AFD User`s Manual
Contents
1. BREAKAW AY CLUTCH OR ROBOT MOUNTING FLANGE STC1510 MOUNTING PLATE CUSTOMER SUPPLIED 4 M 6x1x180mm SOCKET HEAD CAP SCREWS Figure 2 STC1510 Direct Mounting To mount the STC1510 first attach the Mounting Plate to the Robot Mounting Flange or to the Breakaway Clutch per the manufacturer s specifications Once the Mounting Plate is secured place the STC1510 against the Mounting Plate and install 4 four M8x1 25X180mm Socket Head Cap Screws See Figure 2 Tighten the fasteners to the torque specified in Section 4 0 PUSHCORP INC STC1510 Servo Tool Changer Manual 6 2 835 72 0 E 2 500 63 5 ae 2 835 72 0 LL 2 500 63 5 2X 204 5 2 T 04 10 0 4X 335 08 5 THRU 2 004 H50 9 v 10 2 5 Figure 3 STC1510 Mounting Dimensions 3 2 Toolholder Specification The STC1510 is designed to grip a BT30 toolholder The BT30 toolholder is a standard machine tool style and may be purchased from several sources including MSC www msc com and J amp L Industrial Supply www jlindustrial com The Customer can also make their own BT30 toolholder to handle special media See Figure 4 for toolholder dimensions The toolholder must be equipped with a Parlec www parlec com retention knob part number 3003TRK or equivalent Figure 5 shows the Parlec retention knob with the required dimensions d1811 646 60 1 250 31 75 535 13 60 Da d 492 912 50 SESIA aa 1 669 172. Dai MH 276 744 T 1 496 38 2 210 56 13 Az 8 2992 8 2972 642 16 31 642 16 31 669 17 T F 1 906 48 41 866 22 SECTION A A Figure 4 Toolholder Dimensions PUSHCORP INC STC1510 Servo Tool Changer Manual 7 1 693 43 00 906 23 01 1 D 274 6 96 G 431 10 95 i id Pi j M12x1 75 N 45 710 18 03 XxX Figure 5 STC1510 Retention Knob 3 3 Pneumatic Connection The STC1510 Servo Tool Changer requires a dry non lubricated filtered air supply with a minimum pressure of 90 psi 6 2 bar and a maximum pressure of 100 psi 6 9 bar Failure to provide supply air to these specifications can degrade performance and will void any warranty repairs concerning pneumatic components If the supply air pressure is too low then the STC1510 will be unable to open the retention knob gripper fully Not opening the retention knob gripper fully will not allow a toolholder to be clamped or released Exceeding the maximum air pressure could result in permanent damage to the STC The pneumatic supply system should be configured as shown in Figure 6 A manual or electrically operated valve may be used to energize the STC1510 for toolholder release but the valve must exhaust ALL line pressure when unenergized An electrically op
3. INC STC1510 Servo Tool Changer Manual 1 1 0 Limited Warranty 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 industrial equipment or 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 B 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 C Any failure that results from an accident purchaser s abuse neglect unauthorized
4. Perpendicular Axis configuration position the Clamping Housing over the Carriage as shown in Figure 1 Then secure the unit using four 4 M8x1 25x180mm Socket Head Cap Screws Tighten the fasteners to the torque specified in Section 4 0 CAUTION Make sure that the M8x1 25x20 fasteners do not exceed a depth of 0 52 13 3 mm into the AFD Carriage Helicoils or damage will occur AFD1100 OR AFD81 82 SERIES CARRIAGE MOUNTING PLATE PUSHCORP PN ASM02608 4 M8x1 25 FASTENERS CLAMP HOUSING STC1510 4 M8x 25x180mm SOCKET HEAD CAP SCREWS Figure 1 STC1510 Perpendicular Axis Configuration PUSHCORP INC STC1510 Servo Tool Changer Manual 5 3 1 2 Mounting Directly to a Robot For some processes compliance and force control are not required The STC1510 can be mounted directly to the robot and the system can be operated in position mode This robotic system is equivalent to a 6 axis machining center with a very large work volume and lower positional accuracy Certain product types and processes are well suited for a Robotic Machining Center RMC The STC1510 can be attached to the robot mounting flange using a mounting plate For direct mounting it is recommended that a breakaway clutch be installed The breakaway clutch will help protect the motor in the event of a robot crash Loads on the motor shaft of over 9700 Ib 43200 N radially and 4850 Ib 21600 N axially will damage the spindle bearings
5. 0 C Thermal Cutoff 212 F 100 C Max Coolant Pressure 60 psi 4 1 Bar TOOLHOLDER SPECIFICATIONS Toolholder BT30 standard Retention Knob Parlec 3003TRK or equivalent Clamping Supply Air Dry Non lubricated 90 psi 6 2 bar Min 100 psi 6 9 bar Max Requires power amplifier and cables For specific dimensions see www pushcorp com for detail drawings Specifications subject to change without notice Fastener Tightening Torque Specs Torque Minimum Depth Fastener Size in Ibs ft Ibs N m in mm M4x 7 50 4 2 5 6 0 17 4 3 M5 x 8 85 7 1 9 6 0 21 5 3 M6 x 1 140 11 7 15 8 0 25 6 3 M8 x 1 25 348 29 0 39 3 0 33 8 4 M10 x 1 5 600 50 0 67 8 0 41 10 5
6. 1510 High Speed Servo Motor Series Manual PUSHCORP INC Dallas Texas CAUTION Do NOT apply air pressure to release the toolholder while the servo motor is rotating The servo motor spindle must be FULLY STOPPED before actuating Do NOT overheat the servo motor Supply the motor cooling water to maintain a temperature below 176 F 80 C Do NOT start or stop the servo motor instantaneously Doing so will damage the motor and power amplifier All PushCorp Inc electrical cables are rated for high twist and flex robotic applications with a minimum cable bending radius specification of 125mm 5 in Cable damage resulting from failure to abide by this specification will not be covered under warranty PUSHCORP INC STC1510 Servo Tool Changer Manual Table of Contents 1 0 LIMITED WARRANTY siii iaa 1 Z 0 GENERAL OVERVIEW aia 3 30 INSTALLATIO No sail 4 3 1 Mounting the STETS Di dai 4 3 1 1 Mounting to an AFD1100 80 ie 4 3 1 2 Mounting Directly to a Robot i 5 3 2 Toolholder Specification i 6 3 3 PneumaticGonnection ssiia aaa Aia 7 3 4 Electrical GOnnections irrita Aia a iaia 9 3 90 Motor Cool oir A a Rai 9 3 6 Motor Acceleration Deceleration ilaria aaa ion 10 3 7 Positioning Motor Shaft for Tool Change cnc nnnannnnnns 10 4 0 TECHNICAL SPECIFICATIONS rrrrrrer eri 11 PUSHCORP
7. allowing the motor shaft to never be subjected to any clamping forces The STC1510 has sealed duplex spindle bearings to insure a long life and very low runout The front bearings have additional contamination protection from a PushCorp proprietary shaft seal This special contact seal eliminates the need for constant purge air During operation the STC1510 generates considerable heat due to the high torque capability and compact size Excessive operating temperatures will significantly reduce the life of the motor The motor should never be allowed to exceed a temperature of 176 F 80 C Continuously operating the unit above this value will cause the rotor to de magnetize and the bearings to fail High temperatures will also cause the O rings that seal the cooling water to fail PushCorp has provided flow through cooling on the motor to allow high duty cycles without overheating Simple reliable construction combined with high torque and precision speed controlled servo technology make the PushCorp STC1510 Servo Tool Changer a rugged state of the art technology capable of providing flexible cost effective tool changing operations PUSHCORP INC STC1510 Servo Tool Changer Manual 4 3 0 Installation 3 1 Mounting the STC1510 3 1 1 Mounting to an AFD1100 80 The STC1510 Servo Tool Changer is designed to attach to the Carriage of a PushCorp AFD1100 80 Force Device in a Perpendicular Axis configuration To attach the STC1510 to an AFD in a
8. com The cooling unit should be sized based on the motor power output of 10 Hp 7 5 kW with an overall motor efficiency of 90 and the motor load conditions Again it is recommended to closely monitor the motor temperature during actual production operation to ensure that it does not overheat NOTE The life of the STC1510 motor is directly related to the operational temperature so proper cooling is critical The STC1510 is supplied with two 5 16 and 8 mm diameter tube push lock fittings for installation in the Motor Cooling Ports Remove the shipping plugs and install the desired size push lock fittings If another type of fitting is desired replace the existing fitting with a fitting having an R 1 8 Metric Be sure to use a thread seal product and do not over tighten the fitting 3 7 Monitoring Motor Temperature The STC1510 is designed to operate below a temperature of 176 F 80 C and within an optimal range of 122 140 F 50 60 C The motor contains a thermal cutoff switch If the temperature exceeds 212 F 100 C the motor will stop running until it has cooled off This feature should not be used to control the motor temperature The thermal cutoff is designed to operate only when all other precautions have failed 3 6 Motor Acceleration Deceleration Servo Motors have the ability to start and stop very quickly As long as the motor does not overheat or the amplifier exceed the allowable current input the motor will con
9. erated pneumatic valve is normally used in an automated workcell PushCorp highly recommends the installation of a Pressure Switch in the Supply Line to the STC1510 This switch should not allow the STC1510 to start if there is any pressure in the Supply Line Pressure in the line will cause internal components to come into contact This will either cause the motor not to spin or cause very high internal friction eventually friction welding components together 1 4 6mm POLYURETHANE TUBING AIR REGULATOR PRESSURE GAUGE x Dry Non lubricated Air Supply a E 90 psi minimum J f 6 2 Bar S SHUT OFF VALVE Xx 5 um FILTER MANUALLY OR ELECTRICALLY PRESSURE SWITCH OPERATED VALVE Figure 6 Pneumatic Connections PUSHCORP INC STC1510 Servo Tool Changer Manual 8 The STC1510 is provided with inch and 6 mm diameter tubing push lock fittings for installation in the R 1 8 Metric Unclamp Port located on the top of the Clamping Housing See Figure 8 Remove the shipping plug and install the desired size push lock fitting If another type of fitting is desired unscrew the existing fitting and replace it with any fitting having an R 1 8 Metric thread Be sure to use a thread seal product and do not over tighten the fitting The Supply Line to the device should be 1 4 inch or 6 mm diameter flexible polyurethane tubing The t
10. feedback or control cables because of possible noise problems 3 5 Motor Cooling R 1 8 METRIC AIR PORT COLLET UNCLAMP MOTOR COOLING PORT FEEDBACK CONNECTOR POWER CONNECTOR MOTOR HOUSING SHAFT KEYS Figure 7 STC1510 External Connections 3 5 Motor Cooling The STC1510 has a compact high torque 10 Hp 7 5 kW Servo Motor which requires water cooling The motor is designed to operate below a temperature of 176 F 80 C The optimal motor temperature range is 122 140 F 50 60 C The STC1510 contains cooling channels in the Motor Housing surrounding the motor stator These channels allow efficient removal of the heat The coolant enters and exits the Motor Housing through two Motor Cooling Ports as shown in Figure 8 Either of these Motor Cooling Ports can be used as an input the other would then become an output A closed loop water cooling system must be used and requires a separate cooling unit that circulates water through the Motor Housing to remove the heat All of the coolant PUSHCORP INC STC1510 Servo Tool Changer Manual 10 is recirculated in the system and no continuous supply or discharge is required A mixture of pure distilled water and a corrosion inhibitor is required such as DowTherm SR 1 or equivalent Typical cooling units are comprised of a pump water to air heat exchanger and fan These units are commercially available from several manufacturers eg Miller Coolmate 3 www millerwelds
11. repair or failure to operate the products 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 PUSHCORP INC STC1510 Servo Tool Changer Manual 2 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 PUSHCORP INC STC1510 Servo Tool Changer Manual 3 2 0 General Overview The PushCorp Inc STC1510 High Torque Servo Toolholder provides a convenient and effective means to spin and change many different media types The unit incorporates a 10 horsepower 7 5 kW Ser
12. tinue to operate The problem is that the motor and amplifier can experience excessive current spikes with rapid acceleration and declaration Media or tooling with a large mass or large diameter i e high moment of inertia only increases the current surge The amount of time allowed to reach the desired speed or stop will directly effect the life of the motor PushCorp recommends a smooth linear velocity ramp with a minimum period of three seconds be used to accelerate to full speed or to decelerate to zero speed The minimum three second acceleration period must be increased if larger higher inertia tools are used to prevent servo amplifier faults and avoid long term damage 3 7 Positioning Motor Shaft for Tool Change When performing a tool change the motor shaft must be clocked in the same position for drop off and pick up The servo motor shaft has two keys See Figure 7 that are spaced 180 apart and the BT30 toolholder has two corresponding key slots The servo amplifier amplifier provides an input to clock the motor shaft in the proper position PUSHCORP INC STC1510 Servo Tool Changer Manual 11 4 0 Technical Specifications MOTOR SPECIFICATIONS Supply Voltage 700 VDC via servo amplifier Power 10 0 hp 7 5 kW Continuous Stall Torque 14 lb ft 19 N m Maximum Speed 15000 RPM Reversible Speed Regulation 2 Weight 48 Ib 22 kg Dry Operating Temperature Optimal 122 140 F 50 60 C Maximum 176 F 8
13. ubing should be routed to the device such that there are no kinks and that there is plenty of slack to allow for manipulator motion Before inserting the tubing into the STC1510 air fitting open the Shut Off Valve to blow out any contaminates which may be in the Supply Line The tubing can now be pushed into the self locking fitting located on the Clamping Housing as shown in Figure 8 Charge the Supply Line with compressed air and verify that there are no air leaks and that there is a minimum of 90 PSI 6 2 bar at the STC1510 If a minimum air pressure cannot be achieved then an auxiliary air compressor or booster pump must be installed NOTE PushCorp highly recommends the use of flexible polyurethane tubing as opposed to nylon tubing This is because nylon tubing tends to crimp shut when it is bent To remove the Supply Line for service first discharge air pressure in the STC1510 then while pushing inward on the fitting s plastic ring simultaneously pull the tubing out Cover or plug the self locking fitting any time the Supply Line is not connected This will keep contaminants from entering the STC1510 PUSHCORP INC STC1510 Servo Tool Changer Manual 9 3 4 Electrical Connections The STC1510 has two electrical connections the Motor Power and Motor Feedback See Figure 7 If PushCorp supplies the cables and amplifier the tool should be easily connected to the amplifier CAUTION Do not run the Motor Power Cable together with any
14. vo Motor to provide high torque and precise speed control from 0 to 15 000 RPM The pneumatically actuated BT30 toolholder allows a quick change of media or tooling to support a fully automated workcell The STC1510 is comprised of five primary components a high torque Servo Motor a 30 tapered amp keyed shaft a pneumatic actuator high force Bellville springs and a retention knob gripper assembly The motor shaft is designed to accept a standard BT30 toolholder Since the motor shaft is keyed and the toolholder has corresponding slots they must be indexed to a known position before a tool change can occur High force Bellville springs located at the back of the Motor Housing tension a draw bar which pulls the gripper and locks the toolholder in the shaft Energizing the large pneumatic actuator located in the Clamping Housing opens the gripper assembly and releases the toolholder The STC1510 has several clever design features which make it unique First it is fail safe in that no air pressure is required to secure the toolholder Therefore the toolholder will remain held in the motor shaft even when the air pressure is un expectantly lost Likewise applying air pressure to a single input port via a simple manual or electrically operated valve opens the retention knob gripper and releases the toolholder from the motor shaft Finally this mechanical design isolates the bearings from the drawbar tension This greatly improves reliability by
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