KUKA KR AGILUS-3 ultra series small six axis serial robot

KUKA KR AGILUS-3 ultra series small six axis serial robot

KUKA's new generation AGILUS-3 ultra series small six axis serial robot covers three models: KR   10   R1100-3, KR   13   R900-3, and KR   16   R1100-3; Support installation at any tilt angle for ground, wall, and ceiling, compatible with KR C5/KR C5 micro-2 controllers; The complete set of content includes product introduction, safety specifications, technical parameters of the entire model, project planning, transportation, installation and commissioning, maintenance, repair, shutdown, storage and scrapping, options, and appendices.

Product Description

Robot system composition: robotic arm body, controller, connecting cables, teaching pendant, system software, tools and options.

Mechanical arm body structure: straight wrist inline wrist, upper arm, connecting rod arm, rotating column, base frame, lightweight cast aluminum alloy body, all shafts equipped with brake; The motor and cables are all arranged inside the cover plate for protection and dust prevention.

Straight wrist integrated A4-A6 three-axis; Connecting rod arm accommodates A2/A3 motors; Rotate the column to achieve A1 rotation; The rear of the base frame is equipped with an A1 main interface, which integrates power, data, air supply, and purging interfaces, all of which use quick plug connectors.

The cable assembly includes RDC encoder unit, motor cable, signal cable, and internal energy supply pipeline.

Available options: A1 mechanical shaft limit, A2-A6 pipeline package, brake release device, raised base, AIR-CTR/AIR-CTR GIG air source interface kit, special length connecting cable.

Permitted use and prohibited misuse

Permission: Handling, assembly, and workpiece handling must meet environmental conditions and adhere to maintenance cycles.

Prohibition: climbing stairs, carrying people and animals, outdoor activities, explosion-proof areas, radioactive activities, and underground operations; Unauthorized use will result in the loss of warranty.

Robots belong to partially completed machinery and must be integrated into a complete set of CE compliant equipment before they can operate. The integrator issues an EC conformity declaration.

Security Chapter

This chapter focuses on the mechanical arm body; To pair with the KUKA controller, it is also necessary to read the controller's accompanying safety manual.

Disclaimer and EC Machinery Directive: Robots only provide an 'Integration Declaration'; The system integrator is responsible for the risk assessment of the entire equipment, implementation of safety protection, issuance of EC compliance declaration, posting CE marking, and preparation of system operation manual. Unauthorized modification of robots is prohibited; Damage caused by third-party accessories shall be borne by the user; Even if all safety instructions are followed, personal injury and equipment damage cannot be 100% ruled out.

Personnel qualification division

User: Implement labor regulations, supervise personnel, and provide regular safety training.

Integrator: responsible for installation wiring, risk assessment, and safety protection design.

Operators/maintenance personnel must read the complete set of manuals and undergo professional training.

Area definition: Hazardous area=robot workspace+body+external axis stopping distance, priority given to physical fence protection; Non physical protection must strictly comply with the EN   ISO   10218 collaborative robot standards.

List of protective equipment: mechanical terminal hard block (only for equipment protection, not for personnel protection), optional A1-A3 adjustable mechanical shaft limit, manual release device for brake, and safety warning nameplate on the machine body; The nameplate is strictly prohibited from being painted or removed.

After the robot collides with the mechanical hard stopper, it must be stopped and KUKA must be contacted. It is prohibited to continue using it directly.

Scenario specific security measures

General: Power failure of the controller and brake failure can cause the arm to fall, and personnel are prohibited from standing under the arm; High temperature on the surface of the motor during operation; Personnel wearing active implantable devices such as pacemakers must be at least 300mm away from the motor/brake; emergency stop failure occurs when the teaching pendant is disconnected; After modifying the hardware/software configuration, all security functions must be fully retested; Immediately cut off power, lock and tag out the fault.

Transportation: Maintain the designated transportation posture throughout the entire process to avoid impact and vibration.

Start debugging: Change the default password of the controller; The robotic arm can only be matched with the corresponding model controller; Avoid condensation; Check for invisible collision damage before powering on; Complete testing of all safety circuits.

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

Automatic mode: All safety devices are intact, and there are no personnel in the danger zone or in compliance with collaborative robot specifications.

Maintenance and repair: power off and lock; Wait for several minutes for the discharge of high-voltage components with a voltage greater than 50V after power failure; Refer to the MSDS data sheet for handling oil.

Discontinue storage disposal: comply with local regulations and environmental requirements.

Technical Data 

Basic Overview of Three Models

Parameters KR   10   R1100-3 KR   13   R900-3 KR   16   R1100-3

Rated load 10   kg 13   kg 16   kg

Maximum load 12.4 kg 16.2 kg 19.3 kg

Maximum reach distance 1100   mm 900   mm 1100   mm

Repetitive positioning accuracy ISO 9283 ± 0.02 mm ± 0.02 mm ± 0.02 mm

The self weight of the body is about 88 kg, about 92 kg, and about 128 kg

Protection level body IP54, wrist IP67 body IP54, wrist IP67 body IP54, wrist IP67

Noise<70 dB (A)<70 dB (A)<70 dB (A)<70 dB (A)

Installation method: arbitrary tilt angle: ground/wall mounted/suspended ceiling arbitrary tilt angle: ground/wall mounted/suspended ceiling arbitrary tilt angle: ground/wall mounted/suspended ceiling

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

Axis parameters: Each model provides the range of motion for each axis, maximum axis speed, and zero point Mastering calibration position; Tilt installation will limit the movement range of A1 axis, and the actual installation tilt angle must be entered in iiQWorks.Sim software, otherwise overload and accidental movement damage to the robot may occur.

Load section: wrist flange size, load center of gravity, moment of inertia, load curve diagram; Distinguish between axial force, radial force, overturning moment, and torsional moment borne by flanges under normal operation and emergency stop conditions; Provide installation hole drawings for the large arm, connecting rod arm, and rotating column that allow additional loads.

Base load: Provide the vertical force, horizontal force, overturning moment, and A1 torque transmitted by the robot to the base for ground, wall mounted, and ceiling conditions respectively; The structural design must adopt the maximum value of emergency stop conditions to prevent overturning and falling.

Cable parameters: optional lengths of 1-25m for motor cables and data cables; specified dynamic minimum bending radius; It is necessary to independently protect the grounding; Provide dimension drawings of A1 base interface pins and connectors; AIR-CTR air source interface parameters.

Stop distance and stop time: distinguish between STOP0 (cutting off the brake) and STOP1 safe stop; Provide A1-A3 stop angle and stop time curves for three robots according to different arm extension ratios (33%/66%/100%), different program magnifications POV, and different loads; The brake will wear out, it is recommended to conduct an annual on-site review of the actual stopping distance.

Refer to KUKA Xpert for the body nameplate label and REACH regulation information.

Planning and Design

Reminder for accelerated wear conditions: long-term temperature limit operation, corrosive dust environment, continuous performance limit, single axis high duty cycle, monotonic reciprocating short stroke, wrist long-term static, external process force; If the above working conditions occur, it is necessary to consult KUKA to shorten the maintenance cycle; The robot has built-in overheating and overload monitoring, and will automatically shut down if it exceeds the limit.

Two installation base schemes

Base with centering option: concrete ground foundation; Concrete grade C20/25; Including base plate, chemical anchor bolt, positioning pin; Provide a basic cross-sectional dimension drawing.

Rack mounted installation: installed on customer steel structures, elevated platforms, and linear sliding tables; Use positioning pins and high-strength bolts; There are strict drawing requirements for the flatness, roughness, and structural stiffness of the installation plane; Distinguish between KR10/13 and KR16 bolt specifications.

Cable planning: minimum bending radius for motor cables and data cables; Power cables and signal cables are laid separately in metal cable trays to ensure EMC electromagnetic compatibility; Double protection grounding; Cable layout to avoid tripping risks; Do not allow cables to withstand tension.

A1 Base Interface Definition: Motor X30, Data X31, Air Source AIR1-AIR4, I/O Interface X76/X96, PurGE Purge Interface Drawing, introducing the two air source options of AIR-CTR/AIR-CTR   GIG.

Transportation

Each model is required to have an exclusive mandatory transportation posture, which must be maintained throughout the transportation process. It is prohibited to change the posture before fixing it to the base to prevent tipping.

Transportation method: lifting with lifting rings; This series of small robots does not have forklift slots and only allows lifting with lifting equipment; Location drawing of lifting points; Avoid impact and vibration during transportation; Remove the lifting ring after it is in place.

Startup Debugging and Restarting

8 complete installation processes including machine type, ground installation, rack mounted ground, rack mounted wall, and rack mounted ceiling:

Prerequisite: The robot is in a transport position, the base/steel structure is completed, and the lifting equipment is in place.

General installation steps:

Lift into place and install the positioning pin;

Tighten the bolts diagonally in multiple stages to the specified torque;

Connect dual protection grounding;

Connect motor cable X30 and data cable X31, and confirm that the connector lock is in place;

Fill in the actual installation angle of the robot in the controller software (ground/wall/ceiling);

Install tools, power on, jog in T1 mode, perform axis Mastering zero calibration, and perform overall functional testing.

Ceiling and wall mounted installations must strictly verify the base load, and the bolt torque must not be too low to prevent the risk of falling.

Maintenance

Only allow maintenance projects recorded in the manual to be executed; The remaining repairs will be entrusted to KUKA authorized personnel; Emergency stop, lock and power off before maintenance. Provide a comprehensive list of independent maintenance cycles for KR   10   R1100-3, KR   13   R900-3, and KR   16   R1100-3; This series of robots does not have a hydraulic nitrogen balance cylinder.

After 100 hours of operation, recheck the torque of all bolts installed on the base.

The oil change cycle and lubrication point cycle of the gearbox are randomly different.

Cleaning requirements: high-pressure water guns are prohibited, and direct blowing of compressed air on bearing seals is prohibited; Use water-soluble neutral cleaning agents, perform power-off operations, and avoid liquid intrusion into electrical chambers.

Maintenance

The manual describes the key points for replacing motors and disassembling electrical wiring harnesses;

General safety rules for replacing motors: power off, wait for high voltage discharge; Before disassembling the motor, mechanical protection must be applied to the corresponding shaft to prevent the arm from accidentally falling;

Motor installation: Check that the involute spline is not damaged and apply the specified lubricating grease; The O-ring seal must be replaced if it is damaged; Tighten the bolts diagonally in steps; After installation, the axis must undergo Mastering zero calibration and T1 mode trial operation;

Repairs must use KUKA original spare parts, and all safety functions must be fully verified after the repair is completed.

Suspension, Storage, and Disposal

Distinguish between the three installation forms of ground, wall mounted, and suspended ceiling, and provide the disassembly process for shutdown:

Shutdown and disassembly: Move the robot to the specified transport posture; Install lifting rings; Disconnect all cables; Lift the crane off the main body.

Storage: Maintain transportation posture, clean the robot, take rust prevention measures, and meet temperature and humidity storage conditions.

Scrap disposal: Lubricating oil, electronic components, and metal structures should be classified and disposed of according to local environmental regulations.

Options

AIR CTR, AIR CTR GIG air source connector kit;

Various special length connecting cables;

Brake manual release device, A1 axis mechanical limit, pipeline package, elevated base, etc.