KUKA KR QUANTEC PA series heavy-duty palletizing robot

Ground installation usually uses a foundation fixing device with a centering anchor. The quality of concrete foundation should reach C20/25, with a smooth surface and no insulation layer or mortar layer between the footboard and the foundation. Chemical anchor bolt construction should use the same manufacturer's rubber hose and anchor bolt, and diamond drill bits or coring drills should not be used. During installation, first fix the base plate and positioning pin, then place the robot on the foundation, drill 12 anchor bolt holes, install chemical anchor bolts, and connect the cables after curing. 8 M24x65-8.8 hexagonal bolts should be tightened step by step to 640 Nm. After running for 100 hours, they should be tightened again.

The rack fixing device is used for steel structures, installation brackets, or KUKA linear guides. The installation surface needs to be prepared according to the diagram, using two pins and two M8x55-8.8 hexagon socket screws with a torque of 23.9 Nm; then install eight M24x65-8.8 hexagon bolts and tighten them step by step to 640 Nm. When installing on the top or wall, it is also necessary to ensure that the bottom structure can withstand the foundation load.

Connecting cables and interfaces

The connecting cables include motor cables, data cables, and grounding wires. KR C4 uses Han 24 motor cable from X20 to X30, Han 3A Q12 data cable from X21 to X31, with a grounding wire of 16 mm ². KR C5 uses 6 motor plugs XD20.1 to XD20.6, 2 brake plugs XD10.1 and XD10.2 to XD30, and data cables XF21 to XF31. The cable length can be selected from 7 m, 15 m, 25 m, 35 m, and 50 m, with a maximum of 50 m and a maximum of one extension allowed. When fixed laying, the bending radius of motor cables should not be less than 150 mm, and that of data cables should not be less than 60 mm. The cables should be installed in metal cable trays, and the motor and data cables should be laid separately to avoid stretching, sharp edges, and tripping risks.

The grounding wire must be connected using a circular cable terminal, and low resistance connections are required on both sides of the robot base and controller. Check the equipotential connection according to VDE 0100 and EN 60204-1. Interface A1 is located on the back of the base and includes motor cable X30, data cable X31, grounding stud, and optional pipeline package interface. If the robot comes with a pipeline package, there may be additional air and cable interfaces between A1 to A5 and A5 to A6.

Oil change and maintenance cycle

The maintenance cycle is related to the working conditions. Under normal circumstances, check the tightening torque after 100 hours of operation; Lubricate the balance cylinder bearings every 5000 hours or at the latest 1 year, using approximately 10 cm ³ of LGE 2 grease; Check the balance cylinder pressure every 5000 hours, with a rated value of approximately 176 bar and a tolerance of ± 15 bar (20 ° C); Apply anti-corrosion grease to the cable bundle every 10000 hours; Replace gear oil every 20000 hours or no later than 5 years.

In terms of oil change volume, A1 is about 6.50 L; A2 is about 2.40 L at 120 kg wrist and about 2.90 L at 180/240 kg wrist; A3 is about 1.90 L at 120 kg wrist and about 1.80 L at 180/240 kg wrist; A5 is about 0.80 L; A6 is about 1.20 L. The standard model uses Optigear Synt. ALR 150, the arc model uses Optileb GT 1800/220, and the HO model uses food grade lubricants. If the oil temperature exceeds 60 ° C for a long time, the maintenance cycle should be shortened.

When changing the oil, the gearbox should be in a warm state. The emission amount depends on the discharge time and oil temperature, and the refilling amount should be consistent with the discharge amount. If the discharge amount is less than 70% of the specified oil amount, the reducer should be flushed with discharge oil; If it is less than 50%, it should be rinsed twice. Move the axis at a jog speed throughout the entire axis range during flushing. Tightening torque of magnetic plug: A1 is 25 Nm, A2 is 20 Nm, A3 is 20 Nm, A5 is 25 Nm, A6 has an upper part of 25 Nm and a lower part of 7.5 Nm. During operation, be careful of hot oil burns and oil chamber pressure, and exhaust before draining the oil.

Balance cylinder inspection and replacement

The balance cylinder is a hydraulic and pneumatic component between the turntable and the boom, used to reduce the torque of shaft 2. During inspection, manually run A2 to -90 °, wait for 1 minute, press emergency stop, and read the pressure gauge. The pressure should be 176 bar ± 15 bar at 20 ° C. If the pressure is abnormal, a dedicated pressure gauge should be used for retesting and KUKA service should be contacted. Check whether the corrugated pipe is dirty, damaged, or leaking, and clean or replace it if necessary.

Replacing the balance cylinder is a high-risk operation. The balance cylinder weighs about 40 kg and is under pressure. Wear protective gloves and secure with slings and cranes during homework to prevent falls and accidental movements. The steps include: loosening the threaded clamp and pushing back the corrugated pipe; Move the upper arm forward by -95 ° and install it into the spacer block; Move the boom in a negative direction to secure the spacer block; Fix the balance weight and boom with a sling; Remove the cover plate and turntable bolts; Use the bolt fixing component and the M16 bolt puller to pull out the bolt; Push the balance weight out of the turntable bolt; Lift it to a safe location. When installing a new balance cylinder, follow the reverse order. The torque of the cover plate bolt M12x30-10.9 is 104 Nm, and the torque of the stop washer bolt M8x20-10.9 is 31 Nm. After completion, check the pressure and put it back into operation.