KUKA KR 3 D1200 HM Robot Operation and Maintenance Guide

Installation and maintenance of KUKA KR 3 D1200 HM parallel robot

Product positioning: Delta robot for hygiene in the food and pharmaceutical industry

In high-speed Pick&Pack applications, KUKA KR 3 D1200 HM is a four axis Delta parallel robot designed specifically for the food, pharmaceutical, and consumer goods industries. The model suffix "HM" represents Sanitary Machine, mainly targeting the primary and secondary food processing industries. The whole cabinet system consists of a robotic arm, KR C5 micro controller, smartPAD-2 teaching pendant, connecting cables, software, and optional accessories.

The structural composition of a robotic arm is completely different from traditional serial robots, mainly including upper arms, forearms, mounting flanges, moving platforms, base frames, and electrical devices. The base frame is equipped with motors A1 to A3, and there is an interface board at the rear; Three upper arms are connected to the base and forearm through gear units; Each upper arm is equipped with two forearms, which are driven by A1, A2, and A3 gear units to move the moving platform; The moving platform carries the installation flange and performs the rotational movement of the A4 axis. The electrical equipment includes Micro RDC, protection circuits, A1 to A4 motors and data cables, as well as a complete set of cables for connecting controllers.

The expected use red line must be clearly defined: the robot is used for picking up and packaging goods in the food, pharmaceutical, and consumer goods industries. Prohibited items include direct contact between robotic arm components and food, use as a climbing aid, use in potential explosive areas or radioactive environments, outdoor operation, underground mining operations, transporting personnel or animals, and operation without the required safety equipment. Special reminder: Violating the operating conditions specified in the technical data section will result in premature wear and tear; As a component of a complete system, the system can only operate in systems that meet CE requirements.

Core parameters and axis data

Parameter item KR 3 D1200 HM

Axis number 4 (all controlled)

Posture repeatability (ISO 9283) ± 0.05 mm

Self weight approximately 95 kg

Rated load/maximum load 3 kg/6 kg

Maximum working diameter 1200 mm

Protection level IP67 (A4 axis is IP69K)

Installation location only on the ceiling

Base diameter ∅ 350 mm

Controller KR C5 micro

Material: Stainless steel (default color)

Noise<75 dB (A)

The range of axial motion is -109 ° to+42 ° for A1/A2/A3, and ± 355 ° for A4 axis; Under rated load, the speed of axes A1-A3 can reach up to 600 °/s, and axis A4 can reach 840 °/s. The zero calibration positions of all four axes are 0 °. Environmental conditions: Operating temperature from 0 ° C to 45 ° C, storage and transportation from -25 ° C to 55 ° C, environmental condition classification is 3K22 level according to EN 60721-3-3. Frost and condensation must be avoided during low-temperature operation, otherwise it may cause property damage.

There are four cable lengths for connection: 4, 7, 15, and 25 meters. The interfaces include motor cable XD20.1/XD20.2-X30 (Har motion interface) and data cable XF21-X31. The grounding conductor is an optional accessory (M4 ring terminal block).

Flange load and foundation load - key design inputs

Flange load (refers to the rated load without safety factor, the actual value is related to the motion trajectory, load center of gravity, and inertia):

Condition F (a) Axial F ® Radial M (k) overturning moment M (g) flange torque

Running (sustainable) 293 N 312 N 16 Nm 12 Nm

Emergency stop (rarely occurs) 413 N 384 N 19 Nm 24 Nm

Key points of the project: The operating values will continue to appear in the normal motion trajectory, and the tool selection should be checked according to the fatigue strength; The emergency stop value can only be verified based on static strength. The document emphasizes that reducing the load does not necessarily mean a decrease in flange force and torque, and the load data must be input into the robot controller for consideration in trajectory planning.

Foundation load (including the load and the inertial force of the mechanical arm's own weight, also applicable to the inverted ceiling condition):

Maximum normal value of load item

Vertical force F (v) 1327 N 1552 N

Horizontal force F (h) 563 N 654 N

Overturning moment M (k) 544 Nm 588 Nm

Torque M ®  116 Nm 187 Nm

The design of the foundation size must be based on the maximum load, ignoring this point may result in personal injury and property damage; The normal value is the average expected value, and the actual load depends on the program and robot load, which may be higher or lower than the normal value.

Stop distance and danger zone calculation

The STOP 0 reference value (POV=100%, maximum load, robot internal measurement technique) determined according to Appendix B of DIN EN ISO 10218-1 is the three-dimensional TCP data:

X direction: 479.000 mm/0.180 s

Y direction: 4300000 mm/0.164 s

Z-direction: 99.000 mm/0.056 s

Dangerous zone=workspace+stopping distance, must be protected by physical protective devices (safety doors, light barriers, etc.), and the protective devices should be located outside the dangerous zone; There shall be no dangerous points of shearing or squeezing in the loading and unloading area. If there is no physical protection, it must be evaluated according to the EN ISO 10218 collaborative operation requirements. Stacking axis movements may result in longer stopping distances; Brake wear is related to operating mode, application, and the number of STOP 0 triggers. It is recommended to check the stopping distance at least once a year.