KUKA KR IONTEC ultra series six axis heavy-duty industrial robot

Maintenance and Fluid Management

Maintenance cycle: 100 hours to check the tightening torque; Replace A1-A6 gear oil after 20000 hours or 5 years, using Optigear Synt. ALR 150. Initial filling amount: A1 5.80 L, A2 2.10 L, A3 1.40 L, A4 0.35 L, A5 0.60 L, A6 0.30 L. A1 cable group lubrication uses Optitemp RB2, approximately 50g. If the oil temperature exceeds 60 ° C, the maintenance interval should be shortened. Clean with neutral, solvent-free, water-soluble, non flammable, and non corrosive cleaning agents; Prohibit high-pressure cleaning machines and compressed air cleaning of bearings and sealing points.

Before changing the oil, the gear unit should be at operating temperature, but pay attention to high temperature burns and oil chamber pressure. Ventilate first, then drain the oil. A1 floor robot: Remove the M18x1.5 vent plug at the top of the rotating column, remove the base oil drain plug, connect the oil drain pipe, and after draining, add oil from the oil drain pipe to the lower edge of the indicator hole with a torque of 20 Nm for the M18 plug. A1 ceiling robot: Use an expansion tank and oil drain hose. A2: Both oil discharge and refueling are done through the M18 screw plug on the rotating column, and the refueling amount is determined by the discharge amount or indicator hole. A3: A2+A3 angle and 10 ° (example A2-90, A3+80), upper M10x1 vent/indicator hole, lower M18x1.5 oil discharge. A4: When draining, A2+A3=0 °, when refueling, A2+A3=-70 °; M18x1.5 torque 20 Nm. A5: A2+A3=+21 °, A4=+45 °; M10x1 torque 7.5 Nm. A6: A2+A3=+35 °, A4=-48 °; M10x1 torque 7.5 Nm. If the displacement is less than 70%, it needs to be flushed once; Less than 50%, rinse twice and move the entire axis range at jog speed.

Motor and gear input shaft replacement

Before replacing the motor, it is necessary to make an emergency stop and prevent restarting. If necessary, use a sling to secure the connecting rod arm, arm, or inline wrist. A1 motor: 4 M8x25-8.8-A2K, O-ring 23x4. A2 motor: 4 M12x25-8.8-A2K, O-ring 30x5, weight approximately 26 kg, requires a crane. A3 motor: 4 M8x25, O-ring 23x4. A4 motor: 3 M6x22, small gear M5x16-10.9, radial shaft seal 35x62x8x10, O-ring 22x1.5. A5/A6 motors: 3 M6x22, small gears M5x16-10.9, radial shaft seals 35x62x8x10, O-rings 22x1.5. The disassembly and installation of A5/A6 small gears are the same. If they get stuck, a vise and torque bracket can be used. Clean the splines before installation, apply Microlube GL 261, and inspect the teeth. The connector must be aligned with the coding element and locked against torsion. All screws of grade 10.9 and above can only be tightened once to the rated torque and replaced after loosening. After replacement, it is necessary to re master and test in T1 mode.

Replacement of gear input shaft A1: Remove motor A1, take out the 110x4 snap ring, and remove the input shaft and radial shaft seal 58x80x8. Clean the sealing carrier during installation, apply Drei Bond 5204HV to the radial shaft seal, and install the shaft and retaining ring. Afterwards, reinstall motor A1 and master A1.

Mini gauge cartridge replacement

Each axis A1-A6 has a mini gauge cartridge for MEMD mastering. If there is adhesion during replacement, it can be heated with a hot air gun, but pay attention to high temperature and residual lubricating grease. The tools include 0000-280-579 disassembly device and 0000-204-338 installation auxiliary hexagonal tool. Apply Drei Bond 5204HV to the new cartridge thread and tighten to a torque of 2.8 Nm. After replacement, check for free movement and perform a mastering check. If necessary, re teach the points. Before replacing A4/A5/A6, move the shaft to the upward position of the gauge cartridge to prevent oil leakage.

Common faults and troubleshooting

Robot collision end stop or mechanical limit: stop, contact KUKA, cannot be restored directly.

Abnormal stopping distance: check brake wear, load, and speed; The stopping distance and time data should refer to KUKA Xpert and be checked annually.

Mastering loss: A1 standard has no mechanical limitations, and the cable assembly may twist without mastering. Re mastering in two steps: first untwist A1 0 °, and then move in the negative direction to pre mastering. A4 has an overtravel indicator. If the indicator board is crossed, approach the pre mastering from the opposite direction and check the cable assembly.

Oil leakage: Check the magnetic plug, seal, and oil chamber pressure, and ventilate first. Check for leaks after changing the oil.

Motor overheating or abnormal noise: check the load, teeth, O-ring, and connector; Replace the motor and then re master.

Safety function failure: prohibit operation, immediately repair and test all safety circuits.

Cable wear: Check the bending radius, fixation, separation of metal pipes, and ensure that motor and data cables are not under tension.

Condensation: Wait for adaptation when there is a large difference between the internal temperature of the controller and the environment to avoid condensation.

Fault handling: Turn off the controller and lock it, label it, record the fault, and perform functional testing after repair.