Troubleshooting of KUKA KR FORTEC-2 ultra

KUKA KR FORTEC-2 ultra maintenance and troubleshooting

KUKA KR FORTEC-2 ultra is a six axis articulated robot designed for ultra heavy load handling, machine loading and unloading, casting, and high cycle automation, covering KR 480 R3400-2、KR 480 R3700-2、KR 560 R3100-2、KR 640 R2800-2、KR 800 R2800-2  And corresponding F and HI variants. For on-site engineers, the real challenge is not programming, but how to quickly locate the robot according to the system hierarchy and restore operation without compromising safety integrity when the robot experiences abnormal pressure in the dual balance system, abnormal wrist noise, worn connecting shafts, gear oil leakage, motor overheating, or safety circuit shutdown.

Product positioning and core structure

The KR FORTEC-2 ultra adopts a six axis articulated arm structure, with main components including a linear wrist, arm, double link, rotating column, base, dual balance system, electrical installation, and connecting cables. The shaft is driven by an AC servo motor. Unlike the single balancing system model, the KR FORTEC-2 ultra is equipped with a hydraulic pneumatic balancing system on each side of the rotating column to balance the A2 axis load torque. Each balancing system consists of three accumulators, hydraulic cylinders, hoses, and rupture discs, and falls within the scope of pressure equipment instructions.

The straight wrist includes three axes: A4, A5, and A6. A6 motor is directly installed in the wrist to drive the wrist; A4 and A5 are driven by the rear of the arm through a connecting shaft. The arm is connected to a straight wrist and a connecting rod, with A4 and A5 motors installed internally, and A3 motor driving the arm. The connecting rod is divided into left and right parts, which are respectively connected to the rotating column and arm through two gearboxes. Install A2 and A3 gearboxes and motors inside the left connecting rod, and install the corresponding right gearbox inside the right connecting rod. For KR 480 R3700-2 and KR 800 R2800-2, A2 and A3 motors are also equipped with input stages, which drive the gearboxes on both sides through shafts. Install A1 motor inside the rotating column and connect it to the base through A1 gearbox. The base is connected to the installation base, and the internal layout includes electrical installation and interface A1. The electrical installation includes cable groups, RDC boxes, and connectors, with interface A1 located at the rear of the base.

Technical data and load foundation

KR 480 R3400-2 has a rated load of 480 kg, a maximum load of 591 kg, a maximum arm span of 3400 mm, a body weight of approximately 2170 kg, a workspace of approximately 123.4 m ³, a repeatability accuracy of ± 0.08 mm, a protection level of IP65, wrist IP65/IP67, and controller KR C5 L6/L7. KR 480 R3700-2 has a rated load of 480 kg, a maximum load of 580 kg, an arm span of 3700 mm, a weight of approximately 2460 kg, and a workspace of approximately 164.6 m ³. KR 560 R3100-2 has a rated load of 560 kg, a maximum load of 681 kg, an arm span of 3100 mm, a weight of approximately 2170 kg, and a workspace of approximately 87.4 m ³. KR 640 R2800-2 has a rated load of 640 kg, a maximum load of 835 kg, an arm span of 2800 mm, a weight of approximately 2130 kg, and a workspace of approximately 66 m ³. KR 800 R2800-2 has a rated load of 800 kg, a maximum load of 972 kg, an arm span of 2800 mm, a weight of approximately 2400 kg, and a workspace of approximately 66 m ³.

Axis motion range: A1 ± 185 °, A2-130 °/20 °, A3-100 °/165 °, A4 ± 350 °, A5 ± 120 °, A6 ± 350 °. The speed varies according to the model, A1 is about 80-90 °/s, A2 is about 60-80 °/s, A3 is about 60-75 °/s, A4 is about 90 °/s, A5 is about 80-90 °/s, A6 is about 130-140 °/s. The flange standard is ISO 9409-1, IW 500 hole circle 200mm, M12, IW 800 hole circle 200mm, M16. The foundation load varies depending on the model, for example, KR 480 R3400-2 has a normal vertical force of 38000 N, with a maximum of 44000 N; a normal horizontal force of 12000 N, with a maximum of 27500 N; a normal tilting moment of 55000 Nm, with a maximum of 83000 Nm; and a normal moment around A1 of 15000 Nm, with a maximum of 33000 Nm. The foundation must withstand these loads for a long time. The supplementary loads on A1 and A2 are not included in the calculation of foundation loads and must be taken into account as vertical forces.

Installation foundation and transportation

The installation methods mainly include a 200mm mounting base, a 175mm optional base, and machine frame installation. The 200mm base weighs approximately 131 kg and consists of 4 bed plates, 16 chemical anchor bolts, 8 M24x65-8.8-A2K hex bolts, and locating pins. The 175mm base weighs approximately 306 kg and consists of a bed plate, 20 chemical anchor bolts, 8 M24x65 bolts, and locating pins. Machine frame installation weighs approximately 3.52 kg and is used for steel structures, foundations, or linear units. The concrete strength should be at least C20/25, and there should be no insulation layer or mortar layer. The diameter of the chemical anchor bolt drilling hole is 18 mm. Diamond tools or coring drills must not be used, and setting tools approved by the anchor bolt manufacturer must be used. The installation surface must be flat, and the leveling material must not cover the fastening bolt area.