In the field of modern industrial automation, KUKA robots are widely used in various production lines with their excellent performance and reliability. To enable KUKA robots to achieve seamless communication and collaborative work with external devices, signal configuration IO Mapping (input and output mapping) is a key link.
IO Mapping is the process of matching and associating the internal signals of the KUKA robot with the input and output signals of the external device. Through reasonable IO Mapping configuration, the robot can accurately receive the signals of the external sensor and control the actions of the external actuator according to the preset logic, thereby realizing the coordinated operation of the entire automation system.
KUKA robot’s IO Mapping is a fundamental aspect of its operation. It involves configuring the input and output signals to enable seamless communication between the robot and its external devices. By mapping digital and analog inputs and outputs, the robot can receive commands, such as start/stop signals from a PLC, and send feedback like the status of a task completion.
To perform IO Mapping, technicians use KUKA’s software tools. They define the physical connections of the IO modules on the robot controller, assign meaningful names to each signal, and set the appropriate data types. Precise IO Mapping ensures the robot functions accurately in complex industrial processes, enhancing overall productivity and reliability.
- The role of signal configuration
The main role of signal configuration is to realize data exchange between the robot and external devices. Through signal configuration, the robot can receive instructions from external devices and send status information to external devices. Common application scenarios include communication between robots and PLCs, interaction between robots and sensors, and control of robots and actuators. - Signal configuration process
- Plan I/O requirements
Before performing IO Mapping configuration, it is necessary to clarify which external devices the robot is connected to and which input and output signals are required. For example, in an automated warehousing system, the robot needs to communicate with the shelf position sensor, the cargo detection sensor, and the conveyor belt control device. Based on these requirements, determine the required I/O signal quantity, type, and function. - Select I/O hardware or communication method
According to the planned I/O requirements, select the appropriate I/O module or communication method. When selecting, consider factors such as module performance, compatibility, and reliability. It is also necessary to ensure that the selected module can meet the electrical requirements of the system, such as voltage and current; consider whether the device communicating with it has the corresponding communication interface, etc. - Make electrical connections
Correctly connect the selected I/O module to the robot controller and external devices. During the connection process, pay attention to the correctness and firmness of the wiring to avoid problems such as short circuits and open circuits. For some special connection methods, such as EtherCAT bus connection, operations need to be performed in accordance with the corresponding specifications. - Software configuration
Use the software tool WorkVisual provided by KUKA to configure IO Mapping. In the software, find the corresponding I/O configuration interface and map the input and output signals of the external device to the internal signals of the robot one by one according to the actual hardware connection. Before configuring the system, it is recommended to back up the robot system to prevent system crashes. If you need a KUKA robot-specific system backup and restore USB drive, you can reply to the backend “KUKA USB Drive” to obtain it.
(1) Input signal DI
1) Open Workvisual, activate the current project -> select the IO Mapping page
2) Click Inputs on the KR C I/Os page (window 1), click the corresponding communication device or hardware device on the Fieldbus page (window 2), here we take DeviceNet communication as an example
3) Click the input signal filter, select the signal in fieldbus (window 4)
4) Select the starting robot signal (window 3) -> right-click -> connect continuously -> YES to complete the configuration
(2) Input signal DO
1) Open Workvisual, activate the current project -> select the IO Mapping page
2) Click Outputs on the KR C I/Os page (window 1), click the corresponding communication device or hardware device on the Fieldbus page (window 2), here we take DeviceNet communication as an example
3) Click the output signal filter, select the signal in fieldbus (window 4)
4) Select the starting robot signal (window 3) -> right-click -> connect continuously -> YES to complete the configuration - Test verification
Complete IO After the Mapping configuration, comprehensive testing and verification is an essential step. By simulating the actual production scenario, send various input signals to the robot to observe whether the robot can correctly receive and respond accordingly; at the same time, send output signals to external devices to check whether the devices can operate as expected. If problems are found, return to adjust the IO Mapping configuration in time until the system runs stably and reliably.