Kawasaki Robot

Palletizing robots

Palletizing robot

ISO certi�ed in Akashi Works.

Cat. No. 3L1712 Jun. ’17 S

Printed in Japan

Kawasaki RobotCAUTIONS TO BE TAKEN TO ENSURE SAFETY

lFor those persons involved with the operation / service of your system, including Kawasaki Robot, they must strictly observe all safety regulations at all times. They should carefully read the Manuals and other related safety documents.

lProducts described in this catalogue are general industrial robots. Therefore, if a customer wishes to use the Robot for special purposes, which might endanger operators or if the Robot has any problems, please contact us. We will be pleased to help you.

lBe careful as Photographs illustrated in this catalogue are frequently taken after removing safety fences and other safety devices stipulated in the safety regulations from the Robot operation system.

ROBOT DIVISION

Tokyo Head Office/Robot Division1-14-5, Kaigan, Minato-ku, Tokyo 105-8315, JapanPhone: +81-3-3435-2501 Fax: +81-3-3437-9880

Akashi Works/Robot Division1-1, Kawasaki-cho, Akashi, Hyogo 673-8666, JapanPhone: +81-78-921-2946 Fax: +81-78-923-6548

Global Network

Kawasaki Robotics (USA), Inc.28140 Lakeview Drive, Wixom, MI 48393, U.S.A.Phone: +1-248-446-4100 Fax: +1-248-446-4200

Kawasaki Robotics (UK) Ltd.Unit 4 Easter Court, Europa Boulevard, Westbrook Warrington Cheshire, WA5 7ZB, United KingdomPhone: +44-1925-71-3000 Fax: +44-1925-71-3001

Kawasaki Robotics GmbH29 Sperberweg, 41468 Neuss, GermanyPhone: +49-2131-34260 Fax: +49-2131-3426-22

Kawasaki Robotics Korea, Ltd.43, Namdong-daero 215beon-gil, Namdong-gu, Incheon, 21633, KoreaPhone: +82-32-821-6941 Fax: +82-32-821-6947

Kawasaki Robotics (Tianjin) Co., Ltd.1·2/F, Building 6, No.19 Xinhuan Road, TEDA, China Phone: +86-22-5983-1888 Fax: +86-22-5983-1889

Kawasaki Motors Enterprise (Thailand) Co., Ltd.(Rayong Robot Center)119/10 Moo 4 T.Pluak Daeng, A.Pluak Daeng, Rayong 21140 Thailand Phone: +66-38-955-040-58 Fax: +66-38-955-145

https://robotics.kawasaki.com/

] Materials and specifications are subject to change without notice.

Kawasaki’s high-speed palletizing robots

meet the demands for flexibility and speed.

1 2

RD080N ZD130S/250S

CP180L/300L CP700LCP500L

In today’s highly competitive marketplace, meeting the demand for just-in-time deliveries,

flexible packaging, the freshest products, or the highest production line efficiencies can be crucial

to a company’s success. Efforts to meet these demands have led to the development of

automation systems for the end-of-line and distribution processes of palletizing and depalletizing.

Kawasaki’s robotic palletizing solutions provide the pallet pattern flexibility, tooling flexibility,

and cycle times needed to deal with multi-variety and small-batch production, and reduce process

change costs.

Kawasaki Robotics offers three different lines of palletizing robots with a wide range of payload

options to suit most needs, including model RD80N with a maximum payload of 80 kg, models

ZD130S/250S with maximum payloads of 130/250 kg and models CP180L/300L/500L/700L with

maximum payloads of 180/300/500/700 kg. Each has industry leading reach, speed and quality

to deliver high-performance automation technology for most any palletizing application.

Kawasaki can provide a solution to give your production line the palletizing flexibility and

product rate it needs to compete in today's economy.

Features

Palletizing capacity worthy of our high-speed age

Kawasaki palletizing robots deliver the high-speed operation needed for distribution. Based on a robot stroke of 400 mm upward-downward and 2,000 mm in the left-right direction, the RD080N can perform 900 cycles per hour with loads of 80 kg, and the CP180L achieves an industry leading 2,050 cycles per hour with loads of 130 kg.

Compact applications

The Kawasaki RD080N is designed specifically for applications where a compact, high-speed, palletizing robot is required. Despite its slim space saving design, the RD80N can manipulate loads up to 80 kg and create pallet stacks over 2 meters tall.

Large work envelope and high payload capacity

At 3,075 mm and 3,256 mm respectively, the high vertical reach capability of the ZD and CP series robots is ideal for tall pallet stacks and multi-lane applications. The extra-long horizontal reach of 3,255 mm for both series allows for one robot to be used to cover up to four pallets. The high payload capacity CP series robots can handle up to 700 kg. This allows for multiple product picks and complete pallet layer handling, resulting in fewer cycles per completed pallet.

Easy-to-use palletizing software K-SPARC

Available as an option, Kawasaki’s K-SPARC palletizing software enables users to quickly and easily simulate layout planning and operations, as well as create robot operation programs on a computer.

Space and energy saving

The CP series E03 controller is only 25% of the standard palletizing] controller size (41% with transformer unit) and fits under conveyors and other equipment. The E03 controller generates electric power while in a deceleration mode, reducing energy consumption and minimizing CO2 emissions.

] in case of E4X

Electricity Regeneration Function

Palletizing cells

Conventional controller

Sample layout for palletizing cells

Sample of palletizing cells System configuration example

E03 Controller

Return electric power to the primary power source

EnergySaving

Integrated electric regeneration unit

Consume electric power by resistance

Add-on regenerative resistor unit

Kawasaki provides system configurations perfectly adapted to your needs.

Different workpieces sent from the same conveyor are segregated and palletized.

Different workpieces sent from different conveyors are segregated and palletized.

Safety fence

Robot arm

Palletizing hand

Workpieceacceptance

Pallet (outlying)

Robot controller

Pallet sensors

Pallet guideRobot stand

Carry-in conveyor

1,7

50

1,7

50

6,1

00

7,8

50

4,0

50

5,8

00

800 8005,000 6,500

（mm）

Pallets Pallets

Workpieces

Workpieces

PowerControl signal

Cell controller

PC(K-SPARC)

USB memory

Manipulator(with internal or external valves)

Primary air

I/O or communication(CC-Link, DeviceNet, etc)

Robot-controller cable

Robot controller

3 4

Depalletizing cells Easy-to-use palletizing software

lDetects the 3-D position and posture of stacked bag packages.

lA single fixed camera can monitor wide stacking areas.

lAble to adjust to changes in peripheral lighting environments and workpiece surface conditions.

lNo need for configuring the individual settings of each workpiece stacking pattern.

lAble to handle a combination of different types of workpieces at the same time.

You can build an advanced and flexible robot safety system according to the motion condition by monitoring the movements of the robot.

lSave Space by limiting the range of robot movementslSafety function can be switched according to the state of safety

signal inputlIEC61508 (SIL2) and ISO13849-1 (PLd/category 3) certification

Item Specification

Measuring range L1,400mm×W1,400mm×L1,800mm

Objective distance 1,700mm

Laser class Class 3R

Dimension L1,100mm×W125mm×H125mm

Mass About 6.5kg

Range : 1,600mm

Accuracy : ±10mm

1,400mm1,400mm

1,700 -

3,500mm

System configuration example

Other applications ]For these applications, the workpiece sizes and stacking patterns must be configured.

LSC (Laser Slit-scan Camera)

Control signal

Ethernet Ethernet

I/O

LSC(Laser slit-scan camera)

Vision controller

DC24V

Power

Manipulator(with internal or external valves)

Primary air

I/O or communication(CC-Link, Device Net, etc)

Robot-controller cable

Robot controller

Peripheral equipment control panel

Depalletizing carton boxes Depalletizing plastic containers

Save spaceYou can reduce the size of the safety fence area by limiting the range of robot movements to the minimum.

Transporting workpieces during robot motionYou can limit the range of robot movements according to the human work area.

Reduced cycle timeReduced safety fence area

Safety fence area with Cubic-S

Safety fence without Cubic-S

Item Specification

Safety performance IEC61508 (SIL2)

ISO13849-1 (PLd/category3)

Monitoring the number of joints Maximum 9 joints

Safety function Motion area monitoring, Joint monitoring, Speed monitoring,

Stand still monitoring, Tool orientation monitoring,

Protective stop, Emergency stop, Safety status output

Safety input and output Dual channel safety input 8CH

Dual channel safety output 8CH

] It is possible to allocate Safety Status Output Signals and Safety

Input Signals of each Safety functions

5 6

Base installationdimensions

VIEW A

Motion rangeof point "P"

A

180°

180°

D.

TSM VW S/N

20

6

150 1,080

68

08

70

15

8

R397

277

298

307

1,6

96

.5

244

16

5

2,100370.8

1,2

31

.52

,07

9.2

619.2

45

.8

51

6.2

2,0

62

.3

619.2 1,100

1,1

00

X

Y

Xø0.3 Y ø0.04 X

ø80

ø94

30°

6-M8 Dp13

60°

ø8H7 Dp8

ø50H7 Dp6

ø0.06

210±0.1

380

300170

320

40

0 34

0

30

0

38

0

21

0±

0.1

2-ø13H9

8-ø18

ø26

ø18

17

P

JT2105°

JT2140°

JT3

JT340°

JT4±360°

JT1

JT1

JT5±10°

205°

(mm)

RD080N

(mm)

75

01

,20

02

60

255 1,550 250

24

0

2,5

26

R1,161

963

481.5481.5

3,255

88

4.6

2,3

71

.2

3,2

55

.8

1,192.7 1,600

1,8

00

926.8

R2,934.2

27

2.9

2,2

00

Working rangebased on point P

Point P

Rear side interference area

JT2JT2

JT3

JT3

JT6±360°

JT1

JT1

46°95°

110°

15

°

160°

160°

A

ø180

30° 12-M12 Dp24

500100 100

50

01

00

10

0

75

0

375474

8-ø22

45

0

ø22

ø42

30

VIEW A

Base installationdimensions

CP180L/300L

Base installationdimensions

VIEW A

Motion rangeof point "P"

8-ø11

ø150

ø180

JT1

JT1

JT3

JT2

JT2

JT4±360°

A

JT3

37

0

75

125

12

51

25

50

01

00

10

0

500 100100

770

77

0

125

2-ø25G8ø0.05

300

30

03

00

8-ø22

30

67

02

70

1,2

50

R2,875.3

1,600

1,8

00

180°

180°

1,130.9

15

1,450300

25°

90°

120°

50°

2552,257998

3,0

75

.3

81

0

2,2

00

15

°

33

8.2

R1,391

P

P

30

0

R547

(mm)

ZD130S/250S

(mm)

75

01

,20

02

60

255 1,550 250

24

0

2,5

62

R1,298

481.5 481.5

963

3,255

88

4.6

2,3

71

.2

3,2

55

.8

1,192.7 1,600

1,8

00

926.8

R2,934.2

27

2.9

2,2

00

Point P

Rear side interference area

JT2JT2

JT3

JT3

JT6±360°

JT1

JT1

46°95°

110°

15

°

160°

160°

A

ø180

30° 12-M12 Dp24

500100 100

50

01

00

10

0

75

0

375474

8-ø22

45

0

ø22

ø42

30

VIEW A

Working rangebased on point P

Base installationdimensions

CP500L

Motion range & dimensions

7 8

Standard specifications

RD080N ZD130S ZD250S

Arm type Articulated type

Degrees of freedom (axes) 5 4

Max. payload (kg) 80 130 250

Max. stroke (°)

Arm rotation (JT1) ±180 ±180

Arm out-in (JT2) +140 - –105 +90 - –50

Arm up-down (JT3) +40 - –205 +15 - –120

Wrist swivel (JT4) ±360 ±360

Wrist compensation (JT5) ±10 ]4 –

Max. speed (°/s)

Arm rotation (JT1) 180 148 95

Arm out-in (JT2) 180 110 90

Arm up-down (JT3) 175 130 95

Wrist swivel (JT4) 360 400 190

Working area (mm)

Width 1,100 1,800

Depth 1,100 1,600

Height 2,062.3 2,200

Moment of inertia (kg•m2) 13.7 50 100

Palletizing capacity ]1 (cycle/hour) 900 1,700 1,400

Positional repeatability ]2 (mm) ±0.07 ±0.5

Mass (kg) 540 1,350

Power requirements ]3 (kVA) 4.5 10

Controller

America

E03

E33

Europe E43

Japan & Asia E23

]1: Motion pattern (400 mm up, 2,000 mm horizontal, 400 mm down in a to-and-fro motion) ]2: conforms to ISO9283]3: depends on the payload condition and motion patterns ]4: operating angle of the JT5 is ±10 degrees perpendicular to the ground.

CP180L CP300L CP500L CP700L

Arm type Articulated type

Degrees of freedom (axes) 4

Max. payload (kg) 180 300 500 700

Max. stroke (°)

Arm rotation (JT1) ±160

Arm out-in (JT2) +95 - –46

Arm up-down (JT3) +15 - –110

Wrist swivel (JT4) ±360

Wrist compensation (JT5) –

Max. speed (°/s)

Arm rotation (JT1) 140 [5 115 [6 85 75

Arm out-in (JT2) 125 [5 100 [6 80 65

Arm up-down (JT3) 130 [5 100 [6 80 65

Wrist swivel (JT4) 400 [5 250 [6 180 170

Working area (mm)

Width 1,800

Depth 1,600

Height 2,200

Moment of inertia (kg•m2) 50 [5 100 [6 250 500

Palletizing capacity ]1 (cycle/hour) 2,050 [5 1,700r [6 1,000 900

Positional repeatability ]2 (mm) ±0.5

Mass (kg) 1,600 1,650

Power requirements ]3 (kVA) 12

Controller

America

E03Europe

Japan & Asia

]1: Motion pattern (400 mm up, 2,000 mm horizontal, 400 mm down in a to-and-fro motion) ]2: conforms to ISO9283]3: depends on the payload condition and motion patterns ]5: in case of 130 kg payload and less ]6: in case of 250 kg payload and less

3,255

88

4.6

2,3

71

.2

3,2

55

.8

1,192.7 1,600

1,8

00

926.8

R29,34.2

27

2.9

2,2

00

75

01

,20

02

60

255 1,550 250

24

0

25

62

R1,298

481.5 481.5

963

Point P

Rear side interference area

46°95°

110°

15

°

160°

160°

ø22

ø42

30

500100 100

50

01

00

10

0

75

0

375474

8-ø22

45

0

ø180

30° 12-M12 Dp24

A

(mm)

Working rangebased on point P

Base installationdimensions

VIEW A

JT1

JT1

JT2JT2

JT3

JT4±360°

JT3

CP700L

Motion range & dimensions

9 10

Large, color LCD touch screen display.

The key arrangement has been optimised through extensive studies of operator hand movements.

Equipped with Enable switches.

Controller

Specifications

E seriesThe E Controller combines high performance, unprecedented reliability, a host of integrated features and simple operation, all in a compact design.

FeaturesCompactThe E03 controller for CP series palletizing robots has far less volume. You can use it in an upright-position or in a stacked installation to reduce the footprint of this controller.

User-friendly operationThe easy-to-use teach pendant now incorporates motor power and cycle start at your fingertips. Multiple information screens can be displayed simultaneously. The intuitive teaching interface is simple to use.

Programming ease & flexibilityA rich set of programming functions come standard with the E Controller to support a wide range of applications. Functions can be combined and easily configured within a system to suit a particular application. Also, the powerful Kawasaki AS Programming Language provides sophisticated robot motion and sequence controls.

Advanced technologiesThe enhanced CPU capacity allows for more accurate trajectory control, faster program execution, and quicker loading and saving of files. In addition, memory has been expanded to meet the need for higher program storage capacity. The controller comes equipped with a USB port for external storage devices.

Easy maintenanceModular components with limited cables translate into easy diagnostics and maintenance. A host of maintenance functions are available, including self-diagnostics on hardware and application errors to minimize troubleshooting and reduce MTTR (Mean Time To Repair). Remote diagnostics via the web server function enables service support from anywhere in the world.

Space and energy savingThe CP series E03 controller is only 25% of the standard palletizing controller size (41% with transformer unit) and fits under conveyors and other equipment. The E03 controller generates electric power while in a deceleration mode, reducing energy consumption and minimizing CO2 emissions.

E03

Standard Standard Option

America

E03

E33

E03

E33

Europe E43 E43

Japan & Asia E23 E23

Dimensions (mm) W550×D580×H278 W630×D550×H950 W730×D550×H1,200Transformer unit:

W580×D580×H178

Structure Enclosed structure / Indirect cooling system Enclosed structure / Indirect cooling system

Number of controlled axes

5 5 6E33: 8E43: 8E23: 7

Drive system Full digital servo system Full digital servo system

Coordinate systems Joint, Base, Tool Joint, Base, Tool Fixed tool point

Types of motion control Joint/Linear/Circular Interpolated motion Joint/Linear/Circular Interpolated motion

Programming Point to point teaching or language based programming Point to point teaching or language based programming

Memory capacity (MB) 8 8

Generalpurposesignals

External operation Motor power off, Hold Motor power off, Hold

Input (Channels) 32 32 Max. 96 Max. 128

Output (Channels) 32 32 Max. 96 Max. 128

Operation panelE-Stop switch, teach/repeat switch,

control power lightE-Stop switch, teach/repeat switch, control power light

E-Stop switch, teach/repeat/rapid-feed check

switch, control power light

E-Stop switch, teach/repeat switch, control power light

Rapid-feed check mode switch

Cycle start switch, motor-on switch, hold/run switch, error light, error reset switch, rapid-feed check mode switch (only on E23)

Cablelength

Teach pendant (m) 5 5 10, 15

Robot-controller (m) 5 5 10, 15

Mass (kg) 45 110 195 Transformer unit: 45

Power requirements

AC200-220V ±10%, 50/60Hz, 3øAC200-220V ±10%,

50/60Hz, 3øAC380-415V ±10%,

50/60Hz, 3øAC440-480V ±10%,

60Hz, 3ø

]Transformer unitAC380-415V ±10% or AC440-480V ±10% ] 50/60Hz, 3ø

E33AC200-220V ±10%AC380-415V ±10%AC515V ±10%AC575V ±10%AC440-480V ±10%

] 50/60Hz, 3ø

Class-D earth connection (Earth connection dedicated to robots),

leakage current: Maximum 100mA

Class-D earth connection (Earth connection dedicated to robots), leakage current: Maximum 100mA

Environmentalcondition

Ambient temperature (°C) 0 - 45 0 - 45

Relative humidity (%) 35 - 85 (no dew, nor frost allowed) 35 - 85 (no dew, nor frost allowed)

Body color Munsell 10GY9/1 equivalent Munsell 10GY9/1 equivalent

Teach pendantTFT color LCD display with touch-panel, E-Stop

switch, teach lock switch, Enable switchTFT color LCD display with touch-panel, E-Stop switch,

teach lock switch, Enable switch

Auxiliary storage unit – – USB Memory

Interface USB, Ethernet (100BASE-TX), RS-232C USB, Ethernet (100BASE-TX), RS-232C

]Option

]

E23

Teach pendant

11 12

External view & dimensions

E03

E43

E23

E33

(mm)

(mm)

(mm)

(mm)

550 550 180 550 550 180

550 450 180

95

01

,20

0

1,2

00

26

01

81

81

70

580 550

580 550

550 550 180 550 550 180

550 450 180

95

01

,20

0

1,2

00

26

01

81

81

70

580 550

580 550

550 550 180 550 550 180

550 450 180

95

01

,20

0

1,2

00

26

01

81

81

70

580 550

580 550

550 550 180 550 550 180

550 450 180

95

01

,20

0

1,2

00

26

01

81

81

70

580 550

580 550

]Option

Transformer unit ]

Simple palletizing software (option)

This software lets you configure the pick and place positions of the workpieces by robots and register workpieces, pallets, and stacking patterns displayed on your computer’s screen. It also allows you to easily create robot operation programs .

This optional software is one of the application programs built on K-ROSET, Kawasaki’s offline teaching software.

Easy setup by layout selectionSupport for up to two pick positions and four place positions of workpieces by robots.Simply select a layout and enter a distance!

Easy registration of item typesItem types are registered simply by entering data on your computer for workpieces, pallets, and stacking patterns.

K-ROSET functions can be usedWith K-ROSET, users can specify the layout by analyzing the installation positions automatically according to the robot types and place positions.You can also check for interference and perform cycle time analysis.

Support for many kinds of stacking patternsApproximately 100 types of base patterns can be configured for each stage.The place position of workpieces can be specified.Gaps can also be adjusted.

13 14