Maintenance of Kuka robot

Quote from KovBo

-Does the KUKA provide extra services that are not listed in manuals?

of course there are additional repair and maintenance steps that are not mentioned in user documentation. user documentation only covers things that users may choose to do themselves. other things require specialty tools and training which require KUKA service techs.

same is with your car, TV or computer. maintenance and repair steps listed in their documentation are largely superficial since users are not qualified to do much more than wipe screen, refill windshield washer, check tire pressure.

you can contact KUKA and have their service team take care of all maintenance or you can do some of it yourself if you are sure to understand the documented process.

Quote from KovBo

-How does the KUKA perform customer support? For example, the robot or control system have problem, KUKA will give remote consultation or the arrival of a specialist?

that depends on your arrangement with KUKA. it can be as little as nothing or custom royal service. to get KUKA service and support you have to have an account. without relationship nothing happens. then when you have a problem you contact KUKA service hotline. your problem description is collected and entered into a database, suitable remedy is chosen and offered. some things may be resolved over the phone. those that don't would require technician on site. he/they would bring needed tools and parts to perform the task.

Quote from KovBo

-Does the big difference between the official KUKA service and local companies on service?

There is a huge difference - specially in training and competence of the techs.

Clients can get KUKA training. There are several paid courses but they pale in comparison to internal training that only KUKA service techs can get. So if 3rd party says that they are trained by KUKA, that is possible but does not come even close to what KUKA team is capable of. Not to mention that KUKA service team has a lot of insider info and engineering department to relay on for assistance - something that 3rd party will not have.

For example

Training that clients and 3rd party techs can get other than programming courses:

* Electrical servicing (1 week)

* Mechanical servicing (1 week)

And that is pretty much it. Also prerequisites are very low (speak the language and know how to jog robot). If you are KUKA partner or large client, you may also participate in occasional workshop.

Passing grade is 50%.

KUKA service techs requirements are different. They are hired not only for their ability to speak but for their technical background (electrical/mechanical/mechatronics...). They must pass above courses but that is just the beginning. and the passing grade is 75%. And then the real training can begin which takes another 6 weeks (3x 2 weeks) to become certified KUKA technician. This is a long term goal. it may take 2 years or longer to achieve (depends on where you are, where the courses are offered and availability of training seats). Tech sent to deal with your problem may not have reached the legend status yet. And this is not it, there are plenty of other courses that KUKA techs have access to (if they are so inclined).

But that is the training aspect only. There is also access to specialty tools and other internal resources that others are unlikely to have - for example deep database history of service cases around the world, channels to access engineering and even RnD if needed. also KUKA usually has an army of techs (depends on region) meaning they get to specialize in certain things. in other words someone can get very efficient with certain type of work.

Quote from KovBo

-What advice would you give about work with a service company?

not sure what you mean. if you are working for service company get all training you can. identify and obtain tools needed. practice a lot to stay in shape.

if you are client using services and trying to some things yourself - get informed, get as much training as possible, do only things you trained on. let KUKA do at least some of major services, watch over their shoulders and ask questions, do not tackle things yourself that require arm disassembly unless you got the training. do not disassemble small robots, it is very unlikely you will be able to put them back together (at least not correctly). get mastering tool. if you are replacing belts get belt tension frequency meter. if you are changing oil get the proper tools (valves, pump, buckets, etc.) and measure volume of oil for each axis (old and new!). get KUKA USB Recovery stick and make full backup of each robot (archive and HDD image). make sure your robots are commissioned correctly. this means more than being able to run process they are intended for. check the soft limits, tool loads, supplementary loads. test all safety. do regular inspection and check for any sign of wear or contamination (leaks, dust collecting etc.). check logs for critical messages (overcurrent, overtemperature, collisions, loss of mastering...)

Quote from KovBo

P.S. If someone shares an example of a technical task for service of robot, I will be happy.

this is too broad to cover but some tasks are:

oil change

belt replacement

mastering

backlash measurement

counterbalance service or replacement

replacing of components (motors, harnesses,etc) inside and outside of the robot arm and controller.

installing and upgrading of software

maintenance/setup of with specialty cases (roboteam, custom kinematics, external axis luch as linear rail or positioner setup, etc.)