PushCorp AFD1200 User manual

AFD1200
Adjustable Force
Device
Manual
December, 2005 U.S. Patent No. 5,448, 46
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. AFD1200 Manual
Table of Contents
1.0 LIMITED ARRANTY...........................................................................................1
2.0 GENERAL OVERVIE .........................................................................................3
3.0 QUICK START.......................................................................................................3
4.0 INSTALLATION.....................................................................................................4
4. Mounting Process Equipment.......................................................................................................... 4
4.2 Mounting the AFD1200................................................................................................................... 5
4.3 Maximum Carriage Load Calculations.............................................................................................6
4.4 Pneumatic Connection....................................................................................................................8
4.5 Internal Air Cartridge Filter............................................................................................................ 0
5.0 ADJUSTING CARRIAGE PRELOAD..................................................................10
6.0 TECHNICAL SPECIFICATIONS.........................................................................13
7.0 PREVENTATIVE MAINTENANCE SCHEDULE.................................................14

PUSHCORP, INC. AFD1200 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 8 9 5
Dallas, Texas 752 8
Shipping Address:
300 W. Kingsley Rd.
Garland, Texas 7504
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. AFD1200 Manual 2
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. AFD1200 Manual 3
2.0 General Overview
The PushCorp, Inc. AFD1200 Adjustable Force Devices (US Patent No. 5,448, 46)
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
.6 inches (40 mm) of compliant stroke. The AFD is designed to withstand continuous
use in harsh industrial grinding, polishing, and drilling operations.
The AFD1200 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 AFD1200 can apply up to a maximum 250 lbs. ( 2 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 AFD1200. First, dry, non-
lubricated, filtered 80 - 90 psi (5.5 – 6.2 bar) supply air must be provided through flexible
tubing. Second, the AFD must be connected to the FCU 000 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 AFD1200 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 AFD1200
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 AFD1200.
Step : Carefully unpack the AFD1200 Force Device and the FCU 000 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 AFD1200 Mounting Bracket to the manipulator
mounting flange or support table per Section 4.2.
Step 3: Connect a dry, non-lubricated, 5 µm filtered 80 to 90 psi (5.5 to 6.2 bar) air
supply to the force device per Section 4.3.
Step 4: Consult the FCU 000 Manual for electrical connections and software setup
information.
Please read the following sections to learn the full potential and features of the
PushCorp AFD1200 Adjustable Force Device.

PUSHCORP, INC. AFD1200 Manual 4
4.0 Installation
4.1 Mounting Process Equipment
The AFD1200 Adjustable Force Device can accommodate many different types of
process equipment. PushCorp provides a variety of standard process equipment such
as weld shavers, servo 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 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 . Carriage bolt hole pattern

PUSHCORP, INC. AFD1200 Manual 5
The bolt pattern on the Carriage has been designed to facilitate motor installation in a
number of configurations. The Carriage has (34) thirty four M8 x .25 mounting holes
with a depth of 0.52 inch ( 3 mm) to provide secure attachment points. The mounting
holes are spaced as shown in Figure . The Carriage also has (2) two 5mm dowel pin
holes to facilitate alignment (See Figure 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 0.52 inches (13 mm) into the Carriage as this could
damage the Linear Rails.
4.2 Mounting the AFD1200
The basic configuration of the AFD1200 force device allows attachment to a stationary
fixture or a robotic manipulator mounting flange. Adapter plates or "quick-change"
attachments can be used as well for mounting.
The AFD1200-2 is 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 AFD1200.
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. AFD1200 Manual 6
Figure 2. Mounting Bracket allowed hole locations.
4.3 Maximum Carriage Load Calculations
The Linear Rail bearings that support the AFD1200 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 00,000 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 AFD1200 tools. Roller-bearing equations apply to AFD1200 tools ordered with
the –HD, Heavy-Duty option.

PUSHCORP, INC. AFD1200 Manual 7