KUKA KR AGILUS sixx series six axis industrial robot operation instructions

The original operation manual for KUKA KR AGILUS sixx series six axis industrial robots covers complete content such as product introduction, technical parameters, safety, planning, transportation, debugging, maintenance and repair, scrap disposal, and appendices. It is compatible with three installation forms: ground FLR, wall WLL, and suspended CLG (W represents wall mounted, C represents ceiling mounted).

uses

Target audience: personnel with advanced knowledge in mechanical, electrical, and electronic fields, familiar with robot controllers; KUKA suggests attending KUKA College training.

Designated use: for transporting tooling fixtures, processing/transporting component products, and can only be used under designated environmental conditions.

Prohibited misuse scenarios: operating as a climbing bracket; Exceeding operating parameters; Lack of safety equipment operation; Unauthorized drilling and modification of the robot’s body structure may result in loss of warranty; Deviation from the technical manual environmental conditions requires prior consultation with KUKA.

The system must be put into operation as part of the CE compliant complete system.

Product Description

Composition of Robot System

The entire robot system includes: robotic arm body, KR C4 compact controller, smartPAD teaching pendant, various connecting cables, software, and optional accessories. Robot Model List:

KR 6 R700 sixx /‑W /‑C

KR 6 R900 sixx /‑W /‑C

KR 10 R900 sixx /‑W /‑C

KR 10 R1100 sixx /‑W /‑C

Mechanical arm body structure

The robotic arm is a cast light alloy 6-axis articulated structure, with brakes installed on each axis; The motor and current carrying cables are all protected by cover plates to prevent dust and moisture. Main components: Built in hollow wrist A4-A5-A6, boom A3, connecting rod arm A2, rotating column A1, base frame, electrical components.

Built in wrist (Inline wrist): integrates 3 5/2-way solenoid valves, CAT5 data cable, wrist I/O circular connector, A4 energy supply interface for tool control.

Connecting rod arm A2: Install A2 motor reducer, lay energy supply pipeline and 2-6 axis cables.

Rotating column A1: Built in A1/A2 motor to achieve A1 rotation.

Base frame: Robot installation base, A1 interface, all controller connection cables are plugged in here.

Electrical system: 1-6 axis motor cables, internal energy supply, external axis A7/A8 interfaces, integrated RDC rotary digital converter, protection circuit, all connectors are pluggable.

Supporting options: A1 travel limit, brake release device, etc. Refer to separate documentation for options.

Technical data

KR 6 sixx basic parameters

Number of axes: 6 axes; Repetitive positioning accuracy ISO9283: ± 0.03mm

Self weight: R700 is about 50 kg; R900 is about 52 kg; base installation footprint is 320 mm × 320 mm

Protection level: Robot body and wrist IP54; Noise<70   dB (A)

Installation methods: ground, wall mounted, suspended ceiling; Controller model KR C4 compact

environmental conditions

Operation:+5~+45 ℃ (278-318   K), condensation is prohibited;

Storage and transportation: -40~+60 ℃;

Humidity ≤ 90%; Do not reduce power when the altitude is ≤ 1000 meters; For every 1000-4000m increase, the power decreases by 5%.

Cable: motor cable, data cable, standard 4   m; optional 1/7/15/25   m; optional CAT5, external shaft A7/A8 cable, equipotential grounding cable.

KR6 sixx axis motion parameters

Axis software limit speed under rated load

A1 ±170° 360°/s

A2 +45° ~‑190° 300°/s

A3 +156° ~‑120° 360°/s

A4 ±185° 381°/s

A5 ±120° 388°/s

A6 ±350° 615°/s

The manual comes with 2D side and top views of the working envelope for various models of ground/wall/ceiling postures, providing the maximum reach radius.

KR6 sixx load parameters

Rated load 3   kg, maximum load 6   kg; center of gravity Lxy=60   mm, Lz=80   mm; maximum total load 6   kg.

Flange specification: M5 x 7 screws, strength grade 12.9; Positioning pin 5   H7.

Tip: The load and moment of inertia must be checked simultaneously; It is necessary to input load data into the controller and use KUKA. Load to verify inertia. Overloading will shorten the lifespan. Attached is a load curve graph.

KR 6 sixx base foundation stress

Warning: When designing the base structure, the maximum load value must be used, and the normal load is only the average value. Vertical force Fv, horizontal force Fh, overturning moment Mk, torsional moment Mr, the table distinguishes between normal operation and maximum load; The calculation of base load does not include additional loads on the arm, which need to be added separately.

KR 10 sixx basic parameters

Repetitive positioning accuracy ± 0.03mm, IP54, supports ground, wall, and ceiling, controller KR C4 compact; Self weight R900 ≈ 52   kg, R1100 ≈ 55   kg.

The environmental conditions, cable selection, and KR6 sixx are completely consistent.

KR10 sixx axis motion parameters

Axis software limit speed under rated load

A1 ±170° 300°/s

A2 +45° ~‑190° 225°/s

A3 +156° ~‑120° 225°/s

A4 ±185° 381°/s

A5 ±120° 311°/s

A6 ±350° 492°/s

KR10 sixx load parameters

Rated load 5   kg, maximum load 10   kg; center of gravity Lxy=100   mm, Lz=80   mm; flange interface and KR sixx are the same; Attached is a 10kg load curve diagram.

KR10 sixx base under stress

Given the vertical force, horizontal force, overturning moment, and torsional moment, the base design must take the maximum load.

Supplementary load

Robot arms, linkage arms, rotating columns, and wrists can be equipped with accessory components (such as pipeline supports); The total mass of all added components must not exceed the maximum total load of the robot. The manual provides installation hole drawings for three types of arm extensions, R700, R900, and R1100, with mostly M4 threads.

Nameplate identification

Multiple signs are affixed to the robot, including axis safety warnings, transportation location signs, hazardous area warnings, and machine nameplates; The nameplate is not allowed to be painted or torn off; Blurriness must be replaced.

Stopping distance and stopping time (safety critical)

Stop category: STOP0 (category 0, power cut-off), STOP1 (category 1 controlled shutdown), in compliance with IEC60204-1, DIN EN ISO 10218-1 Appendix B.

Definition: The stopping distance is the angle at which the rear axle rotates after triggering a stop; The stop time ranges from the stop signal to complete stillness. When multiple axes move simultaneously, the stopping distance will increase.

The STOP0 value is a reference value for testing and simulation, and is affected by brake wear and operating conditions. It is recommended to conduct actual measurements for actual projects; Brake wear increases with the number of STOP0 cycles, it is recommended to review the stopping distance at least once a year.

The document provides a table and curve graph of the A1/A2/A3 axis stop angles and stop times for all models at I=33%/66%/100% extension length, different loads m, and different program magnifications POV.

Safety

Responsibility and Compliance: EC Declaration of Conformity, Assembly Declaration; Clarify the qualifications of the operators.

Concept of workspace, safety zone, and danger zone.

List of protective equipment: mechanical hard limit; Optional mechanical axis limit; Non actuated manual mobile manipulator mode; Main body warning signs.

Safety measures for various working conditions

General safety; Transportation safety; Start/re debug; Manual T1/T2 mode; Automatic mode; Maintenance and repair; Shutdown storage and disposal.

List the standards and regulations that this product complies with.

System Planning

Pre project planning information; Base design; Rack installation; Cable wiring; Definition of external interfaces on the customer side.

​Transportation

The operation process of mechanical arm handling must keep the robot in the transport position to prevent tipping.

Startup and Re Debugging

Step by step instructions for base installation; Rack assembly; Complete operation steps for ground installation, wall installation, and ceiling installation; Instructions for connecting cables; Operating a mobile robotic arm without driving energy.

Maintenance

Maintenance overview and maintenance schedule; Internal lubrication of A2/A3 cover plate; Synchronous belt replacement; Robot cleaning.

Repairs

Measurement and adjustment of synchronous belt tension.

Shutdown, Storage, and Disposal

Describe the shutdown steps for ground, wall mounted, and suspended ceiling models separately; Long term storage conditions; Requirements for the disposal of robot components.