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 SIMATIC controller. This powerful tool allows users to control the KUKA robot using basic and motion commands directly from the KR C4 controller, offering a more efficient and flexible way to manage robotic operations. This application example demonstrates how to effectively control a KUKA industrial robot using the SIMATIC S7-1516, while also highlighting the key function blocks provided by the KUKA.PLC mxAutomation library.

Industrial robots are becoming increasingly essential in modern manufacturing environments. With their highly standardized mechanical systems and advanced motion control capabilities, they offer great flexibility and efficiency. This makes them ideal for use in complex machinery and automated production lines, allowing for mass production without costly modifications to existing equipment.

However, factory control systems and robot controllers often operate as separate entities. Communication between them is typically limited to low-level bit signals, and the robot’s motion programs are stored permanently within the robot controller itself. As a result, the plant control system cannot directly access or modify these programs, limiting the robot's ability to adapt to unique operational events. Additionally, the programming interfaces of these two systems differ significantly, which can lead to challenges in coordination and maintenance.

To overcome these challenges, the KUKA.PLC mxAutomation module library offers a solution that allows full control of the KUKA industrial robot through the SIMATIC S7-1500 controller. By integrating this module into the TIA Portal, engineers can access all necessary function blocks to seamlessly manage robot operations from the central control system.

Communication between the SIMATIC S7-1500 controller and the KUKA robot occurs via a PROFINET connection. This ensures real-time exchange of command and status information, enabling precise and synchronized control of the robotic system.

Figure 01

The KUKA.PLC mxAutomation library allows the SIMATIC controller to fully manage the KUKA industrial robot. The robot consists of the KUKA KR C4 controller and the mechanical 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.

Figure 02