Point Table Engine & Companion .DAT Auto-Synchronizer

Automated coordinate management, companion data synchronization, and kinematic point transformation.

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Overview

In KUKA KRL programming, motion trajectories in .src files rely on companion .dat files declaring spatial coordinates (E6POS, POS, FRAME, E6AXIS) and motion parameters (FDAT, PDAT, LDAT).

Manual synchronization between .src and .dat during commissioning frequently causes runtime compiler faults (XP1 undeclared variable) or accidental overwrites during SmartPAD Touch-Up operations.

The Point Table Engine & Auto-Synchronizer (krl.syncPointsToDat, krl.batchShiftPoints, krl.mirrorTrajectory) automates companion data consistency, orphan coordinate detection, and 6D geometric frame calculations.

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Key Capabilities

1. Auto-Sync Missing Points to Companion .DAT (krl.syncPointsToDat)

• AST Motion Command Scanner: Scans active .src routines for motion statements (PTP, LIN, CIRC, SPTP, SLIN, SCIRC) and Inline Form FOLD headers (PDAT_ACT, FDAT_ACT, LDAT_ACT).
• Companion .DAT Auto-Generation: If the companion .dat file is missing, the engine creates a standard DEFDAT <MODULE> PUBLIC structure.
• Non-Destructive Declaration Injection: Injects missing coordinate declarations (DECL E6POS, DECL FDAT, DECL PDAT, DECL LDAT) into a clean ;FOLD Auto-Synchronized Points block before ENDDAT. Existing taught coordinates are strictly preserved.

2. Split-View Point Table

• Synchronized Side-by-Side View: Inspect .src motion lines alongside their companion .dat position vectors.
• In-Line Validation: Validates Cartesian coordinates against manipulator reach boundaries in real time.

3. Orphan Point Detector

• Dead Coordinate Audit: Scans .dat files for declared points that are never referenced in any .src routine.
• Memory Optimization: Identifies candidate obsolete points for safe removal, preventing variable memory exhaustion on legacy KSS controllers.

4. SVD Kabsch 3-Point Base & Tool Calibration

• Exact Coordinate Alignment: Calculates TOOL_DATA and BASE_DATA frames using Singular Value Decomposition (SVD Kabsch algorithm) directly from physical calibration points.
• Euler Angles (A, B, C): Computes authentic KUKA Euler rotation angles ($Z-Y'-X''$) with gimbal lock prevention.

5. 6D Trajectory Mirroring & Batch Point Shift

• Geometric Mirroring (krl.mirrorTrajectory): Mirrors motion paths across Cartesian planes X, Y, or Z with automated Status and Turn bit recalculation.
• Batch Frame Shift (krl.batchShiftPoints): Applies 6D geometric transformations (:) for tool offsets, base re-referencing, and fixture repositioning without manual pendant re-teaching.

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Commands

Command	Identifier	Description
KUKA KRL: Auto-Sync Missing Points to .DAT	krl.syncPointsToDat	Scan .src and inject missing declarations
KUKA KRL: Batch Shift Coordinates	krl.batchShiftPoints	Apply 6D spatial frame offset to point group
KUKA KRL: Mirror Trajectory Across Plane	krl.mirrorTrajectory	Reflect trajectory with Turn bit correction
KUKA KRL: Renumber Motion Points	krl.renumberPoints	Synchronized renaming of points across files