Toothed belt axis EGC-TB-KF, EGC-HD-TB en Operating instructions 8076268 2017-11c [8076270]
Translation of the original instructions Symbols: Warning Installation and commissioning may only be performed in accordance with these instructions by technicians with appropriate qualifications. Caution Note Environment Accessories English... 3 2 Festo EGC-TB-KF, EGC-HD-TB 2017-11c
English Toothed belt axis EGC-TB-KF, EGC-HD-TB Table of contents 1 Control sections and connections... 4 2 Function and application... 5 3 Transport and storage... 5 4 Requirements for product use... 6 5 Installation... 7 5.1 Mechanical assembly... 7 5.1.1 Mount axis... 7 5.1.2 Installation of the effective load... 9 5.1.3 Installing external accessories... 10 6 Commissioning... 11 7 Operation... 12 8 Maintenance and care... 13 9 Repair... 14 10 Accessories... 15 11 Troubleshooting... 15 12 Technical data... 16 13 Characteristic curves... 19 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English 3
EGC-TB-KF, EGC-HD-TB Documentation on the product For all available product documentation è www.festo.com/pk 1 Control sections and connections EGC-...-TB-KF 1 2 3 EGC-HD-...-TB 4 5 6 7 8 9 aj 9 aj ac 1 2 3 4 5 6 7 8 ab aa Thread and centring holes for foot mounting Cover cap Drive hollow shaft Thread for motor mounting kit Guide rail (2x with EGC-HD-...-TB) Thread and centring holes for mounting the effective load slide Surface for profile mounting ac 9 aj aa ab ac ab aa Thread for optional switch lug (with EGC-HD-...-TB, both sides) Groove for proximity switch (with EGC-HD-...-TB, both sides) Grooves for slot nut mounting and accessories Relubrication opening (both sides, 2x EGC-...-TB-KF, 4x EGC-HD-...-TB) Toothed belt Fig. 1 4 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English
2 Function and application A toothed belt on a drive hollow shaft 3 converts the rotation of a motor into a linear movement. The slide 7 then moves backwards and forwards. The slide is bearing mounted. The reference position of the slide can be detected using proximity sensors in the slots aj. The EGC-...-TB-KF toothed belt axis is intended to be used to quickly position effective loads with large dimensions. It is approved for slide operating mode. The EGC-...-TB-KF and EGC-HD-...-TB are not approved for operating conditions in which vegetable water-soluble greases or oils could penetrate into the axis. Fig. 2 Note The EGC toothed belt axis is not braked: If the input torque is not applied, the slide is freely movable. Generally self-locking of the complete system can be achieved with motors with an integrated spring-loaded holding brake or with high self-braking torque (e.g. for vertical operation). Please select the corresponding motors from our catalogue ( www.festo.com/catalogue). You will then be operating a mated pair, which are especially adapted to each other. When using other motors: Observe the limit values for forces, torques and speeds ( 12 Technical data and 13 Characteristic curves). 3 Transport and storage Take the product's weight into account. Depending on the version, the EGC can weigh up to 350 kg. For transport, the transport belts must be positioned at the permissible support distances (support distances 13 Characteristic curves). Ensure the following storage conditions: Storage times should be kept to a minimum cool, dry, shaded, corrosion-protected storage locations no oils, greases or grease-dissolving vapours. In this way you ensure the performance of the toothed belt. Festo EGC-TB-KF, EGC-HD-TB 2017-11c English 5
4 Requirements for product use Warning Unexpectedly fast moving masses can harm people or property items (crushing). Apply power to the drive motor, at first limited to low speeds and torques. Note Malfunctions will occur if the device is not used correctly. Make sure that the specifications contained in this chapter are adhered to at all times. Take into consideration the legal regulations applicable for the destination, as well as: regulations and standards regulations of the testing organizations and insurers national specifications. Note the warnings and instructions on the product and in the relevant operating instructions. Remove all transport packaging, such as foils, caps and cardboard. The material used in the packaging is intended for recycling (exception: oil paper = residual waste). Observe the local regulations for environmentally friendly waste management of electronic components. Take into account the material specifications (12 Technical data). Use the product in its original status, without any unauthorised modification. Take into consideration the environmental conditions at the location of use. Corrosive environments reduce the service life of the product (e.g. ozone). Compare the limit values in these operating instructions with those of your application (e.g. forces, torques, temperatures, masses, speeds). Only if the load limits are observed is it possible to operate the product in compliance with the relevant safety regulations. Take the tolerance of the tightening torques into account. Unless otherwise specified, the tolerance is ±20 %. 6 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English
5 Installation 5.1 Mechanical assembly Do not modify the screws and threaded pins. Exception: Direct request to do so in these operating instructions. Mount the motor onto the axis in accordance with the assembly instructions for the motor mounting kit recommended in the catalogue. Fig. 3 5.1.1 Mount axis Requirements Position the product in such a way that its control sections are accessible (e.g. relubrication openings). Make sure that the mounting components are outside the positioning range of the slide. Install product without tension or distortions. Fasten product to a mounting surface with flatness of 0.05 % of the stoke length, but max. 0.5 mm. For gantry applications, attention must also be paid to parallel alignment or product heights in alignment of the axes. For additional information, contact your local Festo Service. Take the required support spacing into account ( 13 Characteristic curves). Fig. 4 Attach the EGC (Tab. 1). Festo EGC-TB-KF, EGC-HD-TB 2017-11c English 7
Interfaces for mounting components on the cover on the profile e.g. with foot mounting HPE 1) (only for EGC-...-TB-KF) e.g. with slot nuts NST 1) e.g. with profile mounting MUE 1) 1) www.festo.com/catalogue Tab. 1 Note Danger of screws being pulled out if the axis is only mounted to the covers and the torque load around the longitudinal axis is too great. If there are heavy loads, mount the axis to the profile with additional mounting components. Tighten the mounting screws evenly with the following tightening torque. Size 50 70 80 120 185 Screw (cover) M4 M5 M5 M8 M10 Tightening torque [Nm] 2.9 5.9 5.9 24 47 Tab. 2 For installation in a vertical or inclined position: Warning Injury to people and material damage! If there is a power failure or if the toothed belt breaks, the work load will slide down. Make sure that you only use motors with an integrated spring-loaded holding brake. Fig. 5 Check whether additional external safety measures against damage due to breaking of the toothed belt are required (e.g. toothed latches, moving bolts or emergency buffers). 8 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English
5.1.2 Installation of the effective load Place the effective load so that the tilting torque resulting from force F (parallel to the axis of motion) and lever arm a remains low. a F Fig. 6 Fasten the effective load to the slide with the screws and centring sleeves. Make sure that the maximum screw-in depth D is adhered to. Fig. 7 Size 50 70 80 120 125 160 185 220 Screw (side/top) M4 M5 M5/M6 M5 M6 M6/M8 M6 Max. screw-in depth D [mm] 4.2 8.4 9.5 10 8.4 9.5 15 10 Centring (H7) [mm] 5 5 7/9 5/9 9 9 9 Tightening torque [Nm] 2.9 5.9 5.9/9.9 5.9 9.9 9.9/24 9.9 Tab. 3 Effective loads with own guide: Adjust the guides of the effective load and of the EGC so that they are exactly parallel. You will then avoid overloading the guide and increased wear. With hard and stiff effective loads (e.g. steel): Note If the aluminium slide becomes bent against a curved effective load, the service life of the guide will be reduced. Make sure that the mounting surface of the effective loads is even to within t=0.01 mm. If additional slides are used, possible differences in height must be compensated for. Fig. 8 t Effective loads projecting in the longitudinal direction of the slide: Make sure that the effective load does not strike against the motor. Fig. 9 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English 9
5.1.3 Installing external accessories To protect the end positions against uncontrolled overrunning: Check whether proximity sensors are required (hardware limit switches). If proximity sensors are used as limit switches: Preferably use proximity switches with normally-closed function. These will protect an EGC with a fractured proximity switch cable from overrunning the end position. If proximity switches are used as reference switches: Use proximity switches that correspond to the input of the controller being used. Use inductive proximity switches with switch lug ae ( assembly instructions of the accessory used). Mounting in the grooves aj ( Fig. 1) with mounting bracket ad ae ad aj ae Tab. 4 Avoid external influence caused by magnetic or ferrite parts in the vicinity of the proximity switches (minimum distance of 10 mm to the slot nuts). To protect the end positions: Use emergency buffer or shock absorber ( Assembly instructions of the accessory used). To avoid contamination: Use slot covers in all unused grooves. 10 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English
6 Commissioning Warning Moving masses can cause personal injury or damage to material items (crushing). Make sure that, in the positioning range nobody can place his/her hand in the path of the moving components (e.g. through a protective guard), there are no foreign objects. It should not be possible to touch the EGC until the mass has come to a complete standstill. Fig. 10 Note Incorrect specification values of the braking ramp in STOP statuses (e.g. EMERGENCY OFF, Quick Stop) result in an overloading of the linear axis and can destroy it or drastically reduce the service life. Check the settings for all braking ramps in your controller or the higher-order control system (deceleration values and jerk). Taking the travel speed, moving mass and mounting position into account, make sure that the delay values (brake delay and time delays) are set in such a way that the maximum actuation moment or feed force of the linear axis used is not exceeded. Use the PositioningDrives design software to design the linear axis ( www.festo.com). Note Block-shaped acceleration profiles (without smoothing) cause high peaks in the drive force that can lead to overloading of the drive. In addition, positions outside the permissible range may occur as a result of overswing effects. A jolt-limited acceleration specification reduces vibrations in the entire system and has a positive effect on stress in the mechanical system. Check which closed-loop controller settings can be adapted (e.g. jerk limitation, smoothing of the acceleration profile). Note The elasticity of the toothed belt delays the acceleration behaviour of the EGC and results in larger accelerations than are set on the controller (spring effect). Take into account possible deviations from the acceleration set at the controller. Festo EGC-TB-KF, EGC-HD-TB 2017-11c English 11
Check travel Homing run Test run Determining the approach direction Comparison of the real situation Checking the overall behaviour of the motor with the figure in the controller Tab. 5 1. Start check travel with low dynamic response. In spite of equal control, motors of the same design sometimes turn in the opposite direction due to different wiring. 2. Start homing in accordance with the operating instructions for your motor drive system with low dynamic response to the reference switch. The homing run may only take place toward the reference switch. 3. Start a test run with low dynamic response. 4. Check whether the EGC fulfils the following conditions: The slide runs through the complete intended positioning cycle. The slide stops as soon as it reaches a limit switch. 7 Operation Warning Moving masses can cause personal injury or damage to material items (crushing). Make sure that, in the positioning range nobody can place his/her hand in the path of the moving components (e.g. through protective guards) there are no foreign objects. It should not be possible to grasp the EGC until the mass has come to complete rest. Note The reference position is lost when the motor is dismounted (e.g. turning of the motor). Start homing ( 6 Commissioning) in order to determine the new reference position. Fig. 11 12 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English
8 Maintenance and care Warning Uncontrolled moving masses can cause injury to people or damage to property (squeezing). If a toothed belt breaks in combination with a vertically or diagonally installed EGC, the work mass will fall down. In case of signs of wear, return the EGC to Festo for repairs. Controller signals can cause the EGC to make unintended movements. Switch off the controller for all maintenance work on the EGC and secure it to prevent it from being restarted unintentionally. On cleaning and maintenance: If required, clean the guide axis with a soft cloth. All media gentle to the material may be used as cleaning agents. Note The lubrication interval S int is dependent on the product load. Cut the lubrication interval S int ( Fig. 12) in half if the following situations are present: dusty and dirty environment nominal strokes 2000 mm at speeds 2 m/s positioning profile Z delta operation (frequent acceleration and braking) ambient temperatures 40 C product has been in operation for 3 years. If several situations occur simultaneously, the lubrication interval must be divided by four. Grease the following components: Bearing guide Guide rail Lubricating point ( Fig. 1) Relubrication opening ab Surface 5 Lubrication interval ( Fig. 12) As required 1) Grease 2) Roller bearing grease 1) or if the component no longer has a layer of grease 2) Grease gun, blast pipe and grease (10 Accessories) Tab. 6 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English 13
For greasing the bearing guide (not possible for EGC-...-GP/GQ): 1. Calculate the load comparison factor fv with the aid of the formula for combined loads ( 12 Technical data) and determine the lubricating interval S int from it ( Fig. 12). fv 2. Grease the bearing guide on both sides at all relubrication openingsab. 3. Move the slide over the complete travel distance during lubrication in order to distribute the grease equally inside. Fig. 12 Fig. 13 ab 9 Repair Note Retensioning of the toothed belt reduces its service life considerably. In addition, the technical data, e.g. the feed constant, change. Make sure that the toothed belt is not retensioned. The toothed belt is pretensioned so that it does not have to be retensioned during its service life. Recommendation: Send the EGC to our repair service. This way the fine tuning and tests that are required will be taken into particular consideration. Information about spare parts and auxiliary means can be found at: ( www.festo.com/spareparts). 14 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English
10 Accessories Designation Part number/type Grease gun with needle-pointed nozzle 647958/LUB-1 1) Nozzle, outlet axial 647959/LUB-1-TR-I 1) Nozzle, outlet radial 647960/LUB-1-TR-L 1) Roller bearing grease LUB-KC1 from Festo 1) 1) ( Spare-parts catalogue at www.festo.com/spareparts) Tab. 7 11 Troubleshooting Malfunction Possible cause Remedy Squeaking noises, vibrations or the axis is not running smoothly Slide does not move Slide travels beyond the end position Toothed belt jumps off Tab. 8 The coupling is mounted too tight Distortions Incorrect regulator settings Roller bearing/bearing guide defective Toothed belt worn Coupling hub slipping Loads too high Mounting screws for effective load too long The proximity switches do not react Toothed belt pretensioning too low Incorrect regulator settings Comply with the permissible coupling spacing dimensions (assembly instructions of the motor mounting kit) Fit the EGC free of tension (evenness of the bearing surface: 5 Installation) Align the EGC so that it is exactly parallel to the second axis Grease the EGC (8 Maintenance and care) Modify travel speed Change the regulator parameters Send EGC to Festo for repair Send EGC to Festo for repair Check mounting of motor mounting kit (assembly instructions of the motor mounting kit) Reduce mass of the effective load/travel speed Observe max. screw-in depth (5.1.2 Installation of the effective load) Check the proximity switches, connections and controller Send EGC to Festo for repair (9 Repair) Change the regulator parameters Festo EGC-TB-KF, EGC-HD-TB 2017-11c English 15
12 Technical data Size 1) 50 70 80 120 125 160 185 220 Design Electromechanical axis with toothed belt Guide Recirculating ball bearing guide Mounting position Any Max. feed force Fx [N] 50 100 350 800 450 1000 2500 1800 Max. driving torque [Nm] 0.46 1.24 5 16 7.3 19.9 93 59.6 Max. no-load driving [Nm] 0.072 0.18 0.4 1.4 0.5 2.1 4.05 4.1 torque 2) Max. speed [m/s] 3 5 3 5 3) Max. acceleration [m/s 2 ] 50 40 50 Repetition accuracy [mm] ±0.08 ±0.1 Feed constant [mm/rev.] 58 78 90 125 102 125 232 208 Ambient temperature [ C] 10 +60 Protection class IP40 1) The following tool is available for sizing: PositioningDrives design software ( www.festo.com) 2) Measured at a speed of 0.2 m/s 3) For variant GP with BG160/220: max. speed 3 m/s Tab. 9 16 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English
EGC-...-TB-KF Size 50 70 80 120 185 Maximum permitted forces on the slide Fy = Fz [N] 650 1850 3050 6890 15200 Maximum permitted torques on the slide Mx [Nm] 3.5 16 36 144 529 My = Mz [Nm] 10 51 97 380 1157 (EGC-GK, EGC-GP) My = Mz (EGC-GV, EGC-GQ) [Nm] 132 228 680 1820 Condition for combined loads: f v Mx My Mz Fy Fz 1 Mx max My max Mz max Fy max Fz max Materials Profile, cover, slide Anodised aluminium Ball bearing, guide, screws Steel Cover caps Polyacetal Toothed belt Fibreglass-reinforced polychloroprene Buffer Nitrile rubber Sealing disc Acrylic butadiene styrene Weight 0-stroke [kg] 0.62 1.85 3 10.5 32.6 per 100 mm stroke [kg] 0.19 0.44 0.62 1.5 3 Tab. 10 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English 17
EGC-HD-...-TB Size 125 160 220 Maximum permitted forces on the slide Fy = Fz [N] 3650 5600 13 000 Maximum permitted torques on the slide Mx [Nm] 140 300 900 My = Mz [Nm] 275 500 1450 Condition for combined loads: f v Mx My Mz Fy Fz 1 Mx max My max Mz max Fy max Fz max Materials Profile, cover, slide Anodised aluminium Ball bearing, guide, screws Steel Cover caps Polyacetal Toothed belt Fibreglass-reinforced polychloroprene Buffer Nitrile rubber Sealing disc Acrylic butadiene styrene Weight 0-stroke [kg] 4.72 9.05 25.51 per 100 mm stroke [kg] 0.73 1.07 2.1 Tab. 11 18 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English
13 Characteristic curves Maximum permissible support span L as a function of the force F for EGC-...-TB-KF L L EGC-50 EGC-70 EGC-80 EGC-120 EGC-185 EGC-50 EGC-70 EGC-80 EGC-120 EGC-185 Fig. 14 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English 19
Maximum permissible support span L as a function of the force F for EGC-HD-...-TB L L EGC-HD-125 EGC-HD-160 EGC-HD-220 EGC-HD-125 EGC-HD-160 EGC-HD-220 Fig. 15 20 Festo EGC-TB-KF, EGC-HD-TB 2017-11c English
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Copyright: Festo AG & Co. KG Ruiter Straße 82 73734 Esslingen Germany Phone: +49 711 347-0 Fax: +49 711 347-2144 Reproduction, distribution or sale of this document or communication of its contents to others without express authorization is prohibited. Offenders will be liable for damages. All rights reserved in the event that a patent, utility model or design patent is registered. E-mail: service_international@festo.com Internet: www.festo.com