intended use 13 Shunt box, inserting in project 34
Interface 12 Shunt box, installingShunt box, connecting 23
Introduction 5 Start-up 23
Status key, deactivating sensor guidance 31
K Status keys, manual correction 30
Knowledge, required 5 Storage 69
KUKA ArcSense Shunt Box Basic 6, 12 Support request 71
KUKA Customer Support 71 System requirements 27

KUKA.ArcSense 2.0
T
Target group 5
Technical data 15
Terms used 6
Terms, used 6
Tool direction 36, 37
Training 5
Transportation 25
U
Uninstallation, ArcSense 28
Update, ArcSense 27
Use, intended 13
User-specific power sources 39
W
Warnings 5
Weave length 45, 49, 54, 58
Weave pattern, height 45, 49, 54, 58
Weave pattern, length 45, 49, 54, 58
WorkVisual 10

KUKA.ArcSense 2.0

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KUKA System Technology KUKA Roboter GmbH

For KUKA System Software 8.3

Version: KST ArcSense 2.0 V3

Publication: Pub KST ArcSense 2.0 (PDF) en

2 / 81 Issued: 28.07.2017 Version: KST ArcSense 2.0 V3

2 Product description ..................................................................................... 7

3 Technical data .............................................................................................. 15

6 Start-up and recommissioning ................................................................... 23

Issued: 28.07.2017 Version: KST ArcSense 2.0 V3 3 / 81

10.4.1 “ArcSense” tab (I/O definition) ........................................................................... 35

15 Decommissioning, storage and disposal .................................................. 69

16 KUKA Service ............................................................................................... 71

4 / 81 Issued: 28.07.2017 Version: KST ArcSense 2.0 V3

1.1 Target group

For optimal use of our products, we recommend that our customers

1.2 Industrial robot documentation

The industrial robot documentation consists of the following parts:

1.3 Representation of warnings and notes

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable

These warnings mean that death or severe injuries may

These warnings mean that minor injuries may occur, if

These warnings mean that damage to property may oc-

These warnings contain references to safety-relevant information or

This warning draws attention to procedures which serve to prevent or remedy

The following procedure must be followed exactly!

Procedures marked with this warning must be followed exactly.

Issued: 28.07.2017 Version: KST ArcSense 2.0 V3 5 / 81

Tip to make your work easier or reference to further information.

1.4 Terms used

Further information about open-source licenses can be requested

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Fig. 2-1: Envelope monitoring

1 Weave amplitude (deflection to one side from the path center)

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Fig. 2-2: Teaching the sensor

1 Minimum distance for teaching the sensor

Production-related contamination of the weld seam prep-

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Fig. 2-3: Positive lateral bias

Fig. 2-4: Negative lateral bias

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 On-the-fly activation/deactivation of the arc

Seam tracking depends, among other things, on the welding process

2.2 General process conditions

Reliable and reproducible sensor guidance requires compliance with a num-

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2.3 Hardware components

The following hardware components are optionally available:

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A 95 mm2 welding cable is permissible up to a maximum weld current

2.3.1 KUKA ArcSense Shunt Box Basic

Fig. 2-5: Shunt box interface

1 Data cable connection X31

Fig. 2-6: Shunt box connection to robot (example)

1 Weld power source

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Fig. 2-7: Shunt box connection to control cabinet (example)

1 Weld power source

Equipotential bonding (ground conductor) between shunt box and

2.4 Intended use

Use KUKA.ArcSense is intended exclusively for arc welding in an industrial envi-

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