KUKA Arc-Welding System with Water Cooled Machine

1. Robot Manipulator: KUKA KR 6 R1840-2 (Cybertech Nano)

• Robot Type: 6-Axis Articulated Industrial Robot

• Max. Reach: 1840 mm

• Rated Payload: 6 kg

• Max. Payload: 9 kg (dependent on load center distance)

• Pose Repeatability (ISO 9283): ±0.04 mm

• Mounting Position: Floor

• Protection Rating:

  • Robot Body: IP65

  • Wrist (In-line wrist): IP67

• Axis Speed:

  • A1: 220°/s

  • A2: 210°/s

  • A3: 270°/s

  • A4: 381°/s

  • A5: 311°/s

  • A6: 472°/s

• Weight: Approx. 162 kg

• Mounting Flange: Mechanical interface for torch mounting (typically DIN ISO 9409-1-A40).

2. Robot Controller: KUKA KR C5 Micro

• Form Factor: Compact, lightweight controller for small robot arm series.

• Input Voltage: 1x 220-240 V AC (Single Phase), 50/60 Hz.

• Dimensions (approx.): 300 mm x 134 mm x 392 mm.

• Protection Rating: IP20 (Must be installed in a clean environment or suitable cabinet).

• Safety Integrated: KUKA Safe Operation (Stop categories 0, 1, 2).

• Interfaces:

  • Fieldbus: EtherCAT (Master), generic Ethernet (KLI).

  • I/O: On-board Digital I/O (16 Inputs / 16 Outputs) for peripheral control.

  • USB: For data backup/program transfer.

• Software: KUKA System Software (KSS) 8.7 

• Teach Pendant: KUKA smartPAD (wired handheld terminal with touch screen).

3. Welding Power Source: 

• Process Type: Full Digital Pulse MIG/MAG / CO2 (Double Pulse capable).

• Cooling Method: Water-cooled (integrated or external water tank system).

• Input Power: 3-Phase 380V ±10%, 50/60 Hz.

• Rated Output Current: 30 – 500 A.

• Rated Duty Cycle: 100% @ 500 A (at 40°C).

• Output Voltage Range: 15.5 – 39 V.

• Control Technology: 32-bit DSP (Digital Signal Processing) for precise waveform control.

• Welding Modes:

  • Standard CV (Constant Voltage)

  • Pulse MIG (Spray transfer at lower currents)

  • Double Pulse MIG (Ripple bead appearance, aluminum/stainless applications)

• Wire Feeder:

  • Type: Separate, fully digital enclosed feeder.

  • Drive: 4-Roll drive system with encoder feedback for stable wire speed.

• Communication Interface (Robot <-> Welder):

  • Digital I/O (Standard): Uses digital signals for Current/Voltage control and signals for Arc Start/Stop, Gas Check, Wire Inch, etc.

4. System Integration & Peripherals

• Welding Torch:

  • Type: Water-cooled robotic torch 

  • Neck Geometry: Typically 22° 

  • Crash Sensor: Safety switch mount to stop robot upon torch collision.

• Torch Cable Assembly (Dress Pack):

  • Includes power cable, water hoses, gas hose, and control wire.

  • Must be routed along the robot arm (Axis 3 to Axis 6) allowing full articulation without snagging.

• Cable Connection:

  • Grounding: Heavy-duty earth clamp and cable connected to the welding table/fixture.

  • Control Cable: Shielded multi-core cable connecting KR C5 Micro I/O X11/X51 to welder interface plug 

5. Installation Requirements

• Power Supply:

  • Robot: Single-phase 230V breaker (approx. 16A).

  • Welder: Three-phase 380V breaker (approx. 32A).

• Gas Supply: Shielding gas cylinder (Argon/CO2 mix) or bulk supply with regulator (Flow rate: 15-25 L/min).

• Floor Mounting: Reinforced concrete floor with chemical anchors (M12/M16) for the robot base.