KUKA KR IONTEC-2 Debugging and Maintenance Guide

KUKA KR IONTEC-2 Debugging and Maintenance Guide

KR IONTEC-2 Product Positioning and System Composition

KUKA KR IONTEC-2 is a series of six axis articulated industrial robots designed for medium load handling, processing, assembly, and material transfer scenarios. This product family covers KR 25 R3100-2、KR 50 R2100-2、KR 50 R2100-2 D01、KR 50 R2100-2 CR lite、KR 50 R2500-2、KR 50 R2500-2 D01、KR 50 R2500-2 F、KR 50 R2500-2 CR lite、KR 70 R2100-2、KR 70 R2100-2 D01、KR 70 R2100-2 F、KR 70 R2100-2 CR lite  Waiting for the model. Different suffixes represent different application orientations: D01 usually corresponds to a specific drive chain configuration, F is the casting environment enhanced protection version, CR lite is the cleanroom version, the F version has a protection level of up to IP65, and CR lite can meet ISO 14644-1 Class 5 cleanroom requirements.

A complete robot system not only includes a robotic arm, but also a robot controller, connecting cables, teaching pendant, system software, options, and accessories. Common controllers include KR C5 mid-2, KR C5 M6/M7, etc. The teaching pendant can be KUKA smartPAD-2, smartPAD pro, or used with a tablet or laptop paired with KUKA smartPLUG on KR C5-2 and KR C5 micro-2, or with a laptop solution without smartPLUG.

The mechanical arm body consists of a base, a rotating column, a connecting rod arm, an arm, an inline wrist, a cable group, etc. The A1 axis is rotated by a rotating column, the A2 axis drives the connecting rod arm, the A3 axis connects the arm, and the A4 to A6 form a three-axis inline wrist. Each axis is equipped with measuring devices, which can be used to complete mechanical zero calibration through electronic probes. The wrist flange is used to install end effectors, and the interface size is close to ISO 9409-1:2004. Install motor cables, data cables, grounding conductors, and energy supply system interfaces on the base.

Security logic and compliance prerequisites

KR IONTEC-2 belongs to partially completed machinery and must be integrated into a complete system and meet the EC Machinery Directive before it can be put into operation. The system integrator is required to complete risk assessment, implement safety functions, install safety protection devices, and issue a complete EC compliance statement for the system. The robot controller is marked with CE, but the robotic arm body must form a compliance system together with the controller, outer shaft, tools, and software.

The core concepts of the safety chapter include: axis range, stopping distance, workspace, danger zone, safety zone, stopping category, T1 manual slow speed, T2 manual high speed, external axis, system integrator, and user. The danger zone is determined by both the workspace and the stopping distance, where the stopping distance is equal to the reaction distance plus the braking distance. The safety protection device must be located outside the danger zone, but the robot stopping process may still be completed within the danger zone. Therefore, safety doors, gratings, scanners, etc. must be arranged according to the risk assessment results.

In terms of personnel requirements, operation, maintenance, and debugging personnel must undergo training and be able to identify tasks and potential hazards. Users should fulfill their supervisory obligations, conduct regular safety briefings, and provide personal protective equipment. The system integrator is responsible for installation, connection, risk assessment, implementation of safety functions, CE marking, and preparation of system operation manuals.

In manual mode, T1 is used for setup, teaching, programming, and program validation. New or modified programs must be tested under T1 first. If it is necessary to work within a safe zone, the operator should be able to observe the danger zone and evacuate at any time; When multiple people enter, each person must have an enabling device, and everyone must maintain visual and eye contact. T2 is only used for testing that requires speeds higher than T1, and teaching and programming are not allowed under T2. Automatic mode requires all safety devices to be available, no one in the danger zone, or to meet the EN ISO 10218 collaboration requirements.

When maintaining and repairing, priority should be given to working outside the danger zone. When entering the danger zone, the robot should be turned off and locked with a tag, and if necessary, it should be done under T1. The emergency stop device must remain effective. If the security function is temporarily cancelled, it must be restored immediately after the work is completed. After the robot controller is powered off, some components may still carry a voltage of 50V to 780V for several minutes, and must wait for discharge and comply with ESD regulations. For controllers with transformers, the transformer should be disconnected before operation. The counterweight system, gas spring, hydraulic accumulator, etc. also need to be inspected according to the pressure equipment regulations.

Quick search of key technical data

KR 25 R3100-2: Rated load 25 kg, maximum load 33 kg, maximum arm span 3100 mm, body weight approximately 510 kg, repeat positioning accuracy ± 0.05 mm, protection level IP54, wrist IP67, controller KR C5 mid-2. A1 has a motion range of ± 185 °, A2 is -175 °/+60 °, A3 is -110 °/+165 °, A4 ± 180 °, A5 ± 125 °, A6 ± 350 °. Speed under rated load: A1 180 °/s, A2 150 °/s, A3 180 °/s, A4 335 °/s, A5 420 °/s, A6 592 °/s.