KUKA KR15 DELTA-2 V2 Robot Installation and Debugging

It should be emphasized that when the upper arm is not connected to the forearm or the spring component is not installed, the A1, A2, and A3 upper arms may have a tendency to sag due to gravity. Operators should always hold or support their upper arms to avoid sudden drops that may cause pinch injuries or collisions. After completing the horizontal adjustment, maintain the posture and prepare to dock with the installation board.

Install the robotic arm onto the mounting plate

When installing the robotic arm onto the rack mounting plate, first clean the bottom surface of the hexagonal mounting plate. If there are impurities on the bottom surface of the installation board, it will cause uneven force on the robot base, affecting accuracy. Then use a crane to lift the robotic arm near the frame and insert the three positioning pins into the interface board. The function of the positioning pin is to pre position and ensure that the robot base is aligned with the mounting plate hole. After inserting the positioning pin, use 12 M8x30-10.9 hex screws to fix the robotic arm to the frame with a tightening torque of 31 Nm.

When tightening screws, a diagonal cross sequence should be used, gradually increasing the torque step by step to avoid deformation of the base caused by excessive tightening on one side. During the installation process, it is necessary to support the A4 moving platform to avoid the weight of the moving platform hanging on the connecting cables. The A4 platform is usually connected to the upper arm through forearm and spring components. If it is suspended and subjected to force, it may cause internal cable damage, ball head wear, or spring deformation. After installation, check if the base and mounting plate are in good fit and if there are any gaps.

Installation of forearm, spring components, and moving platform

The forearm and spring components are important components of the parallel robot motion chain. Install the spring component onto the casting first during installation. Then install the first forearm and connect it to the upper arm and the motion platform, paying attention that the orange mark on the forearm should be close to the upper arm. Then install the second forearm, also bringing the orange mark closer to the upper arm. The ball head D20 must be coordinated with the upper arm and the moving platform to ensure a good fit of the ball head.

When installing the moving platform, install the spring component on the casting of the moving platform, with the spring opening facing upwards. Do not fully stretch the spring to avoid exceeding its elastic range. Connect the two forearms to the moving platform in the order of A1, A2, and A3 axes, and ensure that the direction of the cable outlet conforms to the diagram. The opening direction of the spring at different positions must be strictly followed according to the markings. Some views indicate that the spring opening is facing downwards, while others require it to be facing upwards. Reversing the installation can cause abnormal force, abnormal noise, or even breakage of the spring.

After installation, visually inspect whether the ball head snugly fits the upper arm and A4 platform. If gaps are found, do not forcefully tighten and contact KUKA support. The clearance between the ball heads can cause return errors, vibrations, and noise, affecting the accuracy and lifespan of the robot.

A4 cable and cable clamp layout

The A4 cable must be installed on the A1 arm. Customers can adjust the direction of the base board according to the working environment to avoid wiring interference, but must not change the basic path on the A1 arm. When installing the upper arm cable clamp, place the cable clamp at the white marked line on the A1 upper arm and fix it with 4 M4x50 screws with a torque of 1.2 Nm. Then align the white mark of the A4 cable with cable clamp ① and fix it with 2 M4x50 screws with a torque of 1.2 Nm. Ensure that the cable is parallel to the upper arm before installing cable clamp ②. The installation direction of cable clamps must avoid friction between cables and other structures.

When installing the forearm cable clamp, align the white cable with the white marking line ① on the A1 forearm, and fix the forearm cable clamp with 2 M4x60 screws with a torque of 1.2 Nm. Ensure that the cable is parallel to the forearm, and then install cable clamps ② and ③ in sequence. The direction of the cable clamp is also based on the principle of avoiding friction. If the direction is incorrect, the cable of the robot may interfere with the forearm, spring or protective plate during high-speed movement, causing insulation damage, signal interruption or even short circuit.

User wiring must not bundle, cross, or interfere with A4 cables. It is recommended to bundle the user cable onto other axes and reserve sufficient length for moving parts. The A4 cable is crucial for communication and power supply on the mobile platform, and any additional pulling may shorten its lifespan. After completing the wiring, the robot should be manually moved at a slow speed to observe whether the cable moves smoothly, whether there are scratches or excessive bends.