KUKA KR 1000 titan PA troubleshooting

Practical Maintenance and Troubleshooting of KUKA KR 1000 Titan PA

KUKA KR 1000 1300 titan PA and KR 1000 L950 titan PA are 4-axis industrial robots designed for heavy-duty palletizing, handling, and workpiece transportation scenarios. The former has a rated load of 1300 kg, a maximum arm span of 3202 mm, a working space of about 69.5 m ³, and a body weight of about 4690 kg; the latter has a rated load of 950 kg, a maximum arm span of 3601 mm, a working space of about 102.5 m ³, and a body weight of about 4740 kg. Both have a repeatability accuracy of ± 0.1 mm, a standard protection level of IP65, and the F-variant wrist can reach IP67. The controller can be equipped with KR C5 L6/L7, KR C4 or KR C2 edition2005. For on-site engineers, the factors that truly affect equipment availability are installation quality, oil change specifications, balance weight pressure, zero point calibration after motor replacement, and electrical connection and stopping performance. Below is a set of practical maintenance and troubleshooting ideas for this series of models.

Core parameters and usage boundaries

This series of robots adopts a 4-axis parallelogram motion system. Axis motion range: A1 is ± 150 °, A2 is -130 ° to+17.5 °, A3 is 62 ° to 145 °, A4/A5 is ± 118 °, A6 is ± 350 °. Under rated load, the speed is approximately 58 °/s for A1, 50 °/s for A2, 50 °/s for A3, 60 °/s for A4/A5, and 72 °/s for A6. The zero positions are A1 0 °, A2-90 °, A3 90 °, A4 0 °, A5 0 °, and A6 0 °.

The load must be checked for both mass and mass moment of inertia simultaneously. The rated load is 1300 kg or 950 kg, and the additional load of the forearm is rated at 50 kg, with a maximum of 100 kg. The flange hole is installed with a diameter of 200 mm, 16 M16 threads, a strength grade of 10.9, a minimum engagement depth of 24 mm, a maximum engagement depth of 25 mm, and a positioning element of 12 H7. The flange load during normal operation is approximately 18950 N axial force, 25350 N radial force, 5600 Nm tilt torque, and 9150 Nm flange torque; during emergency stop, it can reach 21400 N, 41850 N, 15850 Nm, and 13650 Nm respectively. In terms of basic load, the vertical force is normal at 61500 N, with a maximum of 70000 N; the horizontal force is normal at 21400 N, with a maximum of 35500 N; the overturning moment is normal at 102200 Nm, with a maximum of 133700 Nm; and the shaft 1 torque is normal at 36600 Nm, with a maximum of 99700 Nm. The foundation must be able to withstand these loads for a long time.

Environmental conditions: Standard operating temperature range of 10 ℃ to 55 ℃, storage and transportation range of -40 ℃ to 60 ℃. The F variant operates at a temperature of 5 ℃ to 55 ℃ and a pH value of 7.0 to 9.0. The F-variant arm requires a positive pressure of 0.01 MPa (0.1 bar) ± 10%, compressed air without oil or water, air consumption of approximately 0.1 m ³/h, input pressure of 0.1 to 1.2 MPa, and pressure regulator of 0.005 to 0.07 MPa. If operating in low-temperature, corrosive, dusty, or high-temperature environments, the maintenance cycle should be shortened and discussed with KUKA.

Safe shutdown and hazardous area control

This robot belongs to partially completed machinery and must be integrated into a complete system that complies with the EU Machinery Directive. The risk assessment, safety functions, EC conformity declaration, and CE mark must be completed by the system integrator. Dangerous areas include workspace, mechanical arm stop stroke, and external axis stop stroke. The stopping stroke is equal to the reaction stroke plus the braking stroke. In the stop category, STOP0 means immediately shutting down the drive and braking the brake; STOP1 is braking along the trajectory; STOP2 is a ramp brake that drives continuously and follows the trajectory.

Manual mode T1 speed does not exceed 250 mm/s, T2 allows for speeds greater than 250 mm/s. New or modified programs must be tested under T1 first. If debugging must be carried out within the protected area, personnel and mechanical arms, including tools, should maintain a reference distance of at least 50 cm, which will be determined by risk assessment. Teaching and programming are not allowed under T2, and operators must be located outside the danger zone.

The power-off operation must turn off the main switch and lock it to confirm that there is no power. Even if the controller is turned off, some components may still carry a voltage of 50 V to 780 V for several minutes. Notify relevant personnel and hang warning signs before starting work. The motor will generate heat during operation, and protective gloves must be worn. Active implant personnel should maintain a distance of at least 300 mm from the motor and brake, applicable in both powered and powered off states. KCP or smartPAD must be clearly assigned to the corresponding robot, and disconnected smartPAD/KCP should be immediately removed from the system.

Installation, transportation, and re-entry into operation

Ground installation can use foundation fixing devices or rack fixing devices with centering devices. The recommended concrete strength is C20/25, and the foundation surface should be flat and smooth. There should be no insulation layer or mortar layer between the bed board and the concrete. The foundation fixing device weighs approximately 1165 kg and requires drilling 20 chemical anchor bolt holes according to the manufacturer's requirements. Robot installation typically uses 12 M30x90-8.8-A2K hex bolts and tapered spring washers, which are tightened diagonally in stages to 1330 Nm. After 100 hours of operation, they must be re tightened.

Rack installation is used for steel structures, brackets, or KUKA linear slides. First, install the center pin and sword pin, and fix them with M8x65 and M8x80 hexagonal bolts with a tightening torque of about 24.9 Nm. Then install the robot, use 12 M30x90-8.8-A2K bolts and tighten them to 1330 Nm. Connect the motor cables X30.1, X30.2, and X30.3, and the data cables KR C4 and KR C5 are X31 and XF31, respectively. The grounding and potential balance must be reliably connected and checked according to VDE 0100 and EN 60204-1.

The transportation positions are A1 0 °, A2-130 °, A3 130 °, A4 0 °, A5 90 °, A6 0 °. The minimum load capacity for forklift transportation is 6 tons; the minimum load capacity for transport frame transportation is 8 tons, including about 5600 kg without equipment. Avoid vibration and collision during transportation, otherwise it may cause insignificant damage, especially to the motor and balance weight. Before resuming operation, check whether the robot is fixed, whether there is external damage, whether the motor and balance weight are abnormal, whether the protective device is intact, whether the power supply system is matched, whether the grounding is reliable, whether the plug is locked, and whether there are foreign objects or loose parts.

Maintenance cycle and oil change specifications

The maintenance intervals are based on nodes such as 100 hours, 2000 hours, 6 months, 10000 hours, etc. Check the fastening bolts after 100 hours of operation. Lubricate the 4 oil nozzles of the main bearing every 2000 hours or at the latest 6 months, with A1 at 0 °,+30 °, and+60 ° positions, a total of 12 times, each time 8 cm ³, for a total of 96 cm ³, using LGEP 2 grease. Check the balance weight pressure every 6 months. If the oil pressure is lower than the set value of 5 bar, supplement Hyspin ZZ 46 hydraulic oil. The maintenance interval for the F variant can be extended to 10000 hours.

Gear oil replacement: A1 uses Optigear ALR 320, add 25 L for the first time; A2 uses Optigear Synt. ALR 150, add 24 L for the first time; A3 uses 12 L for the first time; A4 uses 10 L for the first time; A5 uses 3 L for the first time; A6 uses 10 L for the first time. When changing the oil, the amount of oil discharged depends on the discharge time and oil temperature, and the refilling amount should be the actual discharge amount. If the discharge volume is less than 70% of the specified oil volume, rinse once with the discharged oil; If it is less than 50%, rinse twice. Move the shaft at manual speed throughout the entire shaft range during flushing.

A1 oil change: Move A1 to -90 ° C, the gearbox is at operating temperature. Release the pressure first, then remove the magnetic plug, connect the oil drain hose, and drain the oil. Inject from below when refueling, check the oil level between the two markings, and recheck after 5 minutes. A2 oil change: Open the exhaust nuts on both sides, remove the oil drain hose, drain the oil, and add oil from below until the oil comes out from both joints. A3 oil change: Remove the sealing cover of the maintenance valve, connect the oil drain hose, and after draining the oil, add oil from the lower hose until the oil level is visible at the upper part. A4/A5/A6 oil change: Remove the upper and lower M27x2 magnetic plugs respectively, drain the oil, and add oil from the upper hole. Tighten the lower plug with a torque of 30 Nm and the upper plug with the same torque of 30 Nm. All magnetic plugs must be cleaned and checked for sealing, and any damage must be replaced. There is a risk of burns when the oil temperature is high, and the oil chamber may be under pressure. It is necessary to release the pressure first and wear protective equipment.

Balance weight inspection and replacement

This series adopts hydraulic pneumatic balance weight, and the system includes 2 diaphragm accumulators, hydraulic cylinders, pressure gauges, and safety valves. The accumulators are filled with nitrogen gas. When checking, manually move A2 to -90 °, wait for 1 minute, press emergency stop, and read the pressure gauge. KR 1000 1300 titan PA and PA-F should be 130 bar ± 15 bar at 20 ℃; KR 1000 L950 titan PA and PA-F should be 120 bar ± 15 bar. If the values do not match, a dedicated pressure gauge should be used for measurement and KUKA should be contacted. Check if the lead seal of the safety valve is intact, and if the accessories are damaged, clean, and sealed.

When replacing the balance weight, it weighs approximately 150 kg and is under pressure. First, move A2 to a vertical position and secure it. Remove the protective cap, connect the hose, and drain the hydraulic oil into the collection container until the pressure gauge reads zero. Remove the pin, cover plate, and bolts, fix the counterweight with a sling and crane, and then remove the pin shaft. During installation, clean and rust proof, insert the pin shaft, use M16x230-8.8 hexagon socket bolts and conical spring washers, tighten with a torque of 195 Nm. Check the pressure after installation. Attention: Do not continue to move the balance weight in the negative direction, otherwise it may damage the balance weight, pull rod or turntable. If the balance weight forms an air cushion after storage, remove the exhaust valve protective cover, maintain a safe distance, move A2 ± 30 °, and then reinstall the protective cover.

Motor and online wrist replacement

A4, A5, and A6 motors have the same design and disassembly method. Taking A5 as an example: Remove the XM5 and XP5 plugs, secure the motor with a sling, remove 4 M12x30-8.8 hex bolts, and do not tilt the motor when pulling it out. The F variant is equipped with a seal between the arm shell and the motor, which must be replaced. Before installing the new motor, clean the motor and drive shaft, apply a thin and uniform Microlube GL261, clean the installation surface, arrange sockets XM5 and XP5, insert the motor, install four M12x30-8.8 bolts, and tighten diagonally to 78 Nm. After installation, calibrate A5, and if necessary, calibrate A4, A5, and A6.

Online wrist replacement: The IW 1000 online wrist weighs approximately 570 kg. When disassembling, fix it with a crane and remove 22 M16x180-10.9 black hexagon socket bolts. When pulling out, do not tilt and the gap should be even. Clean the teeth before installation, apply Microlube GL261, ensure that A4 and A6 are in the zero position, insert them into the online wrist, install 22 M16x180-10.9 bolts, and tighten diagonally to 250 Nm. After installation, calibrate A4, A5, and A6. If the O-ring between the wrist and arm shell of the F variant is damaged or deformed, it must be replaced.

Electrical connections and common troubleshooting

KR C4 connection: 3 motor cables X20.1 to X30.1, X20.2 to X30.2, X20.3 to X30.3, data cables X21 to X31, ground/potential balance 16 mm ², M8 ring cable lugs at both ends. KR C5 connection: Motor cable 1 includes XD20.3_TA1, XD20.4_TA1, XD20.6_TA1 to X30.1, and brake connectors XD10.2_TA1 to X30.1; Motor cables 2 and 3 are similar; Data cable XF21 to XF31; The grounding is also 16 mm ². The cable length can be selected from 7, 10, 15, 20, 25, 30, 35, and 50 meters, with a maximum of 50 meters and a maximum extension of 1 time. When fixed laying, the bending radius of motor cables should not be less than 150 mm, and that of data cables should not be less than 60 mm. The cables should be laid indoors, with a temperature range of -10 ℃ to+55 ℃. Motor cables and data cables should be laid separately in metal troughs, and EMC measures should be taken if necessary.

Common troubleshooting ideas:

Stop distance increases or brake abnormality: Conduct a brake test at least once a year. STOP0 imposes a significant load on the system and should be avoided as much as possible. If the stopping distance increases significantly, check the brake wear, load, speed, and program multiplier.

Unexpected movement or sinking of the robot: Check the brake, balance weight, overload, and collision damage. If the robotic arm or external shaft collides with obstacles, mechanical end stops, or shaft limiting devices, it must stop running and contact KUKA.

Gearbox oil leakage: Check the magnetic plug, sealing cover, repair valve, and drain hose joint. If the oil level is abnormal after changing the oil, the oil level should be rechecked and the discharge amount should be confirmed.

Abnormal balance weight pressure: Check the pressure gauge, safety valve lead seal, accessory seal, and cup status. Pressure vessels should undergo internal inspections in accordance with national regulations after 10 years of use.

Motor overheating or abnormal noise: Check the load, ambient temperature, brake, gear engagement, and zero point. After replacing the motor, the zero point must be calibrated.

F variant compressed air issue: Confirm that the pressure regulator is set to 0.01 MPa (0.1 bar) and the compressed air is free of oil and water. Do not operate without a pressure regulator or with incorrect regulation.

Zero point loss: After replacing the motor, online wrist, or using a release device to move the axis, all relevant axes must be recalibrated.

Cable group A1 wear: Lubricate cable group A1 every 10000 hours or as needed, using Optitemp RB2 for approximately 100 g. Remove the 8 M6x16 bolts from the chassis cover plate, clean the cable sheath, brush the hollow shaft sleeve, floor, and cable sheath contact area, then reinstall the cover plate and tighten it.

Discontinuation, storage, and disposal of waste

Before stopping, move the robot to the transport position, remove tools and accessories, disconnect peripheral connections, motor cables, data cables, and grounding wires. Using transport lifting equipment or forklift, with a minimum load capacity of 8 tons, remove 12 M30x90-8.8 hexagonal bolts and conical spring washers, lift vertically to avoid damaging the center pin. The storage location should be dry, dust-free, avoid temperature fluctuations, wind blowing, ventilation, and condensation, and avoid direct sunlight. Clean the robot, remove foreign objects and rust, install all cover plates and check seals, seal electrical interfaces and hose joints, cover with film and seal on the chassis, and add desiccants if necessary.

When disposing of waste, classify according to materials: cast iron parts such as chassis, turntable, pull rod, wrist; Copper cables and core wires; Steel gearbox, bolts and washers; The motor is scrapped as a whole without disassembly; Electrical components such as RDC and EDS recycling; Plastic parts should be processed according to the material markings. Hydraulic and pneumatic balance weights contain nitrogen and hydraulic oil, and must be professionally depressurized in advance. They are only allowed to be disposed of in a non pressurized state.