Programming a KUKA painting robot involves using KUKA Robot Language (KRL) to control its motion and spray-painting operations. Painting tasks require smooth, continuous motion for consistent application and precise control of spray parameters. Here's a basic example and explanation:

Key Components of a Painting Program

1. Base and Tool Configuration:
   • Set the robot's base and tool configuration (painting nozzle).
2. Path Definition:
   • Define precise paths for painting.
3. I/O Control:
   • Control the paint spray ON/OFF using digital outputs.
4. Speed and Motion Control:
   • Use appropriate speed and smoothing for a clean finish.

Sample KUKA Painting Program

&ACCESS RVP
&REL 1
DEF PaintProcess( )
 ; Set base and tool
 BAS(#BASE, 1) ; Base 1 (workpiece coordinate system)
 BAS(#TOOL, 3) ; Tool 3 (painting nozzle)

 ; Set motion parameters
 $VEL.CP = 0.1 ; Linear speed (m/s)
 $APO.CDIS = 5 ; Approximation distance for smoothing (mm)

 ; Define positions
 DECL E6POS StartPos, PaintStart, PaintMid, PaintEnd, RetractPos

 ; Initial and painting positions
 StartPos = {X 1000, Y 500, Z 1000, A 0, B 90, C 0}
 PaintStart = {X 1100, Y 500, Z 500, A 0, B 90, C 0}
 PaintMid = {X 1300, Y 500, Z 500, A 0, B 90, C 0}
 PaintEnd = {X 1500, Y 500, Z 500, A 0, B 90, C 0}
 RetractPos = {X 1000, Y 500, Z 1200, A 0, B 90, C 0}

 ; Move to start position
 PTP StartPos ; Point-to-point motion to StartPos

 ; Move to painting start position
 LIN PaintStart ; Linear motion to PaintStart
 
 ; Activate paint spray
 $OUT[1] = TRUE ; Turn ON paint spray (assign correct output)

 ; Painting motion
 LIN PaintMid ; Paint towards mid-point
 LIN PaintEnd ; Continue painting to the end-point

 ; Deactivate paint spray
 $OUT[1] = FALSE ; Turn OFF paint spray

 ; Retract the robot
 LIN RetractPos ; Move up to RetractPos

 ; Return to start position
 PTP StartPos

END

Explanation

1. Base and Tool:

   • BAS(#BASE, 1)

     : Sets the base (coordinate system of the workpiece).

   • BAS(#TOOL, 3)

     : Configures the tool data for the painting nozzle.

2. Motion Types:

   • PTP (Point-to-Point): For quick movements.
   • LIN (Linear): Ensures smooth, straight-line paths for consistent painting.

3. Speed and Approximation:

   • $VEL.CP

     : Controls linear speed for uniform paint application.

   • $APO.CDIS

     : Enables smooth transitions between points.

4. Spray Control:

   • $OUT[1]

     : Digital output to control spray ON/OFF (adjust based on your setup).

Customization Tips

• Path Design: Use software like KUKA WorkVisual or RoboDK to simulate and fine-tune painting paths.
• Spray Pattern: Adjust nozzle pressure, angle, and distance for optimal coverage.
• Multi-Pass Painting: Use loops or subprograms to repeat passes over the same area for thicker coats.
• Safety: Verify paths to avoid collisions and test with a dry run before live painting.