KUKA LBR iiwa CR Cleanroom Troubleshooting and Maintenance

In terms of modes: T1 manual deceleration, T2 manual high-speed, CRR cooperative mode, AUT automatic. The maximum speed of T1 is 250 mm/s. The speed does not decrease during manual guidance, but is limited by safety speed monitoring. In T1, T2, and CRR, the robot movement can only be initiated by pressing and holding the enable switch. Automatic mode requires all safety equipment and protective devices to be functioning properly, with no one in the system, or to meet the EN ISO 10218 collaboration requirements.

Stop distance: STOP 0 reference value and verification

The technical data provides a reference value for STOP 0. LBR iiwa 7 R800 CR: A1 stopping distance 5.193 °, time 0.182 s; A2 5.092 °, 0.212 s; A3 8.091 °, 0.166 s; A4 7.538 °, 0.114 s. LBR iiwa 14 R820 CR: A1 5.742 °, 0.188 s; A2 5.998 °, 0.200 s; A3 9.323 °, 0.198 s; A4 3.162 °, 0.092 s. These values show a 100% extension POV 100%、 Measured under maximum load conditions, only applicable to single axis motion; The overlapping axis motion may be longer.

The stopping distance is part of the danger zone and must be physically isolated. The actual stopping distance is affected by braking torque, load, and extension POV、 Brake wear affects. It is recommended to check the stopping distance at least once a year. Axis specific or Cartesian workspace monitoring can be triggered through safety monitoring, and measurement data can be evaluated using a Data Recorder. If the stopping distance significantly increases, the brake, load configuration, speed monitoring, and safe stopping category should be checked.

Debugging and Security Testing

Before the first debugging or re debugging, the system must be checked for completeness, safe operation, and no damage. Before starting, the user group password must be changed and transmitted to the controller through the installation program for activation. The password can only be provided to authorized personnel. Functional testing includes: correct installation of the robot, no foreign objects, no loose parts, complete safety equipment, matching power levels, correct grounding and equipotential, and locked connection cables.

Security function testing must cover all security oriented functions. Emergency stop test: Press the emergency stop button, and the teaching pendant will display that the emergency stop has been triggered without displaying any errors in the emergency stop device. Enable switch test: When moving the robot in test mode and releasing the enable, the movement must stop and no enable device errors must be displayed. The full press test must also be stopped. Key switch test: Turn right and return to the correct position without any error. Safety output shutdown capability test: When the controller is powered off and then back on, there must be no safety output errors.

Braking test is used to check whether each axle brake provides sufficient torque. Unless the risk assessment proves that brake failure will not result in unacceptable risks, brake testing must be performed on each axle during start-up and re commissioning; Do it once a day during operation. If the startup is incomplete, alternative measures must be taken and recorded, such as installing safety fences, posting warning signs, and locking the main switch.

Maintenance and Cleaning

Maintenance plan: Check the bolts after 100 hours of operation, with a torque of 23 Nm for 7 R800 CR and 45 Nm for 14 R820 CR, to be executed only after the first installation. Visually inspect and listen to the fan running noise after 1 year. When the ambient temperature is 25 ° C, replace the fan after 3 years. Fan replacement can only be carried out through negotiation between authorized maintenance personnel and KUKA customer service.

Only cleanroom approved cleaning agents and tools, such as cleanroom cloths, can be used for cleaning. Corrosive cleaning agents, steam, refrigerants, and high-pressure cleaning are prohibited. Do not allow cleaning agents to enter electrical or mechanical components. Cleaning steps: Turn off the robot, if necessary, close and lock adjacent systems, clean the robot, thoroughly remove cleaning agents, clean the workspace, dispose of cleaning agents properly, install and inspect safety equipment, replace damaged or unreadable signs and covers, and only resume operation if they are completely normal. The painted surface can only come into contact with cleaning agents for a short period of time.

Common troubleshooting tree

Unable to enable: Check the emergency stop circuit, enable the middle position of the switch, key switch, whether smartPAD is uniquely assigned, safety signal for the safety door operator, external emergency stop, cable locking, and controller diagnostic information.

Frequent safety stops: check if the enable switch is released or fully pressed, if the operator's safety signal is lost, if there is an external safety stop, if there is an error in the safety controller, if there is a mode switch, if there is a manual guide to release the enable, if the speed exceeds 250 mm/s.

Fan alarm or cleanroom level non-compliance: Check if the fan is started, Out7.Output mapping, In1.Input feedback, if the speed is below 2200 rpm, if it has decreased by 25%, if the exhaust duct is connected, if the exhaust system is active, if the fan noise and operating time exceed 3 years.