ROBOT

KR 350

Description

Manipulator

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e Copyright KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim 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, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2.1 Wrist axis motor units A 4 to A 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Link arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.1 Main axis motor units A 1 to A 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Rotating column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Base frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6 Hydropneumatic counterbalancing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6.1 Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7 Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Working range limitation for A 1 to A 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Working range monitoring for A 1 to A 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Description

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 1 General

Valid for KR 350/2

KR 350 L280/2
KR 350 L240/2

1 General
The robot system consists of the manipulator (= robot), control cabinet and connecting
cables (Fig. 1). The manipulator is dealt with in this Doc. Module. The control cabinet and
connecting cables are described in other Doc. Modules.

In the following description, only the KR 350 will be depicted in the illustrations. The
information in the description applies to all robot variants, however. Exceptions to this
will be clearly marked.

1 Manipulator
2 Control cabinet
3 Connecting cables

Fig. 1 Robot system KR 350/2

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Description

2 Description
This section is subdivided in accordance with the breakdown of the manipulator into its main
subassemblies.

2.1 Wrist
The robot is equipped with a triple--axis in--line wrist (Fig. 2) for a payload of 350, 280 or
240 kg, depending on the type. The wrist is fastened onto the arm or the arm extension via
the flange (4). The axes 5, 6 and 4 are driven by shafts (1, 2, 3).
An end effector can be attached to the mounting flange (5) of axis 6. Each axis has a measur-
ing device (6), through which the mechanical zero of the respective axis can be checked by
means of an electronic probe (accessory) and transferred to the controller. For the directions
of rotation, angles of rotation and speeds of the axes see robot Doc. Module “Technical Data”.
The structure and functional principle are described in the robot Doc. Module “Description,
In--line Wrist 350 kg”.

4 5

2
Z

View Z

6
1 Shaft
2 Shaft
3 Shaft
4 Flange
5 Mounting flange
6 Measuring device

Fig. 2 In--line wrist

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 2 Description (continued)

2.2 Arm
The arm assembly (Fig. 3/2) embodies the driven element of axis 3 of the robot. The arm
is flange--mounted to the side of the link arm (6) through a gear unit with integrated bearings
and is driven by main axis motor unit A 3 (5).
The effective software swivel range extends from +60˚ to --184˚, referred to the mechanical
zero position of axis 3, which is given when there is an angle of 90˚ between the longitudinal
axes of the arm and link arm (as shown in Fig. 3). The swivel range is limited by mechanical
limit stops with a buffer function in addition to the software limit switches.
Attached to the rear of the arm housing are the motor units for wrist axes 4 to 6. The arm
housing consists -- as do the housings of the link arm and rotating column -- of a light alloy
construction optimized by means of CAD and FEM. Mounted on the side of the arm is the
counterweight (7) for the counterbalancing of masses about axis 3.
Mounted on the front end of the arm via a standardized interface is the in--line wrist (3), which
is driven by the servomotors (1) through push--on shafts (4) located inside the arm.

1 2 3
--184˚

+60
5 6 5 4

1 Servomotors 5 Main axis drive unit A 3

2 Arm 6 Link arm
3 In--line wrist 7 Counterweight
4 Shafts

Fig. 3 Arm with turning range

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Description

2.2.1 Wrist axis motor units A 4 to A 6

The wrist axes are driven by three servomotors. These motor units are screwed to the arm
(Fig. 4/3) via a common baseplate. The servomotors (1, 2) for axes 4, 5 and 6 are of the same
design. Wrist axes 4 and 5 are driven by universal shafts (4). Wrist axis 6 is driven directly
by servomotor A 6 (2) through a push--on shaft (5).
Each servomotor for the wrist axis drives consists of a brushless AC motor with a perma-
nent--magnet single--disk brake and a hollow--shaft resolver (both integrated into the servo-
motor).
The permanent--magnet single--disk brake performs a holding function when the servo-
motors are at rest and contributes to the braking of the respective axis in an EMERGENCY
STOP. The EMERGENCY STOP function must therefore not be used to stop the robot under
normal circumstances. The permanent--magnet single--disk brakes are not safety brakes.

4
1 A4

2 A6

1 A5

1 Servomotor A 4, A 5
2 Servomotor A 6
3 Arm 5
4 Universal shaft
5 Push--on shaft

Fig. 4 Wrist axis motor units A 4 to A 6

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 2 Description (continued)

2.3 Link arm

The link arm (Fig. 5/1) is the driven element of axis 2. It pivots about rotational axis 2 (3)
through an effective software range of +110˚ to --40˚, referred to the mechanical zero posi-
tion of axis 2, which corresponds to the vertical position of the link arm in Fig. 5. The effective
software swivel range is limited by mechanical limit stops with a buffer function in addition
to the software limit switches.

--40˚ +110

1 Link arm
2 Main axis drive unit A 2
3 Rotational axis 2

Fig. 5 Link arm with turning range

The link arm (Fig. 6/6) contains the gear unit A 3 (5) at its upper end, and the gear unit A 2
(1) at its lower end. The gear units (5, 1) are used both as drive elements and to support the
arm (4) and link arm (6). Reference notches (2, 3) are provided to define the mechanical zero
position of axes 2 and 3. The cables for energy supply and signal transmission are routed
in the interior of the link arm housing from the rotating column to the arm (see robot Doc.
Module “Description, Electrical Installations”).

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Description

3
6
2

7
1

1 Gear unit A 2 5 Gear unit A 3

2 Reference notch A 2 6 Link arm
3 Reference notch A 3 7 Rotational axis 2
4 Arm

Fig. 6 Structure of link arm

2.3.1 Main axis motor units A 1 to A 3

The robot axes 1, 2 and 3 are driven by servomotors as shown in Fig. 7. Each servomotor
for the main axis drives consists of a brushless AC motor (1) with a permanent--magnet
single--disk brake (2) and hollow--shaft resolver (3), both integrated. The servomotors for
axes 1, 2 and 3 are of the same design, but have different power ratings.
The permanent--magnet single--disk brake performs a holding function when the servo-
motors are at rest and contributes to the braking of the respective axis in an EMERGENCY
STOP. The EMERGENCY STOP function must therefore not be used to stop the robot under
normal circumstances. The permanent--magnet single--disk brakes are not safety brakes.

1 Servomotor
2 Permanent--magnet single--disk brake
3 Hollow--shaft resolver
3 2 1

Fig. 7 Servomotor for main axis drives

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 2 Description (continued)

2.4 Rotating column

The rotating column (Fig. 8/2) is the assembly located between the link arm and the base
frame. Screwed to the base frame (4) through a special reduction gear unit (3), which allows
it to rotate, it performs movements about rotational axis 1 (1). It has an effective software
turning range of 185˚ in both the (+) and (--) directions, measured from the mechanical zero
position of axis 1 (6). This range is limited by mechanical limit stops with a buffer function
in addition to the software limit switches. This limit stop system operates with a trailing stop
acting on both sides, which is installed in the base frame and mechanically limits the large
turning range of 185˚ in both directions.

3
4

- -185˚

+185˚

1 Rotational axis 1
2 Rotating column
3 Special reduction gear unit
4 Base frame
5 Main axis drive unit A 2
6 Zero position A 1

Fig. 8 Rotating column with turning range

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Description

Installed in the rotating column is the servomotor for axis 1 (Fig. 9/1), together with the spe-
cial reduction gear unit (3). The servomotor for axis 2 (2) and the associated special reduction
gear unit (4) are mounted to the side.
The complete electrical installations of the robot are routed within the rotating column (see
robot Doc. Module “Description, Electrical Installations”).

1 2

1 Servomotor A 1
2 Servomotor A 2
3 Special reduction gear unit A 1
4 Special reduction gear unit A 2

Fig. 9 Structure of rotating column

2.5 Base frame

The base frame (Fig. 10) is the stationary part of the robot, on which the rotating column turns
with the link arm, the arm and the wrist. Its base flange (7) features through--holes (6) for
holding the robot down, and two locating boreholes (8), with which the robot can be placed
on two locating pins (accessories, see also robot Doc. Module, “Installation, Connection, Ex-
change”).
Attached to the flange (5) in the base frame housing (2) is the special reduction gear unit (4)
of axis 1. Also integrated into this flange (5) is the double--acting trailing stop, which together
with a stop block on the rotating column mechanically safeguards the software--limited move-
ment range of 370˚ about rotational axis 1.
In the base frame, the installation cables leading to the rotating column are routed stress--
free about rotational axis 1 of the robot in a flexible tube. If an energy supply system is used,
these supply lines are also routed through the base frame in a second flexible tube of the
same type. The space between the rotating column and the base frame is coated with cable
grease and is provided with a detachable, one--piece cover (3).
The sockets for the connecting cables from the robot to the control cabinet are located on
the three junction boxes (1).

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 2 Description (continued)

4 5

3 6

8 7

1 Junction boxes (3x) 5 Flange

2 Base frame housing 6 Through--holes (8x)
3 Cover 7 Base flange
4 Special reduction gear unit 8 Locating boreholes (2x)

Fig. 10 Structure of base frame

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Description

2.6 Hydropneumatic counterbalancing system

The robot is equipped with a closed hydropneumatic counterbalancing system for compen-
sating the load moment of axis 2. The robot is provided with the appropriate system variant
depending on whether it is mounted on the floor or on the ceiling (Fig. 11). The system is
installed between the rotating column (10) and the link arm (2).
The principal components of the counterbalancing system are the counterbalancing cylinder
(5), the articulated head (7), the bladder accumulator (4) and the pin (9). The fittings (6)
installed on the counterbalancing cylinder (5) are used for the maintenance and monitoring
of the counterbalancing system.
Improper handling of the counterbalancing system can lead to injury, as the diaphragm accu-
mulator is pressurized.

2.6.1 Functional principle

The starting position for the following functional description is the mechanical zero position
of axis 2, i.e. the link arm (2) is vertical and the pivot points “bearing, rotating column” (11)
and “bearing, link arm” (1) and the rotational axis of axis 2 (3) all lie on a straight line. In this
position, the piston of the counterbalancing cylinder (5) is in the rearmost position and the
oil pressure displayed on the pressure gage (8) corresponds to the set pressure. If the link
arm is now moved forwards, the piston is also drawn forwards and the oil in the rod chamber
is forced into the diaphragm accumulator against the nitrogen pressure. As a result, as the
stroke increases, so a corresponding counterpressure, and thus a counterforce, is built up.
This stroke--dependent counterforce counteracts the weight forces about axis 2. If the link
arm is moved backwards again, the volume of the rod chamber increases and the oil can flow
back into the counterbalancing cylinder (5) under the pressure in the diaphragm accumulator
(4). The pressure decreases and the counterforce diminishes until the link arm reaches the
vertical position again.
The functional sequence is the same if the link arm is moved backwards from the zero posi-
tion.
With the counterbalancing system for ceiling--mounted robots, the sequence is comparable
but differs in that pressure is built up at the opposite end of the counterbalancing cylinder.

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 2 Description (continued)

7
1 6
2
11

3 5

10 4

1 Bearing, link arm

2 Link arm
3 Rotational axis 2
4 Diaphragm accumulator
5 Counterbalancing cylinder
6 Fittings
7 Articulated head
8 Pressure gage 8
9 Pin
10 Rotating column
11 Bearing, rotating column
9

Fig. 11 Hydropneumatic counterbalancing system for floor--mounted robots

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Description

2.7 Gearing
The robot is driven in the main and wrist axes through special planetary gears. The multi--
stage gear units of all axes are identical in function, but differ in size. In the main axes, the
servomotors engage directly with the gear unit, whereas in the wrist axes, universal shafts
and spur gear stages, toothed belts or bevel gears intervene.

3 Accessories
3.1 Working range limitation for A 1 to A 3
Mechanical stops for task--related limitation of the respective working range for axes 1 to 3
can be supplied as the “Working range limitation” accessory (see robot Doc. Module, “Work-
ing Range Limitation”).

3.2 Working range monitoring for A 1 to A 3

Axes 1 to 3 can be equipped with position switches and slotted rings as accessories to which
adjustable cams are attached (see robot Doc. Module, “Working Range Monitoring”). This
allows the position of the robot to be continuously monitored.
Up to three sectors can be monitored on A 1 and A 2, and up to two sectors on A 3.
If axes 2 and 3 are equipped with working range monitoring, an energy supply system with
an additional control cable is required.

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