描述
一、产品定位与核心功能
1.目标应用场景
汽车制造：
作为焊接机器人、喷涂机器人、装配机器人的控制器核心模块，支持多轴同步运动控制，确保车身焊接精度±0.1mm、喷涂均匀性±5%。
典型应用：汽车车身点焊、车门喷涂、发动机装配线。
电子装配：
用于3C行业（计算机、通信、消费电子）的精密装配机器人，如手机摄像头模组组装、PCB板插件，支持高速拾放（Pick&Place）与视觉定位，实现装配节拍0.3秒/件、定位精度±0.02mm。
金属加工：
集成于切割机器人、打磨机器人的控制系统，通过力控技术实现复杂曲面自适应加工，减少材料浪费与刀具损耗。
物流搬运：
作为码垛机器人、分拣机器人的电源与控制模块，支持重载搬运（最大负载500kg）与高速分拣（每小时2000件），提升仓储物流效率。
2.核心功能
电源管理与分配：
将输入电源（如380V AC）转换为机器人各部件所需的稳定电压（如24V DC、48V DC），确保伺服驱动器、控制器、传感器等设备可靠运行。
具备过压、欠压、过流、短路保护功能，防止电源故障导致设备损坏。
通信枢纽：
作为KUKA机器人控制系统（KR C4/C5）的核心通信节点，通过EtherCAT、KUKA.ControllerLink等总线协议，实现控制器与伺服驱动器、I/O模块、HMI之间的高速数据交换（通信周期≤1ms）。
支持实时同步多轴运动控制，确保机器人关节、外部轴（如变位机）的协调运动。
部分控制功能：
集成基础运动控制算法（如轨迹规划、速度前馈），减轻主控制器计算负担，提升系统响应速度。
提供安全功能接口，如紧急停止（E-Stop）、安全扭矩关闭（STO），符合ISO 13849-1（PL d/e）、IEC 61508（SIL 2/3）等安全标准。
二、技术规格与性能参数
1.硬件参数
输入电源：
三相交流电（380V±10%，50/60Hz），适应全球工业电网标准。
最大输入电流：32A，满足重载机器人（如KR QUANTEC系列）的功率需求。
输出电源：
直流24V：
输出电流：20A，为控制器、I/O模块、传感器供电。
纹波电压：<50mV，确保敏感电子设备稳定运行。
直流48V：
输出电流：10A，为伺服驱动器辅助电源供电。
通信接口：
EtherCAT主站端口：
数量：2个，支持环形拓扑与冗余通信，确保总线故障时的系统可靠性。
传输速率：100Mbps，满足多轴实时控制需求。
KUKA.ControllerLink端口：
数量：1个，用于与KUKA主控制器（如KR C4）高速通信，传输运动指令、状态反馈等数据。
以太网端口：
数量：1个（10/100Mbps），支持TCP/IP协议，用于与HMI、PLC、SCADA系统集成。
USB端口：
数量：2个（USB 2.0），用于程序下载、日志导出、固件升级。
物理尺寸与重量：
尺寸（长×宽×高）：482.6mm×292.1mm×88.1mm（19英寸标准机架安装），适配控制柜内部空间。
重量：约8kg，便于安装与维护。
环境适应性：
工作温度：0℃至+55℃（存储温度：-25℃至+70℃），适应常规工业环境。
防护等级：IP20，需安装于控制柜内，避免灰尘与液体直接接触。
振动耐受****：≤5m/s²（5-500Hz），符合ISO 16750-3标准，适应冲压、焊接等振动场景。
2.软件参数
操作系统：
KUKA.OperatingSystem（基于VxWorks实时内核），提供确定性任务调度与低延迟通信，确保机器人运动控制的实时性。
控制软件：
KUKA.SystemSoftware（KSS）：
版本：KSS 8.6及以上（兼容KR C4/C5控制器），支持KUKA.WorkVisual编程工具。
功能：运动规划、逻辑控制、安全监控、HMI交互，提供图形化编程界面与离线仿真功能。
安全软件：
KUKA.SafeOperation：
支持安全功能块（SFB），如STO、SSL、SBC，实现机器人安全停止与限速。
符合ISO 10218-1/2（机器人安全标准），通过TÜV认证。
I.Product Positioning and Core Functions
1.Target Application Scenarios
Automotive Manufacturing:
As the core controller module for welding robots,painting robots,and assembly robots,it supports multi-axis synchronous motion control,ensuring body welding accuracy of±0.1mm and painting uniformity of±5%.
Typical Applications:Automotive body spot welding,door painting,and engine assembly lines.
Electronic Assembly:
Used in precision assembly robots for the 3C industry(computers,communications,and consumer electronics),such as mobile phone camera module assembly and PCB board insertion,it supports high-speed pick&place and vision positioning,achieving an assembly cycle of 0.3 seconds per part and a positioning accuracy of±0.02mm.
Metal Processing:
Integrated into the control systems of cutting and polishing robots,it uses force control technology to achieve adaptive machining of complex curved surfaces,reducing material waste and tool wear.Logistics Handling:
Serving as the power supply and control module for palletizing and sorting robots,it supports heavy-load handling(maximum load 500kg)and high-speed sorting(2,000 pieces per hour),improving warehouse logistics efficiency.
2.Core Functions
Power Management and Distribution:
Converts input power(e.g.,380V AC)to the stable voltages(e.g.,24V DC,48V DC)required by various robot components,ensuring reliable operation of servo drives,controllers,sensors,and other devices.
Provides overvoltage,undervoltage,overcurrent,and short-circuit protection to prevent equipment damage from power failures.
Communication Hub:
Serving as the core communication node for the KUKA robot control system(KR C4/C5),it enables high-speed data exchange(communication cycle≤1ms)between the controller and servo drives,I/O modules,and HMIs via bus protocols such as EtherCAT and KUKA.ControllerLink.
Supports real-time synchronized multi-axis motion control,ensuring coordinated motion of robot joints and external axes(such as positioners).Partial Control Functions:
Integrates basic motion control algorithms(such as trajectory planning and velocity feedforward),reducing the computational burden on the main controller and improving system response speed.
Provides interfaces for safety functions such as Emergency Stop(E-Stop)and Safe Torque Off(STO),complying with safety standards such as ISO 13849-1(PL d/e)and IEC 61508(SIL 2/3).
II.Technical Specifications and Performance Parameters
1.Hardware Parameters
Input Power Supply:
Three-phase AC(380V±10%,50/60Hz),compatible with global industrial grid standards.
Maximum input current:32A,meeting the power requirements of heavy-load robots(such as the KR QUANTEC series).
Output Power Supply:
24V DC:
Output current:20A,powers the controller,I/O modules,and sensors.
Ripple voltage:<50mV,ensuring stable operation of sensitive electronic equipment.48V DC:
Output current:10A,provides auxiliary power for the servo drives.
Communication Interface:
EtherCAT Master Ports:
Quantity:2,supports ring topology and redundant communication,ensuring system reliability in the event of bus failures.
Transmission rate:100Mbps,meeting the requirements of multi-axis real-time control.
KUKA.ControllerLink Port:
Quantity:1,used for high-speed communication with a KUKA master controller(such as the KR C4),transmitting motion commands,status feedback,and other data.
Ethernet Port:
Quantity:1(10/100Mbps),supports TCP/IP protocol,for integration with HMI,PLC,and SCADA systems.
USB Ports:
Quantity:2(USB 2.0),used for program downloads,log exports,and firmware upgrades.
Physical Dimensions and Weight:
Dimensions(L×W×H):482.6mm×292.1mm×88.1mm(19-inch standard rack mount),suitable for control cabinet interiors.Weight:Approximately 8 kg,easy to install and maintain.
Environmental Adaptability:
Operating Temperature:0°C to+55°C(Storage Temperature:-25°C to+70°C),suitable for typical industrial environments.
Protection Level:IP20.Must be installed in a control cabinet to avoid direct contact with dust and liquids.
Vibration Tolerance****:≤5 m/s²(5-500 Hz),compliant with ISO 16750-3,suitable for vibrating environments such as stamping and welding.
2.Software Parameters
Operating System:
KUKA.OperatingSystem(based on the VxWorks real-time kernel),provides deterministic task scheduling and low-latency communication,ensuring real-time robot motion control.
Control Software:
KUKA.SystemSoftware(KSS):
Version:KSS 8.6 and above(compatible with KR C4/C5 controllers),supports the KUKA.WorkVisual programming tool.Functions:Motion planning,logic control,safety monitoring,HMI interaction,and a graphical programming interface with offline simulation capabilities.
Safety Software:
KUKA.SafeOperation:
Supports safety function blocks(SFBs)such as STO,SSL,and SBC,enabling safe stopping and speed limiting of robots.
Compliant with ISO 10218-1/2(robot safety standard)and TÜV certified.
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