Troubleshooting KUKA SCARA X

Manual movement, simulation, and automatic operation

Manual operation mode is used for debugging work, including jogging, teaching, programming, and program verification. T1 is a manual slow mode with a speed not exceeding 250 mm/s, suitable for testing, programming, and teaching. T2 is a manual fast mode that allows for speeds greater than 250 mm/s and is only used for testing operations. When manually moving axis 1 and axis 2, follow the instructions on the controller; When manually moving axis 3 and axis 4, attention should be paid to the safety of the Z-axis and rotation axis. New or modified programs must be tested under T1 first. Tools, robotic arms, or additional shafts must not touch or extend beyond the barrier. Debugging work should be carried out outside the protected area as much as possible. If it must be carried out within a protected area, personnel must be equipped with confirmation devices, visible to each other, and maintain a gap of at least 50 cm, as determined by risk assessment.

The simulation program does not fully match reality. The program created in the simulation must be tested in a real system under T1 and may need to be modified. Automatic operation is only allowed when all protective devices are installed and functioning properly, there are no personnel in the hazardous area, and the prescribed workflow is followed. If the reason for the shutdown of the robotic arm is unknown, an emergency stop must be triggered before entering the danger zone.

Maintenance and Repair

After maintenance and repair, safety requirements must be checked and all safety functions tested. Maintenance must be carried out outside the hazardous area; If it is necessary to be in a hazardous area, additional safety measures must be taken. Industrial robots must be turned off and prevented from restarting, such as padlocks. If it is necessary to work while the controller is turned on, it is only allowed to work in T1 mode and additional safety measures should be taken. The emergency stop device must remain activated. If the safety function or protective device is disabled, it must be immediately reactivated after the operation is completed.

Before working with live parts, the power supply must be disconnected. Triggering an emergency stop or safety stop is not sufficient to ensure safety, as the components are still energized. The main switch must be turned off and prevented from being reconnected. For controllers without a main switch, turn off the device switch, disconnect the power cord, and secure it. Then check that the system has been powered off. Within a few minutes after the controller is turned off, there may be voltages exceeding 50V or even 780V in the components, and it is strictly prohibited to work during this period. The controller with a transformer must first turn off the transformer. Water and dust must be prevented from entering the controller. ESD regulations must be followed. Dangerous goods handling should avoid long-term skin contact, avoid inhaling oil mist, and pay attention to skin cleaning and care. The latest security data page must be used.

The maintenance schedule is executed periodically. Although the document does not provide a complete table, it usually includes screw lubrication, spline inspection, cable wear, fan cleaning, battery replacement, limit inspection, brake testing, etc. During maintenance, only new parts with the same part number or external parts approved by the manufacturer are allowed to be used. Clean and maintain according to the operating instructions.

Common troubleshooting

Resonance and screw shaking: Due to insufficient rigidity of the installation platform, large inertia of the end load, and specific angles and velocities, resonance may occur. When the end load is large, the arm is close to being extended, and the screw stroke is long, it is necessary to carefully evaluate the impact of end shaking and lifespan under high-speed motion. You can try changing the robot's movement speed, adjusting the teaching point position, and changing the load mass and inertia of the end fixture. If it is ineffective, contact KUKA support.

Z-axis positioning drift: Check the wear of the ball spline screw, whether the insertion force exceeds the limit, whether the load center of gravity is too large, and whether the Z-axis limit collides. Insertion force KR 6 is about 150 N, KR 10 is about 200 N, exceeding it will accelerate wear.

Axis 1/Axis 2 limit alarm: Check the mechanical terminal stop, software limit, zero calibration, and cable interference. After the collision terminal stops, the machine must be stopped and KUKA must be contacted.

Emergency stop cannot be reset: Check the smartPAD touch connection, emergency stop circuit, X11 safety interface, safety door, enable switch, and controller safety configuration. If smartPAD is disconnected, an external emergency stop must be used.

Enable switch failure: Enable switches must undergo functional testing every 12 months. If there is no response when pressed, check the connector, cable, and switch body, and replace the smartPAD touch if necessary.