KUKA KR AGILUS-2 New Generation Small Six Axis Robot

KUKA KR AGILUS-2 New Generation Small Six Axis Robot

Assembly manual for KR AGILUS-2 new generation small six axis robot, including standard model and EP electrostatic protected version; Support KR C4 compact, KR C5 micro/C5 micro-2 controllers; Support installation at any tilt angle for ground, wall, and ceiling. Robots belong to the partially completed machinery defined by the EU Machinery Directive and must be integrated into a complete CE compliance system before they can be put into production.

Product Description

Product Family Model List

KR 6 R700‑2 / KR 6 R700‑2 EP

KR 6 R900‑2 / KR 6 R900‑2 EP

KR 10 R900‑2 / KR 10 R900‑2 EP

KR 10 R1100‑2 / KR 10 R1100‑2 EP

EP version: The surface of the entire machine is coated with a special layer to achieve static dissipation and meet IEC 61340-5-1 static protection requirements, making it suitable for static sensitive production scenarios. Complete system: robotic arm body, control cabinet, smartPAD-2 teaching pendant, motor/data cable, software, various optional accessories.

Structure of Robot Arm Body

6-axis cast light alloy articulated arm with brake on each axis; All motors and cables are protected inside the cover plate. Main components: Inline Wrist built-in wrist (A4-A5-A6), boom, link arm, rotating column A1, base frame, built-in electrical components (RDC, motor cables).

Reserved energy supply system interface on wrist A4 side; The rear side of base A1 is the external wiring interface.

There are three sets of electrical cable configurations: basic cable set, CTR-AIR internal energy supply, and AIR-CTR-GIG (with Gigabit Ethernet GIG).

Optional configurations: A1 axis limit, brake release device, BOOSTER base frame; 4 PURGE cavity pressurization options A/B/C/D (with clean compressed air introduced to achieve IP67 protection level); Connector adapter kit, special length cable.

Designated use and prohibition of misuse

Designated use: For the transportation of tooling fixtures, parts processing and transportation, environmental conditions and maintenance cycles must be followed.

Prohibited behaviors: carrying people, climbing scaffolds; Hyperparameter operation; Lack of safety equipment operation; Outdoor, explosion-proof, radioactive, and underground environments; Without the permission of KUKA, drilling and modifying the body directly results in the loss of all warranty.

The robotic arm is a semi-finished product and cannot be powered on separately for operation. The system integrator completes a complete risk assessment and issues an EC compliance statement.

Safety

Legal responsibility framework: KUKA provides assembly declaration; The integrator is responsible for the risk assessment of the entire machine, CE conformity declaration, and affixing CE markings; Unauthorized modification of the robot results in loss of compensation, and the responsibility for damage to third-party accessories belongs to the user.

Personnel classification: system integrator, operator, debugging and maintenance personnel, cleaning personnel. All personnel must read the complete safety chapter.

Area Definition

Workplace: Robot's reachable range of motion;

Dangerous area=workspace+stopping distance (including external axis), must be physically fenced for protection.

The body comes with built-in protection: mechanical hard limit; Optional adjustable mechanical shaft limit; Brake release device (optional, emergency rescue only); The safety warning nameplate of the entire machine must not be torn off or altered.

After hitting the mechanical hard limit, it is prohibited to continue operating and KUKA evaluation must be contacted.

Safety points for each working condition

General safety: Do not stand under the arm; After a power outage, there is a risk of the arm falling and mechanical support is required; High temperature anti scalding of motor casing; Pacemaker personnel are at least 300mm away from the motor; dedicated personnel are responsible for controlling the teaching pendant; Modify the program hardware to prioritize T1 mode testing; The faulty equipment is powered off, locked, and tagged. After the control cabinet is powered off, the maximum internal high voltage is 780V, and it needs to wait for discharge.

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

Start debugging: Change default password when powered on; The robotic arm controller must be paired and cannot be mixed; Complete safety circuit testing; Prevent condensation.

Manual mode T1/T2: T1 is used for teaching demonstration; T2 is only for high-speed testing and programming is prohibited.

Automatic mode: All protective devices must be in good condition and there must be no personnel in the danger zone before operation.

Maintenance and repair: power off, lock, and verify electricity; ESD anti-static; Refer to MSDS for hazardous chemicals.

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

Technical Data

Common basic information: Supports installation at any tilt angle of 0~± 180 °; Non ground installation requires inputting the installation angle in WorkVisual, and incorrect parameters can overload and damage the robot; Base installation hole C246, base footprint   208  ×   208   mm; protection IP65, can achieve IP67 with PURGE compressed air chamber overpressure; Cleanliness level ISO 14644-1 Class 4 (program magnification 80%); Noise level<57 dB (A); Operating temperature 0~45 ℃; Storage -40~+60 ℃. Controller support: KR   C4 smallsize-2/C4 compact; KR C5 micro, KR C5 micro-2; The cable length can be selected from 1-25 meters, and a maximum of one splicing is allowed; The minimum bending radius of the motor cable is 5 × D. Mandatory requirement: both the load mass and the moment of inertia must be checked simultaneously, using the KUKA-Load tool, and the load data must be entered into the controller; Each model comes with a load curve diagram, working envelope side view+top view drawing; Provide axial force, radial force, overturning moment, and torque for flange operation/emergency stop conditions; Provide three types of foundation loads (normal value, maximum value) for ground/wall mounted/suspended ceilings, and the base design must adopt the maximum value; Additional loads are allowed on various parts of the arm (including the rotating column, connecting rod arm, and boom, all of which have upper limits and are included in the total load). Nameplate identification, REACH regulation SVHC information; Stop distance and stop time: STOP0 category (cutting off the drive brake), STOP1 category path controlled deceleration stop; Provide reference values for testing under different arm extension ratios and POV magnifications; The brake will wear out with the number of STOP0s, and the stopping distance will be measured on site every year.

Summary of Key Parameters for Each Model

Model Rated load Maximum load Maximum arm span Self weight Repeat positioning accuracy ISO9283

KR   6   R700-2/EP 6   kg 6.8   kg 726   mm Approximately 53   kg ± 0.02   mm

KR   6   R900-2/EP 6   kg 6.7   kg 901   mm Approximately 55   kg ± 0.02   mm

KR   10   R900-2/EP 10   kg 11.3   kg 901   mm Approximately 56   kg ± 0.02   mm

KR   10   R1100-2/EP 10   kg 11.2   kg 1101   mm Approximately 57   kg ± 0.02   mm

The mechanical dimensions and motion parameters of the EP version are exactly the same as the standard version, with only differences in coating color and ESD electrostatic protection capability.

Wrist flange: 7 M5-12.9 screws, locating pin 5H7.

PURGE pressurization system: maximum internal cavity pressure of 0.3 bar, working pressure of 0.1 bar; Compressed air requires ISO 8573-1:2010 (7-4-4) to be oil-free and water free, with a gas consumption of 0.1 m ³/h and a 4mm quick connector.

Cycle cycle data: Each model provides standard palletizing cycles (25-305-25 mm, 1 kg load) with the number of cycles per minute.

Unified range of axial motion: A1 ± 170 °; A2 ‑190°~+45°； A3 ‑120°~+156°； A4 ±185°； A5 ±120°； A6 ±350°； The maximum shaft speed varies under different rated loads of different models.

Project Planning

Planning risk warning: Long term temperature/power limits, high-frequency reciprocating, static loading, and external process forces can accelerate component wear and require shortened maintenance cycles. If necessary, consult with KUKA; The robot automatically stops when it exceeds the limit.

Two installation schemes

Installation on a concrete floor with a fixed base;

Installation of steel structure frame (positioning pin+bolt); The steel structure/concrete base must withstand all maximum foundation loads.

Cable and Interface Planning: Definition of Base A1 Interface; CTR-AIR and AIR-CTR-GIG energy supply systems; Cable laying cannot withstand tensile force, EMC electromagnetic compatibility; Equipotential grounding is necessary.

PURGE option planning: selection and prerequisites for four pressurization schemes A/B/C/D.

Transportation

Forced transport posture: The manual defines the angles of each axis, and when not fixed to the base, the robot must maintain a transport posture throughout the entire process.

Handling: lifting operations; Prohibition of savage impact; Provide the overall dimensions for transportation of the entire machine.

Startup and Re Debugging

Provide a complete description of the installation process for ground, wall, and ceiling robots:

Concrete foundation: The bottom plate positioning pin is in place, the robot lifts and lowers it, levels it, and diagonally locks the bolts step by step; After the first 100 hours of operation, tighten the anchor bolts again.

Steel structure frame: assembly of positioning pins, locking bolts for positioning.

Wiring operation: Define complete connectors for motor cables and data cables of KR C4 and KR C5 micro/micro-2 controllers; Complete equipotential conduction verification.

Key points for non ground installation: The installation tilt angle (ground 0-0-0, wall mounted 0-90-0, ceiling 0-0-180) must be entered in the WorkVisual software.

Mobile manipulator without driving conditions: brake release device, limited to emergency rescue only; ⚠️ The arm will fall in an unpowered state, and the arm must be mechanically supported before operation.

Maintenance

The maintenance cycle is based on standard operating conditions; Heavy duty high-frequency working conditions must shorten maintenance cycles.

Maintenance Summary Table: Tighten the foundation bolts for the first 100 hours; Regularly apply RB2 grease inside the cover plate; A3 and A5 synchronous belt replacement and tension adjustment; Body cleaning.

A3 synchronous belt replacement: mechanical locking arm body; Dismantle the cover plate, replace the belt, measure and adjust the tension using vibration frequency method; Reinstall the cover plate, perform axis zero calibration, and perform functional testing.

A5 synchronous belt replacement process; Tension measurement adjustment, zero point calibration.

Cleaning: Do not use high-pressure water guns or steam cleaning. Use solvent-free and non corrosive cleaning agents to prevent liquids from seeping into the gaps.

Maintenance

The manual only describes the replacement of fine fuses; Disassembly of other components such as joints, motors, and gearboxes is not covered in this manual and must be done by contacting KUKA service.

Shutdown, Storage, and Disposal

Shutdown and disassembly: move to the transport position; power failure; Remove all cable grounding wires; Lift the lifting device off the main body; All electrical connectors are protected against dust.

Long term storage: maintain transportation posture; Dry and dust-free environment without condensation; All interfaces are sealed and protected.

Scrap disposal: Metal recycling of cast aluminum steel; Classify motors and circuit boards as electrical waste; Lubricating grease, seals, and various consumables should be treated as hazardous chemicals; Follow local environmental regulations.

Options

CTR-AIR, AIR-CTR-GIG connector adapter kit;

Special length optional connection cable;

PURGE option A/B/C/D four internal cavity pressurization options, describe the installation and debugging steps respectively.