KUKA KR C5 slim-2 Robot Controller

The secure interface is a key focus on site. The default allocation for XG11.1 is: safety output 1 is local emergency stop, safety input 1 is external emergency stop, safety input 2 is operational safety, and safety input 3 is not used. XG11.3 provides 5 secure inputs and 3 secure outputs, which can be freely configured. XG13.1 and XG13.2 are used for SafeRangeMonitoring, SafeOperation, and SafeSingleBrake, and need to be configured before use. XG58 is used for external enable switches and additional emergency stops, and can also be used as a reference switch. The secure input adopts a dual channel design with external testing and loop detection shutdown capability. The test outputs TA_S and TA_S are alternately turned off, with a turn off pulse length of 600 μ s, a single channel turn off period of less than 1 second, and a 50 ms offset between the two channels. The input channel N_A [x] must be powered by TA_S, and N_B [x] must be powered by TA_S, and no other power sources must be used. Only sensors that can access test signals and provide floating contacts are allowed to be connected.

Safe stop is divided into STOP 0, STOP 1, and STOP 2. Immediately cut off the drive and brake power supply for safety stop 0, KR C5 slim-2 uses STO signal, KR C5-2 uses SPO signal, and the brake power supply is cut off by SBC signal. Safety stop 1 is monitored by the safety controller, and the brake is applied and the drive is cut off no later than 2.3 seconds. In case of a fault, safety stop 0 is executed. Safe stop 2: Do not cut off the drive or apply the brake, maintain the braking slope deceleration along the path. The safety function complies with Category 3 and Performance Level d of EN ISO 13849-1, with a PFH value less than 1 × 10 ⁻⁷. The prerequisite is that safety related machinery and electromechanical components undergo functional testing at start-up and at least once every 12 months.

The operation modes include T1, T2, Automatic, and Automatic External. T1 is used for testing, programming, and teaching, with a maximum speed of 250 mm/s; T2 is used for high-speed testing and cannot be used for jogging; Automatic and Automatic External are used for program execution. The teaching pendant can be a smartPAD, smartPLUG with a tablet or laptop, or a laptop without a smartPLUG. When there is no smartPLUG, there is no emergency stop and enable device. The Motion enable external switch (non safety function) must be used, and an immediately accessible emergency stop must be configured near the laptop, with at least one additional emergency stop. The enable switch has three positions: not pressed, middle position, and fully pressed. Under T1/T2, only the middle position can move the axis; Release all intermediate position enable switches to trigger safety stop 1, and fully press one enable switch to trigger safety stop 1. Enable switches must not be fixed with tape and must undergo regular functional testing.

Installation, power on, and initial debugging

The KR C5 slim-2 must be installed in the sliding module of the KR C5 smallsizecab or compactcab. Before installation, it is necessary to confirm that there is no condensation or damage. Connect equipotential, motor cables, data cables, and power cables. The security interfaces XG11.1, XG11.3, and XG58 can only be plugged in and out when the controller is turned off, and live plugging may cause property damage. Power on sequence: Close the motor circuit breaker, close the cabinet door, release the emergency stop on the teaching pendant, and turn on the main switch. Control the PC startup sequence as recovery stick, external hard drive, internal hard drive; If an external hard drive is detected, the internal hard drive will be disabled; If no external hard drive is detected, it will not automatically switch to an internal hard drive. The robot controller can only operate together with the connected teaching pendant.

Functional testing must be performed: after all connected emergency stop devices are pressed, the user interface displays that the emergency stop has been triggered and does not display an error in the emergency stop device; After all enable switches are released in test mode, the robot stops without displaying any enable device errors; Press and hold the panic function of all enable switches for 3 seconds, and the robot will stop without any errors; Safety output shutdown capability test, after turning off and then turning on the controller, no safety output error is displayed. Braking test is used to check the braking torque of each axle, and whether it is executed and the frequency is determined by risk assessment. Security acceptance must be completed on a real system and cannot be replaced by simulation. The security configuration check must be performed after the security ID is changed, and all security configuration parameters must be checked, not just the modified parameters. Machine data inspection requires actual testing when there is an external axis, and the deviation must be less than 5%. In addition, the safety controller will automatically confirm connection errors on the safety input and output, and the output may switch from LOW to HIGH, causing peripheral devices to automatically restart, which must be prevented through appropriate measures.