KUKA robot’s safety signal is a key part of ensuring operational safety, usually including emergency stop signals and other safety-related signals. Understanding and applying KUKA robot’s safety signals is an important step to ensure the safety of operators and equipment. When configuring and using these signals, be sure to follow the manufacturer’s guidance and relevant safety specifications. KUKA robot’s safety signals can be connected in a variety of ways. This article mainly introduces the application of safety signals connected through the X11 connector for each KRC4 series control cabinet.
The KUKA robot KRC4 full series control cabinet’s X11 wiring diagram shows the connection of various components. It typically includes power supply, signal, and communication lines. It’s essential for proper robot operation, guiding the interconnection of modules and ensuring safe and efficient data and power transmission between them.
- Safety signal
Robots are generally equipped with many safety-related devices, such as emergency stop switches, safety doors, safety gratings, etc. There is a red emergency stop switch on the teach pendant. Safety devices are not directly connected to the robot through the IO module. There are many ways for them to communicate with the robot. There are two main ways to connect safety signals.
The more common safety bus methods include Profisafe (safety communication protocol based on Profinet bus) and CIP-Safety (safety communication protocol based on EtherNetIP bus). They are all installed in the robot KSS system in the form of software packages. The safety signal is transmitted to the robot through the pre-defined communication protocol in the corresponding bus communication mode. Therefore, this method requires customers to configure the corresponding bus communication, such as Profinet and EtherNetIP bus communication. The safety bus method is generally used more in automobile factories. It is necessary to configure the safety signal through the software communication protocol, which is implemented in the supporting PLC software programming. For detailed description and configuration, please refer to the previous article “KUKA Robot Profisafe Configuration”.
Safety interface board SIB (Safety Interface Board, interface board for connecting safety signals), as shown in the figure below, is generally available in standard robot control cabinets. The so-called X11 external safety interface is directly connected to this board inside the robot control cabinet, and then the X11 interface is connected to other safety devices outside the control cabinet. In addition, the safety signals of KUKA robots all use dual-channel mode to ensure the safety of the system and comply with the corresponding safety signs. This method is common in some general fields, such as handling, palletizing, arc welding, etc. This article mainly introduces the situation where safety signals are connected in this way. - X11 connector wiring instructions
It should be noted that the wiring of X11 needs to be differentiated according to the type of control cabinet. Different types of control cabinets have different wiring methods. The type of control cabinet can be judged by the appearance of the control cabinet or by checking the nameplate of the control cabinet. It is recommended to connect the emergency stop and safety door signals to the corresponding safety device. If it is determined that they do not need to be connected, short-circuit the corresponding channels.
(1) KRC4 standard & KRC4 Midsize & KRC4 Extend control cabinet
There are two versions according to different regions. When debugging some transformation projects, I encountered the North American version of the robot.
European version
X11 connector wiring method:
Emergency stop group A: 1 and 2 short-circuited
Emergency stop group B: 19 and 20 short-circuited
Safety door group A: 3 and 4 short-circuited
Safety door group B: 21 and 22 short-circuited
Channel group A, channel group B:
5 and 6 short-circuited, 23 and 24 short-circuited
7 and 8 short-circuited, 25 and 26 short-circuited
9 and 10 short-circuited, 27 and 28 short-circuited
11 and 12 short-circuited, 29 and 30 short-circuited
13 and 14 short-circuited, 31 and 32 short-circuited
North America Version
X11 connector wiring method:
Emergency stop group A: 76 and 20 short-circuited
Emergency stop group B: 74 and 2 short-circuited
Safety door group A: 3 and 4 short-circuited
Safety door group B: 21 and 22 short-circuited
Channel group A, channel group B:
5 and 6 short-circuited, 23 and 24 short-circuited
7 and 8 short-circuited, 25 and 26 short-circuited
9 and 10 short-circuited, 27 and 28 short-circuited
11 and 12 short-circuited, 29 and 30 short-circuited
13 and 14 short-circuited, 31 and 32 short-circuited
(2) KRC4 Compact & KRC4 Smallsize control cabinet
Interface for small cabinet
Wiring method for X11 connector:
Emergency stop group A: 1 and 2 short-circuited
Emergency stop group B: 10 and 11 short-circuited
Safety door group A: 3 and 4 short-circuited
Safety door group B: 12 and 13 short-circuited
Channel group A, channel group B:
5 and 6 short-circuited, 14 and 15 short-circuited
7 and 8 short-circuited, 16 and 17 short-circuited
18 and 19 short-circuited, 28 and 29 short-circuited
20 and 21 short-circuited, 30 and 31 short-circuited
22 and 23 short-circuited, 32 and 33 short-circuited