KUKA KR 30 L16-2 Robotic Welding Cells

KUKA KR 30 L16-2 robotic welding station was built in 2017 in Germany by KUKA Roboter GmbH. The welding station has been specially designed for the precision welding of structural components with even the most complex geometries. All the necessary equipment and machinery with the best technical specifications were integrated inside a cell with service doors and light curtains. This created a complete, fully-automated system that significantly speeds up production, increases weld repeatability and reduces downtime to a minimum.

The machining process is performed by a KUKA 6-axis robot, distinguished by, among others, its clever design and robust arm with an increased range of movement. The arm’s reach of 3102 mm and a payload of 16 kg enable the welding of large and complex structures, while maintaining a highly dynamic and repetitive process. During automated welding, dynamic and accurate feeding of the welding wire is very important. To achieve this, a reliable FRONIUS wire feeder is placed directly on the machine body. The welding torch, in turn, is automatically cleaned at defined intervals. A THIELMANN cleaning station injects a special anti-adhesion substance into it, which significantly extends the life of the torch. All processing parameters are, in turn, programmed in a modern controller that offers intuitive operation and access to advanced functions.

The KUKA KR 30 L16-2 works together with a 3-axis welding positioner, designed to rotate the workpiece during the welding process. It consists of two independent workstations, enabling the machining and preparation of the next workpiece for welding at the same time. Each of the 3 axes is driven by powerful servomotors, guaranteeing excellent dynamics combined with process repeatability.

The welding station is fully complete and consists of the following components:
– robot arm: KUKA KR30 L16-2
– controller: KUKA KR-C4
– welder: FRONIUS TPS 400i Pulse
– 3-axis, 2-station welding positioner
– welding wire feeder: FRONIUS WF 25i
– torch cleaning station: THIELMANN BRG-2000 D
– water-cooled torch: FRONIUS MTB 330i
– welding hose: FRONIUS MHP 500i
– KP3-V2H500-L3000 welding cell with service doors and light curtains

Technical specifications of individual parts of the KUKA KR 30 L16-2 welding station
Welding robot
- number of axes: 6
- maximum payload: 16 kg
- maximum arm reach: 3102 mm
- KUKA.ArcTech software for automated inert gas welding
- KUKA SmartPAD portable control unit (pendant)
- weight of the KR 30 L16-2 machine: approx. 700 kg

Welder
- Welding Package Pulse – pulsed arc welding for significantly improved spatter control and arc stability
- Welding Package Standard – short-arc and spray arc welding
- communication interface for integration with robot
- complete set of welding hoses and equipment

Welding positioner
- number of axes: 3
- working length: 3000 mm
- working width: 1600 mm
- rotation angle: 180°
- two independent work stations
- possibility to mount a tool or a welding holder
- servo drives on all axes

Welding cell
- complete safety fence with service doors
- light curtains
- approximate external dimensions (L x W x H): 4800 x 7800 x 2800 mm