KUKA QUANTEC-2 PA maintenance troubleshooting

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 the emergency stop button, read the pressure gauge, and verify with the maintenance table requirements. 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 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.

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.

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: Fix the connecting rod arm with a sling, remove XM3 and XP3, hang A3 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.

The A5 and A6 motors are located on the wrist. A5 motor replacement: Remove XM5 and 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 A5, A6, T1 test. A6 motor replacement is similar, please note that the motor connector is located diagonally in the lower left corner and the compression spring is in good condition. To replace the rotating housing, it is necessary to first remove the A5 and A6 motors, then remove the rotating housing, install a new housing, and restore it in reverse order, and zero point calibrate A5 and A6.

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. Under KR C4, At 100% operating range, 100% POV, and maximum load, the stopping distance of A1 at STOP 0 is about 40.13 °, and the stopping time is about 0.65 s; A2 is about 16.26 °, 0.36 s; A3 is about 15.16 °, 0.26 s. The A1 of KR 180 R3200-2 PA is about 40.33 °, 0.69 s; A2 is about 15.74 °, 0.41 s; A3 is about 16.53 °, 0.33 s. The A1 of KR 240 R3200-2 PA is about 35.57 °, 0.72 s; A2 is about 17.89 °, 0.51 s; A3 is about 19.12 °, 0.43 s. At KR C5, the A1 of KR 140 R3200-2 PA is about 30.89 °, 0.59 s; A2 is about 13.04 °, 0.41 s; A3 is about 19.73 °, 0.31 s. The A1 of KR 180 R3200-2 PA is about 29.95 °, 0.62 s; A2 is about 12.93 °, 0.38 s; A3 is about 18.17 °, 0.40 s. The A1 of KR 240 R3200-2 PA is about 28.76 °, 0.58 s; A2 is about 15.46 °, 0.38 s; A3 is about 17.16 °, 0.41 s. In actual site conditions, regular retesting should be conducted based on load, speed, and brake wear, and it is recommended to check at least once a year.