Parallel kinematic system EXPT. Description. Mechanical installation c [ ]

Parallel kinematic system EXPT Description Mechanical installation 806045 608c [806047]

EXPT Translation of the original instructions EXPT-EN CoDeSys is a registered trademark of its respective trademark holder in certain countries. Identification of hazards and instructions on how to prevent them: Danger Immediate dangers which can lead to death or serious injuries Warning Hazards that can cause death or serious injuries Caution Hazards that can cause minor injuries Other symbols: Material damage or loss of function Recommendations, tips, references to other documentation Essential or useful accessories Information on environmentally sound usage Text designations: Activities that may be carried out in any order. Activities that should be carried out in the order stated General lists Result of an action/references to more detailed information 2 Festo EXPT-EN 608c

EXPT Table of Contents EXPT Safety and requirements for product use... 5. Safety... 5.. General safety instructions... 5..2 Intended use... 5.2 Requirements for product use... 6.2. Technical requirements... 6.2.2 Qualification of trained personnel... 6.2.3 Range of application and certifications... 6 2 Transport and storage... 7 2. Transport... 7 2.2 Storage conditions... 7 2.3 Unpacking... 8 2.4 Checking the scope of delivery... 9 3 Overview... 0 3. Features... 0 3.2 Function and application... 2 3.3 Design... 3 4 Mounting... 4 4. Mounting instructions... 4 4.. Dimensions... 4 4..2 Installation location... 4 4.2 Rack mounting... 5 4.3 Types of mounting... 6 4.3. Direct mounting... 6 4.3.2 Slot nut mounting... 7 4.4 Preparations for mounting... 9 4.5 Grippers and suction cups... 23 4.5. EXPT-...-T0... 23 4.5.2 EXPT-...-T to T4... 23 Festo EXPT-EN 608c English 3

EXPT 5 Installation... 24 5. Interfaces... 24 5.2 Connections at the interface housing... 25 5.2. Rod loss detection... 25 5.2.2 Rotary drive... 26 5.3 Motor cables and encoder cables... 27 5.4 Earthing... 27 6 Commissioning... 28 7 Operation and diagnostics... 29 7. Maintenance and care... 29 7.2 Troubleshooting... 3 8 Disassembly and repair... 32 8. Disassembly... 32 8.. Dismounting the parallel kinematic system... 32 8..2 Dismounting motor... 35 8..3 Dismantling the front unit... 36 8..4 Dismounting the protective conduit... 38 8..5 Dismounting a pair of rods... 39 8.2 Repair... 40 8.3 Accessories... 40 8.4 Disposal... 40 A Technical appendix... 4 A. Technical data for parallel kinematic system... 4 A.. General... 4 A..2 Mechanical... 4 A..3 Dynamic... 42 A..4 Operating and environmental conditions... 42 A.2 Technical data - front unit... 43 A.2. General... 43 A.2.2 Mechanical... 43 A.2.3 Electrical... 43 4 Festo EXPT-EN 608c English

Safety and requirements for product use Safety and requirements for product use. Safety.. General safety instructions Observe the general safety instructions in the corresponding chapters. Specific safety regulations can be found immediately before the task instructions...2 Intended use The parallel kinematic system EXPT is intended for installation in machines and automation systems for moving an end-effector in the kinematics working space. It should be used as follows: in excellent technical condition in original status without unauthorised modifications within the limits of the product defined by the technical data ( Technical appendix A) in an industrial environment. The removal of mechanical components (e.g. motor, axis, pair of rods) causes referencing to be lost and thus results in a reduction in absolute positioning accuracy. When commissioning, referencing or calibration must be carried out again. In the event of damage caused by unauthorised manipulation or other than intended use, the guarantee is invalidated and the manufacturer is not liable for damages. Festo EXPT-EN 608c English 5

Safety and requirements for product use.2 Requirements for product use Make this documentation available to the design engineer, installer and personnel responsible for commissioning the machine or system in which this product is used. Make sure that the specifications of the documentation are always complied with. Also read and follow all accompanying documentation and the documentation for any associated accessories. Take into consideration the legal regulations applicable for the destination, as well as: regulations and standards regulations of testing organisations and insurers national specifications..2. Technical requirements All warnings and instructions in this documentation for the correct and safe use of the product must be observed at all times. Comply with the connection and ambient conditions of the product and all connected components specified in the technical data ( Technical appendix A). Only compliance with the limit values or load limits permits operation of the product in accordance with the relevant safety regulations..2.2 Qualification of trained personnel The product should only be installed by properly trained personnel in accordance with these instructions. The trained personnel must be familiar with: the applicable regulations for accident protection and occupational safety, and the documentation for the product..2.3 Range of application and certifications Standards and test values that the product must comply with and fulfil can be found in appendix ( Technical appendix A). 6 Festo EXPT-EN 608c English

2 Transport and storage 2 Transport and storage 2. Transport At delivery, the parallel kinematic system lying on the mounting frame is safely fastened on the pallet against sliding and packaged in a plastic sheet and transportation box against mechanical and environmental influences. EXPT 45 70 95 20 Dimensions [mm] H 090 320 L 725 925 B 425 725 Weight [kg] Parallel kinematic 45 47.5 6.5 66 system Overall weight ) 65 70 220 225 ) With max. accessories Tab. 2. For transport, observe the marking on the upper side on the transport box.. Transport the pallet with the parallel kinematic system to the installation/storage location. 2. Set down the pallet on a firm and flat base at the installation/storage location. 2.2 Storage conditions For safe later use, the following storage conditions must be complied with. Storage conditions Storage temperature [ C] 0 +60 Air humidity EXPT-...-T0 [%] 5 95, non-condensing EXPT-...-T to T4 [%] 20 80, non-condensing Maximum shelf life 60 months Requirements of storage location Dry, solid and flat base Tab. 2.2 Festo EXPT-EN 608c English 7

2 Transport and storage 2.3 Unpacking Damage to the product from incorrect removal of the transport box At least two people are required for dismantling of the transport box. Use the correct tool to loosen the screws. Make sure that packaging parts cannot fall onto the parallel kinematic system. Keep the packaging for later use or dispose of it properly. Removing the transport box cover. Loosen and remove all screws 2. Lift the cover so you can transport it further 3. Put or lay down the cover at a safe distance from the parallel kinematic system Fig. 2. Removing the transport box side walls Remove each side wall individually and in the sequence long - short 2- long 3 - short 4 side wall. 4. Loosen and remove all screws 5. Remove the side wall and put or lay it down at a safe distance from the parallel kinematic system 2 3 4 Fig. 2.2 Removing the plastic sheet for packaging 6. Cut the plastic sheet parallel to the contour of the product with an appropriate tool. When cutting, make sure that you do not damage or scratch the tripod kinematics. Then pull the plastic sheet up and away from the product. Fig. 2.3 8 Festo EXPT-EN 608c English

2 Transport and storage 2.4 Checking the scope of delivery. After unpacking, check the following parts: Check Possible malfunction Remedy Rod pair Damaged Replace ) Detached ( Fig. 3.) Install ( 8..5 Dismounting a pair of rods) Compressed air/supply air hose Damaged Replace ) Disconnected from the port Connect Protective conduit Damaged Replace ) Mounting clip Damaged Replace ) Electrical or pneumatic connection Damaged Replace ) ) ( www.festo.com/spareparts) Tab. 2.3 2. Open the accessories box fastened to the pallet and remove its contents. 3. Remove all mounting screws in the cardboard box and remove the box from the pallet. 4. Check that the delivery is complete. Name Number for EXPT-...-T0 Number for EXPT-...-T up to T4 Description of parallel kinematic system Description of operator unit, mounting and installation ) ) Description of operator unit, software manual ) ) Washer for oblong hole 6 6 Distance piece for referencing the axes USB memory card Lubricating grease LUB-KC Operating instructions for motor Kinematics Assembly instructions Axial kit Kinematics Motor cable Kinematics ) ) Encoder cable Kinematics ) ) Front unit with rotary drive Motor cable and encoder cable Kinematics 3 ) 3 ) Rotary drive ) Sensor cable Pressure switch ) ) Position sensing for rotary drive ) Tubing Rod loss detection Rotary drive air ) (T2 and T4 only) Inscription label for cables 3 x 2 ) 4 x 2 ) ) Optional Tab. 2.4 Festo EXPT-EN 608c English 9

3 Overview 3 Overview 3. Features Parallel kinematic system feature Code Specification Working space 45 450 mm, height 00 mm 70 700 mm, height 00 mm 90 900 mm, height 00 mm 20 20 mm, height 00 mm Drive E DGE-25 E4 EGC-80 Attachment components T0 Without rotary drive T Rotary drive size 8 T2 Rotary drive size 8 with pneumatic rotary through-feed T3 Rotary drive size T4 Rotary drive size with pneumatic rotary through-feed Attachment position of the motors ( Fig. 4.0) HHH Motor axis A, A2, A3 rear HHV Motor axis A rear Motor axis A2 rear Motor axis A3 front HVH Motor axis A rear Motor axis A2 front Motor axis A3 rear HVV Motor axis A rear Motor axis A2 front Motor axis A3 front VHH Motor axis A front Motor axis A2 rear Motor axis A3 rear VHV Motor axis A front Motor axis A2 rear Motor axis A3 front VVH Motor axis A front Motor axis A2 front Motor axis A3 rear VVV Motor axis A, A2, A3 front Particle protection Standard P8 Protected version Tab. 3. 0 Festo EXPT-EN 608c English

3 Overview Accessories feature Code Specification Control system None C Mounting plate CC Control cabinet CS Control cabinet with base Multi-axis controller None C With CMXR-C C2 With CMXR-C2, with integrated PLC Operator terminal None B With operator unit CDSA Cable length None 5K 5 m 0K 0 m 5K 5 m Presetting Standard S With calibration Tab. 3.2 Festo EXPT-EN 608c English

3 Overview 3.2 Function and application The parallel kinematic system includes three toothed belt axes, each driven by a servo motor with absolute displacement encoder. The linear movements of the axes are transferred to the front unit by the principle of parallel kinematics. The integrated rod loss detection detects detached rods and initiates an emergency stop. It is achieved through permanent compressed air monitoring by means of a compressed air switch. Grippers and suction cups can be directly attached to the front unit. A rotary drive is mounted on the front unit for variants T to T4 (4th axis). Suction cups or grippers can either be attached to these directly or via the corresponding adapter kits. In addition, variants T2 and T4 are also equipped with a pneumatic rotary through-feed, which can be used as an air connection. Variant P8 with particle protection is functionally identical to the standard variants. Deviating from this are the toothed belt axes with the slide oriented upward so that abrasion particles of the toothed belt remain in the axis and do not reach the working space. The optional control solution includes the multi-axis controller and motor controller required for activation. There is also an integrated safety circuit which, together with the operator unit CDSA, represents the basic functionality. The control solution is pre-programmed and already tested together with the relevant parallel kinematic system. 2 Festo EXPT-EN 608c English

3 Overview 3.3 Design The attachment position of the motors varies according to the configuration of the parallel kinematic system ( Fig. 4.0). The illustration is an example and corresponds to the variant parallel kinematic system EXPT-...-T4-HHH (with rotary drive, pneumatic rotary through-feed and attachment position of the motors HHH). 2 aa 3 aj 4 5 9 6 8 7 Front unit with rotary drive and pneumatic rotary through-feed 2 Pair of rods 3 Joint 4 Toothed belt axis 5 Earthing screw M6 (x) mounting option (6x) Fig. 3. 6 Mounting frame 7 Corner bracket 8 Motor 9 Interface housing aj Connection block (variant P8 deviating) aa Protective conduit Festo EXPT-EN 608c English 3

4 Mounting 4 Mounting 4. Mounting instructions 4.. Dimensions Dimensions [mm] EXPT 45 70 95 20 B 947 077 23 355 B2 67 703 794 888 B3 549 590 626 672 B4 530 622 705 800 H 659 727 827 944 H2 493 56 636 70 H3 66 66 9 234 H8 ) 27 27 27 27 L 088 238 394 558 L2 652 727 803 885 ) Only for EXPT-...-T up to T4 Tab. 4. 4..2 Installation location Observe the catalogue specifications for the exact positioning of the mounting holes ( www.festo.com/catalogue). The following conditions must be met in order to fully use the function range: enough room for the parallel kinematic system to move, including room outside the working space catalogue specifications regarding interference contour ( www.festo.com/catalogue) torsionally rigid, tension-free suspension of the parallel kinematic system flat bearing surface at the mounting corners sufficient attachment to absorb the maximum forces ( www.festo.com/catalogue) consideration of the influence of load and rigidity on positioning accuracy and path accuracy adherence to the catalogue specifications for vibration limits, permissible forces and torques ( www.festo.com/catalogue). 4 Festo EXPT-EN 608c English

4 Mounting 4.2 Rack mounting The frame is not included in the scope of delivery. Installation varies according to the design of the frame. If the oblong holes are used, the bearing surface of the screws is too small. Use the accompanying washers with the screws. ( Fig. 4.). Use screws with strength class of at least 8.8. The parallel kinematic system must be fastened to a frame only in the area of the corner bracket of the mounting frame. There must be a torsionally rigid, flat bearing surface in the area of the corner bracket. In order for the parallel kinematic system to attain the positioning accuracy described in the technical data, the following minimum requirements apply to the bearing surface: Flatness = 0.05 mm Parallelism = 0.5 mm. Other holes can be used only as an assembly aid or for fastening additional installation elements, such as cable ducts. Fig. 4. Deviations from the minimum requirements lead to increased wear and/or inaccuracies in positioning during later operation. 2 Frame with reinforcements (example) 2 Mounting frame of parallel kinematic system Fig. 4.2 Festo EXPT-EN 608c English 5

4 Mounting 4.3 Types of mounting Removing a motor causes the referencing of the corresponding axis to be lost. When commissioning, the axis must be referenced again. If possible, use mounting holes which do not require the motor to be removed. 4.3. Direct mounting Variant : Screws M8 in accordance with DIN 92 Direct mounting to the frame with at least 4 screws per corner bracket. Dimensions: ( www.festo.com/catalogue) These 4 screws should be placed as far apart as possible to ensure a torsionally rigid connection. If the oblong holes are used, the bearing surface of the screws is too small. Use the accompanying washers. Fig. 4.3 Variant 2: Screws M20 in accordance with DIN 92 Direct mounting to the frame with one screw per corner bracket. There is a central hole for this purpose on every corner. Make sure that the bearing surface is in the area of the corner bracket. Fig. 4.4 6 Festo EXPT-EN 608c English

4 Mounting 4.3.2 Slot nut mounting The holes in the corner brackets are arranged so that a profile column 80x80 with 40 mm distance between slots can be fastened in various positions. Variant : 2 If the oblong holes are used, the bearing surface of the screws is too small. Use the accompanying washers. Profile column (e.g. HMBS-80/80) 2 Slot nut (e.g. NST-HMV-8-2-M8) 3 Screw (e.g. M8x35 DIN 92 ) Fig. 4.5 3 Variant 2: 2 If the oblong holes are used, the bearing surface of the screws is too small. Use the accompanying washers. Profile column (e.g. HMBS-80/80) 2 Slot nut (e.g. NST-HMV-8-2-M8) 3 Screw (e.g. M8x35 DIN 92 ) Fig. 4.6 3 Festo EXPT-EN 608c English 7

4 Mounting The additional user-specific angle brackets in the following examples are required in order to increase the torsional rigidity and the bearing surface. Variant 3: 2 3 Profile column (e.g. HMBS-80/80) 2 Slot nut (e.g. NST-HMV-8-2-M8) Fig. 4.7 3 Screw (e.g. M8x35 DIN 92 ) Variant 4: 2 3 Profile column (e.g. HMBS-80/80) 2 Slot nut (e.g. NST-HMV-8-2-M8) Fig. 4.8 3 Screw (e.g. M8x35 DIN 92 ) 8 Festo EXPT-EN 608c English

4 Mounting 4.4 Preparations for mounting Caution Lifting large loads can lead to permanent injury. Depending on size and weight, the parallel kinematic system should be lifted and turned over by 2 to 3 persons ( Tab. 2.). An additional person is required for attachment to the mounting frame. Caution Danger of injuries from squeezing and cuts. In case of incorrect transport, strong forces can be applied to the front unit or rods. As a result, rods can break or rod connections can loosen up. The loosened front unit can result in squeezing injuries and the broken, sharp-edged rods in cuts. Grip the EXPT only in the area of the motors and axes or on the mounting frame. Set down the parallel kinematic system only on the mounting frame. Lift up the parallel kinematic system in such a way that you can turn it freely. After being turned over, the parallel kinematic system cannot be set down without damage. First, therefore, make the following preparations: Prepare the required mounting accessories for attachment to the frame. In doing so, observe the instructions corresponding to the frame used and the intended method of mounting. 2 3 4 Pair of rods 2 Toothed belt axis Fig. 4.9 3 Motor 4 Mounting frame Festo EXPT-EN 608c English 9

4 Mounting When installing on the frame, be mindful of the position of the pneumatic and electrical ports on the interface housing or 2. The axes of the parallel kinematic system EXPT are, seen from the top, numbered anticlockwise from A to A3 and correspondingly marked on the side. The interface housing is located on the mounting frame opposite motor in relation to axis. The attachment position V or H of the motors depends on the type ordered. The alignment of the A axis determines the position of the X axis for the motor controller s coordinate system. Mounting position of the motors A Coordinate system V H X Z Y 2 H H V V A2 A3 V H Interface housing with motor position H of axis A 2 Interface housing with motor position V of axis A Fig. 4.0 Warning Squeezing of body parts. If incorrectly mounted, the parallel kinematic system can come undone and fall down. Fasten the parallel kinematic system to the frame in accordance with the specifications on the assembly drawing ( 4.2 Rack mounting). Observe the specifications for mounting ( 4.3 Types of mounting). Secure the screw connections. 20 Festo EXPT-EN 608c English

4 Mounting Raising the parallel kinematic system to the upright position 2 3 4 Pair of rods 2 Toothed belt axis Fig. 4. 3 Motor 4 Mounting frame. Use the correct tool to loosen the screws. 2. Loosen and remove all six transport screws. 3. Grip the parallel kinematic system together with a second person and only in the area of the motor, axis and mounting frame at the positions and 2. 4. Lift the parallel kinematic system until the corner of the mounting frame at position 3 has a firm footing on the pallet. 5. Now turn the parallel kinematic system around position 3 into the vertical position. Festo EXPT-EN 608c English 2

4 Mounting Turning and installing the parallel kinematic system 2 3 4 Pair of rods 2 Toothed belt axis 3 Motor 4 Mounting frame Fig. 4.2 6. Hold the parallel kinematic system firmly in the upright position by gripping only on the motor, axis or mounting frame. Position a third person at corner 3 of the mounting frame where that person can grip the product in the area of the motor, axis and mounting frame. 7. The third person turns the parallel kinematic system by pulling corner 3 upwards in the area of the motor, axis and mounting frame. 8. Have three people raise the parallel kinematic system into the mounting position on the frame, where it can be attached by a fourth person. 9. The tightening torque is 0 Nm ± 20 % in the case of slot nut mounting. 22 Festo EXPT-EN 608c English

4 Mounting 4.5 Grippers and suction cups The calibration of the parallel kinematic system is lost if the original alignment of the front unit and the pairs of rods is not maintained. Observe the instructions when dismounting the front unit ( 8..3 Dismantling the front unit). EXPT-...-T0 2 3 EXPT-...-T to T4 6 7 3 8 4 5 Ball 2 Central drill hole 4 mm 3 Ball stud with pneumatic port 4 Air port (variant T2 and T4) Fig. 4.3 5 Connection for motor cable 6 Connection for encoder cable 7 Connection for sensor cable 8 Connection for earthing cable 4.5. EXPT-...-T0 User-specific applications, such as grippers or suction cups, can be mounted to the front unit of the parallel kinematic system. Connect earthing cable depending on the application.. Mark the front unit prior to disassembly so that, when re-installing it, you can put it into exactly the same position as before removal. 2. Dismantle the front unit ( 8..3 Dismantling the front unit). 3. Mount grippers or other tools to the front unit. There is no special hole pattern. When the product is in its delivery status, there is only one central hole 4 mm on this plate, corresponding to the centre point (TCP = Tool Centre Point). This hole can be used as a starting point for configuring the front unit with attachments. 4. When re-mounting, make sure that the front unit s original alignment to the pairs of rods is not lost. In doing so, observe the markings made before dismounting. 4.5.2 EXPT-...-T to T4 For attaching grippers, suction cups, adapter kits and other accessories to the rotary drive: ( assembly instructions for the accessories). Festo EXPT-EN 608c English 23

5 Installation 5 Installation 5. Interfaces The attachment position V or H of the motors depends on the type ordered. During mounting and installation, pay attention to the alignment of the motors and the position of the interface housing ( Fig. 4.0). 6 3 4 5 2 Connections for motor ) 2 Connections for motor 2 ) 3 Connections for motor 3 ) 4 Earthing screw M6 (x) mounting option (6x) ) ( accompanying operating instructions of the motors) 2) The illustration is an example and corresponds to the variant EXPT-...-T4-H HH (with rotary drive, pneumatic rotary through-feed and attachment position of the motors HHH). Fig. 5. 5 Interface housing with pneumatic and electrical ports 2) 6 Front unit with rotary drive and pneumatic rotary through-feed 2) You can expand the installation by ordering additional installation material as accessories ( www.festo.com/catalogue). 24 Festo EXPT-EN 608c English

5 Installation 5.2 Connections at the interface housing 4 2 5 3 6 Supply port for rod loss detection 2 Sensor cable connection for position sensing of rotary drive (variant T to T4) 3 Encoder cable connection for rotary drive (variant T to T4) 4 Pressure switch SDE5 for rod loss detection 5 Air port for pneumatic rotary through-feed (variant T2 and T4) 6 Motor cable connection for rotary drive (variant T to T4) Fig. 5.2 5.2. Rod loss detection Connect the compressed air supply port for rod loss detection at the interface housing to the compressed air supply. On the interface housing, mount the sensor cable for the pressure switch SDE5 4. Rod loss detection is preset in the factory. The built-in pressure switch SDE5 4 sets an output signal when at least one pair of rods is detached Pressure switch connection SDE 5 Port identification/signal Pin Plug pattern Circuit diagram +24 V DC operating voltage Switching output A (out A) 2/4 0 V 3 Fig. 5.3 Festo EXPT-EN 608c English 25

5 Installation 5.2.2 Rotary drive Only for variant T to T4 with rotary drive: Connect the air port 5 for pneumatic rotary through-feed to the front unit (variant T2 and T4 only) on the interface housing with the air supply. On the interface housing, mount the motor cable 6 and encoder cable 3 for the rotary drive. On the interface housing, install the sensor cable for the position sensing option SIEN of the rotary drive 2. Connection U power supply for rotary drive Port identification/signal Pin Colour in accordance with IEC 757 Plug pattern Operating voltage W WH Operating voltage U 2 BN Operating voltage V 3 GN Protective earth conductor PE 4 YE Fig. 5.4 Connection of ENC encoder for rotary drive Port identification/signal Pin Colour in accordance with IEC 757 Plug pattern Signal trace A WH Signal trace A\ 2 BN Signal trace B 3 GN Signal trace B\ 4 YE Signal trace Z 5 GY Signal trace Z\ 6 PK Signal trace U 7 BU Signal trace V 8 RD Signal trace W 9 BK GND encoder 0 VT 5 V supply GYPK Screening 2 RDBU Fig. 5.5 SIEN connection Port identification/signal Pin Plug pattern Circuit diagram +0... +30 V DC operating voltage Switching output A (out A) 4 0 V 3 Fig. 5.6 26 Festo EXPT-EN 608c English

5 Installation 5.3 Motor cables and encoder cables For the installation, use the optionally supplied cables with pre-assembled plug connectors ( www.festo.com/catalogue). Mount one motor cable and one encoder cable on each motor to 3 ( accompanying assembly instructions). Later installation and connection to the control components can be carried out only by a specialist trained as an electrotechnician. 5.4 Earthing For earthing, use one of the earth terminals 4 on the mounting frame ( Fig. 5.) and observe national regulations. Festo EXPT-EN 608c English 27

6 Commissioning 6 Commissioning Commissioning must always be carried out by a specially trained technician (a robotics specialist). The following knowledge is required: Specialist knowledge of robotics and CoDeSys Knowledge of the handling of the Festo components CMMP and CMXR Knowledge of the handling and operation of the parallel kinematic system EXPT. Commissioning is described in separate documents. For support in commissioning: Please contact your Festo contact person or via the internet ( www.festo.com). 28 Festo EXPT-EN 608c English

7 Operation and diagnostics 7 Operation and diagnostics Caution Squeezing of body parts and damage to the system. Unintended starting can trigger unexpected movements. Before any conversion or maintenance work or inspections of the system, ensure that the system is safely brought to a standstill and is locked to prevent restarting. Detached parts could fall or execute unexpected movements. Secure the parts so that they cannot move unexpectedly or bring them into a secure end position. Maintenance work should only be conducted by properly trained personnel in accordance with these instructions. 7. Maintenance and care Lubricating ball joints Lubricate the ball joints (2 Fig. 8.4) every 2000 operating hours with lubricant LUB-KC (tube included). Removal is described in ( 8..5 Dismounting a pair of rods). Lubricating toothed belt axes Lubricate the toothed belt axes as follows: Size 45/70 Toothed belt axis Maintenance task Lubrication interval in operating hours Lubricant (oil) Lubricating point DGE-25-...-ZR-RF Lubricating the roller bearing guide [h] 6000 Constant OY 390 (from Klüber) Tab. 7. Festo EXPT-EN 608c English 29

7 Operation and diagnostics Size 95/20 Toothed belt axis EGC-80-...-TB-KF Maintenance task Greasing the bearing guide Lubrication interval [h] 6000 in operating hours Lubricant (grease) Lub-KC (from Festo) Lubricating point Tab. 7.2 30 Festo EXPT-EN 608c English

7 Operation and diagnostics Size 95/20-P8 Toothed belt axis EGC-80-...-TB-KF Maintenance task Greasing the bearing guide Lubrication interval [h] 6000 in operating hours Lubricant (grease) Lub-KC (from Festo) Lubricating point Tab. 7.3 7.2 Troubleshooting Malfunction Possible cause Remedy Audible leakage of compressed air Tab. 7.4 Rod loss Tubing disconnected Clean, check and grease the ball heads and cups and re-attach the pair of rods ( 8..5 Dismounting a pair of rods) Re-install the tubing at the intended place Festo EXPT-EN 608c English 3

8 Disassembly and repair 8 Disassembly and repair 8. Disassembly Caution Squeezing of body parts and damage to the system. Unintended starting can trigger unexpected movements. Before any conversion or maintenance work or inspections of the system, ensure that the system is safely brought to a standstill and is locked to prevent restarting. Remove the following components: all cables and tubes from the interface housing the motor and encoder cables of the servo motors. 8.. Dismounting the parallel kinematic system Caution Lifting large loads can lead to permanent injury. Due to its size and weight, the parallel kinematic system should be held and turned over by a total of three persons ( Tab. 2.). An additional person is required to release the attachment. Caution Squeezing of body parts. In the event of stress on the joints of the parallel kinematic system, the rods can break or the balls can spring out of the ball cups. This can cause the parallel kinematic system to fall down or tilt over. The front unit must not strike against anything or be placed on the floor.. Grip the parallel kinematic system only in the area of the motors and axes or on the mounting frame. 2. Hold the parallel kinematic system in such a way that you can turn it freely. 3. Set down the parallel kinematic system only on the mounting frame. The parallel kinematic system can be set down without damage only after being turned over: Prepare the required supporting surface (pallet). 32 Festo EXPT-EN 608c English

8 Disassembly and repair Removing and turning the parallel kinematic system 4 3 2 Pair of rods 2 Toothed belt axis Fig. 8. 3 Motor 4 Mounting frame. Pay special attention that the parallel kinematic system is supported at all three corners when loosening the mounting screws. 2. Have three people hold the parallel kinematic system while a fourth person unscrews it. 3. Carefully remove the parallel kinematic system from the mounting frame and bring it to the prepared pallet. 4. The third person turns the parallel kinematic system by gripping corner 3 at the motor and axis and setting it down on the supporting surface (e.g. transport pallet). 5. Hold the parallel kinematic system firmly in the upright position by gripping on the motor, axis or mounting frame. Festo EXPT-EN 608c English 33

8 Disassembly and repair Lowering the parallel kinematic system 2 3 4 Pair of rods 2 Toothed belt axis Fig. 8.2 3 Motor 4 Mounting frame 6. Acting together, lower the parallel kinematic system until it is resting on the mounting frame: Make sure that the corner 3 on which the parallel kinematic system is standing is securely in place and cannot slide off the pallet. For transport later: 7. To secure the parallel kinematic system for transport, fasten it with 6 self-tapping screws on the base plate. 34 Festo EXPT-EN 608c English

8 Disassembly and repair 8..2 Dismounting motor Caution Squeezing of body parts. When dismounting the motor, the slide of the toothed belt axis can move freely. This can cause the parallel kinematic system to move unexpectedly. Secure the parallel kinematic system so that it cannot move unexpectedly or bring it into a secure end position. Removing a motor causes the referencing of the corresponding axis to be lost. When commissioning, the axis must be referenced again. Removal of the motor is required when: a concealed mounting hole is used the motor needs to be replaced due to a defect. To remove a motor: Undo the screws. If necessary, also remove the coupling housing. When re-mounting: Make sure that the motor has the same alignment when it is mounted again ( accompanying assembly instructions for axial kit). Fig. 8.3 Festo EXPT-EN 608c English 35

8 Disassembly and repair 8..3 Dismantling the front unit Grippers, suction cups or other accessories required by the customer can be mounted on the front unit of the parallel kinematic system. Ball studs with balls for receiving the pairs of rods are attached to the front unit. The balls form ball joints with the ball cups of the pairs of rods 2. Located on the ball studs are the T-fittings 3 to connect the compressed air for rod loss detection. 3 2 Tubing 2 Ball joint Fig. 8.4 3 Push-in T-fitting Caution Danger of squeezing exists when disconnecting the ball cups from the balls. Be sure that you do not put your fingers between the balls and the ball cups. The calibration of the parallel kinematic system is lost if the original alignment of the front unit to the pairs of rods is not maintained. Mark the front unit for variant T0 so that, when re-installing, you can put it into exactly the same position as before removal. By default, variants T to T4 are provided with the marking A, which points to axis. After the first pair of rods is disconnected, the other two pairs can move, causing the front unit to lose its stability and position. 36 Festo EXPT-EN 608c English

8 Disassembly and repair To disconnect the front unit, proceed as follows:. Vent the compressed air supply port. 2. Pull the rod-loss-detection hoses coming from the protective conduit out of the push-in T-fittings 3 ( Fig. 8.4). For variants T to T4, the motor cable 5, encoder cable 6, sensor cable 7 and earthing cable 8 must also be removed. For variants T2 and T4, the hose from the air supply port 4 must also be removed. EXPT-...-T0 2 3 EXPT-...-T to T4 6 7 3 8 4 5 Ball 2 Central drill hole 4 mm 3 Ball stud with pneumatic port 4 Air port (variant T2 and T4) Fig. 8.5 5 Connection for motor cable 6 Connection for encoder cable 7 Connection for sensor cable 8 Connection for earthing cable 3. Disconnect the first pair of rods from the balls as follows: Hold the front unit firmly in one hand and pull the first rod off the ball with the other hand. The pretension of the springs means that a relatively high force is needed to separate the joints 2 ( Fig. 8.4). The spring forces between the rods can cause the partially disconnected pair of rods to cross over. Keep holding the front unit firmly in one hand and pull the second rod from the ball. 4. Position the front unit in an appropriate position which allows you to disconnect the other two pairs of rods from the front unit. 5. Disconnect the second and third pair of rods and remove the front unit. Festo EXPT-EN 608c English 37

8 Disassembly and repair 8..4 Dismounting the protective conduit EXPT-...-T0 bis T4 EXPT-...-T to T4 6 4 5 7 8 2 3 Protective conduit 2 Fixture 3 T-fitting 4 Air port (variant T2 and T4) Fig. 8.6 5 Connection for motor cable 6 Connection for encoder cable 7 Connection for sensor cable 8 Connection for earthing cable To remove the protective conduit, proceed as follows:. Vent the supply ports. 2. Pull the rod-loss-detection hoses coming out of the protective conduit out of the push-in T-fittings 3. For T to T4: remove encoder cable 6, motor cable 5, sensor cable 7 and earthing cable 8. For T2 and T4: remove the air hose 4. 3. Loosen the screws of the fixtures 2 (tightening torque for re-assembly: 0.25 Nm ± 20 %). 4. Pull the protective conduit out of the fixtures. For installation of a new tubing holder ( assembly instructions). Accessories and spare parts can be found at: ( www.festo.com). 38 Festo EXPT-EN 608c English

8 Disassembly and repair 8..5 Dismounting a pair of rods The following preparation work is necessary before dismounting a pair of rods: removal of the front unit removal of the protective conduit and the tubing holder if necessary ( 8..4 Dismounting the protective conduit). Removing pairs of rods Interchanging pairs of rods causes loss of calibration and thus a reduction in absolute positioning accuracy. Mark the pairs of rods so that, when re-installing, you can put them into exactly the same position as before removal. Remove the protective conduit and the tubing holder, if present, before removing the pairs of rods ( 8..4 Dismounting the protective conduit). After removal of the front unit ( 8..3 Dismantling the front unit) and, if necessary, the protective conduit and tubing holder( 8..4 Dismounting the protective conduit):. Carefully separate a pair of rods from the upper ball studs and remove the pair of rods. 2. Disconnect and remove the other pairs the same way as the first. Cleaning, inspecting and greasing the parallel kinematic system. Use a cloth to clean the balls and ball cups of the detached rods. 2. Check the balls and ball cups for damage. 3. Likewise, check the springs, pins, washers and supports for damage. If there is any damage: Replace the corresponding components. Replacements must always be done in pairs ( www.festo.com/spareparts). 4. Thinly coat the friction marks on the balls and ball cups with silicone-free grease, e.g. B. LUB-KC ( www.festo.com/spareparts). Installing the pairs of rods Interchanging pairs of rods causes loss of calibration and thus a reduction in absolute positioning accuracy. Maintain the original arrangement of the pairs of rods and the front unit. To install the rods: Start by attaching the pairs of rods on the side of the connection block 9 ( Fig. 3.).. Place the ball cup of the first rod on the ball on the ball stud. 2. Pull apart the springs with the second rod. 3. Place the ball cup of the second rod on the other ball. 4. Repeat the procedure until all pairs of rods are attached to the connection block. 5. Attach the pairs of rods to the front unit. 6. After mounting the pairs of rods, remove the excess grease on the balls and/or ball cups, if necessary. Festo EXPT-EN 608c English 39

8 Disassembly and repair 8.2 Repair Observe the information regarding mounting ( 4 Mounting) and dismounting ( 8. Disassembly). Recommendation: Consult our repair service. This will ensure that special attention is given to the necessary fine tuning and testing. Information about spare parts and aids can be found at: ( www.festo.com/spareparts). 8.3 Accessories Please select the corresponding accessories from our catalogue ( www.festo.com/catalogue). 8.4 Disposal When dismantling parts, observe the instructions ( 8. Disassembly). Observe the local regulations for environmentally-friendly disposal of modules. Some materials are listed in the technical data section to enable separate disposal of particular materials ( A. Technical data for parallel kinematic system, Tab. A.2). Handle the lubricants (greases, oils) in accordance with the applicable regulations governing health and safety and hazardous materials. Observe the local regulations regarding disposal and the environment. 40 Festo EXPT-EN 608c English

A Technical appendix A Technical appendix A. Technical data for parallel kinematic system A.. General Size 45 70 95 20 Design Mounting position Type of mounting Parallel kinematic system Horizontal Direct mounting Profile mounting (with additional angle brackets, if necessary) Tab. A. A..2 Mechanical Size 45 70 95 20 Working space Nominal diameter [mm] 450 700 950 200 Nominal height [mm] 00 Rod loss detection Pneumatic connection Hose with a nominal diameter of 4 mm Operating pressure [bar] 2 8 on materials Contains PWIS substances ) Materials Front unit Aluminium Ball stud Coupling housing Pair of rods Plastic, carbon-fibre reinforced Balls Ceramic Ball cups Polyamide Screws, pins, washers nuts, springs, sleeves Steel Base weight of the kinematics [kg] 45 47.5 6.5 66 ) PWIS = paint-wetting impairment substances Tab. A.2 Festo EXPT-EN 608c English 4

A Technical appendix A..3 Dynamic Size 45 70 95 20 Motor type Servo motor Max. acceleration ) [m/s 2 ] 0 Max. speed ) [m/s] 7 Max. picking rate )5) [picks/min] 50 (in 2 inch cycle) Repetition accuracy [mm] ± 0. Positioning accuracy 2) [mm] ± 0.5 Track precision 3) [mm] ± 0.5 Effective load 4) With min. dynamic response [kg] 5 With max. dynamic response [kg] Max. process force in Z direction With working space [mm] 0 0 0 0 Process force in Z direction [N] 300 000 000 850 With working space [mm] 2.5 75 237.5 300 Process force in Z direction [N] 000 750 750 750 Max. frame strength horizontal [N] ± 45 ± 50 ± 200 ± 25 Max. frame strength vertical [N] ± 250 ± 290 ± 325 ± 475 ) When used in conjunction with motor controller CMMP-AS-C5-3A and controller CMXR (multi-axis control). 2) Only with calibrated system (order code S) 3) Only with calibrated system (order code S) and a speed of 0.3m/s 4) Sum of load mass and accessories attached to the front unit 5) With a max. transient response of ± 0.5 mm Tab. A.3 A..4 Operating and environmental conditions Size 45 70 95 20 Operating medium Compressed air in accordance with ISO 8573-:200 [5:4:] Ambient temperature [ C] 0 +40 Storage temperature [ C] 0 +60 Air humidity [%] 5 95, non-condensing T to T4 [%] 20 80, non-condensing Duty cycle [%] 00 Tab. A.4 42 Festo EXPT-EN 608c English

A Technical appendix A.2 Technical data - front unit A.2. General Variant T T2 T3 T4 Size 8 8 Design Electromechanical rotary module Air through-feed Yes Yes Pneumatic connection G/8 G/8 Nominal size [mm] 4 4 Compressed air Operating pressure [bar] 0.9 +0 0.9 +0 Standard nominal flow rate [l/min] 350 350 Permissible leakage ) [l/h] 0 0 ) At 6 bar nominal pressure after 0 million cycles Tab. A.5 A.2.2 Mechanical Variant T T2 T3 T4 Rotation angle Infinite Gear ratio 30: Repetition accuracy [ ] ± 0.0 Max. output speed [rpm] 200 Max. continuous speed [rpm] 7 Nominal torque [Nm] 0.75 0.75.8.8 Peak torque [Nm].8.8 4.5 4.5 Max. axial force [N] 200 200 300 300 Max. pull-out torque, static [Nm] 5 5 40 40 Permissible mass moment of [kgm 2 ] 0.0026 0.0026 0.006 0.006 inertia of load Load mass for EXPT ) [g] 640 690 850 900 ) The load mass must be taken into account when calculating the effective load of the EXPT Tab. A.6 A.2.3 Electrical Variant T T2 T3 T4 Nominal voltage AC [V] 230 Max. output speed [rpm] 200 Nominal motor current [A] 0.3 0.3 0.74 0.74 Peak motor current [A] 0.6 0.6.5.5 Rated motor output [W] 9.2 9.2 22. 22. Duty cycle [%] 00 Tab. A.7 Festo EXPT-EN 608c English 43

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