KUKA KR IONTEC HO Maintenance Troubleshooting Guide

Safe operation and mode management

In the safety logic of this series of robots, the A1 to A3 axes are equipped with mechanical end stops, but these end stops are mainly used to protect the machine rather than personnel. Personnel protection relies on the safety robot function of the controller or the optional A1 to A3 mechanical axis limiting device. The danger zone consists of a workspace and a stopping distance, and must be isolated by physical barriers, safety doors, etc. The safety door should be located outside the danger zone. If there is no physical protection, collaborative operation requirements must be met.

In terms of operation mode, T1 is a manual deceleration mode with a speed not exceeding 250 mm/s, suitable for teaching, programming, and program verification. T2 is a manual high-speed mode, only used for testing situations that require speeds higher than T1, and teaching and programming are not allowed. Automatic mode is only allowed to be used when all safety equipment and protective devices are complete and effective. If the robot stops inexplicably in automatic mode, it must not directly enter the danger zone and must first trigger an emergency stop.

When maintaining and repairing, five safety rules must be followed: power-off, prevent restart, confirm no power, ground and short circuit, cover or isolate adjacent live parts. The emergency stop device must remain available. If it is necessary to work while powered on, it can only be carried out in T1 mode and limited to the absolutely necessary range. Personnel with implants should maintain a minimum distance of 300 mm from the motor and brake. SmartPAD or KCP must be operated by authorized personnel and should be removed from the system immediately after disconnection to prevent misuse. The external keyboard and mouse can only be used during startup or maintenance, and the driver must be turned off and there must be no one in the danger zone.

Maintenance system and oil management

The maintenance cycle of KR IONTEC HO is closely related to load, environment, and operating mode. The routine maintenance nodes include: checking the tightening torque for the first 100 hours; 5000 hours of inspection to see if the hoses and cables are damaged; Lubricate cable group A1 for 20000 hours using Kl ü berfood NH1 34-401 grease, with a dosage of approximately 0.03 kg; replace A1 to A6 gear oil every 10000 hours or up to 5 years using Optileb GT 1800/460. The initial filling amounts are: A1 5.66 L, A2 2.49 L, A3 1.00 L, A4 0.33 L, A5 0.60 L, A6 0.24 L.

Before changing the oil, the robot should be at an operable temperature, but attention must be paid to the possibility of burns caused by high temperature oil and surfaces. The oil chamber may be under pressure, so ventilation should be done before opening the drain plug. When changing the oil in A1, move A1 to -90 °, remove the cover plate on the rotating column and base, and use M18x1.5 magnetic plug and oil drain pipe. When changing the oil in A2, place the robot in a position that is accessible to the refueling and draining holes. When changing the A3 oil, keep the arm and inline wrist level, and set the angle of A2+A3 to 0 ° for checking the oil level. When changing the A4 oil, the angle between A2 and A3 should be -68 °. When changing the oil in A5, A2+A3=0 °, A4=-77 °. When changing the oil in A6, A2+A3=0 °, A5=0 °, A4=53 °. The tightening torque for M18x1.5 plugs is usually 20 Nm, and for M10x1.0 plugs it is 7.5 Nm.

When lubricating cable group A1, it is necessary to remove the cover plates on the rotating column and base, check and apply lubricating grease, and then move A1 to evenly distribute the lubricating grease. Neutral, solvent-free, water-soluble, non flammable, and non corrosive cleaning agents should be used when cleaning robots. Do not use high-pressure cleaning machines, do not use compressed air to clean bearings and sealing points, and prevent cleaning agents from entering electrical or mechanical components. After cleaning, the cleaning agent should be completely removed, the corroded area should be inspected, and anti-corrosion measures should be taken again.

Practice of Motor Replacement and Maintenance

Motor replacement is a high-frequency task for on-site maintenance. When replacing the A1 motor, first disconnect the XM1 and XP1 connectors, remove the 4 M10x25-8.8-A2K hex screws, carefully remove the motor to avoid tilting. Clean the splines of the motor and gear input shaft before installation, apply Microlube GL 261 grease, check the O-ring, tighten the screws step by step in diagonal order, and finally insert the connector back and perform A1 mastering again. Before replacing the A2 motor, the connecting rod arm must be fixed with a sling to prevent the robot from moving on its own after disassembly. A2 uses 4 M10x25 screws. Before replacing the A3 motor, it is necessary to fix the inline wrist and robot arm with a sling, remove the 14 M6x16 screws on the A3 cover plate, and then remove the 4 M8x22 screws. After installation, it is also necessary to re master and test in T1 mode.

When replacing the motor, it is important to note that damaged gears or motor teeth can cause wear and early failure; Check if the teeth are damaged before installation; When inserting the connector, it must be aligned with the coding element to ensure anti twist locking; All high-strength screws, such as grade 10.9 and above, can only be tightened once to the rated torque and must be replaced after loosening. After the repair is completed, the corresponding axis should be moved to check for abnormalities, mastering should be performed, and then the program should be run in T1 mode. If the robot is equipped with a release device, it can move the A1 to A3 axes without driving energy after an accident or malfunction. After using the release device, all axles must be remastered and subjected to brake testing and T1 trial operation.