Controlling KUKA Industrial Robots with SIMATIC S7-1500

The KUKA.PLC mxAutomation function package from KUKA Roboter GmbH enables seamless integration between the KUKA robot and the KR C4 controller, allowing users to execute basic and motion commands via the SIMATIC controller. This practical example demonstrates how to control a KUKA robot using the SIMATIC S7-1516, while also providing a detailed overview of the available function blocks within the mxAutomation library.

Industrial robots are rapidly gaining traction in modern manufacturing environments. These systems are now widely used across machines and production lines, thanks to their highly standardized mechanical design and flexible motion control capabilities. Their adaptability makes them an excellent choice for specialized machinery, enabling cost-effective mass production without requiring extensive modifications to existing equipment.

However, factory control systems and robot controllers typically operate as separate entities. Communication between them is often limited to bit-level interactions, and the robot’s motion control programs are stored directly on the robot controller, making it difficult for the plant control system to access or modify them. As a result, robots may struggle to respond quickly to unique operational events. Moreover, the programming languages and interfaces differ significantly between the two systems, which means that different specialists are usually required to manage each one. This leads to inevitable challenges in integration and coordination.

This application example illustrates how to fully control a KUKA industrial robot using the SIMATIC S7-1500 controller. The solution leverages the KUKA.PLC mxAutomation module library, which is accessible through the TIA Portal and contains all the necessary function blocks for this purpose.

The communication between the SIMATIC S7-1500 controller and the KUKA industrial robot is established via a PROFINET connection. This ensures that all command and status information is exchanged efficiently and reliably over the network.

Figure 01

The SIMATIC controller uses the KUKA.PLC mxAutomation module library to take full control of the KUKA industrial robot. The system includes the KUKA KR C4 robot controller and the physical robotic arm. The command decoder from the mxAutomation library is installed on the robot controller, receiving instructions from the SIMATIC system and executing them on the mechanical structure, including precise motion control and transformation.

Figure 02