KUKA Sunrise Cabinet Next Generation Small Control Cabinet

KUKA Sunrise Cabinet Next Generation Small Control Cabinet

KUKA Sunrise Cabinet is a robot controller launched by KUKA for industrial applications, mainly used to operate KUKA axes, including industrial robots and mobile platforms. It adopts a 19 inch chassis structure, weighs about 23 kg, has a protection level of IP20, and an average noise of about 54 dB (A). The power supply is 110 V/230 V AC single-phase, with an allowable deviation of ± 10%, frequency of 50 Hz ± 1 Hz or 60 Hz ± 1 Hz, rated power of about 1 kVA, heat dissipation of about 370 W, and recommended 2x15 A slow melting protection on the power supply side. The control cabinet must be connected to a power system with a grounded neutral point. The operating environment temperature ranges from 5 ° C to 45 ° C, and the storage and transportation temperature ranges from -25 ° C to 40 ° C. Without a battery, the storage and transportation temperature can be extended to -25 ° C to 70 ° C. No derating is required below an altitude of 1000 meters, and a derating of 5%/1000 meters is required below 3000 meters. The controller can be installed in a 19 inch rack with a depth of at least 600 mm, and a 70 mm cooling air gap must be left on both sides to prevent deformation and overheating of the casing. For on-site engineers, mastering their architecture, safety interfaces, maintenance cycles, LED diagnostics, fuse specifications, and component replacement processes is key to reducing downtime.

System architecture and key components

The core of KUKA Sunrise Cabinet consists of a control PC, CCU_SR, low-voltage power supply, battery, main filter, fan, interface, and connection panel. The control PC is responsible for graphic interface, program creation and maintenance, sequence control, path planning, drive circuit control, monitoring, safety equipment, and external communication. The control PC can use D3076-K, D3236-K, or D3445-K motherboards. D3076-K provides fieldbus slots, USB 2.0, DVI-I, and LAN Onboard interfaces; D3236-K provides fieldbus slots, USB 3.0/2.0, DVI-I, and LAN Onboard; D3445-K provides fieldbus slots, USB, DVI-D, Display Port, and LAN Onboard. Control PCs are typically equipped with quad core processors, at least 2 GB of memory, and SSD hard drives.

CCU_SR stands for Small Robot Cabinet Control Unit, which is the central power distribution and communication interface composed of CIB_SR and PMB_SR. It is responsible for safety input and output, contactor activation, 3 floating outputs, 7 safety inputs, identification of teaching pendant insertion, monitoring of fan power supply, and temperature detection inside the control box. Connect the Power Drive System through the KUKA controller bus; Connect the KUKA operation panel interface, diagnostic LED, and EDS interface through the KUKA system bus. The power supply with battery backup includes smartPAD, control PC quad core processor, and Power Drive System; The power supply without battery backup includes motor brake and customer interface. The low-voltage power supply supplies power to the control cabinet components and provides 48 V DC for the mechanical arm drive, with two green LEDs indicating the working status. The battery maintains a controlled shutdown in case of power failure or shutdown, charges through CCU_SR, and checks the battery level.

In terms of interfaces, the standard configuration includes X11 security interface, X19 smartPAD interface, X65 expansion interface, X69 service interface, X650 media flange interface, X21 robotic arm interface, X66 KUKA Line Interface, K1 power connection, and PE connection. X65 is used to connect external EtherCAT slaves; X66 is used to connect external computers for installation, programming, debugging, and diagnosis; X69 is used for diagnosing, configuring, and updating service laptops through KSI; X650 is used to power the external media flange of LBR iiwa wrist. The cooling system is completed by two fans, with air entering from both sides and exiting from the rear. Do not install filter cotton upstream of the ventilation duct, otherwise it will cause temperature rise and shorten equipment life.

Security features and X11 interface

The safety guidance function of KUKA Sunrise Cabinet complies with EN ISO 13849-1 Category 3 and Performance Level d, as well as EN 62061 SIL 2. The safety oriented function is used to protect personnel and must be tested at least once a year, unless otherwise specified in the workplace risk assessment. The test objects include local emergency stop devices, teaching pendant enabling devices, manual guidance enabling devices, external enabling devices, smartPAD key switches, and safety guidance outputs of discrete safety interfaces. The non safety oriented function is used to protect the machine, including mode selection, T1 speed monitoring, and software limit switches. The speed monitoring limit in T1 mode is 250 mm/s, and 250 mm/s is also pre configured for manual guidance, but can be adjusted based on risk assessment. The software limit switch is only used for machine protection, and stops under servo control when the axis exceeds the limit.