KUKA AGILUS-3 troubleshooting

The replacement cycle of the toothed belt is 5000 hours or at the latest 1 year. KR 4 variant A3 toothed belt specification 80-MTS3M-408G, target frequency 165 ± 10 Hz; A5 toothed belt specification 60-MTS3M-255G, target frequency 239-287 Hz. KR 7 variant A5 toothed belt specification 60-MTS3M-330G, target frequency 200 ± 10 Hz. When replacing the A3 toothed belt, first fix the arm, remove the 6 M3x8-8.8 bolts on the A3 cover plate, loosen the 2 M4x12-8.8 bolts, and remove the old belt. After installing the new belt, use the A3 belt tensioning tool and frequency meter to measure. The sensor should be 2 to 3 mm away from the belt, and the frequency should be read by moving the belt side. If the target value is not reached, fine tune the tension screw and repeat the measurement. After reaching, tighten 2 M4x12-12.9 hexagon head bolts with a torque of 2.8 Nm. When controlling the measurement, if tools are used, A3 should not be affected by gravity, for example, if the arm is horizontal and A3 is at+90 ° or -90 °; Any position without tools. Measure the frequencies on both sides and take the average. After completion, calibrate A3 and run the program to check T1.

When replacing the A5 toothed belt, first fix A5, remove 5 M3x8-8.8 bolts from the A5 cover plate, loosen 2 M5x10 hexagon head down bolts and 1 M4x16-8.8 adjustment screw, and remove the old belt. After installing the new belt, gently tighten the adjusting screw to move the pulley in the A4 direction, pre tighten it, and then lightly tighten the 2 M5x10 bolts. Measure with a frequency meter. If the target value is not reached, loosen 2 M5x10 bolts, adjust with adjusting screws, and repeat the measurement. After reaching, tighten 2 M5x10 bolts with a torque of 3.8 Nm (KR 4) or 5.6 Nm (KR 7). When controlling measurements, if tools are used, A5 should not be affected by gravity, for example, if the arm is horizontal and A4 is at+90 ° or -90 °; Any position without tools. Measure the frequencies on both sides and take the average. After completion, calibrate A5 and perform program checks on T1.

Mastering and Zero Calibration

The KR 7 variant can be Mastered using the MEMD tool, A1 to A5 are calibrated using the MEMD Mastering set, and A6 uses standard flat keys and zero calibration tools. Step: Rotate A6 flange to make the flange groove close to the casting Mastering surface; Insert the zero calibration tool to ensure a tight fit with the slot; Slowly rotate the flange to align the flat key with the casting reference surface, completing A6 calibration. If A6 is forcibly rotated, it may damage the components. For a robotic arm with a motor brake release button, the A6 can be manually rotated by pressing the button to bring the zero calibration tool closer to the casting Mastering surface.

Emergency Mastering is suitable for emergency situations without EMD and dial indicators. The KR 4 and KR 7 variants have Mastering markings on each axis. When operating, follow the specified steps to align the engraved lines. If the zero point is lost after using emergency Mastering, the normal operation of the previous program cannot be guaranteed. Therefore, to teach programming in Cartesian coordinate system, EMD or micrometer should be used for Mastering.

Common troubleshooting

Robot unable to enable or emergency stop failure: Check if the teaching pendant is correctly connected and assigned to the corresponding robot, disconnect the device and immediately remove it from the system.

Slipping or abnormal noise of the toothed belt: Check the tensioning frequency of the toothed belt and adjust it according to the target values of A3/A5; Check if the toothed belt teeth are damaged. If damaged, replace them and contact KUKA.

Abnormal noise or wear inside the cover plate: Lubricate the inside of the cover plate every 5000 hours or 1 year, use Optitemp RB2, and pay attention to the tightening torque.

Loose connectors or abnormal communication: Check if motor cables XD20.1/XD20.2 to X30 and data cables XF21 to X31 are securely locked; When the KR C5 motor connector is locked, there should be a clicking sound, and the red ring should not be visible and should be fully inserted.

Grounding abnormality: Check the grounding conductor of 4 mm ², M4 ring cable terminal, M8 hex nut and tapered spring washer, with a tightening torque of 1.6 Nm (KR 4) or 2.8 Nm (KR 7).

IP67 protection failure: check PURGE connection, maximum 0.3 bar, no oil or water; Check if the compressed air is supplied according to ISO 8573-1:2010 7:4:4.

Zero point loss: After replacing the toothed belt, motor, or using the brake release device, it is necessary to re master the relevant shaft.

External axis no feedback: Check XP7.1 and XP8.1, only allow connection of rotary transformers.

Robot accidentally sinks: Check for brake, load, and collision damage. If the robotic arm or external shaft collides with obstacles, mechanical end stops, or shaft limiting devices, it must stop running and contact KUKA.

Abnormal compressed air pressure: Check the pressure regulator, PURGE working pressure 0.01 MPa (0.1 bar), input pressure 0.1 to 1.2 MPa.

Discontinuation, storage, and disposal