KUKA KR 500 MT FORTEC Maintenance and Inspection

In terms of foundation load, the normal vertical force F (v) is about 37000 N, with a maximum of 40500 N; the horizontal force F (h) is normal at 15900 N, with a maximum of 23500 N; the tilting moment M (k) is normal at 58900 Nm, with a maximum of 84500 Nm; and the moment M (r) around A1 is normal at 18500 Nm, with a maximum of 45500 Nm. The foundation must withstand these loads for a long time. The supplementary loads on A1 and A2 are not included in the calculation of foundation loads and must be taken into account as vertical forces.

Installation foundation and transportation

The installation methods mainly include 175mm installation base, 200mm installation base, machine frame installation, and ground installation. The concrete foundation strength shall be at least C20/25, and there shall be no insulation layer or mortar layer between the base and the concrete. When using resin anchor bolts, the drilling diameter should be 18 mm. Diamond tools or coring drills must not be used, and setting tools approved by the anchor bolt manufacturer must be used. The installation surface must be flat and filled with leveling material if necessary, but the area where the robot tightens the bolts must not be covered by leveling material. The 175mm base weighs approximately 302 kg, the 200mm base weighs approximately 155 kg, and the machine frame installation weighs approximately 3.695 kg.

The robot must be moved to the transport position before transportation. The standard transportation positions are A1 0 °, A2-130 °, A3 130 °, A4 0 °, A5 90 °, A6 0 °. If the A2 buffer needs to be removed due to the minimum transportation height requirement, the transportation positions are A2-136.5 °, A3 136.5 °, but a clear warning must be attached. The buffer should be restored immediately after transportation. When transporting by forklift, there are two fork slots on the base, and the minimum load capacity of the forklift is 3500 kg. Three M20 DIN 580 lifting rings and three legged lifting devices are used for lifting, arranged along the direction of the robot. During transportation, vibration and impact should be avoided, and tools and additional equipment should be removed to prevent the center of gravity from shifting.

The standard lengths of connecting cables are 7 m, 10 m, 15 m, 20 m, 25 m, 35 m, and 50 m, with a maximum of 50 m and a maximum of one expansion allowed. The bending radius for the fixed laying of motor cables shall not be less than 150 mm, and for data cables shall not be less than 60 mm. Motor cables and data cables shall be laid separately, and EMC measures shall be taken if necessary. The grounding conductor must be connected with low resistance, with a cross-sectional area of 16 mm ² and M8 ring terminals at both ends. The F variant also needs to be connected to compressed air, and the pressure regulator is initially set to 0.01 MPa. Connecting cables is limited to indoor installation, with a fixed installation temperature range of -10 ° C to+55 ° C. Cable routing must prevent tripping hazards and be marked where necessary.

Safety and Debugging Inspection

The danger zone of KR 500 MT FORTEC consists of workspace and stopping distance. Mechanical end stop and optional mechanical axis limit are used to restrict the working range of A1 to A3. Before debugging, all safety functions must be checked, including emergency stop, enable switch, mode selection, safety door, external safety stop, and safety output. T1 is in manual deceleration mode, with a speed not exceeding 250 mm/s; T2 is manual high-speed mode; AUT is in automatic mode. New or modified programs must be tested under T1 first.

Five safety rules must be followed during maintenance and repair: power off, prevent accidental restart, confirm that the system is out of power, ground and short-circuit, cover or isolate adjacent live parts. Even if the controller is turned off, some components may still be charged. The robot system must be disconnected from the main power supply and cannot rely solely on emergency stop or safe stop. Hot surfaces, oil pressure, nitrogen pressure, and extrusion risks should all be prevented. The motor and brake will generate electromagnetic fields, and personnel wearing implants should maintain a distance of 300 mm from the motor and brake. Unauthorized modifications may render warranty and liability invalid.

Before starting, the default password must be changed, and the robot installation, fastening, cable connection, grounding conductor, and equipotential connection must be checked. If there is a significant difference between the internal temperature of the controller and the ambient temperature, it is necessary to wait for temperature equilibrium to prevent condensation. If the robot is subjected to external forces such as collisions or impacts, it may cause invisible damage and the motor and balance system must be checked. Security features must be tested. The brake test must be performed regularly and the system will force it to be carried out, and it cannot be turned off.

Maintenance cycle and oil management

The maintenance cycle is based on technical data and operating conditions. Check the torque of the fastening bolts and nuts 100 hours after startup. O-rings A4 and A5 require regular lubrication: the standard robot takes about 10000 hours, the F variant takes about 5000 hours, and Microlube GL 261 is used. Balance system bearing lubrication: 5000 hours or at least once a year; If A2 frequently has a short stroke of less than 40 ° and the interval is shortened to 3000 hours, use LGEV2/5, with each lubrication point approximately 10 cm ³.