KUKA Robots KR CYBERTECH With F variant Assembly Instructions

KR CYBERTECH series body assembly guide, covering models: KR 8 R2010, KR 12 R1810, KR 16 R1610, KR 16 R2010, KR 20 R1810, KR 20 R1810 F (Foundry casting version), KR 22 R1610; Compatible with KR C4, KR C5 S controllers; Support installation at any angle for ground, wall, and ceiling. Includes product introduction, safety, complete set of model technical parameters, project planning, transportation, installation and commissioning, maintenance, repair, decommissioning, storage and scrapping, options, appendix, complete set of body information.

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, assembly: straight wrist inline wrist, linkage arm, rotating column, base frame, complete set of electrical wiring.

A1-A3 is equipped with mechanical terminal hard blocks, which are only used for equipment protection and cannot protect personnel; Personnel protection relies on the SafeRobot safety function of the controller or the optional A1-A3 adjustable mechanical shaft limit.

Straight wrist: A4-A6 integrated wrist; A6 motor is arranged inside the boom; A4/A5 rely on the drive shaft for transmission; The wrist flange follows ISO 9409-1:2004.

The rear of the base is a Combo junction box, which integrates RDC units; All motors and signal cables use quick plug connectors; Use circular wire ear screws to secure the grounding.

Unique features of KR   20   R1810-F cast version: The robot arm supports PURGE positive pressure blowing (0.1 bar) inside, requiring clean and dry compressed air; The wrist can withstand high temperatures for a short period of 180 ℃; Special casting resistant coating/coolant coating for the entire machine.

Permitted use and prohibited misuse

✅ Allow: handling, assembly, and workpiece handling; F casting plate is used for casting dust and coolant working conditions; It is necessary to 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 will result in the loss of warranty.

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

Available options: Release device for brake release, fork slot transport component, lifting sling, A1-A3 mechanical shaft limit, pipeline package; Version F adds PURGE-A/PURGE-B blowing kits.

Technical Data (Independent Parameters of 7 Models)

7 models independently provide basic parameters, axis parameters, load parameters, base load, and stopping distance time; Includes work envelope diagram, inclined installation A1 axis motion limit curve, load curve diagram, flange drawing.

Model rated load, maximum load, maximum weight, repeated positioning accuracy, installation method

KR   8   R2010 8   kg 9.7   kg 2013   mm 255   kg ± 0.04   mm Any tilt angle

KR   12   R1810 12   kg 14.5   kg 1813   mm 250   kg ± 0.04   mm Any tilt angle

KR   16   R1610 16   kg 20   kg 1612   mm 245   kg ± 0.04   mm Any tilt angle

KR   16   R2010 16   kg 19.2   kg 2013   mm 255   kg ± 0.04   mm Any tilt angle

KR   20   R1810 20   kg 23.9   kg 1813   mm 250   kg ± 0.04   mm Any tilt angle

KR   20   R1810-F 20   kg 23.9   kg 1813   mm 250   kg ± 0.04   mm at any inclination angle, cast with positive pressure blowing

KR   22   R1610 22   kg -1610   mm – ± 0.04   mm at any inclination angle

Axis parameters: Range of motion for each axis of each model, maximum axis speed, Mastering zero 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 chapter: Wrist flange ZH   8/12/16/20 (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; Provide installation hole drawings for the large arm, connecting rod arm, and rotating column that allow additional loads.

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

Cable parameters: distinguish between KR-C4 and KR-C5-S sets of cables; Motor cables and data cables can be selected in lengths of 4-50 meters; the maximum total length is 50 meters, and a maximum of one extension is allowed; Specify the minimum bending radius; It is necessary to independently protect the grounding; Definition of A1 base interface pins.

Stop distance and stop time: distinguish between STOP0 (cutting off the brake) and STOP1 safe stop; For all models, provide A1-A3 stop angle and stop time charts 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.

Refer to KUKA Xpert for nameplate labels and REACH regulatory information.

Planning and Design

Reminder for accelerated wear conditions: long-term temperature limit operation, corrosive dust environment, continuous performance limit, single axis high duty cycle, monotonic reciprocating short stroke, wrist long-term static, external process force; If the above working conditions occur, it is necessary to consult KUKA 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

Base with centering option: concrete ground foundation; Concrete grade C20/25; Including base plate, chemical anchor bolt, positioning pin; Provide basic cross-sectional drawings and prohibit adding soundproof leveling layers between the base and concrete.

Rack mounted installation: installed on the customer’s steel structure and KUKA linear slide table; M20 bolt+2 positioning pins; There are strict drawing requirements for 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 ensure 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; F version has an additional PURGE blowing air source interface.

Transportation

Each model is required to have an exclusive mandatory transportation posture, which must be maintained throughout the transportation process. It is prohibited to change the posture before fixing it to the base to prevent tipping.

Transportation method: Supports forklift fork slots (optional) and crane lifting rings for hoisting; Hanging point location drawing; Avoid impact and vibration during transportation; Remove the lifting ring/fork groove after it is in place.

Description of overall dimensions and center of gravity position for transportation of the entire machine.

Chapter 7 Startup Debugging and Restarting

The complete process of covering the installation of fixed base flooring, rack mounted flooring/wall mounted/suspended ceiling, and KR   20   R1810-F has added special points for the installation of casting plates.

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;

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; Distinguish between KR-C4 and KR-C5-S wiring;

Fill in the actual installation posture and inclination angle of the robot using WorkVisual software; F version is equipped with compressed air for blowing and adjusting the blowing pressure;

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.

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 is above 60 ℃.

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; Replace all gearboxes with Optigear Synt. ALR   150 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; The gearbox must be flushed if the oil release rate is less than 70% of the rated value; 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.

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.

Additional maintenance for casting F version: Regularly check PURGE blow pressure and filter status.

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/A5 motor 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, the lifting device supporting the wrist, and the entire set for disassembly and replacement.

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: manual movement of 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.

PURGE-A, PURGE-B (KR20-F casting version only): Internal positive pressure blowing system to prevent casting dust and coolant from entering the interior of the arm body; Compressed air parameters, debugging, and maintenance.

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