Hi All,
The background
From what I was told the cell was originally build and setup at KUKA Systems premises, pass FAT and sent to the client. It was on client side of the contract to install it on site, carry on the commissioning and SAT. The cell was installed but never fully commissioned. The access was locked for next 18 months due to construction of the rest of the site. I was asked by the control engineer, who design the whole system to support the client's commissioning team to finish the installation and run SAT.
The cell: KR270 R2700 ultra with KRC4 (KSS 8.5.8) and turntable set as external rotary axis E1, made of two servos (ME-60_110_30_S0 connected to KPP2-40) set in master-slave setup. Servos are connected to the gear train with a clutch in the middle.
After power up and fix all errors related to mistakes in wiring the site I stuck with below set of errors on the Smartpad:
- KSS36014 - Synchronization run, master-slave position deviation E1 active
- KSS36001 - Master-slave position deviation {Slave drive}
- KSS26024 - Ackn. Max. following error exceeded (E1,S1)
Unfortunately I couldn't find any solutions in Kuka Expert Pro database for the first two errors. I hope that during the installation servos were mechanically misalign from the factory alignment, so some kind of setting up process could fix it and KSS26024 is just a result of the first two. When I tried to jog the E1 on the Smartpad in T1 and watched the actual position with motor and slave boxes selected, I saw that the value of the slave motor angle changes but the value on the master almost didn't change at all.
Display Spoiler
I was told, the installation (mechanical and electrical) was done by construction workers under supervision of client's commissioning team which non has any experience in industrial automation. Half of the buried in walls cabling for this cell was installed wrong direction.
It would be much appreciated if you guys could share some knowledge how to do the synchronization or point me to a manual where I can find more information about the subject.
Update: I did a fault finding and found out that each clutch engage turntable at different angles. Looks like clutches are mechanically misaligned.
