Motor Specification
NON-KUKA MOTORS
Specification
and procedures
for control with the
KUKA KR C4
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Motor Specification
NON-KUKA MOTORS SPECIFICATION AND PROCEDURES FOR CONTROL WITH
THE KUKA KR C4
1
1
GENERAL PROCEDURE
1.1
1.2
1.3
3
KUKA MOTORS
NON KUKA-STANDARD MOTORS (PM SERVOMOTORS)
INTEGRATION AND MACHINE DATA DEPENDENT ON MECHANICAL EQUIPMENT
3
3
4
2
KUKA STANDARD MOTORS
5
3
NON-KUKA MOTORS (PM SERVO MOTORS)
6
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
4
14
14
15
15
15
16
16
DESIGN
DUTY FACTOR
SPINDLE
17
17
17
17
CHECKLIST
6.1
6.2
6.3
7
DATA SHEET
M-N CHARACTERISTIC
BRAKE DATA
MOMENT OF INERTIA
RESOLVER
MOTOR- UND SERVODATEI
ADDITIONAL REQUIREMENTS FOR TORQUE MODE
5.1
5.2
5.3
6
6
6
6
6
7
8
8
8
8
8
9
12
12
DATA REQUIRED FROM MOTOR SUPPLIERS
4.1
4.2
4.3
4.4
4.5
4.6
5
RATING PLATE / LABELING
LABELING
MOTOR TYPE
VOLTAGE
CURRENT
SHORTCUT BREAKING
MAXIMUM SPEED
PHASE SEQUENCE
TORQUE RIPPLE
BRAKE
RESOLVER
TEMPERATURE MONITORING
CONNECTOR
18
18
18
18
MOTOR
RESOLVER
BRAKE
EXPLANATION OVER FULFILLMENT OF THE SPECIFICATION:
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Motor Specification
1 General procedure
KUKA Roboter GmbH, or KUKA for short, offers the possibility to integrate motor data for special
kinematics and external axes into the KUKA KR C4 robot controller.
The following items must be agreed with KUKA prior to integration:
1.1
KUKA motors
It must always be verified to what extent (optimized) KUKA motors can be used for the
kinematics systems.
1.2
NON KUKA-STANDARD motors (PM servomotors)
If for technical or strategic reasons other servomotors have to be used, they must satisfy the
specifications listed below, and their suitability must be tested by KUKA. Doing this the
customer has two different choices of test procedures (see below „Test procedure“).
The customer must ensure that the motors being used are unambiguously labeled and that
they are within the specified tolerance limits. The customer shall provide data sheets containing
the necessary motor data. The motor must be supplied without any gear unit, spindle or other
mechanical device, since testing is not possible otherwise. A measurement of the phase-tophase voltage constant (EMF) must be provided with the motor. If a resolver is used which has
not been approved, a manufacturer’s data sheet and measurements as specified in Section
3.11.2 must be supplied.
Motor related machine code (servo file)
For each motor type, a so called motor- and servo file has to be stored in the respective
locations in the KR C4 control, whose name is being declared in the axis-file.
The generation of these files is currently not integrated in the robot control and/or work visual
and can only be carried out by KUKA. The import of motor- and servo files into the robot control
as well as the configuration of axis- and kinematical data is possible with WorkVisual.
KUKA offers testing of the motor and creation of the corresponding servo file as a service.
Sample file.
For this, one of each type of motor WITHOUT devices (clutch, gear unit etc.) must be provided
to KUKA, together with all of the specified technical data for the motor, brake and resolver.
On consultation, a motor should be left at KUKA for reference purposes.
Test procedure
Basically we offer to our customers two different complex test procedures which will be priced
accordingly:
Test procedure 1 – Specification compliance
The motor will be checked against the Non-KUKA motor specification compliance and will be
tested to prove controllability. A motor specific machine data file (servo file) is generated and
will be send to the customer with a detailed test report. A measurement of the watt
consumption and of the regulation behaviour will not be done.
Test procedure 1 – Declaration of compatibility
To gain a declaration of compatibility the motor must be tested with great detail and
complexity. The tests result in a final report with the servo file and a KUKA certification.
Among others following tests will be proceeded:
- Determine the regulation parameters with engine idle
- Measuring the resolver data and adjustment
- Different inertia speed ups
- Motor „worst case scenario“
- Watt consumption of the motor
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Motor Specification
In both cases, by using the motor within a machine or cell, the customer has to carry the
responsibility for a risk analysis and the CE-conformity.
1.3
Integration and machine data dependent on mechanical equipment
To ensure smooth running of the motor in special kinematics, the appropriate machine data
must be created. This is based on variables dependent on mechanical equipment, such as
gear ratios, friction, etc. and the process parameters.
Creation of the machine data dependent on mechanical equipment is the sole responsibility of
the customer.
KUKA offers a special training course in creation of machine data dependent on mechanical
equipment. Participants learn how to analyze the mechanical equipment and process data to
create by them self machine data for each individual motor.
Alternatively, this service can be ordered from KUKA for each individual motor/kinematics
combination.
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Motor Specification
2 KUKA standard motors
Technical data are contained at the KUKA motor documentation.
These motors have undergone long-term testing with the KUKA robot controller and are approved
by KUKA Roboter GmbH.
When planning external axes and special kinematics, it should first be checked whether KUKA
motors can be used before carrying out time-consuming tests on unknown NON-KUKA motors.
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Motor Specification
3 NON-KUKA motors (PM servo motors)
If NON-KUKA standard motors which can’t be replaced by KUKA standard motors (see above)
have to be operated with the KR C4 controller, the following minimum requirements must be met:
3.1
Rating plate / labeling
A rating plate with the motor-specific data must be attached to each motor.
The motor must be clearly assigned to the corresponding data sheets of the motor and resolver
(including the resolver mastering) by means of the type designation and an unambiguous serial
number.
The type label on the motor must be identical with the type label indicated on the accompanying
data sheet.
3.2
Labeling
A CE mark in accordance with the Low Voltage and Machinery Directives is required.
In addition, labels must be present warning of high temperatures and high voltage.
3.3
Motor type
Permanent - magnet synchronous motor with sinusoidal electromotive force.
3.4
Voltage
Insulation class F (or higher)
Voltage endurance: IEC 60034-1
• The intermediate voltage is drawn from the 3phase supply voltage
U = 400V−+1015%% or
U = 480V−+1010%% , depending on the supply voltage.
• The intermediate circuit voltage can get as high as 780V with in braking mode. The motor
insulation must be voltage proof for this range.
• Max. allowable periodic peak voltage ÛLL (and partial discharge inception voltage Vpk) shall be
min 1.56kV according to EN 60034-25.
• The robot controller may only be operated with grounded-neutral power sup-ply systems (see
operating instruction).
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Motor Specification
ÛLL [V]
Impuls voltage ÛLL in relation to raise time
1800
1600
1400
1200
1000
800
600
400
200
0
Limit
characteristic
0
200
400
600
800
1000
tr[nsec]
• Electrical separation: precondition for operating on a KRC4 is a reinforced isolation between
motor phases and temperature sensor, brake, resolver and any other sensors against 480V
motor voltage. Motor internal cable routing and connectors must be taken into consideration.
3.5
Current
The following KUKA Servo Packs (KSP) and KUKA Power Packs (KPP) are available:
KSP 600-3x20
KSP 600-3x40
KPP 600-20-1x40
KPP 600-20-2x40
KSP 600-3x64
KPP 600-20-1x64
Imax
20 A
40 A
64 A
INenn
I0
9A
17 A
10 A
19,5 A
20 A
27 A
Imax is the current that the motor must be able to withstand for at least 2 seconds without damage!
Inom is limited to 95% of the value specified in the table!
I0 is the maximum sustained holding current of the drive module which the motor must withstand!
The values referred to in the table are values which the power packs are able to deliver. If the
motor is not capable to deal with these values, a limitation will take place to values entered in the
respective parameter locations.
Imax <5Hz In a rotating field frequency of <5Hz (rotation speed) the KSP or KPP limits the allowable
current to 1.5 * Inom automatically.
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Motor Specification
3.6
Shortcut breaking
The motor must be able to withstand without damage short-circuit braking from nominal speed nN
(without brake resistors).
3.7
Maximum speed
fel ≤ 266 Hz (corresponds to 4000 rpm for a motor with 4 pairs of poles)
fel ≤ 266 Hz (corresponds to 5000 rpm for a motor with 3 pairs of poles)
3.8
Phase sequence
U-V-W with clockwise motion (looking towards the drive end (side ”A”) of the motor)
Can be measured in generator mode when loaded with a star resistor network.
See Section 3.12, Connector.
3.9
Torque ripple
KUKA recommends:
•
Low torque ripple
•
Sinusoidal electromotive force characteristic
Cogging torques and harmonic content of the electromotive force can lead to oscillations in the
control loops!
3.10 Brake
Play-free holding brake with emergency stop function (In certain operating states the brake may be
applied by the controller while the motor is still turning!).
The brake must have a double or reinforced isolation against the motor phases.
Supply voltage
24 V +/-10%
Allowable brake current
0,14A - 1,5A
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Motor Specification
3.11 Resolver
3.11.1 Approved types
At present the following resolvers have been approved by KUKA and are recommended:
Size 21:
-
Siemens V23401-T2510-D209, identical to Tyco type 5-1393048-0
; 3 speed
-
Siemens V23401-T2610-D209, identical to Tyco type 5-1393048-2
; 3 speed
-
Siemens V23401-T2614-D209, identical to Tyco type 5-1393048-3
; 4 speed
-
Tamagawa TS2640N663E70
; 3 speed
Size 15:
-
Siemens V23401-R3710-E101
; 3 speed
-
Siemens V23401-D1010-B101
; 3 speed
An updated overview of all approved resolvers is available from KUKA on request.
3.11.2 Specifications for RDC
In special cases, KUKA can be commissioned to test other resolvers.
The ratio of the number of pairs of poles of the motor and the resolver must be a whole number!
KUKA recommends a motor: resolver pair of poles ratio of 1:1 (KUKA standard).
The following constraints must always be observed with a supply voltage Urms from 5.3 to 7.0 V and
a supply frequency of 8 kHz:
(When making measurements, the connecting cables must be taken into account in all of the
lengths used!)
- Max. input current Imax on the resolver 50 mA
Measurement without load:
- Phase shift ϕ
- Transmission ratio TR
3° +/-5°
max. 0.5 / min. 0.45 -5%
Measurement with load from the following circuit:
- Phase shift ϕ
- Transmission ratio TR
-9° +/-4°
0.44 +/-10%
Messpunkte differenziell =
Differential measurement points
R1 = 475 Ohm
C1 = 10nF (50V)
Notes:
The control quality is dependent on the resolver accuracy. Angle errors less than +/-7’
(mechanical angular minutes) are desirable.
The angle error correlates to the resolver which is mounted in the motor. It also includes
excentricity from resolver mounting.
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Motor Specification
It must be ensured that the resolver wiring in the motor is unsusceptible to interference. Pay
particular attention to possible interference from the motor cables!
Even if the above values are complied with, the resolver must still be tested at KUKA!
3.11.3 Mastering
The standard resolver mastering is defined by KUKA as follows:
With positive peak value of phase U / electromotive force: (PPR = 1)
Pins 1-2: S2-S4 (sin) = 0
Pins 11-12: S1-S3 (cos) = pos. max.
With positive zero passage of phase U / electromotive force: (PPR = 1) (increasing from negative to
positive)
Pins 1-2: S2-S4 (sin) = pos. max.
Pins 11-12: S1-S3 (cos) = 0
Mastering tolerance:
+/-1.5° (electrical)
Every motor of the same type must show the same resolver mastering!
1st. Example for checking the mastering
The motor must be free-standing, with the brake released, and is brought into position using
direct current (phase energization). In addition positive voltage is designed at the motor
phases U and at the motor phases V and W negative voltage. Attention: voltage and
current are to be limited!
One observes the exciting voltage by means of oscilloscope (pins 10 – 7: R1 – R2) as well
as the cosine - (pins 11 – 12: S1 – S3) and the sine signal (pins 1 – 2: S2 – S4), is watching
the adjusted condition following image.
The sine signal has maximal amplitude and is shifted around 180° phases to the exciting
voltage. (S2-S4 (sin) = neg. max.) The cosine signal is ZERO. (S1-S3 (cosine) = 0)
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Motor Specification
The image below shows the measuring system.
Mastering positions of the resolver other than 0° can be determined by KUKA on request.
Error-free configuration of the machine data (Servo File) is only possible if the motor and resolver
cabling and resolver mastering are always the same for identical motors.
The test specimen shall remain at KUKA for future reference in the event of a fault.
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Motor Specification
3.12 Temperature monitoring
KUKA recommends the use of type KTY84-130 thermal overload protection.
The construction und cabling of the temperature-sensor must be in conformity to DIN-ENrequirements for “safe electrical insulation”.
The Sensor must have a double or reinforced isolation against the motor phases.
If instead of the KTY84-130 a 680-ohm fixed resistor is installed, the temperature monitoring is
deactivated.
a)
The installation position of the sensor must ensure monitoring of all motor phases
b)
I0 must be possible continuously for every motor position.
(i.e.
I PhaseU = 2 ⋅ I 0 and
I v = IW = −
2 ⋅ I0
)
2
3.13 Connector
Alternative 1: connection in accordance with Sections 3.12.1 through 3.12.3 and supplied
adapter cable
•
3.13.1 Power connector, size 1
Compatible with Intercontec B ST A 085
Connector pin assignments:
5
4
1
6
2
3
Pin
Assignment
1
U
2
V
3
GND
4
BR+
5
BR-
6
W
3.13.2 Power connector, size 1.5
Rotary right-angle flanged socket (pins), compatible with Intercontec C ST A 263
V
BRW
BR+
U
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Motor Specification
3.13.3 Signal (resolver) connector
Compatible with Intercontec A ST A 021
20° coded!
Interconnectron
pin
Assignment
Color
1
S2
yellow
2
S4
blue
7
R2
yellow/white
8
KTY +
9
KTY -
10
R1
red/white
11
S1
red
12
S3
black
3
4
5
6
3.13.4 Cables
KUKA recommends the use of approved KUKA motor and resolver cables.
When cables which don’t belong to the KUKA product range are used, it must be ensured that their
cross-sections and shielding are suitable.
In this case the brake cable must have its own shield!
2
We recommend a wire cross-section of at least 0.25 mm for sensor / resolver cables. It must be
ensured that the resolver and sensor wiring is unsusceptible to interference.
Both the shortest and the longest resolver cables intended for use must be provided for the tests at
KUKA.
Our tests cover only the values shown in Section 3.11.2. General approval of the cables is not is
not included in these tests.
The resolver cable must not change the transmission ratio or cause any additional phase
shift!
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Motor Specification
4 Data required from motor suppliers
4.1
Data sheet
The following data must be provided for the control of NON-KUKA motors:
1. Motor manufacturer
____________________
2. Type
____________________
3. Nominal speed
nnom
__________ rpm
4. Nominal torque
Mnom
__________ Nm
5. Nominal current
Inom
__________ A
6. Static torque
M0 (S1-100K) __________ Nm
7. Static current (> 60 s)
I0 (S1-100K)
__________ A
8. Max. torque
Mmax
__________ Nm
9. Max. current (duration >= 2 s)
Imax
__________ A
10. Torque ripple
__________ [%]
11. Torque constant
kT
__________ Nm/A,
12. Voltage constant
(electromotive force)
kE
__________ V/1000 1/ min Toleranz +/- 5%
13. Winding resistance
(phase to phase)
Rph.
__________ Ω
14. Winding inductance
(phase to phase)
Lph.
__________ mH
15. Number of pairs of poles, motor
p
__________
16. Mass of motor
m
__________ kg
17. Moment of inertia (with brake)
Jmot
__________ kg m
18. Pulse-voltage-proof for
Ûpp/2
Tolerance +/- 5%
2
__________ kV
19. Pulse-voltage-proof for Ûp-earth
__________ kV
Only for motors in torque mode:
A measurement of the phase-to-phase voltage constant (EMF) kE must be provided with the motor.
The sine-wave form and the EMF value at 1000 rpm. must be depicted.
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Motor Specification
4.2
M-n characteristic
1. Mmax (at Imax and Uic = 540 V DC) to nbreak
2. Mmax (at Imax and Uic = 486 V DC) to nbreak (-10% mains under voltage)
3. S1(100 K) (continuous load characteristic with M0 and Mnom)
Sample characteristic:
Torque
M-n characteristic
Limit characteristic
Mlimit
Mnom
nbreak
4.3
nlimit Speed
Brake data
1. Brake holding torque
___________________ Nm
2. Dynamic braking torque
___________________ Nm
3. Maximum switch work per braking operation ___________________ J
4. Interval between two braking cycles with maximum energy ________ s
4.4
5. Opening time
___________________ ms
6. Closing time
___________________ ms
Moment of inertia
1. Moment of inertia relative to motor shaft
_______________ kg m
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Motor Specification
4.5
4.6
Resolver
1. Resolver manufacturer
___________________
2. Resolver type
___________________
3. Number of pairs of poles, resolver (speed)
___________________
Motor- und Servodatei
The KR C4 can be operated at different supply voltages (380V ; 400V ; 440V ; 480V) without
transformer.
The motor and servo file is only valid for the respective combination of KUKA Servo Pack (KSP) /
KUKA Power Pack (KPP) and the supply voltage. For what kind of combinations should a motor
and servo file be generated?
380V*
400V / with transformer
440V*
480V*
KSP 600-3x20
KSP 600-3x40
KPP 600-20-1x40
KPP 600-20-2x40
KSP 600-3x64
KPP 600-20-1x64
*) only relevantly in operation without transformer
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Motor Specification
5 Additional requirements for torque mode
e.g. servomotor-driven spot weld guns
5.1 Design
1. For what process is the motor designed?
2. Describe the process/cycle with reference to motor torque, holding duration, acceleration ramps:
5.2 Duty Factor
For what duty factor I
designed?
2
t (number of spot welds per minute, torque and duration) is the motor
One spot weld: duration T0
T
M eff (T0 ) =
1 0 2
M (t )dt
T0 ∫0
N spot welds: duration T
T = N ⋅ (T0 + TPause )
T
1
M eff (T ) =
⋅ ∫ M 2 (t )dt
T 0
M = kT ⋅ I
T
1
I eff (T ) =
⋅ ∫ I 2 (t )dt
T 0
5.3 Spindle
1. Screw pitch of spindle:
S
__________
2. Please indicate the characteristic of the breakaway torque as a function of the holding torque
Mhold and temperature δ:
Characteristic: Mbreakaway = f (Mhold δ)
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Motor Specification
6 Checklist
6.1
6.2
6.3
Motor
-
Data sheet
-
Measurements/characteristics as per requirements
-
No kinematics or spindle
-
Connector as per specification
Resolver
-
Data sheet
-
Measurements as per requirements
-
Connector as per specification
Brake
-
Data
7 Explanation over fulfillment of the specification:
With this I explain that the motor fulfills all points of the specification and all required data are
provided.
_________________________
__________________________
City, Date
Company stamp, Name, Signiture
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