The daily maintenance of the gear of the KUKA arm is the key to ensure the stable operation and extended service life of the equipment. The following aspects of maintenance cycle, inspection points, lubrication management, parts replacement, operation specifications and safety precautions for you to systematically organize the maintenance plan:
1. Maintenance cycle and check points
Periodic maintenance
Routine inspection: Check whether there is oil leakage and oil seepage on the surface of the gear box every day, and observe whether there is abnormal sound or vibration during operation.
Comprehensive maintenance: In-depth maintenance every 10,000 hours of operation or once a year (under harsh conditions), including:
Check the wear degree of gears and bearings (minor wear can be repaired by adjusting the clearance or changing the lubricating oil, serious wear needs to be replaced).
Check seals for aging or cracking to avoid oil leakage.
Monitor the gearbox temperature to prevent overheating from accelerating the oxidation of lubricating oil and component wear.
Critical component inspection
Gear and bearing: Observe whether the tooth surface is pitted, spalling or plastic deformation, and whether the bearing rotates smoothly.
Lubricating oil status: regular sampling test oil quality, if the deterioration or water content exceeds the standard need to be replaced immediately.
2. Lubrication management
Lubrication cycle
Change the lubricating oil at the manufacturer's recommended cycle (usually every 5,000 hours), with shorter cycles required in harsh environments.
Lubrication mode
Use synthetic gear oils specified by KUKA (such as Optitemp RB 2) and avoid mixing different brands or models.
When filling, ensure that the oil level is in the middle line of the oil window to avoid excessive or insufficient.
3. Parts replacement specifications
Gear change
Select the new parts that are completely consistent with the material, modulus and number of teeth of the original gear, and strictly match the positive meshing position when installing.
Bearing replacement
Note the bearing installation direction when disassembling. The new bearing should be pre-tightened to the torque specified by the manufacturer.
Seal replacement
Replace the entire sealing assembly first, clean the sealing tank before installation, and apply a small amount of grease to assist the sealing.
4. Cleaning and calibration
Cleaning specification
Use dry compressed air or a soft brush to clean the dust on the surface of the gearbox and avoid direct contact with water or solvents.
When deep cleaning, choose neutral water-soluble detergent, and do not use flammable or corrosive liquids.
Zero calibration
After changing gears or lubrication, the robot zero point needs to be recalibrated (with the special KUKA calibration tool).
5. Safety operation specifications
Power failure and protection
Before maintenance, cut off the main power supply and wear protective equipment such as anti-cutting gloves and goggles.
Tool usage specification
When removing the gear box, use a torque wrench to tighten the bolts to the standard torque (for example, the torque of the cover A2 bolt is 1.9Nm).
Troubleshooting principle
When abnormal sound or vibration is found, stop the machine immediately for inspection to avoid the expansion of the fault.
6. Special maintenance scenarios
Gear belt replacement: the shaft 5/6 gear belt should be removed synchronously, and the tension should be adjusted to the specified range after installation (usually detected by a special dynamometer).
Anti-rust treatment: After cleaning, it is necessary to spray anti-rust agent on exposed metal parts to prevent moisture erosion.