KUKA KR 15-2 robotic welding station

KUKA KR 15-2 robotic welding station was built in 2007. The fully automatic workpiece welding process is performed inside an enclosed work area, which includes among others a rotary table and a KUKA 6-axis robot. The robot, specially modified by the IGM company, features a simple design with a minimum number of components, making it fast, reliable and easy to maintain. The arm, made of light-alloy castings, furthermore gives the possibility of free operation in all positions, even in hard-to-reach places.

Each of the 6 axes is driven by a brushless plug-in AC servo motor, which requires no maintenance and provides reliable overload protection. In addition, thanks to the use of modern, compact gears, the KUKA KR 15-2 robot arm achieves high positioning repeatability of ± 0.1 mm. Along with the machine, a KUKA KR C2 controller with a wide range of diagnostic and troubleshooting functions works together.

Directly on the welding torch body there is a wire feeder, which ensures dynamic and accurate feeding of the welding wire during machining. In turn, a precision rotary table with a maximum load capacity of 250 kg is used to rotate the workpiece during welding. All this makes the KUKA KR 15/2 robotic welding cell the perfect choice for precision welding of workpieces with even the most complex shapes.

The robotic welding cell is complete and consists of the following components:
– KUKA KR 15/2 industrial robot
– KUKA KR C2 controller
– rotary indexing table
– FRONIUS TransPuls Synergic 4000 power source
– light curtains
– IGM K5 control panel
– IGM wire feeder
– PARKER COMPAX IP servo controller
– control cabinet

Technical specifications of the KUKA KR 15-2 robot

• number of axes: 6
• maximum payload: 16 kg
• axis movement range

axis 1: ± 185°
axis 2: -55°/+115°
axis 3: -210°/+70°
axis 4: ± 350°
axis 5: ± 135°
axis 6: ± 350°

• axis motion speed

axis 1: 152°/s
axis 2: 152°/s
axis 3: 152°/s
axis 4: 284°/s
axis 5: 293°/s
axis 6: 604°/s

• positioning repeatability: ± 0.1 mm
• drive type: electromechanical with transistor-controlled brushless AC servo motors
• noise level: < 75 db(A)
• dimensions for transport (L x W x H): 990 x 550 x 1320 mm
• weight of machine: approx. 235 kg

Technical specifications of the rotary table

• maximum load: 250 kg
• maximum rotational speed: 27 rpm
• maximum torque: 240 Nm
• maximum axis rotation speed: 13.5 rpm
• maximum torque of rotation axis: 485 Nm
• cycle time: 3.5 s/180°