Technical maintenance of the Kuka robot is the key to ensure its high performance and high reliability operation. Combined with official documentation and field experience, the following are the core maintenance points:
1. Daily inspection and cleaning
Inspection of moving parts
Joints and cables: Check the wear of moving parts such as arms, joints and grippers daily to ensure that the cable harness is not damaged or aged.
Brake and zero position: Verify whether the brake function is normal and check whether the robot zero position calibration is accurate.
Environmental cleanliness
Dust removal: Use dry compressed air to clean the motor, gear box and body dust, avoid direct contact with water or solvent.
Perimeter management: Keep the environment around the robot dry, remove flammable materials (such as tarpaulin, paint), and ensure no magnetic field interference.
2. Lubrication and component maintenance
Lubrication cycle
Joint lubrication: Lubricate bearings, chains and rails according to the manufacturer's recommended cycle (usually every 500-1000 hours).
Gear box maintenance: Check the gear box for oil leakage, and replace the lubricating oil regularly (refer to the recommended period of the manual).
Battery and storage
Battery replacement: Replace the control cabinet battery every 3-5 years to prevent data loss or system time errors.
Data backup: Periodically back up controller memory to ensure program and parameter security.
3. Control system maintenance
Control cabinet inspection
Heat dissipation cleaning: Clean the fan and heat sink of the control cabinet to prevent dust blockage.
Voltage monitoring: Check the stability of the 27V low-voltage power supply to ensure the normal power supply of the control board.
Software upgrade
System updates: Periodically install official software patches to fix vulnerabilities and improve functionality.
Parameter calibration: Use special tools for kinematic parameter calibration to ensure positioning accuracy (such as soft floating calibration combined with dynamic testing).
4. Rectify the fault and replace parts
Common fault handling
Collision alarm: Check for balance cylinder leakage or joint wear, calibrate torque parameters.
Motor overload: Check the aging line, poor contactor contact or load matching problems.
Parts replacement process
Reducer replacement:
Power off and stop, disassemble the motor and protective cover;
Use torque wrench to loosen the fixed bolt and lift the old reducer;
Clean the installation surface, locate the new reducer and fill lubricating oil;
Low speed test to verify no abnormal noise or vibration.
5. Safety specifications
Operation safety
Protective equipment: Wear insulation gloves, goggles and special workwear during maintenance.
Emergency stop function: Periodically check the effectiveness of the emergency stop button to ensure that there is no short circuit in the safety circuit.
Compliance check
Safety labels: Keep the safety warning labels on the robot body and the control cabinet legible.
Compliance testing: Annual safety compliance checks are conducted to comply with ISO 10218, ISO 13849 and other standards.
6. Preventive maintenance program
Annual maintenance: Complete inspections are performed annually, including oil changes, battery testing, and system calibration.
Status monitoring: Analyzes running data based on controller logs to predict potential faults, such as abnormal vibration and high temperature.
By strictly implementing the above maintenance points, the stability and life of Kuka robots can be significantly improved. It is recommended to make a personalized maintenance plan by referring to the KUKA Robot Maintenance Manual and shorten the maintenance period for scenarios with high loads and high frequency of use.