KUKA KR QUANTEC PA series heavy-duty palletizing robot

KUKA KR QUANTEC PA series heavy-duty palletizing robot

The KUKA KR QUANTEC PA series is a medium to high load robot designed for palletizing, handling, food processing, and low-temperature environments. The common models in this series include KR 120 R3200 PA, KR 180 R3200 PA, KR 240 R3200 PA, and are derived from HO and Arctic models. HO type is aimed at the food related industry, using special gear oil and higher rust prevention protection; The Arctic model is designed for the low-temperature freezing industry, with an operating temperature range of -30 ° C to 10 ° C, and is equipped with low-temperature adapted electrical equipment and RDCool. For on-site engineers, mastering transportation posture, foundation fixation, oil change cycle, balance cylinder pressure inspection, motor replacement, and troubleshooting are key to ensuring stable operation of the production line.

Quick search for model and basic data

KR QUANTEC PA adopts a 5-axis articulated arm motion system, which can control up to 4 axes. The main differences between different models are rated load and cycle time. KR 120 R3200 PA has a rated load of 120 kg, a maximum arm span of 3195 mm, a body weight of approximately 1075 kg, a pose repeatability accuracy of ± 0.06 mm, a protection level of IP65, and a noise level below 75 dB (A). The controller can be selected as KR C4 or KR C5 M6/M7. KR 180 R3200 PA has a rated load of 180 kg, a weight of approximately 1093 kg, and approximately 27.6 cycles per minute. KR 240 R3200 PA has a rated load of 240 kg, a weight of approximately 1103 kg, and approximately 25.6 cycles per minute. All three workspaces have a volume of 77.9 m ³ and are installed on the ground, with a permissible inclination angle of ± 5 °.

In terms of axis data, A1 has a motion range of ± 185 °, A2 is -140 °/-5 °, A3 is 0 °/155 °, and A4 to A6 are ± 350 °. The rated load speed of KR 120 is approximately A1 124 °/s, A2 115 °/s, A3 112 °/s, A4-A5 217 °/s, A6 242 °/s; the speed of KR 180 and KR 240 is slightly lower. The zero calibration positions are A1-20 °, A2-120 °, A3 120 °, A4-A5 90 °, A6 0 °. The load center of gravity and inertia must be input into the controller, otherwise trajectory planning and dynamic performance will deviate from expectations.

The HO type and arc type have similar data to the standard type, but differ in oil and sealing materials. The Arctic type must use gear oil suitable for low temperatures and consider preheating when starting at low temperatures. When replacing RDC, only RDCool must be installed, otherwise abnormal driving performance and malfunctions may occur.

Safety logic and homework prerequisites

KR QUANTEC PA 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 system integrator is responsible for risk assessment, implementation of safety functions, CE labeling, and complete system operation manuals. The danger zone consists of a workspace and a stopping distance, where the stopping distance is equal to the reaction distance plus the braking distance. The safety protection device must be located outside the danger zone, but the robot stopping process may still be completed within the danger zone.

The manual operation mode is divided into T1 and T2. T1 is the manual slow debugging mode, with a speed not exceeding 250 mm/s, suitable for jogging, teaching, programming, and program verification. T2 is a manual quick debugging mode that allows for speeds exceeding 250 mm/s, but is only used for testing that requires speeds higher than T1. Teaching and programming are not allowed under T2. When multiple people enter a safe area, each person must be equipped with an enabling device, and everyone must be able to see the robot unobstructed and maintain mutual visibility. 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.

When maintaining and repairing, priority should be given to working outside of hazardous areas. When it is necessary to enter a dangerous area, the robot should be turned off and locked with a tag, and if necessary, it should be done under T1. The emergency stop device must remain effective. If the security function is temporarily disabled, it must be restored immediately after the work is completed. After the robot 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. For controllers with transformers, the transformer should be disconnected before operation. The balance cylinder belongs to pressure equipment, and the pressure status must be confirmed before operation and operated by professional personnel.

Key points of transportation and installation

The robot must be placed in the transport position before transportation. The transport poses of KR QUANTEC PA are A1 0 °, A2-140 °, A3 150 °, A4-A5 80 °, A6 0 °. Vibration and impact should be avoided during transport until the robot is securely fixed. When transporting by forklift, the forks are inserted into the base forklift slot, with a minimum load capacity of about 2.0 tons. When using transport lifting equipment, connect the M16 lifting ring and slings G1, G2, G3. The slings must be arranged according to the diagram to prevent the robot from overturning or being damaged. It is prohibited to use cranes to lift robots in other ways.

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.

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.

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

Oil leakage: Check the magnetic plug, seal, oil pipe, and reducer joint surface. When replacing the seal, use spare parts of the same specification and tighten them according to the torque.

Abnormal noise or shaking during movement: Check the lubrication of the teeth, gear oil level, bearings, and flange connections. When cleaning the teeth, do not damage the tooth surface. Before installation, check if the teeth are damaged.

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.

Storage, Disposal, and Options

Before long-term storage, the robot should be moved to the transport position, tools and accessories should be removed, cleaned and dried, rust should be removed, electrical interfaces and hose joints should be sealed, covered with film and sealed at the base to prevent dust, and desiccants should be placed if necessary. The storage environment should be dry, dust-free, avoid temperature differences, wind, condensation, and direct sunlight, and maintain an allowable temperature range.

When disposing of waste, classify according to materials: cast iron parts such as base, turntable, and boom; Copper is used for cables; Light metal castings are used for wrist shells and gearbox shells; Steel is used for gearboxes, bolts, and washers; Electronic components such as RDC and EDS are recycled as electronic waste; The motor is scrapped as a whole and will not be disassembled. Plastic parts such as ETFE, PA, PE, PU, PUR, FKM, etc. shall be treated according to the material markings. 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.

In terms of options, single axis control cables can be used to control external axes, and the free rotation device can be used to manually move the robotic arm after accidents or malfunctions. The free rotation device covers motors A1 to A3 as well as A5 and A6, and is only used in emergency situations. After use, all axes must undergo zero point calibration, brake testing, and a trial run at T1.

Overall, the stable operation of KUKA KR QUANTEC PA relies on standardized installation, correct load data, regular oil changes, balance cylinder pressure checks, and timely troubleshooting. On site engineers should incorporate transportation posture, foundation fixation, grounding, oil change volume, torque value, and T1 testing into standard operating procedures to reduce downtime risks and extend the service life of robots.