Option KR QUANTEC Working Range Limitation A1 en
Option KR QUANTEC Working Range Limitation A1 en
Issued: 31.08.2012
© Copyright 2012
KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
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.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
Translation of the original documentation
KIM-PS5-DOC
Contents
1 Introduction .................................................................................................. 5
1.1 Documentation for the options ................................................................................... 5
1.2 Representation of warnings and notes ...................................................................... 5
2 Purpose ........................................................................................................ 7
2.1 Target group .............................................................................................................. 7
2.2 Intended use .............................................................................................................. 7
5 Safety ............................................................................................................ 13
6 Planning ....................................................................................................... 15
6.1 Angle settings, working range limitation A1 ............................................................... 15
7 Transportation ............................................................................................. 17
8 Start-up and recommissioning ................................................................... 19
8.1 Installing working range limitation A1 ......................................................................... 19
9 Maintenance ................................................................................................. 21
9.1 Maintaining the working range limitation .................................................................... 21
9.2 Cleaning the working range limitation ........................................................................ 21
11 Appendix ...................................................................................................... 27
11.1 Tightening torque ....................................................................................................... 27
Index ............................................................................................................. 37
1 Introduction
Notes These hints serve to make your work easier or contain references to further
information.
2 Purpose
This documentation is aimed at users with the following knowledge and skills:
Advanced knowledge of mechanical engineering
Advanced knowledge of electrical and electronic systems
Knowledge of the robot controller system
Use The working range limitation for axis 1 enables additional limitation of the
working range.
The range of motion of axis 1 is limited by one or two supplementary stops that
can be retrofitted by means of screws.
Operating the system within the limits of its intended use also involves contin-
uous observance of the operating instructions of the robot and the options,
with particular attention to the maintenance work.
Misuse Any use or application deviating from the intended use is deemed to be imper-
missible misuse. The manufacturer cannot be held liable for any damage re-
sulting from such use. The risk lies entirely with the user.
3 Product description
Description The working range (>>> Fig. 3-1 ) of axis 1 is additionally limited by one or two
supplementary stops that can subsequently be screwed to the rotating column
via gear unit A1. A supplementary stop can be fastened either side of the stan-
dard stop.
This mechanical limitation takes effect if a software limit switch is exceeded.
The supplementary stops then hit the trailing stop in the base frame and thus
limit the working range.
When installing a supplementary stop, the corresponding Allen screws must
be removed from the gear unit. After that the supplementary stop can be in-
stalled. For each stop there are six mounting positions available, enabling the
working range to be limited by 5° to 105° on both sides. Irrespective of the
combination of mounting positions, there always remains a minimum total
working range of 90° that cannot be limited.
4 Technical data
5 Safety
For this assembly or option, the safety instructions of the higher-level system
with which it is operated apply. In addition, the safety instructions contained in
this documentation apply. All applicable safety measures required by national
law, as well as all regulations and ordinances for the avoidance of personal in-
jury and material damage, must likewise be observed at all times.
The relevant personal protective equipment must be worn during performance
of all work on the system, system components or equipment.
6 Planning
Description The available working range limits are shown in the following illustration
(>>> Fig. 6-1 ). The angle of +/-185° is achieved when no supplementary stop
is installed and thus corresponds to the standard design. The supplementary
stops can be used to limit the angle of the working range in 20° steps.
The largest limitation angle that can be selected is +/-105°. The smallest avail-
able angle is 5° in each direction.
The following diagram shows the available angles in the minus direction. The
same ranges are available in the plus direction. The numbers in the diagram
indicate the mounting position of the supplementary stop and the resultant re-
maining angle. The table shows all the available ranges.
This table gives the possible combinations of the supplementary stops and the
resultant remaining angles.
7 Transportation
The component must be suitably and properly packaged for transportation.
The components must be protected against damage with shock-resistant and
break-proof packaging.
The following measures are to be taken before assemblies and individual com-
ponents are transported:
Clean components.
Assign small parts to their respective components in plastic bags to pre-
vent them from getting lost.
Protect components against impacts and slipping; fill gaps with suitable
approved padding materials.
Mark transport cases and packing according to the sensitivity of their contents
(e.g. TOP, FRAGILE, DO NOT BEND) and attach labels to ensure correct
transportation (e.g. indication of center of gravity). In addition to these mea-
sures, the regulations and conditions of the company entrusted with the trans-
portation are to be observed.
Description The working range limitation for A1 is mounted on gear unit A1.
Procedure 1. Determine the installation range of each supplementary stop (>>> Fig. 8-
1 ).
2. Put the robot into operation and move axis 1 so that the installation area
for the supplementary stop to be installed is freely accessible.
3. Remove the trailing stop.
For ranges smaller than 210°, it is necessary to remove the trailing stop.
For this, remove 4 Allen screws and conical spring washers and take off
the plate; then remove the trailing stop from the guide.
4. Secure the robot by pressing the E-STOP device.
11. Put the robot into operation and enter the software limit switches in accor-
dance with the modified axis angle A1.
12. Move A1 through its working range and check the new range limits.
13. Secure the robot by pressing the E-STOP device.
9 Maintenance
Description If used for its intended purpose, the supplementary stop requires minimal
maintenance, i.e. visual inspections are recommended. In certain operating
conditions, regular visual inspections may allow timely detection of changes.
This enables early detection of damage, thereby preventing failure of compo-
nents and assemblies. Exchange damaged components or assemblies.
Description The supplementary stops must be cleaned at regular intervals. The supple-
mentary stops must be cleaned in compliance with the instructions given here
in order to prevent damage. These instructions only refer to the supplementary
stop.
The following must be taken into consideration when using cleaning agents
and carrying out cleaning work:
Only use solvent-free, water-soluble cleaning agents.
Do not use flammable cleaning agents.
Do not use aggressive cleaning agents.
Do not use steam or refrigerants for cleaning.
Do not use high-pressure cleaners.
10.1 Decommissioning
Description This section describes all the work required for decommissioning the working
range limitation if the working range limitation is to be removed from the robot.
After decommissioning, it is prepared for storage or for transportation to a dif-
ferent location.
Depending on the installation area, it may be necessary to move the robot be-
tween the individual work steps. Observe the applicable instructions.
Procedure
When carrying out the following work, the robot must be
moved several times between the individual work steps.
While work is being carried out on the robot, it must always be secured by
activating the EMERGENCY STOP device.
Unintentional robot motions can cause injuries and damage to property. If
work is carried out on an operational robot that is switched on, the robot can
only be moved in T1 mode (reduced velocity). It must be possible to stop the
robot at any time by activating an EMERGENCY STOP device. Operation
must be limited to what is absolutely necessary.
Warn all persons concerned before switching on and moving the robot.
1. Put the robot into operation and move axis 1 so that the installation area
for the supplementary stop to be removed is freely accessible.
2. Remove the trailing stop.
For ranges smaller than 210°, it is necessary to remove the trailing stop.
For this, remove 4 Allen screws and conical spring washers and take off
the plate; then remove the trailing stop from the guide.
3. Secure the robot by activating the E-STOP device and then shut down the
robot.
8. Put the robot into operation and enter the software limit switches in accor-
dance with the modified axis angle A1.
9. Move A1 through its working range and check the new range limits.
10. Secure the robot by pressing the E-STOP device.
11. Prepare the supplementary stop for storage.
10.2 Storage
Description If the component is to be put into long-term storage, the following points must
be observed:
Clean the components and protect against corrosion.
The place of storage must be as dry and dust-free as possible.
Protect mechanical components against damage.
Avoid temperature fluctuations.
Avoid wind and drafts.
Avoid condensation.
Use appropriate packaging that can withstand the expected environmental
conditions.
Do not leave any loose parts on the product, especially ones that might
knock against other parts.
Do not expose to direct sunlight.
Observe and comply with the permissible temperature ranges for storage.
Select a storage location in which the packaging materials cannot be dam-
aged.
10.3 Disposal
Description When the components reach the end of their useful life, they can be removed
and disposed of. The materials must be disposed of in accordance with the
pertinent regulations and, where possible, separated and sorted for recycling.
The following table provides an overview of the materials used.
11 Appendix
Tightening torque The following tightening torques are valid for screws and nuts where no other
specifications are given.
Strength class
Screw size 8.8 10.9
M3 1.2 Nm 1.6 Nm
M4 2.8 Nm 3.7 Nm
M5 5.6 Nm 7.5 Nm
M6 9.5 Nm 12.5 Nm
M8 23.0 Nm 31.0 Nm
M10 45.0 Nm 60.0 Nm
M12 78.0 Nm 104.0 Nm
M14 125.0 Nm 165.0 Nm
M16 195.0 Nm 250.0 Nm
M20 370.0 Nm 500.0 Nm
M24 640.0 Nm 860.0 Nm
M30 1330.0 Nm 1700.0 Nm
12 KUKA Service
Introduction The KUKA Roboter GmbH documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.
Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.
Index
A W
A1, working range limitation 9 Warnings 5
Ambient temperature, operation 11 Working range limitation A1 9
Ambient temperature, storage 11 Working range limitation A1, angle settings 15
Ambient temperature, transportation 11 Working range limitation A1, installing 19
Angle increments 11 Working range limitation, basic data 11
Angle settings, working range limitation A1 15 Working range limitation, cleaning 21
Appendix 27
B
Basic data, working range limitation 11
D
Disposal 25
Documentation, options 5
H
Humidity rating 11
I
Installation, working range limitation A1 19
Intended use 7
Introduction 5
K
KUKA Customer Support 29
L
Limitation range A1 11
M
Maintenance 21
P
Product description 9
Purpose 7
R
Recommissioning 19
Relative air humidity 11
S
Safety 13
Safety instructions 5
Service, KUKA Roboter 29
Start-up 19
Storage 25
Support request 29
T
Technical data 11
Tightening torque 27
Training 7
Transportation 17
Type 11
U
Users 7