KUKA KR SCARA HO Assembly and Maintenance

Startup and Debugging

Before starting, it should be confirmed that the robot has been correctly installed, all safety equipment is available, the power supply voltage is consistent with the nameplate, the grounding and equipotential connections are correct, and the connecting cables are locked. If there is a significant difference between the internal temperature of the controller and the ambient temperature, wait for temperature equilibrium to avoid condensation. The default password for system software must be changed before startup and only authorized personnel should be informed.

The usual debugging sequence is: installing the base; Install the robotic arm; Connect ground wires, air ducts, motor cables, and data cables; Check the equipotential; Installation tools; Start the system according to the controller operation instructions; Test run in T1 mode. When starting or restarting for the first time, all safety circuit functions should be checked to confirm that there is no damage, foreign objects, or loose parts. If the startup is incomplete, temporary alternative measures must be taken, such as safety fences, warning signs, main switch locking, etc.

Manual movement and brake release

The brake release button on the A2 interface can be used for axis 1 to axis 4. When the button is pressed, the four axis brakes are released, allowing for manual movement of the robotic arm; Release the button to restore the brake. When using, the load must be supported by hand to prevent it from falling off. Attention: Improper use of brake release while the robot is powered on or off may result in loss of mastering position and require recalibration.

For emergency movements after accidents or malfunctions, an optional brake release device can be used. The controller must be turned off and locked before operation. The steps are: unplug XD20.1 and XD20.2 from the controller; Insert the two connectors into the adapter box; Insert the adapter box X20 into the brake release device; Insert handheld device X1 into the brake release device; Select the axis to be released by selecting the switch; Press the handheld device button, release the brake, and the robotic arm can be manually moved. This operation is only for exceptional and emergency situations, such as rescue personnel. Do not stand below the motion axis during operation.

Maintenance plan and lubrication

Maintenance work can only be carried out according to the document description, and any work beyond the scope should be completed by KUKA training personnel. Before maintenance, power should be cut off, locked, and tagged, and emergency stop devices should be kept effective. If it is necessary to work with electricity, it can only be carried out in T1 mode and additional safety measures should be taken. After the controller is powered off, some components may still carry a voltage of 50 V to 780 V for several minutes and must wait for discharge. ESD regulations must be followed.

KR 6 maintenance plan: Check the tightening torque of the four screws on the installation base for 100 hours, only to be executed after the first start-up or re commissioning; Lubricate the A3/A4 spline shaft for 1500 hours using Kl ü bersynth UH1 14-151, approximately 5 g; replace the bellows for 4000 hours or at least annually, and visually inspect for wear and cracks. This task must be completed by authorized personnel from KUKA.

KR 13 maintenance plan: 100 hour inspection of 4 screws on the base; 1500 hours of lubrication for A3/A4 spline shaft, approximately 10g; 4000 hours or at least annual replacement of bellows, A3/A4 toothed belt, lubricating cable assembly, using Kl ü berfood NH1 34-401, approximately 20g; 20000 hours or at least every 5 years to replace A1 gearbox lubricant, using Cassida Fluid GL150, initial filling amount of approximately 0.31 L; annual inspection of base screws. The replacement of toothed belts and corrugated pipes must be completed by authorized personnel.

After maintenance, functional testing must be conducted to confirm that all safety functions are functioning properly. If the security function is disabled during maintenance, it must be restored immediately after the work is completed.

Common faults and troubleshooting ideas

The faults of KUKA KR SCARA HO are often related to safety circuits, connecting cables, load data, brake release, negative air pressure, and maintenance deficiencies. The following are common problems and solutions for engineering sites.

Possible causes and suggestions for handling the phenomenon

Robot unable to enable or move safety door, enabling device, T1/T2 mode, emergency stop circuit abnormality check safety circuit, confirm correct mode, test enabling device and emergency stop function

Error in connection of motor cable, data cable, and grounding conductor during startup. Check XD20.1/XD20.2, X30, XF21, X31 to confirm locking

Abnormal positioning or large vibration load data not input, load center of gravity too large, inertia moment exceeding limit. Input correct load data into the controller and check the load diagram

Motor overheating, high ambient temperature, high duty cycle, excessive load, frequent emergency stops. Check the ambient temperature, reduce the load or duty cycle, and confirm that the motor temperature does not exceed 95 ° C