PushCorp AFD1000 Series User manual

AFD1000
Adjustable Force
Device
Manual
April, 2001 U.S. Patent No. 5,44 ,146PAR01640-1
PUSHCORP, INC.
Dallas, Texas

CAUTION
Active Force Devices contain
calibrated electronics.
HANDLE ITH CARE DO NOT DROP
DO NOT USE LUBRICATED AIR.
This device requires a dry, non-
lubricated 80 to 90 psi (5.5 – 6.2 bar)
air supply filtered to 5 µm and a 0.3
micron oil mist separator.
Non-compliance with these
requirements will void the
manufacturer’s warranty.
(See Section 4.3)
All fasteners, mounting holes and
pipe threads on this tool are
METRIC.
All PushCorp, Inc. electrical cables are rated for
high twist and flex robotic applications with a
minimum cable bending radius specification of
125mm (5 in). Cable damage resulting from
failure to abide by this specification will not be
covered under warranty.

PUSHCORP, INC. AFD1000 Manual
Table of Contents
1.0 LIMITED ARRANTY...........................................................................................2
2.0 GENERAL OVERVIE .........................................................................................4
3.0 QUICK START.......................................................................................................4
4.0 INSTALLATION.....................................................................................................5
4.1 Mounting Process Equipment.......................................................................................................... 5
4.2 Mounting the 1000 Series................................................................................................................ 6
4.2.1 Mounting the AFD1000-1 Vertical and AFD1000-2 Horizontal.....................................................6
4.2.2 Mounting the AFD1000-3 Table Top............................................................................................
4.3 Maximum Carriage Load Calculations.............................................................................................
4.4 Pneumatic Connection.................................................................................................................. 10
4.5 Internal Air Cartridge Filter............................................................................................................12
5.0 ADJUSTING CARRIAGE PRELOAD..................................................................12
6.0 TECHNICAL SPECIFICATIONS.........................................................................14
7.0 PREVENTATIVE MAINTENANCE SCHEDULE.................................................15

PUSHCORP, INC. AFD1000 Manual
1.0 Limited arranty
Duration:
One year from date of delivery to the original purchaser.
ho gives this warranty (warrantor):
PushCorp, Inc.
Telephone: [phone]
Corporate Address:
P. O. Box 1 1915
Dallas, Texas 7521
Shipping Address:
3001 W. Kingsley Rd.
Garland, Texas 75041
ho receives this warranty (purchaser):
The original purchaser (other than for purposes of resale) of the PushCorp,
Inc. product
hat products are covered by this warranty:
Any PushCorp, Inc. Adjustable Force Device or Adjustable Force Device
accessory supplied or manufactured by the Warrantor.
hat is covered under this warranty:
Defects in material and/or workmanship which occur within the duration of the
warranty period.
hat is NOT covered in this warranty:
A. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANT-ABILITY
AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO ONE
YEAR FROM THE DATE OF ORIGINAL PURCHASE. Some states do
not allow limitations on how long an implied warranty lasts, so the above
limitations may not apply to you.
B. ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE
or EXPENSE THAT MAY RESULT FROM ANY DEFECT, FAILURE,
MALFUNCTION OF THE PUSHCORP, INC. PRODUCT. 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.
C. 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 the arrantor under this warranty:
Repair or replace, at Warrantor's option, products or components which have
failed within the duration of the warranty period.

PUSHCORP, INC. AFD1000 Manual
Responsibilities of the purchaser under this warranty:
A. Deliver or ship the PushCorp, Inc. product or component to PushCorp,
Inc. Service Center, 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).
hen warrantor will perform repair or replacement under this 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. AFD1000 Manual
2.0 General Overview
The PushCorp, Inc. 1000 Series Adjustable Force Devices (US Patent No.
5,44 ,146) provide a superior force application system. The AFD can be placed in
any position to enable a variety of manufacturing operations requiring a consistent
applied force with . in. (20 mm) of compliant stroke. The AFD is designed to
withstand continuous use in harsh industrial grinding, polishing, and drilling
operations.
The 1000 Series force tools utilize a pneumatic actuator to provide the force and a
load cell force sensor to provide closed-loop feedback to an FCU1000 Active
Compliance Controller. The 1000 Series can apply up to a maximum 50 lbs. (222
N) of force. The AFD contains an accelerometer that monitors orientation and
allows the unit to automatically compensate for gravitational and inertial effects. A
linear potentiometer is also present within the AFD to sense the position of the
Carriage.
Only two external connections are required to operate the 1000 Series. First, dry,
non-lubricated, filtered 0 - 90 psi (5.5 – 6.2 bar) supply air must be provided
through flexible tubing. Second, the AFD must be connected to the FCU1000
Controller with a PushCorp high flex multi-conductor cable. An optional Purge Port
is provided for applications where excessive fine dust particles are created. This
Purge Port connection provides additional airflow and internal positive pressure to
minimize contamination entering the AFD. The Carriage has threaded mounting
holes to provide easy process equipment attachment.
All these features combine to make the PushCorp 1000 Series Adjustable Force
Device a rugged, state-of-the-art technology capable of providing reliable, precise,
and consistent results in a variety of industrial applications.
3.0 Quick Start
This section contains step-by-step instructions on how to quickly get the 1000
Series Adjustable Force Device up and running for a quick test of its capabilities.
Complete details on all the features are described in the sections that follow. It is
recommended that the user read the entire manual before beginning any operations
to fully understand all the aspects and features of the 1000 Series.
Step 1: Carefully unpack the 1000 Series Force Device and FCU1000
Controller. Verify that all parts indicated on the packing list are
present and in good condition. If there is a problem, please notify the
factory immediately so that corrective action may be promptly initiated.
Step 2: Securely attach the 1000 Series Mounting Bracket to the manipulator
mounting flange or support table per Section 4.2.
Step 3: Connect a dry, non-lubricated, 5 m filtered 0 to 90 psi (5.5 to 6.9
bar) air supply to the 1000 Series per Section 4.3.
Step 4: Consult the FCU1000 Manual for electrical connections and software
setup information.

PUSHCORP, INC. AFD1000 Manual
Please read the following sections to learn the full potential and features of the
PushCorp 1000 Series Adjustable Force Device.
4.0 Installation
4.1 Mounting Process Equipment
The 1000 Series Adjustable Force Device can accommodate many different types of
process equipment. PushCorp provides a variety of standard process equipment
such as weld shavers, high speed motors, plus other specialized tooling. Many end
users also develop process equipment for their own applications. The AFD can be
oriented parallel or perpendicular to the robotic manipulator mounting flange,
although it is important to note that the AFD can apply force only in the direction of
Carriage translation.
When mounting process equipment to the Carriage extreme care should be taken
while designing and installing the brackets. Correctly designed brackets will
increase the stiffness of the Carriage by becoming an external superstructure for the
Carriage. The Carriage can gain a tremendous amount of rigidity if this approach is
executed correctly. Incorrectly designed brackets will deform the Carriage surface
causing internal Linear Rail misalignment. A symptom of Carriage deformation is
“slop” or “binding” of the Carriage. A deformed or loose Carriage will damage the
Linear Rails and effect the consistency of your process. The Carriage preload is
correctly set at the factory and should not require adjustment. If the Carriage
becomes loose or binds after installing the process equipment, then the brackets
must be removed and the problem corrected. PushCorp, Inc. can design and
fabricate brackets to user supplied specifications as an option.
Figure 1. Carriage bolt hole pattern

PUSHCORP, INC. AFD1000 Manual
The bolt pattern on the Carriage has been designed to facilitate process equipment
installation. The Carriage has (16) sixteen M6x1 mounting holes with a depth of
0.40 inch (10 mm) to provide secure attachment points. The mounting holes are
spaced 5 inches (127 mm) across and on 1 inch (25.4 mm) centers along the length
of the Carriage. (See Figure 1) The Carriage also has (4) four 5mm dowel pin holes
to facilitate alignment. (See Figure 1 for location) These dowel pin holes are
oversized to allow the pins to be glued into place using Loctite 609, or equivalent.
DO NOT press pins into the AFD Carriage as this will damage the Linear Rails.
Caution: The Fastener Tightening Torque Specs chart in Section 6.0 should
be used to determine proper fastener length and torque for fasteners into the
Carriage. This is to prevent pull-out of the Carriage helicoil inserts.
Fasteners must not exceed a depth of 0.40 inches (10 mm) into the Carriage
as this could damage the Linear Rails.
4.2 Mounting the 1000 Series
The basic configuration of the 1000 Series force device allows attachment to a
stationary fixture or a robotic manipulator mounting flange. Specifying an AFD1000 -
1, -2, or -3 determines which Mounting Bracket is supplied. Adapter plates or
"quick-change" attachments can be used as well for mounting. The 1000 Series
has (2) two 4mm dowel pins pressed into the base for location and alignment of the
cover and Mounting Brackets.
4.2.1 Mounting the AFD1000-1 Vertical and AFD1000-2 Horizontal
The AFD1100-1 and AFD1100-2 are supplied with a standard Mounting Bracket
with a 90 mm three hole mounting pattern, See Figure 2. All three holes should be
utilized to secure the Mounting Bracket to the robot mounting flange. If the
Mounting Bracket is supplied blank or additional holes are required, it must first be
removed from the device before drilling. Four cap screws are used to attach the
Mounting Bracket to the 1100 Series. Once the Mounting Bracket is removed,
mounting holes may be placed anywhere within the crosshatched area shown in
Figure 2. PushCorp, Inc. will supply engineering support to determine the mounting
hole locations at no cost.
After drilling the required hole pattern, remove any burrs and clean any machining
residue from the Mounting Bracket. The Mounting Bracket can then be reattached.

PUSHCORP, INC. AFD1000 Manual
Figure 2. AFD1000-1 and AFD1000-2 Mounting Brackets

PUSHCORP, INC. AFD1000 Manual
4.2.2 Mounting the AFD1000-3 Table Top
The AFD1000-3 is designed for mounting on a stationary fixture. It has (3) three
0.2 ” (7.0 mm) mounting holes spaced as shown in Figure 3. The AFD1000-3
Table Top Mounting Bracket should not be modified without first consulting
PushCorp, Inc.
Figure 3. AFD1000-3 Table Top Mounting Plate
4.3 Maximum Carriage Load Calculations
The Linear Rail bearings that support the 1000 Series sliding Carriage have been
selected to provide optimal performance with respect to capacity, size, and low
friction. To ensure continued optimal performance it is very important not to
overload these bearings. The following diagrams and associated equations are
provided to check your application for excessive loading.
It is important to note that these equations require the use of Metric units. The
necessary conversions are provided for your convenience. Insert your maximum
applied force and process equipment weight (W) and overhang distances (D) to
calculate an actual bearing load (L) that must be less than the maximum bearing
load shown on the right side of the equation. The life of the bearings is 100,000
meters of linear motion, at the maximum allowable bearing load value. Exceeding
this value (L) will reduce the life and operating at less than this value (L) will
increase the life. It is common to have combined weight and force loads on the
Carriage. These situations may require adding two or more of the scenarios shown
below. If your tooling is not similar to any of the designs listed here, or if the
information is not clear, please contact PushCorp Technical Support for assistance.
Ball-bearing equations apply to the standard 1000 Series. Roller-bearing equations
apply to 1000 Series ordered with the –HD, Heavy-Duty option.