KUKA Sunrise Cabinet Med Medical Collaborative Robot Special Control Cabinet

KUKA Sunrise Cabinet Med Medical Collaborative Robot Special Control Cabinet

Sunrise Cabinet Med is a dedicated control cabinet for KUKA LBR Med medical collaborative robots, running the Sunrise. OS Med medical version operating system; The hardware is based on the CCU_SR platform and meets the relevant requirements of medical electrical equipment IEC 60601-1. It is positioned as a component of medical equipment and integrated into the final medical product by medical equipment manufacturers. It cannot be directly used as a terminal medical device.

Product Description

The entire system consists of LBR-Med robotic arm, Sunrise Cabinet Med control cabinet, smartPAD teaching pendant, connecting cables, Sunrise. OS Med software, and optional components.

Core Hardware

KPC Control PC: Fixed use of D3445-K motherboard; Responsible for HMI human-machine interface, motion planning, drive control, and safety monitoring.

CCU_SR small robot control unit (CIB_SR+PMB_SR): complete machine power distribution, internal bus, 7-way safety input, 3-channel floating safety relay output; Fan/temperature monitoring; Power outage relies on backup battery storage location and controlled shutdown; Capable of load testing battery health.

EDS electronic data storage card, storing robot origin and hardware configuration.

Low voltage power supply unit, backup battery pack, power filter, DC/DC converter.

Bus system

KCB controller bus; KSB safety bus; KEB expansion bus (EtherCAT).

Main interface panel

X11:50 pin D-Sub dual channel secure interface;

X21: Robot body medium flange interface, outputting 48V/24V power supply and robot data;

X65: EtherCAT expansion bus;

X66: KLI upper communication;

X69: KSI service debugging port;

X55: Optional external power supply interface;

X19: SmartPAD teaching pendant interface.

Cooling system: dual fan ambient air cooling; It is prohibited to install filter cotton on the ventilation opening, as it may overheat and shorten the lifespan of the device.

Installation form: independent floor standing, also supports 19 inch rack installation; Rack depth ≥ 600   mm; left and right ventilation gap of cabinet ≥ 70   mm; cabinet shell medical white.

Designated use and prohibited use scenarios

Specially designed to drive LBR Med-7 R800/LBR Med-14 R820 medical lightweight robots, integrated into complete medical devices by medical equipment manufacturers; Used for tool guidance and repetitive movements.  

It is prohibited to operate directly as terminal medical equipment, in ordinary industrial scenarios, in explosion-proof environments, outdoors, or in sterile environments; Prohibited from being used for handheld portable medical devices; The robot is designed to have a lifespan of 10000 operating hours.

Technical Data

Mechanical parameters: total weight of 23 kg; IP20 protection; Noise level of 54 dB (A); Provide dimension drawings for the handling handle and smartPAD bracket; 19 inch rack opening size.

Electrical parameters: single-phase 110/230 V AC, ± 10%, 50/60 Hz; rated power 1 kVA; Maximum heat loss 370   W; fuse 2 × 16   A slow melting C type; External 24V is DC 27.1V ± 0.1V.

Environmental conditions: working+5~+45 ℃; Equipped with battery storage -25~+40 ℃; No battery -25~+70 ℃; Humidity 5-85%; When the altitude is greater than 1000 meters, the power will decrease by 5% for every 1000 meters increase.

CIB_SR safety board electrical parameters: input OFF interval -3-5   V; ON interval 11-30   V; 5-11   V is an undefined transition zone; Dual channel dynamic test output TA-A/TA-B; Pulse t1=625 μ s, period t2=106 μ s; maximum cable length 50 μ m.

Medical related: EMC meets EN   55011 Group B Class 1 (note: cannot reach Class B after connecting smartPAD-2); REACH SVHC List of Substances of Very High Concern; Nameplate warning label (for electric shock, unplug the power cord before opening the cover, and risk assessment is required for label removal).

Planning and Design (Early Stage of Medical Integration)

EMC electromagnetic compatibility: All external cables are shielded, and the shielding layer is extensively crimped with PE bars; Note that smartPAD-2 will enhance electromagnetic emissions.

Installation conditions: Floor standing or 19 inch rack; Rack depth ≥ 600   mm; left and right ventilation ≥ 70   mm; control cabinet must be physically protected and not accessible to patients.

Power supply conditions: Only power supply systems with neutral grounding can be connected, and non grounded neutral power grids are prohibited; Recommend a 300 mA selective leakage protector.

PE equipotential bonding is mandatory and meets the DIN EN 60601-1/EN 62353 grounding continuity test.

X11 security interface (50 core D-Sub)

7-channel dual channel secure input; 3-channel floating safety relay output; Dynamic pulse testing; Complete schematic diagram of emergency stop and safety door wiring; Schematic diagram and timing diagram of floating contact input and output wiring.

The load power output of the relay must meet 2 x MOOP isolation.

X65 EtherCAT； X66 KLI； X69 KSI service port; X55 external power supply interface.

Mandatory conditions for external device access: The isolation level of external devices must be ≥ 2 × MOOP, and devices that require MOPP patient protection cannot be directly connected; The leakage current of the entire machine needs to be tested and evaluated by medical manufacturers.

Hardware change rules: When replacing hard drives, boards, or adding or deleting peripherals, the Sunrise Workbench Med software must be used to reconfigure the project.

Transportation

Before transportation: Power off, remove all cables, and close the cabinet door;

Two modes of transportation: cart transportation; Directly use the handling handle for transportation;

Transportation prohibits impact and condensation; The returned equipment for repair must be accompanied by a health status statement to prevent the risk of biological contamination.

Startup and Re Debugging

Complete power on process:

Visually inspect the entire machine and confirm that there is no transportation damage or condensation;

Install control cabinet to ensure ventilation clearance;

Connect the X21 medium flange cable of the robot; Comply with the bending radius of cables;

Install smartPAD and plug in X19;

Connect PE equipotential and perform grounding continuity testing according to medical standards;

Restore battery discharge protection plug X305;

Plug in X11 safety interface in power-off state, and hot plugging is strictly prohibited;

Connect to the main power supply and distinguish between two wiring methods: with mains-connector and without connector; Strictly distinguish L/N/PE colors without connectors;

After hardware modifications, Sunrise Workbench Med downloads project configurations;

Clear the dangerous area of personnel and objects, release the emergency stop switch and turn on the power;

Medical version mandatory startup test items: all emergency stops, all enable switches, mode switches, safety outputs, brake tests; All security functions must be fully verified.

Unplugging the teaching pendant triggers an emergency stop; Reconnect and wait for about 30 seconds. The emergency stop and all enable switches must be fully retested.

Equipment Operation

Complete panel description of smartPAD/smartPAD-2 teaching pendant: front buttons, back three level enable switch;

The teaching pendant supports controlled hot plugging: pressing the disconnect button counts down to 25 seconds to unplug the plug; Directly unplugging the plug without pressing the button will immediately trigger an emergency stop;

Usage limitation of teaching pendant: Only for system integrators to use for debugging and maintenance; Not allowed for terminal medical personnel to operate medical equipment;

USB interface: only supports FAT32 USB flash drives; Medical manufacturers need to control USB drives to prevent malicious software.

Maintenance

Maintenance of safety prerequisites: power off and lock, disconnect the incoming power supply; Waiting for internal high-voltage discharge; ESD anti-static; Do not blow compressed air directly into the cabinet.

maintenance cycle

Annual: CCU_SR relay output function inspection; Mandatory testing of the entire set of safety components (emergency stop, all enable switches, mode switches, safety outputs); Clean the fan radiator according to dirt and stains;

Three shift operation for 5 years: replacement of motherboard button batteries and cabinet fans;

Battery monitoring alarm, battery packs must be replaced in pairs.

Maintenance work:

CCU_SR relay output verification;

Only use a soft cloth and solvent-free cleaning agent for cleaning, and do not spray water;

Maintenance completed: Check fuses, plugs, PE grounding, and cable wear.

Maintenance and Replacement

Maintenance must be carried out by qualified personnel trained in KUKA; Original spare parts must be used; The high-strength 10.9 screw must be replaced when disassembled. Each repair includes: safety prerequisites, tool list, step-by-step disassembly and assembly, connector definition, and functional testing after replacement. List of replaceable parts:

Cabinet fan components;

KPC complete set, motherboard button battery, SSD solid state drive; Replacing the SSD requires reinstalling Sunrise. OS Med and importing the Workbench Med project configuration;

CCU_SR small robot control unit; Pay attention to the connector unlocking mechanism during disassembly and assembly, and prohibit violent plugging and unplugging;

Backup battery pack, replace in pairs, strictly pay attention to polarity; Storage battery recharge cycle: ≤ 20 ℃ every 9 months; 20-30 ℃ every 6 months; 30-40 ℃ every 3 months;

Low voltage power supply unit; Power filter, DC-DC converter;

Sunrise. OS Med Medical Edition software installation process.

Troubleshooting

CCU_SR board complete set of LED indicator lights: power supply, KCB/KSB bus, EtherCAT safety node, various power sources, temperature, fuse LED; Different color flicker frequencies correspond to fault phenomena and corresponding solutions;

CCU_SR all fuse numbers, rated currents, and purposes; The fuse has a red LED indicator; DC-DC converters, low-voltage power unit fuses;

Interpretation of Network Port Link Activity Indicator Light;

Troubleshooting process: Check the power supply fuse and wiring; Disconnect the external device and restart it; Replace the CCU_SR module despite the malfunction.

Shutdown, Storage, and Scrap Disposal

Shutdown and return: Disconnect all peripherals and robot cables, and disconnect the grounding wire;

Long term storage: indoor dry and dustproof, no condensation; Remove the battery sealing interface shell protection; Strictly implement regular battery recharging;

Scrap and disassembly: classified by material; Batteries are classified as hazardous waste and should be returned to suppliers for recycling. Disposal of household waste is prohibited; Medical scene return equipment requires completion of a hygiene declaration.

Options

Mainly the smartPAD connection cable, model, length, and installation precautions; Cable stress release and bending radius; After replacing the cable, perform a mandatory full function test of the teaching pendant enable switch.