Troubleshooting and Maintenance of KUKA KR AGILUS sixx

Maintenance is divided into daily, 100 hour, and annual maintenance. After 100 hours, check the torque of the 4 anchor bolts to 45 Nm; thereafter, check annually. A2 and A3 cover plates need to be coated with Optitemp RB 2 grease inside. A5 and A6 toothed belts must be replaced in pairs, and the tension should be measured after replacement. IW 6 R700 uses AT3/267 toothed belt with a frequency of 305 ± 5 Hz; IW 6/10 R900 and IW10 R1100 use AT3/351 with a frequency of 205 ± 5 Hz. M4 screw torque is 1.9 Nm, M3 screw torque is 0.8 Nm.

When cleaning, only use neutral water-soluble cleaning agents. Flammable, highly corrosive, steam, and high-pressure cleaning are prohibited. After cleaning, thoroughly remove any residue, check for corrosion, and apply rust prevention. During maintenance or repair, the power must be turned off and locked, and emergency stop must remain effective; If it is necessary to be electrified, only T1 mode can be used and safety measures can be added.

Common troubleshooting tree

1. Unable to enable: Check if the safety door, emergency stop, and KCP/smartPAD are uniquely assigned; Check X21/X31 data cables; Check the X20/X30 motor cables; Check grounding and equipotential; Check the diagnostic information of the controller.

2. Increase stopping distance: Check brake wear, whether the load exceeds the limit, whether the POV is too high, extension distance, toothed belt tension, and STOP 0/1 configuration. If necessary, re measure the stopping distance.

3. Abnormal shaft noise or shaking: Check the tension of the toothed belt, lubrication of the cover plate, gearbox, motor, and foundation bolts. If a collision occurs, it is necessary to check the motor and balance system, as there may be invisible damage.

4. Communication interruption: Check CAT5 XPN1, X21/X31, shielding and grounding, cable bending radius, and spacing between power and data lines. If necessary, redo the EMC wiring.

5. Abnormal air circuit: Check the pressure, filtration accuracy, valve island DO7-DO12, X41 power supply and fuse of AIR1/AIR2. The gas source needs to be oil-free, dry, filtered, and comply with ISO 8573.1.

6. Wall mounted/roof mounted sagging: Check the transportation position, load lifting accessories, M12x30 and M10x35 torque, positioning pins, and foundation bearing capacity.

7. Motor overheating: Check the ambient temperature, altitude derating, duty cycle, load, brake release, fan and heat dissipation.

Engineering method similar to the replacement of discontinued modules

If you need to replace old components or discontinued modules, don't just look at their appearance. The steps should be: confirm the robot model and variant; Confirm controller KR C4 compact and conversion name; Verify interfaces X30/X31/XPN1/X41; Check the load diagram and mass inertia; Verify the stopping distance and safety category; Check the specifications and tension frequency of the toothed belt; Verify installation torque and foundation load; Configure input and output in WorkVisual; Finally, verify all security functions in T1 mode. Only when all pass can it be put into automatic mode.

Retirement, storage, and disposal

When retiring, first move the robot to the transportation position, cut off the power, unplug the motor and data cable, remove the grounding, install the lifting equipment, remove the anchor bolts, and lift it vertically. The storage environment should be dry, dust-free, away from sunlight and condensation, with a temperature that meets regulations, covered with dust-proof film, and dried with desiccant. During disposal, materials are classified as follows: cast aluminum, copper, steel, electronic components, motors, plastics, and lubricating grease. Electronic components and motors should not be disassembled and should be treated as electrical scrap.