KUKA KR 18 R1450-3 PP six axis ground mounted industrial robot

Product Description

Composition of the entire robot system

Robot arm body, KR C5 silm-2 M6/M7 control cabinet, smartPAD-2 teaching pendant, motor/data cable, system software, optional accessories. Unique model: KR   18   R1450-3 PP.

Structure of Robot Arm Body

6-axis cast light alloy articulated arm configuration, with brakes on each axis; All motors and cables are equipped with built-in cover plates for internal protection.

Main components: Inline Wrist built-in wrist (A4-A5-A6), arm, link arm, rotating column (A1), base frame;

Electrical system: micro RDC, protection circuit, 1-6 axis motor/data cable, base A1 interface (plug-in plug);

Available options: A1 axis limit, brake release device, Booster base frame kit, LLA assembly fixture.

Designated use and prohibition of misuse

Designated use: The handling of fixtures, parts processing, and transportation must comply with environmental conditions and maintenance requirements.

Prohibited behaviors: carrying people and animals, climbing scaffolds; Hyperparameter operation; Lack of safety equipment operation; Outdoor, explosion-proof, radioactive, and underground mining environments; Without the permission of KUKA, modifying the structure of the main body directly results in the loss of all warranty.

Safety

Legal and Liability: 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 an assembly declaration. Unauthorized modification of robots results in loss of the right to claim compensation; The responsibility for damage caused by third-party accessories belongs to the integrator.

Personnel classification: system integrators, operators, debugging and maintenance personnel, cleaning personnel; All personnel must read the safety chapter and possess the corresponding qualifications.

Area Definition

Workplace: Robot’s reachable range of motion;

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

Safe zone: outside the danger zone.

The body comes with built-in protection: mechanical hard limit; Optional adjustable mechanical shaft limit; Brake release device (optional for non actuated mobile robotic arm); Warning nameplate for the entire machine (no tearing or alteration allowed).

After the mechanical arm collides with the mechanical hard limit, it cannot continue to operate and must be evaluated by KUKA.

Safety measures for each working condition

General safety: Personnel are prohibited from standing under their arms; After a power outage, there is a risk of the robotic arm falling and it must be mechanically supported; High temperature anti scalding of motor casing; The distance between the pacemaker implantation personnel and the motor/brake is ≥ 300mm; the teaching pendant is controlled by a dedicated person; Hardware/program modifications must prioritize T1 mode testing; Fault power outage, locking and tagging. After the control cabinet is powered off, the maximum internal high voltage can reach 780V, and it needs to wait for discharge.

Transportation: The prescribed transportation posture must be used to avoid impact and vibration.

Start/Re debug: Change default password when powered on; The robotic arm controller must be paired and mixed use is prohibited; Complete safety circuit testing; Prevent condensation.

Manual mode T1/T2: T1 is used for teaching programming; T2 is only for high-speed testing and programming is prohibited; Personnel constraints for operations within the protective zone.

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

Maintenance and repair: power off, lock, and verify electricity; ESD anti-static; The handling of pressure balance cylinders and hazardous chemicals must comply with regulations.

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

List the EU directives and international safety standards to be followed.

Technical Data

KR   18   R1450-3-PP Basic Parameters

Project parameters

Number of axes: 6 axes

ISO9283 repeatability accuracy ± 0.03mm

Self weight approximately 96 kg

Rated load 18 kg; maximum load 18.2 kg

Maximum arrival radius 1451mm

Work envelope volume 9.8 m ³

Protection level body, wrist IP67

Noise<70   dB (A)

Installation posture only for ground installation

Base footprint 260   mm  × 260   mm; mounting hole S220

Controller KR C5 silm-2 M6/M7

Environmental conditions: Operating temperature range of 0-55 ℃; Storage -25~+60 ℃; Avoid condensation; Support ESD anti-static (IEC61340-5-1).

Axis motion parameters

Maximum speed under rated load within the range of axial motion

A1 ±170° 260 °/s

A2 ‑195° ~ +55° 220 °/s

A3 ‑100° ~ +150° 225 °/s

A4 ±200° 450 °/s

A5 ±120° 380 °/s

A6 ±355° 700 °/s

Zero calibration position: A1=0 °, A2=-90 °, A3=90 °, A4=0 °, A5=0 °, A6=0 °; side view and top view working envelope drawings are attached to the manual.

Load and additional load

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 a complete load curve graph.

Upper limit of additional load: maximum 1 kg for the rotating column; maximum 1 kg for the connecting rod arm; maximum 2 kg for the boom; no additional load is allowed on the base frame.

Wrist flange: 7 M6-12.9 screws, locating pin 6H7; provides axial force, radial force, overturning moment, and torque of the flange under normal operation and emergency stop conditions.

Foundation base load (ground installation)

Provide the normal working condition, maximum working condition vertical force Fv, horizontal force Fh, overturning moment Mk, and A1 axis torsional moment Mr.

The design of the base structure must adopt the maximum load value; The additional load of the rotating column and connecting rod arm needs to be added to the vertical force.

Nameplate identification, REACH regulation

The nameplate and multilingual safety warning label of the entire machine are prohibited from being torn off or altered; Search KUKA Xpert for SVHC high concern substance information.

Stopping distance and stopping time (safety critical)

The evaluation object is spindle A1/A2/A3; The stopping distance of multi axis compound motion will increase.

STOP0 category: Directly cutting off the drive, locking the brake; STOP1 category path controlled deceleration shutdown.

The manual provides reference values for testing the stopping angle and stopping time under different arm extension lengths and POV program magnifications; The brake will wear out with the number of STOP0 triggers; Require annual on-site measurement of stopping distance.

Project Planning

Planning risk warning: Long term temperature/power limits, high-frequency reciprocating, static loading, and external process forces can accelerate component wear, and maintenance cycles must be shortened. If necessary, consult with KUKA; The robot is equipped with an over limit monitoring system, which automatically shuts down when exceeding the limit.

Two ground installation schemes

Installation with fixed base (concrete floor): chemical anchor bolt components; Concrete grade C20/25; Drawing requirements for leveling, thickness, and edge distance of the base plate.

Rack installation (steel structure/base): positioning pin+4 M16 bolts; Steel structures must withstand the maximum foundation load.

Cable planning

The cable can be selected in lengths of 4   m/7   m/10   m/25   m, with a maximum of one splice allowed;

Dynamic minimum bending radius: motor cable ≥ 75   mm; data cable ≥ 45   mm;

The cable cannot withstand tension, and the metal trunking is laid separately to meet EMC requirements; Equipotential grounding is necessary.

A1 base interface definition: motor cable X30, data cable X31, with matching grounding terminal.

Transportation

Mandatory transportation posture (must be strictly enforced) A1=0 °; A2=-127 °; A3=140 °; A4=0 °; A5=115 °; A6=0 °.

Lifting: Use a sling to wrap around the connecting arm; Prohibit incorrect lifting; Provide the overall dimensions and center of gravity position drawings for the transportation of the entire machine; Maintain the transport posture throughout the entire transportation process until the robot is fully secured in place.

Chapter 7 Startup and Debugging (Ground Installation)

Concrete ground base scheme: Clean the foundation → Install the bottom plate positioning pin → Robot lifting and positioning → Leveling; Strictly control the thickness of the filling material when leveling is required; Chemical anchor bolt infusion solidification.

Steel structure frame scheme: positioning pins are in place, and M16 bolts are locked diagonally in steps.

Wiring operation: equipotential grounding, motor cable, data cable connection; The connector must be locked and verified for equipotential conductivity.

After installation, connect the tools and perform system power on debugging according to the controller manual.

Maintenance

The maintenance cycle is based on standard operating conditions; Severe working conditions require a shortened cycle. 

|Cycle | Homework Content | Consumables |

| First 100 hours | Recheck the torque of 4 foundation bolts (195 Nm) |

| Every year | Recheck the torque of foundation bolts (195 Nm) |

| 5000 hours or at the latest 1 year | Apply Optitemp RB2 grease inside A2/A3/A5 cover plate | Optitemp RB2 | 

| 5000 hours or at the latest 1 year | Replace A5 synchronous belt |

| 20000 hours or at the latest 5 years | A2 gearbox oil change | Optigear Synt. ALR 150 (0.25) L) | 

| 20000 h or at the latest 5 years | A1 gearbox oil change | Optigear Synt. ALR 150 (0.36 L)|

Maintenance tasks beyond the manual description must be carried out by KUKA certified personnel; It is recommended to conduct a comprehensive inspection of the entire machine in 7 years.

Maintenance

This manual only describes the maintenance operations mentioned above; Other maintenance work (such as joint disassembly, motor replacement, etc.) is not within the scope of this manual and requires contacting KUKA service.

Shutdown, Storage, and Disposal

Shutdown disassembly: The robot moves to the transport position; power failure; Dismantle all cables and grounding wires; Lift the lifting device off the main body; Provide dust-proof protection for the interface.

Long term storage: maintain transportation posture; The storage environment should be dry, dust-free, without condensation, and avoid direct sunlight; Seal all electrical connectors; Cover with protective film and place desiccants.

Scrap disposal:

Metal recycling of cast aluminum, magnesium alloy, and steel;

Motors, RDC circuit boards, and other electrical waste are prohibited from being dismantled without authorization;

Seals, hoses, various lubricants, and sealants should be disposed of as hazardous chemical waste, referring to the MSDS material safety data sheet.