KUKA Wood Milling Cell

1.0 System Overview & Purpose

The system is a fully integrated robotic machining cell designed for the high-precision, flexible milling of wood components. It combines a heavy-payload industrial robot with a high-speed spindle and auxiliary systems to automate complex milling, carving, and shaping operations, enabling unattended or minimally attended production cycles.

2.0 Core Robotic System

2.1 Robot Manipulator

• Model: KUKA KR 120 R2700-2

• Reach: 2700 mm

• Payload Capacity: 120 kg

• Number of Axes: 6

• Mounting: Floor-mounted

• Protection Class: Standard 

• Repeatability: ±0.05 mm

2.2 Robot Controller

• Model: KUKA KR C5

• Control Cabinet: Integrated into main electrical cabinet

• Software: KUKA System Software 8.7

• User Interface Option: KUKA.UserTech (Graphical User Interface) for simplified, icon-based programming of milling tasks.

• Programming Device: KUKA SmartPAD-2

2.3 External Rotary Axis

• Component: KUKA External Axis Kit (Includes drive unit and all necessary cables)

• Servo Motor: KUKA External Servo Motor, 4.2 KW

• Driven Device: Heavy-Duty Rotary Table

• Control: Fully integrated into the KR C5 controller as the 7th axis (A7).

3.0 Machining System

3.1 Spindle Unit

• Type: High-Frequency, Water-Cooled Spindle

• Power: 8.5 KW (Continuous)

• Speed: 24,000 RPM

• Cooling: Integrated water circuit, connected to external heat exchanger.

• Tool Interface: HSK-63F

• Lubrication: Grease-lubricated, maintenance-free bearings.

3.2 Spindle Drive & Control

• Variable Frequency Drive (VFD): 12 KW capacity.

• Function: Provides precise speed control (0-24,000 RPM) for the spindle. Controlled via digital communication signals from the KRC5.

• Integration: Mounted in the main electrical cabinet.

3.3 Tool Management System

• Tool Holder: HSK-63F, balanced for high-speed operation.

• Tool Fork: HSK-63F compatible gripper, pneumatically actuated, mounted on the robot wrist.

• Tool Storage: Tool rack with a capacity for 4 tools. Automatically loaded by robot.

• Tool Set: A selection of milling tools (end mills, ball nose, engraving bits, etc.) suitable for wood.

4.0 Workholding & Positioning

4.1 Rotary Table

• Type: Servo-driven, position-controlled rotary axis.

• Payload Capacity: 1,500 kg (including fixture and workpiece)

• Drive: Connected to the KUKA 4.2 KW external servo motor.

• Function: Serves as the 7th robot axis (A7), allowing for 4/5-axis simultaneous machining or precise indexing.

• Fixture Interface: Customizable mounting plate

5.0 Cell Infrastructure & Enclosures

5.1 Cell Base & Structure

• Base Frame: Welded metallic base, providing a rigid and level foundation for the robot and rotary table.

5.2 Main Electrical & Control Cabinet

• Enclosure: IP54 rated industrial cabinet.

• Contents:

  • KUKA KR C5 controller modules.

  • 12KW VFD for spindle.

  • Soft-PLC for cell sequencing.

  • Power distribution (Main disconnect, circuit breakers, transformers).

  • I/O modules for interfacing with peripheral devices.

• Cooling: Panel-mounted Air Conditioner (A/C) unit to maintain internal temperature and prevent electronic overheating.

6.0 Auxiliary Systems

6.1 Spindle Cooling System

• Coolant: 5 liters of specified water-glycol coolant liquid.

• Circuit: Closed-loop cooling circuit with:

  • Heat Exchanger: Air-to-liquid type, to dissipate spindle heat.

  • Coolant Hoses: 15 meters of flexible, insulated hoses between spindle, pump, and heat exchanger.

  • Reservoir & Pump: Integrated unit (implied).

6.2 Pneumatic System

• Supply: Requires clean, dry plant air at 6-8 bar.

• Components:

  • Pneumatic Valves & Regulator: Manifold for controlling pneumatic actuators (tool gripper, clamps, blow-off).

  • Internal & External Pneumatic Hoses: For distribution within the cabinet and to cell devices.

• Function: Powers tool fork actuation and any auxiliary workholding or cleaning functions.

6.3 Safety System

• Standard: All safety devices shall be integrated per Category 3 per ISO 13849-1 and shall interface with the KUKA KRC5 X11 safe robot interface to initiate protective stops.

6.4 Wiring & Cabling

• Internal & External Wiring: All necessary power, signal, and feedback cables for a complete turn-key installation, including robot-to-cabinet, spindle-to-VFD, and all field device connections.

7.0 Utilities & Site Requirements

• Electrical Supply: 400VAC, 3-phase + Neutral + Earth, 50/60Hz. Total connected load approximately 25KVA. 

• Compressed Air: 6-8 bar, filtered and dried, ~50 l/min consumption.

• Environment: Recommended temperature 10-40°C. 

8.0 Deliverables

1. Fully assembled and integrated robotic milling cell.

2. Complete electrical and pneumatic schematic diagrams.

3. Software backup with basic milling programs and tool data.

4. Operational and safety training for end-user personnel.

5. Full documentation pack (mechanical drawings, manuals, certificates).