AFD User`s Manual
Contents
1. 4 fasteners 1 2 inch 12 mm in diameter These fasteners are to be provided by the installer Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 6 3 2 Electrical Connections The SFS81 requires 208 480 VAC 3 Phase 50 60 Hz power to operate This should be supplied via conduit connection to the Control Box The electrical connections are made to the User Interface Blocks as shown in Figure 2 USER INTERFACE BLOCKS 3 PHASE AG SUPPLY Figure 2 User Interface terminal blocks Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 7 USER INTERFACE TERMINAL BLOCK 24 OUT 2 OVDC RETURN ANALOG SHIELD SPEED INPUT SPEED INPUT 12 MEDIA POSITION OUTPUT 0 10VDC Figure 3 SFS81 Typical User Interface Schematic The circuit diagram in Figure 3 shows the SFS81 wired for stand alone panel operation All digital I O on the SFS81 is designed for 24 VDC control voltages The Mounting Shaft rotational speed is controlled via a 0 10VDC analog signal applied to terminals 9 and 10 The analog input is a true floating differential signal connected directly to the servo amplifier The circuit shown in Figure 2 is an example of how the shaft speed may be controlled with a simple panel mount linear potentiometer If remote robot teach pendent adjustment is desired the potentiometer would be replaced with an analog signal from a robot2. a minimum 80 psi 5 Bar air pressure must be maintained for the device to operate within published specifications Low air pressure will cause inferior force control performance The pneumatic supply system should be configured as shown in Figure 5 Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 10 FLOW CONTROL NEEDLE VALVE REGULATOR R1 4 INPUT Figure 5 Pneumatic Connections WARNING If water condensation is present in your air supply system an air dryer device is highly recommended Moisture inside the device will cause premature failure that will not be covered under warranty The SFS81 Finishing Stand AFD maintains a positive air pressure to impede the infiltration of contaminate materials The amount of air entering the AFD is set by adjusting the Flow Control Needle Valve located on the rear of the unit It is important to provide a continuous compressed air supply to the device at all times if the work environment contains airborne contaminates If the environment is clean during non operational periods the air supply to the device may be shut off The SFS81 has one pneumatic input an R 1 4 Metric port located on the SFS81 Regulator Figure 5 This port supplies all the air needed to operated the Finishing Stand Before connecting the supply to the air fitting open the supply valve to blow out any contaminates which may be in the line Charge the supply line with compressed a
3. analog output card connected directly to Pins 9 and 10 WARNING The differential voltage applied to terminals 9 and 10 should not exceed 10 VDC or damage will occur to the servo amplifier Terminal 7 shown in Figure 2 provides the servo amplifier enable signal Connecting Terminal 7 to 24VDC enables the servo amplifier and applies voltage to the servo motor Removing voltage from terminal 7 disables the amplifier The DRIVE OK output on Terminal 11 should be continuously monitored by the End user control system This signal should be ON during normal operation An OFF condition indicates a drive fault The cause of the fault will be indicated by a flashing code on the servo drive amplifier OPERATION SHOULD CEASE UNTIL THE FAULT CONDITION IS CORRECTED The Electrical Control box includes a built in E Stop push button switch that when pressed immediately removes all electrical power from the motor If desired the SBS81 can be connected to an external dual channel E Stop circuit by connecting to the STO1 and STO2 signal on Terminals 3 4 5 and 6 as shown lt is the responsibility of the System Integrator and or End user to follow all applicable electrical codes and OSHA safety standards when wiring the SFS81 Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 8 This includes the proper and judicious use of fuses contactors cut off switches lock out switches and Emergenc
4. 1 has been designed from the ground up as a Finishing Stand for robotic applications with many new and unique features Accurate force and speed control allows you to achieve unprecedented levels of quality and consistency The SFS81 enables maximum flexibility for any part in hand grinding sanding buffing or polishing application Linear compliance with 1 6 inches 40 mm of travel and excellent access allow a robot to easily manipulate parts over the Media An important feature of the SFS81 Finishing Stand is the high torque servo motor and belt drive The belt drive system provides a 2 1 increase in torque at the Media for heavy material removal The force control technology in the SFS81 is based on the PushCorp Passive AFD80 Series Force Devices This technology has proven itself in thousands of hours of production robotic applications The standard regulator supplied with the SFS81 allows the force to be varied from 2 to 100 lbs 8 to 445 N This regulator has a coarse adjustment and must be manually set to the desired force output If the force must vary during the finishing process then an electrically controlled proportional regulator is required Very accurate force output requires a precision regulator that operates in a narrow pressure range The electrical control box is mounted remotely from the Finish Stand outside the robot enclosure to protect it from dust and vibration Electrical interface cables are ordered separately and can
5. SFS81 Series Servo Finishing Stand PUSHCORP INC Dallas Texas NEVER OPERATE THE SFS81 MANUALLY NEVER OPERATE THE SFS81 WITH PERSONEL IN THE WORKCELL DO NOT USE LUBRICATED AIR This device requires a dry non lubricated 100 psi 6 9 bar maximum air supply filtered to 5 um and a 0 3 micron oil mist separator Non compliance with these requirements will void the manufacturer s warranty See Section 3 4 All fasteners mounting holes and pipe threads on this tool are METRIC PUSHCORP INC SFS81 Series Manual 1 Table of Contents 1 0 LIMITED WARRANTY silla iaia 2 2 0 GENERAL OVERVIEW oi ed a lee ivi ao alia 4 SO INSTALLATION asia 5 3 1 Mounting the SFS8 Tiss iosa ii et eed Lee eed fh eee ee acct ace as 5 3 2 Electrical Connections deri ironia 6 3 3 Electrical Gontrol Box sore ala a ad dat 8 3 4 PneumatieGONNEGHOnS 1 00 eda rt tata bles 8 4 0 OPERATION ere dt de si odono elia lA i 10 4 1 Media Munting cne ae ATE EE lea alinea iaia 10 4 2 Achieving Desired Force i ic aa 11 4 3 Achieving Desired Media Speed cn anar nn nan nnnnnnnnnnnnnnnnnnn 11 4 4 Drive Belt Replacement dial ae ela iaia pia asian 11 4 5 Media Position Feedback nn nn nn nana n nn nn nn nnnnnnnnnnnnnnnnnnnnnncnnnnnns 11 5 0 TECHNICAL SPECIFICATIONS ses sti 13 Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 1 0 Limited Warra
6. a 4 4 Drive Belt Replacement The SFS81 uses a 2 1 reduction timing belt drive to transfer power from the Servo Motor to the Mounting Shaft This drive incorporates a high strength Gates Poly Chain GT2 belt PushCorp Part No PAR01889 1 Should this Drive Belt ever require replacement contact PushCorp for the proper procedure 4 5 Media Position Feedback The SFS81 comes equipped with an internal potentiometer that provides a voltage signal based on the linear position of the Media The voltage signal is at a minimum value when the Media is pushed back against the rubber stops and a maximum value when the Media is forward against the rubber stops The total linear compliant stroke is 1 6 in 40 mm Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 13 The linear position signal must be calibrated for each installation User calibration is easily accomplished using the following steps 1 2 Turn off the supply air to the SFS81 Push the Media to the rearward negative position Read the voltage signal on Pin 12 of the User Interface Connector Record this voltage for future reference This will be referred to as V Pull the Media to the forward positive position Read the voltage signal on Pin 12 of the User Interface Connector Record this voltage for future reference This will be referred to as V The position of the Media can now be determined by measuring the voltage V
7. be made to any length up to 30 meters as required by the customer s installation In most any finishing process consistency is of paramount importance For this reason the SFS81 is powered by a high torque servo motor with adjustable speed control that can be varied at any time during the finishing process The SFS81 has a 6 horsepower 4 5 kW motor that supplies 16 lb ft 22 Nem of continuous torque and a maximum rotational speed of 2000 RPM at the media mounting shaft With dual 30mm shafts the user can mix 8 match their Media allowing multiple finishing operations at the same piece of equipment This flexibility allows the SFS81 to perform a wide variety of finishing applications Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 5 3 0 Installation 3 1 Mounting the SFS81 The SFS81 Servo Finishing Stand is secured by four 4 fasteners passing through mounting holes located in the Base Plate The Base Plate mounting hole locations are shown in Figure 1 The SFS81 must be securely mounted to keep the unit from moving during operation and must be mounted level to achieve the desired force output A spirit level can be place on the top of the Finishing Stand and shims can be inserted under the Base Plate as required WARNING Do NOT operate the unit without first mounting it securely 13 72 4X D 540 254 10 000 Figure 1 SFS81 Base Plate mounting holes The SFS81 attaches with four
8. cts in accordance with the instructions provided in the owner s manual s supplied with the product Responsibilities of the Warrantor under this warranty Repair or replace at Warrantor s option products or components which have failed within the duration of the warranty period Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 3 Responsibilities of the purchaser under this warranty A Deliver or ship the PushCorp Inc product or component to PushCorp Inc Service Center Dallas TX Freight and insurance costs if any must be borne by the purchaser B Use reasonable care in the operation and maintenance of the product as described in the owner s manual s When warrantor will perform repair or replacement under this warranty Repair or replacement will be scheduled and serviced according to the normal work flow at the service center and depending on the availability of replacement parts Purchasers requiring quicker repair may receive such with payment of a PushCorp Inc predetermined expediting fee This Limited Warranty gives you specific legal rights and you may also have other rights which vary from state to state Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 4 2 0 General Overview The PushCorp SFS81 Series Servo Finishing Stand combines passive compliant force control and closed loop servo motor speed control technology The SFS8
9. eve a desired force output at the Media Use the following equations to determine the pressure required to achieve the desired output force F 1 4xP Applied Force Ibs F 89xP Applied Force N Where P Regulator pressure PSI or Bar PushCorp has included a manual regulator to allow for quick set up This manually adjustable pressure regulator may be sufficient but if remote operation of the force output is needed then an electrically controlled proportional air regulator will be required The accuracy of the force output is directly related to the precision and quality of the pressure regulator A regulator that operates over a limited range i e 0 15 psi is required for the most precise low force output 4 3 Achieving Desired Media Speed The Output Shaft rotational speed is controlled via a 0 10VDC analog signal applied to Pins 9 and 10 of the User Interface Connector The user must scale the command voltage to the servo motor amplifier from 0 to 10 Volts which commands an Output Shaft rotational speed of 0 to 2000 rpm The user is responsible for determining the maximum allowable speed for their Media The SFS81 is factory limited to operate at a maximum Mounting Shaft rotational speed of 2000 rpm Figure 2 shows a simple circuit using a linear potentiometer to control Media speed however most installations will require a remote voltage command from a robot or PLC analog output card to vary the rotational speed of the Medi
10. ir and verify that there are no air leaks and that there is a minimum of 80 psi 5 Bar If a minimum air pressure of 80 PSI cannot be achieved then an auxiliary air compressor or booster pump must be installed Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 11 4 0 Operation 4 1 Media Mounting The SFS81 has dual 30mm diameter Mounting Shafts that protrude 10 6 in 271 mm The user is responsible for choosing the appropriate means to attach their Media to the Mounting Shafts One option PushCorp recommends is to use an SKF 30mm Shaft Hub SKF Part SHT30 PushCorp P N PARO2456 These may be purchased directly from SKF or through PushCorp The hubs securely lock the Media Adapter Arbor to the Output Shaft in a way that keeps the Media concentric to the Mounting Shaft and transmits the required torque Media adapter assemblies are not supplied with the SFS81 Figure 6 below illustrates one method of mounting utilizing the SKF Shaft Hubs 30mm MOUNTING SHAFT SKF MOUNTING HUB MEDIA ADAPTER ARBOR 2X MEDIA FLANGE MEDIA LOCKNUT Figure 6 Example of Media mounting Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 12 4 2 Achieving Desired Force The SFS81 uses a modified passive 80 Series AFD to supply a compliant force from 2 to 100 lbs 8 to 445 N The passive force device requires the user to provide regulated air pressure to achi
11. nty Duration One year from date of delivery to the original purchaser Who gives this warranty warrantor PushCorp Inc Telephone 972 840 0208 Corporate Address P O Box 181915 Dallas Texas 75218 Shipping Address 3001 W Kingsley Rd Garland Texas 75041 Who receives this warranty purchaser The original purchaser other than for purposes of resale of the PushCorp Inc product What products are covered by this warranty Any PushCorp Inc Adjustable Force Device or Adjustable Force Device accessory supplied or manufactured by the Warrantor What is covered under this warranty Defects in material and or workmanship which occur within the duration of the warranty period What is NOT covered in this warranty A IMPLIED WARRANTIES INCLUDING THOSE OF MERCHANT ABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL PURCHASE Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you ANY INCIDENTAL INDIRECT OR CONSEQUENTIAL LOSS DAMAGE or EXPENSE THAT MAY RESULT FROM ANY DEFECT FAILURE MALFUNCTION OF THE PUSHCORP INC PRODUCT Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you Any failure that results from an accident purchaser s abuse neglect unauthorized repair or failure to operate the produ
12. on Pin 12 of the User Interface Connector and inserting the value into the following equation m n zy English units Dp n 361 x E p 1 0m 7 m n 40 X p 40mm x p n Metric units Where p Media Wheel Position in mm V Voltage measured on Pin 12 V V Calibrated voltage at rearward position V V Calibrated voltage at forward position V Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 14 5 0 Technical Specifications Maximum Applied Force 100 Ibs 445 N Weight Force Scale Factor Compliant Stroke Supply air Supply Voltage Max Cont Current Max Peak Current 370 lbs 168 kg 1 4 Ibs psi 890 N MPa 1 6 in 40 mm Non lubricated Dry 5um Filtered 100 psi 0 7 MPa Max 208 480 VAC 3 Phase 30 Amps 60 Amps 2 Seconds Specifications subject to change without notice Fastener Tightening Torque Specs Torque Minimum Depth Fastener Size in Ibs ft Ibs N m in mm M4 x 7 50 4 2 5 6 0 17 4 3 M5 x 8 85 7 1 9 6 0 21 5 3 M6x1 140 11 7 15 8 0 25 6 3 M8 x 1 251 348 29 0 39 3 0 33 8 4 M10 x 1 5 600 50 0 67 8 0 41 10 5 Copyright PushCorp Inc 2012 All rights reserved
13. y Stop circuits PushCorp Inc assumes no responsibility or liability for the electrical system design and implementation of the SFS81 in the End user application Refer to OSHA rules and regulations as well as the CE Machinery Regulations IEC 204 1 when designing systems that include motors and drives to ensure that the user is protected PushCorp will provide answers to any questions regarding the servo drive system and will be responsible for any warranty issues Copyright PushCorp Inc 2012 All rights reserved PUSHCORP INC SFS81 Series Manual 9 3 3 Electrical Control Box The SFS81 Electrical Control Box is designed to be wall mounted outside the robot work area in a relatively clean environment Figure 4 shows the mounting dimensions of the electrical enclosure a A 4X 0 43 21 24 MAIN POWER SWITCH i SFS81 CABLE FEED THRU Figure 4 Electrical Control Box Mounting It is the responsibility of the installer to punch holes in the enclosure for conduit and or cord grips as required for the electrical supply power wiring and low voltage control signals 3 4 Pneumatic Connections The SFS81 Finishing Stand requires a dry non lubricated 5 micron filtered 80 to 100 psi 5 7 Bar air supply with a 0 3 micron oil mist separator Failure to provide supply air to these specifications can degrade performance and will void any warranty repairs concerning pneumatic components Additionally
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