KUKA QUANTEC-2 K/P Maintenance Troubleshooting Guide

Balance cylinder inspection and replacement

The balance cylinder is a hydraulic and pneumatic component between the turntable and the connecting rod arm, 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 ground mounted robot should have a pressure of 168 bar ± 15 bar at 20 ° C, while the top mounted robot KR 120 R3500-2 P-C should have a pressure of 273 bar ± 15 bar. If the pressure is abnormal, a dedicated pressure gauge should be used for retesting and KUKA service should be contacted. Check if the attachments are dirty, damaged, or leaking, and clean or replace them if necessary. Check the bellows and clamps, and replace them by professionals 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 for replacing the ground mounted robot include: loosening the threaded clamp and pushing back the corrugated pipe; Move the connecting rod arm forward and install it into the locking pin; Move the connecting rod arm in the negative direction to make the piston lightly touch the locking pin; Fix the balance cylinder and connecting rod arm with a sling; Remove the cover plate and turntable bolts; Use a bolt fastener and a bolt puller to remove the bolt; Push the balance cylinder out of the turntable bolt; Lift it to a safe location. Install the new balance cylinder in reverse order. After completion, check the pressure and put it back into operation. When replacing the top mounted robot, it is necessary to first drain the hydraulic oil until the pressure gauge reading is zero, and then follow similar steps for disassembly and installation.

Motor and wrist replacement

Before replacing the motor, it is necessary to comply with electrical safety regulations: cut off the power supply, lock and prevent restart, confirm no voltage, ground and short-circuit, cover or isolate 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 M12x25-8.8 screws, 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. Install the screws and tighten them diagonally step by step. Connect plug, zero point calibration, T1 test. The K-F casting version also requires inspection of the installation surface seals.

A2 motor replacement: First, fix the connecting rod arm with a sling, remove XM2 and XP2, hang A2 motor, unscrew 4 M12x25-8.8 screws, and pull out the motor. Clean the teeth, apply lubricating grease, install screws, and tighten diagonally during installation. Connect the plug, remove the stopper, calibrate the zero point, and conduct T1 testing.

A3 motor replacement: Secure the robot arm with a sling, remove XM3 and XP3, suspend the A3 motor, unscrew 4 M12x25-8.8 screws, and pull out the motor. Pay attention to the installation of protective tube A3. Clean the teeth, apply lubricating grease, install screws, and tighten diagonally during installation. Connect the plug, remove the stopper, calibrate the zero point, and conduct T1 testing.

A4 and A5 motor replacement: Remove XM4/XP4 or XM5/XP5, unscrew 4 M8x25-8.8 screws, and take out the motor and connecting shaft. Check the compression spring. If there is a retaining ring when removed, it must not be reused. Clean the teeth during installation, apply lubricating grease, push the connecting shaft into the motor shaft, install screws, and tighten diagonally. Connect the plug, zero point calibration A4, A5, A6, T1 test.

The replacement of A6 motor is the most complex, requiring the disassembly of A4 and A5 motors, connecting shafts, wire harness wrist, and then A6 motor. The harness wrist weighs approximately 100 kg and must be securely fixed with a crane. During installation, follow the reverse order and ensure that the motor connector is located diagonally in the lower left corner, and that the compression spring is in good condition. 20 M10x200-10.9 screws are alternately tightened step by step. After completion, MAMES values need to be adjusted (KSS 8.3 requires KUKA. KristMamesOffset plugin), zero calibration A4, A5, A6, and T1 testing.

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. KR 120 R3500-2 P, under 100% operating range, 100% POV, and rated load, at STOP 0, the stopping distance of A1 is about 25.66 ° and the stopping time is about 0.70 s; A2 is about 24.64 ° and 0.52 s; A3 is about 19.09 ° and 0.35 s. The A1 of KR 120 R3900-2 K is about 31.78 ° and 0.68 s; A2 is about 19.28 ° and 0.68 s; A3 is about 18.44 ° and 0.61 s. The A1 of KR 180 R3500-2 K is about 33.80 ° and 0.75 s; A2 is about 26.00 ° and 0.64 s; A3 is about 18.85 ° and 0.58 s. The A1 of KR 210 R3300-2 K is about 44.03 ° and 0.83 s; A2 is about 24.54 °, 0.50 s; A3 is approximately 25.54 °, 0.58 s. KR 270 R3100-2 K's A1 is approximately 29.22 °, 0.66 s; A2 is approximately 19.51 °, 0.55 s; A3 is approximately 16.83 °, 0.37 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.