KUKA LBR iiwa CR Cleanroom Troubleshooting and Maintenance

Fan monitoring backend task parameters: Delay of 20 seconds, cycle of 10 ms, speed calculated as "pulse count x 60/4", minimum speed of 2200 rpm. The programming logic is: start the fan during initialization, wait for about 5 seconds, and create an edge observer to count pulses; Calculate the speed per second in the loop, and if it is below the minimum limit, output a signal to the PLC indicating that the fan is not running; Otherwise, output a normal signal. This allows for parallel monitoring of fans while the robot executes applications.

In terms of exhaust interface, a 120mm diameter exhaust hole is required in the center of the LBR CR base ring, and the customer needs to install the exhaust duct themselves. The exhaust duct is not within the scope of supply and must be provided by the customer. If the fan is not connected to the exhaust duct and the rotating fan is exposed, there is a risk of injury. Therefore, LBR iiwa CR must not operate without connecting the exhaust duct. In order to remove particulate matter from the clean room, it is necessary to ensure that the specified airflow is not restricted. It is recommended to connect an active exhaust system to the fan interface.

Installation and transportation: positioning pin, torque and foundation load

The installation adopts a machine frame with centering. LBR iiwa 7 R800 CR uses 4 M8x65-8.8 hex socket screws, and LBR iiwa 14 R820 CR uses 4 M10x70-8.8 hex socket screws. The positioning pin is 6x12, divided into cylindrical pin and flat head pin. Installation sequence: First, drive the positioning pin into the prefabricated hole, lower the LBR CR base ring vertically, insert the positioning pin, then lower the robot vertically onto the base ring, and finally cross tighten the 4 screws. After running for 100 hours, it must be tightened again: 7 R800 CR is 23 Nm, 14 R820 CR is 45 Nm.

The basic load must be designed according to the maximum load. 7 R800 CR: vertical force of 545 N, horizontal force of 240 N, overturning moment of 318 Nm, and torque around A1 of 156 Nm. 14 R820 CR: vertical force of 568 N, horizontal force of 228.4 N, overturning moment of 290 Nm, and torque around A1 of 172.6 Nm. These values include the load and the robot's own weight, and the foundation must be able to safely withstand them. The control box is fixed with 4 M4x8-8.8 screws and must be located outside the robot workspace.

Before transportation, the robot must be placed in the transportation position: A1 0 °, A2+25 °, A3 0 °, A4+90 °, A5 0 °, A6 0 °, A7 0 °. The outer dimensions of the transportation packaging are 1180 mm × 780 mm × 595 mm. When lifting, the force should be applied between A2/A3 and A4/A5, and inappropriate lifting equipment is prohibited. Avoid vibration and impact during transportation, tools must be removed, and connecting cables must be unplugged.

Safety functions and stop categories

The safety functions of LBR iiwa CR are divided into safety oriented functions and non safety oriented functions. The safety oriented function meets EN ISO 13849-1 category 3, performance level d, and EN 62061 SIL 2. The premise is that all safety related machinery and electromechanical components are tested at start-up and at least once every 12 months, unless otherwise specified in the workplace risk assessment. These components include: local emergency stop on the teaching pendant, teaching pendant enable device, manual guidance enable device (if any), external enable device (if any), smartPAD key switch (if used as a teaching pendant), and safety output of discrete safety interface.

The standard safety functions include emergency stop devices and enable devices. The functions that are pre configured and can be integrated into the system security interface include: operator safety signals (used to monitor physical protection such as safety doors), external emergency stop, and external safety stop 1 (path maintenance). External enablement, external safety operation stop, axis specific workspace monitoring, Cartesian workspace monitoring, speed monitoring, stationary monitoring, axis torque monitoring, collision detection, etc. can also be configured.

Stop category: STOP 0 means the driver immediately loses power, the brake is applied, and the robot brakes in the direction of the path. STOP 1 is the path holding brake, and after about 1 second, the power is cut off and the brake is applied. Emergency stop triggers safety stop 1 (path maintenance). Enable switch in three positions: not pressed, middle, fully pressed. Only the middle position can move. Release or fully press to trigger safety stop 1. The operator safety signal is required by default in T2 and automatic mode, and T1 and CRR are not evaluated; Loss of signal triggers safety stop 1. Restoring automatic mode cannot rely solely on closing the door, it must be reset by an additional confirmation button to prevent automatic recovery when personnel are still in the danger zone.

External security stop 1 is triggered through the security interface input. When the signal is False, it remains stopped, and when it is True, it can be moved again without confirmation. External enablement is used for multiple people entering hazardous areas, with a pre configured maximum speed of 250 mm/s for manual guidance. The specific value needs to be determined through risk assessment. External safety operation stop is static monitoring, without stopping the movement, only monitoring whether the axis is stationary.