Troubleshooting KUKA SCARA X

Troubleshooting KUKA SCARA X

The KUKA SCARA X series is a 4-axis SCARA robotic arm designed for small component handling, assembly, inspection, and loading/unloading scenarios, covering KR 6 R500 Z200 X、KR 6 R600 Z200 X、KR 6 R700 Z200 X、KR 10 R600 Z300 X、KR 10 R700 Z300 X、KR 10 R800 Z300 X  Waiting for the model. Unlike six axis articulated arms, the core of SCARA lies in fast positioning in the horizontal plane and Z-axis linear motion in the vertical direction. Therefore, on-site problems often focus on resonance, screw shaking, Z-axis limit, load inertia matching, abnormal stopping distance, and enable switch circuits. For engineers searching for solutions, what is really needed is a layered troubleshooting method: first look at the safety circuit, then look at the load and stop, then look at the machinery and screw, and finally look at the controller and periphery.

Product positioning and model coverage

KR SCARA X belongs to a 4-axis articulated arm robot. The robotic arm is mainly composed of a small arm, ball spline screw, large arm, base, wiring harness assembly, and electrical equipment. The controller adopts KR CS Box-2, and the teaching pendant is smartPAD touch. The rated load of this series is divided into two categories: KR 6 series has a rated load of 3 kg and a maximum load capacity of 6 kg; KR 10 series has a rated load of 5 kg and a maximum load capacity of 10 kg. The maximum range of motion ranges from 500 mm to 800 mm, and the Z-axis stroke is available in two types: 200 mm and 300 mm. All models have a protection level of IP20, are installed on the ground, and have a noise level below 75 dB (A).

The model coverage is as follows: KR 6 R500 Z200 X weighs about 17.3 kg, with a workspace volume of about 0.136 m ³ and a cycle time of about 0.38 s; KR 6 R600 Z200 X weighs about 18.25 kg, with a workspace of about 0.195 m ³ and a cycle time of about 0.39 s; KR 6 R700 Z200 X weighs about 18.9 kg, with a workspace of about 0.25 m ³ and a cycle time of about 0.40 s; KR 10 R600 Z300 X weighs about 26.8 kg, with a workspace of about 0.286 m ³ and a cycle time of about 0.41 s; KR 10 R700 Z300 X weighs about 27.7 kg, with a workspace of about 0.407 m ³ and a cycle time of about 0.43 s; KR 10 R800 Z300 00 X provides a larger horizontal arm span. In terms of repeatability accuracy, XY is ± 0.02 mm, Z is ± 0.01 mm, and R is ± 0.01 °. These parameters determine the advantages of SCARA in high-speed small item handling, and also determine that the load and inertia must be strictly checked.

Axis data and motion range

The motion range of KR 6 series axis 1 is ± 135 °, axis 2 is ± 150 °, axis 3 is -200 mm/0 mm, and axis 4 is ± 360 °. KR 10 series axis 1 is ± 132 °, axis 2 is ± 150 °, axis 3 is -300 mm/0 mm, and axis 4 is ± 360 °. In terms of speed, the KR 6 series axis 1 is about 414 °/s, axis 2 is about 720 °/s, axis 3 is about 1.1 m/s, and axis 4 is about 2000 °/s. The KR 10 series axis 1 is about 355 °/s, axis 2 is about 450 °/s, axis 3 is about 1.1 m/s, and axis 4 is about 2700 °/s. The zero calibration positions are usually axis 10 °, axis 20 °, axis 30 mm, and axis 40 °.

The Z-axis adopts a ball spline screw, and the insertion force is clearly limited: the KR 6 series shaft 3 has an insertion force of about 150 N, and the KR 10 series has an insertion force of about 200 N. If press fitting, insertion or compression is required in the process, it must be confirmed that the insertion force does not exceed the allowable value, otherwise it will accelerate the wear of the screw and spline, and even cause Z-axis positioning drift. The mechanical terminal stops of axis 1 and axis 2 are used to protect the machine, but after a collision, the robotic arm may not operate reliably and must be stopped and confirmed with KUKA.

Safety logic and personnel requirements

The safety chapter applies to the mechanical components of industrial robots. If mechanical components are used together with KUKA robot controllers, it is also necessary to refer to the safety chapter of the robot controller. Industrial robots belong to incomplete machinery and are only allowed to be put into operation after being integrated into a complete system, combined with other machinery to form a complete system, or equipped with all safety functions specified in the EU Machinery Directive. The system integrator must issue an EC conformity declaration, affix the CE mark, and prepare a system operation guide.

In terms of personnel, operators must receive training and only qualified personnel are allowed to operate the equipment. Staff must understand the type of work, specific content, and potential hazards. The system integrator is responsible for installation, connection, risk assessment, safety features, protective devices, and compliance statements. Operators must fulfill their regulatory obligations, provide regular training, and comply with personal protective equipment regulations.

Dangerous areas include work areas and stopping routes. The protective device must be located outside the danger zone. The robotic arm must be located inside the protective shed, and the controller supports safety door sensors, but does not directly support light curtains or intrusion sensors; If other devices are used, a risk assessment and verification must be conducted. The mechanical terminal stop is used to limit the range of the shaft and cannot continue to operate after a collision.