KUKA KR QUANTEC PA series heavy-duty palletizing robot

Motor replacement process

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 hexagon socket bolts, 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 and support ring. Install 4 M12x25-8.8 screws and tighten them diagonally in steps. Connect the plug, remove the stopper, calibrate the zero point, and conduct T1 testing.

A2 motor replacement: First, fix the boom with a sling, remove XM2 and XP2, hang A2 motor, unscrew 4 hexagon socket bolts, and pull out the motor. Clean the teeth and apply lubricating grease during installation. Install 4 M12x25-8.8 screws and tighten diagonally. Connect the plug, remove the arm stopper, zero point calibration, T1 test.

A3 motor replacement: Secure the forearm with a sling, remove XM3 and XP3, suspend A3 motor, unscrew 4 hexagon socket bolts, and pull out the motor. Clean the teeth and apply lubricating grease during installation. Install 4 M12x30-8.8 screws and tighten diagonally. Connect the plug, remove the forearm stopper, calibrate the zero point, and conduct T1 testing.

A5 motor replacement: Secure the wrist with a sling or base, remove XM5 and XP5, hang A5 motor, unscrew 4 hexagon socket head screws, and pull out the motor. Clean the teeth and apply lubricating grease during installation. Install 4 M10x30-8.8 screws and tighten diagonally. Connect the plug, remove the stopper, calibrate A5 and A6 zero points, and conduct T1 testing.

A6 motor replacement: Remove XM6 and XP6, unscrew 4 hexagon socket bolts, and lift the motor upwards. Clean the teeth and apply lubricating grease during installation. Install 4 M10x30-8.8 screws and tighten diagonally. Connect the plug, remove the tool stopper, calibrate A5 and A6 zero points, and conduct T1 testing. All motors must undergo zero point calibration and T1 trial operation after replacement.

Stop distance and stop time

The stopping distance and stopping time are related to the load, program multiplier, range of action, and type of shutdown. STOP 0 immediately closes the drive and the brake is applied; STOP 1 is to brake along the trajectory and turn off the drive after reaching a standstill. At 100% operating range, 100% POV, and rated load, the stopping distance of A1 is about 68.54 ° and the stopping time is about 1.02 s; A2 is about 32.64 ° and 0.61 s; A3 is about 40.09 ° and 0.53 s. The A1 of KR 180 R3200 PA is about 61.47 ° and 1.00 s; A2 is about 36.00 ° and 0.73 s; A3 is about 46.55 ° and 0.63 s. The A1 of KR 240 R3200 PA is about 57.23 ° and 1.01 s; A2 is about 24.26 ° and 0.54 s; A3 is about 35.21 ° and 0.49 s. 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.

Common troubleshooting ideas

On site troubleshooting should follow the principles of "safety first, power outage confirmation, record analysis, and step-by-step verification". Firstly, trigger the emergency stop, turn off the main switch and lock and tag, and confirm that the system has been discharged. Then check the controller diagnostic information, safety circuit, drive enable, RDC communication, encoder, and cable connections.

Unable to activate or emergency stop alarm: Check the enable switch, emergency stop button, safety door, light barrier, KCP/smartPAD connection. The disconnected smartPAD must be immediately removed from the system to avoid confusion. If an external keyboard or mouse is used, it must meet the requirements of driver shutdown, no one in the danger zone, and KCP/smartPAD cannot be used simultaneously.

Communication interruption or RDC failure: Check if the X20/X30, X21/X31, XF21/XF31 connectors are locked, if the cable bending radius is too small, and if the shielding and grounding are good. The arc type must use RDCool, and installing it incorrectly can cause abnormal operation.

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.

Abnormal balance cylinder pressure: Check the pressure gauge, leakage points, bellows, and seals. If the pressure is below the allowable range, KUKA service should be contacted and unauthorized pressurization is not allowed.

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.