KUKA KR CYBERTECH-3 maintenance troubleshooting

Common fault three: Insufficient lubrication of cable assembly

The maintenance table of KR 35 R1840-3 clearly requires: lubricating cable group A4 for 10000 hours, using Optitemp RB2 for about 0.06 kg; lubricating cable group A1 for 10000 hours, using Optitemp RB2 for about 0.08 kg. The lubrication items for cable groups are not listed in the document of KR 25 R1840-3, but if the base or arm cables are worn, make abnormal noises, or accumulate dust on site, the hoses, cables, and drag chains should still be inspected. Clean the hose and contact surface during processing, apply the approved lubricating grease thinly and evenly, wipe off excess grease after reinstallation, and move the relevant shaft to evenly distribute the grease. Lubricating grease should not be excessive to avoid adsorbing dust. If the hose is damaged, the cable assembly must be replaced.

Common fault four: Mastering loss and zero calibration

Performance: teaching point offset, program unable to reproduce, abnormal axis angle display. Reason: Replacement of motor, manual release of brake, loss of encoder data, collision. The Mastering positions for this series are: A1 0 °, A2-90 °, A3 90 °, A4 0 °, A5 0 °, A6 0 °. Priority should be given to using EMD or a dial gauge for standard Mastering. After replacing the motor, gearbox, toothed belt, connecting shaft or manually moving the brake, it is necessary to re master. If the release device is used to move the motor, the shaft will lose its zero point and must be re Mastered. The accuracy of emergency Mastering is relatively low, and standard methods should be used to recalibrate as soon as possible afterwards.

Common Fault 5: Installation Base and Foundation Load

Performance: Robot shaking during operation, abnormal noise from the feet, and poor repeated positioning. Reason: Insufficient torque of base bolts, cracking of concrete foundation, and failure of chemical anchor bolts. KR CYBERTECH-3 can be installed on a base S310, weighing approximately 25.4 kg, using 4 M20x55-8.8 hex bolts and chemical anchor bolts; It can also be installed using a machine frame, weighing approximately 1.05 kg, using 4 M20x50-8.8 hex bolts. The basic concrete grade shall be at least C20/25. Tighten the base bolts after 100 hours and conduct annual inspections thereafter.

In terms of basic load: KR 25 R1840-3 floor installation Fv normal 4058 N，Fv max 5660 N，Fh normal 2080 N，Fh max 6132 N，Mk normal 3386 Nm，Mk max 9792 Nm，Mr normal 1819 Nm，Mr max 5095 Nm； ceiling installation Fv normal 4367 N，Fv max 5775 N，Fh normal 2259 N，Fh max 6028 N，Mk normal 3808 Nm，Mk max 9921 Nm，Mr normal 1858 Nm，Mr max 5097 Nm； Wall installation Fv normal 4332 N，Fv max 7705 N，Fh normal 1812 N，Fh max 3935 N，Mk normal 3733 Nm，Mk max 9415 Nm，Mr normal 1895 Nm，Mr max 5215 Nm。 KR 35 R1840-3 Floor Installation Fv normal 3822 N，Fv max 5618 N，Fh normal 1780 N，Fh max 6177 N，Mk normal 2837 Nm，Mk max 9855 Nm，Mr normal 1778 Nm，Mr max 5201 Nm； ceiling installation Fv normal 4397 N，Fv max 5833 N，Fh normal 2145 N，Fh max 5976 N，Mk normal 3116 Nm，Mk max 10149 Nm，Mr normal 1854 Nm，Mr max 5197 Nm； Wall installation Fv normal 4337 N，Fv max 8242 N，Fh normal 1488 N，Fh max 4015 N，Mk normal 3637 Nm，Mk max 9420 Nm，Mr normal 1925 Nm，Mr max 5319 Nm。 The maximum load is used for foundation design and must be followed.

Common Fault 6: Connecting Cable and Grounding

Performance: The controller reports motor/data line faults, intermittent shutdowns, and abnormal shielding. Solution: Check motor cables XD20.1... XD20.6/XD10.1/XD10.2 to XD30, and data cables XF21 to XF31. The grounding conductor has a cross-sectional area of 16 mm ², an M8 ring terminal, and an M8 nut torque of approximately 15.0 Nm. The cable length can be selected from 2.7 m, 4 m, 7 m, 10 m, 15 m, 20 m, 25 m, 35 m, and 50 m, with a maximum of 50 m and a maximum extension of once. The minimum bending radius for motor cables is approximately 150 mm dynamically, and for data cables it is approximately 60 mm. The cables should not withstand tensile forces and should be laid separately from the power lines. The connector must be locked during installation. When the motor connector is locked, there is a "click" sound and the red locking ring is not visible. If using an external axis, it is necessary to confirm the cascode RDC option and corresponding interface XP7.1/XP8.1.

Planned maintenance: Block faults before they occur

KR 25 R1840-3 maintenance node: Replace A5 gear oil by about 0.15 L and A4 by about 0.20 L after 20000 hours or 5 years. KR 35 R1840-3 maintenance node: Lubricate cable group A4 by about 0.06 kg and cable group A1 by about 0.08 kg after 10000 hours; replace A5 by about 0.15 L, A4 by about 0.20 L, A3 by about 0.40 L, A2 by about 1.10 L, and A1 by about 1.70 L after 20000 hours or 5 years. Before maintenance, the maintenance point must be accessible and any obstructing tools and accessories must be removed. If the oil temperature exceeds 60 ° C for a long time, the maintenance interval should be shortened and KUKA should be consulted. All accessories must use approved products, otherwise it may lead to early wear and tear.