Assembly instructions for KUKA KR SCARA-2 CS series robotic arm body

Assembly instructions for KUKA KR SCARA-2 CS series robotic arm body

Product Description

Overview of Robot Systems

Complete system: SCARA-2 CS robotic arm body+KR CS Box-2 controller+smartPAD touch teaching pendant+connecting cables+system software+optional accessories.

Structure of Robot Arm Body

4-axis SCARA robot: A1/A2 horizontal rotating arm, A3 vertical ball spline screw Z-axis, A4 end rotating axis; Main components: base frame, connecting rod arm, cable assembly.

C01 cleanroom version: optimized for cleanroom and adapted to ISO 14644-1 cleanroom applications.

Electrical: WEIPU series quick plug connector (motor X30, encoder X31); The body is equipped with a brake release button, which can manually release the A3/A4 brake locally.

Protection level IP20; The body does not have a built-in balance cylinder.

Designated Use and Misuse

Intended use: for transporting tooling workpieces, assembling, picking up and unloading materials, ground installation, and use under specified environmental conditions.  

Misuse will result in loss of warranty: manned/animal, outdoor, explosion-proof environment, radioactive working conditions, personnel stepping on the body, overload and overtravel, ceiling and wall mounted installation.

The ontology only provides an integration statement and cannot be directly put into operation; The system integrator completes the overall risk assessment, EC conformity declaration, CE marking, and overall operation manual.

Technical Data

Covering basic parameters, axle parameters, load charts, foundation loads, flange forces, stopping distance time, nameplates, for 6 models REACH SVHC。

Model Core Parameter Summary Table

Model Rated Load Maximum Load Reach Z Travel Weight XY Repeat Positioning Z Repeat Positioning R Repeat Positioning

KR 6 R500 Z200‑2 CS 3 kg 6 kg 500 mm 200 mm ~20 kg ±0.02 mm ±0.01 mm ±0.01°

KR 6 R500 Z200‑2 CS C01 3 kg 6 kg 500 mm 200 mm ‑ ±0.02 mm ±0.01 mm ±0.01°

KR 6 R600 Z200‑2 CS 3 kg 6 kg 600 mm 200 mm ~21 kg ±0.02 mm ±0.01 mm ±0.01°

KR 6 R600 Z200‑2 CS C01 3 kg 6 kg 600 mm 200 mm ‑ ±0.02 mm ±0.01 mm ±0.01°

KR 6 R700 Z200‑2 CS 3 kg 6 kg 700 mm 200 mm ‑ ±0.02 mm ±0.01 mm ±0.01°

KR 6 R700 Z200‑2 CS C01 3 kg 6 kg 700 mm 200 mm ‑ ±0.02 mm ±0.01 mm ±0.01°

Protection level IP20; Noise<70 dB (A); Only ground installation; The base footprint is 262 mm × 190 mm.

Environmental conditions: Operating at 5-40 ℃; Storage -25~55 ℃; Environmental level 3K22; Low temperature operation requires preheating and deceleration first.

Controller: KR CS Box-2; Cycle time 0.36-0.38 seconds.

Load critical rules

The load mass, center of gravity Lx/Ly/Lz, and flange moment of inertia Iz must be verified simultaneously using the KUKA Load tool; Enter the load parameters into the controller, otherwise the motor gear will be damaged due to overload.

The forearm allows for the installation of additional loads, up to a maximum of 1 kg; additional loads will reduce the robot's dynamic rhythm.

Flange output axial force Fa, radial force Fr, overturning moment Mk, flange torque Mg; divided into normal operating conditions and emergency stop peak operating conditions; All values do not include safety factors, and additional safety factors must be added to the design of fixtures.

Reference benchmark for load center of gravity: A4 flange installation surface.

Foundation load

Output vertical force Fv, horizontal force Fh, overturning moment Mk, A1 turning torque Mr; the values already include the body weight+rated load; Excluding safety factor, the design of civil foundation must be overlaid with safety factor; The additional load weight needs to be manually included in the load.

Stop distance and stop time

Distinguish between cutting off power at Stop0 and maintaining shutdown at Stop1 path; Provide 100% program magnification POV, reference values for A1-A3 axis stop angle and stop time under rated/maximum load conditions.

The actual stopping stroke of multi axis composite motion will increase; It is recommended to regularly verify the stopping performance of the brake on site.

REACH regulation

SVHC substances of high concern can be found in the KUKA Xpert system.

Project Planning

Base Base: User provided; The base plane is flat and the holes are drilled strictly according to the drawings; Ensure that the entire machine is resistant to overturning.

Connecting cables and interfaces

Motor cable X30, encoder data cable X31; WEIPU WS28/WSF28 connectors; The grounding cable should be provided by the user themselves, and M4 grounding terminals should be reserved on the base.

Cable bending radius: motor cable ≥ 55   mm; data cable ≥ 45   mm; separate metal trunking wiring meets EMC requirements; Reserve a cable activity space of ≥ 200mm behind the A1 interface.

Indoor cable laying, working temperature -30~+80 ℃; The connector cannot withstand tensile force.

Transportation

Standard transport posture: A1=0 °, A2=0 °, A3=0mm, A4=0 °.

Transportation method: Original packaging box forklift handling; The net weight of the body is relatively light and supports manual handling by two people.

Remove all external cables before transportation; Avoid impact and vibration; The carrying capacity of the handling equipment must be sufficient.

Startup and Restarting

Installation process: Position and level the base; Lifting manipulator body; Tighten the base fixing bolts diagonally and step by step; Recheck the torque of the base bolts after 100 hours of initial operation.

Wiring: motor cable X30, encoder X31, protective grounding; Lock the plug tightly.

There are two ways to manually move the axis

A1/A2: T1 mode, KUKA. ControlStudio enables servo free mode, and the software releases the brake to manually move.

A3/A4: Press and hold the release button of the body brake to manually move; ⚠️ A3 releasing the brake load vertically along the Z-axis will cause it to fall, and the workpiece must be manually lifted.

Origin Mastering Calibration: After replacing the motor, gearbox, battery, and cable, the origin must be recalibrated; Use specialized calibration tool 0000-396-617; Calibration completed T1 mode trial run.

Pre operation inspection: no condensation, no collision damage, grounding continuity, and functional testing of all safety equipment.

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

Periodic maintenance project consumables/remarks

Recheck the torque of the 4 fixed bolts on the base for 100 hours (only once during initial operation)

1500   h/100   km stroke ball spline screw lubrication THK AFB-LF grease, approximately 5   g

4000 hours or at the latest 1 year, the replacement of A3/A4 synchronous toothed belt is limited to qualified personnel authorized by KUKA

Replace the main battery pack within one year

1 year re inspection of the torque of 4 fixed bolts on the base -

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

Maintenance

All maintenance operations are limited to KUKA or KUKA authorized personnel.

After replacing components such as motors, gearboxes, batteries, cables, etc., Mastering origin calibration must be performed.

There is a risk of shaft falling when using the brake release device, and personnel are prohibited from standing under the shaft.

Discontinuation, Storage, and Scrap Disposal

Shutdown disassembly: the robotic arm switches to the standard transport posture; Disconnect all cables; Loosen the base bolts and lift off the body.

Long term storage: in a dry and dust-free environment to avoid condensation due to temperature differences; Sealed electrical connectors; It is necessary to add desiccants; Body coverage protection.

Scrap: aluminum castings, copper cables, gears, motors, plastic parts, and seals are classified and disposed of; Refer to the manufacturer's safety data sheet for lubrication consumables.