KUKA KR AGILUS-2 maintenance troubleshooting

KUKA KR AGILUS-2 maintenance troubleshooting

KUKA KR AGILUS-2 is a series of 6-axis articulated robots designed for small and medium-sized loads, high-speed handling, assembly, and inspection scenarios. This series includes KR 6 R700-2, KR 6 R900-2, KR 10 R900-2, KR 10 R1100-2, and corresponding EP anti-static variants. The rated load covers 6 kg and 10 kg, the maximum arm span ranges from 726 mm to 1101 mm, the repeatability accuracy can reach ± 0.02 mm, the protection level is IP65/IP67, and the noise level is below 57 dB (A). The controller can be equipped with KR C5 micro-2, KR C5 micro, KR C4 smallsize-2, and KR C4 compact. For on-site engineers, the real factors that affect equipment availability are installation fixation, toothed belt tensioning, fine fuse replacement, PURGE positive pressure maintenance, cable connection management, and common troubleshooting. Below is a set of practical maintenance and troubleshooting ideas for this series of models.

Core parameters and usage boundaries

The KR AGILUS-2 adopts a 6-axis articulated arm structure, and the body is made of light alloy casting. All motors and current carrying cables are hidden under the cover plate, and each axis is equipped with a brake. The installation position supports floors, ceilings, walls, and any angle, allowing for a tilt angle of ± 180 °. The installation hole is C246, and the chassis size is 208 mm × 208 mm. The operating environment temperature is from 0 ℃ to 45 ℃, and the storage and transportation temperature is from -40 ℃ to 60 ℃. The humidity level is 3K3, and the cleanroom level can reach Class 4 at 80% magnification.

The load must be checked for both mass and mass moment of inertia simultaneously. KR 6 R700-2 has a rated load of 6 kg, a maximum load of 6.8 kg, and a working space of 1.47 m ³; KR 6 R900-2 rated 6 kg, maximum 6.7 kg, working space 2.84 m ³; KR 10 R900-2 is rated at 10 kg, maximum 11.3 kg; KR 10 R1100-2 is rated at 10 kg, maximum 11.1 kg, with a workspace of 5.2 m ³. Install flange hole circle 31.5 mm, 7 M5 threads, strength grade 12.9, engagement depth 5.5 to 7 mm, positioning element 5 H7. The flange load during normal operation is approximately KR 6 R700-2 axial force 209 N, radial force 235 N, tilt torque 31 Nm, flange torque 17 Nm; it can reach 324 N, 297 N, 36 Nm, 24 Nm during emergency stop. During normal operation of KR 10 R1100-2, the axial force is 289 N, the radial force is 265 N, the tilt torque is 34 Nm, and the flange torque is 27 Nm; during emergency stop, the axial force is 390 N, 407 N, 54 Nm, and 42 Nm. Tool design must consider these loads, not just static weight.

The EP variant uses a special coating to keep the surface resistance of all accessible surfaces within the dissipation range, thereby improving ESD protection. The EP variant must meet the requirements of IEC 61340-5-1 and ANSI/ESD S20.20. If there are static sensitive components on site, EP variants should be preferred and ESD requirements should be checked regularly.

Safe shutdown and hazardous area control

This robot belongs to partially completed machinery and must be integrated into a complete system that complies with the EU Machinery Directive. The risk assessment, safety functions, EC conformity declaration, and CE mark must be completed by the system integrator. Dangerous areas include workspace, mechanical arm stop stroke, and external axis stop stroke. The stopping stroke is equal to the reaction stroke plus the braking stroke.

Manual mode T1 speed does not exceed 250 mm/s, T2 allows for speeds greater than 250 mm/s. T1 is used for testing, programming, and demonstration purposes; T2 is only used for testing and does not allow teaching or programming. New or modified programs must be tested under T1 first. If debugging must be carried out within the protected area, personnel and mechanical arms, including tools, should maintain a reference distance of at least 50 cm, which will be determined by risk assessment. The operator under T2 must be located outside the danger zone, and there must be no other personnel inside the protective zone.

The power-off operation must follow 5 safety steps: power-off, prevent restart, confirm no power, ground and short circuit, cover or isolate adjacent live parts. Even if the controller is turned off, some components may still carry a voltage of 50 V to 780 V for several minutes. Notify relevant personnel and hang warning signs before starting work. The motor will generate heat during operation, and protective gloves must be worn. Active implant personnel should maintain a distance of at least 300 mm from the motor and brake, applicable in both powered and powered off states. KCP or smartPAD must be clearly assigned to the corresponding robot, and disconnected smartPAD/KCP should be immediately removed from the system. External keyboard and mouse are only allowed to be used during startup or maintenance work, driver shutdown, and when no one is in the danger zone; It must be removed immediately after use. After modifying the robot, the safety level must be rechecked, all safety functions must be tested, and existing programs must be tested under T1 first.