IC80 Series INTRODUCTION

Transcription

1 SN-PL/2011/002

2 IC80 Series INTRODUCTION Sankyo America, Inc. is proud to offer the IC80 inline chassis precision link conveyor to manufacturers around the world. This innovative design features zero-backlash positioning performance by preloading the chain link cam followers and needle bearings in all directions. Links are supported on each corner with dual needle bearings. Each bearing is preloaded with precision ground guide rails to eliminate axial backlash. The back of the link includes multiple cam followers preloaded with precision guide rails to eliminate radial and twisting backlash. Rigid enough for light machining processes, each conveyor is certified for non-accumulative positioning accuracy. Numerous feed pitch options are offered with fixed stop cam indexing units that rotate the conveyor links with extreme accuracy at high speeds and frequent cycle rates. Sankyo s programmable servo driven indexers with our RollerDrive Technology offers continuous rotation or intermittent feed pitch lengths. Both drive options can be reversed or oscillate for special operations. The chart below lists multiple feed options by link size and drive type. Links per Feed Pitch mm Link 120mm Link 160mm Link Servo Drive Feed Pitch Index Stops Feed Pitch Index Stops Feed Pitch Index Stops Feed Pitch 80mm mm mm mm / 4 120mm mm mm mm mm mm mm mm Unlimited 4 Unlimited / Unlimited 2 Unlimited Frame rails are design with precision components for an open architecture. Large windows in the rails behind the chain link offers access to the back of the part with the hollow chain link option. Process operation can be done on both side of the part simultaneously without flipping the part. Spacing between the frame rails can quickly integrate tooling for machining operations, inspection and reject part ejection. Link sizes are available in three accurate length sizes. Machined from stress relieved tooling steel or aluminum, each link is designed to maintain dimensional form. Steel links are nickel-plated and anodized aluminum links prevent oxidation. Steel links are preferred for applications where manufacturing environment temperatures fluctuate and positioning accuracy is critical. Aluminum links are preferred for applications running at higher speeds to reduce the moving mass weight. Both are available with solid or open centers to reduce weight or gain access to both sides of the part. Synchronous or asynchronous line shafts are available to drive supporting equipment with multiple mounting configurations. Loading, inspection or assembly is easily incorporated with versatile belt driven or coupled systems. Pre-engineered or custom tooling mounts for chains links, frame or motor drives are available. Made in the USA, we offer fast deliveries, high quality, reliable and accurate systems with local and global sales and service. Sankyo employs over 600 employees worldwide and is undisputedly the world s premier cam manufacturer. Please visit to see the IC80 precision link conveyor video and many other Sankyo automation products in action. Table of Contents Introduction.2 Features...3 Features...4 Options 5 Specifications..6 Dimensions..7 Application Quote Request..8 Cam Indexing Units. 9 2

3 IC80 Series FEATURES Description versatility 0~120 cycles per minute X-Y & Z axis preloaded links Variable or multiple feed pitch options Continuous or on demand cycling Custom base & tooling plate options Chordal chain tensioning reduces vibration Sankyo's IC80 Series precision link conveyor accurately advances and positions part fixtures in a carousel or over/under type configuration. Its open frame design allows access to both sides of the conveyor rails and through the hollow chain link option. Frame components are nickel plated steel. Link components include sealed bearings compatible with most industrial environments including medical or light machining applications. Frame lengths are available in 480mm (18.89 ) increments. Standard cam driven indexers provide nonaccumulative, repetitive positioning accuracies of ± 0.1mm (±0.004 ) to each station. Other drive options include servo drives, clean room indexers, and torque limiter input overloads. Part handlers or other supporting equipment can be asynchronous or synchronous driven with the line shaft option. ±0.1mm (±0.004 ) position accuracy Open frame & hollow link design for access to the part front & back sides Line shaft to drive support equipment Over/under or carousel configurations Motorized indexer or servo driven 960~9600mm (3~31 feet) lengths 80, 120 or 160mm link sizes 480mm sections allow for growth or reduction before shipping Rigid enough for light machining Linear and/or rotary handlers can be synchronously driven with line shafts Open Framework accessibility Open frame architecture and hollow link design allows access to the front and back of the part. Processes requiring operations on both sides of the part can be done faster without flipping the part or providing additional tooling. Part escapements are simplified with back side ejection tooling. With the part supported in the X-Y-Z axis accurately, machining can be performed on the back and the front of the part simultaneously. Center rail struts can be modified to mount escapement tooling, drilling & tapping tooling. Chordal Chain Tension longevity Each conveyor design incorporates a chordal compensating cam to keep the conveyor length consistent with every link feed cycle. To reduce vibration, the idler sprocket is assembled with precision machined cams cut to match the chordal motion of the links. This eliminates the need for air or spring devices to tension the chain. Long term positioning accuracy is maintained by minimizing backlash and chain stretch. Bearing wear is minimized and predictable. Vibrations are minimized, ensuring stable dynamics, which allows the conveyor to run faster. 3

4 IC80 Series FEATURES Chain Link Design rigidity Front Side Back Side Pivot Pin Bearings Link Support Bearings Nickel plated steel links provide precise positioning accuracy if processing temperatures fluctuate. Light weight, anodized aluminum links are offered for high speed applications. Hollow links are lighter and designed with pass through openings but, still rigid enough for machining. Link sizes are 80mm tall with center distances of 80mm, 120mm and 160mm. Various drive options offer multiple links to be accurately indexed with one feed pitch. All pass through openings are 40mm tall with the length scaled to each link size. Each link is supported in the X axis with two needle type roller bearings on each corner. The back of the links have four cam followers to support the X axis (80mm links have two cam followers). Each link pivot rod is hollow to provide grease lubrication to the precision needle bearings. All bearings are preloaded and made of high grade steel to sustain heavy shock loads providing years of service. Link Preload Design stability Six sealed bearings support the chain link on each end. Each link is preloaded in all directions to reduce backlash and vibration when running high speeds. Rigidity is increased enough to perform milling and machining operations. Inherently, this design increases life, weight carrying capacity, and larger bending capacity. Positioning accuracy is increased in the Z axis at higher speeds. In most cases, the idler and drive ends of the conveyor are supported adequately for processing or loading operations. This increases the station quantities and requires a smaller overall machine footprint. Motor Drive Option reliability Multiple drive options include Sankyo s economical indexing units featuring accurate positioning with high torque capacity. Indexing units with geared motor drives are available in multiple mounting positions on either side of the conveyor. Sankyo s zero-backlash RollerDrive units use servo drives to achieve frequent stop/starting cycles and large torque requirements with programmable motion patterns. Servo motors with optional low backlash reducers are also offered for flexible motion. Sankyo s TC series torque limiting safety clutches (shown right), features accurate, automatic, reset positioning, easy adjust torque range settings, misalignment error compensation and overload detection. Multiple mounting configurations can be customized to meet your needs. Cleanroom and corrosion resistant indexers with safety clutches are available for medical & packaging applications. 4

5 IC80 Series OPTIONS Over-Under Configuration The over & under mounting configuration features a narrow footprint with compact motor drive and line shaft options, mounted on either side of the conveyor. Multiple units mounted side by side or stacked can share a common drive motor for synchronous applications. Options include line shafts, mounted motor drives, safety clutch couplers, controllers, leg stands, machine base frames and custom configurations. Carousel Configuration The carousel mounting configuration displays a wider footprint and more usable links. Compact motor drives or lines can mount on the top or bottom of the conveyor. Multiple units mounted side by side or stacked can share a common drive motor for synchronous applications. Options include line shafts, mounted motor drives, safety clutch couplers, controllers, leg stands, machine base frames and custom configurations. Line Shaft Option Line Shafts can be driven synchronously with the indexer or asynchronously with a separate drive motor. The shaft, as shown, can be mounted at multiple heights, on one or both sides of the conveyor. Leg stands can be modified to support line shaft flange bearings, tooling plates or custom drive mounting. Mounted Part Handlers Linear part handlers are designed for pick & place motions, accurate part insertion or applying crimping forces for stacking operations. Narrow housing sizes match the chain link feed pitch. Motions incorporate dwell periods for gripper actuation while the drive input is rotating continuously. Each motion is designed to your specification. Synchronized handlers are line shaft driven or asynchronous with independent drives for cycle-on-demand applications. This system is pre-engineered to save design and installation time, just add tooling to the part handlers to start production. Independent GY Linear Part Handler Sankyo s GY series linear pick & place part handlers are renowned for high-speed capabilities, accuracy, and reliability. Cam driven linear slides accurately position parts within 0.02mm ( ) up to 120 cycles per minute. Maximum stroke lengths are 50 x 150mm (2 x 6 ). Thin housing widths, 70~90mm (2.8 ~ 3.5 ) match the conveyor link stroke pitch. Optional linear overloads can be mounted between the handler output arm and tooling to prevent damage to tooling in the event of a crash. Force thresholds are easily adjusted without any disassembly. Photo eye sensors detect when force threshold overloads occur. 5

6 IC80 Series SPECIFICATIONS Specification Quick Reference Model Units IC80-80 IC IC Cycles per Minute cpm 0~120 0~120 0~120 Center to Center Distance mm (ft) 960 to 9600 (3.1 to 31.5) in 480mm sections Chain Link Length mm (in) 80 (3.14 ) 120 (4.72 ) 160 (6.29 ) Linear Feed Pitch Accuracy mm (in) ±0.10 (±0.004 ) Examples of Index Periods for Cam Driven Indexing Units deg 90 (1:3 ratio index to dwell time running continuously) 120 (1:2 ratio index to dwell time running continuously) 180 (1:1 ratio index to dwell time running continuously) 270 (3:1 ratio index to dwell time running continuously) Indexer Cam Curves - Modified Sine(MS), Sankyo Modified Sine (SMS-3) & Modified Constant Velocity (MCV50) Line Shaft Option Availability - Yes GY Pick & Place Part Handler Availability - Yes Drive End Section Weight kg (lb) 53 (118) 58.0 (128) 54 (120) Return End Section Weight kg (lb) 25 (56) 29.5 (65) 26 (57) Single 480mm Mid Section Weight kg (lb) 17 (37) 17.2 (38) 17 (37) Indexer w/ Gearmotor & Torque Limit Weight kg (lb) ED11-91 (201), 14D- 171 (378), 18D- 311 (686), 23AD- 411 (905) Chain Link Loading Capacities Our innovative design features four needle roller bearings mounted on the link pins to support in the X axis. To support the Y axis, multiple cam followers are mounted to the back of the chain link. All needle bearings and cam followers are preloaded to eliminate backlash in every direction. 120mm Chain Link Loading Example Link Size Axis Units Dynamic Allowable Load per Link (45 cpm) Static Allowable Load per Link Fx Newton Fy Newton Fx Newton Fy Newton Fx Newton Fy Newton CPM 45CPM Load (N) Fy Static Fx Static A or B dimension (mm) Conversions: 1 Newton = pound, 1 millimeter = inch 6

7 IC80 Series DIMENSIONS Conveyor Dimensions Model Units A B C D E F G H I J K L M N O P Q IC80-80 mm 80 (2) 50 (4) IC mm Ø6mm 90 M6x or 190 to IC mm 160 dowel 130 tapped C E G D F R Q S (in 480mm increments) A B H T P O M N I J L K LINK FACE AC AA W U V X Y 120MM LINKS SHOWN AB AB AA AD AE AF AG Model Units R S T U V W X Y AA AB AC AD AE AF AG IC80-80 mm M10x1.5 Ø8 mm IC mm 244 to 362 TAPPED / to to TYP. TYP. TYP. IC mm TYP. DOWEL Chassis Center to Center Distance mm/inch Model Code Nomenclature IC T- Link Height Link Length Drive mm/inch mm/inch Sprocket 80/ / / / Teeth 12 Teeth 8 Teeth 960/ / / / / / / / / / / / / / / / / / /378.0 SH Link Material and Type AH (AL Hollow) AS (AL Solid) SH (Steel Hollow) SS (Steel Solid) /X Special Requires Drawing Drive Mounting Index Mount Pos-1 Index Mount Pos-2 Index Mount Pos-3 Index Mount Pos State Route 47 Sidney, Ohio Tel: (937) Fax: (937) sales@sankyoamerica.com

8 IC80 Series OVERALL LENGTH Overall Dimensions State Route 47 t Sidney, Ohio Tel: (937) t Fax: (937) t sales@sankyoamerica.com 8

9 IC80 Series APPLICATION DATA SHEET Fax-back Sizing Data Sheet Company Phone Address City State Zip Fax Contact Item Feed Pitch [P] mm in Index Transfer Time (sec) Chain Link Pitch mm in Dwell or Idle Time (sec) Stations Required Cycle on Demand Yes Jig/Tooling Quantity Continuous Duty Cycle Yes Jig/Tooling Weight kg lb Torque Limiting Clutch Yes Work/Part Quantity Link Type Solid Hollow Work/Part Weight kg lb Link Material Steel Alum. Voltage Requirements Sensor Style PNP NPN Carousel Type Yes Over & Under Type Yes (as shown) Line Shaft Required Yes Pick & Place Units Yes Special: Item Notes: Service Sankyo offers engineering support, repair or rebuild service at our facility in Sidney, Ohio. On-site service is available throughout the world by contacting Sankyo America or any of Sankyo s international service centers. 9

10 Cam Indexing Units Related Products SANKYO Innovation Fixed Stop Rotary Indexers Sankyo offers a full line of dial index units to rotate tables up to 26 feet in diameter. Standard hollow bore centers can route supplies with a stationary flange for mounting a second dial above the indexing dial. Standard units index or oscillate with an average of ±15 arcsec accuracy (but not to exceed ±30 arcsec) with optional high accuracy units available. AD Series (high torque capacity) DT Series (designed for specials) DTR Series (integrated reducer) Ed Series (cleanroom option) Programmable Rotary Indexers Each series below features programmable stops or non-patterned motions driven with servo motor drives. Constant lead cams include an internal ratio which can be driven with or without optional reducers for combined ratios up to 1600:1. Multiple housing sizes are available in each series with stationary or rotating hollow outputs, for cycle rates up to cycles/minute. AR/ServoDEX Series (high torque) RA Series (high accuracy/high speed) RT Series (machine tool) RY Series (integrated motor) Linear & Rotary Handlers Sankyo s handlers feature rotary & linear motions combined with lift motions. All internal cams include gripper dwell times and easy synchronization (1 input shaft revolution for one full cycle). Multiple sizes for each series are available. FN Series (rotary/lift handler) FH Series (600 cpm handler) GY Series (linear handler) GV Series (walking beam) GSeries (large walking beam) Rotary & Linear Assembly Our rotary and linear assembly machine can incorporate synchronizes or asynchronous handlers. Our BH series can mount 0~12 synchronized handlers above a 6~36 station indexing dial plate. The IC80 series precision chain conveyor can use our GY series handler with 12~256 stations. BH Series (rotary assembly) 90 cycles/min 6~36 stations 0~12 handlers 3 frame sizes 1 motor drives index & handler clutch protected IC80 Series (linear assembly) 120 cycles/min 80~160mm link Various pitches 960~9600 long line shaft drive for handlers clutch protected SankyoAmerica To view Sankyo products in action 10

11 Service Network State Route 47 Sidney, Ohio USA Phone: (937) Fax: (937) SEISAKUSHO CO. Sankyo Japan World Headquarters KOREA CO., LTD. Sankyo Korea Sankyo China SN-PL/2011/002