Troubleshooting KUKA KR 1000 Titan

Installation foundation and transportation

The installation methods mainly include installing the base with centering C1300 and installing the machine frame. Install the base weighing approximately 1165 kg, using chemical anchor bolts and 12 M30x90-8.8-A2K hex bolts, with concrete strength of at least C20/25. There shall be no insulation layer or mortar layer between the base and the concrete. When using chemical anchor bolts, the drilling diameter should be 18 mm. Diamond tools or coring drills must not be used, and setting tools approved by the anchor bolt manufacturer must be used. The installation surface must be flat and filled with leveling material if necessary, but the area where the robot tightens the bolts must not be covered by leveling material. When installing the robot, gradually tighten the 12 M30 bolts in diagonal order to 1330 Nm. After running for 100 hours, they must be tightened again.

The machine frame is installed for steel structures and linear units, weighing approximately 3.52 kg, using 12 M30x90-8.8-A2K hex bolts, sword pins, and centering pins. The installation surface needs to be processed, with high flatness requirements. After installation, tighten to 1330 Nm and re tighten after 100 hours.

The robot must be moved to the transport position before transportation. The standard transportation positions are A1 0 °, A2-130 °, A3 130 °, A4 0 °, A5 90 °, A6 0 °. During forklift transportation, there are fork slots on the base, and the minimum load capacity of the forklift is 6 tons. If a transport frame is used, the minimum load capacity of the forklift or crane is 8000 kg, and the total weight of the robot and transport frame is about 5600 kg. Three lifting rings and three legged lifting devices are used during lifting, with leg markings G1 to G3. Vibration and impact should be avoided during transportation, and tools and additional equipment should be removed to prevent center of gravity deviation. The standard lengths of connecting cables are 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, and 50 m, with a maximum of 50 m and a maximum of one expansion allowed. The bending radius for the fixed laying of motor cables shall not be less than 150 mm, and for data cables shall not be less than 60 mm. Motor cables and data cables shall be laid separately, and EMC measures shall be taken if necessary.

Safety and Debugging Inspection

The danger zone consists of a workspace and a stopping distance. Mechanical end stop and optional mechanical axis limit are used to restrict the working range of A1 to A3. Before debugging, all safety functions must be checked, including emergency stop, enable switch, mode selection, safety door, external safety stop, and safety output. T1 is in manual deceleration mode, with a speed not exceeding 250 mm/s; T2 is manual high-speed mode; AUT is in automatic mode. New or modified programs must be tested under T1 first.

Five safety rules must be followed during maintenance and repair: power off, prevent accidental restart, confirm that the system is out of power, ground and short-circuit, cover or isolate adjacent live parts. Even if the controller is turned off, some components may still have a voltage of 50 V to 780 V for several minutes. The robot system must be disconnected from the main power supply and cannot rely solely on emergency stop or safe stop. Hot surfaces, oil pressure, nitrogen pressure, and extrusion risks should all be prevented. The motor and brake will generate electromagnetic fields, and personnel wearing implants should maintain a distance of 300 mm from the motor and brake. Unauthorized modifications may render warranty and liability invalid.

Before starting, the default password must be changed, and the robot installation, fastening, cable connection, grounding conductor, and equipotential connection must be checked. If there is a significant difference between the internal temperature of the controller and the ambient temperature, it is necessary to wait for temperature equilibrium to prevent condensation. If the robot is subjected to external forces such as collisions or impacts, it may cause invisible damage and the motor and balance system must be checked. Security features must be tested. The brake test must be performed regularly and the system will force it to be carried out, and it cannot be turned off. The balancing system belongs to pressure equipment and must be operated by qualified personnel. Before maintenance, the supported components must be fixed and depressurized.

Maintenance cycle and oil management

The maintenance cycle is based on technical data and operating conditions. Check the torque of the fastening bolts and nuts 100 hours after startup. Every 2000 hours or up to 6 months, lubricate the main bearings with 4 lubrication nozzles, A1 at 0 °,+30 °, and+60 ° positions, using LGEP 2, with a total usage of approximately 12 × 8 cm ³=96 cm ³. Check the balance system pressure every 6 months. If the oil pressure is lower than the set value of 5 bar, adjust or supplement Hyspin ZZ 46 hydraulic oil, and check the lead seal of the accumulator safety valve. Lubricate the rotating column and connecting rod bearings every 5000 hours or up to 1 year, using LGEV 2, with approximately 50 g per lubrication point.