KUKA KR IONTEC-2 Debugging and Maintenance Guide

Startup and Debugging Process

Before starting, it is necessary to confirm that the installation location is accessible, the robot is in the transport position, the basic dimensions are qualified, the surface is flat, and the connecting cables and grounding conductors have been laid. If the ground is uneven, leveling compound can be used, but the bolt area must not be covered by leveling material. When installing the base, first clean the foundation, install the positioning pin, fix the bottom plate to the robot with M20x60-8.8 bolts, and then lift it to the installation position. Anchor bolt construction shall follow the manufacturer's instructions for drilling, cleaning, gluing, and curing. For rack installation, first clean the installation surface, check the hole position, install the positioning pin, vertically lower the robot, insert eight M20x60-8.8 bolts, and tighten them diagonally step by step.

When making electrical connections, first connect the grounding conductor, and then connect the motor cable and data cable. The connector must be locked, the motor connector should have a clicking sound, and the red ring should not be visible. The locking button can be rotated 90 degrees to prevent accidental release. Then check the equipotential connection and enter the robot installation position in WorkVisual, which defaults to ground. Finally, install the tool and complete the startup according to the controller and system software instructions.

Maintenance and Lubrication

The maintenance cycle may vary slightly depending on the model. Usually check the tightening torque 100 hours after startup; Visually inspect the cable assembly every 5000 hours, and if any damage or cracks are found, KUKA Service should replace them; Replace gear oil every 20000 hours or 5 years. A1 gearbox is about 4.55 L, A2 is about 1.75 L, A3 is about 1.06 L, A4 is about 0.22 L, A5 is about 0.40 L, A6 is about 0.12 L, using Optigear Synt. ALR 150. Cable group A1 needs to be coated with Optitemp RB2 grease, approximately 0.03 kg. If the oil temperature exceeds 60 ° C, the maintenance interval should be shortened. It is recommended to conduct an overall inspection every 7 years or when there is a change in usage.

Before maintenance work, it is necessary to ensure that the maintenance point is accessible and remove tools and attachments. The robot must be fixed by emergency stop. If working while powered on, it can only move at a reduced speed and can be stopped urgently at any time. After maintenance, all security functions need to be restored and functional testing should be conducted. Only auxiliary materials and consumables approved by KUKA can be used, non approved materials may cause premature wear.

Discontinuation, storage, and disposal

When not in use, first move the robot to the transport position, install the fork slot, disconnect the peripheral connections, motor cables, data cables, and grounding conductors, loosen the eight M20 bolts, lift it vertically, and transport it away. Be careful not to damage the locating pin. If the robot is not reinstalled temporarily, it should be cleaned, rust proofed, electrical interfaces sealed, hoses sealed, covered with plastic film, and sealed to prevent dust at the base. If necessary, desiccants should be placed. The storage environment should be dry, dust-free, avoid temperature differences, wind, condensation, and direct sunlight, and maintain an allowable temperature range.

Disposal can be classified by material: aluminum alloy is used for wrists, arms, connecting rods, and rotating columns; Copper is used for cables; Cast steel is used for the base; Steel is used for gearboxes, screws, washers, and covers; Electronic components such as RDC and EDS are treated as electronic waste; The motor is not disassembled for processing. Plastics include ABS, ETFE, FKM, NBR, PA, PE, PU, PUR, etc. Gear oil, adhesives, sealants, and lubricants need to be handled according to the safety data sheet.

Release device and non driving energy movement

The release device is used for manually moving the robotic arm after accidents or malfunctions, mainly covering motors A1 to A3, and is only used for abnormal and emergency situations, such as rescue personnel. The device includes a ratchet and an indicator board, which indicate the direction of rotation and the direction of movement of the robotic arm. Before use, remove the M4x8 screws from the motor cover, pry open the cover plate in the slot with a flathead screwdriver, and push the release device or 12 mm open-end wrench onto the motor to overcome the brake and load resistance and move the shaft. After operation, it is necessary to clean the motor and cover plate, reinstall the cover plate, and tighten the screws. Due to the possibility of losing zero point when moving the rear axle without driving energy, it is necessary to re master all axles, perform brake tests, and test run under T1.

Common troubleshooting ideas

The troubleshooting of KR IONTEC-2 should follow the principle of "safety first, power-off confirmation, record analysis, and step-by-step verification". Firstly, trigger the emergency stop, turn off the main switch and lock and tag, and confirm that the system has been discharged. Then check the controller diagnostic information, safety circuit status, drive enable, encoder, RDC communication, and cable connections. Common issues include: incomplete locking of connectors, small bending radius of cables, damage to motor or data cables, poor grounding, missing equipotential connections, condensation, dust, oil stains, high temperatures, incorrect input of load data, tool center of gravity and inertia exceeding limits, mechanical end collision, brake wear, gearbox oil leakage, abnormal counterweight system, loose foundation bolts, etc.