KUKA robot data backup and restore is not only important for ensuring production continuity, safety and improving work efficiency, but also an indispensable part of system maintenance and long-term planning. One thing to note is that the data involved in KUKA robot data backup and restore are important parameters and user programs of the robot system, not the complete system of the KUKA robot. The complete system backup involves the overall system status of the robot, including software, hardware configuration and all program data. The backup of the complete system requires the use of a KUKA robot-specific backup and restore USB flash drive.
Data backup and restoration of KUKA robots is crucial. For backup, use the KUKA system software to store robot programs, configurations and parameters to an external device like a USB. For restoration, access the system settings, select the option to restore, and then choose the backed – up file from the external device to reload the data.
Data backup is recommended after debugging is completed and regularly (such as weekly or monthly) to prevent misoperation or other unexpected situations. System backup may be performed before and after major changes to the system or in accordance with higher safety requirements (such as several months or every year). If you need a KUKA robot-specific USB flash drive, you can reply to the background to get more information. From the experience of use, it is recommended to back up and archive each robot system in case of emergency.
1 Ways to archive and restore data
(1) Data archiving
The relevant data of KUKA robots can be archived. During each archiving process, a zip file will be generated on the corresponding target medium. The file name has the same name as the robot. The file name can be changed individually under the robot data.
There are three storage locations for KUKA robots: 1) USB (KCP) – that is, insert a USB flash drive from the teach pendant 2) USB (control cabinet) – that is, insert a USB flash drive from the robot control cabinet
3) Network – that is, archive on a network path. The required network path must be configured under the robot data. For the data of KUKA robots, you can select the following menu items.
① All: Archive the data required to back up the current system
② Application: All user-defined KRL modules and corresponding system files are archived
③ System data: Archive machine parameters
④ LOG data: Archive log files
⑤ KrcDiag: Archive data so that it can be provided to KUKA Roboter GmbH for fault analysis. A folder will be generated here, in which 10 zip files can be written. In addition, the archive files are stored in the control system under C:/KUKA/KrdcDiag
When archiving robot data, please pay attention to the following points:
① If you archive using the “All” method and there is already an archive, the original archive is overwritten.
② If you do not select “All” and select other menu items or KrcDiag for archiving, and there is already an archive, the robot control system compares the robot name with the archive name. If the two names are different, a security query will pop up.
③ If you archive multiple times with KrcDiag, you can create up to 10 archives. When adding more archives, the oldest archive is overwritten.
④ In addition, the operation log can also be saved.
(2) Data Restoration
KUKA robots can also restore archived data. When restoring, you can select the following menu items:
① All
② Application
③ System Data
In KUKA robots, usually only documents with corresponding software versions are allowed to be loaded. If other documents are loaded, the following consequences may occur:
① Fault information: Fault information mostly occurs in the following two situations: one is when the archived file version is different from the file version in the system, and the other is when the application package version is inconsistent with the installed version.
② The machine controller cannot run
③ Personal injury or property damage
2 Data archiving and restoration operation steps
(1) Archiving operation steps
① Select the menu sequence File>Archive>USB (KCP) or USB (control cabinet) and the required options
② Click “Yes” to confirm the safety query. When the archiving process is completed, an information prompt window will be displayed
③ When the file is archived, remove the USB flash drive
(2) Restoration operation steps
① Open the menu sequence File>Restore and select the required sub-item
② Click Yes to confirm the safety query. The archived files are restored in the robot control system. When the restoration process is completed, the relevant message appears on the screen.
③ If the restoration from the USB flash drive has been completed, remove the USB flash drive.
④ Restart the robot control system. A cold start is required for this.
Cold start steps: In expert user mode, KUKA key>Shutdown>Cold start