KUKA KR 3 AGILUS Operation and Maintenance Safety Essentials

Load, inertia, and flange stress

KR 3 R540 has a rated load of 2 kg, a maximum load capacity of 3 kg, and a rated mass moment of inertia of 0.045 kgm ². The rated distance of the load center of gravity is Lxy 60 mm and Lz 80 mm. The total sum of all loads fixed on the robot shall not exceed the maximum total load. The load curve corresponds to extreme load capacity, and both load capacity and mass moment of inertia must be checked simultaneously. Exceeding the limit will affect the service life of the robot and overload the motor and gearbox. It is necessary to use KUKA. Load to check inertia and input load data into the robot control system.

In terms of flange force, the flange load during operation is approximately F (a) 194 N, F (r) 144 N, M (k) 21 Nm, M (g) 9 Nm; During emergency stop, it is approximately F (a) 244 N, F (r) 263 N, M (k) 35 Nm, and M (g) 19 Nm. These values are related to the load mass, center of gravity, moment of inertia, and motion trajectory. It is recommended to pay attention to fatigue strength when designing tools, and if necessary, measure the force and torque under the actual conditions of the robot's use site.

Safe operation and personnel requirements

This industrial robot is only allowed to be used according to regulations, that is, for handling tools and devices, or for processing and transporting workpieces or products. Unauthorized use includes using it as a climbing aid, using it outside the allowed operating range, and not using necessary additional protective devices. Changing the structure of the robot, such as punching holes, will be considered as improper use and may result in loss of warranty and claim eligibility. Robot systems are only allowed to operate on systems that comply with CE certification.

The system integrator is responsible for integrating industrial robots into equipment, conducting risk assessments, using necessary safety functions and protective devices, issuing EC conformity declarations, affixing CE marks, and creating equipment operation guidelines. Users must receive training and only personnel with professional qualifications are allowed to operate. The work area must be limited to the minimum range, and protective devices should be located within the protective area. Dangerous areas include work areas and stopping routes. Mechanical terminal stops, mechanical shaft limiting devices, free rotation devices, brake opening devices, and hazardous position markings are common protective equipment.

In terms of safety measures: It is not allowed to operate the robot with safety functions or protective devices deactivated or removed; Prohibit staying under the robotic mechanical system; During operation, the temperature of the motor may cause skin burns, and protective gloves should be worn. KCP/smartPAD is only allowed to be operated by authorized personnel, and multiple handheld programmers must be clearly matched with corresponding robots. When using an external keyboard and mouse, it must have been put into operation or maintained, the drive device must be turned off, and there must be no one in the danger zone. After being put into operation or maintenance, the external keyboard and mouse must be removed.

Stop travel and shutdown category

The stopping stroke refers to the angle of rotation of a robot from triggering a stop signal to complete stop, and the stopping time refers to the time taken from triggering the stop signal to complete stop. The data mainly focuses on the base axes A1, A2, and A3. Shutdown category 0 means the drive system will immediately shut down and the brake will apply; Shutdown category 1 is the mechanical arm braking along the trajectory, and after 1 second, the drive device is turned off and the brake is applied; Shutdown category 2 is when the drive system is not turned off, using regular brake ramp braking.

For shutdown 0, axis 1 has a stopping stroke of approximately 49.12 ° and a stopping time of 0.15 s; axis 2 has a stopping stroke of approximately 54.73 ° and 0.19 s; and axis 3 has a stopping stroke of approximately 86.99 ° and 0.24 s. These values are based on the operating range I=100%, program multiplier POV=100%, and mass m as the maximum load. The actual stopping stroke and stopping time may vary due to internal and external influences of braking torque. Depending on the operating mode, usage, and number of shutdowns, brake wear may vary. It is recommended to check the stopping stroke at least once a year. If the axis movements overlap with each other, the stopping stroke may become longer.

Transportation and commissioning

Before transportation, the robot must be placed in the transportation position: A1 0 °, A2-130 °, A3+150 °, A4 0 °, A5 0 °, A6 0 °. As long as the robot is not fixed on the foundation, it must be kept in the transportation position. When transporting with a circular sling, the sling must be threaded from below the boom towards the wrist of the robot, and all rope lengths and threading methods must ensure that the robot is not damaged. During transportation, avoid vibration or collision, and pay special attention to preventing tipping over. It is prohibited to use cranes to lift robots in other ways.