PushCorp AFD92 User manual

AFD92
Adjustable Force
Device
Manual
January, 2006
PUSHCORP, INC.
Dallas, Texas

DO NOT USE LUBRICATED AIR.
This device requires a dr , non-
lubricated 90 psi (6.2 bar) maximum
air suppl filtered to 5 µm and a 0.3
micron oil mist separator.
Non-compliance with these
requirements will void the
manufacturer’s warrant .
(See Section 4.4)
All fasteners, mounting holes and
pipe threads on this tool are
METRIC.
HANDLE WITH CARE
DO NOT DROP
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 b this specification will not be
covered under warrant .

PUSHCORP, INC. AFD92 Manual 1
Table of Contents
1.0 LIMITED WARRANTY..................................................................................................2
2.0 GENERAL OVERVIEW................................................................................................4
3.0 INSTALLATION............................................................................................................4
3.1 MOUNTING PROCESS EQUIPMENT.........................................................................4
3.2 MOUNTING THE AFD92..............................................................................................5
3.2.1 MOUNTING THE HORIZONTAL AFD92..................................................................6
3.2.2 MOUNTING THE TABLE TOP AFD92.....................................................................7
3.3 MAXIMUM CARRIAGE LOAD CALCULATIONS.......................................................7
3.4 PNEUMATIC CONNECTION.......................................................................................9
3.5 INTERNAL AIR CARTRIDGE FILTER......................................................................10
4.0 ADJUSTING CARRIAGE PRELOAD........................................................................11
5.0 ELECTRICAL CONNECTIONS..................................................................................13
5.1 CARRIAGE POSITION FEEDBACK CONNECTION................................................13
6.0 ACHIEVING DESIRED FORCE..................................................................................15
6.0.1 TABLE TOP.............................................................................................................15
6.0.2 WRIST MOUNT.......................................................................................................16
7.0 TECHNICAL SPECIFICATIONS................................................................................18
8.0 PREVENTATIVE MAINTENANCE SCHEDULE........................................................19
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PUSHCORP, INC. AFD92 Manual 2
1.0 Limited Warrant
Duration:
One year from date of delivery to t e original purc aser.
Who gives this warrant (warrantor):
PushCorp, Inc.
Telep one: [phone]
Corporate Address:
P. O. Box 181915
Dallas, Texas 75218
S ipping Address:
3001 W. Kingsley Rd.
Garland, Texas 75041
Who receives this warrant (purchaser):
T e original purc aser (ot er t an for purposes of resale) of t e PushCorp, Inc.
product
What products are covered b this warrant :
Any PushCorp, Inc. Adjustable Force Device or Adjustable Force Device
accessory supplied or manufactured by t e Warrantor.
What is covered under this warrant :
Defects in material and/or workmans ip w ic occur wit in t e duration of t e
warranty period.
What is NOT covered in this warrant :
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 ow long an implied warranty lasts, so t e 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 t e exclusion or limitation of incidental or consequential damages so
t e above limitation or exclusion may not apply to you.
C. Any failure t at results from an accident, purc aser's abuse, neglect,
unaut orized repair or failure to operate t e products in accordance wit t e
instructions provided in t e owner's manual(s) supplied wit t e product.
Responsibilities of the Warrantor under this warrant :
Repair or replace, at Warrantor's option, products or components w ic ave
failed wit in t e duration of t e warranty period.
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PUSHCORP, INC. AFD92 Manual 3
Responsibilities of the purchaser under this warrant :
A. Deliver or s ip t e PushCorp, Inc. product or component to Pus Corp, Inc.
Service Center, Dallas, TX. Freig t and insurance costs, if any, must be
borne by t e purc aser.
B. Use reasonable care in t e operation and maintenance of t e product as
described in t e owner's manual(s).
When warrantor will perform repair or replacement under this warrant :
Repair or replacement will be sc eduled and serviced according to t e normal
work flow at t e service center, and depending on t e availability of replacement
parts. Purc asers requiring quicker repair may receive suc wit payment of a
PushCorp, Inc. predetermined expediting fee.
T is Limited Warranty gives you specific legal rig ts and you may also ave ot er rig ts
w ic vary from state to state.
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PUSHCORP, INC. AFD92 Manual 4
2.0 General Overview
T e PushCorp 90 Series Passive AFD was designed as a lower cost alternative to t e
1200 Series Active Force Device. As suc t e 90 Series is a very basic unit t at still
provides outstanding performance. To increase force accuracy t e 90 Series uses low
friction glass pneumatic cylinders wit grap ite pistons and linear ball bearings. T e 90
Series may be supplied to apply only a positive force, t e AFD91, or bot positive and
negative forces, t e AFD92. It is offered in eit er robotic or table top mounting
configurations.
T e 90 Series requires t e user to supply at least one pressure regulator to control
t e force output. If an AFD92 is specified t en two pressure regulators are required.
T e device’s low friction components mean t at t e force output resolution and
repeatability is ig ly dependent on t e pressure regulator accuracy. T e pressure
regulator can be manual or electrically adjustable based on t e user’s application
requirements. If only one force level is required and t e AFD orientation does not
c ange, a manual pressure regulator is sufficient. If t e force and/or AFD orientation
c anges during t e process, t en an electrically controlled proportional pressure
regulator is required. In some cases t e process equipment weig t must be taken into
account so t at a constant force can be applied regardless of t e AFD orientation. T is
situation requires calculation of t e regulator pressure based on t e process equipment
weig t and AFD orientation. T e Carriage position of t e AFD92 can be monitored by
connecting to a DC power source and an analog input device using a Pus Corp ig -
flex cable.
All t ese features combine to make t e PushCorp 90 Series Adjustable Force Devices
rugged, reliable, and capable of delivering consistent results in any number of industrial
applications.
3.0 Installation
3.1 Mounting Process Equipment
T e AFD92 Adjustable Force Device can accommodate many different types of process
equipment. Pus Corp provides a variety of standard process equipment suc as weld
s avers, ig speed motors, belt sanders, and ot er specialized tooling. Users may
also develop process equipment for t eir own proprietary applications. T e AFD can be
oriented parallel or perpendicular to t e manipulator mounting flange, alt oug it is
important to note t at t e AFD can apply force only in t e direction of Carriage
translation.
W en mounting process equipment to t e Carriage extreme care s ould be taken w ile
designing and installing t e brackets. Correctly designed brackets will increase t e
stiffness of t e Carriage by becoming an external superstructure for t e Carriage. T e
Carriage can gain a tremendous amount of rigidity if t is approac is executed correctly.
Incorrectly designed bracketry will deform t e Carriage causing internal Linear Rail
misalignment. A symptom of Carriage deformation is “slop” or “binding” of t e Carriage.
A deformed or loose Carriage will damage t e Linear Rails and degrade t e consistency
of your process. T e Carriage preload is correctly set at t e factory and s ould not
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PUSHCORP, INC. AFD92 Manual 5
require adjustment. If t e Carriage becomes loose or binds after installing t e process
equipment, t en t e brackets must be removed and t e problem corrected. PushCorp,
Inc. can design and fabricate brackets to user supplied specifications as an option.
Figure 1. Carriage bolt ole pattern
T e bolt pattern on t e Carriage as been designed to facilitate process equipment
installation. T e Carriage as t irty-four (34) M8x1.25 mounting oles wit a dept of
0.52 inc (13 mm) to provide secure attac ment points. T e mounting oles are spaced
as s own in Figure 1. T e Carriage also as two (2) 5mm dowel pin oles to be used
for process equipment alignment. (See Figure 1 for location) T ese dowel pin oles are
oversized to allow t e 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 7.0 should be
used to determine proper fastener length and torque. 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.
3.2 Mounting the AFD92
T e design of t e AFD92 force device allows attac ment to a stationary table top fixture
or a robotic manipulator mounting flange. Specifying a -2 or -3 determines w ic
Mounting configuration is supplied. Adapter plates or "quick-c ange" attac ments can
be used as well for mounting. T e AFD92 as two (2) 6mm dowel pins pressed into t e
base for location and alignment of t e Mounting Bracket.
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PUSHCORP, INC. AFD92 Manual 6
3.2.1 Mounting the Horizontal AFD92
T e AFD90-2 is supplied wit a standard Mounting Bracket s own in Figure 2. A
minimum of (3) t ree oles s ould be utilized to secure t e Mounting Bracket to t e
robot mounting flange.
Figure 2. AFD90-2 Mounting Bracket
If additional oles are required, it must first be removed from t e device before drilling.
Four (4) M10x1.5 Socket Head Cap Screws are used to attac t e Mounting Bracket to
t e AFD92 force device. Once t e Mounting Bracket is removed, mounting oles may
be placed anyw ere wit in t e cross atc ed area s own in Figure 2. PushCorp, Inc.
can supply engineering support to determine t e mounting ole locations at no cost.
After drilling t e required ole pattern, remove any burrs and clean any mac ining
residue from t e Mounting Bracket. T e Mounting Bracket dowel pin oles must be
aligned before it can t en be reattac ed. T e fasteners s ould be torqued to t e
specification in Section 7.0.
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PUSHCORP, INC. AFD92 Manual 7
3.2.2 Mounting the Table Top AFD92
T e AFD90-3 is designed for mounting on a stationary fixture. It as four (4) 0.41”
(10.5 mm) mounting oles spaced as s own in Figure 3. T e AFD90-3 Table Top
Mounting Bracket s ould not be modified wit out first consulting Pus Corp, Inc. T e
surface t at t e Mounting Bracket is mounted to must be flat to avoid distorting t e
base.
Figure 3. AFD90-3 Mounting Bracket ole locations
3.3 Maximum Carriage Load Calculations
T e Linear Rail bearings t at support t e AFD92 Carriage ave been selected to
provide optimal performance wit respect to capacity, size, and low friction. To ensure
optimal performance it is very important not to overload t ese bearings. T e following
diagrams and associated equations are provided to c eck your application for excessive
loading.
It is important to note t at t ese equations require t e use of Metric units. T e
necessary unit conversions are provided for your convenience. Insert your maximum
applied force and process equipment weig t (W) and over ang distances (D) to
calculate an actual bearing load (L) t at must be less t an t e maximum bearing load
s own on t e rig t side of t e equation. T e life of t e bearings is 100,000 meters of
linear motion, at t e maximum allowable bearing load value. Exceeding t is value (L)
will reduce t e life, and operating at less t an t is value (L) will increase t e life. It is
common to ave combined weig t and force loads on t e Carriage. T ese situations
may require adding two or more of t e scenarios s own below. If your application is not
similar to any of t e designs listed ere, or if you are unsure of your application, please
contact PushCorp Tec nical Support for assistance. Ball-bearing equations apply to t e
standard AFD92. Roller-bearing equations apply to AFD92 ordered wit t e –HD,
Heavy-Duty option.
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PUSHCORP, INC. AFD92 Manual 8
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