KUKA KR C2 edition2005 Robot Controller Operation Manual

The green LED on the module visually displays the working status: the LED flashes during normal operation, and turns off or stays on when there is a communication failure. The DSE-RDW diagnostic tool allows for in-depth analysis of the communication quality between DSE and RDC.

2.4 KVGA graphics card: KCP's visual channel

The KVGA card is specifically designed to connect KCP teaching devices and supports parallel operation of external VGA displays. There are two KCP connection ports on the card, and the resolution and color count (16 colors or 256 colors) are automatically configured during system installation. This design allows for the simultaneous use of a teaching pendant and an external display during the debugging phase, greatly facilitating system maintenance.

Chapter 3: RDC/SafeRDC Analysis Techniques

3.1 Working principle of rotary digital converter (RDC)

RDC (Resolving Digital Converter) is installed in the RDC box of the robot base and is a key component for achieving precise position control. Its core functions include:

Provide excitation power for a rotating transformer with 8 axes

Provide isolated power supply for 8 motor temperature sensors (KTY84)

Convert analog signals to digital signals

Automatically perform offset and symmetry adjustment

Monitoring the open circuit fault of the rotary transformer circuit

Monitor motor temperature

Communicate with DSE-IBS3 through RS422 serial interface

The RDC board stores important data: runtime counter, absolute position, rotation position, and adjustment data (offset, symmetry). This means that after replacing the RDC, it is necessary to perform offset and symmetry adjustments again.

3.2 SafeRDC: Safety level location monitoring

SafeRDC is a security enhanced version of RDC, consisting of a SafeRDC board, an I/O Print board, and a security shell, suitable for application scenarios that require higher levels of security:

SafeRDC core functions:

Redundant evaluation of rotary signals

Monitor the position of the robot based on the set safety parameters

Monitoring the dual channel operation status of secure input and output

Actual location of safety assessment

Safely cut off the drive power supply

Communicate with the robot controller

Safe Input/Output Pulse Test

SafeRDC meets the safety requirements of ISO 13849-1 PL d level through hardware redundancy and self checking mechanism. Its onboard LED indicator system provides detailed status information to help maintenance personnel quickly diagnose faults.

3.3 Quick measurement function (option)

The rapid measurement function records robot position data through high-speed measurement input and digital sensors for measuring workpieces and subsequent calibration applications. This feature supports two modes of internal power supply (via RDC) and external power supply:

Single RDC configuration: 5 measurement inputs directly connected to X33 interface

Dual RDC configuration: requires special wiring to connect two RDC boxes in series

For the SafeRDC version, the X33 interface provides 7 pins, including 5 measurement inputs,+24V internal power supply and GND, and 0V internal reference voltage.

Chapter 4: ESC Safety Logic System

4.1 Dual channel security architecture

ESC (Electronic Safety Circuit) is the safety core of KR C2, which adopts dual channel computer-aided design and permanently monitors all safety related components. Once the safety circuit malfunctions or is interrupted, the system immediately cuts off the driving power supply, causing the robot to stop moving.

Key input signals monitored by ESC system:

Local emergency stop (emergency stop button on KCP)

External emergency stop (connected through customer interface)

Operator protection (safety door switch)

Enable switch (three-level switch on the back of KCP)

Drive off/on button

Operation mode selection (T1, T2, AUT, AUT EXT)

Verify Input (QE)

Output status monitored by ESC system:

Operation mode indication

Drive on status

Local emergency stop status

4.2 CI3 series interface board

The CI3 board connects various nodes of the ESC system to the customer interface, and there are four versions according to application requirements:

CI3 standard board: No independent nodes, connected to various nodes in the ESC circuit, indicating local emergency stop status through relays, and resetting the ESC circuit through the reset button.

CI3 expansion board: With independent nodes, it can display operation mode, drive on and local emergency stop status, and is equipped with multiple relay outputs.

CI3 bus board: Connect the ESC circuit to PILZ's safety bus system through the SafetyBUS gateway board, suitable for complex safety network integration.

CI3 Tech board: has independent nodes, supports KUKA. RoboTeam, KUKA. SafeRobobot, SafetyBUS gateway, and external axis control, and must be used in conjunction with MFC3 Tech card.

4.3 Safety Features and Stop Response

The ESC system triggers different types of stop responses based on different triggering conditions:

Trigger conditions T1/T2 mode AUT/AUT EXT mode

Safety door open - STOP 1

Emergency stop press STOP 0 STOP 1

Enable the switch to release STOP 0-

Press the start button to release STOP 2-