Arc welding robots

Kawasaki Robot

Arc welding robots

ROBOT DIVISION Tokyo Head Office/Robot Division

1-14-5, Kaigan, Minato-ku, Tokyo 105-8315, Japan Phone: +81-3-3435-6852 Fax: +81-3-3437-9880

Akashi Works/Robot Division

1-1, Kawasaki-cho, Akashi, Hyogo 673-8666, Japan Phone: +81-78-921-2946 Fax: +81-78-923-6548

Global Network Kawasaki Robotics (USA), Inc.

28140 Lakeview Drive, Wixom, MI 48393, U.S.A. Phone: +1-248-446-4100 Fax: +1-248-446-4200

Kawasaki Robotics (UK) Ltd.

Unit 4 Easter Court, Europa Boulevard, Westbrook Warrington Cheshire, WA5 7ZB, United Kingdom Phone: +44-1925-71-3000 Fax: +44-1925-71-3001

Kawasaki Robot CAUTIONS TO BE TAKEN TO ENSURE SAFETY l For those persons involved with the operation / service of your system, including Kawasaki Robot, they must strictly observe all safety regulations at all times. They should carefully read the Manuals and other related safety documents.

Kawasaki Robotics Korea, Ltd.

l Products described in this catalogue are general industrial robots. Therefore, if a customer wishes to use the Robot for special purposes, which might endanger operators or if the Robot has any problems, please contact us. We will be pleased to help you.

Kawasaki Robotics (Tianjin) Co., Ltd.

l Be careful as Photographs illustrated in this catalogue are frequently taken after removing safety fences and other safety devices stipulated in the safety regulations from the Robot operation system.

Kawasaki Robotics GmbH

29 Sperberweg, 41468 Neuss, Germany Phone: +49-2131-34260 Fax: +49-2131-3426-22 43, Namdong-daero 215beon-gil, Namdong-gu, Incheon, 21633, Korea Phone: +82-32-821-6941 Fax: +82-32-821-6947 Bldg 3, No.16, Xiang’an Road, TEDA, Tianjin 300457 China Phone: +86-22-5983-1888 Fax: +86-22-5983-1889

Kawasaki Motors Enterprise (Thailand) Co., Ltd.

(Rayong Robot Center) 119/10 Moo 4 T.Pluak Daeng, A.Pluak Daeng, Rayong 21140 Thailand Phone: +66-38-955-040-58 Fax: +66-38-955-145

https://robotics.kawasaki.com/

ISO certified in Akashi Works.

] Materials and specifications are subject to change without notice.

Cat. No. 3L1561 Jan. ’16 M Printed in Japan

Kawasaki arc welding robots use the latest arc welding technology to rival the quality of a skilled human welder

Features Application specific operation Each robot is equipped standard with an easy to view and operate color LCD touchscreen teach pendant. The operator teaches the process path using dedicated arc welding teaching screens that are designed for simplified use and easy operation.

Welding condition database During an automated process, the operator can change the welding conditions on-the-fly, and then store these changes to a built-in database. The saved conditions can then be recalled from the database and reused.

Reduced downtime A standard, dedicated start sequence function improves the arc establishment. Also, for weld process faults, the robot includes a restart sequence function to automatically conduct overlap welding and resume the operation.

Manual arc control The Kawasaki arc welding robots feature a one button “arc on / arc off” function to allow operators to easily and quickly turn the weld off and on during the automatic weld process. This manual arc control helps operators deal with part anomalies.

Advanced technology Servo-torch, touch sensing, special weaving pattern, real-time path modification (RTPM) sensor, start-point sensing, multilayer welding function, and auto voltage control (AVC) sensor are some of the advanced arc welding options available with the Kawasaki welding robots.

Offline programming Kawasaki offers arc welding specific offline programming software to automatically generate robot programs from 3D CAD data. Kawasaki’s KCONG software significantly reduces robot teaching time and lowers production costs.

BA006N 1

RA005L

RA006L

RA010N

RA010L

RA020N 2

Standard specifications

BA006N

RA005L

RA006L

Type Degree of freedom (axes)

Max. reach (mm) Positional repeatability (mm)

Max. speed (°/s)

Moment (N·m)

Moment of Inertia (kg·m2)

]1

KCONG

Kawasaki Common Offline NC data Generator

5

6

10

10

20

1,445

903

1,650

1,450

1,925

1,725

±0.06

±0.03

±0.06

±0.06

±0.06

±0.06

Features

±180

±180

±180

±180

±180

No need for time-consuming robot teaching

(JT1)

±165

Arm out-in

(JT2)

+150 - –90

+135 - –80

+145 - –105

+145 - –105

+155 - –105

+155 - –105

Arm up-down (JT3)

+90- –175

+118 - –172

+150 - –163

+150 - –163

+150 - –163

+150 - –163

Wrist swivel

(JT4)

±180

±360

±270

±270

±270

±270

Wrist bend

(JT5)

±135

±145

±145

±145

±145

±145

Wrist twist

(JT6)

±360

±360

±360

±360

±360

±360

Arm rotation

(JT1)

240

300

250

250

190

190

Arm out-in

(JT2)

240

300

250

250

205

205

Arm up-down (JT3)

220

300

215

215

210

210

Wrist swivel

(JT4)

430

460

365

365

400

400

Wrist bend

(JT5)

430

460

380

380

360

360

Wrist twist

(JT6)

650

740

700

700

610

610

Wrist swivel

(JT4)

12

12.3

13

22

22

45

Wrist bend

(JT5)

12

12.3

13

22

22

45

Wrist twist

(JT6)

3.75

7

7.5

10

10

29

Wrist swivel

(JT4)

0.4

0.4

0.45

0.7

0.7

0.9

Wrist bend

(JT5)

0.4

0.4

0.45

0.7

0.7

0.9

Wrist twist

(JT6)

0.07

0.12

0.14

0.2

0.2

0.3

150

37

150

150

230

230

Munsell 10GY9/1 equivalent

Installation

Floor, Ceiling 0 - 45

Relative humidity (%)

35 - 85 (No dew, nor frost allowed)

]2

2.0

1.5

2.0

America

E77 E01

Japan & Asia ]1: conforms to ISO9283 ]2: depends on the payload and motion patterns

E71 E74

Offline process verification Once KCONG automatically generates the robot welding path, users can then view the simulation of the arc welding process, check for collisions, weld access, and system layout issues, and make fine adjustments to the generated welding path.

Direct program download After verifying the weld process and making any necessary adjustments, the operation program is generated by KCONG. The completed weld operation program can then be downloaded directly to the robot controller.

Servo Torch

Features 3.0

IP65

Degree of protection

Europe

2.0

KCONG generates robot welding paths quickly and easily from 3D CAD data such as DXF, IGES, STEP or VRML.

Kawasaki’s servo torch option delivers high quality welding.

Ambient temperature (°C)

Power requirements (kVA)

KCONG, our offline programming software, automatically generates a robot’s welding path based off of workpiece geometry.

6

Body color

Controller

RA020N

Arm rotation

Mass (kg)

Environmental condition

RA010L

6

Max. payload (kg)

Motion range (°)

RA010N

Articulated robot

E01

3.0

Can be used with small-gauge iron or aluminum wire Feeds small-gauge iron wire (ø 0.6 mm) or aluminum wire steadily with no buckling.

Excellent arc stability The constant-speed wire feed control improves wire feeding performance, resulting in excellent arc stability.

Improved arc ignition performance

Optional equipment • Shock sensor

The servo torch can control complex wire feeding at the start and end of welding operations, thereby improving arc ignition.

• Torch bracket (350 A/500 A) • Installation base (600 mm / 300 mm) • Base plate (750 mm × 750 mm × 25 mm) • Linear slide • Positioner • Servo torch • RTPM (arc sensor) • AVC (arc-sensor dedicated to TIG welding) • 3D laser sensor • Wall mounting

3

4

Motion range & dimensions

BA006N

RA006L

JT1 165° JT5:±135° 294

160 276

4-ø18

1,450

JT6:±360°

Working range based on point P

1,650

°

45

ø6H7 Dp6

Y

ø0.04 X

ø0.3 X Y VIEW A

JT4 : ±270°

P

305.6

6

6-M4 Dp8

437.1

ø0.06

ø18

VIEW A

Installation dimensions

(mm)

(mm)

RA005L

RA010N

°

90° 1,780

138±0.1 220 92

184

300

430

4-ø18

210

305.6

2-ø13H9 ø0.06

ø30 13

438.2

ø0.04

220

153±0.1

650

1,195

2-ø6H7

15

391

76

JT5 : ±145°

JT2 : 105° JT2 : 145°

194

ø9

5

JT4 : ±270°

170

125 88±0.1

130

295

130

242

4-ø9

ø18

Installation dimensions

(mm)

100

VIEW A

A

173 152 88±0.1

JT2 : 135°

ø4

JT6 : ±360°

P

57

125 126

JT3 : 150°

88

P

JT5 : ±145° JT2 : 80°

207

VIEW A

152

JT3 : 172°

148

802.4

A

380

825

ø4

JT4 : ±360°

ø25H7 X Dp6

4-M6 Dp8 ø0.3 X Y

JT3 : 163° 700

JT1 : 360°

4-M5 Dp8 ø0.2 X Y

1,093

105

80

JT3 : 118°

1.5

JT6 : ±360°

78

ø6H7 Dp6 ø0.04 X

0

ø3

0H 7

410

Y

1,450

1,250

ø20H7 X Dp3

90

120

ø5H7 Dp8 ø0.04 X

JT1 : 360° 118

45

Working range based on point P

100

903

Y

90°

687

°

45

Working range based on point P

220

2-ø13H9

220

ø6 777.1

184

300 ø30

ø0.2 X Y 464.4

4-ø18

194 210

6

300.8

303.3

92

153±0.1

430

60

°

150°

ø0.04 X ø45H7 X

ø5

207.5

138±0.1 220

430

Y ø6H7 Dp8

JT2

220

JT2 : 145°

638.2

JT2

JT5 : ±145°

1,002.4

30°

JT2 : 105°

650

1,710.8

Installation dimensions

90 °

1,271

550

P

ø18 1,195

210

156

A A

13

115

100

1,980

JT3 : 150°

4-M6 Dp8

JT6 : ±360° 88 100

700

207

13

165

JT3 : 163° 900

JT1 : 360° 148

°

90

JT3

ø4

0

Working range based on point P

JT3 17 5

352

ø25H7 X Dp6

90°

1,445.8

°

81

330

JT1 165° 1,115.8

276

JT4:±180°

Installation dimensions

(mm)

6

Motion range & dimensions

RA010L

1,625

Working range based on point P

1,925

°

45

ø6

VIEW A

P

JT2 : 105°

4-M6 Dp9 ø0.3 X Y

ø7 5

A

770

3

JT6 : ±360°

JT4 : ±270°

1,360

X

90° 95

1,005

2,240

150

120

JT3 : 150°

170 260

ø40H7 Dp6

JT3 : 163°

JT1 : 360°

ø6H7 Dp6 ø0.04 X

Y

JT5 : ±145°

250

JT2 : 155°

163±0.1

276 4-ø18

276

500.5

2-ø13H9 ø0.06

13

1,237.9

ø30

168±0.1

330

260 739.3

220

240

465

120

ø18 Installation dimensions

(mm)

RA020N

1,425

Working range based on point P

1,725

° 45

Y

ø6H7 Dp6 ø0.04 X ø40H7 Dp6

150

805 JT4 : ±270°

ø6

95

3

JT6 : ±360°

P

JT2 : 105°

ø0.3 X Y VIEW A

JT5 : ±145°

1,360

770

A

4-M6 Dp9

ø7 5

JT3 : 150°

2,040

170 260

120

JT1 : 360°

X

90°

JT3 : 163°

163±0.1

250 276

120

4-ø18

1,037.9

168±0.1

383.9 ø30 13

260 539.3

220

276

330

240

465

JT2 : 155°

2-ø13H9 ø0.06

ø18 Installation dimensions

(mm)

7

8

Controller

E series - An evolution of engineering excellence Kawasaki has incorporated more than 45 years of experience as a robot industry leader into the development of the most technically advanced controller available. The E Controller combines high performance, unprecedented reliability, a host of integrated features and simple operation, all in a compact design.

Specifications Standard America

E77

Europe

E01

Japan & Asia

Features

]

Dimensions (mm)

E01

W550×D580×H278

Structure

The overall volume of the E Controller has been reduced compared with the previous model. The small footprint of this compact controller allows for installation in “high-density” applications. For further space saving options, an upright-position or stacked installation ] is possible, without impeding performance.

Drive system

The easy-to-use teach pendant now incorporates motor power and cycle start at your fingertips. Multiple information screens can be displayed simultaneously. The intuitive teaching interface is simple to use.

E7X

External view & dimensions E01 OFF

100% ON

TEACH

REPEAT

ＲＧＥＮＣ ＭＥ

Ｙ

ＣＯＮＴＲＯＬ ＰＯＷＥＲ

Ｅ

(mm)

260

ＳＴＯＰ

580

18

550

Transformer unit ] 170

POWER

580

18

550

Types of motion control

Point to point teaching or language based programming

Memory capacity (MB)

E7X

Three external axes can be added to the E01 controller for a total of nine controlled axes, while two can be added to the E7X for a total of eight controlled axes. Numerous communication fieldbuses are available for controlling peripheral devices. The Kawasaki K-Logic sequencer software can be combined with user customized interface panels on the teach pendant.

420

500

9

250

REPEAT

32

Output (Channels)

Max. 96

32

Max. 96

E-Stop switch, teach/repeat switch, control power light (Cycle start, motor-on, hold/run, and error reset are activated from the teach pendant.)

Cycle start switch, motor-on switch, hold/ run switch, error light, error reset switch (E7X), rapid-feed check mode switch

Teach pendant (m)

5

10, 15

Robot-controller (m)

5

Operation panel

Mass (kg)

10, 15

40

30

Transformer unit: 45 (E01 only)

AC200-220V ±10%, 50/60Hz, 3ø

AC200-240V ±10%l 50/60Hzl 1ø

]Transformer unit (E01 only) AC380-415V ±10% or AC440-480V ±10% 50/60Hz, 3ø

Power requirements Class-D earth connection (Earth connection dedicated to robots), leakage current: Maximum 100mA Environmental Ambient temperature (°C) condition Relative humidity (%) Body color

0 - 45 (0 - 40 for E7x in vertical use) 35 - 85 (no dew, nor frost allowed) Munsell 10GY9/1 equivalent

—

TFT color LCD display with touch-panel, E-Stop switch, teach lock switch, Enable switch

Auxiliary storage unit

Expandable

Motor power off, Hold

Input (Channels)

The enhanced CPU capacity allows for more accurate trajectory control, faster program execution, and quicker loading and saving of files. In addition, memory has been expanded to meet the need for higher program storage capacity. The controller comes equipped with a USB port for external storage devices.

Modular components with limited cables translate into easy diagnostics and maintenance. A host of maintenance functions are available, including selfdiagnostics on hardware and application errors to minimize troubleshooting and reduce MTTR (Mean Time To Repair). Remote diagnostics via the web server function enables service support from anywhere in the world.

8

External operation

Teach pendant

Easy maintenance

Fixed tool point

Joint/Linear/Circular Interpolated motion

Programming

Cable length

Max. 9 (E01) Max. 8 (E7X)

Joint, Base, Tool

Advanced technologies

]Option

TEACH

9

A rich set of programming functions come standard with the E Controller to support a wide range of applications. Functions can be combined and easily configured within a system to suit a particular application. Also, the powerful Kawasaki AS Programming Language provides sophisticated robot motion and sequence controls.

6 Full digital servo system

Programming ease & flexibility Teach pendant

7

Coordinate systems

General purpose signals

Transformer unit: W580×D580×H178 (E01 only)

W500×D420×H259

Enclosed structure / Indirect cooling system

Number of controlled axes

User-friendly operation ]Option

E74

Compact

]E01 only

Option

E71

—

Interface

USB Memory

USB, Ethernet (100BASE-TX), RS-232C

System configuration diagram Optional board DIO board

Optional device Option switch ✽2

Standard

Rapid-feed check mode switch ✽1

Option

Brake release switch Transformer unit✽1

RS-232C

External-axis motor

USB USB Memory Teach pendant ✽1 E01 only ✽2 E7X only

Ethernet

DIO board: 32 points each max. 3 boards (96 points) DeviceNet board, master/slave CC-Link board, master/slave PROFIBUS board, master/slave PROFINET board, master/slave Ethernet/IP board, master/slave

Terminal software

CAN open board, slave

Terminal software

EtherCAT board, master/slave

Vision controller

Conveyor I/F board

Cubic-S ✽1 (area monitor /speed monitor) 10