Discover KUKA Robotics: Frequently Asked Questions and Basics
This article will provide Xi materials on the KUKA robot, answer frequently asked questions, and introduce the basics of using the robot. This is a comprehensive introduction to KUKA Industrial Robots Xi that covers a wide range of common problems from basic operation to troubleshooting. It includes the basic knowledge of the composition and function of the KUKA robot system, how to use the teach pendant, the coordinate system of the robot, and the setting of tool coordinates. Both beginners and engineers with some experience can benefit from it. By reading these materials, you can better understand robotics and improve your operation and maintenance capabilities to better meet the challenges of real-world work.
Why does the robot have the problem of zero point loss?
Whether the zero point of the robot is lost mainly depends on a piece of data carrier (EDS) in the system, which not only affects whether the zero point of the robot is lost during the normal operation of the robot, but also after the robot is shut down. Therefore, during the normal operation of the robot or after the power failure, zero point loss may occur.
, the password of the external display of the library card
68kuka1secpw59
What steps do you need to do when the KUKA robot is put into operation (start-up).
1.Check before booting: aMake sure the ambient temperature is within 5 -55. b.The body-control cabinet cables and connectors are normal without external injury, and after being connected according to the wire standard, the buckle is firm and there is no shaking. c.After the power supply cable is energized, open the control cabinet door, close the Q3 switch to open Q1, and measure whether the line voltage of the 3 phases at Q3 is within the range and whether there is any phase loss. Disconnect Q1 and turn Q3 on.
2.Operation of the first start-up: Please refer to the quick start manual attached to the door of the control cabinet to turn on the battery power and turn on the machine. Follow the instructions in the manual to process the alarms related to the initial start-up, select the robot and activate the safety configuration (if any). At this point, the robot uses the input to operate the robot in T1 (operation mode), and connects it through the X11 safety loop interface to realize the interaction with safety signals such as external emergency stop safety doors before all modes of action can be used. This is the end of the run-in-operation, so please continue to check back on the run-up defined by KUKA.
3.[Main Menu] - [Put into Operation] - [Put into Operation Assistant] Enter the Put into Operation Assistant, click the relevant options step by step to operate, and complete the operation.
, how to modify the network address of the robot
1.Go to the teach pendant and set the user group to Expert.
2.Click Put into operation - Network Configuration;
3.Network configuration, click Save to complete.
What problems need to be paid attention to in the process of external shaft configuration?
You need to pay attention to the relevant parameters of the motor and the external axis, the conversion relationship of the coordinate system, etc., please refer to the external axis configuration manual for details.
、How to start the robot automatic mode
1.Make sure that the program traces have been manually tested without problems.
2.The robot has no associated alarms.
3.In T1 mode, select the program to be executed, and manually move until the BCO appears.
4.Switch the mode to AUX and adjust the program rate by about 30% at the same time, enable it and press the forward button, the robot can be started automatically, pay attention to the low-speed operation and increase the speed after confirming the safety.
There is an abnormal sound when the robot is running
First of all, it is necessary to determine the source of the abnormal noise. If the reducer makes an abnormal noise, first check whether the robot load data is correct, whether the program acceleration is optimized and other software reasonsThen check the reducer itself, such as lubrication status, internal wear, etc. If the motor makes an abnormal noise, most of the time it is that the motor is worn. In addition, if the balance cylinder is damaged, the robot will also have abnormal noise.
, EMD is connected to the robot, and the teach pendant is not connected
If the EMD does not work, please confirm the following:1Confirm that the EMD is functioning properly and that the probe is shrinking. 2.Check whether the connected interfaces are normal.
, PC failure, power supply is normal, fan does not run.
It is recommended to replace the PC. Here's how to do it:
1.Disconnect the power supply and make sure there is no voltage.
2.Unplug the PC cable, replace the PC, and make sure that the hard disk needs to be restored to the new PC.
The device system cannot be turned on normally
Note: Because the SmartPad and the KPC are connected through the remote desktop, when the PC system or CCU cannot work normally, it is possible that the SmartPad interface cannot be entered.
Scenario: The following steps are recommended:
1.Please guide according to the status of the CSP fault lamp at the customer's site, and the customer's site conditions can be viewed with the monitor, which can quickly judge whether the PC is a hard disk failure or a CCU failure.
2.If there is no external monitor condition, check whether the PC fan is running normally, and if the PC fan does not rotate, it is recommended to replace the PC motherboard and motherboard for testing. If the PC fan is running normally, it is recommended to reinstall the system files and replace the hard disk for testing.
3.Check whether the motherboard's memory modules are plugged in properly and whether the KPC motherboard and hard disk are connected properly. Whether it's because of the dust on the motherboard.
4.Conditionally, swap hard disks to check if the robot can enter the system. If you can get in, try to redo the system with the faulty hard drive, if the system fails, you need to replace the hard drive.
There is no electricity in the control cabinet
Power failure is recommended to check the following:
1.Check whether the power supply of the main power supply Q1 is normal.
2.Check the 27V power module line connection.
3.Switching low-voltage power supply device test.
, 4-axis encoder failure
Operation suggestion: whether the encoder wire is transferred, such as transfer, cable failure or RDC side plug failure, if not, motor failure.
There is no alarm jitter in the robot
There is no alarm jitter in the robot
It is recommended to check whether the power cables from the control cabinet to the robot body, and the X20 and X30 plugs are firmly connected to the robot body.
If the cable connection is normal, check the configuration of the project.
、The robot time cannot be saved, and it will be reset when restarted
Cause: PC motherboard battery failure.
Recommended Steps:
1.Power off the controller completely.
2.Do a good job of electrostatic protection.
3.Replace the coin cell battery.
The exchanger has no electricity
Cause: The power supply to the switch is faulty.
1.Check the LED indicator of the CCU board.
2.Check the voltage on the power side of the exchanger.
, the robot zero point is frequently lost
KSS00106 performs zero correction and needs to restore zero point. If it is a fault in the production and operation state, it is necessary to determine whether it is caused by an emergency power failure or electrical fault caused by a collision, it is recommended to check the grounding motor, connecting cables, and RDC board of the equipment. If the equipment is the delivery time is due to bumps in transportation.
Recommended check steps:
1.Check the alarm log to confirm whether there is a collision monitoring alarm, and check whether the site is grounded in a safe and standardized manner.
2.On-site inspection of each axis cable joint is not loose or virtual.
3.Adjust or replace the motor, encoder data line and current axis data acquisition channel (or RDC board), and re-EMD zero calibration test.
, emergency stop
Please check whether it is a human emergency stop or an automatic abnormal emergency stop. There are several possibilities for automatic abnormal emergency stops:
1.Check each emergency stop circuit.
2.Check the teach pendant emergency stop button or swap the teach pendant.
3.Check for teach pendant electromagnetic interference.
4.Check the teach pendant firmware version, latest v111.0。
, robot robot digital model or CAD model can be found in **
Go to the official website of KUKA wwwkuka.com, main menu - after-sales service - **filter the required file format and robot model can be direct**.
、I can't enter the system when I boot it
Note: Because the SmartPad and the KPC are connected through the remote desktop, when the PC system or CCU cannot work normally, it is possible that the SmartPad interface cannot be entered.
Scenario: The following steps are recommended:
1.Please guide according to the status of the CSP fault lamp at the customer's site, and the customer's site conditions can be viewed with the monitor, which can quickly judge whether the PC is a hard disk failure or a CCU failure.
2.If there is no external monitor condition, check whether the PC fan is running normally, and if the PC fan does not rotate, it is recommended to replace the PC motherboard and motherboard for testing. If the PC fan is running normally, it is recommended to reinstall the system files and replace the hard disk for testing.
3.Check whether the motherboard's memory modules are plugged in properly and whether the KPC motherboard and hard disk are connected properly. Whether it's because of the dust on the motherboard.
4.Conditionally, swap hard disks to check if the robot can enter the system. If you can get in, try to redo the system with the faulty hard drive, if the system fails, you need to replace the hard drive.
What steps do you need to do when the KUKA robot is put into operation (start-up).
1.Check before booting: aMake sure the ambient temperature is within 5 -55. b.The body-control cabinet cables and connectors are normal without external injury, and after being connected according to the wire standard, the buckle is firm and there is no shaking. c.After the power supply cable is energized, open the control cabinet door, close the Q3 switch to open Q1, and measure whether the line voltage of the 3 phases at Q3 is within the range and whether there is any phase loss. Disconnect Q1 and turn Q3 on.
2.Operation of the first start-up: Please refer to the quick start manual attached to the door of the control cabinet to turn on the battery power and turn on the machine. Follow the instructions in the manual to process the alarms related to the initial start-up, select the robot and activate the safety configuration (if any). At this point, the robot uses the input to operate the robot in T1 (operation mode), and connects it through the X11 safety loop interface to realize the interaction with safety signals such as external emergency stop safety doors before all modes of action can be used. This is the end of the run-in-operation, so please continue to check back on the run-up defined by KUKA.
3.[Main Menu] - [Put into Operation] - [Put into Operation Assistant] Enter the Put into Operation Assistant, click the relevant options step by step to operate, and complete the operation.
The robot cannot be started
Note: Because the SmartPad and the KPC are connected through the remote desktop, when the PC system or CCU cannot work normally, it is possible that the SmartPad interface cannot be entered.
Scenario: The following steps are recommended:
1.Please guide according to the status of the CSP fault lamp at the customer's site, and the customer's site conditions can be viewed with the monitor, which can quickly judge whether the PC is a hard disk failure or a CCU failure.
2.If there is no external monitor condition, check whether the PC fan is running normally, and if the PC fan does not rotate, it is recommended to replace the PC motherboard and motherboard for testing. If the PC fan is running normally, it is recommended to reinstall the system files and replace the hard disk for testing.
3.Check whether the motherboard's memory modules are plugged in properly and whether the KPC motherboard and hard disk are connected properly. Whether it's because of the dust on the motherboard.
4.Conditionally, swap hard disks to check if the robot can enter the system. If you can get in, try to redo the system with the faulty hard drive, if the system fails, you need to replace the hard drive.
, the bot cannot run
Hello, you may encounter one of the following situations:1Toggle the main switch of the control cabinet Q1, there is no electricity in the control cabinet, and there is no indicator light 2Toggle the main switch of the control cabinet Q1, there is electricity in the control cabinet, but it will "trip" after a period of time 3The control cabinet can be started, but it will eventually appear as "could not set up IP address" or "waitting for cyclic connection" on the teach pendant or external display4The teach pendant or external display can enter the system, but there is an "alarm", and the robot does not respond when it is enabled, and it cannot be manually in T1 mode 5The robot can be manually operated in T1 mode, but cannot be automatically or externally automated. Please confirm the status of your robot and ask your questions.
What are the causes of robot jitter?Mechanical reasons account for more
The causes of jitter problems are complex. Imagine the reason why a person moves bricks to move to shaky hands, it may be that the bricks are too heavy, it may be that the pursuit of speed is too strong, or it may be that the physical condition is not good and too weak. For the robot, the possible reasons are: 1. The load data input is incorrect (the input load data is too high or too low, and the difference between the actual load is too large and will cause jitter.) 2. There is a large turning or attitude change in the running trajectory of the robot, and too much acceleration will also cause jitter. 3. The default parameters of the motor in the project configuration of some models are incorrect, which makes the motor output mismatched and causes the robot to shake. The need to update the bot catalog and reconfigure the bot project can be solved. 4. The fastening of the foot bolts is not up to standard. 5. Optimize the position of the robot to avoid singular bits and limit bits. 6. The motor feedback control parameters are incorrect, and the configuration file needs to be changed.
The robot alarm torque is too large
1.Whether the additional load and load data are reasonable.
2.If it is an A2 axis alarm, focus on checking whether the balance bar is working normally.
3.Check whether the motor of the alarm shaft is in normal working condition and whether it has suffered an impact.
4.Whether the drive is working properly.
Why can the robot gearbox still run without oil?
The gearbox used by KUKA robots is a high-end product in the industry, and the material is very good, and it may not be possible to operate in the short term in the absence of oil or even lubricating oil, but the life of the gearbox will be greatly reduced. For example, a person's long-term high-pressure work will definitely affect his health and lifespan.
Why are robots overloaded in winter?
Winters are cool, especially in northern China. Gearbox lubricants are much thicker and put more resistance to gearbox operation. If the robot load is already close to critical, the additional resistance of the lubricant can cause an overload reaction. Preheat and run for a period of time, and it will operate normally after the oil temperature rises.
How to use the 3-point method to make a base coordinate system
1.You need to make a tool (tool coordinate system) 2Choose the 3-point method to make base 3Confirm three points according to the wizard prompts: the first point is the origin of the base coordinate system;The second point is a point in the positive direction of x, as far away from the origin as possible to guarantee accuracy;The third point is a point in the positive direction of y, as far away from the origin as possible to be accurate.
Can the teach pendant be directly interchangeable?
Interchangeable, the teach pendant is hot-swappable. For details on how to interchange, please refer to the KUKA SmartPad Handheld Programmer section of the Integrator's Manual, and most of the basics can be found in the Integrator's Manual.
, how to create a TCP tool coordinate system
1.You need to make a tool in advance
2.Select the 3-point method to make the base
3.Confirm three points according to the wizard prompts: the first point is the origin of the base coordinate system;The second point is a point in the positive direction of x, as far away from the origin as possible to guarantee accuracy;The third point is a point in the positive direction of y, as far away from the origin as possible to be accurate.
How to transport KUKA robots?
Please refer to the operating instructions and installation instructions for the corresponding model of your robot, which are detailed in the "Transportation" section. Please click on the "Robot Ontology Data Quick Query Channel<<<
, KUKA robot installation requirements
Please refer to the operating instructions for your robot model and the installation guide, which is described in detail in "Planning". Please click on the Robot Operation Manual, Installation Manual, Quick Query Channel<<<
What are the items of robot maintenance?
There is a detailed introduction in the operation manual of the corresponding model of your robot, please find the "maintenance" chapter in the catalog Please click on the operation manual of the robot body to quickly get the channel <<<
How long can the battery last if it is not charged?
The battery in the control cabinet is continuously charged while it is running. The function of the battery is to provide buffered power supply to equipment (KPP, PC, etc.) that needs to be buffered when the power supply is turned off.
、How to move the robot in global coordinates?
1.On the right side of the teach pendant interface, select the reference motion coordinate system as the global coordinate system
2.Power on the robot via the right button of the teach pendant. The movement of the robot in the world coordinate system can be realized.
Does the robot have relevant certification certificates to provide?
The robot needs to be used in conjunction with the tools and the safety equipment and facilities in the robot working area before it can be certified by CCC or CE certification.
How to match the robot body with the control cabinet or teach pendant?
You can view the shipment history of your robot, C: the back represents the control cabinet serial number, and R: the back represents the robot serial number. You can also bring the serial number of your teach pendant robot control cabinet to get in touch with us directly.
、Can KUKA robots be backed up?
KUKA robot supports **backup, which can be carried out through the teaching pendant operation interface file --> backup in the running state of the robot.
KUKA robots have several types of movement
Manual Slow Run (T1) Manual Fast Run (T2) Automatic Run (AUT) External Automatic Run (AUT Ext).
How to check the real-time speed of the KUKA robot when it is connected to an external axis motor of the KUKA brand
The speed of the robot and its external axis can be monitored by the variable $vel axis act[n], where n is 1 to 6 for the robot axis and 7 to 12 for the robot external axis.
、Is it possible to use the robot without a teach pendant?
The teach pendant supports hot swapping, click the white button above the teach pendant to pull out the teach pendant within 25 seconds.
, grounding standards for KUKA robots
Yes, the equation potential lines for the robot and the control cabinet must be present.
How to fill in the load data
Step 1Select the main menu Put into Run > Measure > Tool > Tool Load Data. 2.Enter the number of the tool in the Tool Number field. Confirm with the Continue key. 3.Enter load data: M column: Mass x, y, z columns: Position of the center of gravity relative to the flange a, b, c columns: Orientation of the principal axis of inertia with respect to the flange JX, JY, JZ columns: Moment of inertia (jx is the inertia of a coordinate system about the x-axis that turns at an angle with respect to the flange through a, b, and c. By analogy, jy and jz refer to the inertia around the y- and z-axis. ） 4.Confirm with the Continue key.
How many loads does the robot have, how to detect it?
The load of the robot is divided into the additional load of the robot (the additional load is used in the software package kukaloaddetect) and tool payload (tool payload is used with the package kukaloaddetermination).
、How to install the system on the USB flash drive without kuka system image?
If you do not have a KUKA to restore the USB flash drive, you need to use the installation CD to install Windows and KSS and other related software one by one. The installation disc is sold separately.
, KUKA robot accuracy
Accuracy data can be searched by searching for the installation guide document of the corresponding robot.
, glass gluing applications, and a 3D measurement system to guide the final glass pressing position, is there a need for an additional robot software package?
For gluing applications, we recommend the KUKA gluetech software package. In order for a 3D measurement system to exchange data with the robot and guide the robot to move, a data communication software package such as Ethernatkrl or Profinet is required. For package purchase and details, please contact 4008208865 or transfer to labor.
、Are all the gear oils added by KUKA robots the same type?
No. The KUKA AGILUS series of small robot gearboxes are filled with grease. Most models fill the gearbox with liquid lubricating oil. Some robots are used in the food industry to fill food-grade lubricating oil, and some robots work in a cold chain environment and need to be filled with low-temperature lubricating oil. Please refer to the robot operation manual for details.
If the robot is maintained once a year, will it improve the service life?
The maintenance frequency is high, which is beneficial and harmless to the operation status of the equipment. The maintenance interval specified by KUKA is obtained through durability testing, and the service life of the robot can be guaranteed as long as the maintenance is standardized within the specified cycle of KUKA.
, robot jitter
1.Check the anchor bolt tightening.
2.Check the tool load, which needs to match the actual load and not be overloaded (confirm that the information of the center of gravity moment of inertia of the weight is correct).
3.Optimize the robot position to avoid singular and limit bits.
4.Adjust the PID control parameters.
, the robot shakes
If the robot shakes, it is very likely to cause a safety accident, please stop the machine immediately to check whether the anchor bolts of the machine are tightened and whether the torque value is in accordance with the KUKA standard. For specific standard information, please call KUKA after-sales service**.
、How to configure profinet
1.The robot is the master station, and you need to install the device description file, set the device IP address, device name, etc., and assign it to the corresponding device signal mapping project.
2.Robot as slave You need to provide the PLC with the equipment documentation of the robot Robot sets the correct IP address (restart) Activates PROFINET Select the number of points to communicate Signal mapping.
, how to disassemble and install the external fan
1.Unplug the fan power connector in the control cabinet.
2.Remove the control cabinet back cover (four Phillips screws).
3.Remove the fan clip and cable clip (loose).
4.Carefully remove the power connector from the clamp to remove the fan.
5.When installing, you can do it in reverse order.
Why does the robot report an overload after it hits?
The robot runs somewhere, but in case of collision, blocking its way, the motor drive is resisted, the current and torque increase instantaneously, and the control system is overload protected to avoid further damage to the robot.
What is the cause of oil leakage?
Most KUKA robot gearboxes are lubricated with liquid oil, while some small robot gearboxes are lubricated with solid grease. If it is a small amount of grease oozing, there is no need to panic, this is due to the heat of the gearbox and the increase in internal pressure, just wipe it clean. Solid grease does not leak light continuously. Liquid lubricating oil leakage is divided into robot gearbox oil leakage, center hand oil leakage, and balance cylinder oil leakage. The gearbox and the center hand are lubricating oil, and the temperature rises during operation due to excessive lubricating oil, and the internal pressure increases, and the oil will seep out of the oil seal. Oil leakage can also occur if the oil seal is worn or opened. Inside the balance cylinder is hydraulic oil, and if the oil inlet valve or oil discharge valve is damaged, it will leak oilThe piston rod is dusted, and the oil seal will leak if it wears out over time;The weakest point of the balance cylinder is the pressure gauge, which can also cause oil leakage if it is hit.
, KUKA robot motor & cable burned out
1.Confirm whether there is an overcurrent caused by virtual plugging in the power supply socket of the robot control cabinet.
2.Whether there is excessive humidity in the working conditions on site.
3.Whether there is voltage instability in the external power grid on site, and the voltage value fluctuates greatly.
and how to optimize the running speed of KUKA robots
The KUKA robot motion online form has corresponding parameter setting buttons for linear motion and axis motion, and the operator can click on the online form setting button to operate.
, the IO module is faulty, and the input and output are not responding
Solution:1Measure the supply voltage of the IO module.
2.Check whether there is a fault in the network communication of the network cable.
3.Check whether the I/O configuration of the bot project is consistent with the actual configuration.
What are the external starting methods of KUKA robots?
It is mainly to use the IO signal of the upper PLC to complete the start, of course, it can also realize the communication mode to complete the start. Please refer to the Integrator's Manual for details.
The ambient temperature is too low, and the teach pendant is black
Confirm whether the ambient temperature is lower than 5 degrees Celsius, if the ambient temperature is lower than 5 degrees Celsius, the robot cannot be turned on, such a situation will occur, if not, it may be hardware damage. Please troubleshoot the fault in the following order from easy to difficult: 1. Teach pendant 2. Motherboard 3. Hard disk system.
Why does the oil seal of the robot gearbox fall off?
If the oil seal falls off after the gearbox has been replaced, you need to check to see if too much new oil has been added. The old oil inside the gearbox cannot be completely drained, so the amount of new oil injected cannot be greater than the amount of old oil released. Otherwise, it will cause too much oil and excessive pressure in the gearbox, causing the oil seal to detach. In the case of a new robot, it is necessary to send it back to KUKA for analysis according to the specific axis and operating conditions.
What software packages and configurations are required for robot welding
kuka.ethernet i/p，kuka.usertech，kuka.Servogunbasic, etc. The specific needs are determined according to your welding machine brand and welding needs.
How to judge the cause of the fault when the battery on the teach pendant is aging or the charging fuse is damaged
In the variable view window, enter $accu state in the name field to confirm the cause of the fault based on the obtained value. In addition, in order to ensure the battery life of the new robot before leaving the factory, the battery cable is not plugged in, and the battery needs to be connected to the X305 of the CCU.
, 5 shafts do not get an effective motor temperature
Cause: The 5-axis encoder cable is faulty or abnormally connected.
Recommended Steps:
1.Swap the A5 and A6 motor and encoder cables to determine whether the fault is transferred.
2.If the fault fails, the motor needs to be replaced, and if the fault does not fail, the encoder cable needs to be replaced.
When the non-standard external shaft is configured, why does there be a jitter noise?
The main reason is that the external shaft motor is not an official KUKA motor, and when configuring the motor, some of the motor parameter configuration data is still set according to the default parameters of the KUKA motor, which may not be suitable for the operation of the motor.
KUKA is an internationally renowned automation company with its headquarters in Augsburg, Germany. As a global provider of intelligent automation solutions, KUKA offers its customers solutions from a single source: from robots and work cells to fully automated systems and their networking, in the fields of automotive, electronics, metals and plastics, consumer goods, e-commerce retail, and healthcare. In November 2022, Midea Group completed a comprehensive acquisition and privatization of KUKA.