KUKA released the KR FORTEC ultra family of high-payload robots that set new standards in the heavy payload range from 480 to 800kg. Ideally rated for high payloads and moments of inertia, they especially meet the new requirements of the electromobility sector.

Five Robot Variants

The new KUKA KR FORTEC ultra family includes five robot variants – each ideally suited to a specific application. The KR 800, for example, impressively handles payloads up to 800kg. The two KR 480 variants reach up to 3,700mm. The High Inertia variants of KR 640 and KR 560 increase the maximum permissible mass moment of inertia significantly with extended grippers.

“We developed the robots of the new KR FORTEC ultra family in close cooperation with our customers. They are our response to the automotive industry’s changing requirements, with bigger vehicles, heavy batteries, and very large components for electric cars,” Wolfgang Bildl, Portfolio Manager at KUKA.

Innovative Double Link Arm Design

The most striking feature of the new KR FORTEC ultra family of robots is its double link arm. The arm features an innovative design that reduces weight while ensuring high stiffness and accuracy. This design reduces the use of materials. This results in higher dynamic performance, optimal cycle times, less energy consumption and a lower CO₂ footprint.

Incredibly Strong, Extremely Compact

“To cover a payload range of 800kg and high mass moments of inertia, customers of other manufacturers must settle for robots in the next payload class up, which are significantly heavier and more cost-intensive to purchase and maintain,” said Bildl. With a first-class power-to-weight ratio, the new KR FORTEC ultra family eliminates these drawbacks.

Significantly Lower Operating Costs

The very high Mean Time Before Failure (MTBF) of up to 400,000 hours offers customers low spare parts costs and high availability. Furthermore, the new KR FORTEC ultra family robots meet all customer upkeep requirements. Also, they offer very good component accessibility and ease of maintenance and repair. For example, these robots need only three forms of maintenance: oil changes, visual inspection, and lubrication of the cable set and the bearings on the counterbalancing system.

Intelligent Modular Concept

The KR FORTEC ultra modular system focuses on the use of as many shared parts as possible within the robot family, including castings, motors, and gear units. This helps minimize the cost of stocking spare parts and standardize maintenance processes.

Newly Developed Equipment and Extensions

KUKA is also launching a new high-performance linear unit – the KL 5000 – to increase robot workspace. With a standard length of up to 31m, it offers great flexibility in system design, including extensions and up to four robots per unit. Modular segments enable easy weld-free integration. The automatic lubrication system reduces maintenance work and increases availability.

Another highlight is the new energy supply system with a new K-pipe and a modified interface on axis 2. This development offers impressive durability and minimized wear, combined with a smaller disruptive contour, simplified maintenance and exchange, and customization to meet various requirements. Coordinated equipment saves time and cost during integration.