Simulation KUKA Roboter GmbH

KUKA.RCS Module 8

Installation and Operating Instructions

Issued: 30.05.2011

Version: KUKA.RCS Module 8 V3 en

 KUKA.RCS Module 8

© Copyright 2011
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 KUKA.RCS Module 8 en

Bookstructure: KUKA.RCS Module 8 V1.4
Label: KUKA.RCS Module 8 V3 en

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 Contents

Contents
1 Introduction .................................................................................................. 5
1.1 Representation of warnings and notes ................................................................. 5
1.2 Overview ............................................................................................................... 5

2 Installation of KUKA.RCS modules ........................................................... 7

2.1 System requirements ............................................................................................ 7
2.2 Installing KUKA.RCS modules .............................................................................. 7

3 Licensing the KUKA.RCS module .............................................................. 9

3.1 License types ........................................................................................................ 9
3.2 Requesting licenses for KUKA.RCS modules ...................................................... 9
3.3 Transferring licenses for KUKA.RCS modules ..................................................... 9
3.4 Licensing single PC licenses of the KUKA.RCS module ...................................... 10
3.5 Starting up the license server for KUKA.RCS Module .......................................... 12

4 Configuration of the KUKA.RCS module ................................................... 15

4.1 Addressing the KUKA.RCS module correctly in the simulation system ................ 15
4.2 The machine data structure for KUKA.RCS Module 8 .......................................... 15
4.3 Determining cycle times using the KUKA.RCS module ........................................ 16

Index ............................................................................................................. 17

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 1 Introduction

1 Introduction

1.1 Representation of warnings and notes

Safety Warnings marked with this pictogram are relevant to safety and must be ob-
served.

Danger!
This warning means that death, severe physical injury or substantial material
damage will occur, if no precautions are taken.

Warning!
This warning means that death, severe physical injury or substantial material
damage may occur, if no precautions are taken.

Caution!
This warning means that minor physical injuries or minor material damage
may occur, if no precautions are taken.

Notes Notes marked with this pictogram contain tips to make your work easier or ref-
erences to further information.

Tips to make your work easier or references to further information.

1.2 Overview

KUKA.RCS Module can be used in robot simulation systems for simulation

and cycle time analysis of KUKA robots.
KUKA.RCS modules are distributed to simulation system users by manufac-
turers of simulation software. These software manufacturers (Siemens PLM or
Dassault Systemes) also provide technical support (hotline, software updates)
for users and customers of KUKA.RCS Module.
Please observe the instructions in this document before using KUKA.RCS
modules:
 Introduction to simulation with RRS1
 Installation and licensing of KUKA.RCS modules
 Configuration and cycle time analysis with the KUKA.RCS module
In order to be able to work correctly with the KUKA.RCS module, programming
must also be carried out correctly with the corresponding teach pendant.
Please observe the operating instructions for the corresponding teach pen-
dant, particularly for special cases such as external axes.

VDI 3633: The word “SIMULATION” is defined as follows in VDI guideline 3633:
Simulation is the replication of a system with its dynamic processes on the ba-
sis of an experimental model in order to apply the acquired knowledge to the
real world.

The principal simulation technologies are:

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 KUKA.RCS Module 8

 Process simulation
This type of simulation is used for planning complex production and mate-
rial flow systems.
 FEM simulations
FEM simulations are used primarily for calculating the stability or load ca-
pacity of a system. It is also possible to simulate the dynamic characteris-
tics of a system.
 Graphical 3D simulations
3D simulations of kinematic systems that can depict and optimize the mo-
tions of a production system. You can also use this software to optimize
the layout and predict cycle times.
A simulation is always based on assumptions and simplifications. The KU-
KA.RCS modules support a number of 3D simulation functions. Due to the ori-
entation on the RRS1 standard, a simulation with the KUKA.RCS module has
the following limitations:
 The KUKA.RCS module cannot represent the dynamic characteristics
of a robot (e.g. oscillation, vibrations). Only setpoint values are taken
into consideration; no actual values are taken into consideration in the KU-
KA.RCS module.
 The KUKA.RCS module cannot simulate the inputs and outputs of a ro-
bot (restriction due to RRS1).
 The KUKA.RCS module cannot simulate the external friction and inertia
of a system (e.g. holding force of a gripper, forces generated during spot
welding, recoil).
 The KUKA.RCS module cannot simulate a flexible connection (e.g. of a
dress package); simulation suppliers often have additional software that
can help to estimate this, at least qualitatively.

Payloads Every robot load must also be checked using KUKA.Load for static and dy-
namic overloading.

Accuracy The accuracy of the cycle time analysis is generally within +/-5% of the actual
cycle times in the real system. These discrepancies must be taken into con-
sideration when designing the system.

Warning!
The user is responsible for the transferability of the simulation results to the
real world. It must be ensured that the real world resembles the representa-
tion in the simulation software as closely as possible and vice versa.

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 2 Installation of KUKA.RCS modules

2 Installation of KUKA.RCS modules

2.1 System requirements

Operating system  Windows XP SP3 (32 bit)

 Windows 7 (32 bit) and Windows 7 (64 bit); running the simulation soft-
ware as a 32-bit application requires up to 4 GB of memory
 Windows operating systems that are fully downwards compatible with the
operating systems specified above
The KUKA.RCS module is not tested or supported by KUKA Roboter GmbH
on virtual machines.

Hardware The hardware requirements are determined by the requirements of the simu-
lation software. Please contact your simulation software provider, e.g. Sie-
mens PLM or Dassault Systemes.

2.2 Installing KUKA.RCS modules

Procedure 1. You can download the required RCS module from your simulation soft-
ware provider. To find out which version of the KUKA.RCS module match-
es your robot, please refer to the current KUKA Mapping Table provided
by your simulation supplier (e.g. Siemens PLM or Dassault Systemes).
2. To install your KUKA.RCS Module 8, copy the KUKA.RCS module file fold-
er (including the folders bin and flexlm) to your KUKA.RCS Module in-
stallation directory under \rrs_bin\rcs_krc1\. For version krc8.1_r01, for
example, this could be:
C: \ .... \ rrs_bin \ rcs_krc1 \ krc8.1_r01

File contents The following information can be found in the individual files:

version/readme.txt Notes about the current version

version/bin/Con- Configuration of the paths to the robot axis
figXML.xml files (A1.xml .... A6.xml, E1.xml .... Ex.xml)
version/bin/ Main component of the RCS module
KUKA_KRC4ctrl.exe
version/bin/ DLL interface to the RCS module
KUKA_KRC4.dll
version/bin/ Interface library for KUKA_KRC4.dll
KUKA_KRC4.lib
version/bin/ Auxiliary program for adaptation to simulation
KUKA_KRC4hlpr.exe software
version/flexlm/KUKAROB License mechanism
version/flexlm/lmgrd FlexLm license server
version/flexlm/lmutil License management tool for receiving sta-
tus and statistical information
version/flexlm/enduser.pdf Documentation about the flexlm license
mechanism; of interest for further questions
about licenses, license problems, license
error numbers, etc.

The installation files of the KUKA.RCS Modul must not be modified, re-
named, deleted, etc.!

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 3 Licensing the KUKA.RCS module

3 Licensing the KUKA.RCS module

Below are brief instructions relating to license management of the KUKA.RCS
module; further details about the flexlm license mechanism used can be found
in your RCS module under /flexlm/enduser.pdf.

3.1 License types

Single PC A single PC license (node-locked license) can only be used for one machine.
licenses If switching to a different machine, a new *.lic license file is required.
(>>> 3.3 "Transferring licenses for KUKA.RCS modules" Page 9)
For this, simply specify the file path to the *.lic file. Single PC licenses are as-
signed to the HostID of the corresponding PC using the option HOSTID =
<hostid> in the *.lic file.

Server licenses A license manager runs as a background application on the license server.
The user can call and borrow licenses on any client PC that has access via the
network to the license server, as long as licenses are still available (floating
licenses). Server licenses are easily recognizable by the expression Use
Server in the *.lic license file.
(>>> 3.5 "Starting up the license server for KUKA.RCS Module" Page 12)

3.2 Requesting licenses for KUKA.RCS modules

Precondition You have received an order confirmation/invoice for the purchase of your KU-
KA.RCS module.

Procedure Send the license information to the license administration center of your sim-
ulation software manufacturer (Siemens PLM or Dassault Systemes). Once
the license information has been verified, a license file (*.lic) will be sent back
to you. Due to the fact that computers are frequently exchanged, licenses are
only issued for 12 months.

Description The following license information is required:

 HostID address (12-character alphanumeric combination)
Under the MS-DOS command prompt (Start/Run/ Input: cmd/OK=), call
the command:ipconfig /all.
You then receive a list of all your HostID addresses (also called physical
network addresses). Select the 12-character physical address of your
active default network card (no WLAN, Bluetooth or virtual network
card). Please set your network card in such a way that it is always active
when the PC is switched on, even if no cable is connected. The following
HostID addresses are not permitted: 0002e2000000 and aabbccddee01
 Required KUKA.RCS module versions
 SoldTo no. including specification of whether software maintenance is
present or not
 Number of licenses and borrow time in the case of license servers
 Your contact information (e-mail address, telephone number, e-mail sig-
nature)

3.3 Transferring licenses for KUKA.RCS modules

The following 5 options are available for license transfer. Costs may be in-
curred in some cases:

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 KUKA.RCS Module 8

 Exchange PC – Please enter the HostID of your new PC. The license on
the old PC will no longer be renewed (if you inadvertently attempt to run
the old license on your new PC, “Flexlm Error Code -9: HostID invalid” ap-
pears).
 License expired – Licenses are automatically renewed for one year ap-
proximately 4 weeks before they expire and the new license file is sent to
you by e-mail. Please make sure that your simulation provider always has
your current e-mail address. If this old license has not been successfully
replaced by the new license, the information “License expired” (Flexlm Er-
ror Code -10) appears. In this case, please send your old license file to
your simulation provider.
 The KUKA.RCS license must be expanded to include new features. Send
your old license file, together with your order number, to your simulation
provider, stating whether an upgrade or maintenance agreement is avail-
able for this expansion.
 Modification of number of floating licenses on your license server.
Please also send the order number to your simulation provider.
 Modification of the maximum possible borrowing time (only possible
for floating licenses). Please send the amended number of hours desired
to your simulation provider.

3.4 Licensing single PC licenses of the KUKA.RCS module

The modifications to your license configuration will not become available until
the next initialization of your RCS module, e.g. by opening your teach pendant.

Procedure The first time a simulation is started, the Flexlm License Finder opens. Here
you can enter the path to the *.lic file:

Fig. 3-1

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 3 Licensing the KUKA.RCS module

Fig. 3-2

Alternatively, you can look up and edit the path to your license file in the fol-
lowing folder in the Windows Registry (Start/Run/Regedit). Write-access is re-
quired for this:
HKEY_LOCAL_MACHINE\SOFTWARE\FLEXlm License Manager]

Contents of the The *.lic license file contains all the information required by the FLEXlm li-
license file cense mechanism for activating and managing licenses.
The following is an example of a license file (*.lic) for a single PC license:

Fig. 3-3

Please keep this file in a safe place and send it to your simulation software
provider when renewing your license.

This information, found in the first lines of every feature, includes the following:
 Feature information describes the version of your RCS module (here:
KUKAROB_RCS_8, sub-version 1.0)
 Name of provider (flexlm designation: Vendor Daemon, here KU-
KA.ROB)
 Expiry date of this license feature (here: 30-Dec-2010)
 HostID (physical network address (MacID) of the active network card (no
WLAN card, no virtual network card) (here: 00188b76bc03)
 License key as alphanumeric combination
 Additional information as comments, not checked by the license mecha-
nism, such as host name, user name, creation date, etc.
If the license is a server license, the file additionally begins with Use Server
and the number of licenses is indicated in the license block.

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 KUKA.RCS Module 8

Error treatment The KUKA.RCS module can be started without a license and the robot can
also be initialized, but the GET_NEXT_STEP service will not function correctly
until a valid license has been set. The following error message appears:
No valid License found
The most common error messages (Error Codes) during creation of the li-
cense are:
 Flexlm Error -9 (Invalid host) The HostID of your current PC does not
match the HostID in the license file.
 Flexlm Error -10 (Feature expired) The license has expired.
Various other license error codes, e.g. -5 (License feature not available), are
described in the FLEXlm End User Guide enduser.pdf in Annex E (pp. 137 ff).

3.5 Starting up the license server for KUKA.RCS Module

Procedure 1. Start the file lmtools.exe on your license server. Create a new service un-
der “Config Service” and enter the path to the desired files (lmgrd.exe, li-
cense file and log file).

Fig. 3-4

2. Activate the check box if you want the service to start when the computer
is booted. You can now start or stop the RCS service or reload the server
license file.

Fig. 3-5

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 3 Licensing the KUKA.RCS module

License server Under Server Status, the administrator can check important status informa-
monitoring tion relating to your license server:

Fig. 3-6

Information on how to install your Flexlm license server on a Unix server (e.g.
HP, SGI, IBM) is also contained in /flexlm/enduser.pdf.

Borrowing Options for borrowing licenses can be defined in the Borrowing menu. It is
licenses thus possible, for example, to use a client license for a certain period of time if
there is no connection to the license server. Observe, in particular, points 1, 2
and 3 in the “Borrowing” menu if you wish to define the manner in which licens-
es are borrowed:

Fig. 3-7

You can borrow you licenses for up to the maximum borrowing time (in hours)
defined in the *.lic file. (Predefined default value is 72 hours; on request, your
simulation software provider can create a new license file for you with a differ-
ent borrowing time.) More detailed information can be found in your RCS in-
stallation (under flexlm/enduser.pdf) or obtained from your simulation support
provider (Siemens PLM or Dassault Systems)

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 4 Configuration of the KUKA.RCS module

4 Configuration of the KUKA.RCS module

4.1 Addressing the KUKA.RCS module correctly in the simulation system

Here is an example of how you can integrate the applied RCS module in the
simulation system from Siemens PLM. Your robot component or robot cell
contains an rrs folder with the .rrs file. Here you have to define the path in your
file system to the desired KUKA.RCS module.
Here is an example of a .rrs file (Release krc8.1_r01):
MODULE_NAME rcs_krc1/krc8.1_r01/bin/rcskrc1
MODULE_PATH_NAME rcs_krc1/krc8.1_r01/bin
ROBOT_PATH_NAME . /

Alternatively, it is also possible to enter absolute paths.

If you do not know which KUKA.RCS module you require, please refer to the
KUKA Mapping Table provided by your simulation software manufacturer.
Furthermore, you should have read and understood the operating instructions
of your teach pendant mapped as a program window, as this will have a major
influence on the behavior of the KUKA.RCS module.
Particularly for external axes, you require special machine data and settings
that are described in the operating instructions of the teach pendant.

4.2 The machine data structure for KUKA.RCS Module 8

The machine data structure has changed from KUKA.RCS Module Version 8
onwards.
3 types of files in the RRS directory are now required for cycle time analysis:
Previously used files depending on the specific robot type:
 KRC/R1/Mada/$config.dat
Required to define the special configuration (e.g. tools, base, velocities,
accelerations, advance run pointer) for this specific robot.
 KRC/R1/Mada/$machine.dat
Special machine data (e.g. motor and gear unit data) for this robot type
(e.g. KR 150-2). Under no circumstances may these data be modified of-
fline!
 KRC/R1/Mada/$robcor.dat
Special machine data (e.g. motor and gear unit data), particularly for the
dynamic model, for this robot type (e.g. KR 150-2). Under no circum-
stances may these data be modified offline!
Previously used controller-specific files (irrespective of the robot type)
 KRC/STEU/Mada/$custom.dat
 KRC/STEU/Mada/$machine.dat
 KRC/STEU/Mada/$option.dat
New files required from KUKA.RCS v8.1/v8.2 onwards:
 Only necessary for v8.1:
Config/System/Common/ConfigXML.xml
Indicates where the System or User directory is located.
 Config/User/Common/Mada/SimuAxis.xml
Indicates where the SimuAxis folder is located.

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 KUKA.RCS Module 8

 Config/User/Common/Mada/SimuAxis/A1.xml.....A6.xml
The files A1.xml to A6.xml contain special dynamic data, mapping axes 1-
6 in the simulation system. Under no circumstances may these data be
modified offline! In the case of external axes, these files are called E1.xml,
etc.
It is not necessary to restart your simulation system to reload your machine da-
ta. You merely need to press the button for reloading machine data.

4.3 Determining cycle times using the KUKA.RCS module

Precondition Before cycle time measurement is commenced, the Status and Turn defini-
tions for the entire robot program path must be defined using your simulation
system.

Procedure 1. Move your robot to the start position of the program path. Now start your
simulation to measure the cycle time with the KUKA.RCS module.
2. Now start your simulation to measure the cycle time with the KUKA.RCS
module.

Example The following example with comparable KRL code enables you to see where
exactly the cycle time analysis with the KUKA.RCS module starts and finishes:
PTP Px
.......
PTP Py

Line Description
PTP Px First point, no approximate positioning motion,
when you click on “Start”.
-->->Timer start
PTP Py PTP Py (last point, no approximate positioning
motion)
-->Timer stop

The cycle time from Px to Py is represented as the time value in the simulation
software.

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 Index

Index
Symbols S
.rrs file 15 Safety instructions 5
Server license 11
B Server licenses 9
Borrowing 13 SimuAxis.xml 15
Borrowing licenses 13 Simulation 5
Simulation software 5
C Single PC license 10
config.dat 15 Single PC licenses 9
Configuration 15 Software updates 5
Controller-specific files 15 System requirements 7
Cycle times 16
T
D Teach pendant 5
Detailed instructions, Flexlm 13
W
E Warnings 5
Error messages 12 Windows Registry 11
Exchange PC 10 Without a license 12

H
Hardware requirements 7
HostID address 9
HostID addresses 9
Hotline 5

I
Installation 7
Installation directory 7
Introduction 5
ipconfig /all 9

K
KUKA Mapping Table 7, 15
KUKA.RCS license, requesting 9
KUKA.RCS module selection 15

L
License expired 10
License file 11
License server 12
lmtools.exe 12

M
Machine data structure 15
machine.dat 15
MS-DOS command prompt 9

N
New features 10
No valid License found 12

O
Operating system 7
Overview 5

R
robcor.dat 15

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