Project Book

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Version 6.5 Number of pages: 20

KUKA Robotics

Chrysler Group

Powertrain

KUKA Robotics

Corporation

Version 6.5

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General

Foreword:

This Project Book Defines the Specifications for the Application of KUKA Robotics Products at All Production Sites and Centers of Chrysler Group LLC North American Powertrain Manufacturing Locations (PTT).

Modification Log:

Revision

Date Version Document Name Revision

Paragraph

Effected Revised By

07012006 1.0 Project Book 1.0 First Revision

Released All

Soeren Papsdorf Bruce Kinnie 01012007 2.0 Project Book 2.0 Content

Updated 2, 3, 6, 8

Soeren Papsdorf/ Bruce Kinnie

07012007 3.0 Project Book 3.0 Content

Updated 2 Soeren Papsdorf

Updated All Soeren Papsdorf

Updated All Jim Foreman

07/01/2010 6.5 Project Book 6.5 Content Updated Industrial Robots & External Axes Jim Foreman Soeren Papsdorf

Chrysler Group Facilities in the US:

Kokomo Transmission, Kokomo, IN. Indiana Transmission 1, Kokomo, IN. Indiana Transmission 2, Kokomo, IN Mack 1, Detroit, MI.

Mack 2, Detroit, MI.

Trenton Engine, Trenton, MI. Kenosha Engine, Kenosha, WI. GEMA 1, Monroe, MI.

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Contacts at KUKA Robotics Corporation and KUKA Roboter AG:

Jim Foreman Global CHRYSLER Group LLC Key Account Manager Address: KUKA Robotics

22500 Key Drive

Clinton Township, Michigan 48036 Telephone: (586) 465-8861 [email protected]

Michael Dewitte Director; Automotive Accounts Address: KUKA Robotics

22500 Key Drive

Mike Maximiuk Senior Engineering Manager Address: KUKA Robotics

22500 Key Drive

Korea Office: Dr.-Ing Dae-Kern KANG General Manager Address: KUKA Robot Automation Korea Co., Ltd

4Ba 806 Sihwa Ind. Complex Sung-Gok Dong, Ansan City Kyunggi Do, 425 – 110, Korea Telephone: +82-31-496-9937-8 [email protected]

India Office: Raj Singh Rathee Managing Director Address: KUKA Robotics India Pvt Ltd

621 Galleria Towers

DLF Phase – 1V, Gurgaon – 122009 Haryana, India

Telephone +91-124-41-88220/221

[email protected]

Italy Office: Paolo Gioia Managing Director Address: KUKA Robotics Italia S.p.A.

Via Pavia 9/a – int. 6 10098 Rivoli (TO) Italia

Tel.: +39 011 959 50 13 Fax: +39 011 959 51 41 [email protected]

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General Points (Industrial Robots)

2.1 Industrial Robots

This Project Book is only valid for KUKA jointed-arm robots. The following points must be taken into consideration.

2.2 Provision of Robots

Industrial Robots For Individual Projects Are to be Provided by Chrysler Group LLC (Planning).

2.3 Payload Categories

As a General Rule, Highlighted Robots Are Standard For Chryaler Group LLC. Other Robots May be Used if Required.

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KR 5 arc

The new KUKA KR 5 arc rounds off

the range of KUKA robots at the lower

end. Its payload of 5 kg makes it

outstandingly well-suited to standard

arc welding tasks. With its attractive

price and compact dimensions, it is the

ideal choice for your application too.

Whether mounted on the floor or

inverted overhead, the KR 5 arc always

performs its tasks reliably.

LOADS:

Payload 5 kg

Supplementary load 12 kg

Working envelope

Max. reach 1412 mm

Other data and variants

Number of axes 6

Repeatability ± 0,1 mm

Weight 127 kg

Mounting positions Floor, ceiling

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KR 5 arc HW:

KUKA Roboter presents the

absolute specialist for arc

welding: the KR 5 arc HW

(Hollow Wrist). This new robot

type offers several features that

put it in a class of its own. The 50

mm opening in the arm and wrist,

for example, allows the arc

welding dress package to be

routed in the protective interior of

the arm. This not only shields the

dress package from mechanical

influences, but also prevents

undesirable whiplash motion

during reorientation of the robot.

Both torsion-type dress packages

and infinitely rotating arc welding

dress packages are possible. For

the user, this means not only

improved component accessibility

and optimal protection of the

dress package, but also simplified

offline programming.

LOADS:

Loads 5 kg

Supplementary load 12 kg

Working envelope

Max. reach 1423 mm

Other data and variants

Number of axes 6

Repeatability <±0,1 mm

Weight 120 kg

Mounting positions; Floor, ceiling

Angle ± 15°

IP 54

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External Axes

Linear Axis KL

1500-3

KUKA linear units are translational

motion units. They can be used to

extend a robot’s work envelope or

alternatively to move workpieces or

tools within the work envelopes of a

number of robots. This allows

applications such as the tending of

more than one machine or fixture,

order picking from rows of pallets, or

work on very large components.

Control of the linear unit is integrated

as a mathematically coupled axis in the

robot controller, dispensing with the

need for an additional controller.

Vertical Dual Turnover Positioner

This positioner package comprises the

external axis package with failsafe

technology, the required top-mounted

cabinet, a vertical dual turnover positioner,

and the required motor and resolver cables.

The maximum distance between face plates

is 2600 mm, and the maximum tool radius is 800 mm. The positioner can

be combined with any KUKA Industrial Robot through

Drive Modules located inside the Robot

Conrol Cabinet.

KUKA Robotics provides a range of part positioners in one, two, three,

four, and five axes plus turntables.

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Colors:

Robot: KUKA Orange – Black Base Std., Additional Colors Avail For Added Cost. Control Cabinet: Anthracite Gray Std., 26 Other Colors Avail for Added Cost. See Tender Specifications – PPA, Part 1, “General Specifications”.

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User Dress Packages Without Tool Changing System:

User dress packages with power and signal cables and fluid hoses are available from KUKA for a wide range of different applications. The dress package is routed from the base of the robot to the arm or wrist (see 2.5.1 - 2.5.5 for a detailed specification).

The user dress packages have a Multibus cable for Interbus, Profibus and DeviceNet (CAN) (see Appendix 1). The dress package extends 1.2 m beyond axis 6. The system builder will specify the required cables and hoses. Spare supply lines will be removed or fitted after consultation with CHRYSLER. Such modifications must be documented. If Profibus nodes are installed on the arm of KUKA robots with the standard CHRYSLER installation (Multibus cable with M23 and power supply via separate cable with Harting connector routed to the 3rd axis in the dress package), the Profibus is routed via an adapter that can be obtained from KUKA (M23 to M12x1 (B-coded). Details about the adapter can be found in Appendix 1. The power supply is routed via the Harting connector to a 7/8" connector.

If the bus signals and power supply are routed via the Multibus cable, the bus signals are rerouted in the adapter to an M12x1 connector (B-coded) and the power supply is rerouted to a 7/8" connector. Details about the adapter can be found in Appendix 1.

1.1.1 Dress Package 1 (KR 150, 210, 360, 500, 1000)

KUKA Designation: Dress Package for Handling, Generation 2000

Integrated energy supply system from robot base to axis 6. Connection plate with connectors (Interconnectron for Bus Cable) and couplings for air (M22 x 1.5) on the robot base with connector bypack.

Flexible tube with the following supply lines: 2 x ½" air hose with coupling

1 x control cable 25 x 1 mm2 with 25-pole Harting connector

1 x Multibus cable for Interbus/Profibus with Interconnectron connector (power supply cables are integrated into the dress package)

Set of holders for dress package along exterior of robot

Axes 1-3 for KR 150/210 Axes 3-6 for KR 150/210 Axes 1-6 for KR 360/500

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1.1.2 Dress Package 2 (KR 150, 210, 360)

KUKA designation: Dress package for servo gun, Generation 2000

Integrated energy supply system from robot base to axis 6. Connection plate with connectors (Multi-Contact for primary current and Interconnectron for bus cable) and couplings for air and water (M22 x 1.5) on the robot base with connector bypack.

Flexible tube with the following supply lines:

1 x control cable 25 x 1 mm2 with 25-pole Harting connector 1 x ½" air hose with coupling

1 x ½" and 1 x 3/8" water hose with coupling, unions made of stainless steel

2 x 35 mm2, 1 x 25mm² primary current cable, e.g. Elocab ERK 3421/0, for max. 100 A continuous current at max. 40 oC ambient temperature (in accordance with EN60204) with 180 A Multi-Contact connector (pin diameter 8 mm):

1 x control cable (4 x 2 x 0.25 mm2) with Interconnectron connector

1 x motor cable 2 x (4 x 1.0 mm2 + 2 x 0.35 mm2) with Interconnectron connector Set of holders for dress package along exterior of robot

Axes 1-3 for KR 150/210 Axes 3-6 for KR 150/210

1.1.3 Dress Package 3 (KR 150, 210, 360)

KUKA designation: Dress package “Water/hydraulic/air/bus”, Generation 2000

Integrated energy supply system from robot base to axis 6. Connection plate with connectors (Multi-Contact for primary current and connector for bus cable) and couplings for air and water (M22 x 1.5) on the robot base with connector bypack.

1 x control cable 25 x 1 mm2 with 25-pole Harting connector 1 x ½" air hose with coupling

2 x Techno Chemie Hydraulic Hose (woven textile insert and polyurethane outer layer) for industrial clarified water, 200 bar, nominal diameter 10 with 12L fittings (DKOL series with O-ring) (see Appendix 1)

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1.1.4 Dress Package 4 (KR 150, 210, 360) (Welding, Single)

KUKA designation: Dress package “Welding, single”, Generation 2000

Integrated energy supply system from robot base to axis 6. Connection plate with connectors (Multi-Contact for primary current and Interconnectron for bus cable) and couplings for air and water (M22 x 1.5) on the robot base with connector bypack.

Flexible tube with the following supply lines: 1 x ½" air hose with coupling

2 x 3/8" water hose with coupling, unions made of stainless steel

1 x MultiPbus cable for Interbus/Profibus with Interconnectron connector (power supply cables are integrated into the dress package)

3 x 35 mm2 current cable for max. 400 A continuous current at max. 40 oC ambient temperature (in accordance with EN60204) with cable lugs for common contact

1.1.5 Dress Package 5 (KR 16)

KUKA designation: Dress package “KR 16”

Energy supply system, Handling, for KR 16 Flexible tube with the following supply lines:

1 x control cable (25 x 0.5 mm2) with 25-pole Harting connector 3/8" air hose with coupling

Axes 1-2 for KR 15 Axes 2-3 for KR 15

1.1.6 Dress Package 6 (KR 30)

KUKA designation: Dress package “KR 30”

Integrated energy supply system from robot base to axis 6 (handling package). Connection plate with connectors (Interconnectron for bus cable) and couplings for air (M22 x 1.5) on the robot base with connector bypack:

1 x control cable (25 x 1 mm2) with 25-pole Harting connector 1 x ½" air hose with coupling

Axes 1-3 for KR 30 Axes 3-6 for KR 30

Drawings for all Dress Packages Mentioned Above Can be Found in Appendix 1.

User Dress Packages in Conjunction With Tool Changing System as per Section 3.0 but with cable length (beyond axis 6) < 1.2 m adapted to the tool changing system.

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KUKA Robotics “K – BOX” Dress Package Option:

KUKA Robotics has recently introduced the “K – Box” offering significant improvement in control of the dress package beyond the 3rd axis. This Product Has Been Installed and Available For Review at The KUKA Toledo Production Operations facility.

Warranty:

The warranty period for the industrial robots is 36 months commencing on the date of delivery.

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Software Modules (KUKA)

Standard Equipment:

KUKA.UserTech v2.4 (Create Custom Applications) KUKA.ExpertTech v2.5

KUKA.Gripper&SpotTech v2.4 KUKA.SmartGUI StudioLite v1.1 KUKA.CR.ArcTech Digital v3.0/1 KUKA.ArcTech Analog v1.0/1 KUKA.LoadDetect; Touch Sensor KUKA.ConveyorTech v3.2

Application-Specific Software Modules (optional):

The following application-specific software modules are available as options: KUKA.LaserTech v2.1 for welding/cutting

KUKA.LaserTech RPFOLaser cutting KUKA.GlueTech

KUKA.ServoGun (with or w/o Torque or Force Control)

KUKA.ForceTorqueControl v2.3 (mounting, grinding, deburring, “pin in a hole”) KUKA Soft-PLC; external multi-axis control

See Appendix 9 – Brief description of the software

Vision:

The KUKA Robot Controller is able to communicate with state-of-the-art vision systems such as Perceptron, VMT, ISRA and other manufacturers using KUKA Vision Software. The RSI (Robot Sensor Interface) allows real time communication and path correction of the robot. VMT camera systems are available for this, Perceptron is under development. Connection to Material and Production Data Acquisition Systems:

All industrial robots are to be connected to PRISMA via ObjectBroker. An OPC server on the robot controller is required for this. ObjectBroker communicates directly with the IT application. KUKA OPC Server: http://www.kuka.com/en/products/software/communication/start.htm

Automatic TCP Calibration:

A measurement system (TRACC) is available for automatic TCP calibration. This measurement system includes the TCP calibration unit and the software required for the robot controller. The system is connected via the “fast measuring inputs” in the base of the robot; (Can be ordered as an option if required.)

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Robot Arm:

Mechanical Hard Stops for the Main Axes (Workspace Limitation)

Mechanical hard stops are mandatory for axis 1. The software limit switches for all axes must be parameterized in accordance with the required workspace. Mechanical stops for axes 2 and 3 can be ordered as an option as required.

Workspace Monitoring:

Quick-exchange workspace monitoring systems are available for the main axes A1, A2 and A3. (Can be ordered as an option if required.)

Absolute Accuracy:

Robot calibration must be carried out with absolute accuracy for laser and foundry applications and for offline programming of the robot. The calibration required for an absolute accurate robot can be carried out by KUKA; extra charge option.

Collision Protection:

The robot controller contains a simple collision protection function (software solution). If required; additional collision detection software can be ordered specifically adapted to a given application.Manufacturers are ATI, IPR, or Schunk.

KUKA Safe Operation:

KUKA.SafeOperation is now available for sale in the United States and Canada. This option offers significant savings for end users in reduction of cell size and cycle times.

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Adapter for different payload categories

Bayonet ring Tool Changing Systems:

1.1.7 Automatic Tool Changing System:

ATI, Schunk or other manufacturer’s tool changers are to be used for applications that

require an automatic tool change. Application-specific media transfer modules can be ordered.

1.1.8 Manual Rapid Tool Mounting System:

The RTMS developed in-house at CHRYSLER should be used for applications that require a tool change (e.g. in the event of damage). The tool changing system works on the principle of a bayonet fitting. Contact CHRYSLER for more information.

Robot wrist flange

Collision protection Tool changing system,

robot side

Tool rack system

Tool changing system, tool side

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Robot Control Cabinet

General:

The North American Version KR C2 ed05 Controller includes all the components and control functions which are required to operate the robot. It includes the computer and power units, which are both installed in a common easy to service control cabinet. The processor unit is based on standard PC hardware with a powerful Pentium microprocessor using a VXWORKS® operating system for motion control, and

Windows XP® for the user interface. This processor is able to scan and process I/O

signals, while simultaneously calculating robot motion. This allows the robot controller the ability to act as the processor for the entire automated system.

Electrical interfaces 1.1.9 Power supply:

Main Supply Voltage; 480 Volt 3 Phase Power Frequency;: 49 - 61 Hz.

Rated Connected Load;: 4 kVA (max. 8 kVA). 1.1.10 Connectors:

All electrical connections on the robot control cabinet are situated at the bottom of the front side of the cabinet. (Interface assignment: see Appendix 4.)

1.1.11 Bus systems

The robot controller can be ordered with the following fieldbus systems:

- Interbus-S -DeviceNet

- Profibus -SafetyBus P

- Ethernet / Ethernet IP -Profisafe

PLC Interface / Safety Signals

Only the version with the safety signals (Emergency Stop) wired conventionally is currently authorized (CHRYSLER 2000/4 interface with conventional safety wiring).

Connectors on front side of cabinet, bottom

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Control of Application-Specific Functions (PLC)

The application-specific division between PLC and robot controller must be arranged with the competent department.

Control Cabinet Rollers

The control cabinet is supplied with four integrated 75 mm diameter rollers to allow easy movement of the cabinet for cleaning or exchange.

Digital Inputs / Outputs

As a standard, the control cabinet is supplied with fieldbus, but without digital inputs/outputs. If digital signals are required for the application, an external converter module must be used and can be ordered as an option. I/O modules can be placed either inside the control cabinet or outside the cabinet in any spot as fieldbus modules.

Air / Water Heat Exchanger

Up to an ambient temperature of 45 oC, the cabinet can be operated using the standard-fitted control cabinet fan. The use of an air/water heat exchanger in accordance with MFL-E and depending on the specific site must always be agreed with Chrysler LLC. Teach Pendant

The connecting cable of the teach pendant is not supplied as a spiral cable. Extension cables can be ordered up to a total length of 50m.

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Cooperation Robots:

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Documentation

The following documentation is to be supplied in addition to the standard documentation: Digital pictures illustrating the mounting of components such as dress packages, etc., on the

robot (robot in home position)

Documentation of all non-standard software/hardware

10. Appendix

Appendix 1; User dress packages

Appendix 9: Brief description of the software

Abbreviations:

Abbreviation; Explanation;

CHRYSLER Chrysler Group LLC

KCP KUKA Control Panel

KPS KUKA Power Supply

KSD KUKA Servo Drive

TCP Tool Center Point

Project Book - KUKA Robotics

KUKA Robotics

Project Book

Chrysler Group

Powertrain

KUKA Robotics

Corporation

Version 6.5

Contents:

General

General Points (Industrial Robots)

KR 5 arc

The new KUKA KR 5 arc rounds off

the range of KUKA robots at the lower

end. Its payload of 5 kg makes it

outstandingly well-suited to standard

arc welding tasks. With its attractive

price and compact dimensions, it is the

ideal choice for your application too.

Whether mounted on the floor or

inverted overhead, the KR 5 arc always

performs its tasks reliably.

LOADS:

Payload 5 kg

Supplementary load 12 kg

Working envelope

Max. reach 1412 mm

Other data and variants

Number of axes 6

Repeatability ± 0,1 mm

Weight 127 kg

Mounting positions Floor, ceiling

KR 5 arc HW:

KUKA Roboter presents the

absolute specialist for arc

welding: the KR 5 arc HW

(Hollow Wrist). This new robot

type offers several features that

put it in a class of its own. The 50

mm opening in the arm and wrist,

for example, allows the arc

welding dress package to be

routed in the protective interior of

the arm. This not only shields the

dress package from mechanical

influences, but also prevents

undesirable whiplash motion

during reorientation of the robot.

Both torsion-type dress packages

and infinitely rotating arc welding

dress packages are possible. For

the user, this means not only

improved component accessibility

and optimal protection of the

dress package, but also simplified

offline programming.

LOADS:

Loads 5 kg

Supplementary load 12 kg

Working envelope

Max. reach 1423 mm

Other data and variants

Number of axes 6

Repeatability <±0,1 mm

Weight 120 kg

Mounting positions; Floor, ceiling

Angle ± 15°

IP 54

External Axes

1500-3

KUKA linear units are translational

motion units. They can be used to

extend a robot’s work envelope or

alternatively to move workpieces or

tools within the work envelopes of a

number of robots. This allows

applications such as the tending of

more than one machine or fixture,

order picking from rows of pallets, or

work on very large components.