Festo EXPT 45 User manual

Description
Mechanical assembly
8003784
1204a
Tripod kinematics
EXPT

EXPT
2 Festo – GDCP-EXPT-KM-KOMP-EN – 1204a –
Translation of the original instructions
GDCP-EXPT-KM-KOMP-EN
CoDeSys
®
is a registered trademark of its respective trademark holder in certain countries.
Identification of hazards and instructions on how to prevent them:
Warning
Hazards that can cause death or serious injuries.
Caution
Hazards that can cause minor injuries or serious material damage.
Other symbols:
Note
Material damage or loss of function.
Recommendations, tips, references to other documentation.
Essential or useful accessories.
Information on environmentally sound usage.
Text designations:
• Activities that may be carried out in any order.
1. Activities that should be carried out in the order stated.
– General lists.

EXPT
Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English 3
Table of Contents – EXPT
1 Safety and requirements for product use 5......................................
1.1 Safety 5..................................................................
1.1.1 General safety regulations 5..........................................
1.1.2 Intended use 5.....................................................
1.2 Safety conditions 6.........................................................
1.2.1 Technical requirements 6............................................
1.2.2 Qualification of trained personnel 6....................................
1.2.3 Areas of application and approval by authorities 6........................
2Overview 7................................................................
2.1 Features 7................................................................
2.2 Function and application 9....................................................
2.3 Overview of interfaces 9.....................................................
2.4 Control elements and connections 10............................................
3 Assembly and installation 11..................................................
3.1 Transport 11................................................................
3.2 Storage conditions 11........................................................
3.3 Unpacking 12...............................................................
3.4 Checking tripod kinematics and scope of delivery 13................................
3.5 Preparations for assembly 14..................................................
3.5.1 Dimensions 14......................................................
3.5.2 Requirements for the assembly site 14..................................
3.6 Assembly on a frame 15.......................................................
3.7 Mounting options 16.........................................................
3.7.1 Direct mounting with screws 16........................................
3.7.2 Mounting with slot nuts 17............................................
3.8 Preparing tripod kinematics for mounting 19......................................
3.9 Mounting of attachments 23...................................................
3.9.1 Attachment for EXPT-...-T0 23..........................................
3.9.2 Attachment for EXPT-...-T1 to T4 23.....................................
3.10 Installation 24..............................................................
3.10.1 Overview 24........................................................
3.10.2 Overview of connections 25...........................................
3.10.3 Connect compressed air 25............................................
3.10.4 Installing motor cables and sensor cable 25..............................
3.10.5 Earthing 27........................................................

EXPT
4 Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English
4 Commissioning 28...........................................................
5 Operation and diagnostics 29..................................................
5.1 Maintenance and care 29......................................................
5.2 Troubleshooting 31..........................................................
6 Disassembly and repair 32....................................................
6.1 Dismantling 32..............................................................
6.1.1 Dismounting the tripod kinematics from the frame 32.......................
6.1.2 Dismounting motors 35...............................................
6.1.3 Dismounting the front unit 36..........................................
6.1.4 Dismantling the protective conduit 38...................................
6.1.5 Dismounting a pair of rods 39..........................................
6.2 Repair 40..................................................................
6.3 Accessories 40..............................................................
6.4 Disposal 40................................................................
A Technical appendix 41........................................................
A.1 Technical data for tripod kinematics EXPT-...-T0 to T4 41.............................
A.1.1 General 41.........................................................
A.1.2 Mechanical 41......................................................
A.1.3 Dynamic 42........................................................
A.1.4 Operating and environmental conditions 42...............................
A.2 Technical data of front unit for EXPT-...-T1 to T4 43.................................
A.2.1 General 43.........................................................
A.2.2 Mechanical 43......................................................
A.2.3 Electrical 43........................................................

1 Safety and requirements for product use
Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English 5
1 Safety and requirements for product use
1.1 Safety
1.1.1 General safety regulations
• Follow the general safety instructions in the relevant chapters.
Specific safety instructions can be found immediately before the task instructions.
1.1.2 Intended use
The EXPT tripod kinematics are intended for installation in machines and automation systems and are
to be used as follows:
– in excellent technical condition
– in original status without unauthorised modifications
– within the limits of the product defined by the technical data (Appendix A.1)
– in an industrial environment.
Note
The removal of mechanical components (e.g. motor, axis, pair of rods) causes
referencing to be lost and thus results in a reduction in absolute positioning accuracy.
When commissioning, referencing or calibration must be carried out again.
Note
In the event of damage caused by unauthorised manipulation or other than intended
use, the guarantee is invalidated and the manufacturer is not liable for damages.

1 Safety and requirements for product use
6 Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English
1.2 Safety conditions
• Make this documentation available to the design engineer, installer and personnel responsible for
commissioning the machine or system in which this product is used.
• Make sure that the specifications of the documentation are always complied with. Also read and
follow all accompanying documentation and the documentation for any associated accessories.
• Take into consideration the legal regulations applicable for the destination, as well as:
– regulations and standards
– regulations of the testing organizations and insurers
– national specifications.
1.2.1 Technical requirements
• All warnings and instructions in this documentation for the correct and safe use of the product must
be observed at all times.
• Comply with the connection and environmental conditions of the product (Appendix A.1) and all
connected components.
Only compliance with the limit values or load limits permits operation of the product in accordance
with the relevant safety regulations.
1.2.2 Qualification of trained personnel
The product should only be installed by properly trained personnel in accordance with these instruc-
tions. The trained personnel must be must be familiar with:
– the applicable regulations on accident protection and industrial safety, and
– the documentation for the product.
1.2.3 Areas of application and approval by authorities
Standards and test values, which the product complies with and fulfils, can be found in the “Technical
data” section (Appendix A.1).

2Overview
Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English 7
2Overview
2.1 Features
Tripod kinematics feature Code Specification
Working space –45 ∅450 mm, height 100 mm
–70 ∅700 mm, height 100 mm
–90 ∅900 mm, height 100 mm
– 120 ∅120 mm, height 100 mm
Attachment components –T0 Front unit without attachment component
–T1 Front unit with rotary drive, size 8
–T2 Front unit with rotary drive, size 8, and pneumatic
rotary through-feed
–T3 Front unit with rotary drive, size 11
–T4 Front unit with rotary drive, size 11, and pneumatic
rotary through-feed
Motor attachment position
(Fig. 3.12)
– HHH Motor axis A1, A2, A3 rear
–HHV Motor axis A1 rear
Motor axis A2 rear
Motor axis A3 front
–HVH Motor axis A1 rear
Motor axis A2 front
Motor axis A3 rear
–HVV Motor axis A1 rear
Motor axis A2 front
Motor axis A3 front
–VHH Motor axis A1 front
Motor axis A2 rear
Motor axis A3 rear
–VHV Motor axis A1 front
Motor axis A2 rear
Motor axis A3 front
– VVH Motor axis A1 front
Motor axis A2 front
Motor axis A3 rear
– VVV Motor axis A1, A2, A3 front
Particle protection Standard
–P Protected version
Tab. 2.1

2Overview
8 Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English
Accessories feature Code Specification
Control system Without control system
–C Control system on a mounting plate for installation in a
control cabinet
–CC Complete control system with control cabinet
Multi-axis controller Without control system
–C1 Control system with multi-axis controller CMXR-C1
–C2 Control system with multi-axis controller CMXR-C2 and
integrated PLC
Operator terminal Without operator unit
–B With operator unit CDSA
Cable length No cables or tubing included
–5 Connecting cable and 5 m long tubing included
–10 Connecting cable and 10 m long tubing included
–15 Connecting cable and 15 m long tubing included
Calibration Standard
–S With calibration
Tab. 2.2

2Overview
Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English 9
2.2 Function and application
The EXPT is a tripod kinematics unit with three servo motors, each powering a toothed belt axis. The
linear movements of the axes are transferred to the front unit by the principle of parallel kinematics.
A rotary drive is mounted on the front unit for variants T1 to T4. Suction cups or grippers can either be
attached to these directly or via the corresponding adapter kits. In addition, variants T2 and T4 are also
equipped with a pneumatic rotary through-feed for an air connection.
Variant P8 with particle protection is functionally identical to the other variants. The only difference
being that the axes are rotated by 180° and the toothed belt faces upwards. This prevents abrasion in
the working space.
The optional control system includes a higher-order multi-axis controller. This controls the interplay of
movements for the three motor controllers.
The EXPT tripod kinematics are intended for installation in machines and automation systems.
2.3 Overview of interfaces
Interface Documentation Description
Motors Accompanying user manual
for the motors
Connections of the motors
Pneumatic
components
Chapter 3.10. Compressed air supply for rod loss detection
Air supply for actuators (T2 and T4)
Sensors Chapter 3.10. Sensor connection for rod loss detection
Sensor connection for position sensing of the
rotary drive on the front unit (T1 to T4)
Tab. 2.3

2Overview
10 Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English
2.4 Control elements and connections
Note
The attachment position of the motors will vary according to the configuration of the
tripod kinematics and depends on the order code (www.festo.com/catalogue).
• Be mindful of the following during assembly and installation:
– the motor attachment position (Fig. 3.12).
The illustrated variant is an example and corresponds to the variant T1 to T4 with
rotary drive and motors in attachment position HHH.
– the position of the electrical and pneumatic connections.
The interface housing is located opposite the motor of axis 1 on the mounting
frame.
The EXPT has the following components, connections and display components:
1
2
3
4
5
6 7
8
9
aJ
1Front unit
(Variant T1 to T4 with rotary drive)
2Rod pair
3Joint
4Toothed belt axis
5EarthconnectionM6(6x)
6Mounting frame
7Motor (standard alignment HHH)
8Interface housing
9Manifold block (different for variant P8)
aJ Protective conduit
Fig. 2.1

3 Assembly and installation
Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English 11
3 Assembly and installation
3.1 Transport
Note
• Always transport the tripod kinematics lying on the mounting frame 6(Fig. 2.1)
(delivery status).
When delivered, the tripod kinematics are lying on the mounting frame, bolted to the pallet and packed
in a box.
EXPT 45 70 95 120
Dimensions [mm]
H1090 1320
L1725 1925
B1425 1725
Weight [kg]
Tripod kinematics 45 47.5 61.5 66
Tota l weight
1)
165 170 220 225
1) With max. accessories
Tab. 3.1
Note
• For transport, observe the marking on the upper side of the transport box.
1. Transport the packed tripod kinematics to the prepared installation site on the pallet.
2. Set down the pallet on a stable, flat ground or base as close as possible to the installation site.
3.2 Storage conditions
If the tripod kinematics are not assembled immediately, they must be stored under the following condi-
tions.
Storage conditions
Storage temperature [°C] –10 … +60
Maximum storage period 60 months
Requirements of storage location Dry, stable and flat
Tab. 3.2

3 Assembly and installation
12 Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English
3.3 Unpacking
Note
Damage to the product from incorrect handling.
• To unpack, set down the pallet on a stable, flat ground or base as close as possible
to the installation site.
• Have ready an appropriate triple square screwdriver to undo the screws.
• Make sure that packaging parts cannot fall onto the tripod kinematics.
• Keep the packaging for later use or dispose of it in the proper manner.
Removing transport packaging
1. Remove the four screws of the lid and lift the
lid up and off the transport box.
2. Remove all screws from the side walls and
remove them.
Start with one of the long sides.
As you do so, secure the other side walls to
make sure they do not fall over.
3. Remove the transparency. Do this by using an
appropriate tool to cut the transparency
parallel to the contour of the product. When
cutting, make sure that you do not damage or
scratch the tripod kinematics. Then pull the
transparency up and away from the product.
Fig. 3.1

3 Assembly and installation
Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English 13
3.4 Checking tripod kinematics and scope of delivery
1. After unpacking, check the following parts:
Checking Possible defect Remedy
Rod pair broken or damaged replace
1)
detached from the joint
(Fig. 2.1)
install (Chapter 6.1.5)
Compressed air/supply air hose damaged replace
1)
disconnected from the port re-connect
Protective conduit damaged replace
1)
Mounting clip damaged replace
1)
Electrical or pneumatic
connection
damaged replace
1)
1) (www.festo.com/spareparts)
Tab. 3.3
2. Open the accessories box fastened to the pallet and remove its contents.
3. Remove the mounting screw in the box and remove the box from the pallet.
4. Check that the delivery is complete.
Designation Number for
EXPT-...-T0
Number for
EXPT-...-T1 to T4
Description of tripod kinematics 1 1
Washer for oblong hole 6 6
Spacer for referencing the axes 1 1
USB memory card 1 1
Lubricating grease LUB-KC1 1 1
User manual for motor Kinematics 1 1
Assembly
instructions
Axial kit Kinematics 1 1
Motor cable Kinematics 1
1)
1
1)
Encoder cable Kinematics 1
1)
1
1)
Front unit with rotary drive – 1
Motor cable Kinematics 3
1)
3
1)
Rotary drives – 1
1)
Encoder cable Kinematics 3
1)
3
1)
Rotary drives – 1
1)
Sensor cable Pressure switch 1
1)
1
1)
Position detection for rotary drive – 1
1)
Tubing Rod loss detection 1 1
Rotary drive air – 1
1)
(T2 and T4 only)
Inscription label for cables 3x2
1)
4x2
1)
1) Optional
Tab. 3.4

3 Assembly and installation
14 Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English
3.5 Preparations for assembly
3.5.1 Dimensions
Dimensions [mm]
EXPT 45 70 95 120
B1 947 1077 1213 1355
B2 617 703 794 888
B3 549 590 626 672
B4 530 622 705 800
H1 659 727 827 944
H2 493 561 636 710
H3 166 166 191 234
H8 (for EXPT-...-T1 to T4 only) 27 27 27 27
L1 1088 1238 1394 1558
L2 652 727 803 885
Tab. 3.5
3.5.2 Requirements for the assembly site
Note
• Observe the catalogue specifications for the exact positioning of the mounting holes
(www.festo.com/catalogue).
The following conditions must be met, otherwise the range of functions may be restricted:
– enough room for the tripod kinematics to move, including room outside the working space
(see catalogue specifications regarding obstructions www.festo.com/catalogue)
– torsionally rigid, tension-free suspension of the tripod kinematics
– flat bearing surface at the mounting corners
– adequate mounting to absorb the maximum forces (www.festo.com/catalogue)
– allowance made for the affects of mass and rigidity on positioning accuracy and path accuracy
– adherence to the catalogue specifications for vibration limits, permissible forces and torques
(www.festo.com/catalogue).

3 Assembly and installation
Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English 15
3.6 Assembly on a frame
Note
The frame is not included in the scope of delivery. Installation varies according to the
design of the frame.
Note
If the oblong holes 1are used, the bearing surface of the screws is too small.
• Use the accompanying washers with the screws. (Fig. 3.2).
Note
• Use screws with strength class of at least 8.8.
The tripod kinematics must be fastened to a
frame only in the area of the corner bracket of the
mounting frame. There must be a torsionally rigid,
flat bearing surface in the area of the corner
bracket. In order for the tripod kinematics to
attain the positioning accuracy stated in the tech-
nical data, the following minimum requirements
apply to the bearing surface:
– flatness = 0.05 mm
– parallelism = 0.5 mm.
Other holes can be used only as an assembly aid
or for fastening additional installation elements
such as cable ducts. Fig. 3.2
1
Note
Deviations from the minimum requirements lead to increased wear and/or inaccuracies
in positioning during later operation.
1Frame with reinforcements (example)
2Mounting frame of tripod kinematics Fig. 3.3
1
2

3 Assembly and installation
16 Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English
3.7 Mounting options
3.7.1 Direct mounting with screws
Note
Removing a motor causes the referencing of the corresponding axis to be lost. When
commissioning, the axis must be referenced again.
• If possible, use mounting holes which do not require the motor to be removed.
Screws M8 to DIN 912
Direct mounting with at least 4 screws per corner
bracket directly on the frame
(dimensions catalogue specifications).
These 4 screws should be placed far enough
apart to ensure a torsionally rigid connection.
If the oblong holes 1are used, use the accompa-
nying washers.
Fig. 3.4
1
Screws M20 to DIN 912
Direct mounting with one screw per corner
bracket directly on the frame.
There is a central hole for this purpose on every
corner.
• Make sure that the bearing surface is in the
area of the corner bracket.
Fig. 3.5

3 Assembly and installation
Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English 17
3.7.2 Mounting with slot nuts
Slot nut mounting parallel to mounting frame
Example 1
The holes in the corner brackets are arranged so
that a 80x80 profile 1with 40 mm between slots
can be fastened in a number of different posi-
tions.
1Profile (e.g. HMBS-80/80)
2Slot nut (e.g. NST-HMV-8-2-M8)
3Screw (e.g. M8x35 DIN 912 )
1
2
3
Fig. 3.6
Example 2
Fig. 3.7

3 Assembly and installation
18 Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English
Slot nut mounting across the mounting frame with additional angle brackets
Note
The additional angle brackets are required in the following examples in order to
increase the torsional rigidity and the bearing surface.
Example 1
Holes for slot nut mounting Holes for additional angle brackets
Example 2
Holes for slot nut mounting Holes for additional angle brackets
Fig. 3.8

3 Assembly and installation
Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English 19
3.8 Preparing tripod kinematics for mounting
Caution
Lifting large loads can lead to permanent injury.
• Depending on size and weight, the tripod kinematics should be lifted and turned
overbytwotothreepersons(Tab. 3.1). An additional person is required for
fastening on the mounting frame.
Caution
Crushing of body parts.
In the event of stress on the joints of the tripod kinematics, the rods can break or the
balls can spring out of the ball cups. This can cause the tripod kinematics to fall down or
tip over. The front unit must not strike against anything or be placed against the floor.
• Grip the EXPT only in the area of the motors and axes or on the mounting frame.
• Set down the tripod kinematics only on the mounting frame.
• Lift up the tripod kinematics in such a way that you can turn them freely.
Note
After being turned over, the tripod kinematics cannot be set down without damaging
them. First, therefore, make the following preparations:
• Prepare the required mounting accessories for mounting on the frame.
• Observe the instructions for the frame used and the intended method of mounting.
• When installing on the frame, be mindful of the position of the pneumatic port 5
(Fig. 3.14).
1
2
3
4
1Pair of rods
2Toothed belt axis
3Motor
4Mounting frame
Fig. 3.9

3 Assembly and installation
20 Festo – GDCP-EXPT-KM-KOMP-EN – 1204a – English
Raising the tripod kinematics to the upright position
3
1
2
4
1Pair of rods
2Toothed belt axis
3Motor
4Mounting frame
Fig. 3.10
1. Remove the screws using the appropriate tool.
The tripod kinematics are fastened to the base pallet with 6 triple square socket screws.
2. Grip the tripod kinematics together with a second person and only in the area of the motors, axes
and mounting frame (corners 1 + 2).
3. Acting together, raise the tripod kinematics until upright:
• Make sure that the corner 3 on which the tripod kinematics are standing is securely in place and
cannot slip off the pallet.
• Acting together, push the tripod kinematics up until it is resting on corner 3.