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Configuring RSI on the controller

This guide highlights the steps needed in order to successfully configure the RSI interface on the controller to work with the kuka_rsi_hardware_interface on your PC with ROS.

1. Controller network configuration

Windows runs behind the SmartHMI on the teach pad. Make sure that the Windows interface of the controller and the PC with ROS is connected to the same subnet.

  1. Log in as Expert or Administrator on the teach pad and navigate to Network configuration (Start-up > Network configuration > Activate advanced configuration).
  2. There should already be an interface checked out as the Windows interface. For example:
    • IP: 192.168.250.20
    • Subnet mask: 255.255.255.0
    • Default gateway: 192.168.250.20
    • Windows interface checkbox should be checked.
  3. Minimize the SmartHMI (Start-up > Service > Minimize HMI).
  4. Run RSI-Network from the Windows Start menu (All Programs > RSI-Network).
  5. Check that the Network - Kuka User Interface show the Windows interface with the specified IP address.
  6. Add a new IP address on another subnet (e.g. 192.168.1.20) for the RSI interface.
    • Select the entry New under RSI Ethernet in the tree structure and press Edit.
    • Enter the IP address and confirm with OK.
    • Close RSI-Network and maximize the SmartHMI.
  7. Reboot the controller with a cold restart (Shutdown > Check Force cold start and Reload files > Reboot control PC).
  8. After reboot, minimize the SmartHMI (Start-up > Service > Minimize HMI).
  9. Run cmd.exe and ping the PC you want to communicate with on the same subnet (e.g. 192.168.250.xx).

If your PC has an IP address on the same subnet as the Windows interface on the controller, the controller should receive answers from the PC:

  • If this is the case, add another IP address to the current PC connection (e.g. 192.168.1.xx) on the same subnet as the RSI interface.

2. KRL Files

The files included in this folder specifies the data transferred via RSI. Some of the files needs to be modified to work for your specific configuration.

ros_rsi_ethernet.xml
  1. Edit the IP_NUMBER tag so that it corresponds to the IP address (192.168.1.xx) previously added for your PC.
  2. Keep the PORT tag as it is (49152) or change it if you want to use another port.

Note that the rsi/listen_address and rsi/listen_port parameters of the kuka_rsi_hw_interface must correspond to the IP_NUMBERand PORT set in these KRL files.

ros_rsi.rsi.xml

This file may be edited with application specific joint limits in degrees.

  • Edit the parameters within the RSIObject AXISCORR to specify joint limits such as LowerLimA1, UpperLimA1 etc. Note that these limits are in reference to the start position of the robot.
  • Edit the parameters within AXISCORRMON to specify the overall correction limitation. If this limit is exceeded in either of the joint directions, RSI is stopped. The values of MaxA1, MaxA2 etc. may be large to allow free movement within the specified joint limits in AXISCORR.

Notice the RSIObject of type ETHERNET. Within this object is a parameter called Timeout. This parameter is set to 100 by default. The RSI interface operates at 250 Hz (4ms cycle). The kuka_rsi_hardware_interface does not have a period configured and is completely driven by the controller's output. Every controller RSI output has a IPOC timestamp which increments for every cycle. The kuka_rsi_hardware_interface will answer as quickly as possible. The answer includes the last IPOC received. If the connected PC with ROS did not manage to answer within the RSI cycle of 4ms, the IPOC timestamp of RSI has incremented. The IPOC included in the answer is not matched and the controller will increment a counter. When this counter hits the Timeout parameter (100), the RSI connection will shut down. If this parameter is lowered, the demand for real-time computation will increase.

If you have problems with the connection to RSI shutting down now and then while moving the robot it is suggested to:

  • Compile and install a RT-Preempt kernel for your PC.
  • Give kuka_rsi_hardware_interface on your PC real-time priority when the RSI connection is established.
ros_rsi.src

This should only be edited if the start position specified within the file is not desirable for your application.

Copy files to controller

The files ros_rsi.rsi and ros_rsi.rsi.diagram should not be edited. All files are now ready to be copied to the Kuka controller:

  1. Copy the files to a USB-stick.
  2. Plug it into the teach pad or controller.
  3. Log in as Expert or Administrator.
  4. Copy the ros_rsi.src file to KRC:\R1\Program.
  5. Copy the rest of the files to C:\KRC\ROBOTER\Config\User\Common\SensorInterface.

3. Configure the kuka_rsi_hw_interface

The kuka_rsi_hardware_interface needs to be configured in order to successfully communicate with RSI. Inside /kuka_rsi_hw_interface/test and /kuka_rsi_hw_interface/config in this repository is a set of *.yaml files. These configuration files may be loaded into a launch-file used to start the kuka_rsi_hardware_interface with correct parameters, such as:

  • Joint names corresponding to the robot description (URDF or .xacro).
  • IP address and port corresponding to the RSI setup specified in ros_rsi_ethernet.xml.

We recommend that you copy the configuration files, edit the copies for your needs and use these files to create your own launch file. A template will be provided at a later time. However, at this time, have a look at test_hardware_interface.launch, test_params.yaml, controller_joint_names.yaml and hardware_controllers.yaml to achieve a working test-launch.

In order to successfully launch the kuka_rsi_hardware_interface a parameter robot_description needs to be present on the ROS parameter server. This parameter can be set manually or by adding this line inside the launch file (replace support package and .xacro to match your application):

<param name="robot_description" command="$(find xacro)/xacro.py '$(find kuka_kr6_support)/urdf/kr6r900sixx.xacro'"/>

Make sure that the line is added before the kuka_hardware_interface itself is loaded.

4. Testing

At this point you are ready to test the RSI interface. Before the test, make sure that:

  • You have specified the rsi/listen_address and rsi/listen_port of the kuka_rsi_hardware_interface to correspond with the KRL files on the controller.
  • You have a launch-file loading the network parameters, robot description, kuka_hardware_interface, hardware controller and controller joint names.

The next steps describe how to launch the test file:

  • In a new terminal:
$ roscore
  • Open a new terminal and roslaunch the previously configured launch-file:
$ roslaunch kuka_rsi_hw_interface test_hardware_interface.launch sim:=false

The kuka_rsi_hardware_interface is now waiting for the robot controller to connect. Follow the next steps to connect RSI:

  1. On the teach pad, enter mode T1 for testing purposes.
  2. Navigate to KRC:\R1\Program and select ros_rsi.src.
  3. Press and hold an enabling switch and the run/play-button. The robot will first move to the start position.
    • A message like Programmed path reached (BCO) will be shown at the teach pad.
  4. Press and hold again. The teach pad will post a warning !!! Attention - Sensor correction goes active !!!.
  5. Confirm the warning and press and hold the buttons again. This time the terminal where kuka_rsi_hardware_interface is running should output Got connection from robot. The RSI connection is now up and running.
  6. In a new terminal:
$ rosrun rqt_joint_trajectory_controller rqt_joint_trajectory_controller

Choose controller manager ns and controller and you should be able to move each robot joint.

  • Note that T1-mode limits the robot movement velocity and is intended for testing purposes.