KUKA KR 600 FORTEC heavy-duty six axis ground mounted industrial robot

KUKA KR 600 FORTEC heavy-duty six axis ground mounted industrial robot

KUKA heavy-duty six axis ground mounted industrial robot body assembly manual, compatible with KR C4 and KR C5 controllers. The product family includes KR600 R2830、KR600 R2830‑F、KR510 R3080、KR510 R3080‑F、KR420 R3330、KR420 R3330‑F； The suffix - F represents the casting reinforcement version. Robots belong to semi-finished mechanical equipment, and the responsibility for CE certification and risk assessment of the entire machine belongs to the system integrator.

Product Description

Complete Robot System

Robot arm body, robot controller, smartPAD teaching pendant, connecting cables, system software, optional accessories.

Structure of Robot Arm Body

6-axis series heavy-duty robot, casting+lightweight alloy, driven by AC servo motor; A2 axis is equipped with a hydraulic pneumatic balance cylinder (pressure equipment) to counteract the gravity load of the connecting rod. Main components: base frame, rotating column, connecting rod arm, arm, Inline hollow wrist, balance cylinder system, electrical components (RDC box, MFH multifunctional housing).

F-casting enhanced variant: wrist protection level IP67; Continuously introduce 0.1 MPa (0.1 bar) dry and clean compressed air into the arm to establish internal overpressure and resist dust and coolant mist; Special anti-corrosion varnish coating for the whole machine; Normal version wrist IP65.

Electrical: External connectors at the rear of the base; Motor integrated permanent magnet single disc brake.

Optional accessories: mechanical hard limit, mechanical shaft angle limit module, no drive release device (power off manual release brake mobile manipulator).

Designated use and prohibition of misuse

Designated use: for transporting fixtures and workpieces, for processing and transportation, and for use within rated environmental conditions.   

Misuse (loss of warranty): carrying people and animals, outdoors, explosion-proof, radioactive environment, personnel stepping on the body, overloading and overtraveling operation.

Robots are semi-finished products and cannot be directly put into use. The integrator completes the overall risk assessment, CE marking, and overall operation manual.

Technical Data

Overview of Main Models

table

Model Rated load Maximum load Maximum weight of the main body

KR600 R2830/- F 600   kg 729   kg 2826   mm Approximately 2650   kg

KR510 R3080/- F 510   kg 635   kg 3076   mm Approximately 2680   kg

KR420 R3330/- F 420   kg 515   kg 3326   mm Approximately 2686   kg

General basic parameters

Repetitive positioning accuracy ISO9283: ± 0.08 mm; noise<75 dB (A); Ground installation, base hole position S960.

Flange standard ISO 9409-1-200-11-M12; 12 M12 to 12.9 grade bolts.

Environmental conditions: operating temperature of 10~55 ℃; Storage -25~60 ℃; Environmental level 3K3.

Cable: compatible with KR-C4/KR-C5 controllers; Motor cable, RDC data cable, 16mm ² equipotential grounding wire; The maximum allowable length of the cable is 50 meters.

Requirements for Compressed Air for F-Casting Plate: ISO8573-1 (7:4:4) clean and dry compressed air, maintaining an overpressure of 0.1 bar at the arm and a gas consumption of 0.1 m ³/h.

Load related

It is not enough to only consider the load mass. The center of gravity Lx/Ly/Lz+moment of inertia must be verified using the KUKA Load tool, and the load parameters must be entered into the controller; Otherwise, it may cause overload damage to gears and motors.

Flange stress: distinguish between normal operating conditions and emergency stop peak conditions; Provide axial force, radial force, overturning moment, and flange torque; The values do not include safety factors, and additional safety factors are required for fixture design.

Additional loads: Column, connecting rod arm, and boom are allowed to install additional loads such as pipeline packages and protective covers. The document provides the allowable weight and installation drawings for each part.

Base foundation load

Output the vertical force, horizontal force, overturning moment, and A1 rotational torque transmitted from the robot motion to the concrete base; The values provided in the document do not include safety factors, and additional safety factors must be added in civil engineering design.

Stop distance and time

According to DIN-EN-ISO 10218-1; Distinguish between Stop0 (power cut-off shutdown) and Stop1 (path maintenance shutdown); Provide A1-A3 axis shutdown angle/shutdown time charts under different POV speed ratios and load ratios.

The actual stopping distance of multi axis composite motion will increase; It is recommended to check the stopping distance of the brake at least once a year.

Other

Please refer to the KUKA Xpert system for information on nameplate labels, REACH regulations for SVHC substances of high concern.

Project Planning and Design

Base selection: 175mm base S960, 200mm base S960, complete machine frame and rack installation; Concrete grade C20/25; Insulation layer and leveling mortar interlayer are prohibited between the bottom plate and concrete; The whole machine must ensure anti overturning and prevent tipping.

Cable planning: differentiate the specifications of KR-C4 and KR-C5 motor cables and data cables; Requirements for equipotential grounding; Cable bending radius requirements, EMC wiring requirements.

F variant planning compressed air supply system.

Transportation

The robotic arm must be placed in the standard transport posture specified in the document, and all external cables must be removed; Use the main lifting point or forklift fork slot for handling.

In special scenarios, the A2 buffer block can be removed to obtain a lower transportation height, and the buffer block must be restored before starting up after transportation is completed.

Avoid impact and vibration throughout the transportation process.

Startup and Restarting

Base installation process: Installation of 175mm base, 200mm base, and machine frame rack; Chemical anchor bolt construction; Leveling, maximum allowable tilt of 3 °; Tighten the bolts diagonally in steps; After 100 hours of robot operation, all fixing bolts must be re tightened with torque.

The robot body is lifted into place and the positioning pin is positioned; Apply torque to M24 bolts diagonally in steps.

Cable connection: Describe the pin definitions of the KR C4 and KR C5 controller motor cables, data cables, and equipotential grounding cable connectors.

F-version put into operation: connect compressed air and adjust the pressure to 0.1 bar.

Pre operation inspection checklist: Confirm no condensation; The body has no collision damage; Connector locking; Equipotential conduction test; All safety equipment function tests.

After long-term storage, air cushion will accumulate inside the balance cylinder. Before putting it into operation, it is necessary to perform the balance cylinder exhaust operation to prevent the protective cover from popping out and injuring people.

Maintenance (Power off, Lock and Tag out before Maintenance, ESD Protection)

Important: If the oil temperature exceeds 60 ℃, the maintenance cycle needs to be shortened; Grade 10.9 high-strength bolts must be replaced after loosening and are not allowed to be reused.

Main maintenance projects and cycles

Add lubricating grease Microlube GL261 to the O-ring seal of A4/A5 axis.

Balance cylinder bearing lubrication LGEV2/5; Check the balance cylinder pressure and leakage every 3000 hours; Before disassembling and assembling the balance cylinder, the arm must be mechanically locked.

Check the axial clearance of A4-A6 universal drive shaft; If the gap is greater than 0.8mm, the transmission shaft must be replaced; Annual re inspection interval.

Gearbox oil change (A1-A6): Oil Optigear Synt. ALR 150; Cycle of 10000 hours or at the latest 5 years; Detailed steps for draining and injecting oil; Record the amount of oil released as a reference for refilling oil. If the oil release is less than 70%, the gearbox needs to be flushed.

Cable package lubrication Optitemp RB2; 20000 hours or at the latest 5 years.

Body cleaning: power off; Do not use high-pressure water guns or compressed air to blow the bearing seal; Clean with soft cloth and neutral detergent; Replace the damaged nameplate in a timely manner.

All maintenance is completed, and all safety functions must be retested.

Maintenance

Dismantling and installation of A1/A2/A3 motors; Mechanical locking arm of the lifting device before disassembly and assembly; After the reinstallation is completed, perform the axis origin Master calibration.

Disassembly and assembly of A4-A6 wrist motor and universal drive shaft assembly, distinguishing between two types of universal shaft structures: those with fastening screws and O-rings; Perform A4-A6 origin calibration after repair.

Electrical wiring instructions: MFH multifunctional housing, RDC box, complete set of motor, temperature, and encoder wiring.

Maintenance items beyond the description in this manual must be carried out by contacting KUKA certification personnel.

Discontinuation, Storage, and Scrap Disposal

Shutdown disassembly: The robot moves to the transport position, disconnects the cables, and removes the grounding.

Long term storage: sealed interface, well protected.

Scrap: Mechanical components, hydraulic oil, and pressure components should be classified and disposed of according to local regulations.

Options

Release device without drive: Manually release the brake mobile manipulator under power-off conditions, operation steps and reset requirements.