KUKA KR 15 DELTA-2 Robot Installation and Maintenance

A4 cable group laying: Align the cable clamps of the upper arm and forearm according to the installation size diagram, with 4 M4x50-8.8 (1.2 Nm) cable clamps for the upper arm and 6 M4x60-8.8 (1.2 Nm) cable clamps for the forearm.

Conclusion: Install the tools → Start the system according to the controller documentation → Put it into operation according to the system software documentation.

Cable system: Connecting cables with a length of 7 m/15 m/25 m in three levels, with a maximum of 25 m and a maximum of 1 extension. Combination of two or more cables is not allowed; If the robot operates on a linear unit with its own energy chain, its cables must also be included. The bending radius for the fixed laying of motor cables shall not be less than 85 mm, and for data cables shall not be less than 41 mm. The operating temperature of the cables shall be 0-42 ° C. The motor and data cables shall be laid in separate metal troughs, and EMC measures shall be strengthened if necessary; Can only be installed indoors. Motor cable X30 is Han Jellock 25 pin (6 motor connectors XD20.1-XD20.6), and data cable X31 is M12 Y-code 8-pin. The grounding conductor must be equipped according to DIN EN 60204, with 16 mm ² M4 ring terminal block.

Interface board (rear of base): grounding connection, MEMD connection X32, two external resolution connections XP5.1 and XP5.2 (used to collect conveyor belt speed and position signals, which is the hardware foundation for conveyor belt tracking and picking up - dual interfaces mean that two conveyor lines can be tracked simultaneously), data cable X31, motor cable X30; The bottom of the base is an A4 cable group interface.

Stop distance and hazardous area design

STOP 0 is measured according to ISO 10218-1 combined with KR C5 (POV=100%, maximum load), and STOP 1 data is presented in the form of X/Y/Z three directional curve graphs:

Direction D1200-2 STOP 0 D1600-2 STOP 0

X 271 mm / 0.10 s 266 mm / 0.12 s

Y 403 mm / 0.15 s 389 mm / 0.15 s

Z 138 mm / 0.08 s 176 mm / 0.08 s

In terms of measurement methodology, this series of documents provides a standardized measurement method that is compatible with the KR C5 controller: safe operation stops at the maximum speed trigger point, triggering STOP 0 → trace function starts recording → "brake closing" signal (WDI motor status bit 2) is used as the starting point for timing → the axis is completely stationary as the endpoint. An approximate method can be used with the STOPMESS interrupt program, where the stop distance is equal to the difference between the trigger point position and the rest position.

Dangerous zone=workspace+stopping distance, must be protected by physical protective devices (such as safety doors), and the protective devices should be located outside the dangerous zone - when stopping, the robotic arm should brake and slide within the dangerous zone, and there should be no dangerous points of shearing and squeezing in the loading and unloading area; When there is no physical protection, it must meet the EN ISO 10218 collaborative operation requirements.

Special provisions regarding stopping distance in the document: If the robotic arm or external axis collides with obstacles, mechanical limits, or mechanical axis limit devices, the robotic arm will no longer be able to operate safely and must be stopped and consulted with KUKA before being put back into operation - even if the appearance is not damaged after the collision, there may still be progressive power transmission loss leading to unexpected motion.

Maintenance cycle table and spring unit management

Periodic tasks

Tighten the fastening bolts of the base after 100 hours of start-up

Replace bearings and bushings for 5000 hours or up to 1 year

Replace spring units within 5000 hours or up to 1 year

20000 hours or up to 5 years visual inspection of A4 cable assembly, damage will be replaced by KUKA service

Inspect the forearm visually for 20000 hours or up to 5 years, and replace it if any damage/cracks are found

The maintenance tables for the two models are completely consistent. The spring unit is listed as a mandatory replacement item for 5000 hours - the spring assembly of the Delta forearm stores elastic potential energy and determines the dynamic response of the dynamic platform. Fatigue aging will affect both the motion accuracy and the safety state when the brake fails. Replacement must be performed by personnel specially trained by KUKA, and operations beyond the scope of the document can only be completed by KUKA trained personnel.

Safety discipline during maintenance: During operation, the robotic arm must always be locked with an emergency stop device; When running with electricity, only move at reduced speed and can be stopped urgently at any time; Warning all relevant personnel before homework. Before replacing any motor, the corresponding shaft must be locked in an appropriate manner to prevent movement - the moving platform and upper arm may fall and be squeezed when the brake is released.

Retirement, storage, and scrapping

Retirement process: Activate emergency stop → Remove tools → Run to transport position (A1/A2/A3=50 °, A4=0 °) → Emergency stop locks and stops → Remove A4 cable group (8 M4x12-8.8 on the lower side of the base, pull out the cable group cable tie, disconnect XM4/XP4 connector and PE wire) → Remove the front arm and moving platform before lifting → Forklift for transportation.