PushCorp 0605 Series User manual

PUSHCORP, INC.
Manual
0605 / 1503
Series High Speed
Servo Motor
February, 2023
Dallas, Texas

! CAUTION !
Do NOT apply air pressure to
release t e Collet w ile t e servo
motor is rotating. T e servo motor
spindle must be FULLY STOPPED
before actuating t e Collet.
Do NOT over eat t e servo motor.
Supply t e motor cooling water to
maintain a temperature below
176 F (80 C).
Do NOT start or stop t e servo
motor instantaneously. Doing so
will damage t e motor and power
amplifier.
All PushCorp, Inc. electrical cables are rated for
ig twist and flex robotic applications wit a
minimum cable bending radius specification of
125mm (5 in). Cable damage resulting from
failure to abide by t is specification will not be
covered under warranty.

PUSHCORP, INC. 0605 / 1503 Servo Motor Series Manual
Table of Contents
1.0 LIMITED WARRANTY...........................................................................................1
2.0 GENERAL OVERVIEW.........................................................................................3
3.0 INSTALLATION & OPERATION...........................................................................4
3.1 Mounting the spindle motor............................................................................................................. 4
3.1.1 Mounting to a Push orp AFD compliant tool...............................................................................4
3.1.2 Mounting Directly to a Robot........................................................................................................ 6
3.2 Media and Tool Presentation........................................................................................................... 6
3.3 Tool and Media Specification..........................................................................................................7
3.3.1 SM Toolholder Specification......................................................................................................... 7
3.3.3 BT30 Toolholder Specification...................................................................................................... 9
3.4 SM ollet Operation...................................................................................................................... 10
3.4.1 SM ollet Assembly and Removal............................................................................................. 10
3.5 Pneumatic onnection.................................................................................................................. 11
3.6 Electrical onnections................................................................................................................... 14
3.6.1 S724 Servo Amplifier – Default Electrical onnections..............................................................15
3.6.2 Hall Motor Timing hart............................................................................................................. 16
3.7 Motor ooling................................................................................................................................ 17
3.8 Monitoring Motor Temperature......................................................................................................18
3.9 Motor Acceleration/Deceleration................................................................................................... 19
3.10 ST Spindle Tool hange........................................................................................................... 20
4.0 TECHNICAL SPECIFICATIONS.........................................................................22
5.0 PREVENTATIVE MAINTENANCE SCHEDULE.................................................23

PUSHCORP, INC. 0605 / 1503 Servo Motor Series Manual 1
1.0 Limited Warranty
Duration:
One year from date of delivery to the original purchaser.
W o gives t is warranty (warrantor):
PushCorp, Inc.
Telephone: [phone]
orporate Address:
P. O. Box 181915
Dallas, Texas 75218
Shipping Address:
3001 W Kingsley Rd
Garland, Texas 75041
W o receives t is warranty (purc aser):
The original purchaser (other than for purposes of resale) of the PushCorp,
Inc. product
W at products are covered by t is warranty:
Any PushCorp, Inc. industrial equipment or accessory supplied or
manufactured by the Warrantor.
W at is covered under t is warranty:
Defects in material and/or workmanship which occur within the duration of the
warranty period.
W at is NOT covered in t is warranty:
A. IMPLIED WARRANTIES, IN LUDING THOSE OF MER HANT-ABILITY
AND FITNESS FOR A PARTI ULAR PURPOSE ARE LIMITED TO ONE
YEAR FROM THE DATE OF ORIGINAL PUR HASE. Some states do not
allow limitations on how long an implied warranty lasts, so the above
limitations may not apply to you.
B. ANY IN IDENTAL, INDIRE T, OR ONSEQUENTIAL LOSS, DAMAGE
or EXPENSE THAT MAY RESULT FROM ANY DEFE T, FAILURE,
MALFUN TION OF THE PUSHCORP, INC. PRODU T. Some states do
not allow the exclusion or limitation of incidental or consequential damages
so the above limitation or exclusion may not apply to you.
. Any failure that results from an accident, purchaser's abuse, neglect,
unauthorized repair or failure to operate the products in accordance with
the instructions provided in the owner's manual(s) supplied with the
product.
Responsibilities of t e Warrantor under t is warranty:
Repair or replace, at Warrantor's option, products or components which have
failed within the duration of the warranty period.

PUSHCORP, INC. 0605 / 1503 Servo Motor Series Manual 2
Responsibilities of t e purc aser under t is warranty:
A. Deliver or ship the PushCorp, Inc. product or component to Push orp, Inc.
Service enter, Dallas, TX. Freight and insurance costs, if any, must be
borne by the purchaser.
B. Use reasonable care in the operation and maintenance of the product as
described in the owner's manual(s).
W en warrantor will perform repair or replacement under t is warranty:
Repair or replacement will be scheduled and serviced according to the normal
work flow at the service center, and depending on the availability of
replacement parts. Purchasers requiring quicker repair may receive such with
payment of a PushCorp, Inc. predetermined expediting fee.
This Limited Warranty gives you specific legal rights and you may also have other
rights which vary from state to state.

PUSHCORP, INC. 0605 / 1503 Servo Motor Series Manual 3
2.0 General Overview
This manual will cover both the Push orp 0605 and 1503 Series Servo Motors as
they share many common components. The 0605 and 1503 (motor) are capable of
continuously producing 5 and 3 horsepower, and spinning up to 6000 rpm and 15000
rpm respectively. The motors come in two models; a model SM0605 or SM1503
utilizing a manual collet, and a ST 0605-BT30 or ST 1503-BT30 automatic version
which allows changing out tools via a BT30 toolholder. These versions utilize
identical motor windings, and power amplifiers. Differing only in a few physical
dimensions and how they secure the media. Each of these motors provide a
convenient and effective means to spin and/or change any number of different media
types to support a fully automated workcell.
The Servo Manual (SM) models have a manually tightened collet that is a cost-
effective alternative to the automatic version. The “SM” models use the same motor
winding and housing as the automatic “ST ”, but without the automatic clamping
mechanism. The manual ollet is a standard ER-20 series collet designed to clamp a
½ inch (12.7 mm) diameter Toolholder. The user may choose different sized collets
in the ER-20 series, ranging from .031-.500 inch (1mm – 13mm).
The Servo Tool hanger (ST ) automatic tool-changing models, actuate
pneumatically to secure the BT30 style toolholder. They are comprised of four
primary components: a high-torque Servo Motor, a pneumatic actuator, high force
Belleville springs, and a component to clamp a Toolholder. The ST version uses a
drawbar to pull the ollet/Gripper in. High force Belleville springs located at the back
of the Servo Motor tension the drawbar. Actuating the large pneumatic actuator,
located in the lamping Housing, opens the ollet/Gripper. During pressurization the
cylinder contacts the Belleville springs and compresses them to drive the
ollet/Gripper out, releasing the Toolholder. There is no mechanism to forcibly eject
the Toolholder from the ollet, so gravity or a capturing mechanism must be used.
The ST models use a 30 taper to grip a standard BT30 toolholder. This design
locks the toolholder in the 30 tapered shaft and resists large pull out forces. The shaft
does not have locking keys, so motor indexing for tool change is not required. The
ST motors are fail-safe, in that no air pressure is required to hold the Toolholder.
Therefore, the Toolholder will remain held in the ollet/Gripper even when the air
pressure is un-expectantly lost. Likewise, applying air pressure to a single input port
via a simple manual or electrically operated valve opens the ollet/Gripper and
releases the Toolholder. The clever mechanical design always isolates the motor
bearings from the drawbar tension. This greatly improves reliability by allowing the
motor shaft to spin freely and never be subject to any clamping forces. All Push orp
motors use sealed bearings to ensure a long life. The bearings have additional
contamination protection from a Push orp proprietary contact shaft seal. This special
seal eliminates the need for constant purge air.
During operation the motor generates considerable heat due to the high torque and
compact size of the motor. Excessive operating temperatures will significantly reduce
the life of the motor. Water ooling is required to keep the unit within the internal
temperature operating range. The motor should never be allowed to exceed a
temperature of 176 F (80 ). ontinuously operating the unit above 176 F (80 )
will cause the rotor to de-magnetize and the bearings to fail. High temperatures will

PUSHCORP, INC. 0605 / 1503 Servo Motor Series Manual 4
also cause the O-rings that seal the cooling water channels to fail, possibly filling the
motor with water. Push orp has provided flow through water cooling on the motor to
allow high duty cycles without overheating.
Simple reliable construction combined with high torque and precision speed controlled
servo technology make the PushCorp Servo Motor line a rugged, state-of-the-art tool
capable of providing flexible, cost-effective operations.
3.0 Installation & Operation
3.1 Mounting t e spindle motor
3.1.1 Mounting to a Pus Corp AFD compliant tool
The motors are designed to attach directly to the arriage of any PushCorp
AFD1000/70 Force Device. There are two standard attachment options. The SM
version uses a Mounting Plate, and the ST motor uses the lamping Housing for
attachment.
The Parallel-Axis configuration is shown in Figure 1, where the motor attaches to the
AFD arriage with a Parallel Bracket. The Parallel Bracket is positioned on the
arriage and attached using the four (4) supplied M6x1x20mm Socket Head ap
Screws. The motor is then attached to the Parallel Bracket, as shown, with two (2)
M6x1x20mm Socket Head ap Screws into the front of the Motor Housing. Two (2)
M6x1 Socket Head ap Screws pass through the lamping Housing/Mounting Plate
(length is dependent on motor SMxxxx = 25mm, ST xxxx-BT30 = 145mm). The
fasteners must be tightened to the torque specified in Section 4.0.
To attach the motor to an AFD in a Perpendicular-Axis configuration, position the
lamping Housing/Mounting Plate over the arriage as shown in Figure 2. Then
secure the unit using four (4), M6x1 Socket Head ap Screws (length is dependent
on motor SMxxxx = 25mm, ST xxxx-BT30 = 145mm). Tighten the fasteners to the
torque specified in Section 4.0. 5mm Dowel pins can be inserted and glued into the
arriage to align the motor. The lamping Housings and Mounting Plate have pre-
drilled clearance dowel holes for this configuration.
CAUTION: Make sure t at t e M6x1 fasteners do not exceed a dept of 0.40”
(10 mm) into t e AFD Carriage Helicoils or damage will occur.
CAUTION: Do not press Dowel Pins into t e AFD Carriage, t is will damage
t e linear rails.

PUSHCORP, INC. 0605 / 1503 Servo Motor Series Manual 5
Figure 2: Spindle Motor Perpendicular-Axis onfiguration
Figure 1: Spindle Motor Parallel-Axis onfiguration

PUSHCORP, INC. 0605 / 1503 Servo Motor Series Manual 6
3.1.2 Mounting Directly to a Robot
For some processes compliance and force control are not required. The motor can
be mounted directly to the robot. This robotic system is equivalent to a 5-axis
machining center with a very large work volume and lower positional accuracy.
ertain product types and processes are well suited for a Robotic Machining enter
(RM ).
The motor can be attached to the robot mounting flange using a customer supplied
mounting plate. For direct mounting it is recommended that a breakaway clutch is
installed. The breakaway clutch will help protect the motor in the event of a robot
crash. Loads on the motor shaft of over 300 lb (136 kg) radially and 150 (68 kg)
axially will damage the bearings.
To mount the motor, first attach the customer supplied Mounting Plate to the Robot
Mounting Flange or to the Breakaway lutch, per the manufacturer’s specifications.
Once the Mounting Plate is secured, place the motor against the Mounting Plate and
install (4) four, M6x1, Socket Head ap Screws (length is dependent on motor
SMxxxx = 25mm, ST xxxx-BT30 = 145mm). (See Figure 3) Tighten the fasteners to
the torque specified in Section 4.0.
3.2 Media and Tool Presentation
Media and tool presentation refers to how various disks, drill bits, router bits, etc. are
presented so that a robot may maneuver the motor into position to grasp the
Toolholder reliably. It is ultimately the user’s responsibility to provide a means to
present the media and/or tooling in an effective and repeatable way for a given
application.
Figure 3: Spindle Motor Direct Mounting

PUSHCORP, INC. 0605 / 1503 Servo Motor Series Manual 7
As shown above, in Figure 4, many types of media and tools may be accurately
located in a Tool radle. A robot can then be taught approach paths and docking
locations to reliably bring the motor down over the Toolholders and grasp them. The
motor’s ollapsing ollet allows 0.015 in. (0.38 mm) diametrical clearance around the
Toolholder when open. The Toolholder must have a taper that mates to a Tapered
Holder mounted in the Tool radle. The Tapered Holder requires a slot to allow the
Toolholder to pass through. This same method is applicable to the motor’s design.
3.3 Tool and Media Specification
3.3.1 SM Tool older Specification
The motors are designed to grasp a ½ inch (12.7 mm) diameter steel shaft. Figure 6
shows the Toolholder dimensions required for the motor to operate properly. Notice
that the end of the Toolholder can be tailored to any needed configuration to attach to
various disk back-up pads, drill bits, router bits, grinding stones, etc. If desired,
PushCorp, Inc. can fabricate custom Toolholders, at an additional cost, based on
customer supplied drawings and specifications. To prevent interference between the
Toolholder and the ollet an 11° taper must be included in all Toolholder designs.
Toolholders should be manufactured from carbon or stainless steel with a hardness
less than Rc40. The surface finish on the Toolholder lamping Surface should be Ra
16 – 32. To accurately locate the Toolholder axially the front flat surface of the ollet
can be used. This means that the Toolholder lamping Surface and taper must be
shorter than the ollet depth. When using the ollet face for positioning some form of
compliance must be used on the Tool radle to prevent wedging the ollet in too
tightly, or damaging the motor bearings.
Figure 4: Sample media and tooling presentation scheme