Troubleshooting of KUKA KR FORTEC-2

Troubleshooting of KUKA KR FORTEC-2

KUKA KR FORTEC-2 is a six axis articulated robot designed for heavy-duty handling, machine loading and unloading, casting, and high cycle automation, covering KR 240 R3400-2、KR 240 R3700-2、KR 280 R3100-2、KR 340 R3400-2、KR 340 R3400-2 F、KR 360 R2800-2、KR 420 R3100-2、KR 420 R3100-2 F、KR 420 R3100-2 HI、KR 500 R2800-2、KR 500 R2800-2 F、KR 500 R2800-2 HI  Waiting for the model. 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 balance system, abnormal wrist noise, worn connecting shafts, gear oil leakage, motor overheating, or safety circuit shutdown.

Product positioning and core structure

KR FORTEC-2 adopts a six axis articulated arm structure, with main components including a linear wrist, arm, connecting rod, rotating column, base, balance system, electrical installation, and connecting cables. The shaft is driven by an AC servo motor. The balance system is used to balance the A2 axis load torque, using a closed hydraulic pneumatic system consisting of three accumulators, hydraulic cylinders, hoses, and rupture discs, and belongs to the category of pressure equipment instructions. The F variant is designed for harsh environments such as casting, while the HI variant is designed for high inertia applications.

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 located between the arm and the rotating column. Install A1 and A2 motors inside the rotating column and support the connecting rod. 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 240 R3400-2 has a rated load of 240 kg, a maximum load of 310 kg, a maximum arm span of 3400 mm, a body weight of approximately 1597 kg, a workspace of approximately 111.8 m ³, a repeatability accuracy of ± 0.08 mm, a protection level of IP65, wrist IP65/IP67, and controller KR C5 L6/L7. KR 240 R3700-2 has a rated load of 240 kg, maximum load of 300 kg, arm span of 3750 mm, and weight of approximately 1620 kg. KR 280 R3100-2 has a rated load of 280 kg, maximum load of 360 kg, arm span of 3100 mm, and weight of approximately 1687 kg. KR 340 R3400-2 has a rated load of 340 kg, maximum load of 426 kg, arm span of 3400 mm, and weight of approximately 1728 kg. KR 360 R2800-2 has a rated load of 360 kg, maximum load of 474 kg, arm span of 2800 mm, and weight of approximately 1660 kg. KR 420 R3100-2 has a rated load of 420 kg, maximum load of 527 kg, arm span of 3100 mm, and weight of approximately 1704 kg. KR 500 R2800-2 has a rated load of 500 kg, maximum load of 611 kg, and arm span of 2800 mm. The weight is approximately 1671 kg.

Axis motion range: A1 ± 185 °, A2-130 °/5 °, A3-110 °/162 °, A4 ± 350 °, A5 ± 120 ° or ± 122.5 °, A6 ± 350 °. The speed varies according to the model, A1 is about 100-103 °/s, A2 is about 80-97 °/s, A3 is about 90-104 °/s, A4 is about 80-120 °/s, A5 is about 90-125 °/s, A6 is about 140-210 °/s. The flange standard is ISO 9409-1, IW 300-2 hole circle 160 mm, M10, IW 500 hole circle 200 mm, M12. The foundation load varies depending on the model, for example, KR 240 R3400-2 has a normal vertical force of 28500 N, with a maximum of 34500 N; a normal horizontal force of 11000 N, with a maximum of 23500 N; a normal tilting moment of 45000 Nm, with a maximum of 68500 Nm; and a normal moment around A1 of 15000 Nm, with a maximum of 28500 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.