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

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

KUKA KR IONTEC ultra is a six axis articulated robot series designed for high load, high beat applications, currently including two models: KR 120 R2700 and KR 90 R2700. This series comes standard with the Dynamic Mode option, which requires manual activation once and can shorten the beat time in pure exercise. For on-site engineers, the real factor that affects equipment availability is often not a single parameter, but whether installation, transportation, safety, maintenance, oil change, motor replacement, and troubleshooting can form a closed loop. This article focuses on this series of robots and compiles a technical guide that is easy to use on site.

Core parameters and mechanical structure

KR 120 R2700 has a rated load of 120 kg and a maximum load of 155 kg; KR 90 R2700 has a rated load of 90 kg and a maximum load of 116 kg. Both have a maximum arm span of 2702 mm, a workspace volume of 95.3 m ³, a repeat positioning accuracy of ± 0.05 mm, and a body weight of approximately 773 kg. The protection level is IP65, and the wrist can reach IP65/IP67, with noise levels below 75 dB (A). The installation method is floor or ceiling, allowing a tilt angle of ± 5 °, but the floor robot cannot be installed on the ceiling, and the ceiling robot cannot be installed on the floor. The controller is compatible with KR C5-2 and KR C5 M6, with conversion names of KR120R2700 and KR90R2700, respectively.

Structurally, the robot consists of a base, rotating column, connecting rod arm, arm, inline wrist, and electrical installation. A1 rotating column carrying motor A1; A2 connecting rod arm contains gear unit A2/A3 and motor A2; A3 arm contains A3 motor and A4 motor; A4-A6 is located on the inline wrist, with A5/A6 motors built-in. All motors are connected through plug-in connectors for quick replacement. The RDC box is installed on the rotating column. Interface A1 is located at the rear of the base and includes X30 motor cables, X31 data cables, two grounding conductors, and optional external shafts XP8.1/XP7.1.

Axis motion range: A1 ± 185 °, A2-140 °/60 °, A3-95 °/171 °, A4 ± 180 °, A5 ± 125 °, A6 ± 350 °. Rated load speed: A1 140 °/s, A2 100 °/s, A3 120 °/s, A4 210 °/s, A5 200 °/s, A6 300 °/s. Mastering positions: A1-34 °, A2-112 °, A3 112 °, A4 0 °, A5 45 °, A6 0 °. Transportation positions: A1 0 °, A2-140 °, A3 140 °, A4 0 °, A5 90 °, A6 0 °.

Installation and transportation

There are three types of installation bases: the standard installation base R300x400 II weighs about 40 kg, the 150 mm installation base weighs about 38 kg, and the machine frame installation weighs about 2.3 kg. The standard base uses 12 chemical anchor bolts and 8 M20x60-8.8-A2K hex bolts; A 150mm base is similar. The concrete foundation needs to reach C20/25 and cannot have insulation or mortar layers. The minimum thickness and edge distance of the foundation depend on the presence of edge reinforcement: standard base A 180/200/250 mm, B 130/150/200 mm, etc; 150mm base A 150/200/240 mm, B 160/200/240 mm. The machine frame installation uses 8 M20x60-8.8 hexagonal bolts and two locating pins, suitable for steel structure and ceiling installation.

Transportation must use the transportation location. Forklifts or lifting devices can be used. The forklift has a minimum load capacity of 2.5 tons and forks into the rotating column fork slot to avoid overload. Three M12 rotating lifting rings are used for lifting equipment, installed on the base, and all lifting straps are arranged according to the markings. Vibration and impact are prohibited during transportation, and personnel are not allowed to be under the robot. Ceiling robots can only be transported by forklifts, using transport frames or removing fork slots. After transportation is completed, remove the fork groove and lifting equipment, and restart.

The standard length of the connecting cable is 7/10/15/25/35/50 meters, with a maximum length of 50 meters, allowing for one extension. The fixed bending radius of the motor cable is ≥ 150 mm, and the data cable is ≥ 60 mm. The installation temperature is -10 ° C to+55 ° C. The motor cable and data cable are separately laid in metal pipes. The cross-sectional area of the grounding conductor is 16 mm ², with M8 circular cable plugs at both ends and a tightening torque of 23.0 Nm; the torque of the four fastening screws for the XD30 connector of the motor cable is 3.0 Nm.

Safe operation

A1-A3 have mechanical end stops, but only for machine protection; Personnel protection relies on controller safety robot functions or mechanical axis limitations. The danger zone is equal to the workspace plus the stopping distance. The safety gate must be located outside the danger zone. Automatic mode requires all safety equipment and protective devices to be effective, and there should be no one in the danger zone. If the robot stops in automatic mode without reason, it must trigger an emergency stop before entering.

Manual mode T1 speed not exceeding 250 mm/s, used for teaching, programming, and program verification; T2 speed can exceed 250 mm/s, only for testing purposes, teaching and programming are not allowed. Maintenance and repair must comply with 5 safety rules: power off, prevent restart, confirm no power, ground short circuit, and cover adjacent live parts. After the controller is powered off, the voltage of 50-780V may remain for several minutes. Personnel with implants should maintain a distance of 300 mm from the motor/brake. External keyboard/mouse can only be used when the driver is turned off and there is no one in the danger zone. After modification, all programs must be tested in T1 first.

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.

Discontinuation, storage, and scrapping

Discontinue: Move into the transport position, remove tools and peripheral connections, disconnect motor cables, data cables, and grounding conductors, remove 8 hexagonal bolts, and lift vertically. Storage: Dry, dust-free, avoid temperature fluctuations, wind, condensation, sunlight, maintain allowable temperature. Cover with plastic film after cleaning, seal electrical and hose connections, and add desiccants if necessary. Scrap: Classified by material, metals include cast iron, copper, light alloys, and steel; Electrical components include motors and electronic parts; Plastics include ABS, NBR, PA, PE, PU, PUR; Auxiliary materials include gear oil and lubricating grease. The motor is not disassembled, and electronic components are recycled.