3.3 Single Brake Module (SBM2)
3.3.1 Machine data
$PMCHANNEL[ ] If there is a “1” before the value of a $PMCHANNEL variable, this axis module has an SBM2.
In the case of a industrial robot with 2 asynchronous external axes and SBM2, for example, the following could apply:
$PMCHANNEL[1] = 20
$PMCHANNEL[2] = 20
$PMCHANNEL[3] = 20
$PMCHANNEL[4] = 20
$PMCHANNEL[5] = 20
$PMCHANNEL[6] = 20
$PMCHANNEL[7] = 121
$PMCHANNEL[8] = 121
$BRK_MODE If SBM2s are used, the following applies:
$BRK_MODE = 1101
Further information about SBM2 can be found in the assembly or op-erating instructions of the top-mounted cabinet with mounting plate and in the documentation Single Brake Module for safety-oriented or non-safety-oriented applications.
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4 Safety 4.1 General
4.1.1 Liability
The device described in this document is either an industrial robot or a com-ponent thereof.
Components of the industrial robot:
Manipulator
Robot controller
Teach pendant
Connecting cables
External axes (optional)
e.g. linear unit, turn-tilt table, positioner
Software
Options, accessories
The industrial robot is built using state-of-the-art technology and in accor-dance with the recognized safety rules. Nevertheless, misuse of the industrial robot may constitute a risk to life and limb or cause damage to the industrial robot and to other material property.
The industrial robot may only be used in perfect technical condition in accor-dance with its intended use and only by safety-conscious persons who are ful-ly aware of the risks involved in its operation. Use of the industrial robot is subject to compliance with this document and with the declaration of incorpo-ration supplied together with the industrial robot. Any functional disorders af-fecting the safety of the industrial robot must be rectified immediately.
Safety infor-mation
Safety information cannot be held against KUKA Roboter GmbH. Even if all safety instructions are followed, this is not a guarantee that the industrial robot will not cause personal injuries or material damage.
No modifications may be carried out to the industrial robot without the autho-rization of KUKA Roboter GmbH. Additional components (tools, software, etc.), not supplied by KUKA Roboter GmbH, may be integrated into the indus-trial robot. The user is liable for any damage these components may cause to the industrial robot or to other material property.
In addition to the Safety chapter, this document contains further safety instruc-tions. These must also be observed.
4.1.2 Intended use of the industrial robot
The industrial robot is intended exclusively for the use designated in the “Pur-pose” chapter of the operating instructions or assembly instructions.
Using the industrial robot for any other or additional purpose is considered im-permissible misuse. The manufacturer cannot be held liable for any damage resulting from such use. The risk lies entirely with the user.
Operating the industrial robot and its options within the limits of its intended use also involves observance of the operating and assembly instructions for
Further information is contained in the “Purpose” chapter of the oper-ating instructions or assembly instructions of the industrial robot.
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the individual components, with particular reference to the maintenance spec-ifications.
Misuse Any use or application deviating from the intended use is deemed to be imper-missible misuse. This includes e.g.:
Transportation of persons and animals
Use as a climbing aid
Operation outside the permissible operating parameters
Use in potentially explosive environments
Operation without additional safeguards
Outdoor operation
4.1.3 EC declaration of conformity and declaration of incorporation
This industrial robot constitutes partly completed machinery as defined by the EC Machinery Directive. The industrial robot may only be put into operation if the following preconditions are met:
The industrial robot is integrated into a complete system.
Or: The industrial robot, together with other machinery, constitutes a com-plete system.
Or: All safety functions and safeguards required for operation in the com-plete machine as defined by the EC Machinery Directive have been added to the industrial robot.
The complete system complies with the EC Machinery Directive. This has been confirmed by means of an assessment of conformity.
Declaration of conformity
The system integrator must issue a declaration of conformity for the complete system in accordance with the Machinery Directive. The declaration of confor-mity forms the basis for the CE mark for the system. The industrial robot must be operated in accordance with the applicable national laws, regulations and standards.
The robot controller is CE certified under the EMC Directive and the Low Volt-age Directive.
Declaration of incorporation
The industrial robot as partly completed machinery is supplied with a declara-tion of incorporadeclara-tion in accordance with Annex II B of the EC Machinery Direc-tive 2006/42/EC. The assembly instructions and a list of essential
requirements complied with in accordance with Annex I are integral parts of this declaration of incorporation.
The declaration of incorporation declares that the start-up of the partly com-pleted machinery remains impermissible until the partly comcom-pleted machinery has been incorporated into machinery, or has been assembled with other parts to form machinery, and this machinery complies with the terms of the EC Ma-chinery Directive, and the EC declaration of conformity is present in accor-dance with Annex II A.
The declaration of incorporation, together with its annexes, remains with the system integrator as an integral part of the technical documentation of the complete machinery.
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4.1.4 Terms used
4.2 Personnel
The following persons or groups of persons are defined for the industrial robot:
User
Personnel
User The user must observe the labor laws and regulations. This includes e.g.:
The user must comply with his monitoring obligations.
The user must carry out instruction at defined intervals.
Personnel Personnel must be instructed, before any work is commenced, in the type of work involved and what exactly it entails as well as any hazards which may
ex-Term Description
Axis range Range of each axis, in degrees or millimeters, within which it may move.
The axis range must be defined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance The stopping distance is part of the danger zone.
Workspace The manipulator is allowed to move within its workspace. The work-space is derived from the individual axis ranges.
Operator (User)
The user of the industrial robot can be the management, employer or delegated person responsible for use of the industrial robot.
Danger zone The danger zone consists of the workspace and the stopping distances.
KCP The KCP (KUKA Control Panel) teach pendant has all the operator con-trol and display functions required for operating and programming the industrial robot.
Manipulator The robot arm and the associated electrical installations Safety zone The safety zone is situated outside the danger zone.
Stop category 0 The drives are deactivated immediately and the brakes are applied. The manipulator and any external axes (optional) perform path-oriented braking.
Note: This stop category is called STOP 0 in this document.
Stop category 1 The manipulator and any external axes (optional) perform path-main-taining braking. The drives are deactivated after 1 s and the brakes are applied.
Note: This stop category is called STOP 1 in this document.
Stop category 2 The drives are not deactivated and the brakes are not applied. The manipulator and any external axes (optional) are braked with a normal braking ramp.
Note: This stop category is called STOP 2 in this document.
System integrator (plant integrator)
System integrators are people who safely integrate the industrial robot into a complete system and commission it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s) T2 Test mode, Manual High Velocity (> 250 mm/s permissible)
External axis Motion axis which is not part of the manipulator but which is controlled using the robot controller, e.g. KUKA linear unit, turn-tilt table, Posiflex.
All persons working with the industrial robot must have read and un-derstood the industrial robot documentation, including the safety chapter.
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ist. Instruction must be carried out regularly. Instruction is also required after particular incidents or technical modifications.
Personnel includes:
System integrator
Operators, subdivided into:
Start-up, maintenance and service personnel
Operating personnel
Cleaning personnel
System integrator The industrial robot is safely integrated into a complete system by the system integrator.
The system integrator is responsible for the following tasks:
Installing the industrial robot
Connecting the industrial robot
Performing risk assessment
Implementing the required safety functions and safeguards
Issuing the declaration of conformity
Attaching the CE mark
Creating the operating instructions for the complete system Operator The operator must meet the following preconditions:
The operator must be trained for the work to be carried out.
Work on the industrial robot must only be carried out by qualified person-nel. These are people who, due to their specialist training, knowledge and experience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential hazards.
Example The tasks can be distributed as shown in the following table.
Installation, exchange, adjustment, operation, maintenance and re-pair must be performed only as specified in the operating or assembly instructions for the relevant component of the industrial robot and only by personnel specially trained for this purpose.
Tasks Operator Programmer System
integrator Switch robot controller
on/off x x x
Start program x x x
Select program x x x
Select operating mode x x x
Calibration
(tool, base) x x
Master the manipulator x x
Configuration x x
Programming x x
Start-up x
x
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4.3 Workspace, safety zone and danger zone
Workspaces are to be restricted to the necessary minimum size. A workspace must be safeguarded using appropriate safeguards.
The safeguards (e.g. safety gate) must be situated inside the safety zone. In the case of a stop, the manipulator and external axes (optional) are braked and come to a stop within the danger zone.
The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). It must be safeguarded by means of physical safeguards to prevent danger to persons or the risk of material dam-age.
4.4 Triggers for stop reactions
Stop reactions of the industrial robot are triggered in response to operator ac-tions or as a reaction to monitoring funcac-tions and error messages. The follow-ing table shows the different stop reactions accordfollow-ing to the operatfollow-ing mode that has been set.
Repair x
Decommissioning x
Transportation x
Work on the electrical and mechanical equipment of the industrial ro-bot may only be carried out by specially trained personnel.
Tasks Operator Programmer System
integrator
Fig. 4-1: Example of axis range A1
1 Workspace 3 Stopping distance
2 Manipulator 4 Safety zone
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STOP 0, STOP 1 and STOP 2 are the stop definitions according to DIN EN 60204-1:2006.
4.5 Safety functions
4.5.1 Overview of safety functions
Safety functions:
Mode selection
Operator safety (= connection for the guard interlock)
Local EMERGENCY STOP device (= EMERGENCY STOP button on the KCP)
External EMERGENCY STOP device
Enabling device
External enabling device
Local safety stop via qualifying input
RoboTeam: disabling of robots that have not been selected
These circuits conform to the requirements of Performance Level d and cate-gory 3 according to EN ISO 13849-1. This only applies under the following conditions, however:
The EMERGENCY STOP is not triggered more than once a day on aver-age.
The operating mode is not changed more than 10 times a day on average.
Number of switching cycles of the main contactors: max. 100 per day
Trigger T1, T2 AUT, AUT
EXT
Safety gate opened - STOP 1
EMERGENCY STOP pressed STOP 0 STOP 1
Enabling withdrawn STOP 0
-Start key released STOP 2
-“Drives OFF” key pressed STOP 0
STOP key pressed STOP 2
Operating mode changed STOP 0
Encoder error
(DSE-RDC connection broken)
STOP 0
Motion enable canceled STOP 2
Robot controller switched off Power failure
STOP 0
If these conditions are not met, KUKA Roboter GmbH must be con-tacted.
In the absence of operational safety functions and safe-guards, the industrial robot can cause personal injury or material damage. If safety functions or safeguards are dismantled or deacti-vated, the industrial robot may not be operated.
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4.5.2 ESC safety logic
The function and triggering of the electronic safety functions are monitored by the ESC safety logic.
The ESC (Electronic Safety Circuit) safety logic is a dual-channel computer-aided safety system. It permanently monitors all connected safety-relevant components. In the event of a fault or interruption in the safety circuit, the pow-er supply to the drives is shut off, thus bringing the industrial robot to a stand-still.
The ESC safety logic triggers different stop reactions, depending on the oper-ating mode of the industrial robot.
The ESC safety logic monitors the following inputs:
Operator safety
Local EMERGENCY STOP (= EMERGENCY STOP button on the KCP)
External EMERGENCY STOP
Enabling device
External enabling device
Drives OFF
Drives ON
Operating modes
Qualifying inputs
The ESC safety logic monitors the following outputs:
Operating mode
Drives ON
Local E-STOP
4.5.3 Mode selector switch
The industrial robot can be operated in the following modes:
Manual Reduced Velocity (T1)
Manual High Velocity (T2)
Automatic (AUT)
Automatic External (AUT EXT)
The operating mode is selected using the mode selector switch on the KCP.
The switch is activated by means of a key which can be removed. If the key is removed, the switch is locked and the operating mode can no longer be changed.
If the operating mode is changed during operation, the drives are immediately switched off. The manipulator and any external axes (optional) are stopped with a STOP 0.
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4.5.4 Operator safety
The operator safety input is used for interlocking physical safeguards. Safety equipment, such as safety gates, can be connected to the dual-channel input.
If nothing is connected to this input, operation in Automatic mode is not possi-Fig. 4-2: Mode selector switch
1 T2 (Manual High Velocity) 2 AUT (Automatic)
3 AUT EXT (Automatic External) 4 T1 (Manual Reduced Velocity)
Operatin
g mode Use Velocities
T1
For test operation, pro-gramming and
Jog velocity, maximum 250 mm/
s
T2 For test operation Program verification:
Programmed velocity
AUT
For industrial robots without higher-level controllers
Only possible with a connected safety cir-cuit
Program mode:
Programmed velocity
Jog mode: Not possible
AUT EXT
For industrial robots with higher-level con-trollers, e.g. PLC Only possible with a connected safety cir-cuit
Program mode:
Programmed velocity
Jog mode: Not possible
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ble. Operator safety is not active in the test modes T1 (Manual Reduced Ve-locity) and T2 (Manual High VeVe-locity).
In the event of a loss of signal during Automatic operation (e.g. safety gate is opened), the manipulator and the external axes (optional) stop with a STOP 1.
Once the signal is active at the input again, automatic operation can be re-sumed.
Operator safety can be connected via the peripheral interface on the robot controller.
4.5.5 EMERGENCY STOP device
The EMERGENCY STOP device for the industrial robot is the EMERGENCY STOP button on the KCP. The button must be pressed in the event of a haz-ardous situation or emergency.
Reactions of the industrial robot if the EMERGENCY STOP button is pressed:
Manual Reduced Velocity (T1) and Manual High Velocity (T2) modes:
The drives are switched off immediately. The manipulator and any external axes (optional) are stopped with a STOP 0.
Automatic modes (AUT and AUT EXT):
The drives are switched off after 1 second. The manipulator and any ex-ternal axes (optional) are stopped with a STOP 1.
Before operation can be resumed, the EMERGENCY STOP button must be turned to release it and the stop message must be acknowledged.
It must be ensured that the operator safety signal is not automatically reset when the safeguard (e.g. safety gate) is closed, but only after an additional manual acknowledgement signal has been given. Only in this way can it be ensured that automatic operation is not resumed inadvertently while there are still persons in the danger zone, e.g.
due to the safety gate closing accidentally.
Failure to observe this precaution may result in death, severe physical inju-ries or considerable damage to property.
Fig. 4-3: EMERGENCY STOP button on the KCP
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4.5.6 External EMERGENCY STOP device
There must be EMERGENCY STOP devices available at every operator sta-tion that can initiate a robot mosta-tion or other potentially hazardous situasta-tion.
The system integrator is responsible for ensuring this.
There must always be at least one external EMERGENCY STOP device in-stalled. This ensures that an EMERGENCY STOP device is available even when the KCP is disconnected.
External EMERGENCY STOP devices are connected via the customer inter-face. External EMERGENCY STOP devices are not included in the scope of supply of the industrial robot.
4.5.7 Enabling device
The enabling devices of the industrial robot are the enabling switches on the KCP.
There are 3 enabling switches installed on the KCP. The enabling switches have 3 positions:
Not pressed
Center position
Panic position
In the test modes, the manipulator can only be moved if one of the enabling switches is held in the central position. If the enabling switch is released or pressed fully down (panic position), the drives are deactivated immediately and the manipulator stops with a STOP 0.
Tools and other equipment connected to the manipulator must be integrated into the EMERGENCY STOP circuit on the system side if they could constitute a potential hazard.
Failure to observe this precaution may result in death, severe physical inju-ries or considerable damage to property.
The enabling switches must not be held down by adhe-sive tape or other means or manipulated in any other way.
Death, serious physical injuries or major damage to property may result.
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4.5.8 External enabling device
External enabling devices are required if it is necessary for more than one per-son to be in the danger zone of the industrial robot. They can be connected via the peripheral interface on the robot controller.
External enabling devices are not included in the scope of supply of the indus-trial robot.
4.6 Additional protective equipment
4.6.1 Jog mode
In the operating modes T1 (Manual Reduced Velocity) and T2 (Manual High Velocity), the robot controller can only execute programs in jog mode. This means that it is necessary to hold down an enabling switch and the Start key in order to execute a program.
If the enabling switch is released or pressed fully down (panic position), the drives are deactivated immediately and the manipulator and any external axes (optional) stop with a STOP 0.
Releasing only the Start key causes the industrial robot to be stopped with a STOP 2.
4.6.2 Software limit switches
The axis ranges of all manipulator and positioner axes are limited by means of adjustable software limit switches. These software limit switches only serve as machine protection and must be adjusted in such a way that the manipulator/
positioner cannot hit the mechanical end stops.
Fig. 4-4: Enabling switches on the KCP
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The software limit switches are set during commissioning of an industrial ro-bot.
4.6.3 Mechanical end stops
The axis ranges of main axes A1 to A3 and wrist axis A5 of the manipulator are limited by means of mechanical end stops with buffers.
Additional mechanical end stops can be installed on the external axes.
4.6.4 Mechanical axis range limitation (optional)
Some manipulators can be fitted with mechanical axis range limitation in axes A1 to A3. The adjustable axis range limitation systems restrict the working range to the required minimum. This increases personal safety and protection of the system.
In the case of manipulators that are not designed to be fitted with mechanical axis range limitation, the workspace must be laid out in such a way that there is no danger to persons or material property, even in the absence of mechan-ical axis range limitation.
If this is not possible, the workspace must be limited by means of photoelectric barriers, photoelectric curtains or obstacles on the system side. There must be no shearing or crushing hazards at the loading and transfer areas.
4.6.5 Axis range monitoring (optional)
Some manipulators can be fitted with dual-channel axis range monitoring sys-tems in main axes A1 to A3. The positioner axes may be fitted with additional
Some manipulators can be fitted with dual-channel axis range monitoring sys-tems in main axes A1 to A3. The positioner axes may be fitted with additional