KUKA KR CYBERTECH CR (KR   20   R1810-CR) Clean Room (CR) Version 6-Axis Industrial Robot

KR 20 R1810-CR is a Clean Room (CR) version 6-axis industrial robot that is compatible with KR   C4/KR   C5   S controllers. It supports installation at any angle from the ground, wall, or ceiling and meets ISO   14644-1 cleanroom standards. The manual includes a complete set of product introduction, safety, technical parameters, project planning, transportation, installation and commissioning, maintenance, repair, decommissioning, storage and scrapping, options, and appendices for the assembly of the main body.

Product Description

Robot system composition: robotic arm body, controller, connecting cables, teaching pendant, software, tools, and options.

Mechanical arm body structure: 6-axis series articulated robot, consisting of straight wrist inline wrist, linkage arm, rotating column, base frame, and a complete set of electrical wiring.

A1-A3 is equipped with mechanical terminal hard blocks, which are only used for equipment protection; Personnel protection relies on the SafeRobot safety function of the controller or optional mechanical axis limit.

Straight wrist: A4-A6 integrated into the wrist; The rear A1 interface of the base integrates RDC units, and all motor and signal cables use quick plug connectors.

CR cleanroom version features: a large number of stainless steel fasteners, anti precipitation surface treatment, reducing particle generation, and meeting cleanroom requirements.

Permitted use and prohibited misuse

Permission: Handling, assembly, workpiece handling, and clean room operations must comply with environmental conditions and maintenance cycles.

Prohibited: climbing, carrying people and animals, outdoor activities, explosion-proof areas, radioactive activities, and underground operations; Unauthorized use results in loss of warranty.

Robots belong to partially completed machinery and cannot be put into operation alone; After completing the entire set of equipment, the system integrator shall issue an EC conformity declaration and affix the CE mark.

Available options: brake release device, fork groove transport component, lifting sling, A1-A3 mechanical shaft limit, pipeline package.

Technical Data (KR   20   R1810-CR)

Basic parameters of the ontology

Project KR   20   R1810-CR

6 axes fully controlled

Rated load of 20 kg; maximum load of 23.9 kg

Maximum reach distance 1813mm

Repetitive positioning accuracy ISO 9283 ± 0.04 mm

The self weight of the body is about 250 kg

Protection level: IP65 for the main body; Wrist IP67

Noise<75 dB (A)

Installation method: Ground/Wall mounted/Ceiling, with any inclination angle of ± 180 °

Cleanliness level ISO 14644-1:4 (40% procedural magnification); Level 5 (80% program magnification)

Operating at an ambient temperature of 5-45 ℃; Storage -20~60 ℃

Axis motion parameters

Motion range: A1 ± 185 °; A2‑185°~+65°； A3‑138°~+175°； A4/A6 ±350°； A5 ±130°

Rated load maximum shaft speed: A1   200 °/s; A2   175 °/s; A3   190 °/s; A4   430 °/s; A5   430 °/s; A6   630 °/s

Zero Mastering calibration position; Tilt installation will limit the range of motion of the A1 axis, and the actual installation tilt angle must be filled in the WorkVisual software, otherwise overload or accidental motion may damage the robot.

Load parameters: wrist flange ZH8/12/16/20 (ISO 9409-1); Load center of gravity, moment of inertia, load curve diagram; Distinguish between normal operation and emergency stop conditions, flange bearing axial force, radial force, overturning moment, and torsional moment; Additional loads are allowed to be added to the boom, connecting rod arm, and rotating column, and installation hole drawings for each part are provided.

Base load: Provide vertical force, horizontal force, overturning moment, and A1 torque transmitted by the robot to the base for ground, ceiling, and wall mounted working conditions respectively; The structural verification must take the maximum value of the emergency stop condition to prevent overturning and falling.

Cable parameters: compatible with two sets of KR C4 and KR C5 S cables; The standard length of motor cables and data cables is 4-50 meters; the maximum total length is 50 meters, and a maximum of one extension is allowed; Independent protective grounding; Provide the pin diagram for the A1 base interface.

Stop distance and stop time: distinguish between STOP0 (cutting off the brake) and STOP1 safe stop; Provide stop angle and stop time charts for A1-A3 based on different arm extension ratios (33%/66%/100%), program magnification POV, and different loads; The brake has wear and tear, it is recommended to conduct an annual on-site review of the actual stopping distance.

Please refer to KUKA Xpert for information on the location of the body nameplate and REACH regulations.

Planning and Design

Accelerated wear conditions: long-term temperature limit operation, abrasive dust environment, sustained performance limit, single axis high duty cycle, monotonic reciprocating short stroke, wrist long-term static, external process force; If the above working conditions occur, KUKA must be consulted to shorten the maintenance cycle; The robot has built-in overheating and overload monitoring, and automatically shuts down when exceeding the limit.

Two installation base schemes

Centering option base S310: concrete floor; Concrete grade C20/25; Bottom plate, chemical anchor bolt, positioning pin; Basic section drawings prohibit adding sound insulation leveling layers between the base and concrete.

Rack mounted installation: installed on the customer’s steel structure and KUKA linear slide table; 4 M20 bolts+2 locating pins; Strict requirements are placed on the flatness, roughness, and structural stiffness of the installation surface.

Cable planning: The minimum static bending radius for motor cables is 150   mm, and for signal cables it is 60   mm. Power cables and signal cables are laid separately in metal cable trays to achieve EMC electromagnetic compatibility; Double protection grounding; Cable layout eliminates tripping risks; Cables are prohibited from withstanding tensile forces.

A1 Base Interface Definition: Motor X30/XD30, Data X31/XF31, Mastering Calibration Interface, External Shaft Interface Drawing.

Transportation

Forced transportation posture (maintain throughout the transportation process, do not change the posture before fixing to the base to prevent tipping)

A1=0°，A2=‑138°，A3=139°，A4=0°，A5=90°，A6=0°

Shipping Method

Forklift: Optional fork slots need to be installed;

Crane: Use KUKA specialized lifting equipment and M10 lifting rings, with lifting points distributed around rotating columns and bases;

Prohibit lifting from non-standard lifting points; Avoid impact and vibration; Remove the lifting ring/hoist after it is in place; Provide the overall dimensions and center of gravity position for the transportation of the entire machine.

Startup Debugging and Restarting

The complete process of covering the installation of fixed base flooring, rack mounted flooring/wall mounted/suspended ceiling.

Prerequisite: The robot is in a transport position, the base steel structure is completed, and the lifting equipment is in place.

General installation steps:

Lift into place and install the positioning pin;

M20 bolts are tightened diagonally in multiple stages to the specified torque;

Connect dual protection grounding (torque 23 Nm);

Connect motor cables and data cables; The sound of a click on the connector indicates locking, and the lock buckle can rotate 90 degrees to prevent accidental unlocking;

Fill in the actual installation posture and inclination angle of the robot using WorkVisual software;

Install tools, power on, jog in T1 mode, perform axis Mastering zero calibration, and perform overall functional testing.

After 100 hours of operation, all anchor bolt torques must be rechecked.

Provide a complete schematic diagram of the wiring of KR C4 and KR C5 S motor cables, data cables, and grounding cable pins.

Maintenance

Only allow maintenance projects recorded in the manual to be executed; The remaining repairs will be entrusted to KUKA authorized personnel; Emergency stop, lock and power off before maintenance; The maintenance cycle needs to be shortened when the operating oil temperature exceeds 60 ℃; Maintaining in a clean room environment can compromise the cleanliness level.

Maintenance cycle summary table

Periodic homework content consumables

After being put into operation, only one 100 hour recheck of the torque of all bolts on the base will be conducted

5000 hours visual inspection of A1 flexible pipeline package for damage –

10000   h A1 cable package coated with lubricating grease PETAMO GHY   133   N

20000 hours or at the latest 5 years, A1-A6 axis gradual flowering key inspection and fat supplementation; Change all gearbox oil Cassida Fluid GL150 gear oil; Microlube GL261 grease; Drei Bond 5204HV sealant

Suggest KUKA to conduct a comprehensive on-site inspection of the entire machine after 7 years or changes in operating conditions.

Key maintenance process

A1 cable package lubrication: Remove the base cover plate, visually inspect the corrugated tube, apply lubricating grease with a brush, restore the cover plate, and jog A1 to evenly distribute the grease.

Gradual flowering key inspection and lubrication of each axis motor (A1-A6)

Before disassembling the motor, the corresponding shaft must be mechanically locked with a sling fixture to prevent the arm from falling;

Remove the motor, clean the gradually blooming key, and check for wear and tear; Damage must be replaced; Thin and continuous application of Microlube GL261;

Apply Drei Bond 5204HV to the O-ring/sealing surface; tighten the bolts diagonally in steps; Connect the plug back; The axis must undergo Mastering zero calibration.

The disassembly of A6 motor is complex, requiring the removal of A4 and A5 motors first, followed by the removal of the entire straight arm before the A6 motor can be removed.

General rules for gearbox oil change: The gearbox is at operating temperature; Measure the actual amount of oil released during oil discharge; If the oil release rate is less than 70% of the rated value, the gearbox needs to be flushed; Rinse twice with less than 50%, and move the entire stroke during rinsing; Magnetic plug inspection for metal debris; Tighten the plug according to the specified torque; Oil change completed T1 mode jog operation, check for leaks.

Initial oil filling amount for each gearbox: A1=1.20   L; A2=0.80   L; A3=0.32   L; A4=0.32   L; A5/A6=0.37   L.

Robot cleaning: Prohibit high-pressure water guns and direct blowing of compressed air on bearing seals; Use water-soluble neutral cleaning agents; Power off operation to prevent liquid from entering the electrical chamber.

Maintenance

Manual description: A1-A6 motor replacement, straight row wrist assembly replacement, A4/A5 transmission shaft replacement;

General safety for motor replacement: power off, lock the main switch, wait for 5 minutes for high voltage discharge; Before disassembling the motor, the corresponding shaft must be mechanically locked to prevent the arm from accidentally falling;

Motor installation: Check that the gradual flowering key is not damaged and apply Microlube GL261 evenly; The O-ring seal must be replaced if it is damaged; Tighten the bolts diagonally in steps; After installation, the axis must undergo Mastering zero calibration and T1 mode trial operation.

Special difficulties:

Dismantling of A2/A3 motors, fixing the connecting rod arm/boom with a sling to prevent self weight from falling;

A6 motor: The A4 and A5 motors must be removed first, and the entire straight arm must be dismantled before the A6 motor can be removed;

Replacement of straight row wrist assembly: It is necessary to remove the A4/A5/A6 motors and the lifting device supporting the wrist (about 23 kg) in sequence, and disassemble and replace the entire set.

Overview of Electrical Wiring; Repairs must use KUKA original spare parts; Complete verification of all safety functions after maintenance is completed.

Suspension, Storage, and Disposal

Shutdown disassembly: The robot moves to the designated transport posture; Install lifting rings and slings; Disconnect all cables; Lift the crane off the main body.

Storage: Maintain transportation posture, clean the robot, provide rust prevention protection, and meet temperature and humidity storage conditions.

Scrap disposal: Lubricating oil, electronic components, and metal structures should be classified and disposed of according to local environmental regulations.

Options

Release device: manually move the robotic arm in power-off state; Provide a complete explanation of the installation process and safety constraints for a non actuated mobile robotic arm.

Forklift transport components, lifting equipment, A1-A3 mechanical shaft limit, pipeline package.