KUKA KR C4 compact assembly and debugging

KUKA KR C4 compact assembly and debugging

KUKA KR C4 compact is a compact controller launched by KUKA for small robot applications. It adopts a 19 inch chassis structure, can control up to 6 axes, weighs about 33 kg, has a protection level of IP20, and an average noise of about 54 dB (A). It consists of two main parts: a control box and a drive box, with internal integrated control PC, CCU_SR, low-voltage power supply, battery, main filter, fan, etc KPP_SR、KSP_SR、 Braking resistor and interface panel. For on-site engineers, mastering the assembly, wiring, safety configuration, and start-up debugging processes is the foundation for ensuring the safe and stable operation of robot systems.

System composition and core modules

The industrial robot system of KR C4 compact includes a robotic arm, robot controller, smartPAD teaching pendant, connecting cables, software, and options. The robot controller is used to control KUKA small robots and consists of a control PC, power unit, safety logic, smartPAD control panel, and connection panel. The control box contains a fan, hard drive, low-voltage power supply, EDS storage card CCU_SR、 Cover interface, device switch, interface, options, motherboard, and battery. The drive box contains X20 motor interface, braking resistor KPP_SR、 Main filter, KSP_SR, and fan.

The control PC is responsible for graphic interface, program creation and maintenance, sequence control, path planning, drive circuit control, monitoring, safety equipment, and external communication. CCU_SR stands for Small Robot Cabinet Control Unit, consisting of CIB_SR and PMB_SR. It serves as the central power distribution and communication interface, responsible for safety input/output, contactor activation, 4 floating outputs, 9 safety inputs, teaching pendant insertion recognition, mastering testing, 6 rapid measurement inputs, power fan monitoring, and temperature detection inside the control box. If the main power supply fails, the battery will continue to supply power to the control components until the position data is saved and the controlled shutdown is completed. The low-voltage power supply supplies power to the control cabinet components, and the green LED indicates the working status. The main filter suppresses interference voltage on the power line. The drive box generates intermediate circuit voltage, controls the motor and brake, and checks the intermediate circuit voltage in braking mode.

Interface layout and motherboard selection

The standard configuration of the KR C4 compact's connection panel includes device connection cables, motor cables, data cables, smartPAD cables, and peripheral cable interfaces. The specific interfaces include X11 security interface, X19 smartPAD connection, X65 expansion interface, X69 service interface, X21 robotic arm interface, X66 Ethernet security interface, K1 power connection, X20 motor interface, and control PC interface. X11 and X66 cannot be connected and used simultaneously, only one can be selected.

The control PC can be equipped with D3076-K, D3236-K, or D3445-K motherboards. D3076-K provides 4 fieldbus slots, 2 USB 2.0, DVI-I, 4 USB 2.0, and LAN Onboard interfaces. D3236-K provides 2 fieldbus slots, 2 USB 3.0, DVI-I, 4 USB 2.0, and LAN Onboard interfaces. D3445-K provides 2 fieldbus slots, 2 USB 3.0, DVI-D, Display Port, 4 USB 2.0, and LAN Onboard interfaces. VGA can be achieved through a DP or DVI to VGA adapter, but external displays are only available when not connected to a smartPAD or virtual remote teaching pendant. All contactors, relays, and valve coils connected by users must be equipped with suitable suppression diodes, RC components, and VCR resistors are not applicable.

Cooling and installation conditions

The components of the control box and drive box are cooled by two fans using ambient air. Air enters from both sides and exits from the back. Do not install filter cotton upstream of the ventilation duct, otherwise it will cause temperature rise and shorten equipment life. The control cabinet can be installed in a 19 inch rack or used as a standalone device. The rack depth should be at least 700 mm. The controller is designed for horizontal installation or can be installed vertically. A 70 mm cooling air gap must always be maintained on both sides to prevent deformation of the casing. When installed vertically, the fan opening and ventilation duct must not face upwards.

The installation environment must avoid conductive dust and condensation. If there is conductive dust or condensation, it may cause the internal electrical connections to lose control. Environments with pollution levels of 3 or 4 require the installation of protective enclosures with a minimum protection level of IP54, depending on the environmental conditions. The operating environment temperature ranges from 5 ° C to 45 ° C, and the storage and transportation temperature ranges from -25 ° C to 40 ° C. Without a battery, the storage and transportation temperature can be extended to -25 ° C to 70 ° C. No derating is required below an altitude of 1000 meters, and a derating of 5%/1000 meters is required below 3000 meters. Transport vibration 0.37 g, continuous operation 0.1 g, frequency 4 to 120 Hz; impact transport 10 g, operation 2.5 g, half sine 11 ms. If mechanical stress is high, anti vibration components need to be installed. Charge the battery every 9 months when the storage temperature is not higher than+20 ° C, every 6 months when the temperature is between+20 ° C and+30 ° C, and every 3 months when the temperature is between+30 ° C and+40 ° C to prevent damage from deep discharge.