POF115. Reference & Maintenance Manual. Reference & Maintenance Manual

Transcription

1 POF115 1

2 32114 Mallard Ave. PO Bx 409 Tangent, OR U.S.A. Phne: [541] Fax: [541] Tll Free: [888] Web: POF115 Manual Revisin Infrmatin Publicatin Date July 2003 March 2003 April 2005 January 2007 January 2015 Ntes Changed recmmended grease frm Lithium #2 t NSK Clean rm grease Updated lk & frmatting Updated Ordering Inf Updated Lg Ntice: The descriptins, drawings, and specificatins cntained herein are subject t change. Primatics is nt respnsible fr errrs r missins herein r fr incidental damages in cnnectin with the furnishing r use f this infrmatin. This dcument shall nt be reprduced, phtcpied, r duplicated, in whle r in part, withut prir written apprval f Primatics Crpratin. Fr Specificatins, Dimensined Drawings and additinal infrmatin, refer t the POF115 Datasheet available frm ur website at Cpyright by Primatics, Inc; All Rights Reserved. Primatics, the Primatics lg, PrimaFlex, PrimaSeal & SimpleMatch are trademarks f Primatics, Inc. 2

3 POF115 Manual Revisin Infrmatin ) Overview ) Intrductin Abut the POF ) Mdel Cnfiguratin ) Persnal Safety ) Cnventins ) Directin f Mtin ) Units f Measure ) Installatin Preparatins ) Linear Mtrs ) Heat and Humidity ) Cntaminatin ) Electrical Nise ) Installatin Prcedures ) Tls yu will need ) Unpacking ) Munting surface preparatin ) Munting the POF ) Electrical Cnnectins ) Clr Cdes fr Pigtailed Cable ) Hall Effect Cmmutatin Sequence ) Hme and Limit Sensrs ) Hme Optins: ) Limit and Hme Switch Adjustment ) Recmmended System Test ) Preventive Maintenance ) Lubricatin ) Cables ) Trubleshting & Service ) Trubleshting Help ) Service

4 1) Overview This user guide is designed t help yu install and maintain yur POF115 Series linear psitining stage applicatin. Fllw these steps t ensure crrect stage installatin and maximum stage life: Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Review this entire user manual. Becme familiar with all installatin prcedures prir t integrating yur system. Review the safety summary t develp an understanding f standard safety practices when installing and perating autmated equipment. Familiarize yurself with the cnventins summary. Review installatin prcedures. Fr best results, fllw these prcedures carefully. Once yu successfully cmplete all the installatin prcedures, yu will be ready t install and perate yur stage. Review preventive maintenance sectin fr prper lubricatin schedule. 4

5 2) Intrductin Abut the POF115 The POF115 is a dual axis, large aperture psitining stage that prvides accurate, flat mtin. It prvides high stiffness and lad capacity. The pen frame design gives the flexibility fr access t the paylad frm bth abve and belw. There are tw drive cnfiguratins fr the POF115. Each is briefly described in the table belw. POF115 Single Drive POF115 Dual Drive Basic Width x Height (mm) 336 x 115 Travel Lengths (mm) 300 x 300 Drive Types Single Linear Mtr Dual Linear Mtr Encder Optin Linear Paylad (kg) Each can be cnfigured with ptins listed in Sectin 3. Many custmers chse the Primatics Mtin Drive Chassis (MDC) t pwer POF115 stages. The MDC is a mdular system that packages mtr drivers, encder interfaces, pwer supplies and safety systems int a single chassis. It acts as an intermediary between a Galil Optima, Natinal Instruments 7344 r Delta Tau PMAC II mtin cntrl cards and a Primatics psitining stage. Pre-wired high-flex cables are available t allw a cnvenient cnnectin frm the stage t the MDC chassis. The MDC drive chassis interfaces 3 rd party cntrllers via a remvable intercnnect mdule. These intercnnect mdules cnfrm t each manufacturers intercnnect cable, and internally rute all the cmmand and I/O signals. Optinally, a Primatics psitining stage can be used with many third party cntrller and amplifier systems. In this case, a pigtailed cable is available t simplify the cnnectin between the POF stage and cntrls. 5

6 3) Mdel Cnfiguratin 6

7 4) Persnal Safety Please review befre installing yur psitining stage Observe cmmn industrial safety practices when installing and perating autmated equipment. Have pwer cnnectins made by qualified persnnel. Keep fingers and ther items ut f any pening in the stage while it is in peratin since injury r damage may result. Prvide a safe access rute and adequate rm fr servicing. Perfrm the recmmended peridic maintenance described in this dcument. Verify that the wrk envelpe is free f bstructins befre the psitining stage is pwered. Insure that yu have the feedback wired prperly t the cntrller befre applying pwer t the psitining stage. Imprper feedback cnnectins can cause a mtr run-away cnditin that has the ptential t damage the stage and injure an peratr. Only trained peratrs f the psitining stage shuld be allwed near the wrk envirnment. If s equipped, identify emergency stp circuits and actuatrs in the wrkcell. Nte the places in the wrkcell where pinch pints ccur, and prvide adequate safety clearance r safety curtain. Never perate the mtr in a lcatin that culd be splashed by water, expsed t crrsive r flammable gases r is near cmbustible substances since this may cause an electric shck, fire r malfunctin. Never tuch the mtr, driver, r peripheral devices when the pwer is n r immediately after the pwer is turned ff. The high temperature f these parts may cause burns. 7

8 5) Cnventins 5.1) Directin f Mtin The psitive directin f mtin fr bth axes is defined as shwn in Figure 5-1. A psitive directin f mtin als signifies the encder cunt is increasing. The frward limit switches are encuntered just befre the end f travel in the frward directin. The reverse limit perates similarly in the reverse directin. 5.2) Units f Measure Figure 5-1: Psitive directin cnventin Primatics uses the metric system fr all specificatins and dimensins. All linear dimensins are specified in millimeters. Accuracy, repeatability, reslutin, flatness and straightness fr the POF is specified in micrns. Lad capacity is specified in kilgrams and mment capacity is given in Newtn-meters. All trque specificatins are given in Newtn-meters. Thrust specificatins are given in Newtns. The fllwing table gives sme cmmn cnversins int English units: Metric Unit English Unit 1 Kilgram equals slug* 1 micrn equals inch 1 millimeter equals inch 1 Newtn-meter equals 8.85 in-lbs 1 Newtn equals lbs *1 Kg has a weight f lb when g = 9.8 m / s 2 8

9 6) Installatin Preparatins This sectin utlines installatin envirnments. Unfavrable installatin cnditins may cause electric shck, fire, r breakdwn. Certain breakdwn situatins r malfunctins in particular may lead t serius injury r ther cnsequences. Assure that the unit is used under the fllwing installatin cnditins: Indrs, free frm being splashed by water N crrsive r inflammable gases present Well ventilated place, minimum level f dust r waste An envirnmental temperature range between 0-40 C, and humidity between 20-80% RH (lcatin with n cndensatin) Nte - These values shw the range in which peratin can be carried ut safely, but nt the envirnmental range in which stages accuracy can be guaranteed. Stage accuracy can be guaranteed at 20 C +/- 1 C. Lcatin shuld nt be affected by electrical nise. Lcatin shuld be where inspectin and cleaning can be perfrmed withut difficulty. 6.1) Linear Mtrs Linear mtrs have large magnetic flux that can draw ferrus metals inside them frm large distances, destry magnetic media, and disrupt sme electrnic circuits. Materials attracted t the magnets can pinch fingers and cause injury. Great care must be taken when perating less than 25mm frm the surface f the mtr. In additin, braking is difficult fr linear mtrs making them inapprpriate fr many vertical applicatins. Make sure n lad is attached t the linear mtr stage when stage is first cnnected t the electrnics. Linear mtrs can generate large acceleratins and imprper wiring t the cntrl system can result in a high-speed crash. 9

10 6.2) Heat and Humidity All psitining stages are assembled and tested at 20 C. Any stage calibratins are als perfrmed at 20 C. Fr ptimum accuracy the ambient temperature shuld be maintained at 20 C. Deviatins frm this nminal temperature may result in degraded accuracy perfrmance. Large thermal gradients in the interir f the stage can result frm mtr heat created by high acceleratin mves. Care must be taken t limit the duty cycle f the linear mtr t maintain stage perfrmance. Airflw acrss the mtr will help minimize thermal expansin effects and increase the allwable duty cycle. 6.3) Cntaminatin Applicatins in dirty r dusty envirnments require the electrical, ptical and mechanical cmpnents t be prtected. The POF115 series is intended fr clean envirnments free frm small particulates and fluids. 6.4) Electrical Nise Electrical nise is the crruptin f signals carried ver lw vltage wires. Encder signals can be crrupted resulting in spurius encder cunts thus causing the stage t drift. Grunding, shielding, and spatial separatin are all cuntermeasures t reduce the influences f electrical nise n perfrmance. Yu can minimize the ptential fr electrical nise by bserving the fllwing installatin precautins: Physically separate lw vltage cnductrs frm thse carrying high vltage. Ensure that all cmpnents are prperly grunded. Ensure that all wiring is prperly shielded. 10

11 7) Installatin Prcedures 7.1) Tls yu will need The POF linear psitining stage uses M8x16mm sckethead cap screws fr the base plate munting. The carriage plate has M6 tapped hles fr custmer munting. 7.2) Unpacking Carefully remve the stage frm its shipping crate and inspect it fr evidence f shipping damage. Reprt any damage immediately t yur authrized dealer. If s equipped, remve the red shipping clamp frm the stage. Imprper handling f the stage may degrade its perfrmance. Fllw these guidelines when handling and munting yur stage. 1) D nt drp the stage nt its munting surface. Place the stage gently n the munting surface. Impact lads can cause high spts n munting surfaces, misalignment f drive cmpnents and warping f the base. 2) D nt drill hles int the stage. If additinal hles are necessary, cntact yur lcal distributr. 3) Lift the stage by its base structure nly. D nt lift by the mtr drive assembly. 4) Stage disassembly and alteratin, unless specified therwise, may vid warranty. 7.3) Munting surface preparatin The characteristics f the surface the psitining stage is munted t will have a large effect n system perfrmance. An accurate and flat psitining stage will cnfrm t the shape f its munting surface, therefre a flat munting surface is required. The flatness and straightness specificatins can be affected under large lads. Fr best results in maintaining stage specificatins we suggest the fllwing: 1) Use a labratry Grade AA granite surface plate 2) Befre munting stage, inspect fr burrs r dings n the stage munting surfaces 3) Clean all munting surfaces with acetne In the absence f a granite surface plate, we recmmend a base plate made f the same material as the base f the stage. A munting surface cnstructed ut f a material different frm the stage base material can intrduce warping in the stage in the presence f a thermal gradient. The surface flatness shuld match the requirements f the applicatin; a gd starting pint is t have the munting surface flat t less than 5-8µm. 11

12 7.4) Munting the POF115 The POF115 has fur munting hles that can be accessed by mving the X-Axis t its frward and reverse limits. Figure 7-1 shws the lcatin f these munting hles. 7.5) Electrical Cnnectins Figure 7-1: Munting Hle Lcatins Electrical cnnectins t the stages depend n the type f stage in use. All POF115s are terminated with a 450mm flexible cable with a 28 psitin circular cnnectr n the end. The pin-ut f this cnnectr is shwn with Table 7-1. This particular cnfiguratin is ptimized fr use with Primatics MDC drive chassis via an extensin cable. Cnnectins t ther drives and cntrls are als made thrugh this cnnectr. A ppular ptin fr applicatins nt using the Primatics MDC drive chassis is the pigtailed extensin cable. This is similar t the extensin cable used t cnnect a stage t the MDC drive chassis, except the end that cnnects t the mtr drive and cntrller is un-terminated. Sectin shws the cnductr assignments fr this cable. 12

13 Table 7-1: Axis Cnnectr (Mtr, encder, limits, hme, temp) FCI circular cnnectr, 28 pins, size 20 shell Pin Functin A Mtr A B Mtr B C Mtr C D Mtr Shield E Encder 5V pwer fr encder F Encder A+ utput G Encder A- utput H Encder B+ utput J Encder B- utput K Encder Shield L 12VDC - fr limit, hme, and temp sensr M DCCOM N Hme Switch t DCCOM when n frward side f hme psitin P Nt used R Nt used S Chassis T Hall V+ U Hall V- V Encder Cmmn W Encder Index + X Encder Index - Y Frward Limit Switch switch t DCCOM in nrmal peratin Z Reverse Limit Switch switch t DCCOM in nrmal peratin A Signal Shield B Hall A C Hall B D Temperature mnitr cnnect t DC Cmmn fr temperature OK e Hall C 13

14 7.5.1) Clr Cdes fr Pigtailed Cable Cable cnsists f 3 independent shielded pds : One fr mtr signals, ne fr encder signals & a 3 rd fr sensrs. Each f the pds is described belw. Cable 1 Clr Functin Black Mtr A Red Mtr B White Mtr C Shld Mtr Shield Cable 2 Clr Functin Red Encder 5V White Encder A+ utput Yellw Encder A- utput Green Encder B+ utput Blue Encder B- utput Shld Encder Shield Black Encder Cmmn Orange Encder Index + Brwn Encder Index - Cable 3 Clr Functin Green 12VDC Blue DCCOM White Hme / Wht/Red Nt used / Wht/Black Nt used Shld Chassis Black Hall V+ Brwn Hall V- Vilet Frward Limit Switch Gray Reverse Limit Switch Red Hall A Orange Hall B Tan Temperature Mnitr Yellw Hall C 14

15 7.6) Hall Effect Cmmutatin Sequence The fllwing diagram shws the mtr signal timing fr the Serv Mtr ptin Figure 7-2: Mtr cmmutatin chart The fllwing diagram shws the encder signal timing fr the Encder ptin Figure 7-3: Timing diagram fr the encder signals 7.7) Hme and Limit Sensrs Each POF115 stage includes Frward and Reverse Limit sensrs and a Hme sensr. Figure 7-4 shws the equivalent schematic fr these switches. 15

16 Figure 7-4: Equivalent Limit, Hme, and Temp circuit schematic 7.7.1) Hme Optins: The Hme switch is rdered in either the Nrmally Clsed (H1) r Nrmally Open (H2) cnfiguratin H1: Switch is clsed when carriage is between the negative (reverse) end f travel and the hme transitin pint. It is pen frm the transitin pint t frward end f travel. H2: Switch is pen when carriage is between the negative (reverse) end f travel and the hme transitin pint. It is clsed frm the transitin pint t frward end f travel ) Limit Optins: The Limit switches are rdered in either the Nrmally Clsed (L1) r Nrmally Open (L2) cnfiguratin L1: When the carriage is in the nrmal perating range f travel, bth limit switches are clsed. When the carriage encunters a limit the switch pens. The switch will clse again when the carriage is mved away frm the switch. L2: When the carriage is in the nrmal perating range f travel, bth limit switches are pen. When the carriage encunters a limit the switch clses. The switch will pen again when the carriage is mved away frm the switch. 16

17 7.8) Limit and Hme Switch Adjustment The limit and hme switch psitins are preset at the factry. The limits are nminally set t yield slightly mre travel than specified in the mdel cnfiguratin. The nminal hme switch transitin pint is abut 2mm t the psitive side f the center f travel. Figure 7-5: Limit and Hme Sensr Transitin Ranges The hme and limit signals are each prduced by separate reflective sensrs munted t the underside f the carriage. A white reflective strip (the hme vane) munted t the base runs the length f the stage and is viewed by each sensr. A special nn-reflective black tape is applied t the hme vane. Each switch is clsed when viewing the white area and is pen when viewing the nn-reflective tape. Figure 7-6A shws the tape cnfiguratin fr the nrmally clsed sensr ptins (H1, L1). Figure 7-6B shws the tape cnfiguratin fr the nrmally pen sensr ptins (H2, L2). Limited adjustments can be made t the limit transitin signals by adding r remving black tape. Figure 7-6A: Hme Vane Cnfiguratin H1, L1 Optins (Nrmally Clsed) Figure 7-6B: Hme Vane Cnfiguratin H2, L2 Optins (Nrmally Open) 17

18 7.9) Recmmended System Test Befre attaching a lad r applying pwer t yur stage, verify the encder and limit switches are wrking prperly. Mve the stage carriage by hand in the psitive directin and verify the encder cunt is increasing. Runaway cnditins caused by miswired encders can result in stage damage and persnal injury. Mve the carriage t each end f travel t ensure limit switches are wrking prperly. When clsing the psitin lp fr the first time, set the trque limit f yur cntrller t a lw value and use cnservative tuning gains. Once the cntrl lp is wrking prperly, paylads can be added t the stage carriage. 8) Preventive Maintenance Perfrming preventive maintenance prcedures n yur stage will extend its life and imprve its lng-term perfrmance. 8.1) Lubricatin Use clean rm grease t lubricate the linear guide cmpnents. We recmmend NSK grease part #GRS LG2. Fr lw duty cycle applicatins, it is recmmended that linear guides are re-greased every six mnths. High duty cycle applicatins may require mre frequent re-lubricatin. Lubricatin intervals depend n duty cycle, lad and ambient cnditins. The linear mtr is a nn-cntact device and requires n lubricatin. Primatics ffers a grease kit that has all the necessary hardware t re-lubricate the linear bearings. Grease prts are lcated n the ends f the linear guide blcks alng the axis f the rails. Use a grease gun with the apprpriate fitting t cnnect t the grease prt. Figure 8-1: Bearing blck lubricatin fitting 18

19 8.2) Cables The flat cables inside the stage are designed fr millins f cycles f use. The pigtail cables exiting the stage are strain relieved but excessive frce r repetitive cycling frces shuld nt be applied t the pigtail cables. 9) Trubleshting & Service 9.1) Trubleshting Help Fr further assistance cntact the factry: M-F 8AM t 5PM Pacific Time Phne: [541] Fax: [541] Tll Free: [888] Web: service@primatics.cm 9.2) Service Shuld yur device require factry service, cntact the factry fr a Return Materials Authrizatin (RMA). When inquiring abut an RMA please have the fllwing infrmatin available: Yur cntact infrmatin (name, phne, , address) Unit Serial Number (see Figure 9-1) Symptm f prblem Histry f trubleshting steps already taken Figure 9-1: POF115 Serial Number Lcatin(s) 19