KUKA Robots KR CYBERTECH-2 arc Assembly Instructions

KUKA Robots KR CYBERTECH-2 arc Assembly Instructions

KR 8 R2100-2 arc HW, belonging to the CYBERTECH-2 arc welding dedicated six axis robot, HW=Hollow Wrist hollow wrist, the center through-hole of the wrist can directly pass the welding gun pipeline through the wrist, reducing the interference of pipeline winding during arc welding operations; Compatible with KR C4 controller, supporting installation at any angle on the ground, wall, or ceiling. The document fully covers product introduction, safety, technical parameters, project planning, transportation, installation and operation, maintenance, repair, decommissioning, storage and disposal, options, appendices, and a complete set of ontology assembly and maintenance content.

Product Description

Robot system composition: robotic arm body, KR C4 controller, power/data cables, smartPAD teaching pendant, software, tools, and options.

Mechanical arm body structure: 6-axis serial joint robot, the assembly includes a hollow wrist (HollowWrist), a connecting rod arm, a rotating column, a base frame, and a complete set of electrical wiring.

A1-A3 is equipped with mechanical terminal hard blocks, which only provide equipment protection and cannot protect personnel; Personnel protection relies on the SafeRobot safety function of the controller, or by selecting the A1-A3 adjustable mechanical shaft limit.

Hollow wrist core features: Both A4 and A6 have 50mm through holes, allowing welding gun cables and air tubes to be directly connected to tools from the inside of the arm, greatly reducing the pulling, twisting, and wear of arc welding application pipelines; A5/A6 adopts synchronous belt transmission.

The Combo junction box at the back of the base integrates an RDC unit, and all motor and signal cables use quick plug Han Yellock connectors.

Permitted use and prohibited misuse

✅ Allow: arc welding, workpiece handling; Environmental conditions and maintenance cycles must be followed.

❌ Prohibited: climbing, carrying people and animals, outdoor activities, explosion-proof areas, radioactive activities, and underground operations; Unauthorized use will result in the loss of warranty.

Robots belong to partially completed machinery and cannot be put into operation independently; The system integrator completes the entire system, issues an EC conformity declaration, and affixes the CE mark.

Available options: Release device for brake release, transport fork groove, lifting ring, A1-A3 mechanical shaft limit, pipeline package, booster frames reinforcement frame.

Technical Data (KR   8   R2100-2   arc   HW)

Basic parameters of the ontology

Project KR   8   R2100-2   arc   HW

6 axes fully controlled

Rated load 8 kg; maximum load 9.3 kg

Maximum reach distance 2101mm

Repetitive positioning accuracy ISO 9283 ± 0.04 mm

The self weight of the body is about 260 kg

Protection level: IP65 for the main body; Wrist IP54

Noise<65dB (A)

Installation method: Ground/Wall mounted/Ceiling, with any inclination angle

Hollow wrist through-hole A4=50mm, A6=50mm

Compatible controller KR C4

Operating at a temperature of 5-55 ℃; Storage -20~60 ℃

Axis motion parameters

Motion range: A1 ± 185 °; A2‑185°~+65°； A3‑138°~+175°； A4/A6 ±350°； A5‑115°~+140°

Rated load maximum shaft speed: A1   200 °/s; A2   175 °/s; A3   190 °/s; A4   430 °/s; A5   430 °/s; A6   630 °/s

Mastering zero position; Tilt installation will limit the range of motion of the A1 axis, and the actual installation tilt angle must be filled in by WorkVisual. Otherwise, overloading or accidental movement may damage the robot. The document includes the A1 axis tilt angle restriction curve diagram and two-dimensional work envelope diagram.

Load parameters: ZH8   HW hollow wrist flange; Load center of gravity, moment of inertia, load curve diagram; Distinguish between normal operation and emergency stop conditions, flange bearing axial force, radial force, overturning moment, and torsional moment; Additional loads are allowed to be added to the boom, connecting rod arm, and rotating column. Provide installation hole drawings and allowable additional load values.

Base load: Output vertical force, horizontal force, overturning moment, and A1 torque for ground, ceiling, and wall mounted working conditions respectively; The structural verification must take the maximum value of the emergency stop condition to prevent overturning and falling.

Cable parameters: motor cable X20-X30, data cable X21-X31; The standard length is 4-50 meters, the maximum total length is 50 meters, and a maximum of one extension is allowed; Specify the minimum bending radius; Independent dual protection grounding; Complete A1 base Combo box interface pin diagram.

Stop distance and stop time: distinguish between STOP0 cutting off the brake and STOP1 keeping the path stopped; Provide stop angle and stop time curves for A1-A3 according to different arm extension ratios (33%/66%/100%), program magnification POV, and different loads; The brake has wear and tear, it is recommended to conduct an annual on-site review of the actual stopping distance.

Refer to KUKA Xpert for the body nameplate label and REACH regulation information.

Planning and Design

Reminder for accelerated wear conditions: long-term temperature limit operation, corrosive dust environment, continuous performance limit, single axis high duty cycle, monotonic reciprocating short stroke, wrist long-term static, external process force (arc welding continuous process force); Consult KUKA for the above working conditions to shorten the maintenance cycle; The body comes with overheating and overload monitoring, and automatically shuts down when exceeding the limit.

Two base schemes

Centering option base: concrete floor; Concrete grade C20/25; Bottom plate, chemical anchor bolt, positioning pin; Prohibit adding soundproof leveling layers between the base and concrete, and provide a foundation section drawing.

Rack mounted installation: customer steel structure, KUKA linear slide table; 4 M20 bolts+2 locating pins; Strictly follow the drawing requirements for the flatness, roughness, and structural stiffness of the installation surface.

Cable planning: The minimum static bending radius for motor cables is 75mm, and for signal cables it is 45mm. Power cables and signal cables are laid separately in metal cable trays to ensure EMC electromagnetic compatibility; Double protection grounding; Cable layout eliminates tripping risks; Cables are prohibited from withstanding tensile forces.

A1 Base Interface Definition: Motor X30, Data X31, Mastering Calibration X32, External Shaft XP7.1/XP8.1 Interface Drawing.

Transportation

Forced transportation posture (must be maintained throughout the entire process, and the posture must not be changed before being fixed to the base to prevent tipping)

A1=0°，A2=‑138°，A3=161°，A4=0°，A5=0°，A6=0°

Shipping Method

Forklift: Optional fork slots must be installed;

Crane: using M12 lifting rings, with lifting points distributed around rotating columns and base frames;

Prohibit lifting from non-standard lifting points; Avoid impact and vibration; Dismantle the lifting ring/fork groove in place; Provide the overall dimensions and center of gravity position drawings for the transportation of the entire machine.

Startup Debugging and Restarting

Distinguish between two installation types: floor mounted with fixed base and rack mounted (floor/wall/ceiling) installation.

Prerequisite: The robot is in a transport position, the base steel structure is completed, and the lifting equipment is in place.

General installation steps

Lift into place and install the positioning pin;

M20 bolts are tightened diagonally in multiple stages to the specified torque;

Connect double protection grounding (torque 15   Nm);

Connect motor cable X30 and data cable X31; The clicking sound of the connector indicates locking, and the lock buckle can rotate 90 degrees to prevent accidental unlocking;

Fill in the actual installation posture and inclination angle of the robot using WorkVisual software;

Install welding gun/tool, power on, jog in T1 mode, perform axis Mastering zero calibration, and perform overall functional testing.

After 100 hours of operation, all anchor bolt torques must be rechecked.

Provide a complete schematic diagram of the wiring for KR-C4 motor cables, data cables, and grounding cables.

Maintenance

Only allow maintenance projects recorded in the manual to be executed; The remaining repairs will be entrusted to KUKA authorized personnel; Emergency stop, lock and power off before maintenance; The maintenance cycle is shortened when the oil temperature is above 60 ℃.

Maintenance cycle summary table

Periodic homework content consumables

After being put into operation, only one 100 hour recheck of the torque of all bolts on the base will be conducted

5000 hours visual inspection of A1 flexible pipeline package for damage -

Replace A5, A6 synchronous belt kit SPP set of belts A5/A6 HW within 5000 hours or at the latest 1 year

10000   h A1 cable package coated with Optitemp RB2 grease

20000 hours or at the latest 5 years of A1/A2/A3 gradual flowering key examination for fat supplementation; A1-A4 gearbox oil change; A5/A6 gearbox oil free Optigear ALR320, Optigear Synt. ALR   150; Microlube GL 261 grease

Suggest KUKA to conduct a comprehensive on-site inspection of the entire machine after 7 years or changes in operating conditions.

Key maintenance process

A1 cable package lubrication: Remove the base cover plate, visually inspect the corrugated tube, apply lubricating grease with a brush, restore the cover plate, and jog A1 to evenly distribute the grease.

A5&A6 synchronous belt paired replacement

Return the wrist to zero and remove the straight row wrist side cover plate; Disassemble M4 screws step by step, do not remove them all at once to prevent the motor from falling off;

Replace A5 and A6 synchronous belts in pairs and measure the tension frequency using a frequency meter;

Apply sealant to the sealing surface and restore the cover plate; Complete A5/A6 axis Mastering zero calibration and T1 mode testing.

A1/A2/A3 motor gradual flowering key inspection lubrication

Before disassembling the motor, the corresponding shaft must be mechanically locked with a sling fixture to prevent the arm from falling;

Remove the motor, clean the gradually blooming key, and check for wear and tear; Damage must be replaced; Thin and continuous application of Microlube GL 261;

Inspect the O-ring and replace it if it is damaged; Tighten the bolts diagonally and step by step; Connect the plug back; The axis must undergo Mastering zero calibration.

General rules for gearbox oil change: The gearbox is at operating temperature; Measure the actual amount of oil released during oil discharge; The gearbox must be flushed if the oil release rate is less than 70% of the rated value; Rinse twice with less than 50%, and move the entire stroke during rinsing; Magnetic plug inspection for metal debris; Tighten the plug according to the specified torque; Oil change completed T1 mode jog operation, check for leaks.

Initial oil filling amount for each gearbox: A1=1.90   L; A2=1.50   L; A3=0.36   L; A4=0.08   L.

The A5/A6 gearbox is maintenance free and does not require oil change.

Robot cleaning: Prohibit high-pressure water guns and direct blowing of compressed air on bearing seals; Use water-soluble neutral cleaning agents; Power off operation to prevent liquid from entering the electrical chamber.

Maintenance

The manual describes the replacement of A1/A2/A3 motors, and only provides electrical wiring drawings for the disassembly and assembly of A4-A6 motors. Complex disassembly and assembly require KUKA authorized personnel.

General safety for motor replacement: power off, lock the main switch, wait for 5 minutes for high voltage discharge; Before disassembling the motor, the corresponding shaft must be mechanically secured with a sling to prevent the arm from accidentally falling;

Motor installation: Check that the gradual flowering key is not damaged and apply Microlube GL261 evenly; The O-ring seal must be replaced if it is damaged; Tighten the bolts diagonally in steps; After installation, the axis must undergo Mastering zero calibration and T1 mode trial operation.

Overview of electrical wiring, complete wiring diagrams for each motor and RDC; Repairs must use KUKA original spare parts; Complete verification of all safety functions after maintenance is completed.

Suspension, Storage, and Disposal

Shutdown disassembly: The robot moves to the designated transport posture; Install lifting rings and slings; Disconnect all cables; Lift the crane off the main body.

Storage: Maintain transportation posture, clean the robot, provide rust prevention protection, and meet temperature and humidity storage conditions.

Scrap disposal: Lubricating oil, electronic components, and metal structures should be classified and disposed of according to local environmental regulations.

Options

Release device: manual movement of the robotic arm in power-off state; Provide a complete explanation of the installation process and safety constraints for a non actuated mobile robotic arm.

Booster frames enhance the framework for overloading additional load conditions.

Fork groove transportation components, lifting rings, A1-A3 mechanical shaft limit, pipeline package.