"user manual"
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1. zx 1 1 Identification Label 1 2 Manufacturer uum ML Date of Manufacture Sus Actuator SW44 Model Serial Num 555121 7 Maximum 152 4 mm Stroke 6 00 in Displacement 5 mm rev Ratio 0 20 in rev Continuous 8 9 kN Force 2000 Ibs Peak 17 8 kN Force 4000 Ibs Max Terminal 455 Ydc Volts Max Current 22 ARMS Maximum Speed 333 mm sec Feedback Mfg Model 274 PATENT PENDING Figure 1 1 Actuator identification label 7 ATOR f 3t A TOLABMATIG ING BALL SCREW Date of Manufacture yo Actuator Model Serial Num 555121 7 Maximum 152 4 mm Stroke 6 00 in Displacement 5 mm rev Ratio 0 20 in rev Continuous 8 9 kN Force 2000 Ibs Peak 17 8 kN Force 4000 Ibs Max Terminal 455 Yde Volts Max Current 22 A RMS Maximum 333 mm sec Speed Feedback MigiModel 7210 PATENT PENDING Do not remove the identification label Do not render it unreadable Tol O Matic Inc 3800 County Road 116 Hamel MN 55340 USA 763 478 8000 www tolomatic com email help tolomatic com 00090000000000000900000000000900000000000000000000000000000000000000000000000000000000000000000900000000000000000000092000000000000090000 1 1 GENERAL2. EO 1 3 Intended Use The SW44 weld actuator see figure 1 2 is a compact high force screw drive servo actuator The weld actuator provides linear motion of the moveable weld gun tip and develops the required thrust squeeze force for spot welding SW44 Actuator Figure 1 2 Example of welding actuator installed on C Style weldgun unit WARNING Before installation and commissioning of the equipment this manual and all accompanying manufacturer documents and manuals MUST be completely read by the appropriate personnel All warning texts must be given special attention 9000000000000009900000090000000900000000000000000000000000000900000009000000000000000000009000000000000900000000090000000000000000000099909 GENERAL 1 1 4 General Operation The SW44 actuator functions by translating the rotary motion of the integral brushless servo motor into linear motion using a planetary roller screw or a ball screw The linear travel speeds and for
3. 2 General Operations NM oon enne rri irc 3 Noc oM gt 4 2 Functional Description c ccccccccccsssesscssssessesssssssscsssssssosscssssessacsessessnses 5 PATELE M Im 5 Pulsegff g IW emeret ren nne terr trennt 6 9 rout M T 7 Weld 7 t a Shafa Wiring 2 reete rtr ine tetti hne Regreso 7 M S di D 7 4 Inspection and Settings sees 8 Inspection and Settings etre nett et 8 Inspection of Mechanical Travel Limits eee 8 Weld Motion 9 5 Repair and Maintenance 10 Pulsecoder Replacemient eerte ntt eher 11 LIB gendo bp Saal H 13 Specifications NER E antes 13 Thermal Sensor Specifications eee 14 Connector PUN OU n a E 14 Troubleshooting Proce dute ie nn e tette an rennen nda 15 16 600900000000000009000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000092000000000000090000 i List of Figures Figure Description Page 1 1 Actuator identification label 5 rere 1 1 2 Examples of welding actuator instal
4. 74 ELECTRIC LINEAR MOTION PRODUCTS Welding Actuator SW44 with Fanuc Pulsecotder User Manual O MATIC INC Patent Pending 3604 4157 00 Information furnished is believed to be accurate and reliable However Tol O Matic assumes responsibility for its use or for any errors that may appear in this document Tol O Matic reserves the right to change the design or operation of the equipment described herein and any associated motion products without notice Information in this document is subject to change without notice Contents 09000000900900000099000009000000000000009000009000000000000000000009000000000000000900000900000000000000000000900000009000000090900000999 boe ccn i List of FIBUIBS ioo paired Ua ru anai e a ii HEALTH AND SAFETY REGULATIONS seen iii General Warning for Hot Surfaces e IN eee iv Modifications to the Equipment iv Requirements regarding Personnel eee iv Packing Transport and Unpacking eene iv Risk Area and iv Repair and Maintenance 3 iv 1 General Identification Label 1 Manufacturer orte 1 Intended Use
5. 2 FUNCTIONAL DESCRIPTION 2 2 Fanuc Pulsecoder The Fanuc Pulsecoder is mounted in a housing on the rear of the SW44 The pulsecoder provides position feedback to the 7th axis controller drive of the robot controller Figure 2 2 Exploded view of Fanuc Pulsecoder for SW44 09000000000000009000000000000000000900000000000000000000000000000000000000000000000000000000000000000000000090000000000000000000009000 Basic Installation 0900000000000009900000900000000000000090000090000000000000000000090000000000000000000090000090000000000000009000009900009 poooz 3 1 Installing the Weld Actuator Please refer to the weld gun documentation supplied by the weld gun manufacturer for mechanical installation 3 2 Electrical Wiring See the electrical circuit diagram supplied by the weld gun manufacturer that accompanied the weld gun at delivery CAUTION Excessive side load on the output thrust rod of the actuator will dramatically reduce the life of the actuator and should be avoided Side load can be caused from misalignment or loading that is not inline with the actuator output thrust rod NOTE The distance travelled under load dramatically affects life when specified in cycle count Tol O Matic recommends loaded stroke ofless than 0 10 2 5mm when used at maximum actuator output specifications 3 3 Cable Routing Over time liquid contaminants such as oil and cleaning solutions will run down the cables and into the connectors
6. normal use and service The foregoing warranties are exclusive and in lieu of all other expressed and implied warranties whatsoever including but not limited to implied warranties of merchantability and fitness for a particular purpose Tol O Matic Inc shall not be subject to any other obligations or liabilities whatsoever with respect to product manufactured or supplied by Tol O Matic Inc or service rendered by it Pe ee 090000000090000009900000900000000000000090000090000000000000000000090000090000000000000009000009000000000000000900000900900000000000009900 Copyright 2005 Tol O Matic Incorporated All rights reserved Axidyne Axiom Tol O Matic and Excellence In Motion are registered trademarks of Tol O Matic Incorporated All other products or brand names are trademarks of their respective holders www tolomatic com 11 05 Denison 06009000000000000090000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000092000000000000090900 TOL 0 MATIC INC 3800 County Road 116 Hamel MN 55340 763 478 8000 Telephone 763 478 8080 Fax 1 800 328 2174 Toll Free http www tolomatic com
7. if they are of an exposed type To minimize the introduction of contaminants to the connector route the cables so that there is a loop in the cable just prior to its attachment to the connector Two examples are shown below depending on the orientation of the connectors Units mounted in such a way that the connectors are on the bottom surface of the actuator require no looping Top Side Mount Mount Loop Loop 9 o o o Figure 3 1 Cable routing for top and side mounted connectors 00000009000000000900000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000009200000000000090000 Inspection and Settings 4 1 Inspection and Settings Before commissioning the weld actuator there are certain inspections and settings that must be completed After all maintenance activities the gun must be inspected before it is returned to service 4 2 Inspection of Mechanical Travel Limits The mechanical travel limits of the actuator must be verified to ensure the actuator will not reach an internal hard limit during normal operation The end of stroke bumpers should NOT be engaged during normal programmed servo actuator operation Step 1 Turn the controller power off see documentation for controls system for details Step 2 With the actuator installed on a weld gun manually rotate the servo gear extending the rod until the weld gun tips are clo
8. or weld gun equipment e Perform repairs maintenance and inspections before storing equipment to ensure that the equipment is in good working order e sure the equipment is placed in a suitable storage position to prevent damage to the connectors and electronics e Protect the feedback device which is located at the blind non rod end of the SW44 actuator 6 900000000000000900000000000000000900000000000000000000000000000000000000000000000000000000000000000000000090000000000000000000009000 4 Functional Description 090000000000000090000009000000000000009000009000000000000000090000090000000900000000000009000000090000000000000090900000090900000 c 9999999 2 1 Actuator The weld actuator provides movement to the moveable electrode bringing the moveable electrode in contact with the material to be welded and the stationary electrode Once the electrodes are in position the weld actuator maintains thrust squeeze force throughout the weld cycle WARNING The welding actuator stroke must be compatible with the weld gun tip opening WARNING Do not attempt any repairs or equipment modifications without authorized factory assistance
9. starwheel port up and the other down 2 Install the connecting portion of the pulsecoder coupler onto the coupler half on the actuator Orient the connector on the pulsecoder bottom left 3 Position a connector gasket between the motor connector and encoder housing and with 4 socket head cap screws 10 and lock washers attach the motor connector to the pulsecoder housing Use no Loctite on these fasteners 4 Position the rubber boot over the pulsecoder harness and the inboard side of the connector 5 Install the pulsecoder connector to the housing with 4 socket head cap screws and lock washers no Loctite Be sure to locate the rubber boot gasket between the inboard side of connector and the outside of the cap Connect harness to the pulsecoder and connect 2 pin motor temp leads to the harness connector 6 Locate a gasket 2 between the pulsecoder housing 5 and the pulsecoder cover plate 7 and with the 4 cap screws 8 attach the pulsecoder housing and cover to the main bearing plate Coil the harness so that it will not create any interference 6 09000000000000009000000000000000000900000000000000000000000000000000000000000000000000000000000000000000000090000000000000000000009000 12 Appendix 090000009009000009900000900000000000000909000009000009000000000000000900000000000000000000900000900000000000000090000009909000 6 1 Specifications SW44 Motor Specifications Continuous Stall Torque Peak Stall Torque Contin
10. 11 3 x 4 38 111 3 15 53 394 4 6 00 152 4 5mm 30 9 Ibs 14 kg 0600000009000000009000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000092000000000000090000 6 APPENDIX 6 2 Thermal sensor specifications The current thermal sensor will shut down the motor at 155 F 68 C The motor should not perform a duty cycle that repeatedly generate motor temperatures above 155 F 68 C or premature bearing failure will result 6 3 Connector pinout MOTOR POWER CONNECTIONS MOTOR SERVO AMP MOTOR CONNECTOR PHASE LEAD A U RED B BLK C W WHT D GND GRN YEL MS3102A 18 10P Figure 6 1 Motor Power Connections 64 PULSECODER CONNECTIONS PULSECODER AS SUPPLIED BY FANUC SIGNAL PIN NO SD A SD D REQ G 5V OV N T SEALED H 6VA R OVA S MS3102A 20 29PW Figure 6 2 Pulsecoder Connections 6 900000000000000900000000000000000000000000000000000000000000000000000000000000000000000000000000000000000900000000000090000000009000 APPENDIX 6 6 4 Troubleshooting Procedure SYMPTOM No response from SW actuator SW Actuator is e
11. al is not followed Items that are specifically marked DANGER WARNING CAUTION OR NOTE Are arranged in a hierarchical system and have the following meaning DANGER Indicates a very hazardous situation which if not avoided could result in death or serious injury This signal word is limited to the most extreme situations WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided this situation may result in property damage or minor or moderate injury NOTE Information that requires special attention is stated here 9900009009000000990000009000000090900000090000009000000090000000090000009090000000000000090000009000009000000000090000009000000000000009000009999 Warning for Hot Surfaces WARNING Normal operating temperature of weld actuator can range from 135 degrees F 57 C to 175 degrees F 79 C Modifications to the Equipment WARNING The manufacturer takes no responsibility whatsoever if the equipment is modified or if the equipment is used in any way beyond performance specification
12. ces are controlled in conjunction with a properly sized brushless servo drive The relationship between the rotary motion of the motor and the linear motion of the actuator corresponds to the following relationships Linear distance traveled motor revolutions displacement ratio Linear Speed motor RPM 60 displacement ratio Motor Torque in Ibf 2 x efficiency Roller Screw Lead in rev Linear Force Motor RMS current must be maintained at a level below the continuous current rating of the SW44 actuator or damage to the motor stator will result The peak current setting must be maintained at a level below the peak current rating of the SW44 actuator or damage to the motor stator will result Care should be taken not to exceed the physical travel limits of the SW44 actuator Doing so will cause the actuator to reach mechanical end of stroke internally Although protected by the end of stroke bumpers frequently reaching internal end of stroke can physically damage the screw and the internal components of the actuator POPP 1 GENERAL 1 5 Storage Pay attention to the following when storing the weld actuator and
13. for evaluation WARNING Never rotate the actuator via the Pulsecoder connection Doing so may result in the loss of phasing between the Pulsecoder and motor windings 6 090000000000000090000000000000000000000000000000000000000000000090000000000000000000000000000000000000000009000000000000000000009000 10 REPAIR AND MAINTENANCE 5 Figure 5 1 Exploded view of Fanuc Pulsecoder DISASSEMBLY 1 Remove the 4 cover plate cap screws 8 2 Remove cover 7 3 Remove the gasket 2 4 Disconnect the pulsecoder harness 18 from the pulsecoder 17 5 Disconnect the motor temp sensor harness from motor leads 15 13 6 Remove the harness from the assembly 7 Remove the 4 stainless steel socket head cap screws 6 The pulsecoder is now free to come off the assembly Do not remove the black oxide fasteners as they are holding the pulsecoder together 0900000900000009000000000000000000000000000000000000000000000000000000000000000000000000000090000000000000000000000920000000900000090000 5 REPAIR AND MAINTENANCE ASSEMBLY 1 Orient the leadscrew shaft such that the pulsecoder coupler half is oriented up down with one
14. led on weldgun unit 4 2 2 1 Exploded view of actuator sss eeens ee a 5 2 2 Exploded view of Fanuc Pulsecoder sess a 6 3 1 Cable routing for top and side mounted connectors snas 7 4 1 Manual operation of welding 1 8 4 2 Weld motion profile eene nn 9 5 1 Exploded view of Fanuc Pulsecoder sse 11 6 1 Motor Power Qe 14 6 2 14 6 090000000000000090000000000000000000000000000000000000000000000000000000000000000000000000000000000000000009000000000000000000009000 HEALTH AND SAFETY REGULATIONS meee ee General Read completely through the applicable sections of the manual before the equipment unit is unpacked installed or operated Pay careful attention to all of the dangers warnings cautions and notes stated in the manual Serious injury to persons or damage to the equipment may result if the information in the manu
15. nabled but is not operating or is operating erratically SW Actuator is operating but is not up to rated speeds force Actuator cannot move the weld gun Actuator housing moves or vibrates when shaft is in motion Actuator is overheating CAUSE Controller Drive not enabled Controller Drive faulted Improper Failed wiring Feedback cable may be damaged Feedback wiring may be incorrect Motor phases are wired incorrectly or in incorrect order Amplifier may be improperly tuned Amplifier may be set up improperly for SW actuator used Feedback is improperly aligned Force is too large for the capacity of the actuator or too much friction is present Excessive side load Misalignment of output rod to weld gun Amplifier has too low current capacity or is limited to too low of current capacity Loose mounting Amplifier is improperly tuned wrong gain settings Duty cycle is higher than actuator rating Actuator is being operated outside of continuous ratings Amplifier is poorly tuned causing excessive unnecessary current to be applied to motor SOLUTION Enable Controller Drive Reset the Controller Drive Check the wiring Test the feedback cable Verify feedback wiring Verify correct wiring of motor armature Check all gain settings Check amplifier settings for number of poles voltage current resistance inductance inertia etc Contact Tol O Matic Inc Verify force requirements Verify c
16. orrect gun operation Verify correct alignment Verify correct amplifier and settings Check actuator mounting Tune amplifier Verify weld forces and actuator ratings Reduce time that weld force exceeds 1800 Ibf 8007N Check gain settings 000900000900000000900000000000090000000000000000000000000000000000000000000000000000000000000000900000000000000000000092000000000000090000 6 APPENDIX 6 5 Warranty Tol O Matic Inc warrants product manufactured by it to be free from defects in material and workmanship for a period of one year from date of shipment by Tol O Matic Inc If within such period any such product shall be proved to Tol O Matic Inc s satisfaction to be defective such product shall either be repaired or replaced at Tol O Matic Inc s option This warranty shall not apply a To product not manufactured by Tol O Matic Inc with respect to product not manufactured by Tol O Matic Inc the warranty obligations of Tol O Matic Inc shall in all respects conform and be limited to the warranty actually extended to Tol O Matic Inc by its supplier b To product which shall have been repaired or altered by parties other than Tol O Matic Inc so as in Tol O Matic Inc s judgment to affect the same adversely or c To product which shall have been subject to negligence accident or damage by circumstances beyond the control of Tol O Matic Inc or to improper operation maintenance or storage or to other than
17. s Unauthorized modifications or changes to the equipment are strictly forbidden and void all warranties Requirement regarding Personnel NOTE All personnel must be completely informed regarding all safety regulations and the function of the equipment Packing Transport and Unpacking NOTE Anchor and secure actuator in such a way as to prevent damage during transport Also make sure the actuator is clean and dry and protected from moisture Risk Area and Personnel When installed on a weld gun pinch points are generated capable of high damaging forces The risk area surrounding the weld actuator must either be enclosed or clearly marked including display signage in accordance with all applicable national and international legal requirements for welding actuators The risk area must be protected by a safety system that stops the equipment if anyone enters the risk area Personnel who enter the risk area must be authorized trained and qualified for the different tasks inside the risk area Repair and Maintenance All power and supply media must be shut OFF before any work is performed on any equipment that is associated with the welding gun application 90000000000000090000009000000000000000900000000000000000000000000090000000000009000000000090000000000000000000090000000000000000000099900 General
18. sed Record the distance the rod is extended as 41 Step 3 Remove one cap and manually rotate the servo gear extending the rod until the actuator reaches its end of travel Record the distance the rod is extended as d2 The difference between the two measurements minus the gun deflection d3 should be greater than end of stroke bumper 5 mm d2 dl d3 gt 5mm ROTATE WHEEL TUBE EXTENDS ROTATE WHEEL TUBE RETRACTS Figure 4 1 Manual operation of welding actuator 6 09000000000000009000000000000000009000000000000000000000000000000000000000000000000000900000000000000000000090000000000000000000009000 INSPECTION AND SETTINGS 4 090000000090000009900000900000000000000900000900000000000000090000909000009000000000000000900000900000000000000090000000900000000000009000 4 3 Weld Motion Profile The rated force of 2500 Ibs 1 1 kN is based on a duty cycle that will not cause the maximum surface temperature of the actuator to exceed 155 F 68 C The motion profile for the duty cycle used to determine rated force is shown below The motion profile is a 6 inch 152mm move at max speed and acceleration The weld move is repeated with a one second dwell between welds and a 3 second dwell every 10 welds Weld Move Velocity Open Time Close Time Weld Time Figure 4 2 Weld Motion Profile Move Initial Final Accel Move Mo
19. uous Stall Current Peak Current Number of Poles Kt Ke Resistance 25C Stator Inductance Maximum Bus Voltage Rated Speed Maximum Voltage Moment of Inertia Demagnetization Current SW44 Actuator Specifications Operating Force Peak Force Continuous Force Travel Under Force Side Load Peak Speed Max Acceleration no load SW44 Assembly Specifications Frame Size Length with Fanuc Encoder Stroke Screw Lead Weight LV3 Low Voltage 8 5 Nm 75 23 Ib in 17 1 Nm 151 35 Ib in 10 6 A RMS 21 2A RMS 8 0 80 Nm A per phase RMS 0 46 V rad s L L RMS 0 74 ohms L L 3 65 mH L L 325 Vdc 4 000 RPM 0 0013 Kg m2 26 A RMS Ball Screw Up to 1 000 Ibs 4448 N 4400 Ibf 19 6 kN 1850 Ibf 8 2 Up to 0 10 2 5mm travel under max load for 5M cycles Unidirectional side load less than 196 axial load 13 in sec 330 2 mm sec 350 in sec Ball Screw 4 38 111 3 x 4 38 111 3 15 53 394 4 6 00 152 4 5mm 30 9 Ibs 14 kg HV3 High Voltage 7 6 Nm 67 27 lb in 15 3 Nm 135 42 Ib in 5 9 A RMS 11 9 A RMS 8 1 29 Nm A per phase RMS 75 8 L L RMS 4 18 ohms L L 15 7 mH L L 680 Vdc 5000 RPM 0 0013 kg m2 26 A RMS Roller Screw Less than 2 500 lbs 11 120 N 4400 Ibf 19 6 kN 1850 Ibf 8 2 Up to 0 10 2 5mm travel under max load for 10M cycles Unidirectional side load less than 3 axial load 13 in sec 330 2 mm sec 350 in sec Roller Screw 4 38 1
20. ve Velocity Velocity Decel Time Distance in sec in sec in sec2 s in 1 0 10 300 0 02 0 1 2 10 10 0 0 55 2 8 3 10 1 300 0 02 0 1 4 1 1 0 0 13 0 13 5 1 1 0 0 05 0 05 6 1 0 300 0 002 0 7 0 0 0 0 5 0 8 0 10 300 0 02 0 1 9 10 10 0 0 58 2 8 10 10 0 300 0 02 0 1 0009000000000000090000000000000000000000000000000000000000000000000000000000000000000000000000900000000000000000000092000000000000090000 Repair and Maintenance NOTE Before starting any maintenance activities make sure that the supply power is shut OFE No lubrication is required during the service life of the servo weld actuator The only user serviceable component in the servo weld actuator is the Fanuc Pulsecoder The pulsecoder is aligned to the servo weld actuator motor by an Oldham coupling One segment of the Oldham coupling is pressed onto the servo weld actuator shaft during manufacturing of the actuator Should this press fitting become altered it is recommended that the actuator be returned to Tol O Matic for realignment The remaining Oldham components assure appropriate motor phasing alignment between the Pulsecoder and motor windings through slotted connections See figure 2 2 page 4 for and exploded assembly view Disassembly of the weld actuator is not recommended Servo weld actuators should be returned to Tol O Matic for evaluation and repair Contact the weldgun manufacturer for instructions on how to return the weld actuator
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