KUKA, FANUC and ABB technical reference: KUKA, FANUC and ABB.
Controllers, languages, the backups to send us, and where each manufacturer keeps its official manuals.
- Robots
- KUKA, FANUC, ABB
- Languages
- KRL, TP and KAREL, RAPID
- Offline
- WorkVisual, ROBOGUIDE, RobotStudio
Hardware and software
Families at a glance.
Status is only what the manufacturer says, with the source beside it. For a specific part, check its number in the manufacturer’s lifecycle tool.
| Family | What it is | Software | Status |
|---|---|---|---|
| KUKA KR C4, KR C5 (and KR C2) | Robot controllers with the smartPAD teach pendant | KRL; WorkVisual (configuration), KUKA.Sim (simulation), KUKA.OfficeLite (virtual controller) | KR C5 is the newest generation; KR C4 is widely installed; KR C2 is legacy. |
| FANUC R-30iB Plus, R-30iB Mate Plus (and R-30iA, R-J3iB) | Robot controllers with the iPendant | TP (teach pendant) and KAREL; ROBOGUIDE (HandlingPRO, WeldPRO and others) | R-30iB Plus is widely installed; R-30iA and R-J3iB are legacy. |
| ABB OmniCore, IRC5 (and S4C+) | Robot controllers with the FlexPendant | RAPID; RobotStudio; RobotWare 7 (OmniCore) and RobotWare 6 (IRC5) | OmniCore is ABB’s newest controller; IRC5 is widely installed; S4C+ is legacy. |
| Safety options | KUKA SafeOperation, FANUC DCS, ABB SafeMove | Configured on the controller, with a signed checksum | Changes need a safety review and re-validation. |
Before you send an RFQ
What to send us.
| Software or system | Send | How |
|---|---|---|
| KUKA | A full archive (.zip) from the controller, and the WorkVisual project | smartPAD main menu > File > Archive > All. Programs are .src and .dat pairs. |
| FANUC | An "All of above" backup to USB or memory card; an image backup if you have one | Programs are .TP (binary) and .LS (text); variables .VR; system .SV. |
| ABB | A controller backup folder, and the RobotStudio station (Pack and Go) | RAPID program modules are .mod; system modules .sys. |
| Every cell | Cell layout, fixture drawings, EOAT drawings, and the PLC program that runs the cell | So paths and interlocks can be checked offline first. |
From the floor
Worth knowing first.
Simulate first
A cell mapped in WorkVisual/KUKA.Sim, ROBOGUIDE or RobotStudio catches reach, collision and cycle-time problems before anyone climbs the cage.
Safety configuration is separate
Program changes and safety-configuration changes are different jobs. A changed safety checksum needs a documented review.
Back up before touching points
Take a full backup before touch-ups. It is the only fast way back if a path goes wrong mid-shift.
PLC handshake
Most cells run the robot from the PLC over PROFINET or EtherNet/IP. Signal maps belong in the backup and the PLC project.
Official documentation
Straight from the manufacturer.
These open the live source, so you always get the current revision. Manufacturer manuals are copyrighted, so we link to them rather than copy them.
Field notes
Answered on The Floor.
- ABB MultiMove calibration drifted after a tool change — which cal do you rerun?
- Dual-channel E-stop — channel 2 lags 40 ms and the safety PLC hates it
- ABB RAPID — World zone stops the cell only on shift change
- FANUC TP program — skip/jump that only fails on the second cycle
- Weld touchups creeping back on a KUKA + TIA cell we thought was done
- FANUC BG Logic vs a TP loop for a clamp interlock — where do you put it?
- KUKA interrupt fires twice on the same skip — path jerks, then continues
- Light curtain on a standard CompactLogix — or do I buy GuardLogix for one cell?
Robotics work on your line
Send it to us.
The files above, the symptom and the outage window. We come back with a plan, not a brochure.