Festo EXPT-95 User manual

EXPT-95/120
Parallel kinematic system
Operating instruc-
tions
8159609
2021-08d
[8159611]

Translation of the original instructions

Festo — EXPT-95/120 — 2021-08d
3
Table of contents
1 Safety and requirements for product use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Requirements for product use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.1 Technical prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.2 Training of qualified personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Storage conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Function and application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Mounting instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1.1 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1.2 Installation location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Rack mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Types of mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3.1 Direct fastening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3.2 Slot nut mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4 Preparations for mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.5 Grippers and suction cups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.5.1 EXPT-...-T0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.5.2 EXPT-...-T1 to T4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Connections at the interface housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.1 Rod loss detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.2 Rotary drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Motor cables and encoder cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4 Earthing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Operation and diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1 Maintenance and care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Fault clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8 Disassembly and repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1.1 Disassembling the parallel kinematic system. . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1.2 Demounting motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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8.1.3 Demounting the front unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1.4 Demounting the protective conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1.5 Demounting a pair of rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.1 Technical data for parallel kinematic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.1.2 Mechanical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.1.3 Pneumatic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.1.4 Operating and environmental conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.1.5 Dynamic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.2 Technical data - front unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2.1 Mechanical data of the front unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2.2 Pneumatic data of the front unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2.3 Electrical data of the front unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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Safety and requirements for product use
5
1 Safety and requirements for product use
1.1 Safety
1.1.1 General safety instructions
–Observe the general safety information in the corresponding chapters.
Specific safety regulations can be found immediately before the task instructions.
1.1.2 Intended use
The parallel kinematic system EXPT is intended for installation in machines or automated systems for
moving an end effector in the working space of the kinematics. It should be used as follows:
–in excellent technical condition
–in its original condition, without unauthorised modifications
–within the limits of the product defined by the technical data
–in an industrial environment.
1.2 Requirements for product use
–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 in the documentation are observed at all times. Also take into
account all the documentation supplied and, if applicable, that of the associated accessories.
1.2.1 Technical prerequisites
–Observe all warnings and instructions in this documentation for correct and safe use of the product.
–Comply with the connection and ambient conditions of the product and all connected components
as specified in the technical data.
Only compliance with the limit values and/or load limits will enable operation of the product in
accordance with the relevant safety directives.
1.2.2 Training of qualified personnel
The product should only be installed by properly trained personnel in accordance with this description.
The trained personnel must be familiar with:
–the applicable instructions for accident prevention and occupational safety and
–the documentation for the product.

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Transport and storage
2 Transport and storage
2.1 Transport
At delivery, the parallel kinematic system lying on the mounting frame is securely fastened on the
pallet to prevent movement and it is wrapped in foil and packed in a transport crate for protection from
mechanical and environmental influences.
EXPT 95 120
Dimensions [mm]
H 1320
L 1925
B 1725
Weight [kg]
Parallel kinematic system 61.5 66
Total weight with maximum
accessories
220 225
Tab. 1: Dimensions and weights
NOTICE
• For transport, observe the identification on the upper side on the transport crate.
1. Transport the pallet with the parallel kinematic system to the installation/storage location.
2. Place the pallet on a firm and flat base at the mounting/storage location.
2.2 Storage conditions
The following storage conditions are essential to ensure safe subsequent use.
Design EXPT-...-T0 EXPT-...-T1 to T4
Storage temperature [°C] –10 … +60
Humidity [%] 5 … 95, non-condensing 20 … 80, non-condensing
Maximum shelf life 60 months
Requirements for
storage location
dry, solid and flat base
Tab. 2: Storage conditions

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Transport and storage
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2.3 Unpacking
NOTICE
Damage to the product from incorrect removal of the transport crate
• At least two people are required to dismantle the transport crate.
• Use the appropriate tool to loosen the screws.
• Make sure that packaging parts cannot fall onto the parallel kinematic system.
• Keep the packaging for later use or dispose of it properly.
Removing the transport crate cover
1. Unscrew and remove all screws
2. Lift the cover enough to transport it away
3. Place or lay down the cover at a safe distance from
the parallel kinematic system
Removing the transport crate side walls
4. Remove each side wall one by one in the sequence
"long 1, short 2, long 3; short 4" side wall.
1
23
4
5. Unscrew and remove all screws
6. Remove the side wall and place or lay it down at a
safe distance from the parallel kinematic system
Removing the packaging foil
7. Cut the foil parallel to the contour of the product
with an appropriate tool. When cutting, make sure
that the parallel kinematic system is not scratched
or damaged. Then pull the foil up and away.
Tab. 3: Unpacking

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Overview
3 Overview
3.1 Characteristics
Key feature of the parallel
kinematic system
Code Type
Working space – 95 Æ 900 mm, height 100 mm
– 120 Æ 120 mm, height 100 mm
Drive – E4 EGC-80
Attachment components – T0 without rotary drive
– T1 Rotary drive size 8
– T2 Rotary drive size 8 with pneumatic rotary through-feed
– T3 Rotary drive size 11
– T4 Rotary drive size 11 with pneumatic rotary through-feed
Motors - EMMT
– M4 without motors
Mounting position of the
motors è Mounting position
of the motors
Axis A1 Axis A2 Axis A3
- HHH rear rear rear
- HHV rear rear front
- HVH rear front rear
- HVV rear front front
- VHH front rear rear
- VHV front rear front
- VVH front front rear
- VVV front front front
Protection against particles – Standard
– P8 protected version
Preset – Standard
– S with calibration
Tab. 4: Characteristics

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Overview
9
3.2 Function and application
The parallel kinematic system includes three toothed belt axes, each driven by a servo motor with
absolute displacement encoder. The linear movements of the axes are transferred to the front unit
according to the parallel kinematic principle.
The integrated rod loss detection detects detached rods and triggers an emergency stop. It is achieved
by continuous compressed air monitoring by a pressure sensor.
Grippers and suction cups can be directly attached to the front unit. A rotary drive is mounted on the
front unit for variants T1 to T4 (4th axis). Suction cups with connectors or grippers can be attached
to them either directly or using appropriate adapter kits. In addition, variants T2 and T4 are also
equipped with a pneumatic rotary through-feed, which can be used as an air connection.
Variant P8 with protection against particles is functionally identical to the standard variants. Deviating
from this are the toothed belt axes with the slide oriented upward so that abraded particles of the
toothed belt remain in the axis and do not reach the working space.

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Overview
3.3 Design
The mounting position of the motors varies depending on the configuration of the parallel kinematic
system è Mounting position of the motors. The illustration is an example and corresponds to the
variant parallel kinematic system EXPT-...-T4-HHH with rotary drive, pneumatic rotary through-feed
and attachment position of the motors HHH.
1
3
4
5
6
7
8
9
10
11
2
Fig. 1: Design
1
Front unit with rotary drive and pneumatic
rotary through-feed
2
Rod pair
3
Joint
4
Toothed belt axis
5
Earthing screw M6 (1x), mounting option
(6x)
6
Mounting frame
7
Corner bracket
8
Motor (optional)
9
Interface housing
10
Manifold block (P8 variant is different)
11
Protective conduit
3.4 Accessories
Please select the corresponding accessories from our catalogue è www.festo.com/catalogue.

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Assembly
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4 Assembly
4.1 Mounting instructions
4.1.1 Dimensions
Dimensions [mm]
B1 B2 B3 B4 H1 H2 H3 H81) L1 L2
EXPT–
95
1213 794 705 663 820 636 184 27 1394 826
EXPT–
120
1355 888 800 716 938 710 228 27 1558 920
1) Only for EXPT-...-T1 to T4
Tab. 5: Dimensions
4.1.2 Installation location
NOTICE
• Observe the exact position of the mounting holes è www.festo.com/catalogue.
The following conditions must be met in order to make full use of the range of functions:
–There is enough room for the movements of the parallel kinematic system, including
space outside the working area. Catalogue specifications for the interference contour
è www.festo.com/catalogue.
–The suspension of the parallel kinematic system is torsion-resistant and free of stress.
–The bearing surface at the mounting corners is flat.
–The mounting is sufficient for retaining the maximum forces è www.festo.com/catalogue.
–The effects of mass and stiffness on positioning and path accuracy are taken into account.
–Vibration limits, forces and torques are in compliance è www.festo.com/catalogue.

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Assembly
4.2 Rack mounting
NOTICE
The frame is not in scope of delivery. Installation is carried out according to the design of the frame.
• Use screws with a minimum strength class of 8.8.
When using the elongated holes 1, the bearing surface of the screws is too small.
• Use screws with the enclosed washers.
The parallel kinematic system must be fastened to a frame only in the area of the corner bracket of the
mounting frame. A flat bearing surface that is resistant to torsion is essential in the area of the corner
brackets. In order for the parallel kinematic system to attain the positioning accuracy described in the
technical data, the following minimum requirements apply to the bearing surfaces:
–Evenness = 0.05 mm
–Parallelism = 0.5 mm.
Other holes can be used only as an assembly aid or for mounting additional installation elements,
such as cable guide.
Rack mounting
Support surface Example of frame
1
1 Slotted hole
2
3
2 Frame (example)
3 Mounting frame of parallel kinematic system
Tab. 6: Rack mounting
NOTICE
Deviations from the minimum requirements will cause increased wear or positioning inaccuracies in
later operation.

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Assembly
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4.3 Types of mounting
NOTICE
The removal of a motor results in a loss of homing on the corresponding axis. The axis must be homed
again during commissioning.
• Preferably choose mounting holes where the motor does not need to be removed.
4.3.1 Direct fastening
Direct fastening variant 1 with M8 screws in accordance with DIN 912
Direct fastening to the frame with at least 4 screws per
corner bracket.
Dimensions è www.festo.com/catalogue
The 4 screws should be as far apart as possible to
ensure a torsionally rigid connection.
If the slotted holes 1 are used, the bearing surface
of the screws is too small. Use the accompanying
washers.
1
Tab. 7: Direct fastening variant 1
Direct fastening variant 2 with M20 screws in accordance with DIN 912
Direct fastening to the frame with one screw per corner
bracket.
There is a central hole for this purpose at every
bracket.
–Make sure that the bearing surface lies in the area
of the corner brackets.
Tab. 8: Direct fastening variant 2

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Assembly
4.3.2 Slot nut mounting
The holes in the corner brackets are arranged so a profile column 80x80 1 with 40 mm distance
between slots can be fastened in various positions.
Slot nut mounting variant 1
If the slotted holes are used, the bearing surface of the
screws is too small. Use the accompanying washers.
1 profile column, e.g. HMBS-80/80
2 Slot nut e.g. NST-HMV-8-2-M8
3 Screw e.g. M8x35 DIN 912
1
2
3
Tab. 9: Slot nut mounting variant 1
Slot nut mounting variant 2
If the slotted holes are used, the bearing surface of the
screws is too small. Use the accompanying washers.
1 profile column, e.g. HMBS-80/80
2 Slot nut e.g. NST-HMV-8-2-M8
3 Screw e.g. M8x35 DIN 912
1
2
3
Tab. 10: Slot nut mounting variant 2

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Assembly
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Slot nut mounting variant 3
The additional user-specific brackets increase the tor-
sional rigidity.
1 profile column, e.g. HMBS-80/80
2 Slot nut e.g. NST-HMV-8-2-M8
3 Screw e.g. M8x35 DIN 912
1
2
3
Tab. 11: Slot nut mounting variant 3

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Assembly
Slot nut mounting variant 4
The additional user-specific brackets increase the tor-
sional rigidity.
1 profile column, e.g. HMBS-80/80
2 Slot nut e.g. NST-HMV-8-2-M8
3 Screw e.g. M8x35 DIN 912
1
2
3
Tab. 12: Slot nut mounting variant 4

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Assembly
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4.4 Preparations for mounting
CAUTION
Lifting heavy loads can result in permanent health damage.
• Depending on its size and weight (è Tab. 1 Dimensions and weights), the parallel kinematic
system should be lifted and turned over by 2 to 3 persons. An additional person is required during
attachment to the mounting frame.
CAUTION
Danger of injuries from crushing and cuts.
If it is transported incorrectly, high forces may be applied to the front unit or rods. As a result, rods can
break or rod connections come loose. The loosened front unit can result in crushing injuries and the
broken, sharp-edged rods in cuts.
• Grip the EXPT only in the area of the motors, axes or the mounting frame.
• Place the parallel kinematic system only on the mounting frame.
•Lift up the parallel kinematic system in such a way that you can turn it freely.
NOTICE
After being turned over, the parallel kinematic system cannot be set down without damage. Therefore,
first make the following preparations:
• Prepare the required mounting accessories for attachment to the frame.
• In doing so, observe the instructions corresponding to the frame used and the intended method of
mounting.
1
2
3
4
Fig. 2: Preparations for mounting
1
Rod pair
2
Toothed belt axis
3
Motor (optional)
4
Mounting frame

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Assembly
NOTICE
When installing in the frame, take into account the position of the pneumatic and electrical connec-
tions on the interface housing 1 or 2.
The axes of the parallel kinematic system EXPT are, seen from the top, numbered anti-clockwise from
A1 to A3 and correspondingly marked on the side.
The interface housing is located on the mounting frame opposite motor 1 in relation to axis 1. The
attachment position V or H of the motors depends on the type ordered. The alignment of the A1 axis
determines the position of the X-axis for the motor controller’s coordinate system.
Mounting position of the motors
1
2
Fig. 3: Mounting position of the motors
1
Interface housing with motor position H of
axis A1
2
Interface housing with motor position V of
axis A1
WARNING
Crushing of body parts. If incorrectly mounted, the parallel kinematic system may become discon-
nected and fall down.
• Fasten the parallel kinematic system to the frame in accordance with the specifications on the
assembly drawing è 4.2 Rack mounting.
• Observe the specifications for mounting è 4.3 Types of mounting.
• Lock the screw connections.

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Assembly
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Raising the parallel kinematic system to the upright position
1
2
3
4
Fig. 4: Raising the parallel kinematic system to the upright position
1
Rod pair
2
Toothed belt axis
3
Motor (optional)
4
Mounting frame
1. Use the appropriate tool to loosen the screws.
2. Unscrew and remove all six transport screws.
3. Grip the parallel kinematic system with a second person in the area of the motor 3, axis 2 and
mounting frame 4 at positions 1 and 2.
4. Lift the parallel kinematic system until the corner of the mounting frame at position 3 has a firm
footing on the pallet.
5. Now turn the parallel kinematic system around position 3 into the vertical position.

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Assembly
Turning and installing the parallel kinematic system
1
2
3
4
Fig. 5: Turning and installing the parallel kinematic system
1
Rod pair
2
Toothed belt axis
3
Motor (optional)
4
Mounting frame
1. Hold the parallel kinematic system firmly at the motor 3, axis 2 or mounting frame 4. Position a
third person at corner 3 of the mounting frame where that person can grip in the area of the motor,
axis and mounting frame.
2. The third person turns the parallel kinematic system by pulling corner 3 upwards in the area of the
motor, axis and mounting frame.
3. Have three persons raise the parallel kinematic system into the mounting position on the frame,
where it can be attached by a fourth person.
4. The tightening torque for fastening the slot nuts is 10 Nm ± 20%.