Aerotech VascuLathe ACS Series User manual

VascuLathe®-ACS Series
Stage User’s Manual
P/N: EDS116 (Revision 1.05.00)
Dedicated to the Science of Motion
Aerotech, Inc.
101 Zeta Drive,
Pittsburgh, PA, 15238
Phone:412-963-7470
Fax:412-963-7459
www.aerotech.com

Product Registration Register online at: http://www.aerotech.com/prodreg.cfm
Technical Support United States Headquarters:
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Revision History 1.05.00 December 27, 2011
1.03.00 August 27, 2009
1.02.00 December 2, 2008
1.01.00 October 16, 2008
1.00.00 October 19, 2006
1.00.00 October 19, 2006
Product names mentioned herein are used for identification purposes only and may be trademarks of
their respective companies.
Copyright © 2006 - 2011. Aerotech, Inc. All Rights Reserved.

VascuLathe®-ACS Hardware Manual Table of Contents
Table of Contents
Table of Contents iii
List of Figures v
List of Tables vii
Chapter 1: Overview 1
1.1. Standard Features 2
1.1.1. Linear Axis 2
1.1.2. Rotary Axis 3
1.2. Optional Features 4
1.2.1. CMS (Cable Management System) Options 4
1.2.2. Wet Cut Option 4
1.2.3. Tooling Options 4
1.2.4. Gripper Jaws Option 4
1.2.5. Pneumatics Option 5
1.2.6. Electronics / Controller Option 5
1.3. Model Numbers 6
1.4. Dimensions 7
1.5. Safety Procedures and Warnings 8
1.6. EC Declaration of Incorporation 9
Chapter 2: Installation 11
2.1. Unpacking and Handling the Stage 11
2.2. Preparing the Mounting Surface 11
2.3. Securing the Stage to the Mounting Surface 12
2.4. Attaching the Payload to the Stage 13
2.5. Changing ACS Workholding Devices 14
2.5.1. Collet Installation and Removal Procedure 14
2.6. Changing Collet Chucks 16
2.7. (-AG) Alignment / Gripper Operation 18
2.8. (-G) Gripper Operation 20
2.9. Electrical Installation 21
2.10. Air Requirements 21
2.11. Wet Cut Fluid Requirements 21
Chapter 3: Operating Specifications 23
3.1. Environmental Specifications 23
3.2. Basic Specifications 24
3.3. Load Capability 27
Chapter 4: Maintenance 29
4.1. Service and Inspection Schedule 29
4.2. Lubrication and Cleaning 30
4.2.1. Collet & Collet Chuck Lubrication and Cleaning 31
4.3. Seal Replacement 32
4.3.1. Piston Seal Change Procedure 32
4.3.2. Ringseal O-Ring Replacement 36
4.3.3. Wet Cut Rotary Union Seal Replacement 38
4.4. Wet Cut Rotary Union Removal 42
4.5. Linear Lubrication and Cleaning Process 44
4.6. Linear Spar Cover Removal 45
Appendix A: Warranty and Field Service 51
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Table of Contents VascuLathe®-ACS Hardware Manual
Appendix B: Technical Changes 53
Index 55
Reader's Comments 57
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VascuLathe®-ACS Hardware Manual List Of Figures
List of Figures
Figure 1-1: VascuLathe®-ACS Series Positioning Stage 1
Figure 1-2: VascuLathe®-ACS Rotary Stage with ER Collet 3
Figure 1-3: VascuLathe®-ACS Dimensions 7
Figure 2-1: VascuLathe®-ACS Stage Showing Mounting Holes (Top View) 12
Figure 2-2: Schematic of Collet Insertion Into and Removal From Collet Nut 15
Figure 2-3: Installation Procedure for Collet 15
Figure 2-4: Collet Assembly Exploded View 16
Figure 2-5: Alignment Gripper Detail 18
Figure 2-6: Gripper Detail 20
Figure 3-1: VascuLathe®-ACS Wet Cut Rotary Union Location 27
Figure 4-1: Piston Seal Change Exploded View 32
Figure 4-2: Piston Seal Installation Procedure 35
Figure 4-3: Cross-Section View of Piston Showing Seal Orientation 35
Figure 4-4: Typical Ringseal 36
Figure 4-5: Ringseal Removal Tool Dimensions 37
Figure 4-6: Cross-Section View of Ringseal Showing O-Ring 37
Figure 4-7: Cross-Section View of Wet Cut Rotary Union 38
Figure 4-8: Carriage Cover Removal 39
Figure 4-9: End Cap Mounting Screw Location 39
Figure 4-10: Rotary Seal Installation / Removal 40
Figure 4-11: Seal Housing Location 40
Figure 4-12: Wet Cut Rotary Union Shaft Inspection 41
Figure 4-13: Wet Cut Rotary Union 42
Figure 4-14: Wet Cut Rotary Union Installation 43
Figure 4-15: Linear Bearing Grease Nipple 44
Figure 4-16: Removing the Inside Spar Cover 45
Figure 4-17: Removing the Outer Spar Cover 46
Figure 4-18: Removing the Carriage Side Cover 47
Figure 4-19: Removing M4 MHCS Screws 48
Figure 4-20: Releasing Tension on the Belt 49
Figure 4-21: VascuLathe®-ACS with Belts Folded Back 49
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List of Figures VascuLathe®-ACS Hardware Manual
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VascuLathe®-ACS Hardware Manual List of Tables
List of Tables
Table 1-1: Model Numbering System 6
Table 3-1: Environmental Specifications 23
Table 3-2: VascuLathe®-ACS Series Specifications 24
Table 3-3: VascuLathe®-ACS Rotary Motor Specifications 25
Table 3-4: VascuLathe®-ACS Linear Motor Specifications 26
Table 4-1: Recommended Lubricants 31
Table B-1: Current Changes (1.05.00) 53
Table B-2: Archived Changes 54
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List of Tables VascuLathe®-ACS Hardware Manual
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VascuLathe®-ACS Hardware Manual Overview
Chapter 1: Overview
The VascuLathe®-ACS series dual axis positioning stage represents a revolutionary approach to satisfying
the demanding requirements of tubular manufacturing applications. This fully integrated motion system cou-
ples automated material handling with high performance direct drive linear and rotary motion.
The VascuLathe®-ACS has been designed with a collet chuck that supports ER25 or ER40 collets (man-
ufactured to DIN6499 specs) to allow for a wide range of materials and applications. This product is intended
for light industrial manufacturing or laboratory use.
Figure 1-1: VascuLathe®-ACS Series Positioning Stage
N O T E : Aerotech continually improves its product offerings; listed options may be superseded at any
time. Refer to the most recent edition of the Aerotech Motion Control Product Guide for the most current
product information at www.aerotech.com.
N O T E : This manual should be read in its entirety before operating the VascuLathe®-ACS system.
N O T E : For the wet cut option, it is recommended that the rotary seal be replaced before 1000 hours of
service. Failure to follow the maintenance procedures outlined in Section 4.3.3. Wet Cut Rotary Union Seal
Replacement will result in voiding of warranty.
DANGER: To minimize the possibility of electrical shock and bodily injury or death, dis-
connect all electrical power prior to making any electrical connections.
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Overview VascuLathe®-ACS Hardware Manual
1.1. Standard Features
1.1.1. Linear Axis
The main feature of the linear axis is its proprietary linear drive technology coupled with a rigid mechanical
design allowing for high-speed, accurate positioning performance.
All VascuLathe®-ACS stages include a fully-sealed design. Metal waycovers are designed to protect the
internal components (linear bearings and encoder, for example) from damage by preventing dust or debris
from entering the stage. The external stage surfaces have a black hardcoat finish to withstand rugged envi-
ronments.
To aid in stage setup and mounting, the stage base plate mounting holes are accessible without removing
any components.
A pair of sealed linear bearings are common to all VascuLathe®-ACS series stages. The bearings provide
smooth motion and excellent stiffness characteristics.
Two options to improve the already outstanding accuracy of the VascuLathe®-ACS series are HALAR and
HALSF. HALAR is linear error correction for accuracy and repeatability, and HALSF systems include
improved straightness and flatness characteristics.
Other features include optical limit switches mounted at each end of travel. These switches are configured
as normally-closed. If the stage is driven beyond these electrical limits, a mechanical hard stop is in place
slightly past each limit switch.
The VascuLathe®-ACS is offered with a non-contacting linear encoder with an achievable resolution of .001
µm, and accuracies of ±1.0 µm.
Travels available are 200 mm to 300 mm.
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VascuLathe®-ACS Hardware Manual Overview
1.1.2. Rotary Axis
All VascuLathe®-ACS stages come standard with a direct drive brushless motor with a non-contacting inte-
gral rotary union. These features combine to create a low friction, low maintenance rotary stage capable of
high accelerations and low positioning error. With a non-contact rotary union, there are no seals to replace or
lubricate, allowing for a lifetime of maintenance free performance. The brushless, slotless motor design
allows for extremely high torque coupled with smooth motion. There are no brushes to wear, no belts to ten-
sion, and no gears to wear resulting in a completely maintenance-free motor.
The VascuLathe®-ACS is available with either an ER25 or ER40 style collet chuck. Aerotech recommends
using an ER25 collet for holding requirements of 1 mm to 16 mm and using an ER40 collet for holding require-
ments of 15.5 mm to 30 mm.The collet is retained with a threaded collet nut enabling quick changeover. It is
configured in a “fail-safe” normally-closed mode where full clamping force is applied when no air pressure is
present.
N O T E : Aerotech recommends using only electro-polished collets manufactured to DIN6499 spec-
ifications.
Figure 1-2: VascuLathe®-ACS Rotary Stage with ER Collet
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Overview VascuLathe®-ACS Hardware Manual
1.2. Optional Features
1.2.1. CMS (Cable Management System) Options
The VascuLathe®-ACS can be ordered so that an optional cover is included to enclose the moving CMS com-
ponents from the system operator.
N O T E : The cover is a stationary guard designed to isolate the operator from moving components in the
CMS and is not intended to prevent contaminants from entering.
1.2.2. Wet Cut Option
Use the wet cut rotary union configuration for fluid delivery (@100 psi max pressure) in wet laser cutting
applications. Connect a pressure vessel to the 1/2 NPT tapped hole located on the rear of the rotary stage.
The length of the pressure vessel is dependent on the length of the tube being cut. This option is only avail-
able on stages with an ER25 collet chuck. See Section 3.3. Load Capability,Section 4.3.3. Wet Cut Rotary
Union Seal Replacement, and Section 4.4. Wet Cut Rotary Union Removal for details regarding use and
maintenance of the wet cut rotary union.
N O T E : The purchase of a ringseal will also be required based on the tube diameter used in the cutting
application. Consult Aerotech for more information.
1.2.3. Tooling Options
VascuLathe®-ACS can be equipped with two types of tube advance systems that give the customer a more
advanced, highly integrated tubular manufacturing system.
l-AG: This option equips the system with a parallel gripper for automated tube advancement along with a
Y/Z adjustment stage. The adjustment stage has a travel range of ±0.75 mm to aid in the alignment of
material support bushings (see Section 2.7. (-AG) Alignment / Gripper Operation).
l-G: This option equips the system with a parallel gripper for automated tube advancement and material
handling (see Section 2.8. (-G) Gripper Operation).
1.2.4. Gripper Jaws Option
This option is selected when a tooling option is ordered and is sized based on application requirements. The
gripper supplied on the VascuLathe®-ACS has a 10 mm stroke and therefore requires the selection of dif-
ferent jaw types depending on the tube size being processed. Jaws have been sized to cover the ranges of
tubes the ER25 and ER40 options can support (0 mm - 30 mm). Refer to Table 3-2 for a list of jaw options.
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VascuLathe®-ACS Hardware Manual Overview
1.2.5. Pneumatics Option
This option is offered in three configurations and is supplied with every VascuLathe®-ACS system. Two con-
figurations (-PNG and -PN) include the required filters, driers, solenoids, relays, fittings, valves, and hose
required to connect the VascuLathe®-ACS. The third configuration (-FD) includes only the filter and dryer
assembly to condition the incoming air.
l-PNG: This option will supply the pneumatics to control the air supply to both the collet and the optional
gripper.
l-PN: This option is ordered when the pneumatics to control the air supply are required for the collet only.
l-FD: This option is ordered when the customer will implement their own pneumatics controls. The
filter/dryer assembly is supplied to guarantee the conditioning of incoming air.
Refer to the documentation package shipped with your system for proper interconnection of the pneumatics.
1.2.6. Electronics / Controller Option
The VascuLathe®-ACS stage can be purchased as part of a complete Aerotech motion control system,
which is adjusted at the factory for optimum performance. If bought as a complete system, setup usually
involves connecting a stage to the appropriate drives with the cables provided. Refer to your electrical doc-
umentation package for further information.
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Overview VascuLathe®-ACS Hardware Manual
1.3. Model Numbers
The stage model number indicates the optional features on a particular stage.
Example: VascuLathe-ACS-300S-ER25-WC-AG-J0-10-PNG
Table 1-1: Model Numbering System
VascuLathe, Direct Drive Linear and Rotary Motion
-ACS Direct drive rotary stage with integral ER-style collet chuck
Linear Travel / Cable Management System (CMS) Style
-200S 200 mm linear travel, with standard cms configuration
-200C 200 mm linear travel, with covered cms configuration
-300S 300 mm linear travel, with standard cms configuration
-300C 300 mm linear travel, with covered cms configuration
Collet Type
-ER25 Air-actuated ER25 collet chuck, normally closed
Supports tube diameters from 1 mm to 16 mm
-ER40 Air-actuated ER40 collet chuck, normally closed
Supports tube diameters from 15.5 mm to 30 mm
Wet Cut / Dry Cut
-DC Dry cut, standard option for both ER25 and ER40 configurations
-WC Wet cut, used only on ER25 configuration. Limits tube size to 12 mm dia.
Gripper
-AG Gripper with X/Y bushing alignment
-G Gripper Only
Gripper Jaws
-J0-10 Gripper jaws for tube diameters ranging from 0 mm –10 mm
-J8-18 Gripper jaws for tube diameters ranging from 8 mm –18 mm
-J16-26 Gripper jaws for tube diameters ranging from 16 mm –26 mm
-J24-34 Gripper jaws for tube diameters ranging from 24 mm –34 mm
-J32-40 Gripper jaws for tube diameters ranging from 32 mm –40 mm
Pneumatics
-PNG Pneumatics kit for ER collet and optional gripper
-PN Pneumatics kit for ER collet
-FD Pneumatics kit, filter/dryer assembly only
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VascuLathe®-ACS Hardware Manual Overview
1.4. Dimensions
Figure 1-3: VascuLathe®-ACS Dimensions
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Overview VascuLathe®-ACS Hardware Manual
1.5. Safety Procedures and Warnings
The following statements apply wherever the Warning or Danger symbol appears within this manual. Failure
to observe these precautions could result in serious injury to those individuals performing the procedures
and/or damage to the equipment. Operators should be trained before operating this equipment.
DANGER: To minimize the possibility of electrical shock and bodily injury or death, dis-
connect all electrical power prior to making any electrical connections.
DANGER: To minimize the possibility of electrical shock and bodily injury or death when any
electrical circuit is in use, ensure that no person comes in contact with the circuitry when the
VascuLathe®-ACS is connected to a power source.
DANGER: To minimize the possibility of bodily injury or death, disconnect all electrical power
prior to making any mechanical adjustments.
DANGER: Moving parts of the VascuLathe®-ACS can cause crushing or shearing injuries. All
personnel must remain clear of any moving parts.
W A R N I N G : If the VascuLathe®-ACS is used in a manner not specified by the manufacturer,
the protection provided by the VascuLathe®-ACS can be impaired and result in damage, shock,
injury or death.
W A R N I N G : Cables can pose a tripping hazard. Securely mount and position all
VascuLathe®-ACS cables to avoid potential hazards.
W A R N I N G : Do not expose the VascuLathe®-ACS to environments or conditions outside the
specified range of operating environments. Operation in conditions other than those specified
can cause damage to the equipment.
W A R N I N G : The VascuLathe®-ACS must be mounted securely. Improper mounting can
result in injury and damage to the equipment.
W A R N I N G : Use care when moving the VascuLathe®-ACS. Manually lifting or transporting
the VascuLathe®-ACS can result in injury.
W A R N I N G : Only trained personnel should operate, inspect, and maintain the VascuLathe®-
ACS.
W A R N I N G : This VascuLathe®-ACS is intended for light industrial manufacturing or lab-
oratory use. Use of the VascuLathe®-ACS for unintended applications can result in injury and
damage to the equipment.
W A R N I N G : Before using this VascuLathe®-ACS, perform an operator risk assessment to
determine the needed safety requirements.
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VascuLathe®-ACS Hardware Manual Overview
1.6. EC Declaration of Incorporation
Manufacturer: Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238
USA
herewith declares that the product:
Aerotech, Inc. VascuLathe®-ACS Stage
is intended to be incorporated into machinery to constitute machinery covered by the Directive
2006/42/EC as amended;
does therefore not in every respect comply with the provisions of this directive;
and that the following harmonized European standards have been applied:
EN ISO 12100-1,-2:2003+A1:2009
Safety of machinery - Basic concepts, general principles for design
ISO 14121-1:2007
Safety of machinery - Risk assessment - Part 1: Principles
EN 60204-1:2005
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.
Authorized Representative: Manfred Besold
Address: AEROTECH GmbH
Süd-West-Park 90
D-90449 Nürnberg
Name / Alex Weibel
Position Engineer Verifying Compliance
Location Pittsburgh, PA
Date September 2010
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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

Overview VascuLathe®-ACS Hardware Manual
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VascuLathe®-ACS Hardware Manual Installation
Chapter 2: Installation
This chapter describes the installation procedure for the VascuLathe®-ACS stage, including handling the
stage properly, preparing the mounting surface to accept the stage, securing the stage to the mounting sur-
face, attaching the payload, and making the electrical connections.
W A R N I N G : Installation must follow the instructions in this chapter. Failure to follow these
instructions could result in injury and damage to the equipment.
2.1. Unpacking and Handling the Stage
Carefully remove the VascuLathe®-ACS from the protective shipping container. Before operating the Vas-
cuLathe®-ACS, it is important to let the VascuLathe®-ACS stabilize at room temperature for at least 12
hours. Allowing the VascuLathe®-ACS 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. Set the VascuLathe®-
ACS on a smooth, flat, and clean surface.
Each VascuLathe®-ACS has a label listing the system part number and serial number. These numbers con-
tain information necessary for maintaining or updating system hardware and software. Locate this label and
record the information for later reference. If any damage has occurred during shipping, report it immediately.
W A R N I N G : Improper handling could adversely affect the VascuLathe®-ACS’s performance.
Use care when moving the stage. Manually lifting or transporting the stage can result in injury.
W A R N I N G : Lift the stage only by the base at [QTY-3] 1/2-13 tapped holes. Do not use the
stage table or motor as lifting points.
2.2. Preparing the Mounting Surface
The mounting surface should be flat and have adequate stiffness in order to achieve the maximum per-
formance from the VascuLathe®-ACS. When the VascuLathe®-ACS series stage is mounted to a non-flat sur-
face, the stage can be distorted as the mounting screws are tightened. This distortion will decrease the
overall accuracy of the stage. Adjustments to the mounting surface must be done before the stage is
secured.
N O T E : To maintain accuracy, the mounting surface should be flat within 1 µm per 50 mm.
N O T E : The VascuLathe®-ACS base 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 VascuLathe®-ACS base. Shimming should be avoided if possible. If
shimming is required, it should be minimized to improve the rigidity of the system.
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Installation VascuLathe®-ACS Hardware Manual
2.3. Securing the Stage to the Mounting Surface
Secure the stage to the mounting surface with the M8 or 5/16 SHCS. If necessary, move the stage carriage
to access the base plate mounting holes (refer to Figure 2-1).
W A R N I N G : The VascuLathe®-ACS must be mounted securely. Improper mounting can
result in injury and damage to the equipment.
Figure 2-1: VascuLathe®-ACS Stage Showing Mounting Holes (Top View)
W A R N I N G : Do not attempt to move the VascuLathe®-ACS's carriage (or table top) until the
lifting brackets and shipping brackets have been removed. Moving the carriage with the lifting
brackets and shipping brackets installed can cause permanent damage to the VascuLathe®-
ACS.
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