描述
一、硬件架构与核心组件
1.控制器主体
型号与外观：
KRC2采用模块化设计，主体为金属机箱（IP54防护等级），尺寸约600mm×400mm×200mm，支持标准机柜安装或独立放置。
前面板集成电源开关、急停按钮、状态指示灯（运行/故障）、USB接口（程序备份），便于操作与维护。
2.核心硬件模块
模块名称功能描述
主控板（CCU）-基于Intel Pentium M（1.6GHz）或Celeron M（1.2GHz）处理器，运行VxWorks实时操作系统，确保控制周期≤4ms。
集成1GB DDR2内存、2GB CompactFlash存储，支持程序与数据存储。|
|驱动模块（DSU）|-控制机器人电机驱动器，支持6轴同步运动，峰值电流20A/轴，适配KUKA伺服电机（如KR 16的KR 500/2）。
具备过流、过压、过热保护，确保电机安全运行。|
|I/O模块（IOU）|-提供数字量/模拟量输入输出接口：
数字输入（DI）：32路（24V DC，源型/漏型可配置）
数字输出（DO）：32路（24V DC，0.5A驱动能力）
模拟输入（AI）：8路（0-10V/4-20mA，12位分辨率）
模拟输出（AO）：4路（0-10V/4-20mA，驱动能力20mA）|
|电源模块（PSU）|-支持200-480V AC三相输入，输出24V DC（5A）为控制器供电，具备冗余设计（双电源可选）。
集成滤波电路，抑制电网谐波干扰。|
|示教器（KCP）|-6.5英寸TFT触摸屏，分辨率640×480，支持手写笔或按键操作。
运行KUKA System Software（KSS），提供程序编辑、示教、监控、诊断功能。|
3.扩展能力
总线接口：
支持EtherCAT（主站），可连接KUKA外部轴（如变位机、轨道）或第三方设备（如视觉系统、PLC）。
集成PROFINET、EtherNet/IP、Modbus TCP接口，便于与西门子PLC、施耐德变频器等设备通信。
安全模块：
可选配KUKA Safety Controller，支持ISO 13849-1（PL e/Cat.4）和IEC 61508（SIL3）安全标准，集成安全光幕、急停按钮、STO（安全扭矩关闭）功能。
二、软件功能与操作系统
1.KUKA System Software（KSS）
版本与架构：
KRC2运行KSS 5.x或6.x，基于VxWorks实时操作系统，提供多任务处理、实时调度、运动控制能力。
核心功能：
程序编辑：支持KRL（KUKA Robot Language）编程，提供线性插补、圆弧插补、样条插补等运动指令。
示教功能：通过KCP示教器记录机器人位姿，生成运动轨迹程序。
仿真与离线编程：集成KUKA.Sim Pro软件，支持3D模型导入、碰撞检测、路径优化。
诊断与维护：提供故障日志、I/O状态监控、电机温度监测功能，便于快速定位问题。
2.运动控制算法
路径规划：
支持CP（Continuous Path）控制，确保机器人末端执行器沿规划路径平滑运动，减少振动与超调。
速度控制：
通过加速度前馈补偿优化动态响应，适应高速焊接、喷涂等场景。
力控制（可选）：
集成力传感器接口，支持阻抗控制、力/位置混合控制，适用于精密装配、打磨抛光等应用。
I.Hardware architecture and core components
1.Controller body
Model and appearance:
KRC2 adopts modular design,with a metal chassis(IP54 protection level)and a size of about 600mm×400mm×200mm,supporting standard cabinet installation or independent placement.
The front panel integrates power switch,emergency stop button,status indicator(operation/fault),USB interface(program backup)for easy operation and maintenance.
2.Core hardware module
Module name Function description
Main control board(CCU)-Based on Intel Pentium M(1.6GHz)or Celeron M(1.2GHz)processor,running VxWorks real-time operating system,ensuring control cycle≤4ms.
Integrated 1GB DDR2 memory,2GB CompactFlash storage,supporting program and data storage.|
|Drive Module(DSU)|-Controls the robot motor drive,supports 6-axis synchronous motion,peak current 20A/axis,and is compatible with KUKA servo motors(such as KR 500/2 of KR 16).
It has overcurrent,overvoltage,and overheating protection to ensure safe operation of the motor.|
|I/O module(IOU)|-Provides digital/analog input and output interfaces:
Digital input(DI):32 channels(24V DC,source/sink configurable)
Digital output(DO):32 channels(24V DC,0.5A drive capability)
Analog input(AI):8 channels(0-10V/4-20mA,12-bit resolution)
Analog output(AO):4 channels(0-10V/4-20mA,drive capability 20mA)|
|Power supply module(PSU)|-Supports 200-480V AC three-phase input,outputs 24V DC(5A)to power the controller,and has a redundant design(dual power supply optional).
Integrated filter circuit to suppress grid harmonic interference.|
|Teaching pendant(KCP)|-6.5-inch TFT touch screen,resolution 640×480,supports stylus or key operation.
Run KUKA System Software(KSS)to provide program editing,teaching,monitoring,and diagnostic functions.|
3.Expansion capability
Bus interface:
Supports EtherCAT(master station),which can connect KUKA external axes(such as positioners,rails)or third-party devices(such as vision systems,PLCs).
Integrated PROFINET,EtherNet/IP,and Modbus TCP interfaces facilitate communication with Siemens PLCs,Schneider inverters,and other devices.
Safety module:
Optional KUKA Safety Controller supports ISO 13849-1(PL e/Cat.4)and IEC 61508(SIL3)safety standards,and integrates safety light curtains,emergency stop buttons,and STO(safe torque off)functions.
2.Software functions and operating system
1.KUKA System Software(KSS)
Version and architecture:
KRC2 runs KSS 5.x or 6.x,based on the VxWorks real-time operating system,providing multi-tasking,real-time scheduling,and motion control capabilities.
Core functions:
Program editing:supports KRL(KUKA Robot Language)programming,and provides linear interpolation,circular interpolation,spline interpolation and other motion instructions.
Teaching function:Record the robot posture through the KCP teaching pendant and generate motion trajectory programs.
Simulation and offline programming:Integrate KUKA.Sim Pro software,support 3D model import,collision detection,and path optimization.
Diagnosis and maintenance:Provide fault log,I/O status monitoring,and motor temperature monitoring functions to facilitate rapid problem location.
2.Motion control algorithm
Path planning:
Support CP(Continuous Path)control to ensure that the robot end effector moves smoothly along the planned path and reduce vibration and overshoot.
Speed control:
Optimize dynamic response through acceleration feedforward compensation to adapt to high-speed welding,spraying and other scenarios.
Force control(optional):
Integrated force sensor interface,supports impedance control,force/position hybrid control,suitable for precision assembly,grinding and polishing and other applications.
ABB Model: GBU72 3BHE055094R0002 Model: 3BHE055094R0002 GBU72 Model: GBU72 Model: 3BHE055094R0002 Model: 3BHE031197R0001 Model: 3BHB030310R0001 Model: 73BHE055094R0002 GBU72 Model: 73BHE055094R0002 Model: GBU72 Model: ABB PCS6000 PRODUCT FAMLIY ABB 5SHY4045L0006 3BHB030310R0001 3BHE039203R0101 GVC736CE101
