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

PUSHCORP, INC. AFD1200 Manual 8
4.4 Pneumatic Connection
The AFD1200 Adjustable Force Devices require a dry, non-lubricated, 5 µm filtered, 80
to 90 psi (5.5 – 6.2 bar) air supply. Failure to provide supply air to these specifications
can degrade performance and will void any warranty repairs concerning pneumatic
components. Filtered air is required since the high speed servo spool valve used in the
AFD cannot tolerate ANY foreign material in the supply air. Additionally, a minimum 80
psi (5.5 bar) air pressure must be maintained at the supply air port for the device to
operate within published specifications. Operating at lower air pressure can cause
inferior force control performance and possibly instability.
The pneumatic supply system should be configured as shown in the Figure 3.
Figure 3. Pneumatic configuration
If water condensation is a problem in your air supply system, an air dryer device is
highly recommended. The ideal solution is an industrial chiller dryer capable of reducing
the dewpoint to less than 32 F (0C). Moisture inside the force device will cause
premature failure that will not be covered under warranty.
Under most circumstances the standard internal purge will provide sufficient air to keep
the AFD1200 free of contaminates. In applications where the environment contains very
small suspended particulate matter, additional purge air flow must be used to ensure
that the AFD remains clear of foreign matter. An auxiliary Purge Port on the AFD1200
(See Figure 4.) provides a pneumatic connection to supply this additional air flow. The
port accepts a metric R /8 tapered pneumatic fitting. PushCorp can provide fittings for
English or metric tubing. The input pressure to the purge port can range from 0 PSI to
60 PSI (0.7 – 4. bar) with a flow rate of 0.5 to 2.0 SCFM ( 4 – 56 l/min) depending on
the application. The purge air must be dry and non-lubricated, however it need only be
filtered to 20 microns.

PUSHCORP, INC. AFD1200 Manual 9
Figure 4. AFD 200 External Connections
The Supply Line and Purge Line to the device should be /4 inch or 6mm diameter
flexible polyurethane tubing. The tubing should be routed to the AFD such that there are
no kinks and that there is plenty of slack to allow for manipulator motion. Before
inserting the Supply Line into the force device air fitting, open the Shut-off valve to blow
out any contaminates which may be in the line. The tubing can now be pushed into the
self-locking fitting located on the side of the AFD. Charge the Supply Line with
compressed air and verify that there are no air leaks and that there is a minimum of 80
PSI (5.5 bar) at the AFD. If a minimum air pressure cannot be achieved, then an
auxiliary air compressor or booster pump with at least 2 SCFM (56 l/min) must be
installed.
NOTE: PushCorp highly recommends the use of flexible polyurethane tubing as
opposed to nylon tubing. This is because nylon tubing tends to crimp shut when
it is bent. This severely limits air flow to the AFD and causes instability.
To remove the Supply Line, first discharge all air pressure in the system, then while
pushing inward on the fitting's plastic ring, simultaneously pull the tubing out. Cover or
plug the self-locking fitting any time the Supply Line is not connected. This will keep any
contaminants from entering the AFD.

PUSHCORP, INC. AFD1200 Manual 0
4.5 Internal Air Cartridge Filter
The AFD1200 force device contains a Cartridge Filter in the base housing. The
Cartridge Filter is designed to be the last line of defense to protect the AFD from
contamination. The Cartridge Filter is not designed to be the sole means of AFD supply
air filtration. The pneumatic supply system must be configured as described in Section
4.4. If the filter becomes clogged the AFD1200 will not function properly. Replacement
Cartridge Filters may be purchased from PushCorp (Part No. PAR0 943- ), or from the
manufacturer directly (Parker, Part No. 050-05-DQ). To remove the Cartridge Filter
loosen the Cartridge Filter Holder located on the side of the AFD base housing, See
Figure 4. Remove the Cartridge Filter and perform a visual inspection. The condition of
the Cartridge Filter will give an indication of the quality of your supply air system. Place
a new Cartridge Filter on the Cartridge Filter Holder and insert them into the AFD base
housing. Tighten the Cartridge Filter Holder to a torque of 90 lb-in. ( 0 N-m).
5.0 Adjusting Carriage Preload
The required preload on the AFD1200 Linear Rails has been set at the factory for
optimal performance and, in general, should not require field adjustment. However,
there are situations that could arise that cause the Linear Rails to need adjustment.
Often a loose, or tight, Carriage on a new AFD is indicative of an improperly designed
process equipment bracket. If the problem disappears when the brackets are removed
then this is the case. Normally the Carriage will only require adjustment after removal for
field service.
To check for a loose Carriage, attempt to move the Carriage in a lateral direction as
shown in Figure 5. If the Carriage moves or seems to exhibit any "slop", then the Linear
Rail preload must be readjusted. A dial indicator is helpful, but not necessary to
diagnose and correct a loose Carriage.
A Carriage that is too tight will require additional force to move. This is often detected
during the weighing of the process equipment mounted on the Carriage. The weight will
be inconsistent, varying higher or lower each time the process equipment is weighed.

PUSHCORP, INC. AFD1200 Manual
Figure 5. Carriage preload adjustment
The Linear Rails are attached to the underside of the Carriage with (6) six M 0x .5
Socket Head Cap Screws. Located on the side of the Carriage are the two Preload
Adjustment Set Screws used to translate the Movable Linear Rail. Moving the Linear
Rail associated with the Preload Adjustment Set Screws is all that is necessary to adjust
the Carriage preload.
To perform the preload adjustment, follow the procedure below:
. Check the tightness of the (3) three Fixed Linear Rail M 0x .5 Socket Head
Cap Screws holding the Fixed Linear Rail opposite the Movable Linear Rail. If
these fasteners are loose then the Fixed Linear Rail must be seated against
the flange inside the Carriage. To do this, loosen all (6) six fasteners located
on the face of the Carriage just enough to allow the Linear Rails to move.
Next tighten the Preload Adjustment Set Screws to force the Fixed Linear Rail
to seat against the flange. Tighten the (3) three Fixed Linear Rail M 0x .5
Socket Head Cap Screws, which hold the Fixed Linear Rail, to the torque
specified in Section 6.0. The Fixed Linear Rail is now correctly seated and the
Preload Adjustment Set Screws can be loosened. You are now ready to
continue on to preload the Carriage Linear Rails.

PUSHCORP, INC. AFD1200 Manual 2
2. To preload the Carriage Linear Rails, loosen the Movable Linear Rail M 0x .5
Socket Head Cap Screws holding the Movable Linear Rail only enough to allow
the rail to move relative to the inside Carriage surface. The Carriage has
slotted holes on the Movable Linear Rail side which allow the rail to move in
the same direction as the Preload Adjustment Set Screws. Make sure that the
Movable Linear Rail M 0x .5 Socket Head Cap Screws are loose before
attempting to set the preload.
3. If a dial indicator is available, place it against the Carriage surface that contains
the Preload Adjustment Set Screws. Attempt to move the Carriage laterally
while monitoring the dial indicator. If the reading on the dial indicator varies,
then gradually tighten each of the Preload Adjustment Set Screws. Note that
one of the Preload Adjustment Set Screws could require more adjustment than
the other. When the dial indicator ceases to vary, the preload is set correctly.
Do not continue to tighten the Preload Adjustment Set Screws. Too much
preload on the Linear Rails will cause excessive friction resulting in force
errors.
4. If a dial indicator is not available, the preload can be adjusted by feel. Attempt
to move the Carriage laterally and feel for movement. If the Carriage moves
rotate each of the Preload Adjustment Set Screws no more than 5 degrees. As
soon as no lateral movement can be felt, stop rotating the Preload Adjustment
Set Screws. Note that one of the Preload Adjustment Set Screws could require
more adjustment than the other. Do not over tighten the Preload Adjustment
Set Screws. Over tightening the Preload Adjustment Set Screws will result in
excessive friction and possible deformation of the Carriage. (If the adjustment
cannot be performed, contact the factory service center.)
The Carriage preload should now be correct.
5. After verifying that the Carriage no longer moves laterally, tighten the (3) three
Movable Linear Rail M 0x .5 Socket Head Cap Screws on the Moveable Rail
side to the torque specified in Section 6.0.

PUSHCORP, INC. AFD1200 Manual 3
6.0 Technical Specifications
Maximum Applied Force: 250 lbs. ( 2N)
Maximum Payload: 200 lbs. (9 kg)
Tool Weight: AFD 200-2: 56 lb. (26 kg) (excluding payload)
Compliant Stroke: .6 in. (40 mm)
Force Accuracy: +/-0.5 lb. (+/-2.2 N)
Response Time: 300ms
Temperature: 50 to 22 F ( 0 to 50 C)
Humidity: 5% to 95%, Non-Condensing
Supply air: Non-lubricated, Dry, 5µm Filtered, 80 psi (5.5 bar) Min.,
90 psi (6.2 Bar) Max., 3 SCFM (85 l/min)
Specific tions subject to ch nge without notice. These v lues re b sed on me surements t ken in
l bor tory environment. Re l-world results m y be degr ded due to extern l f ctors beyond PushCorp’s
control.
Fastener Tightening Torque Specs
Torque Minimum Depth
Fastener Size in.-lbs. ft.-lbs. N·m in. mm
M4 x .7 50 4.2 5.6 0. 7 4.3
M5 x .8 85 7. 9.6 0.2 5.3
M6 x 40 .7 5.8 0.25 6.3
M8 x .25 348 29.0 39.3 0.33 8.4
M 0 x .5 600 50.0 67.8 0.4 0.5

PUSHCORP, INC. AFD1200 Manual 4
7.0 Preventative Maintenance Schedule
It is highly recommended to adhere to the preventative maintenance schedule in order help
extend the longevity of the specified PushCorp, Inc. equipment. Failing to do so could cause a
loss in functionality as well as a decrease in product life.
PUSHCORP, INC. AFD
Maintenance eekly Monthly 3 Months
Remove debris from AFD X
Check that the connectors are not bent/damaged X
Check to see if the carriage moves back and forth
easily
X
Check for flow in the purge and supply ports X
Agency/Organization:_________________________________________________
Date Completed:_____________________________________________________