KUKA KR 15 DELTA-2 Robot Installation and Maintenance

Load planning and flange design

Rated 8 kg, maximum 15 kg, flange maximum mass inertia Iz=0.22 kgm ². The rated and maximum additional load for the upper arm and forearm are both 0 kg - this is the hard difference between the Delta platform and SCARA (which allows for an additional load of 2 kg on the arm), and any visual camera or vacuum generator must be integrated into the flange end of the moving platform, with its mass included in the load.

The load inertia must be verified using KUKA Load, and the load data must be input into the robot controller - the controller takes into account the load in trajectory planning, and reducing the load does not necessarily result in lower flange force. Exceeding the load capacity will shorten the lifespan of the robot and overload the motor reducer. Such applications require prior consultation with KUKA services.

Installation flange specifications: hole distribution circle of 50mm, screw grade A4-80, specification M6, 7 fastening threads, minimum depth of 7.5 mm, maximum depth of 9 mm, positioning element 6 H7.

Flange load (under rated load, without safety factor):

Operating condition D1200-2 D1600-2

Running F (a)/F ®  871 N / 775 N 866 N / 662 N

Running M (k)/M (g) 82 Nm/25 Nm 68 Nm/24 Nm

Emergency stop F (a)/F ®  691 N / 550 N 729 N / 613 N

Emergency stop M (k)/M (g) 67 Nm/37 Nm 67 Nm/37 Nm

The running value continuously appears in the normal motion trajectory, and the tool is checked according to fatigue strength; Emergency stop values rarely occur, static strength verification is sufficient. Note that the radial force (775 N) during operation of D1200-2 is actually higher than D1600-2 (662 N), and the tool design cannot be applied across different models.

Foundation load - structural input for ceiling installation

This series is ceiling inversion, and the load direction is defined opposite to that of a floor standing robot. The "vertical force" in the table actually acts on the direction of frame pulling, and the frame anchoring design must be checked according to this:

Load item D1200-2 normal/maximum D1600-2 normal/maximum

F(v) 2394 N / 1860 N 2444 N / 1944 N

F(h) 1168 N / 801 N 972 N / 812 N

M(k) 1345 Nm / 976 Nm 1255 Nm / 966 Nm

M ®  232 Nm / 248 Nm 277 Nm / 245 Nm

It already includes the load and the inertial force of the robotic arm's own weight. The foundation design must be based on the maximum load, ignoring the maximum load can cause personal injury and property damage. Special reminder: The normal value of this series (such as F (v)=2394 N for D1200-2) is higher than the maximum value (1860 N), indicating that the normal value represents the dynamic peak value under typical trajectories rather than conservative values. When checking the rack and anchor components, the larger of the two sets of data should be taken, which is 2394 N.

Ceiling installation - complete on-site assembly process

Rack requirements (self-made by the user): The rack must have sufficient load-bearing capacity, and the recommended material is square steel with a specification of 120-150mm. It must be stable enough that the mechanical arm does not shake during operation; The rack size must be executed according to the drawing to ensure reliable anchoring force is transmitted to the foundation. The assembly chain consists of three layers: frame and welding block → hexagonal plate (self-made by the user, recommended steel) → robotic arm.

Anti interference design: When the robot leaves the factory, the upper arm is at a 50 ° angle (note: KR 3 D1200 has a 45 ° angle, which is different between the two generations of products). To avoid interference between the upper arm and the mounting plate, the minimum distance from the upper arm to the center point of the robot when designing the mounting plate is 300 mm. Otherwise, the upper arm must be moved to a horizontal position through the brake release button before installation.

Conveyor line layout: If the robot is installed above one or more conveyor lines, it is recommended to install the robot at a certain angle to the conveyor lines to achieve better load balancing.

Seven step installation process:

Lifting: Three M8 lifting rings are installed into the robot base, and the ropes are connected to the lifting equipment to slowly lift it off the ground. Adjust A1/A2/A3 to 0 ° and adjust the ropes so that the lifting equipment passes vertically through the center of gravity.

Wiring: Secure 2 grounding conductors at the rear of the base → Connect data cable X31 (confirm connector is securely locked) → Install a ferrite magnetic ring near the XF21 connector end → Connect motor cable X30 → Check the equipotential connection according to VDE 0100 and EN 60204-1.

Upper arm leveling: Move the upper arm to a horizontal position.

Tightening: Clean the bottom surface of the hexagonal plate → Lift it to the frame → Insert 3 cylindrical positioning pins into the interface plate → Tighten 12 M8x30-10.9 hexagonal bolts.

Forearm on-site assembly: Install a spring unit on the forearm assembly (the spring assembly contains a large amount of elastic potential energy, and full force pulling is strictly prohibited). Connect the two ends of the forearm to the upper arm and the moving platform respectively, and repeat the entire forearm one by one.