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

CR version top cover double tightening - a unique clause of this series: The CR version top cover must be tightened twice with 12 M4x60-8.8 washers and 8 M4x12-8.8 fastening screws (first 1.2 Nm and then re tightened according to the specified torque), otherwise the top cover may crack - this is the biggest installation discipline difference between the CR version IP54 sealing structure and the standard version. The standard version can be tightened once.

Battery Replacement - Different Location from Previous Generation: The battery unit is located at the A1 interface instead of the base battery box: Remove 4 M3x10-8.8 interface battery units (CR version also has 4 JB982-77 M3 washers) → Insert the new battery into the empty connector first → Pull out the old battery occupying the connector → Cut the zip ties to remove the old battery → Only use 2 zip ties to tie the battery body to the new battery, do not tie the battery cable → Reinstall the A1 interface and tighten it. The zero calibration must be performed on A1/A2/A3/A4 at the end, and a trial run must be conducted in T1 mode.

Key points for A1 oil change: The gear unit must be at working temperature and A1 level, using KUKA oil pump (0000-180-812). Remove 10 M4x12-8.8 cable box covers (reassemble with 1.9 Nm) → replace the lower M10x1 magnetic plug with a new oil discharge pipe → ventilate and drain the upper magnetic plug → measure the amount of oil discharged and recharge according to this amount - when the discharge amount is less than 70%, rinse the gearbox with the discharged oil once and recharge it; Less than 50% (if installed at an angle) needs to be flushed twice, during which the full stroke motion axis of the jog speed is required. Clean the magnetic plug and inspect the sealing components. Tighten to 7.5 Nm and perform a leak test. Conclusion: Remove oil stains, visually detect leaks, and conduct T1 mode trial operation.

Zero point calibration and top cover replacement

After replacing components such as motors, reducers, cables, batteries, etc., the zero point may shift and cause positioning errors, and must be recalibrated. A1/A2 should first use the calibration fixture to insert it into the calibration slot for alignment, and then select Set Current on the ControlStudio or smartPAD touch calibration page; When there is no fixture, visually align the two calibration slots, but relying on manual judgment may result in errors.

The SPP ordering numbers for top cover replacement are divided into two levels: SPP top cover 20 scar (0000-434-705) for the standard version six, and SPP top cover 20 scar CR (0000-446-915) for the CR version three - ordering the wrong part number will not match the sealing structure of the CR version. Replace the CR version shaft end cover with SPP shaft cover (0000-481-647). Before reinstalling, check the O-ring, apply THK AFB-LF grease to the O-ring, and confirm that it is in the groove. Tighten it with 1.2 Nm. After replacing all cover plates, conduct a T1 mode trial run to observe any abnormalities.

Early wear warning and retirement disposal

During the planning phase, five types of accelerated wear conditions must be evaluated: temperature limit or continuous operation in corrosive environments, performance limit continuous operation (such as high shaft speed), single axis high load rate, monotonic motion trajectory (short stroke high-frequency reciprocating), external process forces - any of which must be consulted with KUKA service. The built-in monitoring automatically shuts down when reaching or approaching the operating limit. Quantitative red line: The temperature of each axis motor should not exceed 368 K (+95 ° C). Long term overheating directly shortens the lifespan of the robotic arm. It is recommended to include it in the equipment health dashboard through ControlStudio trend monitoring.

Cleaning boundary: Prohibit high-pressure cleaning equipment and steam/refrigerant; Only solvent-free, water-soluble, non flammable, and non corrosive cleaning agents are allowed; Cleaning agents are strictly prohibited from entering electrical and mechanical system components; Clean the corroded area and reapply anti-corrosion agent; Replace damaged or illegible signs and confirm that all safety equipment is functioning properly before resuming operation.

Retirement process: Adjust to the transport position → Remove all peripherals and motor/data cables → Release the grounding conductor → Remove 4 M12/M14 bolts and washers → Carefully lift off the installation surface - the robotic arm may suddenly detach when stuck on the installation surface, and the fasteners and adhesives must be completely removed. Long term storage requirements: dry and dustproof, avoid temperature fluctuations and condensation, use environmentally resistant coverings, leave no loose parts, and avoid direct sunlight; Wrap with plastic film and seal at the base, and add desiccant under the film if necessary. Scrap classification: The base/arm/connecting rod arm is made of cast aluminum, the reducer/screw spline/fastener is made of steel, electronic components (EDS, etc.) are treated as electronic waste and cannot be disassembled, and the motor is disposed of as a whole; Lubricant Accessories Archive: Optigear Synt. ALR 150 (A1 gear oil), THK AFB-LF (lead screw), Optitemp RB2 (cable), Harmonic Drive 4B No.2, Microlube GL 261, and Drei Bond/Sikaflex/LOCTITE 510 adhesive sealant.