ServoTube 25/38 Module USER GUIDE Publication Ref: UM03016/A Copley Motion Systems LLC Luckyn Lane, Pipps Hill, Basildon, Essex SS14 3BW England Tel: +44 (0)1268 287070 Fax +44 (0)1268 293344
Prelims ServoTube 25/38 Module UserGuide WARRANTY Copley Motion Systems guarantees its equipment against faulty components for a period of twelve months from delivery. Replacement components will be free of charge. Copley Motion Systems shall not in any event be liable for consequential damage or loss. Copley Motion Systems operates a customer care facility and all requests for repair and replacement should be directed to the Customer Care Department.
ServoTube 25/38 Module User Guide Prelims ServoTube 25/38 Module USER GUIDE Contents Preliminary pages Title page...................................................................................................................... 1 Copyright notice / disclaimer......................................................................................... 2 Contents list (this page)................................................................................................ 3 Warnings . ....................
Prelims ServoTube 25/38 Module UserGuide WARNINGS Warning symbols and meanings In this User Manual warning symbols are used. These are intended to alert you to the potential hazards to personnel which are associated with the equipment described, in all aspects of use, including handling, installation, operation and maintenance. Heart pacemakers. Personnel fitted with pacemakers must not handle or work on this equipment. Strong magnets.
ServoTube 25/38 Module User Guide Prelims READER’S NOTES GENERAL This manual describes the Installation, Maintenance and Spares of the ServoTube module. ASSOCIATED PUBLICATIONS The following publications are associated with the ServoTube 25/38 Module User Guide.
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Chapter 1 Overview ServoTube 25/38 Module User Guide Chapter 1 Product Overview The ServoTube Module with fully integrated bearing rail and position encoder offers unprecedented value in high performance applications. The ServoTube Module is a cost effective alternative to ballscrew and belt drive systems where high speed and flexibility are required. absolute accuracy, from a non-contact, integral position sensor.
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Chapter 2 Installation ServoTube 25/38 Module User Guide Chapter 2 Installation UNPACKING • Check packaging for signs of damage. • Remove packaging. Do not discard. In the event of items requiring return, it is recommended that the original packaging be used. • Metal surfaces may be hot or below 0oC following prolonged storage. • Ensure that the delivery note correctly reflects your order and the items delivered. • Check equipment for signs of damage.
Chapter 2 Installation ServoTube 25/38 Module User Guide Mounting user’s payload to module moving forcer The payload is mounted to the moving forcer top surface using the T-nut slots provided. It is recommended that a minimum of four fixings are used. • On the SM25 and SB25 modules, the fixings are M5 and should be tightened to a torque of 12 Nm. • On the XM38 and XB38 modules, the fixings are M6 and should be tightened to a torque of 20 Nm.
Chapter 2 Installation ServoTube 25/38 Module User Guide SM25 OUTLINE DRAWINGS MAGNETIC THRUST ROD (NOT LOAD BEARING) FORCER LH THRUST ROD SUPPORT CABLES: 1. 2. 3. Ø7.6 POWER CABLE Ø5.8 SENSOR CABLE Ø4.5 ENCODER CABLE (OPTIONAL) BEARING LUBRICATION PORT 68 50 RH THRUST ROD SUPPORT (SEE NOTE) 17 SECTION A-A 94 D 65 18.5 1 2 3 33.0 C 38.5 21 50 DATUM ACTUATION AT 20.0mm FROM END OF STROKE 78 FOR LARGER DRAG CHAIN (ORDER REF. I3) 86 0.5 NOM. 102 (CLAMP BOLT CENTRES) 4.8 10.5 LENGTH 10.
Chapter 2 Installation ServoTube 25/38 Module User Guide SM38 OUTLINE DRAWINGS MAGNETIC THRUST ROD (NOT LOAD BEARING) FORCER THRUST ROD SUPPORT CABLES: 1. 2. 3. Ø7.6 POWER CABLE Ø5.8 SENSOR CABLE Ø4.5 ENCODER CABLE (OPTIONAL) BEARING LUBRICATION PORT 84.0 60.0 SECTION A-A 110 D 73 38.0 1 2 3 C 38.5 21 0.5 EACH END 50 2.5 LENGTH 11.8 8.2 Approximate module mass (kg) 6.8 5.2 4.5 9.0 A 6.2 DETAIL B CUSTOMER ADJUSTABLE LIMIT SWITCHES (OPTIONAL) FACTORY SET FOR 5.
Chapter 2 Installation ServoTube 25/38 Module User Guide SB25 outline drawing FORCER BELLOWS CABLES: 1. 2. 3. Ø7.6 POWER CABLE Ø5.8 SENSOR CABLE Ø4.5 ENCODER CABLE (OPTIONAL) SYSTEM END PLATE 68 17 SECTION A-A 1 2 3 65 94 18.5 38.5 21 FORCER LENGTH B CUSTOMER ADJUSTABLE LIMIT SWITCHES (OPTIONAL) FACTORY SET FOR 5.0mm FROM END OF STROKE 50 LINEAR ENCODER (OPTIONAL) A 62 DATUM ACTUATION AT 20mm FROM END OFSTROKE 78 FOR LARGER DRAG CHAIN (ORDER REF. I3) 86 102 (CLAMP BOLT CENTRES) 4.
Chapter 2 Installation ServoTube 25/38 Module User Guide XB38 OUTLINE DRAWINGS FORCER BELLOWS CABLES: 1. 2. 3. SYSTEM END PLATE Ø7.6 POWER CABLE Ø5.8 SENSOR CABLE Ø4.5 ENCODER CABLE (OPTIONAL) 84 SECTION A-A DRAG CHAIN FOR CABLE ROUTING (LARGER SIZE OPTIONAL) 110 SYSTEM CLAMPS (MOUNTED NOT MORE THAN 150mm APART) EACH SIDE, IF REQUIRED 1 2 3 73 38 C CUSTOMER ADJUSTABLE LIMIT SWITCHES (OPTIONAL) FACTORY SET FOR 5.0mm FROM END OF STROKE 38.
Chapter 2 Installation ServoTube 25/38 Module User Guide Electrical All electrical connections to the ServoTube Module are made via two cables. One carries power to the forcer and the other carries signals from the position sensor. These cables are supplied either pre-terminated for a specific drive amplifier or with flying leads. Where they are pre-terminated, simply plug the cables into the relevant connectors on the drive amplifier.
Chapter 2 Installation ServoTube 25/38 Module User Guide The connections for the three options are shown in the table below: SENSOR FUNCTION +SIN -SIN +COS -COS +5Vd.c. 0V +TH (Thermistor) -TH (Thermistor) SCREEN D-(XTL-S) 14 13 12 11 4 5 10 15 1+ shell 15-way high density D J8 M-(XSJ-S) 1 11 2 12 17 7 20 14 1+ shell 20-way 2.
Chapter 2 Installation ServoTube 25/38 Module User Guide ADDITIONAL ENCODER If an additional encoder has been specified there will be a third cable that should be connected to the relevant encoder input on the drive amplifier used. When used with the Copley Xenus (XTL-S) or Xenus (XSJ-S) an adaptor cable is supplied. Connections are available via a 9-way D-sub male connector. FUNCTION +5Vd.c. 0V A+ A- B+ B- Z+ Z- Screen 5 1 2 6 4 8 3 7 Case PIN NUMBER LIMIT SWITCHES WARNING.
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Chapter 3 Maintenance ServoTube 25/38 Module User Guide Chapter 3 Maintenance WARNING ISOLATE AND DISCONNECT ALL SOURCES OF ELECTRICAL SUPPLY BEFORE WORKING ON THE EQUIPMENT. PREVENTATIVE MAINTENANCE All Modules Bearing System The ServoTube modules are supplied as complete, ready to use mechanical systems. Each system incorporates a profile rail re-circulating ball bearing system for support and guidance.
Chapter 3 Maintenance ServoTube 25/38 Module User Guide Re-greasing Procedure for modules without bellows (SM25 and XM38) • Move the forcer to one end. • Each thrust rod end support has an M10 through hole which lines up with the bearing carriage lubrication nipple. These can be seen in Figure 3.1. For clarity, the forcer has been removed. • Insert the grease gun delivery tube through the M10 hole and engage the nozzle with the bearing carriage lubrication nipple.
ServoTube 25/38 Module User Guide Chapter 3 Maintenance Note. There is only one bearing carriage on the SB2504 module. • Move the forcer to the other end. Repeat the above steps to re-grease the other bearing carriage. • Move the forcer by hand to and fro in order to distribute the grease. Note. If too much grease has been transferred into the bearing carriages the excess should be cleaned away. If left, it may interfere with the function of an optional encoder where fitted.
Chapter 3 Maintenance ServoTube 25/38 Module User Guide CORRECTIVE MAINTENANCE The corrective maintenance by the user is limited to the following items: • Power and Sensor cables • Thrust rod • Bellows (SB25 and XB38 only) • Forcer • Encoder readhead CABLE REPLACEMENT Note. It is not possible to replace an encoder cable. If an encoder cable needs replacing, the complete encoder assembly will have to be replaced. See ENCODER READHEAD on page 31 in this chapter. CAUTION.
Chapter 3 Maintenance ServoTube 25/38 Module User Guide • To gain access to the cable termination connectors inside the pod, unscrew the four M3 fixing screws, see Figure 3.5. Note that the pod lid fixing screws are of different lengths. Make a record from where each fixing is removed so they can be correctly replaced later. Sensor cable M3 lid fixing screws (4 off) Power cable Pod lid Figure 3.
Chapter 3 Maintenance ServoTube 25/38 Module User Guide • Refit and tighten the cable retaining clamp. • Screw on and tighten the pressure nut. • Replace the pod cover taking care not to damage the sealing gasket on the pod. • Fit the M3 fixings according to the record made when they were removed, and tighten to a torque of 0.7 Nm. • Place the cables back inside the drag chain. • Fit new cable ties to secure the cables as originally fitted. • Re-clip the covers that were previously unclipped.
Chapter 3 Maintenance ServoTube 25/38 Module User Guide • Extract the bellows fixing plate from the last fold on the bellows. • Remove the two M4 button head fixings securing the bellows to the bellows fixing plate in the first fold of the bellows. • Extract this fixing plate from the bellows. Replacement • Insert the bellows fixing plate into the first fold on the bellows (the end that connects to the system end plate).
Chapter 3 Maintenance ServoTube 25/38 Module User Guide THRUST ROD REPLACEMENT SM25 and XM38 Removal • Move the forcer to the centre of the module, Figure 3.12. Forcer Position forcer to centre of module Figure 3.12 • Place spacers around or under the thrust rod to prevent it coming into contact with the bearing rail or other ferrous material. Foam pipe insulation or wooden blocks are ideal for this. • Loosen the two M10 bolts on each of the thrust rod end supports.
Chapter 3 Maintenance ServoTube 25/38 Module User Guide Thrust rod removed from module Figure 3.14 Replacement • Check the orientation of the thrust rod with regard to the end with the serial number label. • Carefully slide the thrust rod in through the first thrust rod support. Place spacers around or under the thrust rod as soon as it passes through the thrust rod support. • Continue to slide the thrust rod to pass through the forcer and into the other thrust rod support.
Chapter 3 Maintenance ServoTube 25/38 Module User Guide SB25 and XB38 Removal • Remove the bellows as previously described.The module will appear as it is shown in Figure 3.15. • Place spacers around or under the thrust rod to prevent it coming into contact with the bearing rail or other ferrous material. Foam pipe insulation or wooden blocks are ideal for this. Note. On the SB25 modules, M8 bolts secure the thrust rod to the thrust rod supports. The XB38 module uses M10 bolts. Important.
Chapter 3 Maintenance ServoTube 25/38 Module User Guide FORCER REPLACEMENT When the forcer is removed from the module, it will have the following items attached that will need to be transferred to the replacement forcer. • Bearing carriage(s). There will be 1 or 2 bearing carriages depending on the particular version. • The encoder readhead bracket fitted with the encoder readhead. • The limit switch actuator if fitted. • The drag chain upper mounting bracket.
Chapter 3 Maintenance ServoTube 25/38 Module User Guide • On the SB25 or XB38, Figure 3.18, remove the four M4 fixings securing one thrust rod support to the backing bar and slide the thrust rod support out of the backing bar, Figure 3.19. • Remove the forcer by sliding it off the bearing rail taking care to keep the forcer square to the bearing rail so that balls are not lost from the re-circulating bearing carriage(s). If balls do fall out they can be re-inserted into the carriages.
ServoTube 25/38 Module User Guide Chapter 3 Maintenance Replacement • Slide the newly assembled forcer on to the bearing rail taking care to keep the forcer square to the bearing rail so that balls are not lost from the re-circulating bearing carriage(s). If balls do fall out they can be reinserted into the carriages. Push the ball bearings using a small screwdriver into the end of the re-circulating path at the plastic end plates on the carriage.
Chapter 3 Maintenance ServoTube 25/38 Module User Guide Alignment The encoder may need aligning. To check: • Connect the encoder to the control system and apply power to the encoder only. • Move the forcer along the entire length of the module and check that the LED indicator on the back of the readhead lights up green. It will light up red as it passes over the reference mark. If this does not happen, alignment is necessary.
Chapter 4 Service ServoTube 25/38 module User Guide Chapter 4 Service SERVICE Should you need to return any items to Copley Motion Systems, before doing so, please call our Sales coordinator on +44 (0)1268 287070 or send a fax to +44 (0)1268 293344 in order to obtain an RMA (Returned Materials Authorisation) number. The RMA number should then be quoted on all items returned and quoted for all enquiries. Please note that when returning items it is recommended that the original packaging be used.
Chapter 4 Service ServoTube 25/38 module User Guide Table 4.
Appendices ServoTube 25/38 module User Guide Appendices CONTENTS APPENDIX A - GLOSSARY OF TERMS & ABBREVIATIONS APPENDIX B - TROUBLE SHOOTING APPENDIX C - TECHNICAL SPECIFICATION Page 35
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Appendices ServoTube 25/38 module User Guide Appendix A Glossary of Terms & Abbreviations GLOSSARY OF TERMS TERM Peak force DESCRIPTION OF TERM Peak force is the force produced when the peak current is applied to the forcer. It is the product of Force constant (N/Apk) and Peak current (Apk). The forcer is not moving, there is no forced cooling and no additional heat-sinking. The duration of the peak force is thermally limited and is therefore only allowable for a period of 1 second.
Appendices ServoTube 25/38 module User Guide Power dissipation Maximum phase temperature Rthphase-houslng Power dissipation is the maximum power that can be dissipated by the forcer when the forcer phases are at their maximum operating temperature, the ambient temperature is 25°C, the forcer is not moving and there is no forced cooling. It is quoted with and without the addition of a 25 x 25 x 2.5cm heatsink plate mounted with thermal grease to the mounting surface of the forcer.
Appendices ServoTube 25/38 module User Guide Appendix B Troubleshooting TROUBLESHOOTING CHART Check to see if the problem you are experiencing is listed in the chart below. If the problem cannot be solved with reference to this chart, contact the customer services department. Fault Possible cause Action Forcer fails to move and produces no force. 1. Drive not powered. 1. Apply power to drive. 2. Forcer phase connections not made. 2. Check forcer phase connections on drive. 3.
Appendices ServoTube 25/38 module User Guide Appendix C Technical Specifications FORCER ELECTRICAL SPECIFICATIONS FORCER TYPE Peak force @ 25oC ambient for 1 sec Peak current @ 25oC ambient for 1 sec With 25 x 25 x2.
Appendices ServoTube 25/38 module User Guide FORCER ELECTRICAL SPECIFICATIONS (continued) FORCER TYPE S 3804 (1) Peak force @ 25oC ambient for 1 sec Peak current @ 25oC ambient for 1 sec 744 Force constant (sine commutation) Back EMF constant (phase to phase) Fundamental forcer constant Eddy current loss Sleeve cogging force Resistance @ 25oC (phase to phase) Resistance @ 100oC (phase to phase) Inductance @ 1kHz (phase to phase) Electrical time constant Maximum working voltage Pole pitch (one electr
Appendices ServoTube 25/38 module User Guide FORCER THERMAL SPECIFICATIONS FORCER TYPE Maximum phase temperature Thermal resistance Rthphase-housing With 25 x 25 x2.5cm heatsink plate Power dissipation @ 25oC ambient Thermal resistance Rthhousing-ambient Without heatsink plate Power dissipation @ 25oC ambient Thermal resistance Rthhousing-ambient Thermal time constant 2504 2506 2508 2510 3804 3806 3808 3810 100 0.41 0.27 0.20 0.16 0.23 0.16 0.13 0.11 62.3 0.79 77.0 0.69 89.2 0.64 100.
Appendices ServoTube 25/38 module User Guide FEEDBACK The ServoTube Module is available with three feedback options with option S supplied as standard. Option S feedback outputs analogue, differential sine and cosine signals for providing position feedback. Shown below are the relationships between forcer phase back EMF and position sensor outputs for one direction of motion (as shown by arrows). It should be noted that +SIN or -SIN is always in phase with forcer phase U.
Appendices ServoTube 25/38 module User Guide OPTION S SPECIFICATION Output signal period Signal amplitude (between +/- signals) Output current Supply voltage Supply current (output current=0) Resolution(1) Position repeatability(2) Absolute accuracy(3) Sx25 51.2 Xx38 71.2 1 ± 10 5 ± 0.
Appendices ServoTube 25/38 module User Guide LIMIT SWITCHES If required, the ServoTube Module can be supplied with limit switches. There are two types available, NPN output and PNP output. Each output type is available with 2 metres of standard cable for non-flexing applications or 5 metres of cable suitable for continuous flexing. Each limit switch position is adjustable and switching is achieved by an actuator vane mounted on the forcer.
Copley Motion Systems LLC Luckyn Lane, Pipps Hill, Basildon, Essex SS14 3BW England Tel: +44 (0)1268 287070 Fax +44 (0)1268 293344 Ref: UM03016/A
