KUKA KR FORTEC-2 Ultra Heavy duty Ground Six Axis Robot Mechanical Assembly Manual

KUKA KR FORTEC-2 Ultra Heavy duty Ground Six Axis Robot Mechanical Assembly Manual

KUKA ultra heavy ground six axis robot mechanical body assembly manual, compatible with controller KR C5 L6/L7. Product family models: KR480 R3400-2, KR480 R3400-2   F, KR480 R3700-2, KR480 R3700-2   F, KR560 R3100-2, KR560 R3100-2   F, KR560 R3100-2   HI, KR640 R2800-2, KR640 R2800-2   F, KR640 R2800-2   HI, KR800 R2800-2, KR800 R2800-2   F.

Product Description

Composition of a complete robot system

Robot arm body, KR C5 L6/L7 controller, smartPAD-2 teaching pendant, motor/data connection cable, system software, various optional accessories.

Structure of Robot Arm Body

6-axis series only ground mounted heavy-duty robot, cast+lightweight alloy structure, driven by AC servo motor; A2 axis is equipped with two independent liquid pressure balance systems (pressure equipment Class I, fluid group 2) to counteract the gravitational torque of the connecting rod; Composed of an accumulator, oil cylinder, and explosion-proof diaphragm. Main components: base frame, rotating column, left and right connecting arms, boom, IW500/ZH800 hollow wrist, dual balance cylinder assembly, RDC box, complete set of plug-in motors and signal cables.

F-casting variant: special corrosion-resistant coating for the whole machine; Wrist IP67; PURGE pressurization option, which introduces dry compressed air to establish internal overpressure, resists dust, coolant, and thermal splashes, and can withstand a short-term 180 ° C thermal shock on the wrist.

HI high inertia variant: dynamic parameter optimization, suitable for large moment of inertia workpieces.

Electrical: All motor quick plug connectors; RDC box is installed on the rotating column; The base integrates external interfaces.

Optional accessories: A1-A3 mechanical hard limit, A1-A3 optional mechanical angle limit module, no drive release device Release device (power-off manual release brake moving shaft), A1 hollow shaft cover, PURGE pressure regulator.

A1-A3 body comes with mechanical hard limit, only used for equipment body protection; Personnel protection still requires the SafeRobot safety function of the controller or optional mechanical angle limit.

Designated Use and Misuse

Designated use: heavy-duty handling, tooling processing, heavy-duty loading and unloading, ground installation and use under rated environmental conditions.   

Misuse will result in loss of warranty: carrying people/animals, outdoors, explosion-proof, radioactive environment, personnel stepping on the body, overloading and overtraveling, ceiling/wall hanging (this series only supports ground).

The ontology only provides a Declaration of incorporation and cannot be directly put into operation as a whole; The system integrator completes the overall risk assessment, CE marking, and overall operation manual.

Technical Data

This chapter contains the basic parameters, axis motion range, speed, load chart, supplementary load, flange force, foundation load, stopping distance time, nameplate label, REACH SVHC high concern substance for all models in the entire series.

Model Core Parameter Summary Table

Model Rated load Maximum load Maximum weight of the main body

KR480 R3400‑2 /‑F 480 kg 591 kg 3400 mm ~2200 kg

KR480 R3700‑2 /‑F 480 kg 580 kg 3700 mm ~2460 kg

KR560 R3100‑2 /‑F /‑HI 560 kg 681 kg 3100 mm ~2350 kg

KR640 R2800‑2 /‑F /‑HI 640 kg 835 kg 2800 mm ~2130 kg

KR800 R2800‑2 /‑F 800 kg 972 kg 2800 mm ~2400 kg

General basic parameters

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

Protection: IP65 for the body; F-cast variant wrist with IP67 rating.

Environmental conditions: Operating temperature range of 0-55 ℃; Storage -25~60 ℃; Environmental grade EN 60721-3-3; PH is 7-9.

Flange standards: IW500/ZH800, ISO 9409-1-200, M16-10.9 bolts.

Cable: compatible with KR C5; motor cable, XF31 data cable, 16 mm ² equipotential grounding wire; The maximum allowable length of the cable is 50 meters, with a maximum of one extension allowed; ESD meets IEC61340-5-1.

Range of motion for each axis, shaft speed under rated load, and Mastering origin calibration position; Complete work envelope 2D drawing.

Key load requirements

It is not enough to only look at the load quality, it is necessary to simultaneously verify the center of gravity Lx/Ly/Lz+three directions of rotational inertia, and use the KUKA Load tool for calculation; The load parameters must be entered into the controller, otherwise the gear motor will be damaged due to overload.

The robot's rotating column, left and right connecting arms, upper arm, and wrist are allowed to install supplementary loads such as pipeline packages and protective covers. The document provides the maximum allowable mass and installation hole drawings for each part; There is a total limit on the amount of load added to the left and right linkage arms.

Flange load: distinguish between normal operating conditions and emergency stop peak conditions; The value does not include a safety factor; The design of fixtures and jigs must have an additional safety factor added.

Base foundation load

Output the vertical force Fv, horizontal force Fh, overturning moment Mk, and A1 rotational torque Mr transmitted from the robot motion to the base.

The values provided in the document do not include a safety factor, and the civil engineering design must add a safety factor; The supplementary load on the rotating column and connecting rod arm needs to be manually added to the vertical force calculation.

Stop distance and time

According to DIN-EN-ISO 10218-1; Distinguish between Stop0 cutting off power shutdown and Stop1 path maintaining shutdown; Provide A1-A3 axis shutdown angles and downtime under different POV speed ratios and load ratios; The actual stopping distance of multi axis composite motion will increase; It is recommended to regularly inspect the brake system.

Other

Nameplate label; REACH regulation SVHC substances of high concern can be found in the KUKA Xpert system.

Chapter 5 Project Planning and Design

Choose one of three pedestal schemes: 200mm pedestal S960; 175   mm optional base S960; Installation of steel structure for the entire machine frame.

Concrete grade C20/25; Insulation layer and leveling mortar interlayer are prohibited between the substrate and concrete; The whole machine must ensure resistance to overturning; The maximum allowable installation tilt angle is ± 5 °.

Cable planning: motor cables, data cables, equipotential grounding; Bending radius; EMC cabling requirements.

The PURGE pressurized gas supply system is planned for the F casting version, with an interface of 6mm quick plug connector.

Transportation

The robot must move to the standard transport posture specified in the document and remove all external cables.

Support lifting equipment and forklift handling; Use the designated lifting points and fork slots for the body; Do not impact or fall.

Startup and Restarting

Base installation process: chemical anchor bolt construction, leveling; Robot hoisting in place, positioning pin positioning; Tighten the bolts diagonally in steps; After 100 hours of robot operation, all fixed anchor bolts must be re tightened with torque.

Cable connection: motor cable XD30. x, XF31 data cable, 16mm ² equipotential grounding cable; The connector must be locked tightly.

F-version put into operation: connect compressed air and enable PURGE pressurization option.

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

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

Distinguish between two maintenance cycles: standard/HI variant maintenance table; Special maintenance table for F casting variants; If the oil temperature exceeds 60 ℃, the maintenance cycle needs to be shortened; High strength bolts must be replaced after loosening and cannot be reused.

Main maintenance projects

Oil change for each axle gearbox: A1/A2/A3/A4/A5/A6; If the oil level is less than 70%, the gearbox must be flushed; Record the volume of discharged oil as a reference for refilling oil.

Maintenance of Double Balance Cylinder System: Regularly check pressure and leaks; Before disassembling and assembling the balance cylinder, the connecting arm must be mechanically locked.

Inspection and lubrication of A1 cable package.

Robot body cleaning: power off; Prohibit high-pressure water guns; 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

Disassembly and assembly of A1/A2/A3 large motors: Before disassembly and assembly, the arm of the lifting device is mechanically locked; After reinstallation, the axis origin Master calibration must be performed.

Disassembly and assembly of A4-A6 wrist motor; Disassembly and assembly of A4/A5 transmission shaft components; Perform wrist axis origin calibration after repair is completed.

In line hollow wrist assembly overall disassembly and replacement.

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

If the repair items exceed the manual description, it is necessary to contact a KUKA certified engineer for execution.

Discontinuation, Storage, and Scrap Disposal

Shutdown disassembly process: 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 driver: manually release the brake and move the robotic arm under power-off conditions; The operation steps and reset requirements must be calibrated at the origin after use.

A1 Hollow Shaft Shield: Installation, Cleaning, and Maintenance Process.

PURGE Boost Option (- F Casting Version): Installation and commissioning of pressure regulator inside the base.