KUKA iiwa Robot Safety Operation and Maintenance

The standard length of the connecting cable is 4 meters, with options of 1 meter, 3 meters, 7 meters, and 15 meters. The maximum length should not exceed 15 meters. When laying, the bending radius of the data cable should not be less than 45 mm, and mechanical stress and joint pulling should be prevented. It can only be installed indoors, with a temperature range of 263 K (-10 ° C) to 343 K (+70 ° C). If necessary, it should be laid in metal pipes and additional electromagnetic compatibility (EMC) measures should be taken.

Safety Function System and Stop Reaction

The safety functions of LBR iiwa are divided into two categories: safety oriented functions for personnel protection (meeting EN ISO 13849-1 category 3, performance level PL d, and SIL 2 of EN 62061) and non safety oriented functions for machine protection.

The permanently defined security features include:

Emergency stop device (equipped with an emergency stop button on smartPAD as standard, Sunrise. OS 2.4 can be configured with external emergency stop as local emergency stop input)

Enabling device (3 three-stage enabling switches on smartPAD: not pressed/neutral/fully pressed dead position)

Operator safety signal (monitoring physical protective devices such as safety doors)

External emergency stop, external safety stop 1 (path keeping type), external enabling device, external safety operation stop

Typical stop reaction logic:

Trigger condition T1/T2/CRR mode AUT mode

Enable switch release safety stop 1 (path hold) -

Press the enable switch to the bottom (panic position) for safe stop 1 (path maintenance) -

Press local emergency stop safety stop 1 (path hold) safety stop 1 (path hold)

Safety controller malfunction, safety stop 1, safety stop 1

Safety door open (operator safety) - Safety stop 1 (path maintenance)

It should be noted that the 250 mm/s deceleration in T1 mode does not belong to the safety level deceleration in the standard safety configuration. If the application requires safety level speed monitoring, Cartesian speed monitoring must be configured through the KUKA Sunrise. SafeOperation option. In addition, the soft limit switch is only for machine protection and does not have safety oriented properties.

Stop distance data and hazardous area design

The stopping distance is the core data for planning hazardous areas (hazardous area=workspace+stopping distance). The document provides the measured reference values for STOP 0 (Class 0 stop) according to Appendix B of DIN EN ISO 10218-1, under the conditions of elongation l=100%, program multiplier POV=100%, and maximum load:

LBR iiwa 7 R800 STOP 0：

Axis stop angle (°) Stop time (s)

A1 5.193 0.182

A2 5.092 0.212

A3 8.091 0.166

A4 7.538 0.114

LBR iiwa 14 R820 STOP 0：

Axis stop angle (°) Stop time (s)

A1 5.742 0.188

A2 5.998 0.200

A3 9.323 0.198

A4 3.162 0.092

Three engineering points that must be kept in mind: firstly, data is based on single axis motion, and overlapping axis motion may result in longer stopping distances; Secondly, these average values obtained from experiments and simulations should be re measured under real working conditions in practical applications (which can be triggered by safety monitoring to stop and analyzed using a Data Recorder for trajectory data); Thirdly, brake wear is related to operating mode, application, and the number of STOP 0 triggers. It is recommended to check the stopping distance at least once a year.

Dangerous areas must be protected by physical protective devices (gratings, light curtains, safety fences, etc.) that meet EN ISO 14120 standards; If there is no physical protection, the EN ISO 10218 cooperative operation requirements must be met, and there must be no cutting or squeezing danger points in the loading and unloading area.

Key points for transportation, start-up, and daily operation and maintenance

Transportation specifications: Under the transportation packaging method, the transportation positions are A1=0 °, A2=25 °, A3=0 °, A4=90 °, A5/A6/A7=0 °, and the outer dimensions of the packaging are 1180 × 780 × 560 mm. Under the transportation box method (optional), all axes are zeroed, and the box size is 1450 × 480 × 340 mm. The lifting points are located between A2 and A3 and between A4 and A5. Before transportation, the tools must be removed and the connecting cables must be unplugged. After delivery, transportation fasteners such as nails or screws must be removed first.

Pre startup functional testing checklist:

All emergency stop device function tests (after pressing, the teaching pendant must display an emergency stop message without any error prompts)

All enable switch function test (release triggers stop)

Enable switch panic function test (press to the bottom to trigger stop)

SmartPAD Key Switch Function Test

Security oriented output shutdown capability test

Brake Testing - When conducting a risk-free assessment, default requirements can be followed: brake testing should be performed on each axis during start-up and re commissioning, and daily execution during operation

Maintenance and troubleshooting: The robot does not require planned maintenance when used for its intended purpose. Only solvent-free and water-soluble cleaning agents can be used for cleaning, and steam, refrigerant, and high-pressure cleaning equipment are strictly prohibited. The standard process when a malfunction occurs is: turn off and lock the controller (such as adding a padlock) → hang a warning sign → record the fault → troubleshoot and perform a functional test. Attention during maintenance: After the controller is powered off, some components may still have voltage exceeding 60 V for several minutes, during which operation is strictly prohibited; Replacement parts must use new parts with the same order number or equivalent parts approved by KUKA.