KUKA KR 8 R2100-2 arc HW robotic welding station

KUKA KR 8 R2100-2 arc HW robotic welding station was built in 2021 in Germany by KUKA Deutschland GmbH. The system is designed for precision welding of workpieces with even the most complex geometry. All the necessary components are integrated inside the modular design, enabling the workstation to be adapted accordingly to current production needs.

The workpiece welding process is performed by a KUKA 6-axis robot from the KR CYBERTECH ARC series. The machine is distinguished by its compact design, which provides a high degree of movement freedom even in hard-to-reach places. To avoid any collision of cables with other station components, they were routed inside the robot arm. All this is complemented by an easy-to-use controller with a range of additional functions.

During automated welding, dynamic and accurate feeding of the welding wire is very important. To achieve this, a reliable KEMPPI feeder is mounted directly on the machine body. The torch, in turn, is continuously cleaned by the ABICOR BINZEL cleaning station, which injects a special anti-adhesion substance into the torch. The cleaning and humidification process is performed fully automatically, at set intervals.

The welding station is fully complete and consists of the following components:
– robot arm: KUKA KR 8 R2100-2 arc HW
– controller: KUKA KR C4
– inverter welder: KEMPPI KempArc Pulse 350
– welding cell: Robopartner RoboArc_C3
– welding positioner with rotary table
– portable control unit (pendant): KUKA SmartPad
– welding wire feeder: KEMPPI KempArc DT 400
– torch cleaning station: ABICOR BINZEL TCS-CC

Technical specifications of KUKA KR 8 R2100-2 arc HW welding robot

• number of axes: 6
• maximum payload: 8 kg
• maximum arm reach: 2101 mm
• axis movement range

A1 axis: ±185°
A2 axis: -185° / +65°
A3 axis: -138° / +175°
A4 axis: ±165°
A5 axis: -115° / +140°
A6 axis: ±350°

• axis motion speed

A1 axis: 200°/s
A2 axis: 175°/s
A3 axis: 190°/s
A4 axis: 430°/s
A5 axis: 430°/s
A6 axis: 630°/s

• positioning repeatability: ± 0.04 mm
• mounting: floor, ceiling, wall, any angle
• ambient temperature: 5-55°C
• KUKA.ArcTech software for automated inert gas welding
• KUKA.SafeOperation safety software for workspace monitoring
• KUKA.TouchSense option package for the detection and compensation of weld shape deviations
• KUKA.ArcSense option package for real-time tracking and correction of the weld path
• weight of the KUKA KR 8 R2100 machine: 281 kg

Technical specifications of the welding positioner type H

• maximum payload: 500 kg
• maximum workpiece diameter: 1400 mm
• rotation angle: 180°
• distance between discs: 2200 mm