Troubleshooting and Maintenance of KUKA KR AGILUS sixx

The installation methods are divided into foot installation, machine frame installation, wall installation, and roof installation. The foundation installation adopts leveling pads, resin anchor bolts, and leveling compounds. The recommended concrete strength is C20/25, and there should be no insulation layer or mortar layer between the foundation and the pad. The torque of the M10x35 anchor bolt is 45 Nm. After running for 100 hours, it needs to be tightened again and checked once a year thereafter. The machine frame installation uses positioning pins and M10x35 bolts with the same torque of 45 Nm. Wall and top installations require load lifting attachments, with M12x30 hex screws having a torque of 40 Nm and M10x35 hex bolts having a final torque of 45 Nm.

After installation, it is necessary to connect the motor cable X30, data cable X31, grounding conductor, and check the equipotential connection. The connector should be locked with a "click" sound and the red ring should be fully inserted. The grounding conductor must be connected with low resistance and comply with EN 60204-1.

Interfaces and cables: high-risk areas for troubleshooting

Robot side interface A1 includes: X30 motor cable, X31 data cable, XPN1 CAT5 data cable, XP7.1/XP8.1 external axis, AIR1/AIR2 air circuit, X41 customer interface, XPN41, etc. Wrist interface A4 includes X41, XPN41, and pneumatic circuits. The standard cable length is 4 meters, with options of 1 meter, 7 meters, 15 meters, and 25 meters, and the maximum should not exceed 25 meters. The fixed bending radius of motor cables should not be less than 50 mm, and the control cables should not be less than 30 mm. Motor cables and data cables should be laid separately, and metal cable trays should be used if necessary to ensure EMC.

Common communication faults are often related to the following: X21/X31 plug not locked; CAT5 cable XPN1 is pulled; The cable and power line are running in parallel for too long; Poor grounding; External axis XP7.1/XP8.1 only connected to a rotary transformer but mistakenly connected to other signals; Abnormal pressure or inadequate filtration in the AIR1/AIR2 air circuit. The X41 customer interface provides 2 digital outputs, 6 digital inputs, and a 24 V/3 A power supply. A 3 A fuse must be added downstream. Valve islands DO7 to DO12 drive 5/2 solenoid valves, and the output does not prevent short circuits. Special attention should be paid when wiring.

Safe stop: STOP 0, STOP 1 and stop distance

The core of troubleshooting security systems is to stop categories. STOP 0: The driver is immediately powered off, the brake is engaged, and the robot brakes in the direction of the path. STOP 1: The robot first maintains braking along the path, and after about 1 second, the power is cut off and the brake is applied. STOP 2: Normal braking, without power interruption or brake holding. Stopping distance=Reaction distance+Braking distance, which is part of the danger zone.

The technical data provides a reference value for STOP 0. For example, KR 6 R700 sixx: A1 stops at a distance of about 133.67 ° for 0.494 s; A2 stops at a distance of about 122.43 ° for 0.556 s; A3 stops at a distance of about 79.29 ° for 0.371 s. KR 6 R700 W: A1 stops at a distance of about 182.04 ° for 0.665 s; A2 stops at a distance of about 68.31 ° for 0.377 s; A3 stops at a distance of about 63.48 ° for 0.379 s. KR 6 R900: A1 stops at a distance of about 113.59 ° for 0.507 s; A2 stops at a distance of about 126.76 ° for 0.684 s; A3 stops at a distance of about 68.10 ° for 0.370 s. KR 6 R900 W: A1 stops at a distance of about 163.11 ° for 0.745 s; A2 stops at a distance of about 67.78 ° for 0.404 s; A3 stops at a distance of about S. KR 10 R900/R1100: A1 is about 106.21 °, 0.536 s; A2 is about 96.06 °, 0.647 s; A3 is about 46.99 °, 0.373 s.

These values are subject to load POV、 Extension distance and brake wear effects. It is recommended to check the stopping distance once a year, especially for high-frequency STOP 0 applications. If the stopping distance significantly increases, check the brake, load configuration, toothed belt tension, safety circuit, and STOP category settings.

Debugging and load verification: T1 mode is the bottom line

After the first debugging or replacement of components, functional testing must be completed: the robot is firmly installed, without external damage or foreign objects, the safety equipment is complete, the power level matches, the grounding and equipotential are correct, and the connector is locked. Then test all safety functions in T1 manual deceleration mode, and then test the program. New or modified programs must be T1 first and then automated.

The load configuration must be input into the controller, including tool mass, center of gravity, and inertia. If additional loads are used, it should be noted that A1 and A2 additional loads are not included in the calculation of basic loads, but must be included in the total load. If tools, fixtures, air pipes, and valve islands exceed the allowable range, they will accelerate wear and change stopping performance.

Maintenance plan: lubrication, toothed belt and cleaning