Troubleshooting of KUKA KR FORTEC-2 ultra

When installing the robot, first clean the foundation, install the positioning pin, lift the robot with a forklift, install the bed board, tighten the M24 bolts in diagonal order, check the flatness of the foundation, fill in leveling materials if necessary, drill anchor bolt holes, and cure. When connecting the cable, use an M8 nut with a torque of 23 Nm for the grounding conductor; connect the data cable XF31 to ensure that the lock is closed; Connect motor cables XD30.1 and XD30.4; Check the equipotential. The transportation positions are A1 0 °, A2-130 °, A3 130 °, A4 0 °, A5 90 °, A6 0 °. When transporting by forklift, each of the four fork slots is fixed with 3 M16x50-8.8-A2K Allen screws, and the minimum load of the forklift is 2.5 t. During lifting, 3 M20 eyebolts are used, and the ropes are arranged according to the diagram. The transport protection strap should be located on the transport protection device and the connecting rod boss, and should not be placed on the motor, cable bridge or other components. The standard length of the connecting cable is 7-50 meters, with a maximum of 50 meters and a maximum of one extension. The bending radius for the fixed laying of motor cables shall not be less than 150 mm, and for data cables shall not be less than 60 mm. Motor cables and data cables shall be laid separately, and EMC measures shall be taken if necessary.

Safety and Debugging Inspection

The danger zone consists of a workspace and a stopping distance. Mechanical end stop is used to protect the machine, and personnel protection can be selected through the Safe Robot function or mechanical axis limitation. Before debugging, it is necessary to check the safety functions, including emergency stop, enable switch, mode selection, safety door, external safety stop, and safety output. T1 is in manual deceleration mode, with a speed not exceeding 250 mm/s; T2 is manual high-speed mode; AUT is in automatic mode; AUT External is in automatic external mode. New or modified programs must be tested under T1 first.

Five safety rules must be followed during maintenance and repair: power off, prevent accidental restart, confirm that the system is out of power, ground and short-circuit, cover or isolate adjacent live parts. After the controller is turned off, some components may still have a voltage of 50 V to 780 V for several minutes. The robot system must be disconnected from the main power supply and cannot rely solely on emergency stop or safe stop. Hot surfaces, oil pressure, nitrogen pressure, and extrusion risks should all be prevented. The motor and brake will generate electromagnetic fields, and personnel wearing implants should maintain a distance of 300 mm from the motor and brake. Unauthorized modifications may render warranty and liability invalid. Before starting, the default password must be changed, and the robot installation, fastening, cable connection, grounding conductor, and equipotential must be checked. If there is a significant difference between the internal temperature of the controller and the ambient temperature, it is necessary to wait for temperature equilibrium to prevent condensation. Functional testing must confirm the correct installation of the robot, no external damage, no debris, complete safety equipment, matching power supply, reliable grounding and equipotential, and locked connection cables. External force damage such as collision may cause invisible damage, and the motor and balance system must be checked. The safety function must be tested, and the braking test must be performed regularly. The system will force it and cannot be turned off. The balancing system belongs to pressure equipment and must be operated by qualified personnel. Before maintenance, the supported components must be fixed and depressurized.

Maintenance cycle and oil management

The maintenance cycle for standard and HI variants is 100 hours to check the torque of fastening bolts and nuts. 5000 hours or up to 1 year, lubricate the bearings of the dual balance system, one lubrication point each for the rotating column and connecting rod, using LGEP 2, with each lubrication point approximately 10 cm ³; If A2 frequently short trips less than 40 °, the interval should be shortened to 3000 hours. After 5000 hours or 1 year, check the pressure, leakage, and appearance of the balance system. Replace gear oil after 20000 hours or 5 years: A5/A6 in ZH500 is 1.50 L, A6 is 1.30 L, A5 in ZH800 is 1.60 L, A6 is 1.40 L; A4 is 3.00 L; A3 without input stage is 5.90 L, with input stage is 6.50 L; A2 without input stage is 8.50 L, with input stage is 9.00 L; A1 is 10.60 L; the oil product is Optigear Synt. ALR 150. Lubricate the A1 cable assembly for 20000 hours or 5 years, using Optitemp RB2 for approximately 50 g. Replace the dual balancing system in 10 years. F variant has a shorter maintenance cycle: 100 hours for checking and tightening; Inspect the gearbox and structural components for sedimentation, damage, and corrosion after 2500 hours or 6 months; 2500 hours or 1 year lubrication balance system bearings; Check the balance system pressure after 2500 hours or 6 months; Change oil after 10000 hours or 5 years; 10000 hours or 5-year lubrication cable set; Replace the balance system in 10 years. If the oil temperature exceeds 60 ° C, the maintenance interval must be shortened and KUKA Service consulted.