Product Description

The KUKA KSD1-48​is a compact,integrated drive and power supply unit designed for the KUKA KR C4 compact controller,specifically used to power and control KUKA’s small robot series like the KR 3 AGILUS and KR 6 AGILUS.It functions as a combined DC power supply and single-axis or multi-axis servo drive,converting mains AC voltage into the controlled DC and 3-phase AC power required for the robot’s servo motors.This all-in-one unit is the power core for high-speed,precision small-robot applications.

Application Scenario

In an electronics assembly cell,a KR 3 AGILUS robot performs ultra-high-speed pick-and-place of microchips onto a PCB.The robot’s movements are a blur,with cycle times under 0.5 seconds.The KUKA KSD1-48​unit is the heart of its motion system.It takes 400V AC 3-phase input and generates a stable high-voltage DC bus.From this bus,its integrated drive circuitry synthesizes the precise 3-phase AC waveforms for the robot’s small,high-acceleration motors.During a placement move,the robot’s path requires an instantaneous reversal of direction.The KSD1-48’s drive section manages the rapid regeneration of energy as the motor decelerates,feeding it back to the DC bus to be reused by other axes,maximizing efficiency.Simultaneously,its integrated safety functions monitor the DC link voltage.If a fault were to cause an over-voltage,the unit would activate its internal brake chopper circuit to dissipate the excess energy as heat,protecting the drive electronics and maintaining system stability.This seamless integration of power conversion,multi-axis drive,and energy management in one compact package enables the extreme performance and efficiency required for high-throughput electronics manufacturing.

Key Parameters

Main Parameters

Value/Description

Product Model​

KUKA KSD1-48​

Manufacturer​

KUKA AG

Product Category​

Compact Drive and Power Supply Unit

Compatible Controller​

KUKA KR C4 compact

Input Voltage​

3-phase AC,400-480V,50/60 Hz.

Output Functions​

Generates DC bus voltage and contains integrated servo drive electronics.

Cooling​

Integrated forced-air cooling with fan.

Protections​

Over-current,over-voltage,under-voltage,short-circuit,over-temperature.

Status Indication​

LEDs for power,status,and error indications.

Communication​

Connects to the KR C4 compact main computer via internal digital bus.

Technical Principles and Innovative Values

All-in-One Power and Drive Integration:​The KSD1-48’s key innovation is its highly integrated design.It combines the functions of a 3-phase active infeed/regenerative supply,a DC link circuit,and one or more servo drive amplifiers​into a single,compact housing.This contrasts with larger KUKA systems that have separate power supply and drive modules.This integration dramatically reduces the footprint of the controller cabinet,simplifies internal wiring,and optimizes the power path for efficiency,making it ideal for the space-constrained cabinets of the KR C4 compact controller used with small robots.

Regenerative Active Front End for Energy Efficiency:​Unlike simple diode bridges,the KSD1-48​typically uses an Active Front End(AFE)for the AC/DC conversion.The AFE draws a sinusoidal current from the mains,improving power factor and reducing harmonics.More importantly,it is bidirectional.When the robot decelerates,the motors act as generators,sending energy back to the DC bus.The AFE can convert this excess DC energy back into AC and feed it into the power grid.This regenerative capability​significantly reduces energy consumption and heat generation compared to systems that waste regenerative energy as heat in brake resistors,especially in highly dynamic start-stop applications common with small robots.

Optimized for High Dynamic Performance:​The drive electronics within the unit are specifically tailored for the low-inertia,high-acceleration motors of the AGILUS series.They provide very high switching frequencies and fast current control loops,enabling the extremely precise torque control needed for the robot’s”agile”movements—quick starts,precise stops,and smooth path following at high speed.This optimization at the system level(drive+motor)is what gives these small robots their characteristic speed and precision.

Application Cases and Industry Value

Case Study:Pharmaceutical Lab Automation&Sample Handling

A pharmaceutical research lab automated its sample preparation using a KUKA KR 6 AGILUS robot inside a safety enclosure.The robot’s task was to pick up vials,present them to various analyzers,and place them in a storage rack.The compact KR C4 compact​controller with the KSD1-48​drive unit was mounted directly on the enclosure frame,saving valuable lab floor space.The lab manager highlighted the benefits:”The compactness and quiet operation of the system were major factors.The KSD1-48​unit is remarkably efficient and cool-running.In an application with thousands of small,precise moves per day,we’ve seen no degradation in performance.Its reliability has been perfect over two years.When we needed to add a seventh axis(a linear rail),the system’s architecture made it straightforward.The integrated nature of the KSD1-48​meant we didn’t have to deal with separate power supplies and drives,which simplified both the initial integration and our ongoing maintenance understanding.”This demonstrates the unit’s value in sensitive,space-constrained environments:its integration,efficiency,and reliability enable automation in areas where traditional bulky robot controllers would not be feasible,thereby accelerating research and improving repeatability.

Related Product Combination Solutions

The KUKA KSD1-48​is the central power and drive component within the KR C4 compact ecosystem:

KUKA KR C4 compact Main Computer(KPC):​The”brain”of the controller.It runs the robot operating system(KSS),executes programs,and sends motion commands to the KSD1-48​over the internal bus.

KUKA AGILUS Robot(KR 3/6 R series):​The small,high-speed robot whose motors are driven by the KSD1-48.The robot’s mechanical design and motors are optimized for this drive system.

KR C4 compact Control Cabinet:​The small enclosure that houses the KSD1-48,the KPC,and other associated components like the Safety Interface(X11)and optional fieldbus boards.

KUKA SmartPAD(Teach Pendant):​The handheld operator interface used to program the robot,jog it,and view system information,including any status or error messages originating from the KSD1-48.

KUKA.WorkVisual Engineering Software:​The configuration and project planning software used to set up the entire controller system.The KSD1-48​is configured as a hardware component within this software.

External Safety Controller(e.g.,KUKA KSP):​While the KR C4 compact has integrated safety,complex cells may use an external safety PLC that interfaces with the controller to monitor the drives and initiate safe stops.

Installation,Maintenance,and Full-Cycle Support

Installation of the KSD1-48​is part of the KR C4 compact controller assembly.It involves mounting the unit in the cabinet,connecting the 3-phase mains power,and plugging in its internal communication and power cables to the motherboard.This work must be performed by qualified personnel due to high voltages.​Configuration is done within KUKA.WorkVisual when setting up the controller project.

Routine maintenance primarily involves keeping the cabinet air filters clean to ensure proper cooling of the KSD1-48​unit.Monitoring system logs for any drive-related warnings is a good practice.The unit is designed as a field-replaceable unit(FRU).Our support provides genuine,factory-tested KUKA KSD1-48​drive units.We verify the part number for your specific KR C4 compact controller version.We can provide technical documentation and emphasize the need for proper safety procedures during any intervention.We are committed to supplying reliable components to keep your high-performance automation cells running.

Power your high-speed,precision automation with an integrated drive solution.Contact us for a genuine KUKA KSD1-48 compact drive unit and expert support for your KR C4 compact controller system.

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