KUKA KR 23 SCARA-2 Robot Installation and Maintenance Detailed Explanation

A2 interface (arm): brake release button (only valid for A3/A4 axis), X94 Ethernet extension, X41 I/O extension, AIR 1/2/3 air circuit adapter, motor working indicator light (on=robotic arm working).

User cable discipline: It is strictly prohibited to tie user cables to corrugated pipes; High flexibility cables must be used and shielded to ensure good grounding of the entire machine; After installation, confirm that the stress state and working space of the cable and corrugated pipe are not restricted. The arm is reserved with a user cable bracket interface, and the base does not have a dedicated interface, but some bolt holes can be borrowed to assist installation. A wiring space of at least 200mm must be reserved behind the A1 interface.

Cable system: The motor cable X30 and data cable X31 are unified into the WEIPU WF 28 series, with a length standard of 5 meters and optional options of 3 meters or 10 meters. The fixed laying bending radius of the motor cable is not less than 55 mm, and the data cable is not less than 45 mm. The operating temperature is -30 ° C to+80 ° C. The motor and data cables are laid in separate metal slots and strengthened with EMC measures; The grounding conductor must be equipped with M4 ring terminal according to DIN EN 60204, and connected to the base frame by the user with a tightening torque of 2.8 Nm.

Manual movement and transportation

Manual dual path movement: A1/A2 axis activates Servo Free mode through ControlStudio and enables slow manual movement of the corresponding axis (premise: drive OFF); Press and hold the arm brake release button on the A3/A4 axis to release the brake and manually move it. Key warning: A3 axis may fall when the button is pressed without load, and the load must be held by hand to prevent injury from falling.

Transportation position: A1=-90 °, A2=-90 °, A3=-100 mm, A4=0 °. Forklift transportation is used for the original packaging state. Lifting and transportation (optional) must use Qingling DF fixed plate (0000-433-013) and fixed plate B (0000-433-014): 5 M6x20-12.9 (9.5 Nm) are used to fasten the two fixed plates, and 3 M10x17 lifting rings (9.5 Nm) are installed. The rope length must be greater than 1500 mm and follow the path shown in the diagram. No other lifting methods are allowed, and standing under the robotic arm is not allowed throughout the transportation process. The transportation dimensions and center of gravity of the nine models are different (for example, the distance between the center of gravity of R1200 series models is 922 mm, while R800 series models are 522/797 mm), and the transportation dimension table must be checked according to the model before lifting.

Maintenance cycle table -1500 hour lubrication starting point

Cycle task consumables

Tighten 4 mounting base bolts for 100 hours (only once) -

1500 hour lubricated ball screw spline THK AFB-LF approximately 10 g

4000 hours or 1 year replacement of corrugated pipe (KUKA authorized personnel) SPP corrugated pipe 0000-481-648

4000 hours or 1 year replacement of toothed belt A3/A4 (KUKA authorized personnel) A3: 0000-434-702, A4: 0000-434-704

4000 hours or 1 year cable group coated with Optitemp RB2 grease, approximately 20 g

Replace battery unit SAFT LS battery pack 0000-439-232 within 1 year

Tighten installation bolts for 1 year -

20000 hours or 5 years A1 gearbox oil replacement Optigear Synt. ALR 150, 0.30 L

Screw lubrication - process difference between standard version and CR version: standard version moves A3 to the upper limit position (do not hit the limit block) → activates emergency stop → removes old grease → brushes THK AFB-LF → moves it back to the lower limit position and repeats. The CR version requires removing the shaft end cover first: remove 8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8.8 M4x12-8; Remove 8 M4x8-8.8 bellows from the bottom and lubricate them. Reinstall with 1.9 Nm. Remove excess grease at the end and empty A3/A4 to evenly distribute the grease.

Tooth shaped belt replacement - A3 fixing is the first step: The opening action of this process is to place the worktable below A3, operate the robot to move A3 down to the point where the load is supported by the worktable, and then press emergency stop to fix it - to prevent A3 from suddenly falling due to the load when releasing the A3 motor or belt. Remove the top cover (12 M4x60-8.8+8 M4x12-8.8) → Remove 4 M6x25-12.9 flanges → Remove 4 M5x20-12.9 flanges each for A3 motor and A4 motor/reducer → Remove two belts. During assembly, the A4 belt is inserted into the lead screw from above and moves down with the transition wheel assembly to the correct position, while the A3 belt is moved to the A3 driven wheel in the same way. The belt and pulley must mesh correctly; Install the flange back screw nut, M6x25-12.9 pre tighten first, move A3 vertically 3 times, and then tighten diagonally step by step to 15 Nm.

Tension calibration of toothed belt (frequency meter TSM alpha 20071-053-386): After assembling the motor/reducer, move it left or right for pre tensioning. Install the tensioning fixture (Dev. tensioning assy, 0000-435-853) and run in - adjust A4 axis ± 20 ° back and forth 2-3 times, adjust A3 axis upper and lower limits back and forth 2-3 times, and then move the belt and sensor 2-3 mm away from the vibration belt. Read the frequency: A3 belt (150MTS3M927) target 59-70 Hz, A4 belt (150MTS5M1000) target 83-90 Hz. Adjust M5x25-12.9 and adjust the screw to meet the standard. The fluctuation value after adjustment is within 30% of the deviation from the table. Internally considered normal, otherwise readjusted; After meeting the standard, tighten 4 M5x20-12.9 diagonally in steps to 9 Nm. The A3/A4 zero point calibration must be performed at the end, and any abnormalities must be observed during the T1 mode trial run.