KUKA KR QUANTEC-2 HC Maintenance and Rescue Guide

KUKA KR QUANTEC-2 HC Maintenance and Rescue Guide

KUKA KR QUANTEC-2 HC is a six axis articulated robot designed for medical environments, covering two models: KR 300 R2700-2 HC and KR 300 R2700-2 HC II. HC stands for Health Care, which means that the robot has added a patient rescue system, additional brakes, medical environment compliance declaration, and stricter safety logic on the basis of the standard QUANTEC-2 platform. For hospital equipment engineers, system integrators, and on-site maintenance personnel, mastering patient rescue operations, replacement of additional brakes, oil change cycles, and common fault troubleshooting are key to ensuring equipment availability and patient safety.

Model positioning and core differences

KR 300 R2700-2 HC and HC II both adopt a six axis articulated arm structure, with a rated load of 300 kg, a maximum arm span of 2701 mm, a body weight of about 1150 kg, a pose repeatability accuracy of ± 0.05 mm, a protection level of IP65, wrist IP65, and noise below 75 dB (A). The HC version supports KR C4 HC and KR C5 M6/M7 controllers, while HC II only supports KR C5 M6/M7. There is a slight difference in the axis data between the two: A4 for HC is infinite rotation, A6 is infinite rotation; The A4 of HC II is ± 350 °, A5 is ± 122.5 °, and A6 is infinite rotation. In terms of speed, A1 is about 105 °/s, A2 is about 100 °/s, A3 is about 105.4 °/s, A4 is about 135.8 °/s, A5 is about 113 °/s, and A6 is about 180 °/s.

The biggest difference from the standard QUANTEC-2 is the security architecture. The HC version is equipped with delayed additional brakes on the A2 to A5 axes as redundancy for the main brake. The additional brake is located between the motor and gearbox, providing holding and braking torque in the event of main brake failure. In addition, the HC version comes standard with a patient rescue system consisting of a storage box and a handheld device with an emergency stop button, which can manually move the robot by releasing the A1 or A1+A6 brake in case of power failure or emergency. The medical environment also requires compliance with RoHS and REACH declarations, and system integrators need to complete a risk assessment for medical use.

Operation and inspection of patient rescue system

The patient rescue system is used for manually moving robots in emergency situations, such as when a patient is stuck or requires emergency evacuation. The system consists of a storage box, handheld devices, emergency stop buttons, and connecting cables. When operating, first open the storage box cover, and the robot immediately triggers the safety STOP 1 and displays a confirmation message on the smartPAD. Take out the handheld device, pull up the emergency stop button, release the brake of A1 or A1+A6, and the shaft can be manually moved. Press the emergency stop button to reactivate the brake and manually move to stop.

Patient rescue can be performed with the controller turned on or off. If the controller is turned on, there is no need to re master after rescue; If the controller is turned off, all axes must be remade after rescue. The battery is the key to the rescue system, and the controller must be powered on for at least 24 hours before first use to ensure that the battery is fully charged. Battery failure will prevent rescue operations and must be replaced. The system integrator needs to ensure that the rescue system is always accessible during equipment operation. According to the maintenance table, patient rescue function testing should be performed at least once a year. Open the storage box cover during inspection, confirm that the robot stops and displays STOP 1, remove the handheld device, pull out the emergency stop button, confirm that the axis can be manually moved, press the emergency stop button, and confirm that the brake is restored. After the inspection is completed, run the program in T1 mode and observe for any abnormalities.

The function and replacement logic of the additional brake

The additional brake is installed on the A2 to A5 axes and belongs to the delayed action secondary brake. When the main brake (built-in to the motor) fails, the additional brake is responsible for maintaining and braking torque. When replacing the additional brake, the motor of the corresponding shaft must be removed first, and then the additional brake must be removed. Taking A2 as an example: first fix the connecting rod arm with a sling, remove motor A2, and then remove the additional brake A2; during installation, install the additional brake in reverse order, first install the additional brake, and then install the motor. The A3 axis needs to first fix the robot arm, then remove the motor A3, and then remove the additional brake A3. The replacement of the additional brake on the A4 and A5 axes is more complex, requiring the motor A4/A5 to be removed first, and then the additional brake to be removed. When installing, pay attention to the coordination between the connecting shaft and the compression spring.

All installation surfaces of additional brakes need to be cleaned, and a small amount of Microlube GL 261 grease should be applied to the teeth to prevent grease from entering the brake and affecting the braking effect. Tighten the bolts step by step in diagonal order to the specified torque, and apply white thread locking adhesive. When inserting the connector, pay attention to the coding element and rotate it to the buckle lock. After the replacement is completed, it is necessary to re master the relevant axes and test them in T1 mode.

Oil change cycle and oil quantity

The oil change cycle of the HC version is similar to that of the standard version, but it needs to refer to the maintenance table. The standard model lubricates the balance cylinder bearings every 5000 hours or at the latest 1 year, checks the balance cylinder pressure every 5000 hours, replaces the gear oil every 20000 hours or at the latest 5 years, and replaces the balance cylinder every 10 years. The maintenance cycle of the F variant is shorter, with lubrication and pressure checks every 2500 hours or 1 year, and oil changes every 10000 hours or 5 years.

Oil change amount: A1 about 5.70 L, A2 about 2.10 L, A3 about 1.40 L, A4 about 2.10 L, A5/A6 about 1.90 L. Use Optigear Synt. ALR 150 gear oil. When changing the oil, the gearbox should be at operating temperature, and the discharge amount depends on the discharge time and oil temperature. The refilling amount must be consistent with the emission amount. If the emission amount is less than 70% of the specified oil amount, it needs to be flushed once with discharge oil; If it is less than 50%, rinse twice. Move the axis within the full axis range at a jog speed during flushing. The tightening torque of the magnetic plug is 25 Nm for A1, 20 Nm for A2, 20 Nm for both the upper and lower parts of A3, 40 Nm for both the upper and lower parts of A4, and 20 Nm for A5/A6. When operating, pay attention to hot oil burns and oil chamber pressure, and exhaust before discharging.

When checking the balance cylinder, manually move A2 to -90 ° C, wait for 1 minute, press the emergency stop button, and read the digital sensor pressure: 176 bar ± 5 bar at 20 ° C. The deviation between the analog pressure gauge and the digital sensor should not exceed ± 10 bar. If the pressure is abnormal, please contact KUKA service and do not adjust it without authorization.

Key points for motor replacement

Before replacing the motor, it is necessary to comply with 5 electrical safety regulations: cutting off the power supply, locking to prevent restart, confirming no voltage, grounding and short circuiting, covering or isolating adjacent live parts. Simultaneously press the emergency stop button to prevent the robot from accidentally moving. When the motor is just stopped, the surface temperature is high and protective gloves should be worn; There is a risk of crushing during disassembly and assembly, and protective gloves should also be worn.

A1 motor replacement: Remove XM1 and XP1, unscrew 4 M12x25-8.8 screws, and lift out the motor. Clean the teeth before installing the new motor, apply a small amount of Microlube GL 261, and check the O-ring. Install 4 M12x25-8.8 screws and tighten them diagonally in steps. Connect plug, zero point calibration, T1 test.

A2 motor replacement: First, fix the connecting rod arm with a sling, remove XM2 and XP2, hang A2 motor, unscrew 4 M12x45-8.8 screws, and pull out the motor. Clean the teeth and apply lubricating grease during installation. Install 4 M12x45-8.8 screws and tighten diagonally. Connect the plug, remove the connecting rod arm stopper, calibrate the zero point, and conduct T1 testing.

A3 motor replacement: Secure the robot arm with a sling, remove XM3 and XP3, suspend the A3 motor, unscrew 4 M12x45-8.8 screws, and pull out the motor. Clean the teeth and apply lubricating grease during installation. Install 4 M12x45-8.8 screws and tighten diagonally. Connect the plug, remove the arm stopper, zero point calibration, T1 test.

A4 and A5 motor replacement: Remove the motor cover, unplug XM4/XP4 or XM5/XP5, unscrew 4 M8x40-8.8 screws, and remove the motor. Clean the teeth and apply lubricating grease during installation. Install 4 M8x40-8.8 screws and tighten diagonally. Connect the plug, zero point calibration A4, A5, A6, T1 test.

The replacement of A6 motor is the most complex, requiring the removal of A4 and A5 motors, additional brakes A4/A5, and then the wire harness wrist, followed by the removal of A6 motor. During installation, follow the reverse order and ensure that the motor connector is located diagonally in the lower left corner, and that the compression spring is in good condition. After completion, MAMES values need to be adjusted (KSS 8.3 requires KUKA. KristMamesOffset plugin), zero calibration A4, A5, A6, and T1 testing.

Common troubleshooting ideas

Patient rescue failure: Check if the battery is fully charged, if the storage box cover triggers STOP 1 normally, if the emergency stop button on the handheld device is reset, and if the connecting wires X25/XG25 are locked. If rescue is carried out after the controller is turned off, re mastering is required.

Additional brake alarm: Check if the additional brake connectors XBr2 to XBr5 are locked and if the brake is worn or stuck. After replacing the additional brake, it is necessary to re master the corresponding axis.

Abnormal balance cylinder pressure: Check the pressure gauge, digital sensor, leakage point, and bellows. When the pressure is below the allowable range, contact KUKA service and do not inflate it without authorization.

Communication interruption or RDC failure: Check if the X30/XD30, X31/XF31, X21/XF21 connectors are locked, if the cable bending radius is too small, and if the shielding and grounding are good.

Zero point loss: replace motor, add brake RDC、 After the encoder battery or collision occurs, it is necessary to recalibrate the zero point. After calibration, test under T1 first.

Stop distance becoming longer or brake noise: Check the wear, load, speed, and STOP 0 triggering times of the main brake and auxiliary brake. Replace the brake or motor if necessary.

Overheating or Overload: Check if the load data is entered correctly, if the tool's center of gravity and inertia exceed the limit, if the ambient temperature is too high, if the gear oil is aging, and if the maintenance cycle is overdue. If the oil temperature exceeds 60 ° C, the maintenance interval should be shortened.

Abnormal security function: All security functions must be tested regularly. Enable the switch to be checked at least once every 12 months. The patient rescue function is tested annually. After the safety function or protective device is disabled, it must be immediately restored and functional testing must be conducted.

Stopping distance and safety

The stopping distance and stopping time are related to the load, program multiplier, range of action, and type of shutdown. Under KR C4, the KR 300 R2700-2 HC stops at a distance of approximately 35.24 ° and a stop time of approximately 0.82 seconds for A1, 18.66 ° and 0.44 seconds for A2, and 15.79 ° and 0.32 seconds for A3 at 100% operating range, 100% POV, and rated load. Under KR C5, at STOP 0, A1 stops at a distance of approximately 22.12 ° and 0.58 seconds for A2, 11.69 ° and 0.35 seconds for A2, and 9.87 ° and 0.21 seconds for A3. Regular retesting should be conducted on site based on load, speed, and brake wear, and it is recommended to check at least once a year.

Storage and Disposal

Before long-term storage, move the robot to the transport position (A1 0 °, A2-135 °, A3 150 °, A4 0 °, A5-105 °, A6 0 °), remove tools and accessories, clean and dry, seal electrical interfaces and hose joints, cover with film and seal the base to prevent dust, and place desiccants if necessary. The storage environment should be dry, dust-free, and avoid temperature differences, wind, condensation, and direct sunlight.

When disposing of waste, materials are classified as cast iron parts, copper cables, light metal castings, steel parts, electronic components, motors, plastic parts, etc. Hydraulic and pneumatic balance cylinders must be professionally depressurized in advance and are only allowed to be disposed of in a non pressurized state. Gear oil, hydraulic oil, and lubricating grease should be handled according to the requirements of the safety data sheet.

Overall, the stable operation of KUKA KR QUANTEC-2 HC relies on standardized installation, regular inspection of patient rescue systems, timely maintenance of additional brakes, correct load data, regular oil changes, and balancing cylinder pressure checks. On site engineers should incorporate transportation posture, foundation fixation, grounding, oil change volume, torque value, patient rescue testing, and T1 testing into standard operating procedures to reduce downtime risks, extend robot lifespan, and ensure patient and operator safety in medical environments.