KUKA LBR iiwa CR Operations and Troubleshooting

External enabling device: used when multiple people are needed in a hazardous area. Can connect multiple external enabling devices. When manually guided, the robot can only move at a reduced speed, with a pre configured maximum allowable speed of 250 mm/s.

External safety operation stop: used for stationary monitoring, does not stop movement, only monitors whether the axis is stationary.

The permanently defined stop triggers include: switching modes during operation, releasing the enable switch, fully pressing the enable switch, pressing the local emergency stop, and safety controller error, all of which trigger safety stop 1. User specific triggers may include opening of safety doors, pressing of external emergency stop, external safety stop, etc.

T1 is the manual speed reduction mode, with a speed not exceeding 250 mm/s; T2 is in manual high-speed mode, allowing for speeds exceeding 250 mm/s. Automatic mode must be used when all safety equipment and protective devices are complete, there is no one in the system, or when EN ISO 10218 cooperation requirements are met. If the robotic arm stops without reason, it must not directly enter the danger zone and must first trigger an emergency stop.

Braking testing is an important maintenance project. Unless the risk assessment proves that mechanical brake failure will not result in unacceptable risks, brake tests should be performed on each axis during start-up and re commissioning, and daily during daily operation. Check the stopping distance and stopping time at least once a year. The stopping distance will be affected by braking torque, wear, load, speed, extension distance, etc. In practical applications, it should be measured under real conditions.

Installation, transportation, and electrical connections

Before transportation, the robot must be in the transport position: A1 0 °, A2+25 °, A3 0 °, A4+90 °, A5 0 °, A6 0 °, A7 0 °. The outer dimensions of the transport packaging are approximately 1180 mm in length, 780 mm in width, and 595 mm in height. During handling, it can only be lifted between A2 and A3, A4 and A5. Authorized handling equipment with sufficient load-bearing capacity must be used to avoid vibration and impact.

Installation adopts rack installation with positioning method. The preparation work includes: machining positioning pin holes, threaded holes, and exhaust holes on the base. LBR iiwa 7 R800 CR uses M8 thread, LBR iiwa 14 R820 CR uses M10 thread. When installing, first drive the positioning pin into the hole, lower the LBR CR base ring vertically, then insert the positioning pin, and then lower the robot vertically onto the base ring. It must be kept completely vertical to prevent damage to the positioning pin.

Tighten with 4 hexagon socket bolts and washers: 7 R800 is M8 × 65-8.8, 14 R820 is M10 × 70-8.8. Tighten gradually in diagonal order to the specified torque. After running for 100 hours, it needs to be re tightened. Torque reference: 7 R800 is about 23 Nm, 14 R820 is about 45 Nm. The control box is installed near the robot controller with 4 M4 × 8-8.8 hex bolts and must be located outside the robot workspace.

The electrical connections include: WX55 connected to controller X55, WX65 connected to controller X65, WXE1 connected to LBR iiwa CR base ring. When the bending radius of the connecting cable is fixed and laid, the data cable should not be less than 45 mm; avoid mechanical stress and tensile force; Indoor installation only; Fixed installation temperature range -10 ℃ to+70 ℃; Suggest using metal cable trays and taking EMC measures if necessary. Cable layout should prevent tripping risks.

The exhaust duct is not within the scope of supply and will be installed by the customer. It is necessary to ensure that the specified airflow is not restricted, and it is recommended to connect an active exhaust system. After installation, the control box must be closed and the exhaust outlet must be connected to the exhaust duct.

Fan monitoring and WorkVisual integration

Cleanroom compliance relies on the fan running at 2200 rpm. If the fan speed decreases by 25% or more, the cleanroom level cannot be guaranteed. Therefore, it is necessary to write periodic background tasks to monitor the fan speed in parallel during the operation of the robot application. If it deviates from the specified range, the program must trigger the corresponding response.

Integrating a fan controller in WorkVisual: Start FHIR figuration-wvs, close the project, and import the device description file. Need to import Bus terminal EL6695（KRC4 primary EL6695-1001）、Fan controller EM8905-1002 I/O module、Beckhoff bus coupler EK1100 EtherCAT coupler。 Then add the expansion bus SYS-X44, EK1100, EL6695, and EM8905-1002 to the controller bus structure. Next, create a fan controller I/O group in I/O Mapping, which includes three signals: fan start, speed signal evaluation, and fault evaluation. Map Out7.Output to fan start and In1.Input to speed evaluation. Save the project and export the I/O mapping to Sunrise Workbench if necessary.

Sunrise backend task parameters can refer to: delay of 20 seconds, cycle of 10 ms, speed calculation (pulses * 60)/4, minimum fan speed of 2200 rpm. The example logic is to create process data during initialization, start the fan, wait for about 5 seconds, create an edge observer to count pulses, and initialize the cycle task. Read the minimum speed during periodic operation, calculate the actual speed, reset the counter, and update the smartPAD display; If the actual speed is less than or equal to the minimum limit, output a signal to the PLC or upper system that the fan is not running, such as setting fanIO and run to false; Otherwise, set it to true. This logic can help engineers quickly detect fan aging, blockage, abnormal power supply, or obstructed exhaust.