KUKA KR C4 Smallsize-2 family's smallest control cabinet

KUKA KR C4 Smallsize-2 family's smallest control cabinet

KUKA KR C4 smallsize-2 is a compact control cabinet launched by KUKA for applications involving small robots, linear units, and positioners. It can control up to 6 servo axes, weighs about 60 kg, has a protection level of IP54, and the cabinet adopts RAL 7016 side panels and KUKA orange cabinet doors. The control cabinet supports AC power supply of 3x380 V, 3x400 V, 3x440 V or 3x480 V, with a rated load of 3.3 kVA, a rated short-circuit current of 5 kA, and a system impedance not exceeding 300 m Ω. The recommended melting point for the main power supply is 3x32 A slow melting; If the drive box is not equipped, we recommend 3x16A slow melting. The operating environment temperature ranges from+5 ° C to+45 ° C, and the storage and transportation temperature ranges from -25 ° C to+40 ° C. When without a battery, the storage and transportation temperature can be extended to -25 ° C to+70 ° C. The controller only supports KSS V8.3.20 and above versions. For on-site engineers, mastering LED diagnosis, fuse specifications, driver unit replacement, control PC maintenance, and safety interface inspection is the key to shortening downtime.

System architecture and key components

The core of KR C4 smallsize-2 is the driving unit, which integrates KUKA Power Pack Small Robot and KUKA Servo Pack Small Robot internally. The driving unit is responsible for generating intermediate circuit voltage, controlling the motor, controlling the brake, and checking the intermediate circuit voltage in braking mode. 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. Control PC can be equipped with D3236-K or D3445-K motherboard. D3236-K provides 7 fieldbus slots, LAN Onboard interface, USB 2.0/3.0, DVI-I; D3445-K provides fieldbus slots, LAN Onboard, USB, DVI-D, Display Port, and more. VGA can be achieved through an adapter, but external displays are only available when not connected to a smartPAD or virtual remote teaching pendant.

CCU_SR stands for Small Robot Cabinet Control Unit, which is the central power distribution and communication interface composed of CIB_SR and PMB. It is responsible for safety input/output, contactor activation, 4 floating outputs, 9 safety inputs, smartPAD insertion recognition, mastering testing, 6 rapid measurement inputs, external fan monitoring, power fan monitoring, and temperature detection inside the control cabinet. Connect the driver unit, RDC, and digital I/O module through the KUKA controller bus; Connect the operation panel interface, diagnostic LED, and EDS interface through the KUKA system bus. The power supply with battery backup includes a drive unit, an external fan smartPAD、 Multi core control PC, RDC; The power supply without battery backup includes motor brake and customer interface. The low-voltage power supply supplies power to the control cabinet components, and the green LED indicates the working status. The battery maintains controlled shutdown in the event of power failure and undergoes regular charging and load testing.

In terms of bus system, KCB includes driver units, RDC, CIB_SR, and EMD; KSB includes CIB_SR, SION, smartPAD, and extended SIB; Please refer to the optional interface document for KEB devices. The cooling system adopts a dual circuit design: the inner area is cooled by a controlled PC fan, while the outer area is directly cooled by an external fan for the ballast resistor, low-voltage power supply, and drive unit heat sink. The customer option space is located on the right side of the control cabinet, with a top cap guide rail structure that can accommodate bus modules, etc. It has a maximum power consumption of 20 W, a depth of approximately 200 mm, a width of 250 mm, and a height of 150 mm. The optional transient limiter consists of a base module and a plug-in protection module to suppress surge voltage.

Safety regulations and power-off operation

Before maintenance or replacement of KR C4 smallsize-2, five safety rules must be followed: power off, prevent accidental restart, confirm that the system is out of power, ground short circuit, and cover or isolate adjacent live parts. Wait for at least 5 minutes after power failure to allow the intermediate circuit to discharge. KPP_SR, KSP_SR, intermediate circuit cables, motor connections, and motor cables in the drive unit may still carry a voltage of 50 V to 330 V, and it must be confirmed that there is no power before operation. Wear protective gloves during operation, avoid contact with high-temperature radiators, and comply with ESD regulations. The main switch of the control cabinet cannot isolate the incoming power supply. The cable connecting power supply X1 to the main switch is always live and must be disconnected from the upper power supply. If power on operation is required, it can only be carried out in T1 mode and additional protection measures should be taken. The safety functions include operation mode selection, operator safety, emergency stop devices, enabling devices, external safety stops, and T1 speed monitoring, in compliance with EN ISO 13849-1 Category 3 and Performance Level d. The emergency stop device must be pressed at least once every 12 months.