KUKA KR 3 D1200 Robot Operation and Maintenance

KUKA KR 3 D1200 high-speed sorting robot

Product positioning: Four axis Delta platform for high-speed picking and placing

KUKA KR 3 D1200 is a standard version of a four axis Delta parallel robot on the same platform as HM Sanitary. It is also designed for picking and packaging applications in the food, pharmaceutical, and consumer goods industries. It adopts a ceiling inversion method and is controlled by KR C5 micro. The system consists of a robotic arm, a controller smartPAD-2、 Composed of connecting cables, software, and optional accessories. The robotic arm consists of a base frame (with built-in A1-A3 motors and rear interface board), three upper arms (connected to the base and forearms through gear units, with each upper arm equipped with a spring assembly to fix two forearms), a moving platform (with built-in A4 motor and gearbox, carrying installation flanges), and electrical devices (RDC, protection circuit, A1-A4 motor and data cable).

The prohibited items are consistent with the HM version: do not use as a climbing aid, mechanical arm components must not come into direct contact with food, outdoor/explosive area/radioactive/underground operation is prohibited, transportation of personnel and animals is prohibited, and structural modifications (such as drilling) without KUKA permission are prohibited - structural modifications will result in the invalidation of warranty and liability claims.

Differences in core parameters compared to HM version

Parameter item KR 3 D1200 KR 3 D1200 HM

Workspace volume 0.387 m ³ -

Posture repeatability ± 0.05 mm ± 0.05 mm

Self weight approximately 105 kg, approximately 95 kg

Rated/maximum load 3 kg/6 kg 3 kg/6 kg

Maximum working diameter 1200 mm 1200 mm

Maximum working height 350 mm -

Protection level IP67 IP67 (A4 axis IP69K)

A4 axis speed 1091 °/s 840 °/s

A1-A3 speed 600 °/s 600 °/s

Maximum inertia of flange Iz 0.03 kgm ² 0.04 kgm ²

Material: Aluminum Alloy+Carbon Fiber Upper Arm/Forearm Stainless Steel

Default color RAL 2009 Orange/7035 Grey/9005 Black Stainless Steel Natural Color

The cleaning method prohibits high-pressure cleaning with a two-stage water wash of 0.7 MPa/2.5 MPa

The most noteworthy difference is that the A4 axis speed reaches 1091 °/s - higher than the HM version's 840 °/s. Coupled with the A1-A3 stroke of 109 °/+42 ° and the A4 stroke of ± 355 °, it performs more aggressively in the standard version beat assessment. The upper arm and forearm are made of aluminum alloy and carbon fiber structure, which greatly reduces the motion quality, which is the physical basis of high cycle time.

Cycle time - the direct basis for calculating the rhythm of sorting production lines

The document provides standardized cycle times for two typical pick and place trajectories (up throw translation drop format, in mm), programmed in DLIN with 0.3 mm approximation positioning (DLIN1) and DLIN endpoint complete stop (DLIN2):

Cycle 25-305-25 mm:

Load 0.1 kg: DLIN1=0.29 s, DLIN2=0.41 s

Load 1 kg: DLIN1=0.31 s, DLIN2=0.43 s

Load 3 kg: DLIN1=0.36 s, DLIN2=0.49 s

Cycle 90-400-90 mm:

Load 0.1 kg: DLIN1=0.36 s, DLIN2=0.50 s

Load 1 kg: DLIN1=0.39 s, DLIN2=0.50 s

Load 3 kg: DLIN1=0.46 s, DLIN2=0.58 s

Two engineering conclusions: using approximate positioning can obtain the fastest cycle time; According to the application (especially when it comes to workpiece characteristics), the picking and placing process may require additional pause time - visual triggering, vacuum suction cup establishment, release delay and other process waiting must be included in the beat calculation, and the values in the table cannot be directly copied.

Load, flange load, and foundation load

Key points of load planning: rated at 3 kg, maximum at 6 kg, no additional loads are allowed on the upper and lower arms and forearms; The maximum mass inertia of the flange plane Iz=0.03 kgm ²; The load inertia must be verified using KUKA Load, and the load data must be 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 load curve corresponds to the maximum load-bearing capacity, exceeding which will shorten the robot's lifespan and overload the motor and gearbox. Such applications require prior consultation with KUKA services.

Installation flange specifications: hole distribution circle of 31.5 mm, screw grade A4-80, specification M5, 7 fastening threads, minimum screw depth of 4.5 mm, maximum screw depth of 6 mm, positioning element 5 H7.

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

Condition F (a) F ®  M(k) M(g)

Running 513 N 365 N 26 Nm 17 Nm

Emergency stop 516 N 417 N 30 Nm 17 Nm

The operating value continues to appear in the normal trajectory, and the tool is checked according to fatigue strength; Emergency stop values rarely occur, static strength verification is sufficient.

Foundation load (including load and self weight inertia force):

Maximum normal value of load item

Vertical force F (v) 1649 N 1701 N

Horizontal force F (h) 567 N 649 N

Overturning moment M (k) 508 Nm 619 Nm

Torque M ®  112 Nm 231 Nm

The foundation design must be checked according to the maximum value. Compared with the HM version, the standard version has a greater vertical force (1701 N vs. 1552 N) and higher torque margin requirements (231 Nm vs. 187 Nm). When selecting the rack, the data of the two models cannot be mixed.

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.

A4 cable group replacement (expected to take 45 minutes, SPP 0000-419-517) - including zero point calibration requirements: power off padlock → wait for at least 5 minutes after power off before checking the power (there may be residual voltage exceeding 50V and up to 780V in the controller before) → wear protective gloves to prevent motor burns → remove A4 cover, unplug motor plug, remove 4 M5 × 16-10.9 bolts from the gearbox, take out the motor/gear assembly → remove the cable group from the driven platform housing (open wrench to remove 10 Nm hex nut) → remove 6 M4 × 12 from the bottom of the base, unplug XM4/XP4, remove PE (M3 nut 1.2 Nm) → reverse installation (apply LGFP 2/1 on the inner side of the shaft seal, M5 × 16-1) 10.9 is 7.5 Nm, and the shield M4 × 12-8.8 is 1.8 Nm). Closing must: operate A4 in T1 mode to observe abnormalities and perform A4's zero point calibration (mastering, requires MEMD calibration kit 0000-208-642) - skipping this step will result in inaccurate positioning of A4.

Eight conditions for early wear and tear and retirement disposal

During the planning phase, eight conditions that can cause premature wear must be evaluated: continuous operation near the temperature limit, abrasive environment, continuous operation at the performance limit, full power start-up of the chiller, high single axis load rate, monotonic motion trajectory, static axis position, external process forces - meeting any of the requirements for consulting KUKA services; When the robot approaches its limit, the built-in monitoring will automatically shut down, and capacity planning should reserve margin.

Cleaning boundary: The standard version prohibits the use of high-pressure cleaning equipment, as cleaning agents may infiltrate electrical devices and mechanical components and cause damage; Only solvent-free, water-soluble, non flammable, and non corrosive cleaning agents are allowed. After cleaning with a brush, wipe clean with a cloth. After cleaning the corroded area, apply anti-corrosion agents. This is in sharp contrast to the HM version's 2.5 MPa high-pressure water washing - two cleaning strategies on the same platform, and the selection must match the CIP cleaning system of the production line.

Material disposal: The upper arm/forearm/moving platform is made of aluminum alloy and carbon fiber, the cable is made of copper, and the gear unit/screw/washer/base frame is made of steel; Electronic components (RDC, EDS) and motors as a whole shall not be dismantled for electronic waste disposal; Plastic parts (bearings, shells), FKM O-rings, PUR sheaths, TPU seals are classified according to their markings. Auxiliary material archives: Drei Bond 1305, LOCTITE 510 adhesive, Cassida Fluid GL150 gear oil, Microlube GL 261 and LGFP 2/1 grease.