Adept Technology 300Cr Users Manual AdeptSix Robot Instruction Handbook
300CR AdeptSix_300CR_IHB
2015-02-05
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AdeptSix 300CR Robot
Instruction Handbook
AdeptSix 300CR Robot
Instruction Handbook
P/N 01600-000
Rev. A
August 2002
3011 Triad Drive • Livermore, CA 94550 • USA • Phone 925.245.3400 • Fax 925.960.0452
Otto-Hahn-Strasse 23 • 44227 Dortmund • Germany • Phone (49) 231.75.89.40 • Fax(49) 231.75.89.450
41, rue du Saule Trapu • 91300 • Massy • France • Phone (33) 1.69.19.16.16 • Fax (33) 1.69.32.04.62
The information contained herein is the property of Adept Technology, Inc., and shall not be reproduced in whole or in part without prior written approval of Adept Technology, Inc. The information herein is subject to change without notice and should not be construed as a commitment by
Adept Technology, Inc. This manual is periodically reviewed and revised.
Adept Technology, Inc., assumes no responsibility for any errors or omissions in this document.
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.
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Table of Contents
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Overview of Typical System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Read Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Controller and PA-4 Power Chassis . . . . . . . . . . . . . . . . . . . . .
Installing System Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding End of Arm Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turning On the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
14
14
14
14
1.3 Checking Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Locating the Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.5 How Can I Get Help? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6 Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7 Knowledge Express . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Dangers, Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Precautions and Required Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Definition of a Manipulating Industrial Robot . . . . . . . . . . . . . . . . . . . . . . . 20
Safety Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Risk Assessment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Severity of Injury . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control System Behavior Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
23
24
24
2.4 Intended Use of the Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.5 Robot Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Acceptable Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Unacceptable Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6 AdeptSix 300CR Hazards and Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.8 Safety Requirements for Additional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.9 Working Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.10 Qualification of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
2.14 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Safety Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Safety Standard Information (ISO10218) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Transporting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Using the Crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Using the Forklift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3 Shipping Bracket and Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4 Installing Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . 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 Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Adept SmartController System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2 Cable Connections from Robot to PA-4 Power Chassis . . . . . . . . . . . . . . . . . . . 43
Connection to the Robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Connection to the PA-4 Power Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.3 Cable Connections to MV Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installing the MV Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cable Connections to SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Connecting User-Supplied Safety and I/O Equipment. . . . . . . . . . . . . . . . . 47
5
End of Arm Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.1 Allowable Wrist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Table of Contents
5.2 Wrist Tool Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3 End of Arm Tooling Load Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.4 Calculating the Moment of Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Example 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.5 Mounting Equipment - Allowable Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.6 User Electrical Lines and Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6
System Operation - MV Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.2 Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Power to Adept Components Checks . . . . . . . . . . . . . . . . . . . . . . . . . .
Board and Cable Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User-Supplied Safety Equipment on JUSER and JSIO Connector Checks .
61
62
62
63
6.3 Applying Power to the Adept Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.4 Checks After Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.5 Calibrate Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.6 Turning Off the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.7 Learning to Operate/ Program the AdeptSix 300CR Robot . . . . . . . . . . . . . . . 66
7
System Operation - SmartController . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.2 Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power to the Adept Components Checks . . . . . . . . . . . . . . . . . . . . . . . . . .
Board and Cable Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User-Supplied Safety Equipment on XUSR Connector Checks . . . . . . . . . .
E-Stop Button and Switch Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
68
68
69
70
7.3 Applying Power to the Adept Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.4 Checks After Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.5 Calibrate Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.6 Turning Off the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.7 Learning to Operate/ Program the AdeptSix 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) . . . . . . . . . . . . . . 75
TOOL Coordinate System (TOOL Mode on the MCP) . . . . . . . . . . . . . . . . . 76
Coordinate System Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9
Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.1 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.2 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Battery Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Grease Replenishment for Axis 1 Speed Reducer . . . . . . . . . . . . . . . . . . . . 84
Grease Replenishment for Axis 2 Speed Reducer. . . . . . . . . . . . . . . . . . . . . 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 for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Installing and Using Brake Release Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
9.3 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10
Technical 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
8
AdeptSix 300CR Robot Instruction Handbook, Rev. A
List of Figures
Figure 1-1.
Robot ID Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 2-1.
AdeptSix 300CR — Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 3-1.
Transporting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 3-2.
Using the Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 3-3.
Installing Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 3-4.
Mounting the Robot Baseplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 3-5.
Direct Mounting on the Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 3-6.
Grounding Method for Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 4-1.
System Cable Diagram with Adept MV Controller . . . . . . . . . . . . . . . . . . . . 41
Figure 4-2.
System Cable Diagram with Adept SmartController . . . . . . . . . . . . . . . . . . 42
Figure 4-3.
Interconnect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 4-4.
Interconnect Cable Connection to the Robot . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 4-5.
PA-4 Power Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 5-1.
Moment Arm Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 5-2.
Wrist Tool Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 5-3.
Center of Gravity: Calculating Tool Load Information . . . . . . . . . . . . . . . . . 51
Figure 5-4.
Moment of Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 5-5.
Center of Gravity: Sealing Gun Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 5-6.
Moment of Inertia for Hexahedron and Cylinder . . . . . . . . . . . . . . . . . . . . . 54
Figure 5-7.
Center of Gravity: Large Tool and Workpiece Example . . . . . . . . . . . . . . . 55
Figure 5-8.
Center of Gravity: Dual End Effector Example . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 5-9.
Installing Peripheral Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 5-10.
User Electrical and Air Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 5-11.
Detailed Drawing of Connector Pin Numbers . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 8-1.
Joint Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 8-2.
World Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 8-3.
Tool Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 8-4.
Right Hand Rule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 9-1.
Inspection Parts and Inspection Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 9-2.
Battery Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Figure 9-3.
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 9-4.
Axis 1 Speed Reducer Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 9-5.
Axis 2 Speed Reducer Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 9-6.
Axis 3 Speed Reducer Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 9-7.
Axis 4 and Axis 5 Speed Reducers Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 9-8.
Axis 6 Speed Reducer Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 9-9.
Encoder Connector Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 9-10.
Manual Brake Release Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 10-1.
Part Names and Working Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
AdeptSix 300CR Robot Instruction Handbook, Rev. A
9
List of Figures
Figure 10-2.
Baseplate Dimensions (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 10-3.
Dimensions and Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 10-4.
Axis 5 Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 10-5.
Axis 2 and Axis 3 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10
AdeptSix 300CR Robot Instruction Handbook, Rev. A
List of Tables
Table 1-1.
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Table 2-1.
Sources for International Standards and Directives . . . . . . . . . . . . . . . . . . . . .22
Table 2-2.
Partial List of Robot and Machinery Safety Standards . . . . . . . . . . . . . . . . . . .23
Table 3-1.
Maximum Repulsion Forces of the AdeptSix 300CR . . . . . . . . . . . . . . . . . . . . .37
Table 3-2.
Axis Naming Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Table 5-1.
Moment and Total Inertia. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Table 6-1.
LED Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Table 9-1.
AdeptSix 300CR Maintenance Schedule and Inspection Items . . . . . . . . . . .78
Table 9-2.
Inspection Parts and Grease Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Table 10-1.
Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
AdeptSix 300CR Robot Instruction Handbook, Rev. A
11
Introduction
1.1
1
Product Description
The AdeptSix 300CR is a compact, high-performance cleanroom robot that provides the
application flexibility of six axis articulation running on the Adept platform. The arm
design provides superior reach capability with a very small footprint to maximize system
flexibility and minimize cell layout size. The AdeptSix 300CR is available with either the
Adept MV controller or the Adept SmartController.
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 inspection,
sorting and other high performance tasks.
1.2
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 system 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
• Interconnect cables between controller and robot
14
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Locating the Serial Number
WARNING: Confirm that the robot and the controller have
the same serial number. Special care must be taken when
more than one robot is to be installed. If the numbers do
not match, robots may not perform as expected and cause
injury or damage.
1.4
Locating the Serial Number
The ID serial number of the AdeptSix 300CR robot corresponds to the ID number of the
controller. You can check the controller ID using the V+ ID command. The robot’s ID serial
number is located on a label on the robot base. See Figure 1-1.
Location
of serial
label
Figure 1-1. Robot ID Serial Number
AdeptSix 300CR Robot Instruction Handbook, Rev. A
15
Chapter 1 - Introduction
1.5
How Can I Get Help?
Refer to the How to Get Help Resource Guide (Adept P/N 00961-00700) for details on
getting assistance with your Adept software and hardware.
Additionally, you can access the following information sources on Adept’s corporate web
site:
• For Contact information: http://www.adept.com/main/contact/index.html
• For Product Support information: http://www.adept.com/main/services/index.asp
• For general information about Adept Technology, Inc.: http://www.adept.com
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 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 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
2
Dangers, Warnings, Cautions, and Notes
There are four levels of special alert notation used in this manual. In descending order of
importance, they are:
DANGER: This indicates an imminently hazardous
situation which, if not avoided, will result in death or
serious injury.
WARNING: This indicates a potentially hazardous
situation which, if not avoided, could result in serious
injury or major damage to the equipment.
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, especially
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
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-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.
20
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 = 1--- mv2.
2
NOTE: In the Projectile energy formula above:
•E = Energy
•m = Mass
•v = Velocity
Additional Safety Information
The standards and regulations listed in 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
American National Standards Institute (ANSI)
11 West 42nd Street, 13th Floor
New York, NY 10036
USA
Phone: 1.408.943.6900
Fax: 1.408.428.9600
Phone 212-642-4900
Fax 212-398-0023
http://www.semi.org/web/wcontent.nsf/url/stds_home
http://www.ansi.org
BSI Group (British Standards)
389 Chiswick High Road
London W4 4AL
United Kingdom
Document Center, Inc.
1504 Industrial Way, Unit 9
Belmont, CA 94002
USA
Phone +44 (0)20 8996 9000
Fax +44 (0)20 8996 7400
Phone 415-591-7600
Fax 415-591-7617
http://www.bsi-global.com
http://www.document-center.com
DIN, Deutsches Institut für Normung e.V.
German Institute for Standardization
Burggrafenstrasse 6
10787 Berlin
Germany
Global Engineering Documents
15 Inverness Way East
Englewood, CO 80112
USA
Phone 800-854-7179
Fax 303-397-2740
Phone.: +49 30 2601-0
Fax: +49 30 2601-1231
http://global.ihs.com
http://www.din.de
http://www2.beuth.de/ (publishing)
IEC, International Electrotechnical Commission
Rue de Varembe 3
PO Box 131
CH-1211 Geneva 20
Switzerland
Robotic Industries Association (RIA)
900 Victors Way
PO Box 3724
Ann Arbor, MI 48106
USA
Phone 41 22 919-0211
Fax 41 22 919-0300
Phone 313-994-6088
Fax 313-994-3338
http://www.iec.ch
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
ISO 10218
Europe
EN 775
ANSI/RIA
R15.06
CAN/CSAZ434-94
Title of Standard
Manipulating Industrial Robots Safety
Industrial Robots and Robot
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 intended
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
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 control 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. The 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.
24
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Intended Use of the Robots
The standard AdeptSix 300 robot control system meets or exceeds the requirements
imposed by the EN 954 specified Category 1 level of safety.
2.4
Intended Use of the Robots
The installation and use of Adept products must comply with all safety instructions and
warnings in this manual. Installation and use must also comply with all applicable local
and national requirements and safety standards (see Section 2.8 on page 28).
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 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
• In mobile, portable, marine, or aircraft systems
• In life-support systems
• In residential installations
• In situations where the Adept equipment will be subject to extremes of heat or
humidity.
CAUTION: The instructions for operation, installation, and
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 performance, 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
AdeptSix 300CR Hazards and Warning Labels
2.6
AdeptSix 300CR Hazards and Warning Labels
Risks from injury are clearly identified on the AdeptSix 300CR by warning labels. The
location of these labels is illustrated in Figure 2-1.
1BC
2BC
3BC
WARNING
Moving parts may
cause injury
WARNING
Do not enter
robot work area
Figure 2-1. AdeptSix 300CR — Warning Labels
2.7
Transport
Always use adequate equipment to transport and lift Adept products. 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
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 safety 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.
2.9
Working Areas
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.
28
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Qualification of Personnel
2.10 Qualification of Personnel
This manual assumes that all personnel have attended an Adept training course and have
a working knowledge of the system. The user must provide the necessary additional
training for all personnel who will be working with the system.
As noted in this handbook, certain procedures should be performed only by skilled or
instructed persons. 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
2. Has read the instruction handbook
3. Understands the instruction handbook
4. Will work in the manner specified by the instruction handbook.
2.11 Safety Equipment for Operators
Operators must wear safety equipment in 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
The system must be protected against unauthorized use. The user or operator must
restrict access to the keyboard and the Manual Control Pendant by locking them in a
cabinet or use another adequate method to prevent access to them.
2.13 Safety Aspects While Performing Maintenance
Only skilled persons with the necessary knowledge about the safety and operating the
equipment are allowed to maintain the robot, controller, and power chassis.
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.
2.14 Risks That Cannot Be Avoided
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 motion in
Manual Mode
• Failure of hardware associated with enabling device or E-Stop system
2.15 Risks Due to Incorrect Installation or Operation
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
• Ejection of workpiece (see “Hazards From Expelling a Part or Attached Tooling”
on page 21).
30
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 CO2 to extinguish the fire.
AdeptSix 300CR Robot Instruction Handbook, Rev. A
31
Chapter 2 - Safety
32
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Robot Installation
3.1
3
Safety Guard Installation
To ensure safety, make sure to install safety guards, which prevent unforeseen accidents
with personnel and damage to equipment. The following standard is noted below for
your information and guidance.
Safety Standard Information (ISO10218)
Responsibility for Safeguarding
The user of a manipulator or robot system shall ensure that safeguards are provided and
used in accordance with Sections 6, 7, and 8 of this standard. 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
damaged or lacking parts. Failure to observe this 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
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.
34
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Transporting Method
1X Urethane washer
M6 8 mm Hexagon
socket head cap bolt
(anti-corrosive)
Details of C
2X M6 40 mm Hexagon
socket head cap bolts
(anti-corrosive)
A
2X M6 Coned disc springs
(anti-corrosive)
C
2X Urethane washers
Details of D
D
2X M8 Eyebolts
(provided at factory)
B
2X Urethane washers
2X M5 10 mm Hexagon
socket head cap bolts
(anti-corrosive)
2X M5 Washers
(anti-corrosive)
E
Details of E
Figure 3-1. Transporting Position
WARNING: Sling applications 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.
4 x M10 Bolts
Pallet
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 transporting. 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
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.
3.4
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
A
B
( Attached with shipping products)
2X M6 Hexagon socket head bolts (anti-corrosive)
2X M8 Eyebolts
Shipping jig
2X Urethane washers
Remove shipping jig and
insert the cover bolts
Detail A
Detail A
2X M5 Hexagon socket head bolts (anti-corrosive)
2X M5 Washers (anti-corrosive)
2X Urethane washers
Use shipping bolts
Shipping jig
Remove shipping jig and
insert the cover bolts
Detail B
Detail B
Figure 3-3. Installing Cover Bolts
3.5
Types of Mounting
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.
38
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
(direction of motion Axis 1)
500 N·m (51.0 kgf·m)
Maximum vertical rotating torque
(direction of motion Axes 2 and 3)
700 N·m (71.4 kgf·m)
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
(anti-corrosive, provided at factory)
A
Anchor bolts M10 or more
Details of A
Common installation base
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 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
(anti-corrosive)
A
Details of A
Installation base
Grating
Anchor bolts M10 or more
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
Labels
Legacy Axis
Labels
Axis 1 (J1)
S-axis
Axis 2 (J2)
L-axis
Axis 3 (J3)
U-axis
Axis 4 (J4)
R-axis
Axis 5 (J5)
B-axis
Axis 6 (J6)
T-axis
See Figure 10-1 on page 96 for a drawing that identifies the various axes.
3.8
Grounding the Robot
Follow local regulations for grounding line size.
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.
WARNING: Ground resistance must be 100 Ω or less.
Failure to observe this warning may result in fire or
electric shock.
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
A
WARNING: Wiring must be performed by authorized or
certified personnel. Failure to observe this caution may
result in fire or electric shock.
View A
5.5
mm2
or more
M8 Bolt - for grounding
(provided at factory)
Figure 3-6. Grounding Method for Robot
3.9
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 +45° C
• No moisture should be present (20 to 80% RH)
• Level of the mounting plane for installation must be 0.5 mm or less
• System must be isolated from excessive electrical interference or noise (plasma)
• The area must be free from:
• Dust, soot, and water
• Corrosive gases and liquids, as well as explosive gases
• Excessive vibration (less than 0.5 G)
42
AdeptSix 300CR Robot Instruction Handbook, Rev. A
4
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
MAI-2 Module
DUAL E AMP
DUAL E AMP
DUAL E AMP
DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED
IS COMPLETELY DISTINGUISHED
DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED
IS COMPLETELY DISTINGUISHED
DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED
IS COMPLETELY DISTINGUISHED
M A I-2
AWC II
DSP STATUS
SF
STP
A
SCR
B
D
MAI STATUS
C
VME
HIGH VOL TS ON
HIGH VOL TS ON
HIGH VOL TS ON
PWM ON
PWM ON
PWM ON
LO
W
LO
W
LO
W
VO
L TS ON
OPEN CKT FAULT
VO
L TS ON
OPEN CKT FAULT
R
S
2
3
2
X
S
L
V
1
X
S
L
V
2
VOL TS ON
OPEN CKT FAULT
HV SAG/O
V ER TEMP FAULT
HV SAG/O
V ER TEMP FAULT
HV SAG/O
V ER TEMP FAULT
SHORT FAULT
SHORT FAULT
SHORT FAULT
CH1 CH2
B
R
A
K
E
CH1 CH2
CH1 CH2
A
M
P
L
I
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I
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R
A
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ENC
IEEE
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PORTS
1
C
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4
5
6
CH2
CH1
CH1
CH2
M
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1
2
3
2
C
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5
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®
USE ONLY WITH
250V FUSES
Ethernet to PC
CIP (JAWC) to AWC (CIP)
M
O
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R
CH2
CN29
Cable
CH1
adept
technology,
WARNING:
FOR CONTINUED PROTECTION
AGAINST RISK OF FIRE,
REPLACE ONLY WITH SAME
TYPE AND RATING OF FUSE.
inc.
Arm Power Cable
5AF
~100-240V
50/60HZ
AdeptSix 300CR
Robot
Adept MV
Controller
Adept PA-4
Power Chassis
STOP
MCP
< 250 mm/s
100%
CIP-2
NET
CIP 2
- +
MCP
Arm
Signal
Cable
Desktop or Laptop PC
1BC 2BC
User-Supplied
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
User-Supplied Ground Wire
Between PA-4 and SmartController
Dual E Amp #3
MAI-2 Module
DUAL E AMP
DUAL E AMP
DUAL E AMP
DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED
IS COMPLETELY DISTINGUISHED
DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED
IS COMPLETELY DISTINGUISHED
DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED
IS COMPLETELY DISTINGUISHED
M A I-2
DSP STATUS
MAI STATUS
Adept PA-4
Power Chassis
HIGH VOLTS ON
HIGH VOLTS ON
HIGH VOLTS ON
PWM ON
PWM ON
PWM ON
LOW VOLTS ON
LOW VOLTS ON
LOW VOLTS ON
OPEN CKT FAULT
OPEN CKT FAULT
OPEN CKT FAULT
HV SAG/OVER TEMP FAULT
HV SAG/OVER TEMP FAULT
HV SAG/OVER TEMP FAULT
SHORT FAULT
SHORT FAULT
SHORT FAULT
CH1 CH2
Adept
rtController
B
R
A
K
E
R
S
2
3
2
X
S
L
V
1
X
S
L
V
2
CH1 CH2
CH1 CH2
A
M
P
L
I
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R
A
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P
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ENC
IEEE
1394
PORTS
ntroller CS
CH2
CH1
CH2
CH1
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1
2
3
2
C
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2
5
C
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2
9
Arm
Power
Cable
CN29
Cable
1
C
N
P
G
4
5
6
CH1
M
O
T
O
R
adept
technology, inc.
User-Supplied Ground Wire
AdeptSix 300CR
Robot
Ethernet to PC
Controller (XFP) to
Front Panel (XFP)
24VDC Power from
User-Supplied
Power Supply to
Controller (XDC1)
STOP
R
Front Panel
User-Supplied
Power Supply
MCP Adapter Cable
Controller (XMCP) to MCP
- +
MCP
Arm
Signal
Cable
1BC 2
User-Supplied
Ground Wire
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 covers 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
M3 Bolt
Connector
Connector
A
1BC
CNPG123
1 BC
CNPG456
Terminal
Arm Signal
Cable
Robot Base Side
Ground
B
2BC
Ground
2BC
CN29
Arm Power
Cable
CN1
Robot Base Side
CN2
CN3
CN4
CN5
CN6
Motor Output
Connector Clamp
Figure 4-3. Interconnect Cables
AdeptSix 300CR Robot Instruction Handbook, Rev. A
45
Chapter 4 - System Cable Installation
1BC
1BC 2BC
Connection details
of the power supply cable
(robot)
Figure 4-4. Interconnect Cable Connection to the Robot
Connection to the PA-4 Power Chassis
Refer to the following information for details on connecting the cabling between the robot
and the Adept PA-4 power chassis, and peripheral equipment. See Figure 4-1 on page 43
or Figure 4-2 on page 44, depending on which controller you are using.
1. 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).
2. Install the plug labeled CN29 on the Arm Power cable in the CN29 connector on
the Multi-Axis Interface (MAI-2) module.
3. 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.
4. 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.
46
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Cable Connections from Robot to PA-4 Power Chassis
Dual E Amp #3
Dual E Amp #2
Dual E Amp #1
MAI-2 Module
DUAL E AMP
DUAL E AMP
DUAL E AMP
M A I-2
DSP STATUS
MAI STATUS
DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED
IS COMPLETELY DISTINGUISHED
DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED
IS COMPLETELY DISTINGUISHED
DO NOT REMOVE OR INSTALL THIS
MODULE UNLESS HIGH VOLTS LED
IS COMPLETELY DISTINGUISHED
HIGH VOLTS ON
HIGH VOLTS ON
HIGH VOLTS ON
PWM ON
PWM ON
PWM ON
LOW VOLTS ON
LOW VOLTS ON
OPEN CKT FAULT
OPEN CKT FAULT
R
S
2
3
2
X
S
L
V
1
X
S
L
V
2
HV SAG/OVER TEMP FAULT
SHORT FAULT
OPEN CKT FAULT
HV SAG/OVER TEMP FAULT
SHORT FAULT
CH1 CH2
CH1 CH2
A
M
P
L
I
F
I
E
R
A
M
P
L
I
F
I
E
R
C
O
N
T
R
O
L
C
O
N
T
R
O
L
Þ
C
O
N
T
R
O
L
CNPG456
IEEE 1394 Port 1
IEEE 1394 Port 2
ENC
CH2
C
N
P
G
4
5
6
CH1
CH2
CH1
CH1
CH2
M
O
T
O
R
M
O
T
O
R
M
O
T
O
R
P
O
W
E
R
P
O
W
E
R
P
O
W
E
R
O
U
T
P
U
T
O
U
T
P
U
T
O
U
T
P
U
T
CH4
XSLV2
XSLV1
A
M
P
L
I
F
I
E
R
CH3
CH1
Status LEDs
Break Release Box
RS-232
LOW VOLTS ON
HV SAG/OVER TEMP FAULT
SHORT FAULT
CH1 CH2
B
R
A
K
E
CH2
ENC
C
N
P
G
1
2
3
C
N
2
5
CN25 (Future options)
C
N
2
9
CN29 Arm Brake
CNPG123
CH5
adept
technology, inc.
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.
2. Connect the MCP to the CIP-2.
3. Connect AC power to the controller.
4. Install the AdeptWindows PC user interface.
Cable Connections to MV Controller
See Figure 4-1 on page 43.
1. 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 between 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 I/O 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.
2. Connect the Front Panel to the SmartController.
3. Connect the MCP to the SmartController.
4. Connect user-supplied 24 VDC power to the controller.
5. Install a user-supplied ground wire between the SmartController and ground.
6. 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 1394 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 I/O 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
5
Allowable Wrist Load
The allowable wrist load is 3 kg. If force is applied to the wrist instead of the load, force on
Axes 4, 5, and 6 should be within the values shown in Table 5-1. Contact your Adept
representative for further information or assistance.
Table 5-1. Moment and Total Inertia
Moment N·m (kgf·m) a
Axis
GD2/4 Total Inertia kg·m2
Axis 4
5.39 (0.55)
0.1
Axis 5
5.39 (0.55)
0.1
Axis 6
2.94 (0.3)
0.03
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 with an outside force
Load Gravity Position
L Axis 5
200
90
LAxis 6
a
LAxis6
(mm) 100
W=1.5 kg
Axis 6 Rotation
Centerline
W=3 kg
0
Axis 5 Rotation
Centerline
100
200
300
L Axis5
(mm)
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
45
˚
Tram mark
.5
6
45°
Ø20H6
Ø40H6
D31
P.C.
Ø5H7 Depth 7 mm
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.
Inertia moment around center of gravity
Ix, Iy, Iz
XF*
XF
Ix
YF*
Iy
YF
ZF*
Iz
Weight: W
ZF
Center of Gravity Position
(Xg, Yg, Zg)
* Flange Coordinates
XF: Direction right above when Axis 6 (T axis)
is at 0 pulse position and the flange surface
of the robot is turned to the front.
YF: Y axis led by XF, ZF
ZF: Perpendicular direction from flange surface
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: lx, ly, lz (kg.m²)
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 drastic impact on arm performance
and reliability. See Figure 5-4.
AdeptSix 300CR Robot Instruction Handbook, Rev. A
53
Chapter 5 - End of Arm Tooling
The size of the tool is not too big.
Setting the inertia moment at the
center or gravity is not necessary.
The size of the tool is sufficiently large
that setting the inertia moment at the
center of gravity is necessary.
Figure 5-4. Moment of Inertia
5.4
Calculating the Moment of Inertia
The following methods can be used to calculate the rough values for the moment of
inertia, based on the center of gravity.
• Approximate the entire tool as a hexahedron or cylinder.
• Calculate the center of gravity position (plural mass) for each part weight.
The following examples provide details on the calculation methods.
Example 1
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.
54
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Calculating the Moment of Inertia
YF
XF
70
Center of Gravity Position
= (100, 0, 70)
Total Weight
Approx. 6.3 [kg]
7.00 [kg]
100
ZF
Figure 5-5. Center of Gravity: Sealing Gun Example
Tooling Details
• W:7.000 kg
• Xg:100.000 mm
• Yg:0.000 mm
• Zg:70.000 mm
• lx:0.000 kg.m²
• ly:0.000 kg.m²
• lz: 0.000 kg.m²
AdeptSix 300CR Robot Instruction Handbook, Rev. A
55
Chapter 5 - End of Arm Tooling
The following figures show examples of the moment of inertia for a hexahedron and
cylinder.
Z
Z
Ly
r
Lx
Iz
Iz
Iy
Lz
Ix
Y
Y
H
Iy
Ix
X
X
Ix =
Iy =
Iz =
Weight: W
Ly2 + Lz2
12
Lx2 + Lz2
12
Lx2 + Ly2
12
*W
*W
Weight: W
3 r 2 + H2
Ix = Iy =
Iz =
12
r2
2
*W
* Unit of Weight: [kg]
*W
* Unit of Length: [m]
* Unit of Ix, Iy, Iz: [kg.m 2]
Figure 5-6. Moment of Inertia for Hexahedron and Cylinder
56
AdeptSix 300CR Robot Instruction Handbook, Rev. A
*W
Calculating the Moment of Inertia
Example 2
It is necessary to set the moment of inertia at the center of gravity when the entire size of
the tool and workpiece are large compared with the distance from the tool flange relative
to the position of the center of gravity. See Figure 5-7.
Roughly calculate the moment of inertia at the center of gravity based on “Example 1” on
page 54, using the hexahedron and cylinder concept for the entire tool.
250
YF
0
50
ZF
Weight of Workpiece:
Approx. 40 kg
400
XF
Weight of Hand:
Approx. 55 kg
1000
Figure 5-7. Center of Gravity: Large Tool and Workpiece Example
Tooling Details
• W:100.000 kg
• Xg:0.000 mm
• Yg:0.000 mm
• Zg:250.000 mm
• lx:10.000 kg.m²
• ly:3.500 kg.m²
• lz: 10.500 kg.m²
Weight: W=55 + 40 = 95, approximated to 100 kg.
Center of gravity: Z offset position (Xg, Yg, 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.
lx = (Ly²*Lz²/12) * W = ((0.400²+1.000²)/12) * 100=9.667 Approx. 10.000
ly = (Lx²*Lz²/12) * W = ((0.500²+0.400²)/12) * 100=3.417 Approx. 3.500
lz = (Lx²*Ly²/12) * 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)
lcxi, lcyi, lczi: Moment of inertia of each i-th parts (kg.m²)
3. The position of the center of gravity for the entire tool is calculated using the
following formula.
xg={w1*x1+w2*x2+…+wi*xi}/(w1+w2+…+wi)
yg={w1*y1+w2*y2+…+wi*yi}/(w1+w2+…+wi)
zg={w1*z1+w2*z2+…+wi*zi}/(w1+w2+…+wi)
4. The moment of inertia at the center of gravity for the entire tool is calculated
using the following formula.
{w1*((y1-yg)²+(z1-zg)²)*10-6 +lcx1}
+
{w2*((y2-yg)²+(z2-zg)²)*10-6 +lcx2}
………………………………….
+
{wi*((yi-yg)²+(zi-zg)²)*10-6 +lcxi}
lx =
{w1*((x1-xg)²+(z1-zg)²)*10-6 +lcy1}
+
{w2*((x2-xg)²+(z2-zg)²)*10-6 +lcy2}
………………………………….
+
{wi*((xi-xg)²+(zi-zg)²)*10-6 +lcyi}
ly =
{w1*((x1-xg)²+(y1-yg)²)*10-6 +lcz1}
+
{w2*((x2-xg)²+(y2-yg)²)*10-6 +lcz2}
………………………………….
+
{wi*((xi-xg)²+(yi-yg)²)*10-6 +lczi}
lz =
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 shows how to calculate the required values.
(Top View)
Center of Flange
YF
50
40
X F
100
YF
150
70
Gun 1
Gun 1
ZF
Gun 2
XF
(Gun 1)
Weight: w1 = 3 kg
Center of Gravity:
x1 = 100 mm
y1 = 50 mm
z1 = 40 mm
Gun 2
(Gun 2)
Weight: w2 = 6 kg
Center of Gravity:
x2 = 100 mm
y2 = -150 mm
z2 = 70 mm
Figure 5-8. Center of Gravity: Dual End Effector Example
Weight:
W=w1+w2 = 3+6 = 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:
lx =
+
=
+
=
ly =
+
{w1*((y1-Yg)²+(z1-Zg)²)*10-6 +lcx1}
{w2*((y2-Yg)²+(z2-Zg)²)*10-6 +lcx2}
3*((50(-83))² + (40-60)²* 10-6
6*(((-150) – (-83))²+(70-60)²)* 10-6
0.082 = Approx. 0.100
3*((100-100)²+(40-60)²)* 10-6
6*((100-100)²+(70-60)²)* 10-6
AdeptSix 300CR Robot Instruction Handbook, Rev. A
59
Chapter 5 - End of Arm Tooling
=
lz =
+
=
0.002 = Approx. 0.010
3*((100-100)²+(50-(-83))²)* 10-6
6*((100-100)²+((-150)-(-83))²)* 10-6
0.080 = Approx. 0.100
Tooling Details:
• W:10.000 kg
• Xg:100.000 mm
• Yg:-83.333 mm
• Zg:60.000 mm
• lx:0.100 kg.m²
• ly:0.010 kg.m²
• lz: 0.100 kg.m²
5.5
Mounting Equipment - Allowable Load
When peripheral equipment is attached to Axis 3, the following conditions must be
observed:
The allowable load on Axis 3 is a maximum of 4 kg, including the wrist load.
For instance, when the mass installed at the wrist point is 3 kg, the mass which can be
installed on the upper arm becomes 1 kg.
119
A
49
45
Axis 3 Rotation Center
View A
Figure 5-9. Installing Peripheral Equipment
60
AdeptSix 300CR Robot Instruction Handbook, Rev. A
2-M6XP1.0 Tapped
Depth 12 mm
User Electrical Lines and Air Lines
5.6
User Electrical Lines and Air Lines
There are 9 electrical cables (0.2mm) and an 1 air line that are used in the robot for the
peripheral devices mounted on the arm, as shown in Figure 5-10
The connector pins (1 to 9) are assigned as shown in Figure 5-11. Wiring must be
performed by user.
• The allowable current for cables is 2.5A or less for each cable
• The maximum pressure for the air hose is 490kPa (5 kgf/cm2). The inside diameter
is φ2.5 mm.
A
Air Supply Inlets: 1 to 4
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: 5
Barb couplings for flexible tube
Use a tube with an inner diameter of 2.5 mm
B
wA
Air Ducts
Valve type: 10-VQD1151W-5M-M5(SMC)
Air Inlet
Port 1 (IN)
Ø4
Air Inlet
Port 2 (IN)
Ø4
f4
f4
(OUT)
Ø4
Ø4
Valve 2
A
f4
f4
Air supply inlet 4
Air supply inlet 5
f4
Axis 1
Air supply inlet 1
Air supply inlet 2
Air Intake Inlets (2)
Tapped holes PT1/8 - with cover plugs
Upper inlet: Port 1
Lower inlet: Port 2
User cable connector:
HR10A-10TR-12S
Mating plug:
HR10A-10TP-12P
J2
Internal Air Intake Port
Outer diameter: 34 mm
J3
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
1
2
9
3
4
8
1
2
10
5
Pin numbers
6
7
12
3
11
7
8
4
6
5
9
10 (For incorporated valve) 24VDC, common
11 (For incorporated valve) For driving the valve 1 (24VDC, 4W)
12 (For incorporated valve) For driving the valve 2 (24VDC, 4W)
Figure 5-11. Detailed Drawing of Connector Pin Numbers
Pins number (1 to 9) of both connectors are used for end-of-arm tooling signals (0.2 mm2).
62
AdeptSix 300CR Robot Instruction Handbook, Rev. A
System Operation MV Controller
6.1
6
Introduction
This chapter covers system operation for AdeptSix robot systems using the Adept MV
Controller. If you have an Adept SmartController, refer to Chapter 7.
Verifying that the system is correctly installed and that all safety equipment is working
correctly is a three-step process. This chapter discusses the first two steps.
• Step one reviews starting the control system for the first time and verifying that all
components have been correctly installed.
• 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
AC Power to Adept Components Checks
Verify that the Adept controller is correctly connected to the AC power source.
1. Make sure that AC power is shut off to the Adept controllers (MV and PA-4
power chassis).
2. Verify that the single phase AC power (180-245 VAC) is connected to the Adept
power controller.
3. Verify that the three-phase AC power (200-240 VAC or 380-415 VAC) is connected
to the Adept PA-4 power chassis. For information on single-phase AC power to
the PA-4, see the AdeptSix Controller Installation Guide.
4. If the System Power On/Off switch on the CIP-2 is used, check the connections to
this switch.
Board and Cable 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.
2. 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.
3. 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.
• 1394 AWC-II connector to MAI-2 IEEE 1394 connector
• CIP-2 to optional MCP (install bypass plug if not used)
• CIP-2 (JAWC connector) to AWC-II (CIP) connector
• CIP-2 (JSLV connector) to MAI-2 (XSLV1) connector
• JUSER to user-supplied equipment (install jumper plug if not used)
64
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-II board. Unshielded cables will degrade the integrity of the
AdeptWindows PC link, particularly when power is applied to the robot or
mechanism. Use “straight” cables to a hub or a “crossover” cable to a stand-alone
PC.
User-Supplied Safety Equipment on JUSER 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 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 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.
2. Verify that the MCP jumper plug on the CIP-2 is installed or that the optional
MCP is mounted on a rack that holds the MCP Enable switch in the ON position.
3. 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
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 tests of the robot system.
1. Turn the AC power switch on the Adept PA-4 power chassis to the ON (l)
position.
2. Turn the AC power switch on the Adept MV controller to the ON (l) position
3. Turn the System Power switch on the CIP-2, if used, to the ON (l) position.
4. The AWC-II 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.
5. 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. An oscillation 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.
6. If the E-Stop LED is continuously 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.
66
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 indicating that High Power
has successfully been enabled.
c. If the light does not stay on, the High Power enable process has failed and a
message will be displayed on the monitor and MCP indicating why.
2. Verify that all E-Stop devices are functional (MCP, 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
6.5
Calibrate Robot
The AdeptSix robot uses optical absolute encoders to determine position of each axis, and
establish commutation reference for the phases of the motors. Since the motors are
brushless AC, the rotor must be commutated by electronics rather that using physical
brushes to switch current from phase to phase. The absolute encoders have the ability to
determine position for a full turn of the motor rotor. 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 prompt in the monitor window:
calibrate
When calibration is complete, the monitor displays the dot prompt. This means
the system is ready for operation.
6.6
Turning Off the System
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.
6.7
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
optional manuals:
• V+ Language User’s Guide
• V+ Language Reference Guide
• V+ Operating System Reference Guide
68
AdeptSix 300CR Robot Instruction Handbook, Rev. A
System Operation SmartController
7.1
7
Introduction
This chapter covers system operation for AdeptSix 300CR robot systems using the Adept
SmartController. If you have an Adept MV Controller, refer to Chapter 6.
Verifying that the system is correctly installed and that all safety equipment is working
correctly is a three-step process. This chapter discusses the first two steps.
• Step one reviews starting the control system for the first time and verifying that all
components have been correctly installed.
• 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
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 - SmartController
Power to the Adept Components Checks
Verify that the Adept control system is correctly connected to the DC and AC power
sources.
1. Make sure that power is shut off to the Adept SmartController and the PA-4
power chassis).
2. Verify that 24 DC power is connected to the Adept SmartController.
3. Verify that the three-phase AC power (200-240 VAC or 380-415 VAC) is connected
to the Adept PA-4 power chassis. 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.
2. Secure the motor output connector clamp of the arm power cable onto the six
motor power output (Motor Power Outlet) connections on the three Dual E amps.
Verify that the clamp is securely latched.
3. 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)
• 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
• SmartController XSYS connector to MAI-2 XSLV1 connector
• SmartController XFP to Front Panel XFP
• 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)
70
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-II board. Unshielded cables will degrade the integrity of the
AdeptWindows PC link, particularly when power is applied to the robot or
mechanism. Use “straight” cables to a hub or a “crossover” cable to a stand-alone
PC.
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 connection 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 that the MCP jumper plug is installed on the controller or that the optional
MCP is mounted on a rack that holds the MCP Enable switch in the ON position.
3. 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 tests of the robot system.
1. Turn the AC power switch on the Adept PA-4 power chassis to the ON (l)
position.
2. Turn on DC power to the Adept SmartController.
3. The SmartController 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
b. When the High Power push button/light on the Front Panel begins flashing,
press and hold the push button for 1 - 2 seconds. When you release the push
button, the light should remain lit continuously indicating that High Power
has successfully been enabled.
c. If the light does not stay on, the High Power enable process has failed and a
message will be displayed on the monitor and MCP indicating why.
2. Verify that all E-Stop devices are functional (MCP, Front Panel, and user
supplied). 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. Verify that you have enabled power as described above.
2. 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. 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 DC power to the SmartController.
5. 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
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
74
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Using the Manual Control
Pendant (MCP)
8.1
8
MCP Usage for Six-Axis Robots
This section describes the coordinate system used by the AdeptSix 300CR robot. This
information is necessary when using the MCP to control the robot. See the Adept MV
Controller User’s Guide or the Adept SmartController User’s Guide for general details on
using and programming the MCP.
Joint Mode (Single-Axis Movement)
Joint motion is made around the axes of the various joints J1, J2, J3, etc. 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)
Axis 3
(J3)
Axis 4
(J4)
Axis 5
(J5)
Axis 6
(J6)
Axis 2
(J2)
Axis 1
(J1)
J1
J4
Rotates main body
Rotates upper ar m
x
X-
J4-
X+
J1-
J1+
x
J4+
J2
Moves lower ar m forward/
backward
J5
Moves wrist up/down
y
Y-
J5-
J2-
Y+
J2+
y
J5+
J3
Moves upper ar m up/
down
J6
Rotates wrist
Z-
J3-
z
J6-
z
Z+
J6+
J3+
Figure 8-1. Joint Mode
76
AdeptSix 300CR Robot Instruction Handbook, Rev. 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.
Z-Axis
Y-Axis
X-Axis
X
Z
Moves in parallel with X- Axis
Moves in parallel with
Z-Axis
X-
Z+
X+
Y
Moves in parallel with Y- Axis
Y+
Z-
YFigure 8-2. 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 Figure 8-3.
RX
RY
Rotates around X- axis
RZ
Rotates around Y- axis
Rotates around Z -axis
RYRXRZ+
RY+
RX+
RZ-
Figure 8-3. 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
Z
X
Y: Middle Finger
OR
Z: Middle Finger
Y
Z: Thumb
X
Z
Y
Figure 8-4. Right Hand Rule
78
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Maintenance and Inspection
9.1
9
Inspection Schedule
Proper inspections are essential not only to assure that the mechanism will be able to
function for a long period, but also to prevent malfunctions and assure safe operation.
Inspection intervals are displayed in six levels. Conduct periodic inspections according to
the inspection schedule in Table 9-1 on page 80.
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
WARNING: Before maintenance or inspection, make sure
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. AdeptSix 300CR Maintenance Schedule and Inspection Items
Schedule
Items a
Da
ily
50
0
H
Cy
cle
30
00
H
Cy
cle
90
00
H
Cy
cle
Inspection Charge
18
00
0
H
Tram mark
Lice
nsee
Serv
ice
Com
pany
Check tram mark
alignment and
damage at the
home position.
X
X
X
Clean the work
area if dust or
spatter is present.
Check for damage
and outside
cracks.
X
X
X
Spanner
Wrench
Tighten loose
bolts. Replace if
necessary.
X
X
X
Screwdriver,
Wrench
Tighten loose
bolts. Replace if
necessary.
X
X
X
Manual
Check for loose
connectors.
X
X
X
Manual
Check for belt
tension and wear.
X
X
Visual
Multimeter
Check for
conduction
between the main
connector of the
base and the
intermediate
connector by
manually shaking
the wire. Check for
wear of the
protective spring. b
X
X
Visual
Working
area and
robot
Visual
X
3
Baseplate
mounting
bolts
X
4
Cover
mounting
screws
X
5
Base
connectors
X
6
Axes 4 & 5
timing belt
X
Wire
harness in
robot
(Axis 1)
X
7
X
80
Spe
cifie
d
Pers
on
Metho
d
X
1
2
36
00
0
H
Operation
Replace. c
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Inspection Schedule
Table 9-1. AdeptSix 300CR Maintenance Schedule and Inspection Items
Schedule
Items a
8
Wire
harness in
robot
(Axis 2)
Da
ily
50
0
H
Cy
cle
30
00
H
Cy
cle
90
00
H
Cy
cle
Inspection Charge
18
00
0
H
36
00
0
H
Metho
d
X
1
1
1
2
1
3
Lice
nsee
Serv
ice
Com
pany
X
b
Replace.c
Wire
harness in
robot
(Axis 3)
Visual
Multimeter
X
Check for
conduction
between terminals
and wear of the
protective spring.
X
X
b
Replace. c
X
1
0
Spe
cifie
d
Pers
on
Check for
conduction
between terminals
and wear of the
protective spring.
X
9
Operation
Battery unit
in robot
X
Axis 1
speed
reducer
Axis 2
speed
reducer
Axis 3
speed
reducer
Grease
Gun
X
Grease
Gun
X
Grease
Gun
X
X
Replace the battery
unit when the
battery alarm
occurs or when the
robot has operated
for 36000 H.
X
X
Check for
malfunction
Replace if
necessary. Supply
grease d (9000 H
cycle). See page
91.
X
X
Check for
malfunction.
Replace if
necessary. Supply
grease. d (9000 H
cycle). See page
86.
X
X
Check for
malfunction.
Replace if
necessary. Supply
grease. d (9000 H
cycle). See page
88.
X
X
AdeptSix 300CR Robot Instruction Handbook, Rev. A
81
Chapter 9 - Maintenance and Inspection
Table 9-1. AdeptSix 300CR Maintenance Schedule and Inspection Items
Schedule
Items a
1
4
1
5
Axes 4 and
5 speed
reducers
Axis 6
speed
reducer
Da
ily
50
0
H
Cy
cle
30
00
H
Cy
cle
90
00
H
Cy
cle
Inspection Charge
18
00
0
H
36
00
0
H
Metho
d
Grease
Gun
X
Grease
Gun
X
Spe
cifie
d
Pers
on
Lice
nsee
Serv
ice
Com
pany
Check for
malfunction.
Replace if
necessary. Supply
grease. d (9000 H
cycle). See page
89.
X
X
Check for
malfunction.
Replace if
necessary. Supply
grease. d (9000 H
cycle). See page
X
X
Operation
90.
1
6
Overhaul
X
a
X
Inspection item numbers correspond to the numbers in Figure 9-1 on page 83.
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).
c
Replace the wire harness in the robot at the 24000 H inspection.
d
For the grease, refer to Table 9-2 on page 83.
b
82
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Inspection Schedule
6
3
Axis 1 1
5
10
9
15
1 Axis 6
6
Axis 5 14
Axis 5
14 Axis 4
11
7
1
1 Axis 5
13
Axis 4
1 Axis 3
8
12
1 Axis 2
Figure 9-1. Inspection Parts and Inspection Numbers
Table 9-2. Inspection Parts and Grease Used
No.
11, 12, 13, 14, 15
Grease Used
Harmonic Grease SK-1A
Inspected Parts
Axes 1, 2, 3, 4, 5, and 6 speed
reducers
The numbers in the above table correspond to the item numbers in Table 9-1 on page 80.
AdeptSix 300CR Robot Instruction Handbook, Rev. 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. Switch off the main power supplies to the controller and PA-4 power chassis.
2. Remove the connector base plate and grease tube from the union.
3. Remove the battery-unit mounting screw on the Connector Base.
4. Remove the plastic tape (insulation tape) protecting the connector of the battery
unit in the robot.
5. Connect the new battery.
6. 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.
7. Protect the connector of the battery unit in the robot with plastic tape (insulation
tape).
8. 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)
1BC
A
2BC
3BC
B
Battery Unit
Connector Base Bolt
Mounting Screw
A
60660-00010
Washer
60660-00020
Base
Connector base
Figure 9-2. Battery Location
84
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Maintenance Procedures
Battery Unit for Axes 1, 2, and 3
Before Replacement
See Procedure 6
See Procedure 7
0BT1
a
b
0BT1
BAT1
b
a
BAT1
0BT1
a
BAT1
b
a: Insertion-type Pin Terminal (Male)
b: Insertion-type Pin Terminal (Female)
b 0BT1
a BAT1
hw27230hw927089401hw721.0y
See Procedure 4
See Procedure 6
Battery Unit for Axes 4, 5, and 6
Before Replacement
See Procedure 7
See Procedure 5
0BT4
a
b
0BT4
BAT4
b
a
BAT4
0BT4
a
b 0BT4
BAT4
b
a BAT4
New Battery Unit
See Procedure 4
Figure 9-3. Battery Connection
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. Remove the So plug (hexagon socket head plug PT 1/8).
NOTE: It is absolutely necessary 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.
2. Replace the PT 1/8 socket head plug (Si) with a A-PT1/8 grease nipple
3. 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.
4. 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.
5. Degrease the tapped hole on the So air flow, and then reinstall the hexagon socket
head plug. Apply Three Bond 1211 on screwed parts.
86
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Maintenance Procedures
Grease Replenishment for Axis 2 Speed Reducer
Axis 2 speed reducer
Lo: Air flow
Hexagon socket head plug PT1/16
Cover
Li: Grease inlet
G Nipple A-PT1/16
Figure 9-5. Axis 2 Speed Reducer Diagram
NOTE: For ceiling-mounted robots, the exhaust and grease inlet ports are
inverted.
Replenish the grease according to the following procedure. Refer to Figure 9-5.
1. Remove the Axis 2 side cover.
2. Replace the PT 1/16 socket head plug (Li) with a A-PT 1/16 grease nipple.
3. Remove the Lo plug (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
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 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
Axis 5 speed reducer
Cover
Ro: Air flow
Hexagon socket head plug PT1/16
Bo: Air flow
Hexagon socket head plug PT1/16
Bi: Grease inlet
G Nipple A-PT1/16
Ri: Grease inlet
G Nipple A-PT1/16
Figure 9-7. Axis 4 and Axis 5 Speed Reducers Diagram
Replenish the grease according to the following procedure. Refer to Figure 9-7.
1. Remove the Joint 5 access cover.
2. 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 Figure 9-8.
1. Remove the Ti plug (PT 1/16 Allen head plug).
2. Replace the PT 1/16 Allen head plug (Ti) with the A-PT 1/16 grease nipple.
3. Inject the grease into the Ti grease inlet using a grease gun.
4. 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.
5. Degrease the tapped hole on the Ti grease inlet, and then reinstall the hexagon
socket head plug. Apply Three Bond 1211 on screwed parts.
90
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
Motor Cable, etc.
Internal
Wire
a: Insertion-type pin terminal (male)
b: Insertion-type pin terminal (female)
Power Connector
b 0BT4
WARNING
Connect battery to encoder
to save the data before
removing conector.
WARNING label
0BT
a
BAT
b
a BAT4
Encoder connector
Battery Unit
Connection Diagram
WARNING
0BT
a
b
0BT4
BAT
b
a
BAT4
Battery Unit Type:
60660-00020
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.
Axis selector switch
1
2 3 4
5
6
Status LED
OFF
BRAKE
RELEASE
Brake Release
Pushbutton
15-pin male
D-Sub connector
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
10.1 Technical Specifications
Table 10-1. Technical Specifications
Operation Mode a
Degrees of Freedom
Payload
Repetitive Positioning Accuracy b
Axis 1 (turning)
Axis 2 (lower arm)
Axis 3 (upper arm)
Axis 4 (wrist roll)c
Axis 5 (wrist
pitch/yaw)
Axis 6 (wrist twist)
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
Axis 4
Axis 5
Axis 6
Axis 4
Axis 5
Axis 6
Motion
Range
Maximum
Speed
Allowable
Moment d
Allowable
Inertia
(GD2/4)
Vertically Articulated
6
3 kg
±0.03 mm
±170°
+60° , -135°
+250° , -10°
±165°
±135°
±350°
3.66 rad/s, 210° /s
2.79 rad/s, 170° /s
3.93 rad/s, 225° /s
5.23 rad/s, 300° /s
5.23 rad/s, 300° /s
7.33 rad/s, 420° /s
5.39N•m (0.55 kgf•m)
5.39N•m (0.55 kgf•m)
2.94N•m (0.3 kgf•m)
0.1 kg•m2
0.1 kg•m2
0.03 kg•m2
39 kg
Mass
Ambient
Conditions
Temperature
Humidity
Vibration
Others
Power Capacity
0° to 45° C
20 to 80% RH (non-condensing)
Less than 0.5° G
Free from corrosive gases and
liquids, as well as explosive gases
Clean and dry
Free from excessive electrical noise
(plasma)
1 kVA
AdeptSix 300CR Robot Instruction Handbook, Rev. A
95
Chapter 10 - Technical Specifications
a
SI units are primarily used in this table. However, gravitational units are
used for values that appear in parentheses ( ).
b
Conforms to ISO9283.
c
The Axis 4 Working range is affected by the working range of Axis 2 and
Axis 3. See text and Figure 10-5 on page 100 for details.
d
Refer to “Allowable Wrist Load” on page 51 for details on the permissible
moment of inertia.
10.2 Robot Cleanroom Specifications
The AdeptSix 300CR has the FEDERAL STANDARD 209E Cleanliness Class 1.a
a
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
J4-
J3-
J5-
Wrist
J6+
J6J4+
Upper
Arm
J3+
J2-
J5+
J2+
J1+
Rotary Head
J1-
Lower Arm
Base
Figure 10-1. Part Names and Working Axes
96
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Wrist Flange
Baseplate Dimensions
A
12
10.4 Baseplate Dimensions
113 ± 0.1
180
+0.012
77 ± 0.1
Ø60
Reference Hole
113 ± 0.1
220
195
50
160
97 ± 0.1
50
195
Ø11 Mounting Holes (4 holes)
220
View A
Dimensions in mm
Figure 10-2. Baseplate Dimensions (mm)
AdeptSix 300CR Robot Instruction Handbook, Rev. A
97
Chapter 10 - Technical Specifications
10.5 Dimensions and Working Range
R2
46
170˚
R312
R6
94
142
90
˚
74
119
49
19
0
67
844
0˚
697
45˚
15
260
590
484
54
70
˚
70
600
Point P
82
680
431
346
300
286
159
12
Ø220
0
Ø246
156
114
168
209
Point P working
envelope
Figure 10-3. Dimensions and Working Range
98
44
275
150
694
Dimensions in mm
229
230
245
250
312
0
142
237
318
170˚
AdeptSix 300CR Robot Instruction Handbook, Rev. 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
135
°
Wrist axis
Axis 3 rotation center
135
°
Axis 2 rotation center
Axis 1 rotation center
Note: Prevent the wrist from touching the main body of the robot by depending
on the posture of Axes 1,2 and 3 for the base axes.
Figure 10-4. 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°.
185˚
(Axis
3)
-15˚ (Axis
2)
+70˚ (Axis 2)
-51˚ (Axis 3)
Figure 10-5. Axis 2 and Axis 3 Rotation
100
AdeptSix 300CR Robot Instruction Handbook, Rev. A
Index
Numerics
1BC cable
2BC cable
B
43
43
A
accuracy (repetitive positioning) 93
Adept control system, applying power
MV controller 64
SmartController 70
air lines, user 59
allowable inertia 93
allowable moment 93
applying power to Adept control system
MV controller 64
SmartController 70
Arm Power cable 43
Arm Signal cable 43
avoidance of injury 24
axes speeds, maximum 93
Axis 1
motion range 93
speed reducer greasing 84
Axis 2
effect on Axis 4 98
motion range 93
speed reducer greasing 85
working range 98
Axis 3
allowable load 58
effect on Axis 4 98
motion range 93
speed reducer greasing 86
working range 98
Axis 4
motion range 93
speed reducer greasing 87
working range 98
Axis 5
motion range 93
speed reducer greasing 87
working range 97
Axis 6
motion range 93
speed reducer greasing 88
axis names 38, 94
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
controller (serial number) 15
cover bolts, installing 35
Customer Service assistance
phone numbers 16
from expelling a part 21
hazards labels, locating 27
How Can I Get Help? 16
humidity, operating 40, 93
I
D
definition of a Manipulating Industrial
Robot 20
degrees of freedom 93
dimensions
baseplate 95
robot 96
wrist tool flange 50
dual end effector example 57
E
electrical
grounding arm power and signal
cables 44
grounding robot 39
grounding SmartController to PA-4
interference 40
user lines 59
EMC 24
emergency situation, what to do 30
encoder connector warning 89
end of arm tooling 49–60
center of gravity 51
definitions 51
moment of inertia 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
47
I/O equipment, connecting 46, 47
ID number of robot 15
impact and trapping points 20
inertia
allowable 49, 93
moment of 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
system cables 41, 42
system overview 13
user air lines 59
user electrical lines 59
installing
MV Controller 14
SmartController 14, 47
system cables 14
intended use of the robot 25
ISO 10218 safety standards 31
J
jig, shipping 35
joint mode, on MCP 73
JSIO, connector checks 63
JUSER, connector checks 63
K
floor installation 38
forklifts, for lifting robot
Knowledge Express
17
34
L
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
102
LED status indicators
on AWC 65
on SmartController 70
level of mounting plane 40
loads
allowable wrist 49
on Axis 3 58
lubrication, see grease replenishment
21
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
motion range 93
MV controller
applying power 64
cable connections to 46
connection diagram 41
in system cable diagram 41
system operation 61
turning off 66
user-supplied safety equipment 63
N
Notes, Cautions, and Warnings, description
of 19
O
operating environment
operation mode 93
93
P
PA-4 power chassis
connecting to 43
connector identification
45
package contents 14
part names 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 of industrial 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
serial number 15
specifications 93
transporting 32
AdeptSix 300CR Robot Instruction Handbook, Rev. A
103
Index
user electrical and air lines
working area 28
wrist loads 49
wrist tool flange 50
59
S
safeguarding responsibility 31
safety 19
AdeptSix 300CR pinch hazard 27
during maintenance 30
equipment for operators 29
expelling a part 21
impact and trapping points 20
required safeguards 20
requirements for additional
equipment 28
sources for information 21
standards 31
safety barriers 20
safety guard installation 31
schedule for maintenance 78
scheduling robot inspections and
maintenance 77
serial numbers 15
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
Axis 1 84
Axis 2 85
Axis 3 86
Axis 4 87
Axis 5 87
Axis 6 88
speed, maximum per axis 93
support information, finding 16
TOOL coordinate system, on MCP
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 air lines 59
user-supplied equipment
connecting 46, 47
user-supplied safety equipment
on JUSER 63
on XUSR 69
V
verifying system installation
MV controller 61
SmartController 67
vibrations, maximum allowable
93
W
warning labels, locating 27
weight, end of arm tooling 51
working areas 28
working range 96
WORLD coordinate system, on MCP
wrist
allowable loads 49
tool flange dimensions 50
X
XUSR, connector checks
T
teaching robot use, safety 24
technical specifications 93
temperature, operating 40, 93
104
76
AdeptSix 300CR Robot Instruction Handbook, Rev. A
69
75
01600-000, Rev. A
3011 Triad Drive
Livermore, CA 94551
925•245•3400
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