Kuka ready2 educate User manual

Application Module
ready2_educate
Operating Instructions
Issued: 05.09.2018
BA ready2_educate V8
KUKA Deutschland GmbH

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© Copyright 2018
KUKA Deutschland 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 Deutschland 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 soft-
ware 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 regu-
lar basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Translation of the original documentation
Publication: Pub BA ready2_educate (PDF) en
PB9389
Book structure: BA ready2_educate V6.1
BS8817
Version: BA ready2_educate V8

Contents
1 Introduction.............................................................................................. 8
1.1 Documentation ready2_educate............................................................................ 8
1.2 Representation of warnings and notes................................................................. 8
1.3 Terms used............................................................................................................ 9
2 Purpose..................................................................................................... 10
2.1 Target group.......................................................................................................... 10
2.2 Intended use.......................................................................................................... 10
3 Product description................................................................................. 11
3.1 Overview................................................................................................................ 11
3.2 ready2_educate_basic ......................................................................................... 13
3.2.1 KR C4 compact robot controller........................................................................... 13
3.2.2 Control panel......................................................................................................... 14
3.2.2.1 Operator control and display elements................................................................. 14
3.2.3 Gripper system...................................................................................................... 15
3.2.4 Mounting plate, pneumatic system....................................................................... 15
3.2.5 Mounting plate, electrical system.......................................................................... 16
3.3 ready2_educate_pro.............................................................................................. 17
3.3.1 KR C4 compact robot controller........................................................................... 17
3.3.2 Control panel......................................................................................................... 18
3.3.2.1 Operator control and display elements................................................................. 18
3.3.3 Gripper system...................................................................................................... 19
3.3.4 Application components........................................................................................ 19
3.3.5 Mounting plate, pneumatic system....................................................................... 20
3.3.6 Mounting plate, electrical system.......................................................................... 21
3.4 ready2_educate_advanced.................................................................................... 22
3.4.1 KR C4 compact robot controller........................................................................... 22
3.4.2 Control panel......................................................................................................... 23
3.4.2.1 Operator control and display elements................................................................. 24
3.4.3 Gripper system...................................................................................................... 24
3.4.4 Application components........................................................................................ 25
3.4.5 Mounting plate, pneumatic system....................................................................... 26
3.4.6 Mounting plate, electrical system.......................................................................... 27
3.4.7 Media interface...................................................................................................... 27
3.4.8 Cover..................................................................................................................... 28
3.5 ready2_educate_pro_vision................................................................................... 29
3.5.1 KR C4 compact robot controller........................................................................... 29
3.5.2 Control panel......................................................................................................... 30
3.5.2.1 Operator control and display elements................................................................. 30
3.5.3 Gripper system...................................................................................................... 31
3.5.4 Application components........................................................................................ 31
3.5.5 Mounting plate, pneumatic system....................................................................... 32
3.5.6 Mounting plate, electrical system.......................................................................... 33
3.5.7 Vision..................................................................................................................... 34
3.5.8 Ejector / mounting plate, electrical system........................................................... 35
3.6 ready2_educate_advanced_vision........................................................................ 35
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3.6.1 KR C4 compact robot controller........................................................................... 36
3.6.2 Control panel......................................................................................................... 37
3.6.2.1 Operator control and display elements................................................................. 37
3.6.3 Gripper system...................................................................................................... 38
3.6.4 Application components........................................................................................ 38
3.6.5 Mounting plate, pneumatic system....................................................................... 39
3.6.6 Mounting plate, electrical system.......................................................................... 40
3.6.7 Media interface...................................................................................................... 41
3.6.8 Cover..................................................................................................................... 42
3.6.9 Vision..................................................................................................................... 43
3.6.10 Ejector / mounting plate, electrical system........................................................... 43
4 Technical data.......................................................................................... 45
4.1 Technical data, overview....................................................................................... 45
4.2 Technical data, ready2_educate_basic................................................................. 46
4.2.1 Basic data, ready2_educate_basic....................................................................... 46
4.2.2 Dimensions, ready2_educate_basic...................................................................... 48
4.2.3 Dimensions of gripper, ready2_educate_basic..................................................... 49
4.2.4 Pneumatic diagram................................................................................................ 50
4.2.5 Load data of gripper, ready2_educate_basic....................................................... 51
4.3 Technical data, ready2_educate_pro.................................................................... 51
4.3.1 Basic data, ready2_educate_pro.......................................................................... 51
4.3.2 Dimensions, ready2_educate_pro......................................................................... 53
4.3.3 Dimensions of gripper, ready2_educate_pro........................................................ 54
4.3.4 Pneumatic diagram................................................................................................ 55
4.3.5 Load data of gripper, ready2_educate_pro.......................................................... 56
4.4 Technical data, ready2_educate_advanced.......................................................... 57
4.4.1 Basic data, ready2_educate_advanced................................................................ 57
4.4.2 Dimensions, ready2_educate_advanced.............................................................. 59
4.4.3 Dimensions of gripper, ready2_educate_advanced.............................................. 59
4.4.4 Pneumatic diagram................................................................................................ 60
4.4.5 Load data of gripper, ready2_educate_advanced................................................ 61
4.5 Technical data, ready2_educate_pro_vision......................................................... 62
4.5.1 Basic data, ready2_educate_pro_vision............................................................... 62
4.5.2 Dimensions, ready2_educate_pro_vision.............................................................. 64
4.5.3 Dimensions of gripper, ready2_educate_pro_vision............................................. 64
4.5.4 Pneumatic diagram................................................................................................ 65
4.5.5 Load data of gripper, ready2_educate_pro_vision............................................... 65
4.6 Technical data, ready2_educate_advanced_vision............................................... 67
4.6.1 Basic data, ready2_educate_advanced_vision..................................................... 67
4.6.2 Dimensions, ready2_educate_advanced_vision................................................... 69
4.6.3 Pneumatic diagram................................................................................................ 70
4.6.4 Load data of gripper, ready2_educate_advanced_vision..................................... 70
4.7 Plates and labels................................................................................................... 72
5 Safety......................................................................................................... 76
5.1 General.................................................................................................................. 76
5.1.1 EC declaration of conformity................................................................................. 76
5.1.2 Disclaimer.............................................................................................................. 76
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5.1.3 Intended use.......................................................................................................... 77
5.1.4 Personnel............................................................................................................... 77
5.2 Safety functions..................................................................................................... 78
5.2.1 EMERGENCY STOP device................................................................................. 78
5.2.2 Safety door switches............................................................................................. 78
5.2.3 Main switch on the control panel.......................................................................... 79
5.2.4 Mode selection...................................................................................................... 79
5.3 Start-up and recommissioning.............................................................................. 80
5.4 Maintenance and repair........................................................................................ 81
5.5 Decommissioning, storage and disposal.............................................................. 81
5.6 Performance level.................................................................................................. 82
5.7 Applied norms and regulations............................................................................. 82
6 Planning.................................................................................................... 84
6.1 Installation conditions............................................................................................ 84
6.2 Energy supply interface......................................................................................... 84
7 Transportation.......................................................................................... 85
7.1 Transporting the ready2_educate cell................................................................... 85
7.1.1 Installing the transport safeguard......................................................................... 85
7.1.2 Transport packaging.............................................................................................. 86
7.1.3 Transportation by fork lift truck............................................................................. 87
7.1.4 Transportation by pallet truck................................................................................ 87
8 Start-up and recommissioning............................................................... 89
8.1 Removing the transport safeguard....................................................................... 89
8.2 Installing the ready2_educate cell........................................................................ 89
8.3 Connecting the ready2_educate cell.................................................................... 90
8.4 Switching on the cell............................................................................................. 91
8.5 Restarting operation following an EMERGENCY STOP...................................... 91
8.6 Removing/attaching the detachable doors........................................................... 92
9 Installation................................................................................................ 93
9.1 Installation, ready2_educate.................................................................................. 93
9.1.1 System requirements, ready2_educate................................................................ 93
9.1.2 Installing or updating ready2_educate.................................................................. 93
9.1.3 Uninstalling ready2_educate................................................................................. 95
9.2 Installation, ready2_educate_advanced ............................................................... 95
9.2.1 System requirements, ready2_educate_advanced............................................... 95
9.2.2 Installing or updating ready2_educate_advanced................................................ 96
9.2.3 Uninstalling ready2_educate_advanced................................................................ 97
9.3 ready2_educate_vision installation........................................................................ 97
9.3.1 System requirements, ready2_educate_vision..................................................... 97
9.3.2 Installing or updating ready2_educate_vision....................................................... 98
9.3.3 Uninstalling ready2_educate_vision...................................................................... 99
10 Operation.................................................................................................. 100
10.1 KUKA smartPAD teach pendant........................................................................... 100
10.1.1 Front view.............................................................................................................. 100
10.1.2 Rear view............................................................................................................... 102
10.2 Status keys............................................................................................................ 103
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10.3 Operator control via touch panel.......................................................................... 104
11 Configuration............................................................................................ 108
11.1 I/Os for activation, ready2_educate...................................................................... 108
11.2 I/Os for activation, ready2_educate_advanced.................................................... 108
11.3 I/Os for control, ready2_educate_vision............................................................... 110
12 Programming............................................................................................ 111
12.1 Inline forms – overview......................................................................................... 111
12.1.1 Gripper SET inline form........................................................................................ 111
12.1.2 Gripper SYN SET inline form............................................................................... 112
12.1.3 Gripper CHECK inline form................................................................................... 112
12.1.4 Gripper SYN CHECK inline form.......................................................................... 113
13 Maintenance.............................................................................................. 115
13.1 Maintenance table................................................................................................. 115
13.2 Drainage of condensate on the compressed air service unit.............................. 116
13.3 Cleaning ready2_educate...................................................................................... 116
14 Repair........................................................................................................ 118
14.1 Repair.................................................................................................................... 118
14.2 Repair, overview.................................................................................................... 118
14.3 Repair, ready2_educate_basic.............................................................................. 119
14.3.1 Gripper change, ready2_educate_basic............................................................... 119
14.3.1.1 Removing the basic gripper.................................................................................. 119
14.3.1.2 Installing the basic gripper.................................................................................... 120
14.3.2 Exchanging safety door switches......................................................................... 121
14.3.3 Exchanging the proximity switches on the gripper.............................................. 122
14.3.4 Exchanging the blade-type fuse........................................................................... 122
14.4 Repair, ready2_educate_pro................................................................................. 123
14.4.1 Gripper change, ready2_educate_pro.................................................................. 123
14.4.1.1 Removing the pro gripper..................................................................................... 123
14.4.1.2 Installing the pro gripper....................................................................................... 124
14.4.2 Exchanging safety door switches......................................................................... 125
14.4.3 Exchanging the proximity switches on the gripper.............................................. 125
14.4.4 Exchanging the blade-type fuse........................................................................... 126
14.4.5 Exchanging the gripper cable............................................................................... 126
14.4.6 Exchanging the switch.......................................................................................... 127
14.4.7 Exchanging the suction gripper............................................................................ 128
14.4.8 Exchanging the camera........................................................................................ 128
14.5 Repair, ready2_educate_advanced....................................................................... 128
14.5.1 Gripper change, ready2_educate_advanced........................................................ 128
14.5.1.1 Removing the gripper............................................................................................ 128
14.5.1.2 Installing the gripper.............................................................................................. 129
14.5.2 Exchanging safety door switches......................................................................... 130
14.5.3 Exchanging the touch panel................................................................................. 131
14.5.4 Exchanging the proximity switches on the gripper.............................................. 131
14.5.5 Exchanging the blade-type fuse........................................................................... 132
14.5.6 Exchanging the gripper cable............................................................................... 132
14.5.7 Exchanging the CPU............................................................................................. 133
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14.5.8 Exchanging the SIMATIC BUS ADAPTER........................................................... 134
14.5.9 Exchanging the switch.......................................................................................... 134
14.5.10 Exchanging the suction gripper............................................................................ 135
14.5.11 Exchanging the camera........................................................................................ 135
15 Decommissioning, storage and disposal............................................. 136
15.1 Decommissioning................................................................................................... 136
15.1.1 Switching off the ready2_educate cell.................................................................. 136
15.1.2 Decommissioning................................................................................................... 136
15.2 Storage.................................................................................................................. 136
15.3 Disposal................................................................................................................. 137
16 Appendix................................................................................................... 138
16.1 Spare parts list...................................................................................................... 138
16.2 Tightening torques................................................................................................. 139
16.3 EU Declaration of Conformity according to EC Machinery Directive
2006/42/EC, Annex II A........................................................................................ 139
16.4 EU Declaration of Conformity according to EC Machinery Directive
2006/42/EC, Annex II A........................................................................................ 140
16.5 EU Declaration of Conformity according to EC Machinery Directive
2006/42/EC, Annex II A........................................................................................ 141
16.6 EU Declaration of Conformity according to EC Machinery Directive
2006/42/EC, Annex II A........................................................................................ 141
16.7 EU Declaration of Conformity according to EC Machinery Directive
2006/42/EC, Annex II A........................................................................................ 142
17 KUKA Service........................................................................................... 144
17.1 Requesting support............................................................................................... 144
17.2 KUKA Customer Support...................................................................................... 144
Index 152
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1 Introduction
1.1 Documentation ready2_educate
The documentation for ready2_educate consists of the following parts:
• Operating instructions for ready2_educate
(this document)
• Operating instructions for the manipulator
• Operating instructions for the robot controller
• Operating and programming instructions for the KUKA System Soft-
ware (KSS)
• Documentation for the gripper
• Documentation for the touch panel
• Documentation for the CPU
• Instructions for options and accessories
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.
DANGER
These warnings mean that it is certain or highly probable that death or
severe injuries will occur, if no precautions are taken.
WARNING
These warnings mean that death or severe injuries may occur, if no
precautions are taken.
CAUTION
These warnings mean that minor injuries may occur, if no precautions
are taken.
NOTICE
These warnings mean that damage to property may occur, if no pre-
cautions are taken.
These warnings contain references to safety-relevant information or
general safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.
This warning draws attention to procedures which serve to prevent or rem-
edy emergencies or malfunctions:
SAFETY INSTRUCTION
The following procedure must be followed exactly!
Procedures marked with this warning must be followed exactly.
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Introduction

Notices
These notices serve to make your work easier or contain references to
further information.
Tip to make your work easier or reference to further information.
1.3 Terms used
Term Description
CPU Central Processing Unit
I/O Input/output
EMC Electromagnetic compatibility
ESD English: ElectroStatic Discharge
Electrostatic discharge
KSS KUKA System Software
KOP KUKA option package
smartPAD The KUKA smartPAD teach pendant for
KR C4 has all the operator control and display
functions required for operating and program-
ming the industrial robot.
TCP Tool Center Point
The TCP constitutes the working point of the
robot.
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Introduction

2 Purpose
2.1 Target group
This documentation is aimed at users with the following knowledge and
skills:
• User
• Start-up personnel with the following qualifications
‒ Advanced knowledge of electrical and electronic systems
‒ Advanced knowledge of the robot controller
‒ Advanced knowledge of the Windows operating system
• Operating personnel with the following qualifications:
‒ Theoretical knowledge of robotics
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 obtained di-
rectly from our subsidiaries.
2.2 Intended use
Use
ready2_educate has been designed as a training system for training with
KUKA industrial robots and production technology.
The cell is not intended for use in industrial production.
If the scope of the supplied application components is expanded by the
user, the following conditions must be met:
• Only passive components, without any drive unit, may be used.
• Components may not have sharp edges.
• Components must be capable of being fastened securely on the hole
pattern (50x50) of the application plate.
• The weight of the components that are gripped must be kept to a min-
imum (robot force, max. 3 kg)
Misuse
Any use or application deviating from the intended use is deemed to be
misuse. This includes e.g.:
• Using the cell or its components in an industrial system.
• Use for experimental purposes.
• Alteration of the components (e.g. modification of the gripper).
• Use of a tool or a training application without taking the associated
risks into account.
• Exceeding the operating times.
• Use outside the permissible operating parameters
• Operation in potentially explosive environments
• Outdoor operation
The manufacturer cannot be held liable for any resulting damage. The risk
lies entirely with the user.
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Purpose

3 Product description
3.1 Overview
Description
ready2_educate is a modular training cell that can optionally be supplied
in five expansion levels.
ready2_educate is used for carrying out practical courses with a KUKA in-
dustrial robot in basic, programming and application training. The training
cell forms a self-contained unit.
The gripper is controlled via I/O communication.
The following ready2_educate variants are possible:
Variant Components included
ready2_educate_basic • KR 3 R540 robot
• KR C4 compact robot control-
ler
• Cell housing
• Control panel
‒ Operator control and dis-
play elements
• Gripper system
• Cubes
• Mounting plate, pneumatic
system
• Mounting plate, electrical sys-
tem
(>>> 3.2 "ready2_educate_basic "
Page 13)
ready2_educate_pro • KR 3 R540 robot
• KR C4 compact robot control-
ler
• Cell housing
• Control panel
‒ Operator control and dis-
play elements
• Gripper system
• Application components
• Mounting plate, pneumatic
system
• Mounting plate, electrical sys-
tem
(>>> 3.3 "ready2_educate_pro"
Page 17)
ready2_educate_advanced • KR 3 R540 robot
• KR C4 compact robot control-
ler
• Cell housing
• Control panel
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Product description

Variant Components included
‒ Operator control and dis-
play elements
‒ Touch panel
• Gripper system
• Application components
• Mounting plate, pneumatic
system
• Mounting plate, electrical sys-
tem
• CPU
• Media interface
(>>> 3.4 "ready2_educate_ad-
vanced" Page 22)
ready2_educate_pro_vision • KR 3 R540 robot
• KR C4 compact robot control-
ler
• Cell housing
• Control panel
‒ Operator control and dis-
play elements
• Gripper system
• Application components
• Mounting plate, pneumatic
system
• Mounting plate, electrical sys-
tem
• Vision
(>>> 3.5 "ready2_educate_pro_vi-
sion" Page 29)
ready2_educate_advanced_vision • KR 3 R540 robot
• KR C4 compact robot control-
ler
• Cell housing
• Control panel
‒ Operator control and dis-
play elements
‒ Touch panel
• Gripper system
• Application components
• Mounting plate, pneumatic
system
• Mounting plate, electrical sys-
tem
• CPU
• Media interface
• Vision
(>>> 3.6 "ready2_educate_ad-
vanced_vision" Page 35)
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Product description

3.2 ready2_educate_basic
Description
The ready2_educate_basic cell is used for teaching operator control and
basic programming of KUKA robots. It contains ten cubes that can be
used for programming simple pick-and-place tasks.
Overview
Fig. 3-1: Overview, ready2_educate_basic
1 KR 3 R540 robot
2 Mounting plate for control elements
3 2-jaw parallel gripper
4 Application plate
5 Cell housing
3.2.1 KR C4 compact robot controller
Description
The KR C4 compact robot controller is used for the robot.
Further information is contained in the operating instructions for the ro-
bot controller.
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Product description

Fig. 3-2: KR C4 compact
3.2.2 Control panel
Description
The control panel contains the display and operator control elements, the
EMERGENCY STOP device and the “Ackn.” button for operator safety.
Fig. 3-3: Control panel
1 smartPAD 2 Operator control and display
elements
3.2.2.1 Operator control and display elements
Fig. 3-4: Operator control and display elements
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Product description

Item Description
1 Main switch
The main switch is used to switch the cell on and off. If the
main switch is turned off, the robot drives and the entire robot
cell are switched off and all motions are stopped.
2 EMERGENCY STOP device with key
Pressing the EMERGENCY STOP device stops all motions.
Before operation can be resumed, the key in the
EMERGENCY STOP device must be turned to release it.
3 “Ackn.” button for acknowledging operator safety
4 USB connection
5 KSI connection
6 Knob-operated switch for inputs E1 to E2
7 Indicator lamps for visualization of outputs A1 and A2
3.2.3 Gripper system
Description
The 2-jaw parallel gripper is used for gripping, positioning and setting
down parts.
Fig. 3-5: 2-jaw parallel gripper
1 Energy supply system
2 Gripper holder
3 2-jaw parallel gripper
3.2.4 Mounting plate, pneumatic system
Description
The service unit supplies the gripper with compressed air. The operating
pressure for the gripper can be set using the pressure regulating valve.
The shut-off valve is used for locking and unlocking the service unit.
The pneumatic system mounting plate may vary according to the
ready2_educate variant.
Setting:
• Operating pressure: 6 bar
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Product description

Fig. 3-6: Mounting plate, pneumatic system
1 Shut-off valve
2 Pressure regulating valve
3 Multiple distributor
4 Solenoid valve
5 Service unit
6 Pressure gauge
7 Filter unit
8 Condensate drainage screw
3.2.5 Mounting plate, electrical system
Fig. 3-7: Mounting plate, electrical system
Item Description
1X0
Power supply, 200-240V, 50-60Hz
2F1.5.1
Fuse, 4A
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Product description

Item Description
3X1
Power supply, 24V, PE connections
4X1B
Connections for gripper pressure valve, E-STOP, acknowledg-
ing operator safety, safety switches, Profinet
3.3 ready2_educate_pro
Description
The ready2_educate_pro cell is used for teaching advanced programming
of KUKA robots using an application.
Overview
Fig. 3-8: Overview, ready2_educate_pro
1 KR 3 R540 robot
2 Mounting plate for control elements
3 2-jaw parallel gripper
4 Application plate with components
5 Cell housing
3.3.1 KR C4 compact robot controller
Description
The KR C4 compact robot controller is used for the robot.
Further information is contained in the operating instructions for the ro-
bot controller.
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Product description

Fig. 3-9: KR C4 compact
3.3.2 Control panel
Description
The control panel contains the display and operator control elements, the
EMERGENCY STOP device and the “Ackn.” button for operator safety.
Fig. 3-10: Control panel
1 smartPAD 2 Operator control and display
elements
3.3.2.1 Operator control and display elements
Fig. 3-11: Operator control and display elements
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Product description

Item Description
1 Main switch
The main switch is used to switch the cell on and off. If the
main switch is turned off, the robot drives and the entire robot
cell are switched off and all motions are stopped.
2 EMERGENCY STOP device with key
Pressing the EMERGENCY STOP device stops all motions.
Before operation can be resumed, the key in the
EMERGENCY STOP device must be turned to release it.
3 “Ackn.” button for acknowledging operator safety
4 USB connection
5 KSI connection
6 Knob-operated switch for inputs E1 to E2
7 Indicator lamps for visualization of outputs A1 and A2
3.3.3 Gripper system
Description
The 2-jaw parallel gripper is used for gripping, positioning and setting
down parts.
Fig. 3-12: 2-jaw parallel gripper
1 Energy supply system
2 Gripper holder
3 2-jaw parallel gripper
3.3.4 Application components
Description
The gripper is used to grip the various components and set them down in
new positions.
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Product description

Overview
Fig. 3-13: Application components
1 Magazine with tool holder
2 Paper holder
3 Quick-action clamp
4 Cube 25x25 mm
5 Coordinate system
6 Positioning pin
7 Wire contour PATH + SPLINE
8 Metal loop tool
9 Pen tool
10 Calibration tip
It is possible for the users to make application components themselves.
It is only necessary to ensure that these are adapted to the application
plate with its 50x50 mm hole pattern.
The user-made application components may not have a drive of their
own.
In the case of user-made application components, the user is responsi-
ble for reanalyzing the risk and hazard situation and implementing cor-
responding safeguards.
3.3.5 Mounting plate, pneumatic system
Description
The service unit supplies the gripper with compressed air. The operating
pressure for the gripper can be set using the pressure regulating valve.
The shut-off valve is used for locking and unlocking the service unit.
The pneumatic system mounting plate may vary according to the
ready2_educate variant.
Setting:
• Operating pressure: 6 bar
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Product description