Omron Hornet 565 User manual

I596-E-03
Hornet 565 Robot
User’s Guide

Copyright Notice
The information contained herein is the property of Omron Adept Technologies, Inc., and shall not be
reproduced in whole or in part without prior written approval of Omron Adept Technologies, Inc. The
information herein is subject to change without notice and should not be construed as a commitment by
Omron Adept Technologies, Inc. The documentation is periodically reviewed and revised.
Omron Adept Technologies, Inc., assumes no responsibility for any errors or omissions in the doc-
umentation. Critical evaluation of the documentation by the user is welcomed. Your comments assist us
in preparation of future documentation. Please submit your comments to: [e-mail].
Copyright 2015 - 2017 by Omron Adept Technologies, Inc. All rights reserved.
Any trademarks from other companies used in this publication
are the property of those respective companies.
Created in the United States of America

Hornet 565 Robot User's Guide, 14608-000 Rev F
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Revision History
Revision
code Date Revised Content
01 June,
2016
Original release
02 January,
2016
Updated graphics with platform oriented correctly, showing current
drive shaft. Updated to OAT logo on status panel, front panel. Updated
safety chapter, minor changes to stopping distance graph section in
Technical Specifications. Fixed rotation of tool flange in Fig. 5-2, added
graphic for J4 alignment.
03 July,
2017
Updated drawing of tool flange to show 41.14 mm pilot bore that was
added since original release.

Table of Contents
Chapter 1: Introduction 11
1.1 Hornet 565, Product Description 11
eAIB Amplifier 11
Hornet 565 Base 12
Inner Arms 12
Ball Joints, Outer Arms 13
Platforms 13
SmartController EX 15
1.2 Installation Overview 16
1.3 How Can I Get Help? 17
Corporate Addresses 17
Related Manuals 17
Chapter 2: Safety 19
2.1 Warnings, Cautions, and Precautions 19
2.2 What to Do in an Emergency/Abnormal Situation 19
Stopping the Robot 19
Fire Response 19
Entrapment and Brake Release Button 20
2.3 Safety Precautions 20
2.4 Robot Behavior 21
Hardstops 21
Limiting Devices 21
Singularities 21
2.5 Intended Use of the Robots 21
2.6 Additional Safety Information 21
Manufacturer’s Declaration of Incorporation 22
Robot Safety Guide 22
Emergency Stop Circuit and Buttons 22
Manual Control Pendant 22
Chapter 3: Robot Installation 23
3.1 Transport and Storage 23
3.2 Unpacking and Inspecting the Hornet 565 23
Before Unpacking 23
Upon Unpacking 23
Unpacking 23
3.3 Repacking for Relocation 25
3.4 Environmental and Facility Requirements 25
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Table of Contents
3.5 Mounting Frame 25
Robot-to-Frame Considerations 26
Mounting 26
3.6 Mounting the Robot Base 27
Robot Orientation 27
Mounting Surfaces 27
Mounting Procedure 27
Install Mounting Hardware 28
3.7 Attaching the Outer Arms, Platform, and Theta Drive Shaft 29
Aligning the Platform with the Base 29
Attaching the Outer Arms 30
Attaching the Theta Drive Shaft 34
3.8 Mounting the Front Panel 35
3.9 End-Effectors 35
Attaching an End-Effector 35
Aligning an End-Effector 35
Grounding 36
Accessing Vacuum 36
Routing End-effector Lines 36
Chapter 4: System Installation 39
4.1 System Cables, eAIB Only (no SmartController EX) 39
List of Cables and Parts 40
Cable Installation Overview 41
Optional Cables 42
4.2 System Cables, with SmartController EX 43
Installing a SmartController EX Motion Controller 43
List of Cables and Parts 44
Cable Installation Overview 45
Less Common Cables 45
4.3 System Cables for Systems with Belt Encoders 46
List of Cables and Parts 46
Cable Installation Overview 47
Pinouts for eAIB XBELT IO Adapter 48
4.4 ACE Software 49
User-supplied PC 49
Installing ACESoftware 49
4.5 Robot Interface Panel 50
4.6 Connecting 24 VDC Power to Robot 51
Specifications for 24 VDC Robot and Controller Power 51
Details for 24 VDC Mating Connector 51
Procedure for Creating 24 VDC Cable 52
Installing 24 VDC Robot Cable 52
4.7 Connecting 200-240 VAC Power to Robot 53
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Table of Contents
Specifications for AC Power 54
Details for AC Mating Connector 56
Procedure for Creating 200-240 VAC Cable 56
Installing AC Power Cable to Robot 57
4.8 Grounding the Hornet 565 57
Grounding Robot-Mounted Equipment 57
Grounding Robot Base to Frame 58
4.9 Installing User-Supplied Safety Equipment 59
Emergency Stop Circuits 63
Remote Manual Mode 65
User Manual/Auto Indication 65
User High Power On Indication 65
Remote High Power On/Off Control 65
High Power On/Off Lamp 66
Remote Front Panel or User-Supplied Control Panel Usage 66
Remote Pendant Usage 67
Chapter 5: System Operation 69
5.1 Robot Status Display Panel 69
5.2 Status Panel Fault Codes 70
5.3 Using the Brake-Release Button 70
Robot Brakes 70
Brake-Release Button 71
5.4 Optional Front Panel 72
5.5 Connecting Digital I/O to the System 74
I/O on the eAIB 74
I/O with an Optional SmartController EX 74
5.6 Using Digital I/O on eAIB XIO Connector 76
Optional I/O Products 78
XIO Input Signals 78
XIO Output Signals 80
XIO Breakout Cable 82
5.7 Starting the System for the First Time 84
Verifying Installation 84
Turning on Power and Starting ACE 85
Enabling High Power 86
Verifying E-Stop Functions 86
Aligning the Platform and J4 Motor 86
Verify Robot Motions 87
5.8 Robot Motions 88
Straight-line Motion 88
Containment Obstacles 88
5.9 Learning to Program the Hornet 565 88
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Table of Contents
Chapter 6: Options 89
6.1 Tall Frame Adapters 89
6.2 ePLC Connect 90
Configuration 90
Setting the Robot IP Address 90
Configuring the Omron PLC 92
Enabling High Power 92
6.3 SmartVision MX Industrial PC 92
6.4 SmartController EX Motion Controller 92
6.5 sDIO Module 92
6.6 IOBlox I/ODevice 92
6.7 eAIB XBELT IOAdapter Cable 92
6.8 Cable Inlet Box 93
Overview 93
Installation Procedure 94
6.9 Intelligent Force Sensor 99
6.10 Ball Stud Locks 99
Installing a Ball Stud Lock 100
Removing a Ball Stud Lock 101
Chapter 7: Maintenance 103
7.1 Cleaning 103
Water Shedding 103
Wash-Down 103
Chemical Compatibility 104
7.2 Periodic Maintenance Schedule 104
7.3 Checking Labels 106
Warning Labels 106
Informative Labels 107
7.4 Checking Safety Systems 107
7.5 Checking Robot Mounting Bolts 108
7.6 Checking for Gear Drive Oil Leakage 108
7.7 Checking Fan Operation 109
7.8 Theta Drive Shaft 110
Replacing the Drive Shaft Bushings 110
Removing the Drive Shaft 113
Installing a Drive Shaft 114
Aligning the Platform and J4 Motor 115
7.9 Replacing the Encoder Battery Pack 115
7.10 Non-Periodic Maintenance 118
7.11 Changing the Front Panel High-Power Indicator Lamp 118
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Table of Contents
7.12 Replacing a Platform 120
7.13 Replacing a Ball Joint Insert 120
7.14 Replacing Outer Arm Spring Assemblies 120
7.15 Replacing the eAIB Chassis 124
Removing the eAIB Chassis 124
Installing a New eAIB Chassis 128
7.16 Commissioning a System with an eAIB 128
Safety Commissioning Utilities 129
E-Stop Configuration Utility 130
E-Stop Verification Utility 131
Teach Restrict Configuration Utility 131
Teach Restrict Verification Utility 132
Chapter 8: Technical Specifications 135
8.1 Dimension Drawings 135
8.2 Robot Specifications 139
8.3 Environmental Specifications 139
Operating 139
Shipping and Storage 139
8.4 Payload Specifications 140
Payload 140
Torque 140
8.5 Performance 141
Repeatability, Unidirectional 141
Cycle Times 141
Power Consumption 141
Stopping Time and Distance 142
Payload Mass vs. Acceleration 148
Payload Inertia vs. Acceleration 148
8.6 Robot Mounting Frame 149
Chapter 9: Environmental Concerns 155
9.1 Ambient Environment 155
9.2 Cleanroom Classification 155
9.3 Design Factors 155
Robot Base and Components 156
Inner Arms 156
Ball Joints 156
Outer Arms 156
Spring Assemblies 157
Platforms 157
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Chapter 1: Introduction
1.1 Hornet 565, Product Description
The Hornet 565 is a three-arm parallel robot. The three identical arm motors control movement
of the robot tool in X, Y, and Z directions. On the four-motor model, a fourth motor on the
robot base turns a telescoping drive shaft, which provides theta rotation of the tool flange
through a geared platform.
The Hornet 565 is available in two models. One has a J4 platform, a theta motor and theta
drive shaft. This provides ±360° of rotation at the tool flange. The other model has a fixed plat-
form with no tool flange rotation.
Joint 3
eAIB
Robot
Base
Tool Flange
Platform
and Ball
Joints
Theta
Drive
Shaft
Ball Joints,
Joint 1
Outer Arms
Status Display Panel
Joint 4
Cover
Robot Base
Cover
Inner Arm
Motor Plug
Mounting Pad
x3
Joint 2
Inner Arm
(Spring Assemblies
not shown)
Figure 1-1. Major Robot Components
eAIB Amplifier
The Hornet 565 uses an eAIB amplifier. The robot is powered and controlled using the eAIB.
The amplifiers and full servo control for the Hornet 565 are contained in the eAIB, which is

Chapter 1: Introduction
embedded in the base of the robot. The eAIB also provides the platform for running the eV+ OS
and language.
The eAIB features:
lOn-board digital I/O: 12 inputs, 8 outputs
lLow EMI for use with noise-sensitive equipment
lNo external fan for quiet operation
l8 kHz servo rate to deliver low positional errors and superior path following
lSine-wave commutation to lower cogging torque and improve path following
lDigital feed-forward design to maximize efficiency, torque, and velocity
lTemperature sensors on all amplifiers and motors for maximum reliability and easy
troubleshooting
lHardware-based E-Stop and Teach Restrict controls
For improved safety relative to European standards implemented in 2012.
Figure 1-2. eAIB
Hornet 565 Base
The Hornet 565 base is an aluminum casting that houses the four or three drive motors, and
supports the eAIB. It provides three mounting pads for attaching the base to a rigid support
frame. The Status Display panel is mounted on the side of the robot base.
Inner Arms
Three robot motors attach directly to the inner arms through high-performance gear reducers. If
the robot has a theta rotation motor, it is mounted at the top of the robot base. The following
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Chapter 1: Introduction
figure shows an inner arm from a Hornet 565. RIA-compliant hard stops limit the inner arm
motion to -53° and +114.6°.
Ball Joints, Outer Arms
The inner arm motion is transmitted to the platform through the outer arms, which are con-
nected between the inner arms and platform with precision ball joints. The outer arms are car-
bon fiber epoxied assemblies with identical ball joint sockets at each end. A bearing insert in
each socket accepts the ball joint studs on the inner arms and platform, and allows for approx-
imately ± 60° of relative motion. No ball joint lubrication is required.
Inner
Arm
Ball Joint
Socket
Ball Joint
Socket Insert
Outer Arm Springs Spring
Horseshoe
Pressed Pin
Ball Joint Stud
Outer Arms
Figure 1-3. Ball Joint Assembly
Each pair of outer arms is held together with spring assemblies that pre-tension the ball joints.
The outer arms can be installed and removed without tools.
Platforms
The platform converts the motion of the Hornet 565 motors into Cartesian motion, and, for the
four-motor version, theta rotation of the robot tool flange.
The fixed platform, with no theta rotation, is stainless steel.
The J4 platform has a fourth motor, theta drive shaft, and geared J4 platform that can rotate its
tool flange ±360°. The platform is electroless-nickel-plated aluminum.
Both platforms have a 38 mm hole through their center, for users to route air lines or electric
cables to the tool flange.
For the J4 version of the Hornet 565, a stainless steel theta drive shaft attaches to a U-joint at
both the platform and the J4 motor on the robot.
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Chapter 1: Introduction
Figure 1-4. J4 Platform (Electroless Nickel-plated Aluminum)
Figure 1-5. Fixed Platform (Stainless Steel)
Platform Clocking
The J4 platform, which is rotational, is constructed such that the clocking, or rotational align-
ment, of the platform relative to the robot base is critical. This is detailed in Aligning the Plat-
form with the Base on page 29.
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Chapter 1: Introduction
Platform Shipping
lThe platform, outer arms, and theta drive shaft are removed.
lThe platform is shipped assembled as a unit.
You will need to connect the outer arms between the inner arms and the platform to
reassemble the robot. The outer-arm assemblies are interchangeable.
For the Hornet 565 with the J4 platform, you will also have to connect the telescoping
drive shaft that connects the platform to the fourth motor on the robot base.
Any end-effectors and their air lines and wiring are user-supplied.
SmartController EX
The optional SmartController EXmotion controller supports tracking more conveyors, as well
as other options. Like the eAIB, the SmartController EX uses the eV+ operating system. It offers
scalability and support for IEEE 1394-based digital I/O and general motion expansion mod-
ules. The SmartController EX also includes Fast Ethernet and DeviceNet.
Figure 1-6. SmartController EX
Refer to the SmartController EX User’s Guide for SmartController specifications.
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Chapter 1: Introduction
1.2 Installation Overview
The system installation process is summarized in the following table. Also, refer to System
Installation on page 39.
NOTE:For dual-robot installations, see the Dual-Robot Configuration Procedure,
which is available in the Document Library.
Table 1-1. Installation Overview
Task to be Performed Reference Location
If purchased, mount the optional cable box. Options on page 89.
Mount the robot to a level, stable mounting frame. Mounting on page 26.
Attach the robot outer arms and platform. Attaching the Outer Arms on page
30.
Attach the theta drive shaft, for the J4 platform. Attaching the Theta Drive Shaft on
page 34.
Install the Front Panel and Pendant, if purchased,
and ACE software.
System Cables, eAIB Only (no
SmartController EX) on page 39 and
ACE Software on page 49.
Create a 24 VDC cable and connect it between the
robot and the user-supplied 24 VDC power supply.
Procedure for Creating 24 VDC Cable
on page 52.
Create a 200-240 VAC cable and connect it between
the robot and the facility AC power source.
Connecting 200-240 VAC Power to
Robot on page 53.
Install user-supplied safety barriers in the workcell. Installing User-Supplied Safety
Equipment on page 59.
Connect digital I/O through the robot XIO connector. Using Digital I/O on eAIB XIO Con-
nector on page 76.
Start the system, including system operation testing. Starting the System for the First Time
on page 84.
Install optional equipment, including end-effectors,
user air and electrical lines, external equipment, etc.
Options on page 89.
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Chapter 1: Introduction
1.3 How Can I Get Help?
Refer to the corporate websites:
http://www.ia.omron.com
and
http://www.adept.com
Corporate Addresses
Omron Adept Technologies, Inc.
4550 Norris Canyon Road, Suite 150
San Ramon, CA 94583
USA
925 245-3400
Omron Corporate Headquarters
Shiokoji Horikawa, Shimogyo-ku, Kyoto 600-8530 Japan
TEL: [phone] FAX: [phone]
Related Manuals
This manual covers the installation, operation, and maintenance of a Hornet 565 system.
There are additional manuals that cover programming the system and adding optional com-
ponents. See the following table. These manuals are available on the software media shipped
with each system.
Table 1-2. Related Manuals
Manual Title Description
Robot Safety Guide Contains safety information for our robots.
A printed copy of this guide ships with each robot.
ACE User’s Guide Describes the installation and use of ACE.
T20 Pendant User's Guide Describes the use of the optional T20 manual control pendant.
SmartController EX User’s
Guide
Contains complete information on the installation and oper-
ation of the optional SmartController EX and sDIO products.
SmartVision MX User's
Guide
Instructions for use of the optional SmartVision MX industrial
PC.
ePLC Connect 3 User’s Guide Describes the installation and use of the ePLC Connect 3 soft-
ware, for using a user-supplied PLC as controller.
IO Blox User’s Guide Describes the IOBlox product.
Dual-Robot Configuration
Procedure
Contains cable diagrams and configuration procedures for a
dual-robot system.
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Chapter 2: Safety
2.1 Warnings, Cautions, and Precautions
There are six levels of special alert notation used in our manuals. In descending order of
importance, they are:
DANGER: This indicates an imminently hazardous electrical situation which,
if not avoided, will result in death or serious injury.
DANGER: This indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING: This indicates a potentially hazardous electrical situation which,
if not avoided, could result in injury or major damage to the equipment.
WARNING: This indicates a potentially hazardous situation which, if not
avoided, could result in injury or major damage to the equipment.
CAUTION: This indicates a situation which, if not avoided, could result in
damage to the equipment.
Precautions for Safe Use: This gives precautions on what to do and what not
to do to ensure safe product use.
2.2 What To Do in an Emergency/Abnormal Situation
Stopping the Robot
Press any E-Stop button (a red push-button on a yellow background) and then follow the
internal procedures of your company or organization for an emergency situation.
Fire Response
If a fire occurs, use CO2to extinguish the fire.

Chapter 2: Safety
Entrapment and Brake Release Button
In case of entrapment of a person by the robot, or any other emergency or abnormal situation,
the robot can be manually moved to a safe state without high voltage electric power. Arms 1
through 3 are held by brakes, which can only be released with the brake release button. This
requires 24 V power to the robot.
DANGER: Hornet 565s are not collaborative robots. They require a dedicated
work area that will prevent personnel from coming into contact with them dur-
ing operation.
2.3 Safety Precautions
DANGER: During maintenance, disconnect AC power from the robot, and
install a lock-out tag-out to prevent anyone from reconnecting power.
DANGER: A Hornet robot can cause serious injury or death, or damage to
itself and other equipment, if the following safety precautions are not observed:
lAll personnel who install, operate, teach, program, or maintain the system must read
this guide, read the Robot Safety Guide, and complete a training course for their respons-
ibilities in regard to the robot.
Figure 2-1. Read Manual and Impact Warning Labels
lAll personnel who design the robot system must read this guide, read the Robot Safety
Guide, and must comply with all local and national safety regulations for the location in
which the robot is installed.
lThe Hornet 565 must not be used for purposes other than described in Intended Use of
the Robots on page 21. Contact Customer Support if you are not sure of the suitability
for your application.
lThe 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.
lPower to the robot and its power supply must be locked out and tagged out before any
maintenance is performed.
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