KUKA KR C4 Smallsize-2 Debugging Guide

The cooling system is divided into two circuits. The inner area contains control and power electronics, cooled by a control PC fan; The outer area includes braking resistors, low-voltage power supplies, and drive unit heat sinks, which are directly cooled by ambient air introduced by an external fan. Do not install filter cotton in front of the ventilation opening, otherwise the temperature rise will shorten the service life of the equipment. During installation, it is necessary to maintain the minimum spacing and ensure that the maintenance channel can open the cabinet door.

Security Chain: Engineering Logic for X11, X13, X66 and STOP 0/1/2

The safety controller of smallsize-2 is located inside the control PC and is responsible for switching drivers, applying brakes, monitoring brake slopes, monitoring stillness, T1 speed monitoring, evaluating safety signals, and setting safety outputs. The safety functions include operation mode selection, operation safety, emergency stop device, enable device, external safety operation stop, external safety stop 1, external safety stop 2, and T1 speed monitoring. Installing flanges at a speed exceeding 250 mm/s under T1 will trigger a safety stop of 0.

Safe stop is divided into STOP 0, STOP 1, and STOP 2. STOP 0: The safety controller immediately cuts off the driving and braking power supply; STOP 1 is executed by the non safety part for braking, monitored by the safety controller, and the power supply for driving and braking is cut off after the robot stops; After STOP 2 braking, the driver remains activated, the brake is released, and it switches to safe operation stop monitoring. Understanding the differences between these three is crucial for determining "why cannot be reset" and "why drive enable is lost".

There are various safety interfaces: X11 parallel safety interface, X13 parallel safety Safe Robot, X66 Ethernet safety interface PROFIsafe/CIP Safety, X55/X67.1/X67.2 Ethernet safety interface FSoE. X11 is internally connected to CCU_SR. The X11 pins include CIB_SR test output A/B, safety operation stop channel A/B, safety stop 2 channel A/B, external E-STOP channel A/B, confirm operation safety channel A/B, operation safety channel A/B, Peri enabled output, and confirm operation safety output. The secure input adopts a dual channel design and cyclically detects the shutdown capability. The test output TA_S and TA_S are alternately turned off, with a turn off pulse length of about 625 μ s, a single channel turn off period of about 106 ms, and a two channel offset of about 53 ms. The input channel SIN_X_A must be powered by TA_S, and SIN_X_B must be powered by TA_S, and other power sources must not be used. Only sensors that can access test signals and provide floating contacts are allowed to be connected.

The external enable switch can be connected through X11. External enable 1 requires pressing when jogging under T1/T2, input to close; External Enable 2 requires the switch to not be in the panic position and the input to be closed. If connected to smartPAD, its enable switch performs AND logic with external enable. When external enable 1 is not connected, channel A's 11/12 and channel B's 29/30 must be short circuited; When external enable 2 is not connected, channel A's 13/14 and channel B's 31/32 must be short circuited.

Operation safety signals are used to monitor physical protections such as safety doors. Without this signal, it cannot operate in automatic mode; Opening the safety door during operation will trigger safety stop 1. When restoring, the safety gate must be closed and the dual channel confirmation button must be pressed outside the fence. This confirmation function is not activated by default and needs to be set in the security configuration. Automatic closure of safety doors cannot replace manual confirmation.

X20, X19, X21, and USS2: Wiring errors are more dangerous than parameter errors

The motor is connected through X20. X20 uses Harting Han Jellock monoblock size 30, with pin definitions including U1, V1, W1 from M1 to M6, 24V and GND for brake shafts 1 to 3, 24V and GND for brake shafts 4 to 6, and PE. Motor cables must be laid separately from data cables to avoid interference. The fixed installation bending radius is 3 to 5 times the cable diameter, and the drag chain installation is 7 to 10 times.

SmartPAD is connected via X19 and uses the Intercontinental series 615. X19 includes TD+, TD -, RD+, RD -, smartPAD insertion recognition, 24V PS2, and GND. If smartPAD is disconnected, the E-STOP on it is no longer valid, so the system must have at least one external E-STOP.

RDC is connected via X21 using Harting HAN3A/Q12. X21 provides+24 V, GND with battery backup,+24 V without battery backup, TD+, TD -, RD+, RD -. For the X21 US2 RDC interface, the US1 with battery backup is used to power the RDC, and the US2 voltage is switchable through safety technology. USS 2 is used to cut off actuators through Beckhoff plates or other means when the drive is disabled. There are three variants of US2: external PLC switching, KRC switching, and deactivation. If US1 and US2 are short circuited due to cross connection of system cables, they will not be detected during normal operation, and the result is that US2 cannot be turned off, which may cause a dangerous state. Therefore, US1 and US2 must be wired separately or reinforced with insulated cables.