KUKA KR FORTEC-2 new generation heavy-duty ground six axis robot

KUKA KR FORTEC-2 new generation heavy-duty ground six axis robot

The product family includes KR240 R3400‑2、KR240 R3700‑2、KR280 R3100‑2、KR340 R3400‑2、KR340 R3400‑2 F、KR360 R2800‑2、KR420 R3100‑2、KR420 R3100‑2 F、KR420 R3100‑2 HI、KR500 R2800‑2、KR500 R2800‑2 F、KR500 R2800‑2 HI； Compatible with KR C5 L6/L7 controllers. Definition of suffix: - F: Foundry casting reinforced version (PURGE internal pressurization); Hi: High Inertia high inertia variant; Robots belong to semi-finished mechanical equipment, and the CE, risk assessment, and safety protection of the entire machine are all borne by the system integrator.

Product Description

Composition of a complete robot system

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

Structure of Robot Arm Body

6-axis series ground mounted heavy-duty robot, cast structure, driven by AC servo motor; A2 axis is equipped with a liquid air pressure balance system (pressure equipment, pressure equipment instruction class I, fluid group 2), which offsets the gravitational torque of the connecting rod and consists of an accumulator, oil cylinder, and explosion-proof diaphragm. Main components: base frame, rotating column, connecting rod arm, forearm, Inline hollow wrist (IW300-2/IW500), balance cylinder assembly, RDC box, complete set of motor and signal plug-in cables.

Casting version: Special corrosion-resistant varnish coating; Wrist IP67; Support PURGE pressurization option, connect dry compressed air to establish internal overpressure, resist dust, coolant, and thermal splashes, and the wrist can withstand a short-term 180 ° C thermal shock.

HI high inertia version: optimizes dynamic parameters for large moment of inertia loads.

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

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

Important: A1-A3 comes with mechanical hard limit, only for machine 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, processing loading and unloading, ground installation and use within specified environmental parameters.   

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

The main body only provides an integrated declaration of incorporation and cannot be directly put into operation as a whole. The system integrator shall complete the whole machine risk assessment, CE marking, and operation manual.

Technical Data

This chapter covers all models in the entire series, including basic parameters, axis motion range, speed, load charts, additional loads, flange forces, foundation loads, stopping distance time, nameplate labels, REACH SVHC substances of high concern.

Overview of Series Models

Model Rated Load Maximum Load Maximum Arrival

KR240 R3400‑2 240 kg 310 kg 3400 mm

KR240 R3700‑2 240 kg 290 kg 3700 mm

KR280 R3100‑2 280 kg 360 kg 3100 mm

KR340 R3400‑2 /‑F 340 kg 426 kg 3400 mm

KR360 R2800‑2 360 kg 474 kg 2800 mm

KR420 R3100‑2 /‑F /‑HI 420 kg 527 kg 3100 mm

KR500 R2800‑2 /‑F /‑HI 500 kg 611 kg 2800 mm

General basic parameters

Repetitive positioning accuracy ISO9283: ± 0.08 mm; noise<75 dB (A); Only supports ground installation.

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.

The flange standards are divided into IW300-2 (Φ 160   mm, M10-10.9) and IW500 (Φ 200   mm, M12   12.9).

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

Range of motion for each axis, shaft speed under rated load, and Mastering origin calibration position; Work envelope diagram.

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 column, linkage arm, and forearm are allowed to install supplementary loads such as pipeline packages and shields. The document provides the maximum allowable mass and installation hole drawings for each part.

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 additional load on the 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.

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.

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.

Balance cylinder system maintenance: 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.