AdeptSix 300CR Robot Instruction Handbook
AdeptSix 300CR Robot Instruction Handbook P/N 01600-000 Rev. A August 2002 3011 Triad Drive • Livermore, CA 94550 • USA • Phone 925.245.3400 • Fax 925.960.0452 Otto-Hahn-Strasse 23 • 44227 Dortmund • Germany • Phone (49) 231.75.89.40 • Fax(49) 231.75.89.450 41, rue du Saule Trapu • 91300 • Massy • France • Phone (33) 1.69.19.16.16 • Fax (33) 1.69.32.04.
The information contained herein is the property of Adept Technology, Inc., and shall not be reproduced in whole or in part without prior written approval of Adept Technology, Inc. The information herein is subject to change without notice and should not be construed as a commitment by Adept Technology, Inc. This manual is periodically reviewed and revised. Adept Technology, Inc., assumes no responsibility for any errors or omissions in this document.
Table of Contents 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.1 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.2 Overview of Typical System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Read Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Robot . . . . . . . . . . . . .
Table of Contents 2.13 Safety Aspects While Performing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 30 2.14 Risks That Cannot Be Avoided . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2.15 Risks Due to Incorrect Installation or Operation . . . . . . . . . . . . . . . . . . . . . . . . 30 2.16 What to Do in an Emergency Situation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 3 Robot Installation . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 5.2 Wrist Tool Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 5.3 End of Arm Tooling Load Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.4 Calculating the Moment of Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Example 2 . . . . . . . . .
Table of Contents WORLD Coordinate System (WORLD Mode on the MCP) . . . . . . . . . . . . . . 75 TOOL Coordinate System (TOOL Mode on the MCP) . . . . . . . . . . . . . . . . . 76 Coordinate System Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 9 Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 9.
List of Figures Figure 1-1. Robot ID Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Figure 2-1. AdeptSix 300CR — Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Figure 3-1. Transporting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Figure 3-2. Using the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Figures Figure 10-2. Baseplate Dimensions (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Figure 10-3. Dimensions and Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Figure 10-4. Axis 5 Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Figure 10-5. Axis 2 and Axis 3 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Tables Table 1-1. Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Table 2-1. Sources for International Standards and Directives . . . . . . . . . . . . . . . . . . . . .22 Table 2-2. Partial List of Robot and Machinery Safety Standards . . . . . . . . . . . . . . . . . . .23 Table 3-1. Maximum Repulsion Forces of the AdeptSix 300CR . . . . . . . . . . . . . . . . . . . . .37 Table 3-2. Axis Naming Conventions . . . . . .
Introduction 1.1 1 Product Description The AdeptSix 300CR is a compact, high-performance cleanroom robot that provides the application flexibility of six axis articulation running on the Adept platform. The arm design provides superior reach capability with a very small footprint to maximize system flexibility and minimize cell layout size. The AdeptSix 300CR is available with either the Adept MV controller or the Adept SmartController.
Chapter 1 - Introduction Installing the Controller and PA-4 Power Chassis Adept MV Controller 1. Refer to the AdeptSix Controller Installation Guide to install the Adept MV controller and the PA-4 power chassis. 2. Install the AdeptWindows PC user interface according to instructions in the controller manual. Adept SmartController 1. Refer to the AdeptSix Controller Installation Guide to install the SmartController and the PA-4 power chassis. 2.
Locating the Serial Number WARNING: Confirm that the robot and the controller have the same serial number. Special care must be taken when more than one robot is to be installed. If the numbers do not match, robots may not perform as expected and cause injury or damage. 1.4 Locating the Serial Number The ID serial number of the AdeptSix 300CR robot corresponds to the ID number of the controller. You can check the controller ID using the V+ ID command.
Chapter 1 - Introduction 1.5 How Can I Get Help? Refer to the How to Get Help Resource Guide (Adept P/N 00961-00700) for details on getting assistance with your Adept software and hardware. Additionally, you can access the following information sources on Adept’s corporate web site: • For Contact information: http://www.adept.com/main/contact/index.html • For Product Support information: http://www.adept.com/main/services/index.asp • For general information about Adept Technology, Inc.: http://www.adept.
Knowledge Express 1.7 Knowledge Express In addition to the Knowledge Express CD-ROM containing Adept manuals, you can find Adept product documentation on the Adept web site in the Knowledge Express area. The Knowledge Express search engine allows you to locate information on a specific topic. Additionally, the Library menu provides a list of available product documentation. To access Adept’s Knowledge Express, type the following URL into your browser: http://www.adept.com/Main/KE/DATA/adept_search.
Safety 2.1 2 Dangers, Warnings, Cautions, and Notes There are four levels of special alert notation used in this manual. In descending order of importance, they are: DANGER: This indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING: This indicates a potentially hazardous situation which, if not avoided, could result in serious injury or major damage to the equipment.
Chapter 2 - Safety 2.2 Precautions and Required Safeguards This manual must be read by all personnel who install, operate, or maintain Adept systems, or who work within or near the workcell. CAUTION: Adept Technology strictly prohibits installation, commissioning, or operation of an Adept robot without adequate safeguards. These must be compliant with applicable local and national standards.
Precautions and Required Safeguards Hazards From Expelling a Part or Attached Tooling The maximum joint tip speeds that can be achieved by the AdeptSix 300CR robot are listed in Table 10-1 on page 95. Any tooling, fixtures, end effectors, etc., mounted to the user flange, or one of the other axes of the robot must be attached by sufficient means to resist being expelled from the robot.
Chapter 2 - Safety Table 2-1. Sources for International Standards and Directives SEMI International Standards 3081 Zanker Road San Jose, CA 95134 USA American National Standards Institute (ANSI) 11 West 42nd Street, 13th Floor New York, NY 10036 USA Phone: 1.408.943.6900 Fax: 1.408.428.9600 Phone 212-642-4900 Fax 212-398-0023 http://www.semi.org/web/wcontent.nsf/url/stds_home http://www.ansi.org BSI Group (British Standards) 389 Chiswick High Road London W4 4AL United Kingdom Document Center, Inc.
Risk Assessment 2.3 Risk Assessment Without special safeguards in its control system, the AdeptSix 300 robot could inflict serious injury on an operator working within its work envelope. Safety standards in several countries require appropriate safety equipment to be installed as part of the system. Table 2-2 lists some of the safety standards that affect industrial robots. It is not a complete list.
Chapter 2 - Safety Avoidance Due to its light payload capacity, it is likely that such personnel could avoid being hit by the robot even in a high-acceleration, runaway, failure condition. However, the programmer must always carry the MCP when inside the work envelope, as the MCP provides both E-Stop and Enabling switch functions. For normal operation (AUTO mode), user-supplied interlocked guarding must be installed to prevent any person entering the workcell while Arm Power is on.
Intended Use of the Robots The standard AdeptSix 300 robot control system meets or exceeds the requirements imposed by the EN 954 specified Category 1 level of safety. 2.4 Intended Use of the Robots The installation and use of Adept products must comply with all safety instructions and warnings in this manual. Installation and use must also comply with all applicable local and national requirements and safety standards (see Section 2.8 on page 28).
Chapter 2 - Safety • Have the necessary qualifications • Read and follow the instructions in this Instruction Handbook exactly If there is any doubt concerning the application, ask Adept to determine if it is an intended use or not. 2.5 Robot Modifications It is sometimes necessary to modify the robot in order to successfully integrate it into a workcell. Unfortunately, many seemingly simple modifications can either cause a robot failure or reduce the robot’s performance, reliability, or lifetime.
AdeptSix 300CR Hazards and Warning Labels 2.6 AdeptSix 300CR Hazards and Warning Labels Risks from injury are clearly identified on the AdeptSix 300CR by warning labels. The location of these labels is illustrated in Figure 2-1. 1BC 2BC 3BC WARNING Moving parts may cause injury WARNING Do not enter robot work area Figure 2-1. AdeptSix 300CR — Warning Labels 2.7 Transport Always use adequate equipment to transport and lift Adept products.
Chapter 2 - Safety 2.8 Safety Requirements for Additional Equipment Additional equipment used with the AdeptSix 300 robot (grippers, conveyor belts, etc.) must not reduce the workcell safeguards. Emergency stop switches must be accessible at all times.
Qualification of Personnel 2.10 Qualification of Personnel This manual assumes that all personnel have attended an Adept training course and have a working knowledge of the system. The user must provide the necessary additional training for all personnel who will be working with the system. As noted in this handbook, certain procedures should be performed only by skilled or instructed persons.
Chapter 2 - Safety 2.12 Protection Against Unauthorized Operation The system must be protected against unauthorized use. The user or operator must restrict access to the keyboard and the Manual Control Pendant by locking them in a cabinet or use another adequate method to prevent access to them. 2.13 Safety Aspects While Performing Maintenance Only skilled persons with the necessary knowledge about the safety and operating the equipment are allowed to maintain the robot, controller, and power chassis.
What to Do in an Emergency Situation 2.16 What to Do in an Emergency Situation Press any E-Stop button (a red push-button on a yellow background/field) and then follow the internal procedures of your company or organization for an emergency situation. If a fire occurs, use CO2 to extinguish the fire. AdeptSix 300CR Robot Instruction Handbook, Rev.
Chapter 2 - Safety 32 AdeptSix 300CR Robot Instruction Handbook, Rev.
Robot Installation 3.1 3 Safety Guard Installation To ensure safety, make sure to install safety guards, which prevent unforeseen accidents with personnel and damage to equipment. The following standard is noted below for your information and guidance. Safety Standard Information (ISO10218) Responsibility for Safeguarding The user of a manipulator or robot system shall ensure that safeguards are provided and used in accordance with Sections 6, 7, and 8 of this standard.
Chapter 3 - Robot Installation WARNING: When mounting the robot on the ceiling or wall, the base section must have sufficient strength and rigidity to support the weight of the robot. Also, it is necessary to consider countermeasures to prevent the robot from falling. Failure to observe these warnings may result in injury or damage. WARNING: Do not install or operate a robot that is damaged or lacking parts. Failure to observe this caution may cause injury or damage.
Transporting Method 1X Urethane washer M6 8 mm Hexagon socket head cap bolt (anti-corrosive) Details of C 2X M6 40 mm Hexagon socket head cap bolts (anti-corrosive) A 2X M6 Coned disc springs (anti-corrosive) C 2X Urethane washers Details of D D 2X M8 Eyebolts (provided at factory) B 2X Urethane washers 2X M5 10 mm Hexagon socket head cap bolts (anti-corrosive) 2X M5 Washers (anti-corrosive) E Details of E Figure 3-1.
Chapter 3 - Robot Installation Using the Forklift When using a forklift, the robot should be fixed on a pallet with its shipping bracket and jig, as shown in Figure 3-2. Insert the forklift blades under the pallet and lift it. The pallet must be strong enough to support the robot. Transportation of the robot must be performed slowly in order to avoid overturning, slippage, or damage. 4 x M10 Bolts Pallet Forklift Blade Entry Figure 3-2.
Shipping Bracket and Jig 3.3 Shipping Bracket and Jig The robot is provided with a shipping bracket and jig at points A and B. See Figure 3-3 on page 38 for details. • The shipping bracket and jig are painted yellow. • The number of hexagon socket head cap screws are: A: M6 X 2, B: M5 X 2. • To prevent the jigs from damaging the paint of the robot, the resin washers are inserted between the robot and the jigs.
Chapter 3 - Robot Installation A B ( Attached with shipping products) 2X M6 Hexagon socket head bolts (anti-corrosive) 2X M8 Eyebolts Shipping jig 2X Urethane washers Remove shipping jig and insert the cover bolts Detail A Detail A 2X M5 Hexagon socket head bolts (anti-corrosive) 2X M5 Washers (anti-corrosive) 2X Urethane washers Use shipping bolts Shipping jig Remove shipping jig and insert the cover bolts Detail B Detail B Figure 3-3. Installing Cover Bolts 3.
Mounting Procedures for Robot 3.6 Mounting Procedures for Robot The robot should be firmly mounted on a baseplate or foundation strong enough to support the robot and withstand repulsion forces during acceleration and deceleration. Construct a solid foundation with the appropriate thickness to withstand maximum repulsion forces of the robot as shown in Table 3-1. During installation, if the level of the mounting plane is not right, the robot’s functional ability may be compromised.
Chapter 3 - Robot Installation When the Robot is Mounted Directly on the Floor The floor should be strong enough to support the robot. Construct a solid foundation with the appropriate thickness to withstand maximum repulsion forces of the robot as shown in Table 3-1 on page 39. As a rough standard, when there is a concrete thickness (floor) of 150 mm or more, the base of the robot can be fixed directly to the floor with M10 anchor bolts.
Grounding the Robot Table 3-2. Axis Naming Conventions Current Axis Labels Legacy Axis Labels Axis 1 (J1) S-axis Axis 2 (J2) L-axis Axis 3 (J3) U-axis Axis 4 (J4) R-axis Axis 5 (J5) B-axis Axis 6 (J6) T-axis See Figure 10-1 on page 96 for a drawing that identifies the various axes. 3.8 Grounding the Robot Follow local regulations for grounding line size.
Chapter 3 - Robot Installation A WARNING: Wiring must be performed by authorized or certified personnel. Failure to observe this caution may result in fire or electric shock. View A 5.5 mm2 or more M8 Bolt - for grounding (provided at factory) Figure 3-6. Grounding Method for Robot 3.
4 System Cable Installation 4.
Chapter 4 - System Cable Installation Adept SmartController System Controller (XSYS) to MAI-2 (XSLV1) Controller SmartServo (Port 1.
Cable Connections from Robot to PA-4 Power Chassis 4.2 Cable Connections from Robot to PA-4 Power Chassis There are two interconnect cables: the arm signal cable (1BC) and the arm power cable (2BC). Connect these cables to the robot base connectors and the PA-4 power chassis. Refer to Figure 4-3 and Figure 4-4 on page 46. Connection to the Robot 1. Remove the protective covers from the 1BC and 2BC connectors on the back plate of the robot prior to installing the power and signal cables. 2.
Chapter 4 - System Cable Installation 1BC 1BC 2BC Connection details of the power supply cable (robot) Figure 4-4. Interconnect Cable Connection to the Robot Connection to the PA-4 Power Chassis Refer to the following information for details on connecting the cabling between the robot and the Adept PA-4 power chassis, and peripheral equipment. See Figure 4-1 on page 43 or Figure 4-2 on page 44, depending on which controller you are using. 1.
Cable Connections from Robot to PA-4 Power Chassis Dual E Amp #3 Dual E Amp #2 Dual E Amp #1 MAI-2 Module DUAL E AMP DUAL E AMP DUAL E AMP M A I-2 DSP STATUS MAI STATUS DO NOT REMOVE OR INSTALL THIS MODULE UNLESS HIGH VOLTS LED IS COMPLETELY DISTINGUISHED DO NOT REMOVE OR INSTALL THIS MODULE UNLESS HIGH VOLTS LED IS COMPLETELY DISTINGUISHED DO NOT REMOVE OR INSTALL THIS MODULE UNLESS HIGH VOLTS LED IS COMPLETELY DISTINGUISHED HIGH VOLTS ON HIGH VOLTS ON HIGH VOLTS ON PWM ON PWM ON PWM ON LOW V
Chapter 4 - System Cable Installation 4.3 Cable Connections to MV Controller Installing the MV Controller Refer to the AdeptSix Controller Installation Guide for complete information on installing the Adept MV controller. This list summarizes the main steps. 1. Connect the CIP-2 to the AWC-II in the MV controller. 2. Connect the MCP to the CIP-2. 3. Connect AC power to the controller. 4. Install the AdeptWindows PC user interface. Cable Connections to MV Controller See Figure 4-1 on page 43. 1.
Cable Connections to SmartController 4.4 Cable Connections to SmartController Installing the SmartController Refer to the AdeptSix Controller Installation Guide for complete information on installing the Adept SmartController. This list summarizes the main steps. 1. Mount the SmartController and Front Panel. 2. Connect the Front Panel to the SmartController. 3. Connect the MCP to the SmartController. 4. Connect user-supplied 24 VDC power to the controller. 5.
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End of Arm Tooling 5.1 5 Allowable Wrist Load The allowable wrist load is 3 kg. If force is applied to the wrist instead of the load, force on Axes 4, 5, and 6 should be within the values shown in Table 5-1. Contact your Adept representative for further information or assistance. Table 5-1. Moment and Total Inertia Moment N·m (kgf·m) a Axis GD2/4 Total Inertia kg·m2 Axis 4 5.39 (0.55) 0.1 Axis 5 5.39 (0.55) 0.1 Axis 6 2.94 (0.3) 0.
Chapter 5 - End of Arm Tooling 5.2 Wrist Tool Flange The wrist tool flange dimensions are shown in Figure 5-2. In order to see the tram marks, it is recommended that the attachment be mounted inside the fitting. The fitting depth of the inside and outside fittings must be 6 mm or less. 4-M5 x P0.8 Depth 9 mm 5 45 ˚ Tram mark .5 6 45° Ø20H6 Ø40H6 D31 P.C. Ø5H7 Depth 7 mm Figure 5-2.
End of Arm Tooling Load Definitions 5.3 End of Arm Tooling Load Definitions The end of arm tooling payload includes weight, location of the center of gravity, and the moment of inertia at the center of gravity of the installed tool. See Figure 5-3.
Chapter 5 - End of Arm Tooling The size of the tool is not too big. Setting the inertia moment at the center or gravity is not necessary. The size of the tool is sufficiently large that setting the inertia moment at the center of gravity is necessary. Figure 5-4. Moment of Inertia 5.4 Calculating the Moment of Inertia The following methods can be used to calculate the rough values for the moment of inertia, based on the center of gravity. • Approximate the entire tool as a hexahedron or cylinder.
Calculating the Moment of Inertia YF XF 70 Center of Gravity Position = (100, 0, 70) Total Weight Approx. 6.3 [kg] 7.00 [kg] 100 ZF Figure 5-5. Center of Gravity: Sealing Gun Example Tooling Details • W:7.000 kg • Xg:100.000 mm • Yg:0.000 mm • Zg:70.000 mm • lx:0.000 kg.m² • ly:0.000 kg.m² • lz: 0.000 kg.m² AdeptSix 300CR Robot Instruction Handbook, Rev.
Chapter 5 - End of Arm Tooling The following figures show examples of the moment of inertia for a hexahedron and cylinder. Z Z Ly r Lx Iz Iz Iy Lz Ix Y Y H Iy Ix X X Ix = Iy = Iz = Weight: W Ly2 + Lz2 12 Lx2 + Lz2 12 Lx2 + Ly2 12 *W *W Weight: W 3 r 2 + H2 Ix = Iy = Iz = 12 r2 2 *W * Unit of Weight: [kg] *W * Unit of Length: [m] * Unit of Ix, Iy, Iz: [kg.m 2] Figure 5-6. Moment of Inertia for Hexahedron and Cylinder 56 AdeptSix 300CR Robot Instruction Handbook, Rev.
Calculating the Moment of Inertia Example 2 It is necessary to set the moment of inertia at the center of gravity when the entire size of the tool and workpiece are large compared with the distance from the tool flange relative to the position of the center of gravity. See Figure 5-7. Roughly calculate the moment of inertia at the center of gravity based on “Example 1” on page 54, using the hexahedron and cylinder concept for the entire tool. 250 YF 0 50 ZF Weight of Workpiece: Approx.
Chapter 5 - End of Arm Tooling The steps below describe how to calculate the center of gravity, including the moment of inertia, based on the center of gravity of the plural mass. This can be calculated based on the weight and the center of gravity of each mass, when the tool is considered to consist of two or more large mass objects, like a dual gun system. 1. Divide the tool into individual parts, so as to calculate the weight and center of gravity of each part. 2.
Calculating the Moment of Inertia Example 3 The following example shows how to calculate the center of gravity in cases where more then two workpieces, such as the dual end effector system shown in Figure 5-8, are utilized. 1. Define the center of gravity, based on the position of the center of gravity of the tool being used, and define the moment of inertia based on the center of gravity of the entire tool. Use the hexahedron and cylinder principle as described in “Example 1” on page 54. 2.
Chapter 5 - End of Arm Tooling = lz = + = 0.002 = Approx. 0.010 3*((100-100)²+(50-(-83))²)* 10-6 6*((100-100)²+((-150)-(-83))²)* 10-6 0.080 = Approx. 0.100 Tooling Details: • W:10.000 kg • Xg:100.000 mm • Yg:-83.333 mm • Zg:60.000 mm • lx:0.100 kg.m² • ly:0.010 kg.m² • lz: 0.100 kg.m² 5.5 Mounting Equipment - Allowable Load When peripheral equipment is attached to Axis 3, the following conditions must be observed: The allowable load on Axis 3 is a maximum of 4 kg, including the wrist load.
User Electrical Lines and Air Lines 5.6 User Electrical Lines and Air Lines There are 9 electrical cables (0.2mm) and an 1 air line that are used in the robot for the peripheral devices mounted on the arm, as shown in Figure 5-10 The connector pins (1 to 9) are assigned as shown in Figure 5-11. Wiring must be performed by user. • The allowable current for cables is 2.5A or less for each cable • The maximum pressure for the air hose is 490kPa (5 kgf/cm2). The inside diameter is φ2.5 mm.
Chapter 5 - End of Arm Tooling 1 2 9 3 4 8 1 2 10 5 Pin numbers 6 7 12 3 11 7 8 4 6 5 9 10 (For incorporated valve) 24VDC, common 11 (For incorporated valve) For driving the valve 1 (24VDC, 4W) 12 (For incorporated valve) For driving the valve 2 (24VDC, 4W) Figure 5-11. Detailed Drawing of Connector Pin Numbers Pins number (1 to 9) of both connectors are used for end-of-arm tooling signals (0.2 mm2). 62 AdeptSix 300CR Robot Instruction Handbook, Rev.
System Operation MV Controller 6.1 6 Introduction This chapter covers system operation for AdeptSix robot systems using the Adept MV Controller. If you have an Adept SmartController, refer to Chapter 7. Verifying that the system is correctly installed and that all safety equipment is working correctly is a three-step process. This chapter discusses the first two steps. • Step one reviews starting the control system for the first time and verifying that all components have been correctly installed.
Chapter 6 - System Operation - MV Controller AC Power to Adept Components Checks Verify that the Adept controller is correctly connected to the AC power source. 1. Make sure that AC power is shut off to the Adept controllers (MV and PA-4 power chassis). 2. Verify that the single phase AC power (180-245 VAC) is connected to the Adept power controller. 3. Verify that the three-phase AC power (200-240 VAC or 380-415 VAC) is connected to the Adept PA-4 power chassis.
Installation Check List 4. Check the manual brake release box cable into the MAI-2 connector marked Manual Brake Release. (if used) 5. If you are using the AdeptWindows PC user interface, connect a shielded Ethernet cable from the hub (or server) to the shielded RJ-45 connector on the AWC-II board. Unshielded cables will degrade the integrity of the AdeptWindows PC link, particularly when power is applied to the robot or mechanism. Use “straight” cables to a hub or a “crossover” cable to a stand-alone PC.
Chapter 6 - System Operation - MV Controller E-Stop Button and Switch Checks 1. Verify that the red E-Stop push buttons on the CIP-2, MCP, and User Panel (if installed) are in the normal, unlatched (electrically closed) position. 2. Verify that the MCP jumper plug on the CIP-2 is installed or that the optional MCP is mounted on a rack that holds the MCP Enable switch in the ON position. 3.
Checks After Applying Power LED Status Indicators on the AWC-II The LEDs on the front of the AWC-II indicate the following conditions: O = off G = green R = red Table 6-1. LED Status Indicators LED Display Error # Description O-O-O 0 No error. O-O-R 1 System clock is dead or too fast. Clock interrupts are not being received. O-R-O 2 Hardware configuration error. Address switches/SYSCTL wrong. O-R-R 3 Graphics board failure. VGB not responding. R-O-O 4 Memory test failure.
Chapter 6 - System Operation - MV Controller 6.5 Calibrate Robot The AdeptSix robot uses optical absolute encoders to determine position of each axis, and establish commutation reference for the phases of the motors. Since the motors are brushless AC, the rotor must be commutated by electronics rather that using physical brushes to switch current from phase to phase. The absolute encoders have the ability to determine position for a full turn of the motor rotor.
System Operation SmartController 7.1 7 Introduction This chapter covers system operation for AdeptSix 300CR robot systems using the Adept SmartController. If you have an Adept MV Controller, refer to Chapter 6. Verifying that the system is correctly installed and that all safety equipment is working correctly is a three-step process. This chapter discusses the first two steps. • Step one reviews starting the control system for the first time and verifying that all components have been correctly installed.
Chapter 7 - System Operation - SmartController Power to the Adept Components Checks Verify that the Adept control system is correctly connected to the DC and AC power sources. 1. Make sure that power is shut off to the Adept SmartController and the PA-4 power chassis). 2. Verify that 24 DC power is connected to the Adept SmartController. 3. Verify that the three-phase AC power (200-240 VAC or 380-415 VAC) is connected to the Adept PA-4 power chassis.
Installation Check List 4. Secure the optional manual brake release box cable into the MAI-2 connector marked Manual Brake Release. (if used) 5. If you are using the AdeptWindows PC user interface, connect a shielded Ethernet cable from the hub (or server) to the shielded RJ-45 connector on the AWC-II board. Unshielded cables will degrade the integrity of the AdeptWindows PC link, particularly when power is applied to the robot or mechanism.
Chapter 7 - System Operation - SmartController E-Stop Button and Switch Checks 1. Verify that the red E-Stop push buttons on the Front Panel, MCP, and User Panel (if installed) are in the normal, unlatched (electrically closed) position. 2. Verify that the MCP jumper plug is installed on the controller or that the optional MCP is mounted on a rack that holds the MCP Enable switch in the ON position. 3.
Calibrate Robot b. When the High Power push button/light on the Front Panel begins flashing, press and hold the push button for 1 - 2 seconds. When you release the push button, the light should remain lit continuously indicating that High Power has successfully been enabled. c. If the light does not stay on, the High Power enable process has failed and a message will be displayed on the monitor and MCP indicating why. 2. Verify that all E-Stop devices are functional (MCP, Front Panel, and user supplied).
Chapter 7 - System Operation - SmartController 7.7 Learning to Operate/ Program the AdeptSix 300CR Robot When the robot has been calibrated, refer to the MCP chapter to learn how to move the robot with the optional MCP or go to the V+ Operating System User’s Guide to find information on basic operation of the V+ Operating System. Also refer to the Instructions for Adept Utility Programs for information on using the Adept utility programs.
Using the Manual Control Pendant (MCP) 8.1 8 MCP Usage for Six-Axis Robots This section describes the coordinate system used by the AdeptSix 300CR robot. This information is necessary when using the MCP to control the robot. See the Adept MV Controller User’s Guide or the Adept SmartController User’s Guide for general details on using and programming the MCP. Joint Mode (Single-Axis Movement) Joint motion is made around the axes of the various joints J1, J2, J3, etc.
Chapter 8 - Using the Manual Control Pendant (MCP) Axis 3 (J3) Axis 4 (J4) Axis 5 (J5) Axis 6 (J6) Axis 2 (J2) Axis 1 (J1) J1 J4 Rotates main body Rotates upper ar m x X- J4- X+ J1- J1+ x J4+ J2 Moves lower ar m forward/ backward J5 Moves wrist up/down y Y- J5- J2- Y+ J2+ y J5+ J3 Moves upper ar m up/ down J6 Rotates wrist Z- J3- z J6- z Z+ J6+ J3+ Figure 8-1. Joint Mode 76 AdeptSix 300CR Robot Instruction Handbook, Rev.
MCP Usage for Six-Axis Robots WORLD Coordinate System (WORLD Mode on the MCP) The WORLD coordinate system is fixed. All translation motions are parallel to the WORLD coordinates. The RX, RY, and RZ rotations are made with respect to the WORLD coordinates. Use the + or - speed bar key to specify motions. See Figure 8-2. Z-Axis Y-Axis X-Axis X Z Moves in parallel with X- Axis Moves in parallel with Z-Axis X- Z+ X+ Y Moves in parallel with Y- Axis Y+ Z- YFigure 8-2.
Chapter 8 - Using the Manual Control Pendant (MCP) TOOL Coordinate System (TOOL Mode on the MCP) All motions are parallel to the TOOL coordinates. Joint X is attached by the groove in the tool attachment clamp. Specify RX, RY, and RZ rotations with respect to the TOOL coordinates. Use the + or - speed bar key to specify motions. See Figure 8-3. RX RY Rotates around X- axis RZ Rotates around Y- axis Rotates around Z -axis RYRXRZ+ RY+ RX+ RZ- Figure 8-3.
Maintenance and Inspection 9.1 9 Inspection Schedule Proper inspections are essential not only to assure that the mechanism will be able to function for a long period, but also to prevent malfunctions and assure safe operation. Inspection intervals are displayed in six levels. Conduct periodic inspections according to the inspection schedule in Table 9-1 on page 80.
Chapter 9 - Maintenance and Inspection NOTE: The inspection interval must be based on the servo power supply on time. These inspections were developed for applications where the robot is used for high duty cycle applications. For any different or special applications, the inspection process should be developed on a case-by-case basis. For axes which are used very frequently (in handling applications, etc.), it is recommended that inspections be conducted at shorter Intervals.
Inspection Schedule Table 9-1. AdeptSix 300CR Maintenance Schedule and Inspection Items Schedule Items a 8 Wire harness in robot (Axis 2) Da ily 50 0 H Cy cle 30 00 H Cy cle 90 00 H Cy cle Inspection Charge 18 00 0 H 36 00 0 H Metho d X 1 1 1 2 1 3 Lice nsee Serv ice Com pany X b Replace.c Wire harness in robot (Axis 3) Visual Multimeter X Check for conduction between terminals and wear of the protective spring. X X b Replace.
Chapter 9 - Maintenance and Inspection Table 9-1. AdeptSix 300CR Maintenance Schedule and Inspection Items Schedule Items a 1 4 1 5 Axes 4 and 5 speed reducers Axis 6 speed reducer Da ily 50 0 H Cy cle 30 00 H Cy cle 90 00 H Cy cle Inspection Charge 18 00 0 H 36 00 0 H Metho d Grease Gun X Grease Gun X Spe cifie d Pers on Lice nsee Serv ice Com pany Check for malfunction. Replace if necessary. Supply grease. d (9000 H cycle). See page 89. X X Check for malfunction.
Inspection Schedule 6 3 Axis 1 1 5 10 9 15 1 Axis 6 6 Axis 5 14 Axis 5 14 Axis 4 11 7 1 1 Axis 5 13 Axis 4 1 Axis 3 8 12 1 Axis 2 Figure 9-1. Inspection Parts and Inspection Numbers Table 9-2. Inspection Parts and Grease Used No. 11, 12, 13, 14, 15 Grease Used Harmonic Grease SK-1A Inspected Parts Axes 1, 2, 3, 4, 5, and 6 speed reducers The numbers in the above table correspond to the item numbers in Table 9-1 on page 80. AdeptSix 300CR Robot Instruction Handbook, Rev.
Chapter 9 - Maintenance and Inspection 9.2 Maintenance Procedures Battery Unit Replacement If the battery alarm occurs in the controller, replace the battery according to the following procedures. 1. Switch off the main power supplies to the controller and PA-4 power chassis. 2. Remove the connector base plate and grease tube from the union. 3. Remove the battery-unit mounting screw on the Connector Base. 4.
Maintenance Procedures Battery Unit for Axes 1, 2, and 3 Before Replacement See Procedure 6 See Procedure 7 0BT1 a b 0BT1 BAT1 b a BAT1 0BT1 a BAT1 b a: Insertion-type Pin Terminal (Male) b: Insertion-type Pin Terminal (Female) b 0BT1 a BAT1 hw27230hw927089401hw721.
Chapter 9 - Maintenance and Inspection Grease Replenishment for Axis 1 Speed Reducer Si: Grease Inlet G Nipple A-PT1/8 Axis 1 Speed Reducer So: Air flow Hexagon socket head plug PT1/8 Figure 9-4. Axis 1 Speed Reducer Diagram NOTE: For ceiling-mounted robots, the exhaust and grease inlet ports are inverted. Replenish the grease according to the following procedure. Refer to Figure 9-4. 1. Remove the So plug (hexagon socket head plug PT 1/8). NOTE: It is absolutely necessary that you remove the So plug.
Maintenance Procedures Grease Replenishment for Axis 2 Speed Reducer Axis 2 speed reducer Lo: Air flow Hexagon socket head plug PT1/16 Cover Li: Grease inlet G Nipple A-PT1/16 Figure 9-5. Axis 2 Speed Reducer Diagram NOTE: For ceiling-mounted robots, the exhaust and grease inlet ports are inverted. Replenish the grease according to the following procedure. Refer to Figure 9-5. 1. Remove the Axis 2 side cover. 2. Replace the PT 1/16 socket head plug (Li) with a A-PT 1/16 grease nipple. 3.
Chapter 9 - Maintenance and Inspection Grease Replenishment for Axis 3 Speed Reducer Uo:Air flow Hexagon socket head plug PT1/16 Cover Axis 3 speed reducer Ui: Grease inlet G Nipple A-PT/16 Figure 9-6. Axis 3 Speed Reducer Diagram NOTE: For ceiling-mounted robots, the exhaust and grease inlet ports are inverted. Replenish the grease according to the following procedure. Refer to Figure 9-6. 1. Remove the Axis 3 side cover. 2. Replace the PT 1/16 socket head plug (Ui) with a A-PT 1/16 grease nipple 3.
Maintenance Procedures Grease Replenishment for Axis 4 and Axis 5 Speed Reducers Axis 4 speed reducer Axis 5 speed reducer Cover Ro: Air flow Hexagon socket head plug PT1/16 Bo: Air flow Hexagon socket head plug PT1/16 Bi: Grease inlet G Nipple A-PT1/16 Ri: Grease inlet G Nipple A-PT1/16 Figure 9-7. Axis 4 and Axis 5 Speed Reducers Diagram Replenish the grease according to the following procedure. Refer to Figure 9-7. 1. Remove the Joint 5 access cover. 2.
Chapter 9 - Maintenance and Inspection Grease Replenishment for Axis 6 Speed Reducer Ti: Grease Inlet G Nipple A-PT1/16 Axis 6 speed reducer Figure 9-8. Axis 6 Speed Reducer Diagram Replenish the grease according to the following procedure. Refer to Figure 9-8. 1. Remove the Ti plug (PT 1/16 Allen head plug). 2. Replace the PT 1/16 Allen head plug (Ti) with the A-PT 1/16 grease nipple. 3. Inject the grease into the Ti grease inlet using a grease gun. 4.
Maintenance Procedures Notes for Maintenance Connect the battery unit with reference to the following figure before removing the encoder connector (the connector with a WARNING label). Encoder Motor Motor Cable, etc. Internal Wire a: Insertion-type pin terminal (male) b: Insertion-type pin terminal (female) Power Connector b 0BT4 WARNING Connect battery to encoder to save the data before removing conector.
Chapter 9 - Maintenance and Inspection Installing and Using Brake Release Box The manual brake release box can be used to release the brakes on a specific axis of the robot. This procedure describes how to install and use this device. See Figure 9-10. WARNING: Secure the robot prior to releasing the brakes on axes 2 and 3, to prevent injury to personnel or equipment damage. 1. Make sure that high power is disabled (off). 2.
Spare Parts 9.3 Spare Parts Go to the Adept web site for complete information on spare parts for your system. http://www.adept.com/main/services/PartsCat/index.html AdeptSix 300CR Robot Instruction Handbook, Rev.
Chapter 9 - Maintenance and Inspection 94 AdeptSix 300CR Robot Instruction Handbook, Rev.
Technical Specifications 10 10.1 Technical Specifications Table 10-1. Technical Specifications Operation Mode a Degrees of Freedom Payload Repetitive Positioning Accuracy b Axis 1 (turning) Axis 2 (lower arm) Axis 3 (upper arm) Axis 4 (wrist roll)c Axis 5 (wrist pitch/yaw) Axis 6 (wrist twist) Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Axis 4 Axis 5 Axis 6 Axis 4 Axis 5 Axis 6 Motion Range Maximum Speed Allowable Moment d Allowable Inertia (GD2/4) Vertically Articulated 6 3 kg ±0.
Chapter 10 - Technical Specifications a SI units are primarily used in this table. However, gravitational units are used for values that appear in parentheses ( ). b Conforms to ISO9283. c The Axis 4 Working range is affected by the working range of Axis 2 and Axis 3. See text and Figure 10-5 on page 100 for details. d Refer to “Allowable Wrist Load” on page 51 for details on the permissible moment of inertia. 10.
Baseplate Dimensions A 12 10.4 Baseplate Dimensions 113 ± 0.1 180 +0.012 77 ± 0.1 Ø60 Reference Hole 113 ± 0.1 220 195 50 160 97 ± 0.1 50 195 Ø11 Mounting Holes (4 holes) 220 View A Dimensions in mm Figure 10-2. Baseplate Dimensions (mm) AdeptSix 300CR Robot Instruction Handbook, Rev.
Chapter 10 - Technical Specifications 10.5 Dimensions and Working Range R2 46 170˚ R312 R6 94 142 90 ˚ 74 119 49 19 0 67 844 0˚ 697 45˚ 15 260 590 484 54 70 ˚ 70 600 Point P 82 680 431 346 300 286 159 12 Ø220 0 Ø246 156 114 168 209 Point P working envelope Figure 10-3. Dimensions and Working Range 98 44 275 150 694 Dimensions in mm 229 230 245 250 312 0 142 237 318 170˚ AdeptSix 300CR Robot Instruction Handbook, Rev.
Axis 5 Working Range 10.6 Axis 5 Working Range The working range of Axis 5, maintaining a constant angle to the center of Axis 4 (forearm), is shown in Figure 10-4. Axis 5 rotation center 135 ° Wrist axis Axis 3 rotation center 135 ° Axis 2 rotation center Axis 1 rotation center Note: Prevent the wrist from touching the main body of the robot by depending on the posture of Axes 1,2 and 3 for the base axes. Figure 10-4.
Chapter 10 - Technical Specifications 10.7 Axis 2 and 3 Effect on Axis 4 Working Range When the working envelope of the Axis 2 is -15° or more and the working envelope of the Axis 3 is +185° or more, the working envelope of the Axis 4 is -67° to +165°. When the working envelope of the Axis 2 is +70° or more and the working envelope of the Axis 3 is -51° or more, the working envelope of the Axis 4 is -68.5°to +165°. 185˚ (Axis 3) -15˚ (Axis 2) +70˚ (Axis 2) -51˚ (Axis 3) Figure 10-5.
Index Numerics 1BC cable 2BC cable B 43 43 A accuracy (repetitive positioning) 93 Adept control system, applying power MV controller 64 SmartController 70 air lines, user 59 allowable inertia 93 allowable moment 93 applying power to Adept control system MV controller 64 SmartController 70 Arm Power cable 43 Arm Signal cable 43 avoidance of injury 24 axes speeds, maximum 93 Axis 1 motion range 93 speed reducer greasing 84 Axis 2 effect on Axis 4 98 motion range 93 speed reducer greasing 85 working range 98
Index contents of package 14 controller (serial number) 15 cover bolts, installing 35 Customer Service assistance phone numbers 16 from expelling a part 21 hazards labels, locating 27 How Can I Get Help? 16 humidity, operating 40, 93 I D definition of a Manipulating Industrial Robot 20 degrees of freedom 93 dimensions baseplate 95 robot 96 wrist tool flange 50 dual end effector example 57 E electrical grounding arm power and signal cables 44 grounding robot 39 grounding SmartController to PA-4 interfer
Index M maintenance performing 78 scheduling 77 maintenance procedures 82 Axis 1 grease replenishment 84 Axis 2 grease replenishment 85 Axis 3 grease replenishment 86 Axis 4 grease replenishment 87 Axis 5 grease replenishment 87 Axis 6 grease replenishment 88 battery replacement 82 using brake release box 90 maintenance schedule 78 Manipulating Industrial Robot, defined 20 Manual Control Pendant (MCP), using 73 mass (weight) 93 maximum axis speeds 93 mechanical checks, before using the robot MV system 61 S
Index user electrical and air lines working area 28 wrist loads 49 wrist tool flange 50 59 S safeguarding responsibility 31 safety 19 AdeptSix 300CR pinch hazard 27 during maintenance 30 equipment for operators 29 expelling a part 21 impact and trapping points 20 required safeguards 20 requirements for additional equipment 28 sources for information 21 standards 31 safety barriers 20 safety guard installation 31 schedule for maintenance 78 scheduling robot inspections and maintenance 77 serial numbers 15
01600-000, Rev.
