As the application of KUKA industrial robots becomes increasingly widespread, the vast number of teachers and students in colleges and universities are no longer satisfied with just programming and operation. Additionally, engineering technicians in enterprises, especially those engaged in electrical control-related work, are eager to understand and learn the detailed circuit structure and maintenance skills of KUKA industrial robots. Today, I would like to share this book “Illustrated Guide to KUKA Industrial Robot Circuit Connections and Testing”.
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Content Introduction
“Illustrated Guide to KUKA Industrial Robot Circuit Connections and Testing” explains the circuit connections and testing of KUKA industrial robots through illustrations. This book covers the KUKA industrial robot KR C4 standard control cabinet and KR C4 compact control cabinet. The main content includes the composition of the KUKA industrial robot control cabinet, low-voltage power supply, KUKA industrial robot computer component KPC, KUKA industrial robot control bus KCB, KUKA industrial robot system bus KSB, KUKA industrial robot expansion bus KEB, KUKA industrial robot line interface KLI, KUKA industrial robot service interface KSI, connection of the control system operation panel CSP, KUKA industrial robot control cabinet control unit CCU, circuit connections and fault diagnosis methods for KUKA compact industrial robots, as well as communication between KUKA industrial robots and PLCs. This content can help readers improve their debugging and maintenance levels of KUKA industrial robots.Contact QQ296447532 for free PPT courseware.This book is suitable for engineering technicians engaged in the debugging and maintenance of industrial robots in enterprises, as well as teachers and students in related majors such as industrial robot maintenance and debugging, mechatronics, and electrical automation in colleges and universities.
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Chapter 1 KUKA Industrial Robot Control Cabinet 1
1.1 Composition and connection of KUKA industrial robot standard control cabinet 1
1.1.1 Power Filter 2
1.1.2 Control System Operation Panel CSP 2
1.1.3 PC Components of KR C4 Control System 3
1.1.4 KUKA Drive Device of KR C4 3
1.1.5 Brake Filter 3
1.1.6 Control Cabinet Control Unit CCU 4
1.1.7 Safety Interface Board SIB 5 1.1.8 Fuse Elements 5
1.1.9 Battery 6
1.1.10 Terminal Panel 6
1.1.11 Teach Pendant 7
1.1.12 KR C4 Drive Bus 7
1.2 Composition and connection of KUKA industrial robot compact control cabinet 8
Chapter 2 KUKA Industrial Robot Low Voltage Power Supply 12
2.1 Interface of KR C4 standard low voltage power supply 12
2.2 Connection of KR C4 standard low voltage power supply 13
2.3 Filter K1 13
2.4 Circuit Breaker Q3 14
2.5 X1, X2 Interfaces of Low Voltage Power Supply 15
Chapter 3 KUKA Industrial Robot Computer Component KPC 16
3.1 KPC Motherboard 16
3.2 DualNIC Network Card 19
3.3 KPC RAM 19
3.4 KPC Storage Media 20
3.5 KPC Power Supply 21
3.6 KPC Fan 21
3.7 Circuit Connection of KPC’s X961, X962 Interfaces 22
3.8 KPC LED Indicators 23
Chapter 4 KUKA Industrial Robot Control Bus KCB 24
4.1 Connection of KUKA Industrial Robot Control Bus KCB 24
4.1.1 Connection Diagram of KUKA Industrial Robot Control Bus KCB 24
4.1.2 Circuit Diagram of KUKA Industrial Robot Control Bus KCB 25
4.1.3 Interface Locations of KUKA Industrial Robot Control Bus KCB 26
4.2 KUKA Industrial Robot Power Package KPP 27
4.2.1 Function and Interface Location of KUKA Industrial Robot Power Package KPP 27
4.2.2 Circuit Connection of KUKA Industrial Robot Power Package KPP 29
4.3 KUKA Industrial Robot Servo Package KSP 31
4.3.1 Function and Interface Location of KUKA Industrial Robot Servo Package KSP 31
4.3.2 Circuit Connection of KUKA Industrial Robot Servo Package KSP 32
4.4 Connection Interface Locations of KUKA Industrial Robot Power Package KPP and Servo Package KSP 33
4.5 Connection of KUKA Industrial Robot Standard Control Cabinet Bottom X20 34
4.5.1 Connection Diagram of KUKA Industrial Robot Standard Control Cabinet Bottom X20 34
4.5.2 Circuit Diagram of KUKA Industrial Robot Standard Control Cabinet Bottom X20 34
4.6 Rotary Transformer Digital Converter RDC 37
4.6.1 Function and Interface Location of Rotary Transformer Digital Converter RDC 37
4.6.2 Circuit Diagram of Rotary Transformer Digital Converter RDC 38
4.6.3 Rotary Transformer Digital Converter RDC and Interface Locations 39
4.7 Servo Motor (AC Synchronous Motor) 40
4.7.1 Structure of Servo Motor 40 4.7.2 Circuit Diagram of Servo Motor 41
4.7.3 Circuit Diagram of Rotary Transformer 42
4.8 Circuit Diagram of KUKA Industrial Robot Servo Motor Connection 43
4.8.1 Connection of KUKA Industrial Robot Axis 1 Motor M1 43
4.8.2 Connection of KUKA Industrial Robot Axis 2 Motor M2 43
4.8.3 Connection of KUKA Industrial Robot Axis 3 Motor M3 44
4.8.4 Connection of KUKA Industrial Robot Axis 4 Motor M4 45
4.8.5 Connection of KUKA Industrial Robot Axis 5 Motor M5 45
4.8.6 Connection of KUKA Industrial Robot Axis 6 Motor M6 45
4.8.7 Signals of Rotary Transformer Digital Converter RDC X1~X8 46
4.9 Electronic Data Storage Device EDS 47
4.9.1 EDS Connected to Rotary Transformer Digital Converter RDC (RDC-EDS) 48
4.9.2 EDS Connected to Control Cabinet Control Unit CCU (CCU-EDS) 48
4.10 Electronic Calibration Device EMD 49
4.11 LED Diagnosis of KUKA Industrial Robot Power Package KPP 50
4.12 LED Diagnosis of KUKA Industrial Robot Servo Package KSP 52
4.13 LED Diagnosis of Rotary Transformer Digital Converter RDC 53
Chapter 5 KUKA Industrial Robot System Bus KSB 55
5.1 Connection of KUKA Industrial Robot System Bus KSB 56
5.1.1 Connection Diagram of KUKA Industrial Robot System Bus KSB 56
5.1.2 Circuit Diagram of KUKA Industrial Robot System Bus KSB 56
5.1.3 Interface Locations of KUKA Industrial Robot System Bus KSB 57
5.2 KUKA Industrial Robot Teach Pendant smartPAD 58
5.3 Safety Interface Board SIB 59
5.3.1 Power Circuit Diagram of Safety Interface Board SIB 60
5.3.2 Connection Diagram of Interface X11 with Safety Interface Board SIB and Control Cabinet Control Unit CCU 60
5.3.3 Circuit Diagram of Interface X11 with Safety Interface Board SIB and Control Cabinet Control Unit CCU 61
5.4 Safety Interface Expansion Board SIB ext 68
5.4.1 Connection of Interface X13 when executing Safe Operation function 69
5.4.2 Connection of Interface X13 when executing Safe Range Monitoring function 73
5.4.3 Connection of Interface X13 when executing Safe Single Brake function 75
5.5 LED Indicators of Safety Interface Board SIB 76
5.6 LED Indicators of Safety Interface Expansion Board SIB ext 78
Chapter 6 KUKA Industrial Robot Expansion Bus KEB 80
6.1 Connection Diagram of KUKA Industrial Robot Expansion Bus KEB 81
6.2 Wiring Diagram of Bus Coupler EK1100, Input Module EL1809, Output Module EL2809 82
6.2.1 Wiring Diagram of Bus Coupler EK1100 83
6.2.2 Wiring Diagram of Input Module EL1809 84
6.2.3 Wiring Diagram of Output Module EL2809 85
6.3 Configuration of Bus Coupler EK1100, Input Module EL1809, Output Module EL2809 85
6.3.1 GSD File Download for Bus Coupler EK1100, Input Module EL1809, Output Module EL2809 85
6.3.2 Importing GSD File for Bus Coupler EK1100, Input Module EL1809, Output Module EL2809 87
6.3.3 DTM Sample Management for GSD File of Bus Coupler EK1100, Input Module EL1809, Output Module EL2809 90
6.3.4 Setting IP Address for Laptop and KUKA Industrial Robot 92
6.3.5 Adding Bus Coupler EK1100, Input Module EL1809, Output Module EL2809 94
6.3.6 Address Configuration for Input Module EL1809, Output Module EL2809 98
Chapter 7 Connection of KUKA Industrial Robot Line Interface KLI, Service Interface KSI, Control System Operation Panel CSP 102 7.1 Connection of KUKA Industrial Robot Line Interface KLI 102
7.1.1 Connection Diagram of KUKA Industrial Robot Line Interface KLI 103
7.1.2 Power Connection Circuit Diagram of Industrial Switch 103
7.1.3 Circuit Diagram of KUKA Industrial Robot Line Interface KLI Connection 104
7.2 Connection of KUKA Industrial Robot Service Interface KSI 106
7.3 Control System Operation Panel CSP 107
Chapter 8 KUKA Industrial Robot Control Cabinet Control Unit CCU 112
8.1 Connection Diagram of Control Cabinet Control Unit CCU 114
8.2 Circuit Diagram of Control Cabinet Control Unit CCU 117
8.2.1 Circuit Diagram of Control Cabinet Control Unit CCU X1 Interface 117
8.2.2 Circuit Diagram of Control Cabinet Control Unit CCU X3 Interface 118
8.2.3 Circuit Diagram of Control Cabinet Control Unit CCU X11, X12, X14 Interfaces 119
8.2.4 Circuit Diagram of Control Cabinet Control Unit CCU X29, X30, X41 Interfaces 119
8.2.5 Circuit Diagram of Control Cabinet Control Unit CCU X302, X305, X308 Interfaces 119
8.2.6 Circuit Diagram of Control Cabinet Control Unit CCU X3, X4 Interfaces 121
8.2.7 Circuit Diagram of Control Cabinet Control Unit CCU X34, X21 Interfaces 121
8.2.8 Circuit Diagram of Control Cabinet Control Unit CCU X42, X306 Interfaces 122
8.2.9 Circuit Diagram of Control Cabinet Control Unit CCU X307 Interface 122
8.2.10 Circuit Diagram of Control Cabinet Control Unit CCU X311 Interfaces 124
8.2.11 Circuit Diagram of Control Cabinet Control Unit CCU X31, X32, X41, X48 Interfaces 124
8.3 Fuses of Control Cabinet Control Unit CCU 125
8.4 LED Indicators of Control Cabinet Control Unit CCU 127
Chapter 9 Circuit Connections and Fault Diagnosis Methods for KUKA Compact Industrial Robots 131
9.1 Composition of KUKA Compact Industrial Robot Control Box 131
9.1.1 Control Box Fan 131
9.1.2 Hard Disk 133 9.1.3 KR C4 Compact Low Voltage Power Supply G1 133
9.1.4 Electronic Data Storage Device EDS 135 9.1.5 Motherboard 136
9.1.6 Battery 139
9.2 Composition of KUKA Compact Industrial Robot Drive Device Box 140
9.2.1 Power Package KPPsr of Drive Device Box 140
9.2.2 Servo Package KSPsr of Drive Device Box 141
9.2.3 Circuit Diagram of KUKA Compact Industrial Robot Drive Device Box 142
9.3 Control Bus of KUKA Compact Industrial Robot 143
9.4 Control Unit CCUsr of KUKA Compact Industrial Robot Control Cabinet 150
9.4.1 Power Diagram of KUKA Compact Industrial Robot Control Unit CCUsr 152
9.4.2 Connection Diagram of KUKA Compact Industrial Robot Control Unit CCUsr 152
9.4.3 Circuit Diagram of KUKA Compact Industrial Robot Control Unit CCUsr X4, X12, X15, X29, X308 152
9.4.4 Circuit Diagram of KUKA Compact Industrial Robot Control Unit CCUsr X32, X43, X301, X305 154
9.4.5 Circuit Diagram of KUKA Compact Industrial Robot Control Unit CCUsr X3, X21, X6, X34 155 9.4.6 Circuit Diagram of KUKA Compact Industrial Robot Control Unit CCUsr X31, X41, X42, X407, X306 155
9.5 Safety Interface X11 156
9.5.1 Circuit Diagram of Safety Interface X11 Connection with Control Unit CCUsr X402, X403, X406 156
9.5.2 Circuit Diagram of External Emergency Stop Button Connection of Safety Interface X11 160
9.5.3 Circuit Diagram of Safety Interface X11 Safety Door Limit Switch Connection 160
9.5.4 Connection of External Confirmation Switch of Safety Interface X11 161
9.6 Fuses of Control Unit CCUsr 161
9.7 LED Indicators of Control Unit CCUsr 163
Chapter 10 Communication between KUKA Industrial Robot and PLC 168
10.1 PROFINET Communication between KUKA Industrial Robot and Siemens PLC 168
10.1.1 PLC Configuration 169
10.1.2 PROFINET Communication Configuration for KUKA Industrial Robot 177
10.1.3 Interface Signals between KUKA Industrial Robot and PLC 184
10.1.4 Setting IP Address for KUKA Industrial Robot 185
10.2 Configuration Method for External Automatic Operation of KUKA Industrial Robot 186
Appendix 202
Appendix A Layout of Components in KUKA KR C4 Standard Control Cabinet 202
Appendix B Layout of Components in KUKA KR C4 Compact Control Cabinet 205
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☞ Source: Jinfeng Mall, Reprint Platform: Public Account ☞ Editor: Li Yifan, Reviewer: Han Jingchun ☞ Media Cooperation: 010-88379798 ext 520 ☞ Only Submission Website for Metal Processing Magazine: http://tougao.mw1950.cn/