AFD User`s Manual
Contents
1. Insert Size 11 Insert Style N331 1A 11 50 Diameter 4 9 inch 125mm No Inserts 8 Cutting Width 20mm 39mm 59mm 79mm For specific dimensions see http www pushcorp com for detail drawings Specifications subject to change without notice Fastener Tightening Torque Specs Torque Minimum Depth Fastener Size in lbs ft lbs Nm in mm MA x 7 50 4 2 5 6 0 17 4 3 M5x 8 85 7 1 9 6 0 21 5 3 M6x1 140 11 7 15 8 0 25 6 3 M8x1 25 348 29 0 39 3 0 33 8 4 M10x1 5 600 50 0 67 8 0 41 10 5 September 2010 PARO1982 1 132. 1212 8 5 0 SLOT CUTTER AND INSERTS rns au kann ao is ok ax as EE EYE and EAR NRI EA EELARERREAEKARyRRE S RRAX dn USUS 9 6 0 MAINTENANGE ciii eitis E eunti tet atia beo dla dut rate fosa ede 11 6 1 REPLACING THE DRIVE 11 6 2 SETTING THE PROPER DRIVE BELT 044040 0 nnn 12 1 0 5 13 Copyright PushCorp Inc 2010 All rights reserved 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 B 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
3. separation force with tools readily available on the factory floor Placing a Pry Tool on top of the Cutter Housing and underneath the mid point of the Servo Motor flange The pry bar location is shown in Figure 5 as the pry point This allows the Drive Belt to be easily tensioned The lever fulcrum creates a force multiplier With the Weld Shaver in the vertical position as shown in Figure 5 the proper Tension Force at 15 inches 381 mm will be 20 Ibs 87 for a new belt and 17 lbs 74 fora used belt Once the proper Tension Force has been applied tighten the 4 four M10 Flange Head Bolts to the torque specified in Section 7 0 Replace the Belt Cover and re install the 8 eight M6 Socket Head Cap Screws Tighten the M6 Socket Head Cap Screws to the torque specified in Section 7 0 CAUTION Never operate the SWS100 3 7 Weld Shaver without the Belt Cover properly installed September 2010 1982 1 12 7 0 Specifications TOOL WEIGHT SWS100 3 7 20 60 Ibs SWS100 3 7 39 67 Ibs SWS100 3 7 59 75 Ibs SWS100 3 7 79 85 Ibs MOTOR SPECIFICATIONS Power 4 8 Hp 3 6 kW Continuous Cutter Torque 15 6 lb ft 14 7 N m Maximum Cutter RPM 2800 RPM Motor to Cutter Belt Ratio 1 5 1 Supply Voltage 208 480 VAC 50 60 Hz Drive Belt Specification Gates P N 8MGT 640 21 Requires separate power supply amplifier and cables CUTTER SPECIFICATIONS Manufacturer Sandvik 331 Coromill 27 kg 30 kg 34 kg 39 kg
4. 7 Series Weld Shavers are designed to attached to the carriage of a PushCorp AFD1100 80 via an Adapter Plate SWS100 3 7 20mm SWS100 3 7 39mm SWS100 3 7 59mm The SWS100 3 7 79mm is designed to bolt directly to an AFD1200 90 Adjustable Force Device Figure 1 and Figure 2 below illustrates how these units are mounted to the AFD Carriage FEEDBACK CONNECTOR POWER CONNECTOR SWS100 3 7 SERIES AFD CARRIAGE Figure 1 Mounting the SWS100 3 7 20 SWS100 3 7 39 and SWS100 3 7 59 September 2010 PARO01982 1 4 POWER CONNECTOR FEEDBACK CONNECTOR SWS100 3 7 79 L M8X1 25 X 20 FLANGE HEAD BELT HOUSING COVER AFD 90 1200 X 18 CAP HEAD A Figure 2 Mounting the SWS100 3 7 79mm The SWS100 3 7 attaches to the AFD Carriage with M8x1 25 flange head fasteners provided by PushCorp Refer to Figure 1 and Figure 2 for the proper location of the fasteners CAUTION If alternate fasteners are used make sure they do not exceed a depth of 0 525 inch 13 3 mm into the AFD Carriage or damage can occur The Adapter Plate can be extended beyond the end of the carriage to allow more clearance In this case only six M8 fasteners would be required to secure the plate to the carriage 3 2 Electrical Connections To use the SWS100 3 7 Series Weld Shavers it is necessary to connect the Servo Power and Servo Feedback cables correctly The servo amplifier is pre configured to accept a 0 10VDC analog command velocity sign
5. min Eq 3 Feed Cutter Insert in Cutter Insert Eq 2 September 2010 01982 1 7 The above equations are provided to help determine initial settings for the Weld Shaver Note that the Servo Motor rotates at 1 5 times the speed of the Slot Cutter Each Slot Cutter has eight 8 identical inserts This has been included in the equations above These equations apply only to the SWS100 3 7 Weld Shaver and should not be used for any other machines To help illustrate the use of the equations the following Example Problems are provided Example Problem 1 Determine the Servo Motor RPM for a Steel weld seam Material Steel Cutting Speed 450 ft min See Table 1 Servo Motor RPM 450 x 1 2 540 Rev min Eq 1 Example Problem 2 Determine the Feed Cutter Insert for a Robot Feed Rate of 20 in min and a Servo Motor RPM of 540 Rev min 20 Feed Cutter Insert Axa 7 0 007 in Cutter Insert Eq 2 Example Problem 3 Determine the Robot Feed Rate based on a 0 007 in Cutter Insert and a Servo Motor RPM of 540 Rev min Robot Feed Rate 5 4 x 0 007 x 540 20 in min Eq 3 4 3 Problems and Corrective Measures Table 2 shows some of the more common troubles encountered and the recommended corrective measures involving variations in Cutter Speeds Servo Motor RPM and Feeds Robot Feed Rate Problem Corrective Action Lack of rigidity Robot Flexing Increase Cutting Speed r
6. 100 3 7 is comprised of two primary components a Slot Cutter assembly and a high torque Servo Motor The machining operation is performed by a 5 inch 125mm diameter Sandvik Coromill amp 331 Slot Cutter with replaceable Cutter Inserts Each Slot Cutter is capable of machining a 20mm wide path The SWS100 3 7 Series Weld Shavers may be configured with one two three or four Slot Cutters allowing a width of cut ranging from 20mm to 79mm The cutting depth of the Slot Cutter can be adjusted to any position from 0 1 inch 2 5mm above the surrounding part surface to 0 1 inch 2 5mm below A Servo Motor provides the power to turn the Slot Cutter and allows precision adjustable speed control through a 0 10VDC analog interface The SWS100 3 7 Series uses a 3 7 Horsepower motor with a speed range of 0 to 4000 RPM The belt and pulley drive provides a 1 5 1 reduction ratio which reduces the speed and increases the output torque at the Slot Cutter The Servo Motor allows the Weld Shaver to control Slot Cutter speed within 59e The projected life of this high quality Servo Motor is over 30 000 hours Simple reliable construction combined with high torque precision speed controlled servo technology make the PushCorp SWS100 3 7 Servo Weld Shaver a rugged state of the art technology capable of providing flexible cost effective weld machining operations September 2010 1982 1 3 0 Installation 3 1 Mounting the SWS100 3 7 The SWS100 3
7. SWS100 3 7 Series Servo Weld Shavers User Manual PUSHCORP INC Dallas Texas DANGER REMOVE SERVO MOTOR ELECTRICAL POWER before replacing Slot Cutter inserts or servicing weld shaver WARNING SAFETY GLASSES ARE ALWAYS REQUIRED Insert breakage or shatter presents great potential for eye injury 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 SWS100 3 7 Series Weld Shavers Table of Contents 1 55 1 2 0 GENERAL OVERVIEW ioiii i waedadindertaaaeatede 3 3 0 INSTALLATION x SEL 4 3 1 MOUNTING THE 8 5100 3 7 444244404 1 421222 aeai ae ananasa danaa E sa aas inna 4 3 2 ELECTRICAL 5 4 0 OPERATION xem 6 4 1 SETTING THE DEPTH OF 6 4 2 SETTING FEEDS AND 5 8 4 1 1 11 7 4 3 PROBLEMS AND CORRECTIVE 5 4 444 4444 8 4 4 TEACHING THE WELD SHAVER
8. al and a 24VDC digital signal to enable the motor These are the only two signals that are required for operation and no other configuration is required to operate the motor Other more advanced features are available and may be configured by referring to the supplied servo amplifier documentation September 2010 PARO01982 1 5 4 0 Operation 4 1 Setting the Depth of Cut DEPTH ADJUSTMENT CAM KNOB DEPTH ADJUSTMENT LOCKING SCREW TRACKING WHEEL Figure 3 Depth of cut Adjustment Adjusting the Weld Shaver s depth of cut is accomplished by raising or lowering the Tracking Wheels Figure 3 Raising the Tracking Wheels to the maximum position will result in an approximately 0 1 inch 2 5 mm deep slot Lowering the Tracking Wheels to their lowest position will cause the Slot Cutter to be offset approximately 0 1 inch 2 5 mm above the surface Adjusting the Tracking Wheels to the middle position will produce a cut that is flush with the surface CAUTION Remove all power from the Servo Motor before performing any adjustments to the SWS100 3 7 Series Weld Shaver To adjust the depth of cut first loosen the four 4 Depth Adjustment Locking Screws approximately 1 4 turn CAUTION It is required that the Depth Adjustment Locking Screws are released before the Depth Adjustment Knob is rotated Failure to release the Depth September 2010 PARO1982 1 6 Adjustment Locking Screws can damage the mechanism and require the unit to be
9. educe Feed Excessive abrasion on the insert Reduce Cutting Speed increase Feed of the cutting Reduce Feed Cutter Insert Burning of the cutting edge Reduce Cutting Speed Cratering of cemented carbide Reduce Feed and Cutting Speed Chatter Try other combinations of Feed and Cutting Speed Table 2 Troubles and Corrective Measures 4 4 Teaching the Weld Shaver Path Teaching the path over the part surface is greatly simplified because of the force device s compliance The force control carriage stroke of the AFD allows the Weld Shaver Guide Wheels to easily maintain consistent contact with the part surface Both Guide Wheels must maintain continuous contact with the part surface during the machining operation The required AFD force is dependent on the application however 20 lbs 89 applied force is usually a good starting point If the force is too low the Guide Wheels can rise from the surface and cause damage to the cutter inserts Conversely applying September 2010 1982 1 8 too much force can cause the part surface to deflect or deform and places unnecessary loads on the Guide Wheels The Guide Wheels should straddle the weld seam to produce the best results Remember the Weld Shaver only follows the part surface Therefore any dirt contamination or weld spatter will affect the final quality of the cut 5 0 Slot Cutter and Inserts The Slot Cutter provides for Cutter Insert location plu
10. inery s Handbook or from the Insert manufacturer http www sandvik com Work Material Cutter Speed ft min Aluminum 1000 Silicon Bronze 1500 Table 1 Cutter Speed for various materials Feed is usually measured in inches per minute It is the product of Feed per Cutter Insert times revolutions per minute times the number of Inserts in the Slot Cutter Feed per Cutter Insert affects chip thickness which is a very important factor in Insert life Very thin or feather edge chips dull cutting edges more rapidly than thick chips In general the highest possible Feed per Cutter Insert will usually produce longer Insert life However excessive Feeds may also overload the Cutter Inserts and cause breakage or chipping of the cutting edge Excessive feed can also cause the shaver motor to stall or the servo amplifier to fault As a guideline use higher Feeds for heavy roughing cuts easily machined materials high tensile strength materials abrasive materials Use lower Feeds for light and finishing cuts difficult to machine materials low tensile strength materials A typical Feed per Cutter Insert for the SWS100 3 7 is 0 005 inches 0 12 mm The Robot Feed Rate is the speed that the robot moves the Weld Shaver across the part in inches per minute Servo Motor RPM Cutter Speed ft min x 1 2 Rev min Eq 1 Robot Feed Rate in min 5 4 x Servo Motor RPM Robot Feed Rate 5 4 x Feed Cutter Insert x Servo Motor RPM in
11. returned to the factory service center for a non warranty repair Rotate the Depth Adjustment Cam Knob to move the Tracking Wheels relative to the Slot Cutter Rotating the Depth Adjustment Knob one complete revolution will result in the Tracking Wheels moving 0 2 inches 5mm A straight edge can be placed on the Tracking Wheels to position the Cutter Inserts to cut flush with the surface In other cases it is most expeditious to approximate the initial setting and fine tune the Tracking Wheel position with sample passes Once a depth of cut has been selected the four 4 M8 Depth Adjustment Locking Screws should be re tightened to the torque specified in Section 7 0 before beginning machining operations 4 2 Setting Feeds and Speeds Speed and Feed are important factors to consider for best results in milling Improper Feed and Speed often cause low production poor work quality and unnecessary wear to the inserts In milling Cutter Speed is measured in peripheral feet per minute revolutions per minute times the Slot Cutter circumference in feet This will be referred to as the Cutter Speed here In general use lower Cutter Speeds for hard materials tough materials abrasive materials heavy cuts and maximum insert life Use higher Cutter Speeds for softer materials light cuts better finishes maximum production rates Table 1 gives approximate starting Cutter Speed values for some common materials Additional information can be found in Mach
12. s adjustable width and indexing capabilities The Cutter Inserts are retained securely in position by Insert Screws which permit the Cutter Inserts to be indexed A large selection of Cutter Inserts are available from Sandvik COROMILL 331 n 3 U a f 1 RIGHT K Figure 4 Slot Cutter Assembly Item Sandvik Part Number Description 1 RIGHT 5321 240 07 RIGHT CASSETTE 1 LEFT 5321 240 08 LEFT CASSETTE 2 5513 020 29 INSERT SCREW 3 USER SELECTED CUTTER INSERT 4 5431 105 04 WEDGE 5 339 831 WEDGE SCREW September 2010 PAR01982 1 9 DANGER Remove all power from the Servo Motor before changing or indexing Cutter Inserts WARNING Insure Wedge Screws are securely tightened into the Slot Cutter before rotating with the Servo Motor Set up Procedure 1 Determine the correct insert for the material to be milled 2 Remove the Insert Screw 2 shown in Figure 4 and install or index the dull Cutter Insert 3 Insure that the Slot Cutter is Cassette Pocket 1 is clean 4 Hand position the Cutter Insert 3 between in the Cassette 5 Securely tighten the Insert Screw 2 with a torque of 26 Ib 3 N m The Insert Screw is a type Torx Plus 15IP The recommended Sandvik torque wrench is listed below 6 Continue this process until all 8 eight Cutter Inserts are replaced or correctly indexed NOTE Cutter Inserts can be indexed i e rotated 180 Cutter Insert Screw
13. 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 purchasers abuse neglect unauthorized 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 September 2010 1982 1 1 Responsibilities of the purchaser under this warranty A Deliver or ship the PushCorp Inc product or component to PushCorp Inc Service Center 3001 Kingsley Rd Garland TX 75041 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 par
14. to move but constrain the Drive Pulley to remain essentially parallel to the Driven Pulley during tensioning 3 Move the Servo Motor in the slots toward the Driven Pulley This is the shortest distance between the two pulleys September 2010 PARO01982 1 11 4 Slide the Drive Belt off the Driven Pulley no flanges until it is clear and slip the Drive Belt off of the Drive Pulley 5 To install the new Drive Belt first place it over the Drive Pulley and then slide it over the Driven Pulley It is absolutely critical that the belt teeth are correctly meshed with the teeth on both of the pulleys This is accomplished by moving the Servo Motor away from the Driven Pulley while rotating the pulleys in opposite directions by hand 6 Proceed to Section 6 2 to set the proper Drive Belt tension 6 2 Setting the Proper Drive Belt Tension Applying the proper Drive Belt tension is a very important factor in the life of the Drive Belt and the Servo Motor Too little tension will allow the Drive Belt to jump teeth on the pulleys Too much tension will cause premature failure of the Servo Motor bearings The Weld Shaver requires tension in each belt segment of 118 lbs 525 N for a new belt and 101 Ibs 450 for a used belt which results a separation force of 235 Ibs 1045 and 200 Ibs 892 respectively between the Drive and Driven Pulleys The main problem with tensioning the Drive Belt is accurately applying the required
15. torque wrench Sandvik P N 5680 100 06 Torx Plus Wedge Screw Key Sandvik P N 265 2 817 3 0mm Cutter Inserts Sandvik ordering code N331 1A 11 50 September 2010 1982 1 10 6 0 Maintenance 6 1 Replacing the Drive Belt The Drive Belt used in the Weld Shaver transfers power from the Servo Motor to the Slot Cutter The Drive Belt has been sized to handle the largest possible peak Servo Motor torque so that fatigue will most likely be the cause of any belt failure It is not unusual for a belt of this type to perform for thousands of hours however actual performance is highly dependent on the application M10 FLANGE HEAD NUT DRIVE PULLEY DRIVE BELT PRY POINT DRIVEN PULLEY Figure 5 Replacing the Drive Belt One of the benefits of synchronous belt drives is lower belt pretensioning in comparison to other belt drives However proper installation tension is still important in achieving the best possible performance In general terms belt tensioning is needed for proper belt pulley meshing to prevent belt ratcheting under peak loading DANGER Remove all power from the Servo Motor before servicing the SWS100 3 7 Weld Shaver Drive Belt Replacement Procedure 1 Remove the 8 eight M6x1 Socket Head Cap Screws securing the Belt Cover to provide access to the Drive Belt See Figure 2 2 Loosen the 4 four M10x1 5 Flange Head Nuts shown in Figure 5 approximately turn This will allow the Servo Motor
16. ts 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 September 2010 1982 1 2 2 0 General Overview The PushCorp Inc SWS100 3 7 Series Servo Weld Shaver provides a fast and effective means to accurately remove excess material from a surface The Weld Shaver is designed to remove random inconsistent surface features such as seam welds parting lines and flashing leaving behind a known consistent smooth surface SWS100 3 7 is ideal for use in applications where force based abrasive only operations fail Using the SWS100 3 7 can produce significant cost savings since one set of inserts can often out last hundreds of abrasive disks A large selection of replaceable Carbide cutting inserts are used to literally peel metal away The Weld Shaver AFD combination forms a unique system where force control and positioning are used to perform accurate machining operations with a robot The SWS100 3 7 enables accurate surface machining by utilizing Tracking Wheels to follow over the part surface profile An appropriate Adjustable Force Device is used to hold the Tracking Wheels firmly against the part surface This arrangement allows the Weld Shaver to maintain contact with complex surfaces while compensating for any robot part misalignment The SWS
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