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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 2006, 2010, 2012 by Adept Technology, Inc. All rights reserved.
Adept, the Adept logo, the Adept Technology logo, AdeptVision, AIM, Blox, Bloxview, FireBlox, Fireview, HexSight, Meta Controls, MetaControls, Metawire, Soft Machines, and Visual Machines are registered trademarks of Adept Technology, Inc. Brain on Board is a registered trademark of Adept Technology, Inc. in Germany. ACE, Adept Cobra 350, Adept Cobra 350 CR/ESD, Adept MotionBlox-40R, Adept sDIO, Adept SmartController CX, IO Blox, MotionBlox, and V+ are trademarks of Adept Technology, Inc. Any trademarks from other companies used in this publication are the property of those respective companies.
Table of Contents
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adept Cobra s350 Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adept MotionBlox-40R Distributed Servo Controller. . . . . . . . . . . . . . . . . . . 12 Adept SmartController CX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.2 Warnings, Cautions, and Notes in Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.4 What to Do in an Emergency Situation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.5 Additional Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Manufacturers Declaration of Compliance (MDOC) . . . . . . . . . . . . . . . . 15 Adept Robot Safety Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.6 Intended Use of the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.7 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.8 Manufacturers Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1.9 How Can I Get Help? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Adept Document Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Robot Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.2 Unpacking and Inspecting the Adept Equipment. . . . . . . . . . . . . . . . . . . . . . . 21 Before Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Upon Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3 Repacking for Relocation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.4 Environmental and Facility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.5 Mounting the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Mounting Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Robot Mounting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table of Contents
3.6 Connecting 24 VDC Power to MB-40R Servo Controller. . . . . . . . . . . . . . . . . . . 29 Specifications for 24 VDC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Details for 24 VDC Mating Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Procedure for Creating 24 VDC Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Installing the 24 VDC Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.7 Connecting 200-240 VAC Power to MB-40R . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Specifications for AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Facility Overvoltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 AC Power Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Details for AC Mating Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Procedure for Creating 200-240 VAC Cable . . . . . . . . . . . . . . . . . . . . . . . . 34 Installing AC Power Cable to MB-40R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3.8 Grounding the Adept Robot System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Ground Point on Robot Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Ground Point on MotionBlox-40R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Robot-Mounted Equipment Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3.9 Installing User-Supplied Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
MotionBlox-40R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Introduction to the MotionBlox-40R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 4.2 Description of Connectors on MB-40R Interface Panel . . . . . . . . . . . . . . . . . . . 38 4.3 MB-40R Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Status LED on MB-40R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Status Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Brake Release Button on MB-40R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Brake Release Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4.4 Connecting Digital I/O to the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4.5 Using Digital I/O on MB-40R XIO Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Optional I/O Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 XIO Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 XIO Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Typical Input Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 XIO Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 XIO Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Typical Output Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 XIO Breakout Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 4.6 MB-40R Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Programmable E-Stop Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Brake Release Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 5.2 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.3 Commissioning the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Verifying Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Cable Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . User-Supplied Safety Equipment Checks . . . . . . . . . . . . . . . . . . . . . Turning on Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Adept ACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enabling High Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using Adept ACE to Enable High Power . . . . . . . . . . . . . . . . . . . . . Verifying E-Stop Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Verify Robot Motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 54 54 55 55 55 56 56 56 56
Table of Contents
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.1 Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 7.2 Checking of Safety Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 7.3 Checking Robot Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 7.4 Lubricate Joint 3 Ball Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Required Grease for the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 7.5 Replacing Encoder Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Battery Replacement Time Periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 7.6 Inspecting Timing Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8 9
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.1 Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 8.2 Robot Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Cleanroom Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.1 Cobra s350 CR/ESD Cleanroom Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 9.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 9.3 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 9.4 ESD Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 9.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Bellows Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Procedure for Lower Bellows Replacement . . . . . . . . . . . . . . . . . . . 79 Procedure for Upper Bellows Replacement . . . . . . . . . . . . . . . . . . . 80 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 9.6 Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
List of Figures
Figure 1-1. Adept Cobra s350 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Figure 1-2. Robot Joint Motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 1-3. MotionBlox-40R (MB-40R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Figure 1-4. Adept SmartController CX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Figure 2-1. Transporting Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Figure 2-2. Mounting Hole Pattern for Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Figure 2-3. Rotate J2 Axis to Safe Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Figure 3-1. System Cable Diagram for Adept Cobra s350 Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Figure 3-2. User-Supplied 24 VDC Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Figure 3-3. Typical AC Power Installation with Single-Phase Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Figure 3-4. Single-Phase Load across L1 and L2 of a Three-Phase Supply . . . . . . . . . . . . . . . . . . . . . 33 Figure 3-5. AC Power Mating Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Figure 3-6. Ground Point on Robot Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Figure 3-7. Earth Ground Location on MB-40R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Figure 4-1. Adept MB-40R Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Figure 4-2. MB-40R Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Figure 4-3. Controls and Indicators on MB-40R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Figure 4-4. Connecting Digital I/O to the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Figure 4-5. Typical User Wiring for XIO Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Figure 4-6. Typical User Wiring for XIO Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Figure 4-7. Optional XIO Breakout Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Figure 4-8. MB-40R Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Figure 5-1. Brake Release Button for Third and Fourth Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Figure 5-2. Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Figure 6-1. Tool Flange Removal Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Figure 6-2. User Air and Electrical Connectors on Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Figure 6-3. Mechanical End Bolts and Stoppers on Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Figure 6-4. Stay Attached to Robots Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Figure 6-5. Dimensions for Fabricating User-Supplied Stay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Figure 6-6. Camera Mounting Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Figure 6-7. Camera Bracket Drawing, Page 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Figure 6-8. Camera Bracket Drawing, Page 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Figure 7-1. Lubrication of Joint 3 Quill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Figure 7-2. Replacement Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Figure 7-3. Removing Battery Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Figure 7-4. Attaching New Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Figure 7-5. New Batteries in Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
List of Figures
Figure 8-1. Adept Cobra s350 Top and Side Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Figure 8-2. Adept Cobra s350 Robot Working Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Figure 8-3. Tool Flange Dimensions for Adept Cobra s350 Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Figure 9-1. Adept Cobra s350 CR/ESD Cleanroom Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Figure 9-2. Cleanroom Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Figure 9-3. Cleanroom Lower Bellows Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Figure 9-4. Cleanroom Upper Bellows Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Figure 9-5. Adept Cobra s350 CR/ESD Top and Side Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Figure 9-6. Adept Cobra s350 CR/ESD Robot Working Envelope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10
Introduction
1.1 Product Description
11
Chapter 1 - Introduction
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12
Product Description
Adept SmartController CX
The SmartController CX is the foundation of Adepts family of high-performance distributed motion controllers. The SmartController CX is designed for use with: Adept Cobra s-series robots Adept Quattro robots Adept Viper s-series robots Adept Python linear modules Adept MotionBlox-10 Adept sMI6 (SmartMotion) The SmartController CX supports an integrated conveyor-tracking option, as well as other options. It offers scalability and support for IEEE 1394-based digital I/O and general motion expansion modules. The IEEE 1394 interface is the backbone of Adept SmartServo, Adept's distributed controls architecture supporting Adept products. The controller includes Fast Ethernet and DeviceNet.
*S/N 3562-XXXXX*
R
CAMERA
RS-232/TERM
RS-422/485
SmartServo
OK SF HPE ES LAN HD
Device Net
SW1 1 2 3 4
ON OFF
1.1
1.2
XDIO
XUSR
XSYS
XFP
XMCP
XDC1 XDC2
24V 5A
-+
-+
SmartController CX
13
Chapter 1 - Introduction
1.2
DANGER: This indicates an imminently hazardous electrical situation which, if not avoided, will result in death or serious injury.
DANGER: This indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING: This indicates a potentially hazardous electrical situation which, if not avoided, could result in injury or major damage to the equipment.
WARNING: This indicates a potentially hazardous situation which, if not avoided, could result in injury or major damage to the equipment.
CAUTION: This indicates a situation which, if not avoided, could result in damage to the equipment.
NOTE: Notes provide supplementary information, emphasize a point or procedure, or give a tip for easier operation.
1.3
Safety Precautions
DANGER: An Adept Cobra s350 robot can cause serious injury or death, or damage to itself and other equipment, if the following safety precautions are not observed: All personnel who install, operate, teach, program, or maintain the system must read this guide, read the Adept Robot Safety Guide, and complete a training course for their responsibilities in regard to the robot.
14
All personnel who design the robot system must read this guide, read the Adept Robot Safety Guide, and must comply with all local and national safety regulations for the location in which the robot is installed. The robot system must not be used for purposes other than described in Section 1.6. Contact Adept if you are not sure of the suitability for your application. The user is responsible for providing safety barriers around the robot to prevent anyone from accidentally coming into contact with the robot when it is in motion. Power to the robot and its power supply must be locked out and tagged out before any maintenance is performed.
1.4
1.5
1.6
15
Chapter 1 - Introduction
The Adept Cobra s350 robots, MB-40R, and Adept SmartController are component subassemblies of a complete industrial automation system. The controller must be installed inside a suitable enclosure. The controller and MB-40R must not come into contact with liquids. Additionally, a standard Adept Cobra s350 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. See Table 2-1 on page 22 for allowable temperature and humidity ranges.
WARNING: The instructions for installation, operation, and maintenance given in this users guide must be strictly observed.
Non-intended use of an Adept Cobra s350 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: Have the necessary qualifications Read and follow exactly the instructions in this manual If there is any doubt concerning the application, ask Adept to determine if it is an intended use or not.
1.7
Installation Overview
The system installation process is summarized in the following table. Refer also to the system cable diagram in Figure 3-1 on page 27.
16
Manufacturers Declaration
Table 1-1. Installation Overview Task to be Performed 1. Mount the robot on a flat, secure mounting surface. 2. Install the SmartController, Front Panel, optional T2 pendant (if present), and Adept ACE software. 3. Install the IEEE 1394 and XSYS cables between the MB-40R and SmartController. 4. Install the Arm Power/Signal cable between the MB-40R and the robot. 5. Create a 24 VDC cable and connect it between the MB-40R and the user-supplied 24 VDC power supply. 6. Create a 24 VDC cable and connect it between the SmartController and the user-supplied 24 VDC power supply. 7. Create a 200-240 VAC cable and connect it between the MB-40R and the facility AC power source. 8. Install user-supplied safety barriers in the workcell. 9. Learn about connecting digital I/O through the XIO connector on the MB-40R. 10.Read Chapter 5 to learn about system start-up and testing operation. 11.Read Chapter 6 if you need to install optional equipment, including end-effectors, user air and electrical lines, external equipment, etc. Reference Location See Section 2.5 on page 23. See Section 3.3 on page 28. See Section 3.4 on page 28. See Section 3.5 on page 29. See Section 3.6 on page 29.
See Section 3.9 on page 36. See Section 4.4 on page 41. See Chapter 5. See Section 6.1 on page 57.
1.8
Manufacturers Declaration
The Manufacturers Declaration of Incorporation and Conformity for Adept robot systems can be found on the Adept website, in the Download Center of the Support section.
http://www.adept.com/support/downloads/file-search
NOTE: The Download Center requires that you are logged in for access. If you are not logged in, you will be redirected to the Adept website Login page, and then automatically returned to the Download Center when you have completed the login process. 1. From the Download Types drop-down list, select Manufacturer Declarations
17
Chapter 1 - Introduction
2. From the Product drop-down list, select your Adept robot product category (such as Adept Cobra Robots, Adept Viper robots, etc.). 3. Click Begin Search. The list of available documents is shown in the Search Results area, which opens at the bottom of the page. You may need to scroll down to see it. 4. Use the Description column to locate the document for your Adept robot, and then click the corresponding Download ID number to access the Download Details page. 5. On the Download Details page, click Download to open or save the file.
1.9
Related Manuals
This manual covers the installation, operation, and maintenance of an Adept Cobra s350 robot system. There are additional manuals that cover programming the system, reconfiguring installed components, and adding other optional components. See the following table. Table 1-2. Related Manuals Manual Title Adept Robot Safety Guide Adept SmartController Users Guide Adept ACE Users Guide Adept IO Blox Users Guide V+ Operating System Users Guide V+ Language Users Guide Description Contains safety information for Adept robots. Contains complete information on the installation and operation of the Adept SmartController and the optional sDIO product. Instruction for the use of the Adept ACE software. Describes the IO Blox product. Describes the V+ operating system, including disk file operations, monitor commands, and monitor command programs. Describes the V+ language and programming of an Adept control system.
18
To locate information on a specific topic, use the Document Library search engine on the ADL main page. To view a list of available product documentation, select the Active Documents option.
19
Robot Installation
2.1 Transport and Storage
This equipment must be shipped and stored in a temperature-controlled environment, within the range 10 to +60 C (14 to 140 F). The recommended humidity range is 5 to 90 percent, non-condensing. It should be shipped and stored in the Adept-supplied packaging, which is designed to prevent damage from normal shock and vibration. You should protect the package from excessive shock and vibration. The robots must always be stored and shipped in an upright position in a clean, dry area that is free from condensation. Do not lay the crate on its side or any other position: this could damage the robot.
2.2
Before Unpacking
Carefully inspect all shipping crates for evidence of damage during transit. If any damage is indicated, request that the carriers agent be present at the time the container is unpacked.
Upon Unpacking
Before signing the carriers delivery sheet, please compare the actual items received (not just the packing slip) with your equipment purchase order and verify that all items are present and that the shipment is correct and free of visible damage. If the items received do not match the packing slip, or are damaged, do not sign the receipt. Contact Adept as soon as possible. If the items received do not match your order, please contact Adept immediately. Inspect each item for external damage as it is removed from its container. If any damage is evident, contact Adept (see Section 1.9 on page 18). Retain all containers and packaging materials. These items may be necessary to settle claims or, at a later date, to relocate equipment.
21
2.3
2.4
Table 2-1. Robot System Operating Environment Requirements Ambient temperature Humidity Altitude Pollution degree Robot protection class Note: See Section 8.1 for robot dimensions. 5 to 40 C (41 to 104 F) 5 to 90%, noncondensing up to 2000 m (6500 ft.) 2 IP-20 (NEMA Type 1)
22
2.5
Worker A
Worker B
Figure 2-1. Transporting Robot
CAUTION: Do not hold the robot by parts other than those shown above.
Mounting Surface
The Adept Cobra s350 robot is designed to be mounted on a smooth, flat, level surface. The mounting surface must be rigid enough to prevent vibration and flexing during robot operation. Adept recommends a 25 mm (1 in.) thick steel plate mounted to a rigid tube frame. Excessive vibration or mounting flexure will degrade robot performance. Figure 2-2 shows the mounting hole pattern for the Adept Cobra s350 robot. NOTE: On the under-side of the base there are two holes that can be used as locating points for user-installed dowel pins in the mounting surface. See Figure 2-2. Using locating pins can improve the ability to remove and reinstall the robot in the same position. The Adept Cobra s350 robot can be mounted on a moving platform with proper attention paid to adequately supporting the robot cabling. The motor/encoder cable connecting the robot to the MB-40R is not designed to withstand repeated bending operations and has a minimum recommended bend radius of 200 mm. The connectors on this cable are not designed to support any dynamic forces and Adept always advises users to support the weight of the cable with external supports and tie-downs. Any additional user cabling should be installed with user-designed cabling supports that do not use these motor/encoder connectors as attachment points for auxiliary cabling.
23
120
4x 12 Thru
7 R 1500 2x 6 H7 0
+0.012
17
2. Install a diamond-shaped pin into one of the 6H7 diameter holes. 3. Install an internally-threaded positioning pin into the other 6H7 hole. 4. Turn the J2 axis until it comes into contact with the mechanical hardstop to keep the robot in a safe position.
24
Bolts
Bolts
Pallet
Figure 2-3. Rotate J2 Axis to Safe Position 5. Remove the four bolts securing the robot base to the pallet. One person should support the J1 axis arm while another person removes the bolts. Retain these bolts for possible later relocation of the equipment. 6. Lift the robot and position it directly over the mounting surface. 7. Slowly lower the robot while aligning the base and the tapped mounting holes in the mounting surface. NOTE: The base casting of the robot is aluminum and can easily be dented if bumped against a harder surface. Verify that the robot is mounted squarely (will not rock back and forth) before tightening the mounting bolts. 8. Install the user-supplied mounting bolts and washers. Tighten bolts to the torque specified in Table 2-2.
WARNING: The center of mass of the robot may cause the robot to fall over if the robot is not secured with the mounting bolts.
NOTE: Check the tightness of the mounting bolts one week after initial installation, and then recheck every 6 months. See Chapter 7 for periodic maintenance. Table 2-2. Mounting Bolt Torque Specifications Standard Metric SAE Size M10 x 30 mm 3/8-16 UNC Specification ISO Property Class 8.8 SAE Grade 5 Torque 70 Nm 52 ft-lbf
25
3
EXPIO Connector External Brake Connector
CAMERA
RS-232/TERM
RS-422/485
SmartServo
OK SF HPE ES LAN HD
Device Net
SW1 1 2 3 4
ON OFF
1.1
1.2
XDIO
XUSR
XSYS
XFP
XMCP
XDC1 XDC2
24V 5A
-+
-+
Terminator Installed
SmartController CX
Front Panel
24 VDC Power from User-Supplied Power Supply to MB-40R (+24 VDC Input)
Figure 3-1. System Cable Diagram for Adept Cobra s350 Robots
27
3.2
Cable List
Table 3-1. Cables and Parts List Cable Description IEEE 1394 Cable, 4.5 M XSYS Cable, 4.5 M Front Panel Cable Power Cable Kit - contains 24 VDC and AC power cables XIO Breakout Cable, 12 inputs/ 8 outputs, 5 meters Notes Standard cable supplied with system Standard cable supplied with system Supplied with Front Panel Available as option Available as option see page 48.
3.3
3.4
28
3.5
3.6
User-supplied 24 VDC power supply must incorporate overload protection to limit peak power to less than 300 W, or 8 A in-line fuse protection must be added to the 24 V power source.
The power requirements for the user-supplied power supply will vary depending on the configuration of the robot and connected devices. Adept recommends a 24 V, 6 A power supply to allow for startup current draw and load from connected user devices, such as digital I/O loads. CAUTION: Make sure you select a 24 VDC power supply that meets the specifications in Table 3-2. Using an underrated supply can cause system problems and prevent your equipment from operating correctly. See the following table for recommended power supplies.
29
Table 3-3. Recommended 24 VDC Power Supplies Vendor Name XP Power Mean Well Astrodyne Model JPM160PS24 SP-150-24 ASM150-24 Ratings 24 VDC, 6.7 A, 160 W 24 VDC, 6.3 A, 150 W 24 VDC, 6.66 A, 150 W
Connector receptacle, 2-position, type: Molex Saber, 18 A, 2-Pin Molex P/N 44441-2002 Digi-Key P/N WM18463-ND
+24 V
Pin Details
Molex connector crimp terminal, female, 14-18 AWG Molex P/N 43375-0001 Digi-Key P/N WM18493-ND
NOTE: The 24 VDC cable is not supplied with the system, but is available in the optional Power Cable kit. See Table 3-1 on page 28.
30
3. Crimp the pins onto the wires using the crimping tool recommended in Table 3-4. 4. Insert the pins into the connector. Confirm that the +24 V and Ground wires are in the correct terminals in the plug. 5. Install a user-supplied ring lug (for an M3 screw) on the shield at the MB-40R end of the cable. 6. Prepare the opposite end of the cable for connection to the user-supplied 24 VDC power supply, including a terminal to attach the cable shield to frame ground.
GND
Attach shield from usersupplied cable to ground screw on MB-40R Interface Panel.
+ 24V, 8A
Frame Ground
+ 24V, 5A
Attach shield from usersupplied cables to frame ground on power supply.
Adept SmartController
Attach shield from user-supplied cable to side of controller using star washer and M3 x 6 screw.
-+
User-Supplied Shielded Power Cable
31
NOTE: In order to maintain compliance with EN standards, Adept recommends that DC power be delivered over shielded cables, with the shield connected to frame ground at the power supply, and to the ground points shown in the diagram above for the MB-40R and SmartController. The length of the wire from the cable shield to the ground points should be less than 50 mm.
3.7
Frequency/ Phasing
Specifications are established at nominal line voltage. Low line voltage can affect robot performance. NOTE: The Adept robot system is intended to be installed as a piece of equipment in a permanently-installed system. DANGER: AC power installation must be performed by a skilled and instructed person - see the Adept Robot Safety Guide. During installation, unauthorized third parties must be prevented from turning on power through the use of fail-safe lockout measures. Facility Overvoltage Protection The user must protect the robot from excessive overvoltages and voltage spikes. If the country of installation requires a CE-certified installation, or compliance with IEC 1131-2, the following information may be helpful: IEC 1131-2 requires that the installation must ensure that Category II overvoltages (i.e., line spikes not directly due to lightning strikes) are not exceeded. Transient overvoltages at the point of connection to the power source shall be controlled not to exceed overvoltage Category II, i.e., not higher than the impulse voltage corresponding to the rated voltage for the basic insulation. The user-supplied equipment or transient suppressor shall be capable of absorbing the energy in the transient. In the industrial environment, nonperiodic over-voltage peaks may appear on mains power supply lines as a result of power interruptions to high-energy equipment (such as a blown fuse on one branch in a 3-phase system). This will cause high-current pulses at relatively low voltage levels. The user shall take the necessary steps to prevent damage to the robot system (such as by interposing a transformer). See IEC 1131-4 for additional information.
32
AC Power Diagrams
Note: F1 is user-supplied, must be slow-blow. L
1 200240 VAC 20 A
F1 10A N E
200240 VAC
3 200240 VAC
L2 L3 E F4 10 A
33
NOTE: The AC power cable is not supplied with the system, but is available in the optional Power Cable kit. See Table 3-1 on page 28.
34
3.8
Ground Point
Ground Point
35
See also Figure 8-3 on page 75 for the grounding point on the tool flange.
DANGER: Failing to ground robot-mounted equipment or tooling that uses hazardous voltages could lead to injury or death of a person touching the end-effector when an electrical fault condition exists.
3.9
36
MotionBlox-40R
4.1 Introduction to the MotionBlox-40R
The Adept MotionBlox-40R (MB-40R) is a distributed servo controller and amplifier. It has a dedicated digital signal processor to communicate, coordinate, and execute servo commands. The MB-40R consists of: a distributed servo amplifier a RISC processor for servo loop control a node on the IEEE 1394 network a power controller that uses single-phase AC power, 200-240 Volts a status panel with a 2-digit alpha-numeric display to indicate operating status and fault codes
Interface Panel
37
Chapter 4 - MotionBlox-40R
4.2
SmartServo Port 2
+24 V Pin
RS-232
XIO
XPANEL
Figure 4-2. MB-40R Interface Panel 24 VDC - for connecting user-supplied 24 VDC power. The mating connector is provided. Ground Point - for connecting cable shield from user-supplied 24 VDC cable. 200/240 VAC - for connecting 200-240 VAC, single-phase, input power. The mating connector is provided. XSLV - for connecting the supplied XSYS cable from the controller XSYS connector. (DB-9, female) SmartServo 1 & 2 - for connecting the IEEE 1394 cable from the controller (SmartServo 1.1) to the upper connector (SmartServo 1). RS-232 - Reserved for future use (DB-9, male) XPANEL - Reserved for future use (DB-26, high density, male) XIO - for user I/O signals for peripheral devices. This connector provides 8 outputs and 12 inputs. See Section 4.5 on page 44 for connector pin allocations for inputs and outputs. That section also contains details on how to access these I/O signals via V+. (DB-26, high density, female)
38
MB-40R Operation
4.3
MB-40R Operation
EXPIO Connector
Brake Connector
Figure 4-3. Controls and Indicators on MB-40R Table 4-1. Status LED Definition LED Status Off Green, Slow Blink Green, Fast Blink Green/Red Blink Red, Fast Blink Solid Green or Red Description 24 VDC not present High Power Disabled High Power Enabled Selected Configuration Node Fault, see Status Panel Display Initialization or Robot Fault
39
Chapter 4 - MotionBlox-40R
Status Panel
The status panel, shown in Figure 4-3 on page 39, displays alpha-numeric codes that indicate the operating status of the MB-40R. The following table gives definitions of the fault codes. These codes provide details for quickly isolating problems during troubleshooting. Table 4-2. Status Panel Codes LED OK ON MA 24 A# B# AC D# E# ES F# FM FW Status Code No Fault High Power ON Status Manual Mode 24V Supply Fault Amp Fault (Joint #) IO Blox Fault (Address #) AC Power Fault Duty Cycle Exceeded (Joint #) Encoder Fault (Joint #) E-Stop External Sensor Stop Firmware Mismatch 1394 Fault LED h# H# hV I# M# NV P# PR RC SW S# T# V# Status Code High Temp Amp (Joint #) High Temp Encoder (Joint #) High Voltage Bus Fault Initialization Stage (Step #) Motor Stalled (Joint #) Non-Volatile Memory Power System Fault (Code #) Processor Overloaded RSC Fault Watchdog Timeout Safety System Fault (Code #) Safety System Fault (Code 10 + #) Hard Envelope Error (Joint #)
NOTE: Due to the nature of the Cobra s350 bus line encoder wiring, a single encoder wiring error may result in multiple channels of displayed encoder errors. Reference the lowest encoder number displayed. For more information on status codes, go to the Adept Document Library on the Adept website, and in the Procedures, FAQs, and Troubleshooting section, look for the Adept Status Code Summary document.
40
Pin Location
4.4
Product XIO Connector on MB-40R XDIO Connector on SmartController Optional IO Blox Devices, connect to EXPIO connector on the MB-40R Optional sDIO Module, connects to controller
I/O Capacity 12 inputs 8 outputs 12 inputs 8 outputs 8 inputs, 8 outputs per device; up to four IO Blox devices per system 32 inputs, 32 outputs per module; up to four sDIO devices per system
For more details see Section 4.5 on page 44 see Adept SmartController Users Guide see Adept IO Blox Users Guide see Adept SmartController Users Guide
41
Chapter 4 - MotionBlox-40R
Optional sDIO #1
LINK
XDC1 XDC2
24V 0.5A
OK SF
-+
-+
*S/N 3562-XXXXX*
R
CAMERA
RS-232/TERM
RS-422/485
SmartController
SmartServo
OK SF HPE ES LAN HD
Device Net
SW1 1 2 3 4
ON OFF
1.1
1.2
XDIO
XUSR
XSYS
XFP
XMCP
XDC1 XDC2
24V 5A
-+
-+
XDIO Connector 12 Input signals: 1001 to 1012 8 Output signals: 0001 to 0008 XIO Connector 12 Input signals: 1097 to 1108 8 Output signals: 0097 to 0104
42
SmartController CX
SC-DIO
*S/N 3563-XXXXX*
X1
X2
X3
X4
Table 4-5. Default Digital I/O Signal Configuration, Single Robot System Location SmartController XDIO connector sDIO Module 1 sDIO Module 2 MB-40R 1 XIO connector IO Blox 1 IO Blox 2 IO Blox 3 IO Blox 4 Type Inputs Outputs Inputs Outputs Inputs Outputs Inputs Outputs Inputs Outputs Inputs Outputs Inputs Outputs Inputs Outputs Signal Range 1001 - 1012 0001 - 0008 1033 - 1064 0033 - 0064 1065 - 1096 0065 - 0096 1097 - 1108 0097 - 0104 1113 - 1120 0105 - 0112 1121 - 1128 0113 - 0120 1129 - 1136 0121 - 0128 1137 - 1144 0129 - 0136
43
Chapter 4 - MotionBlox-40R
4.5
Signal Bank
V+ Signal Number
Pin Locations
44
NOTE: The input current specifications are provided for reference. Voltage sources are typically used to drive the inputs.
45
Chapter 4 - MotionBlox-40R
Adept-Supplied Equipment
User-Supplied Equipment
Wiring Terminal Block Typical User Input Signals
Note: all Input signals can be used for either sinking or sourcing configurations.
(equivalent circuit)
4 5 6 7 8 9
Input Bank 1
Input Bank 2
Figure 4-5. Typical User Wiring for XIO Input Signals NOTE: The off-state current range exceeds the leakage current of XIO outputs. This guarantees that the inputs will not be turned on by the leakage current from the outputs. This is useful in situations where the outputs are looped-back to the inputs for monitoring purposes.
46
47
Chapter 4 - MotionBlox-40R
Adept-Supplied Equipment
XIO Connector 26-Pin Female D-Sub
User-Supplied Equipment
Wiring Terminal Block
+24 VDC 19 20 21 22 23 24 25 26 1 10
Signal 0097
Outputs 1-8
(equivalent circuit)
Signal 0098 Signal 0099 Signal 0100 Signal 0101 Signal 0102 Signal 0103 Signal 0104 GND GND
M
L N
48
Table 4-9. XIO Breakout Cable Wire Chart Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Shell Signal Designation GND 24 VDC Common 1 Input 1.1 Input 2.1 Input 3.1 Input 4.1 Input 5.1 Input 6.1 GND 24 VDC Common 2 Input 1.2 Input 2.2 Input 3.2 Input 4.2 Input 5.2 Input 6.2 Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Wire Color White White/Black Red Red/Black Yellow Yellow/Black Green Green/Black Blue Blue/White Brown Brown/White Orange Orange/Black Gray Gray/Black Violet Violet/White Pink Pink/Black Light Blue Light Blue/Black Light Green Light Green/Black White/Red White/Blue Shield
Pin 26 Pin 18 Pin 9 Pin 19 Pin 10 Pin 1
Pin Locations
49
Chapter 4 - MotionBlox-40R
4.6
MB-40R Dimensions
See the following figure for dimensions of MB-40R chassis and mounting holes.
197.8
32.7
377.8
47.6
377.8
47.6
0 A
0 7.6 45.7 129.54
425.5 404.9
331.7
204.2
45.7
7.6
32.7
6X, SHCS,M4 X 6
67.3 106.7
197.8
Note: 112 mm clearance required in front of unit to remove AIB from box enclosure.
45.7
228.6
7.6
45.7 7.6 0
377.8
50
47.6
0 0 32.7
System Operation
5.1 Brakes
The robot has a braking system that decelerates the robot in an emergency condition, such as when the emergency stop circuit is open or a robot joint passes its softstop. The E-Stop is a dual-channel, passive E-Stop that supports Category 3 CE safety requirements. It supports a customer-programmable E-Stop delay that maintains motor power for a programmed time after the E-Stop is activated. This customizable feature allows the motors to decelerate under servo control to a stop. This can aid in eliminating coasting or overshooting on low friction mechanisms. It can also aid in the reduction of wear on highly-geared, high-inertia mechanisms, while maintaining safety compliance per all standards. The braking system will not prevent you from moving the robot manually once the robot has stopped (and High Power has been removed). In addition, Joints 3 and 4 have electromechanical brakes. The brakes are released when high power is enabled. When High Power is turned off, the brakes engage and hold the positions of Joints 3 and 4. There is a Brake Release button for Joints 3 and 4 on the MB-40R and a Brake Release button on the robot itself. See Brake Release Button on MB-40R on page 40 for information on the Brake Release button on the MB-40R. The Programmable E-Stop delay can be set up in Adept ACE, in the robot editor. The default setting is appropriate for most applications. See the following section.
51
Figure 5-1. Brake Release Button for Third and Fourth Axes
CAUTION: When the Brake Release button is pressed, Joint 3 may drop to the bottom of its travel. To prevent possible damage to the equipment, make sure that Joint 3 is supported while releasing the brake and verify that the end-effector or other installed tooling is clear of all obstructions.
52
Front Panel
5.2
Front Panel
2 1
Manual Mode
Auto Mode
3
Figure 5-2. Front Panel 1. XFP connector Connects to the XFP connector on the SmartController CX. 2. System 5 V Power-On LED Indicates whether or not power is connected to the robot. 3. Manual/Automatic Mode Switch Switches between Manual and Automatic mode. In Automatic mode, executing programs control the robot, and the robot can run at full speed. In Manual mode, the system limits robot speed and torque so that an operator can safely work in the cell. Manual mode initiates software restrictions on robot speed, commanding no more than 250 mm/sec. 4. High Power On/Off Switch and Lamp Controls high power, which is the flow of current to the robot motors. Enabling high power is a two-step process. An Enable Power request must be sent from the user-supplied PC, an executing program, or the T2 pendant. Once this request has been made and the High Power On/Off lamp/button is blinking, the operator must press and release this button, and high power will be enabled. NOTE: The use of the blinking High Power button can be configured (or eliminated) in software. Your system may not require this step. NOTE: If enabled, the Front Panel button must be pressed while blinking (default time-out is 10 seconds). If the button stops blinking, you must enable power again. 5. Emergency Stop Switch The E-Stop is a dual-channel, passive E-Stop that supports Category 3 CE safety requirements. Pressing this button turns off high power to the robot motors.
53
NOTE: The Front Panel must be installed to be able to Enable Power to the robot. To operate without a Front Panel, the user must supply the equivalent circuits.
5.3
Verifying Installation
Verifying that the system is correctly installed and that all safety equipment is working correctly is an important process. Before using the robot, make the following checks to ensure that the robot and controller have been properly installed.
DANGER: After installing the robot, you must test it before you use it for the first time. Failure to do this could cause death, or serious injury or equipment damage.
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 System Cable Checks Verify the following connections: Front Panel to the SmartController Pendant to the SmartController, via the pendant adapter cable User-supplied 24 VDC power to the controller User-supplied ground wire between the SmartController and ground One end of the IEEE 1394 cable into the SmartServo port 1.1 connector on the SmartController, and the other end into the SmartServo port 1 connector on the MB-40R interface panel.
54
XSYS cable between the MB-40R interface panel XSLV safety interlock connector and XSYS connector on the SmartController, and the latching screws tightened User-supplied 24 VDC power to the MB-40R 24 VDC connector User-supplied 200/240 VAC power to the MB-40R 200/240 VAC connector User-Supplied Safety Equipment Checks Verify that all user-supplied safety equipment and E-Stop circuits are installed correctly.
Turning on Power
After the system installation has been verified, you are ready to turn on AC and DC power to the system and start up Adept ACE. 1. Switch on AC power to the MB-40R. .
DANGER: Make sure personnel are skilled and instructed refer to the Adept Robot Safety Guide.
2. Switch on the 24 VDC power to the MB-40R. 3. Switch on the 24 VDC power to the controller. The Status Panel displays OK. The Status LED will be off. 4. Verify the Auto/Manual switch on the Front Panel is set to Auto Mode.
55
2. Press and release the blinking High Power button on the Front Panel within 10 seconds. The Front Panel is shown in Figure 5-2 on page 53. (If the button stops blinking, you must Enable Power again.) NOTE: The use of the blinking High Power button can be configured (or eliminated) in software. Your system may not require this step. This step turns on high power to the robot motors and calibrates the robot. The MB-40R Status LED displays a fast green blink. The code on the MB-40R displays ON (see Controls and Indicators on MB-40R on page 39).
5.4
56
The user is responsible for providing and installing any end-effector or other end-of-arm tooling. End-effectors can be attached to the tool flange using four M6 screws. See Figure 8-3 on page 75 for a detailed dimension drawing of the tool flange. A 6 mm diameter x 12 mm dowel pin (user-supplied) fits in the through-hole in the tool flange and can be used as a keying or anti-rotation device in a user-designed end-effector. If hazardous voltages are present at the end-effector, you must install a ground connection from the base of the robot or the outer link to the end-effector. See Grounding the Adept Robot System on page 35. NOTE: A threaded hole is provided on the tool flange. The user may attach a ground wire through the quill, connecting the outer link and the tool flange.
6.2
57
Setscrew
CAUTION: The setscrew must align with the flat section of the shaft or damage to the quill will result.
2. Support the flange while using a 2.5 mm Allen driver to tighten the setscrew to finger tightness. Do not over-tighten the setscrew because this will cause the flange to be off-center from the quill shaft. 3. Tighten one of the M4 screws part of the way, then tighten the other one the same amount. Alternate between the two screws so there is even pressure on both when they are tight. The torque specification for each screw is 8 Nm (70 in-lb).
58
6.3
10 11 12 13 14 15
(A)
16 17 18 19
(B)
Air No. AIR 1,2 AIR 3,4 Air piping joint 4, BSPT 1/8 6, BSPT 1/4 Maximum allowable pressure 0.59 MPa
59
for CN21
CN21 Pin # 1 2 3 4 5 6 7 8 9 10
1 2
Inputs 1001 to 1005 are preconfigured as low-active (sinking) inputs. Outputs 0007 and 0008 are preconfigured as high-side (sourcing) outputs. 3 Limited to a combined total of 1 A of current.
60
Figure 6-3. Mechanical End Bolts and Stoppers on Robot Routing User Connections Through the Z-Axis Shaft You can route air and electrical lines from the CN21 connector or the air line joints on the top of the outer arm (Joint 2) through a hollow space (14 mm) in the Z-axis shaft.
CAUTION: If routing lines in this manner, make sure that, when the robot is in motion, including when the Z-axis is moving, the air and electrical lines do not become taut or interfere with other parts of the robot.
61
Attaching Stays to Support User Connections You can attach a user-supplied stay on the exterior of the robot to support air and electrical lines - see Figure 6-4. See Figure 6-5 for the dimensions to fabricate the stay. To install the stay, attach four M3 bolts to the four threaded holes on the bottom of the outer arm to mount the stay. The mounting holes are the same as those used for the camera bracket, see Figure 6-6 on page 63.
User Air and Electrical Lines Routed Through Z-Axis Shaft Stay Attached to Robot User Air and Electrical Lines
.98
1.18
62
Camera Mounting
6.4
Camera Mounting
A camera can be mounted on the Cobra s350 by installing a user-supplied camera bracket. The bracket is installed on the underside of the robot - see Figure 6-6 for the location and dimensions of the mounting holes. See Figure 6-7 on page 64 and Figure 6-8 on page 65 for drawings of the brackets. The user must fabricate this bracket, it is not available from Adept. An optional camera channel (40861-00830) and camera mounting block (40861-00660) are available from Adept. These can be attached to the user-supplied camera bracket, see Figure 6-6.
30 82 (66)
4x M3 x 0.5
63
64
A .010 A
(5.01)
(6.97) .88
B 3X
4.01
UNLESS OTHERWISE SPECIFIED: - DIMENSIONS APPLY AFTER PROCESS. - INTERPRET DRAWING PER ANSI Y14.5. - DIMENSIONS ARE IN INCHES. TOLERANCES 2 PLACE DECIMALS: +/- .03 3 PLACE DECIMALS: +/- .015 ANGULAR DIMS: +/- 1 degree Page 1 of 2
10 1.22 .89 .26 3.23 R2.0 3.64 2.25 1.00 5 2X 1.06 1.27
A
2X 4.53 15 15 5 5
2X R.25 .91
2X 6.59
R.50
.56
DETAIL A
2 PLACES 1 AS SHOWN 1 MIRROR/OPPOSITE R 2.00 INSIDE
2X R MIN.
3.08
.13
.50
ITEM 2
MOUNT, CAMERA AL ALLOY 6061 T651, .38 THK
2X R .12 MAX.
ITEM 1
BRACKET, CAMERA AL ALLOY 5052 H32, .063 THK
Camera Mounting
Page 2 of 2
65
Maintenance
7.1 Periodic Maintenance Schedule
The following table gives a summary of the preventive maintenance procedures and guidelines on frequency. Table 7-1. Inspection and Maintenance Item Check E-Stop, enable and key switches, and barrier interlocks Check robot mounting bolts Lubricate Joint 3 (Z-axis) ball screw Replace Encoder battery Inspect timing belts on 3rd and 4th axes Period 3 months 3 months 6 months 2 - 4 years 12 months Reference See Section 7.2 See Section 7.3 See Section 7.4 See Section 7.5 See Section 7.6
WARNING: The procedures and replacement of parts mentioned in this section should be performed only by skilled or instructed persons, as defined in the Adept Robot Safety Guide. The access covers on the robot are not interlocked turn off and disconnect power if covers have to be removed.
7.2
67
Chapter 7 - Maintenance
7.3
7.4
CAUTION: Using improper lubrication products on the Adept Cobra s350 robot may cause damage to the robot.
Lubrication Procedure
1. Turn off main power to the controller and robot.
68
2. Raise the Joint 3 quill shaft to the upper position. 3. Apply grease to the entire shaft. See Table 7-2 on page 68 for details. 4. Move the Joint 3 shaft up and down to distribute the grease. Wipe off any excess grease.
7.5
CAUTION: Replace the batteries only with 3.6 V, 2.7 Ah lithium batteries, Adept part number: 06126-000. Battery information is located in the base of the robot.
NOTE: Dispose of the battery according to all local and national environmental regulations regarding electronic components.
69
Chapter 7 - Maintenance
2. Switch off the SmartController. 3. Switch off the 24 VDC input supply to the MB-40R. 4. Switch off the 200/240 VAC input supply to the MB-40R. 5. Disconnect the 24 VDC supply cable from the MB-40R +24 VDC input connector. See Figure 4-2 on page 38 for locations of connectors. 6. Disconnect the 200/240 VAC supply cable from the MB-40R AC input connector. 7. Remove the battery cover from the robot, by removing 4 hex socket-head bolts (M3 x 8). See Figure 7-3. NOTE: On the cleanroom robot, the cover has a packing for sealing. Take care not to lose or pinch it.
Battery Cover
Figure 7-3. Removing Battery Cover 8. Attach the two new backup batteries to unused connectors on the battery board. See Figure 7-4. NOTE: Always leave at least two batteries connected at all times. Failure to do so may lose the encoder positional data, requiring factory recalibration.
70
9. Disconnect the two old batteries from the battery board and then remove them from the holders. 10. Put the new batteries into the battery holders. See the following figure.
New connectors
Figure 7-5. New Batteries in Holders 11. Reinstall the battery cover on the robot. Tightening toque: Hex socket-head bolt (M3 x 8): 1.6 0.3 Nm (1.2 0.2 ft-lbf) NOTE: On the cleanroom robot, reinstall the packing under the cover. Take care not to pinch it.
7.6
71
Technical Specifications
8.1 Dimension Drawings
75 60 0 60 75 60 0 4x, 12 60
8
709
245
Cabling Space
Work Area
Figure 8-1. Adept Cobra s350 Top and Side Dimensions NOTE: The supplied Adept flange sits 10.0 mm below the bottom of the quill shown in Figure 8-1.
73
155
155
145
145
74
Dimension Drawings
See Detail A
43 mm (1.69 in.)
45 Dowel Pin Hole 6.0 mm +.01 mm 0 mm (0.2362 in.) (+.0005 in.) ( 0 in.) -CBC
-A-
30
50.0 mm (1.9685 in.) 4X M6 x 1- 6H Thru .10 mm (.004 in.) M A M B C M User Ground R 3.56mm (R 0.140in) 5.08mm (0.20in) M3 X 0.5-6H Thru
4.14 mm (0.163 in.) 1.5 mm (0.059 in.) 6.80 mm (0.268 in.) -B-
Detail A
Figure 8-3. Tool Flange Dimensions for Adept Cobra s350 Robots
25
75
8.2
Robot Specifications
Table 8-1. Adept Cobra s350 and s350CR/ESD Robot Specifications1 Description Reach Payload - rated/maximum Moment of Inertia Downward Push Force Burst (no load) Repeatability x, y z Theta Joint Range Joint 1 Joint 2 Joint 3 Joint 4 Joint Speed (maximum) Joint 1/Joint 2 Joint 3 Joint 4 Encoder type Robot Brakes Airline pass-through (quantity) Electrical pass-through Weight (without options)
1
Specification 350 mm 2.0 kg/5.5 kg Joint 4 - 450 kg-cm (150 lb-in) - max 98 N - maximum
0.015 mm 0.01 mm 0.005 155 145 200 mm (7.8 in.) 360 720/sec 2000 mm/sec 2400/sec Absolute Joints 1, 2: Dynamic Joint 3, 4: Electric 6 mm diameter (2) 4 mm diameter (2) 19 conductors 20 kg
Table 8-2. Softstop and Hardstop Specifications Joint Joint 1 Joint 2 Joint 3 Joint 4 Softstop 155 145 0 to 200 mm 360 Hardstop Approx. 158 147 -5 to 205 mm not applicable
76
Cleanroom Robots
9.1 Cobra s350 CR/ESD Cleanroom Option
Introduction
The Adept Cobra s350 CR/ESD Cleanroom Option is a modification to the standard robot that certifies the robot to meet the Class 4 Airborne Particulate Cleanliness Limits as defined by ISO Standard 14644 (Class 10 for Federal Standard 209E), as well as special requirements for control of Electrostatic Discharges to the robot surface. NOTE: Federal Class 1 Limits (ISO 3) can be achieved by running the robot at lower speeds and increasing the vacuum flow from the robot base. This option is a factory-installed configuration. Changes to the robot include the addition of bellows assemblies mounted at the Joint 3 quill, increased sealing at the joints, fully sealed access covers, and a vacuum system to evacuate the arm.
77
Specifications
Table 9-1. Adept Cobra s350 CR/ESD Cleanroom Robot Specifications Robot Performance Specification Ambient Temperature Specification Same as standard robot. 5 - 35 C (41 - 95 F)
9.2
Connections
AIR1 and AIR2 4, BSPT 1/8 CN22 AIR3 and AIR4 6, BSPT 1/4
78
Requirements
9.3
Requirements
Table 9-2. Cleanroom Robot Requirements Vacuum source 0.10 m3/min (3 ft3/min) minimum volumetric flow rate 350 mm of water (13.5 inches of water) differential pressure measured between the robot and the vacuum source 15 mm OD tube fitting at the back of the robot Quill inside diameter The inside diameter of the quill must be plugged by the users end-effector in order to maintain cleanliness at the tool flange.
9.4
9.5
Maintenance
Bellows Replacement
Check the bellows periodically for cracks, wear, or damage. Replace the upper and lower bellows if necessary, using the procedures below. Adept part numbers: 05555-000 (upper) and 05556-000 (lower). Procedure for Lower Bellows Replacement 1. Remove the lower clamp ring from the bearing ring by loosening the screw on the clamp. See Figure 9-3. 2. Remove the tool flange. Refer to Section 6.2 on page 57 for the tool flange removal procedure. 3. Remove the upper clamp ring by loosening the screw on the clamp. 4. Slide the old bellows down off of the quill.
79
5. Install a new bellows, and reverse the steps listed above. Take care to correctly seat the tool flange firmly up against its hardstop and rotate the flange so that the setscrew lies in the middle of the machined flat of the quill.
Bellows
Tool Flange
Figure 9-3. Cleanroom Lower Bellows Replacement Procedure for Upper Bellows Replacement 1. Remove the clamp rings from the top and bottom of the upper bellows. 2. Slide the bellows down and remove the assembly at the top of the quill with a M3 Allen wrench. Note the position of the top assembly is such that the split nut lies just at the top of the quill. 3. Replace bellows.
80
Maintenance
4. Replace the top assembly to the flange with the vertical position set so that the split of the nut lies level with the top of the quill. (failure to do so may result in decreased vertical stroke.)
Top Assembly
Bellows
Lubrication
The upper and lower ends of the Joint 3 quill shaft require lubrication in the same manner as the standard Cobra s350 robot. See Section 7.4 on page 68.
81
9.6
Dimension Drawings
75 60 0 60 75 60 0 60 4x, 12 810
245
Cabling Space
Work Area
Figure 9-5. Adept Cobra s350 CR/ESD Top and Side Dimensions NOTE: The total height of the Cobra s350 CR/ESD robot is different than the standard robot. See Figure 8-1 on page 73 for a comparison.
82
Dimension Drawings
155
155
145
145
83
Index
Numerics
200/240 VAC connector 38 24 VDC connector 38 24 VDC power 30 circuit protection 29 connecting to MB-40R 29 making cable 30 mating connector 30 specifications 29 user-supplied cable, shielding 31 24 VDC power supplies cautions 29 recommended 30
C
cable diagram for system 27 cables list 28 camera mounting description 63 dimensions for mounting holes 63 user-supplied bracket dimensions 64 circuit protection 24 VDC power 29 Cleanroom robot connections 78 description 77 ESD control features 79 lubrication 81 replacing bellows 79 requirements 79 specifications 78 vacuum specifications 79 CN20/CN21 connector, signal wiring 60 commissioning the system 54 connectors 200/240 VAC 38 24 VDC 38 brake release on MB-40R 41 EXPIO 39 on MB-40R 38 SmartServo 38 XIO 38 XSLV 38 Customer Service assistance 18
A
AC power connecting to MB-40R 32 diagrams 33 making cable 34 mating connector 33 specifications 32 turning on 55 Adept ACE starting 55 Adept Document Library 19 air lines user, in robot 59 AIR1/2/3/4 air lines, description
59
B
bellows replacing on Cleanroom robot 79 Brake Release button on MB-40R 40 on robot 52 brake release connector, on MB-40R 41 brakes releasing J3 for manual movement 40, 52 Breakout Cable, XIO 48
D
DC power, see 24 VDC power Digital I/O connecting to system 42 input specifications 45 on MB-40R XIO connector 44 optional products 45 output specifications 47 signal designations 44, 49 dimensions 73 Cobra s350 robot 73 Cobra s350CR/ESD robot 82 MB-40R 50 tool flange 75 Document Library 19 dowel pin, for keying on end-effectors
57
85
Index
E
electrical lines, user, in robot 60 emergency situation, what to do 15 Emergency Stop switch, Front Panel 53 enable power using Adept ACE 56 encoder battery, replacing 69 end-effectors dowel pin 57 grounding 57 installation 57 environmental requirements 22 ESD control features, in Cleanroom robot EXPIO connector for IO Blox 41 location on MB-40R 39 external equipment installing user-supplied stay 62 mounting locations on robot 61 external mounting holes 6263
J
Joint 3 Brake Release button joint motions 12 40, 52
L
lubrication Joint 3 68 type of grease for robot 79
68
M
maintenance checking safety systems 67 lubricating Joint 3 68 replacing bellows on Cleanroom robot 79 replacing encoder battery 69 schedule 67 Manual/Automatic Mode switch, Front Panel 53 MB-40R 37 brake release button 40 brake release connector 41 dimensions 50 interface panel 38 mounting 50 operation 39 status LED 39 status panel codes 40 mounting bolt specifications 25 mounting hole pattern 24 mounting locations, external equipment 61 mounting procedure 24
F
Front Panel cable 28
G
ground point, on MB-40R interface panel 38 grounding at MB-40R 35 at robot base 35 robot-mounted equipment 35 user-supplied 24 VDC cable 31
H
hardstop specifications 76 High Power On/Off Switch, Front Panel How Can I Get Help? 18 53
O
operating environment requirements optional I/O products 45 overvoltage protection 32 22
I
I/O products, optional 45 IEEE 1394 cable 28, 38 installation 21 24 VDC power to MB-40R 29 AC power to MB-40R 34 end-effectors 57 overview 16 robot 23 SmartController 28 user-supplied safety equipment verifying 54 intended use of the robots 15 interface panel on MB-40R 38
P
performance specifications, robot power 24 VDC 30 power cable kit, optional 28 Power On LED, Front Panel 53 programming 56 protection overvoltage 32 76
36
86
Index
R
related manuals 18 repacking for relocation 22 requirements environmental 22 facility 22 robot system operating environment
V
vacuum source, for Cleanroom robot VDC power 30 79
W
22
work envelope 74 Cobra s350 robot 74 Cobra s350CR/ESD robot
S
shipping and storage 21 SmartController description 13 installation 28 SmartServo connector 38 softstops specifications 76 solenoid cable, optional 60 specifications 76 24 VDC power 29 AC power 32 robot 76 startup using Adept ACE 56 status LED, description 39 status panel codes, on MB-40R 40 stay, user-supplied 62 storage information 21 system 5 V Power On LED, Front Panel 53 cable diagram 27 connecting digital I/O 42 operating environment requirements, robot 22
83
X
XFP connector Front Panel 53 XIO Breakout Cable 28 description 48 wire chart 49 XIO connector description and location 38 digital input circuit specifications 45 digital output circuit specifications 47 signal designations 44 XIO Termination Block, description 45 XSLV connector 38 XSYS cable 28
Z
Z Brake Release button 40, 52
T
tool flange installation 57 tool flange dimensions 75 transport and storage 21
U
unpacking and inspecting Adept equipment information 21 user air lines, in robot 59 connections 59 electrical lines, in robot 60 21
87
P/N:05624-000, Rev. C