KUKA LBR iiwa CR Clean 7-Axis Lightweight Collaborative Robot

KUKA LBR iiwa CR Clean 7-Axis Lightweight Collaborative Robot

Official Operating Manual for KUKA LBR iiwa CR Clean 7-Axis Lightweight Collaborative Robot, targeting two models: LBR iiwa 7 R800 CR and LBR iiwa 14 R820 CR; The robot only supports ground installation and is specially developed for clean room (only controlling particle pollution) scenarios. It has a built-in exhaust fan to remove particles inside the body and is equipped with KUKA Sunrise Cabinet controller. It fully covers product introduction, technical parameters, safety, project planning, transportation, installation and debugging, fan monitoring programming, maintenance and repair, shutdown storage and scrapping, torque appendix, technical support, and all other contents.

Product Description

Composition of the entire robot system

Robot arm body, KUKA Sunrise Cabinet control cabinet, smartPAD teaching pendant, connecting cables, software, optional accessories, CR control box (fan controller).

Characteristics of LBR iiwa CR robotic arm body

7-axis redundant degree of freedom lightweight collaborative robot, all drive motors and power cables are built into the joint module. Each axis integrates multiple sensors: position sensor, torque sensor, and temperature sensor. If the temperature is too high, the robot will automatically shut down for cooling, and can be restarted after cooling.

Main components: built-in wrist (A6/A7), multiple joint modules, base frame, LBR CR base ring (integrated clean exhaust fan), CR control box, complete set of built-in electrical wiring.

Unique design of CR cleanroom: The base ring is equipped with a built-in fan to extract particles generated inside the robot. Customers must connect an external exhaust duct to remove the particles from the cleanroom; The control box is responsible for fan speed regulation and speed signal acquisition.

Interface: Base A1 interface, all cable plug-in connectors.

Attention: The base ring kit will raise the robot Z-direction by 35 mm, and this offset will not be automatically included in the robot's base coordinate system. When performing Cartesian coordinate positioning, manual compensation for this 35 mm offset is required.

Chapter 4 Technical Data (Core Chapter)

Overview

Two models: LBR iiwa 7 R800 CR, LBR iiwa 14 R820 CR; Only supports ground installation.

LBR iiwa 7 R800 CR

Number of axes: 7 axes; The work envelope volume is 1.7 m ³; ISO9283 repeatability accuracy ± 0.1 mm; self weight approximately 26.1 kg; rated load 7 kg; maximum reach radius 800 mm

Protection level: IP54 for the main body; Base frame IP20; Noise level<75 dB (A); Footprint 220  × 220   mm; Color RAL9016 Traffic White; Controller KUKA Sunrise Cabinet

Environmental conditions: Operating at 5-45 ℃; Storage -40~+60 ℃; Cleanliness level Class3 (80% program magnification, equipped with exhaust system)

Range of motion and rated speed of each axis; The manual comes with a top view and a side view of the work envelope drawing.

Load parameters: rated load of 7 kg; rated moment of inertia of 0.3 kg · m ²; Center of gravity Lxy=35   mm, Lz=60   mm; No additional loads are allowed to be added to the robot body; Provide a load curve graph. Both load and inertia must be checked simultaneously, exceeding the limit will shorten the service life.

Base force (including robot self weight+rated load): Provide vertical force, horizontal force, overturning moment, A1 axis torque, and the maximum value must be used for structural design.

LBR iiwa 14 R820 CR

7-axis, maximum reach radius of 820 mm; rated load of 14 kg; attached working envelope drawing; Center of gravity parameters and load curve diagram; Maximum force data of the base.

Both models only allow the use of "Inside Electrical" medium flanges, and the manual provides the corresponding flange installation dimensions.

Nameplate identification

The nameplate and multilingual safety warning label of the entire machine are strictly prohibited from being altered or torn off.

REACH Regulation Information

The proportion of SVHC substances of high concern in product components is less than 0.1%.

Stopping distance and stopping time (safety critical)

Definition: The stopping distance is the angle at which the rear axle rotates triggered by the stop signal; Stop time from stop signal to complete stillness; Only evaluate A1-A4 (the four axes with the largest deformation). When multiple axes are moving simultaneously, the actual braking distance will be greater.

Stop category:

STOP0 (Category 0): Directly cut off the drive, lock the brake;

STOP1 (Category 1, Path Protection Braking): The drive is controlled to decelerate and stop, then cut off the drive and brake after coming to a stop.

Data source: PTP point-to-point motion, as a reference value for simulation and testing; The brake will wear out with the number of STOP0s, and it is required to measure the actual stopping distance at least once a year; The test conditions differentiate the arm extension ratio (33%/66%/100%), program magnification POV, and load mass m; the document comes with a large number of stop distance and stop time curve graphs.

Safety

Legal Framework and Responsibilities

Robots are semi-finished products, and system integrators are responsible for risk assessment of the entire equipment, issuing EC compliance statements, and affixing CE markings; KUKA provides an Assembly Declaration. Unfinished machinery is not allowed to be started separately.

Prohibit modifying robots without permission from KUKA; Any damage caused by third-party fixtures or accessories shall be the responsibility of the user/integrator.

safety function

Definition: Hazardous area=workspace+stopping distance; The safety zone is outside the danger zone; CRR mode (controlled robot retraction mode: after the robot is triggered to stop by safety monitoring, it can enter this mode to resume manual movement); T1 manual deceleration mode; T2 manual high-speed mode.

Personnel classification: system integrator, operator, maintenance personnel, cleaning personnel; Responsibilities of different roles; Only trained and qualified personnel are allowed to work.

Safety Function List

Built in: emergency stop device, enable device;

External connection: external emergency stop, external enable, external safety stop 1, operator safety (safety door signal); Support axis/Cartesian workspace monitoring, torque monitoring, and collision detection.

Teaching pendant enable switch with three gears: not pressed, middle gear (allowing movement), fully pressed (panic position, triggering safety stop 1); Do not use tape or other means to fix the enable switch.

Stop triggering response logic in each mode; The software limit switch is only used for equipment protection and does not belong to the safety limit for personnel protection.

Additional protective equipment

Jog jog mode rules; Requirements for ontology labels; External protective fence and safety gate requirements, safety gate circuit must meet PL d/Cat.3.

Safety measures for various working conditions

General safety: Do not stand under the robotic arm; Collaborative HRC mode must have status visualization indicator lights; The teaching pendant cannot be inserted or removed at will. If it is configured as non removable, the system must be equipped with an external emergency stop that can be reached at any time.

IT Security: Require users to establish an overall information security management system.

Transportation: It is necessary to use a transportation posture to avoid impact and vibration.

Startup/Debugging: Change user password before booting up; Conduct a complete set of security function tests; Brake test (mandatory for start-up, daily brake holding test is required without risk assessment).

Manual mode T1/T2; Automatic mode; Maintenance and repair; Shutdown, storage, and disposal; Single point of control (SPOC) principle.

Project Planning

Planning considerations: Long term approaching of performance limits, frequent short movements, static loading, external process forces will accelerate wear and tear, and maintenance cycles need to be shortened. If necessary, consult KUKA; Z-direction+35   mm base ring height compensation prompt again.

Installation form: frame installation with only positioning pins; Provide complete installation dimension drawings for 7 kg and 14 kg models; A Φ 120   mm exhaust vent must be reserved at the center of the base.

Exhaust duct interface: The customer should provide their own exhaust duct, and the robot is strictly prohibited from operating without an exhaust duct. Exposed fans can cause mechanical damage.

CR control box installation: must be installed outside the robot workspace; Provide the opening size.

Cable planning: Fixed laying with a bending radius of ≥ 45   mm; the cable cannot withstand tension; Laying of metal trunking to meet EMC electromagnetic compatibility requirements; Working temperature -10~+70 ℃.

Transportation

Original factory shipping packaging must be used; The outer packaging dimensions of the two robots are uniform: length 1180mm x width 780mm x height 595mm; the robots must be placed in a transport position before handling.

Startup and Re Debugging

Complete installation steps for ground robots: installation of positioning pins → positioning of base rings → hoisting of robot body → diagonal torque locking bolts (M8 for 7kg; M10 for 14kg); Tighten the foundation bolts after 100 hours of operation; Install CR control box; Connect the exhaust duct; Connect all cables.

WorkVisual software integrated fan controller: Import device description files (Beckhoff EK1100, EL6695, fan IO module EM8905-1002) and configure IO mapping.

Programming (Cleanroom Fan Monitoring)

Cleanroom compliance requires a rated fan speed of 2200 rpm; If the speed drops by ≥ 25%, it no longer meets the cleanliness level.

Need to write a loop backend task to periodically read fan speed measurement pulses; Provide complete example Java (Sunrise OS) backend task code; Monitor the speed below the threshold and output an alarm signal.

Maintenance

Maintenance Summary Table; The only replaceable part on site is the fan.

Robot cleaning: It is necessary to use cleanroom specific dust-free cloths and cleaning agents; Prohibit high-pressure water guns and steam cleaning; Prevent cleaning agents from infiltrating the internal electrical and mechanical structures; Stop the machine and press the emergency stop button before cleaning.

Maintenance

Only describe the disassembly and replacement of the entire machine; Users are not allowed to disassemble joint modules; Before disassembly, the robot must be switched to the transport position; Dismantling process: Dismantle tools → Move to transport position → Power off → Dismantle cables → Dismantle control box → Loosen the anchor positioning pin bolts and lift off the robot.

Shutdown, Storage, and Scrap Disposal

Shutdown: Ground robot shutdown and complete disassembly process; The connector should be well protected against dust.

Long term storage: dry and dust-free, avoid condensation, and avoid direct sunlight; All interfaces are sealed; The robot maintains a transport posture.

Disposal: Parts should be classified and disposed of (motors, circuit boards, cables, etc. should be treated as electrical waste, and unauthorized disassembly of motors is not allowed), in accordance with local environmental regulations.