KUKA LBR iiwa CR Operations and Troubleshooting

KUKA LBR iiwa CR Operations and Troubleshooting

Model positioning and system composition

KUKA LBR iiwa CR is a seven axis lightweight articulated robot designed for cleanroom environments. CR stands for Clean Room, emphasizing its ability to control particulate matter pollution. This model is suitable for handling tools, fixtures, workpieces, or products, but the operating environment must be a clean room contaminated with monitored particles and meet the specified environmental conditions. It is not a universal outdoor robot and is not allowed to be used in potential explosive environments, medical or food technology, manned and animal carrying, climbing assistance, and other scenarios.

A complete LBR iiwa CR system typically includes: robotic arm, KUKA Sunrise Cabinet robot controller, KUKA smartPAD handheld control panel, connecting cables, control box, LBR CR base ring kit, software, options, and accessories. The mechanical arm body is a seven axis redundant structure, and all drive units and current carrying cables are arranged inside the robot. Each axis is equipped with position, torque, and temperature sensors for position control, impedance control, and protection functions. If the axis range, axis load, or electronic component temperature exceeds the allowable value, the system will trigger protection and automatically shut down; After cooling, it can usually be restarted without additional measures.

The LBR CR base ring is located below axis 1 and below the shielding plate. The base ring integrates a fan, which is used to extract particles from the shell and then discharge them through the clean room exhaust duct. The control box is responsible for controlling the operation of the fan and reading the speed measurement signal. If the exhaust duct is not connected, the rotating fan will be exposed, posing a risk of injury. Therefore, LBR iiwa CR must not operate without connecting the exhaust duct.

Quick search of main technical data

There are two main specifications for LBR iiwa CR: LBR iiwa 7 R800 CR and LBR iiwa 14 R820 CR.

Project LBR iiwa 7 R800 CR LBR iiwa 14 R820 CR

Number of axes/number of control axes 7/7 7/7

The work envelope volume is about 1.7 m ³ and about 1.8 m ³

Position repeatability accuracy ISO 9283 ± 0.1 mm ± 0.15 mm

Weight approximately 26.1 kg, approximately 32.7 kg

Rated load 7 kg 14 kg

Maximum arm span 800 mm 820 mm

Protection level IP54; Base IP20 IP54; Base IP20

Installation location: Ground level

Controller KUKA Sunrise Cabinet KUKA Sunrise Cabinet

Cleanroom Class ISO 14644-1 Class 3, 80% override, with exhaust system as on the left

Operating at an ambient temperature of 5-45 ℃; Storage/Transportation: 0-45 ℃ Same as Left

Fan power supply 24 VDC, approximately 0.3 A, minimum 2200 rpm, same as left

Control box fuse 2 A 2 A

In terms of axial motion range, A1 is ± 170 °, A2 is ± 120 °, A3 is ± 170 °, A4 is ± 120 °, A5 is ± 170 °, A6 is ± 120 °, and A7 is ± 175 °. The speed varies with the rated load, for example, A1/A2 of 7 R800 is about 98 °/s, A3 is about 100 °/s, A4 is about 130 °/s, A5 is about 140 °/s, A6/A7 is about 180 °/s. A1/A2 of 14 R820 is about 85 °/s, A3 is about 100 °/s.

Special attention should be paid: The LBR CR base ring kit will raise the robot position by 35 mm in the positive Z direction. When using the "Robot Base Coordinate System" and "World Coordinate System", this height increase will not be automatically incorporated. When displaying the actual position of Descartes or using a "world" base, a deviation of+35 mm must be considered.

Safety function and stop reaction

The safety function of LBR iiwa CR is oriented towards personnel protection and meets the requirements of EN ISO 13849-1 Category 3, Performance Level d, and EN 62061 SIL 2. But the prerequisite is that all safety related machinery and electromechanical components undergo functional testing at start-up and at least once every 12 months, unless otherwise specified in the risk assessment. The test objects include local emergency stop, enabling devices, manual guidance enabling devices, external enabling devices, key switches, and safety outputs of discrete safety interfaces on smartPAD.

Common security features include:

Local emergency stop: The standard configuration is an emergency stop on smartPAD. After pressing, the robotic arm stops with a safe stop 1 (path maintenance). Reset before continuing.

Enabling device: There are three enabling switches on the smartPAD, namely, not pressed, middle, and fully pressed (panic position). In T1, T2, and CRR modes, movement is only possible by maintaining the middle position. Release or full press both trigger safety stop 1.

Operation safety signal: used to monitor physical protection such as safety doors. By default, T2 and automatic modes cannot operate without this signal. Trigger safety stop 1 when signal loss occurs.

External emergency stop: Every operating station that may cause robot movement or danger must be equipped. By connecting through a secure interface, security stop 1 is triggered by default.

External security stop 1: Triggered through a security interface input, the signal remains stopped when it is false, and can be moved again when it is true without confirmation.