KUKA KR 15 DELTA-2 Robot Installation and Maintenance

KUKA KR 15 DELTA-2 Robot Installation and Maintenance

Product positioning: 15kg heavy-duty Delta platform

KUKA KR 15 DELTA-2 is a four axis Delta parallel robot product series designed by KUKA for high-speed Pick&Place applications. It consists of two models: KR 15 D1200-2 (order number 0000-474-575) and KR 15 D1600-2 (order number 0000-470-149), both of which are ISO 10218-1 Class II robot grades. Compared with the previously introduced KR 3 D1200 (3 kg load), this series increases the rated load of the Delta platform to 8 kg and the maximum load to 15 kg, directly entering the heavy-duty sorting and palletizing front-end handling scenarios that were previously only covered by traditional six axis robots.

The complete robot system consists of a robotic arm (including the mechanical system and cable assembly), a robot controller, connecting cables, tools, and other equipment. The accompanying teaching pendant is smartPAD-2, and the controller is KR C5 S6. The robotic arm mainly consists of an upper arm, a forearm, an installation flange, a movable plate, a base frame, and a cable assembly - the forearm and the movable plate are delivered through on-site assembly, which runs through the entire process of transportation, installation, and retirement.

The prohibited items are consistent with the KUKA general framework: not to be used as climbing aids, not to operate outdoors, not to be used in potential explosive areas or radioactive environments, not to be used in underground mining operations, not to transport personnel and animals, and not to operate without necessary safety equipment. Deviation from the operating conditions specified in the technical data can lead to premature wear, and such applications require consultation with KUKA services. As a component of a complete system, robot systems can only operate in systems that meet CE requirements.

Comparison of Core Parameters between Two Models

Parameter item KR 15 D1200-2 KR 15 D1600-2

Workspace volume 0.435 m ³ 0.762 m ³

Repetitive accuracy XY/Z/R ± 0.04 mm/± 0.04 mm/± 0.025 ° same as left

Self weight approximately 94.8 kg, approximately 95 kg

Rated/maximum load 8 kg/15 kg 8 kg/15 kg

Maximum working diameter 1200 mm 1600 mm

Maximum working height 450 mm 455 mm

Protection level (IEC 60529) IP65 IP65

Noise<77 dB (A)<77 dB (A)

Installation location: Ceiling Ceiling

Base occupies Ø 350 mm circle Ø 350 mm circle

Controller KR C5 S6 KR C5 S6

The range of motion for the two models is exactly the same: A1/A2/A3 each -80 ° to+40 °, A4 axis ± 355 °; Under rated load, the speed of axes A1-A3 is 670 °/s, and A4 axis is 720 °/s. The zero calibration positions of the four axes are all 0 °. Environmental conditions: Operating temperature range from 0 ° C to 45 ° C, storage and transportation range from -25 ° C to 60 ° C, environmental classification level 3K22. Preheating may be necessary before low-temperature operation, and frost and condensation must be avoided during low-temperature operation, otherwise it may cause property damage.

The default color scheme is base signal white (RAL 9003) and black (RAL 9005). The IP65 protection level means that this series can directly cope with dust and splashes in food secondary packaging, daily chemical products, and other working conditions, without the need for outer cover protection - this is the essential difference from the selection of IP20 SCARA products.

Tip for using the motion range: The document suggests limiting the actual motion range to the maximum diameter and shrinking it by 100 mm during operation to avoid the robot running to the edge of the workspace - this should be included in the point planning during the trajectory teaching stage, otherwise the edge speed will be limited and the beat will be directly stretched.

Cycle time - the direct basis for rhythm calculation

The cycle time given in the document is the continuous motion data between the picking and placing points, with a path format of up forward down. The programming method is divided into DLIN with 0.3 mm approximation positioning (DLIN1) and DLIN endpoint complete stop (DLIN2):

Load 25-305-25 DLIN1 25-305-25 DLIN2 90-400-90 DLIN1 90-400-90 DLIN2

1 kg 0.48 s 0.61 s 0.56 s 0.67 s

4 kg 0.50 s 0.62 s 0.58 s 0.70 s

8 kg 0.59 s 0.72 s 0.63 s 0.76 s

15 kg 0.61 s 0.75 s 0.68 s 0.82 s

Three engineering conclusions are worth writing into the beat calculation table: firstly, approximating the positioning can obtain the fastest cycle time, and DLIN1 is shortened by about 0.13 seconds relative to DLIN2; secondly, the cycle schedules of the two models are completely the same - although D1600-2 has a longer arm span, it is not inferior to D1200-2 in these two standardized cycles. When selecting, if the working diameter needs to be 1600 mm, there is no need to worry about the beat; Thirdly, according to the application (especially when it comes to workpiece characteristics), the picking or placing process may require an increase in waiting time. Process delays such as vacuum suction cup establishment and visual triggering must be taken into account and cannot be directly copied from the values in the table.

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.

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.

Eight requirements for long-term storage: dry and dust-proof storage location, avoiding temperature fluctuations, avoiding wind and drafts, avoiding condensation, using a cover that will not fall off on its own and can withstand environmental conditions, leaving no loose parts, avoiding direct sunlight, and complying with the storage temperature range. In terms of operation: clean and dry → visually inspect → reinstall all cover plates and confirm that they are sealed properly → add appropriate protective covers to electrical interfaces → seal gas pipe interfaces → wrap with plastic film and seal at the base to prevent dust, and if necessary, add desiccants under the film.

Classification of scrapped materials: Upper arms/forearms/moving platforms are made of aluminum alloy and carbon fiber, cables are made of copper, gear units/screws/washers/bases are made of steel; Electronic components (RDC, EDS) shall not be dismantled as electronic waste, and motors shall not be dismantled as a whole; Plastic bearings/shells, FKM O-rings, PUR cable sheaths, TPU seals are classified according to material markings.

Auxiliary Material Archive List (Must Check Items for Maintenance and Reassembly): Drei Bond 1305 (Dynamic Platform Adhesive Sealing), LOCTITE 510 (Upper Arm Flange and Dynamic Platform Flange, EMD Fixture), Cassida Fluid GL150 Gear Oil (A1-A4 Gear Units), Microlube GL 261 (Gear Tooth Surface), LGFP 2/1 (Flange Surface Lubrication) - Cassida GL150 is a food grade gear oil that shares a lubrication system with the HM series, and the heavy-duty Delta platform also retains compatibility with the food industry.

General torque meter and selection points

The fastening torque table provided in the appendix covers the full specifications of M1.6 to M30 with a third level strength of 8.8/10.9/12.9 (such as 31 Nm for M8x30-10.9, 104 Nm for M12-10.9, and 250 Nm for M16-10.9), as well as ISO7991 countersunk screws and DIN7984 cylindrical head specific values. The iron rule is still valid: 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.

Five selection actions for integration engineers: First, check the frame and anchor pulling force according to F (v)=2394 N (D1200-2 normal value), with a specification of 120-150 mm square steel; Secondly, reserve a 300mm anti-interference distance for the installation board and arrange it according to the angle of the conveyor line; Thirdly, the DP5.1/XP5.2 dual external resolution interface is pre embedded with dual line tracking. When wiring, confirm that the X31 connector is locked and install the XF21 end ferrite magnetic ring; Fourthly, 100 hours of re tightening, 5000 hours of spring unit and bearing replacement, and 20000 hours of forearm visual inspection written into CMMS; Fifth, during load planning, the additional load on the upper arm/forearm is zero, and both the camera and vacuum generator are included in the dynamic platform load and verified by KUKA Load. Incorporating these five points into the project checklist is the shortest path for the 15 kilogram Delta sorting unit to pass a one-time debugging and operate stably for a long time.