Oh well... i have to evaluate my options. Anyways i think the troubleshooting process has come to a conclusion. Thanks again for the help!
Posts by Nikolaos WS4
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Sorry for coming back to you only now. But I measured the backlash on every axis and found out you were right about it. Its the accumulation of many wear issues in all of the axis. I didn't mean to doubt you since i only have a tiny fraction of your experience. But since mechanical issues are the most laborious and risky to fix i thought it would be wise to eliminate any other possibility. Now we decided with a dear friend of me, who has very good mechanical knowledge and with the help of some manuals to take the arm apart in order access the gearboxes and did so with success. Finally its crystal clear where the problems are. The big question now is:
-Can you refurbish the gearboxes (by third parties or is kuka the only way to go)?
-If i have to buy new ones would you have a good reference for me or again kuka is the only way to go?
-Would it worth? Considering the purchase cost of the robot including transport and VAT was 12.5k euros (From Germany to Switzerland)
I know Nabtesco and Harmonics AG are making gearboxes for Kuka and other robot manufacturers but haven't tried yet to contact them.
Now my next questions are forum related.
-Should i change the title of the thread to make it better relate with the actual problem? If yes would you have any suggestions?
-Shall i mark it as resolved and open a new one concerning the repairs?
Thank you for your understanding and help!
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Just start-up the controller to proceed with further testing and got 1223 error saying ackn.under voltage A1 (it was maybe overlooked all this time and if that's the case i deeply apologize). Once acknowledged it doesn't reappear until next start-up. I will proceed with the further testing tonight, but thought that would be wise to let you know.
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Thanks for the clarification! Got some time with the bot today and here is what i got so far:
-Concerning the backlash when you say "set up a dial gauge on each axis" do you mean in the mastering plugs or externally attached to measure against something fixed (Sorry if this sounds stupid)? Because when i test in Cartesian in the same spot as the test in the first video at X and Y directions i get between 0.3mm and 0.4mm of lost motion (I have no idea what should i expect... but as long as i get an average accuracy of around 1mm on my millings i would be satisfied)
-Opened the belt cap and took a video of the "visible backlash" by moving the belt manually. I would like to know if this is looking nominal to you.
-Another thing that i forgot to mention before... Every time after start-up the robot jumps in its first move as shown in the beginning of the following video. Don't know if its related to my problem but it feeds my curiosity.
-Run also the precision test that you suggested (included as well in the following video) and everything looked inside the tolerance.
-Now the most interesting thing is the o-scope traces (while performing the same test as in the beginning of the thread) and A1 following error Spiked.
Video order:
0:03 Robot jumps in first move after start -up
0:08 Cartesian move in X 0.1 increments jog speed 100%
0:23 Cartesian move in Y
0:56 Cartesian move in Z
1:14 Backlash on A5 and A6External Content www.youtube.comContent embedded from external sources will not be displayed without your consent.Through the activation of external content, you agree that personal data may be transferred to third party platforms. We have provided more information on this in our privacy policy. -
First of all tnx for your answers!
I was a complete newbie when i bought the bot and there is a lot of thinks that i regret now (e.g. not to have the manuals delivered with robot)...
But nevertheless its a nice adventure and this forum was the greatest help so far
Have been said all that, i am also suspecting backlash since its an old bot but din't know how to measure it.
I will aply your methods as well the ones mentioned in this thread:
Also spend some time in the forum and found out that tool load data was set correctly (or at least this is what i think) but the robot is seriously under loaded (20kg). Skyfire stretched it enough in many threads "at least 30% of max weight"... So i will scrap some lead and built a couple of weights. Is there something like KUKA.LoadDataDetermination for kss 5,6? Or is somewhere a good explanation on how to do it manualy? So i can compare it with what i did so far.
Now concerning the O-scope traces definitely worth trying. I know where it exists but have no idea how to use it. I will need to spend some time with the Fault-Analysis-Diagnosis manual. It has an extended explanation about it.
I will come back to you once i will acquire all this valuable data. Until then Farewell!
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Hello all,
I have a similar problem to the one described in an old thread: kr200 odd movement behavior
its difficult to explain indeed, as uberdoom said. So i will try my best... Also attached a video link:
External Content www.youtube.comContent embedded from external sources will not be displayed without your consent.Through the activation of external content, you agree that personal data may be transferred to third party platforms. We have provided more information on this in our privacy policy.The robot i use for wood milling and foam wire cutting:
-kr200 L140 comp 2,
-krc2 ed05 Daimler version,
-windows XP embedded 2.0, KSS 5.6.6.
-Manufactured 2007-11
-RDC said 15.400h when bought and i put another 600h
Problem appears in this example when Jogging the robot in T1-global using the A +/- also appears in the beginning of all moves in global or tool specific and at change of direction in LIN and CIRC motions in T2 and AUT. The exception is the Axis specific which works fine although i get a slow rotation of the A5 servo after releasing the green button. Its like comming back to the correct position. The error is repeatable and speed proportional. Also i think it worth to mention that the error was there since commissioning but it seams to have intensified. I would like to give it a shoot in fixing it as much as possible before going for the expensive service with kuka.
I already checked:
-Mechanical wear and nothing obvious,
-DSE-RDW tool for errors and got 00C0 in the error box of the "RDC - Check communications"
-Tool load data but only tested in jog and did not have any effect (not sure if it needs to run in a program to have effect)
-Mastering with dial gauge
-tool calibration
-Mada file as prescribed in the attached thread
Any ideas?
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Thanks spirit! I will take your advice and do this tonight.
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Hi all and thanks for your quick replies!
I have connected keyboard, mouse and external monitor. When pressing F2 i am able to access bios settings, when pressing F12 I get boot options and when pressing F10 it directly resumes windows (Although when in bios the message: "F10 key detected..." appears on the bottom left of the screen). Now when i choose cd-rom from boot options it appears like if clonezilla live cd is not bootable or a timeout occurs in boot priorities. I followed instructions here:
https://clonezilla.org/show-live-doc-…nezilla_live_CD
Now concerning taking out HDD from controller its something that i would like to avoid for now, at least not before i allready have a working backup image, or if i have no other choise! In that case i have both IDE to usb adaptor and an old alienware which supports IDE (I still have to mount it in a case thought).Any further suggestions would be highly appreciated, thanks in advance!
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Hello all, its my 1st time posting on this forum, i am completely new to robotics and we recently bought a:
-kr200 L140 comp 2,
-krc2 ed05 Daimler version,
-Celeron 2.0Ghz and 512 mb ram,
-windows XP embedded 2.0, KSS 5.6.6.
-BIOS V4.06 R1.05-08.1688.01I would like to create a backup image of HDD before doing something stupid, but so far did not manage to boot with clonezilla. Installed cd-rom drive with success, burned 2 cd's with 2 different clonezilla (.iso) versions i486 and i686, choose cd-rom from boot menu, then the cursor is blinking on top of the screen for a few seconds... before finally loading to windows. Does anyone know which version of clonezilla works with this controller or should i continue burning cd's until i find a working one?
Do i miss something else?Thanks in advance for any help!