KUKA KR 3 D1200 HM Assembly Manual

KUKA KR 3 D1200 HM Assembly Manual

Product Description

Composition of Robot System

Robot arm body+KR C5 micro controller+smartPAD-2 teaching pendant+connecting cable+system software+options (installation base, eyebolt, sealing kit).

Hardware structure of robotic arm body (Delta parallel mechanism)

Base frame: Built in A1/A2/A3 motors, interface board arranged at the rear;

Three upper arms, each driven by a gearbox and connected to the forearm Forearm; Spring components are used to secure the forearm;

Forearm, 6 in total;

Movable plate: End motion platform, integrated A4 rotary motor and gearbox, output mounting flange;

Electrical system: Micro RDC, protective circuit, A1-A4 motor cables, data cables, complete set of prefabricated A4 cable assemblies.

Designated use and prohibition of misuse

Designated use: For picking and packing operations in the food, pharmaceutical, and consumer goods industries, it must be used within the environmental parameters specified in the manual.

Prohibited use:

The body components come into direct contact with food; As a climbing pedal; Carrying humans and animals; Outdoor, explosive environment, radioactive environment, underground mining;

Drilling or modifying the body structure without the permission of KUKA will directly result in the loss of warranty and accountability;

Robots belong to partially completed machinery and must be integrated into complete equipment for the entire system to meet CE requirements.

Safety (Key)

Legal responsibility: The entity provides an integrated declaration of incorporation; The system integrator is responsible for completing the risk assessment of the entire machine, issuing an EC compliance statement, affixing the CE mark, and writing the operating instructions for the entire machine. Complete machine integration has not been completed, direct startup is prohibited.

Personnel classification: system integrators, operation and maintenance personnel, operators, cleaning personnel; All personnel must read the safety chapter; Joint/electrical repairs are only authorized by KUKA personnel.

Workplace and danger zone: danger zone=robot workspace+stopping distance, must be physically protected (fence, safety light barrier); No physical protection must fully meet all the requirements of EN ISO10218 human-machine cooperation.

Protective device: mechanical hard limit (A1-A3 can be equipped with adjustable mechanical shaft limit); Brake release device; All types of nameplate warning signs are strictly prohibited from being removed or altered.

Important safety rules

Power off lock tag: Even if the controller is powered off, there is still a risk of the brake failing and the body falling; Before maintenance, the robot needs to be placed in a safe position with necessary mechanical support; Personnel are prohibited from standing under the robot.

The surface of the motor during operation is hot, posing a risk of burns.

Electric motors and brakes generate electromagnetic fields; Personnel wearing active implantable devices such as pacemakers must maintain a safe distance of ≥ 300   mm, and the power on/off status is valid.

After disconnecting the smartPAD teaching device, its emergency stop fails; The disconnected teaching pendant must be removed and cannot be left on site.

After modifying hardware/software/parameters, all programs must first be tested in T1 mode.

Fault handling: Power off, lock and tag, post fault labels, record faults; The repair must be completed with a complete set of security function testing.

Maintenance and repair: When working with live parts, simply pressing the emergency stop button is not enough. The main power switch must be disconnected and the power must be checked; After the controller is powered off, the internal high-voltage capacitor will maintain voltage for several minutes.

The spring component has elastic potential energy. It is strictly prohibited to disassemble three forearms at the same time when disassembling the forearms, otherwise the movable plate at the end will fall and squeeze, causing injury.

Technical Data

Basic parameters of the whole machine

Project KR 3 D1200 HM

4 axes (A1/A2/A3 parallel+A4 end rotation)

Rated load 3 kg; maximum load 6 kg

Working diameter 1200   mm

Repetitive positioning accuracy ISO9283 ± 0.05   mm

The weight of the body is about 95 kg

Protection level IP67; A4 axis can achieve IP69K high-pressure flushing

Noise<75   dB (A)

Installation method limited to ceiling lifting only

Controller KR C5 micro

Shell material: stainless steel

Cable optional length 4  /  7  /  15  /  25   m

Axis motion parameters

A1/A2/A3: Motion range -109 °~+42 °, maximum speed 600 °/s

A4 end rotation axis: ± 355 ° unrestricted rotation, maximum speed 840 °/s

Flange Load and Base Load

Flange load (operating/emergency stop conditions): axial force, radial force, overturning torque, rotational torque; Tool selection needs to consider both normal operation and emergency stop impact loads simultaneously.

Base lifting force (including robot weight+load)

Vertical force: Normal 1327   N/Maximum 1552   N

Horizontal force: Normal 563 N/Maximum 654 N

Overturning moment: normal 544 Nm/maximum 588 Nm

The design of the lifting frame must be checked according to the maximum value.

Shutdown distance and downtime

STOP0 (Class 0 shutdown, directly cutting off the drive brake) provides TCP X/Y/Z shutdown distance and shutdown time reference values;

STOP1 path maintenance shutdown provides multiple sets of curve graphs, variables: load m (33%/66%/100%), program speed POV percentage;

The manual values are the average of simulation and testing; The actual stopping distance of multi axis composite motion will be greater; Brake wear increases with the number of STOP0 triggers; The shutdown distance must be measured on the project site, and it is recommended to retest it once a year.

Nameplate REACH、RoHS

The nameplate is located on the main body and its content complies with the mechanical instructions; Meet Article 33 of REACH; Refer to KUKA Xpert for relevant information.

Project Planning

Reminder on operating conditions that affect lifespan: Continuously approaching the upper temperature limit, abrasive environment, long-term full load, frequent start stop, monotonous reciprocating motion, etc. will shorten the lifespan of components, and maintenance cycles need to be shortened. It is necessary to consult KUKA services.

Design of lifting base

There is an original factory available stainless steel installation base; Users can also make their own hexagonal transition plates, and the document provides a complete set of processing drawings;

Robot factory default upper arm+45 ° posture; The base structure must ensure a minimum distance of 300mm from the upper arm to the center to prevent motion interference;

Suggest arranging the robot at a 30 ° angle relative to the conveyor line to optimize load distribution.

bolt specification

Robot fixed to base: 12 M12 × 40-8.8 pieces; Positioning pin 3 × Φ 6   H7;

Base fixed to user frame: 9 M16 × 40-8.8 pieces.

Cable planning

The minimum bending radius for fixed installation of motor cables is ≥ 150   mm; for data cables, it is ≥ 60   mm;

It is recommended to separate motor cables and data cables into metal cable trays for wiring;

Equipotential grounding conductor must be configured (optional, customer order); Reserved grounding screw holes on the body base;

Rear interface board of the base: X30 motor cable, X31 data cable, X32 EMD calibration interface, vacuum system interface.

The installation size of the cable clamp for A4 cable assembly: The document provides a size diagram, and it must be assembled strictly according to the size to avoid damaging the cable due to movement and pulling.

Transportation

Transport posture: A1/A2/A3=+45 °; A4=0 °; original packaging boxes must be used.

Two ways of handling: forklift; Lifting with lifting rings and crane (3 M10 lifting rings screwed into the base).

Before hoisting: remove tools, tie and fix cables; The rated load of the lifting equipment must be greater than the overall weight of the machine; Prevent overturning throughout the entire process.

Startup and Re commissioning (Complete Ceiling Lifting Process)

Preparation tools: crane, torque wrench, hexagon socket kit, seal, eyebolt.

Step Overview: 1) Install the base/self-made hexagonal panel onto the user's ceiling frame; 2) Screw the lifting ring into the robot base, lift the crane, and maintain the transport posture; 3) Insert 3 positioning pins and tighten 12 M12 bolts diagonally with a torque of 78 Nm. 4) Connect the equipotential grounding wire, motor cable X30, and data cable X31, and check the locking buckle; Perform equipotential continuity testing; 5) Press the brake release button at the bottom of the base and manually adjust A1-A3 to a horizontal position;

Risk of using the brake release button: Without driving status, this device will fall, and standing below is prohibited. 6) Install spring components and three forearms; It is prohibited to remove three forearms at the same time, and individual forearms can be disassembled in sequence to prevent the movable plate from falling; The spring component has a huge elastic potential energy, and strong pulling is prohibited; 7) Assemble the entire A4 cable assembly and install all cable clamps according to the drawings; The bolt torque M4 × 35 is 2.4 Nm, using sanitary Usit washers;

Complete inspection before power on: installation fastening, no pulling of cables, safety circuit testing; Change the system password and do not use the factory default password; All programs are tested in T1 mode.

Maintenance

The components of the robot body have clear maintenance cycles; Spring components, forearm bearings, buffer bushings, and A4 cable assemblies are vulnerable parts.

Maintenance cycle maintenance project

Recheck the torque of the fixing bolts on the base after 100 hours of initial installation with M8=23Nm; M12=78Nm

Replace the forearm cushion liner after 5000 hours or at the latest 1 year; Replace the forearm bearing; Regular cleaning of bearings according to working conditions

20000 hours or at the latest 5 years, visual inspection of the forearm (replace immediately if cracks appear); Appearance inspection of A4 cable assembly, if damaged, please contact KUKA for replacement

Hygiene grade flushing and cleaning standards

Body IP67, A4 axis supports IP69K high voltage flushing; Clearly define the upper limits of water pressure, nozzle angle, distance, and water temperature; Do not directly punch the connector; Power off and emergency stop before flushing.

Disassembly and assembly tips:

High strength bolts of 10.9 and above must be replaced with new bolts once tightened and loosened, and are not allowed to be reused;

Forearm disassembly must be done one by one, not all three at the same time, to prevent injury from falling from the end platform.

Complete steps for replacing A4 cable assembly: 45 minutes of work, marking the position of the wiring harness, matching sanitary Usit washers, and strictly implementing all torques.

Maintenance

Maintenance work beyond the manual description can only be performed by authorized personnel from KUKA; After the repair is completed, a complete set of safety and functional tests must be conducted.

Discontinuation, Storage, and Scrap Disposal

Deactivation: Move to transport position; Dismantling tools; Disconnect all cables; Remove the forearm in sequence, and then disassemble the entire machine.

Storage: Dry and dust-free, avoiding condensation; Seal electrical connectors.

Scrap: As electronic waste, motors and RDC electronic boards are prohibited from disassembling the motor gearbox on their own; Bearings, seals, and cables are treated as ordinary industrial waste; The document provides a list of materials for specialized adhesives, gear oils, and lubricants.