Aerotech HexGen HEX500-350HL User manual

Revision 2.01
HexGen®HEX500-350HL Hexapod Six-DOF
Positioning System
HARDWAREMANUAL

GLOBALTECHNICALSUPPORT
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Aerotech, Inc. products. The website supplies software, product manuals, Help files,
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This manual contains proprietary information and may not be reproduced,
disclosed, or used in whole or in part without the express written permission of
Aerotech, Inc. Product names mentioned herein are used for identification purposes
only and may be trademarks of their respective companies.
Copyright © 2016-2023, Aerotech, Inc., All rights reserved.

Table of Contents
HexGen® HEX500-350HL Hexapod Six-DOF Positioning System 1
Table of Contents 3
List of Figures 4
List of Tables 5
EU Declaration of Incorporation 6
UKCADeclaration of Incorporation 7
Safety Procedures and Warnings 8
Installation and Operation 9
Electrical Warnings 10
Motor-Related Warnings 11
Pinch Points 12
Handling and Storage 13
Chapter 1: Overview 17
1.1. Environmental Specifications 18
1.1.1. Accuracy and Temperature Effects 18
1.2. Basic Specifications 19
1.3. Understanding Basic HEX500-350HL Operation 20
1.3.1. Hexapod Axes 20
1.3.2. Strut Limits and Hexapod Range 20
1.3.3. Homing 21
Chapter 2: Mechanical Specifications and Installation 23
2.1. Dimensions 24
2.2. Securing the Hexapod to the Mounting Surface 25
2.3. Attaching the Payload to the HEX500-350HL 27
Chapter 3: Electrical Specifications and Installation 29
3.1. Motor and Feedback Connectors 30
3.2. Motor and Feedback Wiring 33
3.3. Motor and Feedback Specifications 35
3.4. Machine Direction 37
3.5. Feedback Phasing 38
Chapter 4: Maintenance 41
4.1. Service and Inspection Schedule 41
4.2. Cleaning and Lubrication 42
4.3. Troubleshooting 43
Appendix A: Warranty and Field Service 45
Appendix B: Revision History 47
Index 49
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List of Figures
Figure 2-1: Lifting and Shipping Brackets 15
Figure 1-1: HEX500-350HL Callouts 17
Figure 1-2: Axis Orientation 20
Figure 2-1: HEX500-350HL Dimensions 24
Figure 2-2: Mounting Hole Locations 26
Figure 2-3: HEX500-350HL Vertical Load Capabilities 27
Figure 2-4: HEX500-350HL Horizontal Load Capabilities 28
Figure 2-5: HEX500-350HL Inverted Load Capabilities 28
Figure 3-1: Motor and Feedback Wiring (-E2 Connector) 33
Figure 3-2: Motor and Feedback Wiring (-E3 Connector) 34
Figure 3-3: Machine Direction 37
Figure 3-4: Hall Phasing 38
Figure 3-5: Encoder Phasing Reference Diagram (Standard) 39
Figure 4-1: Ball Joint Location 43
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List of Tables
Table 1-1: Model Options 17
Table 1-2: Environmental Specifications 18
Table 1-3: HEX500-350HL Series Specifications 19
Table 2-1: Hexapod to Mounting Surface Hardware 26
Table 3-1: -E2 Option Motor and Feedback Pinout 31
Table 3-2: Mating Connector Part Numbers 31
Table 3-3: -E3 Option Motor and Feedback Pinout 32
Table 3-4: Mating Connector Part Numbers 32
Table 3-5: Hall-Effect Sensor Specifications 35
Table 3-6: Thermistor Specifications 35
Table 3-7: Encoder Specifications 35
Table 3-8: Rotary Encoder Resolution 35
Table 3-9: Linear Encoder Resolution (-E2 Option) 35
Table 3-10: Limit Switch Specifications 35
Table 3-11: HEX500-350HL Motor Specifications 36
Table 4-1: Grease Specifications 42
Table 4-2: Troubleshooting 43
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EU Declaration of Incorporation
Manufacturer Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
herewith declares that the product:
HEX500-350HL hexapod
is intended to be incorporated into machinery to constitute machinery covered by the Directive 2006/42/EC
as amended; and that the following harmonized European standards have been applied:
EN ISO 12100:2010
Safety of Machinery - Basic concepts, general principles for design
EN 60204-1:2010
Safety of Machinery - Electrical equipment of machines - Part 1:General
requirements
and further more declares that
it is not allowed to put the equipment into service until the machinery into which it is to
be incorporated or of which it is to be a component has been found and declared to
be in conformity with the provisions of the Directive 2006/42/EC and with national
implementing legislation, for example, as a whole, including the equipment referred
to in this Declaration.
This is to certify that the aforementioned product is in accordance with the applicable requirements
of the following directive(s):
EU 2015/863 Directive, Restricted Substances (RoHS 3)
Authorized
Representative: / Norbert Ludwig
Managing Director
Aerotech GmbH
Gustav-Weißkopf-Str.18
90768 Fürth
Germany
Engineer Verifying
Compliance / Alex Weibel
Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Date 3/30/2023
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UKCADeclaration of Incorporation
Manufacturer Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
herewith declares that the product:
HEX500-350HL hexapod
To which this declaration relates, meets the essential health and safety requirements and is in
conformity with the relevant UK Legislation listed below:
Supply of Machinery (Safety) Regulations 2008
Hazardous Substances in Electrical and Electronic Equipment Regulations
2012
Using the relevant section of the following UK Designated Standards and other normative
documents when installed in accordance with the installation instructions supplied by the
manufacturer.
EN ISO 12100:2010
Safety of Machinery - Basic concepts, general principles for design
EN 60204-1:2010
Safety of Machinery - Electrical equipment of machines - Part 1:General
requirements
and furthermore declares that it is not allowed to put the product into service until the machinery
into which it is to be incorporated or of which it is to be a component has been found and declared
to be in conformity with the provisions of the Supply of Machinery (Safety) Regulations 2008 UK
Legislation and with national implementing legislation, for example, as a whole, including the
equipment referred to in this Declaration.
Authorized
Representative: / Simon Smith
Managing Director
Aerotech Ltd
The Old Brick Kiln, Ramsdell, Tadley
Hampshire RG26 5PR
UK
Engineer Verifying
Compliance / Alex Weibel
Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
Date 3/30/2023
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Safety Procedures and Warnings
IMPORTANT: This manual tells you how to carefully and correctly use and operate the
hexapod.
lRead all parts of this manual before you install or operate the hexapod or before you
do maintenance to your system.
lTo prevent injury to you and damage to the equipment, obey the precautions in this
manual.
lAll specifications and illustrations are for reference only and were complete and
accurate as of the release of this manual. To find the newest information about this
product, refer to www.aerotech.com.
If you do not understand the information in this manual, contact Aerotech Global
Technical Support.
IMPORTANT: This product has been designed for light industrial manufacturing or
laboratory environments. If the product is used in a manner not specified by the
manufacturer:
lThe protection provided by the equipment could be impaired.
lThe life expectancy of the product could be decreased.
Safety notes and symbols are placed throughout this manual to warn you of the potential risks at the
moment of the safety note or if you fail to obey the safety note.
Shock/Electrocution Hazard Pinch, Shear, or Crush Hazard
General/Conditional Awareness Rotational Machinery Hazard
Hot Surface Hazard Pinch/Entanglement Hazard
Magnetic Field Hazard Trip Hazard
Heavy, Bulky Lifting Hazard Appropriate Equipment Required
Pressure/Explosive Atmosphere
Hazard Electrostatic Discharge Hazard
A blue circle symbol is an action or tip that you should obey. Some examples include:
General tip Read the manual/section
Wear personal protective equipment
(PPE): Safety Glasses If applicable, do not lift unassisted
Wear personal protective equipment
(PPE): Gloves
Wear personal protective equipment
(PPE): Hearing Protection
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Installation and Operation
To decrease the risk of damage to the equipment, you must obey the precautions that follow.
DANGER: General Hazard Warning!
This product can produce high forces and move at velocities that could cause injury.
The user is responsible for its safe operation. The following general equation is
provided to assist with risk assessments in regards to contact and pinch points:
WARNING: General Hazard Warning!
lOnly trained operators should operate this equipment.
lAll service and maintenance must be done by approved personnel.
lUse this product only in environments and operating conditions that are approved in
this manual.
lNever install or operate equipment that appears to be damaged.
lMake sure that the product is securely mounted before you operate it.
lUse care when you move the HEX500-350HL or you could negatively affect the per-
formance of it.
WARNING:Trip Hazard!
Route, house, and secure all cables, duct work, air, or water lines. Failure to do so could
introduce trip hazards around the system that could result in physical injury or could
damage the equipment.
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Electrical Warnings
To decrease the risk of electrical shock, injury, death, and damage to the equipment, obey the
precautions that follow.
DANGER: Electrical Shock Hazard!
lStage motor phase voltage levels could be hazardous live.
lPersonnel are protected from hazardous voltages unless electrical interconnections,
protective bonding (safety ground), or motor/stage enclosures are compromised.
lDo not connect or disconnect stage/motor interconnections while connected to a live
electrical power source.
lBefore you set up or do maintenance, disconnect electrical power.
lIt is the responsibility of the End User/System Integrator to make sure that stages are
properly connected and grounded per Engineering Standards and applicable safety
requirements.
lIt is the responsibility of the End User/System Integrator to configure the system
drive or controller within the Aerotech motor/stage electrical and mechanical
specifications.
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Motor-Related Warnings
Aerotech motors are capable of producing high forces and velocities. Obey all warnings and all
applicable codes and standards when you operate a system that incorporates Aerotech motors.
DANGER: Mechanical Hazard!
Personnel must be made aware of the mechanical hazards during set up or when you
do service to the stage.
lUnintentional manual movement into the stage "end-of-travel" stops, could damage
the stage or undo precision alignments.
lStage movement could create pinch points, entanglement hazards, or rotational
mechanical hazards.
DANGER: Hot Surface Hazard!
lThe stage/motor frame temperature could exceed 70°C in some applications.
lDo not touch the stage/motor frame while it is in operation.
lWait until the stage/motor has cooled before you touch it.
Figure 1: Motor Location
DANGER:Risk of Explosive Atmosphere!
lStandard Aerotech stage/motors are not rated for applications with explosive
atmospheres such as airborne dust or combustible vapors.
lDo not operate stage/motors outside of Aerotech environmental specifications.
DANGER: Magnetic Field Hazard!
Aerotech stage/motors contain magnets which can present a Magnetic Field Hazard.
lDo not disassemble a stage motor under any circumstances.
lStrong magnetic fields could interfere with external/internal medical devices.
lStrong magnetic fields could present mechanical hazards such as pinch points.
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Pinch Points
A pinch point is a mechanical hazard that can occur when there are exposed parts of the stage or
system that can move. For example, the travel of a stage tabletop could expose the user to a pinch
point between the tabletop and a strut. The images that follow will show you typical external and
internal pinch point locations.
DANGER: Mechanical Hazard!
lSystem travel can cause crush, shear, or pinch injuries.
lOnly trained operators should operate this equipment.
lDo not put yourself in the travel path of machinery.
lRestrict access to all motor and stage parts
owhen the system moves under power (during normal operation, for example).
owhen the system is moved manually (during the installation process or when you
do maintenance, for example).
lMotors are capable of very high speeds and acceleration rates.
Figure 2: Typical Pinch Point Locations
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Handling and Storage
IMPORTANT: It is the responsibility of the customer to safely and carefully lift and
move the hexapod.
lBe careful when you move or transport the hexapod.
lRetain the shipping materials for future use.
lTransport or store the hexapod in its protective packaging.
WARNING: Electrostatic Discharge (ESD) Sensitive Components!
Wear an ESDwrist strap when you handle, install, or do service to the system assembly.
You could damage the power supply or drives if you fail to observe the correct
ESDpractices.
Inspect the shipping container for any evidence of shipping damage. If any damage exists, notify the
shipping carrier immediately.
Remove the packing list from the shipping container. Make sure that all the items specified on the
packing list are contained within the package.
The documentation for the hexapod is on the included installation device. The documents include
manuals, interconnection drawings, and other documentation pertaining to the system. Save this
information for future reference.
Unpacking and Handling
It is the responsibility of the customer to safely and carefully lift and move the hexapod.
IMPORTANT: All electronic equipment and instrumentation is wrapped in antistatic
material and packaged with desiccant. Ensure that the antistatic material is not
damaged during unpacking.
DANGER:Lifting Hazard! Use care when you move the HEX500-350HL or you could
negatively affect the performance of it.
lUse the correct lifting techniques, mechanical assistance, or additional help to lift or
move this product.
lMake sure that all moving parts are secure before you move the hexapod. Unse-
cured moving parts could shift and cause injury or damage to the equipment.
lDo NOT use the struts or joints as lift points.
lDo not manually lift and move the HEX500-350HL.
lDo not use the cables to lift or move the hexapod.
lIf the hexapod is heavy, a single person lift could cause injury. Use assistance when
you lift or move it.
oRefer to Section 2.1. for dimensions
oRefer to Section 1.2. for mass specifications.
Carefully remove the hexapod from its protective shipping container.
lUse lifting straps fed through the lifting rings of the shipping brackets (refer to Figure 2-1).
lIf necessary, use a cart, dolly, or similar device to move the stage to a new location.
lGently set the hexapod on a smooth, flat, and clean surface.
lUse compressed nitrogen or clean, dry, oil-free air to remove any dust or debris that has collected
during shipping.
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lLet the hexapod stabilize at room temperature for at least 12 hours to make sure that all of the
alignments, preloads, and tolerances are the same as they were when they were tested at Aero-
tech.
lRemove the shipping brackets before you operate the hexapod. Retain them for future use.
Each HEX500-350HL has a label that lists the system part number and serial number. These numbers
are necessary to maintain or update system hardware and software. Locate this label and record the
information for later reference.
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Shipping Brackets
Red, anodized aluminum shipping brackets have been installed to prevent unwanted motion and
potential damage that could occur during shipment. You must remove the brackets before the
HEX500-350HL can be operated. Retain the brackets and hardware for future use.
DANGER: Mechanical Hazard!
lThe product can move manually without electrical power connected.
lWhen the shipping brackets are removed, the operator could be exposed to pinch
points.
Figure 2-1: Lifting and Shipping Brackets
Storage
Store the hexapod in the original shipping container. If the original packaging included
ESDprotective packaging, make sure to store the hexapod in it. The storage location must be dry,
free of dust, free of vibrations, and flat.
Refer to Section 1.1. Environmental Specifications
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Chapter 1: Overview
The base of a hexapod has a flat mounting surface on the bottom and holds electronics for the
hexapod. The base should be mounted to a flat, rigid mounting surface (refer to Section 2.2.). The
base joints allow the attached strut to pivot from the base.
The platform is the moving plate of a hexapod. The threaded holes on the top surface are designed
to hold customer equipment (refer to Section 2.3.). The platform joints allow the attached strut to
pivot from the platform.
The six struts of a hexapod change length in order to control the position of the platform. The struts
attach only to the joints of the base and platform.
The cables exit out of the back of the base. These six cables connect the hexapod to the controller
(refer to the Section 3.2.).
Figure 1-1: HEX500-350HL Callouts
Table 1-1: Model Options
HexGen®HEX500-350HL Hexapod 6-DOF Positioning System
HEX500-350HL Six degree-of-freedom hexapod positioning system; 500 mm diameter base;
300 mm height at mid-travel; high-load capacity version
Feedback (Required)
-E2 Incremental encoders
-E3 Absolute encoders
Performance Grade (Optional)
-PL3 Base performance
-PL4 Ultra high-accuracy performance
Customization
Additional customization may be available (Vacuum preparation, custom geometry, etc.). Contact
Aerotech for details.
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1.1. Environmental Specifications
WARNING: Use this product only in environments and operating conditions that are
approved in this manual.
Table 1-2: Environmental Specifications
Ambient
Temperature
Operating: 10° to 35° C (50° to 95° F)
Deviation in temperature can result in performance degradation.
Storage: 0° to 40° C (32° to 104° F) in original shipping packaging
Humidity
Operating: 20% to 60% RH
Storage: 10% to 70% RH, non-condensing in original packaging. The machine
should be packaged with desiccant if it is to be stored for an extended time.
Altitude
Operating: 0 m to 2,000 m (0 ft to 6,562 ft) above sea level
Contact Aerotech if your specific application involves use above 2,000 m or below
sea level.
Vibration
Use the system in a low vibration environment. Excessive floor or acoustical
vibration can affect system performance. Contact Aerotech for information
regarding your specific application.
Protection
Rating
Not suited for dusty or wet environments (IP30 equivalent ingress protection
rating).
Use Indoor use only.
1.1.1. Accuracy and Temperature Effects
Aerotech products are designed for and built in a 20°C environment. Moderate temperature
changes will affect the accuracy while extreme temperature changes could cause damage to the
machine. At a minimum, the environmental temperature must be controlled to within 1°C per hour
to ensure the safety of the hexapod. The severity of temperature effects on all specifications
depends on many different environmental conditions, including how the hexapod is mounted.
Contact the factory for more details.
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1.2. Basic Specifications
Table 1-3: HEX500-350HL Series Specifications
X Y Z A (θx) B (θy) C (θz)
Travel (1) 100 mm 110 mm 54 mm 22° 22° 40°
Axis
Positioning
Accuracy
(2,3)
Full
Travel
Standard (-
PL3) ±4 μm ±4 μm ±3 μm
±50 μrad
(±10.3
arc-sec)
±50 μrad
(±10.3
arc-sec)
±25 μrad
(±5.2 arc-
sec)
ULTRA
(-PL4) ±1 μm ±1 μm ±0.75 μm
±10 μrad
(±2.1 arc-
sec)
±10 μrad
(±2.1 arc-
sec)
±5 μrad
(±1.0 arc-
sec)
Limited
Travel
(7)
Standard (-
PL3) ±1.25 μm
±12.5
μrad
(±2.6 arc-
sec)
±12.5
μrad
(±2.6 arc-
sec)
±7.5 μrad
(±1.5 arc-
sec)
ULTRA
(-PL4) ±0.75 μm ±0.75 μm ±0.5 μm
±5 μrad
(±1.0 arc-
sec)
±5 μrad
(±1.0 arc-
sec)
±2.5 μrad
(±0.5 arc-
sec)
Resolution
(Minimum Incremental Motion) 20 nm 0.2 μrad (0.04 arc sec)
Bidirectional
Repeatability, pk-pk(3) ±0.6 μm ±0.6 μm ±0.35 μm ±1 μrad (±0.2 arc sec)
Unidirectional
Repeatability, pk-pk ±0.25 μm ±0.25 μm ±0.15 μm ±0.5 μrad (±0.1 arc sec)
Maximum Speed (4) 50 mm/s 50 mm/s 25 mm/s 10 °/s 10 °/s 20 °/s
Load Capacity,
All Positions (5)
Vertical 200 kg (Push); 120 kg (Pull)
Horizontal 35 kg
Holding Capacity,
De-Energized (6) 165 kg
Stage Mass 49 kg
Material Anodized Aluminum Platform and Base;
Steel Used in Joints and Inside Struts
1. Travels are mutually-exclusive. Consult the HexGen®Hexapod Sizer on the Aerotech website for detailed workspace
sizing.
2. Measured with single-axis moves at a height of 50 mm above the moving platform. Results can be payload and workpoint
dependent.
3. X, Y, Z performance certified as standard. X, Y, Z, A, B, C performance certified with -PL4.
4. Requires the selection of an appropriate amplifier with sufficient voltage and current.
5. Centered loading (refer to Section 2.3.).
6. Horizontal base plate, centered loading (refer to Section 2.3.).
7. Over any 20 mm (X, Y, Z) or 5° (A, B, C)
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1.3. Understanding Basic HEX500-350HL Operation
1.3.1. Hexapod Axes
The hexapod platform can be actuated in six degrees of freedom by changing the lengths of the six
struts that connect the platform to the base. Since the axes of motion are not obvious from the
mechanics of the hexapod, the axis convention is outlined below. These axes can be used to orient
the hexapod in the global workspace. Refer to the HexGen®Programming Guide for more
information about controlling hexapod motion. To get a copy of this guide, go to the Resources
section of www.aerotech.com. Select the Manuals and Help Files tab. Then download Hexapod
Programming User Guide from the User Guides category.
The six axes include 3 translational axes, X, Y, and Z, and 3 rotational axes, A, B, and C. As shown in
the overview, the cables exit out of the back of the base. The positive direction of the X axis goes to
the right when looking at the front of the hexapod, and the Z axis goes up vertically. The Y axis goes
toward the back of the hexapod. Rotational axes are oriented in the same direction as the
translational axes, and positive rotation is clockwise when looking in the direction of the axis. The A
axis rotates about the X axis, B rotates about the Y axis, and C rotates about Z. The control software
enables the user to customize the coordinate system with certain restrictions. Please refer to the
HexGen Programming guide for details regarding coordinate system manipulation.
Figure 1-2: Axis Orientation
1.3.2. Strut Limits and Hexapod Range
Limits on the strut keep the strut within the useable travel range. When any strut has reached the
end of travel in either direction, an error will occur in the controller. Because the ranges of the
hexapod axes are interdependent, the limits of the hexapod axes are not constant, and the range of
motion of a hexapod cannot be concisely described. Refer to Section 1.2. for the independent travel
of each hexapod axis and the strut travel. If a strut limit is triggered, the hexapod is out of range. In
this case, follow the directions of the controller to return the hexapod to a position within the range
of motion. Refer to the HexGen®Programming Guide for more information.
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