KUKA.RSI Real-Time Suite & CAM CNC/SVG Importer

Hard real-time sensor control (4ms IPO) and automated toolpath generation from CNC G-Code and 2D vector drawings.

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Overview

High-precision industrial applications require tight sensor integration (seam tracking, force-torque grinding) and complex motion paths (milling, dispensing, deburring).

The KUKA.RSI Real-Time Suite (krl.validateRsiXml, krl.generateRsiCode) provides tools for KUKA RobotSensorInterface 4ms/12ms sensor loops, while the CAM Tooling Suite (krl.importGcodeToKrl, krl.generateVisionCalibration, krl.exportPlcTags) bridges CNC CAD/CAM programs directly into KRL trajectories.

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KUKA.RSI (RobotSensorInterface) Real-Time Suite

• Hard Real-Time Control: Supports high-frequency #IPO_FAST (4ms / 250 Hz) and #IPO (12ms / 83 Hz) sensor correction cycles.
• SensorInterface XML Schema Validator (krl.validateRsiXml): Validates SensorInterface/*.xml descriptors, checking <ROOT>, <CONFIG>, <IP_NUMBER>, <PORT>, element data types (BOOL, LONG, DOUBLE), and index continuity (INDX="1..N").
• Real-Time Driver Generator (krl.generateRsiCode): Generates synchronized KRL driver routines (RSI_CREATE, RSI_ON, RSI_MOVECORR, RSI_OFF, RSI_DELETE) and XML socket configurations for:
  • Cartesian Correction (#POSCORR): External optical and laser seam tracker feedback.
  • Axis Correction (#AXISCORR): Real-time multi-axis joint control for ROS 2 (kuka_rsi_driver).

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CAM CNC G-Code & Vector SVG Importer (krl.importGcodeToKrl)

Direct conversion of CNC machining programs and 2D vector contours into synchronized KRL .src and .dat modules:

1. ISO CNC G-Code Parsing

• Linear Moves: G0/G00 -> PTP / SPTP, G1/G01 -> LIN / SLIN.
• Circular Arc Interpolation: G2/G3 circular blocks converted to KRL CIRC / SCIRC with exact 3D midpoint (XAUX) calculation from arc parameters I, J, K or radius R.
• Feedrate Conversion: Translates CNC feedrates F (mm/min) into KUKA continuous-path velocities $VEL.CP (m/s).
• M-Code Mapping: Maps auxiliary codes (M3, M5, M8, M9) to digital output signals $OUT[...].

2. 2D Vector SVG Toolpath Generation

• Vector Elements: Parses <path>, <polyline>, <polygon>, <rect>, and <circle> SVG geometry.
• Bezier Curve Approximation: High-density spline approximation for complex curves.
• Safe Height Transitions: Automatically inserts Z_Safe approach and retract motions between contours.

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Vision Hand-Eye Calibration Wizard (krl.generateVisionCalibration)

• 9-Pose Calibration Pyramid: Generates a standard calibration grid for both Eye-in-Hand and Eye-to-Hand 2D/3D camera setups.
• Euler Angles Calculation: Computes 3D camera Look-At rotation matrices converted into KUKA Euler angles (A, B, C).
• Pre-Grasp Approach Pattern: Generates safe approach vectors along the tool Z axis ($TOOL) before part pick-up.

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Commands

Command	Identifier	Description
KUKA KRL: Validate RSI XML Configuration	krl.validateRsiXml	Validate SensorInterface/*.xml schemas
KUKA KRL: Generate Real-Time RSI Driver	krl.generateRsiCode	Generate 4ms/12ms RSI control loops
KUKA KRL: Import CNC G-Code / SVG to KRL	krl.importGcodeToKrl	Convert G-Code / SVG into .src + .dat
KUKA KRL: Vision Hand-Eye Calibration Wizard	krl.generateVisionCalibration	9-pose camera calibration generator
KUKA KRL: Export PLC Fieldbus Tags	krl.exportPlcTags	Export I/O to TIA Portal, TwinCAT, EPLAN