KUKA KR AGILUS-2 maintenance troubleshooting

Installation, transportation, and re-entry into operation

The installation methods include base installation and rack installation. The base installation uses a C246 base, weighing approximately 16.5 kg, with 4 chemical anchor bolts and 4 M10x35-8.8-A2K hex bolts, equipped with conical spring washers. The recommended concrete strength is C20/25, and the foundation surface should be flat and smooth. There should be no insulation layer or mortar layer between the bed board and the concrete. The rack installation uses standard rack installation components, weighing approximately 0.161 kg, with 4 M10x35-8.8-A2K hex bolts and tapered spring washers, tightened to a torque of 45 Nm. Positioning pins must be used during installation to ensure that the robot falls vertically and avoid damaging the pins.

The transportation positions are A1 0 °, A2-105 °, A3 156 °, A4 0 °, A5 39 °, A6 0 °. During transportation, rope slings are used to wrap around the pull rod and rotating column to ensure that all edges are long enough and will not damage the robot. Avoid vibration and collision during transportation, otherwise it may cause subtle damage. Before resuming operation, check whether the robot is fixed, whether there is external damage, whether the motor and brake are abnormal, whether the protective device is intact, whether the power supply system is matched, whether the grounding is reliable, whether the plug is locked, and whether there are foreign objects or loose parts.

Wall and ceiling installation requires additional Load Lifting Attachment and LLA assembly stand KR AGILUS, part number 0000-214-888. When installing on the wall, the robot is first fixed to the Load Lifting Attachment, rotated 90 °, then positioned on the wall with a forklift, and finally fixed with M10x35-8.8-A2K hex bolts with a tightening torque of 45 Nm. Ceiling installation is similar, rotated 180 °. After installation, the grounding conductor connection must be reinstalled.

Connecting cables and interfaces

Connecting cables are used to transmit power and signals between the robot controller and the robot. The standard lengths are 1 m, 4 m, 7 m, 15 m, and 25 m, with a maximum of 25 m and a maximum extension of 1 time. When the cross-section of the grounding conductor is at least 4 mm ² and the maximum cable length is 25 m. When fixed laying, the bending radius of the motor cable should not be less than 50 mm, and the control cable should not be less than 30 mm. The cable can only be installed indoors, with a temperature range of -10 ℃ to+45 ℃. Motor cables and data cables should be laid separately in metal troughs, and EMC measures should be taken if necessary.

KR C4 connection: motor cable X20 to X30, Han Jellock 30; Data cables X21 to X31, Han Q12; Grounding conductor 4 mm ², M4 ring cable terminal. KR C5 micro and KR C5 micro-2 connection: motor cables XD20.1 and XD20.2 to XD30, Han Jellock 30; Data cables XF21 to X31, Han Q12; Grounding conductor 4 mm ², M4 ring cable terminal. Interface A1 is located at the rear of the chassis, including motor cable connection X30 and data cable connection X31.

Energy supply system CTR AIR: Customer interface A1 includes MEMD connection X32, PURGE exhaust connection (IP67 option, maximum 0.3 bar, oil-free and waterless, compliant with ISO 8573-1:2010 7:4:4), AIR1 to AIR4 air circuit connection, outer diameter 4 mm, I/O cable connection X76. Customer interface A4 is located on the side of the online wrist, including X96, AIR1 to AIR4. X76 and X96 are M12, A-code, 8-pole, rated current 2 A, rated voltage 24 V. AIR1 to AIR4 have a maximum pressure of 7 bar, and vacuum to atmospheric pressure minus 0.95 bar.

Energy supply system AIR CTR GIG: Customer interface A1 includes MEMD X32, PURGE, AIR1 valve unit, fuse F41-F3A, CAT5e data cable X74, AIR2, external axis A8 XP8.1, external axis A7 XP7.1. The fuse is a 5x20mm thin fuse, fast breaking, 3A, protecting digital input and output, power supply, and valve activation. Customer interface A4 includes X41, valve unit air circuit X94、 Valve exhaust R, AIR2. The valve type is a 5/3-way solenoid valve, with a working pressure of 3 to 7 bar, a switching frequency of 10 Hz, M5 thread, and a medium of oil-free dry filtered air. The maximum filtration accuracy is 5 μ m, and the working temperature is+5 ℃ to+45 ℃. X41 digital output with 2 channels, short-circuit protection, rated 24 V DC, maximum output current of 0.5 A, maximum short-circuit current of 2 A; digital input with 4 channels, signal 0 ranging from -3 to+5 V, signal 1 ranging from 15 to 30 V, typical input current of 3 mA, typical input filtering of 0.3 ms; power supply of 24 V/3 A. If a 3A device is connected, other digital outputs or valves cannot be switched, otherwise the 3A fuse on the robot will be triggered. X74 and X94 are M12, X-encoded, and 8-pole.

PURGE options A/B/C/D are used for compressed air preparation and pressure limitation. The working pressure is fixed at 0.01 MPa (0.1 bar), the air consumption is 0.1 m ³/h, the input pressure is 0.1 to 1.2 MPa (1 to 12 bar), and the outer diameter of the air circuit connection is 4 mm. PURGE options A and C include a service unit and a pressure regulation unit, and option C has an additional robot connection M5-6. PURGE options B and D only include a pressure regulating unit, while option D has an additional robot connection. PURGE is only for cleaning purposes and is prohibited from use during operation to prevent the emission of foreign particles. The highest protection level of the component is IP54, avoiding water mist and water jets, and must not be immersed in water.