Programming a KUKA welding robot involves creating a KUKA Robot Language (KRL) script to control the robot's motion and welding operations. Here's a basic outline for such a program:

Key Components of the Program

1. Base and Tool Configuration:
   • Set the robot's base and tool configurations for accurate motion.
2. Motion Commands:
   • Define movements to approach, weld, and retract.
3. I/O Signals:
   • Control the welding torch's ON/OFF state using digital outputs.
4. Safety Parameters:
   • Include speed limits, collision detection, and other safety measures.

Sample KUKA Welding Program

&ACCESS RVP
&REL 1
DEF WeldProcess( )
 ; Set base and tool
 BAS(#BASE, 1) ; Select Base 1
 BAS(#TOOL, 2) ; Select Tool 2 (e.g., welding torch)

 ; Set motion parameters
 $VEL.CP = 0.2 ; Linear speed (m/s)
 $APO.CDIS = 10 ; Approximation distance (mm)
 
 ; Define positions
 DECL E6POS StartPos, WeldStart, WeldEnd, RetractPos

 ; Initial positions
 StartPos = {X 1000, Y 0, Z 500, A 0, B 90, C 0}
 WeldStart = {X 1100, Y 0, Z 500, A 0, B 90, C 0}
 WeldEnd = {X 1300, Y 0, Z 500, A 0, B 90, C 0}
 RetractPos = {X 1000, Y 0, Z 600, A 0, B 90, C 0}

 ; Move to start position
 PTP StartPos ; Move in joint motion to StartPos
 
 ; Move to welding start
 LIN WeldStart ; Move in a straight line to WeldStart

 ; Start welding (activate output for welding torch)
 $OUT[1] = TRUE ; Welding ON
 
 ; Perform welding motion
 LIN WeldEnd ; Weld along the defined path

 ; Stop welding (deactivate output for welding torch)
 $OUT[1] = FALSE ; Welding OFF

 ; Retract the robot
 LIN RetractPos ; Move up to RetractPos
 
 ; Return to home position
 PTP StartPos

 ; End of program
END

Explanation

1. Tool and Base:

   • BAS(#BASE, 1)

     : Sets the coordinate system (Base 1).

   • BAS(#TOOL, 2)

     : Sets the tool data (Tool 2).

2. Motion Types:

   • PTP

     : Point-to-point motion, used for faster movements.

   • LIN

     : Linear motion, used for precise welding paths.

3. Speed and Approximation:

   • $VEL.CP

     : Sets the robot's speed during linear motions.

   • $APO.CDIS

     : Defines the approximation radius for smoother transitions.

4. Welding Control:

   • $OUT[1]

     : Digital output to control the welding torch.

5. Safety and Testing:

   • Verify base and tool calibrations.
   • Simulate the program before execution to ensure collision-free operation.

Tips for Customization

• Adjust position values (

  X

  ,

  Y

  ,

  Z

  ) to match your workpiece dimensions.
• Incorporate loops or subprograms for repetitive welding tasks.
• Use KUKA WorkVisual or KUKA SmartPAD to visualize and fine-tune the program.