Control cabinet (CCU) design based on KUKA C4 robot

Control cabinet (CCU)

CCU - Control Cabinet contains two circuit boards:

CIB - Control Cabinet Board

PMB - Board

The control cabinet is the power distribution device and communication interface for all components.

All data are transmitted to the control system via internal communication and further processed there.

When power is lost, the control system components take over the battery until position data backup is complete and the control system is shut down.

Check the charge state and quality of the battery by performing a load test.

The control cabinet (CCU) contains two circuit boards (CIB control cabinet interface board and PMB power management board) and is the power distribution device and communication interface for all components of the robot control system. All data is transmitted to the control system via internal communication and further processed there. In the event of a power failure, the control system components are powered by batteries until the position data backup is completed and the control system is shut down. The charge state and quality of the batteries are checked by load testing.

1 Connector plate connector (needs to be inserted into the slot during installation)

2 fixing screws (for installation/replacement)

Functions of CIB board:

Communication interfaces for robot control system components

Safety outputs and inputs

Zero point reset

Inserted KUKA smartPAD

Option: US2 Controllable load voltage

Option: X311 External Acknowledgement and Emergency Stop Control Cabinet

4 measuring inputs for customer applications (clock rate: 125 μsec)

Main switch contacts

Monitoring fan speed in robot control systems

External fan

Control system fans

Temperature value collection:

Transformer thermal automatic switch input voltage (option)

Cooling unit signal contact (option)

Ballast

Cabinet temperature sensor

The following components are connected to the control system computer via the KUKA controller bus:

KUKA Power Pack / KUKA Servo Packs

Resolver Digital

The following components can be connected to the control computer via the KUKA system bus:

KUKA smartPAD (Operator Panel Interface)

Safety interface board

CSP Diagnostics

Data storage interface

PMB Board Function

Buffered power supply

KPP

KUKA smartPAD

Control system multi-core computer

Control System Operation Panel (CSP)

Resolver Digital Converr (R)

Unbuffered power supply

KSP

Braking device

External fan

Customer Interface

Fast measurement input

Functions of the control cabinet:

1. Communication interface of robot control system components

2. Safety output and input

Control main contactors 1 and 2

Calibration positioning

Inserted KUKA smartPAD

3.8 measuring inputs for customer applications (cycle time: 125 μsec)

4. Monitor fans in robot control systems

(1)-------X14 external fan interface

External fan

(33)----X4 KPP, KPC and PC fan supply voltage

Controls the fan of the system computer

5. Temperature value collection:

Thermal efficiency automatic switch of transformer

Signal contact for cooler

Signal contact of main switch

Ballast resistor temperature sensor

Cabinet temperature sensor

6. The following components are connected to the control system computer via the KUKA controller bus:

∎ KUKA Power Pack / KUKA Servo Packs

 Resolver to digital converter

7. Through the KUKA system bus, the following components can be connected to the control system computer:

 KUKA smartPAD (Operator Panel Interface)

 Safety interface board

8. Diagnostic LED

9. Interfaces for electronic data storage

Power supply for control cabinet (CCU) --- buffered power supply

(33)----X4 KPP, KPC and PC fan supply voltage

KPP

KSP

(4)------X306 smartPAD power supply

KUKA smartPAD

Control system multi-core computer

(34)----- X307 CSP power supply

Control System Operation Panel (CSP)

(41)-----X21 RDC power supply

Resolver Digital Converter (RDC) KPP

Unbuffered power supply

Motor brake device

(6) ------X3 KSP and brake system

(1)------ X14 external fan interface

External fan

Customer Interface

Fast measurement input

Do not confuse the plug positions. Check the cables, connectors and plug position markings. The plugs for the X14 external fan and X305 battery have the same shape. If the two connectors are confused, the CCU will be damaged. There is a risk of fire. The SmartPad is loaded with additional voltage via the X18 interface.

When replacing the CUU, remove the bolts on the fixing plate and pull the fixing plate together with the CCU out of the opening of the connecting plate.

Check the new CCU for damage. Insert the fixing plate with the CCU into the connection plate opening and tighten.

Editor: Huang Fei