ROBOT

POSTPROCESSOR MANUAL

Version 3 1 KUKA Robot Post Processor Manual 11/26/21

1. Create NC Program

NC Program can organize several Setups into a single NC program output, writing multiple toolpaths when
needed:

It’s important to use NC Program for writing your nc codes.

The NC Program dialog has an ordered tab to manage all the properties you need for the KUKA nc code.

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2. NC Program Settings properties

This is an overview of all the properties available for KUKA output:

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3- Confirm the tool orientation on the robot

The robot can be driven manually along the tool coordinate system, this is one option to check the orientation
of the tool workplane.

- Select the tool coordinate system

- Select the appropriate tool number to jog
- Use the teach pendant/enabling device to drive the robot along each axis individually
- This is a good way to check the orientation of X, Y and Z axis of the tool workplane.

If Z+ is pointing up along the tool axis and the X+ is pointing in front, use No Flip option:

If Z+ is pointing down along the tool axis and X+ i s pointing backwards, use Flip option:

X Y

Note: if the tool orientation is not one of the above, Autodesk CAM post will not support the application
correctly.

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 4 - WCS setup (workplane)

On the KUKA robot it is possible to define a coordinate system on the part which is known as a Base Data
(Base). The Base Data, located on the part/block, will be referenced from the zero of the robot, which is
located at its base.

Z
Y

When a Base is defined on the part, the robot will have defined a:

- Number
- Position & Orientation

To run a toolpath successfully on the robot, users must ensure the robot Base Data and the WCS in Autodesk
CAM are in the same location and orientation.

The WCS Offset number in Autodesk CAM defines the Base number, select the number defined on the robot.

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 Note: WCS 0 cannot be use, if zero is selected an error will be raised while post processing and no output will
be written.

Use the WCS setup menu to replicate the location and orientation of the Base Data on the part.

Z
Y

The robot can be jogged along the Base Data Coord inate System, this is one option to check the orientation
of the Base Data.

- Select the Base Data

- Select the appropriate Base Data to jog
- Use the teach pendant/enabling device to drive the robot along each axis individually
- This is a good way to verify the orientation of X, Y and Z axis of the Base Data
- You can also jog the robot to the location of the origin and visualize the coordinates of the Base Data

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 5 - Define Tool Number (replicate settings on the robot)

The tool number is defined via the Tool Post Processor menu.

The tool will be declared in the main file, before the toolpath file is called.

6 - Create a toolpath

Follow the usual steps inside Autodesk CAM in order to generate one or more toolpaths in your setup.

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 7 - Post processing

Autodesk CAM post-processor generates a few files.

▪ A pair of files is created, this means for each file a .src and a .dat file are generated.
▪ Toolpath files are named using the toolpath name given in Autodesk CAM adding the prefix ‘s’.
File name should NOT start with a number and should not contain any special characters.
▪ A main file is generated, this will manage the call of the toolpath(s) and define tool and base used
The main file uses the name defined in the post processor menu or in the setup.

Once ready to post process, some post-processor properties need to be defined before output files can be
generated:

Process properties

▪ End-effector state: This option is for all the non-subtractive operations when the end-effector needs
to be turned on/off.

Codes to use end-effectors are non-standard and they must be customized according to the robot
integration. The postprocessor simply writes these 2 lines as a comment:

==> END EFFECTOR ON: DEFINE YOUR CODE HERE IN THE POST
and
==> END EFFECTOR OFF: DEFINE YOUR CODE HERE IN THE POST

You can define your proper instructions inside the postprocessor editing these lines.

▪ Head angle: This allows the user to enter an angle of rotation around the tool axis, this will effectively
rotate the spindle, the angle will be kept throughout the entire toolpath. This angle is relative to the
X axis of the WCS defined on the part.

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 Below an example of a 15 degrees (left) and -15 degree (right) relative to the X axis, for a tool defined with
Z+ going up the spindle.

If the X axis is defined on another orientation the spindle angle will be relative to this orientation.
Note: X axis on the Base Data is NOT pointing forward in this example

Y X

15 degree (left) and -15 degree (ri ght)

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 Configuration properties

▪ First point move type: Allows the user to choose the first move type using robot joints or a
cartesian position.

Default is joint move, below the axis position defined by a PTP move where
A1=5, A2=-80, A3=100, A4=75, A5=-60, A6=-65 is the axis position.

▪ Robot joint: The joint values are defined in the form below.

If cartesian position is defined, the robot will move to the first toolpath point using a PTP (with Cartesian
coordinates) relative to the WCS/Base Data defined on the part, this will require reading the robot
configuration from the teach pendant and updating fields Status and Turn below.

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 ▪ Robot ‘Status’ configuration: This allows the user to define the Status configuration.
▪ Robot ‘Turn’ configuration: This allows the user to define the Turn configuration.

Both properties should be used when using cartesian position as the first point move type since the robot
configuration must be defined in order to have a unique solution.

An example of the same tool tip position & orientation but with 2 different robot configurations. Notice that
robot axis 4, 5 and 6 are reversed.

Status=2 ('B010') Turn=10 ('B001010') Status=6 ('B110') Turn=50 ('B110010')

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 Parameter properties

▪ Robot acceleration/deceleration (%): This will set the Robot acceleration/deceleration.

▪ Robot look-ahead: This allows the end user to define how many points the controller reads ahead.

▪ Robot PTP velocity: This defines the robot velocity on PTP move (first move).

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 ▪ Robot path smoothing: This defines the robot smoothing distance (see KUKA technical
documentation for details)

General properties

▪ Use coolants: When this option set as No (default) post-processor will ignore Coolant definition set
in Autodesk CAM.

▪ Use subfolder: Default is to write out all data in a sub folder.

A dummy file with standard information is created after posting if you chose to Use subfolder.
It contains the name of the directory where you can find your nc files.
It is called as the Program Name in NC Program form. This is a dummy file example:
This is a dummy file.
Your program files are located here: C:\Users\xyz\AppData\Local\Fusion 360 CAM\nc\1001

▪ Toolpath name max 30 chars: Default is to check each toolpath name length. An error will be raised
when length is more than 30 char.

▪ Write date and time: Writes date & time of file creation in the main .MOD file:

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 Below an example setup with two toolpaths, KUKA is the name of the folder and the Main file.
The toolpath files use the toolpath names with the prefix ‘s’.

6 – General information

For more information get help or post your questions on the forum:

https://forums.autodesk.com Select “Fusion 360“ and then “Fusion 360 Manufacturing“

In KUKA Robot Language (KRL files), the default unit of speed is millimeters per second: m/s.
$VEL.CP=0.10; means robot TCP speed = 1.6667 mm/s (≈100 mm/min)

If the Autodesk CAM session is running in inches, the output file will still be written in mm as this is the unit
system used on robots.

IMPORTANT: Please remember that program and toolpath names should not contain any symbol or special
character.

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 7 – Program sample

Autodesk CAM post-processor generates a few files, as described above on point 5.

This is an example of KUKA postprocessor output. The example has one only toolpath.

--- main.src file Start ---

&ACCESS RVO
DEF KUKA()
;FOLD INI
;FOLD BASISTECH INI
GLOBAL INTERRUPT DECL 3 WHEN $STOPMESS==TRUE DO IR_STOPM ( )
INTERRUPT ON 3
BAS (#INITMOV,0 )
;ENDFOLD (BASISTECH INI)
;FOLD USER INI
;Make your modifications here
; Robot Postprocessor

;ENDFOLD (USER INI)

;ENDFOLD (INI)

; Generated by AUTODESK Fusion 360 CAM 2.0.8176

; Creation date: Wednesday, May 06, 2020 18:11:22

; Set PTP velocity and acceleration

$VEL_AXIS[1] = 25
$VEL_AXIS[2] = 25
$VEL_AXIS[3] = 25
$VEL_AXIS[4] = 25
$VEL_AXIS[5] = 25
$VEL_AXIS[6] = 25

; To set 'Tool On Robot' Mode

$IPO_MODE = #BASE

; Set smoothing value

$APO.CDIS = 2

; Set $ADVANCE value (number of points read in advance)

$ADVANCE = 3

; Set BASE
$BASE = BASE_DATA[54]

; Load Tool
;TOOL_CHANGE(1)

; Set Tool
BAS(#TOOL,1)
$TOOL = TOOL_DATA[1]

; Spindle ON/speed
;SPINDLE_ON(4850)

sTP01()

; Spindle OFF
;SPINDLE_OFF()

END
--- main.src file End ---

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 --- main.dat file Start ---
&ACCESS RVO
DEFDAT KUKA
;FOLD EXTERNAL DECLARATIONS;%{PE}%MKUKATPBASIS,%CEXT,%VCOMMON,%P
;FOLD BASISTECH EXT;%{PE}%MKUKATPBASIS,%CEXT,%VEXT,%P
EXT BAS (BAS_COMMAND :IN,REAL :IN )
;ENDFOLD (BASISTECH EXT)

EXT sTP01()

;ENDFOLD (EXTERNAL DECLERATIONS)

ENDDAT
--- main.dat file End ---

--- stoolpath.src file Start ---

&ACCESS RVO
DEF sTP01()
; Generated by AUTODESK Fusion 360 CAM 2.0.8176
; Creation date: Wednesday, May 06, 2020 18:11:22
;FOLD sTP01
; Start position (joint) = {A1 5,A2 -80,A2 -80,A3 100,A4 75,A5 -60,A6 -65}
; Tool Number =1
; Spindle Speed = 4850 RPM
; Program file name = sTP01.src

PTP {A1 5,A2 -80,A3 100,A4 75,A5 -60,A6 -65,E1 0,E2 0,E3 0,E4 0,E5 0,E6 0}
$VEL.CP=0.02
LIN {X 64.000,Y -32.892,Z 15.000,A -150.000,B 0.000,C 180.000} C_DIS
LIN {X 64.000,Y -32.892,Z 5.000,A -150.000,B 0.000,C 180.000} C_DIS
LIN {X 64.000,Y -32.892,Z 1.000,A -150.000,B 0.000,C 180.000} C_DIS
LIN {X 63.732,Y -32.892,Z 0.000,A -150.000,B 0.000,C 180.000} C_DIS
LIN {X 63.000,Y -32.892,Z -0.732,A -150.000,B 0.000,C 180.000} C_DIS
LIN {X 62.000,Y -32.892,Z -1.000,A -150.000,B 0.000,C 180.000} C_DIS
LIN {X 51.000,Y -32.892,Z -1.000,A -150.000,B 0.000,C 180.000} C_DIS
LIN {X -51.000,Y -32.892,Z -1.000,A -150.000,B 0.000,C 180.000} C_DIS
LIN {X -53.384,Y -32.515,Z -1.000,A -150.000,B 0.000,C 180.000} C_DIS
LIN {X -55.534,Y -31.419,Z -1.000,A -150.000,B 0.000,C 180.000} C_DIS
;ENDFOLD
--- stoolpath.src file End ---

--- stoolpath.dat file Start ---

&ACCESS RVO
DEFDAT sTP01
;FOLD EXTERNAL DECLARATIONS;%{PE}%MKUKATPBASIS,%CEXT,%VCOMMON,%P
;FOLD BASISTECH EXT;%{PE}%MKUKATPBASIS,%CEXT,%VEXT,%P
EXT BAS (BAS_COMMAND :IN,REAL :IN )
;ENDFOLD (BASISTECH EXT)

;ENDFOLD (EXTERNAL DECLERATIONS)

ENDDAT
--- stoolpath.dat file End ---

Version 3 16 KUKA Robot Post Processor Manual 11/26/21