Posts by Cyberamos

Quote from SkyeFire

As a general rule, DO NOT restore an Archive from one robot onto another, unless you really know what you're doing. If all you want is the programs, then just copy/paste those module files.

The error might be RAM-related rather than storage. But RAM is limited by VxWorks, and the physical RAM needs to meet VxWorks requirements, so typical PC RAM is a crapshoot, and using the extra RAM requires risky tinkering with system config files.

How large is the /KRC/R1 directory on the hard drive? How large are these programs you're trying to import?

I modified the VxWorks settings and was able to restore the files successfully. Regarding the difference in KSS versions, everything seems to be working fine so far, as I only restored the program files, and they were restored without any issues.

Hello everyone,

I am currently restoring a backup on a KUKA KR30-3 with KRC2. The installed KSS version is 5.6.10, but the backup comes from a robot running KSS 5.6.7. During the restoration process, I receive an error message stating "No physical memory free" when attempting to restore program files, and the process does not complete successfully.

I am using a 125GB SSD.

Has anyone encountered this issue before? Any suggestions on how to resolve it?

Thanks in advance!

Quote from hermann

This are different mechanics, or had you a typo in the first post?

On the original controller try to copy the correct machine data for your arm. You should find them somewhere on drive D:

I found the issue, and it is related to the internal mechanics of the wrist. There was a small gap between the transmission gears, and after addressing this gap, it worked normally with the original KSS

manipulo=wrist

Quote from hermann

What exactly mean by that?

Did you change machine data to the data that matching your arm or not? If you didn't, forget the test, you used the robot with complete wrong machine parameters.

What I mean is that I tested the manipulator with both its original KSS and the KSS from another robot model (KR16L6 ZH16).

The original robot model is a KR16-2 ZH16-2. When using the KSS from the KR16L6 ZH16, the faulty manipulator worked normally in both T1 and automatic mode. However, the issue persists only when using the original manipulator (ZH16-2) with its own KSS. When using another ZH16-2 manipulator, the problem does not occur. This suggests that the issue might be mechanical or tuning-related in the original manipulator.

Quote from SkyeFire

This all suggests an issue with the A6 motor. Swapping the A6 motor with another robot, or with the A4 or A5 motor on the same robot, should be a simple test to rule this out.

It's hard to be certain, but my first thought is that the coupling between the resolver and the motor drive shaft may be coming loose, creating an illusion that the motor is moving.

Running your A6 loop test with a Trace running might also shed some light on the issue.

I’ve already performed this test. I swapped the A4 servo with the A6, as well as the A5 with the A6, and the same fault occurred since all three servomotors are of the same type and model.

I believe the issue is either software or mechanical because, when using the KSS from a different robot model (KR16L6 ZH16), the faulty manipulator worked fine. Additionally, I installed a new manipulator (ZH16-2), and it worked correctly with the original KSS. However, when using the KSS from another robot model and another new manipulator (ZH16-2), the same fault occurred again.

Question – Vibration on Axis A6 (KUKA KR16-2, Manipulator ZH16-2, KRC2)

I noticed an abnormal vibration in the servo motors of axes A5 and A6, especially in axis A6, which sometimes triggers the alarm:

"Confirm velocity monitoring axis A6"

Troubleshooting Performed:

The vibration mainly occurs in automatic mode, sometimes continuously, causing the robot to stop.

When I installed another manipulator, the problem did not occur, ruling out issues with the servo, drive, or controllers.

I tested the servo mechanically detached from the transmission, and the same alarm appeared when moving axis A6 in T1.

I removed the side cover of the manipulator to observe the transmission gears and created a program to move only axis A6 in a loop.

When the vibration started, I manually held one of the transmission gears, increasing resistance on the system, and the vibration immediately stopped.

I tested the same manipulator on a KR16L6 ZH16 using its KSS configuration, and it worked normally in both T1 and automatic mode.

Mechanical Checks Performed:

The servo and gearbox are properly coupled and aligned.

No excessive mechanical resistance was found in the system.

The transmission system is properly lubricated and assembled.

Question:

Could this issue be related to PID tuning?

What could be causing this vibration in axis A6, and what solutions should I try to resolve it?

Hello everyone,

I recently deactivated the Arctech A10 and activated the Arctech A20 on the same hard drive and image. Previously, with the A10, the wirefeed function worked correctly, allowing me to advance and retract the welding wire. Outputs 4 and 7 control the advance and retract functions, respectively, and they are functioning normally. However, after switching to the A20, I am unable to move the wire in the wirefeed function.

It's important to note that I was previously using a Fronius welding source and have now switched to an ESAB welding source. After installing the ESAB source, everything worked fine with the A10 package. However, when I tried to use it with the A20 package, this issue occurred.

When I check the digital output screen and press the wirefeed advance and retract buttons, the outputs do not light up.

I am using KSS version 4.1.18. Additionally, there is a Fronius Tech package created by KUKA Brazil for Fronius welding sources, which includes configurations for the Fronius Tech functions on the shortcut keys. Could this be interfering with the wirefeed buttons?

I have attached two backups for reference:

1. The latest backup with the A20 package activated and using the ESAB welding source.
2. Another backup where the ESAB welding source worked normally with the A10 package.

Any insights or suggestions would be greatly appreciated.

Thanks!

I have a KR 6 R900 sixx, and the A1 servo motor was burnt. I replaced the servo motor with a new one, but now I can't move the first three axes, A1, A2, and A3. I can only move the last three, A4, A5, and A6. When I try to move these first axes, it generates an error alarm with the code KSS26024.

Note: I only connected the cables for the A1 axis; I haven't done the mechanical assembly, and the RDC used to belong to a KR16 L8 arc, but it has the same article number. Could this issue be related to the mechanical assembly, internal cables, or the RDC?

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?

I have a similar issue, but I'm unable to run the brake test.