Troubleshooting of KUKA KR 600 FORTEC

Troubleshooting of KUKA KR 600 FORTEC

KUKA KR 600 FORTEC is a six axis heavy-duty articulated arm robot that covers KR 600 R2830、KR 600 R2830 F、KR 510 R3080、KR 510 R3080 F、KR 420 R3330、KR 420 R3330 F  Waiting for the model. It is designed for machine tool loading and unloading, heavy-duty handling, casting, and high cycle automation scenarios. For on-site engineers, what really needs to be solved is not a single parameter, but how to quickly locate the problem at the system level and restore operation without compromising safety integrity when the robot experiences abnormal pressure in the balance system, abnormal wrist noise, excessive transmission shaft clearance, gear oil leakage, motor overheating, or safety circuit shutdown.

Product positioning and core structure

The KR 600 FORTEC adopts a six axis articulated arm structure, with main components including a linear wrist, arm, counterweight, connecting rod, rotating column, base, balance system, electrical installation, and connecting cables. The linear wrist consists of three axes A4, A5, and A6, which are driven by three AC servo motors installed at the rear end of the arm through transmission shafts. The motor unit integrates brushless AC servo motor, permanent magnet single disc brake, and hollow shaft rotary transformer. The holding brake plays a holding role when the motor is stationary and participates in braking during short-circuit braking, but short-circuit braking cannot be used as a normal stopping method. The wrist gearbox is supplied with oil from three independent oil chambers. The rotation range of A5 is limited by the mechanical end stop.

The arm is connected to a straight wrist and a connecting rod, and A3 to A6 motors and transmission shafts are installed internally. Install counterweights on the side of the arm to balance the mass of the A3 axis. The connecting rod is located between the arm and the rotating column, and is installed on one side of the rotating column through a gearbox. Install A1 and A2 motors inside the rotating column. The base is connected to the installation base, and the internal layout includes electrical installation and energy supply system interfaces. The balancing system is installed between the rotating column and the connecting rod, using a closed hydraulic pneumatic system consisting of two accumulators, hydraulic cylinders, pressure gauges, and accumulator safety valves, used to balance the A2 axis load torque. The accumulator belongs to Class III of the Pressure Equipment Directive and Fluid Group 2.

The electrical installation includes power and control cables from A1 to A6, and all motor connections are plug-in. The cable assembly, multifunctional housing, and RDC box form an electrical installation assembly. The connection cable interface is located at the rear of the base, and the motor cable and data cable are connected through a plug. The F variant is designed for higher mechanical and thermal loads, with pressure applied inside the arm to prevent moisture and dust from entering.

Technical data and load foundation

KR 600 R2830 has a rated load of 600 kg, a maximum load of 729 kg, a maximum arm span of 2826 mm, a body weight of approximately 2650 kg, a workspace of approximately 68 m ³, a repeatability accuracy of ± 0.08 mm, a protection level of IP65, and an F-variant wrist that can reach IP67. The noise level is below 75 dB (A). KR 510 R3080 has a rated load of 510 kg, a maximum load of 635 kg, a maximum arm span of 3076 mm, a body weight of approximately 2680 kg, and a workspace of approximately 88 m ³. KR 420 R3330 has a rated load of 420 kg, a maximum load of 515 kg, a maximum arm span of 3326 mm, a body weight of approximately 2686 kg, and a workspace of approximately 114.5 m ³. The controller can be equipped with KR C5 L6/L7 or KR C4.

Axis motion range: A1 ± 185 °, A2-130 °/20 °, A3-100 °/144 °, A4 ± 350 °, A5 ± 120 °, A6 ± 350 °. Speed under rated load: A1 80 °/s, A2 75 °/s, A3 70 °/s, A4 70 °/s, A5 70 °/s, A6 110 °/s. In terms of flange load, during normal operation, the axial force F (a) is about 9200 N, the radial force F (r) is about 7900 N, the tilting moment M (k) is about 4200 Nm, and the flange moment M (g) is about 2310 Nm. Under emergency stop conditions, F (a) is about 10500 N, F (r) is about 12500 N, M (k) is about 9000 Nm, and M (g) is about 5600 Nm. Tools and loads must be able to withstand these forces and moments for a long time. The load data must be input into the robot controller, and path planning will consider the load. The mass inertia must be verified by KUKA Load.

The installation flange standard is ISO 9409-1-200-11-M12, with a hole diameter of 335 mm, threaded M12, a minimum depth of 14 mm and a maximum depth of 18 mm, 12 threads, screw grade 12.9, and positioning element 12 H7. Supplementary loads can be installed on arms, connecting rods, and rotating columns, but must comply with the maximum allowable total load. 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.