KUKA QUANTEC-2 HO Maintenance Guide

A3 motor replacement: Secure the robot arm with a sling, remove XM3 and XP3, suspend the A3 motor, unscrew 4 M12x25-8.8 screws, and pull out the motor. Pay attention to the installation of protective tube A3. Clean the teeth, apply lubricating grease, install screws, and tighten diagonally during installation. Connect the plug, remove the stopper, calibrate the zero point, and conduct T1 testing.

A4 and A5 motor replacement: Remove XM4/XP4 or XM5/XP5, unscrew 4 M8x25-8.8 screws, and take out the motor and connecting shaft. Check the compression spring. If there is a retaining ring when removed, it must not be reused. Clean the teeth during installation, apply lubricating grease, push the connecting shaft into the motor shaft, install 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 disassembly of A4 and A5 motors, connecting shafts, wire harness wrist, and then A6 motor. The harness wrist weighs approximately 100 kg and must be securely fixed with a crane. 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. 20 M10x200-10.9 screws are alternately tightened step by step. After completion, zero point calibration A4, A5, A6, T1 testing.

Cleaning and anti-corrosion

The food environment has high requirements for cleanliness. Turn off the controller before cleaning, and if necessary, turn off and lock adjacent devices. Remove the necessary casing and clean the robot with a neutral cleaner. After cleaning, thoroughly remove any residue of the cleaning agent, clean the corroded area, and reapply the anti-corrosion coating. Reinstall safety devices and enclosures. Cleaning agents must not enter electrical or mechanical components, high-pressure cleaners must not be used, and compressed air must not be used to clean bearings and sealing points. After cleaning, test run in T1 mode and observe for any abnormalities.

Common troubleshooting

CBS HO filter blockage: manifested as pressure fluctuations in the balance cylinder, poor breathing, or leakage. Check the color of the filter and replace it if it turns black. Check if the coupling is loose and if the valve cover is sealed.

Gear oil error: Cassida Fluid GL150 must be used for HO type. If the standard ALR 150 is misused, it can lead to food compliance risks and a mismatch in lubrication performance. Confirm the label and oil type when changing the oil. Check the oil level, leaks, and oil quality.

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

Connector not locked: Check connectors such as X30/XD30, X31/XF31, XF21, X21, etc. The data cable is correctly locked and closed with a buckle, and the motor cable needs to be inserted with 4 fastening screws with a torque of 3.0 Nm.

Zero point loss: replace the motor RDC、 After the encoder battery or collision occurs, it is necessary to recalibrate the zero point. After calibration, test under T1 first, and then gradually restore automatic operation.

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.

Improper cleaning leads to corrosion: Check the type of cleaning agent and confirm that there is no chlorine or strong acid or alkali. After cleaning, remove any residue and apply a new anti-corrosion layer. Check the seals and surface coatings.

Abnormal security function: All security functions must be tested regularly. Enable the switch to be checked at least once every 12 months. 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. At 100% operating range, 100% POV, and rated load, the stopping distance of A1 at STOP 0 is about 41.52 ° and the stopping time is about 0.72 s; A2 is about 18.28 ° and 0.46 s; A3 is about 14.86 ° and 0.30 s. The stopping distance and time of A1 at KR 240 R2900-2 HO are about 32.41 ° and 0.66 s; A2 is about 16.20 ° and 0.43 s; A3 is about 17.04 ° and 0.37 s. The stopping distance and time of STOP 1 vary with POV and load, and should refer to the corresponding chart. The actual site should be retested regularly based on load, speed, and brake wear, and it is recommended to check at least once a year.

In terms of safety, KR QUANTEC-2 HO belongs to incomplete machinery and must be integrated into a complete system and meet the EU Machinery Directive before it can be put into operation. The hazardous area consists of both the workspace and the stopping distance. The safety protection device must be located outside the danger zone. Manual mode is divided into T1 and T2. T1 is used for setting, teaching, programming, and program verification, while T2 is only used for testing that requires a speed higher than T1. Automatic mode requires all safety protection devices to function properly, with no one in the hazardous area, or to meet the EN ISO 10218 cooperation requirements. Priority should be given to working outside of hazardous areas during maintenance. If it is necessary to enter, the robot should be turned off and locked with a tag. After the controller is turned off, some components may still carry a voltage of 50V to 780V for several minutes, and must wait for discharge and comply with ESD regulations. The balance cylinder belongs to pressure equipment, and the pressure status must be confirmed before operation and operated by professional personnel.