K-ROSET

How to create conveyor

synchronization project

97060-2637DEB

Kawasaki Heavy Industries, Ltd

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4
Summary 3

Safety Instruction 4

1 General Description 5
1.1 Outline of Conveyor Synchronization 5

1.2 Coordinate System of Consecutive Conveyor Line 7

2 Procedure to Create Conveyor Project 9

2.1 Target System 9

2.2 Start 10

2.3 Plug-ins Settings 11

2.4Creation of Project 12
Creating a New Project 12

2.5 Addition of Robot and Pedestal 14

Addition of Robot 14
Addition of Robot Pedestal 15

2.6 Addition of Spray Gun 18

2.7 Addition of Conveyor and Work 21

Addition of Conveyor 21
Setting of Conveyor Parameter 23
Addition of Work 25

2.8 Addition of Obstacle 30

2.9 Teaching 32
Set Teach panel to Floating 32
Setting of the Pair of Collision 34
Setting of Motion Limits 36

2.10 Creation of Teaching Point 39

Addition of Teaching Point by Click 40
Alignment of Teaching Point 43
Copy of Teaching Point 47

2.11 Creation of Teaching Program 50

Creation of Move Instruction 50

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 Creation of Motion Instruction 54
Operation Check of Move Instruction 56
Addition of Paint instruction 58

2.12 Simulation 61
Check of Conveyor Setting 61
Setting of Simulation Screen 61
Settings of Repeat 63
Repeat 66

3 Various Setting Procedures 69

3.1 Procedure of Wal-Hang Installation 69

3.2 Notice When Saving a Project 72

3.3 Change of Paint Pattern 74

3.4 Attachment of Arm Cover 78

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Summary
This manual describes operating instructions for the K-ROSET . This manual should
be read with careful review of the related manuals listed below. Once the contents of all
the manuals are thoroughly read and understood, the robot can be used.

1. Robot Instruction manual

2. Option Manual
3. AS language reference Manual

The contents of this manual are described on condition that installation and connection
of the robot are done in accordance with the above listed manuals.

This manual provides as much detailed information as possible on the standard

operating methods for the Kawasaki robot. However, not every possible operation,
condition or situation that should be avoided can be described in full. Therefore,
should any unexplained questions or problems arise during robot operation, please
contact Kawasaki Machine Systems. Refer to the contact information listed on the
rear cover of this manual for the nearest Kawasaki Machine Systems office.

The explanations in this manual include information on optional functions, but

depending on the specification of each unit, not every optional function detailed here
may be included with the robot. Also, note that figures given here may differ partially
from actual screens.

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

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

teaching, maintenance or inspection of the robot attend the necessary
education/training course(s) prepared by Kawasaki, before assuming their
responsibilities.

3 Kawasaki reserves the right to change, revise, or update this manual without
prior notice.

4 This manual may not, in whole or in part, be reprinted or copied without the prior
written consent of Kawasaki.

5 Store this manual with care and keep it available for use at any time. If the
robot is reinstalled or moved to a different side or sold off to a different use,
attach this manual to the robot without fail. In the event the manual is lost or
damaged severely, contact Kawasaki.
Copyright © 2011 Kawasaki Heavy Industries Ltd. All rights reserved.

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

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

[NOTE]

Denotes precautions regarding K-ROSET specification,

handling, teaching, operation and maintenance.

WARNING

1. The accuracy and effectiveness of the diagrams, procedures, and

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

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1 General Description
This manual describes directions and precautions of the explosion proof painting robot of
K-ROSET on the conveyor synchronization function.
For details on the functions of the robot unit and the procedure to create a conveyor
synchronization program, refer to an instruction manual of the robot.

1.1 Outline of Conveyor Synchronization

With the consecutive conveyor line where a painting work is loaded on the conveyor and
transferred (consecutively), the teaching of the robot also carried out with the work in a static
condition.

A robot paints automatically following the painting work loaded and carried on the conveyor.
This function is called a conveyor synchronization function.

The teaching at the consecutive conveyor line should be added with the following command,
compared with the teaching at the line where painting is carried out with the work being
stopped (such as takt line).

Synchronization start [CVSTART]

The teaching point after this command is reppeated following the conveyor.
Information of the record conveyor position recorded at teaching point (a position of the work
in the teaching compared with the input position of the robot repeat start signal) is included.

Synchronization exit [CVEND]

The teaching point after this command repeats asynchronously (not following) to a conveyor.

CV WAIT [CVWAIT #1, 2000mm]

While a work is transferred to the preset conveyor position, the robot waits.

For details of commands, refer to an instruction manual of the robot controller (90210-1199
D/E Conveyor Synchronization Manual).
K-ROSET can reproduce the environment shown in (Figure 1.1) on the window for teaching
and repeat.

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 Direction of World
Coordinate
Start LS, etc..

Conveyor Start
Conveyor Position
syncronization Conveyor
section Waiting Section

Hanger

図
Convey
or Work
Origin of
Conveyor Work

Origin of
Conveyor
Origin of
Robot

Figure 1.1: Example of System Configuration of Conveyor Synchronization

Conveyor Speed
The actual robot synchronizes with the conveyor by a conveyor synchronizer.
On the K-ROSET, conveyor speed is set in a value, and the conveyor working at a constant
speed is simulated. The conveyor speed is set using simulating function.

Record Conveyor Position

For teaching an actual robot, advance the conveyor carrying works to the operating range of
the robot, and record the conveyor position at that time as a record conveyor position as well
as a position/posture of the robot.
Selection of the teaching step recording a conveyor position advances the conveyor work to
the record conveyor position automatically.
At the time of the modification, since the work is moved to the record conveyor position on
teaching, modification work can be started straight.

Conveyor Start Position

In the K-ROSET, one "conveyor" is certainly added to a layout at the time of the conveyor
synchronization.
Speed, type of motion axis, and plus/minus direction of axis are set in the conveyor. The work
to be taught as a child model of this conveyor is added. This is called a conveyor work. When
synchronized repeat is carried out, the added conveyor work operates.
For creating a layout, allocate the devices and the actual robots so that the positional
relationship between the devices matches the positional relationship of the actual robots.

Even the consecutive conveyor line where a paint work is loaded on the conveyor and
transferred (consecutively), the teaching of the robot is carried out work with a work stopped.

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1.2 Coordinate System of Consecutive Conveyor

Line
K-ROSET can define a virtual space including a robot, work, and peripheral devices. Refer to
the K-ROSET instruction manual for details.
The positional relationship of typical devices of the consecutive conveyor line and the
relationship of the coordinate system to indicate it are shown here. Refer to Figure 1.2.

Direction of World
Coordinate
Start LS, etc..

Conveyor Start
Conveyor Position
syncronization Conveyor
section Waiting Section

Hanger

Convey
or Work
Origin of
Conveyor Work

Origin of
Conveyor
Origin of
Robot

Figure 1.2:
Relationship between Allocation of Consecutive Conveyor Line and Coordinate System

Description of Figure 1.2

This system has a base x-axis of the robot displosed parallel to a world x-axis and a conveyor
x-axis.

★ The conveyor work realizes simulation of work moving with a conveyor by having a logical bonding relationship
(a parenting relationship) with a conveyor so that a conveyor is a parent and a conveyor work is a child.
★ Motion of the conveyor using simulation function moves the conveyor work to a forward direction of the
x-axis of the conveyor origin at the set constant conveyor speed. The conveyor is fixed and does not run..
★ The creation of an origin of the conveyor work model to match the coordinate direction of the conveyor will
simplify the additional operation of the work.
★ The initial position of the conveyor origin is set at the conveyor start position (LS setting position).

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Memo

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2 Procedure to Create Conveyor Project

This chapter describes a procedure to simulate the conveyor synchronization of the explosion
proof painting robot with K-ROSET.

2.1 Target System

Figure 2.1 shows the specification of the project to be created.

Direction of World
Coordinate
Start LS, etc..

Conveyor Start
Conveyor Position
syncronization Conveyor
section Waiting Section

Hanger

Convey
or Work
Origin of
Conveyor Work

Origin of
Conveyor
Origin of
Robot

Figure 2.1: Target System of Conveyor Simulation

Brief description of Figure 2.1

★ The conveyor is set parallel to the x-axis of the world.

★ The conveyor is allocated so that the direction of the conveyor work to move matches the plus and minus of
the world.
★ The conveyor speed is to be 3.3m/minute.
★ As for the robot, KG264 equipped with a conveyor function is installed on the floor.
★ The base coordinate x-axis of the robot is installed to be parallel to the world coordinate x-axis, and the
direction of the x-axis is allocated so that a base coordinate directs reversely to a world coordinate.
★ An electrostatic bell is used as the tool.

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 2.2 Start
This chapter describes a procedure to start K-ROSET.

1 Double-click the shortcut icon on the Desktop.

Example of shortcut icon

K-ROSET starts. The screen after the start will be figure 2.2, for example.

Figure 2.1: Example of screen after start

 When the shortcut icon is not on the desktop, select Start - Programs - Kawasaki - K-ROSET Hisui or
SolidWorks

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 2.3 Plug-ins Settings
This chapter describes a procedure to specify the Plug-ins necessary for consecutive conveyor
simulation of the explosion proof painting.

1 Select Plug-ins Setting from Settings menu.

Plug-ins starts.

2 Place a check mark as follows in the function column of the Plug-ins screen.
When a check mark has already been placed, you do not have to place.
For details of functions, refer to the K-ROSET instruction manual.

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 2.4Creation of Project
This chapter describes creating procedure of the project.

Creating a New Project

Make sure to save the project before this operation.

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1 Right-click the Project icon [ ] in the layout.
The menu related to the project is displayed.

2 Click [Project] - [New] from the menu.

The view is cleared, and Project Setting screen is displayed.

 In Project Name, "new_project" is specified by default.。

 When a project already exists at the time of clicking OK, a confirmation message asking to overwrite is
displayed.

3 Enter a project name in the Project Name column. Enter a description of the project in Comment column.

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4 Click OK button.
The project with the specified project name is newly created.

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 2.5 Addition of Robot and Pedestal
This chapter describes a procedure to a robot and an obstacle (pedestal).

Addition of Robot

1 Right-click the Project icon [ ] in the layout, and select [Add] - [Robot] from menu.
The robot load screen is displayed.

2 Select the selection items as follows (shown on the right), and click OK button.

Selection of items
Application Painting

Controller E controller
Series KG-Series
Library Type Custom
Product Code KG264-A001-CV-J3CoverL
AS Version 8000001E

 For details of items, refer to the K-ROSET instruction manual

 KG264-A001-CV-J3CoverL is the special specification attached with a large cover.

3 Display a Position screen to allocate a robot.

4 Double-click the robot icon [ ] in the layout.

Position screen is displayed.

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5 Set the value shown on the following screen to each coordinate value, and click OK button.

The robot is allocated at the specified position.

Addition of Robot Pedestal

1 Right-click the Project icon [ ] in the layout.

The menu related to the project is displayed.

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2 Click [Add] - [Environment] - [Obstacle…] from menu.
Select Shape File screen is displayed.

3 Click KHIlibraries folder icon on the left of the screen.

Select KHIlibraries\Envs\Equipment\Pedestals folder.

4 Select Pedestal_500_500_500.stl file, and click Open button.

The robot pedestal is added to the layout as Obstacle 1. A robot pedestal of 500mm in height
is added.

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 Left-click the Obstacle 1 in the layout to change the name.
You can enter a name. Enter "Pedestal" and press Enter key to fix.

5 Allocate the pedestal. Double-click the pedestal in the layout (Obstacle icon [ ]).
The position screen is displayed.

6 Set the value shown on the following screen to each coordinate value, and click OK button.

The pedestal is allocated at the specified position.

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 2.6 Addition of Spray Gun
This chapter describes a procedure to add a spray gun. The procedure to load the spray gun
already registered is described.

1 Right-click the robot icon [ ] in the layout.

The menu related to the robot is displayed.

2 Click [Tool] - [Load..].

Select Tool File screen is displayed.

3 Click KHIlibraries folder icon on the left of the screen, and select Tools\Paint\ESA200VP_T4023_150 folder.

 Select the file registered as a tool to display the Thumb nail with T.

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4 Select ESA200VP_T4023_150 .krprj, and click [open] button.
The tool file is loaded, and a gun is attached to the wrist flange of the robot.

Paint Pattern

 When a tool has been already attached, the attachment of the tool is released, and the loaded tool is
attached.
 The paint pattern of gun distance 150mm has been previously specified in this spray gun.

 Make sure to carry out a synchronous operation just after the addition of a spray gun to a layout, or after the
change of tool transformation value. Synchronization of [Controller <- Layout] is carried out on the
synchronization screen.

5 Click the robot R01[C01] tab of the controller tab.

6 Click synchronization button of the R01[C01] tab.

Synchronize screen is displayed.

7 Place a check mark in the Controller Settings.

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8 Click Layout -> Controller button.
The synchronization screen is displayed. Click Yes.

Synchronous operation of tool transformation

Value
When linear interpolation step and converted value variables are added to a certain
program, recording is carried out according to the tool transformation value of the tool
attached at the time of addition. When this program is transferred to the controller and
executed, the tool transformation value of the attached tool should be set to the
controller.

When several tools are loaded, pay a special attention to execute the program with the
tool attached again.
After attachment of the tool or modification of the tool transformation value, we
recommend that you make sure to carry out a synchronous operation of Layout ->
Controller on the synchronization screen.

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 2.7 Addition of Conveyor and Work
This chapter describes a procedure to add a conveyor and a conveyor work.

Addition of Conveyor

1 Right-click the Project icon [ ] in the layout.

The menu related to the project is displayed.

2 Click [Add] - [Conveyor].

Select Shape File screen is displayed.

3 Click KHIlibraries folder icon on the left of the screen.

Select KHIlibraries\Envs\SimpleShapes\Cones folder.

 The conveyor is fixed and does not run. Any form of STL file is acceptable.
 Selection of STL does not display image. Only structured files of extension krprj are displayed in image.

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4 Select Cone_LightBlue_S.STL file and click [Open] button.
The model is loaded in the world origin and added as a model file name in the layout.

2 The name is changed. Left-click Cone_LightBlue_S.STL in the layout.

You can enter a name. Enter "Conveyor" and press Enter key to fix.

3 Allocate a conveyor. Double-click the conveyor in the layout.

The position screen is displayed.

4 Set the values shown in the following screen to each coordinate values, and then click OK button.

The conveyor is allocated at the specified position.

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 Conveyor

Setting of Conveyor Parameter

1 Set a parameter of the conveyor. Click Plug-ins, and then Simulation.

Simulation screen is displayed. Select a Conveyor Settings tab.

2 Set the followings in the Conveyor Settings tab. Click Apply button after setting.
Speed 55mm/s
Direction Forward
Axis Type XSlide

3 To set a conveyor environment of the virtual controller to the conveyor, display a virtual teach pendant.

4 Click the robot R01[C01] tab of the controller tab.

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5 Click the pendant display on the controller screen.
The Virtual Teach Pendant is displayed.

6 Click auxiliary button on a LCD screen, and select 11. Handling/Conveyor Setting, 2. Conveyor
synchronization, and then 3. Environmental Data Setting.
Environmental data setting screen is displayed.

7 Specify "Line Direction" and "Line Increase Direction- Set Axis Increase Direction" as follows.
Line Direction X
Line Increase Direction Opp.

 Specify "Opposite" since the forward direction of the setting axis is reversely allocated against the forward
direction of the X-axis of the conveyor and the forward direction of the X-axis of the robot base coordinate.

8 Click Register button of the teach pendant keyboard screen.

A message is displayed to indicate the setting is completed.

9 Click the robot R01[C01] tab of the controller tab. Click the Synchronize button.
The synchronization screen is displayed.

10 Check a box in Controller Settings.

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11 Click Layout<- Controller button.
The synchronization screen is displayed. Click Yes.

 To reflect the setting modified on the virtual pendant and the terminal to the layout, synchronize Layout <-
Controller on the synchronization screen.

Addition of Work

This chapter describes a procedure to add a conveyor work.

1 Right-click the Conveyor in the layout.

The menu related to the conveyor is displayed.

2 Click [Add] - [Environment] - [Work].

Select Shape File screen is displayed.

3 Click KHIlibraries folder icon on the left of the screen.

Select KHIlibraries\Envs\Equipment\Others folder.

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4 Select HangerJigFloor.stl file and click [Open] button.
The model is loaded in the conveyor origin and added as Work 1[ ] in the layout.

5 The name is changed. Left-click the Work 1 icon [ ] under the conveyor in layout.
You can enter a name. Enter "Hanger" and press Enter key to fix.

6 Change the layout. Left double-click Hanger [ ] in the layout.

The position screen is displayed.

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7 Set the values shown in the following screen to each coordinate values, and then click OK button.

Hanger is allocated at the specified position.

8 Add the works for painting to the Hanger. Right-click Hanger icon [ ], and then click [Add] -
[Environment] - [Work].
Select Shape File screen is displayed.

9 Click KHIlibraries folder icon on the left of the screen.

Select KHIlibraries\Envs\CarParts folder.

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10 Select Car2Rr.stl file, and then click [Open] button.
The model is loaded in the Hanger origin and added as Work 1[ ] under Hanger in the layout..

11 Change the layout. Left double-click Work 1 [ ] under hanger in the layout.
The position screen is displayed.

12 Set the values shown in the following screen to each coordinate values, and then click OK button.

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The parts are allocated as follows.

 Instead of the left double-click on the icon of the work, double-clicking on the work model on the view or
selecting [Position] - [Change] from the menu of the work can also display the position change screen.

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 2.8 Addition of Obstacle
This chapter describes a procedure to add obstacles. An obstacle is added using a simplified
shape creating function.

1 Start a simplified shape creating screen. Click Plug-ins, and then Simple Shape Generator from the main
menu.

2 Create a wall of the robot.

The simple shape generator screen starts. Select box form tab, and enter the dimensions of
X/Y/Z as shown below.
Specify a memory of the transparent gauge at the center in the output column.

 Specify the dimensions in world coordinate.

3 Click the obstacle button.

The model is output in the size specified in the view. The model is output as Obstacle 1 in the
layout.

 The origin of the model created by the simplified shape creation is located at the center of the XY plane
under the model.

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4 Change the name for simple recognition. Left-click Obstacle 1 in the layout.
You can enter a name. Enter "Wall Left" and press Enter key to fix.

5 Allocate the wall. Double-click the wall left in the layout (Obstacle icon [ ]).
The position screen is displayed.

6 Set the values shown in the following screen to each coordinate values, and then click OK button.

The wall left is allocated at the specified position.

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 2.9 Teaching
This chapter describes a procedure to teach with a Teach panel.
Preliminary preparation work is described.

Set Teach panel to Floating

Floating of the Teach panel removes the panel from the right task panel. In addition,
simultaneous checking with the program screen is allowed, and the usability is improved. When
this clause is unneeded, please skip.

 Restart of K-ROSET is needed to enable the floating setting. When the project is opened, make sure to save
the project before this work.

1 Click the setting of main menu, and then the setting menu of Plug-ins.
The setting menu of Plug-ins is displayed.

2 Place a check mark in a Floating column of the Teach panel, and then click OK button.
A confirmation screen is displayed. Click OK button.

3 Restart the K-ROSET.

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The Teach panel is displayed as floating from the right task panel. Since the Teach panel can
be separated from the program, a program step can be created with changing a posture of the
robot.

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 Setting of the Pair of Collision

During the teaching, when Collision occurs between a robot, a work, and an obstacle, the
model can be displayed in different color.
The setting of Collision pair between models is needed for the display. When this clause is
unneeded, please skip.

1 Click Plug-ins of main menu, and then click Collision Check.

The setting menu of Collision Check is displayed.

 Limitation to the necessary model improves performance of the K-ROSET.

2 Create the pair of Collision.

Setting of the pair of Collision below which may possibly occur in this system is carried out.
J2 to J6 Hanger/Work 1
Wall Left
Tool Hanger/Work 1
Wall Left

3 Expand a tree of the robot in the left tree, and select J2. Click the Hanger in the right tree. Click Add
button.
The pair is added to the list of Collision pair. When a parent is specified, all the following children
are added to the pair list.

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4 Repeat the same procedure as 7 to add pairs of J3 to J6 and Hanger.

5 Add pairs of the tool (ESA200VP) and Hanger.

6 Select J2 to J6 and Wall Left to add pairs. Add the tool and Wall Left.

 When the pair of the tool is created, Pattern, that is, a child of the tool is registered in the collision pair as
shown below. Pattern is a paint pattern, and should be excluded from a collision target basically.

7 Exclude Pattern of the tool from collision pair list. Select Patten in the left tree. Select Project in the right
tree. The target pair is highlighted in red.

8 Click Delete button.

The list highlighted in red is deleted.

9 The pair list is ready. Click Apply button to fix.

Bold face disappears from the pair list. In addition, the items registered as pair are placed with
a check mark.

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 Setting of Motion Limits

The movable range of each joint of the robot is set. In the real system, the mechanical stopper
and uppler/lower limit of user operation are provided to prevent a Collision with walls, etc.
caused by evolution of JT1 of the robot.
In K-ROSET, upper/lower limit of user operation can be set. When this clause is unneeded,
please skip.

1 Right-click the robot icon in the layout.

The menu of the robot is displayed.

2 Click the RobotArm Configuration menu.

The RobotArm Configuration menu is displayed.

3 Left-click the R01 icon from the left tree.

4 Select UP-LIM from the drop-down list of the extension setting column.

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5 After selecting UP-LIM, left-click ... at the rightmost of the numeric input field.
The Working Area Limitation Setting screen is displayed. Set the upper limit and the lower limit.

6 In the layout, carry out the user setting of the each joint as follows.
Enter 105 degrees into the upper/lower limit of JT1, -46 degrees into the lower limit of JT2,
and 180 degrees into the upper/lower limit of JT5, respectively.
The unfixed numeric-field because of change is displayed in green.

7 Click OK button to return to the Working Area Limitation Setting screen.

8 Click Apply button, and a confirmation message asking to restart the controller is displayed.
Click Yes to reflect the set value of the layout to the controller.

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  System data of the robot can be set in the RobotArm setting. When the details changed on this screen should
be also reflected to the virtual controller, restart of the controller is needed to reflect to the controller.

9 Click Controller each joint limiting value button on the optional screen of the Teach panel.
The button sinks down, and the display turns to ON.

 Turning this option to On prevents the robot from the operation exceeding upper/lower limits of each joint
when the robot is operated on the Teach panel.

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2.10 Creation of Teaching Point
This chapter describes a procedure to create a teaching point on the conveyor work and
teach.
Before creating the teaching point, painting part to be created here is described. Refer to
Figure 2.10.1 below.
The blue line shows an outline of robot motion. Red points show the painted trace. Red and
blue arrows on the work are teaching points.
The points are created to be almost straight along the longitudinal direction of the work. The
teaching points 1 to 8 are created as one route (paint pass) this time, and will be a base for
creating teaching programs afterward.
(Teaching point 9 is created separately to copy a teaching point.)
The spray painting are taught so that a gun faces perpendicularly to the paint surface.
Therefore, in the K-ROSET, teaching points are created perpendicularly to the clicked point as
default.

2.10.1 Top view

2.10.1 Side view

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  The positions of the created teaching points are shown with points in the figure, but they can also be shown
with a line.

Addition of Teaching Point by Click

Teaching point is created with the Teach panel.

1 Move a conveyor work to the movable range of the robot.

2 Right-click the conveyor in the layout, and display a conveyor menu to select a current position.
A current position screen is displayed.

3 Enter 4000 in the current position, and click Apply button. The unit is mm.
The work moves to the position of 4,000mm.

4 Click the Click teach button on the optional screen of the Teach panel.
The button sinks down, and the display turns to ON to enable Click teach.
After this, teaching points are added by each left click of a mouse on the model in the view.

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5 Add a teaching point to the work.
Move the viewpoint to the position where a teaching point should be created, and left-click the
work. A teaching point arrow is added on the work plane. A teaching point is also added under
the conveyor work of the layout. The figure below shows the example of creating Teaching
point 1.

 When a wall prevents a smooth operation, you can hide the wall. Right-click the Wall Left in the layout, and
click the display of the menu. The check mark is removed, and the Wall Left is hidden.
 When a teaching point has been already created, the teaching point may not be created with the name of
Teaching Point 1. The number increases consecutively by every creation.

6 Move the robot to TP1. Left-click the Teaching Point 1 icon created in the layout.
The robot and tool arrow move (jump) to match the coordinate of TP1. When they do not
move, the robot cannot take the posture for the teaching point.
To take the posture, adjust the direction of the teaching point adequately, or move the work
closer to the robot.

7 When the robot cannot take the posture, change the direction of the teaching point. Double-click Teaching
Point 1 in the layout.
The position screen is displayed.
Increase/decrease the value of O with the base coordinate as a local coordinate. X and Y axes
rotates to the Z-axis of the teaching point (rotation in a bule arrow). Increase of the O value

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 rotates X and Y axes clockwise to the work surface as shown in a blue arrow in the right figure
below.

Increase/decrease O slightly, and click Apply button on the position screen to fix.
Click Teaching Point 1 in the layout again to ensure that the robot jumps.
When the robot does not move, repeat the procedure 7 until the robot moves.

 Alignment of the Y-axis of the teaching point (green arrow) to the robot allows the robot to take the
posture easily, but not allows all postures.

8 Create eight teaching points in reference to 2.10.1 Top View and Side view of this chapter, and the figure
below.
Click a work and create eight points roughly. Create the Teaching points 1 to 8 so that they are
almost allocated on the same pass. Alignment of the teaching points are carried out in the
following chapter, and carry out the fine adjustment such as jumping later.
The figure below shows only teaching points for reference.

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  Teach from the teaching point 1 like moving in ascending order. For easy recognition, the teaching points
should be created so that as a teaching point moves closer to the conveyor direction, the number of the
teaching point increases.
 Prevent a large change of the posture between the points next to each other. It is important to keep a fixed
posture of the gun wherever possible, and move on the plane to keep paint quality.

Alignment of Teaching Point

This chapter describes a procedure to align a position of the roughly-created teaching point
for one pass.
The teaching point was created by click teaching, and it takes time to align one teaching point
each for making a trace of one straight line. Several teaching points can be aligned at the same
time.
The teaching point 1 and point 8 should not be created on the work; they protrude from the
work slightly. The point protruding from the work enables the edge of the work to be painted
uniformly.
Subsequently, let a robot jump to each point to adjust the robot for operation.

The teaching point 1 and point 8 are created to protrude from a

work.

1 Enlarge a view so that the ball of teaching point 1 or the arrow of the coordinate can be clicked.

2 Bring a mouse cursor to a ball of teaching point 1 or an arrow, and right double-click.
A menu is displayed.

3 Select Position, and then select Change of the menu.

The position screen is displayed.

 Left double-click of teaching point 1 in the layout shows a position screen. But when a robot can jump, a
move of a gun nose to teaching point 1 disturbs the amendment of the position of the teaching point.
 Selection in this procedure will allow an easy amendment of the position without a robot move.

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4 Selecting Local for a standard coordinate, move the robot about 200mm in a forward direction of the X-axis
(a direction of the red arrow), and click Apply button.
The robot moved 200mm along an arrow of the teaching point.

5 Create the teaching point 8 to protrude from a work in the same way. Enlarge a view so that the ball of
teaching point 8 or the arrow of the coordinate can be clicked.

6 Bring a mouse cursor to a ball of teaching point 8 or an arrow, and right double-click.
A menu is displayed.

7 Select Position, and then select Change of the menu.

The position screen is displayed.

8 Selecting Local for a standard coordinate, move the robot about 300mm in a negative direction of the
Y-axis (an opposite direction of the green arrow), and click Apply button.
The robot moved 300mm along an arrow of the teaching point.

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 Align the teaching points 1 to 8 straight along the work.
(When the work is unneeded, please skip.)
Align the teaching points 1 to 8 to the Y value of the world coordinate of teaching point 1.
Write down the value previously on a position screen. The value is 450mm for this example.

1 Select some among 1 to 8 teaching points under the work 1 in the layout.

2 Display a region of the layout so that the entire of the teaching point 1 to 8 in the layout.

3 Select the teaching point 1, and click the teaching point 8 with pressing the shift key. Left double-click with
pressing the shift key.
The position screen is displayed.

4 Select World for the standard coordinates.

The symbol <*> is displayed for Title, and * mark is displayed for the numeric-field. These
symbols indicate that several objects are selected and several different positions coexist.

5 Enter the Y value 450mm of the world coordinate of teaching point 1 to a Y column of the position screen,
and press Enter key.
All the Y values of the selected teaching points are changed to 450mm.

Create the teaching point 9.

Copy the teaching points 1 to 8 with an automatic copy function of teaching points, and
record as a direction for creating the second pass.

1 Bring a mouse cursor to the teaching point 8 in the view, and right double-click.
A menu is displayed.

2 Click Edit, and then Copy from a menu.

The teaching point 8 is copied.

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3 Right double-click the work 1 in the view to display a menu.

4 Select Edit, and then Paste.

The teaching point is pasted as teaching point 9.

5 Right-click the teaching point 9 in the layout, and select Position, and then Change from a menu.
The position screen is displayed.

 Left double-click in the layout opens a position screen, but a robot jump disturbs the work. Therefore, the
Position screen is opened from a menu.

6 Select World for the standard coordinates. Move 100mm to the Y minus direction, and press Enter key.
Ensure that the robot moved to the point 100mm away, and click Apply button to fix.

7 Click each teaching point in the layout, and ensure that the robot jumps to the clicked teaching point.
When the robot does not move, the robot cannot take the posture for the teaching point. To
take the posture, adjust the position and direction of the teaching point adequately,

 When letting the robot jump, check an angle of the wrist by the gauge display on the Teach Panel to check if
a wrist does not turn excessively.

8 Select a Teach Panel, and click a gauge button.

The gauge is displayed as follows.

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  A wrist of the KG264 is a hollow structure, and paint and an air hose run inside it. The JT4 can be rotated 360
degrees and more. However, excessive rotation may twish off the hose inside. Take care on teaching.

9 When the robot takes the posture and each axis value is around the limit values or the twist rotates 360
degrees and more, we recommend modifying to be almost 0 degrees.

Copy of Teaching Point

A teaching point for one pass is created. This chapter describes a procedure to copy a
teaching point.
Use an automatic program creating (copy) function. For details, refer to an instruction manual.

1 To use a copy function, add a group under Work 1. Right-click the Work 1.
A menu is displayed.

2 Click Add, and then Group from a menu.

Group 1 is created under the Work 1.
Move the teaching points 1 to 8 under Work 1 to Group 1.

3 Select the teaching point 1, and select the teaching point 9 with pressing the shift key. Left-click the
teaching point 9 with pressing the shift key, and drag and drop in Group 1.

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4 Select a copy function from the right task panel. Click icon.
A copy function is displayed.

5 Click Add, and then Group from a menu.

Group 1 is created under the Work 1.

6 Enter the settings of the column for auto creating teaching points as follows.
The robot name currently selected in the layout is displayed.
As for the program name, select a group to enter a default name "group name _copy"
automatically.
Select Group 1 from the list box for Reference Group.
A name of "group 1_copy" enters automatically in Group Name.
Select as follows:
100mm for Pitch,
Two Times for repeating frequency, and
Opposite direction (Opposite direction will create teaching points of second pass and after in
return direction.

 Teaching points as well as programs can be created with this function. Please try.

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7 Click Create button.

8 The "group 1_copy" is created under a project in the layout.

9 Drag and drop the created "group 1_copy" under Work 1

When a work moves in the conveyor synchronization, the teaching point also moves with the
work.

10 Click the teaching points 10 to 25 to ensure that the robot can take a posture.

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 2.11 Creation of Teaching Program
This chapter describes a procedure to create a teaching program.
This chapter mainly describes a procedure to insert a move instruction and an auxiliary
command. The move instruction is created based on the teaching point created previously.

Creation of Move Instruction

Create a new program on a program screen.

1 Right-click the controller node, and then click [Add] - [Program].

A program node is created with a name of Pg001 under the controller.

2 Drag and drop all the teaching points of group 1_copy to create move instruction in linear interpolation.
Check on the followings in advance.

★ Move instruction in linear interpolation can be created by drag and drop.

★ The conveyor value when droping is reflected. A current position of the conveyor is 4,000mm.
★ The program node on the program screen of the dropping destination can be observed.

3 Right-click the root node of the program. Click Setting.

The Setting screen is displayed.

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4 Select motion command amont the D&D additional setting column, and select "Move by linear interpolation
motion".
Click Apply button to fix.

5 Right-click the conveyor in the layout. Select the current position from a menu.
A setting screen is displayed.

6 Left-click the teaching point 10 of group 1_copy, and select the teaching point 25 with pressing the shift
key.
All teaching points are selected.

7 Next, drag the teaching point 25 with pressing the shift key, and drop it in the program node on the program
screen.
Bringing a mouse cursor to a program name will display + mark. Release the mouse button
there.

The linear line move instruction of the explosion proof paint command was created. A column
at the end of the command line is a conveyor value.

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8 Left-click the move instruction.
The robot jumps to the posture.

9 Press the DownArrow key on the keyboard from the selected move instruction (or step).
Move to the following move instruction to jump to the move destination. Moving among
columns with a top and bottom key will make the robot to take a specified positional posture.
Since the conveyor value is specified, the Hanger and Work 1 under the conveyor move to the
position together.

Create an Original Position.

Under the condition where a robot does not work, the posture which does not collide even
when the conveyor or a conveyor work moves and which is easy to start painting motion is
registered as a move instruction.
Record the following postures of each axis.
Jt1 Jt2 Jt3 Jt4 Jt5 Jt6 Conveyor position
89.529 30.59 -51.337 94.567 -55.256 -36.392 0

 Since the the conveyor value is recorded as an asynchronous operating position, any conveyor value is
acceptable.

1 Select tab from the task panel on the lower part of the screen of K-ROSET.
Click the top move instruction in a program.
Move instruction tab is selected automatically for the tab, and a position/posture of the
selected move instruction is displayed.

2 Select Move in Each Axis Interpolation Function in a combobox.

The each axis posture at the position is displayed.

3 Enter the axis values mentioned above, and click Insert button.
Instruction is inserted in the previous line.

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4 Add the same instruction at the end of the motion program.

5 Select the each axis instruction at the top, and right-click. Click Edit, and then Copy from a menu.
The instruction is copied.

6 Right-click the move instruction at the bottom line of this program, and click Edit, and then Paste from a
menu.

The copied each axis instruction is copied at the bottom line.

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 The creation of the move instruction is completed.

Creation of Motion Instruction

Add an instruction related to speed and a motion of the conveyor.

Enter a conveyor instruction.

Add a conveyor instruction behind each axis instruction of the program with a tab.

1 Click the second line of Pg001 on the program screen.

Move instruction tab is selected automatically on the program instruction screen.

2 Select Conveyor/Gun Instruction tab on the program instruction screen.

3 Select CV_WAIT, enter 1 for Conveyor number 1, 4000 for Waiting distance, and click Insert button.
Conveyor waiting instruction is inserted.

4 Select Conveyor Synchronization Start, and click Insert button.

Conveyor synchronization start instruction is inserted.

5 Click the each axis move instruction at the bottom line.

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 Move instruction tab is selected for the program instruction.

6 Select Conveyor/Gun instruction tab, and select Track OFF, and then click Insert button.
Conveyor synchronization exit instruction is inserted in front of each axis move instruction.

Enter Speed and Smooth instruction.

1 Click the each axis move instruction at the bottom line.

Move instruction tab is selected for the program instruction.

2 Select Speed instruction tab, and select Aircut Speed. Enter 1200, and click Insert button.
Aircut speed instruction is inserted.

3 Select Speed instruction tab, and select Spray peed. Enter 800, and click Insert button.
Spray speed instruction is inserted.

4 Select Speed instruction tab, and select Aircut JSpeed. Enter 100, and click Insert button.
Aircut JSpeed instruction is inserted.

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5 Select each axis instruction at the fourth line.

6 Select Accuracy/Timer instruction tab on a program instruction screen, and select Smooth Range. Enter
80, and click Insert button.
Smooth Range instruction is inserted.

An input of the motion instruction is completed.

Subsequently, repeat and check whether the created program in this state works.

Operation Check of Move Instruction

Execute a program from a program screen.

1 Right-click the program name Pg001, and right-click the controller node.

2 Click Load from a menu.

The program is loaded to a virtual controller.

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3 Right-click the program name, and click Execute, and then Only Motion Steps (Simple Mode) from a menu.
A simplified animation is created to show a program jumping to steps consecutively.

 The interpolation function is not carried out.

4 Right-click the program name, click Execute, and then Execute All Steps from a menu.
The program is executed by a virtual robot controller.

The virtual controller repeats a motion accurately in an interpolation function equivalent to the
actual machine.

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 In addition, the conveyor returns to an initial position at the timing of execution, and the robot
moves to the top of the program.
At the conveyor speed set previously at the time of adding a conveyor, the virtual controller
realizes a motion of the conveyor synchronization equivalent to the actual machine. The
following dialog is displayed during execution. Click Half button to exit the motion in the middle.

When the virtual controller does not work properly after all steps are executed, the cause may
be one of the followings: the robot cannot take posture(s) which violate(s) an operating range
restriction in the middle of a trace between the move instructions, or the robot takes a singular
point posture in the middle of a trace to take a motion to which a conveyor value is added by
conveyor synchronization.
Check a transition of each axis value during repeat on the gauge of Teach Panel or on the
monitor display of the virtual teaching pendant, and modify the teaching points.

Addition of Paint instruction

After move instruction is created, add paint-related instruction.

Enter Spray Instruction.

1 Click move step starting the paint in Pg001 on the program screen.
Move instruction tab is automatically selected on the program instruction screen.

2 Select Spray instruction tab on a program instruction screen.

3 Select Spray, and enter1 for Spray No. Select ON for status Click Insert button.
Spray ON instruction is inserted in the previous line of the move instruction for starting sparay.

Spray instruction should be inserted behind the line of the move instruction to be executed.

4 Drag a line of SPRAY #1.ON, and move a mouse cursor behind the move instruction to start spray, and then
drop.
When a mouse cursor is dragged to move, a black line is displayed between line space. This
black line indicates a line space when dropping.

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 After drag and drop

5 On the program screen Pg001, click the next move instruction after the move instruction completing the
paint.
On the program instruction screen, move instruction tab is selected automatically.

6 On a program instruction screen, select spray instruction tab.

7 Select Spray, and enter1 for Spray No. Select OFF for Status. Click Insert button.
Spray OFF instruction is inserted behind the line of the move instruction to exit spray.

 In this operation, since spray OFF instruction was inserted behind the line of the move instruction to exit, it is
unnecessary to move the line of the spray instruction.

Enter paint conditional instruction.

Enter flow rate, shaping air, air motor, and high voltage instruction.

 Since the program is a system using the electrostatic gun during creation, the instruction name in the
electrostatic gun specification is entered in the instruction.

1 Click the top of Pg001 on a program screen.

2 On a program instruction screen, select Spray Out tab.

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3 Select Flowrate, and enter 1. Click Insert button.
Flow rate 1 instruction is inserted at the top.

4 Select Shaping /Pattern Air, and enter 1. Click Insert button.

Shaping Air 1 instruction is inserted at the top.

5 Select Air Motor/Atmization Air, and enter 1. Click Insert button.

Air Motor 1 instruction is inserted at the top.

6 Select High Voltage, and enter 1. Click Insert button.

High Voltage 1 instruction is inserted at the top.

Insertion of the instruction of the paint condition is completed.

Simulate the program, and display a paint trace.

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 2.12 Simulation
This chapter describes a procedure to repeat a program with a simulation screen while
displaying a painting trace.

Check of Conveyor Setting

Check the conveyor setting before executing a program.

Use the conveyor parameter set in the chapter of addition of a conveyor and a work.

1 Start a simulation screen. Click Plug-ins, and then Simulation.

Simulation screen is displayed.

2 Check the conveyor setting. Select the conveyor setting tab.

3 The screen switches to the conveyor setting tab.

Simulation is carried out in this setting here.

Speed 55mm/s
Direction Forward
Axis Type XSlide

Setting of Simulation Screen

Set a robot, a program, and a conveyor.

1 Select a Basic Settings tab.

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 Click the state column of R01[C01], and place a check mark.

 The robot with a check mark is for repeat. The robot without a check mark is not repeated.

2 Click the PG name column of R01[C01].

3 mark is displayed. Click it.

4 The created list is displayed on the R01[C01] of the program screen. Select "Pg001".
The "Pg001" is selected.

 As for the program list displayed with the PG name column, the same name may be displayed.
 The program screen can be created with the same program name. In addition, a group can be created for
containing the programs in it. The same program names are displayed in the list, but they are displayed on the
tree in order. Be careful when selecting.

5 Select "Conveyor" in the Conveyor column.

"Conveyor" is already selected.

 Since the conveyor of the current explosion proof painting robot is only 1 in a system, the added conveyor is
displayed. When a conveyor is not added to the layout, no additional conveyor is displayed.

6 Set the LS offset position to 0.

7 Subsequently, register an initial position of the robot for rewind.

Register an initial position of the robot.

A procedure is described to register a returning repeat start position when rewinding in
simulation.

1 Click the joint move instruction at the top of PG001 on the program screen.
The robot jumps to the specified step position.

2 Right-click the 1HOME button on the Teach panel, and click the setting of the menu.

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 The home setting screen is displayed.

3 Select the robot on the Home Settings screen, and select 1HOME.

4 Click the current position button, and then click Apply button.
The joint values of the robot are loaded, and this position is registered.

Click Close button to close a screen.

5 Click the rewind button.

 When a cursor is placed on the button, the button name is displayed on a tool tip.

Settings of Repeat

Preparations for repeat are completed by the descriptions above. K-ROSET has several
animation effects at the time of repeat. Check the setting of each effect here.
The effects are repeat speed, display of painting trace, painting pattern ON/OFF, cycle time,
Collision check settings.

Repeat Speed
Check the speed during repeat.

1 Click the pendant display on the controller screen.

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 The Virtual Teach Pendant is displayed.

2 Ensure 100% is indicated.

3 To indicate 100%, click the gauge of the repeat speed, and set the speed on the speed specification screen.

Display of Painting Trace Line

The trace can be displayed at the nose of the tool during repeat.

1 Ensure that the Painting simulation on the Plug-ins setting screen is checked in a box.

When this function is enabled, the setting is correct.

Display of ON/OFF of Painting Pattern

During repeat, the painting pattern added at the nose of the tool can be shown/hidden linked
with a spray ON/OFF signal.

1 Ensure that the Painting simulation on the Plug-ins setting screen is checked in a box.

2 Ensure that Pattern is added to the attached tool.

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 Cycle Time Display
Repeat time is displayed when repeat is completed.

1 Ensure that a check mark is placed in the cycle time of the Plug-ins setting screen.

2 Ensure that a check mark is placed to Output Trace File with the quick setting on the controller screen.

Cycle time is not displayed when a check mark is not placed.

Collision Check Display

When the model with Collision pair setting interferes during REPEAT, the result of the Collision
is displayed. In addition, repeat can be stopped at the interfered point.

1 Ensure that a check mark is placed in the Collision check on the Plug-ins setting screen.
To display the Collision log, place a check mark to the Collision log.

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2 Ensure that a check mark is placed to "Enable Collision Detection" with the Quick Settings tab on the
Controller screen.

Collision Check is not active when this check box is checked off.

 When checking/unchecking a check mark, make sure to click Apply button on the right side of the screen to
reflect the change.

3 When the robot is stopped if the Collision occurs, ensure that a check mark is placed to "Stop the Robot
when Collision is Detected" with the Quick settings tab on the Controller screen.

 When the robot interfered and stopped after this setting is enabled, the robot cannot start again.

Repeat

Execute a program with a simulation screen.

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1 Click the rewind button on the simulation screen.
The conveyor moves to the initial position, and the conveyor work also moves to the initial
position.
The robot moves to the posture of home position.
When a trace line is displayed, it disappears.

2 Click Repeat button.

The conveyor work starts to move. A conveyor position of the monitor tab of the simulation
starts to count up.

The robot waits for the conveyor at 4,000mm. When the coun reach 4,000mm, the robot
starts operation.
Click the pause button to stop repeat temporarily. Press the repeat button to start again.
Press the stop button to exit. The robot will be in the same state as turning on an emergency
stop. The robot cannot start again. Return the robot to the home position with a rewind button,
and start again with a repeat button.

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After repeat, a TrackLine is displayed with a point. The TrackLine is Painting line (R01[C01]) in
the layout.
Right-click the TrackLine icon line to display the menu related to TrackLine. A point of the track
line can be changed to a line, and a color of the track line and a size of a point can be changed.
The yellow points are teaching point group [pg001] in the layout. This indicates a position of
program steps. The color and size of the point can be specified the same as the trace.

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3 Various Setting Procedures
This chapter describes various setting procedures used frequently.
For details of functions of the robot main unit, refer to an instruction manual of the robot.

3.1 Procedure of Wal-Hang Installation

This chapter describes a procedure to install a Wall-Hang using the sample project of the
Wall-Hang.
As for the rotation angle OAT for the setting of the robot in the view, select Local for the
standard coordinate, and specify O=0 degrees, A=90 degrees, and T =-90 degrees.
As for the base converted value, select Local for the base coordinate, and specify O=-90
degrees, A=90 degrees, and T =-90 degrees.

1 Read a project of the Wall-Hang sample.

2 Right-click the project icon, and click Read.

3 Right-click the project icon, and click Read.

A project read screen is displayed.

4 Project icons are displayed. Specify KG264x2_Wall-hang_Accu and click Read button.
The project is read.

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5 When KG264x2_Wall-hang_Accu is not in the list, specify a file, and click Read ... button.
Click KHIlibraries icon, and specify Demo\Paint\KG264x2_Wall-hang_Accu.krprj.
Click Open button to read.

The project was read.

6 Double-click any robot icon.

The position screen is displayed. Specify XYZOAT specified at the installation position in a new
robot as a reference data.

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 Particularly, as for the rotation angle, select Local for the base coordinate, and specify O=0
degrees, A=90 degrees, and T =-90 degrees.
Change X, Y, and Z appropriately depending on the system.

Reference example

7 Right-click the robot icon, and click Base converted value, and then change.
The position change screen of the base arrow is displayed.

As for the base converted value, select Local for the base coordinate, and specify O=-90
degrees, A=90 degrees, and T =-90 degrees.

8 Make sure to synchronize Layout -> Controller of the data after the base coordinate value of the robot is
changed.

9 Click the robot R01[C01] tab in the controller tab. Click synchronization button in the R01[C01] tab.
The Synchronize screen is displayed.

10 Place a check mark in Controller Setting.

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11 Click Layout -> Controller button.
A synchronization screen is displayed. Click Yes.

The procedure ends.

3.2 Notice When Saving a Project

 After having saved the project with a different name, make sure to load again the project for the continuous
work. The procedure is shown below.

1 As an example, when a project A should be saved in a project A1, select Project and then Save to open the
project setting screen.

2 Save the project A as Project A1.

The project name becomes A1. Click OK button.

3 Click Project and then Load.

The layout becomes a new project, and a project loading screen is opened.

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4 Select the A1 project saved previously, and click Load button.
Project A1 is load.

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 3.3 Change of Paint Pattern
This chapter describes a procedure to replace a Paint Pattern model when a gun distance or a
size of the diameter is changed.

3.3.1 Replacement of Paint Pattern

1Select Pattern, and select Replace of the right-click menu.

 When Pattern already disappears, add Patter in reference to the operation to add an obstacle.
 Make sure to change the name of the obstacle to be add to Pattern.

2 A shape file selection dialog is displayed. Select a file to be replaced.

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 3.3.2 Replacement of Paint Pattern with Change of Tool

Converted Value

1 Select Pattern, and select Replace of the right-click menu.

2 Select Shape File screen is displayed. Select a file to be replaced.

The length of 250mm is changed to 200mm here.

3 Drag and drop Pattern right under the tool arrow.

4 Double-click Pattern to display a position dialog.

5 Change Z from 200 to 50.

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6 Drag and drop Pattern to the original position.

7 Double-click Pattern to display a position dialog.

The value displayed here is a tool converted value when the pattern is changed to 250mm.

8 Double-click a tool arrow, and change the tool converted value with a position dialog.

9 Drag and drop Pattern right under the tool arrow.

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10 Double-click Pattern to display a position dialog. Change Z to -250.

11 Drag and drop Pattern to the original position.

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 3.4 Attachment of Arm Cover
This chapter describes a procedure to fix an arm cover to the joint as an obstacle.

1 Select J3, and select Add Obstacle from a menu.

2 Select Shape File screen is displayed. Select J3 arm cover file.

78