KUKA KR C2 edition2005 Robot Controller Operation Manual

Drive shutdown button STOP 0 STOP 0

STOP key STOP 2 STOP 2

Operation mode switch STOP 0 STOP 0

STOP 0: Immediately cut off the drive power and apply the mechanical brake

STOP 1: Maintain path braking, cut off drive power after 1 second

STOP 2: Normal deceleration stops, drive remains powered on

Chapter 5: KUKA Servo Drive System

5.1 KPS600 power supply unit

KPS600 is the main power module of KR C2, integrating multiple functions:

Rectification circuit: converts three-phase AC power into DC bus voltage

Charging circuit: Control the pre charging process of DC bus capacitor

Braking circuit: consumes regenerative energy to prevent bus overvoltage

Discharge circuit: Quickly discharge after shutdown to ensure safe maintenance

Main contactor K1: controls the on/off of the main power supply

KPS600 provides multiple 24V power supplies, which respectively supply power to the DC/DC converters of the motor brake, customer interface, control PC, and servo drive module. The 6 LED indicator lights on the panel display the working status and fault codes in real time:

LED1 (red) and LED2 (green) combined display processor status, bus voltage, communication errors, etc

LED3 and LED4 indicate emergency stop status

LED5 indicates the braking status of the robot

LED6 indicates the external shaft brake status

5.2 KSD servo drive module

The KSD module is divided into two size series based on current capacity: BG1 (KSD-08/16/32) and BG2 (KSD-48/64). Each KSD integrates:

Power output stage

current regulator

Interbus driver bus interface

Motor current monitoring and short-circuit protection

Temperature monitoring of radiator

Communication monitoring

The two LEDs (red/green) on the module provide rich status information: from power loss to overcurrent faults, from bus undervoltage to servo enable, maintenance personnel can quickly determine the type of fault by observing the LED status.

5.3 Dual loop cooling system

KR C2 adopts an innovative dual loop cooling design, significantly improving the thermal stability and lifespan of the system:

Internal cooling circuit: using a heat exchanger to cool and control the electronic component area, keeping sensitive components operating within a suitable temperature range.

External cooling circuit: Directly cool the brake resistor, servo module, and KPS radiator with ambient air, and these high heat generating components directly exchange heat with the outside world.

The key to this design is to prohibit the installation of filter cotton at the air inlet, otherwise it will cause an increase in internal temperature and shorten the service life of the equipment!

Chapter 6: Detailed Explanation of KCP Teaching Device

6.1 Human Computer Interaction Design

As the core device for operator robot interaction, KCP (KUKA Control Panel) is designed with full consideration for operational convenience and safety

Front panel layout:

Mode selection switch: With a removable key, the operating mode cannot be changed after locking

6D Space Mouse: Intuitively Control Robot Motion

Emergency stop button: Mushroom head red button

Drive on/off button

Numerical keypad and function soft keys

Start/Stop/Back button

8-inch VGA display screen (640 × 480 resolution)

Back panel design:

Three three-level enable switches (position 1: not pressed, position 2: middle position, position 3: panic position)

Start button (physical redundancy)

nameplate label

6.2 Safety Logic of Enabling Switches

The design of the enable switch embodies the perfect combination of ergonomics and safety engineering:

In T1 (manual slow) and T2 (manual fast) modes, the operator must keep the enable switch in the middle position (position 2) to drive the robot. If the switch is fully released (position 1) or pressed firmly to the bottom (position 3-panic), the system immediately executes STOP 0 to stop and cut off the drive power.

This three-level design ensures that the robot can safely stop in any unexpected situation (such as the operator falling due to nervousness, losing consciousness, being forced to let go, etc.). KUKA explicitly warns: Do not use tape or other methods to fix the enable switch!

6.3 Operating Mode and Application Scenarios

KR C2 supports four operating modes, each corresponding to specific application scenarios and security requirements:

T1 (manual slow speed):

Maximum speed 250mm/s

Used for programming, teaching, and program testing

Enable switch is valid, safety door is invalid

T2 (manual quick):

Capable of programming speed (exceeding 250mm/s)

Only used for program verification, not programmable

The operator must be outside the safe area

AUT (Automatic):

No superior controller, independent operation

It is necessary to connect the safety circuit

Cannot be manually operated

AUT EXT (External Automatic):

Controlled by higher-level controllers such as PLC

It is necessary to connect the safety circuit

Used for production line integration

Chapter 7: Installation Planning and Electrical Connections

7.1 Installation conditions and space requirements

The installation of KR C2 must meet strict space requirements:

Minimum gap requirement:

Left/Right: 50mm (when installed side by side)

Rear: 50mm

Front: Door opening space (approximately 180 ° for independent cabinets and 155 ° for side-by-side cabinets)