QKM AH20 User manual

Maintenance Manual
AH20 Robot
AH20-0850-0204-2000
AH20-0850-0204-4000
AH20-1050-0204-2000
AH20-1050-0204-4000
Document version
V1.0.1
Issued on
September 21, 2022
QKM Technology (Dongguan) Co., Ltd.

Preface
Document Version V1.0.1 (09-21-2022) I
Preface
Thank you for purchasing the robot produced by QKM!
This manual describes the instructions to maintain the robot.
Refer to the contents of this manual for maintenance.
Please keep this manual properly for future reference.
Overview
This manual provides detailed information on the routine maintenance and safety
inspection of AH20 Robot, as well as the maintenance of mechanical and electrical
components, so that users can better use AH20 Robot; this manual can serve as a
reference for system integrators to design user workstation systems by using our AH20
Robot, and can also be used to guide system installation, commissioning and
maintenance.
Target readers
This manual is for the reference of:
Electrical Engineer
Maintenance Engineer
Mechanical Engineer
Technical Support Engineer
Signs
The signs in this document clearly indicate any dangers, warnings, attentions and
notes that may occur while users perform the operations described in this manual;

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be sure to pay attention to the following signs when they appear in this document.
The signs in this manual are described in the table below:
Signs
Description
It indicates that a dangerous situation would occur and
cause serious personal injury or death if it is not avoided.
It indicates that a potentially dangerous situation would
occur and cause personal injury or robot damage if it is
not avoided.
It indicates that an unpredictable situation would occur
and cause robot damage, performance degradation, data
loss, etc. if it is not avoided.
It gives the description on key information and operation
tips.

Preface
Document Version V1.0.1 (09-21-2022) III
Copyright© 2022 QKM Technology (Dongguan) Co., Ltd.
All Rights Reserved.
QKM Technology (Dongguan) Co., Ltd. (hereinafter referred to as QKM) owns the
patents, copyrights and other intellectual property rights of this product and its
software. Without the written authorization of QKM, any unit or individual shall not
extract or copy the contents of this document; and shall not directly or indirectly
reproduce, manufacture, process and use this product and related parts.
Caution
The contents of this document are subject to change any time due to product upgrade
or other reasons. QKM reserves the right to change the contents of maintenance and
operation in this manual without prior notice. For the recent information on this
product, please download the latest manual from our official website.
Trademark statement
is the trademark of QKM, and QKM possesses the ownership of the
trademark.
Disclaimer
Users need to be careful to maintain and operate the robot in a safe environment.
QKM assumes no obligation and responsibility for incidental or consequential losses
arisen therefrom.

AH20 Robot Maintenance Manual
IV Document Version V1.0.1 (09-21-2022)
QKM does not assume any direct, indirect, special or incidental loss or liability due to
improper use of this product.
QKM Technology (Dongguan) Co., Ltd. (Headquarters)
Tower A, Building 17, Headquarters 1, No. 4 Xinzhu Road, Songshan Lake High-tech
Industrial Development Zone, Dongguan City
Tel.: [phone]
Fax: [phone]-8053
Post code: 523808
Email: [e-mail]
Website: www.qkmtech.com

Version History
Document Version V1.0.1 (09-21-2022) V
Version History
The version history contains the accumulated information on each update of the
document, and the latest version of the document includes the updates in all previous
versions of the document.
Version
Time
Change Content
V1.0.0
June 10, 2022
The first version of the document was
released.
V1.0.1
September 21, 2022
The description of encoder battery
maintenance in Section 5.2 was modified.

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Table of Contents
Preface................................................................................................................................... I
Version History..................................................................................................................... V
List of Figures....................................................................................................................... X
List of Tables ...................................................................................................................... XII
Chapter 1 Safety Precautions .......................................................................................... 1
1.1 Precautions for operation....................................................................................... 1
1.2 Precautions for electrical safety............................................................................. 2
1.3 Warning sign ............................................................................................................ 3
Chapter 2 Safety Maintenance......................................................................................... 5
2.1 Use of robot in accordance with regulations......................................................... 5
2.2 Safe area................................................................................................................... 5
2.3 E-stop device............................................................................................................ 6
2.4 Precautions for general safety................................................................................ 7
Chapter 3 Routine maintenance and safety inspection ................................................ 9
3.1 Routine inspection .................................................................................................. 9

Table of Contents
Document Version V1.0.1 (09-21-2022) VII
3.2 Regular inspection................................................................................................. 10
3.3 Cleaning and maintenance................................................................................... 10
3.4 Safety inspection................................................................................................... 11
3.5 Handling of common exceptions ......................................................................... 12
Chapter 4 Maintenance of Mechanical Components................................................... 14
4.1 Lubrication of spline screw shaft ......................................................................... 14
4.1.1 Standard type................................................................................................. 14
4.1.2 Protective type ............................................................................................... 19
4.2 Removal and installation of protective cover...................................................... 19
4.2.1 Removal of protective cover.......................................................................... 20
4.2.2 Installation of protective cover ..................................................................... 26
4.3 Cover ...................................................................................................................... 33
4.3.1 Robot cover..................................................................................................... 33
4.3.2 Base side door................................................................................................ 35
4.3.3 Connector panel............................................................................................. 37
4.4 Timing belt tension measurement....................................................................... 39
4.4.1 Measuring instrument.................................................................................... 39
4.4.2 Parameter setting........................................................................................... 41

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4.4.3 Measuring steps and display......................................................................... 41
4.4.4 Measuring results........................................................................................... 44
4.4.5 Precautions..................................................................................................... 45
Chapter 5 Maintenance of Electrical Components ...................................................... 47
5.1 Replacement and maintenance of 1-axis motor fan........................................... 48
5.1.1 Replacement of 1-axis motor fan.................................................................. 48
5.1.2 Maintenance of 1-axis motor fan .................................................................. 51
5.2 Replacement and maintenance of encoder battery........................................... 53
5.3 Replacement and maintenance of controller assembly .................................... 56
5.4 Replacement and maintenance of IO-free-distribution PCBA........................... 58
5.5 Replacement and maintenance of surge suppressor......................................... 61
5.6 Replacement and maintenance of filter .............................................................. 64
5.7 Replacement and maintenance of QBUS module .............................................. 67
5.8 Replacement and maintenance of QBUS fuse .................................................... 70
5.9 Replacement and maintenance of 24 V switching power supply...................... 72
5.10 Replacement and maintenance of 24 V switching power module cooling
fan ........................................................................................................................................ 74

Table of Contents
Document Version V1.0.1 (09-21-2022) IX
5.11 Replacement and maintenance of the fan assembly of the mechanical arm
2............................................................................................................................................ 77
5.12 Replacement and maintenance of brake PCBA ................................................ 79
Chapter 6 Technical service........................................................................................... 83
6.1 Consulting and services........................................................................................ 83

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List of Figures
Figure 1-1 Position of warning sign ................................................................................... 4
Figure 4-1 Special oil brush............................................................................................. 15
Figure 4-2 Push down the spline screw shaft ................................................................ 16
Figure 4-3 Apply lubricating grease................................................................................ 17
Figure 4-4 Push up the spline screw shaft ..................................................................... 17
Figure 4-5 Diagram of robot covers ................................................................................ 33
Figure 4-6 Removal of fastening screws......................................................................... 34
Figure 4-7 Lift the cover................................................................................................... 35
Figure 4-8 Removal of fastening screws......................................................................... 36
Figure 4-9 Take out the side door of the base................................................................ 37
Figure 4-10 Remove the fastening screws from the connector panel.......................... 38
Figure 4-11 Open the connector panel........................................................................... 38
Figure 4-12 Appearance of the instrument .................................................................... 39
Figure 4-13 Introduction of the screen........................................................................... 40
Figure 5-1 1-axis motor fan ............................................................................................. 48
Figure 5-2 Tear off the warning sign ............................................................................... 49
Figure 5-3 Take out the protective cover........................................................................ 49
Figure 5-4 Remove the fan assembly ............................................................................. 50
Figure 5-5 Take out the fan assembly............................................................................. 50

List of Figures
Document Version V1.0.1 (09-21-2022) XI
Figure 5-6 Diagram of encoder battery .......................................................................... 54
Figure 5-7 Position of encoder battery connector......................................................... 55
Figure 5-8 Controller assembly....................................................................................... 56
Figure 5-9 Remove the controller assembly .................................................................. 57
Figure 5-10 IO-free-distribution PCBA............................................................................ 59
Figure 5-11 Removal of IO-free-distribution PCBA........................................................ 59
Figure 5-12 Removal of IO-free-distribution PCBA........................................................ 60
Figure 5-13 Surge suppressor ......................................................................................... 62
Figure 5-14 Removal of fastening screws....................................................................... 63
Figure 5-15 Filter .............................................................................................................. 65
Figure 5-16 Removal of fastening screws....................................................................... 66
Figure 5-17 QBUS module............................................................................................... 68
Figure 5-18 Removal of QBUS module........................................................................... 69
Figure 5-19 QBUS fuse..................................................................................................... 71
Figure 5-20 Diagram of 24 V switching power supply ................................................... 73
Figure 5-21 Removal of power module .......................................................................... 74
Figure 5-22 Switching power supply fan assembly....................................................... 75
Figure 5-23 Remove the power module cooling fan ..................................................... 76
Figure 5-24 Fan assembly of the mechanical arm 2...................................................... 78
Figure 5-25 Removal of the fan from the mechanical arm 2......................................... 79
Figure 5-26 Brake PCBA of the mechanical arm 2 ......................................................... 80
Figure 5-27 Removal of the brake PCBA from the mechanical arm 2 .......................... 81

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List of Tables
Table 1-1 Warning signs..................................................................................................... 3
Table 3-1 Routine cleaning and maintenance schedule............................................... 10
Table 3-2 Handling of common exceptions ................................................................... 12
Table 4-1 Selection of lubricating grease....................................................................... 15
Table 4-2 Accessories....................................................................................................... 21
Table 4-3 Accessories....................................................................................................... 26
Table 4-4 Belt tension parameters.................................................................................. 44
Table 5-1 Fan inspection and maintenance record....................................................... 53

Chapter 1 Safety Precautions
Document Version V1.0.1 (09-21-2022) 1
Chapter 1 Safety Precautions
Before starting maintenance on the robot, please read all the following precautions:
1.1 Precautions for operation
The maintenance of the robot system must be performed by safety-trained personnel.
Safety-trained personnel are those who have received safety training (on knowledge,
operation, teaching, etc. of industrial robots, knowledge related to inspection and other
operations, and related laws and regulations) prescribed by laws and regulations of
relevant countries for workers engaged in services related to industrial robots.
Make sure that there are no other persons within the safety fence
before operating the robot system. Operators are safe when the
robot always acts in the restricted state (low speed, low power).
Do not disassemble the parts that are not described in this manual
or perform maintenance in a different way from that described.
Improper disassembly or maintenance will disable the normal
operation of the robot system and may cause serious safety
problems.

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1.2 Precautions for electrical safety
The discontinuation, storage and waste disposal of the robot and related parts must
be handled in accordance with relevant laws, regulations and standards to protect the
environment.
Be sure to unplug the power cable and lock the power supply
when the robot is not used.
Be sure to connect the AC power cable to the power plug when
using the robot. Do not connect directly to the factory power
supply.
Be sure to make replacement after turning off the
controller and the related equipment and unplugging the
power plug. If the replacement is performed while the
power is on, it may cause electric shock or malfunction.
Reliably connect the cable. Do not place heavy objects on
the cable, or forcibly pull or clamp the cable. Failure to do
so may result in cable damage, disconnection or poor
contact, abnormal system operation or electric shock.
Do not plug or unplug the cables on the connector panel
while the robot is powered on.

Chapter 1 Safety Precautions
Document Version V1.0.1 (09-21-2022) 3
1.3 Warning sign
There are corresponding dangers and warnings near the location where the signs
are labeled, so take sufficient care when operating. In order to operate and maintain
the robot system safely, be sure to observe the cautions and contents on the warning
signs.
Table 1-1 Warning signs
SN
Labeling
Notes
A
A triangle sign for
warning of high voltage
B
Grounding sign
C
Do not touch the screw
shaft. Prevent the
screw shaft from
rusting to ensure the
normal operation of
the robot.

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D
Non-professionals are
not allowed to open it.
E
A sign for protection
from residual voltage
F
Warning! Hot surface.
G
Beware of collisions
Figure 1-1 Position of warning sign

Chapter 2 Safety Maintenance
Document Version V1.0.1 (09-21-2022) 5
Chapter 2 Safety Maintenance
2.1 Use of robot in accordance with regulations
Do not use the robot illegally. QKM will not be liable for any losses due to illegal use by
users. To ensure the service life of the robot, please regularly maintain it in accordance
with the contents of this manual.
Common situations involving illegal use:
use beyond specified operating range;
unsafe use of electricity;
non-use of additional protective devices;
use beyond specified environmental requirements;
use under overload conditions;
excessive moment of inertia.
2.2 Safe area
Understand the safe area during operation of the robot. Users need to pay full attention
to the safe area during use to avoid accidents caused by neglecting it.
Work area

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The work area refers to the range of working area of the robot determined by its
motion trajectories and guaranteed by protective devices.
Protective area
The protective area must be larger than the work area, inside which protective
devices need to be placed for warning and safe use.
Common isolated protective device: safety fence; common safety reminders:
warning sign and slogan.
Dangerous area
The dangerous area includes any position where the robot body and the robot
arms may stay in their motion trajectories, which can be protected by isolated
protective devices to avoid personal injury or property damage.
When the robot stops running, the robot arms will stop in the dangerous area.
2.3 E-stop device
The robot may be damaged in the case of incomplete safety functions and protective
devices. Do not use the robot when safety functions are disabled or protective devices are
removed.
The supporting equipment (such as jigs at the end of robot
arms or other devices) of the robot may cause danger and must
be connected to the E-stop circuit of the robot.