KUKA LBR iiwa CR (Clean Room Version Robot) Operating Instructions

KUKA LBR iiwa CR (Clean Room Version Robot) Operating Instructions

Purpose

Target readers

Advanced knowledge in mechanical and electrical fields is required, as well as familiarity with robot controller systems; KUKA recommends users to attend KUKA Academy training.

Designated Use

Only used for clean room environment (particle monitoring only), for tool/fixture handling, workpiece processing and transportation, must be used under specified environmental conditions.

Prohibited misuse scenarios

Transporting people and animals; As a climbing tool;

Exceeding allowed operating parameters, explosion-proof environment, outdoor or underground use;

Medical and food processing scenarios; Relying on a robotic arm;

Operating without particulate matter extraction and exhaust conditions;

Unauthorized drilling or modification of robot structures will result in loss of warranty and accountability rights.

Product Description

The complete robot system consists of a robotic arm body, KUKA Sunrise Cabinet control cabinet, smartPAD teaching pendant, connecting cables, software, options, and accessories.

LBR iiwa CR ontology features:

7-axis redundant degree of freedom articulated arm lightweight robot; All drivers and power cables are built-in;

Each axis integrates multiple types of sensors: position sensors, torque sensors, and temperature sensors. If the temperature exceeds the limit, it will automatically shut down and can be restarted after cooling down;

Structural components: 2-axis built-in wrist (A6/A7 built-in motor), aluminum joint module, base frame, LBR CR base ring (built-in clean room exhaust fan);

LBR CR control box: specifically controls the base ring fan and reads the fan speed feedback;

All motor connectors are plug-in type, and all cables have built-in wiring.

The function of the base ring fan is to extract particles from the shell, which must be discharged by an external clean room exhaust system.

Technical Data

Includes complete parameters, loads, base forces, nameplates, REACH regulations, and downtime for two models.

LBR iiwa 7 R800 CR

Project parameters

7 axes fully controlled

Maximum arm span 800   mm

The weight of the body is about 26.1 kg, and the rated load is 7 kg

Repetitive positioning accuracy ± 0.1 mm (ISO9283)

Protection level: body IP54, base frame IP20

Noise<75   dB (A)

Installation method: Ground installation, base size 220 × 220   mm

Fan parameters 24V, approximately 0.3A, minimum speed 2200rpm

Load: Rated moment of inertia 0.3   kg · m ², no additional load is allowed; Load center of gravity reference A7 flange end face; Provide a load curve chart, and both the load and inertia must be verified.

Base force: maximum horizontal force of 240N, maximum overturning moment of 318Nm, maximum A1 axis torque of 156Nm. The selected base must meet the maximum load.

LBR iiwa 14 R820 CR

7-axis, rated load of 14 kg, base size of 256 × 256 mm;

The CR base ring will raise the robot by 35 mm in the Z direction, and the robot coordinate system is not compensated by default. When doing Cartesian positioning, this offset needs to be manually compensated;

The rated moment of inertia is 0.3 kg · m ², and no additional load is allowed; Attached is the corresponding load diagram.

REACH Regulation (Article 33 of EC 1907/2006)

The product does not contain SVHC candidate list materials with a quality score exceeding 0.1%.

Shutdown distance and downtime (safety critical)

Definition

Shutdown distance: the angle at which the shaft rotates from triggering the shutdown signal to complete stop;

Shutdown time: the time it takes for the shutdown signal to trigger and come to a complete stop;

Only providing data on the A1-A4 large inertia axis will result in a longer stopping distance for composite motion; Testing is based on PTP point-to-point motion.

Two types of downtime categories

STOP0 (Class 0 shutdown): Immediately cut off the drive and apply the brake;

STOP1 (Class 1 path keeping stop): Slow down and stop along the original path, and cut off the drive brake after stopping.

Influencing factors: load mass m, arm extension (0-100%), program speed POV%. The manual comes with a large number of curve charts.

Maintenance reminder: Brake wear is related to the number of STOP0 triggers. It is recommended to measure the stopping distance annually; Data can be recorded using a Data Recorder.

Safety

Legal Framework and Responsibilities

Even if robots are used according to regulations, they cannot completely eliminate personal and equipment risks;

Without the permission of KUKA, it is prohibited to modify the robot, otherwise the warranty will be lost; Any damage caused by third-party tools or software shall be the responsibility of the integrator/user;

Only allowed to be operated by personnel who are in good technical condition, meet the specified purpose, and are aware of the risks; Safety faults must be repaired immediately; EC conformity declaration/assembly declaration is required.

Safety Features

Safety function level: EN ISO13849-1 Cat.3 PL d; EN 62061 SIL2； All safety related components shall be tested upon start-up and at least once every 12 months. The SISTEMA library can be downloaded from the official website.

core concept

Workplace: allowable range of motion for robotic arms; Dangerous zone, safe zone;

STOP0 and STOP1 paths remain stationary; CRR mode (can enter reset mode after the safety controller triggers shutdown);

T1 manual deceleration mode (nominal ≤ 250 mm/s, this speed is not a safety monitoring speed under standard configuration, if safety monitoring is required, safety options need to be configured); T2 manual high-speed mode; AUT automatic mode.

Built in permanent safety features: emergency stop device, enable device; Configurable external security features: external emergency stop, external path maintenance safety stop, external enable, safety operation stop; It also supports axis/Cartesian workspace monitoring, speed monitoring, collision detection, etc.

Shutdown trigger source: Release the enable button, press the emergency stop button, open the safety door, overspeed, collision, torque limit, etc. Different modes trigger corresponding shutdown responses.

The manual drag and drop teaching preset maximum speed is 250 mm/s, which can be modified according to risk assessment.

Protective equipment, safety measures, and applicable standards

Do not stand under the robotic arm; Human machine collaboration HRC scenarios must be equipped with collaboration status indicator lights;

If the smartPAD teaching pendant is set to be non pluggable, it must be equipped with an external emergency stop that can be reached at any time;

After modifying hardware/software/parameters, all programs must first be tested in T1 mode;

Brake test: A brake test is required for starting/re debugging; Daily brake testing is required for daily operation without risk assessment;

List the complete set of applicable EU machinery EMC、 List of Robot Safety Standards.

Project Planning 

Installation: Ground frame centering installation;

7R800: 4 M8 × 65-8.8 hexagon socket screws; 14R820 uses M10 × 70-8.8; Equipped with 2 positioning pins to ensure positioning accuracy;

Reserve a Φ 120mm exhaust hole in the center of the base for ventilation in the clean room; The customer shall purchase and supply the exhaust duct themselves.

Installation of control box: Size 146   mm × 66   mm, must be installed outside the robot workspace.

Cable planning:

The minimum fixed laying bending radius of the cable is ≥ 45   mm;

Cable model: Robot control box 7 meters, control box control cabinet 1.5 meters;

Use metal trunking for wiring to meet EMC requirements; Environmental temperature -10 ℃~+70 ℃; Avoid tripping risks.

Transportation 

Original factory shipping packaging must be used and transported to the designated installation location.

Startup and Debugging

The cleanroom level cannot be guaranteed during the installation and debugging phase, and cleaning needs to be completed according to the process requirements before production.

Installation process: Pre install positioning pin → Place base ring → Lift robot body → Tighten base screws diagonally in sequence; After 100 hours of operation, the base bolts must be tightened again;

It is necessary to connect the exhaust duct and it is strictly prohibited to operate without an exhaust duct (there is a risk of injury if the fan is exposed). It is recommended to connect an active exhaust system;

Wiring: Connect the cables between the robot, control box, and control cabinet, and check that the cables are not pulled or rubbed;

WorkVisual software integrated fan controller: Import EtherCAT device description files (EK1100, EL6695, EM8905 fan IO modules), configure IO mapping; Fan output Out7.Output, speed feedback input In1.Input.

Programming - Fan Monitoring 

The cleanroom requires a minimum fan speed of 2200rpm; If the speed drops by ≥ 25%, it no longer meets the cleanliness level.

Need to write a cycle background loop task to continuously monitor the fan speed pulse signal;

Pulse conversion speed formula: Speed=(number of pulses x 60)/4 (fan outputs 4 pulses per revolution);

Provide Java style example code: including initialization, cycle counting, edge counting, and outputting an alarm signal to the PLC when the speed is below the threshold.

Parameter: Cycle period of 10ms, wait for the fan to start for 5 seconds when powered on.

Maintenance

maintenance cycle

Periodic maintenance work

Tighten the base bolts for the first 100 hours of operation: 7R800 (23Nm), 14R820 (45Nm)

Visually inspect every year and listen to the running noise of the fan

Replace the fan every 3 years at an environment of 25 ℃ (requires KUKA authorized maintenance personnel and technical support)

Robot cleaning: Only cleanroom specific dust-free cloths can be used; Prohibit strong corrosive cleaning agents, high-pressure cleaning machines, and steam cleaning; Avoid the infiltration of cleaning agents into components; Power off+press emergency stop to perform cleaning.

Maintenance - Robot Body Replacement 

It includes the complete steps of dismantling the old robot and installing the new robot. The installation points are the same as Chapter 8, which also requires tightening the bolts after 100 hours and connecting the exhaust duct.

Discontinuation, storage, and disposal 

Shutdown and dismantling: power off, protect the joint, lift off the body and base ring;

Long term storage: dry and dust-free, reduce temperature fluctuations, avoid condensation, avoid light, seal electrical interfaces;

Scrap and disassembly: Dispose of according to material classification (aluminum, stainless steel, copper, various plastics, motors, circuit boards are treated as electronic waste, and motors are prohibited from disassembly).