KUKA AGILUS-3 troubleshooting

KUKA AGILUS-3 troubleshooting

KUKA KR AGILUS-3 is a series of 6-axis articulated robots designed for small load, high-speed assembly, handling, and inspection scenarios, covering KR 4 R500-3, KR 4 R600-3, KR 7 R700-3, and KR 7 R900-3. This series has a compact structure, high dynamic performance, and the controller is compatible with KR C5 micro. For on-site engineers, the factors that truly affect equipment availability are installation fixation, transportation posture, cable connection, cover lubrication, toothed belt tensioning, Mastering zero calibration, and common troubleshooting. Below is a set of practical maintenance and troubleshooting ideas for this series of models.

Model positioning and core data

KR 4 R500-3 has a rated load of 4 kg, a maximum load of 5.4 kg, a maximum arm span of 500 mm, a working space of approximately 0.25 m ³, a body weight of approximately 21 kg, a repeatability accuracy of ± 0.015 mm, and a protection level of IP54. KR 4 R600-3 has a rated load of 4 kg, a maximum load of 5.2 kg, a maximum arm span of 600 mm, a working space of approximately 0.43 m ³, a weight of approximately 23 kg, a repeatability accuracy of ± 0.015 mm, and a protection level of IP54. KR 7 R700-3 has a rated load of 7 kg, a maximum load of 10.2 kg, a maximum arm span of 703 mm, a workspace of approximately 1.6 m ³, a weight of approximately 29 kg, a repeatability accuracy of ± 0.02 mm, and a protection level of IP67. KR 7 R900-3 has a rated load of 7 kg, a maximum load of 8.8 kg, a maximum arm span of 902 mm, a workspace of approximately 2.7 m ³, a weight of approximately 31 kg, a repeatability accuracy of ± 0.02 mm, and a protection level of IP67.

In terms of axis range, the KR 4 series A1 is ± 170 °, A2 is -195 ° to+40 °, A3 is -115 ° to+150 °, A4 is ± 185 °, A5 is ± 120 °, and A6 is ± 350 °. The speed under rated load is approximately: A1 487 °/s, A2 360 °/s, A3 488 °/s, A4 552 °/s, A5 529 °/s, A6 800 °/s. The KR 7 series A1 has a speed of ± 185 °, A2 ranges from -190 ° to+40 °, A3 ranges from -115 ° to+160 °, A4 has a speed of ± 200 °, A5 has a speed of ± 120 °, and A6 has a speed of ± 350 °. The speed is approximately: A1 450 °/s, A2 380 °/s, A3 525 °/s, A4 580 °/s, A5 541 °/s, A6 832 °/s. The zero position is A1 0 °, A2-90 °, A3 90 °, A4 0 °, A5 0 °, A6 0 °.

The load must be checked for both mass and mass moment of inertia simultaneously. Install flange hole circle 31.5 mm, 7 M5 threads, strength grade 12.9, engagement depth 5.5 to 6 mm, positioning element 5 H7. During normal operation, the KR 4 R50-3 has an axial force of approximately 200 N, a radial force of 147 N, a tilt torque of 14 Nm, and a flange torque of 7 Nm. During emergency stop, it can reach 250 N, 350 N, 34 Nm, and 25 Nm. During normal operation of KR 7 R700-3, the axial force is 377 N, the radial force is 249 N, the tilt torque is 39 Nm, and the flange torque is 15 Nm; during emergency stop, the axial force is 379 N, 465 N, 86 Nm, and 65 Nm. Tool design must consider these loads, not just static weight. If the center of gravity, moment of inertia or additional load of the tool exceeds the load diagram, it will cause overload of the motor and gearbox, which must be negotiated with KUKA.

Safety 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. In the stop category, STOP0 means immediately shutting down the drive and braking the brake; STOP1 is braking along the trajectory. 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. Automatic mode is only allowed to operate when all protective devices are intact, there is no one in the danger zone, and the workflow is clear. If the robotic arm or external shaft stops for no reason, an emergency stop must be triggered before entering the danger 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. The teaching pendant must be clearly assigned to the corresponding robot, and disconnected teaching pendant or components 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.