KUKA AGILUS-3 troubleshooting

Installation and transportation

The installation methods include base installation and rack installation. The base installation uses C288 mounting base, weighing approximately 15.6 kg, with 4 chemical anchor bolts and 4 M8x30 ISO4017-10.9 hex bolts (KR 4) or 4 M10x35-8.8-A2K hex bolts (KR 7), 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 bottom plate and the concrete. The rack installation uses standard rack installation components, using 4 M8x30 ISO4017-10.9 (KR 4) or M10x35-8.8-A2K (KR 7) hex bolts and tapered spring washers, with a tightening torque of 45 Nm. During installation, positioning pins must be used to ensure that the robot falls vertically and avoid damaging the pins.

Transportation positions: KR 4 is at A1 0 °, A2 120 °, A3 149.9 °, A4 0 °, A5 60 °, A6 0 °; KR 7 is at A1 0 °, A2-110 °, A3 156 °, A4 0 °, A5 44 °, 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.

Additional Load Lifting Attachments are required for wall and ceiling installation, part number 0000-459-988. 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, 5 m, 7 m, 10 m, 15 m, and 25 m, with a maximum of 25 m and a maximum extension of 1 time. The cross-section of the grounding conductor should be at least 4 mm ². When fixed laying, the bending radius of the motor cable should not be less than 75 mm, and the control cable should not be less than 45 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 C5 micro connection: motor cables XD20.1 and XD20.2 to XD30, interface is Shell Size 20; Data cables XF21 to X31, interface M12 Y-code; 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. The interface A1 of KR 4 variant also includes EMD calibration interface X32, AIR1 to AIR4 air circuit connection (outer diameter 4 mm), and user connection X76 (M12, A code, 8 poles). The interface A1 of KR 7 variant also includes MEMD connection X32, PURGE exhaust connection (maximum 0.3 bar, oil-free and waterless, compliant with ISO 8573-1:2010 7:4:4), AIR1 to AIR4, I/O connections X76, X31, X30.

CTR AIR energy supply system: X76 and X96 are M12, A codes, KR 4 is 8-pole, KR 7 is 12 pole. The maximum pressure from AIR1 to AIR4 is 7 bar, and the vacuum is reduced to atmospheric pressure by 0.95 bar. AIR CTR GIG energy supply system: including interfaces X74, X94, X41, X3, X4, etc., supporting CAT5e data cables and valve units. 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 ℃. The PURGE option is used for compressed air preparation and pressure limitation, with a fixed working pressure of 0.01 MPa (0.1 bar), a gas consumption of 0.1 m ³/h, an input pressure of 0.1 to 1.2 MPa, and an outer diameter of 4 mm for the air circuit connection. PURGE is only for cleaning work and is prohibited during operation to prevent the emission of foreign particles.

Maintenance cycle and cover lubrication

Maintenance interval: Check the fastening bolts, anchor bolt nuts with 80 Nm, and fixing bolts with 45 Nm after 100 hours; check the base fastening torque after 1 year; Lubricate the inside of the cover plate for 5000 hours or at the latest 1 year, and replace the A3 and A5 toothed belts. Before maintenance, it is necessary to ensure that the maintenance point is freely accessible and remove tools and additional equipment that hinder maintenance. Robots must be secured by emergency stop and prevented from unauthorized activation.

KR 4 variant cover plate lubrication: A1 cover plate has 6 M3x8-8.8 hexagon socket bolts, A2 cover plate has 3 M3x12-8.8 bolts, A3 cover plate has 6 M3x8-8.8 bolts, A5 cover plate has 5 M3x8-8.8 bolts. After removing the cover plate, apply Optitemp RB2 grease on the inside with a brush, about 10 g. Tighten the torque to 1.2 Nm during installation. After completion, move A1, A2, A3, A5 to check for abnormalities. KR 7 variant cover lubrication: A2 cover plate with 6 M4x10-8.8 Torx, A3 cover plate with 8 M4x10-8.8 Torx, A5 cover plate with 6 M4x8-8.8 Torx. The lubricating grease is also Optitemp RB2, about 10 g. When installing, tighten the torque to 2.8 Nm. After completion, move A2, A3, A5 to check for abnormalities.