Reservdelsförteckning/

Spare Parts List

504 852-400
2002-09
IRBP 500K/M2001

504 852-400 3
IRBP 500K
Reservdelsförteckning/Spare Parts List

Positions-
nummer Antal Beställningsnummer $QPlUNQLQJDU
Benämning 'HQRPLQDWLRQ
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A 504 280-880 Lägeställare IRBP 500 K Positioner IRBP 500 K L=1600,D=1000
B 504 280-881 Lägeställare IRBP 500 K Positioner IRBP 500 K L=2000,D=1000
C 504 280-882 Lägeställare IRBP 500 K Positioner IRBP 500 K L=2500,D=1000
D 504 280-883 Lägeställare IRBP 500 K Positioner IRBP 500 K L=3150,D=1000

E 504 280-884 Lägeställare IRBP 500 K Positioner IRBP 500 K L=3500,D=1000

F 504 280-885 Lägeställare IRBP 500 K Positioner IRBP 500 K L=4000,D=1000
G 504 280-886 Lägeställare IRBP 500 K Positioner IRBP 500 K L=1600,D=1200
H 504 280-887 Lägeställare IRBP 500 K Positioner IRBP 500 K L=2000,D=1200

I 504 280-888 Lägeställare IRBP 500 K Positioner IRBP 500 K L=2500,D=1200

J 504 280-889 Lägeställare IRBP 500 K Positioner IRBP 500 K L=3150,D=1200
K 504 280-890 Lägeställare IRBP 500 K Positioner IRBP 500 K L=3500,D=1200
L 504 280-891 Lägeställare IRBP 500 K Positioner IRBP 500 K L=4000,D=1200

M 504 280-892 Lägeställare IRBP 500 K Positioner IRBP 500 K L=1600,D=1400

N 504 280-893 Lägeställare IRBP 500 K Positioner IRBP 500 K L=2000,D=1400
O 504 280-894 Lägeställare IRBP 500 K Positioner IRBP 500 K L=2500,D=1400
P 504 280-895 Lägeställare IRBP 500 K Positioner IRBP 500 K L=3150,D=1400

Q 504 280-896 Lägeställare IRBP 500 K Positioner IRBP 500 K L=3500,D=1400

R 504 280-897 Lägeställare IRBP 500 K Positioner IRBP 500 K L=4000,D=1400
1 503 808-880 Stationsväxel Station shifting unit MIC 2.2
2 418 109-512 Skruv Screw M24x80

3 418 118-007 Bricka Washer 44/25x4

4 418 698-007 Prymstift Guide pin D 16x40
5 418 109-512 Skruv Screw M24x80
6 418 118-007 Bricka Washer 44/25x4

7 418 109-205 Skruv Screw M12x40

8 418 118-004 Bricka Washer 24/13x3
9 211 101-148 Pinne Pin
10 503 801-880 Vriddon Rotary unit MTC 500

11 418 109-411 Skruv Screw M20x70

12 418 118-006 Bricka härdad Washer harded 37/21x4
13 418 698-004 Prymstift Guide pin
14 505 388-001 Stoppklack Stop lug

20 504 215-880 Stödlager Ball bearing

25 192 207-111 Stållagerhus Bearing housing
26 418 109-409 Skruv Screw M20x60

4 504 852-400
 IRBP 500K
Reservdelsförteckning/Spare Parts List

75

7,8,9,14
28

10 11,12

57 55

13

32

70
20
30

5,6

1 31
2,3
4

25,26,27

53 52

43
44
65
45 35
48
50
51
38

37
504275A01880

503863A01
36

504 852-400 5
IRBP 500K
Reservdelsförteckning/Spare Parts List

Positions-
nummer Antal Beställningsnummer $QPlUNQLQJDU
Benämning 'HQRPLQDWLRQ
3RVLWLRQ 4XDQWLW\ 2UGHULQJ QXPEHU 5HPDUNV
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27 418 118-006 Bricka Washer 37/21x4
28 504 541-001 Täcklock Cover cap
30 504 233-001 Sidostycke Side plate
31 504 234-001 Sidostycke Side plate

32 504 235-001 Svep Cover

35 503 863-001 Anslutningsplåt Connection plate MIC
36 160 362-881 Maskinkontakt Welding current terminal OKC50
37 192 230-110 Blindpropp Blind plug D=20

38 192 230-112 Blindpropp Blind plug D=26

43 504 504-901 Återledare Return cable 120mm² L=3,1m
44 504 504-892 Återledare Return cable 95mm² L=1,1m
45 504 236-001 Kabelfäste Cable bracket 250/500/750K

48 418 675-002 Täckhatt Cover cap

50 191 418-065 Distanshylsa Spacer sleeve D10/7x18
51 504 192-880 Kabelsats, intern Cable kit, internal
52 2183 010-05 Lyftögla Lifting eye bolt

53 418 109-207 Skruv Screw M12x50

55 504 237-001 Täcklock Cover plate
57 192 230-116 Blinpropp Blind plug D=38
65 504 228-xxx Stativ Stand A-R

70 504 200-xxx Vriddonsram Rotary unit frame A-R

75 504 229-xxx Skärm Screen A-R

6 504 852-400
 IRBP 500K
Reservdelsförteckning/Spare Parts List

75

7,8,9,14
28

10 11,12

57 55

13

32

70
20
30

5,6

1 31
2,3
4

25,26,27

53 52

43
44
65
45 35
48
50
51
38

37
504275A01880

503863A01
36

504 852-400 7
 Reservdelsförteckning/Spare Parts List

32
10
11
12,13

20

35
15
33
503808A01880
IRBP 500K
Reservdelsförteckning/Spare Parts List

Positions-
nummer Antal Beställningsnummer Anmärkningar
Benämning Denomination
Position Quantity Ordering number Remarks
number
503 801-880 Vriddon Rotary unit MTC 500

1 503 810-880 Växel Gear box MTC 500

5 503 831-001 Vriddonskiva Rotary unit disc MTC 500/750
6 503 835-001 Friktionsbricka Washer MTC 750

10 503 880-001 Skruv, strömavtagare Screw, current collector

12 254 500-001 Nippel smörj AH M6 Nipple
15 503 853-001 Kontaktstång Carbon brush MTC 500/750
16 418 554-003 Fjäder Spring

17 503 857-001 Bricka Washer MTC

20 503 845-001 Bottenplåt Bottom plate MTC 500/750
21 503 843-880 Skydd Cover MTC 500/750
22 503 861-001 Fäste Bracket MTC

25 504 189-007 Skyddplugg Plug D25x33/3

26 192 230-112 Blindpropp Blind plug D=26
27 192 230-107 Blindpropp Blind plug D=16
28 504 189-010 Skyddsplugg Plug D32x40/3

30 503 839-002 Lock Cover MTC 500/750

32 192 230-106 Blindpropp Blind plug D=14
 Reservdelsförteckning/Spare Parts List

1 21
6

22

30

16
17
10

27
32

12
15 28
25
26
A
5
0
3
8
0
2

0
1
8
8
0

20
 IRBP 500K
Reservdelsförteckning/Spare Parts List

4
1

5,6

14 504 852-400
 IRBP 500K
Reservdelsförteckning/Spare Parts List

12 14 14 12

15
13

11
500793pluto

504 852-400 15
 IRBP 500K
Reservdelsförteckning/Spare Parts List

Returnc abl e
W1 W2 Återledare/
IRBP
 IRBP 500K
Reservdelsförteckning/Spare Parts List

504840A1b
504480A1
IRBP 500K
Reservdelsförteckning/Spare Parts List

Positions-
nummer Antal Beställningsnummer Anmärkningar
Benämning Denomination
Position Quantity Ordering number Remarks
number
OPTION OPTION
503 886-880 Svivelsats Swivel MTC 750

1 501 728-007 Roterande koppling Rotating coupling

2 503 882-001 Nippel Nipple
3 504 478-001 Slang Hose
4 193 761-002 Slangklamma Hose clamp

5 192 200-103 Slangnippel Hose nipple

3,4,5
2 1
503885-880spr
 IRBP 500K
Reservdelsförteckning/Spare Parts List
504505A01-1, -2,-3
IRBP 500K
Reservdelsförteckning/Spare Parts List

Positions-
nummer Antal Beställningsnummer Anmärkningar
Benämning Denomination
Position Quantity Ordering number Remarks
number
504 456-880 Strömavtagare Current collector MTC 500/750

1 504 457-001 Styrhylsa aluminium Guide bush, aluminium

2 504 459-001 Kontaktstång Contact bar MTC 500/750
3 418 554-003 Fjäder Spring
4 503 880-001 Skruv, strömavtagare Screw,

5 211 102-942 Pinne Pin

6 215 100-018 Bricka Washer 16/8,4X1,5
7 192 238-449 Skruv Screw M8x16
8 254 500-001 Nippel Nipple

4
6,7
8
504456A01
II.
DK
Compact style
Two axes positioner
1-station

Precise servo technology

This is a 1-station positioner with a rotary and a tilt axis.

The rotary axis can be rotated endlessly and the tilt axis +/- 90°.
The DK 250 and DK 500 positioners do not have a thrust bear-
ing. For greater loads the DK 1000 to DK 2500 positioners are
used, because the rotary axis is supported by a thrust bearing.
The workpiece diameter can be 1200 mm for all DKs.
Use the diagram to fi nd the positioner needed for the required
application based on the weight and the distance to the face-
plate from the centre of gravity.

Other options are:

- Electrical feedthroughs (16-pin, ASI bus, Profi bus)
- Feedthroughs for compressed air and hydraulics
- Zero calibration for both axes

Technical data DK-250 DK-500 DK-1000 DK-1500 DK-2500

Rated payload kg 250 500 1000 1500 2500

Height of tilt axis mm 620 620 620 620 620
Diameter workpiece mm 1200 1200 1200 1200 1200
Tilt drive DH-750 DH-1000 DG-1500 DG-200
Type Hollow shaft drive Gear drive
Rated torque Nm 1290 2050 4700 7720 11750
Maximum torque Nm 2075 5550 10770 17600 27000
Maximum speed °/sec 2075 5550 10770 17600 27000
Index time (90°) sec 0,9 1,1 0,9 1,0 1,2
Rotation drive DH-250 DH-500 DG-1000 DH-1500 DH-1500
Rated torque Nm 370 740 2050 3230 3230
Rated offset COG (center of gravity) mm 148 148 205 215 129
Maximum speed °/sec 168 163 135 90 90
Index time (180°) sec 1,7 1,7 2,0 2,7 2,9
Positioner KUKA Roboter GmbH

KUKA Positioner

KP3-V2H
Specification

Issued: 25.02.2014

Version: Spez KP3 V2H V5

3 Product description

3.1 Overview of positioner

The KP3-V2H product family comprises the following positioner types:

Type Payload (per planetary axis)

KP3-V2H250 250 kg
KP3-V2H500 500 kg
KP3-V2H750 750 kg
KP3-V2H1000 1000 kg

3.2 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. locating holes and threaded holes). The system may optionally
have an energy supply system integrated into it (e.g. for compressed air, elec-
trical current).
In the document, the axes of the positioner are designated Axis 1 (A1), Axis 2
(A2) and Axis 3 (A3). In the actual application, A1, A2, A3 might already be
assigned to different system components.

Fig. 3-1: Principal components

1 Planetary axis (cross-member)

2 Planetary axis drive unit
3 Main beam
4 Planetary axis counterbearing unit
5 Base frame
6 Interface A1
7 Central support

The main beam forms the main axis and supports the two planetary axes on its arms.
The planetary axes consist of drive with motor, gear unit, counterbearing and face plates; the workpiece fixtures
are mounted on the face plates.

The electrical installations consist of the cables and connectors. Holders, flex-ible tubes and accessories are also
included.
The positioner has its own RDC (2nd RDC), which is located in the main beam.

Only accessories authorized by KUKA Roboter GmbH for this positioner may be used. All items of equipment
must possess the appropriate certification and declarations of conformity.

The positioner can be equipped with the following options:

 Application-specific energy supply system:

 Air, control/parameter cable, ground,
water  Signal transmission by bus cable
(Profibus)
 Support strips for
fixtures  Weld current
return cable  Screen
 Bedplates

3.3 Control and integration

Description The drive units of the positioner are operated as external axes of the
robot controller. The following couplings are possible:
 Asynchronous operation. There is no mathematical coupling with the
ro-bot.
 Mathematical coupling of one or more drive units into the robot
kinematic system.
Root point calibration is required for the mathematical coupling.

Further information about calibration of an external kinematic

system is contained in the Operating and Programming
Instructions for Sys-tem Integrators.

An example of a mathematical coupling is depicted in the following diagram.

3 Product description
 Fig. 3-2: Robot with external axes and extended kinematic system

With mathematical coupling, the robot constantly follows the movement of the
coupled external axes. 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.

4 Technical data

4.1 Basic data

Basic data Positioner type KP3-V2H250

KP3-V2H500
KP3-V2H750
KP3-V2H1000
Number of axes 3
Pose repeatability < 0.08 mm
(ISO 9283)
Max. weight, positioner KP3-V2H250: 1331 kg
KP3-V2H500: 1389 kg
KP3-V2H750: 1491 kg
KP3-V2H1000: 1619 kg
Max. weight, screen 129 kg
Mounting position Floor
Protection rating IP 67
Sound level < 78 dB (A) outside the working envelope
Standard colors Base frame including platform: Black (RAL 9005)
Moving parts: KUKA orange 2567
Covers: Black (RAL 9005)
Controller KR C2 edition2005
KR C4

Ambient Operation +5 °C to +40 °C (278 K to 313 K)

temperature
Storage and transpor- -40 °C to +60 °C (233 K to 333 K)
tation
 Ambient conditions Class 3K3
DIN EN 60721-3-3

4.2 Axis data

Axis data Axis Range of motion, software-limited

without energy supply sys- with energy supply system
tem
A1 +/-185 ° +/-185 °
A2 infinitely rotating +/-180 °
A3 infinitely rotating +/-180 °

Positioner Turning time A1 Turning time A2 and A3

per 180° per 180° per 360°
KP3-V2H250 3.7 s 2.2 s 3.5 s
KP3-V2H500 3.8 s 2.7 s 4.6 s
KP3-V2H750 3.3 s 2.9 s 4.9 s
KP3-V2H1000 3.7 s 2.3 s 4.0 s
13 / 59
KUKA Positioner

Direction of 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: Direction of rotation of the axes

Working The following diagrams show the shape and size of the working envelope. The
envelope positioners are manufactured with project-specific dimensions according to
the specified dimension ranges.

Fig. 4-2: Working envelope, front view

 4 Technical data

Fig. 4-3: Working envelope, side view

Fig. 4-4: Working envelope, top view

The tool radius can be implemented in gradations of 100 mm and the distance
between the face plates in gradations of 200 mm. The loading height for all po-
sitioner types is 950 mm.

Dimensions
KP3-V2H250 KP3-V2H500 KP3-V2H1000
KP3-V2H750
A D + 670 mm D + 810 mm D + 860 mm
B F + 2C F + 2C F + 2C

Issued: 25.02.2014 Version: Spez KP3 V2H V5 15 / 59

 KUKA Positioner

Dimensions
KP3-V2H250 KP3-V2H500 KP3-V2H1000
KP3-V2H750
C 500 … 1000 mm 500 … 1000 mm 500 … 1000 mm
Tool radius
D 1600 … 3000 mm 1600 … 3000 mm 1600 … 3000 mm
Distance between
face plates
E 2 x C + 400 mm 2 x C + 400 mm 2 x C + 400 mm

Interference circle F in mm
Tool radius Distance between face plates in mm
in mm 1600 1800 2000 2200 2400 2600 2800 3000
500 1880* 1930* 1980* 2030* 2080* 2140* 2210* 2270*
600 1970 2020 2060 2110 2170 2220 2280 2350
700 2070 2110 2150 2200 2250 2310 2360 2420
800 2160 2200 2240 2290 2340 2390 2450 2500
900 2250 2290 2330 2370 2420 2470 2530 2580
1000 2350 2380 2420 2460 2510 2560 2610 2670

* The interference circle of a positioner with energy supply

system is 100 mm larger.

4.3 Payloads

Payload Load torque Moment of inertia

(per
planetary A2/A3 A1 A2/A3
axis)
KP3-V2H250 250 kg 368 Nm 3517 kgm2 180 kgm2
KP3-V2H500 500 kg 736 Nm 4896 kgm2 359 kgm2
KP3-V2H750 750 kg 736 Nm 6212 kgm2 530 kgm2
KP3-V2H1000 1000 kg 1472 Nm 7887 kgm2 719 kgm2

The load difference between the planetary axes in automatic

mode should not exceed approx. 20%.
 4.4 Loads acting on the foundation

Description The specified forces and torques already include the payload
and the inertia force (weight) of the positioner.

4 Technical data

Fig. 4-5: Loads acting on the foundation

Type of load Force/torque/mass

KP3-V2H250 KP3-V2H500 KP3-V2H750 KP3-V2H1000
Fv = vertical 24,024 N 32,088 N 39,132 N 51,352 N
force
Mk = tilting 3,311 Nm 6,622 Nm 9,933 Nm 13,244 Nm
moment*
Mr = torque 9,867 Nm 12,489 Nm 15,525 Nm 18,400 Nm
about A1

*Only occurs during start-up or change of fixture.

4.5 Plates and labels

Description The following plates, labels and signs are attached to the
positioner. They must not be removed or rendered illegible.
Illegible plates, labels and signs must be replaced.

KUKA Positioner

Fig. 4-6: Plates and labels on positioner

4.6 Stopping distances

4 Technical data
 es on the braking torque. 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.
 The wear on the brakes varies depending on the operating
mode, robot application and the number of STOP 0 triggered.
It is therefore advisable to check the stopping distance at
least once a year.

Description The table shows the stopping distances after a STOP 0

(category 0 stop) is triggered.

Positioner Stopping distance (°)

STOP 0
A1 A2/A3
KP3-V2H250 23.2 26.4
KP3-V2H500 19.5 21.6
KP3-V2H750 21.7 24.7
KP3-V2H1000 18.4 21.2