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.

Ceiling Installation - Core Process Different from Conventional Robots

KR 3 D1200 HM only supports ceiling installation, and the installation process includes multiple unique steps:

1. Installation foundation (optional, order number 0000-371-960): The user made rack must meet the load-bearing requirements. It is recommended to use square steel Ø 120 mm or Ø 150 mm material, and the rack must be stable enough to avoid shaking of the robotic arm during operation; There shall be no insulation or leveling layer between the base plate and the rack. Confirm that the surface of the base is flat and level before installation.

2. Minimum distance for anti-interference: When the robot leaves the factory, the upper arm is at a 45 ° angle. To avoid interference between the upper arm and the mounting plate, the design of the mounting plate must ensure that the minimum distance from the upper arm to the center point of the robot is 300 mm. Otherwise, the upper arm must be lowered through the brake release button before installation.

3. Layout suggestion: It is recommended to install the robot at a 30 ° angle to the conveyor line for better load balancing.

4. Tightening system: Three layer fastening - there are 12 M8 × 30-8.8 bolts (23 Nm) between the robotic arm and the installation base, 12 M8 × 30 bolts between the installation base and the hexagonal plate, and 12 M12 × 40-8.8 bolts (78 Nm) and 9 M16 × 40-8.8 bolts between the hexagonal plate and the frame. Three cylindrical positioning pins are used for positioning. Screws with a strength grade of 10.9 or above or with test certification are only allowed to be tightened once with the rated torque, and must be replaced with new screws after the first loosening - this rule is repeatedly emphasized in all maintenance operations.

5. On site installation of forearms: Unlike most factory produced machines, the forearms of KR 3 D1200 HM require on-site assembly: first install the spring assembly on the housing, and then assemble the two forearms separately with the upper arm and the moving platform (D20 ball head). The spring assembly stores a large amount of elastic potential energy, and it is strictly prohibited to pull it with full force; It is strictly prohibited to dismantle three forearms at the same time when disassembling the forearms, otherwise the moving platform may fall and cause compression injuries.

6. A4 cable laying: Connect cable group A4 and tighten it with an open-end wrench, equipped with Sanitary Usit sanitary washers and 6 M4 × 12 hexagonal flange bolts; Align the cable clamp according to the installation dimension diagram, tighten the upper arm and the moving platform with 4 M4 × 35 flange bolts each (torque 2.4 Nm), and confirm that the cable is not damaged when the upper arm and forearm move freely.

7. Move to horizontal position: Press the brake release button on the bottom of the base and manually adjust the A1 to A3 axes to horizontal.

Brake release: strict distinction between two methods

The document distinguishes between two ways of moving robotic arms without driving energy, which have completely different applicable scenarios:

Brake release button (standard): located on the bottom of the base, used for installation and debugging phase. The premise is that the controller is fully powered on and the system has been disabled. Press the button to release all axle brakes. Warning: The release of the brake may cause accidental loss of control and falling of the shaft. It is strictly prohibited to stand under the moving shaft.

Brake release device (optional): only used in exceptional situations after accidents or malfunctions, such as rescuing trapped personnel. The operation process must strictly follow: power off the controller and lock it with a padlock → unplug the motor cables XD20.1 and XD20.2 → connect the adapter box X20 → connect the brake release device → insert the handheld device X1 → select the shaft to be released through the selection switch → press the handheld device button. Different from the button mode, this device can selectively release the brake according to the axis, with significantly higher safety.

Maintenance cycle table and key vulnerable parts

Periodic tasks

Tighten the mounting base fastening bolts 100 hours after startup (only once): M8 × 30-8.8 torque 23 Nm, M12 × 40-8.8 torque 78 Nm

Replace the forearm bearing (order number 0000-394-673) after 5000 hours or up to 1 year; Replace the forearm shell (0000-394-674); Regularly clean the bearings with a cloth as needed

Visually inspect the forearm for 20000 hours or up to 5 years, and replace it if any damage or cracks are found (0000-376-891); Visually inspect cable group A4 and replace it with KUKA service if damaged (0000-376-893)

Key points for replacing bearings and shells: Each forearm should be equipped with 4 bearings at the connection between the moving platform and the upper arm, and 4 shells at the connection between the tension spring. The replacement process is to remove the forearm assembly → remove the bearing/housing → inspect → reinstall. When necessary, edible lubricating grease can be added to the bearings, but it must be ensured not to contaminate the product - this is the essential difference between HM sanitary and industrial types. Forearms must be replaced in pairs.

The replacement of the A4 cable group is expected to take 45 minutes, with the following process: remove the outer cover → cut 4 zip ties, unplug the motor plug, loosen the M3 hex nut to disconnect the ground → loosen the A4 housing plug screw → remove 8 M4 × 35 flange bolts → mark the installation position of the wiring harness on the upper arm and forearm before removing → assemble the new part according to the reverse process, with key torque: M4 × 12 with sanitary washer 2.4 Nm, plug screw 20 Nm, PE wire 1.2 Nm. The final work must: operate the A4 shaft to observe abnormalities, and test the program in T1 manual deceleration mode.

Cleaning standards - mandatory requirements for the food industry

The IP67 machine and IP69K A4 axis use different cleaning parameters, which is a unique dual level cleaning specification for HM models:

Parameter machine (IP67) A4 axis (IP69K)

Maximum water pressure 0.7 MPa 2.5 MPa

Minimum scattering angle of fan-shaped nozzle 40 ° 40 °

Minimum distance of nozzle 400 mm 400 mm

Maximum flow rate of 20 L/min -

Maximum water temperature -80 ° C

Cleaning process: Stop the machine and lock adjacent system components → Remove the protective cover if necessary → Clean with a brush and water according to the parameters in the table → Reinstall the safety device and verify its function → Reinstall the protective cover. Functional testing must be conducted at the end, and any damaged or illegible signs must be replaced. During cleaning, the controller must be powered off and the main switch locked with a padlock.

Early Wear Prevention - Eight Warning Conditions in the Planning Stage

The document lists eight conditions that can cause premature wear, require shortened maintenance intervals, or early replacement of parts, and should be evaluated item by item during the planning phase:

Continuously operating near the temperature limit

Continuously operating in an abrasive environment

Continuously approaching performance limit operation (such as high shaft speed)

After shutdown, the refrigeration system starts at full power

Single axis high load rate

Monotonic motion trajectory (such as short stroke high-frequency reciprocating)

Static axis position (such as continuous vertical position of wrist axis)

External process forces acting on robots

If any condition is met, KUKA services must be consulted. When the robot approaches its operating limit, the built-in monitoring function takes effect and automatically shuts down - this protective function may reduce system availability, and a margin should be reserved when calculating production capacity.

Transportation, retirement, and material details

Transport position: A1/A2/A3=+45 °, A4=0 °. During lifting, install three M10 lifting rings on the installation base, adjust A1, A2, and A3 to 0 ° after hoisting with ropes, and adjust the ropes so that the lifting equipment passes vertically through the center of gravity of the robotic arm. Only authorized lifting equipment with sufficient carrying capacity can be used, and the entire transportation process must be in the designated transport position to prevent tipping.

Retirement process: Remove all peripheral connections and motor/data cables → Remove 6 M4 × 12 flange bolts to release the A4 cable group → Release the grounding conductor → Remove the front arm and moving platform before lifting → Transport by forklift or hoist → Wrap with plastic film and seal the base for dust prevention before long-term storage, and add desiccant if necessary.

Material classification and disposal: Stainless steel load-bearing structural components (upper arm/forearm/base/moving platform) are recycled as metal; Electronic components (RDC, EDS) and motors shall be disposed of as electronic waste and shall not be disassembled; Plastic parts (bearings, shells), FKM O-rings, PUR cable sheaths, TPU seals are classified according to their markings. The details of auxiliary materials must be archived: Drei Bond 1305 and LOCTITE 510 adhesive, Cassida Fluid GL150 gear oil, Microlube GL 261 and LGFP 2/1 lubricating grease - the selection of food grade lubricating grease is directly related to product safety and compliance.