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Adept Technology 300CR User's Manual

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1. 17 Ox c RP 19 2 1 Dangers Warnings Cautions and Notes 19 2 2 Precautions and Required Safeguards 20 Definition of a Manipulating Industrial Robot 20 Safety BANGS s peice rerit in hs aoa eee Eg OX Y R3 esa Da p Od pH 20 2 3 RISK ASSESSMENTS u RR ERE E RE ORE Eds wre 23 EXBOSUIE adress nen RE dE si 23 Severity of IMUN s sine 23 PYCIGOMCS nen ea en 24 Control System Behavior Category 24 2 4 Intended Use of the Robots 25 2 5 Robot MOAIFIEAHONS incl de bre did Lie EEG S RE ana eee Ne 26 Acceptable iosificicillOFls s a rear 26 Unacceptable Modifications 26 2 6 AdeptSix 300CR Hazards and Warning Labels 27 2 7 MONSON coos tae ste ee tied OSS RESO NS DONE EDEPOL es eee eS 27 2 8 Safety Requirements for Additional Equipment 28 29 Working Areas una aaa be ee eee ER Ra mE anne tue 28 2 10 Qualification Of Personnel o lel RR Depp egens ea 29 2 11 Safety Equipment for Operators 29 2 12 Protection Against Unauthorized Operation 30 AdeptSix 300CR Robot Instruction Handbook Rev A 5 Table of Contents 2 13 Safety Aspects While Performing Maintenance 30 2
2. 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 46 Connect the end of the Arm Power cable with the motor output connector clamp to the six connectors on the three Dual E amp modules NOTE The CH connectors on all the Dual E Amps are labelled CH1 and CH2 For reference Figure 4 5 on page 47 matches CN plugs 1 to 6 with the CH connectors labelled CH 1 to 6 in the drawing Install the plug labeled CN29 on the Arm Power cable in the CN29 connector on the Multi Axis Interface MAI 2 module Connect the end of the Arm Signal cable with two plugs to the two connectors on the MAI 2 module in the following order a Install the plug labeled CNPG456 in the CNPG456 connector b Install the plug labeled CNPG123 in the CNPG123 connector Install one ground wire each from the Arm Signal Cable and the Arm Power Cable to the front right screw on the top of the Adept PA 4 power chassis NOTE Provide strain relief for the motor power and signal cable connectors at the amplifier modules AdeptSix 300CR Robot Instruction Handbook Rev A Cable Connections from Robot to PA 4 Power Chassis Dual E Amp 3 Dual E Am
3. 0BTih a LI bHOBT1H b Insertion type Pin Terminal Female BATIHb aHBAHH ee rera loj b oBTIH STD C_HaXBATK New Battery Unit See Procedure 4 Battery Unit for Axes 4 5 and 6 See Procedure 6 Before Replacemen See Procedure 7 S po uA Nr m See Procedure 5 tall_bHoBTaH BAT4 b ja BAT4 OBT4 b OBT4H BAT4 See Procedure 4 Figure 9 3 Battery Connection TalBAT4H I NOTE The procedures referenced in the above figure refer to the numbered steps on page 84 AdeptSix 300CR Robot Instruction Handbook Rev A 85 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 86 Remove the So plug hexagon socket head plug PT 1 8 NOTE It is absolutely necessary
4. View A Air Intake Inlets 2 Air Ducts Tapped holes PT1 8 with cover plugs FiValee 1 Valve type 10 VQD1151W 5M M5 SMC Upper inlet Port 1 i P4 inlet Pot IN 5 04 is Sower in gt pona User cable connector Air Inlet s 94 PzB M HR10A 10TR 12S Port 2 IN 94 1 Mati lug is Valve 2 94 Air supply inlet 1 ating plug Air Exhaust Port D pp y con amp aaah Hie H8 d La HR10A 10TP 12P RI A t4 24 5 Air supply inlet 3 Ab pop M O4 Air supply inlet 4 o Internal Air Intake Port M seit subplyiniet s Outer diameter 34 mm Adi 9 B View B Air Exhaust Port Tapped hole PT1 8 with cover plug Figure 5 10 User Electrical and Air Lines AdeptSix 300CR Robot Instruction Handbook Rev A 61 Chapter 5 End of Arm Tooling wo N Pin numbers oN OO 9 10 For incorporated valve gt 24VDC common 11 For incorporated valve gt For driving the valve 1 24VDC 4W 12 For incorporated valve gt 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 mm 62 AdeptSix 300CR Robot Instruction Handbook Rev A System Operation MV Controller 6 1 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 c
5. Yg 0 000 mm Zg 70 000 mm 1x 0 000 kg m 1y 0 000 kg m lz 0 000 kg m AdeptSix 300CR Robot Instruction Handbook Rev A 55 Chapter 5 End of Arm Tooling The following figures show examples of the moment of inertia for a hexahedron and cylinder Ly Y H Y Weight W Weight W Ly Lz 3 r2 H2 IX W Ix ly W 12 12 Lx Lz2 r x Lz _ ly P W Iz 2 W 12 Lx Ly Unit of Weight kg IZ 12 W Unit of Length m Unit of Ix ly Iz kg m Figure 5 6 Moment of Inertia for Hexahedron and Cylinder 56 AdeptSix 300CR Robot Instruction Handbook Rev A 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 I Weight of Hand Approx 55 kg J Weight of Workpiece Approx 40 kg Figure 5 7 Center of Gravity Large Tool and Workpiece Example Tooling Details e W 100 000 kg Xg 0 000 mm Yg 0 000 mm Zg 250 000 mm 1x 10 000 kg m 1y 3 500 kg m lz 10 500 kg m Weight W 55 40 95 approximated to 100 kg Center of gravity Z offset position Xg Yg
6. Location of serial abel P Figure 1 1 Robot ID Serial Number AdeptSix 300CR Robot Instruction Handbook Rev A 15 Chapter 1 Introduction 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 For Contact information http www adept com main contact index html For Product Support information http www adept com main services index asp e For general information about Adept Technology Inc http www adept com 1 5 How Can Get Help site 1 6 Related Manuals This manual covers the installation and maintenance of an AdeptSix 300CR system There are additional manuals that cover programming the system reconfiguring installed components and adding other optional components The following manuals available on the Knowledge Express CD ROM provided with each system provide information on advanced configurations and system specifications Table 1 1 Related Manuals Manual Title Description AdeptSix Controller Installation Guide Describes the installation process for the Adept MV controller and the Adept SmartController Adept MV Controller User s Guide Describes the configuration and interface options for all Adept supplied processor boards and components that can
7. MAH Module Between PA 4 and SmartController DID Adept PA 4 Power Chassis MCP3 Dongle Adept SmartController A ge Arm 219 Power OO Cable Installed fe User Supplied Ground Wire Ill ll AdeptSix 300CR Robot Controller XFP to Front Panel XFP 24VDC Power from o User Supplied 8 Power Supply to i 2 LES A Controller XDC1 8960 im XE MZ b NEN 1 Front Panel User Supplied q MCP Adapter Cable vA Power Supply ui y Controller XMCP to MCP olo Arm mee Signal 1BC 2BC Cable User Supplied 1 Ground Wire e Desktop or Laptop PC Figure 4 2 System Cable Diagram with Adept SmartController 44 AdeptSix 300CR Robot Instruction Handbook Rev A 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 c
8. controller serial number 15 cover bolts installing 35 Customer Service assistance phone numbers 16 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 47 interference 40 user lines 59 EMC 24 emergency situation whatto do 30 encoder connector warning 89 end of arm tooling 49 60 center of gravity 51 definitions 51 moment ofinertia 51 weight 51 environment conditions 93 environmental requirements 40 E Stop button and switch checks MV controller system 64 SmartController system 70 EU EAA directives 24 F floor installation 38 forklifts for lifting robot 34 G greases for lubrication 81 grounding arm power and arm signal cables 44 robot 39 SmartController to PA 4 chassis 47 H hazards from attached tooling 21 from expelling apart 21 hazards labels locating 27 How Can I Get Help 16 humidity operating 40 93 l I O equipment connecting 46 47 ID number of robot 15 impact and trapping points 20 inertia allowable 49 93 momentof 51 inertia total allowable per axis 49 inspection schedule 77 installation brake release box 90 check list MV controller system 61 check list SmartController system 67 directly on a floor 38 on a common flat steel plate 37 robot baseplate 37 safety guards 31
9. 220 11 Mounting Holes 4 holes 220 View A Dimensions in mm Figure 10 2 Baseplate Dimensions mm AdeptSix 300CR Robot Instruction Handbook Rev A 97 Chapter 10 Technical Specifications 10 5 Dimensions and Working Range Dimensions in mm on a RoMnon 5 a zx o ANANAS 8 Je gt l Ti gt gt 150 275 gg 142 S TT i 74 119 D nm o 3 n 680 Un a N e f 600 4 2 S Lo Ap Point P 220 3 484 N AS 8 1L 431 n IND 3 1 346 r i E 286 8 li 159 i y vy d t FAN I 156 168 114 i 209 Point P working envelope Figure 10 3 Dimensions and Working Range 98 AdeptSix 300CR Robot Instruction Handbook Rev A 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 Wrist axis Axis 3 rotation center Axis 2 rotation center Axis 1 rotation center Note Prevent the wrist from touchi
10. CHADIOt Adept Cobra 550 Adept Cobra 550 CleanRoom Adept Cobra 600 Adept Cobra 800 Adept DeskTop Adept Digital Workcell Adept FFE Adept FlexFeeder 250 Adept IC Adept Impulse Feeder Adept LineVision Adept MC Adept MV Adept MV 10 Adept MV 19 Adept MV4 Adept MV 5 Adept MV 8 Adept NanoBonder EBS Adept NanoBonder LWS Adept NanoCell Adept NanoStage L1P2 Adept NanoStage L3 Adept NanoStage L3P2 Adept OC Adept SmartAmp Adept SmartAxis Adept SmartController CS Adept SmartController CX Adept SmartModule Adept SMIF EZ AdeptAlign 650 AdeptAtlas AdeptCartesian AdeptForce AdeptFTP AdeptGEM AdeptModules AdeptMotion AdeptMotion Servo AdeptMotion VME AdeptNet AdeptNFS AdeptOne AdeptOne MV AdeptOne XL AdeptRAPID AdeptSix 300 AdeptSix 300CR AdeptTCP IP AdeptThree AdeptThree MV AdeptThree XL AdeptTwo AdeptVicron AdeptVicron 3005 AdeptVicron 310D AdeptVision AdeptVision AVI AdeptVision AGS AdeptVision GV AdeptVision I AdeptVision II AdeptVision VME AdeptVision VXL AdeptVision XGS AdeptVision XGS IL AdeptWindows AdeptWindows Controller AdeptWindows DDE AdeptWindows Offline Editor AdeptWindows PC AIM AIM Command Server AIM Dispense AIM PCB AIM VisionWare A Series AutoCal AutoTune AutoWidth CCM CCMI CGM CHAD ACM CHAD ACT CHAD AF CHAD AutoClinchMaster CHAD BLT CHAD CH CHAD ClinchMaster CHAD ClinchMaster II CHAD CS CHAD CSII CHAD ECA CHAD GuideMaster CHAD HT CHAD LGM CHAD LLG CHAD MGE
11. PT 1 16 NOTE It is absolutely necessary that you remove the Uo plug If grease is added without removing it the internal pressure will increase and this may case damage to the seals 4 Inject the grease into the Ui grease inlet using a grease gun NOTE Grease is not evacuated by the Uo exhaust port Do not inject excessive grease into the Ui grease inlet Grease type Harmonic grease SK 1A Amount of grease 8 cc 5 Remove the G Nipple from the Ui grease inlet degrease the tapped hole on the Ui grease inlet and then reinstall the PT1 16 socket head plug Apply Three Bond 1211 on screwed parts 6 Degrease the tapped hole on the Uo air flow and then reinstall the PT 1 16 socket head plug Apply Three Bond 1211 on screwed parts 7 Reinstall the Axis 3 side cover 88 AdeptSix 300CR Robot Instruction Handbook Rev A Maintenance Procedures Grease Replenishment for Axis 4 and Axis 5 Speed Reducers Axis 4 speed reducer C Axis 5 speed reducer J P MIDI dA Eaei T LE N Cover Ro Air flow Bo Air flow Hexagon socket head plug PT1 16 Hexagon socket head plug PT1 16 ze e 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 Repl
12. be installed in an Adept control system Adept SmartController User s Guide Contains complete information on the operation of the Adept SmartController and the optional sDIO product AdeptWindows Installation Guide Describes the basic installation process for the AdeptWindows PC user interface AdeptWindows User s Guide Describes complex network installations installation and use of NFS server software the Adept Windows Offline Editor and the AdeptWindows DDE software Instructions for Adept Utility Programs Describes the utility programs used for advanced system configurations system upgrades file copying and other system configuration procedures V Operating System User s Guide Describes the V operating system including disk file operations monitor commands and monitor command programs V Language User s Guide Describes the V language and programming of an Adept control system 16 AdeptSix 300CR Robot Instruction Handbook Rev A 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
13. following URL into your browser http www adept com Main KE DATA adept_search htm or select the Knowledge Base link from the Services area of the Adept web site AdeptSix 300CR Robot Instruction Handbook Rev A 17 Safety 2 1 Dangers Warnings Cautions and Notes There are four levels of special alert notation used in this manual In descending order of importance they are serious injury DANGER This indicates an imminently hazardous A situation which if not avoided will result in death or injury or major damage to the equipment WARNING This indicates a potentially hazardous fh situation which if not avoided could result in serious CAUTION This indicates a situation which if not avoided could result in minor injury or damage to the equipment NOTE This provides supplementary information emphasizes a point or procedure or gives a tip for easier operation AdeptSix 300CR Robot Instruction Handbook Rev A 19 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 Installations in EU and EEA countries must comply with EN 775 ISO 10218 especiall
14. in Multi conduction robot X meter between terminals X X Axis 3 and wear of the 9 protective spring X Replace X Battery unit Replace the battery in robot unit when the 1 battery alarm 0 X occurs or when the X X robot has operated for 36000 H Axis 1 Grease Check for speed Gun malfunction q reducer Replace if 1 X necessary Supply X X grease d 9000 H cycle See page 91 Axis 2 Grease Check for speed Gun malfunction 4 reducer Replace if 2 X necessary Supply X X grease d 9000 H cycle See page 86 Axis 3 Grease Check for speed Gun malfunction 1 reducer Replace if 3 X necessary Supply X X grease 9000 H cycle See page 88 AdeptSix 300CR Robot Instruction Handbook Rev A 81 Chapter 9 Maintenance and Inspection Table 9 1 AdepiSix 300CR Maintenance Schedule and Inspection Items Schedule Inspection Charge 50 30 90 Spe Items o 00 oo 18 136 Memo operation cifie el ems Da 00 00 d E Lice ice alH H H d ily 0 0 nsee Com Cy Cy Cy Pers H H pany cle cle cle on Axes 4 and Grease Check for 5 speed Gun malfunction 1 reducers Replace if 4 X necessary Supply X X grease d 9000 H cycle See page 89 Axis 6 Grease Check for speed Gun malfunction reducer Replace if 5 X necessary Supply X X grease 9000 H cycle See page 90 H Overhaul X X Inspection item numbers correspond to the numbers
15. kgf m direction of motion Axis 1 Maximum vertical rotating torque 700 N m 71 4 kgf m direction of motion Axes 2 and 3 When the Robot and Mounting Fixture are Installed on a Common Installation Base The common base should be rugged and durable to prevent shifting of the robot or the mounting fixture The thickness of the common base should be 30 mm or more and an M10 size or larger anchor bolt is recommended Affix the robot by fastening the plate with the M10 mm anchor bolts The plate is tapped for M10 35 mm length bolts Tighten the plate fixture mounting bolts and anchor bolts securely so that they will not work loose during operation See Figure 3 4 for details 4X M10 35 mm Hexagon socket head cap bolts anti corrosive provided at factory 4X M10 Spring washers anti corrosive provided at factory 4X M10 Washers po ese provided at factory EF O EE i di a A oo _ Details of A cs a Anchor bolts M10 or more AN Common installation base rh ch La E I m uU 7 U Figure 3 4 Mounting the Robot Baseplate AdeptSix 300CR Robot Instruction Handbook Rev A 39 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
16. point is 3 kg the mass which can be installed on the upper arm becomes 1 kg x 119 gt M FR d 2 M6XP1 0 Tapped 49 P Depth 12 mm Axis 3 Rotation Center 5 A 1 el u IN O 8 O Z _ o I View A Figure 5 9 Installing Peripheral Equipment 60 AdeptSix 300CR Robot Instruction Handbook Rev A 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 cm The inside diameter is 2 5 mm Air Supply Inlets Dto Barb couplings for flexible tube 4 couplings Use a tube with an inner diameter of 2 5 mm User cable connector HR10A 10TR 12S Mating plug HR10A 10TP 12P Air exhaust port b Barb couplings for flexible tube Use a tube with an inner diameter of 2 5 mm
17. shows how to calculate the required values Top View Center of Flange Y F Y Xg Gun 1 X Gun 2 G n 4 Gun 1 Gun 2 Weight w1 3 kg Weight w2 6 kg Center of Gravity Center of Gravity EA x1 100 mm x2 100 mm Z yi 50mm y2 150 mm Gun 2 U zi 40mm z2 70mm Figure 5 8 Center of Gravity Dual End Effector Example Weight W w1 w2 346 9 Approx 10 kg Center of gravity g w1 x1 w2 x2 w1 w2 3 100 6 100 3 6 100 mm Yg 3 50 6 150 3 6 83 333 mm Zg 3 40 6 70 3 6 60 mm The moment of inertia at the center of gravity Ix wl y1 Yg z1 Zg 10 lex1 w2 y2 Yg z2 Zg 10 1cx2 3 50 83 40 60 10 6 150 83 70 60 2 10 0 082 Approx 0 100 ly 3 100 100 40 60 106 6 100 100 70 60 10 AdeptSix 300CR Robot Instruction Handbook Rev A 59 Chapter 5 End of Arm Tooling 0 002 Approx 0 010 3 100 100 2 50 83 2 106 6 100 100 2 150 83 2 10 0 080 Approx 0 100 R Il Tooling Details W 10 000 kg Xg 100 000 mm Yg 83 333 mm Zg 60 000 mm 1x 0 100 kg m 1y 0 010 kg m 1z 0 100 kg m 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 For instance when the mass installed at the wrist
18. 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 eeeeeesee 31 3 1 Safety Guard Installation 31 safety standard Information SO1021H 444 vo ee 3 3 2 Transporting Method 32 UNO MME CIIatigos ars 6425S BEG SESE RET Se Pee GR Ed a 32 US TOYS BOTE uisa don cage Sask ipn a aa 34 3 3 Shipping Bracket and Jig 35 3 4 Installing Cover Bolls e008 24484868 te aan new na sd seine aus 35 3 5 Types of Mounting 36 3 6 Mounting Procedures for Robot 37 When the Robot and Mounting Fixture are Installed on a Common Installation Base 37 When the Robot is Mounted Directly on the Floor cee ees 38 3 7 Axis Naming Conventions 38 3 8 Grounding the Robot 39 3 9 Environmental Requirements 40 4 System Cable Installation 41 4 1 System Cable Diagrams 41 Adept MV Controll
19. 394 port 1 connector on the MAI 2 module 2 Install the cable between the MAI 2 module XSLV1 safety interlock connector and XSYS connector on the SmartController and tighten the latching screws Connecting User Supplied Safety and 1 0 Equipment Refer to the Adept SmartController User s Guide for information on connecting the following equipment safety equipment incorporated into the E Stop system digital I O equipment serial I O equipment AdeptSix 300CR Robot Instruction Handbook Rev A 49 Chapter 4 System Cable Installation 50 AdeptSix 300CR Robot Instruction Handbook Rev A End of Arm Tooling 5 1 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 Axis Moment N m kgf m GD 4 Total Inertia kg m Axis 4 5 39 0 55 0 1 Axis 5 5 39 0 55 0 1 Axis 6 2 94 0 3 0 03 Values that appear inside parentheses are given in gravitational units When the volume load is small refer to the moment arm rating shown in Figure 5 1 The allowed total inertia is calculated when the moment is at the maximum Contact your Adept representative when Only load moment is small and inertia moment is large The load mass is combined wi
20. AdeptSix 300CR Hazards and Warning Labels 2 6 AdepiSix 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 O L Moving parts may Do not enter cause injury robot work area Figure 2 1 AdeptSix 300CR Warning Labels 2 7 Transport Always use adequate equipment to transport and lift Adept products See Chapter 3 for more information on transporting lifting and installing AdeptSix 300CR Robot Instruction Handbook Rev A 27 Chapter 2 Safety 2 8 Safety Requirements for Additional Equipment 2 9 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 If the robot is to be used in an EU or EEA member country all components in the robot workcell must comply with the safety requirements in the European Machine Directive 89 392 EEC and subsequent amendments and related harmonized European international and national standards For robot systems these include EN 775 ISO 10218 sections 5 6 EN 292 2 and EN 60204 For saf
21. AdeptSix 300CR Robot Instruction Handbook p X X cce AdeptSix 300CR Robot Instruction Handbook NL oil Ds nen 0 7 P N 01600 000 Rev A August 2002 41 rue du Saule Trapu 91300 Massy France Phone 33 1 69 19 16 16 Fax 33 1 69 32 04 62 al LIN xa 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 EOS The information contained herein is the property of Adept Technology Inc and shall not be repro duced in whole or in part without P rior written approval of Adept Technology Inc The informa tion 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 Critical evaluation of this manual by the user is welcomed Your comments assist us in preparation of future documentation Please email your comments to techpubs adept com Copyright 2002 by Adept Technology Inc All rights reserved The Adept logo CHAD the CHAD logo and Soft Machines are registered trademarks of Adept Technology Inc ActiveV Adept Adept 1060 Adept 1060 Adept 1850 Adept 1850 XP Adept 540 Adept 560 Adept C40 Adept C60 Adept CC Adept CHADIQ Adept CHADIQh Adept
22. CHAD MixTech CHAD MTM CHAD OFM CHAD PIE CHAD QCB CHAD RC CHAD SGE CHAD TM CHAD VT CimStation CimStation Robotics FlexFeedWare HexSight HyperDrive Microenvironment MicroV MotionWare ObjectFinder ObjectFinder 2000 PackOne PalletWare Production PILOT SILMA CellFLEX SILMA CellPRO SILMA PaintPRO SILMA PressPRO SILMA SpotPRO SMIF C SMIF EZX SMIF Z SMIF ZX SoftAssembly S Series UltraOne V V and VisionTeach are trademarks of Adept Technology Inc Any trademarks from other companies used in this publication are the property of those respective companies Printed in the United States of America Table of Contents l introduction 13 1 1 Product Description 13 1 2 Overview of Typical System Installation 13 Read Safety IMOMMCION 6 6 0 chads reihen 13 INSIGIING INS ROBOT re errai kne a excess 13 Installing the Controller and PA 4 Power Chassis 14 Installing System Cables 44 sn sans ann 14 AGEING End of Anm Tool erise Hank 14 MIMIC On ne SYST ME eur aaa 14 1 3 Checking Package Contents 14 1 4 Locating the Serial Number 15 1 5 How Can lGel Help sis ssccassit iividodinmchividedi tei ss sde 16 1 6 Related Manuals uu ku ma 00a mima Ro Dk ara 16 1 7 Knowledge Express
23. ECHON eee tr e ce eR UE ah ne 83 Axis epeed Reducer DIGG Ti aus doe BUR C d 84 Axis 2 Speed Reducer Diagram 4 440 85 AXIS S 5peed Reducer DIGG 4 a tod e Ron od tore pa qo Pete pers 86 Axis 4 and Axis 5 Speed Reducers Diagram wk ees 87 Axis 6 Speed Reducer DAJAN rria esser ra b RR etage 88 Encoder Connector Diagramm ise susanne 89 Manual Brake Release BOX 90 Parn Names and Working AXES aac enced so dans anse dus ds due 94 AdeptSix 300CR Robot Instruction Handbook Rev A 9 List of Figures Figure 10 2 Figure 10 3 Figure 10 4 Figure 10 8 10 Baseplate Dimensions mM ran ae pacts tod prem E Die to 95 Dimensions and WOrkiNG RANGO asd abs ded dod hrec dq oca Rete cia 96 AXIS O Working RINGE u a ea EC eR aee eier 97 AXIS 2 and Ayk o ROTO nase 98 AdeptSix 300CR Robot Instruction Handbook Rev A Table 1 1 Table 2 1 Table 2 2 Table 3 1 Table 3 2 Table 5 1 Table 6 1 Table 9 1 Table 9 2 Table 10 1 List of Tables Related Monucils isi sa iida iea deer sen ae R4 der Pd O AE Poe rb GARE aD 16 Sources for International Standards and Directives 22 Partial List of Robot and Machinery Safety Standards 23 Maximum Repulsion Forces of the AdeptSix 300CR 97 AXIS Naming GORVENTIONS 5e he ee ac prd ade ree Reden 39 Moment and tele earet eriei ipao dod b de cab
24. Figure 8 3 RX Rotates around X axis RY Rotates around Y axis RZ Rotates around Z axis Figure 8 3 Tool Mode Coordinate System Definitions The points below provide information about the coordinate system To locate a point in space 3D a coordinate system is used The coordinate system is represented by the origin and the X Y Z perpendicular axis The orientation of these 3 axes follows the RIGHT HAND rule See Figure 8 4 X Thumb X Index Finger Y Index Finger Y Middle Finger Z Middle Finger Z Thumb Figure 8 4 Right Hand Rule 78 AdeptSix 300CR Robot Instruction Handbook Rev A Maintenance and Inspection 9 1 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 In Table 9 1 the inspection items are classified into three types of operations operations which can be performed by personnel authorized by the user operations which can be performed by trained personnel and operations which can be performed by service company or factory trained personnel Only specified personnel are to do inspection work gt gt gt gt WARNING Before maintenance or inspection make su
25. Specifications 93 10 1 Technical Specifications 93 10 2 Robot Cleanroom Specifications 94 10 3 Part Names and Working Axes 94 10 4 Baseplate Dimensions a sos ee 95 10 5 Dimensions and Working Range 96 10 6 Axis 5 Working Range 97 10 7 Axis 2 and 3 Effect on Axis 4 Working Range 98 lc een Dirt RRERRESRS RASSE 99 8 AdeptSix 300CR Robot Instruction Handbook Rev A Figure 1 1 Figure 2 1 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 5 6 Figure 5 7 Figure 5 8 Figure 5 9 Figure 5 10 Figure 5 11 Figure 8 1 Figure 8 2 Figure 8 3 Figure 8 4 Figure 9 1 Figure 9 2 Figure 9 3 Figure 9 4 Figure 9 5 Figure 9 6 Figure 9 7 Figure 9 8 Figure 9 9 Figure 9 10 Figure 10 1 List of Figures Robot ID Serial Number J P nennen 15 Adeptsix 300CR Warning Labels 27 Transp rfing Position ss p p RR P ESLRRURHPRSQURRGAR PEU R44 P TOES 39 Using the FOIE a IU 34 INSTGIING COVEN BONS sans 32d dub iu POE e D PESE PPS PRRDPRO 2S MESS 36 Mounting the Robot Bas
26. USER and JSIO Connector Checks Check the following safety equipment connected to the JUSER and JSIO connectors on the CIP 2 1 There are eight pairs of contacts that must be connected on the JUSER connector see Adept MV Controller User s Guide to ensure proper continuity of the emergency stop circuitry Verify that these connections are secure and reliable and that a redundant pair of contacts is installed one for each E Stop channel Double check that the state of the contacts on each pair matches and the contacts are closed Each contact is separately connected to its respective E Stop channel Inadvertent connection between the E Stop channels will short the E Stop power supply making it impossible to apply High Power 2 There are two pairs of contacts in the JSIO connector that must be connected to ensure proper continuity of the emergency stop circuitry Verify that these connections are secure reliable and closed prior to enabling power 3 Make sure that guarding around the workcell is properly connected to either the Muted Safety gate inputs on the JUSER connector or if appropriate to the User E Stop connections on the JUSER connector Make sure that all gate E Stop push button switches and other interlocks have two independent electrical poles Make sure that a pair of redundant contacts is installed and that these contacts are separately connected to their respective E Stop channels Make sure that all interlock or emergency s
27. Unit Type 60660 00020 WARNING Connect battery to encoder to save the data before removing conector Figure 9 9 Encoder Connector Diagram AdeptSix 300CR Robot Instruction Handbook Rev A 91 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 Connect the 15 pin male D sub connector into the 15 pin female D sub connector marked Brake on the MAI 2 board 3 Press one of the E Stops MCP CIP Front Panel or external NOTE An E Stop must be activated in order for the brake release box to work 4 Using the axis selector switch select the axis that you want to release the brake 5 Depress the brake release pushbutton to release the brake 6 Repeat steps 4 and 5 above for releasing the brakes on another axis NOTE When the Status LED Green is on it indicates that the circuit is enabled when the brake release pushbutton is pressed Sah A i 23 O Axis selector switch iss Mens LED D6 No oF BRAKE N Ome RELEASE Brake Release Pushbutton U 7 15 pin male Le D Sub conn
28. Zg 0 0 250 Moment of inertia at the center of gravity The hexahedron of 0 500 x 0 400 x 1 000 m which encloses the entire tool including the assumed workpiece Use the following formula to calculate the moment of inertia of a hexahedron Ix Ly2 Lz2 12 W 0 4002 1 000 12 100 9 667 Approx 10 000 ly Lx Lz 12 W 0 500 0 400 12 100 3 417 Approx 3 500 Iz Lx Ly 12 W 0 5002 1 0002 12 100 10 417 AdeptSix 300CR Robot Instruction Handbook Rev A 57 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 Calculate the weight and center of gravity of each part based on the tool flange coordinates Refer to Example 1 on page 54 for details on how to use the hexahedron and cylinder examples to calculate these values Wi Weight of the i th parts kg xi yi zi Center of gravity of the i th parts mm lexi lcyi lczi Moment of inertia of each i th parts kg m 3 The position of the center of gravity for the entire tool is calculated using the following formula x
29. automation system The controller subassembly must be installed inside a suitable enclosure The controller subassembly must not come into contact with liquids Additionally the robot must not come into contact with liquids The Adept equipment is not intended for use in any of the following situations In hazardous explosive atmospheres n mobile portable marine or aircraft systems In life support systems n residential installations In situations where the Adept equipment will be subject to extremes of heat or humidity CAUTION The instructions for operation installation and hh maintenance given in this Instruction Handbook must be strictly observed Non intended use of an AdeptSix 300 robot can Cause injury to personnel Damage the robot or other equipment Reduce system reliability and performance All persons that install commission operate or maintain the robot must AdeptSix 300CR Robot Instruction Handbook Rev A 25 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 perfor
30. c impact on arm performance and reliability See Figure 5 4 AdeptSix 300CR Robot Instruction Handbook Rev A 53 Chapter 5 End of Arm Tooling 5 4 4 The size of the tool is not too big The size of the tool is sufficiently large Setting the inertia moment at the that setting the inertia moment at the center or gravity is not necessary center of gravity is necessary Figure 5 4 Moment of Inertia 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 Calculate the center of gravity position plural mass for each part weight The following examples provide details on the calculation methods Example 1 54 In this example a sealing gun is utilized It is assumed that the location of the center of gravity is slightly offset from the centerline of the head based on the tool flange coordinates See Figure 5 5 In this case there seems to be no problem based on the size and weight of the gun and the moment of inertia with respect to the center of gravity AdeptSix 300CR Robot Instruction Handbook Rev A Calculating the Moment of Inertia Center of Gravity Position 100 0 70 Total Weight Approx 6 3 kg 7 00 kg Figure 5 5 Center of Gravity Sealing Gun Example Tooling Details e W 7 000 kg Xg 100 000 mm
31. cations via crane or forklift must be performed by authorized personnel only Failure to Observe this caution may result in injury or damage CAUTION Avoid excessive vibration or shock during transporting The system consists of precision components so failure to observe this caution may adversely affect performance AdeptSix 300CR Robot Instruction Handbook Rev A 35 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 ET 4 x M10 Bolts Pallet Ue Forklift Blade Entry Figure 3 2 Using the Forklift When using the forklift note the following Check that the eyebolts are securely fastened Use a wire sling that is strong enough to withstand the weight The weight of the robot is approximately 35 kg including the shipping bracket and jig Attached eyebolts are designed to support the robot s weight Do not use them for anything other than transporting the robot Mount the shipping bracket and jig for transporting the robot Avoid exerting force on the arm or motor unit when transp
32. cessive electrical interference or noise plasma The area must be free from Dust soot and water e Corrosive gases and liquids as well as explosive gases Excessive vibration less than 0 5 G 42 AdeptSix 300CR Robot Instruction Handbook Rev A System Cable Installation 4 1 System Cable Diagrams Adept MV Controller System CIP JSLV to MAI 2 XSLV1 AWC IEEE 1394 Port 1 to MAI 2 IEEE 1394 Port 1 Dual E Amp 1 Dual E Amp 2 Dual E Amp 3 r MAI 2 Module Arm Power Cable AdeptSix 300CR Robot Adept MV Controller 419 OMY 01 OMwP 419 Adept PA 4 Power Chassis Od o11eujeui3 User Supplied Desktop or Laptop PC Ground Wire Figure 4 1 System Cable Diagram with Adept MV Controller AdeptSix 300CR Robot Instruction Handbook Rev A 43 Chapter 4 System Cable Installation Adept SmartController System Controller XSYS to MAI 2 XSLV1 Controller SmartServo Port 1 1 to MAI 2 IEEE 1394 Port 1 Dual E Amp 1 Dual E Amp 2 D E Amp 3 User Supplied Ground Wire
33. crossover cable to a stand alone PC User Supplied Safety Equipment on XUSR Connector Checks Check the following safety equipment connected to the XUSR connector on the SmartController 1 There are eight pairs of contacts that must be connected on the XUSR connector see Adept SmartController User s Guide to ensure proper continuity of the emergency stop circuitry Verify that these connections are secure and reliable and that a redundant pair of contacts is installed one for each E Stop channel Double check that the state of the contacts on each pair matches and the contacts are closed Each contact is separately connected to its respective E Stop channel Inadvertent connection between the E Stop channels will short the E Stop power supply making it impossible to apply High Power 2 Make sure that guarding around the workcell is properly connected to either the Muted Safety gate inputs on the XUSR connector or if appropriate to the User E Stop connections on the XUSR connector Make sure that all gate E Stop push button switches and other interlocks have two independent electrical poles Make sure that a pair of redundant contacts is installed and that these contacts are separately connected to their respective E Stop channels Make sure that all interlock or emergency stop devices are wired in series not in parallel before connecting to the User E Stop connections Identify all wiring with Channel 1 or Channel 2 Inadvertent conn
34. d user supplied Test each mushroom button safety gate light curtain etc by enabling High Power and opening the safety device The High Power push button light on the Front Panel should go out and the red HPE ES LED on the SmartController should be lit 7 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 Built into the absolute encoder is a multiple turn counter that keeps track of the number of times the absolute encoder has completed a full revolution The encoder system is powered by the Adept PA 4 power chassis and also has a battery backup to maintain position tracking during shipment of the robot or periods when the system is turned off 1 2 Verify that you have enabled power as described above Enter the following command at the dot prompt in the monitor window calibrate When calibration is complete the monitor displays the dot prompt This means the system is ready for operation 7 6 Turning Off the System Follow these steps to turn off power to the robot system 1 2 3 Make sure that robot motion has stopped Abort any programs that a
35. dicho doi o deba 49 LED Staus Inge GIEOTS ans n me Cin t dem o er acean dog eed Pur 65 AdeptSix 300CR Maintenance Schedule and Inspection Items 78 Inspection Parts and Grease Used 81 ISchniealspechealions 2 5 d au decade ego ase Pp reb p ee a edu we 93 AdeptSix 300CR Robot Instruction Handbook Rev A 11 1 1 Introduction Product Description 1 2 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 Adept software and controllers simplify integration of the robot by combining all of the functions found in a typical robot work cell which is common across the extensive Adept Product Line Available options for the AdeptSix 300CR include integral AVI vision adaptive Force Sensing and real time Conveyor Tracking The overall reach of the AdeptSix 300CR is 677 mm with a footprint of 300 mm Maximum payload is 3 kg The AdeptSix 300CR comes standard with the ability to be mounted either in a tabletop side or overhead position providing maximum application flexibility Applications include assembly packaging machine load unload quality inspect
36. e Com Cy Cy Cy Pers H H pany cle cle cle on Tram mark Visual Check tram mark alignment and X damage at the x x x home position Working Visual Clean the work area and area if dust or robot spatter is present x Check for damage x x x and outside cracks Baseplate Spanner Tighten loose mounting X Wrench bolts Replace if X X X bolts necessary Cover Screw Tighten loose mounting X driver bolts Replace if X X X screws Wrench necessary Base Manual Check for loose connectors X connectors X X X Axes 4 amp 5 X Manual Check for belt X X timing belt tension and wear Wire Visual Check for harness in Multi conduction robot meter between the main Axis 1 connector of the base and the X intermediate X X connector by manually shaking the wire Check for wear of the protective spring b X Replace 80 AdeptSix 300CR Robot Instruction Handbook Rev A Inspection Schedule Table 9 1 AdeptSix 300CR Maintenance Schedule and Inspection Items Schedule Inspection Charge 50 30 90 Spe Items o loo oo 18 36 Memo operation cifie dd m Da 00 00 d E Lice ice ehr IH H d ily 0 0 nsee Com Cy Cy Cy Pers H H pany cle cle cle on Wire Check for harness in conduction robot X between terminals X Axis 2 and wear of the 8 protective spring X Replace Wire Visual Check for harness
37. e Ban rear 71 7 6 Turning Off the System 71 7 7 Learning to Operate Program the AdepiSix 300CR Robot 72 8 Using the Manual Control Pendant MCP 73 8 1 MCP Usage for Six Axis Robots 73 Joint Mode Single Axis Movement 73 AdeptSix 300CR Robot Instruction Handbook Rev A 7 Table of Contents WORLD Coordinate System WORLD Mode on the MCP 08 75 TOOL Coordinate System TOOL Mode on the MCP 76 Coordinate System Definitions es 2v RED ed ERES Ra Rb RE ERG Rad 76 9 Maintenance and Inspection 77 9 1 Inspection Schedule 77 9 2 Maintenance Procedures 82 Battery Unit Replacement sese nn 82 Grease Replenishment for Axis 1 Speed Reducer 84 Grease Replenishment for Axis 2 Speed Reducer saaana aaa 85 Grease Replenishment for Axis 3 Speed Reducer 86 Grease Replenishment for Axis 4 and Axis 5 Speed Reducers 87 Grease Replenishment for Axis 6 Speed Reducer 88 Notes or Maintenance ss 39 3 0 09 79 en 89 Installing and Using Brake Release BOX 90 9 3 Spare PONS isses e ek uec a px RF EUR RUD NUR eK E RR E dea 91 10 Technical
38. e standard AdeptSix 300 robot control system described in this handbook employs hardware components in its safety system that meet or exceed the requirements of the EU Machinery Directive and Low Voltage Directive The standard control system is fully hardened to all EMI influences per the EU EMC Directive and meets all functional requirements of ISO 10218 EN 775 Manipulating Robots Safety In addition a software based reduced speed mode has been incorporated to limit speed and impact forces on the Operator and production tooling when the robot is operated in Manual Mode AdeptSix 300CR Robot Instruction Handbook Rev A Intended Use of the Robots 2 4 The standard AdeptSix 300 robot control system meets or exceeds the requirements imposed by the EN 954 specified Category 1 level of safety 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 The AdeptSix 300CR Robot robots are intended for use in parts assembly and material handling for payloads less than 3 kg See Chapter 5 for complete information tooling and payloads CAUTION For safety reasons it is prohibited to make certain modifications to Adept robots see Section 2 5 The Adept controller is a component subassembly of a complete industrial
39. e that AC power is shut off to the Adept controllers MV and PA 4 power chassis Verify that the single phase AC power 180 245 VAC is connected to the Adept power controller Verify that the three phase AC power 200 240 VAC or 380 415 VAC is connected to the Adept PA 4 power chassis For information on single phase AC power to the PA 4 see the AdeptSix Controller Installation Guide If the System Power On Off switch on the CIP 2 is used check the connections to this switch Board and Coble Installation Checks Make sure that all the boards in the Adept controller and PA 4 power chassis are secured and the connection cables are correctly installed 1 Secure all boards and blank front panels to the Adept controller chassis Tighten both the top and bottom mounting screws on each front panel This ensures proper grounding of the controller from an EMC standpoint and ensures good connection to the controller backplane Secure all amplifier modules and the MAI 2 multi axis interface module in the amp chassis Tighten both the top and bottom mounting screws on each front panel This ensures proper grounding of the amplifier controller subsystems from an EMC standpoint and ensures good connection to the drawer connectors at the rear of the chassis The drawer connectors carry power and interlock signals from into the power chassis from the amplifiers NOTE There is a safety interlock built into the amp chassis that
40. ection between the channels will short the E Stop power supply making it impossible to apply High Power 3 Make sure that workcell components have been properly interlocked to avoid hazards when the robot motion system is operated in Manual Mode Per ISO 10218 Manipulating Robots Safety the robot control system must employ a single point of control when operated in Manual Mode AdeptSix 300CR Robot Instruction Handbook Rev A 71 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 thatthe 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 Verify that the user panel enable contacts are closed that a pair of redundant contacts is installed and that these contacts are separately connected to their respective E Stop channels Inadvertent connection between the channels will short the E Stop power supply making it impossible to apply High Power to the robot 7 3 Applying Power to the Adept Control System After you have made the checks listed above system power is ready to be turned on CAUTION All safety systems must be in place and operating before applying power to the system Extra care should be taken during the initial
41. ector NN Figure 9 10 Manual Brake Release Box 92 AdeptSix 300CR Robot Instruction Handbook Rev A 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 A 93 Chapter 9 Maintenance and Inspection 94 AdeptSix 300CR Robot Instruction Handbook Rev A Technical Specifications 10 1 Technical Specifications Table 10 1 Technical Specifications Operation Mode Vertically Articulated Degrees of Freedom 6 Payload 3 kg Repetitive Positioning Accuracy b 0 03 mm Axis 1 turning 170 Axis 2 lower arm 60 135 Motion CARPE nn t 10 Range xis 4 wrist roll 16 Axis 5 wrist 135 pitch yaw Axis 6 wrist twist 350 Axis 1 3 66 rad s 210 s Axis 2 2 79 rad s 170 s Maximum Axis3 3 93 rad s 225 s Speed Axis 4 5 23 rad s 300 s Axis 5 5 23 rad s 300 s Axis 6 7 33 rad s 420 s Allowable PE 4 5 39N em 0 55 kgfem Moment d Axis 5 5 39N em 0 55 kgfem Axis 6 2 94N em 0 3 kgfem Allowable Axis 4 0 1 kgem Inertia Axis 5 0 1 kgem GD 4 Axis6 0 03 kgem Mass 39 kg Temperature 0 to 45 C Humidity 20 to 80 RH non condensing Vibration Less than 0 5 G Ambient Others Free from corrosive gases and Condit
42. effect on Axis 4 98 motionrange 93 speed reducer greasing 86 working range 98 Axis 4 motionrange 93 speed reducer greasing 87 working range 98 Axis 5 motionrange 93 speed reducer greasing 87 working range 97 Axis 6 motionrange 93 speed reducer greasing 88 axisnames 38 94 Index B baseplate description of 37 dimensions 95 battery replacement 82 behavior category control system 24 board and cable installation checks MV controller system 62 SmartController system 68 brake release box installation 90 C cables connecting to MV controller 46 connecting to power chassis 43 connecting to SmartController 47 MV controller system installation 41 power 2BC 43 signal 1BC 43 SmartController system installation 42 calculating moment of inertia 52 calibration robot in MV controller system 66 in SmartController system 71 center of gravity end of arm tooling 51 center of gravity for installed tool 51 53 55 57 checks after applying power MV controller system 65 SmartController system 70 connecting I O equipment 46 47 user supplied equipment 46 47 connecting cables to AdeptSix 300CR 43 to MV controller 46 to PA 4 power chassis 43 to SmartController 47 connecting diagram to MV controller 41 to SmartController 42 connectors on robot 1BC Arm Signal 35 43 2BC Arm Power 35 43 3BC for user lines 59 AdeptSix 300CR Robot Instruction Handbook Rev A 101 Index contents of package 14
43. en the MAI 2 module XSLV 1 safety interlock connector and CIP 2 JSLV connector and tighten the latching screws 3 Install the cable between the AWC II CIP 2 and CIP 2 JAWC Verify that the plug is latched on both ends of the cable Connecting User Supplied Safety and 1 0 Equipment Refer to the Adept MV Controller User s Guide for information on connecting the following equipment safety equipment incorporated into the E Stop system digital I O equipment serial I O equipment 48 AdeptSix 300CR Robot Instruction Handbook Rev A 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 Connect the Front Panel to the SmartController Connect the MCP to the SmartController Connect user supplied 24 VDC power to the controller Install a user supplied ground wire between the SmartController and ground nur on Install a user supplied ground wire between the SmartController and the PA 4 chassis 7 Install the AdeptWindows PC user interface Cable Connections to SmartController See Figure 4 2 on page 44 1 Install one end of the IEEE 1394 cable into the SmartServo port 1 1 connector on the SmartController and install the other end into the IEEE 1
44. ended applications of the robot The conclusions are summarized below Exposure When arm power is on all personnel must be kept out of the robot work envelope by interlocked perimeter barriers The only permitted exception is for teaching the robot in Manual Mode by a skilled programmer see Qualification of Personnel on page 29 who must wear safety equipment see Safety Equipment for Operators on page 29 and carry the Manual Control Pendant MCP Therefore exposure of personnel to hazards related to the robot is limited seldom and or short exposure time Severity of Injury Provided that skilled personnel who enter the AdeptSix 300CR robot work envelope are wearing protective headgear eyeglasses and safety shoes it is likely that any injuries caused by the robot would be slight normally reversible AdeptSix 300CR Robot Instruction Handbook Rev A 23 Chapter 2 Safety 24 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 DANGER The Adept supplied system components provide a Category 1 cont
45. enish the grease according to the following procedure Refer to Figure 9 7 1 Remove the Joint 5 access cover 2 Remove the Ro and Bo plugs hexagon socket head PT1 16 NOTE It is absolutely necessary that you remove the Ro and Bo plugs If grease is added without removing the plugs the internal pressure will increase and may cause damage 3 Replace the PT 1 16 socket head plugs Ri and Bi with A PT 1 16 grease nipples 4 Inject the grease into the Ri and Bi grease inlets using a grease gun Grease type Harmonic grease SK 1A Amount of grease 4 cc NOTE The grease is not exhausted from the Ro and Bo air flows Do not inject excessive grease 5 Remove the G Nipples from the Ri and Bi grease inlets degrease the tapped holes on the Ri and Bi grease inlets and then reinstall the PT 1 16 socket head plugs Apply Three Bond 1211 on screwed parts 6 Degrease the tapped holes on the Ro and Bo air flows and then reinstall the hexagon socket head plugs Apply Three Bond 1211 on screwed parts 7 Reinstall the Joint 5 access cover AdeptSix 300CR Robot Instruction Handbook Rev A 89 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 Fi
46. eplate 37 Direct Mounfing on The Blot ee ee 38 GroundisgMetihod Tor ROBOT 3 525 a ice ea ea 40 System Cable Diagram with Adept MV Controller 41 System Cable Diagram with Adept SmartController 42 interconnect Cabl86 siu 22 abe e rar Sara back KE E Ra P AU ed Ead 43 Interconnect Cable Connection to the Robot 44 FAA FOW CI GSSISh s qup delit dep dod d dub Ub det n dU depu arti dU de dp 45 Moment Arm Rating sacs scores Rr da e X GR PEE GR Y ER EY VEA 49 Wibi TOOL RIGITIGIO nu toe ra S pet o aes oe go p de de a er ui pe p 50 Center of Gravity Calculating Tool Load Information 5 Momen of etti sed ede enc a e Da nennen aad P 52 Center of Gravity Sealing Gun Example 53 Moment of Inertia for Hexahedron and Cylinder 54 Center of Gravity Large Tool and Workpiece Example 55 Center of Gravity Dual End Effector Example 57 Installing Peripheral Equipment nme 58 User Electrical and Alr LINES usse eem eb he 59 Detailed Drawing of Connector Pin Numbers 60 Joint Mode aptid dpa qe pda Ve beta irata etae HE a eraat a 74 Wald ModE ee ers 75 TOOLMOSO nass nn 76 Righ HONG RUG EP era 76 Inspection Parts and Inspection Numbers 81 Bartem LOCATON na eer v EH PY Q3 82 Boer CONM
47. er System acide x kae e eH Ra RERO Re d es 4 Adept SmartConitoller System 24 25 ieee een 42 4 2 Cable Connections from Robot to PA 4 Power Chassis 43 COonneetnonqe Tie PODON s o inched pd cep ub rnit 43 Connection to the PA 4 Power Chassis 44 4 3 Cable Connections to MV Controller 46 Installing the MY CONOIS a sco sh nens acere cn b ia 46 Cable Connections to MV Controller 46 Connecting User Supplied Safety and I O Equipment 46 4 4 Cable Connections to SmartController 47 Installing the Sra C onttoller 335 5 427279 Ore drca a Ihe ea 47 Cable Connections to SmartController 47 Connecting User Supplied Safety and I O Equipment 47 5 End OF Alii TSG ar RH AHPA CROCO 49 5 1 Allowable Wrist LOG 62i diam mises t RR EE Et DEC Rr n eee 49 6 AdeptSix 300CR Robot Instruction Handbook Rev A Table of Contents 9 2 Wiist TOON FGNOS io coc direi een een 50 5 3 End of Arm Tooling Load Definitions 51 5 4 Calculating the Moment of Inertia 52 BOmMBIE Eee nee een dune uel pee Miata ele ER 52 BOmple Zr sense rn Guid ee T 55 EXONS SE san PITE 57 5 5 Mounting Equipment Allowable Load 58 5 6 User Electrical Lines and Air Lin
48. es 59 6 System Operation MV Controller 61 6 1 Infrodluclion 55x bRPRIOGROCESEPISROTereO Jo PEG FE GNE 61 6 2 Installation Check List 61 Mechanieal Checks 5 22 99e is RR Ie ee RR a 61 AC Power to Adept Components Checks 1 62 Board and Cable Installation Checks 62 User Supplied Safety Equipment on JUSER and JSIO Connector Checks 63 6 3 Applying Power to the Adept Control System 64 6 4 Checks After Applying Power 65 6 5 Calibrate RODOR 55 4 m2 235044553 1111 rain 66 6 6 TUMING Off The System nn nd 66 6 7 Learning to Operate Program the AdepiSix 300CR Robot 66 7 System Operation SmartController 67 ZU INMOGUCHON 259393 Bea ee eig 67 7 2 Installation Check Lists sus sou seems px ae ea aaa xus 67 Mechanical GPeckS srra rrite ee 67 Power to the Adept Components Checks 68 Board and Cable Installation Checks issues ee rk y ia dere ears 68 User Supplied Safety Equipment on XUSR Connector Checks 69 E STopButienendsewlle Cheeks s sn poe pha eas 70 7 3 Applying Power to the Adept Control System 70 7 4 Checks After Applying Power 70 7 9 Calibrate RODO 52 555 Rest
49. ety fences see EN 294 In other countries Adept strongly recommends that a similar level of safety be obtained as well as complying with the applicable local and national regulations including SEMI S2 In the USA applicable standards include ANSI RIA R15 06 and ANSI UL 1740 In Canada applicable standards include CAN CSA Z434 Working Areas 28 Adept robots have a Manual and an Automatic AUTO operating mode While in Automatic Mode personnel are not allowed in the workcell In Manual Mode operators with additional safety equipment see Section 2 11 on page 29 are allowed to work in the robot workcell For safety reasons the operator should whenever possible stay outside of the robot work envelope to prevent injury The maximum speed and power of the robot is reduced but it could still cause injury to the operator Before performing maintenance in the working envelope of the robot High Power must be switched off and the power supply of the robot must be disconnected After these precautions a skilled person is allowed to perform maintenance on the robot See Section 2 10 for the specifications CAUTION Never remove any safeguarding and never make changes in the system that will decommission a physical safeguard AdeptSix 300CR Robot Instruction Handbook Rev A Qualification of Personnel 2 10 Qualification of Personnel 2 11 This manual assumes that all personnel have attended an Adept train
50. g w1 x1 w2 x2 wi xi w1 w2 wi yg w1 yl w2 y2 wi yi w1 w2 wi zg w1 z1 w2 z2 wi zi wl w2 wi 4 The moment of inertia at the center of gravity for the entire tool is calculated using the following formula Ix w1 yl yg z1 zg 10 lex1 w2 y2 yg z2 zg 10 1cx2 wi yi yg Hzi zg 10 1cxi ly w1 x1 xg z1 zg 10 lcy1 w2 x2 xg z2 zg 10 1cy2 wi xi xg 4 zi zg 10 lcyi lz w1 amp 1 xg y1 yg 2 10 6 cz1 w2 x2 xg y2 yg 10 6 lcz2 wi xi xg yi yg 10 lczi 58 AdeptSix 300CR Robot Instruction Handbook Rev A 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 When the weight of each part and the center of gravity have been defined the position of the center of gravity including the moment of inertia at the center of gravity can be calculated for the entire tool Refer to Example 1 on page 54 and Example 2 on page 57 for details Figure 5 8
51. gure 9 8 90 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 4 Inject the grease into the Ti grease inlet using a grease gun Remove the A PT 1 16 grease nipple from the Ti grease inlet Grease type Harmonic grease SK 1A Amount of grease 4 cc NOTE Do not inject excessive grease into the Ti grease inlet If excessive grease is added the internal pressure will increase and may cause damage Degrease the tapped hole on the Ti grease inlet and then reinstall the hexagon socket head plug Apply Three Bond 1211 on screwed parts AdeptSix 300CR Robot Instruction Handbook Rev A 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 amp 7 Bu Internal eo Wire Motor Cable etc a Insertion type pin terminal male b Insertion type pin terminal female bHOBT4 al BAT4 OBT Ha TT 1 BAT H H Encoder connector WARNING label Connection Diagram OBT Ha BAT Hb o O Battery Unit OBTAH BAT4H ONINUWM Y c I o I Battery
52. he connector base plate and grease tube from the union Remove the battery unit mounting screw on the Connector Base Remove the plastic tape insulation tape protecting the connector of the battery unit in the robot Connect the new battery Remove the old battery and washer NOTE Remove the old battery unit after connecting the new one so that the encoder absolute data does not disappear Protect the connector of the battery unit in the robot with plastic tape insulation tape Mount the battery unit and washer with the screws connect the grease tube to the union and then mount the connector base plate Connector Base Top View 84 Battery Unit ES Ps fs Connector Base Bolt Mounting Screw 60660 00010 FOO Washer 60660 00020 ae ee U Base Po Connector base Figure 9 2 Battery Location AdeptSix 300CR Robot Instruction Handbook Rev A Maintenance Procedures Battery Unit for Axes 1 2 and 3 See Procedure 6 Before Replacemen See Procedure 7 S ULL a Insertion type Pin Terminal Male
53. hexagon socket head PT1 16 NOTE It is absolutely necessary that you remove the Lo plug If grease is added without removing it the internal pressure will increase and this may case damage to the seals 4 Inject the grease into the Li grease inlet using a grease gun Grease type Harmonic grease SK 1A Amount of grease 20cc NOTE Grease is not evacuated by the Lo exhaust port Do not inject excessive grease into the Li grease inlet 5 Remove the G Nipple Li grease inlet degrease the tapped hole on the Li grease inlet and then reinstall the PT 1 16 socket head plug Apply Three Bond 1211 on screwed parts 6 Degrease the tapped hole on the Lo air flow and then reinstall the hexagon socket head plug Apply Three Bond 1211 on screwed parts 7 Reinstall the Axis 2 side cover AdeptSix 300CR Robot Instruction Handbook Rev A 87 Chapter 9 Maintenance and Inspection Grease Replenishment for Axis 3 Speed Reducer Uo Air flow Hexagon socket head plug PT1 16 LA ri 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 Remove the Uo plug hexagon socket head
54. his caution may cause injury or damage CAUTION Before turning on the power make sure that the shipping bracket and jig have been removed Failure to observe this caution may result in damage to the gear train motors and other key system components 3 2 Transporting Method 34 Using the Crane As a rule a crane should be used to remove the robot from its package and to move the robot into position The robot should be lifted using wire slings threaded through the attached eyebolts Make sure the robot is fixed with jigs before transporting and lift it into the position shown in Figure 3 1 on page 35 Points A and B in Figure 3 1 identify the locations of the shipping bracket and jig AdeptSix 300CR Robot Instruction Handbook Rev A Transporting Method 1X Urethane washer M6 8 mm Hexagon socket head cap bolt anti corrosive m Details of C O 2X M6 40 mm Hexagon socket head cap bolts T anti corrosive H 2X M6 Coned disc springs 1 anti corrosive C 2X Urethane washers i m 5 1 BN 2X M8 Eyebolts N i En provided at factory Details of D D N 2X Urethane washers 2X M5 10 mm Hexagon socket head cap bolis anti corrosive 2X M5 Washers anti corrosive Details of E Figure 3 1 Transporting Position WARNING Sling appli
55. icating 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 CIP 2 and user supplied Test each mushroom button safety gate light curtain etc by enabling High Power and opening the safety device The High Power push button light on the CIP 2 should go out and the red ES LED on the AWC II should be lit AdeptSix 300CR Robot Instruction Handbook Rev A 67 Chapter 6 System Operation MV Controller 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 Built into the absolute encoder is a multiple turn counter that keeps track of the number of times the absolute encoder has completed a full revolution The encoder system is powered by the Adept PA 4 power chassis and also has a battery backup to maintain position tracking during shipment of the robot or periods when the system is turned off 1 Verify that you have enabled power as described above 2 Enter the following command at the dot pro
56. identifies the various axes 3 8 Grounding the Robot Follow local regulations for grounding line size NOTE Do not use this line in common with other ground lines or grounding electrodes for other electric power motor power welding devices etc NOTE Where metal ducts metallic conduits or distributing racks are used for cable laying ground in accordance with Electric Equipment Technical Standards electric shock WARNING Ground resistance must be 100 Qor less A Failure to observe this warning may result in fire or WARNING Before wiring make sure to switch off the primary power supply and place a warning sign for example Do not switch on the power Failure to observe this warning may result in fire or electric shock AdeptSix 300CR Robot Instruction Handbook Rev A 41 Chapter 3 Robot Installation WARNING Wiring must be performed by authorized or certified personnel Failure to observe this caution may result in fire or electric shock M8 Bolt for grounding 5 5 mm or more provided at factory Figure 3 6 Grounding Method for Robot 3 9 Environmental Requirements The environmental conditions of the area in which the robot is installed must satisfy the conditions listed below Ambient temperature must be from 0 to 445 C No moisture should be present 20 to 80 RH Level of the mounting plane for installation must be 0 5 mm or less e System must be isolated from ex
57. in Figure 9 1 on page 83 P When checking for conduction with a multimeter connect the battery to BAT and OBT of the connectors on the motor side for each axis and then remove the connectors from the motor on the detector side for each axis Otherwise the home position may be lost Refer to Notes for Maintenance on page 91 for more information Replace the wire harness in the robot at the 24000 H inspection 4 For the grease refer to Table 9 2 on page 83 82 AdeptSix 300CR Robot Instruction Handbook Rev A Inspection Schedule 4 Axis 4 BI Axis 1 1 Figure 9 1 Inspection Parts and Inspection Numbers Table 9 2 Inspection Parts and Grease Used No Grease Used Inspected Parts 11 12 13 14 15 Harmonic Grease SK 1A 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 A 83 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 e V M g Switch off the main power supplies to the controller and PA 4 power chassis Remove t
58. ing 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 For a description of the level of qualification Adept uses the standard terms Skilled persons have technical knowledge or sufficient experience to enable them to avoid the dangers electrical and or mechanical Instructed persons are adequately advised or supervised by skilled persons to enable them to avoid the dangers electrical and or mechanical All personnel must observe industry prescribed safety practices during the installation operation and testing of all electrically powered equipment To avoid injury or damage to equipment always remove power by disconnecting the AC power from the source before attempting any repair or upgrade activity Use appropriate lockout procedures to reduce the risk of power being restored by another person while you are working on the system WARNING The user must get confirmation from every entrusted person before they start working with the robot that the person 1 Has received the instruction handbook Has read the instruction handbook Understands the instruction handbook Pw N Will work in the manner specified by the instruction handbook Safety Equipment for Operators Operators must wear safety equipment in
59. ion sorting and other high performance tasks Overview of Typical System Installation This section provides an overview of the installation process for a typical AdeptSix 300CR system Read Safety Information 1 Read Chapter 2 to understand general safety information about the AdeptSix 300CR robot system Installing the Robot 1 Prepare for installation including installing safeguards by following Section 3 1 to Section 3 3 2 Mount the robot according to procedures described in Section 3 4 to Section 3 6 3 Install grounding cable on the robot See Section 3 8 AdeptSix 300CR Robot Instruction Handbook Rev A 13 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 Install the AdeptWindows PC user interface according to instructions in the controller manual Installing System Cables 1 Connect the system cables between the robot controller and PA 4 power chassis See Chapter 4 2 See Figure 4 1 on page 43 for the system cable diagram for an Adept MV controller 3 See Figure 4 2 on page 44 for the sys
60. ion in Manual Mode Failure of hardware associated with enabling device or E Stop system Risks Due to Incorrect Installation or Operation 30 Take precautions to ensure that the following situations do not occur Purposely defeating any aspect of the safety E Stop system Improper installation or programming of the robot system Unauthorized use of cables other than those supplied or use of modified components in the system Defeating interlock so that operator can enter workcell with High Power ON 4 Ejection of workpiece see Hazards From Expelling a Part or Attached Tooling on page 21 AdeptSix 300CR Robot Instruction Handbook Rev A 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 CO to extinguish the fire AdeptSix 300CR Robot Instruction Handbook Rev A 31 Chapter 2 Safety 32 AdeptSix 300CR Robot Instruction Handbook Rev A 3 1 Robot Installation 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 Safeg
61. ions liquids as well as explosive gases Clean and dry Free from excessive electrical noise plasma Power Capacity 1 kVA AdeptSix 300CR Robot Instruction Handbook Rev A 95 Chapter 10 Technical Specifications SI units are primarily used in this table However gravitational units are used for values that appear in parentheses P Conforms to 1509283 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 2 Robot Cleanroom Specifications The AdeptSix 300CR has the FEDERAL STANDARD 209E Cleanliness Class 1 4 Under the condition that the manipulator is in the downflow of 0 4 m s or more in a vertically rectified state and 150 liters min or more are taken in 10 3 Part Names and Working Axes Xy J6 _ wrist Flange Rotary Head Lower Arm M Base Figure 10 1 Part Names and Working Axes 96 AdeptSix 300CR Robot Instruction Handbook Rev A Baseplate Dimensions 10 4 Baseplate Dimensions 12 t 180 1130 1 gt 0 012 77 01 O69 Reference Hole 113x 0 1 160 195
62. let connections on the three Dual E amps Verify that the clamp is securely latched Verify the following cable connections Check to see that the plugs are latched on both ends of the cables See Figure 4 2 Robot to amps in PA 4 power chassis Arm Power Cable Robot CN29 connector to MAI 2 CN29 connector Arm Power Cable e Robot to PA 4 power chassis MAI 2 CNPG123 and CNPG456 Arm Signal Cable Install one ground wire each from Arm Signal Cable and Arm Power Cable to front right screw on the top of the Adept PA 4 power chassis SmartController SmartServo port 1 1 connector to MAI 2 1394 connector e SmartController XSYS connector to MAI 2 XSLV1 connector e SmartController XFP to Front Panel XFP e SmartController XMCP to optional MCP requires MCP adapter cable and MCP3 dongle install bypass plug if not used SmartController XUSR to user supplied equipment install jumper plug if not used AdeptSix 300CR Robot Instruction Handbook Rev A 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 I 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
63. ller 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 Step two referred to as commissioning the system verifies that all safety equipment is working properly after the safe initialization of the control system has been verified Step three verifies that the robot moves correctly The Manual Control Pendant is used for this step For more information about the MCP see the Chapter 8 in this manual and the Adept SmartController User s Guide WARNING After installing the robot it must be tested IN before it is used for the first time Failure to do this could cause serious injury or equipment damage 7 2 Installation Check List Before using the robot make the following checks to ensure that the robot and controller have been properly installed Mechanical Checks Verify that the robot is mounted level and that all fasteners are properly installed and tightened Verify that any end of arm tooling is properly installed Verify that all other peripheral equipment is properly installed and in a state where it is safe to turn on power to the robot system AdeptSix 300CR Robot Instruction Handbook Rev A 69 Chapter 7 System Operation SmartCon
64. mance reliability or lifetime The following information is provided as a guideline to modifications Acceptable Modifications In general the following robot modifications do not cause problems but may affect robot performance Attaching tooling utility boxes solenoid packs vacuum pumps cameras lighting etc to the robot tool mount flange Attaching hoses pneumatic lines or cables to the robot These should be designed so they do not restrict joint motion or cause robot motion errors Unacceptable Modifications The modifications listed below may damage the robot reduce system safety and reliability or shorten the life of the robot The warranty of the entire robot or certain parts may be voided CAUTION Making any of the modifications outlined below voids the warranty of any components that Adept determines were damaged due to the modification You must contact Adept Customer Service if you are considering any of the following modifications Modifying any of the robot harnesses or robot to controller cables Modifying any robot access covers or drive system components Modifying including drilling or cutting any robot surface Modifying any robot electrical component or printed circuit board Routing additional hoses air lines or wires through the inside of the robot Modifications that compromise EMC performance including shielding 26 AdeptSix 300CR Robot Instruction Handbook Rev A
65. mpt in the monitor window When calibration is complete the monitor displays the dot prompt This means the system is ready for operation Follow these steps to turn off power to the robot system 1 Make sure that robot motion has stopped 2 Abort any programs that are running using the abort command 3 Turn off High Power to the robot using the disable power command or by pressing the DIS PWR button on the MCP 4 Turn off the AC power switch on the Adept MV controller 5 Turn off the AC power switch on the PA 4 power chassis Learning to Operate Program the AdeptSix 300CR Robot When the robot has been calibrated refer to Chapter 8 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 For additional programming information you need to refer to the following list of V Operating System Reference Guide 6 5 Calibrate Robot calibrate 6 6 Turning Off the System 6 7 optional manuals V Language User s Guide V Language Reference Guide 68 AdeptSix 300CR Robot Instruction Handbook Rev A System Operation SmartController 7 1 Introduction This chapter covers system operation for AdeptSix 300CR robot systems using the Adept SmartController If you have an Adept MV Contro
66. nd air lines 59 working area 28 wristloads 49 wrist tool flange 50 S safeguarding responsibility 31 safety 19 AdeptSix 300CR pinch hazard 27 during maintenance 30 equipment for operators 29 expelling apart 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 shipping bracket 35 SmartController applying power 70 cable connections to 47 connecting 47 connection diagram 42 in system cable diagram 42 installing 47 system operation 67 turning off 71 user supplied safety equipment 69 sources for international standards and directives 22 spare parts 91 specifications 93 speed reducer grease replenishment Axisl 84 Axis2 85 Axis3 86 Axis4 87 Axis5 87 Axis6 88 speed maximum per axis 93 support information finding 16 T teaching robot use safety 24 technical specifications 93 temperature operating 40 93 TOOL coordinate system on MCP 76 tool flange wrist 50 torque maximum 37 transporting robot 27 32 turning off the system MV controller 66 SmartController 71 turning on the system 14 U user electrical and airlines 59 user supplied equipment connecting 46 47 user supplied safety equipment onJUSER 63 on XUSR 69 V verifying system installation MV controller 61 SmartContr
67. ng the main body of the robot by depending on the posture of Axes 1 2 and 3 for the base axes Figure 10 4 Axis 5 Working Range NOTE In certain configurations it is possible for the robot body to come in contact with itself AdeptSix 300CR Robot Instruction Handbook Rev A 99 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 Age me B A5 Axis 2 Figure 10 5 Axis 2 and Axis 3 Rotation 100 AdeptSix 300CR Robot Instruction Handbook Rev A Numerics 1BC cable 43 2BC cable 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 ofinjury 24 axes speeds maximum 93 Axis1 motion range 93 speed reducer greasing 84 Axis 2 effect on Axis 4 98 motionrange 93 speed reducer greasing 85 working range 98 Axis 3 allowableload 58
68. off circuitry is capable of switching external power systems and can be interfaced to the appropriate user supplied safeguards See the AdeptSix Controller Installation Guide for additional information Impact and Trapping Points Adept robots are capable of moving at high speeds If a person is struck by a robot impacted or trapped pinched serious injury could occur Robot configuration joint speed joint orientation and attached payload all contribute to the total amount of energy available to cause injury AdeptSix 300CR Robot Instruction Handbook Rev A 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 Additionally any payload must be held by the end effector in a manner that prevents the payload from being expelled accidentally The safety fence or barrier constructed around the robot must be designed to withstand the impact of any item expelled accidentally from the robot Projectile energy can be calculated using the formula E mv NOTE In the Projectile energy formula above eE Energy em Mass ev Velocity Additional Safety Information The standards and regulations listed in
69. oller 67 vibrations maximum allowable 93 Ww warning labels locating 27 weight end of arm tooling 51 working areas 28 working range 96 WORLD coordinate system on MCP 75 wrist allowable loads 49 tool flange dimensions 50 X XUSR connector checks 69 104 AdeptSix 300CR Robot Instruction Handbook Rev A caa adept technology inc 3011 Triad Drive Livermore CA 94551 01600 000 Rev A Henson
70. orrectly 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 Step two referred to as commissioning the system verifies that all safety equipment is working properly after the safe initialization of the control system has been verified Step three verifies that the robot moves correctly The Manual Control Pendant is used for this step and is reviewed in Chapter 8 WARNING After installing the robot it must be tested before it is used for the first time Failure to do this could cause serious injury or equipment damage 6 2 Installation Check List Before using the robot make the following checks to ensure that the robot and controller have been properly installed Mechanical Checks Verify that the robot is mounted level and that all fasteners are properly installed and tightened Verify that any end of arm tooling is properly installed Verify that all other peripheral equipment is properly installed and in a state where it is safe to turn on power to the robot system AdeptSix 300CR Robot Instruction Handbook Rev A 63 Chapter 6 System Operation MV Controller 64 AC Power to Adept Components Checks Verify that the Adept controller is correctly connected to the AC power source 1 Make sur
71. orting Exercise caution when using transporting equipment other than a crane or forklift as injury may occur 36 AdeptSix 300CR Robot Instruction Handbook Rev A Shipping Bracket and Jig 3 3 Shipping Bracket and Jig 3 4 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 NOTE Before turning on the power make sure that the robot is securely mounted to its mounting base and that the shipping bracket and jig have been removed Then store the shipping bracket and jig for future use in the event that the robot must be moved again NOTE Remove the protective covers from the 1BC and 2BC connectors prior to installing the power and signal interconnect cables Installing Cover Bolts After mounting the robot remove the shipping bolts and jigs that were attached when using the crane and insert the cover bolts When transporting the robot again replace them with the shipping bolts and jigs Figure 3 3 illustrates the procedure for installing the cover bolts AdeptSix 300CR Robot Instruction Handbook Rev A 37 Chapter 3 Robot Installation 3 5 Attached with shi
72. overs from the 1BC and 2BC connectors on the back plate of the robot prior to installing the power and signal cables 2 Before connecting the two cables described above to the robot verify the numbers 1BC and 2BC on both interconnect cables and the robot base connectors 3 When connecting adjust the cable connector positions to the main key positions of the robot and insert the cables in the following order Arm Power 2BC Arm Signal 1BC 4 Secure the cables via the locking latch Connection to PA 4 Chassis Connection to the Robot n TN y N M3 Bolt Connector Connector CNPG123 E 1BC i HHA o AH Arm Signal CNPG456 MZ Terminal Cable Robot Base Side Ground gt e 2BC 7 Ground SZ SS CN29 Arm Power Y CN1 SAME Robot Base Side CN2 CN3 CN4 CN5 CN6 n Motor Output M zd Connector Clamp Figure 4 3 Interconnect Cables AdeptSix 300CR Robot Instruction Handbook Rev A 45 Chapter 4 System Cable Installation d 1 ji Ex se age EN oO nz 1BC 2BC Connection details of the power supply cable robot
73. ox 131 CH 1211 Geneva 20 Switzerland Phone 41 22 919 0211 Fax 41 22 919 0300 http www iec ch Robotic Industries Association RIA 900 Victors Way PO Box 3724 Ann Arbor MI 48106 USA Phone 313 994 6088 Fax 313 994 3338 http www robotics org 22 AdeptSix 300CR Robot Instruction Handbook Rev A 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 Safeguards must comply with all applicable local and national standards for the location where the robot is installed Table 2 2 Partial List of Robot and Machinery Safety Standards International USA Canada Europe Title of Standard ISO 10218 EN 775 Manipulating Industrial Robots Safety ANSI RIA CAN CSA Industrial Robots and Robot R15 06 ZA34 94 Systems Safety Requirements EN 292 2 Safety of Machinery Basic Concepts General Principles for Design EN 954 1 Safety Related Parts of Control Systems General Principles for Design EN 1050 Safety of Machinery Risk Assessment Adept has performed a Risk Assessment for this product based on the int
74. p 2 Dual E Amp 1 MAI 2 Module o s s Oo o 0 DUAL E AMP DUAL E AMP MAI 2 o A o o DUAL E AMP o Status LEDs Break Release Box RS 232 XSLV2 XSLV1 adaf CNPG456 IEEE 1394 Port 1 IEEE 1394 Port 2 n 4 5 oie 5 vl I CN25 Future options Pm IS A i CN29 Arm Brake CH5 o ol 0 CNPG123 CH3 CH2 CH1 CH4 CH6 Figure 4 5 PA 4 Power Chassis AdeptSix 300CR Robot Instruction Handbook Rev A 47 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 Connect the MCP to the CIP 2 Connect AC power to the controller P N Install the AdeptWindows PC user interface Cable Connections to MV Controller See Figure 4 1 on page 43 1 Install one end of the IEEE 1394 cable into the top upper most 1394 connector on the AWC II board and install the other end into the IEEE 1394 port 1 connector on the MAI 2 2 Install the cable betwe
75. pping products 2X M8 Eyebolts 2X M6 Hexagon socket head bolts anti corrosive 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 Shipping jig 2X Urethane washers Use shipping bolts Remove shipping jig and insert the cover bolts Detail B Detail B Figure 3 3 Installing Cover Bolts Types of Mounting 38 The robot can be mounted in three different ways floor mounted standard wall mounted and ceiling mounted types are available For wall and ceiling mounted types contact Adept AdeptSix 300CR Robot Instruction Handbook Rev A 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 The level of the plane of installation must be kept at 0 5 mm or less Mount the baseplate in either of the two ways described on page 40 Table 3 1 Maximum Repulsion Forces of the AdeptSix 300CR Maximum horizontal rotating torque 500 N m 51 0
76. prevents high power from being applied if the amplifier modules or the MAI 2 module are not correctly screwed into place Verify the following cable connections Check to see that the plugs are latched on both ends of the cables See Figure 4 1 on page 43 Robot to amps in PA 4 power chassis Arm Power Cable Robot CN29 connector to MAI 2 CN29 connector Arm Power Cable Robot to PA 4 power chassis MAI 2 Arm Signal Cable Install one ground wire each from Arm Signal Cable and Arm Power Cable to front right screw on the top of the Adept PA 4 power chassis e 1394 AWC I connector to MAI 2 IEEE 1394 connector CIP 2 to optional MCP install bypass plug if not used e CIP 2 JAWC connector to AWC II CIP connector e CIP 2 JSLV connector to MAI 2 XSLV1 connector JUSER to user supplied equipment install jumper plug if not used AdeptSix 300CR Robot Instruction Handbook Rev A 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 I 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 PES User Supplied Safety Equipment on J
77. re to switch off the main power supply and place a warning sign for example Do not switch on the power Failure to observe this warning may result in electric shock or injury WARNING Maintenance and inspection must be performed by specified personnel Failure to observe this caution may result in electric shock or injury CAUTION For disassembly or repair contact your Adept representative CAUTION The battery unit must be connected before removing the detection connector when performing maintenance and inspection Failure to observe this caution may result in the loss of home position data AdeptSix 300CR Robot Instruction Handbook Rev A 79 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 Contact your Adept representative for more information Table 9 1 AdepiSix 300CR Maintenance Schedule and Inspection Items Schedule Inspection Charge 50 30 90 Spe It a 0 00 00 1 38 Metho Operation che Serv pue Daly j g 00 00 a d Lice ice ily 0 0 nse
78. re running using the abort command Turn off High Power to the robot using the disable power command or by pressing the DIS PWR button on the MCP Turn off DC power to the SmartController Turn off the AC power switch on the Adept PA 4 power chassis AdeptSix 300CR Robot Instruction Handbook Rev A 73 Chapter 7 System Operation SmartController 7 7 Learning to Operate Program the AdeptSix 300CR Robot 74 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 For additional programming information you need to refer to the following list of optional manuals V Language User s Guide V Language Reference Guide V Operating System Reference Guide AdeptSix 300CR Robot Instruction Handbook Rev A Using the Manual Control Pendant MCP 8 1 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
79. 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 Before mounting the robot however check that the floor is level and that all cracks etc are repaired Any thickness less than 150 mm is insufficient for mounting even if the floor is concrete 4X M10 35 mm Hexagon Socket head cap bolts anti corrosive 4X M10 Spring washers anti corrosive 4X M10 Washers pem anti corrosive F Ud Details of A nstallation base Grating Anchor bolts M10 or mort 150 mm or more Figure 3 5 Direct Mounting on the Floor 3 7 Axis Naming Conventions The robot s six axes are referred to throughout this documentation as either Axis 1 6 or Joint J 1 6 These terms are used interchangeably For legacy reasons these axes are labelled on the robot as S axis L axis U axis R axis B axis and T axis The table below shows how these current axis labels correspond to the legacy labels 40 AdeptSix 300CR Robot Instruction Handbook Rev A Grounding the Robot Table 3 2 Axis Naming Conventions Current Axis Legacy Axis Labels Labels Axis 1 J1 S axis Axis 2 J2 L axis Axis 3 J3 U axis Axis 4 JA R axis Axis 5 J5 B axis Axis 6 J6 T axis See Figure 10 1 on page 96 for a drawing that
80. rol system as defined by EN 954 The robot system must be installed with user supplied interlock barriers The interlocked barrier should interrupt the DC and AC supplies to the control system in the event of personnel attempting to enter the workcell when Arm Power is enabled except for teaching in Manual Mode Failure to install suitable guarding could result in injury or death The Risk Assessment for teaching this product depends on the application In many applications the programmer will need to enter the robot workcell while Arm Power is enabled to teach the robot Other applications can be designed so that the programmer does not have to enter the work envelope while Arm Power is on Examples of alternative methods of programming include 1 Programming from outside the safety barrier 2 Programming with Arm Power off 3 Copying program from another master robot 4 Off line or CAD programming Control System Behavior Category The following paragraphs relate to the requirements of European EU EEA directives for Machinery Electric Safety and Electromagnetic Compatibility EMC In situations with low exposure consideration factors European Standard EN 1050 specifies use of a Category 1 Control System per EN 954 EN 954 defines a Category 1 Control System as one that employs Category B components designed to withstand environmental influences such as voltage current temperature EMI and well tried safety principles Th
81. system cables 41 42 system overview 13 user airlines 59 user electrical lines 59 installing MV Controller 14 SmartController 14 47 system cables 14 intended use ofthe robot 25 ISO 10218 safety standards 31 J jig shipping 35 joint mode onMCP 73 JSIO connector checks 63 JUSER connector checks 63 K Knowledge Express 17 L LED status indicators onAWC 6 on SmartController 70 level of mounting plane 40 loads allowable wrist 49 on Axis3 58 lubrication see grease replenishment 102 AdeptSix 300CR Robot Instruction Handbook Rev A 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 SmartController 67 modifications acceptable 26 unacceptable 26 moment of inertia end of arm tooling 51 moment of inertia calculations dual end effector example 57 large workpiece example 55 standard calculation example 52 moment allowable 49 93 motionrange 93 MV controller applying power 64 cable connections to 46 connection diagram 41 in system cable diagram 41 sys
82. t 0 pulse position and the flange surface of the robot is turned to the front Center of Gravity Position YF Y axis led by XF ZF Xg Yg Zg ZF Perpendicular direction from flange surface Zr Figure 5 3 Center of Gravity Calculating Tool Load Information Weight W kg The total weight of the installed tooling is set based on the above calculations For rough calculations set a slightly larger value and keep increasing the value for each unit by 0 5 to 1 kg for small to medium size robots for larger robots increase the value by 0 5 to 5 kg units Center of Gravity xg yg zg mm The location of the center of gravity of the installed tool is set based on the position of the tool flange coordinates Moment of inertia at the center of gravity Ix ly Iz kg m This is the moment of inertia of the tool based on the location of the center of gravity The value is calculated around each axis of the coordinate system which is in parallel to the flange coordinates with its origin at the center of gravity of the tool This is used to calculate the moment of inertia and provide verification based on the arm specification requirements The moment of inertia is typically not critical in many cases calculated moment of inertia values are small based on the payload and the center of gravity However this is extremely critical when either the payload or specifically the moment of inertia is exceeded This condition has a drasti
83. tem cable diagram for an SmartController Adding End of Arm Tooling Refer to Chapter 5 for complete information on adding end of arm tooling to the robot Turning On the System Refer to Chapter 6 for an Adept MV controller or Chapter 7 for an SmartController These chapters contain checklists to verify the installation is correct and to test all safety circuits before using the robot 1 3 Checking Package Contents When the package arrives check the contents for the following standard items check any other options ordered as well AdeptSix 300CR Robot Adept MV controller or SmartController Adept PA 4 power chassis Manual Control Pendant MCP optional Controller Interface Panel CIP2 or Adept Front Panel nterconnect cables between controller and robot 14 AdeptSix 300CR Robot Instruction Handbook Rev A Locating the Serial Number 1 4 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 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 The robot s ID serial number is located on a label on the robot base See Figure 1 1 dia I
84. tem operation 61 turning off 66 user supplied safety equipment 63 N Notes Cautions and Warnings description of 19 O operating environment 93 operation mode 93 P PA 4 power chassis connecting to 43 connector identification 45 package contents 14 partnames 81 94 partial list of worldwide robot and machinery safety standards 23 payload 93 accidental expelling 21 intended 25 safety 25 specification 93 user safety 20 24 peripheral equipment 58 pinch hazard 27 power capacity 93 power to Adept components checks MV controller system 62 SmartController system 68 precautions and required safeguards 20 projectile energy calculation 21 protection against unauthorized operation 30 Q qualification of personnel 29 R related manuals 16 repetitive positioning accuracy 93 replacing the battery 82 repulsion forces 37 responsibility for safeguarding 31 risk assessment 23 risk of injury and warning labels 27 risks that cannot be avoided 30 robot and machinery safety standards 23 axis names 38 94 baseplate 37 brake release box 90 calibration 66 71 definition ofindustrial 20 dimensions 96 environmental requirements 40 intended uses 25 lubrication see grease replenishment maintenance 77 modifications 26 mounting equipment on 58 moving with MCP 73 parts 81 programming 66 72 serialnumber 15 specifications 93 transporting 32 AdeptSix 300CR Robot Instruction Handbook Rev A 103 Index user electrical a
85. tests of the robot system 1 Turn the AC power switch on the Adept PA 4 power chassis to the ON I position 2 Turn on DC power to the Adept SmartController 3 TheSmartController will execute its boot sequence When the boot sequence has completed the OK SF LED should be green If this LED is red the SmartController has not booted properly Turn off power to the controller and reboot If the problem persists call Adept Customer Service Note the state of the LEDs marked 1 to 3 4 If the HPE ES LED is continuously red then at least one pair of E Stop contacts is open Check all E stops NOTE For information on the Status LEDs refer to the Adept SmartController User s Guide 7 4 Checks After Applying Power 1 Verify that High Power can be enabled a Enter the following command at the dot prompt in the monitor window enable power Or press the COMP PWR button on the MCP 72 AdeptSix 300CR Robot Instruction Handbook Rev A Calibrate Robot 2 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 Verify that all E Stop devices are functional MCP Front Panel an
86. th an outside force Load Gravity Position L Axis 5 90 200 es LAxis6 a XIS lt mm 100 PAS Axis 6 Rotation Centerline W 3 kg 0 100 200 300 Axis 5 Rotation L Axi Centerline nm Figure 5 1 Moment Arm Rating AdeptSix 300CR Robot Instruction Handbook Rev A 51 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 H Tram mark I e I E Y A co 5 5H7 Depth 7 mm e SG Jk I Figure 5 2 Wrist Tool Flange NOTE Clean off the anticorrosive material on the tool flange area prior to mounting the end of arm tooling This anticorrosive material is only used to protect the robot during shipping 52 AdeptSix 300CR Robot Instruction Handbook Rev A 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 XF Inertia moment around center of gravity Ix ly Iz Weight W Flange Coordinates XF Direction right above when Axis 6 T axis is a
87. that you remove the So plug If grease is added without removing it the internal pressure will increase and this may case damage to the seals Replace the PT 1 8 socket head plug Si with a A PT1 8 grease nipple Inject the grease into the Si grease inlet using a grease gun Grease type Harmonic grease SK 1A Amount of grease 20 cc NOTE Grease is not evacuated by the So exhaust port Do not inject excessive grease into the Si grease inlet Remove the G Nipple from the Si grease inlet degrease the tapped hole on the Si grease inlet and then reinstall the PT 1 8 socket head plug Apply Three Bond 1211 on screwed parts Degrease the tapped hole on the So air flow and then reinstall the hexagon socket head plug Apply Three Bond 1211 on screwed parts AdeptSix 300CR Robot Instruction Handbook Rev A Maintenance Procedures Grease Replenishment for Axis 2 Speed Reducer Lo Air flow Axis 2 speed reducer Hexagon socket head plug PT1 16 T 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 Remove the Lo plug
88. the axes of the various joints J1 J2 J3 etc Use the or speed bar key to specify rotational direction See Figure 8 1 on page 76 AdeptSix 300CR Robot Instruction Handbook Rev A 75 Chapter 8 Using the Manual Control Pendant MCP 76 Axis 3 J3 Axis 2 Y J2 Axis 1 J1 Axis 4 J1 Rotates main body J4 Axis 5 J5 Axis 6 J6 J2 Moves lower arm forward backward J4 Rotates upper arm J3 Moves upper arm up down J5 Moves wrist up down Q J6 Rotates wrist Figure 8 1 Joint Mode AdeptSix 300CR Robot Instruction Handbook Rev A 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 Figure 8 2 World Mode AdeptSix 300CR Robot Instruction Handbook Rev A 77 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
89. the workcell For safety reasons operators must wear the following when they are in the robot workcell Safety glasses Protective headgear hard hats Safety shoes Warning signs should be posted around the workcell to ensure that anyone working around the robot system knows they must wear safety equipment AdeptSix 300CR Robot Instruction Handbook Rev A 29 Chapter 2 Safety 2 12 Protection Against Unauthorized Operation 2 13 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 Safety Aspects While Performing Maintenance 2 14 Only skilled persons with the necessary knowledge about the safety and operating the equipment are allowed to maintain the robot controller and power chassis CAUTION During maintenance and repair the power of the Adept controller must be turned off Lockout measures must be used to prevent unauthorized personnel from turning on power Risks That Cannot Be Avoided 2 15 The AdeptSix 300 robot control system includes devices that disable High Power if a system failure occurs However certain residual risks or improper situations could cause hazards The following situations may result in risks that cannot be avoided Failure of software or electronics that may cause high speed robot mot
90. this handbook contain additional guidelines for robot system installation safeguarding maintenance testing startup and operator training Table 2 1 on page 22 lists some sources for the various standards AdeptSix 300CR Robot Instruction Handbook Rev A 21 Chapter 2 Safety Table 2 1 Sources for International Standards and Directives SEMI International Standards 3081 Zanker Road San Jose CA 95134 USA Phone 1 408 943 6900 Fax 1 408 428 9600 http www semi org web wcontent nsf url stds_home American National Standards Institute ANSI 11 West 42nd Street 13th Floor New York NY 10036 USA Phone 212 642 4900 Fax 212 398 0023 http www ansi org BSI Group British Standards 389 Chiswick High Road London W4 4AL United Kingdom Phone 44 0 20 8996 9000 Fax 44 0 20 8996 7400 http www bsi global com Document Center Inc 1504 Industrial Way Unit 9 Belmont CA 94002 USA Phone 415 591 7600 Fax 415 591 7617 http www document center com DIN Deutsches Institut f r Normung e V German Institute for Standardization Burggrafenstrasse 6 10787 Berlin Germany Phone 49 30 2601 0 Fax 49 30 2601 1231 http www din de http www2 beuth de publishing Global Engineering Documents 15 Inverness Way East Englewood CO 80112 USA Phone 800 854 7179 Fax 303 397 2740 http global ins com IEC International Electrotechnical Commission Rue de Varembe 3 PO B
91. top devices are wired in series not in parallel before connecting to the User E Stop connections Identify all wiring with Channel 1 or Channel 2 Inadvertent connection between the channels will short the E Stop power supply making it impossible to apply High Power 4 Make sure that workcell components have been properly interlocked to avoid hazards when the robot motion system is operated in Manual Mode Per ISO 10218 Manipulating Robots Safety the robot control system must employ a single point of control when operated in Manual Mode AdeptSix 300CR Robot Instruction Handbook Rev A 65 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 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 Verify that the user panel if installed enable contacts are closed that a pair of redundant contacts is installed and that these contacts are separately connected to their respective E Stop channels Inadvertent connection between the channels will short the E Stop power supply making it impossible to apply High Power to the robot 6 3 Applying Power to the Adept Control System 66 After you have made the checks listed above system po
92. troller 70 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 Verify that 24 DC power is connected to the Adept SmartController Verify that the three phase AC power 200 240 VAC or 380 415 VAC is connected to the Adept PA 4 power chassis For information on single phase AC power to the PA 4 see the AdeptSix Controller Installation Guide Board and Cable Installation Checks Make sure that all the boards in the Adept SmartController and PA 4 power chassis are secured and the connection cables are correctly installed 1 Secure all amplifier modules and the MAI 2 multi axis interface module in the amp chassis Tighten both the top and bottom mounting screws on each front panel This ensures proper grounding of the amplifier controller subsystems from an EMC standpoint and ensures good connection to the drawer connectors at the rear of the chassis The drawer connectors carry power and interlock signals from into the power chassis from the amplifiers NOTE There is a safety interlock built into the amp chassis that prevents high power from being applied if the amplifier modules or the MAI 2 module are not correctly screwed into place Secure the motor output connector clamp of the arm power cable onto the six motor power output Motor Power Out
93. uarding 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 The means and degree of safeguarding including any redundancies shall correspond directly to the type and level of hazard presented by the robot system consistent with the robot application Safeguarding may include but not be limited to safeguarding devices barriers interlock barriers perimeter guarding awareness barriers and awareness signals WARNING Install the safety guards Failure to observe this warning may result in injury or damage WARNING Install the robot in a location where the fully extended arm and end of arm tooling will not reach the wall safety guards or controller Failure to observe this warning may result in injury or damage WARNING Do not start the robot or even turn on the power before it is firmly anchored The robot may overturn and cause injury or damage AdeptSix 300CR Robot Instruction Handbook Rev A 33 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 A damaged or lacking parts Failure to observe t
94. usly red then at least one pair of E Stop contacts is open or the E Stop contacts on the JSIO connector are open Review the checklist items above to resolve the problem If the problem persists call Adept Customer Service AdeptSix 300CR Robot Instruction Handbook Rev A 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 Free storage error R R O 6 Software serial I O configuration error G O O C Uninitialized trap G O G D Bus error detected If the AWC II displays any of the above errors contact Adept Customer Service see How Can I Get Help on page 16 6 4 Checks After Applying Power 1 Verify that High Power can be enabled a Enter the following command at the dot prompt in the monitor window enable power Or press the COMP PWR button on the MCP b When the High Power push button light on the CIP 2 begins flashing press and hold the push button for 1 2 seconds When you release the push button the light should remain lit continuously ind
95. wer is ready to be turned on CAUTION All safety systems must be in place and operating before applying power to the system Extra care should be taken during the initial tests of the robot system Turn the AC power switch on the Adept PA 4 power chassis to the ON I position Turn the AC power switch on the Adept MV controller to the ON I position Turn the System Power switch on the CIP 2 if used to the ON D position The AWC I will execute its boot sequence When the boot sequence has completed the SF OK LED should be green If this LED is red the AWC II has not booted properly Turn off power to the controller and reboot If the problem persists call Adept Customer Service Note the state of the LEDs marked 1 to 3 which indicate the problems shown in Table 6 1 on page 67 The other LEDs should be off If the ES E Stop LED on the AWC II board is flickering red this could result from a Anoscillation may be the result of a mismatch between the contacts forming a pair of contacts in the two E Stop channels Perhaps on one channel the user E Stop contacts are closed and on the other they are open Check each pair of contacts to make sure that they match and that they are all closed per Adept MV Controller User s Guide b Also a short between the two E Stop channels may sometimes result in this oscillating red ES LED If the problem persists call Adept Customer Service If the E Stop LED is continuo
96. y sections 5 6 EN 292 2 and EN 60204 1 especially section 13 Definition of a Manipulating Industrial Robot The definition of a manipulating robot according to ISO 10218 1992 E is as follows A manipulating robot is an automatically controlled reprogrammable multipurpose manipulative machine with several degrees of freedom which may be either fixed in place or mobile for use in industrial automation applications Safety Barriers 20 Safety barriers must be provided that prevent personnel from entering the workcell whenever power is applied to the equipment Adept systems are computer controlled and may activate remote devices under program control at times or along paths not anticipated by personnel It is critical that safeguards be in place to prevent personnel from entering the workcell whenever power to the equipment is present The robot system integrator user or operator must ensure that adequate safeguards safety barriers light curtains safety gates safety floor mats etc are installed The robot workcell must comply with applicable local and national standards see Section 2 8 on page 28 The height and the distance of the safety fence from the robot must ensure that personnel cannot reach the danger zone of the robot The Adept control system has features that aid the user in constructing system safeguards including customer emergency stop circuitry and digital input and output lines The emergency power

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