Kuka KR 20-3 User manual

Robots
KR 20-3
With C Variants
Specification
KUKA Roboter GmbH
Issued: 22.04.2016
Version: Spez KR 20-3 V2
KR 20-3

KR 20-3
2 / 81 Issued: 22.04.2016 Version: Spez KR 20-3 V2
© Copyright 2016
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
Publication: Pub Spez KR 20-3 (PDF) en
Book structure: Spez KR 20-3 V2.1
Version: Spez KR 20-3 V2

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Contents
1 Introduction .................................................................................................. 5
1.1 Industrial robot documentation ................................................................................... 5
1.2 Representation of warnings and notes ...................................................................... 5
2 Purpose ........................................................................................................ 7
2.1 Target group .............................................................................................................. 7
2.2 Intended use .............................................................................................................. 7
3 Product description ..................................................................................... 9
3.1 Overview of the robot system .................................................................................... 9
3.2 Description of the manipulator ................................................................................... 9
4 Technical data .............................................................................................. 13
4.1 Technical data, overview ........................................................................................... 13
4.2 Technical data, KR 20-3 ............................................................................................ 13
4.2.1 Basic data, KR 20-3 .............................................................................................. 13
4.2.2 Axis data, KR 20-3 ................................................................................................ 14
4.2.3 Payloads, KR 20-3 ................................................................................................ 17
4.2.4 Loads acting on the foundation, KR 20-3 ............................................................. 19
4.3 Technical data, KR 20-3 C ......................................................................................... 20
4.3.1 Basic data, KR 20-3 C .......................................................................................... 20
4.3.2 Axis data, KR 20-3 C ............................................................................................ 21
4.3.3 Payloads, KR 20-3 C ............................................................................................ 23
4.3.4 Loads acting on the foundation, KR 20-3 C .......................................................... 25
4.4 Supplementary load ................................................................................................... 26
4.5 Plates and labels ........................................................................................................ 27
4.6 Stopping distances and times .................................................................................... 29
4.6.1 General information .............................................................................................. 29
4.6.2 Terms used ........................................................................................................... 30
4.6.3 Stopping distances and times, KR 20-3 ................................................................ 31
4.6.3.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 31
4.6.3.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 32
4.6.3.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 34
4.6.3.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 36
4.6.4 Stopping distances and times, KR 20-3 C ............................................................ 36
4.6.4.1 Stopping distances and stopping times for STOP 0, axis 1 to axis 3 .............. 36
4.6.4.2 Stopping distances and stopping times for STOP 1, axis 1 ............................. 37
4.6.4.3 Stopping distances and stopping times for STOP 1, axis 2 ............................. 39
4.6.4.4 Stopping distances and stopping times for STOP 1, axis 3 ............................. 41
5 Safety ............................................................................................................ 43
5.1 General ...................................................................................................................... 43
5.1.1 Liability .................................................................................................................. 43
5.1.2 Intended use of the industrial robot ...................................................................... 44
5.1.3 EC declaration of conformity and declaration of incorporation ............................. 44
5.1.4 Terms used ........................................................................................................... 45
5.2 Personnel ...................................................................................................................45
5.3 Workspace, safety zone and danger zone ................................................................. 46
Contents

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KR 20-3
5.4 Overview of protective equipment ............................................................................. 47
5.4.1 Mechanical end stops ........................................................................................... 47
5.4.2 Mechanical axis range limitation (optional) ........................................................... 47
5.4.3 Axis range monitoring (optional) ........................................................................... 47
5.4.4 Options for moving the manipulator without drive energy .................................... 48
5.4.5 Labeling on the industrial robot ............................................................................ 48
5.5 Safety measures ........................................................................................................ 49
5.5.1 General safety measures ..................................................................................... 49
5.5.2 Transportation ...................................................................................................... 50
5.5.3 Start-up and recommissioning .............................................................................. 50
5.5.4 Manual mode ........................................................................................................ 52
5.5.5 Automatic mode ................................................................................................... 52
5.5.6 Maintenance and repair ........................................................................................ 53
5.5.7 Decommissioning, storage and disposal .............................................................. 54
5.6 Applied norms and regulations .................................................................................. 54
6 Planning ........................................................................................................ 57
6.1 Information for planning ............................................................................................. 57
6.2 Mounting base with centering .................................................................................... 57
6.3 Machine frame mounting with centering .................................................................... 59
6.4 Connecting cables and interfaces ............................................................................. 61
7 Transportation ............................................................................................. 63
7.1 Transporting the robot ............................................................................................... 63
8 Options ......................................................................................................... 69
8.1 Working range limitation, supplementary stop (optional) ........................................... 69
8.2 Energy supply systems (optional) .............................................................................. 69
9 KUKA Service ............................................................................................... 71
9.1 Requesting support ................................................................................................... 71
9.2 KUKA Customer Support ........................................................................................... 71
Index ............................................................................................................. 79

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1 Introduction
1Introduction
1.1 Industrial robot documentation
The industrial robot documentation consists of the following parts:
Documentation for the manipulator
Documentation for the robot controller
Operating and programming instructions for the System Software
Instructions for options and accessories
Parts catalog on storage medium
Each of these sets of instructions is a separate document.
1.2 Representation of warnings and notes
Safety These warnings are relevant to safety and must be observed.
This warning draws attention to procedures which serve to prevent or remedy
emergencies or malfunctions:
Notices These notices serve to make your work easier or contain references to further
information.
t
t
These warnings mean that it is certain or highly probable
that death or severe injuries will occur, if no precautions
are taken.
These warnings mean that death or severe injuries may
occur, if no precautions are taken.
These warnings mean that minor injuries may occur, if
no precautions are taken.
These warnings mean that damage to property may oc-
cur, if no precautions are taken.
These warnings contain references to safety-relevant information or
general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.
Procedures marked with this warning must be followed
exactly.
Tip to make your work easier or reference to further information.

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KR 20-3

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2 Purpose
2Purpose
2.1 Target group
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
2.2 Intended use
Use The industrial robot is intended for handling tools and fixtures, or for process-
ing or transferring components or products. Use is only permitted under the
specified environmental conditions.
Misuse Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. This includes e.g.:
Transportation of persons and animals
Use as a climbing aid
Operation outside the permissible operating parameters
Use in potentially explosive environments
Use in underground mining
2
s
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.
Changing the structure of the manipulator, e.g. by drilling
holes, etc., can result in damage to the components. This
is considered improper use and leads to loss of guarantee and liability enti-
tlements.
Deviations from the operating conditions specified in the
technical data or the use of special functions or applica-
tions can lead to premature wear. KUKA Roboter GmbH must be consulted.
The robot system is an integral part of a complete system and may
only be operated in a CE-compliant system.

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3 Product description
3 Product description
3.1 Overview of the robot system
A robot system (>>> Fig. 3-1 ) comprises all the assemblies of an industrial
robot, including the manipulator (mechanical system and electrical installa-
tions), control cabinet, connecting cables, end effector (tool) and other equip-
ment. The product family (model) KR 20-3 comprises the robot variants:
KR 20-3
KR 20-3 C
An industrial robot of this product family comprises the following components:
Manipulator
Robot controller
Connecting cables
KCP teach pendant (KUKA smartPAD)
Software
Options, accessories
3.2 Description of the manipulator
Overview The manipulators (manipulator = robot arm and electrical installations)
(>>> Fig. 3-2 ) of the KR 20-3 model are designed as 6-axis jointed-arm kine-
matic systems. They consist of the following principal components:
In-line wrist
Arm
Link arm
Rotating column
Base frame
t
s
Fig. 3-1: Example of a robot system
1 Manipulator 3 Robot controller
2 Connecting cables 4 Teach pendant KCP (KUKA
smartPAD)

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KR 20-3
Electrical installations
In-line wrist The robot can be equipped with a triple-axis in-line wrist for a payload of 20 kg.
The in-line wrist is screwed to the arm via the flange. End effectors are at-
tached to the mounting flange of axis 6. Each axis has a measuring device,
through which the mechanical zero of the respective axis can be checked by
means of an electronic probe (accessory) and transferred to the controller. Di-
rections of rotation, axis data and permissible loads can be found in Chapter
(>>> 4 "Technical data" Page 13).
The in-line wrist is driven by the motors on the rear of the arm by means of
toothed belts (A4 and A5) and shafts. The drive power within the in-line wrist
is transmitted by means of bevel and spur gear units.
The mounting flange conforms, with minimal deviations, to ISO 9409-1:2004.
Arm The arm of this robot variant is designed as a cast hollow structural element
with interfaces to the in-line wrist and link arm. The interfaces are screwed
connections. The coaxial, one-piece drive shafts for axes 4 to 6 are mounted
in the arm housing. Wrist axes A4 and A5 are driven by the wrist axis motors
(drive units) via toothed belts, while axis A6 is driven directly via a push-fit con-
nection.
The three drive units for the wrist axes are located at the rear of the arm hous-
ing and are arranged one above the other.
Link arm The link arm is the assembly located between the arm and the rotating column.
It consists of the link arm body with the buffers for axis 2.
Rotating column The rotating column houses the motors of axes 1 and 2. The rotational motion
of axis 1 is performed by the rotating column. This is screwed to the base
frame via the gear unit of axis 1 and is driven by a motor in the rotating column.
The link arm is also mounted in the rotating column.
Base frame The base frame is the base of the robot. It is screwed to the mounting base.
The flexible tube for the electrical installations is installed in the base frame.
Fig. 3-2: Main assemblies of the manipulator
1 In-line wrist 4 Electrical installations
2 Arm 5 Base frame
3 Link arm 6 Rotating column

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3 Product description
Also located on the base frame are the junction boxes for the motor and data
cable and the energy supply system.
Electrical
installations
The electrical installations include all the motor and control cables for the mo-
tors of axes 1 to 6. All connections are implemented as connectors in order to
enable the motors to be exchanged quickly and reliably. The electrical instal-
lations also include the RDC box and the multi-function housing (MFH). The
RDC box and MFH with the connectors for the motor and data cables are
mounted on the robot base frame. The connecting cables from the robot con-
troller are connected here by means of connectors. The electrical installations
also include a protective circuit. The ground conductors to the robot are con-
nected to the base frame by means of ring cable lugs and threaded pins.
Options The robot can be fitted and operated with various options, such as energy sup-
ply systems for axes 1 to 3, energy supply systems for axes 3 to 6, or working
range limitation systems for A1. The options are described in separate docu-
mentation.

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4 Technical data
4 Technical data
4.1 Technical data, overview
The technical data for the individual robot types can be found in the following
sections:
4.2 Technical data, KR 20-3
4.2.1 Basic data, KR 20-3
Basic data
4
T
t
Robot Technical data
KR 20-3 Technical data
(>>> 4.2 "Technical data, KR 20-3" Page 13)
Supplementary loads
(>>> 4.4 "Supplementary load" Page 26)
Plates and labels
(>>> 4.5 "Plates and labels" Page 27)
Stopping distances and times
(>>> 4.6.3 "Stopping distances and times, KR 20-3" Page 31)
KR 20-3 C Technical data
(>>> 4.3 "Technical data, KR 20-3 C" Page 20)
Supplementary loads
(>>> 4.4 "Supplementary load" Page 26)
Plates and labels
(>>> 4.5 "Plates and labels" Page 27)
Stopping distances and times
(>>> 4.6.4 "Stopping distances and times, KR 20-3 C" Page 36)
KR 20-3
Number of axes 6
Number of controlled axes 6
Volume of working envelope 14.5 m³
Pose repeatability (ISO 9283) ± 0.05 mm
Weight approx. 254 kg
Rated payload 20 kg
Maximum reach 1611 mm
Protection rating IP65
Protection rating, in-line wrist IP65
Sound level < 75 dB (A)
Mounting position Floor
Footprint 575 mm x 535 mm
Permissible angle of inclination ≤5 °
Default color Moving parts: KUKA orange 2567;
Base frame cover: black (RAL
9005)
Controller KR C4
Transformation name KR C4: KR20_3 C4 FLR ZH16_2

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KR 20-3
Ambient condi-
tions
Connecting
cables
For detailed specifications of the connecting cables, see “Description of the
connecting cables”.
4.2.2 Axis data, KR 20-3
Axis data
The direction of motion and the arrangement of the individual axes may be not-
ed from the following diagram.
Humidity class (EN 60204) -
Classification of environmental con-
ditions (EN 60721-3-3)
3K3
Ambient temperature
During operation 5 °C to 55 °C (278 K to 328 K)
During storage/transportation -40 °C to 60 °C (233 K to 333 K)
Cable designation Connector designa-
tion
robot controller - ro-
bot
Interface with robot
Motor cable X20 - X30 Harting connectors at
both ends
Data cable X21 - X31 Rectangular connec-
tor
at both ends
Ground conductor /
equipotential bonding
16 mm2
(can be ordered as an
option)
M8 ring cable lug at
both ends
Cable lengths
Standard 7 m, 15 m, 25 m, 35 m, 50 m
Minimum bending radius 5x D
Range of motion
A1 ±185 °
A2 -155 ° / 35 °
A3 -130 ° / 154 °
A4 ±350 °
A5 ±130 °
A6 ±350 °
Speed with rated payload
A1 156 °/s
A2 156 °/s
A3 156 °/s
A4 330 °/s
A5 332 °/s
A6 616 °/s

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4 Technical data
Mastering
positions
Working
envelope
The following diagrams show the shape and size of the working envelope for
these variants of this product family.
The reference point for the working envelope is the intersection of axes 4 and
5.
Fig. 4-1: Direction of rotation of robot axes
Mastering position
A1 0 °
A2 -90 °
A3 90 °
A4 0 °
A5 0 °
A6 0 °

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Fig. 4-2: Work envelope, side view, KR 20-3
Fig. 4-3: Work envelope, top view, KR 20-3

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4 Technical data
4.2.3 Payloads, KR 20-3
Payloads
Load center of
gravity
For all payloads, the load center of gravity refers to the distance from the face
of the mounting flange on axis 6. Refer to the payload diagram for the nominal
distance.
Payload diagram
Rated payload 20 kg
Rated mass moment of inertia 0.36 kgm²
Rated total load 30 kg
Rated supplementary load, base
frame
0 kg
Maximum supplementary load,
base frame
0 kg
Rated supplementary load, rotating
column
0 kg
Maximum supplementary load,
rotating column
20 kg
Rated supplementary load, link arm 0 kg
Maximum supplementary load, link
arm
20 kg
Rated supplementary load, arm 10 kg
Maximum supplementary load, arm 10 kg
Nominal distance to load center of gravity
Lxy 100 mm
Lz 120 mm
Fig. 4-4: Load center of gravity
This loading curve corresponds to the maximum load ca-
pacity. Both values (payload and mass moment of iner-
tia) must be checked in all cases. Exceeding this capacity will reduce the
service life of the robot and overload the motors and the gears; in any such
case the KUKA Roboter GmbH must be consulted beforehand.
The values determined here are necessary for planning the robot application.
For commissioning the robot, additional input data are required in accor-
dance with the operating and programming instructions of the KUKA System
Software.
The mass inertia must be verified using KUKA.Load. It is imperative for the
load data to be entered in the robot controller!

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KR 20-3
In-line wrist
Mounting flange
The mounting flange is depicted with axes 4 and 6 in the zero position. The
symbol Xmindicates the position of the locating element (bushing) in the zero
position.
Fig. 4-5: Payload diagram
In-line wrist type ZH16-2
Mounting flange see drawing
Mounting flange (hole circle) 50 mm
Screw grade 10.9
Screw size M6
Number of fastening threads 7
Grip length 1.5 x nominal diameter
Depth of engagement min. 6 mm, max. 10 mm
Locating element 6H7
Fig. 4-6: Mounting flange, IW 16

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4 Technical data
4.2.4 Loads acting on the foundation, KR 20-3
Loads acting on
the foundation
The specified forces and moments already include the payload and the inertia
force (weight) of the robot.
Vertical force F(v)
F(v normal) 3400 N
F(v max) 4600 N
Horizontal force F(h)
F(h normal) 1650 N
F(h max) 5000 N
Tilting moment M(k)
M(k normal) 3250 Nm
M(k max) 5200 Nm
Torque about axis 1 M(r)
M(r normal) 2550 Nm
M(r max) 4200 Nm
Fig. 4-7: Loads acting on the foundation, floor
Normal loads and maximum loads for the foundations
are specified in the table.
The maximum loads must be referred to when dimensioning the foundations
and must be adhered to for safety reasons. Failure to observe this can result
in personal injury and damage to property.
The normal loads are average expected foundation loads. The actual loads
are dependent on the program and on the robot loads and may therefore be
greater or less than the normal loads.
The supplementary loads (A1 and A2) are not taken into consideration in the
calculation of the mounting base load. These supplementary loads must be
taken into consideration for Fv.

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4.3 Technical data, KR 20-3 C
4.3.1 Basic data, KR 20-3 C
Basic data
Ambient condi-
tions
Connecting
cables
KR 20-3 C
Number of axes 6
Number of controlled axes 6
Volume of working envelope 14.5 m³
Pose repeatability (ISO 9283) ± 0.05 mm
Weight approx. 254 kg
Rated payload 20 kg
Maximum reach 1611 mm
Protection rating IP65
Protection rating, in-line wrist IP65
Sound level < 75 dB (A)
Mounting position Ceiling
Footprint 575 mm x 535 mm
Permissible angle of inclination ≤0 °
Default color Moving parts: KUKA orange 2567;
Base frame cover: black (RAL
9005)
Controller KR C4
Transformation name KR C4: KR20_3 C4 CLG ZH16_2
Humidity class (EN 60204) -
Classification of environmental con-
ditions (EN 60721-3-3)
3K3
Ambient temperature
During operation 5 °C to 55 °C (278 K to 328 K)
During storage/transportation -40 °C to 60 °C (233 K to 333 K)
Cable designation Connector designa-
tion
robot controller - ro-
bot
Interface with robot
Motor cable X20 - X30 Harting connectors at
both ends
Data cable X21 - X31 Rectangular connec-
tor
at both ends
Ground conductor /
equipotential bonding
16 mm2
(can be ordered as an
option)
M8 ring cable lug at
both ends
Cable lengths
Standard 7 m, 15 m, 25 m, 35 m, 50 m
Minimum bending radius 5x D