The KUKA KR16-2 (specifically the ZH-16-II high-performance variant) stands as the definitive solution for the "medium-duty" gap in industrial automation. Bridging the divide between light-weight compact robots and heavy-load giants, the KR16-2 is renowned for its exceptional rigidity, compact footprint, and versatility. Whether deployed in high-speed arc welding, precise assembly, or heavy machine tending, this 6-axis robot delivers a masterclass in efficiency and reliability. It is not merely a machine; it is a flexible production partner designed for the harshest environments and the most complex geometries.

Technical Specifications: Power in a Compact Form

The ZH-16-II configuration is optimized for applications requiring extended reach and high precision.

• Kinematics: 6-axis articulated arm with a hollow wrist design for optimal cable management.
• Payload Capacity: 16 kg (at the wrist flange), with a total system load capacity supporting up to 46 kg on the arm/base.
• Maximum Reach: 1611 mm, providing an extensive working envelope suitable for large workpieces.
• Repeatability: ±0.05 mm (standard) / ±0.02 mm (high-precision variants), ensuring consistent quality in high-precision tasks like laser welding or grinding.
• Axis Speeds:

• Axis 1-3: 156°/s
• Axis 4-5: 330°/s
• Axis 6: 615°/s
• Result: Extremely short cycle times, maximizing throughput.

• Mounting Flexibility: Supports floor, wall, ceiling, and angle mounting, making it ideal for dense production lines where floor space is at a premium.
• Protection Rating: IP54 (robot body) / IP67 (central wrist), allowing operation in dirty, dusty, or wet environments (e.g., foundries, welding bays).
• Controller: Compatible with the KRC2 (classic robust control) and the new KR C5 micro-2 (edge-computing capable), supporting seamless integration into Industry 4.0 ecosystems.

Core Applications: The Multi-Talented Specialist

The KR16-2 ZH-16-II is a "Swiss Army Knife" for the factory floor, excelling in three primary domains:

1. Advanced Welding (Arc & Spot)

While traditionally known for material handling, the KR16-2 is a formidable welding robot.

• Arc Welding: With a 16kg payload, it can carry heavy welding torches and wire feeders while maintaining a steady weave. It is widely used in automotive chassis welding and construction machinery (e.g., grader blade bodies), where it achieves Class 1 weld seams with 90%+ accessibility.
• Spot Welding: The robot’s high acceleration allows for rapid repositioning between weld points, essential for automotive body-in-white assembly.
• Laser Welding/Cutting: The high-precision variants are increasingly used for 3D laser processing, utilizing integrated vision systems for seam tracking.

2. Machine Tending & CNC Integration

The KR16-2 is a natural fit for machine tool loading/unloading. Its "hollow wrist" allows coolant lines and gripper cables to pass through the arm, preventing snagging during the high-speed "pick-and-place" cycles required in CNC machining and injection molding.

3. Material Handling & Palletizing

With a reach of over 1.6 meters and a 16kg lift capacity, it handles everything from heavy automotive components to bulk packaging. Its modular design allows it to be deployed in "dual-arm" configurations or mounted on linear tracks (7th axis) to cover vast warehouse areas.

Key Features & Competitive Advantages

1. The "Zero-Interference" Hollow Wrist
Unlike competitors with exposed cabling, the KR16-2 routes all cables internally through the wrist axis. This design eliminates the risk of cables catching on fixtures or the workpiece, significantly reducing downtime for maintenance and increasing the robot's lifespan in high-cycle applications.

2. Intelligent Control & AI Integration
The ZH-16-II variant is prepped for the future. When paired with the KR C5 micro-2 controller, it gains:

• AI Processing: On-board inference for visual recognition (2D/3D cameras).
• Sensor Fusion: Real-time adjustment of paths based on force-torque sensors (crucial for grinding and deburring).
• Predictive Maintenance: Self-diagnosis of motor temperatures and gearbox wear.

3. Modular "CYBERTECH" Architecture
Part of the KR CYBERTECH-3 family, this robot features a slimmer base and optimized weight distribution. This reduces the energy consumption of the servos by up to 15% compared to previous generations and allows for higher dynamic performance without increasing the floor load.

4. Process Software Packages
KUKA provides specialized software packs out-of-the-box:

• KUKA.ArcTech: For advanced welding weave patterns.
• KUKA.GrindingTech: For automated surface finishing with force control.
• KUKA.PalletTech: For rapid generation of palletizing patterns.

Real-World Deployment: The "Grader Blade" Case Study

In heavy engineering, the KR16-2 has revolutionized the production of grader blades (critical components for earth-moving equipment). Previously, these 4-meter-long structures required manual welding—a slow, dangerous process prone to porosity and slag inclusions.

By deploying a ceiling-mounted KR16-2 with a positioner, manufacturers achieved:

• 95% Weld Automation: The robot maintains the optimal "ship-position" for every seam.
• Consistency: Multi-layer, multi-pass welding is programmed perfectly, eliminating human error.
• Safety: Operators are removed from the arc flash zone and heavy lifting hazards.
• ROI: Despite the initial investment, the payback period is typically under 18 months due to reduced rework and 24/7 operation capability.

Conclusion: The Smart Investment

The KUKA KR16-2 (ZH-16-II / 213130) is more than a specification sheet; it is a proven asset for "Light to Medium" heavy industry. It offers the payload of a large robot with the agility of a smaller one. For manufacturers looking to automate welding, handling, or machining without sacrificing precision or floor space, the KR16-2 remains the industry benchmark for reliability and performance.