Troubleshooting and Maintenance of KUKA KR AGILUS sixx

Installation, debugging, safe stopping, and troubleshooting of KUKA KR AGILUS sixx six axis robot

Why does the operation and maintenance of KR AGILUS sixx require a "system level" approach

KUKA KR AGILUS sixx is a compact six axis articulated robot, with common models including KR 6 R700 sixx, KR 6 R900 sixx, KR 10 R900 sixx, KR 10 R1100 sixx, and derived W wall mounted and C ceiling mounted versions. It usually forms a complete system with KR C4 compact controller, smartPAD teaching pendant, connecting cables, end tools, and external shafts. For engineers in the "search for solutions" stage, the real tricky problem is often not the single axis not moving, but the coupling between safe stopping, load configuration, interface cables, foundation installation, toothed belt tension, and controller parameters.

The troubleshooting approach for this type of equipment is similar to replacing the shutdown control module or troubleshooting the safety system: first confirm the model and variant, then check the interface, load, safety function, and verification process, and finally conduct low-speed trial operation in T1 mode, gradually scaling up to automatic mode. Any jumping step may cause the stopping distance to exceed the standard, the axis to sag, communication interruption, and even personal injury.

First identify the model and system boundary

The KR AGLUS sixx product family covers load ranges of 6 kg and 10 kg. The KR 6 series includes R700 and R900; The KR 10 series includes R900 and R1100. W represents wall installation, C represents ceiling installation. The controller is KR C4 compact, and the conversion name varies depending on the model, such as KR6R700 C4SR FLR, KR6R700 C4SR WLL, KR6R700 C4SR CLG, etc. The system boundary includes the robotic arm, control cabinet smartPAD、 Connect cables, software, options, and accessories.

The robotic arm is a 6-axis articulated arm with a lightweight alloy casting structure. Each axis is equipped with a brake, and the motor and current carrying cable are arranged under the cover plate, with a protection level of IP54. The wrist is a three-axis coaxial wrist, integrated with 5/2 solenoid valve and CAT5 data cable, which can control tools. The main motion chain consists of A1 rotating column, A2 connecting rod, A3 arm, and A4-A6 wrist. The A1 interface is located at the rear of the base and serves as a critical entry point for motor cables, data cables, external shafts, and air circuits.

Key technical data: must be verified before selection and replacement

1. Axis range and speed

KR 6 series software restriction range: A1 ± 170 °, A2+45 ° to -190 °, A3+156 ° to -120 °, A4 ± 185 °, A5 ± 120 °, A6 ± 350 °. Under rated load, the speed is approximately 360 °/s for A1, 300 °/s for A2, 360 °/s for A3, 381 °/s for A4, 388 °/s for A5, and 615 °/s for A6.

The KR 10 series has slightly lower speeds: A1 is about 300 °/s, A2 is about 225 °/s, A3 is about 225 °/s, A4 is about 381 °/s, A5 is about 311 °/s, A6 is about 492 °/s. When replacing or modifying, if the speed, inertia, and stopping distance do not match, the safety circuit must be re evaluated.

2. Load and center of gravity

The KR 6 series has a rated load of 3 kg, a maximum load of 6 kg, and a load center of gravity of Lxy 60 mm and Lz 80 mm. The KR 10 series commonly has a maximum load of 10 kg. The total additional load installed on the robot must not exceed the maximum total load. Mass inertia needs to be verified using KUKA. Load, and load data must be written into the controller. The flange is 31.5 mm, with 7 M5 screws, a strength of 12.9, and a meshing depth of 5.5 to 7 mm. The deviation of the tool center of gravity will directly change the stopping distance and the service life of the gearbox.

3. Basic load and environment

The basic load includes vertical force, horizontal force, overturning moment, and torque. Taking KR 6 as an example, the normal vertical force is about 967 N, with a maximum of 1297 N; the normal horizontal force is about 1223 N, with a maximum of 1362 N; the normal overturning moment is about 788 Nm, with a maximum of 1152 Nm; the normal torque is about 367 Nm, with a maximum of 880 Nm. The KR 6 R700 robot weighs about 50 kg, the R900 weighs about 52 kg, and the KR 10 weighs about 52 to 55 kg. The installation foundation must be able to withstand the maximum load and cannot use normal load as a safety margin.

Working environment: Operating temperature+5 ° C to+45 ° C, no condensation is allowed; Storage and transportation -40 ° C to+60 ° C; relative humidity ≤ 90%; For altitudes above 1000 meters, a 5%/1000 meter derating is required. These conditions directly affect the motor temperature, brake life, and stopping distance.

Installation and transportation: from transportation location to foot torque

Before transportation, the robot must be placed in the transportation position: A1 0 °, A2-105 °, A3+156 °, A4 0 °, A5+120 °, A6 0 °. During transportation, use a sling to wrap around the connecting rod and rotating column, and other lifting methods are prohibited. Before the robot is fixed, it must maintain its transport position to avoid tilting due to center of gravity deviation.