KUKA KR 23 SCARA-2 Robot Installation and Maintenance Detailed Explanation

KUKA KR 23 SCARA-2 Robot Installation and Maintenance Detailed Explanation

Product family: 23 kilogram platform with nine model matrices

KUKA KR 23 SCARA-2 CS is a family of four axis articulated arm (SCARA) robots designed for tool and fixture handling, component processing, and transportation applications. It consists of nine models that form a complete matrix of three levels of arm extension (R800/R1000/R1200) and three levels of vertical travel (Z200/Z450/Z390 CR): the standard version six (R800 Z200/Z450, R1000 Z200/Z450, R1200 Z200/Z450) and the CR cleanroom version three (R800/R1000/R1200 Z390-2 CS CR). The controller is KR CS Box-2, the teaching pendant is smartPAD touch, and the system software is KUKA. ControlStudio.

Compared with the previously released KR 20 SCARA CS, this series has increased the maximum load from 20 kg to 23 kg, and the standard version has restored the additional load on the arm to 2 kg (KR 20 series is 0 kg). Camera, valve island and other equipment can be reinstalled on the lower arm support frame - this is the most direct difference in system architecture between the two generations of products.

The robotic arm is a 4-axis articulated arm kinematic system, mainly composed of: arm body (Arm, connecting ball screw spline and connecting rod arm, built-in A3/A4 motor, driven by A2 motor, positive and negative swing angles are mechanically limited by overtravel protection device, with supplementary load interface on the arm), ball screw spline, connecting rod arm (Link arm, located between the arm body and the base, with the same mechanical limit on swing angle), base frame (fixed to the installation base, carrying electrical devices and motor/data cables, energy supply system interfaces) and electrical devices (protection circuit, A1-A4 motors and data cables, I/O cables, trachea, Ethernet cables, controller connection cables).

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 explosive areas/radioactive environments/underground mines, not to transport personnel and animals, and not to operate without safety equipment. Deviation from the technical data specifications can lead to premature wear, and such applications require consultation with KUKA services. Robots can only operate in systems that meet CE requirements. This machine is a partially completed machine (Appendix II B of 2006/42/EC), and the integrator must issue an EC conformity declaration and affix the CE mark for the complete system.

Horizontal comparison of nine model parameters

Parameter item R800 series R1000 series R1200 series

Rated/maximum load 10/23 kg 10/23 kg 10/23 kg

Repetition accuracy XY/Z/R ± 0.025/± 0.01/± 0.01 ° is the same as left ± 0.035/± 0.01/± 0.01 °

Self weight (Z200) 58.4 kg 59.9 kg 61.7 kg

Self weight (Z450) 59.1 kg 60.6 kg 62.4 kg

Self weight (Z390 CR) 60.9 kg 62.4 kg 64.2 kg

A1 speed 350 °/s 270 °/s 245 °/s

A2 speed 475 °/s 450 °/s 390 °/s

A3/A4 Speed 0.91 m/s/1400 °/s Same Left Same Left

Cycle time Z200 0.46 s 0.48 s 0.50 s

Cycle time Z450 0.46 s 0.48 s 0.50 s

Cycle time Z390 CR 0.48 s 0.50 s 0.52 s

Protection level IP20 (CR version IP54) Same as Left Same as Left

Common parameters: A1/A2 stroke ± 140 °, A4 stroke ± 360 °, A3 stroke Z200 is -200 mm to 0, Z450 is -450 mm to 0, CR version is -390 mm to 0; The zero calibration positions of all four axes are 0; Ground installation, occupying an area of 230 × 235 mm; noise level<80 dB (A); Default color KUKA Industrial Orange (RAL 2009)+Signal White (RAL 9003); Environment level 3K22, operating at 0-45 ° C, storage and transportation at -25 ° C to 55 ° C. Before operating at low temperatures, it is necessary to reduce speed and acceleration and preheat before normal use.

The A3 axis allows a process force of 250 N as standard across the entire series, and the pressing and testing processes can be directly undertaken by A3. The maximum mass inertia Iz of all models of flanges is 1 kgm ², with a rated value of 0.05 kgm ² - double the upper limit of 0.5 kgm ² for the KR 20 CR version, providing greater design freedom for load inertia.

Load planning and flange load

Rated at 10 kg and maximum at 23 kg, the rated value is optimized based on dynamic performance. When the load center of gravity distance is reduced, 23 kg is allowed to be used, which needs to be confirmed with KUKA support. The maximum additional load on the arm is 2 kg, and it is installed on the support frame under the arm. When installing, be careful not to exceed the maximum load. The load inertia must be verified using KUKA. Load and input into the controller - the controller takes into account the load in trajectory planning, and reducing the load does not necessarily result in lower flange force; The offset of the center of gravity relative to the flange should be minimized as much as possible to suppress vibration. The flange is self-made by the user (not included in the supply scope), with a 1 mm flat cut positioning hole and a maximum outer diameter of Ø 12.

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

Operating condition R800 R1000 R1200

Running F (a)/F ®  597/696 N 565/694 N 514/495 N

Running M (k)/M (g) 63/13 Nm 60/13 Nm 57/13 Nm

Emergency stop F (a)/F ®  142/230 N 142/133 N 142/160 N

Emergency stop M (k)/M (g) 15/13 Nm 15/13 Nm 15/13 Nm 15/13 Nm

A significant feature of this series is that the emergency stop flange load is much lower than the operating load (such as R800 axial force emergency stop of 142 N versus 597 N), indicating that the dynamic load during the operation of this platform is mainly contributed by process force and centrifugal term. The tool can be checked according to fatigue strength, and the static strength margin is naturally sufficient.

Foundation load - structural input classified by model

Load item R800 (same as Z200/Z450) R1000 (same as Z200/Z450) R1200 (same as Z200/Z450)

F (v) Normal/Maximum 679/1178 N 695/1159 N 713/1211 N

F (h) Normal/Maximum 817/1122 N 350/1119 N 395/828 N

M (k) Normal/Maximum 410/738 Nm 320/857 Nm 408/936 Nm

M ®  Normal/Maximum 259/266 Nm 256/454 Nm 290/382 Nm

The foundation load of the CR version three is completely consistent with the standard version corresponding to the arm span. The foundation design must be checked according to the maximum value, which already includes the load and self weight inertia force. Ignoring the maximum load may cause personal injury and property damage. The pattern is opposite to that of the KR 20 series: the "maximum value" of this series is generally significantly higher than the "normal value" (such as the R1000 overturning moment being normal at 320 Nm to a maximum of 857 Nm), indicating that the dynamic peak value of SCARA high-speed rotation around A1 under a specific trajectory is much higher than the typical mean - the frame anti torsion and anchoring design must be carried out at the maximum value, and cannot be applied across arm deployment gears.

Stop distance - fence design with maximum value taken by model

According to Appendix B of DIN EN ISO 10218-1 (Extension l=100%, Project Velocity=100%), the fence design reference is based on the A1 axis of STOP 0 maximum load condition:

Model A1 STOP 0 rated/maximum load A2 STOP 0 rated/maximum load

R800 Z200 94.99°/0.48 s · 89.23°/0.57 s 134.00°/0.47 s · 116.61°/0.54 s

R800 Z450 90.36°/0.46 s · 86.60°/0.56 s 119.47°/0.43 s · 114.03°/0.53 s

R800 Z390 CR 88.28°/0.45 s · 57.82°/0.44 s 135.95°/0.49 s · 75.59°/0.42 s

R1000 Z200 87.34°/0.57 s · 80.47°/0.66 s 111.62°/0.43 s · 91.23°/0.48 s

R1000 Z450 78.88°/0.53 s · 74.08°/0.63 s 100.14°/0.40 s · 92.32°/0.50 s

R1000 Z390 CR 83.28°/0.54 s · 75.89°/0.62 s 117.35°/0.45 s · 103.28°/0.52 s

R1200 Z200 96.21°/0.70 s · 87.55°/0.79 s 69.70°/0.33 s · 58.13°/0.39 s

R1200 Z450 91.76°/0.67 s · 87.51°/0.80 s 75.23°/0.35 s · 64.19°/0.42 s

R1200 Z390 CR 98.95°/0.72 s · 93.43°/0.84 s 75.60°/0.36 s · 64.51°/0.45 s

Three fence design conclusions: Firstly, the stopping distance of A2 axis rated load exceeds that of A1 axis in some models (134.00 ° to 94.99 ° for R800 Z200 and 135.95 ° to 88.28 ° for R800 CR) - SCARA fence cannot only look at A1 axis, and must take the maximum value for each axis; Secondly, the A3 axis STOP 0 is generally only 35-42 mm (0.06 s), and the vertical safety margin is naturally sufficient; Thirdly, the maximum load stopping distance (0.63-0.80 s) of the A1 standard version of Z450 is significantly longer than that of the CR version with the same arm span. However, due to differences in speed characteristics, the safety distance of the CR version is shorter and cannot be intuitively applied. STOP 1 data is approximately 60-70% of STOP 0 (e.g. A1 for R1200 Z390 CR is 58.36 ° vs. 98.95 °), and applications with safety gate circuits should prioritize configuring Stop 1 for compressible safety distance. Stacking axis motion may 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.

Security protection boundary: The controller directly supports the safety door sensor, while other devices such as light curtains and presence sensors are not directly supported. If they need to be used, a risk assessment and certification scheme must be completed by oneself.

Installation foundation and interface system

Installation foundation (user provided): 4 M12 or M14 bolts are tightened, and the 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 maximum allowable horizontal deviation of the base is 5 °, with 2 positioning pins for positioning. The robotic arm is slowly lowered vertically (tilting will damage the positioning pins), and the corners are tightened step by step to the specified torque. 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. Re tighten once every 100 hours after startup.

A1 interface (back of base) standard layout: AIR 1/2/3 three-way air source (Ø 6mm air tube, maximum 0.7 MPa, vacuum to -0.095 MPa), user connector X40 (15 pin D-sub I/O extension), X74 (8-pin M12 X-code Ethernet extension), X30 motor cable, X31 data cable, grounding connection and battery. The CR version adds an additional AIR 0 negative pressure suction interface for clean room dust management, with slightly different interface order but consistent labeling and usage.

A2 interface (arm): brake release button (only valid for A3/A4 axis), X94 Ethernet extension, X41 I/O extension, AIR 1/2/3 air circuit adapter, motor working indicator light (on=robotic arm working).

User cable discipline: It is strictly prohibited to tie user cables to corrugated pipes; High flexibility cables must be used and shielded to ensure good grounding of the entire machine; After installation, confirm that the stress state and working space of the cable and corrugated pipe are not restricted. The arm is reserved with a user cable bracket interface, and the base does not have a dedicated interface, but some bolt holes can be borrowed to assist installation. A wiring space of at least 200mm must be reserved behind the A1 interface.

Cable system: The motor cable X30 and data cable X31 are unified into the WEIPU WF 28 series, with a length standard of 5 meters and optional options of 3 meters or 10 meters. The fixed laying bending radius of the motor cable is not less than 55 mm, and the data cable is not less than 45 mm. The operating temperature is -30 ° C to+80 ° C. The motor and data cables are laid in separate metal slots and strengthened with EMC measures; The grounding conductor must be equipped with M4 ring terminal according to DIN EN 60204, and connected to the base frame by the user with a tightening torque of 2.8 Nm.

Manual movement and transportation

Manual dual path movement: A1/A2 axis activates Servo Free mode through ControlStudio and enables slow manual movement of the corresponding axis (premise: drive OFF); Press and hold the arm brake release button on the A3/A4 axis to release the brake and manually move it. Key warning: A3 axis may fall when the button is pressed without load, and the load must be held by hand to prevent injury from falling.

Transportation position: A1=-90 °, A2=-90 °, A3=-100 mm, A4=0 °. Forklift transportation is used for the original packaging state. Lifting and transportation (optional) must use Qingling DF fixed plate (0000-433-013) and fixed plate B (0000-433-014): 5 M6x20-12.9 (9.5 Nm) are used to fasten the two fixed plates, and 3 M10x17 lifting rings (9.5 Nm) are installed. The rope length must be greater than 1500 mm and follow the path shown in the diagram. No other lifting methods are allowed, and standing under the robotic arm is not allowed throughout the transportation process. The transportation dimensions and center of gravity of the nine models are different (for example, the distance between the center of gravity of R1200 series models is 922 mm, while R800 series models are 522/797 mm), and the transportation dimension table must be checked according to the model before lifting.

Maintenance cycle table -1500 hour lubrication starting point

Cycle task consumables

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

1500 hour lubricated ball screw spline THK AFB-LF approximately 10 g

4000 hours or 1 year replacement of corrugated pipe (KUKA authorized personnel) SPP corrugated pipe 0000-481-648

4000 hours or 1 year replacement of toothed belt A3/A4 (KUKA authorized personnel) A3: 0000-434-702, A4: 0000-434-704

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

Replace battery unit SAFT LS battery pack 0000-439-232 within 1 year

Tighten installation bolts for 1 year -

20000 hours or 5 years A1 gearbox oil replacement Optigear Synt. ALR 150, 0.30 L

Screw lubrication - process difference between standard version and CR version: standard version moves A3 to the upper limit position (do not hit the limit block) → activates emergency stop → removes old grease → brushes THK AFB-LF → moves it back to the lower limit position and repeats. The CR version requires removing the shaft end cover first: remove 8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8; Remove 8 M4x8-8.8 bellows from the bottom and lubricate them. Reinstall with 1.9 Nm. Remove excess grease at the end and empty A3/A4 to evenly distribute the grease.

Tooth shaped belt replacement - A3 fixing is the first step: The opening action of this process is to place the worktable below A3, operate the robot to move A3 down to the point where the load is supported by the worktable, and then press emergency stop to fix it - to prevent A3 from suddenly falling due to the load when releasing the A3 motor or belt. Remove the top cover (12 M4x60-8.8+8 M4x12-8.8) → Remove 4 M6x25-12.9 flanges → Remove 4 M5x20-12.9 flanges each for A3 motor and A4 motor/reducer → Remove two belts. During assembly, the A4 belt is inserted into the lead screw from above and moves down with the transition wheel assembly to the correct position, while the A3 belt is moved to the A3 driven wheel in the same way. The belt and pulley must mesh correctly; Install the flange back screw nut, M6x25-12.9 pre tighten first, move A3 vertically 3 times, and then tighten diagonally step by step to 15 Nm.

Tension calibration of toothed belt (frequency meter TSM alpha 20071-053-386): After assembling the motor/reducer, move it left or right for pre tensioning. Install the tensioning fixture (Dev. tensioning assy, 0000-435-853) and run in - adjust A4 axis ± 20 ° back and forth 2-3 times, adjust A3 axis upper and lower limits back and forth 2-3 times, and then move the belt and sensor 2-3 mm away from the vibration belt. Read the frequency: A3 belt (150MTS3M927) target 59-70 Hz, A4 belt (150MTS5M1000) target 83-90 Hz. Adjust M5x25-12.9 and adjust the screw to meet the standard. The fluctuation value after adjustment is within 30% of the deviation from the table. Internally considered normal, otherwise readjusted; After meeting the standard, tighten 4 M5x20-12.9 diagonally in steps to 9 Nm. The A3/A4 zero point calibration must be performed at the end, and any abnormalities must be observed during the T1 mode trial run.

CR version top cover double tightening - a unique clause of this series: The CR version top cover must be tightened twice with 12 M4x60-8.8 washers and 8 M4x12-8.8 fastening screws (first 1.2 Nm and then re tightened according to the specified torque), otherwise the top cover may crack - this is the biggest installation discipline difference between the CR version IP54 sealing structure and the standard version. The standard version can be tightened once.

Battery Replacement - Different Location from Previous Generation: The battery unit is located at the A1 interface instead of the base battery box: Remove 4 M3x10-8.8 interface battery units (CR version also has 4 JB982-77 M3 washers) → Insert the new battery into the empty connector first → Pull out the old battery occupying the connector → Cut the zip ties to remove the old battery → Only use 2 zip ties to tie the battery body to the new battery, do not tie the battery cable → Reinstall the A1 interface and tighten it. The zero calibration must be performed on A1/A2/A3/A4 at the end, and a trial run must be conducted in T1 mode.

Key points for A1 oil change: The gear unit must be at working temperature and A1 level, using KUKA oil pump (0000-180-812). Remove 10 M4x12-8.8 cable box covers (reassemble with 1.9 Nm) → replace the lower M10x1 magnetic plug with a new oil discharge pipe → ventilate and drain the upper magnetic plug → measure the amount of oil discharged and recharge according to this amount - when the discharge amount is less than 70%, rinse the gearbox with the discharged oil once and recharge it; Less than 50% (if installed at an angle) needs to be flushed twice, during which the full stroke motion axis of the jog speed is required. Clean the magnetic plug and inspect the sealing components. Tighten to 7.5 Nm and perform a leak test. Conclusion: Remove oil stains, visually detect leaks, and conduct T1 mode trial operation.

Zero point calibration and top cover replacement

After replacing components such as motors, reducers, cables, batteries, etc., the zero point may shift and cause positioning errors, and must be recalibrated. A1/A2 should first use the calibration fixture to insert it into the calibration slot for alignment, and then select Set Current on the ControlStudio or smartPAD touch calibration page; When there is no fixture, visually align the two calibration slots, but relying on manual judgment may result in errors.

The SPP ordering numbers for top cover replacement are divided into two levels: SPP top cover 20 scar (0000-434-705) for the standard version six, and SPP top cover 20 scar CR (0000-446-915) for the CR version three - ordering the wrong part number will not match the sealing structure of the CR version. Replace the CR version shaft end cover with SPP shaft cover (0000-481-647). Before reinstalling, check the O-ring, apply THK AFB-LF grease to the O-ring, and confirm that it is in the groove. Tighten it with 1.2 Nm. After replacing all cover plates, conduct a T1 mode trial run to observe any abnormalities.

Early wear warning and retirement disposal

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 (short stroke high-frequency reciprocating), external process forces - any of which must be consulted with KUKA service. The built-in monitoring automatically shuts down when reaching or approaching the operating limit. Quantitative red line: The temperature of each axis motor should not exceed 368 K (+95 ° C). Long term overheating directly shortens the lifespan of the robotic arm. It is recommended to include it in the equipment health dashboard through ControlStudio trend monitoring.

Cleaning boundary: Prohibit high-pressure cleaning equipment and steam/refrigerant; Only solvent-free, water-soluble, non flammable, and non corrosive cleaning agents are allowed; Cleaning agents are strictly prohibited from entering electrical and mechanical system components; Clean the corroded area and reapply anti-corrosion agent; Replace damaged or illegible signs and confirm that all safety equipment is functioning properly before resuming operation.

Retirement process: Adjust to the transport position → Remove all peripherals and motor/data cables → Release the grounding conductor → Remove 4 M12/M14 bolts and washers → Carefully lift off the installation surface - the robotic arm may suddenly detach when stuck on the installation surface, and the fasteners and adhesives must be completely removed. Long term storage requirements: dry and dustproof, avoid temperature fluctuations and condensation, use environmentally resistant coverings, leave no loose parts, and avoid direct sunlight; Wrap with plastic film and seal at the base, and add desiccant under the film if necessary. Scrap classification: The base/arm/connecting rod arm is made of cast aluminum, the reducer/screw spline/fastener is made of steel, electronic components (EDS, etc.) are treated as electronic waste and cannot be disassembled, and the motor is disposed of as a whole; Lubricant Accessories Archive: Optigear Synt. ALR 150 (A1 gear oil), THK AFB-LF (lead screw), Optitemp RB2 (cable), Harmonic Drive 4B No.2, Microlube GL 261, and Drei Bond/Sikaflex/LOCTITE 510 adhesive sealant.