KUKA KR4 R600 Operation and Maintenance Essentials

Connecting cables and interfaces

Connecting cables are used to transmit power and signals between the control cabinet and the robotic arm, including motor cables XD20.1/XD20.2-X30, data cables XF21-X31, and optional grounding wires. The standard cable length is 3 meters, with options of 10 meters and 25 meters. The motor cable uses Har motion connectors, and the data cable uses M12 Y-code plugs. The two ends of the grounding wire are circular terminals used to establish a low resistance connection according to DIN EN 60204. The grounding wire is not within the scope of supply and needs to be connected by the customer. When planning, the bending radius of motor cables should not be less than 50 mm, and that of data cables should not be less than 30 mm. The cables should avoid mechanical stress, and the connectors should not bear tensile force. They should be installed indoors only, with a fixed laying temperature range of -10 ° C to+70 ° C. Motor cables and data cables should be laid separately in metal cable trays, and additional EMC measures should be taken.

The A1 interface is located at the rear of the base, including the AIR1 to AIR4 air pipeline interfaces, with an outer diameter of 4 mm and a maximum pressure of 0.7 MPa; X32 is used for MEMD; X76 is used for energy supply systems. The A4 interface is located under the inline wrist cover, and the X96 must use a 90 ° angled connector and pay attention to coding. Energy supply system X76-X96 rated current 2A, rated voltage 24V, M12 connector, 8-pin, A standard code. The entire system must be protected from overload and short circuit by the customer upstream of X76. Some models also offer customer Ethernet interface X74-X94, located on the A3 arm and M12 8-pin.

Transportation, commissioning, and functional inspection

Before transportation, the robot must be placed in the transportation position: A1 0 °, A2-120 °, A3 144 °, A4 0 °, A5 66 °, A6 0 °. During transportation, lifting equipment with sufficient load-bearing capacity must be used, and ropes must be threaded through the connecting rod arm and inner wrist in the specified manner to ensure that the robot does not move or tip over. Avoid vibration and impact during transportation, and do not stand under the robot. The robot must be kept in its transport position before it is secured.

Before putting into operation, the system must be checked for completeness and safe operation. The inspection items include: whether the robot is correctly installed and fixed; Is there any damage caused by external forces, such as dents or paint abrasion; Whether there are foreign objects, defects, or loose parts; Are all safety devices installed correctly and functioning properly; Does the power supply voltage match the type of power grid; Is the grounding wire and equipotential bonding wire sufficiently and correctly connected; Whether the connecting cable is correctly connected and the plug is locked. If there is a significant difference between the internal temperature of the control cabinet and the ambient temperature, condensation may form. It is necessary to wait for the temperature to adapt before putting it into operation. The default password for system software must be changed before it is put into operation, and only authorized personnel should be notified. New or modified programs must first be tested in T1 mode.

Maintenance: Cover plate lubrication and toothed belt replacement

In the maintenance table, it is recommended to apply grease to the inside of A1, A2, A3, and A5 cover plates every 5000 hours or every year, using 10 g of lubricating grease. Before starting the homework, the control cabinet should be turned off and locked to ensure that the arm and internal wrist are level. When disassembling the cover plate, A1 cover plate has 5 M3x6-10.9 Torx round head screws, A2 has 3, A3 has 4, and A5 has 4 M3x10-10.9 Torx round head screws. Use a torque wrench during installation with a tightening torque of 0.6 Nm. Wear protective gloves when applying grease to avoid direct skin contact.

When replacing the A3 toothed belt, first fix the arm with a rope, remove the A3 cover plate, loosen the two M4x16-8.8 hex screws and one M4x16-8.8 hex bolt on motor A3, and remove the toothed belt. When installing a new toothed belt, it is necessary to ensure that the toothed belt is correctly engaged with the pulley, and then measure and adjust the tension. A3 uses PowerGrip 410-GT3-5MGT-71 toothed belt with a target frequency of 134 ± 4 Hz. If the fluctuation value deviates from the target value within 30% after adjustment, it can be considered normal, otherwise it needs to be readjusted. Finally, install the cover plate, use 4 new M3x6-10.9 Torx round head screws with a torque of 0.6 Nm, calibrate A3, and perform functional testing.

The replacement of the A5 toothed belt is similar. Remove the A5 cover plate, loosen the two M3x12-8.8 hex screws and one M4x20-8.8 hex screw on motor A5, and remove the toothed belt. After installing the new belt, measure the tension. A5 uses PowerGrip 246-3MGT-61 toothed belt with a target frequency of 184 ± 5 Hz. After adjustment, fluctuations within 30% are also allowed. Install the cover plate and use 4 new M3x6-10.9 Torx round head screws with a torque of 0.6 Nm. Finally, calibrate A5 and perform functional testing. The tension measurement of the toothed belt uses a belt tension measuring instrument, with a sensor distance of 2 to 3 mm from the center of the vibrating toothed belt. If the teeth are damaged, it may cause early wear and failure, and it must be checked and contacted with KUKA.