Kuka KP3-H2H Manual
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Kuka KP3-H2H Manual

Kuka KP3-H2H Manual

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Positioner
KUKA Roboter GmbH
KUKA Positioner
KP3-H2H
Specification
Issued: 07.07.2017
Version: Spez KP3-H2H V5

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  • Page 1 Positioner KUKA Roboter GmbH KUKA Positioner KP3-H2H Specification KUKA Posi- tioner Issued: 07.07.2017 Version: Spez KP3-H2H V5...
  • Page 2 Germany This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Roboter GmbH. Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work.

  • Page 3: Table Of Contents

    Workspace, safety zone and danger zone ..............Overview of protective equipment ................5.4.1 Mechanical end stops ................... 5.4.2 Mechanical axis limitation (optional) ..............5.4.3 Options for moving the manipulator without drive energy ........Issued: 07.07.2017 Version: Spez KP3-H2H V5 3 / 67...
  • Page 4 Base frame, counterbearing pedestal ..............Distance between face plates ..................Dimensions of face plates ..................Length compensation ....................Transportation ..................... Transport, positioner ....................KUKA Service ....................Requesting support ....................KUKA Customer Support ................... Index ......................4 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 5: Introduction

     Documentation for the positioner  Documentation for the robot controller  Operating and programming instructions for the KUKA System Software  Instructions for options and accessories  Parts catalog on storage medium Each of these sets of instructions is a separate document.

  • Page 6: Terms Used

    The KCP variant for the KR C4 is called KUKA smartPAD. The general term “KCP”, however, is generally used in this documentation. KUKA positioning system is a kinematic system that is controlled by the robot controller as an external axis.
  • Page 7 A customer-specific fixture adapted to the rele- vant application is mounted on the positioner. External axis If the positioner is connected to the robot control- ler, its axes are configured as external axes of the robot. Issued: 07.07.2017 Version: Spez KP3-H2H V5 7 / 67...
  • Page 8 KUKA Positioner 8 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 9: Purpose

    Knowledge of the robot controller system For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training program can be found at www.kuka.com or can be ob- tained directly from our subsidiaries.
  • Page 10 KUKA Positioner 10 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 11: Product Description

    3 Product description Product description Overview of positioners The KP3-H2H product family comprises the following positioner types: Type Payload (per planetary axis) KP3-H2H500 500 kg KP3-H2H750 750 kg KP3-H2H1000 1000 kg Description of the positioner Overview The positioner has 3 axes, which are controlled via the robot controller. A cus- tomer-specific or project-specific fixture is mounted by means of a mechanical interface (e.g.

  • Page 12: Control And Integration

    The positioner has its own RDC (2nd RDC), which is fixed to the drive pedes- tal. Accessories Only accessories authorized by KUKA Roboter GmbH for this positioner may be used. All items of equipment must possess the appropriate certification and EC declarations of conformity.
  • Page 13 The mathematical coupling can simplify the program- ming for complex processes, e.g. arc welding. Using this method, a constant defined orientation can be maintained during a CP motion, for example. Issued: 07.07.2017 Version: Spez KP3-H2H V5 13 / 67...
  • Page 14 KUKA Positioner 14 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 15: Technical Data

    Mounting position Floor Default color Moving parts: KUKA orange 2567; Cover: black (RAL 9005); Pedestal: KUKA orange 2567 Controller KR C4 Footprint 2000 mm x (1577 mm + distance between face plates) Issued: 07.07.2017 Version: Spez KP3-H2H V5 15 / 67...

  • Page 16: Axis Data, Kp3-H2H500

    The orientation of a rotational axis is defined on the motor side (drive): rotation  “+” clockwise  “-” counterclockwise The direction of motion and the arrangement of the individual axes may be not- ed from the following diagram (>>> Fig. 4-1 ). 16 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...
  • Page 17 Working envelope, tool radius 500 mm (>>> Fig. 4-2 )  Working envelope, tool radius 600 mm (>>> Fig. 4-2 ) Fig. 4-2: Working envelope, tool radius 400 mm, 500 mm and 600 mm Issued: 07.07.2017 Version: Spez KP3-H2H V5 17 / 67...

  • Page 18: Payloads, Kp3-H2H500

    Tilting moment M(k) M(k normal) M(k max) 9768 Nm Torque about axis 1 M(r) M(r normal) M(r max) Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about axis 1 M(r) 18 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 19: Technical Data, Kp3-H2H750

    Motion range -185 ° / 5 ° Infinite Infinite Motion range with energy supply system -185 ° / 5 ° ±185 ° ±185 ° Turning time 180° 3.8 s 2.9 s Issued: 07.07.2017 Version: Spez KP3-H2H V5 19 / 67...
  • Page 20 600 mm, 700 mm and 800 mm. The positioners are manufac- envelope tured with project-specific dimensions according to the specified dimension ranges.  Working envelope, tool radius 600 mm (>>> Fig. 4-5 ) 20 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...
  • Page 21 Fig. 4-5: Working envelope, tool radius 600 mm  Working envelope, tool radius 700 mm (>>> Fig. 4-6 ) Fig. 4-6: Working envelope, tool radius 700 mm  Working envelope, tool radius 800 mm (>>> Fig. 4-7 ) Issued: 07.07.2017 Version: Spez KP3-H2H V5 21 / 67...

  • Page 22: Payloads, Kp3-H2H750

    4.3.4 Loads acting on the mounting base, KP3-H2H750 Loads acting on The specified forces and torques already include the payload and the inertia force (weight) of the positioner. the mounting base 22 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 23: Technical Data, Kp3-H2H1000

    Rated payload 1000 kg Protection rating IP67 Sound level < 70 dB (A) Mounting position Floor Default color Moving parts: KUKA orange 2567; Cover: black (RAL 9005); Pedestal: KUKA orange 2567 Issued: 07.07.2017 Version: Spez KP3-H2H V5 23 / 67...

  • Page 24: Axis Data, Kp3-H2H1000

    The orientation of a rotational axis is defined on the motor side (drive): rotation  “+” clockwise  “-” counterclockwise The direction of motion and the arrangement of the individual axes may be not- ed from the following diagram (>>> Fig. 4-9 ). 24 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...
  • Page 25  Working envelope, tool radius 600 mm (>>> Fig. 4-10 ) Fig. 4-10: Working envelope, tool radius 600 mm  Working envelope, tool radius 700 mm (>>> Fig. 4-11 ) Issued: 07.07.2017 Version: Spez KP3-H2H V5 25 / 67...
  • Page 26 KUKA Positioner Fig. 4-11: Working envelope, tool radius 700 mm Working envelope, tool radius 800 mm (>>> Fig. 4-12 )  Fig. 4-12: Working envelope, tool radius 800 mm 26 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 27: Payloads, Kp3-H2H1000

    Tilting moment M(k) M(k normal) M(k max) 25614 Nm Torque about axis 1 M(r) M(r normal) M(r max) Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about axis 1 M(r) Issued: 07.07.2017 Version: Spez KP3-H2H V5 27 / 67...

  • Page 28: Basic Data, Screen

    Basic data, screen The screen is an option for KUKA positioners and is fastened onto the posi- tioner. It serves as a safeguard and screen against laser and welding flashes. Basic data The length of the screen (dimension A in the figure below) depends on the dis- tance between face plates.
  • Page 29 Any improper handling can lead to contact with current-carrying components. Electric shock hazard! Hot surface During operation of the robot, surface temperatures may be reached that could result in burn injuries. Protective gloves must be worn! Issued: 07.07.2017 Version: Spez KP3-H2H V5 29 / 67...
  • Page 30 Do not slacken screwed connection Do not slacken screwed connection! Observe safety instructions and assembly instructions! Work on the positioner Before start-up, transportation or maintenance, read and follow the assembly and operating instructions. 30 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 31: Reach Duty To Communicate Information Acc. To Art. 33 Of Regulation (Ec) 1907/2006

    It is therefore advisable to determine the exact stopping distances and stopping times where necessary under the real conditions of the actual positioner application.  Measuring technique The stopping distances were measured using the robot-internal measur- ing technique. Issued: 07.07.2017 Version: Spez KP3-H2H V5 31 / 67...
  • Page 32 The table shows the stopping distances after a STOP 0 (category 0 stop) is triggered. Stopping distance (°) Positioners STOP 0 A2/A3 KP3-H2H500 19.5 27.0 KP3-H2H750 19.5 27.0 KP3-H2H1000 19.5 37.8 32 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 33: Safety

    No modifications may be carried out to the industrial robot without the autho- rization of KUKA Roboter GmbH. Additional components (tools, software, etc.), not supplied by KUKA Roboter GmbH, may be integrated into the indus- trial robot. The user is liable for any damage these components may cause to the industrial robot or to other material property.

  • Page 34: Intended Use Of The Industrial Robot

    EC Machinery Directive, and the EC declaration of conformity is present in accordance with Annex II A. 34 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 35: Terms Used

    External axis Axis of motion that does not belong to the manipulator, yet is controlled with the same controller. e.g. KUKA linear unit, turn-tilt table, Posiflex Personnel The following persons or groups of persons are defined for the industrial robot: ...

  • Page 36: Workspace, Safety Zone And Danger Zone

    Workspace, safety zone and danger zone Workspaces are to be restricted to the necessary minimum size. A workspace must be safeguarded using appropriate safeguards. 36 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 37: Overview Of Protective Equipment

    The manipulator must be taken out of operation and KUKA Roboter GmbH must be consulted before it is put back into operation .

  • Page 38: Labeling On The Industrial Robot

    Information about the options available for the various robot models and about how to use them can be found in the assembly and oper- ating instructions for the robot or requested from KUKA Roboter GmbH. Moving the manipulator without drive energy can dam- age the motor brakes of the axes concerned.
  • Page 39 Faults The following tasks must be carried out in the case of faults in the industrial robot: Issued: 07.07.2017 Version: Spez KP3-H2H V5 39 / 67...

  • Page 40: Transportation

    Avoid vibrations and impacts during transportation in order to prevent damage to the robot controller. External axis The prescribed transport position of the external axis (e.g. KUKA linear unit, turn-tilt table, positioner) must be observed. Transportation must be carried (optional) out in accordance with the operating instructions or assembly instructions of the external axis.

  • Page 41: Manual Mode

    If it can be avoided, there must be no other persons inside the safeguard- ed area. If it is necessary for there to be several persons inside the safeguarded ar- ea, the following must be observed:  Each person must have an enabling device. Issued: 07.07.2017 Version: Spez KP3-H2H V5 41 / 67...

  • Page 42: Automatic Mode

     The EMERGENCY STOP devices must remain active. If safety functions or safeguards are deactivated during maintenance or repair work, they must be reactivated immediately after the work is completed. 42 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...
  • Page 43 Death or severe injuries may result. Faulty components must be replaced using new components with the same article numbers or equivalent components approved by KUKA Roboter GmbH for this purpose. Cleaning and preventive maintenance work is to be carried out in accordance with the operating instructions.

  • Page 44: Decommissioning, Storage And Disposal

    EN 61000-6-4:2007 + Electromagnetic compatibility (EMC): A1:2011 Part 6-4: Generic standards; Emission standard for industrial envi- ronments EN 60204- Safety of machinery: 1:2006/A1:2009 Electrical equipment of machines - Part 1: General requirements 44 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 45: Planning

    Base frame, drive pedestal Description The following figures show the dimensions of the base frames for the drive pedestal depending on the tool radius.  Tool radius 400 mm, 500 mm and 600 mm Issued: 07.07.2017 Version: Spez KP3-H2H V5 45 / 67...

  • Page 46: Base Frame, Counterbearing Pedestal

    Description The following figures show the dimensions of the base frame for the counter- bearing pedestal depending on the tool radius. Tool radius 400 mm, 500 mm and 600 mm  46 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 47: Distance Between Face Plates

    The distance between the face plates (dimension B in the following figures) depends on the customer-specific design of the positioner. The following dimensions can be read from the following figures:  Distance between face plate on drive and bedplate Issued: 07.07.2017 Version: Spez KP3-H2H V5 47 / 67...

  • Page 48: Dimensions Of Face Plates

     Distance between face plate on counterbearing and bedplate Fig. 6-8: Distance between face plates Dimensions of face plates The dimensions of the face plates are specified in the following diagrams. 48 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...
  • Page 49 6 Planning Fig. 6-9: Face plate on drive, hole pattern, KP3-H2H500 and KP3-H2H750 1 Mounting borehole for support strip (option) Issued: 07.07.2017 Version: Spez KP3-H2H V5 49 / 67...
  • Page 50 KUKA Positioner Fig. 6-10: Face plate on drive, hole pattern, KP3-H2H1000 1 Mounting borehole for support strip (option) 50 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 51: Length Compensation

    1 Mounting borehole for support strip (option) Length compensation The counterbearing has self-aligning bearings and a length compensation function for +/- 5 mm (>>> Fig. 6-12 ). Fig. 6-12: Counterbearing length compensation Issued: 07.07.2017 Version: Spez KP3-H2H V5 51 / 67...
  • Page 52 KUKA Positioner 52 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 53: Transportation

    The components must be secured to prevent them from tipping. There must be no fixtures and tools on the components during transportation, as material damage could other- wise result. The KUKA options (e.g. support strips) may remain on the com- ponents during transportation. Transport dimen- The position of the center of gravity and the weight vary according to the spe- cific configuration.
  • Page 54 2000 mm 800 mm 800 mm 800 mm 50 mm 150 mm 250 mm 2000 mm 2000 mm 2000 mm 623 mm 623 mm 623 mm 50 mm 150 mm 250 mm 54 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...
  • Page 55 The eyebolts must be removed after transporta- tion. All ropes of the lifting tackle must be long enough and must be routed in such a way that the pedestals are not damaged. Fig. 7-4: Transporting the pedestals Issued: 07.07.2017 Version: Spez KP3-H2H V5 55 / 67...
  • Page 56 One end is drawn through the other. The free end is attached to the crane. All round slings must be long enough and routed in such a way that the cross- members are not damaged. Fig. 7-5: Transporting the H-beam Crane H-beam Lifting tackle 56 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 57: Kuka Service

    Designations and versions of other software components or modifica- tions Diagnostic package KRCDiag  Additionally for KUKA Sunrise: Existing projects including applications For versions of KUKA System Software older than V8: Archive of the software (KRCDiag is not yet available here.) Application used  External axes used ...
  • Page 58 Tel. +86 21 5707 2688 Fax +86 21 5707 2603 info@kuka-robotics.cn www.kuka-robotics.com Germany KUKA Roboter GmbH Zugspitzstr. 140 86165 Augsburg Germany Tel. +49 821 797-1926 Fax +49 821 797-41 1926 Hotline.robotics.de@kuka.com www.kuka-roboter.de 58 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...
  • Page 59 Fax +81 45 744 7696 info@kuka.co.jp Canada KUKA Robotics Canada Ltd. 6710 Maritz Drive - Unit 4 Mississauga L5W 0A1 Ontario Canada Tel. +1 905 670-8600 Fax +1 905 670-8604 info@kukarobotics.com www.kuka-robotics.com/canada Issued: 07.07.2017 Version: Spez KP3-H2H V5 59 / 67...
  • Page 60 Selangor Malaysia Tel. +60 (03) 8063-1792 Fax +60 (03) 8060-7386 info@kuka.com.my Mexico KUKA de México S. de R.L. de C.V. Progreso #8 Col. Centro Industrial Puente de Vigas Tlalnepantla de Baz 54020 Estado de México Mexico Tel. +52 55 5203-8407 Fax +52 55 5203-8148 info@kuka.com.mx...
  • Page 61 421 30 Västra Frölunda Sweden Tel. +46 31 7266-200 Fax +46 31 7266-201 info@kuka.se Switzerland KUKA Roboter Schweiz AG Industriestr. 9 5432 Neuenhof Switzerland Tel. +41 44 74490-90 Fax +41 44 74490-91 info@kuka-roboter.ch www.kuka-roboter.ch Issued: 07.07.2017 Version: Spez KP3-H2H V5 61 / 67...
  • Page 62 KUKA Roboter Austria GmbH Organisation Tschechien und Slowakei Sezemická 2757/2 193 00 Praha Horní Počernice Czech Republic Tel. +420 22 62 12 27 2 Fax +420 22 62 12 27 0 support@kuka.cz 62 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...
  • Page 63 Tel. +1 866 873-5852 Fax +1 866 329-5852 info@kukarobotics.com www.kukarobotics.com KUKA Robotics UK Ltd Great Western Street Wednesbury West Midlands WS10 7LL Tel. +44 121 505 9970 Fax +44 121 505 6589 service@kuka-robotics.co.uk www.kuka-robotics.co.uk Issued: 07.07.2017 Version: Spez KP3-H2H V5 63 / 67...
  • Page 64 KUKA Positioner 64 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...

  • Page 65: Index

    EMD 6 Max. weight, screen 28 EMT 6 Mechanical end stops 37 EN 60204-12006/A12009 44 Mounting base with centering 45 EN 61000-6-22005 44 Mouse, external 39 EN 61000-6-42007 + A12011 44 Issued: 07.07.2017 Version: Spez KP3-H2H V5 65 / 67...
  • Page 66 Storage 44 Support request 57 System integrator 34, 35, 36 T1 35 T2 35 Teach pendant 33 Technical data 15 Technical data, KP3-H2H1000 23 Technical data, KP3-H2H500 15 Technical data, KP3-H2H750 19 66 / 67 Issued: 07.07.2017 Version: Spez KP3-H2H V5...
  • Page 67 KUKA Positioner Issued: 07.07.2017 Version: Spez KP3-H2H V5 67 / 67...

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