ROBOT
KR 15
Adjustment Instructions
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e Copyright
KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described 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 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 Interleaf
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Contents
1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2
Adjusting toothed belt tension on wrist axis motor units A 4, A 5 . . .
6
3
Checking and adjusting the toothed belt tension on in--line wrist . . .
8
3.1
Belt tension checking device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3.2
Checking and adjusting the toothed belt tension of A 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3.3
Checking and adjusting the toothed belt tension of A 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
3.4
Measuring the belt tension without the checking device . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
4
Measuring and adjusting toothed belt tension on in--line wrist . . . . . .
15
4.1
Measuring and adjusting toothed belt tension A 5/A 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
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Adjustment Instructions
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1
Valid for
1
General
KR 15/2
General
The Doc. Module ”Safety, General” is to be observed!
Apart from adjustment of the toothed belts, the robot does not require any further mechanical
adjustment. For adjustment operations on the electrical/electronic equipment of the robot
system, see Doc. module KR C, Section “Robot Mastering/Unmastering”.
Two axes (A 5 and A 6) of the in--line wrist are driven via toothed belts, as are two of the three
drive shafts in the arm (for A 4 and A 5). The tension of these toothed belts is to be checked
or adjusted in accordance with the following procedure after removal or installation of related
assemblies and at the maintenance intervals specified in the Section “Maintenance”.
When a new toothed belt is installed, the belt tension must be rechecked after
approximately 100 hours of operation and adjusted again if necessary.
Tools and additional equipment must be removed before the adjustment process is started
if they are likely to impede the adjustment work.
The description of the adjustment operations is subdivided into job steps with numbers in
brackets appearing before them. The text which immediately follows these steps must also
be read if it is specially marked by NOTE, CAUTION or a warning triangle, as many of these
marked texts refer to the preceding job step.
Example:
(6)
Press in plunger head (6) by hand until it just comes into contact with union nut (7).
Toothed belt A 6 has the correct tension when mark 1 on the inner sleeve (8) is just visible on the collar.
Some of the specially marked texts refer exclusively to everything that follows -- until the instruction is expressly revoked or the work is completed at the end of a section.
Example:
Turn main switch on the robot control cabinet to ”OFF” and secure it with a padlock to prevent unauthorized persons from switching it on again.
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Adjustment Instructions
2
Adjusting toothed belt tension on wrist axis motor units
A 4, A 5
Section 1 of this Doc. Module is to be observed!
Only the adjustment of the toothed belt stage of axis 4 is described. The procedure is, however, essentially the same for axis 5 (Fig. 1).
Before starting the adjustment work, it must be ensured that the toothed belts
are relieved of any weight, i.e. axis 4 must be vertical and in its zero position.
If the toothed belts are to be adjusted on an operable robot, the main switch on
the robot controller must be turned to the ”OFF” position and secured to prevent unauthorized persons from switching it on again.
(1)
Slacken the four Allen screws (Fig. 1/2, 4) until motor unit A 4 can be shifted without
play.
(2)
Place rope sling (2) around motor unit A 4 (3) and pull motor unit outwards horizontally
with a spring balance, applying a force of 70 N.
(3)
While maintaining the force on the spring balance, tighten the two Allen screws (4) located on the side of the motor unit facing away from the spring balance until motor unit
A 4 is fixed in this position.
(4)
Remove rope sling and spring balance.
(5)
Tighten the four Allen screws (2, 4) in diagonally opposite sequence with torque wrench,
increasing the tightening torque in several stages to the specified value (MA = 5.6 Nm).
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2
Adjusting toothed belt tension on wrist axis motor units (continued)
1
2
3
A5
A4
A6
4
Fig. 1 Adjusting the toothed belt tension on wrist axis motor unit A 4
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Adjustment Instructions
3
Checking and adjusting the toothed belt tension on in--line
wrist
Section 1 of this Doc. Module is to be observed!
3.1
Belt tension checking device
The two toothed belts A 5 and A 6 on the in--line wrist can be quickly and accurately adjusted
with the aid of a belt tension checking device (accessory). For the purpose of checking the
belt tension, this device (Fig. 2) uses a plunger to apply a reproducible measuring force to
the belt, whose subsequent deflection is then measured with the aid of a reference mark. Two
such marks (1, 2) indicate the correct tension settings for toothed belts A 5 and A 6.
A method of testing the belt tension without using this checking device is described in
Section 3.4.
When adjusting or checking the toothed belt tension, it must be ensured that for
toothed belt A 5 rotational axis 5 (Fig. 7/3) and for toothed belt A 6 rotational axis
6 (4) is vertical.
This torque--neutral position is required in order to prevent different strand
forces from occurring, which would invalidate the measurement.
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3
Checking and adjusting the toothed belt tension on in--line wrist (continued)
1
11
10
2
9
3 4
5
8
7
Starting position
6
8
3 4
11
Required position
for A 6
4
1
2
3
4
5
6
7
8
9
10
11
12
Screw
Clamping piece
Marking ring for A 6
Marking ring for A 5
Plunger
Plunger head
Union nut
Inner sleeve
Outer sleeve
Knurled screw
Toothed belt
Test force
12
12
Test insert
Required position
for A 5
Fig. 2 Starting positions and required positions for belt tension checking device
3.2
Checking and adjusting the toothed belt tension of A 6
If the toothed belt is to be adjusted on an operable robot, the main switch on the
control cabinet must be turned to the “OFF” position and secured with a padlock to prevent unauthorized persons from switching it on again.
(1)
Remove twelve M4x16 Allen screws (Fig. 3/1) and lock washers and take off cover (2).
(2)
Place clamping piece (Fig. 2/2) together with test insert into the groove marked “A 6”
milled into clamping piece mount, and fasten it with one M4x16 Allen screw (1).
(3)
Fasten clamping piece mount (Fig. 3/4) to housing A 5 with two M4x25 Allen screws
(5) in two tapped holes (3) so that the test insert comes into contact with toothed belt
A 6 at a distance of 113 mm from the axis, as shown in Fig. 4 and Fig. 7.
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Adjustment Instructions
2
3
1
5
4
Fig. 3 Arrangement of the belt tension checking device for measuring A 5 and A 6
(4)
Slacken knurled screw (Fig. 2/10) on clamping piece (2), and push outer sleeve (9) towards the toothed belt (11) until its end face just comes into contact with toothed belt
(11).
(5)
Tighten knurled screw (10).
(6)
Press in plunger head (6) by hand until it just comes into contact with union nut (7).
Toothed belt A 6 has the correct tension when mark (3) on the inner sleeve (8) is just
visible on the collar. (Required position for A 6 as shown in Fig. 2). If the tension is too
high or too low, steps 7 and 8 are to be carried out.
(7)
Slacken nut (Fig. 4/3) on eccentrically mounted axle (1).
(8)
Turn square (2) of axle in the required direction using an open--end wrench.
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3
Checking and adjusting the toothed belt tension on in--line wrist (continued)
The directions for “tight” and “loose” are marked.
(9)
Tighten nut (3) with 18 Nm.
(10) Check belt tension again in accordance with step 6.
(11) Repeat adjustment and checking procedure if necessary until mark (Fig. 2/3) is correctly positioned.
(12) Remove M4x16 Allen screw (Fig. 4/6) and take off test insert (7).
(13) Remove two M4x25 Allen screws (4) and take clamping piece mount (5) from housing.
(14) Mount cover A 5 (Fig. 3/2) and fasten it with twelve M4x16 Allen screws (1) and lock
washers.
1
2
F= Force applied to plunger
head by hand
3
7
FA 6
6
4
∡A 6
5
Fig. 4 Adjusting toothed belt A 6 (= Section A--A in Fig. 7)
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Adjustment Instructions
3.3
Checking and adjusting the toothed belt tension of A 5
If the toothed belt is to be adjusted on an operable robot, the main switch on the
control cabinet must be turned to the “OFF” position and secured with a padlock to prevent unauthorized persons from switching it on again.
The procedure for adjusting toothed belt A 5 (Fig. 5/1) is essentially the same as described
in Section 3.2, steps 1 to 14. Step (3) must read as follows: “... comes into contact with
toothed belt A 5 at a distance of 76.5 mm from the axis, as shown in Fig. 5 and Fig. 7.”
The clamping piece together with the test insert must be placed into the groove
marked “A 5” milled into the clamping piece mount. The position of the clamping piece mount on the housing is the same as for checking toothed belt A 6.
If the tension is correctly adjusted, the mark (Fig. 2/4) must still be just visible (required
position for A 5 as per Fig. 2).
1
F= Force
applied to
plunger
head by
hand
FA 5
∡A 5
Fig. 5 Adjusting toothed belt A 5 (= Section B--B in Fig. 7)
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3
3.4
Checking and adjusting the toothed belt tension on in--line wrist (continued)
Measuring the belt tension without the checking device
The correct belt tension can also be determined without the belt tension checking device.
The equipment used for this purpose must ensure that the specified values for
--
angle in relation to cover mounting surface,
--
distance from axis,
--
measuring force and
--
deflection of toothed belt
can be measured with sufficient accuracy.
The respective angles, distances, forces and deflections are summarized in Fig. 6. The measuring set--up for the various toothed belts is illustrated in Fig. 7.
Toothed belt
Distance of force
application point
from axis
see Fig./
item
Angle in
relation to
cover
mounting
surface
see Fig.
Test force
Deflection
A6
A5
113 mm
76.5 mm
Fig. 7/1
Fig. 7/2
72°
39°
Fig. 4
Fig. 5
7.5 N
7.5 N
2.5 mm
4.5 mm
Fig. 6 Measuring conditions
A
A
B
B
A5
76,5
113
A6
1
2
3
4
Fig. 7 Measuring set--up
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Adjustment Instructions
3
2
5
3
4
1
Fig. 8 Adjusting belt tension
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4
4
Measuring and adjusting toothed belt tension on in--line wrist
Measuring and adjusting toothed belt tension on in--line wrist
Only the adjustment of the toothed belt stage of axis 5 is described. The procedure is, however, essentially the same for axis 6. The allocation of the eccentric shafts to the respective
toothed belts is illustrated in Fig. 7.
The Doc. Module “Safety, General” and the Doc. Module “Robot, Adjustment Instructions” (Chapter 1) is to be observed!
When measuring or adjusting the toothed belt tension, it must be ensured that
for toothed belt A 5 rotational axis 5 and for toothed belt A 6 rotational axis 6 is
vertical.
This torque--neutral position is required in order to prevent different strand
forces from occurring, which would invalidate the measurement.
If the toothed belts are to be adjusted on an operable robot, the main switch on
the robot controller must be turned to the ”OFF” position and secured to prevent unauthorized persons from switching it on again.
4.1
Measuring and adjusting toothed belt tension A 5/A 6
(1)
Remove twelve M4x16 Allen screws (Fig. 9/1) and lock washers and take off cover (2).
1
2
Fig. 9 Cover
(2)
Switch on belt tension measuring device (Fig. 10/1).
(3)
Pluck toothed belt and hold sensor (2) at a distance of 2 to 3 mm from the vibrating
toothed belt; read measurement on the belt tension measuring device.
(4)
Repeat the measurement three times.
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Adjustment Instructions
1
2
Fig. 10 Belt tension measuring device
If the value indicated in Fig. 11 is not obtained, steps 5 to 9 are to be carried out.
Axis
Toothed belt
Frequency
A5
8 ATS/720--6/8
195 Hz ¦3
A6
8 ATS/620--6/8
210 Hz ¦3
Fig. 11 Toothed belt tension
(5)
Slacken hexagon nut (Fig. 8/1) on eccentric shaft (2).
(6)
Push open--end wrench onto square (3) and turn eccentric shaft (2) in required direction.
The directions for “tight” and “loose” are given on in--line wrist.
When tightening the hexagon nut (1), make sure that adequate locking is
achieved.
(7)
Tighten hexagon nut (1) with 19 Nm, holding the eccentric shaft (2) firmly to prevent it
from turning.
(8)
Measure toothed belt tension again as per steps 2 and 4.
(9)
Repeat measuring and adjustment procedure if necessary until the value in Fig. 11 is
obtained.
(10) Mount cover (4) and fasten it with twelve M4x16 Allen screws (5) and lock washers.
1
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