adept technology AdeptThree User manual

AdeptThree Robot
User’s Guide
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PRELIMINARY
VERSION

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. A form is provided at the back of the
manual for submitting your comments.
Copyright © 1990 by Adept Technology, Inc. All rights reserved.
The Adept logo is a registered trademark of Adept Technology, Inc.
AdeptThree, Adept CC, Adept MC, V and V+
are trademarks of Adept Technology, Inc.
Printed in the United States of America

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TABLE OF CONTENTS
1. GENERAL INFORMATION ..............................................................................1
1.1 This Manual and Related Publications............................................................1
1.2 Notes, Cautions, and Warnings........................................................................1
Orientation......................................................................................................2
Controller High Power Indicator ................................................................2
1.3 Customer Service Assistance ............................................................................2
Service Calls....................................................................................................2
Training Information.....................................................................................3
Application Information...............................................................................3
International Customer Assistance.............................................................3
1.4 Safety ....................................................................................................................3
System Safeguards.........................................................................................4
Equipment Safety...........................................................................................4
1.5 Robot Modifications...........................................................................................5
2. OVERVIEW............................................................................................................7
2.1 Description...........................................................................................................7
General............................................................................................................7
Joint Motions..................................................................................................8
Joint 1 .........................................................................................................8
Joint 2 .........................................................................................................9
Joint 3 .........................................................................................................9
Joint 4 .......................................................................................................10
Limiting Joint Travel...................................................................................11
Softstops...................................................................................................11
Hardstops................................................................................................11
Brakes ............................................................................................................15
2.2 Dimensions........................................................................................................16
2.3 Specifications.....................................................................................................18
2.4 Options...............................................................................................................19
3. INSTALLATION.................................................................................................21
3.1 Environmental and Facility Requirements...................................................21
Facility Ambient Air Quality.....................................................................21
Compressed Air...........................................................................................21

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Electrical........................................................................................................22
Robot Workcell Free Space.........................................................................22
Floor...............................................................................................................22
Mounting Surface ........................................................................................24
Plate..........................................................................................................24
Spool.........................................................................................................26
3.2 Tool and Equipment Requirements...............................................................27
3.3 Unpacking and Inspection ..............................................................................27
Before Unpacking........................................................................................27
Upon Unpacking .........................................................................................27
Repacking For Relocation...........................................................................28
3.4 Preparation For Installation ............................................................................28
3.5 Installing a Mounting Plate.............................................................................29
3.6 Installing a Mounting Spool............................................................................30
3.7 Robot Installation..............................................................................................33
3.8 Facility Interconnection ...................................................................................34
Robot to Controller......................................................................................34
Facility Air Supply.......................................................................................35
3.9 End Effectors .....................................................................................................35
Installation....................................................................................................35
Clamp-mounted End Effector..............................................................35
Screw-mounted End Effector ...............................................................37
3.10 User Signal and Voltage Lines........................................................................39
USR1 Through USR5...................................................................................39
Solenoid Drivers ..........................................................................................40
DC Power......................................................................................................41
4. MAINTENANCE ................................................................................................47
4.1 Introduction.......................................................................................................47
4.2 Lubrication.........................................................................................................47
Lubrication of Joint 3...................................................................................48
Lubrication of Joint 4...................................................................................48
4.3 Draining Moisture from the Air Filter...........................................................50
4.4 Joint 4 Overtravel..............................................................................................50
Diagnostic Procedure..................................................................................50
APPENDIX A - FIFTH AXIS OPTION...................................................................53
A.1 Introduction.......................................................................................................53
A.2 Specifications.....................................................................................................53
A.3 Installation.........................................................................................................53
A.4 Operation...........................................................................................................54
Installing End Effectors...............................................................................54
User Electrical Connector...........................................................................55
Programming Information.........................................................................55

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A.5 Maintenance and Troubleshooting................................................................55
Checking Flange Position...........................................................................55
INDEX...........................................................................................................................57
LIST OF FIGURES
Figure 2-1. AdeptThree Robot Joint Locations ...................................................7
Figure 2-2. Joint 1 Motion ......................................................................................8
Figure 2-3. Joint 2 Motion ......................................................................................9
Figure 2-4. Joint 3 and Joint 4 Motion................................................................10
Figure 2-5. Joint 1 Hardstop ................................................................................12
Figure 2-6. Joint 2 Hardstop ................................................................................12
Figure 2-7. Joint 3 Hardstop ................................................................................13
Figure 2-8. Joint 4 Hardstop ................................................................................14
Figure 2-9. Robot base showing brake release button.....................................15
Figure 2-10. Dimensional Overview ....................................................................16
Figure 2-11. AdeptThree Robot Working Envelope ..........................................17
Figure 3-1. AdeptThree with Calibration Fixture.............................................23
Figure 3-2. Mounting Hole Pattern (Robot-to-Plate/Spool)...........................25
Figure 3-3. Mounting Hole Pattern (Plate/Spool-to-Floor)............................25
Figure 3-4. Recommended Mounting Spool Specifications............................26
Figure 3-5. Mounting Plate-to-Floor Installation Detail..................................29
Figure 3-6. Mounting Spool-to-Floor Installation Detail.................................32
Figure 3-7. User Access to Spare Air Lines and Tower Card Location........34
Figure 3-8. Quill Flange Dimensions..................................................................36
Figure 3-9. Clamp-mounted End Effector Installation....................................37
Figure 3-10. Screw-mounted End Effector Installation .....................................38
Figure 3-11. Tower Card User Signal and Voltage Lines..................................42
Figure 4-1. Joint 3 and Joint 4 Lubrication.........................................................49
Figure A-1. Fifth Axis End Effector Mounting Details.....................................54

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LIST OF TABLES
Table 2-1. Softstop and Hardstop Specifications........................................ 14
Table 2-2. Specifications ................................................................................. 18
Table 3-1. Tower PCA Connector Pinouts................................................... 43
Table A-1. Fifth Axis Specifications............................................................... 53
Table A-2. Fifth Axis User Connector Pin Identification............................ 55

1
CHAPTER 1
GENERAL INFORMATION
1.1 This Manual and Related Publications
This manual provides general, installation, and maintenance information
for the AdeptThree robot, also referred to as a Selective Compliance
Assembly Robot Arm, or SCARA.
The following Adept publications are referenced in this manual:
• V and V+Reference Guide
• Instructions for Adept Utility Programs
• Adept MC Controller User's Guide
• Adept CC Controller User's Guide
• User's Guides for options purchased with the robot.
Throughout this manual you will find references to the V or V+operating
system and control language. V+is Adept’s advanced operating system
and control language, which offers additional capabilities over the V
system.
1.2 Notes, Cautions, and Warnings
There are three levels of special notation used in this equipment manual.
In descending order of importance, they are:
WARNING
If the actions indicated in a “WARNING” are not
complied with, injury or major equipment damage could
result. A Warning statement will typically describe the
potential hazard, its possible effect, and the measures that
must be taken to reduce the hazard.

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CAUTION
If the action specified in the “CAUTION” is not complied
with, damaged to your equipment could result.
NOTE
A “NOTE” provides supplementary information,
emphasizes a point or procedure, or to gives a tip for
easier operation.
Orientation
Throughout this text descriptive words such as "right," "left," "top," and
"bottom" will be used to locate items. Whenever these terms appear they
are oriented from the standard operator's position as though facing the
front of the unit, for example, "right" is that portion of the system to the
operator's right, etc.
Controller HIGH POWER Indicator
On the Adept CC controller front panel there is an amber indicator light
labeled HIGH POWER; on the Adept MC controller the same indicator is
labeled ARM POWER. Any reference in this manual to HIGH POWER also
refers to ARM POWER.
1.3 Customer Service Assistance
Service Calls
Adept Technology maintains a fully staffed Customer Service Center at
its headquarters in San Jose, CA. Two dedicated phone lines are
available for service calls only:
[phone] from outside California
[phone] from within California
When calling Customer Service, please have the unit's serial number
available. The serial number is located on the label on the base of the
robot (refer to Figure 2-9).
Training Information
For information regarding Adept Training Courses, please call
[phone].

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Application Information
There is also a dedicated phone line for assistance with applications. For
Applications assistance call [phone].
International Customer Assistance
For information on training, service, or applications, Adept also has a
Customer Service Center in Dortmund, West Germany. The phone
number is: 0231-129081.
1.4 Safety
The AdeptThree robot may move at high speed and exert considerable
force. Like all mechanical systems and most industrial equipment, it
must be treated with respect by both the User and the Operator.
NOTE
This manual follows Robotic Industries Association (RIA)
definitions of "User" as the responsible person or company
and "Operator" as a person who starts, stops, or monitors
robot or workcell operation.
This User's Guide should be read by ALL personnel who operate or
maintain AdeptThree systems, or who work within, or near, the workcell.
We also recommend you read the American National Standard for
Industrial Robot Systems-Safety Requirements, published by the RIA, in
conjunction with the American National Standards Institute (ANSI). The
publication, ANSI/RIA R15.06-1986, contains guidelines for robot system
installation, safeguards, maintenance, testing, start-up, and operator
training. The document is available from:
American National Standards Institute
1430 Broadway
New York, NY 10018
This Guide assumes that the User has successfully completed an Adept
Training Course and has a basic working knowledge of the Adept
system. The User should provide the necessary additional training for
ALL personnel working within or around the workcell.
System Safeguards
Safeguards should be an integral part of robot workcell design, instal-
lation, Operator training, and operating procedures. 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

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that safeguards be in place to prevent personnel from entering the
workcell whenever equipment power is present.
WARNING
Entering the workcell when the Adept controller HIGH
POWER or PROGRAM RUNNING lights are ON could result
in severe injury.
Adept Technology highly recommends the use of workcell safety features
such as light curtains, safety gates, or safety floor mats to prevent access
to the workcell while power is present. Adept Controller systems have
various control features which may aid the user in constructing system
safeguards, including:
• Emergency stop circuitry
• Binary input and output lines
The emergency power-off circuitry in the controller is capable of
switching external power systems, as well as detecting intrusion signals
from safety barriers.
Equipment Safety
All personnel must observe sound safety practices during the operation
and testing of all electrically powered equipment. To avoid injury or
damage to equipment, always remove power by disconnecting the AC
power cord from the source BEFORE attempting ANY repair or upgrade
activity.
WARNING
DO NOT remove or replace any assemblies, subassem-
blies, Printed Circuit Assemblies (PCAs), or components
with primary power present. To avoid possible personnel
injury or equipment damage, always remove power
BEFORE attempting repair or upgrade procedures.

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1.5 Robot Modifications
It is often necessary to make modifications to Adept robots to
successfully integrate them into a workcell. Unfortunately, many
seemingly simple modifications can either cause a robot failure, or reduce
the robot’s performance, reliability, or lifetime. In general, the following
robot modifications will not cause any problems, but may affect robot
performance:
• Attaching tooling, utility boxes, solenoid packs, vacuum pumps,
screwdrivers, cameras, lighting, etc. to the inner link, outer link, or
column. The total weight of such items on any robot should not
exceed 10 pounds.
• 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.
• Modifying robot access covers as long as adequate protection is
provided after the modification. Covers for the quill, inner and outer
links, Joint 2, and the robot signature card may be modified.
If not done properly, the modifications listed below will damage the
robot, reduce system reliability, or shorten the life of the robot. For this
reason, these modifications will void the warranty of any components
that Adept determines were damaged due to the modification. Please
contact Adept Customer Service before attempting any of the following
modifications to determine if the change can be made without causing
problems.
CAUTION
Making any of the modifications outlined below will void
the warranty of any components that Adept determines
were damaged due to the modification. Please contact
Adept Customer Service before attempting any of the
following modifications.
• Modifying any robot harnesses.
• Modifying any drive system components.
• Modifying, including drilling or cutting, any robot casting.
• Modifying any robot electrical component or PC board other than
those explicitly stated in the robot user’s guide.
• Routing additional hoses, air lines, or wires through the robot.

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NOTES

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CHAPTER 2
OVERVIEW
2.1 Description
General
The AdeptThree is a four-axis SCARA robot. Joints 1, 2, and 4 are
rotational and Joint 3 is translational. Refer to Figure 2-1 for an overview
of the robot joint locations. Refer to Figure 2-11 for the operating
envelope and Table 2-2 for specifications.
The AdeptThree is designed to interface with either the Adept MC or the
Adept CC controller. All control and operation of the AdeptThree is
programmed and performed through the selected controller.
Figure 2-1. AdeptThree Robot Joint Locations

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Refer to the User's Guide for your particular controller for explicit
controller operating instructions. Refer to the V and V+Reference Guide
for programming instructions. The optional Manual Control Pendant
(MCP) is required for manually teaching robot locations. Additionally, it
can serve as the sole operator interface to the system.
All physical connections between the AdeptThree robot, its controller,
and the facility are located at the rear of the robot base, as shown in
Figure 2-9.
Joint Motions
Joint 1
Joint 1, also referred to as the "shoulder", provides the rotational
movement of the inner link and the column. Travel of the inner link is
restricted to 300°. (Refer to Figure 2-2.)
Figure 2-2. Joint 1 Motion

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Joint 2
Joint 2, also referred to as the "elbow", is the pivot point between the
inner link and the outer link. Outer link travel is limited by hardstops
located on top of the inner link. Like Joint 1, travel is restricted to a total
of 300°. This motion can be likened to an elbow capable of acting in
either a left- or right-hand configuration. (Refer to Figure 2-3.)
The AdeptThree is capable of attaining a given location utilizing either a
right-hand ("Righty") or left-hand ("Lefty") configuration. However,
when V or V+moves the arm to a location, it must sometimes make
assumptions about which configuration to use. While this generally
produces the result desired by the Programmer, sometimes the system
assumption may differ from the Programmer's expectations. In those
cases, the Programmer must specify (within the program) "Righty" or
"Lefty" operation.
NOTE
For further information concerning right- and left-hand
configuration, refer to the chapter entitled, "Robot
Locations" in your V and V+Reference Guide.
Figure 2-3. Joint 2 Motion

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Joint 3
Joint 3 provides vertical movement of the quill at the end of the outer
link, with a maximum stroke of 12.0 inches (30.5 cm). (Refer to Figure 2-
4.)
Joint 4
Joint 4, also referred to as the “wrist”, provides rotation of the quill over a
range of 540°. This motion is similar to that of the human hand involved
in tightening a bolt or unscrewing a bottle cap. (Refer to Figure 2-4.)
Figure 2-4. Joint 3 and Joint 4 Motion

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Limiting Joint Travel
The joint motion or travel is limited by both software and hardware. The
programmable software limits are known as softstops; the fixed
hardware limits are called hardstops. (See Figures 2-5 to 2-8 and Table 2-
1.)
Softstops
The robot controller uses softstops to determine the range of motion it
will allow the robot to move under program control, or to be moved by
an operator using the manual control pendant. If a robot joint travels
beyond a softstop, the controller will automatically shut off arm power
(high power), thereby activating the brakes. Furthermore, the controller
will not allow the robot power to be turned on while any joint is beyond
its softstop. If this situation occurs, use the brake release button (see the
section on Brakes later in this chapter) and manually move the arm back
within the softstop limits.
Under operator control (using the manual control pendant to move the
robot) the robot will stop very abruptly when it encounters a softstop.
This abruptness is due to the high-torque motors, there is no hardstop at
these locations.
Occasions may arise when it becomes mandatory to limit the travel of
one or more of the joints within the normal working envelope. This can
be easily accomplished by adjusting softstops using the CONFIG_R
utility program, which is supplied with the system.
NOTE
For further information concerning joint travel limitation,
refer to the Instructions for Adept Utility Programs manual
furnished with your system.
Hardstops
In most cases the softstop will prevent joint travel from contacting a
hardstop; however, contact is possible during high-speed operation. The
hardstops are designed to withstand large forces without damaging the
robot.
The hardstops for Joints 1, 2, and 3 are fixed mechanical stops. The
hardstop for Joint 4 is designed to slip slightly if impacted sufficiently. If
the Joint 4 hardstop slips, it should be reset. Refer to the procedure in
Chapter 4 on how to diagnose a slipped Joint 4 hardstop.

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Figure 2-5. Joint 1 Hardstop (Internal to Joint 1 column)
Figure 2-6. Joint 2 Hardstop