The document describes the KUKA KR 360-3 six-axis industrial robot used in a wheel assembly system. It has 6 axes of movement and is controlled by the KR C4 controller. Two robots work simultaneously with a Matrox Iris GT smart camera each to locate wheel bolts and rims, calculate their positions, and assemble the rims to the wheel hubs in 54 seconds. The system provides advantages over the ABB IRB 6600 such as a larger working range and payload for the KUKA robot. Ongoing research and development continues to improve robot welding, assembly, and human-robot collaboration capabilities.

1. KUKA KR 360-3
SIX-AXIS INDUSTRIAL ROBOT
FOR WHEEL ASSEMBLY SYSTEM

2. Components of the System

3. • Driven by 3 servomotor, installed at the rear end of the arm via drive
shafts
• Made up of light alloy and iron casting
• Has 6 axes
• Axis 1: located at the base of a robot – allows it to rotate from left to
right
• Axis 2: helps the lower arm of a robot to extend forward and backward
• Axis 3: allows the upper arm of a robot to raise and lower
• Axis 4: rotates the upper arm of a robot in a circular movement –also
known as wrist roll
• Axis 5: permits the wrist of the robot’s arm to raise and lower
• Axis 6: allows the wrist of the robot’s arm to rotate freely in a circular
motion

5. • Uses KR C4 (controller) to integrate robot control, PLC control,
motion control and safety control.
• Displayed on smart PAD teach pendant (interface), which have eight
log keys for separate control of axis and is multilingual
• KUKA.PLC mxAutomation (software) allows external controller with
embedded PLC to command the robot which requires simple
programming
• Modifications of software can be implemented at any time with
mxA-based operator control

7. • Matrox Iris GT combines the integration of a smart camera with the
programmability of a PC-based machine vision system
• Powered by Intel Atom Processor with Windows XP Embedded OS –
supports keyboard and mouse
• Supported by the Matrox Imaging Library (MIL) – features
interactive software and programing functions – for image capture,
processing, and analysing

9. Block Diagram of the System

10. Input Controller Actuator Process
ControllerActuatorProcessOutput
•Bolts and rims • KR C4 •KUKA KR 360 - 3 •Pick up the bolts and rims
• KR C4•KUKA KR 360 - 3• Assembling the rims to the wheel
hub with given bolt and rim
•The rim is mounted to the
wheel hub
Feedback Sensor (Matrox GT) – IR sensor
Feedback Sensor (Matrox GT) – IR sensor

11. Functionality and the Interface
Used

12. • Two of the Kuka robots – situated at each side of a car body –
gathers wheel bolts and rims – screw them onto the car
• Robots are synchronized with the conveyor – follows the car’s
movement during assembly
• Each robot has a Matrox Iris GT smart camera – it locates the rim’s
centre point and calculate its positon (x, y, z coordinates)
• It checks whether the rim design located matches the rim that is
expected by PLC
• Entire process takes only 54 seconds

14. • The image processing system is developed with Matrox Design
Assistant (Integrated Development Environment [IDE]) – lets users
to create a flowchart using C++ for machine vision applications
• The project is then executed on the camera and monitored from
web-based HMI on PC
• Image processing are triggered by a command from network link –
contains data about the measurement and the expected rim type.
• Modal Finders are used to locate the bolts and rim design –
calculates the position and orientation based on data collected
• TCP/IP connection – communication between cameras and PLC

16. Advantages and Disadvantages
of the System
(compared to ABB IRB 6600)

17. KUKA KR 360 - 3 ABB IRB 6600

18. KUKA KR 360-3 Specification ABB IRB 6600
-185° to +185° Working Range Axis 1 -180° to +180°
-130° to +20° Working Range Axis 2 -75° to +85°
-100° to +144° Working Range Axis 3 -180° to +60°
-350° to +350° Working Range Axis 4 -300° to +300°
-120° to +120° Working Range Axis 5 -125° to +125°
-350° to +350° Working Range Axis 6 -300° to +300°
2375kg Weight 1700kg
360kg Payload (max) 225kg
75dB Noise Level (max) 73dB
10 – 55°C Operating Temperature 5 – 52°C
±0.08mm Positions Repeatability (ISO test) ±0.1mm
Bold = Advantage

20. State of Research and
Development

21. • Even till this day, the research towards improving the system is
ongoing in many different sectors.
• Current ongoing R&D: Robot Hemming, Bonding/Sealing, Laser
Hybrid Welding, KUKA Hybrid Welding, Laser Cutting, Laser
Welding, Magnetarc Welding, Assembly, Spot Welding, Friction
Welding, Arc Welding, Submerged Arc Welding, Soldering, Roller
Seam Welding, Plasma Welding, Laser Brazing, Human-Robot-
Collaboration, Friction Stir Welding, and Sensitive Assembly
• KUKA Systems will continue to do R&D in order to create systems
that are adaptable, energy and resource-effective, fast and efficient
– which would be the industry of the future