KUKA KR 3 D1200 Robot Operation and Maintenance

Stop distance and danger zone

STOP 0 reference value (POV=100%, maximum load, according to Appendix B of DIN EN ISO 10218-1, robot internal measurement technology): 519 mm/0.16 s in the X direction, 409 mm/0.128 s in the Y direction, and 65 mm/0.049 s in the Z direction. Dangerous zone=workspace+stopping distance, which must be protected by physical protective devices and located outside the dangerous zone; There shall 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. Stacking axis movements may result in longer stopping distances; Brake wear is related to the number of STOP 0 triggers, and it is recommended to check the stopping distance at least once a year.

Installation and Conveyor Tracking Interface - Unique Configuration of Standard Version

Rack requirements: User made racks must have sufficient load-bearing capacity, recommended material size of 120-150mm square steel, and must be stable enough to 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 9 M16 × 40-8.8 hexagonal bolts to secure the hexagonal plate to the frame (hexagonal plate is self-made by the user and steel is recommended), and 12 M8 × 30-8.8 hexagonal bolts to secure the robotic arm. 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 after the first loosening.

Anti interference and layout: The upper arm of the robot is designed at a 45 ° angle when leaving the factory. When designing the installation plate, the minimum distance from the upper arm to the center point of the robot is 300 mm. Otherwise, the upper arm must be lowered using the brake release button first; Suggest arranging the conveyor line at a 30 ° angle to achieve better load balancing.

The conveyor belt tracking capability of the interface board - the key difference between the standard version and the HM version: in addition to the data cable X31, MEMD connection X32, and motor cable X30, the rear interface board also has an external resolver connection and reserved connections for structural components. The external discriminator is used to collect the speed and position signals of the conveyor belt, which is the hardware basis for implementing conveyor tracking and picking. The design of the robot follow-up grabbing scheme on the sorting line should start from this interface.

Cable laying: The bending radius of motor cables shall not be less than 150 mm, and that of data cables shall not be less than 60 mm. The motor and data cables shall be laid in separate slots, and EMC measures shall be strengthened if necessary; Indoor installation only, temperature range -10 ° C to+55 ° C; grounding conductor is a mandatory item (DIN EN 60204 low resistance equipotential connection), connected by the user to the threaded hole of the base frame. After connecting the data cable, it is necessary to install a ferrite magnetic ring near the XF21 connector end - this is a mandatory item in the standard installation checklist, and omission may result in EMC testing failure.

On site assembly process: Lifting (4 M8 lifting rings are installed into the robot base, and after lifting, A1/A2/A3 is adjusted to 0 ° and the rope is adjusted vertically above the center of gravity) → 3 positioning pins are inserted into the interface board → 12 M8x30-10.9 bolts are tightened → X31/X30 is connected and a magnetic ring is added → A1-A3 is leveled by pressing the brake release button → the spring assembly is installed with the forearm (D20 ball head docking, the spring assembly contains a large amount of elastic potential energy, it is strictly prohibited to pull it with full force, and it is strictly prohibited to remove three forearms at the same time) → A4 cables are laid and fixed with cable clamps, with 4 M4 × 35-12.9 screws (2.8 Nm) on the upper arm and 6 M4 × 35-12.9 screws on the forearm.

Maintenance cycle and upper arm replacement process

Maintenance cycle table:

Periodic tasks

Tighten the hexagonal plate bolts 100 hours after startup (only once): M8 × 30-8.8 is 23 Nm, M12 × 40-8.8 is 78 Nm

Replace the casing after 5000 hours or 1 year (0000-436-604); Visually inspect the upper arm, any damage/cracks will be replaced by KUKA service; Replace the bearing (0000-394-673)

20000 hours or 5 years of visual inspection of A4 cable assembly, any damage will be replaced by KUKA service (0000-419-517); Visually inspect the forearm, replace if damaged (0000-419-503, quantity 6)

The standard version allows the addition of edible grease to bearings, but it must ensure that the product is not contaminated - although it is not a sanitary body, the bearing lubrication still retains food grade considerations.

Upper arm replacement (expected to take 60 minutes, SPP order number 0000-419-502) process key points: Remove A4 cable clamp (4 upper arms+6 front arms M4 × 35-12.9, and also remove 4 upper arm M4 × 25-12.9 fixing blocks) → Remove front arm assembly → Remove upper arm cover (6 M4 × 8-8.8) → Remove sealing gasket → Remove 6 M8 × 25-10.9 bolts and adjust plate to remove upper arm → Apply LGFP 2/1 grease on the oil scraper ring during installation → After reinstallation, the torque of M8 × 25-10.9 is 31 Nm, and the cover M4 × 8-8.8 is 2.8 Nm → Reinstall the front arm and cable clamp. Conclusion: Observe abnormalities while operating A1/A2/A3 in T1 mode.