KUKA KR18 R1450-3 PP Operation and Maintenance Essentials

Stop distance and safety integration

The stopping distance is equal to the reaction distance plus the braking distance, and is part of the danger zone. The data is for the main axes A1, A2, and A3, and the superposition of axis movements will lengthen the stopping distance. Stop category 0 for immediate drive shutdown and brake action; Stop category 1 is controlled to brake along the trajectory, and after a delay, drive to close and brake. The STOP 0 value is the average of experimental and simulation results, in accordance with DIN EN ISO 10218-1. It may vary due to internal and external influences on braking torque, and should be measured under actual on-site conditions if necessary. Brake wear depends on the operating mode, application, and STOP 0 times. It is recommended to check the stopping distance at least once a year. The robot speed must be selected by the integrator based on the application and space conditions, taking into account the stopping distance. The integrator/user is responsible for correctly determining the stopping distance. The measurement method provided in the document: activate the safety operation stop at the trigger point, if the robot moves, trigger STOP 0, record trace, brake off (WDI motor status bit 2) as the start time, and when the axis is completely stationary as the end time; The STOPMESS interrupt program can also be used for approximate measurement, with the stopping distance being the difference between the trigger point position and the rest position.

In terms of safety, this industrial robot belongs to partially complete machinery and must be integrated into a complete system in order to operate. The system integrator is responsible for installation, connection, risk assessment, implementation of safety functions and protective devices, issuance of EC conformity declaration, affixing CE mark, and production of system operation instructions. The control cabinet has a CE mark that complies with the EMC Directive and the Machinery Directive. The workspace should be limited to the necessary minimum range, and the danger zone includes the workspace and stopping distance, which must be physically isolated. Protective devices such as safety doors must be located outside the danger zone. If there is no physical protection, the EN ISO 10218 collaboration requirements must be met. Mechanical terminal stops limit the range of the main shaft and wrist axis, and external shafts can be equipped with terminal stops. After colliding with obstacles, terminal stops, or axle restrictions, the robotic arm may not be able to operate safely and must be stopped and consulted with KUKA. Some models can choose A1 to A3 mechanical axis restrictions to improve personnel and equipment safety; When not equipped, the workspace design must ensure that there is no danger, otherwise use gratings, light curtains, or mechanical limitations for isolation. The brake release device, release device, and direct manual movement of the wrist axis are options for moving the robotic arm without driving energy in emergency situations, but personnel must be trained. All nameplates, warnings, safety symbols, cable markings, and model nameplates shall not be modified or removed.

In terms of personnel, operators must undergo training to assess tasks and identify hazards. Users must comply with labor laws, fulfill their supervisory obligations, receive regular training, and provide personal protective equipment. The system integrator is responsible for security integration. Working mode: T1 manual deceleration ≤ 250 mm/s, used for jogging, teaching, programming, and program verification; T2 manual high speed>250 mm/s, only used for testing that requires higher than T1, teaching and programming are not allowed. Automatic mode requires all safety devices to be complete and effective, with no one in the system or meeting collaboration requirements, and following workflow. If the robotic arm or external shaft stops without reason, an emergency stop must be triggered before entering the danger zone. New or modified programs must be tested in T1 first. After modification, it is necessary to check the security level and test the security functions. Immediately shut down the control cabinet and lock it when there is a malfunction, record it with a tag, and perform functional testing after repair. Try to maintain and repair outside the danger zone as much as possible; Additional security measures must be defined upon entry. Turn off and hang the lock. If it is necessary to work while the control cabinet is connected, only T1 is allowed. The work label should be retained, the emergency stop should remain valid, and the safety function should be restored immediately after it is disabled. Before carrying out live work, turn off the main switch and verify the electricity, and do not only trigger emergency stop or safety stop. After the control cabinet is closed, some components can still carry a voltage of 50 V to 780 V for several minutes. Comply with ESD to prevent water and dust from entering the control cabinet. The balancing system may belong to pressure equipment and should comply with domestic regulations. The inspection cycle should not be less than the KUKA maintenance cycle. Avoid prolonged skin contact and inhalation of oil mist with hazardous substances, and regularly request safety data sheets.