kuka各版本隨機文檔接口與設計用kr_30_45ro_me_06_15_05_en

1、ROBOT(V)KR 30, 45, 60; (V)KR 30 L15RepairEnergy Supply System A 1 - A 3Ro/Me/06/15.05 06.00.01 en1 of 22e Copyright KUKA Roboter GmbHThis documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers. Other functions not desc

2、ribed in this documentation may be operable in the controller. The user has no claim to these functions, however, in the case of a replacement or service work.We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot

3、 be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in subsequent editions.Subject to technical alterations without an effect on the function.PD Int

4、erleafRo/Me/06/15.05 06.00.01 en2 of 22Contents1General .5Repair . . . . . . Removal, installation of complete energy supply system A 1 - A 3 . . . . . . . . . . . . . . . . . . . .Removal, installation of hose line . . . . . . . Removal, installation of electric cable . . . . . . . 771920

5、3Safety precautions when handling lubricants.22Ro/Me/06/15.05 06.00.01 en3 of 22RepairRo/Me/06/15.05 06.00.01 en4 of 221GeneralValid for(V)KR 30/2 (V)KR 30 L15/2(V)KR 45/2(V)KR 60/2 (V)KR 60 L45/2(V)KR 60 L30/21GeneralBefore repair work is started, any attached tools or additional equipment that wou

6、ld hinder repair must be dismounted.If the main switch on the control cabinet has been switched to “OFF” for performing repair work, the connecting cables between the robot and the control cabinet must be disconnected at the robot immediately afterwards. They must then be correctly reconnected befor

7、e the robot is put into operation again.Ro/Me/06/15.05 06.00.01 en5 of 22Utmost caution must be exercised when handling cable grease. The use of protective clothing (at least protective gloves, for example) is strongly recommended.All accident prevention regulations and Section 3 of this Doc. Module

8、 must be observed.There must be no oil in any hydraulic oil lines installed in the energy supply system. Escaping oil must be caught in a suitable receptacle and stored in accordance with the regulations or disposed of with minimum environmental impact.Before the supply lines are removed from the en

9、ergy supply system, the hose lines must be depressurized and drained.The electrical connections must be deenergized and measures must be taken to prevent them from being inadvertently reenergized.The Doc. Module “Safety, General” and the robot Doc. Module “Repair, General” are to be observed!Regardl

10、ess of its normal installation position, the robot must be brought into the floor position for all repairs to energy supply system A 1 - A 3, (see robot Doc. Module “Installation, Connection, Exchange”) and must be screwed down so that it will not tilt under any circumstances.This description applie

11、s analogously to all of the robots listed above, regardless of the robot variant depicted.RepairThe operations described below apply analogously to all versions of energy supply system A 1 - A 3, regardless of the number and type of supply lines installed in the particular system involved.Performing

12、 the following work is greatly facilitated if the robot is at a level which can be easily reached by the personnel carrying out the repairs.Ro/Me/06/15.05 06.00.01 en6 of 22Only KUKA-approved cable grease may be used.2Repair22.1RepairRemoval, installation of complete energy supply system A 1 - A 3GR

13、emoval(1)Move robot into its dismantling position (Fig. 1): axis 1 approx. 45 in (+) direction.approx. 45Fig. 1 Moving robot into the dismantling positionDoing this ensures that the tube clamp (Fig. 4/2) for flexible tube A 1 - A 3 (3) and the cable clip (4) for strain relief of the cables (6) are r

14、eadily accessible.Ro/Me/06/15.05 06.00.01 en7 of 22There must be no oil in any hydraulic oil lines installed in the energy supply system. Escaping oil must be caught in a suitable receptacle and stored in accordance with the regulations or disposed of with minimum environmental impact.Turn main swit

15、ch on the robot control cabinet to “OFF” and secure it with a pad- lock to prevent unauthorized persons from switching it on again.The flexible tube is located in the base frame on the side opposite flexible tube A 1 of the robot electric cabling.Section 1 of this Doc. Module is to be observed!(2)(3

16、)Unplug connecting cables on the robot.Remove four M8x12 Allen screws (Fig. 2/1) and lock washers, and take off two-piece cover (2).Remove four M6x12 Allen screws (6) and lock washers, and take off cover (5). Remove four M8x12 Allen screws (4) and lock washers, and take off cover (3).(4)(5)126543 Fi

17、g. 2 Removing covers(6)(7)Unscrew sealing head (Fig. 3/5) from cover (6) on rotating column.Remove four Allen screws (1) and lock washers, and take off connector base (2).Ro/Me/06/15.05 06.00.01 en8 of 22The cover (3) is pretensioned. Great care must therefore be taken to avoid injuries when taking

18、it off.Protective gloves are to be worn due to cable grease on the inside of the cover! All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease.Repair2Repair (continued)651234Fig. 3 Removing sealing heads and connector bases(8) Remove two Allen

19、screws (3) and lock washers, and take off connector base (4).(9) Pull back cables and hoses (Fig. 4/6) a short way out of the rotating column (7) so that they are slack in front of the cable clip (4).(10) Remove two M8x25 Allen screws (5) and lock washers, and then remove cable clip (4).(11) Remove

20、two M8x100 Allen screws (1) and lock washers, take off tube clamp (2) and lay down flexible tube (3).(12)Remove two M8x100 Allen screws (8) and lock washers and take off tube clamp (9).Ro/Me/06/15.05 06.00.01 en9 of 22Protective gloves are to be worn!All accident prevention regulations and Section 3

21、 of this Doc. Module must be observed when using cable grease.673893Fig. 4 Removing energy supply system A 1Ro/Me/06/15.05 06.00.01 en10 of 22Repair2Repair (continued)(13)(14)(15)Unscrew union nuts of hose lines on “interface on arm” (Fig. 5/2). Release and unplug connectors of electric cables.Unscr

22、ew connector bases of electric cables (1).(16)(17)Open all hinged clamps and lay down cable and hose bundle.Take cable and hose bundle out of base frame, rotating column and link arm and lay it down, fully extended, on a clean support surface.12Fig. 5 Schnittstelle Arm(18)Remove two M10x25 Allen scr

23、ews (1) and lock washers, and take off “holder for arm” (2).Remove four M8x20 Allen screws (3) and lock washers, and take off “holder for link arm” (4).Remove four M8x20 Allen screws (5) and lock washers, and take off “holder for rotating column” (6).(19)(20)Ro/Me/06/15.05 06.00.01 en11 of 22If the

24、cable and hose bundle is to be re-installed immediately, the holders (Fig. 6/2, 4, 6) and the “interface A 3” (8) can be left on the robot.Seal all hose line(s) and electric cable(s) with adhesive tape so that no cable grease can penetrate into them.81723465Fig. 6 Removal of holders(21) Remove four

25、M12x80 Allen screws (7) and lock washers, and take off “interface A 3” (8).GInstallation(1)Mount “holder for arm” (Fig. 7/2) and fasten it to arm with two M10x25 Allen screws (1) and lock washers.Mount “holder for link arm” (3) and fasten it with four M8x20 Allen screws (4) and lock washers.Mount “h

26、older for rotating column” (6) and fasten it with four M8x20 Allen screws (5) and lock washers.(2)(3)Ro/Me/06/15.05 06.00.01 en12 of 22The installation process is described as if it were performed immediately after removal. If an energy supply system A 1 - A 3 is installed for the first time (as a r

27、etrofit), steps 1 to 5 of the “Removal” section and steps 1 to 4 of the “Installation” section must be carried out beforehand. In addition, the plugs of the fastening boreholes must be removed.All warnings appearing before or after these steps must also be observed!Section 1 of this Doc. Module is t

28、o be observed!Repair2Repair (continued)(4)Mount “interface A 3” (8) and fasten it with four M12x80 Allen screws (7) and lock washers.81723465Fig. 7 Installation of holders(5)Align cable(s) and hose(s) in the flexible tube, and replenish grease in the flexible tube if necessary.Check configuration of

29、 flexible tube according to Fig. 8, making sure that the wear rings (3), intermediate pieces (2) and endpieces (1) are correctly positioned.(6)321Fig. 8 Configuration of flexible tubeRo/Me/06/15.05 06.00.01 en13 of 22Repair(7)Feed electric cable(s) and hose line(s) first into the base frame and then

30、 into the rotating column and link arm, and align flexible tube (Fig. 9/7) so that the mark (5) is on top.87162534Fig. 9 Installing energy supply system A 1(8)Place tube clamp (3) onto flexible tube and fasten it to the base frame with two M8x100 Allen screws (4) and lock washers.(9)Feed electric ca

31、ble(s) and hose line(s) into the rotating column and align flexible tube(7) so that the mark (6) is at the bottom.Ro/Me/06/15.05 06.00.01 en14 of 22The flexible tube must lie correctly in the indentations of the clamp; the end must project approx. 5 mm beyond the clamp.The cables and hoses of the en

32、ergy supply system must not be crossed inside the flexible tube.The alignment of the electric cable(s) and hose line(s) is best done when the flexible tube is laid out horizontally.If an energy supply system is re-installed which has been previously removed, protective gloves must be worn due to res

33、idual cable grease on the flexible tube.All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease.2Repair (continued)(10)Place tube clamp (2) onto flexible tube and fasten it to the rotating column with two M8x100 Allen screws (1) and lock washers

34、.(11)(12)Attach cable clip (8) and fasten it to the rotating column with two M8x25 Allen screws.Fasten connector base (Fig. 10/6) and connector base (5) to the cover (2) of the base frame with four M3x10 Allen screws (7) and lock washers and two M5x20 Allen screws(4) and lock washers respectively.Bl

35、ow hose lines clean with compressed air.Connect water and air lines to cover (2) of base frame, tightening the union nuts by hand and then tightening them by a further 90.(13)(14)(15)Fasten cover (2) to the base frame with four M6x12 Allen screws (1) and lock washers.867123542Fig. 10 Installing seal

36、ing heads and connector basesRo/Me/06/15.05 06.00.01 en15 of 22Overtightening the union nuts can destroy the sealing heads.The flexible tube must lie correctly in the indentations of the clamp; the end must project approx. 5 mm beyond the clamp.The marks (5, 6) on flexible tube (7) must be opposite

37、each other, i.e. they must be located vertically one above the other.Repair(16) Apply a coating of cable grease at least 1 mm thick to flexible tube (8).(17) If necessary, apply a coating of cable grease at least 1 mm thick to the contact surfaces between the flexible tube and the base frame.(18) Mo

38、unt cover (Fig. 11/4) and fasten it with two M8x12 Allen screws (3) and lock washers.(19) Insert endpiece (5) of flexible tube (4), mount cover (6) and fasten it with two M8x12 Allen screws (7) and lock washers.(20) Insert flexible tube with intermediate pieces into hinged clamps (1) and close hinge

39、d clamps.(21)Insert endpiece (8) and clamping piece (2), and close hinged clamps.Ro/Me/06/15.05 06.00.01 en16 of 22The supply lines must be fitted in the correct recesses of the clamping piece (2). Once the hinged clamp is closed, the supply lines must be clamped firmly in place. They must not be pi

40、nched at the joints of the hinged clamp (1); the clamping piece must be turned if necessary.The endpiece (8) of the flexible tube (4) must lie correctly in the indentations of the hinged clamp (1). It must be possible to turn the flexible tube.Protective gloves must be worn!All accident prevention r

41、egulations and Section 3 of this Doc. Module must be observed when using cable grease.Check again the position of all electric cable(s) and hose line(s) in the flexible tube. They must not be crossed or subjected to excessive mechanical stress.2Repair (continued)11121248761534Fig. 11Installing the c

42、lamping piece(22) Fasten connector base (Fig. 12/2) and connector base (4) to interface A 3 (5) with four M3x10 Allen screws (1) and lock washers and two M5x20 Allen screws (3) and lock washers respectively.(23) Blow hose lines clean with compressed air.(24) Connect water and air lines to interface

43、A 3 (5), tightening the union nuts by hand and then tightening them by a further 90 .Ro/Me/06/15.05 06.00.01 en17 of 22Overtightening the union nuts can destroy the sealing heads.34512Fig. 12 Connection, interface A 3(25) Blow hoses clean with compressed air and then check them for leaks.(26) If nec

44、essary, apply a coating of cable grease at least 1 mm thick to the inside of the cover (Fig. 13/1).(27) Mount cover (1) and fasten it with four M8x12 Allen screws (2) and lock washers.(28) Check the electric cables of energy supply system in accordance with DIN EN 60204 (for insulation and voltage t

45、est, see robot Doc. Module “Repair, Electrical Installations”).21Fig. 13 Fitting the coversRo/Me/06/15.05 06.00.01 en18 of 22Protective gloves must be worn!All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease.Repair2Repair (continued)2.2Remov

46、al, installation of hose lineD Removal(1)Remove cable and hose bundle (see Section 2.1, Removal).(2)Pull hose line to be exchanged out of flexible tube.D Installation(1)Attach new hose to pull-in wire and draw it into the flexible tube.(2)Apply cable grease evenly to hose in the area of the flexible

47、 tube while pulling it in.(3)Align electric cable(s) and hose line(s) in flexible tube.Ro/Me/06/15.05 06.00.01 en19 of 22The alignment of the electric cable(s) and hose line(s) is best done when the flexible tube is laid out horizontally.Only apply cable grease to that part of the hose line which is

48、 located in the flexible tube. A uniform coating is best achieved by applying the grease by hand (using protec- tive gloves).Protective gloves must be worn!All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease.Seal hose line with adhesive tape

49、 so that no cable grease can penetrate into it.It is easier to pull in a new hose if a pull-in wire is attached to the old hose before it is withdrawn, or if the new hose is attached directly to the one to be pulled out.If it is difficult to pull out the hose due to the large number of cables and ho

50、ses in the flexible tube, one of the sealing heads on the hose to be exchanged can be cut off.Protective gloves must be worn!All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease.The flexible tube with cables and hoses inside it must be laid d

51、own fully extended on a clean support surface.Repair(4)(5)(6)(7)Remove coverings (adhesive tape) from the hose. Push hose onto sealing head.Blow hose clean with compressed air and check it for leaks.Install cable and hose bundle (see Section 2.1, Installation).2.3Removal, installation of electric ca

52、bleD Removal(1)Remove cable and hose bundle (see Section 2.1, Removal).(2)(3)(4)Eject connecting wires from the connector base (only on the base frame side).Cover all wires with adhesive tape so that they cannot be fouled by cable grease. Pull the cable to be exchanged out of the flexible tube on th

53、e “interface A 3” side.D Installation(1)Attach new cable to pull-in wire and draw it into the flexible tube.Ro/Me/06/15.05 06.00.01 en20 of22Protect the connecting wires from cable grease and other forms of fouling with adhesive tape before drawing in the electric cable.Protective gloves must be worn!All accident prevention regulations and Section 3 of this Doc. Module must be observed when using cable grease.Seal cable with adhesive tape so that no cable grease can pen