KUKA KR 4 R600 Small Six Axis Industrial Robot

KUKA KR 4 R600 Small Six Axis Industrial Robot

KUKA KR 4 R600 small six axis industrial robot English version assembly manual, compatible with KR C5 micro controller; The robot supports installation at any angle on the ground, wall, and ceiling; Complete coverage of product introduction, safety specifications, technical parameters, project planning, transportation, startup debugging, maintenance, repair, shutdown and scrapping, appendices, technical support, aimed at system integrators, debugging, and maintenance engineers. Copyright belongs to KUKA Robotics (Guangdong) Co., Ltd.

Product Description

Composition of the entire robot system

Robot arm body, KR C5 micro control cabinet, smartPAD-2 teaching pendant, connecting cables, system software, various optional accessories.

Structure of Robot Arm Body

6-axis cast light alloy articulated arm, equipped with brakes on each axis; The motor and cables are all built-in with cover plates for dust and moisture prevention.

Main components: Inline Wrist built-in wrist (A4-A5-A6), boom, link arm, rotating column A1, base frame, built-in electrical components (micro RDC, protection circuit, motor data cable).

Optional configurations: A1 axis limit device, A2-A6 energy supply drag chain system, brake release device, A6 zero calibration section.

Designated use and prohibition of misuse

Designated use: for transporting tooling fixtures, processing/transporting component products, only allowed to operate under the environmental conditions specified in the manual.

Prohibited behavior: used as a climbing bracket; Hyperparameter operation; Lack of safety equipment operation; Drilling or modifying the body structure without KUKA's permission will result in the loss of all warranty.

Robots belong to the semi-finished products (unfinished machinery) defined by the EU Machinery Directive and cannot be produced separately. They must be integrated into a complete CE compliance system for use.

Safety

Responsibility and legal framework: Robots belong to semi-finished products; The integrator is responsible for conducting a risk assessment of the entire machine, issuing an EC compliance statement, and affixing the CE mark; KUKA provides an Assembly Declaration. Without the manufacturer's permission, modifying the robot will result in the loss of warranty and claim rights. The responsibility for damage caused by third-party accessories shall be borne by the integrator/user.

Personnel classification: system integrator, operator, debugging/maintenance, cleaning personnel; All personnel must read the safety chapter and possess the corresponding qualifications.

Area Definition

Workplace: Robot's reachable range of motion;

Dangerous zone=workspace+stopping distance (including external axis), must be physically protected;

Safe zone: an area outside the danger zone.

The body comes with built-in protection: mechanical hard limit; Adjustable mechanical shaft limit can be selected; Option for mobile robotic arm without drive (brake release device); Main body warning nameplate (no tearing or alteration allowed).

Safety measures for each working condition

General safety: Personnel are prohibited from standing under the robotic arm; High temperature anti scalding of motor operating casing; Personnel wearing pacemakers should be at least 300mm away from the motor brake; dedicated personnel should be responsible for controlling the teaching pendant; Hardware/program modifications must be tested in T1 low-speed mode first; The fault must be disconnected, locked, and tagged.

Transportation: The robot must maintain a transportation posture to avoid impact and vibration.

Start/Re debug: Change default password before powering on; Check the grounding and plug fastening; Complete safety circuit testing; Prohibition of mixing robotic arms - controller pairing.

Manual mode T1/T2: T1 low-speed is used for teaching programming; T2 highway is only for testing purposes and does not allow programming demonstrations; Requirements for operators within the protective zone.

Automatic mode: All safety protections are intact, and the dangerous area can only be operated without anyone.

Maintenance and repair: Power off and lock, the control cabinet can maintain a maximum high voltage of 780V for several minutes after power off, and must be tested for electricity; ESD anti-static; Hazardous chemical handling and protection.

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

Technical Data

KR 4 R600 Basic Parameters

Project parameters

Number of axes: 6 axes

ISO9283 repeatability accuracy ± 0.015mm

Self weight approximately 27 kg

Rated load 3   kg; maximum load 4.63   kg

Maximum arrival radius 601   mm

Work envelope volume 0.84   m ³

Protection level body, wrist IP40

Noise<68dB (A)

Installation posture: Ground, wall mounted, suspended ceiling, any tilt angle

Base installation size 179   mm  × 179   mm; installation hole position 1505

Controller KR C5 micro

Cleanliness level ISO 14644-1 Class 5 (under the condition of a program magnification of 30%)

Environmental conditions: Operating temperature range of 0-55 ℃; Storage -40~+60 ℃; Avoid condensation;

Cable: standard 3 mm; optional 10 mm, 25 mm; minimum bending radius of motor cable ≥ 50 mm; data cable ≥ 30 mm.

Non ground installations (wall mounted/suspended/tilted) must have the correct tilt angle entered in the WorkVisual software. Parameter errors can cause overload, accidental movement, and damage to the body.

Axis motion parameters

Maximum speed under rated load within the range of axial motion

A1 ±170° 336 °/s

A2 ‑195° ~ +40° 336 °/s

A3 ‑115° ~ +150° 488 °/s

A4 ±185° 600 °/s

A5 ±120° 529 °/s

A6 ±350° 800 °/s

Provide side view and top view work envelope drawings; Provide the zero calibration positions for each axis.

Load Capacity

The rated load is 3 kg, with a maximum of 4.63 kg; only the arm allows a maximum additional load of 1 kg, while the column and connecting rod arm do not allow additional loads.

The load mass and moment of inertia must be verified simultaneously using the KUKA-Load tool, and the load data must be entered into the controller; Comes with a complete load curve diagram.

Wrist flange IW4: 7 M5-12.9 screws, locating pin 5   H7; provides axial force, radial force, overturning moment, and torque of the flange under normal operation and emergency stop conditions.

Load on Foundation Base

Provide vertical force Fv, horizontal force Fh, overturning moment Mk, and A1 axis torsional moment Mr for normal and maximum working conditions under three installation postures: ground, ceiling, and wall mounted;

The structural design must adopt the maximum load value, and additional loads need to be added to the force calculation.

Nameplate Identification

The nameplate and multilingual safety warning label of the entire machine must not be removed or painted, and must be replaced if they are unclear.

REACH Regulation

Search KUKA Xpert spare parts warehouse for SVHC high concern substance information.

Stopping distance and stopping time (safety critical)

Definition: Stop distance=Reaction distance+Braking distance; Stop time: stop signal until completely stationary; Mainly evaluate A1/A2/A3; The actual stopping distance of multi axis composite motion will increase.

Shutdown category:

STOP   0 (Category 0) directly cuts off the drive and locks the brake;

STOP   1 (Category 1) is controlled to decelerate and stop along the trajectory, and then cut off the driving brake after coming to a stop.

STOP0/STOP1 provides data tables and curve graphs for different arm extension ratios (33%/66%/100%), POV program magnifications, stopping angles under different loads, and stopping times.

The STOP0 value is a reference value for testing and simulation; The brake will wear out with the number of STOP0 triggers; Require on-site measurement of actual stopping distance at least annually.

Project Planning

Points to note in advance planning: Long term approach to temperature/power limits, high-frequency reciprocating motion, static loading, and external process forces can accelerate component wear and require shortened maintenance cycles. If necessary, consult with KUKA; The robot has built-in monitoring and automatically shuts down when exceeding the limit.

Two installation schemes

Installation of base pedestal (concrete floor): chemical anchor bolt components; Concrete grade C20/25; Provide drawings of the bottom plate, anchor bolts, and concrete thickness margins, with a maximum allowable horizontal deviation of 3 ° for the bottom plate.

Installation of rack steel structure: compatible with steel brackets, bases, and linear sliding tables; Positioning pin+4 M8 bolts; Steel structures must withstand the maximum foundation load.

Interface and Cable Planning

Base A1 interface: motor cable X30, data cable X31; 4-way pneumatic interface AIR1-AIR4 (maximum 0.7 MPa), MEMD interface X32; Drag chain interface X76; GIG option adds Ethernet interface X74.

A4 wrist side drag chain interface X96, 24V, 2A, M12 8-core.

Cable laying requirements: Separate metal cable trays to meet EMC electromagnetic compatibility; The cable cannot withstand tensile force; Working temperature -10~+70 ℃; The equipotential grounding cable is an optional item, and the customer must complete the grounding.

The energy supply system is divided into two sets: CTR-AIR and AIR-CTR-GIG (with Ethernet), with wiring diagrams provided.

Transportation

Transportation posture (must be strictly implemented): A1   0 °, A2   -120 °, A3  +144 °, A4   0 °, A5  +66 °, A6   0 °.

Lifting specifications: Use lifting equipment and slings to wrap around the connecting arm and wrist in the specified manner; Personnel are prohibited from standing under the robot during lifting; Prevent tipping and impact; Provide transportation dimension drawings.

Startup and Re Debugging

Ground installation - Base chemical anchor bolt scheme

Bottom plate leveling, chemical anchor bolt grouting and solidification;

The robot is positioned vertically and the bolts are tightened diagonally step by step;

After the first 100 hours of operation, the anchor bolts must be tightened again with a torque of 23 Nm;

Connect motor cables, data cables, and equipotential grounding; Complete equipotential conduction verification.

Ground Installation - Steel Structure Rack Scheme

Pre treatment of steel structure installation surface; Positioning sales in place;

The robot is positioned vertically and diagonally locked with 4 M8 bolts;

Cable wiring and grounding verification.

The mechanical steps for wall and ceiling installation are similar, but the installation tilt angle must be configured in WorkVisual.

Provide complete wiring diagrams for motor cables and data cable pins; Definition of connectors.

Maintenance

The maintenance cycle is based on standard operating conditions; Severe working conditions require a shortened cycle.

Maintenance Summary Table

Periodic homework content consumables

Tighten 4 foundation bolts for the first time in 100 hours (23 Nm) -

Recheck the torque of foundation bolts every year

Apply lubricating grease RB2 (10g) to the interior of A1/A2/A3/A5 cover plate within 5000 hours or at the latest within 1 year

Replace A3 synchronous belt within 5000 hours or at the latest 1 year

Replace A5 synchronous belt within 5000 hours or at the latest 1 year

Lubrication operation: Disassemble the A1/A2/A3/A5 cover plate, apply RB-2 grease internally, and reinstall the cover plate with a specified torque of 0.6 Nm; Pay attention to high temperature protection and wear protective gloves.

A3 synchronous belt replacement: fix the robotic arm with a sling; Remove the cover plate and loosen the motor fixing screws; Replace the synchronous belt; Measure and adjust the tension of the belt (target frequency 134 ± 4   Hz); Reinstall the cover plate, complete A3 zero calibration, and perform functional testing.

A5 synchronous belt replacement: remove A5 cover plate; Replace the synchronous belt; Adjust the tension target to 184 ± 5 Hz; reinstall the cover plate, calibrate the A5 zero point, and perform functional testing.

Robot body cleaning: high-pressure water gun and steam cleaning are prohibited; Use solvent-free, non corrosive cleaning agents; Prevent cleaning agents from infiltrating electrical and mechanical gaps; Perform a functional test on the entire machine after cleaning.

Maintenance

A3 synchronous belt tension measurement and adjustment: use a dedicated belt tension tester; Measurement using vibration frequency method; Adjust the motor position to achieve the target frequency; Allow fluctuations within a range of 30%; Lock the screw after the adjustment is completed.

A5 synchronous belt tension measurement and adjustment: Use the same tension tester with a target frequency of 184 ± 5 Hz; lock after adjustment to complete A5 zero calibration.

Synchronous belt operation must be powered off and locked; After shutdown, the belt temperature is high and needs to be cooled before operation to prevent burns.

Shutdown, Storage, and Disposal

Shutdown disassembly: The robot moves to the transport position; Power off, unplug all cables and grounding wires; Lift with lifting equipment, loosen the anchor bolts and lift vertically off the body.

Long term storage: maintain transportation posture; The storage environment should be dry, dust-free, without condensation, and avoid direct sunlight; All interfaces are sealed and protected; Covered with plastic film, desiccant can be placed inside.

Scrap disposal: classified by material: metal recycling of cast aluminum, copper, and steel; Motors, RDC circuit boards, and other electrical waste are prohibited from being dismantled without authorization; Seals, hoses, lubricants, and grease should be treated as chemical waste; Refer to the Material Safety Data Sheets (MSDS) for each material.