Omron Hornet 565 User Manual
Hornet 565 Robot
User’s Guide
I596-E-03
Copyright Notice
The information contained herein is the property of Omron Adept Technologies, Inc., and shall not be
reproduced in whole or in part without prior written approval of Omron Adept Technologies, Inc. The
information herein is subject to change without notice and should not be construed as a commitment by
Omron Adept Technologies, Inc. The documentation is periodically reviewed and revised.
Omron Adept Technologies, 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 - 2017 by Omron Adept Technologies, Inc. All rights reserved.
Any trademarks from other companies used in this publication
are the property of those respective companies.
Created in the United States of America
Revision History
Revision
code
01 June,
02 January,
03 July,
Date Revised Content
2016
2016
2017
Original release
Updated graphics with platform oriented correctly, showing current
drive shaft. Updated to OAT logo on status panel, front panel. Updated
safety chapter, minor changes to stopping distance graph section in
Technical Specifications. Fixed rotation of tool flange in Fig. 5-2, added
graphic for J4 alignment.
Updated drawing of tool flange to show 41.14 mm pilot bore that was
added since original release.
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Table of Contents
Chapter 1: Introduction 11
1.1 Hornet 565, Product Description
eAIB Amplifier 11
Hornet 565 Base 12
Inner Arms 12
Ball Joints, Outer Arms 13
Platforms 13
SmartController EX 15
1.2 Installation Overview
1.3 How Can I Get Help?
Corporate Addresses 17
Related Manuals 17
11
16
17
Chapter 2: Safety 19
2.1 Warnings, Cautions, and Precautions
2.2 What to Do in an Emergency/Abnormal Situation
Stopping the Robot 19
Fire Response 19
Entrapment and Brake Release Button 20
2.3 Safety Precautions
2.4 Robot Behavior
Hardstops 21
Limiting Devices 21
Singularities 21
2.5 Intended Use of the Robots
2.6 Additional Safety Information
Manufacturer’s Declaration of Incorporation 22
Robot Safety Guide 22
Emergency Stop Circuit and Buttons 22
Manual Control Pendant 22
19
19
20
21
21
21
Chapter 3: Robot Installation 23
3.1 Transport and Storage
3.2 Unpacking and Inspecting the Hornet 565
Before Unpacking 23
Upon Unpacking 23
Unpacking 23
3.3 Repacking for Relocation
3.4 Environmental and Facility Requirements
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23
23
25
25
Table of Contents
3.5 Mounting Frame
Robot-to-Frame Considerations 26
Mounting 26
3.6 Mounting the Robot Base
Robot Orientation 27
Mounting Surfaces 27
Mounting Procedure 27
Install Mounting Hardware 28
3.7 Attaching the Outer Arms, Platform, and Theta Drive Shaft
Aligning the Platform with the Base 29
Attaching the Outer Arms 30
Attaching the Theta Drive Shaft 34
3.8 Mounting the Front Panel
3.9 End-Effectors
Attaching an End-Effector 35
Aligning an End-Effector 35
Grounding 36
Accessing Vacuum 36
Routing End-effector Lines 36
25
27
29
35
35
Chapter 4: System Installation 39
4.1 System Cables, eAIB Only (no SmartController EX)
List of Cables and Parts 40
Cable Installation Overview 41
Optional Cables 42
4.2 System Cables, with SmartController EX
Installing a SmartController EX Motion Controller 43
List of Cables and Parts 44
Cable Installation Overview 45
Less Common Cables 45
4.3 System Cables for Systems with Belt Encoders
List of Cables and Parts 46
Cable Installation Overview 47
Pinouts for eAIB XBELT IO Adapter 48
4.4 ACE Software
User-supplied PC 49
Installing ACESoftware 49
4.5 Robot Interface Panel
4.6 Connecting 24 VDC Power to Robot
Specifications for 24 VDC Robot and Controller Power 51
Details for 24 VDC Mating Connector 51
Procedure for Creating 24 VDC Cable 52
Installing 24 VDC Robot Cable 52
4.7 Connecting 200-240 VAC Power to Robot
39
43
46
49
50
51
53
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Table of Contents
Specifications for AC Power 54
Details for AC Mating Connector 56
Procedure for Creating 200-240 VAC Cable 56
Installing AC Power Cable to Robot 57
4.8 Grounding the Hornet 565
Grounding Robot-Mounted Equipment 57
Grounding Robot Base to Frame 58
4.9 Installing User-Supplied Safety Equipment
Emergency Stop Circuits 63
Remote Manual Mode 65
User Manual/Auto Indication 65
User High Power On Indication 65
Remote High Power On/Off Control 65
High Power On/Off Lamp 66
Remote Front Panel or User-Supplied Control Panel Usage 66
Remote Pendant Usage 67
57
59
Chapter 5: System Operation 69
5.1 Robot Status Display Panel
5.2 Status Panel Fault Codes
5.3 Using the Brake-Release Button
Robot Brakes 70
Brake-Release Button 71
5.4 Optional Front Panel
5.5 Connecting Digital I/O to the System
I/O on the eAIB 74
I/O with an Optional SmartController EX 74
5.6 Using Digital I/O on eAIB XIO Connector
Optional I/O Products 78
XIO Input Signals 78
XIO Output Signals 80
XIO Breakout Cable 82
5.7 Starting the System for the First Time
Verifying Installation 84
Turning on Power and Starting ACE 85
Enabling High Power 86
Verifying E-Stop Functions 86
Aligning the Platform and J4 Motor 86
Verify Robot Motions 87
5.8 Robot Motions
Straight-line Motion 88
Containment Obstacles 88
5.9 Learning to Program the Hornet 565
69
70
70
72
74
76
84
88
88
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Table of Contents
Chapter 6: Options 89
6.1 Tall Frame Adapters
6.2 ePLC Connect
Configuration 90
Setting the Robot IP Address 90
Configuring the Omron PLC 92
Enabling High Power 92
6.3 SmartVision MX Industrial PC
6.4 SmartController EX Motion Controller
6.5 sDIO Module
6.6 IOBlox I/ODevice
6.7 eAIB XBELT IOAdapter Cable
6.8 Cable Inlet Box
Overview 93
Installation Procedure 94
6.9 Intelligent Force Sensor
6.10 Ball Stud Locks
Installing a Ball Stud Lock 100
Removing a Ball Stud Lock 101
89
90
92
92
92
92
92
93
99
99
Chapter 7: Maintenance 103
7.1 Cleaning
Water Shedding 103
Wash-Down 103
Chemical Compatibility 104
7.2 Periodic Maintenance Schedule
7.3 Checking Labels
Warning Labels 106
Informative Labels 107
7.4 Checking Safety Systems
7.5 Checking Robot Mounting Bolts
7.6 Checking for Gear Drive Oil Leakage
7.7 Checking Fan Operation
7.8 Theta Drive Shaft
Replacing the Drive Shaft Bushings 110
Removing the Drive Shaft 113
Installing a Drive Shaft 114
Aligning the Platform and J4 Motor 115
7.9 Replacing the Encoder Battery Pack
7.10 Non-Periodic Maintenance
7.11 Changing the Front Panel High-Power Indicator Lamp
103
104
106
107
108
108
109
110
115
118
118
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Table of Contents
7.12 Replacing a Platform
7.13 Replacing a Ball Joint Insert
7.14 Replacing Outer Arm Spring Assemblies
7.15 Replacing the eAIB Chassis
Removing the eAIB Chassis 124
Installing a New eAIB Chassis 128
7.16 Commissioning a System with an eAIB
Safety Commissioning Utilities 129
E-Stop Configuration Utility 130
E-Stop Verification Utility 131
Teach Restrict Configuration Utility 131
Teach Restrict Verification Utility 132
120
120
120
124
128
Chapter 8: Technical Specifications 135
8.1 Dimension Drawings
8.2 Robot Specifications
8.3 Environmental Specifications
Operating 139
Shipping and Storage 139
8.4 Payload Specifications
Payload 140
Torque 140
8.5 Performance
Repeatability, Unidirectional 141
Cycle Times 141
Power Consumption 141
Stopping Time and Distance 142
Payload Mass vs. Acceleration 148
Payload Inertia vs. Acceleration 148
8.6 Robot Mounting Frame
135
139
139
140
141
149
Chapter 9: Environmental Concerns 155
9.1 Ambient Environment
9.2 Cleanroom Classification
9.3 Design Factors
Robot Base and Components 156
Inner Arms 156
Ball Joints 156
Outer Arms 156
Spring Assemblies 157
Platforms 157
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155
155
155
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 Hornet 565, Product Description
The Hornet 565 is a three-arm parallel robot. The three identical arm 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 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
eAIB Amplifier
The Hornet 565 uses an eAIB amplifier. The robot is powered and controlled using the eAIB.
The amplifiers and full servo control for the Hornet 565 are contained in the eAIB, which is
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Chapter 1: Introduction
embedded in the base of the robot. The eAIB also provides the platform for running the eV+ OS
and language.
The 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. eAIB
Hornet 565 Base
The Hornet 565 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.
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
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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
figure shows an inner arm from a Hornet 565. 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 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, a stainless steel theta drive shaft attaches to a U-joint 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)
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 29.
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Chapter 1: Introduction
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 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.
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. SmartController EX
Refer to the SmartController EX User’s Guide for SmartController specifications.
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1.2 Installation Overview
The system installation process is summarized in the following table. Also, refer to System
Installation on page 39.
NOTE:For dual-robot installations, see the Dual-Robot Configuration Procedure,
which is available in the Document Library.
Task to be Performed Reference Location
If purchased, mount the optional cable box. Options on page 89.
Mount the robot to a level, stable mounting frame. Mounting on page 26.
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
Chapter 1: Introduction
Table 1-1. Installation Overview
30.
page 34.
Install the Front Panel and Pendant, if purchased,
and ACE software.
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
the robot and the facility AC power source.
Install user-supplied safety barriers in the workcell. Installing User-Supplied Safety
Connect digital I/O through the robot XIO connector. Using Digital I/O on eAIB XIO Con-
Start the system, including system operation testing. Starting the System for the First Time
Install optional equipment, including end-effectors,
user air and electrical lines, external equipment, etc.
System Cables, eAIB Only (no
SmartController EX) on page 39 and
ACE Software on page 49.
Procedure for Creating 24 VDC Cable
on page 52.
Connecting 200-240 VAC Power to
Robot on page 53.
Equipment on page 59.
nector on page 76.
on page 84.
Options on page 89.
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1.3 How Can I Get Help?
Refer to the corporate websites:
http://www.ia.omron.com
and
http://www.adept.com
Corporate Addresses
Omron Adept Technologies, Inc.
4550 Norris Canyon Road, Suite 150
San Ramon, CA 94583
USA
925 245-3400
Omron Corporate Headquarters
Shiokoji Horikawa, Shimogyo-ku, Kyoto 600-8530 Japan
Chapter 1: Introduction
TEL: 81-75-344-7000 FAX: 81-75-344-7001
Related Manuals
This manual covers the installation, operation, and maintenance of a Hornet 565 system.
There are additional manuals that cover programming the system and adding optional components. See the following table. These manuals are available on the software media shipped
with each system.
Table 1-2. Related Manuals
Manual Title Description
Robot Safety Guide Contains safety information for our robots.
A printed copy of this guide ships with each robot.
ACE User’s Guide Describes the installation and use of ACE.
T20 Pendant User's Guide Describes the use of the optional T20 manual control pendant.
SmartController EX User’s
Guide
SmartVision MX User's
Guide
Contains complete information on the installation and operation of the optional SmartController EX and sDIO products.
Instructions for use of the optional SmartVision MX industrial
PC.
ePLC Connect 3 User’s Guide Describes the installation and use of the ePLC Connect 3 soft-
ware, for using a user-supplied PLC as controller.
IO Blox User’s Guide Describes the IOBlox product.
Dual-Robot Configuration
Procedure
Hornet 565 Robot User's Guide, 14608-000 Rev F
Contains cable diagrams and configuration procedures for a
dual-robot system.
Page 17 of 160
2.1 Warnings, Cautions, and Precautions
There are six levels of special alert notation used in our 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.
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.
Chapter 2: Safety
CAUTION: This indicates a situation which, if not avoided, could result in
damage to the equipment.
Precautions for Safe Use: This gives precautions on what to do and what not
to do to ensure safe product use.
2.2 What To Do in an Emergency/Abnormal Situation
Stopping the Robot
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.
Fire Response
If a fire occurs, use CO2to extinguish the fire.
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Entrapment and Brake Release Button
In case of entrapment of a person by the robot, or any other emergency or abnormal situation,
the robot can be manually moved to a safe state without high voltage electric power. Arms 1
through 3 are held by brakes, which can only be released with the brake release button. This
requires 24 V power to the robot.
DANGER: Hornet 565s are not collaborative robots. They require a dedicated
work area that will prevent personnel from coming into contact with them during operation.
2.3 Safety Precautions
DANGER: During maintenance, disconnect AC power from the robot, and
install a lock-out tag-out to prevent anyone from reconnecting power.
DANGER: A Hornet robot can cause serious injury or death, or damage to
itself and other equipment, if the following safety precautions are not observed:
Chapter 2: Safety
l
All personnel who install, operate, teach, program, or maintain the system must read
this guide, read the Robot Safety Guide, and complete a training course for their responsibilities in regard to the robot.
Figure 2-1. Read Manual and Impact Warning Labels
l
All personnel who design the robot system must read this guide, read the Robot Safety
Guide, and must comply with all local and national safety regulations for the location in
which the robot is installed.
l
The Hornet 565 must not be used for purposes other than described in Intended Use of
the Robots on page 21. Contact Customer Support 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.
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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2.4 Robot Behavior
Hardstops
If the Hornet 565 runs into one of its hardstops, the robot’s motion will stop completely, an
envelope error will be generated, and power to the robot motors will be cut off.
The robot cannot continue to move after hitting a hardstop until the error has been cleared.
The Hornet 565’s hardstops are capable of stopping the robot at any speed, load, and maximum or minimum extension.
Limiting Devices
There are no dynamic or electro-mechanical limiting devices provided by Omron Adept Technologies, Inc. The robot does not have safety-rated soft axis or space limiting.
However, the user can install their own safety rated (category 0 or 1) dynamic limiting devices
if needed, that comply with ISO10218-1, Clause 5.12.2.
Singularities
No singularities exist that cause a hazardous situation with a Hornet 565 robot.
Chapter 2: Safety
2.5 Intended Use of the Robots
DANGER: Hornet 565s are not collaborative robots. They require a dedicated
work area that will prevent personnel from coming into contact with them during operation.
The normal and intended use of these robots does not create hazards.
The Hornet 565 has been designed and constructed in accordance with the relevant requirements of IEC60204-1.
The Hornet 565 is intended for use in parts assembly and material handling for payloads up
to 3 kg (6.6 lb), or 8 kg (17.6 lb) with the fixed platform. See Robot Specifications on page 139
for complete information on the robot specifications. Refer to the Robot Safety Guide for details
on the intended use of our robots.
Hornet 565 robots are not intended for:
l
Use in the presence of ionizing or non-ionizing radiation
l
Use in potentially explosive atmospheres
l
Use in medical or life saving applications
l
Use in a residential setting. They are for industrial use only.
l
Use before performing a risk assessment
2.6 Additional Safety Information
We provide other sources for more safety information:
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Chapter 2: Safety
Manufacturer’s Declaration of Incorporation
This lists all standards with which the robot complies. The Manufacturer’s Declarations for
the Hornet 565 robot and other products are in the Manufacturer's Declarations Guide.
Robot Safety Guide
The Robot Safety Guide provides detailed information on safety for our robots. It also gives
resources for more information on relevant standards. It ships with each robot.
Emergency Stop Circuit and Buttons
The E-Stop provided complies with ISO 10218-1 (Clause 5.5.2), with stop category 1 (per IEC
60204). The E-stop button complies with ISO 13850. The E-Stop meets the requirements of PL-d
per ISO 13849.
If you design your own front panel, it must meet the requirements of ISO13849, and be at least
PL-d. The E-Stop button must comply with IEC 60204-1 and ISO13850, Clause 5.5.2.
If you choose to use your own E-Stop buttons, they must meet the requirements of IEC 60204-1
and ISO 13850, Clause 5.5.2.
Manual Control Pendant
The protective stop category for the pendant enable switch is category 1, which complies with
the requirements of ISO 10218-1.
The pendant is designed in accordance with the requirements of IEC 60204-1 and ISO 13849.
The E-Stop button is ISO 13850.
NOTE:Omron Adept Technologies, Inc. does not offer a cableless
(wireless)pendant.
The manual control pendant can only move one robot at a time, even if multiple robots are
connected to a SmartController EX, and the pendant is connected to the SmartController EX.
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Chapter 3: Robot Installation
3.1 Transport and Storage
This equipment must be shipped and stored within the range –25 to +60° C (-13 to 140° F).
Humidity should be less than 75%, non-condensing. The robot should be shipped and stored
in the 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 Hornet 565 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).
3.2 Unpacking and Inspecting the Hornet 565
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 your local Omron Support as soon as possible (see How Can I Get
Help? on page 17).
l
If the items received do not match your order, please contact your local Omron Support
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 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 3: Robot Installation
Figure 3-1. 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 U-joints
attached, but separate from the robot and platform.
2.
Lift the top off of the crate sides, and set it aside.
Figure 3-2. Crate, with Top Removed
3.
Remove all cardboard boxes from inside the crate. These will include the outer arms,
theta drive shaft, and platform.
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Chapter 3: Robot Installation
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.
3.3 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.
3.4 Environmental and Facility Requirements
The Hornet 565 system installation must meet the operating environment requirements shown
in the following table.
Table 3-1. Robot System Operating Environment Requirements
Ambient temperature 1 to 40° C (34 to 104° F)
Humidity 5 to 90%, non-condensing
Altitude up to 1000 m
NOTE: See also Dimension Drawings on page 135
3.5 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 27.
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.
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Chapter 3: Robot Installation
The Hornet 565 is designed to be mounted above the work area suspended on a user-supplied
frame. The frame must be adequately stiff to hold the robot rigidly in place while the robot platform moves within the workspace.
While we do 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 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 137 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 135 shows the mounting hole pattern for the Hornet 565. 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:We suggest 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 3: Robot Installation
3.6 Mounting the Robot Base
Robot Orientation
We recommend mounting the Hornet 565 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 135.
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 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 has three mounting pads. Each pad has one hole with an M12 x 1.75 springlock 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 3: Robot Installation
Mounting Pad
Lifting Slots
Figure 3-3. 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 user-supplied. 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.
NOTE:When mounting the robot, note the following:
l
Verify that the robot is mounted squarely before tightening the mounting bolts.
l
Insert the bolts through the holes in the frame and into the threaded holes in the robot
base mounting pads.
l
Ground the robot base to the mounting frame.
Refer to Grounding Robot Base to Frame on page 58.
l
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 3: 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 108.
3.7 Attaching the Outer Arms, Platform, and Theta Drive Shaft
Figure 3-4. Major Robot Components
The Hornet 565 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.
NOTE:The remainder of this section only applies to the J4 platform.
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Chapter 3: 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.
WARNING: Incorrect alignment of the platform with the robot base will result
in incorrect robot performance and possible damage to the drive shaft.
Both the theta drive shaft attachment on the robot base and on 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 Joint 1 on the robot base, 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.
l
Each outer arm has a ball joint socket at each end.
l
The inner arms and the platform have corresponding pairs of ball studs.
Figure 3-5. J4 Platform Orientation, Top View
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