Assembly instructions for KUKA KR AGILUS-3 small six axis robot

Assembly manual for KR AGILUS-3 small six axis robot, including four models: KR   4   R500-3, KR   4   R600-3, KR   7   R700-3, KR   7   R900-3; The supporting controller is KR C5 micro; Support installation at any angle (± 180 °) for ground, wall, and ceiling. Robots belong to the semi-finished products defined by the EU Machinery Directive and must be integrated into a complete CE compliance system before they can be put into production.

Product Description

​System composition

Robot arm body, KR C5 micro control cabinet, smartPAD-2 teaching pendant, motor/data cable, software, various optional accessories.

Robot arm body

Cast light alloy 6-axis articulated arm with brake on each axis; All motors and cables are covered with internal protection.

Core components: Inline Wrist built-in wrist A4-A5-A6, boom, link arm, rotating column A1, base frame, built-in electrical components (micro RDC, motor cables).

Optional configurations: A1 axis limit, brake release device, various energy supply kits CTR-AIR/AIR-CTR-GIG, special length cables, connector adapter kit.

Designated use and prohibition of misuse

Purpose: To transport tooling fixtures, parts processing and transportation, strictly following environmental conditions and maintenance cycles.

Prohibited: carrying people and climbing scaffolds; Hyperparameter operation; Lack of safety equipment; Outdoor, explosion-proof, and radioactive environments; Unauthorized drilling and modification of the main body will result in the loss of warranty.

Safety

Legal responsibility: Robots are semi-finished products; The system integrator shall undertake the risk assessment of the entire machine, issue an EC conformity declaration, and affix the CE mark; KUKA provides assembly declaration; Unauthorized modifications result in loss of compensation, and the responsibility for third-party component damage belongs to the integrator.

Personnel classification: system integrator, operator, debugging and maintenance personnel, cleaning personnel; All personnel must read the complete safety chapter.

Area Definition

Workplace: Robot’s reachable range of motion;

Dangerous area=workspace+stopping distance (including external axis), must be physically fenced for protection.

The body comes with built-in protection: mechanical hard limit; Optional adjustable mechanical shaft limit; Brake release device (optional, emergency rescue only); The warning nameplate of the entire machine must not be torn off or altered.

After hitting the mechanical hard limit, it is prohibited to continue operating and KUKA evaluation must be contacted.

Key safety points for all working conditions

General: Personnel are prohibited from standing under their arms; After power failure, the arm will fall and must be mechanically supported; Motor high-temperature burn prevention; Pacemaker personnel are at least 300mm away from the motor; dedicated personnel are responsible for controlling the teaching pendant; Modify the program hardware to prioritize T1 mode testing; Fault power outage, locking and tagging; After the control cabinet is powered off, there may be a high voltage of 780V inside, and it needs to wait for discharge.

Transportation: It is necessary to maintain the transportation posture and avoid impact and vibration.

Start debugging: Change default password when powered on; The robotic arm controller must be paired and cannot be mixed; Complete safety circuit testing; Prevent condensation.

Manual mode: T1 is used for teaching demonstration; T2 is only for high-speed testing and programming is prohibited.

Automatic mode: All protective measures must be in good condition, and only when there are no personnel in the danger zone can it be operated.

Maintenance and repair: power off, lock, and verify electricity; ESD anti-static; Refer to MSDS for hazardous chemicals.

Shutdown, storage, and disposal: comply with local regulations.

Technical Data

Tilt installation (wall mounted/ceiling mounted) must be entered with WorkVisual for installation tilt angle. Parameter errors can overload and damage the robot; The load mass and moment of inertia must be verified simultaneously, using the KUKA Load tool for verification, and the load parameters must be entered into the controller; Provide load curve diagrams for each model; Provide axial force, radial force, overturning moment, and torque for flange operation/emergency stop conditions; Provide three posture base loads: ground/wall mounted/suspended, and the base design must take the maximum value; Each model comes with a 2D drawing of the working envelope; The nameplate is prohibited from being torn off or altered; REACH SVHC information access KUKA Xpert.

Summary of Core Parameters for Aircraft Models

Model Rated load Maximum load Maximum arm span Self weight Repeat positioning accuracy ISO9283 Protection level

KR 4 R500‑3 4 kg 5.4 kg 500 mm 21 kg ±0.015 mm IP54

KR 4 R600‑3 4 kg 5.2 kg 600 mm 23 kg ±0.015 mm IP54

KR 7 R700‑3 7 kg 10.2 kg 703 mm 29 kg ±0.02 mm IP67

KR 7 R900‑3 7 kg 8.8 kg 902 mm 31 kg ±0.02 mm IP67

Environmental conditions: Operating at 0~45 ℃; Storage -25~+60 ℃; Avoid condensation; Support ESD anti-static IEC 61340-5-1.

Cable: optional 1-25 meters, with a maximum of 1 splicing allowed; Clear bending radius for motor cables and data cables; Requirements for equipotential grounding.

Axis motion range

KR4 series: A1 ± 170 °; A2‑195~+40°；A3‑115~+150°；A4 ±185°； A5 ±120°； A6 ±350°

KR7 series: A1 ± 185 °; A2‑190~+40°；A3‑115~+160°；A4 ±200°； A5 ±120°； A6 ±350°

Additional loads: limited additional loads are allowed for the rotating column, connecting rod arm, and boom, while additional loads are not allowed for the base frame; Provide drawings of installation holes for additional loads on the arm.

Stop distance and stop time: STOP 0 category cuts off the drive and locks the brake; STOP1 category path controlled deceleration shutdown; Provide test data and curve graphs for different arm extension ratios (33%/66%/100%) and POV program magnifications; The brake will wear out with the number of STOP0s, and it is required to measure the stopping distance on site every year.

Project Planning

Planning reminder: Long term operating temperature/power limits, high-frequency reciprocating, static loading, and external process forces will accelerate component wear and require shortened maintenance cycles; The over limit robot automatically shuts down.

Two installation options: installation on a concrete floor with a fixed base; Installation of steel structure frame (positioning pin+bolt); The steel structure/concrete base must withstand all maximum foundation loads.

Cable and Interface Planning: Definition of Base A1 Interface; CTR-AIR, AIR-CTR-GIG energy supply system; Cable laying cannot withstand tensile force, EMC electromagnetic compatibility; Equipotential grounding is necessary.

Transportation

Forced transport posture: Each model specifies the axis angle, and the robot must maintain the transport posture throughout the entire process when it is not fastened to the base.

Lifting operations are prohibited from rough impact; Provide the overall dimensions for transportation of the entire machine.

Startup and Re Debugging

Provide a complete description of the installation process for ground, wall, and ceiling robots:

Concrete foundation: The bottom plate positioning pin is in place, the robot lifts and lowers it, levels it, and diagonally locks the bolts step by step; After the first 100 hours of operation, tighten the anchor bolts again.

Steel structure frame: assembly of positioning pins, locking bolts for positioning.

Wiring operation: Complete connector definition for KR C5 micro controller motor cables and data cables; Complete equipotential conduction verification.

Tilt installation key point: WorkVisual software enters the installation tilt angle.

Non actuated mobile manipulator: brake release device, limited to emergency rescue only; ⚠️ The arm will fall in an unpowered state, and the arm must be mechanically supported before operation.

Maintenance

The maintenance cycle is based on standard operating conditions; Heavy duty high-frequency working conditions must shorten maintenance cycles.

Maintenance Summary Table: Tighten the foundation bolts for the first 100 hours; Regularly apply RB2 grease to the interior of A1/A2/A3/A5 cover plates; A3 and A5 synchronous belt replacement and tension adjustment; Robot body cleaning.

A3 synchronous belt replacement: mechanical locking arm body; Dismantle the cover plate, replace the belt, measure and adjust the tension using vibration frequency method; Reinstall the cover plate, perform axis zero calibration, and perform functional testing.

A5 synchronous belt replacement process; Tension measurement adjustment, zero point calibration.

Cleaning: Do not use high-pressure water guns or steam cleaning. Use solvent-free and non corrosive cleaning agents to prevent liquids from seeping into the gaps.

Maintenance

MEMD tool zero calibration process (KR7 model); Use ontology to mark the emergency zero calibration process.

Disassembly of other components such as joints, motors, and gearboxes is not covered in this manual and must be done by contacting KUKA service.

Shutdown, Storage, and Disposal

Shutdown and disassembly: move to the transport position; power failure; Remove all cable grounding wires; Lift the lifting device off the main body; All electrical connectors are protected against dust.

Long term storage: maintain transportation posture; Dry and dust-free environment without condensation; All interfaces are sealed and protected.

Scrap disposal: Metal recycling of cast aluminum steel; Classify motors and circuit boards as electrical waste; Lubricating grease, seals, and various consumables should be treated as hazardous chemicals; Follow local environmental regulations.

Options

CTR-AIR, AIR-CTR-GIG connector adapter kit;

Special length optional connection cable.