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Robot cells and a PLC controller with a simple display

KUKA.PLC mxAutomation

KUKA.PLC mxAutomation is a universal PLCopen-certified PLC interface. It allows you to program and operate all important robot functions directly in your familiar control environment.

With the KUKA.PLC mxAutomation control software, it is possible for external controllers with an embedded PLC to command KUKA robots on the basis of elementary motion instructions. This provides an easy route to implementing a central, customer-friendly operator control concept for robot-controlled production machines.

The outstanding kinematic and safety-relevant functions of the KUKA KR C4 controller remain fully available since the mxAutomation command interpreter of the KR C4 communicates the PLC commands to the path planning module, which sets the robot in motion with the accustomed precision and reliability.

The simple interface between human and machine 

KUKA.PLC mxAutomation allows your employees to understand, operate and program robotic systems without leaving the familiar control environment.

All important functions of the KUKA.SystemSoftware (KSS) are available directly in the existing PLC (Programmable Logic Controller) of the system. Motions and all safety functions continue to be controlled by the robot controller.

Communication between the robotic system and the PLC is not a one-way street. Just as commands are sent to the robot, diagnostic and status information flows back to the controller.

KUKA.PLC mxAutomation in conjunction with SINUMERIK

Use of the KUKA.PLC mxAutomation control software means greater flexibility and efficiency for your processes. 

The robot

With the exception of the KR DELTA, all KUKA robots can be integrated into an existing system controller via mxAutomation.

The robot controller

Each of our machines is supplied with a control module (KRC). This includes the KUKA.SystemSoftware (KSS), which controls all functions.

The controller also handles safety monitoring, path planning, overload limitation, transformations and energy management. These functions and processes run on the robot controller with the usual high performance and reliability.

KUKA.PLC mxAutomation interpreter

For connection to a system PLC, the KUKA.PLC mxAutomation interpreter translates the control commands into predefined function blocks.

Ethernet/field bus

The connection between KCR and PLC is established via Ethernet/field bus. mxAutomation supports all major manufacturers:

  • Profinet/ProfiSafe
  • EtherCAT/FSoE
  • EthernetIP/CIPsafety
  • UDP

 

PLC Function Blocks Library

The function blocks of the robot controller are stored on the system PLC in the form of a library for commands and diagnostics. Thus, almost all functions of the KSS can be commanded.

PLC

All PLC function blocks of the library can be addressed directly in the user interface of the system controller. Using the predefined blocks or sequences, a controller configuration is thus possible without robot programming knowledge.

Economic advantages of PLC integration with KUKA.PLC mxAutomation

PLC integration with the mxAutomation interface offers many economic advantages. These are a valuable contribution to lower unit costs, more efficient production and thus a competitive advantage in the industry. 

  • Greater time saving

    • During configuration
    • During start-up
    • During adaptation to new production processes

  • Simplified operation

    • During configuration
    • During PLC programming
    • Robot integration without specific programming know-how

  • Seamless integration

    • Use in the familiar control environment
    • Fewer errors due to predefined blocks and sequences
    • Greater efficiency through central programming

  • Compatibility

    • Simple integration into existing machine controllers
    • Suitable for all PLC suppliers
    • Ensuring motion algorithms and safety functions

Optimal robot integration with PLC mxAutomation 

Interface facilitates easy integration of new applications into running processes

With 18 employees, the private brewery Christian Fiedler from the village of Oberscheibe in Saxony very successfully produces premium beers according to the good, old German art of brewing. A KUKA robot palletizes the heavy beer crates, and makes the work easier. Thanks to KUKA.PLC mxAutomation, this automation technology can also be easily integrated digitally into running processes. In this way, the software enables fast start-up, programming and diagnostics by the PLC.
mxAutomation is also making inroads into the food industry and supports robot systems in their tasks, such as controlling the system for palletizing beer crates, for example.

Technical strengths of KUKA.PLC mxAutomation

Simple central programming

With KUKA.PLC mxAutomation, the user requires no specific knowledge of robot programming. The mxAutomation function blocks allow the robot to be commanded within the familiar programming environment.

Certified in accordance with PLCopen

KUKA is the first robot manufacturer to meet the requirements of the PLCopen organization with the KUKA.PLC mxAutomation software and is thus certified in accordance with “PLCopen Motion Control Part 4”. 

 

High flexibility

If a requirement in production is changed, the appropriate modifications or expansions can be implemented at any time with mxAutomation-based operator control. The flexibility made possible by using robots with regard to processing new series of parts or performing additional tasks is made available for the operator in his customary environment.

Simple control

The combination of robot and machine control enables robot systems to be integrated effortlessly into existing operator control concepts. The robotic systems can thus be controlled via the familiar HMI (Human Machine Interface).

As an alternative to the KUKA.SmartPad, it is also possible to jog, teach and program industrial robots with a customer-specific teach pendant.

Gripping moving workpieces

Connecting KUKA.PLC mxAutomation to KUKA.ConveyorTech enables systems to pick up moving workpieces. The motions are adapted by the application software to the motions of assembly lines and conveyors.

Using KUKA.VectorMove enables the robot arm to be switched vectorially to “soft” mode in order to facilitate the removal of components from injection molding machines and die-casting machines.

By integrating the optional add-on package KUKA.LoadDataDetermination, simple and precise load data determination via mxAutomation is possible.

With the optional add-on package KUKA.SafeVelocityMonitoring, it is possible to monitor robot systems at a safe velocity. This simplifies the start-up and jogging of the externally controlled cell.

Practical experience for practical applications

A good integration example is offered by Siemens® with the embedding of mxAutomation in the Sinumerik/Simatic world. The resulting products “RunMyRobot Handling” and “SIMATIC Robot Integrator” make robot integration easier than ever before.

In the injection molding sector, the deep integration “ENGEL® easix robot” is used intensively. It offers a consistent operating logic for greater convenience, safety and efficiency. The controller of the ENGEL easix robots is fully and seamlessly integrated into the controller of the ENGEL injection molding machines.

The integration of BOSCH® nexeed automation control plus is used for the global harmonization of Industrie 4.0 applications.

Functions for motion programming

  • KRC_MoveLinearAbsolute: Move to absolute Cartesian position with linear motion

  • KRC_MoveLinearRelative: Move to relative Cartesian position with a linear motion

  • KRC_MoveDirectAbsolute: Move to absolute Cartesian position as fast as possible – PTP motion

  • KRC_MoveDirectRelative: Move to relative Cartesian position as fast as possible – PTP motion

  • KRC_MoveAxisAbsolute: Move to axis-specific positions as fast as possible

  • KRC_MoveCircAbsolute: Move to absolute Cartesian position with a circular motion

  • KRC_MoveCircRelative: Move to relative Cartesian position with a circular motion

  • KRC_Jog: Moving in jog mode in the TOOL or BASE coordinate system as well as axis-specific jogging

Administrative functions

  • KRC_Initialize: Initialize mxA interface
  • KRC_AutoStart: Automated start of the mxAutomation interface. Sets the interface to an operational state.
  • KRC_SetOverride: Command reduced program override (POV)
  • KRC_ReadActualPosition: Read current Cartesian position permanently
  • KRC_ReadActualAxisPosition: Read current axis position permanently
  • KRC_ReadActualVelocity: Read current path velocity
  • KRC_ReadActualAxisVelocity: Read current axis velocity
  • KRC_ReadActualAcceleration: Read current robot acceleration
  • KRC_SetCoordSys: Select tool, base and interpolation mode
  • KRC_ReadToolData: Read TOOL data
  • KRC_WriteToolData: Write TOOL data
  • KRC_ReadBaseData: Read BASE data
  • KRC_WriteBaseData: Write BASE data
  • KRC_ReadLoadData: Read load data
  • KRC_WriteLoadData: Write load data
  • KRC_ReadSoftEnd: Read software limit switches of the robot axes
  • KRC_WriteSoftEnd: Write software limit switches of the robot axes
  • KRC_ReadSoftEndExt: Read software limit switches of the external axes
  • KRC_WriteSoftEndExt: Write software limit switches of the external axes
  • KRC_ReadAxisGroup: Reading PLC-specific communication into a non-PLC-specific structure
  • KRC_WriteAxisGroup: Writing a non-PLC-specific structure into PLC-specific communication
  • KRC_AutomaticExternal: Activate and read Automatic External signals from the robot controller
  • KRC_Abort: Abort program
  • KRC_AbortAdvanced: Abort program (advanced)
  • KRC_Interrupt: Pause robot motion
  • KRC_Continue: Resume program
  • KRC_WaitForInput: Wait for digital input
  • KRC_TouchUP: Teach points with or without smartPAD
  • KRC_ReadTouchUPState: Read TouchUp state of the TouchUp status keys
  • KRC_Set/GetAdvance: Change and read settings for the command advance run
  • KRC_Forward: Calculate Cartesian robot position from axis angles
  • KRC_Inverse: Calculate axis angle from Cartesian robot position
  • KRC_TechFunction: Execute any KRL programs
  • KRC_ReadSysVar: Read system variables of the KUKA controller
  • KRC_WriteSysVar: Write system variables of the KUKA controller

Switching, reading and trigger functions

  • KRC_DeclareInterrupt: Declare interrupt

  • KRC_ActivateInterrupt: Activate the previously declared interrupts

  • KRC_DeactivateInterrupt: Deactivate the previously declared interrupts

  • KRC_ReadInterruptState: Read state of an interrupt

  • KRC_SetDistanceTrigger: Activate switching action to path points

  • KRC_SetPathTrigger: Activate a path-related switching action

  • KRC_ReadDigitalInput: Read digital inputs, cyclically and acyclically

  • KRC_ReadDigitalOutput: Read digital outputs

  • KRC_WriteDigitalOutput: Write digital outputs, cyclically and acyclically

  • KRC_ReadAnalogInput: Read analog input

  • KRC_ReadAnalogOutput: Read analog output

  • KRC_WriteAnalogOutput: Write analog output

Diagnostic functions

  • KRmsgNet: Transmit all error messages in plain text. Switch the language and synchronize the time of the KRC

  • KRC_Error: Read and acknowledge error states

  • KRC_ReadMXAStatus: Read current state of the mxA interface

  • KRC_ReadMXAError: Read error messages of the mxA interface

  • KRC_MessageReset: Acknowledge error messages of the mxA interface

  • KRC_ReadKRCError: Read error messages of the robot controller

  • KRC_Diag: Read heartbeats and diagnostic signals

Use non-safe workspaces

  • KRC_WriteWorkspace: Configuring Cartesian workspaces

  • KRC_ReadWorkspace: Read configuration of Cartesian workspaces

  • KRC_WriteAxWorkspace: Configuring axis-specific workspaces

  • KRC_ReadAxWorkspace: Read configuration of axis-specific workspaces

  • KRC_ReadWorkstates: Read the state of the workspaces

    •  

Technology functions: Safely define and monitor workspaces

In combination with the KUKA.SafeOperation software, you reduce the space requirements of your system and make your production operations fast, safe and compact. This allows you to use the cell configuration and human-robot collaboration even more cost-effectively.

  • KRC_BrakeTest: Call brake test
  • KRC_MasRef: Call mastering test
  • KRC_ReadSafeOPStatus: Read signals of the safety controller

Note: In order to be able to use these function blocks, KUKA.SafeOperation must be installed on the robot controller.

Technology functions: Organization of conveyor applications

In combination with the KUKA.ConveyorTech software, robot actions can be automatically adapted to the motion of assembly lines and conveyors.
  • KRC_ConvIniOff: Initialize the conveyor driver
  • KRC_ConvOn: Activate the conveyor driver
  • KRC_ConvFollow: Track workpiece on conveyor
  • KRC_ConvSkip: Pick up defined workpiece from conveyor. A total of up to 1024 workpieces can be monitored in the background
  • KRC_ConvDelWPS: Delete workpiece from conveyor memory
  • KRC_ActivateConvInterrupt: Activate interrupts for monitoring
  • KRC_DeactivateConvInterrup: Deactivate interrupts for monitoring

Note: In order to be able to use these function blocks, KUKA.ConveyorTech must be installed on the robot controller.

Technology functions: Removal of workpieces from injection molding and die-casting machines

By connecting it to the KUKA.VectorMove technology package, a robot can be moved from a standstill position along a previously defined vector in Cartesian space by an external force.

  • KRC_VectorMoveOn: Activate motion along a vector

  • KRC_VectorMoveOff: Deactivate motion along a vector

Note: In order to be able to use these function blocks, KUKA.VectorMove must be installed on the robot controller.

Technology functions: Load data determination

KUKA.LoadDataDetermination is an add-on option package for determining the mass, center of gravity and moments of inertia of loads mounted on the robot flange. If these load data are known, the acceleration profile of the robot system can be optimized and overload can be avoided.

  • KRC_LDDconfig: Configuration of the load data determination

  • KRC_LDDtestRun: Execution of a test motion for load data determination at reduced process velocity

  • KRC_LDDstart: Execute load data determination

  • KRC_LDDwriteLoad: Transfer the measured values to a specific tool

Note: A precondition is that KUKA.LoadDataDetermination V7.2 or higher is installed.

Robot programming via PLC:

  • Siemens

- STEP 7 V5.4, S7-300 and S7-400
- STEP 7 (TIA Portal), S7-300 and S7-400
- STEP 7 (TIA Portal), S7-1500
- TIA Portal (SIMATIC)
- SIMOTION
- SINUMERIK (Run myRobot); see below

  • 3S/CoDeSys
  • AllenBradley/Rockwell
  • Beckhoff/TwinCat
  • Schneider Electric/Modicon
  • B&R/X…
  • Lenze/PLC
  • Mitsubishi/CNC controller
Simulation of automated palletizing applications

Robot programming via PC (C#):

  • NI/LabVIEW
  • Robots in Architecture RIA 

Are you a system manufacturer yourself? Then become an mxAutomation partner now!

As a partner, you too can use KUKA.PLC mxAutomation as a solution for operating your machines and robots.
Please do not hesitate to contact us

Operating and programming instructions: All information always at hand for you 

All specifications and documentation for KUKA.PLC mxAutomation for simple robot integration and for all other software solutions can be found in our digital knowledge database KUKA Xpert. You can also order the software directly in the KUKA Marketplace. All you need is a my.KUKA registration.
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Customer examples: easy robot integration into the machine concept