KUKA 4-axis heavy-duty SCARA horizontal multi joint robot KR 60 R1200 Z400 CS

Product Description

Composition of Robot System

Robot arm body+KR CS Box-2 control cabinet+smartPAD touch teaching pendant+motor cable, encoder data cable+system software+optional accessories.

Main mechanical structure (4-axis SCARA)

A1/A2 horizontal rotary joint; A3 ball spline Z-axis lifting shaft; A4 end rotation axis.

Main components: connecting rod arm, main arm, ball spline, base frame; Reserve auxiliary load installation brackets on the arm, allowing for the installation of pipeline accessories.

Electrical system: protection circuit, cables for each axis motor, I/O interface, Ethernet interface, 3-channel pneumatic interface AIR1-AIR3; Base A1 interface board, upper arm A2 interface board, upper arm equipped with A3/A4 brake release button.

Designated use and prohibition of misuse

Designated use: Tool/fixture handling, workpiece processing and transportation, must strictly comply with environmental parameters.   

Prohibition: Carrying people and animals, climbing pedals; Outdoor, explosion-proof, radioactive, underground mining; Drilling/modifying the body without KUKA’s permission directly results in the loss of warranty.

The main body belongs to partially completed machinery and cannot be put into operation independently. It must be integrated into the entire set of equipment.

Security Chapter

Legal responsibility: Declaration of incorporation attached to the entity; The whole machine risk assessment, EC conformity declaration, CE marking, and terminal operation manual all belong to the system integrator; All risks associated with unauthorized modification of the main body shall be borne by the user.

Personnel classification: system integrator, operator, debugging, maintenance, cleaning personnel; The deep disassembly and repair of the main body is only for authorized personnel of KUKA.

Area Definition

Workplace: Robot’s reachable range of motion;

Dangerous area=workspace+parking distance, must be physically protected by fencing/grating; Without physical protection, all conditions of EN   ISO   10218 collaborative robots must be fully implemented.

protective device

A1/A2 configuration with mechanical hard limit; After hitting the hard limit, it is necessary to contact KUKA and prohibit further operation;

Brake release: A3/A4 can be manually released through the body button; A1/A2 can only release the brake in software Servo Free mode;

Nameplates and warning labels are strictly prohibited from being removed or altered.

Core Security Points

After power outage, there is a risk of brake failure and falling. Before maintenance, it should be placed in a safe position and necessary mechanical support should be provided; Personnel are prohibited from staying under their arms.

The high temperature of the motor operating casing poses a risk of burns; Electric motors and brakes generate electromagnetic fields; Personnel wearing active implantable devices such as pacemakers should maintain a distance of ≥ 300mm, and both power on and power off will be effective.

After the teaching pendant is disconnected, its emergency stop fails, and the disconnected teaching pendant must be moved out of the working area; Enable the switch function to be tested at least once every 12 months.

After modifying hardware, software, and parameters, all programs must undergo low-speed testing in T1 mode; The simulation generation program is also T1 tested.

Fault handling: Power off, lock and tag, post fault warning labels; Complete the fault repair and perform a full set of safety function verification.

Live parts operation: If only pressing the emergency stop button is insufficient, the main power switch must be disconnected and the power must be checked to confirm that the power is cut off; After the controller is powered off, the internal high-voltage capacitor still maintains high voltage for several minutes.

Technical Data (KR   60   R1200   Z400   CS)

Basic Parameters

Project KR   60   R1200   Z400   CS

Number of axes: 4 axes

Rated load 20   kg

Maximum load of 60 kg

The maximum additional load on the arm is 6 kg

Maximum horizontal arm span 1200   mm

Z-direction travel 400   mm

A4 infinite rotation ± 360 °

Protection level IP20

Operating at an ambient temperature of 0-45 ℃; Storage -25~+55 ℃

Controller KR CS Box-2

The maximum moment of inertia Iz of the flange is 2.45 kg · m ²; Rated 1   kg · m ²

Load verification: The load mass and moment of inertia must be verified simultaneously and entered into KUKA. ControlStudio software; The manual provides a load curve diagram, with the load center of gravity based on the A4 flange end face.

Flange load: Distinguish between axial force, radial force, overturning torque, and rotational torque under normal operating conditions and emergency stop impact conditions.

Base installation load: including the self weight of the body and the load, the base design must take the maximum value.

Shutdown distance and downtime: STOP0 and STOP1 provide A1-A3 axis data tables; The manual values are for reference only, and the actual shutdown distance must be measured on the project site under actual working conditions.

REACH Article 33 Compliance Statement.

Project Planning

Base planning: Users can design their own steel base; The thickness of the base plate is ≥ 30   mm, the flatness of the installation surface is ≤ 0.4   mm, and the maximum allowable inclination is 5 °; Provide a complete base installation hole diagram.

Cables and interfaces

X30 motor cable, X31 encoder data cable; Optional cables 3   m/5   m/10   m; WEIPU connector.

Minimum bending radius for fixed installation: motor cables ≥ 55   mm; data cables ≥ 45   mm; motor and data cables are wired separately in metal cable trays to meet EMC requirements.

Base A1 interface: X40 I/O, X74 Ethernet; Pneumatic interface AIR1-AIR3, maximum air pressure 0.7 MPa; Upper arm A2 interface: X41 I/O, X94 Ethernet, brake release button.

Reserved M4/M6 threaded bracket on the arm for installing user pipelines; It is prohibited to directly bind cables to corrugated pipes, and high flexibility shielded cables must be used.

Accelerated wear condition prompt: Long term temperature limit, dust corrosion environment, continuous full load, monotonic reciprocating motion, external process force, need to shorten maintenance cycle, necessary consultation with KUKA.

Transportation

Transport posture: It is necessary to enter the transport posture before packaging.

Handling method: Original packaging box forklift handling; Or install lifting rings on the base and hoist the main body with a crane; The length of the suspension rope is greater than 1500mm.

Dismantle tools and tie cables before lifting; Personnel are strictly prohibited from standing under the robot throughout the entire process; Avoid shock and vibration.

Startup and Debugging (Ground Installation Process)

User base leveling, tilt ≤ 5 °; Pre installed positioning pin; The crane vertically lowers the robot body.

Tighten the M12/M14 fixing bolts of the base diagonally according to the specified torque.

Wiring: equipotential grounding, motor cables, encoder cables; Complete the equipotential continuity test.

Manual axis movement: A1/A2 releases the brake through the software Servo Free; A3/A4 manually move using the release button of the body brake; ⚠ There is a risk of falling when releasing brake A3, and the load must be manually lifted.

Complete checklist before power on: mechanical fasteners and cables are not pulled or worn; Change the factory default password; Test run all programs in T1 mode.

Maintenance (a large number of on-site executable maintenance items; emergency stop before maintenance+power-off locking and tagging)

Bolts with a strength of 10.9 or higher must be replaced after loosening and must not be reused.

Maintenance cycle maintenance project consumables

Recheck the tightening torque of the base bolts after 100 hours of initial operation

Add lubricating grease THK AFB-LF to the upper and lower limits of the 1500 inch ball spline

Replace A3 synchronous toothed belt within 4000 hours or at the latest 1 year; Replace A4 synchronous toothed belt; Cable assembly lubrication Optitemp RB2

Clean the body, cut off power and stop wiping urgently. Do not use high-pressure water guns or steam cleaning

A3/A4 synchronous toothed belt replacement: Use a frequency meter TSM alpha-2 to measure the vibration frequency and adjust the belt tension; After replacing the toothed belt, zero point calibration Mastering must be performed.

No on-site replacement of EDS memory battery chapter; A1 and A2 gearboxes complete oil change, oil discharge – oil injection operation process; After replacing the gear oil, zero calibration is required.

Maintenance

Two schemes for zero point calibration Mastering: ① dedicated calibration fixture; ② Manual calibration of A1-A4 without tooling.

The deep disassembly and maintenance of the main body is only allowed to be carried out by authorized personnel of the warehouse card; The component replacement is completed, and a full set of safety tests and zero calibration are performed.

Chapter 10: Discontinuation, Storage, and Scrap Disposal

Deactivation: Adjust to transport posture; Dismantling tools; Power off and unplug the cable; Disassembly of the main body.

Storage: Dry and dust-free, avoiding condensation; Seal electrical connectors.

Scrap: The motor and RDC circuit board are treated as electronic waste, and it is prohibited to disassemble the motor gearbox by oneself; Classification of industrial waste for mechanical parts; The appendix lists all grades of sealant, gear oil, and lubricating grease materials.