KUKA Robots KR QUANTEC-2 PA Assembly Instructions

KUKA Robots KR QUANTEC-2 PA Assembly Instructions

PA=Palletizer palletizing specialized model, 5-axis palletizing robot (A4 axis does not exist, A1/A2/A3/A5/A6 has a total of 5 controlled axes); Model: KR   140   R3200-2   PA, KR   180   R3200-2   PA, KR   240   R3200-2   PA; only supports ground installation, base allows maximum ± 0 ° tilt; Prohibit suspended ceilings and wall hanging; Adapt controllers KR C4 and KR C5. The body is equipped with a liquid gas energy storage balance cylinder (PED Class I pressure equipment), specifically designed for optimizing palletizing processes. The book consists of 13 major chapters.

Product Description

Body structure: 5-axis articulated palletizing robot, without A4 axis; Components: PA special two axis wrist (A5/A6), boom, connecting rod arm, rotating column, base, hydraulic pneumatic pressure balancing cylinder, micro RDC electrical components. A1-A3 are equipped with mechanical hard stops for equipment protection only and cannot be used for personal safety protection; Personal protection relies on the controller's Safe Robot safety function or optional mechanical axis limit.

Installation constraint: Ground installation only, base 0 °, does not support ceiling/wall mounting.

Expected use: palletizing, heavy parts handling; Environmental conditions must be met.

Prohibited misuse (loss of warranty due to misuse): Climbing and trampling, overloading, carrying people and animals, outdoor activities, explosion-proof, radioactive, underground mining.

Wrist flange: PA Hand special flange, ISO 9409-1; The diameter of the hole is 125mm, with 11 M10-10.9 threads; Provide flange axial force, radial force, and overturning moment under normal operation and emergency stop impact conditions.

Additional load: Rotating column, connecting rod arm, and large arm reserved additional load installation interface; The factory load of the foundation does not include additional loads, and the foundation calculation must be additionally superimposed.

Available options: brake manual release device, A1 hollow shaft cover plate.

Technical Data

Covering three models: KR 140 R3200-2 PA, KR 180 R3200-2 PA, KR 240 R3200-2 PA (5-axis, without A4).

Public basic parameters

Protection level: IP65 for the entire machine and IP65 for the wrist; Noise level is less than 75 dB (A).

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

Suitable for KR C4/KR C5; cable 7-50 m, maximum length 50 m; equipped with 16 mm ² equipotential grounding conductor.

Base size 754mm, S780 hole position; The minimum grade of concrete foundation is C20/25.

Summary of Core Parameters for Aircraft Models

Model rated load, maximum load, maximum arm span, body weight, repeat positioning accuracy, axis configuration

KR 140 R3200-2 PA 140 kg 180 kg 3195 mm approximately 1017 kg ± 0.07 mm 5-axis, without A4

KR   180   R3200-2   PA 180   kg 230   kg 3195   mm - ± 0.07   mm 5-axis, without A4

KR 240 R3200-2 PA 240 kg 319 kg 3195 mm - ± 0.07 mm 5-axis, without A4

Complete output for each model: axis motion range, maximum speed of each axis under rated load, load curve diagram (must be verified by KUKA-Load software for quality, center of gravity, and moment of inertia, and entered into the controller); Wrist flange load (normal, emergency stop impact); Column/boom allows additional load; Foundation load (vertical force, horizontal force, overturning moment, A1 rotational moment); Side view and top view of the work envelope.

Stop distance and stop time

Distinguish between STOP 0 (category 0 uncontrolled emergency stop) and STOP 1 (category 1 controlled shutdown);

Provide A1-A3 axis stop angle and stop time curves for different POV program magnifications, extension lengths, and load masses under KR C4 and KR C5 controllers, respectively;

STOP   0 is the reference value for simulation and testing; Composite axis motion will increase the stopping distance; It is recommended to check the stopping distance at least once a year for brake wear, and on-site measurements should be taken based on actual working conditions.

Other

Location of nameplates and warning labels on the main body; REACH regulation information retrieval instructions.

Planning and Design

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

S780 with bottom seat kit (part number 0000-327-118, 58.5 kg): concrete foundation, base plate+locating 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.

150   mm raised base S780 option (0000-338-338261   kg): Raise the robot body.

Rack direct installation kit (0000-310-641, 3.52 kg): 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 cable X20-X30; Data cable X21-X31;

KR C5: Motor cable XD20-XD30; Data cable XF21-XF31;

Minimum bending radius of cables: motor cables ≥ 150   mm, data cables ≥ 60   mm; motor cables and data cables are routed separately; The external interface A1 of the main body is located at the rear of the base; Equipotential grounding must be completed in accordance with VDE 0100 and EN 60204-1.

Long term extreme operating conditions (high temperature, high frequency start stop, continuous full load) will accelerate component aging, and maintenance cycles need to be shortened. Consult KUKA services.

Transportation

Mandatory standard transportation posture (unified for all PA models): A1   0 °; A2‑137°；A3 160°； A4 none; A5 67°； A6   0 °, this posture must be maintained throughout transportation.

Transportation method

Forklift: The base comes with a fork slot; Forklifts have a carrying capacity of ≥ 2 tons and can be used for bi-directional forklifts.

Crane lifting: Official lifting tool part number 0000-342-903; Remove tools and pipeline packages before lifting to avoid center of gravity deviation.

Avoid impact and vibration during transportation; Prohibit non certified lifting points from lifting; Provide the center of gravity coordinates of the entire machine; Transport locking components and fork slots need to be removed during operation.

Startup and Re Debugging

Coverage conditions: standard centering base ground, 150mm raised base ground, and rack steel structure ground installation.

General process: Place the lifting device in place → Clean the installation surface, install the positioning pin → Position the robot → Tighten the M24 bolts diagonally in multiple stages; If necessary, grout and level; Dismantle the transportation lifting equipment.

Wiring specifications

Grounding M8 nut torque 23 Nm;

The tightening torque of the motor cable is 3 Nm; the data cable buckle must be fully locked in place;

The wiring is completed and a complete equipotential conduction test is performed.

Balancing cylinder exhaust steps: Remove the balancing cylinder ventilation protection cover, move the A2 axis ± 30 ° back and forth to release the accumulated air in the cylinder, prevent the protective cover from popping out and injuring people, and then restore the protective cover.

T1 mode low-speed whole machine trial operation; Provide complete KR C4 and KR C5 motor/data cable pin allocation drawings.

Maintenance

Only allow maintenance items listed in the manual to be executed; The remaining repairs will be handled by KUKA certified engineers; Gearbox oil model: Optigear Synt.   ALR   150; Balance cylinder hydraulic oil Hyspin ZZ 46.

Maintenance cycle benchmark

First 100 hours of operation: recheck the torque of all fasteners and bolts;

5000   h or 1 year: Balance cylinder pressure detection, adding LGEP   2 lubricating grease to the balance cylinder bearings at the connecting rod arm and rotating column;

20000 operating hours or 5 years, whichever comes first: replace all gearbox oil;

The balance cylinder is a pressure component that undergoes regular pressure checks, with a pressure standard of 176   bar (20 ℃± 15 bar).

Key points for oil change operation

The gearbox must be in a working hot state; Ventilate and release pressure before draining oil to prevent scalding caused by hot oil splashing; The specified tightening torque for the magnetic drain plug is 20 Nm.

If the oil release rate is less than 70% of the rated volume, the gearbox must be flushed; Less than 50% of the rated volume requires multiple washings; Oil change completed T1 low-speed running in, check all seals for leakage.

Maintenance checklist

Drain, flush, and add oil to the gearboxes of A1-A3/A5-A6 shafts; Each axis needs to be placed in a designated position to ensure that the oil discharge port is at the lowest point.

Balance cylinder: pressure detection, bellows sealing inspection, bearing lubrication; Complete disassembly and replacement process; Before disassembly, the balance cylinder must be mechanically locked with a clamping sleeve.

Whole machine cleaning: Only solvent-free water-soluble neutral cleaning agents are allowed; It is strictly prohibited to use high-pressure steam jet to clean the robot body.

Maintenance

High risk maintenance operations; To disassemble motors A2/A3/A5/A6, it is necessary to use a sling to mechanically lock the arm body and lock the balance cylinder; The failure of the power outage brake and the accumulation of energy in the balance cylinder pose a risk of the arm falling and squeezing to death due to its own weight.

General process for motor replacement: Disconnect the motor from the encoder connector; Remove the bolts; Apply Microlube GL261 lubricating grease to the involute spline of the new motor; Replace all O-ring seals with new ones; Do not install the motor at an angle; Tighten the bolts diagonally in stages; Restore the connector.

Motor replacement completed: The axis must undergo mastering zero calibration; T1 low-speed test run.

Including the complete set of disassembly and assembly steps for A1-A3/A5/A6 motors and A5 A6 swing housing assembly; The weight of the swinging shell is large, and a crane must be used.

Electrical system: micro RDC box, complete set of electrical schematics and wiring diagrams for motors, brakes, temperature feedback, and encoders.

Priority should be given to using KUKA original spare parts for spare parts; 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, lift the body vertically, and protect the positioning pin.

Storage conditions: The storage location should be dry and dust-free, avoiding condensation and direct sunlight; Storage -40~60 ℃; Clean and cover the body, remove tool accessories; Electrical joint sealing protection requires the placement of desiccants.

Scrap and dismantle

Classification and recycling of cast aluminum, cast steel, steel, copper cables, and electrical components; Waste gear oil and hydraulic oil are treated as hazardous waste.

Before dismantling and scrapping the balance cylinder, it must be thoroughly depressurized; Internal storage of high-pressure nitrogen gas poses a risk of explosion if not depressurized.

Options

Brake release device: Emergency manual joint movement for power failure, limited to personnel rescue and escape.

After using the release device to move the joint, all axes must be recalibrated and the brake must be fully functional tested to prevent injury from collision.

A1 Hollow Shaft Textile Shield Cover Assembly: Installation, Cleaning, and Maintenance Steps.