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.

Key points of transportation and installation

The robot must be placed in the transport position before transportation. The transport poses of KR QUANTEC-2 K/P are A1 0 °, A2-115 °, A3-108 °, A4 0 °, A5 115 °, A6 0 °. Vibration and impact should be avoided during transport until the robot is securely fixed. When transporting by forklift, four fork slots are installed on the base, and the forklift can start from the front and rear sides. The minimum load capacity of the forks is about 2.0 tons. When using transportation lifting equipment, connect the two front fork slots and the rotating column, and arrange all lifting equipment 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. The top mounted robot can be transported in the transport frame and is in the correct direction.

Ground installation usually uses the S780 mounting base with centering. The base consists of a base plate, chemical anchor bolts, and fasteners, and requires a flat concrete foundation with sufficient bearing capacity. The recommended concrete grade is above C20/25. If there is an insulation layer or leveling layer between the bottom plate and the concrete, it must be in full contact and have sufficient compressive strength. The basic dimensions, margins, and concrete thickness need to be confirmed according to the drawing. Chemical anchor bolt construction must use the same manufacturer's resin and anchor bolt, and diamond drill bits or core drills should not be used. The drilling tools provided by the anchor bolt manufacturer should be prioritized. 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. Tighten 8 M24x65-8.8 hex bolts step by step to the specified torque. Optional 150mm mounting base S780 with 16 chemical anchor bolts.

Rack installation is used for steel structures, mounting brackets or KUKA linear guides, and can also be used for top mounting. The installation surface needs to be prepared according to the diagram, using two locating pins and eight M24x65-8.8 hexagonal bolts, and tightened step by step to the specified torque. During top installation, 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 16HP motor cable from X20 to X30 and Han 3A Q12 data cable from X21 to X31. 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 to 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 uses a circular cable terminal with an M8 nut torque of 23.0 Nm. The equipotential connection is checked according to VDE 0100 and EN 60204-1.

Interface A1 is located at the rear of the base and includes motor cable X30, data cable X31, grounding conductor, optional external shaft interfaces XP7.1 and XP8.1, and optional air path interface. The K-F cast version also includes PURGE gas interface. If the robot is equipped with a pipeline package, there may be additional air and cable interfaces between A1 to A3 and A3 to A6.

Oil change and lubrication

The maintenance cycle is related to the working conditions. Under normal circumstances, after 100 hours of operation, check the fastening bolts with a torque of 640 Nm. Lubricate the balance cylinder bearings every 5000 hours or at the latest 1 year using approximately 10 cm ³ of LGEP 2 grease; Check the balance cylinder pressure every 5000 hours; Replace gear oil every 20000 hours or no later than 5 years; Replace the balance cylinder every 10 years. The lubrication and pressure inspection cycle of the K-F casting version has been shortened to every 2500 hours or 1 year, and the oil change cycle is every 10000 hours or 5 years. If there is frequent short distance exercise, the maintenance interval can be shortened to 3000 hours.

In terms of oil change volume, A1 floor mount is about 6.30 L, A1 top mount is about 8.80 L, A2 is about 2.90 L, A3 is about 1.40 L, A4 is about 2.10 L, A5/A6 is about 1.40 L (wrist ZH210 or ZH120 HV400) or 1.90 L (wrist ZH300). The K-F cast version A5/A6 is approximately 1.40 L (wrist ZH210 F) or 1.90 L (wrist ZH300 F). The standard model uses Optigear Synt. ALR 150 gear oil. 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 both up and down, A4 is 40 Nm both up and down, A5/A6 is 20 Nm. When operating, pay attention to hot oil burns and oil chamber pressure, and exhaust before draining the oil. Top mounted robot A1 requires the use of oil discharge hoses and quick couplings for oil change.

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.

Common troubleshooting ideas

Abnormal balance cylinder pressure: Check the pressure gauge, leakage points, bellows, and clamps. The pressure for ground mounted robots should be 168 bar ± 15 bar, and for top mounted robots it should be 273 bar ± 15 bar. When the pressure is below the allowable range, contact KUKA service and do not inflate it without authorization.

Gear oil leakage or abnormal oil quality: Check the magnetic plug, seal, oil pipe, and reducer joint surface. Confirm that the oil product is Optigear Synt. ALR 150 when changing the oil. Check the oil level and replenish or replace it if necessary.

Connector not locked: Check connectors such as X30/XD30, X31/XF31, XF21, X21, etc. The data cable is correctly locked and closed with a buckle, and the motor cable needs to be inserted with 4 fastening screws with a torque of 3.0 Nm.

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.

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.

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.

Unique faults of K-F casting version: Check whether the PURGE air circuit pressure is 0.3 bar ± 10%, whether the compressed air is oil-water separated, and whether the air circuit interface is sealed. Does the wrist thermal load exceed the limit of 10 s/min at 180 ° C.

Storage and Disposal

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, connecting rod arm, arm, wrist; Copper is used for cables; Light metal castings are used for the housing of spur gearboxes and rotating housings; Steel is used for gearboxes, bolts, washers, connecting shafts, and bearings; Electronic components such as RDC 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, the release device can be used to manually move the robotic arm after an accident or malfunction, covering motors A1 to A5. A6 motor cannot be used due to being inaccessible. PURGE options A/B/C/D can be selected according to the on-site environment for compressed air pretreatment and pressure regulation. 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-2 K/P 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.