Omron Adept Hornet 565 User Manual
Adept Hornet 565
Robot User’s Guide
Copyright Notice
The information contained herein is the property of Adept Technology, Inc., and shall not be reproduced
in whole or in part without prior written approval of Adept Technology, Inc. The information herein is
subject to change without notice and should not be construed as a commitment by Adept Technology,
Inc. The documentation is periodically reviewed and revised.
Adept Technology, Inc., assumes no responsibility for any errors or omissions in the documentation.
Critical evaluation of the documentation by the user is welcomed. Your comments assist us in
preparation of future documentation. Please submit your comments to: techpubs@adept.com.
Copyright 2015 by Adept Technology, Inc. All rights reserved.
Adept, the Adept logo, the Adept Technology logo, AdeptVision, AIM, Blox, Bloxview, FireBlox, Fireview,
Meta Controls, MetaControls, Metawire, Motivity, Soft Machines, and Visual Machines are registered
trademarks of Adept Technology, Inc.
Brain on Board is a registered trademark of Adept Technology, Inc. in Germany.
Adept ACE, Adept ePLC Connect, Adept Hornet 565, Adept SmartController EX, Adept SmartVision MX,
Adept T20, eAIB, IO Blox, and eV+ are trademarks of Adept Technology, Inc.
Any trademarks from other companies used in this publication
are the property of those respective companies.
Created in the United States of America
Table of Contents
Chapter 1: Introduction 11
1.1 Adept Hornet 565 Robots, Product Description
Adept eAIB Amplifier 12
Adept Hornet 565 Robot Base 12
Inner Arms 13
Ball Joints, Outer Arms 13
Platforms 13
Adept SmartController™ EX 15
1.2 Warnings, Cautions, and Notes in Manual
1.3 Safety Precautions
1.4 What to Do in an Emergency
1.5 Additional Safety Information
1.6 Intended Use of the Robots
1.7 Installation Overview
1.8 Manufacturer’s Declaration
1.9 How Can I Get Help?
Related Manuals 18
Adept Document Library 19
11
15
16
17
17
17
17
18
18
Chapter 2: Robot Installation 21
2.1 Transport and Storage
2.2 Unpacking and Inspecting the Adept Equipment
Before Unpacking 21
Upon Unpacking 21
Unpacking 21
2.3 Repacking for Relocation
2.4 Environmental and Facility Requirements
2.5 Mounting Frame
Robot-to-Frame Considerations 24
Mounting 24
2.6 Mounting the Robot Base
Robot Orientation 25
Mounting Surfaces 25
Mounting Procedure 25
Install Mounting Hardware 26
2.7 Attaching the Outer Arms, Platform, and Theta Drive Shaft
Aligning the Platform with the Base 27
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21
21
23
23
23
25
27
Table of Contents
Attaching the Outer Arms 28
Attaching the Theta Drive Shaft 31
2.8 End-Effectors
Attaching an End-Effector 33
Aligning an End-Effector 33
Grounding 33
Accessing Vacuum 33
Routing End-effector Lines 34
33
Chapter 3: System Installation 35
3.1 System Cables, eAIB Only (no SmartController EX)
List of Cables and Parts 36
Cable Installation Overview 37
Optional Cables 38
3.2 System Cables, with SmartController EX
Installing a SmartController EX Motion Controller 39
List of Cables and Parts 40
Cable Installation Overview 41
Less Common Cables 41
3.3 System Cables for Systems with Belt Encoders
List of Cables and Parts 43
Cable Installation Overview 43
3.4 Adept ACE Software
User-supplied PC 44
Installing Adept ACESoftware 44
3.5 Robot Interface Panel
3.6 Connecting 24 VDC Power to Robot
Specifications for 24 VDC Robot and Controller Power 46
Details for 24 VDC Mating Connector 47
Procedure for Creating 24 VDC Cable 47
Installing 24 VDC Robot Cable 48
3.7 Connecting 200-240 VAC Power to Robot
Specifications for AC Power 49
Details for AC Mating Connector 51
Procedure for Creating 200-240 VAC Cable 51
Installing AC Power Cable to Robot 52
3.8 Grounding the Adept Robot System
Grounding Robot-Mounted Equipment 52
Grounding Robot Base to Frame 53
3.9 Installing User-Supplied Safety Equipment
Emergency Stop Circuits 58
Remote Manual Mode 60
User Manual/Auto Indication 60
User High Power On Indication 60
35
39
42
44
45
46
49
52
53
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Table of Contents
Remote High Power On/Off Control 60
High Power On/Off Lamp 61
Remote Front Panel or User-Supplied Control Panel Usage 61
Remote Pendant Usage 62
Chapter 4: System Operation 63
4.1 Robot Status Display Panel
4.2 Status Panel Fault Codes
4.3 Using the Brake-Release Button
Robot Brakes 64
Brake-Release Button 65
4.4 Optional Adept Front Panel
4.5 Connecting Digital I/O to the System
I/O on the eAIB: 67
I/O with an Optional SmartController EX: 67
4.6 Using Digital I/O on eAIB XIO Connector
Optional I/O Products 70
XIO Input Signals 70
XIO Output Signals 72
XIO Breakout Cable 74
4.7 Starting the System for the First Time
Verifying Installation 76
Turning on Power and Starting Adept ACE 77
Enabling High Power 78
Verifying E-Stop Functions 78
Aligning the Platform and J4 Motor 78
Verify Robot Motions 79
4.8 Robot Motions
Straight-line Motion 79
Containment Obstacles 79
4.9 Learning to Program the Adept Hornet 565 Robot
63
64
64
66
67
69
76
79
79
Chapter 5: Options 81
5.1 Tall Frame Adapters
5.2 ePLC Connect
Configuration 82
Setting the Robot IP Address 82
Setting the Robot IP Address on the PLC 84
Using the PLC to Enable High Power 84
5.3 SmartVision MX Industrial PC
5.4 SmartController EX Motion Controller
5.5 sDIO Module
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81
82
85
85
85
Table of Contents
5.6 IOBlox I/ODevice
5.7 eAIB XBELT IOAdapter Cable
5.8 Cable Inlet Box
Overview 86
Installation Procedure 87
5.9 Intelligent Force Sensor
5.10 Ball Stud Locks
Installing a Ball Stud Lock 93
Removing a Ball Stud Lock 94
85
85
85
92
92
Chapter 6: Maintenance 95
6.1 Cleaning
Water Shedding 95
Wash-Down 95
Chemical Compatibility 96
6.2 Periodic Inspection
Checking Safety Systems 98
Checking Robot Mounting Bolts 98
Checking Robot Gear Drives 98
Checking Fan Operation 99
6.3 Periodic Maintenance
Replacing the Theta Drive Shaft 101
Replacing the Encoder Battery Pack 103
6.4 Non-Periodic Maintenance
Changing the Lamp in the Optional Adept Front Panel High-Power Indicator 106
Replacing a Platform 107
Replacing a Ball Joint Insert 108
Replacing Outer Arm Spring Assemblies 108
Replacing the eAIB Chassis 112
6.5 Commissioning a System with an eAIB
Safety Commissioning Utilities 117
E-Stop Configuration Utility 118
E-Stop Verification Utility 119
Teach Restrict Configuration Utility 119
Teach Restrict Verification Utility 120
95
96
100
106
116
121
Chapter 7: Technical Specifications 123
7.1 Dimension Drawings
7.2 Robot Specifications
7.3 Environmental Specifications
Operating 127
Shipping and Storage 127
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123
126
127
Table of Contents
7.4 Payload Specifications
Payload 127
Torque 127
7.5 Performance
Cycle Times 128
Power Consumption 128
Payload Mass vs. Acceleration 129
Payload Inertia vs. Acceleration 129
7.6 Robot Mounting Frame
127
128
129
Chapter 8: Environmental Concerns 137
8.1 Ambient Environment
8.2 Cleanroom Classification
8.3 Design Factors
Robot Base and Components 138
Inner Arms 138
Ball Joints 138
Outer Arms 138
Spring Assemblies 139
Platforms 139
137
137
137
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Chapter 1: Introduction
Joint 3
eAIB
Robot
Base
Tool Flange
Platform
and Ball
Joints
Theta
Drive
Shaft
Ball Joints,
Joint 1
Outer Arms
Status Display Panel
Joint 4
Cover
Robot Base
Cover
Inner Arm
Motor Plug
Mounting Pad
x3
Joint 2
Inner Arm
(Spring Assemblies
not shown)
1.1 Adept Hornet 565 Robots, Product Description
The Adept Hornet 565™ robot is a three-axis parallel robot. The three identical axis motors
control movement of the robot tool in X, Y, and Z directions. On the four-motor model, a fourth
motor on the robot base turns a telescoping drive shaft, which provides theta rotation of the
tool flange through a geared platform.
The Hornet 565 robot is available in two models. One has a J4 platform, a theta motor and
theta drive shaft. This provides ±360° of rotation at the tool flange. The other model has a fixed
platform with no tool flange rotation.
Figure 1-1. Major Robot Components
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Chapter 1: Introduction
Adept eAIB Amplifier
The Adept Hornet 565 robot uses an Adept eAIB™ amplifier. The robot is powered and
controlled using the eAIB. The amplifiers and full servo control for the Adept Hornet 565 robot
are contained in the eAIB, which is embedded in the base of the robot. The eAIB also provides
the platform for running Adept’s eV+ OS and language.
The Adept eAIB features:
l
On-board digital I/O: 12 inputs, 8 outputs
l
Low EMI for use with noise-sensitive equipment
l
No external fan for quiet operation
l
8 kHz servo rate to deliver low positional errors and superior path following
l
Sine-wave commutation to lower cogging torque and improve path following
l
Digital feed-forward design to maximize efficiency, torque, and velocity
l
Temperature sensors on all amplifiers and motors for maximum reliability and easy
troubleshooting
l
Hardware-based E-Stop and Teach Restrict controls
For improved safety relative to European standards implemented in 2012.
Figure 1-2. Adept eAIB
Adept Hornet 565 Robot Base
The Adept Hornet 565 robot base is an aluminum casting that houses the four or three drive
motors, and supports the eAIB. It provides three mounting pads for attaching the base to a
rigid support frame. The Status Display panel is mounted on the side of the robot base.
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Chapter 1: Introduction
Inner
Arm
Ball Joint
Socket
Ball Joint
Socket Insert
Outer Arm Springs
Spring
Horseshoe
Pressed Pin
Ball Joint Stud
Outer Arms
Inner Arms
Three robot motors attach directly to the inner arms through high-performance gear reducers. If
the robot has a theta rotation motor, it is mounted at the top of the robot base. The following
figure shows an inner arm from a Hornet 565 robot. RIA-compliant hard stops limit the inner
arm motion to -53° and +114.6°.
Ball Joints, Outer Arms
The inner arm motion is transmitted to the platform through the outer arms, which are
connected between the inner arms and platform with precision ball joints. The outer arms are
carbon fiber epoxied assemblies with identical ball joint sockets at each end. A bearing insert
in each socket accepts the ball joint studs on the inner arms and platform, and allows for
approximately ± 60° of relative motion. No ball joint lubrication is required.
Figure 1-3. Ball Joint Assembly
Each pair of outer arms is held together with spring assemblies that pre-tension the ball joints.
The outer arms can be installed and removed without tools.
Platforms
The platform converts the motion of the Hornet 565 robot motors into Cartesian motion, and,
for the four-motor version, theta rotation of the robot tool flange.
The fixed platform, with no theta rotation, is stainless steel.
The J4 platform has a fourth motor, theta drive shaft, and geared J4 platform that can rotate its
tool flange ±360°. The platform is electroless-nickel-plated aluminum.
Both platforms have a 38 mm hole through their center, for users to route air lines or electric
cables to the tool flange.
For the J4 version of the Hornet 565 robot, a stainless steel theta drive shaft attaches to a Ujoint at both the platform and the J4 motor on the robot.
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Chapter 1: Introduction
Figure 1-4. J4 Platform (Electroless Nickel-plated Aluminum)
Figure 1-5. Fixed Platform (Stainless Steel)
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Chapter 1: Introduction
Platform Clocking
The J4 platform, which is rotational, is constructed such that the clocking, or rotational
alignment, of the platform relative to the robot base is critical. This is detailed in Aligning the
Platform with the Base on page 27.
Platform Shipping
l
The platform, outer arms, and theta drive shaft are removed.
l
The platform is shipped assembled as a unit.
You will need to connect the outer arms between the inner arms and the platform to
reassemble the robot. The outer-arm assemblies are interchangeable.
For the Hornet 565 robot with the J4 platform, you will also have to connect the
telescoping drive shaft that connects the platform to the fourth motor on the robot base.
Any end-effectors and their air lines and wiring are user-supplied.
Adept SmartController™ EX
The optional SmartController EXmotion controller supports tracking more conveyors, as well
as other options. Like the eAIB, the SmartController EX uses the eV+ operating system. It offers
scalability and support for IEEE 1394-based digital I/O and general motion expansion
modules. The SmartController EX also includes Fast Ethernet and DeviceNet.
Figure 1-6. Adept SmartController EX
Refer to the Adept SmartController EX User’s Guide for SmartController specifications.
1.2 Warnings, Cautions, and Notes in Manual
There are five levels of special alert notation used in Adept manuals. In descending order of
importance, they are:
DANGER:This indicates an imminently hazardous electrical
situation which, if not avoided, will result in death or serious
injury.
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Chapter 1: Introduction
DANGER:This indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING:This indicates a potentially hazardous electrical
situation which, if not avoided, could result in injury or major
damage to the equipment.
WARNING:This indicates a potentially hazardous situation
which, if not avoided, could result in injury or major damage to
the equipment.
CAUTION:This indicates a situation which, if not avoided,
could result in damage to the equipment.
NOTE:Notes provide supplementary information, emphasize a point or procedure,
or give a tip for easier operation.
1.3 Safety Precautions
l All personnel who install, operate, teach, program, or maintain the system must read
this guide, read the Adept Robot Safety Guide, and complete a training course for their
responsibilities in regard to the robot.
l All personnel who design the robot system must read this guide, read the Adept Robot
Safety Guide, and must comply with all local and national safety regulations for the
location in which the robot is installed.
l The robot system must not be used for purposes other than described in Intended Use of
the Robots on page 17. Contact Adept if you are not sure of the suitability for your
application.
l The user is responsible for providing safety barriers around the robot to prevent anyone
from accidentally coming into contact with the robot when it is in motion.
DANGER:An Adept Hornet robot can cause serious injury or
death, or damage to itself and other equipment, if the following
safety precautions are not observed:
l Power to the robot and its power supply must be locked out and tagged out before any
maintenance is performed.
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Chapter 1: Introduction
1.4 What to Do in an Emergency
Press any E-Stop button (a red push-button on a yellow background) and then follow the
internal procedures of your company or organization for an emergency situation. If a fire
occurs, use CO2to extinguish the fire.
1.5 Additional Safety Information
Adept provides other sources for more safety information.
The Manufacturer’s Declaration of Conformity (MDOC) lists all standards with which each
robot complies. See Manufacturer’s Declaration on page 18.
The Adept Robot Safety Guide provides detailed information on safety for Adept robots. It also
gives resources for more information on relevant standards. It ships with each robot manual,
and is also available from the Adept Document Library. For details, see Adept Document
Library on page 19.
1.6 Intended Use of the Robots
The Adept Hornet 565 robot is intended for use in parts assembly and material handling for
payloads up to 3 kg (6.6 lb).
See Robot Specifications on page 126 for complete information on the robot specifications.
Refer to the Adept Robot Safety Guide for details on the intended use of Adept robots.
1.7 Installation Overview
The system installation process is summarized in the following table. Also, refer to System
Installation on page 35.
NOTE:For dual-robot installations, see the Adept Dual-Robot Configuration
Procedure, which is available in the Adept Document Library.
Task to be Performed Reference Location
If purchased, mount the optional cable box. Options on page 81.
Mount the robot to a level, stable mounting frame. Mounting on page 24.
Attach the robot outer arms and platform. Attaching the Outer Arms on page
Attach the theta drive shaft, for the J4 platform. Attaching the Theta Drive Shaft on
Install the Front Panel and Pendant, if purchased,
and Adept ACE software.
Table 1-1. Installation Overview
28.
page 31.
System Cables, eAIB Only (no
SmartController EX) on page 35 and
Adept ACE Software on page 44.
Create a 24 VDC cable and connect it between the
robot and the user-supplied 24 VDC power supply.
Create a 200-240 VAC cable and connect it between Connecting 200-240 VAC Power to
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Procedure for Creating 24 VDC Cable
on page 47.
Chapter 1: Introduction
Task to be Performed Reference Location
the robot and the facility AC power source. Robot on page 49.
Install user-supplied safety barriers in the workcell. Installing User-Supplied Safety
Equipment on page 53.
Connect digital I/O through the robot XIO connector. Using Digital I/O on eAIB XIO
Connector on page 69.
Start the system, including system operation testing. Starting the System for the First Time
on page 76.
Install optional equipment, including end-effectors,
user air and electrical lines, external equipment, etc.
1.8 Manufacturer’s Declaration
The Manufacturer’s Declaration of Incorporation and Conformity for Adept robot systems can
be found on the Adept website, in the Download Center of the Support section.
http://www.adept.com/support/downloads/file-search
NOTE:The Download Center requires that you are logged in for access. If you are
not logged in, you will be redirected to the Adept website Login page.
1.
From the Download Types drop-down list, select Manufacturer Declarations.
2.
From the Product drop-down list, select Adept Hornet Robots category.
3.
Click Begin Search. The list of available documents is shown in the Search Results area,
which opens at the bottom of the page. You may need to scroll down to see it.
4.
Use the Description column to locate the document for the language you want, and then
click the corresponding Download ID number to access the Download Details page.
5.
On the Download Details page, click Download to open or save the file.
Options on page 81.
1.9 How Can I Get Help?
Refer to the How to Get Help Resource Guide (Adept P/N 00961-00700) for details on getting
assistance with your Adept software and hardware. Additionally, you can access information
sources on Adept’s corporate website:
http://www.adept.com
Related Manuals
This manual covers the installation, operation, and maintenance of an Adept Hornet 565 robot
system. There are additional manuals that cover programming the system and adding
optional components. See the following table. These manuals are available on the Adept
software media shipped with each system.
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Chapter 1: Introduction
Table 1-2. Related Manuals
Manual Title Description
Adept Robot Safety Guide Contains safety information for Adept robots.
Adept ACE User’s Guide Describes the installation and use of Adept ACE.
Adept T20 Pendant User's
Guide
Adept SmartController EX
User’s Guide
Describes the use of the optional Adept T20 manual control
pendant.
Contains complete information on the installation and
operation of the optional Adept SmartController EX and sDIO
products.
Adept SmartVision MX User's
Guide
Adept ePLC Connect 3 User’s
Guide
Instructions for use of the optional Adept SmartVision MX
industrial PC.
Describes the installation and use of the Adept ePLC Connect
3 software, for using a user-supplied PLC as controller.
Adept IO Blox User’s Guide Describes the IOBlox product.
Adept Dual-Robot
Configuration Procedure
Contains cable diagrams and configuration procedures for a
dual-robot system.
Adept Document Library
The Adept Document Library (ADL) contains documentation for Adept products. You can
access the ADL from the Adept website. Select:
Support > Document Library
from the Adept home page. To go directly to the Adept Document Library, type the following
URL into your browser:
http://www.adept.com/Main/KE/DATA/adept_search.htm
To locate information on a specific topic, use the Document Library search engine on the ADL
main page, or select one of the available menu options. To view a list of available product
documentation, use the menu links located above the search field.
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Chapter 2: Robot Installation
2.1 Transport and Storage
This equipment must be shipped and stored within the range –10 to +60° C (14 to 140° F).
Humidity should be less than 75%, non-condensing. The robot should be shipped and stored
in the Adept-supplied crate, which is designed to prevent damage from normal shock and
vibration. You should protect the crate from excessive shock and vibration.
Use a forklift, pallet jack, or similar device to transport the packaged equipment.
The robot must always be stored and shipped in an upright position. Do not lay the crate on
its side or any other non-upright position. This could damage the robot.
The Adept Hornet 565 robot J4 model weighs 52 kg (115 lb) with no options installed.
The fixed model weighs 48.6 kg (107 lb) with no options installed.
The crate weighs 68 kg (150 lb).
2.2 Unpacking and Inspecting the Adept Equipment
Before Unpacking
Carefully inspect all shipping crates for evidence of damage during transit. If any damage is
indicated, request that the carrier’s agent be present at the time the container is unpacked.
Upon Unpacking
Before signing the carrier’s delivery sheet, compare the actual items received (not just the
packing slip) with your equipment purchase order. Verify that all items are present and that
the shipment is correct and free of visible damage.
l
If the items received do not match the packing slip, or are damaged, do not sign the
receipt. Contact Adept as soon as possible (see How Can I Get Help? on page 18).
l
If the items received do not match your order, please contact Adept immediately.
Retain all containers and packaging materials. These items may be necessary to settle claims
or, at a later date, to relocate the equipment.
Unpacking
The Hornet 565 robot is shipped in a crate that holds the robot base, outer arms, platform,
theta drive shaft, and any accessories ordered. The crate is made of wood.
The top of the crate should be removed first.
1.
Remove the Klimp®fasteners holding the top to the rest of the crate. See the following
figure.
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Chapter 2: Robot Installation
Figure 2-1. Klimp Fastener on Crate
The robot base is shipped with the inner arms attached. The outer arms are in a
cardboard box, assembled in pairs. The platform is shipped fully assembled, but
separate from the robot base and outer arms. The theta drive shaft is shipped with Ujoints attached, but separate from the robot and platform.
2.
Lift the top off of the crate sides, and set it aside.
Figure 2-2. Crate, with Top Removed
3.
Remove all cardboard boxes from inside the crate.
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Chapter 2: Robot Installation
These will include the outer arms, theta drive shaft, and platform.
4.
Remove all fasteners (Klimp and lag)holding the crate sides to the base, and lift off the
crate sides.
The four sides will come off as a single piece, so this requires two people lifting from
opposite sides of the crate.
You will be left with the robot base, with eAIB and inner arms, attached to the pallet.
The robot base is held to the pallet with tie-downs.
5.
Remove the tie-downs.
NOTE:The pallet will not fit inside most frames, so the robot will need to be
manually moved to the inside of the frame for mounting.
2.3 Repacking for Relocation
If the robot or other equipment needs to be relocated, reverse the steps in the installation
procedures in this chapter. Reuse all original packing containers and materials and follow all
safety notes used for installation. Improper packaging for shipment will void your warranty.
CAUTION:The robot must always be shipped in an upright
orientation.
2.4 Environmental and Facility Requirements
The Hornet 565 robot system installation must meet the operating environment requirements
shown in the following table.
Table 2-1. Robot System Operating Environment Requirements
Ambient temperature 1 to 40° C (34 to 104° F)
Humidity 5 to 90%, non-condensing
Altitude up to 2000 m (6500 ft)
NOTE: For robot dimensions, see Dimension Drawings on page 123.
NOTE: For power requirements, see Specifications for 24 VDC Robot and Controller Power
on page 46 and Specifications for AC Power on page 49.
NOTE: For chemical cleaning information, refer to Chemical Compatibility on page 96.
2.5 Mounting Frame
The design of the robot mounting frame is the user’s responsibility.
l
The flatness of the frame mounting tabs is critical. See Robot-to-Frame Considerations
(following) and Mounting Surfaces on page 25.
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Chapter 2: Robot Installation
l
The frame must be stiff enough to prevent excessive vibration.
l
The eAIB must be removable from the robot without removing the robot from the frame.
This is needed for maintenance and inspection of the robot.
The Hornet 565 robot is designed to be mounted above the work area suspended on a usersupplied frame. The frame must be adequately stiff to hold the robot rigidly in place while the
robot platform moves within the workspace.
While Adept does not offer robot frames for purchase, and the frame design is the
responsibility of the user, we provide some general guidelines as a service to our users.
Any robot’s ability to settle to a fixed point in space is governed by the forces, masses, and
accelerations of the robot. Since “every action has an equal and opposite reaction”, these forces
are transmitted to the robot frame and cause the frame and base of the robot to move and
possibly vibrate in space. As the robot system works to position the tool flange relative to the
base of the robot, any frame or base motion will be “unobservable” to the robot system, and
will be transmitted to the tool flange. This transmitted base motion will result in inertial
movement of the tool flange mass, and will cause disturbance forces to be introduced into the
robot control system. These disturbance forces cause “work” to be done by the robot servo
control system which may result in longer settling times for robot operations.
It is important to note that, even after the system reports the robot to be fully settled, the tool
flange will still be moving by any amount of motion that the suspended base of the robot may
be experiencing.
Robot-to-Frame Considerations
The Hornet 565 robot has a moderately-complex mounting requirement due to the nature of
the parallel-arm kinematics and the need to minimize the robot size and mass. Arm Travel
Volume on page 125 shows the inner arm travel and how it may encroach on the robot
mounting points. As a starting point, for a frame that is 1440 mm in the X and Ydirections,
(allowing use of the full range of the robots), you should attempt to attain a frame frequency of
25 Hz.
For specialized applications, such as heavy payloads and/or aggressive moves, you may want
to attain a frame frequency of 40 Hz.
In general, a smaller frame will yield a higher frequency. If you aren’t going to use the entire
work envelope, you can increase the frequency simply by using a smaller frame.
A lower frequency frame, more aggressive robot moves, and heavier payloads will all
contribute to longer settling times.
Mounting
Dimension Drawings on page 123 shows the mounting hole pattern for the Hornet 565 robot.
Note the hole location and mounting pad tolerances for position and flatness.
Deviation from this flatness specification will, over time, cause a possible loss of robot
calibration.
NOTE:Adept suggests welding the robot mounting tabs as a last step in the frame
fabrication, using a flat surface as a datum surface during the tack welding
operation.
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Chapter 2: Robot Installation
2.6 Mounting the Robot Base
Robot Orientation
Adept recommends mounting the Hornet 565 robot so that the Status Display Panel faces
away from the conveyor belt. Although the work envelope of the robot is symmetrical, this
orientation gives better access to the status display. It also orients the arm loading for
aggressive moves across the belt.
This orientation places the robot World Y-axis along the conveyor belt, and the X-axis across
the belt. See Mounting Dimensions on page 123.
Mounting Surfaces
Mounting surfaces for the robot mounting tabs must be within 0.75 mm of a flat plane.
CAUTION:Failure to mount the Hornet 565 robot within
0.75mm of a flat plane will result in inconsistent robot locations.
NOTE:The base casting of the robot is aluminum and can be dented if bumped
against a harder surface.
CAUTION:Do not attempt to lift the robot from any points
other than with slings as described here.
Mounting Procedure
The Hornet 565 robot has three mounting pads. Each pad has one hole with an M12 x 1.75
spring-lock Heli-Coil®.
1.
Position the robot directly under the mounting frame.
NOTE:The pallet will not fit inside most frames, so the robot will need to be
manually moved to the inside of the frame.
2.
Put nylon straps through the six slots near the three mounting pads.
The following figure shows two of these slots.
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Chapter 2: Robot Installation
Mounting Pad
Lifting Slots
Figure 2-3. Two of Six Lifting Slots
3.
Take up any slack in the straps.
The mechanism you use for lifting the straps will be dependent on the frame design, so
it is not specified here.
4.
Slowly lift the robot base up, keeping the holes in the robot base pads and the frame
pads aligned, until the top surfaces of the robot base pads are touching the bottom
surfaces of the frame mounting pads.
5.
Follow the instructions in Install Mounting Hardware that follow.
Install Mounting Hardware
Because of the possible variability of the mounting frames, mounting hardware is usersupplied. The bolts need to be M12-1.75, either stainless steel or zinc-plated steel. The threads
must engage 24 mm (0.94 in.) of the robot base threads (Heli-Coil), for sufficient support.
When mounting the robot, note the following:
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Verify that the robot is mounted squarely before tightening the mounting bolts.
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Insert the bolts through the holes in the frame and into the threaded holes in the robot
base mounting pads.
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Ground the robot base to the mounting frame.
Refer to Grounding Robot Base to Frame on page 53.
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Tighten the bolts to 61 N·m (45 ft-lb).
NOTE:The robot base-mounting tabs have spring-lock Heli-Coils in the M12 holes,
so lock washers are not needed on the M12 mounting bolts.
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Chapter 2: Robot Installation
Joint 3
eAIB
Robot
Base
Tool Flange
Platform
and Ball
Joints
Theta
Drive
Shaft
Ball Joints,
Joint 1
Outer Arms
Status Display Panel
Joint 4
Cover
Robot Base
Cover
Inner Arm
Motor Plug
Mounting Pad
x3
Joint 2
Inner Arm
(Spring Assemblies
not shown)
NOTE: Check the tightness of the mounting bolts one week after initial installation,
and then recheck every 3 months. See Checking Robot Mounting Bolts on page 98.
2.7 Attaching the Outer Arms, Platform, and Theta Drive Shaft
Figure 2-4. Major Robot Components
The Adept Hornet 565 robot platform is attached to the inner arms by the outer arms.
NOTE:Except for attaching the outer arms and theta drive shaft, the platform is
shipped fully-assembled.
Aligning the Platform with the Base
NOTE:The fixed platform is symmetrical, and can be mounted in any rotational
position. The tool flange must be down, away from the robot body.
This section only applies to the J4 platform.
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Chapter 2: Robot Installation
Theta
Drive
Shaft
Attachment
Joint 1
Joint 3 Joint 2
Tool
Flange
X+
Y+
The rotational alignment of the platform with the base is critical to the correct operation of the
robot.
CAUTION:Incorrect alignment of the platform will result in
incorrect robot performance.
Both the theta drive shaft attachment on the robot base and the platform are offset by about 2
in. from the centers of the robot base and tool flange. The platform should be attached so that
the shaft aligns with the J4 motor, between Joint 1 and Joint 3 on the robot base. Joint 1 in the
preceding figure should connect to motor 1, which is immediately to the right of the Status
Display panel on the robot base.
Attaching the Outer Arms
One pair of outer arms attaches between each inner arm and the platform. No tools are
needed.
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Each outer arm has a ball joint socket at each end.
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The inner arms and the platform have corresponding pairs of ball studs.
Figure 2-5. J4 Platform Orientation, Top View
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Chapter 2: Robot Installation
Inner
Arm
Ball Joint
Socket
Ball Joint
Socket Insert
Outer Arm Springs
Spring
Horseshoe
Pressed Pin
Ball Joint Stud
Outer Arms
Figure 2-6. Inner Arm Ball Studs
WARNING:Pinch hazard. Ball joints are spring-loaded. Be
careful not to pinch your fingers.
l
Outer arm pairs are shipped assembled. Each pair has two springs and two horseshoes
at each end. See the following figure.
Adept Hornet 565 Robot User's Guide, User’s Guide, Rev A
Figure 2-7. Ball Joint Assembly
CAUTION:Ensure that the bearing insert is in place in the end of each
outer arm.
Page 29 of 142
Chapter 2: Robot Installation
NOTE:In the following steps, take care not to trap debris between the ball studs
and their sockets.
NOTE: The procedure for attaching outer arms is the same for both platforms.
1.
Attach one pair of outer arms to each inner arm.
a.
As illustrated in the following figure, the outer arm assembly is most easily
achieved by pivoting the two arms away from each other lengthwise. This
requires the least stretching of the spring to attach the ball joints.
b.
Slip one ball joint socket over the corresponding ball stud.
c.
Swing the bottom end of the outer arm pair sideways as you slip the other ball
joint socket over the corresponding ball stud.
CAUTION:Do not overstretch the outer arm springs. Separate
the ball joint sockets only enough to fit them over the ball studs.
Figure 2-8. Installing Ball Joints
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Chapter 2: Robot Installation
2.
Attach one pair of outer arms to each of the three pairs of ball studs on the platform.
a.
Swing the bottom end of the outer arm pair to the right, as far as possible.
b.
Slip the right ball joint socket over the right ball stud. (Move the platform
as needed to do this.)
c.
Move the platform and outer arm pair to the left as you slip the left ball
joint socket over the corresponding ball stud.
3.
Ensure that all spring hooks are fully-seated in the grooves of the horseshoes, as shown
in the following figure:
Figure 2-9. Horseshoe and Spring Assembly
Attaching the Theta Drive Shaft
NOTE:The fixed platform does not use a theta drive shaft, so this section does not
apply to systems with a fixed platform.
Each U-joint has two identical ends. When the theta drive shaft is shipped, it will have one
end of a U-joint attached to each end. One connects to the J4 motor drive, the other connects to
a shaft on the top of the J4 platform.
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Chapter 2: Robot Installation
Top U-Joint
at J4 Motor
Upper Section
of Drive Shaft
Lower Section
of Drive Shaft
Bottom U-Joint
at J4 Platform
Theta
Drive
Shaft
Set
Screw
U-Joint
J4 Shaft
(Motor or
Platform)
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Connect the top U-joint to the drive shaft of the J4 motor.
The top (J4 motor)end of the drive shaft is labeled with
a temporary label, indicating Top. Remove the label
before use.
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Connect the bottom U-joint to the shaft on top of the J4
platform.
NOTE:The drive shaft is not symmetrical. There is a top
and a bottom. Installing the drive shaft upside-down
will degrade system performance. Note the orientation
label on the drive shaft. Look for a “Top” label on the
drive shaft.
To attach the free end of the U-joints:
1.
Slide the end of the U-joint over the shaft (platform or J4
motor).
The fit will be fairly tight.
The hole in the side of the U-joint needs to line up with
the hole in the shaft.
Figure 2-10. U-Joint
2.
Screw an M6 x 20 dog point set screw (included) through the shaft, going through the
hole in the side of the U-joint, and into the blind hole on the opposite side of the U-joint.
The U-joint is not threaded.
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Use Loctite 242.
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Tighten to 5 N-m (3.7 ft-lbf)of torque. The head of the set screw should be flush
with the outer surface of the U-joint.
For the top U-joint, use a 3 mm hex key, with a 10 - 15 mm short leg. There is not
enough room at the J4 motor shaft to use a standard hex key.
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10 - 15 mm
3 mm
NOTE:The platform and the J4 motor will have to be aligned after the ACE
software is installed and the robot is power-on. See Aligning the Platform and J4
Motor on page 78.
2.8 End-Effectors
You are responsible for providing and installing any end-effector or other tooling, as well as
vacuum lines and wiring to the end-effector.
See the drawing Tool Flange Dimensions, Both Platforms on page 124 for dimensions of the
tool flange.
Chapter 2: Robot Installation
Figure 2-11. Short 3 mm Hex Key
Attaching an End-Effector
You can attach end-effectors to the tool flange using either four M6 x 1.0 screws, or a ring
clamp. Hardware for both methods is supplied in the accessories kit.
NOTE:The combined weight of the end-effector and the payload must not exceed
the maximum rated payload.
Aligning an End-Effector
A 6 mm diameter x 12 mm dowel pin (user-supplied) fits in a hole in the tool flange and can
be used as a keying or anti-rotation device in a user-designed end-effector.
Grounding
If hazardous voltages are present at the end-effector, you must install a ground connection to
the end-effector. See Grounding Robot-Mounted Equipment on page 52.
Accessing Vacuum
The hole through the center of the tool flange has been made as large as possible to allow
vacuum and/or electric lines to pass through.
WARNING:Do not tap the tool flange, as this would weaken it.
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Chapter 2: Robot Installation
Routing End-effector Lines
End-effector lines (either vacuum/air lines or electrical wires) can be routed to the platform by:
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Attaching them to the inner and outer arms, and then to the platform.
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Routing them from the robot support frame to the outer arms.
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Routing them from the robot base directly to the platform.
If end-effector lines are attached to the outer arms to reach the end-effector, either directly from
the frame, or along the inner arms:
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Make every attempt to keep the load on the outer arms as evenly-balanced as possible.
The added weight should be attached symmetrically about the platform center.
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Verify that the arms can be fully-extended without interference from the lines.
Ensure that there is enough line to reach the end-effector at all platform locations.
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Verify that the platform can be fully-rotated at all positions without affecting or being
affected by the lines.
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Verify that any service loop or excess line does not hang down below the end-effector at
any platform position.
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Verify that excess line cannot become tangled in the outer arms or platform.
If end-effector lines are attached directly to the bottom of the robot base to reach the endeffector:
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Lines attached to the robot base need some form of retraction mechanism or service
loop to take up the slack when the platform is near the robot base.
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Ensure that the lines (and retraction mechanism) do not apply significant force, in any
direction, to the platform.
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Ensure that lines going to the robot base do not block your view of the status LED.
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Ensure that lines going to the robot base do not interfere with the inner arm movement.
User-added end-effector lines:
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Should be checked for the entire work envelope being utilized. They must reach without
being pulled, and without impeding arm or platform movement.
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Cannot pull against the platform with significant force. Robot performance will be
affected.
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Must be considered as part of the payload, if they add weight to the platform or outer
arms.
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Are the user’s responsibility for maintenance.
They are not covered in the Maintenance section of this manual.
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