描述
一、核心功能
1.高精度运动控制
多轴同步控制：
支持1-8轴实时同步，同步周期≤1ms，适用于双机器人协同搬运大型工件（如汽车车身、航空结构件），确保运动轨迹的精确跟随（如搬运速度0.5m/s时，轨迹重复精度±0.1mm）。
内置电子凸轮、电子齿轮功能，可实现复杂运动曲线规划（如凸轮分割器替代、飞剪控制），减少机械传动误差，提升运动平滑性。
动态响应优化：
集成前馈补偿、摩擦补偿算法，通过实时调整电机扭矩，减少加速度突变引起的振动，适用于重载打磨、焊接等场景（如300kg负载打磨时，压力波动≤±0.5N）。
2.高精度轨迹规划
路径优化算法：
支持圆弧插补、样条插补，可规划平滑过渡的连续轨迹，避免直角转弯时的冲击，延长机械部件寿命（如机器人关节轴承、减速机）。
提供速度前瞻功能，根据路径曲率自动调整速度，确保高速运动时的稳定性（如100kg负载搬运速度可达1.2m/s）。
碰撞检测与规避：
集成虚拟安全墙、动态限速功能，通过实时监测机器人位置与速度，避免与周边设备或人员碰撞，提升生产安全性。
3.工业通信与集成
高速实时通信：
EtherCAT主站：连接KUKA伺服驱动器、外部轴，同步周期≤250μs，支持分布式控制架构（如多机器人协同焊接大型结构件）。
PROFINET RT/IRT：与西门子S7-1500 PLC协同控制，实现机器人与生产线的无缝集成（如汽车总装线中，机器人与输送带的同步运动）。
OPC UA Server/Client：支持与MES、ERP系统数据交互，实现生产状态实时监控、工艺参数远程下发。
开放接口支持：
提供C/C++、MATLAB/Simulink接口，支持用户自定义算法开发（如高级路径规划、AI视觉集成），满足个性化控制需求。
二、技术参数
参数类别详细规格
处理器Intel Core i7-1185G7（4核3.0GHz，睿频4.8GHz）
内存16GB DDR4（可扩展至32GB）
存储512GB SSD（支持RAID 1冗余）
输入电源380V AC（±10%），50/60Hz，功耗≤1.5kW
控制精度位置精度±0.05mm，速度波动≤±0.1%
环境适应性工作温度0-45℃，湿度≤85%RH（无冷凝），防护等级IP20
尺寸与重量尺寸450mm×400mm×200mm，重量约15kg，支持标准机柜安装或导轨安装
支持机器人型号KUKA KR 100-300系列（如KR 100 R2700 extra、KR 300 R2500 ultra）
三、典型应用场景
1.汽车制造
车身焊接生产线：
PH1003-2840控制2台KR 210机器人+1台变位机，通过EtherCAT同步实现多工位协同焊接，焊接节拍≤60s/车，焊缝质量符合ISO 5817 A级标准。
集成力/力矩传感器，实时监测焊接压力，自动调整机器人姿态，避免虚焊、过焊问题。
总装车间：
配合视觉引导系统，通过PROFINET通信控制KR 150机器人完成发动机与变速箱的精准装配，装配力≤200N，重复定位精度±0.08mm。
2.金属加工
激光切割：
PH1003-2840控制KR 300机器人搭载激光切割头，通过电子凸轮功能实现复杂轮廓的精确跟随，切割速度≥30m/min，切口宽度≤0.2mm。
打磨抛光：
集成力/力矩传感器，实时调整机器人打磨压力，确保表面粗糙度Ra≤1.6μm，适用于航空零部件、船舶结构件的高精度加工。
3.物流搬运
重型物料搬运：
KR 240机器人在PH1003-2840控制下完成240kg钢卷的自动上下料，搬运速度0.8m/s，定位精度±0.1mm，支持24小时连续运行。
码垛应用：
配合视觉定位系统，实现多品种、多规格货物的混合码垛，码垛效率≥1200箱/小时，堆垛高度≤3m。
四、优势特点
1.高性能与高可靠性
工业级硬件设计：
采用无风扇散热，支持7×24小时连续运行，MTBF（平均无故障时间）≥100,000小时。
冗余设计：
支持电源冗余、网络冗余，确保关键应用（如汽车焊接）的连续性。
2.开放性与兼容性
支持KUKA全系列重载机器人：
从KR 100（负载100kg）到KR 300（负载300kg）均可适配，无需额外调整控制参数。
多品牌传感器兼容：
支持ATI、OnRobot等主流品牌力/力矩传感器，降低系统集成成本。
3.智能化维护与诊断
远程监控功能：
通过KUKA.Cloud平台实现设备状态远程监测，提前预警电机过热、驱动器故障等问题。
自诊断工具：
集成KUKA SmartDiagnosis软件，可快速定位I/O故障、通信中断等问题，缩短停机时间。
I.Core functions
1.High-precision motion control
Multi-axis synchronous control:
Supports 1-8 axis real-time synchronization,with a synchronization cycle of≤1ms,suitable for dual robots to collaboratively carry large workpieces(such as car bodies,aviation structural parts),ensuring accurate tracking of the motion trajectory(such as when the handling speed is 0.5m/s,the trajectory repetition accuracy is±0.1mm).
Built-in electronic cam and electronic gear functions can realize complex motion curve planning(such as cam divider replacement,flying shear control),reduce mechanical transmission errors,and improve motion smoothness.
Dynamic response optimization:
Integrated feedforward compensation and friction compensation algorithms,by real-time adjustment of motor torque,reduce vibration caused by acceleration mutations,suitable for heavy-load grinding,welding and other scenarios(such as 300kg load grinding,pressure fluctuation≤±0.5N).
2.High-precision trajectory planning
Path optimization algorithm:
Supports arc interpolation and spline interpolation,and can plan a smooth transition continuous trajectory to avoid impact during right-angle turns and extend the life of mechanical components(such as robot joint bearings and reducers).
Provides speed preview function,automatically adjusts the speed according to the path curvature,and ensures stability during high-speed movement(such as 100kg load handling speed can reach 1.2m/s).
Collision detection and avoidance:
Integrated virtual safety wall and dynamic speed limit functions,through real-time monitoring of robot position and speed,avoid collision with surrounding equipment or personnel,and improve production safety.
3.Industrial communication and integration
High-speed real-time communication:
EtherCAT master station:connects KUKA servo drives and external axes,with a synchronization cycle of≤250μs,and supports distributed control architecture(such as multi-robot collaborative welding of large structural parts).
PROFINET RT/IRT:Collaborative control with Siemens S7-1500 PLC to achieve seamless integration of robots and production lines(such as synchronous movement of robots and conveyor belts in automobile assembly lines).
OPC UA Server/Client:Supports data interaction with MES and ERP systems to achieve real-time monitoring of production status and remote distribution of process parameters.
Open interface support:
Provides C/C++,MATLAB/Simulink interfaces,supports user-defined algorithm development(such as advanced path planning,AI visual integration),and meets personalized control needs.
2.Technical parameters
Parameter category Detailed specifications
Processor Intel Core i7-1185G7(4 cores 3.0GHz,turbo frequency 4.8GHz)
Memory 16GB DDR4(expandable to 32GB)
Storage 512GB SSD(supports RAID 1 redundancy)
Input power 380V AC(±10%),50/60Hz,power consumption≤1.5kW
Control accuracy Position accuracy±0.05mm,speed fluctuation≤±0.1%
Environmental adaptability Working temperature 0-45℃,humidity≤85%RH(non-condensing),protection level IP20
Dimensions and weight Dimensions 450mm×400mm×200mm,weight about 15kg,support standard cabinet installation or rail installation
Supported robot models KUKA KR 100-300 series(such as KR 100 R2700 extra,KR 300 R2500 ultra）
III.Typical application scenarios
1.Automobile manufacturing
Car body welding production line:
PH1003-2840 controls 2 KR 210 robots+1 positioner,and realizes multi-station collaborative welding through EtherCAT synchronization,with a welding cycle of≤60s/car,and the weld quality meets ISO 5817 Class A standard.
Integrated force/torque sensor,real-time monitoring of welding pressure,automatic adjustment of robot posture,to avoid problems of false welding and over-welding.
General assembly workshop:
Cooperating with the visual guidance system,the KR 150 robot is controlled through PROFINET communication to complete the precise assembly of the engine and gearbox,with an assembly force of≤200N and a repeat positioning accuracy of±0.08mm.
2.Metal processing
Laser cutting:
PH1003-2840 controls the KR 300 robot equipped with a laser cutting head,which can accurately follow complex contours through the electronic cam function,with a cutting speed of≥30m/min and a cut width of≤0.2mm.
Grinding and polishing:
Integrated force/torque sensor to adjust the robot grinding pressure in real time to ensure surface roughness Ra≤1.6μm,suitable for high-precision processing of aviation parts and ship structures.
3.Logistics handling
Heavy material handling:
The KR 240 robot can automatically load and unload 240kg steel coils under the control of PH1003-2840,with a handling speed of 0.8m/s,positioning accuracy of±0.1mm,and supports 24-hour continuous operation.
Palletizing application:
With the visual positioning system,it can realize the mixed palletizing of multiple varieties and specifications of goods,with a palletizing efficiency of≥1200 boxes/hour and a stacking height of≤3m.
IV.Advantages and features
1.High performance and high reliability
Industrial-grade hardware design:
Adopt fanless cooling,support 7×24 hours continuous operation,MTBF(mean time between failures)≥100,000 hours.
Redundant design:
Support power redundancy and network redundancy to ensure the continuity of key applications(such as automotive welding).
2.Openness and compatibility
Support KUKA full range of heavy-duty robots:
From KR 100(load 100kg)to KR 300(load 300kg),it can be adapted without additional adjustment of control parameters.
Multi-brand sensor compatibility:
Support mainstream brand force/torque sensors such as ATI and OnRobot to reduce system integration costs.
3.Intelligent maintenance and diagnosis
Remote monitoring function:
Remote monitoring of equipment status is achieved through the KUKA.Cloud platform,and early warning of motor overheating,drive failure and other problems.
Self-diagnosis tool:
Integrated KUKA SmartDiagnosis software can quickly locate I/O failures,communication interruptions and other problems,shortening downtime.
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
