KUKA CYBERTECH maintenance troubleshooting

KUKA CYBERTECH maintenance troubleshooting

The KUKA KR CYBERTECH series is a six axis articulated robot designed for medium to high load handling, machining, and casting applications, covering KR 8 R2010、KR 12 R1810、KR 16 R1610、KR 16 R2010、KR 20 R1810、KR 20 R1810 F  And models such as KR 22 R1610. This series is usually paired with KR C4 or KR C5 S6/S7 controllers, with a protection level of IP65, and the wrist part can reach IP67. The cast version KR 20 R1810 F also adds positive pressure, PURGE air path, heat-resistant silver paint, and special anti-corrosion coating inside the arm to adapt to dust, coolant, and water vapor environments. For on-site engineers, the real tricky problem is often not "replacing a component", but how to determine the root cause of the fault within the shutdown window and complete the replacement, calibration, and testing according to specifications. Below, we will discuss several aspects including stopping distance, common faults, planned maintenance, involute teeth, oil change, cable group lubrication, and special maintenance for F variant.

First, consider safety and stopping distance

This series of hazardous areas consists of both workspace and stopping distance. The stopping distance is not a fixed value, it is affected by program magnification, load, extension distance, and brake wear. Taking STOP 0 as an example, the A1 stop distance of KR 8 R2010 is about 29.37 °, A2 is about 25.60 °, A3 is about 21.00 °, corresponding to stop times of about 0.24 s, 0.24 s, 0.19 s; The A1 of KR 12 R1810 is about 26.49 °, A2 is about 29.71 °, A3 is about 28.26 °, and the time is about 0.23 s, 0.28 s, 0.23 s; The A1 of KR 16 R1610 is about 25.36 °, A2 is about 23.81 °, A3 is about 22.84 °, and the time is about 0.22 s, 0.24 s, 0.19 s; The A1 of KR 16 R2010 is about 26.72 °, A2 is about 22.74 °, A3 is about 20.34 °, and the time is about 0.26 s, 0.26 s, 0.38 s; The A1 of KR 20 R1810 and KR 20 R1810 F is about 16.27 °, A2 is about 17.61 °, A3 is about 27.24 °, and the time is about 0.23 s, 0.19 s, 0.26 s; The A1 of KR 22 R1610 is about 18.15 °, A2 is about 19.64 °, A3 is about 24.49 °, and the time is about 0.18 s, 0.22 s, 0.22 s. STOP 1 varies with program magnification and mass, and the corresponding curve needs to be checked. If it is found on site that the robot's sliding after braking has significantly increased, there is abnormal braking noise, and there is repeated positioning drift, the first reaction should not be to change the program, but to check the brake wear and stopping distance. It is recommended to retest the stopping distance at least once a year, especially under frequent triggering of STOP 0, high cycle, and high load conditions.

Strict habits must be formed for safe operation: switch T1 before entering the danger zone, press emergency stop, cut off the main switch and lock it; If it is necessary to debug in the powered on state, it can only run at low speed T1 and ensure emergency stop at any time. After the robot loses power, the power components may still be charged for a short period of time. Wait for at least 5 minutes and verify the power. The motor and brake will generate electromagnetic fields, and personnel wearing active implants such as pacemakers should maintain a distance of at least 300 mm. The surface temperature of the motor is high, and protective gloves must be worn when replacing or inspecting it. When it comes to electrical operations, strictly follow the five safety rules: power off, prevent accidental restart, confirm no power, ground short circuit, and block adjacent live parts; After the work is completed, restore in reverse order.

Common faults and troubleshooting ideas

The stopping distance increases or the braking is abnormal

Performance: Stop position deviation, increased collision risk, and abnormal braking sound in automatic mode.

Reason: Brake wear, incorrect input of load data, high program magnification, external axis stacking motion.

Processing: Verify the load data in the controller, including mass, center of gravity Lx/Ly/Lz, moment of inertia Ix/Iy/Iz, and A/B/C directions; Verify with KUKA Load; Check the brake system; Retest the stopping distance. If there is a change in load or supplementary load, it must be re inputted, not based solely on experience.

Wear of involute teeth or abnormal motor noise

Performance: A1 to A6 motion jitter, increased reverse clearance, and high motor temperature.

Reason: Insufficient lubrication of the teeth, aging of the O-ring, improper installation of the motor, and long-term high load.

Solution: Check the involute teeth according to the maintenance table. Clean the teeth and check for wear and tear; If the teeth are damaged, the input shaft of the motor or gearbox must be replaced, and the replacement of the gearbox input shaft requires contacting KUKA Service. Apply Microlube GL 261 to the teeth, thin and continuous, about 2 g. Check the O-ring and replace it if it is damaged.

Gear oil leakage or abnormal oil level

Performance: There are oil stains near A1, A2, A3, A4, A5/A6, and the temperature is high during operation.