KUKA KR4 R600 Operation and Maintenance Essentials

The flange is of IW4 type, with a pitch diameter of 31.5 mm, using 7 M5 threads, strength grade 12.9, and a clamping length of at least 1.5 times the nominal diameter. The flange load during operation is approximately axial force F (a) 179 N, radial force F (r) 131 N, tilt torque M (k) 13 Nm, and torque M (g) 9 Nm; During emergency stop, it is approximately F (a) 244 N, F (r) 365 N, M (k) 39 Nm, and M (g) 22 Nm. Tool design must consider these loads and pay attention to fatigue strength.

In terms of stopping distance and stopping time, at STOP 0, A1 stops at a distance of about 30.53 ° and a stopping time of about 0.15 s; A2 stops at a distance of about 28.32 ° and 0.14 s; A3 stops at a distance of about 59.72 ° and 0.23 s. This data is based on an elongation rate of 100%, a program magnification rate of 100%, and a rated load. The stopping distance and stopping time of STOP 1 will vary with POV, mass, and elongation, and should refer to the corresponding curves. The stopping distance is equal to the reaction distance plus the braking distance, and is part of the danger zone. Brake wear depends on the operating mode, application, and STOP 0 times. It is recommended to check the stopping distance at least once a year. If the axis movements overlap, the stopping distance may be longer.

Security integration and personnel protection

KR 4 R600 belongs to partially complete machinery and must be integrated into a complete system before it can be put into operation. The system integrator is responsible for installation, connection, risk assessment, implementation of safety functions and protective devices, issuance of EC conformity declaration, affixing CE mark, and production of system operation instructions. The robot control cabinet has CE markings that comply with EMC and low-voltage directives. Operators must be trained to assess work tasks and identify potential hazards.

The safety mode includes T1 manual deceleration mode (≤ 250 mm/s) and T2 manual high-speed mode (allows ≥ 250 mm/s). T1 is used for jogging, teaching, programming, and program verification; T2 is only used when testing at speeds higher than T1, and teaching and programming are not allowed. Automatic mode is only allowed to operate when all safety devices are complete and functioning properly, there is no one in the system, or when the EN ISO 10218 cooperation requirements are met. If the robotic arm or external shaft stops without reason, an emergency stop must be triggered before entering the danger zone.

General safety measures include: even if the control cabinet is turned off and locked, the possibility of robot movement should still be considered; Incorrect installation or mechanical defects may cause the robotic arm or external shaft to sink. Before working on a turned off robot, the robotic arm and external axis must be moved to a position where they will not move on their own, or safety support must be provided. Do not stay under the robot arm. The motor will generate heat during operation, which may cause burns. Protective gloves should be worn. The motor and brake will generate electromagnetic fields, which may interfere with active implants such as pacemakers. Relevant personnel should maintain a distance of at least 300 mm from the motor and brake. KCP/smartPAD can only be operated by authorized personnel; If there are multiple handheld programmers in the system, their corresponding relationships must be clearly defined and cannot be interchanged. The disconnected smartPAD emergency stop device is unavailable and must be immediately removed from the system and properly stored. External keyboard and mouse can only be used when put into operation or maintenance, and the driver has been turned off and there is no one in the danger zone; KCP/smartPAD should not be used when using an external keyboard.

During maintenance and repair, it is advisable to work outside the danger zone as much as possible; If it is necessary to be within the danger zone, the user must define additional safety measures. Turn off the robot and lock it to prevent accidental restarts. If it is necessary to work while the control cabinet is connected, only T1 mode is allowed. The homework label should be hung on the system and retained even if temporarily interrupted. The emergency stop device must remain effective. If safety functions or protective devices are disabled during maintenance or repair, they must be restored immediately after completion. Before working on live parts, the main switch must be turned off and locked to confirm that there is no voltage; Cannot only trigger emergency or safety stop, as some components are still live. After the control cabinet is turned off, some components may still carry voltages exceeding 50 V up to 780 V for several minutes. ESD regulations must be followed during homework to prevent water and dust from entering the control cabinet. Models with balance systems may have hydraulic, pneumatic, spring, or cylinder balance systems that belong to pressure equipment and must comply with national pressure equipment regulations and be operated by qualified personnel.