KUKA QUANTEC-2 K/P Maintenance Troubleshooting Guide

KUKA QUANTEC-2 K/P Maintenance Troubleshooting Guide

KUKA KR QUANTEC-2 K and KR QUANTEC-2 P are six axis articulated robots designed for palletizing, handling, processing, and assembly scenarios. The K series is a rack mounted robot, the P series is a palletizing robot, and it has evolved into the K-F casting version and the P-C top mounted version. This product family covers KR 120 R3500-2 P、KR 120 R3500-2 P-C、KR 120 R3900-2 K、KR 180 R3500-2 K、KR 180 R3500-2 K-F、KR 210 R3300-2 K、KR 210 R3300-2 K-F、KR 270 R3100-2 K、KR 270 R3100-2 K-F  Waiting for the model. For on-site engineers, mastering the transportation posture, installation specifications, oil change cycle, balance cylinder pressure inspection, motor replacement, and common fault troubleshooting are key to ensuring the stable operation of the production line.

Model positioning and basic data quick search

The KR QUANTEC-2 K/P series adopts a six axis articulated arm motion system, which can control six axes. The differences between different models mainly lie in rated load, maximum arm span, and workspace. KR 120 R3500-2 P has a rated load of 120 kg, a maximum load of 180 kg, a maximum arm span of 3505 mm, a workspace of 150.5 m ³, a body weight of approximately 1281 kg, a pose repeatability accuracy of ± 0.05 mm, a protection level of IP65, and an optional IP67 for the wrist. The KR 120 R3500-2 P-C is a top mounted version with a workspace of 116.2 m ³ and a weight of approximately 1283 kg. The KR 120 R3900-2 K has a rated load of 120 kg, a maximum load of 146 kg, a maximum arm span of 3904 mm, a workspace of 211.3 m ³, and a weight of approximately 1280 kg. The KR 180 R3500-2 K has a rated load of 180 kg, a maximum load of 228 kg, a maximum arm span of 3505 mm, and a weight of approximately 1256 kg. The KR 180 R3500-2 K-F is a cast version with a protection level of IP65/IP67 and a weight of approximately 1256 kg. The KR 210 R3300-2 K has a rated load of 210 kg, a maximum load of 273 kg, a maximum arm span of 3305 mm, a workspace of 123.9 m ³, and a weight of approximately 1266 kg. KR 270 R3100-2 K has a rated load of 270 kg, a maximum load of 344 kg, a maximum arm span of 3105 mm, a workspace of 100.7 m ³, and a weight of approximately 1260 kg. KR 270 R3100-2 K-F is a cast version with a weight of approximately 1260 kg.

In terms of axis data, A1 has a motion range of ± 185 °, A2 is -120 °/70 °, A3 is -120 °/168 °, A4 ± 350 °, A5 is ± 122.5 ° or ± 125 °, A6 ± 350 °. In terms of speed, the KR 120 R3500-2 P has A1 of about 112 °/s, A2 of about 107 °/s, A3 of about 114 °/s, A4 of about 150 °/s, A5 of about 129 °/s, and A6 of about 219 °/s. The KR 180 R3500-2 K has A1 of about 105 °/s, A2 of about 101 °/s, A3 of about 110 °/s, A4 of about 150 °/s, A5 of about 180 °/s, and A6 of about 260 °/s. The KR 210 R3300-2 K has A4 of about 140 °/s, A5 of about 140 °/s, and A6 of about 219 °/s. The KR 270 R3100-2 K has A5 of about 113 °/s and A6 of about 180 °/s. The zero calibration positions are usually A1-25 °, A2-100 °, and A3 100 °. A4 0 °, A5 0 °, A6 0 °.

In terms of environmental conditions, the operating temperature of KR 120 R3500-2 P and P-C is 0 ° C to 40 ° C, and the storage and transportation temperature is -40 ° C to 60 ° C. The operating temperature of other models is 0 ° C to 55 ° C. Low temperature operation may require preheating and avoid condensation and frost. The K-F casting version has added 0.3 bar in arm overpressure, compressed air for oil-water separation, 6 mm air interface, and 180 ° C wrist thermal load tolerance, and adopts special coatings and protective varnish. ESD requirements comply with IEC 61340-5-1 and ANSI/ESD S20.20. The noise level is below 75 dB (A).

Safety logic and homework prerequisites

KR QUANTEC-2 K/P 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.