Core Parameter Review (Matching Benchmark for Replacement)
| Item | Benchmark Value | Key Matching Requirements |
| Rated Power | 2.4kW/2.5kW | Must be equal or slightly higher (≤10%) |
| Rated Torque | 5.8Nm | Core matching parameter, tolerance ≤5% |
| Rated Speed | 4,000rpm (max. 6,000rpm) | At least meet rated speed |
| Encoder Type | Absolute (1ZZ9) | Must be absolute; EnDat 2.2 recommended |
| Shaft Type | Involute spline shaft | KUKA robot‑specific, must match |
| Protection Class | IP65 | Min. IP65; IP67 for harsh environments |
| Compatible System | KUKA robots (KRC4/KRC5) | Must be compatible with KSD series drives |
| Max. Torque | 18.9Nm (3.26x overload) | At least 3x overload capacity |
- Main Brand Replacement Models (By Brand)
- Yaskawa Replacement Solutions
| Yaskawa Model | Key Matching Parameters | Application Notes | KUKA Compatibility |
| SGMGH-09ACA61-K | 2.5kW, 5.9Nm, 4000rpm, absolute encoder, spline shaft | Custom for KUKA robots, fully compatible | ★★★★★ (Best Replacement) |
| SGMGH-09ACA61 | 2.5kW, 5.9Nm, 4000rpm, absolute encoder | Standard version; spline shaft modification required | ★★★☆☆ (Mechanical modification needed) |
| SGMAS-08ACA41-K | 2.4kW, 5.7Nm, 4000rpm, absolute encoder | Compact custom version for small KUKA robots | ★★★★☆ (For KR AGILUS series) |
- Mitsubishi Replacement Solutions
| Mitsubishi Model | Key Matching Parameters | Application Notes | KUKA Compatibility |
| HF-SP102-K | 2.5kW, 5.8Nm, 4000rpm, absolute encoder, spline shaft | Custom for KUKA, perfect parameter match | ★★★★★ (Best Replacement) |
| HF-SP102 | 2.5kW, 5.8Nm, 4000rpm, absolute encoder | Standard version; custom spline shaft required | ★★★☆☆ (Mechanical modification needed) |
| HF-KP13-K | 2.4kW, 5.7Nm, 4000rpm, absolute encoder | Low inertia, for high‑speed KUKA joints | ★★★★☆ (For KR CYBERTECH nano) |
- ABB Replacement Solutions
| ABB Model | Key Matching Parameters | Application Notes | KUKA Compatibility |
| MPM0920-K | 2.5kW, 5.8Nm, 4000rpm, absolute encoder, spline shaft | Custom for robots, compatible with KUKA controls | ★★★★☆ (Parameter adaptation required) |
| MPM0920 | 2.5kW, 5.8Nm, 4000rpm, absolute encoder | Standard version; shaft & protocol adaptation needed | ★★★☆☆ (Medium modification difficulty) |
| MPM0810-K | 2.4kW, 5.7Nm, 4000rpm, absolute encoder | Compact, for light‑load KUKA robots | ★★★★☆ (For KR 6 series) |
- Schneider Replacement Solutions
| Schneider Model | Key Matching Parameters | Application Notes | KUKA Compatibility |
| BCH1003N12A1C-K | 2.5kW, 5.8Nm, 4000rpm, absolute encoder, spline shaft | Custom for KUKA, IP65 protection | ★★★★★ (Best Replacement) |
| BCH1003N12A1C | 2.5kW, 5.8Nm, 4000rpm, absolute encoder | Standard version; spline shaft modification required | ★★★☆☆ (Mechanical modification needed) |
| BCH0803N12A1C-K | 2.4kW, 5.7Nm, 4000rpm, absolute encoder | Compact, for small KUKA joints | ★★★★☆ (For KR AGILUS axes 2–4) |
- Other Brand Replacements
| Brand | Model | Key Parameters | Application Notes |
| FANUC | A06B-0227-B400-K | 2.5kW, 5.8Nm, 4000rpm | Protocol conversion module required for KUKA |
| Kollmorgen | AKM2G-21V-ANCN-00 | 2.5kW, 5.9Nm, 4000rpm | Custom spline shaft + KUKA interface required |
| Panasonic | MHMF202L1G6M-K | 2.5kW, 5.8Nm, 4000rpm | Compatible with KUKA; parameter tuning required |
- Replacement Selection Matrix (By Application)
| Application | Recommended Brand | Top Model | Advantage |
| Direct replacement for KUKA | Yaskawa / Mitsubishi | SGMGH-09ACA61‑K / HF‑SP102‑K | Full compatibility, no mechanical/electrical changes |
| Cost‑optimized replacement | Schneider / Panasonic | BCH1003N12A1C‑K / MHMF202L1G6M‑K | High cost‑performance, near‑original performance |
| Small robots (KR AGILUS) | Yaskawa / Mitsubishi | SGMAS‑08ACA41‑K / HF‑KP13‑K | Perfect size, better dynamic response |
| Heavy payload (KR 20–30kg) | ABB / Kollmorgen | MPM0920‑K / AKM2G‑21V‑ANCN‑00 | Higher overload, better stability |
| Harsh environment (dust/moisture) | Schneider / Yaskawa | BCH1003N12A1C‑K / SGMGH‑09ACA61‑K | IP65, suitable for tough conditions |
- Critical Implementation Notes (Must Read)
- Mechanical Matching
Shaft type: Must be involute spline shaft (KUKA standard); keyed shafts require adapters.
Mounting dimensions: Match 1FK7081 flange and hole pattern; 3D comparison recommended.
Moment of inertia: Tolerance ≤15% vs original (24 kg·cm²) to avoid performance issues.
- Electrical Matching
| Electrical Item | Matching Requirement | Risk of Mismatch |
| Encoder protocol | Must support EnDat 2.2 (KUKA compatible) | No position feedback; requires converter |
| Motor winding | Suitable for 560V DC bus voltage | Motor/drive burnout |
| Feedback connector | Match KUKA standard (25‑pin) | Custom cable needed, higher failure risk |
| Brake system | Holding torque ≥11Nm, DC 24V | Cannot hold position when powered off |
- Software Configuration
- Update motor parameters in KUKA controller (torque constant, inertia, encoder type, etc.)
- Recalibrate robot zero and dynamic parameters
- Perform load identification and trajectory optimization
- Test full travel and overload performance to validate replacement
- Siemens Original Replacements (Best Compatibility)
- Series Upgrade Options
| Siemens Model | Key Parameters | Application Notes | KUKA Spare Part No. |
| 1FK7081-2AC71-1UA0 | 3.7kW, 12Nm, 3000rpm | Standard replacement; parameter adjustment required | No direct match, custom only |
| 1FK7101-5AZ91-1ZZ9-Z S07 | 3.5kW, 8.5Nm, 4000rpm | Higher power for heavier loads | 00-117-606 |
| 1FK7081-2AF71-1RB0 | 3.7kW, 12Nm, 4500rpm | High‑speed for high‑cycle applications | No direct match |
- Replacement Priority
- Genuine KUKA spare part (00-115-925): Best compatibility, for critical equipment
- Yaskawa/Mitsubishi KUKA custom versions: Near-original, no modification, moderate cost
- Other brand custom versions: Cost advantage, requires professional support
- Standard model modification: Lowest cost, full mechanical/electrical/software changes, high risk
- Implementation Steps (For Success)
- Parameter verification: Confirm all original motor specs and create a matching sheet
- Model selection: Choose brand/model based on budget and application
- Sample testing: Install and test 1 unit to verify mechanical/electrical/software compatibility
- Batch replacement: Implement one by one after validation
- Documentation update: Record replacement model and parameters in equipment files
1FK7081-5AZ91-1ZZ9-Z is a KUKA custom motor. Always use KUKA-approved replacements to avoid performance loss or safety hazards. Full functional and safety testing is strongly recommended after replacement.
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