Problem with KR6 R900 Sixx

    Hello!

    I'm facing an issue with a KUKA KR6 R900 sixx robot and I would like to share my situation to see if anyone can help me. When releasing the "deadman switch," I have noticed an intermittent slipping problem on axes A2 and A3 of the robot. I have already conducted several tests to try to resolve the issue, but so far, I have not been successful.

    Initially, I replaced the RDC (Remote Device Controller) hoping that it would solve the problem. Unfortunately, the slipping issue persisted even after the replacement. Next, I decided to replace the servo motor, thinking that the problem might be related to that specific part of the robot. Unfortunately, even with a new servo motor, the slipping of axes A2 and A3 still occurs.

    In light of this situation, I also swapped the gearbox, suspecting that it could be a transmission of power issue to these axes. However, even with a new gearbox, the intermittent problem continues to occur. Additionally, I attempted to switch the robot cabinets, testing both the KRC4 Compact (KSS version 8.3.19) and Smallsize (KSS version 8.3.33), but unfortunately, the slipping issue persists.

    The problem is further exacerbated by the fact that the robot generates an error, and I have yet to identify the root cause. I have attached the error report to the post for a more detailed analysis.

    It is worth mentioning that I am using KSS version 8.3.33 on the Smallsize cabinet. Perhaps there is a specific configuration or software update that can help resolve this issue. However, on the Compact cabinet, I am using KSS version 8.3.19.

    If anyone has any suggestions or has encountered a similar problem with the KUKA KR6 R900 sixx robot, I kindly request that you share your experience or knowledge. I am open to any suggestions that can help me resolve this intermittent slipping issue on axes A2 and A3 when releasing the "deadman switch."

    I appreciate any assistance that can be provided. I am eager to solve this problem and resume normal operations with the robot.


    Error on smartpad: KSS15016 Ackn.: Stop due to standstill monitoring violation

  • panic mode May 29, 2023 at 2:35 PM

    Approved the thread.

    replacing brakes is done by replacing entire motor. replacing motors on compact robots (like Agilus) is a lot of work. so having some confidence in where the problem lies is important. you already did try robot arm on another controller with the same results so most likely the issue is the brakes themselves. if this was on the wrist axes one could also question belts, camshaft etc.

    another thing is to run Trace (electrical or mechanical servicing config) and jog those axes couple of time. then send this together with KRCDiag to KUKA.

    1) read pinned topic: READ FIRST...

    2) if you have an issue with robot, post question in the correct forum section... do NOT contact me directly

    3) read 1 and 2



    I didn't phrase the question correctly, but I also have the same problem with a KUKA KR6 R900 sixx, but I don't know how to run the brake test program. I found the program at C:\KRC\ROBOTER\KRC\R1\TP1\BrakeTest, but as I mentioned, I don't know how to execute it. Could you help me with that?

    Hello Cyberamos,

    Have you tried the "braketestreq ()" ?

    I have a line on CELL.src, which calls for this function, you may want to test this manually...


    Edit: when go to definition of this routine, the path is "C:\KRC\ROBOTER\KRC\R1\TP1\BrakeTest\BrakeTestReq.src"

    "Hell...Yesterday it was workinG... I sweaR" :o)

    I have installed a new servo motor for the A2 axis, but the A3 axis still has its original servo motor. Despite the replacement, the intermittent slipping issue persists. Could there be any correlation between the two axes causing this problem?

    Quick question, imagine the robot as a Z form, the robot slips in the upper angle or in the lower?

    If the problem is in the upper angle, then the problem is only in axis3.

    Another idea, is the weight of the loads within your robot range? I don't know about tolerances, but if you put 500kg on a little 0.5kg robot, well, it's gonna slip too.

    "Hell...Yesterday it was workinG... I sweaR" :o)

    O robô desliza de acordo com o gradiente, tanto no eixo A2 quanto no eixo A3.

    Ele exibe esse comportamento de deslizamento com e sem carga.

    O que me confunde é que o problema é intermitente e, se fosse um freio com defeito, aconteceria o tempo todo. Existe a possibilidade de ser um chicote elétrico ou uma combinação de servos com defeito?

    Mesmo quando executo apenas A1, ainda faz com que A2 e A3 escorreguem.

    OK, então tente verificar as conexões elétricas dos servos e dos freios. Já me aconteceu no passado que por algum motivo dois servos e dois freios estavam cruzados e isso fazia com que uma mesa de solda se movesse sozinha por gravidade.

    "Hell...Yesterday it was workinG... I sweaR" :o)

    The robot slips according to the gradient, both on axis A2 and axis A3.

    It exhibits this sliding behavior with and without load.

    What confuses me is that the problem is intermittent, and if it were a faulty brake, it would occur all the time. Is there a possibility of it being a wiring harness or a combination of faulty servos?

    Even when I execute only A1, it still causes A2 and A3 to slip.

    the last comentary i posted on portuguese, now in inglish

    Does anyone have any more test tips?

    Hello guys, any hints how to solve this issue KSS15016 ?
    I have this problem just in T1 mode, and on all axes including external axe A7 , i run drycycle on our tool arround 24h. in external mode, without error, just in T1.
    I ll be really thankfull for any hints how to solve it !!
    really thanks

    Kuka Agilus KR6 R900CR

    Hi guys!

    Kuka has a problem with genarating Motor files from workvisual, you will have to contact them...we had the same problem with the robot falling by about 10 mm. They will send you a (new motor file and Activaton filter) so that the file will not get overwritten... Problem is in ¨CloseTime=¨

    Path:

    C/KRC/Robot/Config/User/Common/Motor

    but as I said, you also need ActivatioFilter.config, because it will be overwritten with the new (workvisual) deployment

    Edited once, last by luka krizanec (October 18, 2023 at 2:33 PM).

    Quote from Burago

    Hello guys, any hints how to solve this issue KSS15016 ?
    I have this problem just in T1 mode, and on all axes including external axe A7 , i run drycycle on our tool arround 24h. in external mode, without error, just in T1.
    I ll be really thankfull for any hints how to solve it !!
    really thanks

    Kuka Agilus KR6 R900CR

    the problem is when you release the deadman switch and the brakes dont have enough time to close, in automatic mode that dont happen....you will need to contact KUKA

    Quote from luka krizanec

    the problem is when you release the deadman switch and the brakes dont have enough time to close, in automatic mode that dont happen....you will need to contact KUKA

    thank you Luka, i was in conntact with Kuka Slovakia also with Kuka Germany, and they didnt know how to help me, they try to modify some files inside kuka soft, without help , I was change everything - cables, controller, check wiring many times, and today we came to the decision to replace the robot and it helped, something is with the robot we create complaint and send robot to the KUKA, thats all. :smiling_face:

    Quote from luka krizanec

    Hi guys!

    Kuka has a problem with genarating Motor files from workvisual, you will have to contact them...we had the same problem with the robot falling by about 10 mm. They will send you a (new motor file and Activaton filter) so that the file will not get overwritten... Problem is in ¨CloseTime=¨

    Path:

    C/KRC/Robot/Config/User/Common/Motor

    but as I said, you also need ActivatioFilter.config, because it will be overwritten with the new (workvisual) deployment

    I did exactly these steps with a KUKA technician and it didn't help :thinking_face:

    Check schematics. If i recall A1 to A3 share same brake release circuit. However, brakes need to be energized to release. intermittent problem due to faulty wiring would likely be loss of brake power. In other words, brake would be applied in wrong time and axis would fault due to high torque.

    It is also possible that issue is in the brake release channel (servo drive) and that brake stays released fir too long. On older products this could be due to sticky relay but similar outcome us plausible in any type of circuit if ut is faulty

    1) read pinned topic: READ FIRST...

    2) if you have an issue with robot, post question in the correct forum section... do NOT contact me directly

    3) read 1 and 2

    Quote from panic mode

    Check schematics. If i recall A1 to A3 share same brake release circuit. However, brakes need to be energized to release. intermittent problem due to faulty wiring would likely be loss of brake power. In other words, brake would be applied in wrong time and axis would fault due to high torque.

    It is also possible that issue is in the brake release channel (servo drive) and that brake stays released fir too long. On older products this could be due to sticky relay but similar outcome us plausible in any type of circuit if ut is faulty


    Is this the error you are referring to? In what type of manual can I find more information about this error KSS15016? Or a troubleshooting guide?

    In solution 2, it indicates changing a variable or parameter in a file, but it does not indicate what they are. I found this message in the SafeConfiguration manual, am I looking correctly?

    Thanks for your time!

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