Aerotech AXR Series User manual

Revision: 1.03.00
AXR Hardware Manual

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To get help immediately, contact a service office or your sales representative. Include your customer order number in your
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101 Zeta Drive
Pittsburgh, PA 15238-2811
www.aerotech.com
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This manual contains proprietary information and may not be reproduced, disclosed, or used in whole or in part without the
express written permission of Aerotech, Inc. Product names mentioned herein are used for identification purposes only and
may be trademarks of their respective companies.
Copyright © 2010-2019, Aerotech, Inc., All rights reserved.

AXR Hardware Manual Table of Contents
Table of Contents
AXR Hardware Manual 1
Table of Contents 3
List of Figures 4
List of Tables 5
Safety Procedures and Warnings 6
EU Declaration of Incorporation 7
Chapter 1: Overview 9
1.1. Environmental Specifications 11
1.2. Accuracy and Temperature Effects 11
1.3. Basic Specifications 12
Chapter 2: Installation 13
2.1. Unpacking and Handling the Stage 13
2.2. Dimensions 15
2.3. Securing the Stage to the Mounting Surface 17
2.4. Attaching the Payload to the Stage 18
2.4.1. B Axis With Tabletop Option 18
2.4.2. B Axis With Manual Three Jaw Chuck 19
2.5. Air Line Access 20
2.6. Brake Option 21
2.7. Drive Types 21
2.8. Counterbalance System 22
2.8.1. Offset Mounting Counterbalancing 22
2.8.2. Inline Mounting Counterbalancing 23
2.8.3. Balancing Charts 24
2.8.4. Balancing the A Axis 31
Chapter 3: Electrical Specifications and Installation 33
3.1. Motor and Feedback Connectors 34
3.2. Motor and Feedback Wiring 38
3.3. Motor and Feedback Specifications 39
3.4. Limits, Marker, and Machine Direction 44
3.5. Motor and Feedback Phasing 45
Chapter 4: Maintenance 47
4.1. Service and Inspection Schedule 47
4.2. Cleaning and Lubrication 48
4.3. Troubleshooting 49
Appendix A: Warranty and Field Service 51
Appendix B: Revision History 53
Index 55
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Table of Contents AXR Hardware Manual
List of Figures
Figure 1-1: AXR Integrated Two-Axis Rotary Assembly 9
Figure 2-1: AXR With Shipping Bracket 14
Figure 2-2: AXR100D Dimensions 15
Figure 2-3: AXR150 Dimensions 16
Figure 2-4: Mounting Hole Locations 17
Figure 2-5: Chuck Clamping Ranges 19
Figure 2-6: Air Line Access 20
Figure 2-7: Brake Option: Air Line Access 21
Figure 2-8: Adjustable Counterweight Locations (Offset and Chuck Options) 22
Figure 2-9: Adjustable Counterweight Locations (-0E Option) 23
Figure 2-10: AXR100D-100 Balance Chart 24
Figure 2-11: AXR100D-0E Balance Chart 25
Figure 2-12: AXR100D-100C Balance Chart 25
Figure 2-13: AXR150D-125 Balance Chart 26
Figure 2-14: AXR150D-125C Balance Chart 26
Figure 2-15: AXR150D-0E Balance Chart 27
Figure 2-16: AXR150G50-125 Balance Chart 27
Figure 2-17: AXR150G100-125 Balance Chart 28
Figure 2-18: AXR150G160-125 Balance Chart 28
Figure 2-19: AXR150G50-125C Balance Chart 29
Figure 2-20: AXR150G100-125C Balance Chart 29
Figure 2-21: AXR150G160-125C Balance Chart 30
Figure 3-1: Electrical Connectors and Grounds 33
Figure 3-2: Motor and Feedback Wiring 38
Figure 3-3: Machine Direction 44
Figure 3-4: Hall Phasing 45
Figure 3-5: Analog Encoder Phasing Reference Diagram 46
Figure 3-6: Encoder Phasing Reference Diagram (Standard) 46
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AXR Hardware Manual Table of Contents
List of Tables
Table 1-1: Model Numbering System 10
Table 1-2: Environmental Specifications 11
Table 1-3: AXR Series Specifications 12
Table 2-1: Stage to Mounting Surface Hardware 17
Table 2-2: Clamping Ranges for SelfCentering Scroll Chucks 19
Table 2-3: Gear Drive Specifications 21
Table 2-4: Continuous Current and Torque Ratings 31
Table 3-1: Motor Pin Assignments for the A and B Axes 35
Table 3-2: Feedback Pin Assignments for the A Axis 36
Table 3-3: Feedback Pin Assignments for the B Axis 37
Table 3-4: Feedback Specifications 39
Table 3-5: Encoder Specifications (AXR100D, AXR150D) 40
Table 3-6: Encoder Specifications (AXR150G) 40
Table 3-7: AXRMotors for the A and B Axes 40
Table 3-8: S-76-35 Motor Specifications (for the AXR100D) 41
Table 3-9: S-130-xx Motor Specifications (for the AXR100D, AXR150D, and AXR150G) 42
Table 3-10: S-180-xx Motor Specifications (for the AXR150D and AXR150G) 43
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Table of Contents AXR Hardware Manual
Safety Procedures and Warnings
This manual tells you how to carefully and correctly use and operate the AXR. Read all parts of this manual
before you install or operate the AXR or before you do maintenance to your system. To prevent injury to you
and damage to the equipment, obey the precautions in this manual. The precautions that follow apply when
you see a Danger or Warning symbol in this manual. If you do not obey these precautions, injury to you or
damage to the equipment can occur. If you do not understand the information in this manual, contact
Aerotech Global Technical Support
This product has been designed for light industrial manufacturing or laboratory environments. The protection
provided by the equipment could be impaired if the product is used in a manner not specified by the
manufacturer.
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any
time. All drawings and illustrations are for reference only and were complete and accurate as of this
manual’s release. Refer to www.aerotech.com for the most up-to-date information.
D A N G E R : This product contains potentially lethal voltages. To reduce the possibility of
electrical shock, bodily injury, or death the following precautions must be followed.
1. Access to the AXR and component parts must be restricted while connected to a power
source.
2. Do not connect or disconnect any electrical components or connecting cables while
connected to a power source.
3. Disconnect electrical power before servicing equipment.
4. All components must be properly grounded in accordance with local electrical safety
requirements.
5. Operator safeguarding requirements must be addressed during final integration of the
product.
W A R N I N G : To minimize the possibility of electrical shock, bodily injury or death the
following precautions must be followed.
1. Moving parts can cause crushing or shearing injuries. Access to all stage and motor parts
must be restricted while connected to a power source.
2. Cables can pose a tripping hazard. Securely mount and position all system cables to avoid
potential hazards.
3. Do not expose this product to environments or conditions outside of the listed
specifications. Exceeding environmental or operating specifications can cause damage to
the equipment.
4. The AXR must be mounted securely. Improper mounting can result in injury and damage to
the equipment.
5. Use care when moving the AXR . Lifting or transporting the AXR improperly can result in
injury or damage to the AXR.
6. If the product is used in a manner not specified by the manufacturer, the protection
provided by the product can be impaired and result in damage, shock, injury, or death.
7. Operators must be trained before operating this equipment.
8. All service and maintenance must be performed by qualified personnel.
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AXR Hardware Manual Table of Contents
EU Declaration of Incorporation
Manufacturer: Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2811
USA
herewith declares that the product:
AXR Stage
is intended to be incorporated into machinery to constitute machinery covered by the Directive 2006/42/EC
as amended;
and that the following harmonized European standards have been applied:
EN ISO 12100:2010
Safety of machinery - Basic concepts, general principles for design
EN 60204-1:2010
Safety of machinery - Electrical equipment of machines - Part 1:General requirements
and further more declares that
it is not allowed to put the equipment into service until the machinery into which it is to be
incorporated or of which it is to be a component has been found and declared to be in
conformity with the provisions of the Directive 2006/42/EC and with national
implementing legislation, i.e., as a whole, including the equipment referred to in this
Declaration.
This is to certify that the aforementioned product is in accordance with the applicable requirements of the
following Directive(s):
2011/65/EU RoHS2 Directive
Authorized Representative: Simon Smith, European Director
Address: Aerotech Ltd
The Old Brick Kiln, Ramsdell, Tadley
Hampshire RG26 5PR
UK
Name
/ Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
Date 1/31/2019
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Table of Contents AXR Hardware Manual
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AXR Hardware Manual Overview
Chapter 1: Overview
Aerotech’s AXR integrated two-axis rotary assembly provides high-speed machining capabilities for
complex 3D part geometries. The precision-aligned system allows accurate positioning on a hemispherical
surface. Multiple frame sizes with direct- or gear-driven options provide a wide range of load carrying
capability.
Figure 1-1: AXR Integrated Two-Axis Rotary Assembly
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Overview AXR Hardware Manual
Table 1-1: Model Numbering System
AXRSeries Rotary Assembly
-100D Direct-drive tilt (A) axis and yaw (B) axis rated for 15 kg maximum load
-150D Direct-drive tilt (A) axis and yaw (B) axis rated for 30 kg maximum load
-150G Gear-drive tilt (A) axis with direct-drive yaw (B) axis; rated for 30 kg maximum load
Yaw Axis Configuration
-0 Yaw (B) axis tabletop height of AXR100D and AXR150x located at the center of rotation
of the tilt (A) axis; no counterweight attachment supported
-0E
Yaw (B) axis tabletop height of AXR100D and AXR150D located at the center of rotation
of the tilt (A) axis; includes attachment features for counterweights to balance offset
loads
NOTE:0E option not available on gear-driven AXRs (150G). Gearbox has sufficient holding torque to balance
maximum moment load.
-100
Yaw (B) axis tabletop height for AXR100D is located 100 mm above the center of rotation
of the tilt (A) axis; includes attachment features for counterweights to balance offset
loads
-100C
Yaw (B) axis with 3-jaw 3.25-inch (82.6 mm) diameter manual scroll chuck; chuck jaws of
AXR100D are located 100 mm above the center of rotation of the tilt (A) axis; includes
attachment features for counterweights to balance offset loads and 3-jaw manual chuck
-125
Yaw (B) axis tabletop height for AXR150x is located 125 mm above the center of rotation
of the tilt (A) axis; includes attachment features for counterweights to balance offset
loads
-125C
Yaw (B) axis with 3-jaw 5-inch (127 mm) diameter manual scroll chuck; chuck jaws of
AXR150x are located 125 mm above the center of rotation of the tilt (A) axis; includes
attachment features for counterweights to balance offset loads and 3-jaw manual chuck
Brake Configuration (Optional)
-B Holding brake for tilt (A) axis; only available on 100D and 150D configurations
Sealing Configuration (Optional)
-S Seals on the tilt (A) and yaw (B) axes to prevent ingress of airborne particulates into the
stage; the seal does not protect the AXR system from contact with fluids
Counterweight Configuration(Optional)
-CW1
Counterweight kit for AXR100 (-100, -100C) for offset loads ranging from:
-100: 23.5 N·m to 338 N·m
-100c: 48 N·m to 242 N·m
-CW2
Counterweight kit for AXR100 (-100, -100C) for offset loads ranging from:
-100: 1.4 N·m to 48 N·m
-100c: 6 N·m to 36 N·m
-CW3 Counterweight kit for AXR100 (-100) for offset loads of 41.3 N·m
-CW4 Counterweight kit for AXR100 (-100C) for offset loads of 23.4 N·m
-CW5 Counterweight kit for AXR100 (-0E) for offset loads ranging from 10.8 N·m to 54.2 N·m
-CW6 Counterweight kit for AXR100 (-0E) for offset loads ranging from 31.1 N·m to 124.4 N·m
-CW7 Counterweight kit for AXR100 (-0E) for offset loads of 15.7 N·m
-CW8 Counterweight kit for AXR100 (-0E) for offset loads of 13.1 N·m
1. Offset loads include both the payload and stage unbalance.
2. A linear combination of counterweight kits can be employed to achieve balance. Refer to Section 0.0.1. determine if application
falls within balance limits.
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AXR Hardware Manual Overview
1.1. Environmental Specifications
W A R N I N G : Do not expose this product to environments or conditions outside of the listed
specifications. Exceeding environmental or operating specifications can cause damage to the
equipment.
Table 1-2: Environmental Specifications
Ambient
Temperature
Operating: 10° to 35° C (50° to 95° F)
The optimal operating temperature is 20° C ±2° C (68° F ±4° F). If at any time the
operating temperature deviates from 20° C, degradation in performance could occur.
Storage: 0° to 40° C (32° to 104° F) in original shipping packaging
Humidity
Operating: 20% to 60% RH
Storage: 10% to 70% RH, non-condensing in original packaging. The stage should be
packaged with desiccant if it is to be stored for an extended time.
Altitude
Operating: 0 m to 2,000 m (0 ft to 6,562 ft) above sea level
Contact Aerotech if your specific application involves use above 2,000 m or below sea
level.
Vibration
Use the system in a low vibration environment. Excessive floor or acoustical vibration
can affect system performance. Contact Aerotech for information regarding your spe-
cific application.
Protection
Rating
With the seal option, AXR stages are dust sealed but should not be exposed to water.
This equates to an ingress protection rating of IP60.Without the seal option, AXR
stages are not suited for dusty or wet environments. This equates to an ingress
protection rating of IP00.
Use Indoor use only
1.2. Accuracy and Temperature Effects
Aerotech products are designed for and built in a 20°C (68°F) environment. Extreme temperature changes
could cause a decrease in performance or permanent damage to the AXR. At a minimum, the environmental
temperature must be controlled to within 0.25ºC per 24 hours to ensure the AXR specifications are
repeatable over an extended period of time. The severity of temperature effects on all specifications depends
on many different environmental conditions, including how the AXR is mounted. Contact the factory for more
details.
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Overview AXR Hardware Manual
1.3. Basic Specifications
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any
time. All drawings and illustrations are for reference only and were complete and accurate as of this
manual’s release. Refer to www.aerotech.com for the most up-to-date information.
Table 1-3: AXR Series Specifications
Mechanical Specifications
AXR-100 AXR-150
Tilt (A) Axis
Direct Drive
Yaw (B) Axis
Direct Drive
Tilt (A) Axis
Direct Drive
Tilt (A) Axis
Gear Drive
Yaw (B)Axis
Direct Drive
Travel +10° to -100° Unlimited +10° to -100° +10° to -100° Unlimited
Accuracy(1) Uncalibrated ±145 µrad (±30 arc sec) ±145 µrad
(±30 arc sec)
±242 µrad
(±50 arc sec)
±145 µrad
(±30 arc sec)
Calibrated ±14.5 µrad (±3 arc sec) ±14.5 µrad
(±30 arc sec)
±24.2 µrad
(±50 arc sec)
±14.5 µrad
(±30 arc sec)
Resolution 0.05 arc·sec 0.08 arc·sec 0.04 arc·sec 0.04 arc·sec 0.05 arc·sec
Repeatability(1) (Bi-
Directional) 1 arc·sec 1 arc·sec 5 arc·sec 1 arc·sec
Tilt Error Motion N/A 5 arc·sec N/A N/A 3 arc·sec
Axial Error Motion N/A 1.5 µm N/A N/A 1 µm
Radial Error Motion N/A 3 µm N/A N/A 2 µm
Orthogonality 50 µrad (10 arc-sec) 50 µrad (10 arc-sec)
Axis Intersection ±10 µm (± 0.00039 in) ±10 µm (± 0.00039 in)
Gear Ratio N/A N/A
51:1
101:1
161:1
N/A
Maximum Speed(6) 720 °/sec 1000 rpm 720 °/sec
60 °/s
30 °/s
18 °/s
600 rpm
Maximum Torque
(Continuous) 4.18 N·m 0.2 N·m 11.12 N·m
305 N·m
605 N·m
964 N·m
2.36 N·m
Load Capacity 15 kg 30 kg
Rotor Inertia
(Unloaded)
No Offset
0.070 kg·m20.00107
kg·m2
0.216 kg·m20.211 kg·m2
0.00686
kg·m2
Offset 0.178 kg·m20.174 kg·m2
Chuck
Option 0.212 kg·m20.207 kg·m2
Stage Mass(6)
No Offset 24 kg N/A 45.5 kg 44 kg N/A
Offset 24.4 kg N/A 46.8 kg 45.5 kg N/A
Chuck
Option 24.9 kg N/A 50.7 kg 49.4 kg N/A
Material Aluminum Aluminum
Mean Time Between Failure 20,000 Hours 20,000 Hours 15,000 Hours 20,000 Hours
1. Certified with each stage.
2. On-axis loading is listed.
3. All error motion specifications are measured at 60 rpm.
4. For high speed operation, customer payload must be balanced to G1.0 per ISO 1940.
5. Max speed is listed for unloaded stages. Max speed of gear drive unit is a function of gear ratio. Speeds are 10 rpm, 5 rpm, and 3
rpm.
6. Stage mass listed as system mass.
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AXR Hardware Manual Assembly and Installation
Chapter 2: Installation
W A R N I N G : AXR installation must be in accordance to instructions provided by this manual
and any accompanying documentation. Failure to follow these instructions could result in injury
or damage to the equipment.
2.1. Unpacking and Handling the Stage
D A N G E R / H E A V Y : It is the customer's responsibility to safely and carefully lift the stage.
lRefer to Table 1-3 for chassis mass specifications.
lTo avoid injury, use two or more people to move and install this product.
lOnly lift the AXR with the shipping clamps attached.
lUse a cart or forklift to move the AXR.
lLift the AXR only by the base. Do not use the cables or tabletop to lift or move this product.
lMake sure that all moving parts are secure before moving the AXR. Unsecured moving
parts may shift and cause bodily injury.
lImproper handling could adversely affect the performance of the AXR. Use care when
moving the AXR.
Carefully remove the AXRfrom its protective shipping container. Gently set the AXR on a smooth, flat, and
clean surface.
Before operating the AXR, it is important to let it stabilize at room temperature for at least 12 hours. Allowing
it to stabilize to room temperature will ensure that all of the alignments, preloads, and tolerances are the
same as they were when tested at Aerotech. Use compressed nitrogen or clean, dry, oil-less air to remove
any dust or debris that has collected during shipping.
Each AXR has a label listing the system part number and serial number. These numbers contain information
necessary for maintaining or updating system hardware and software. Locate this label and record the
information for later reference.
Red, anodized aluminum shipping brackets have been installed to prevent unwanted motion and potential
damage from occurring during shipment. The brackets must be removed before the AXR can be operated.
The shipping bracket is located on the cable side of the A axis (refer to Figure 1-1). Retain the brackets and
hardware for future use.
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Assembly and Installation AXR Hardware Manual
Figure 2-1: AXR With Shipping Bracket
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AXR Hardware Manual Assembly and Installation
2.2. Dimensions
Figure 2-2: AXR100D Dimensions
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Assembly and Installation AXR Hardware Manual
Figure 2-3: AXR150 Dimensions
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AXR Hardware Manual Assembly and Installation
2.3. Securing the Stage to the Mounting Surface
W A R N I N G : Make sure that all moving parts are secure before moving the AXR. Unsecured
moving parts may shift and cause bodily injury.
W A R N I N G : The AXR must be mounted securely. Improper mounting can result in injury and
damage to the equipment.
The mounting surface must be flat and have adequate stiffness in order to achieve the maximum
performance from the AXR stage. When it is mounted to a non-flat surface, the stage can be distorted as the
mounting screws are tightened. This distortion will decrease overall accuracy. Adjustments to the mounting
surface must be done before the stage is secured.
Inspect the mounting surface for dirt or unwanted residue and clean if necessary. Clean the mounting
surface with a lint-free cloth and acetone or isopropyl alcohol and allow the cleaning solvent to completely
dry.
N O T E : To maintain accuracy, the mounting surface must be flat to within 1 µm per 50 mm.
N O T E : The AXR is precision machined and verified for flatness prior to product assembly at the factory.
If machining is required to achieve the desired flatness, it should be performed on the mounting surface
rather than the AXR. Shimming should be avoided if possible. If shimming is required, it should be
minimized to retain maximum rigidity of the system.
AXR series stages have a fixed mounting pattern (as shown in Figure 2-4).
Tightening torque values for the mounting hardware are dependent on the properties of the surface to which
the stage is being mounted. Values provided in Table 2-1 are typical values and may not be accurate for your
mounting surface. Refer to Section 2.2. for specific model mounting locations and dimensions.
Table 2-1: Stage to Mounting Surface Hardware
Mounting Hardware Typical Screw Torque
M6x1.0 x 20 mm long [1/4-20 x 3/4 in long] SHCS 8 N·m
Figure 2-4: Mounting Hole Locations
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Assembly and Installation AXR Hardware Manual
2.4. Attaching the Payload to the Stage
The payload attachment method varies depending on whether the B axis is equipped with a tabletop or with a
three jaw chuck. Section 2.4.1. and Section 2.4.2. explain the different attachment methods in more detail.
AXR stages typically require some level of payload balancing to keep the holding torque required of the A
axis drive train to an acceptable level. Depending on the options of the unit, is possible that, before you can
run the stage, you must install a payload to match the balancing of the system as it was shipped. Aerotech
recommends starting the stage for the first time using a dummy payload attached that has the same mass
and center of gravity as the final payload that is to be used with the system. Once the servo tuning and
operating parameters are set to satisfaction, then the final payload should be installed.
For high speed operation of the B axis, payloads must be balanced to G1.0 per ISO 1940.
2.4.1. B Axis With Tabletop Option
Payloads can be bolted to the B axis tabletop via the threaded holes with Helicoil inserts. Hole pattern
details are shown in Figure 2-2 and Figure 2-3.
N O T E : For valid system performance, the mounting interface should be flat within 10 microns or less.
W A R N I N G : Refer to the dimensions in Section 2.2. for maximum allowable thread
engagement. A screw extending through the stage table can affect travel and damage the
stage.
You can access the pneumatic line via the M5 tapped hole in the center of the table top. An o-ring (568A-015)
is also available as a static thrust seal on the table top for direct feed through of the pneumatic line to a
payload.
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AXR Hardware Manual Assembly and Installation
2.4.2. B Axis With Manual Three Jaw Chuck
The three jaw chuck option consists of a manual scroll chuck with three stepped jaws. The chuck is
centered on the B axis at the factory to within 13 microns. Figure 2-2 and Figure 2-3 show the general stage
layout with the -100C and -150C chuck options.
The jaws can be positioned to provide a wide range of clamping capacity as shown in Figure 2-5 and Table 2-
2. A scroll key is provided with the stage for opening and closing the jaws.
Figure 2-5: Chuck Clamping Ranges
Table 2-2: Clamping Ranges for SelfCentering Scroll Chucks
Model
Chuck Diameter d1 d2 d3 d4 d5
inch mm mm
AXR100 3 1/4 80 2.0 to 26.9 22.1 to 46.0 45.0 to 69.1 24.9 to 50.0 48.0 to 71.1
AXR150 5 125 3.0 to 50.0 34.8 to 73.9 71.9 to 115.1 39.1 to 83.1 80.0 to 125.0
Allowable clamping force varies with the structure of the payload. Be sure that the clamping force imparted
on the workpiece is sufficient to hold the part in place before operating the stage.
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Assembly and Installation AXR Hardware Manual
2.5. Air Line Access
AXR series stages are provided with a internal air line for a single pneumatic control signal up to the Yaw
axis tabletop. Access to the air line is located in the rear of the Tilt axis as shown in Figure 2-6. This quick
connect air fitting is sized for 4 mm tubing. The pressure range for the pneumatic line runs from vacuum up to
100 psig.
N O T E : The air line is not available with the Three-Jaw Chuck Option.
Figure 2-6: Air Line Access
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