KUKA KR QUANTEC-2 series heavy-duty ground mounted six axis industrial robot

KUKA KR QUANTEC-2 series heavy-duty ground mounted six axis industrial robot

KR QUANTEC-2 series heavy-duty ground mounted six axis industrial robot body assembly, debugging, maintenance, and repair official manual. Model coverage: KR120/150/180/210/240/250/300, distinguishing between basic version, C01 extended arm, C clean version, and F cast version; Controller compatible with KR C4, KR C5, KR C5-2; The robot only supports ground installation, with a maximum allowable tilt of ± 5 ° for the base, and does not support ceiling or wall mounting.

Product Description

Body structure: 6-axis serial robot; Core components: ZH series hollow wrist HW, boom, connecting rod arm, rotating column, base frame, liquid gas energy storage balance system, complete set of motors and micro RDC electrical components.

A1-A3 are equipped with mechanical hard stops for equipment protection only and cannot be used for personal safety protection; Personnel safety relies on the Safe Robot safety function of the controller or optional mechanical axis limit.

Definition of Main Variants

Standard version: General industrial handling;

C01: Extend the working radius;

C: Clean Room version;

F Foundry casting version: enhanced protection, special coating, high temperature splash resistance, supports PURGE internal blowing positive pressure; The wrist can withstand a short-term heat load of 180 ℃.

Installation constraint: limited to ground installation only, the base allows ± 5 ° tilt; Ceiling and wall hanging are prohibited.

Expected use: handling tools, workpieces, processing loading and unloading; Environmental conditions must be met.

Misuse is prohibited (misuse will result in loss of warranty): stepping on heights, overloading operations, carrying people/animals, outdoor activities, explosion-proof areas, radioactive materials, underground mines.

Wrist flange: ZH210/ZH300 two types of hollow wrist flanges, ISO9409-1 standard. The document provides thread specifications, locating pins, and flange force torque under normal operation and emergency stop impact conditions.

Additional load: Additional load installation interfaces are reserved for the rotating column, connecting rod arm, and boom, specifying the maximum allowable additional load for each part. The calculation of the foundation requires the additional force of the additional load to be added.

Available options: brake manual release device, A1 mechanical limit, PURGE internal positive pressure blowing A/B/C/D kit, A1 hollow shaft cover plate, cable bundle shield, conduit bundle, etc.

Technical Data

This chapter occupies the largest part of the manual, with each sub model having an independent and complete parameter set, including KR   120/150/180/210/240/250/300. Each model is further divided into standard version/C01 extended version/C clean version/F cast version.

Public environmental parameters

Operating temperature: 0~55 ℃; Storage -40~60 ℃;

Protection level: IP65 for the whole machine, IP65/IP67 for the wrist; The F casting version supports PURGE internal blowing;

Noise level<75 dB (A); Support ESD IEC61340-5-1;

Cable adaptation KR C4/KR C5/KR C5-2; Cable length 7-50 mm, maximum 50 mm; 16 mm ² equipotential grounding conductor.

Single model parameter package (uniformly included for each model) 1) Basic data: rated load, maximum load, maximum arm span, total weight of the machine, repeat positioning accuracy, and working envelope volume; 2) Axis parameters: range of motion for each axis, maximum axis speed under rated load, zero calibration mastering angle; 3) Load chart: load curve chart, load center of gravity Lx/Ly/Lz, inertia Ix/Iy/Iz; Mandatory reminder: Quality, center of gravity, and moment of inertia must all be verified using KUKA-Load and data entered into the controller, otherwise the gear motor will be damaged; 4) Wrist flange: flange size, thread specifications, axial force, radial force, overturning moment under normal working conditions and emergency stop impact working conditions; 5) Additional loads: columns, connecting rod arms, and large arms allow for additional loads; 6) Foundation load: vertical force Fv, horizontal force Fh, overturning moment Mk, A1 rotational moment Mr (distinguishing between normal and maximum peak values); The factory foundation load of the main body is not included in the A1/A2 additional load, and the project foundation calculation must be additionally superimposed; 7) Work envelope diagram (side view+top view);

Stop distance and stop time: distinguish between STOP 0 category 0 emergency stop and STOP 1 category 1 controlled stop, with numerical reference to KUKA Xpert.

Nameplate labels, REACH regulatory information.

F casting version specific: wrist short-term 180 ℃ heat resistance, PURGE blowing compressed air specifications, internal micro positive pressure parameters.

Planning and Design

3 sets of ground installation plans, minimum grade of concrete foundation C20/25:

Comes with a fixed base kit: concrete foundation, base plate+positioning pin+M24 bolt+chemical anchor bolt; If the foundation is uneven, it is allowed to level the mortar, and it is strictly prohibited to pour mortar into the bolt holes.

150mm raised base option: Elevate the robot body.

Rack direct installation: installed on the customer's steel structure/slide table; Cylindrical pin+flat pin positioning; Tighten 8 M24 bolts diagonally in steps.

Cable planning

KR   C4: Motor X20-X30; Data X21-X31;

KR C5/C5-2: Motor XD20-XD30; Data XF21-XF31;

The minimum bending radius of the cable must be fully equipotential, following VDE0100 and EN   60204-1; A1 external interface at the rear of the base; Separate the wiring of motor cables and data cables.

Transportation

The robot must be placed in the standard transport posture specified in the manual, and all models must have a uniform transport axis angle.

Transportation method

Forklift: Base fork groove, forklift carrying capacity ≥ 2 tons;

Crane lifting: Use the official KUKA lifting kit and M16 eyebolt; Tools and pipeline packages must be removed to avoid center of gravity deviation.

Avoid impact and vibration during transportation; Prohibit non certified lifting points from lifting; Each model provides the center of gravity coordinates.

Startup and Re Debugging

Four installation conditions: standard base ground, 150mm elevated base ground, and steel structure installation of rack ground.

General process: Install transportation lifting equipment → Clean installation surface → Install positioning pin → Robot positioning → Tighten M24 bolts diagonally multiple times in steps → Level grouting if necessary → Remove transportation lifting equipment.

Wiring specifications

Grounding conductor M8 nut specified torque;

The motor and data cable connectors must be fastened with locking buckles;

Perform equipotential conduction test after wiring is completed.

WorkVisual software confirms the robot installation posture (ground, ± 5 ° tilt parameter).

T1 manual mode low-speed whole machine trial run.

Maintenance

Only execute the maintenance items specified in the manual; The remaining repairs will be handled by KUKA certified engineers.

Maintenance cycle benchmark

First 100 operating hours: re check the torque of all fasteners and bolts;

5000   h: Visual inspection of A1 cable components, lubrication of balancing cylinder bearings;

20000 operating hours or 5 years (whichever comes first): Replace all gearboxes with oil; Balance cylinder system inspection; A1 cable sheath lubrication;

Compulsory replacement of the balance cylinder for 10 years (safety requirements for pressure components).

Gearbox oil model: Optigear Synt.   ALR   150; The capacity manual table for each axis is provided.

Before changing the oil, the robot should be placed in the designated position to ensure the lowest oil outlet; Ventilate and release pressure before draining oil to prevent scalding caused by hot oil splashing; Magnetic drain plug specified torque;

The oil discharge volume is less than 70% of the rated capacity, and the gearbox needs to be flushed; If it is less than 50%, it needs to be rinsed multiple times; After changing the oil, T1 ran in at low speed and checked all sealing positions for leakage.

Whole machine cleaning: only neutral water-soluble cleaning agents are allowed; High pressure steam jet cleaning robots are strictly prohibited.

Maintenance

Core safety for motor replacement: Before disassembling A2/A3/A5/A6 motors, the arm must be locked with a lifting device and the balance cylinder must be mechanically locked; Failure of power-off brake and balance cylinder energy storage may cause the arm to suddenly fall and die.

Apply Microlube GL261 lubricating grease thinly on the new motor spline; Replace all O-ring seals with new ones; Tighten the bolts diagonally in stages; After replacing the motor, the axis must be zero calibrated for mastering and T1 low-speed testing.

Electrical system: micro RDC box, complete set of motor, brake, temperature feedback, encoder schematic diagram; Definition of plug.

Priority should be given to using KUKA original spare parts for maintenance; A repair report is required for the return of faulty parts.

Shutdown, Storage, and Scrap Disposal

Dismantling process: The robot moves to the standard transport posture; Emergency stop, lock and power off; Dismantling tools and fixtures; Disconnect the cable and ground it; Loosen the M24 bolts on the base and lift the body vertically; Protect positioning pins.

Storage conditions: Dry and dust-free environment, avoid condensation, and avoid direct sunlight; Storage temperature -40~60 ℃; Clean and cover the body, remove tool accessories, seal electrical connectors, and place desiccants if necessary.

Scrap and dismantle

Classification and recycling of metal parts (cast aluminum, cast steel, steel, copper cables) and electrical components; Waste gear oil should be treated as hazardous waste.

Before scrapping and dismantling the balance cylinder, it must be thoroughly depressurized and high-pressure nitrogen gas stored inside. Disassembling without depressurization poses a risk of explosion.

Options

Brake release device: only used for emergency rescue personnel to escape when power is cut off.

Mandatory warning: After manually moving the joint using the release device, all axes must be recalibrated and the brake function must be fully tested to prevent injury from collision.

A1 hollow shaft cover plate, cable bundle shield.

PURGE A/B/C/D positive pressure blowing kit (F casting version specific): maintains a slight positive pressure inside the body to prevent dust and thermal splashes from entering; Includes installation, debugging, and maintenance steps.