KUKA KR 13 SCARA-2 CS Detailed Explanation

KUKA KR 13 SCARA-2 CS Selection and Maintenance

Product family: Ten models covering three types of trips

KR 13 SCARA-2 CS is a four axis articulated arm (SCARA) robot product family developed by KUKA for picking, placing, assembling, and handling applications. The controller uses KR CS Box-2 and the accompanying teaching pendant is smartPAD touch. Programming and operation are completed through KUKA. ControlStudio system software - this is the complete software ecosystem that distinguishes the CS series from the KR C4/C5 series (KSS/iiQKA).

The family is composed of three types of arm extensions (R650/R750/R850) and three types of Z-travel (Z170/Z200/Z400/Z600), with a total of ten models: seven standard versions (R650 Z200/Z400, R750 Z200/Z400/Z600, R850 Z200/Z400) and three CR cleanroom versions (R650/R750/R850 Z170-2 CS CR).

Horizontal comparison of core parameters

Parameter item R650 series R750 series R850 series

Rated/maximum load 6 kg/13 kg 6 kg/13 kg 6 kg/13 kg 6 kg/13 kg

Repetition accuracy XY/Z/R ± 0.025 mm/± 0.01 mm/± 0.01 ° same as left

A1 speed (rated load) 430 °/s 410 °/s 390 °/s

A2 speed 600 °/s 650 °/s 650 °/s

A3/A4 Speed 1.1 m/s/2700 °/s Same Left Same Left

Standard version cycle time 0.42 s 0.43-0.44 s 0.44 s

Self weight 44.5-45.5 kg 45.5-46.5 kg 46.5-47 kg

Workspace volume 0.208-0.415 m ³ 0.309-0.925 m ³ 0.397-0.794 m ³

Common parameters of each model: A1 stroke ± 145 ° (R650 Z200 ± 145 °), A4 stroke ± 360 °, protection level IP20 (CR version IP54), installation position on the ground, footprint of only 210 × 210 mm, noise<80 dB (A), environmental conditions 3K22 level, operating temperature 0-45 ° C. Low temperature operation requires deceleration and acceleration preheating before normal use - this is the most easily overlooked start-up requirement for SCARA high-speed mechanisms when put into production in winter workshops.

The key differences of CR cleanroom version are: ISO 14644-1 Class 5 cleanliness (under 100% override), fixed Z-stroke of -170 mm, increased protection level to IP54, slightly reduced A2 speed (600 °/s compared to standard version 650 °/s), slightly increased cycle time (0.44-0.46 s), and the addition of AIR 0 negative pressure suction interface for cleanroom dust management. Semiconductors, pharmaceuticals, and precision electronic assembly are the target scenarios for the CR version.

One design highlight is that the A3 axis allows for a process force of 250 N, which means that pressing, testing probe pressing, and other processes can be directly undertaken by the A3 vertical stroke without the need for an additional Z-axis module.

Load and flange design

All models have a rated load of 6 kg and a maximum load of 13 kg. The flange has a maximum inertia Iz of 0.3 kgm ² and a rated load of 0.02 kgm ². The arm allows for a maximum additional load of 2 kg (installed on the support frame under the arm). The document clearly states that the design of a rated load of 6 kg is to optimize dynamic performance, and a maximum load of 13 kg is allowed under the premise of reducing the distance between the center of gravity of the load. This needs to be confirmed with KUKA technical support. To reduce the vibration caused by the load, the offset of the center of gravity relative to the flange should be minimized as much as possible when installing the end load.

The installation of flanges is not included in the scope of supply and is self-made by the user. It must follow the following rules: hole distribution circle with 1 mm flat cut positioning, maximum outer diameter Ø 18. This open design is a bonus for tool quick change mechanism integrators, but the machining accuracy must be guaranteed by oneself.

Flange load (under rated load, without safety factor, divided by arm span):

Operating condition R650 R750 R850

Running F ®  746 N 679 N 610 N

Running M (k) 105 Nm 95 Nm 85 Nm

Emergency stop F ®  344 N 287 N 257 N

Emergency stop M (k) 48 Nm 41 Nm 36 Nm

Attention to the rule: The longer the arm span, the smaller the flange force during operation (the speed limit of the long arm model is lower). The tool design should be based on the corresponding arm span gear, and cross gear mixing is not allowed.

Foundation load and installation foundation

Load item R650 R750 R850

F(v max) 803 N 811 N 818 N

F(h max) 1381 N 1298 N 1184 N

M(k max) 563 Nm 565 Nm 571 Nm

M(r max) 334 Nm 357 Nm 379 Nm

The foundation design must be checked according to the maximum value, ignoring the maximum load can cause personal injury and property damage.

Installation foundation requirements: fixed with 4 M12 or M14 bolts, the installation base must be made of steel, with a thickness of not less than 20 mm and a flatness of not more than 0.4 mm. The base is not within the scope of supply. Key points of installation process: The maximum allowable horizontal deviation of the base is 5 ° → Insert 2 positioning pins → Slowly lower the robotic arm vertically (not vertical will damage the positioning pins) → Tighten 4 bolts diagonally step by step. Screws with a strength grade of 10.9 or above, grade 70/80 stainless steel, and certified by testing are only allowed to be tightened once with the rated torque, and must be replaced after the first loosening. Tighten the installation bolts again 100 hours after startup.

Before starting, the default password of the system software must be changed, and only authorized personnel should be informed that the CS Box-2 controller has Ethernet and remote access capabilities, which is the baseline for information security.

Cable and pneumatic interface system

Three piece set of connecting cables: motor cable (Motor Power-X30, WEIPU WF 28 series, 20 pin), data cable (Encoder-X31, 26 pin), grounding conductor (optional, M4 ring terminal block, required according to DIN EN 60204). The length standard is 5 meters, with optional options of 3 meters or 10 meters. The fixed laying bending radius is not less than 55 mm for motor cables and 45 mm for data cables. It can only be laid indoors at temperatures ranging from -30 ° C to+80 ° C. The motor and data cables must be laid in separate metal slots.

A1 interface (back of base) layout: Three air sources AIR 1/2/3 (Ø 6mm air tube, maximum 0.7 MPa, vacuum to -0.095 MPa), user connectors X40 (15 pin D-sub I/O expansion), X74 (8-pin M12 X-code Ethernet expansion), motor cable X30, data cable X31, grounding terminal, battery, CR version with additional AIR 0 negative pressure interface.

A2 interface (arm) layout: brake release button (only valid for A3/A4 axis, press and hold to release), X94 Ethernet extension, X41 I/O extension, air path AIR 1/2/3 adapter, motor working indicator light.

User cable installation discipline: It is strictly prohibited to tie user cables to corrugated pipes; High flexibility cables must be used and shielded to connect with the overall electrical potential of the machine; After installation, it is necessary to confirm the stress state of the cable and corrugated pipe, as well as the unrestricted working space of the robot. The arm is reserved with a user cable bracket installation interface, and although the base does not have a dedicated interface, some bolt holes can be borrowed to assist in installation.

Manual movement: dual path of software and hardware

A1/A2 axis: Activate the Servo Free mode through KUKA. ControlStudio, and enable A1 or A2 in the software to slowly move the axis body by hand - the arm axis has no physical release button and completely follows the software path.

A3/A4 axis: Press and hold the brake release button on the arm to manually move. Key warning: When pressing and holding the button to release the A3 brake, if there is no load installed on the flange, A3 may fall due to its own weight - the load/spindle must be held by hand during operation to prevent injury from falling.

Stop category and braking system

The stop category definition of the CS series has its own characteristics, and when troubleshooting, the stop behavior must be judged according to the trigger source:

Stop 0: The drive is immediately powered off, and both the short-circuit brake and the electromechanical brake are activated simultaneously. Trigger source: Robot power failure, CPU failure, fatal drive system failure.

Stop 1: Control the braking within the maximum torque margin of the reserved motor along the original path and apply the shortest distance. After a period of time, the drive system will be powered off, and then the short-circuit brake and electromechanical brake will be activated. Trigger source: emergency stop, safety input, control failure, workspace exceeding limit, program trigger.

Stop 2: The drive does not cut off power, the brake is not engaged, and the braking slope is slowed down according to the path holding type.

The definition of T1/T2 mode is consistent with the KSS system (T1 ≤ 250 mm/s, T2>250 mm/s and manual teaching is not allowed), but the speed implementation of T1 is based on safety configuration oriented speed monitoring rather than mechanical deceleration.

Stop distance data - input for safety fence design

Taking R650 Z200-2 CS as an example (Extension l=100%, Project Velocity=100%):

Condition A1 A2 A3

Stop 0 · Rated load 87.80 °/0.36 s 136.97 °/0.38 s 44.89 mm/0.06 s

Stop 0 · Maximum load 85.69 °/0.41 s 119.44 °/0.39 s 58.40 mm/0.08 s

Stop 1 · Rated load 59.77 °/0.20 s 62.88 °/0.17 s 77.95 mm/0.10 s

Stop 1 · Maximum load 41.90 °/0.19 s 58.30 °/0.19 s 67.30 mm/0.10 s

The Stop 0 A1 axis stop distance of R850 Z200-2 CS is as high as 126.53 ° (0.57 s, rated load), which is the maximum value in the entire family - the SCARA high-speed rotation stop distance far exceeds the joint robot in terms of angle. The fence and light curtain layout must be calculated axis by axis according to the corresponding model's Stop 0 table. Stacking axis motion will lengthen the stopping distance; Brake wear is related to the number of Stop 0 triggers, and it is recommended to check the stop distance at least once a year.

Boundary conditions for safety protection: The controller directly supports the safety door sensor, and other devices such as light curtains and presence sensors are not directly supported - if they are to be used, the integrator must conduct a risk assessment and certify the solution themselves.

Maintenance cycle table and tension calibration of toothed belt

Cycle task consumables

Tighten 4 mounting base bolts for 100 hours (only once) -

1500 hour lubrication ball screw spline (upper/lower limit positions) THK AFB-LF approximately 10 g

4000 hours or 1 year replacement of corrugated pipe (CR version, executed by KUKA authorized personnel) SPP 0000-475-585

4000 hours or 1 year replacement of toothed belt A3/A4 (KUKA authorized personnel) A3: 0000-410-728, A4-1/A4-2: 0000-414-966/967

4000 hours or 1 year cable group coated with Optitemp RB2 grease, approximately 20 g

20000 hours or 5 years A1 gearbox oil change Optigear Synt. ALR 150, 0.31 L

Tighten the installation bolts within one year; Replace battery unit -

Key points for screw lubrication: Move A3 to the upper limit position (be careful not to hit the limit block) → Activate emergency stop → Remove old grease → Brush THK AFB-LF → Move it back to the lower limit position and repeat; The CR version requires first removing the shaft end cover (8 M4x12-8.8, 1.9 Nm) and applying grease to the lead screw and steel ball raceway, while checking the O-ring. Clean up excess grease and run A3/A4 empty to ensure even distribution of grease.

Tooth shaped belt tension - the most professional maintenance skill of this machine: after replacement, use a frequency meter (TSM alpha 20071-053-386) to calibrate with a tensioning fixture, move the belt and sensor 2-3 mm away from the vibration belt to read the frequency, measure three times and take the average:

Belt model new belt target frequency old belt frequency

A3 741-3GT-15 87.7–92 Hz 73.4–78.4 Hz

A4-1 405-3GT-15 209–219 Hz 175–187 Hz

A4-2 570-3GT-25 176–185 Hz 147–158 Hz

Adjust the tension screw (M8x30) until it meets the standard; A deviation of 30% or less between the adjusted fluctuation value and the table is considered normal. The calibration process must include the "motion running in" step: after adjusting A4-2, A2 axis ± 20 ° reciprocating 2-3 times, A3 axis ± 50 mm reciprocating 2-3 times, and then retesting the frequency - skipping running in and directly locking will cause tension drift after operation. In terms of assembly sequence, A4-1 must mesh with the large pulley, A4-2 must mesh with the small pulley, and the flange with the part number facing upwards. The four M6x25-12.9 pieces should not be tightened first, and A3 should be vertically moved up and down three times before being diagonally tightened step by step to 15 Nm.

The replacement of the bellows (CR version exclusive) requires a special tool Dev. KR20 split to locate the limit block at the STOP position (0000-435-961). Reversing the NILOS Ring direction will accelerate the wear of the ball bearing - this is why authorized personnel must perform maintenance on the CR version.

Early Wear Warning and Life Management

During the planning phase, five types of accelerated wear conditions must be evaluated: temperature limit or continuous operation in corrosive environments, performance limit continuous operation (such as high shaft speed), single axis high load rate, monotonic motion trajectory, and external process forces. Meet any requirement to consult KUKA. The built-in monitoring automatically shuts down when the operating limit is reached.

The unique quantitative red line of this machine: the temperature of each axis motor must not exceed 368 K (+95 ° C) - long-term high-temperature operation will directly shorten the service life of the robotic arm. For assembly lines with extremely high rhythms, it is recommended to incorporate motor temperature into the equipment health dashboard through trend monitoring in ControlStudio.

Conclusion: The KR 13 SCARA-2 CS family provides a compact solution for 3C, semiconductor, and pharmaceutical assembly with a repeatability of ± 0.025 mm/± 0.01 °, a 0.42 s cycle time, 250 N A3 process power, and a cleanroom level 5 CR version. The five key actions of an integration engineer are: verifying a 20mm steel base with a horizontal force of 1381 N according to the corresponding arm deployment position, reserving 200mm wiring space and EMC slot laying for A1 interface, calculating the fence with a Stop 0 angle of 126.53 ° according to R850 gear, writing 1500 hours of screw lubrication and 4000 hours of toothed belt frequency calibration into CMMS work orders, and replacing battery units annually to prevent encoder data loss. Incorporating this checklist into the project delivery checklist is the shortest path from installation to long-term stable operation.