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Version 6.5 Number of pages: 20
Issued 07.01.2010
File / Template: Projectbook_KUKA_Robotics_6.5_en.2 07012010/ Normal.dotm
Confidential! All rights reserved. The reproduction or transmission of this documentation in whole or in part,
including the use of summaries, is prohibited without the prior written consent of Chrysler.
KUKA Robotics
Project Book
Chrysler Group
Powertrain
KUKA Robotics
Corporation
Version 6.5
Revision Date: JULY 01, 2010
Version 6.5 Contents Page i
Issued 07.01.2010
File: Projectbook_KUKA_Robotics_6.5_en.2 07012010
Contents:
General ...................................................................................................................................... 1 Foreword: 1 Modification Log: 1 Chrysler Group Facilities in the US: 1 Contacts at KUKA Robotics Corporation and KUKA Roboter AG: 2
General Points (Industrial Robots) ......................................................................................... 3 2.1 Industrial Robots 3 2.2 Provision of Robots 3
2.3 Payload Categories 3
External Axes .......................................................................................................................... 11 Linear Axis KL 1500-3 11 Vertical Dual Turnover Positioner 11
Colors: ..................................................................................................................................... 12
User Dress Packages Without Tool Changing System: ...................................................... 13 1.1.1 Dress Package 1 (KR 150, 210, 360, 500, 1000) 13 1.1.2 Dress Package 2 (KR 150, 210, 360) 14
1.1.3 Dress Package 3 (KR 150, 210, 360) 14 1.1.4 Dress Package 4 (KR 150, 210, 360) (Welding, Single) 15 1.1.5 Dress Package 5 (KR 16) 15
1.1.6 Dress Package 6 (KR 30) 15
Warranty: 16
Software Modules (KUKA) ................................................................................................... 17 Standard Equipment: 17
Application-Specific Software Modules (optional): 17 Vision: 17
Connection to Material and Production Data Acquisition Systems: 17 Automatic TCP Calibration: 17
Robot Arm: ............................................................................................................................. 18 Mechanical Hard Stops for the Main Axes (Workspace Limitation) 18 Workspace Monitoring: 18
Absolute Accuracy: 18 Collision Protection: 18
KUKA Safe Operation: 18 Tool Changing Systems 19 1.1.7 Automatic Tool Changing System: 19 1.1.8 Manual Rapid Tool Mounting System: 19
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Robot Control Cabinet ........................................................................................................... 20 General: 20 Electrical interfaces 20 1.1.9 Power supply: 20 1.1.10 Connectors: 20
1.1.11 Bus systems 20 PLC Interface / Safety Signals 20 Control of Application-Specific Functions (PLC) 21 Control Cabinet Rollers 21 Digital Inputs / Outputs 21
Air / Water Heat Exchanger 21
Teach Pendant 21
KUKA Motion Control .......................................................................................................... 22
Documentation ........................................................................................................................ 24 Appendix 9: Brief description of the software 24
CHRYSLER Powertrain Project Book
Version 6.5 Page 1
Issued 07.01.2010
File: Projectbook_KUKA_Robotics_6.5_en.2 07012010
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
01012008 4.0 Project Book 4.0 Content
Updated All
Soeren Papsdorf
01012009 5.0 Project Book 5.0 Content
Updated All Jim Foreman
07012009 5.5 Project Book 5.5 Content
Updated All Jim Foreman
01012010 6.0 Project Book 6.0 Content
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.
GEMA 2, Monroe, MI.
CHRYSLER Powertrain Project Book
Version 6.5 Page 2
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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
Michael Dewitte Director; Automotive Accounts
Address: KUKA Robotics 22500 Key Drive
Clinton Township, Michigan 48036
Telephone: (586) 465-8849
Mike Maximiuk Senior Engineering Manager
Address: KUKA Robotics 22500 Key Drive
Clinton Township, Michigan 48036 Telephone: (586) 465-8825
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
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
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
CHRYSLER Powertrain Project Book
Version 6.5 Page 3
Issued 07.01.2010
File: Projectbook_KUKA_Robotics_6.5_en.2 07012010
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.
Overview:
CHRYSLER Powertrain Project Book
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CHRYSLER Powertrain Project Book
Version 6.5 Page 5
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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
CHRYSLER Powertrain Project Book
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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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CHRYSLER Powertrain Project Book
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CHRYSLER Powertrain Project Book
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CHRYSLER Powertrain Project Book
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CHRYSLER Powertrain Project Book
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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.
CHRYSLER Powertrain Project Book
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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”.
CHRYSLER Powertrain Project Book
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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
CHRYSLER Powertrain Project Book
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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
1 x Multibus cable for Interbus/Profibus with Interconnectron connector (power supply cables are
integrated into the dress package)
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 mm
2) 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.
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
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)
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
CHRYSLER Powertrain Project Book
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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
Set of holders for dress package along exterior of robot
Axes 1-3 for KR 150/210
Axes 3-6 for KR 150/210
1.1.5 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:
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 Multibus cable for Interbus/Profibus with Interconnectron connector (power supply cables are
integrated into the dress package)
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.
CHRYSLER Powertrain Project Book
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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.
CHRYSLER Powertrain Project Book
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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.)
CHRYSLER Powertrain Project Book
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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.
CHRYSLER Powertrain Project Book
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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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KUKA Motion Control
CHRYSLER Powertrain Project Book
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Cooperation Robots:
Complete Document
CHRYSLER Powertrain Project Book
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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
KR KUKA Robotics