Binpicking Tutorial: Setting up Photoneo BP Studio with KUKA IIWA

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1. Prerequisites

No special prerequisites are known by the time of writing this tutorial.

2. KUKA Controller setup

This tutorial was written using Sunrise Workbench v.1.11, however it should be compatible with different version with minor changes.

2.1 KONI Interface Setup

KUKA IIWA controller has sever Ethernet ports. In order to enable communication with Vision Controller we are going to make use of KONI port.

KONI interface by default belongs to Real Time KUKA OS and is available only for FRI. Make sure that assigning KONI interface to Windows will not break anything important at the customer.

If customer approve this change, follow steps below to assign KONI interface to Windows:

1. Log into the cabinet

Use DVI port + Keyboard + Mouse for direct access to Windows 7 Embedded as KukaUser.

The Windows 7 Embedded should start up with KukaUser already logged in, use following credentials if you have any problems: Login: administrator Password: 68kuka1secpw59

2. Shutdown KRC

Right click on the green icon in the system tray (bottom right, next to clock) and click Stop KRC.

3. Check the network interfaces

Open the list of the network interfaces: Start -> View newtwork connections

At this point you should only have one interface: Realtime OS Virtual Network Adapter - DO NOT EVER CHANGE THIS SETTINGS!

4. Open terminal and type

C:\KUKA\Hardware\Manager\KUKAHardwareManager.exe -assign OptionNIC -os WIN

This will assign the KONI interface to Windows.

5. Change KONI IP settings

Reboot and open Start -> View network connections again.

Change the settings (IP address) of the new Ethernet adapter to the one you want to use - within the Network adapter settings in Windows, for example, is recommended.

NOTE: To revert changes type: C:\KUKA\Hardware\Manager\KUKAHardwareManager.exe -assign OptionNIC -os RTOS

2.2 Create new sunrise project

Start by creating new Sunrise Project. Select New -> Sunrise Project

KUKA IIWA new project.png

Make sure that IP Address of KUKA Controller is configured properly:

KUKA IIWA set IP address.png

Select which version of manipulator you use, KUKA IIWA 7 R800 was used in this tutorial:

KUKA IIWA Select robot.png

Select flange type, Medien Flanch Touch Pneumatisch was use in this tutorial:

KUKA IIWA Select Gripper.png

Review Summary of Sunrise Project and click Finish Button.

KUKA IIWA Project summary.png

2.3 Project Configuration

Enter option in Project Overview

On Topology Tab add your version of KUKA IIWA to the robot to the Used Element under KUKA Sunrise Cabinet:

KUKA IIWA Project topology 2.png

On the Software tab make sure that all important software components are included in installation, especially Robotics API:

KUKA IIWA StationSetup Software.png

On the Configuration Tab select flange type again:

KUKA IIWA StationSetup Configuration.png

Proceed to Installation Tab and Install the project to the controller, click Save and Apply:

KUKA IIWA StationSetup start installation.png

Project files should be copied to the robot controller now:

KUKA IIWA Installation progress.png

OPTIONAL: If you do not use safety PLC and need to disable safety features open file and disable first three rows (Emergency Stop External, Operator protection and Protective Setup).

Safety Settings will be applied during project synchronization later.

KUKA IIWA Safety Config.png

2.4 Installation of Photoneo Module

Photoneo KUKA IIWA Module consists of two tasks - State Server and Client. First we configure Background task for State Server. Right Click on src -> New -> Background Task.

KUKA IIWA Background task.png

Enter following names: Package: photoneo_state_server, Name: PhotoneoStateServer

KUKA IIWA BackgroundTask Configuration.png

Now create new package. Right Click on src -> New -> Package

KUKA IIWA Create package.png

Name: photoneo_module

KUKA IIWA Create package names.png

Now copy files from Photoneo KUKA IIWA USB to your project to reach state as shown in the figure below:

KUKA IIWA Final Project Structure.png

In edit argument in waitForServer function to meet your Vision Controller network configuration:


Synchronize project again:

KUKA IIWA Synchronize progress.png

3. Runtime

OPTIONAL: If you see these errors after reboot you need to activate safety functions first:

KUKA IIWA Pendant Safety.jpg

Select Safety->Activate

KUKA IIWA Pendant Safety Activation.jpg

Open Application select box and make sure that you see both PhotoneoStateServer and RobotApplication (Binpicking Client) available. PhotoneoStateServer should be running from boot:

KUKA IIWA Pendant Applications.png

Now you are about to run Client application. Start Vision Controller side first and decrease joint speed to 10% using Effective Program Override option:

KUKA IIWA Pendant Override.png

Wait until BinPicking server starts on Vision Side and hit Play button on the pendant to connect robot application to Vision Controller. If everything is okay you should see similar output:

KUKA IIWA Pendant Runtime.png

Edit to meet your application specific needs and Synchronize project each time you need to update files in robot controller.