KUKA KR 20 R1820-2 E Six Axis Industrial Robot

KUKA KR 20 R1820-2 E Six Axis Industrial Robot

KUKA KR 20 R1820-2 E six axis industrial robot assembly manual, compatible with controller KR C5 S, fully covering robot introduction, safety specifications, technical parameters, planning and design, transportation, startup debugging, maintenance, repair, shutdown storage disposal, accessories and appendices.

Product Description

Robot system composition: robotic arm, robot controller, connecting cables, smartPAD-2 teaching pendant, software, optional accessories.

Mechanical arm body structure: A 6-axis serial joint robot, consisting of five major components: a built-in wrist, a link arm, a rotating column, a base frame, and electrical wiring. A1-A5 with mechanical terminal block, only used for equipment protection; Personnel protection relies on SafeRobot software for secure space limitations or optional additional mechanical limits.

Built in wrist: A5 adopts synchronous belt transmission, and the flange complies with ISO 9409-1:2004;

Rotating column: built-in A1/A2 gearbox and motor;

Base frame: Robot installation base, integrated junction box, power supply system.

Electrical wiring: divided into A1-A4 cable components and A5-A6 cable components, including RDC cool and interface A1, all using plug-in connectors, and grounded through circular wire ears and fastening screws to the base.

Expected use and prohibition of misuse

Permission: Polishing, handling, and assembly must meet environmental conditions and comply with maintenance standards.

Prohibited: use as climbing tools, operate beyond parameters, lack safety equipment, carry people and animals, outdoors, explosion-proof areas, radioactive environments, underground operations; Misuse will result in loss of warranty.

Robots belong to partially completed machinery and must be integrated into a complete system that complies with CE standards in order to operate.

Safety Chapters

This chapter focuses on the mechanical arm body; When using KUKA controllers, it is also necessary to read the safety section of the controller operation manual.

Disclaimer: Must be in good condition, used according to regulations, and operated by personnel with risk awareness; Faults (especially safety related faults) must be dealt with immediately; Unauthorized modification of the robot is prohibited, and any damage caused by third-party components shall be borne by the user; Even if all safety instructions are followed, personal injury and property damage cannot be completely ruled out.

EC compliance: Robots belong to partially completed machinery and provide an integration statement; After completing the entire system, the system integrator shall issue an EC conformity declaration and affix the CE mark.

personnel qualification

User: Implement labor regulations, guardianship responsibilities, and regular pre job training;

Personnel (integrators, operators, maintenance, cleaning personnel): have professional training and read all robot documents thoroughly;

System integrator: responsible for installing wiring, risk assessment, implementing safety protection, issuing EC statements, and preparing system operation manuals.

Workplace, safety zone, danger zone

Dangerous area=workspace+robotic arm+external axis stopping distance, must be physically protected; Without physical protection, it meets the collaborative operation requirements of EN ISO 10218.

Protective equipment: mechanical end block, optional mechanical shaft limit, release device, brake release device, hazardous area identification sign; The sign is strictly prohibited from being altered or removed.

Various safety measures

Universal: Even if the controller is powered off, the robotic arm may still fall; It is strictly prohibited to stand under the robotic arm; The motor operates at high temperatures; Personnel with active implantable devices such as pacemakers must maintain a minimum distance of 300 mm from the motor/brake; emergency stop failure occurs after the teaching pendant is disconnected; External keyboard and mouse are only allowed to be used in scenarios where the drive is powered off or during maintenance; All safety functions of the modified robot must be tested. Immediately cut off power, lock and tag out the fault.

Transportation: Maintain the prescribed transportation posture and avoid impact and vibration.

Start debugging: Change default password; The robotic arm can only interface with the original controller; Prevent condensation; Visually inspect for collision and hidden damage before startup; Test all safety circuits.

Manual mode T1/T2: New/modified programs must be tested in T1 mode first; T2 mode is only used for high-speed testing and does not allow teaching programming. Operators must be outside the danger zone.

Automatic mode: All safety devices are intact, and there is no one in the area or it meets the standards for collaborative robots.

Maintenance and repair: power off and lock; When it comes to strong electricity, the main switch must be disconnected; Wait for a few minutes after a power outage greater than 50V; Balance cylinder complies with pressure equipment specifications; Refer to the safety data sheet for handling oil chemicals.

Discontinuation, storage, and disposal: comply with local regulations.

Technical data

4.1 Key parameters of the ontology

Project parameters

6 axes, 6 controlled axes

Rated load of 20 kg, maximum load of 23.9 kg

Maximum reach distance 1820   mm

Repetitive positioning accuracy ± 0.04 mm (ISO 9283)

The robot weighs approximately 240 kg

Protection level: IP54 for the body and IP67 for the wrist

Noise<75 dB (A)

Installation method: Ground, ceiling, wall mounted, at any tilt angle

Operating temperature range is 0-55 ℃; Storage -25~60 ℃

Axis motion parameters

Motion range: A1 ± 185 °; A2‑185°~+65°； A3‑138°~+175°； A4/A6 ±350°； A5 ±120°

Maximum shaft speed under rated load: A1 195 °/s; A2 175 °/s; A3 180 °/s; A4 360 °/s; A5 360 °/s; A6 550 °/s

Calibrate the zero position to provide the angles of each axis; Tilt installation will limit the motion range of A1 and requires WorkVisual software to configure the tilt angle.

Load related: Provide definitions of load center of gravity, moment of inertia, and load curve diagram; Wrist flange size ISO 9409-1; Provide the axial force, radial force, overturning moment, and torsional moment that the flange can withstand under normal operation and emergency stop conditions; Allow additional loads to be added to the boom, link arm, and rotating column.

Base load: Provide vertical force, horizontal force, overturning moment, and A1 torque for ground, ceiling, and wall mounted installation conditions respectively; The design base must adopt the maximum value.

Cable parameters (KR C5   S): motor cable XD30, data cable XF31; Standard length 4/7/15/25/35   m, maximum total length 35   m, maximum extension once; Request independent protection grounding.

Stop distance and stop time: distinguish between STOP0 and STOP1; Provide charts of stopping angles and stopping times under different stretching ratios, loads, and program magnifications POV for A1-A3; The brake will wear out, it is recommended to review the stopping distance annually.

Nameplate labels: Hot surface warning, lock shaft before motor disassembly, transportation posture reminder, etc., must not be damaged.

REACH regulation information can be found on KUKA Xpert.

Planning and Design

Accelerated wear conditions: Long term approaching temperature limit, abrasive environment, continuous approaching performance limit, single axis high duty cycle, monotonic reciprocating short stroke, long-term static wrist, external process force; If the above working conditions occur, it is necessary to consult KUKA to shorten the maintenance cycle.

Two installation base schemes

Equipped with a centering installation base (optional): used for concrete floor foundations; Concrete grade C20/25; Including base plate, chemical anchor bolt, positioning pin; Require a flat foundation without sound insulation and leveling layers, and provide the cross-sectional dimensions of the foundation.

Rack mounted installation: installed on the customer's steel structure or KUKA linear slide table; 4 M20 bolts+2 locating pins; Steel structures require sufficient rigidity to resist peeling, and the processing and installation surfaces have requirements for roughness and flatness.

Cable planning: The minimum bending radius for motor cables is 75   mm, and for signal cables it is 45   mm. Motor cables and data cables are laid separately in metal cable trays to achieve EMC; Double grounding is required; Cable layout to avoid tripping risks.

A1 Base Interface Definition: Motor, Data, Calibration, External Axis Interface Layout.

Transportation

Transportation attitude (must be strictly implemented): A1=0 °, A2=-140 °, A3=140 °, A4=0 °, A5=90 °, A6=0 °.

Two transportation methods

Forklift: Install optional fork slots;

Crane: Use M12 lifting rings, which are installed on rotating columns and base frames; Remove the lifting ring after transportation is completed.

Prohibition of non-standard lifting methods; Prevent tipping; Maintain the transportation posture throughout the entire process until the robot is fixed in place; Remove the rust adhesive on the contact surface to avoid impact and vibration.

Start debugging and restart operation

Distinguish between two installation forms: ground mounted with base and rack mounted (ground/wall mounted/suspended ceiling).

Preliminary conditions: The robot is in a transport position, the site is suitable for lifting, and the foundation is completed; Prepare lifting equipment, torque wrenches, and hexagonal tools.

Key points of installation process

Install fork slots or lifting rings;

Positioning of lifting robot; The ground base mode can use leveling fillers;

Tighten the bolts diagonally in steps to the specified torque;

Remove the fork groove/lifting ring;

Connect the grounding conductor (torque 15 Nm), connect the motor cable XD30 and data cable XF31; The sound of a click on the connector indicates locking, and the lock buckle can rotate 90 degrees to prevent accidental unlocking;

Fill in the actual installation posture of the robot using WorkVisual software (default ground);

Install the tool and complete the system startup according to the controller manual and system software manual.

Cable detailed description: Schematic diagram of motor cable XD30, data cable XF31, and assembly details of grounding cable.

External shafts require optional cascading RDC modules.

Maintenance

Only executable document record maintenance projects; The remaining repairs will be handed over to KUKA training personnel; The maintenance cycle is shortened when the operating oil temperature exceeds 60 ℃; Emergency stop and lock before maintenance.

8.1 Maintenance Cycle Summary Table

Cycle work content consumables

After starting, only one 100 hour recheck of the torque of the anchor bolt is required

5000 hours or at the latest 1 year visual inspection of flexible pipelines; Replace A5 synchronous belt -

10000   h lubrication A1 cable assembly Optitemp RB2 grease 0.3   kg

20000 hours or latest 5-year A1/A2/A3/A4 gearbox oil change; Check A1/A2 involute teeth and grease them; Replace the A4 synchronous belt Optigear Synt. ALR-150 gear oil; PETAMO GHY 133 N lubricating grease; Drei Bond 5204HV sealant

It is recommended that KUKA service conduct a comprehensive inspection of the entire machine after 7 years or changes in operating conditions.

8.2 Oil change process for each axis (A1/A2/A3/A4)

General points:

Controller power off and locked, gearbox at operating temperature, wear heat-resistant gloves;

Drain oil: Remove the magnetic plug, connect the oil container, and open the vent plug; Measure the amount of oil released; Compliant disposal of waste oil;

Refueling: Add fuel according to the actual amount released; If the oil discharge is less than 70% of the rated value, the gearbox needs to be flushed; Rinse twice with less than 50% oil discharge, and jog the entire stroke during the flushing process;

Magnetic plug inspection for metal debris; Tighten the plug according to the specified torque;

Clean up oil stains, jog in T1 mode, and check for leaks. Initial oil filling amount for each gearbox: A1=0.77   L; A2=0.70   L; A3=0.25   L; A4=0.05   L.

8.3 Inspection and lubrication of involute gears of A1 and A2 motors

Before disassembling the A2 motor, a sling must be used to secure the connecting rod arm to prevent it from falling;

Unplug the motor plug, remove the motor, protect the opening from contamination;

Clean the involute teeth and check for wear and damage; Damaged components must be replaced; Thin and continuous application of PETAMO GHY 133 N grease;

Apply Drei Bond 5204HV sealant to the O-ring; Tighten the bolt torque diagonally in steps; Connect the plug back;

Perform calibration (Mastering) for the corresponding axis.

8.4 A1 cable package lubrication

Remove the base cover plate; Visually inspect the corrugated pipe for any damage; Brush Optitemp RB2 on the outer surface of the corrugated tube; Reinstall the cover plate; Move A1 to evenly distribute the oil.

8.5 A5 synchronous belt replacement

Horizontal wrist, reset all wrist axes to zero, remove A6 tool;

Remove the wrist side cover plate; M4 screws must be replaced one by one and cannot be completely removed at once to prevent A5 motor from falling and being damaged;

Loosen the adjusting screw, remove the old synchronous belt, install the new synchronous belt, and ensure that the teeth are fully engaged;

The TSM alpha 2 frequency meter measures the vibration frequency and sets the target at 130 ± 5 Hz. Adjust the tension screw;

Cover gasket coated with Drei Bond 5204HV; restore cover plate; Complete A5 axis calibration and T1 mode testing.

8.6 Robot Cleaning

Prohibit high-pressure water guns; Do not blow the bearing seal with compressed air; Use solvent-free, water-soluble non corrosive cleaning agents; Power off operation; Prevent liquids from entering electrical and mechanical components; Clean up and restore safety protection.

Maintenance

This manual only describes the replacement of A1 and A2 motors; Other repairs require KUKA authorized personnel.

General safety for motor replacement: power off, wait for 5 minutes for discharge; Wear protective gloves to prevent compression and burns;

The steps for disassembling the motor are the same as in the maintenance chapter; Before installing the new motor, check that the involute teeth are undamaged and apply lubricating grease; Apply sealant to O-ring; Tighten the bolts diagonally in steps; Connect the plug; Complete axis calibration.

The document also provides an overview of electrical wiring and emergency calibration Mastering using calibration markers.

Deactivation, Storage, and Disposal

Shutdown disassembly: The robot moves to the transport position; Install lifting rings/fork slots; Disconnect the cable; Lift off the robot;

Storage: Maintain transportation posture, clean the robot, take protective measures, and comply with temperature and humidity;

Scrap disposal: Dispose of lubricating oil, electronic components, and metal structures in accordance with the regulations of the country where they are located.