Troubleshooting KUKA KR 1000 Titan

KUKA KR 1000 titan and KR 1000 L750 titan maintenance and troubleshooting

KUKA KR 1000 titan and KR 1000 L750 titan are six axis articulated robots designed for ultra heavy load scenarios, covering models such as KR 1000 titan, KR 1000 titan F, KR 1000 L750 titan, KR 1000 L750 titan F. They are commonly used for handling large workpieces, loading and unloading heavy-duty machine tools, casting, heavy-duty assembly, and special processes. For on-site engineers, the real tricky problem is not "how to program", but how to quickly judge and restore the operation of the robot in a hierarchical manner without compromising safety integrity when there is abnormal pressure in the balance system, abnormal noise in the wrist, gear oil leakage, wear on the straight wrist teeth, motor overheating, or safety circuit shutdown.

Product positioning and core structure

The KR 1000 titan adopts a six axis articulated arm structure, with main components including a linear wrist, arm, connecting rod, rotating column, base, balance system, electrical installation, and connecting cables. The linear wrist consists of three axes A4, A5, and A6, which are driven by a motor installed at the rear end of the arm through a transmission shaft. The wrist gearbox is supplied with oil from three independent oil chambers. The rotation range of A5 is limited by the mechanical end stop. The F variant is designed for harsh environments such as casting, with pressure applied inside the arm to prevent moisture and dust from entering. The wrist is coated with heat-resistant reflective silver paint, and the entire machine has a special paint surface and transparent protective coating.

The arm is connected to a straight wrist and a connecting rod, and A3 to A6 motors and transmission shafts are installed internally. The connecting rod is located between the arm and the rotating column, with a gearbox on each side, driven by two motors through the input stage. Install A1 and A2 motors inside the rotating column. The base is connected to the installation base, and the internal layout includes electrical installation and energy supply interfaces. Forklift slots are also provided on the base for easy transportation. The balancing system is installed between the rotating column and the connecting rod, using a closed hydraulic pneumatic system consisting of two diaphragm accumulators, hydraulic cylinders, hoses, pressure gauges, and safety valves, used to balance the A2 axis load torque. The accumulator is filled with nitrogen gas, and when the connecting rod is vertical, the balance system has the smallest effect. The greater the deflection, the hydraulic oil is pressed into the accumulator, generating reactive force compensation.

The electrical installation includes motor cables and control cables from A1 to A6, all of which are plug-in connections. The RDC box, multifunctional housing, and connector are installed on the push in module of the base. Connect the cable from the controller to the robot, with a grounding conductor cross-sectional area of 16 mm ² and M8 ring terminals at both ends. The F variant also needs to be connected to compressed air, with an initial pressure regulator set at 0.01 MPa. The compressed air should be oil-free and water free, in compliance with ISO 8573-1:2010 7:4:4, and consume approximately 0.1 m ³/h.

Technical data and load foundation

KR 1000 Titan has a rated load of 1000 kg, a maximum load of 1000 kg, a maximum arm span of 3202 mm, a body weight of approximately 4690 kg, a workspace of approximately 79.8 m ³, a repeatability accuracy of ± 0.1 mm, a protection level of IP65, an F-variant wrist IP67, and a noise level of less than 75 dB (A). KR 1000 L750 Titan has a rated load of 750 kg, a maximum load of 750 kg, a maximum arm span of 3601 mm, a body weight of approximately 4740 kg, and a workspace of approximately 122.6 m ³. The weight of the F variant is approximately 4750 kg. The controller can be equipped with KR C5 L6/L7, KR C4, or KR C2 edition2005.

Axis motion range: A1 ± 150 °, A2-130 °/17.5 °, A3-110 °/145 °, A4 ± 350 °, A5 ± 118 °, A6 ± 350 °. Speed under rated load: A1 58 °/s, A2 50 °/s, A3 50 °/s, A4 60 °/s, A5 60 °/s, A6 72 °/s. In terms of flange load, during normal operation, the axial force F (a) is about 11200 N, the radial force F (r) is about 15000 N, the tilting moment M (k) is about 3300 Nm, and the flange moment M (g) is about 5400 Nm. Under emergency stop conditions, F (a) is about 12650 N, F (r) is about 24750 N, M (k) is about 9350 Nm, and M (g) is about 8050 Nm. Tools and loads must be able to withstand these forces and moments for a long time. The load data must be input into the robot controller, and path planning will consider the load. The mass inertia must be verified by KUKA Load.

Install flange with a diameter of 200 mm, thread M16, quantity 16, minimum screw depth of 24 mm, maximum screw depth of 25 mm, screw grade 10.9, positioning element 12 H7. In terms of foundation load, the normal vertical force F (v) is about 61500 N, maximum 70000 N; the horizontal force F (h) is normal 21400 N, maximum 35500 N; the tilting torque M (k) is normal 102200 Nm, maximum 133700 Nm; the torque M (r) around A1 is normal 36600 Nm, maximum 99700 Nm. The foundation must withstand these loads for a long time. The supplementary loads on A1 and A2 are not included in the calculation of foundation loads and must be taken into account as vertical forces.