Harmonic Drive RSF, RSF-3A, RSF-5A, RSF-3B Series Manual

RSF Supermini Actuator

RSF Brushless Servo Actuator

Total Motion Control

P r e c i s i o n G e a r i n g & M o t i o n C o n t r o l

SAFETY GUIDE

CAUTIO

For actuators, motors, control units and drivers

Read this manual thoroughly before designing the application, installation, maintenance or inspection of the actuator.

Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious personal injury.

LIMITATION OF APPLICATIONS:

The equipment listed in this document may not be used for the applications listed below:

Space equipment Automobile, automotive parts Aircraft, aeronautic equipment Amusement equipment, sport equipment, game machines Nuclear equipment Machine or devices acting directly on the human body Household apparatus Instruments or devices to transport or carry people Vacuum equipment Apparatus or devices used in special environments

If the above list includes your intending application for our products, please consult us.

Safety measures are essential to prevent accidents resulting in death, injury or damage of the equipment due to malfunction or faulty operation.

CAUTIONS FOR ACTUATORS AT APPLICATION DESIGNING

Always use under followings conditions:

-Ambient temperature: 0˚C to 40˚C

-Ambient humidity: 20% to 80%RH (Non-condensation)

-Vibration: Max 24.5 m/S

-No contamination by water, oil

-No corrosive or explosive gas

CAUTION FOR ACTUATORS IN OPERATIONS

Keep limited torques of the actuator.

-Keep limited torques of the actuator.

-Be aware, that if arms attached to output element hits by accident an solid, the output element may be uncontrollable.

Do not apply impacts and shocks

-Do not use a hammer during installation

WARNIN

-Failure to observe this caution could damage the encoder and may cause uncontrollable operation.

manufactured by Harmonic Drive LLC

Indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate personal injury and/or damage to the equipment.

NWARNIN

Follow exactly the instructions in the relating manuals to install the actuator in the equipment.

-Ensure exact alignment of actuator shaft center and corresponding center in the application. Failure to observe this caution may lead to vibration, resulting in damage of output elements.

Never connect cables directly to a power supply socket.

-Each actuator must be operated with a proper driver.

WARNIN

-Failure to observe this caution may lead to injury, fire or damage of the actuator.

Avoid handling of actuators by cables.

-Failure to observe this caution may damage the wiring,

WARNIN

causing uncontrollable or faulty operation.

CAUTIONS FOR DRIVERS AT APPLICATION DESIGNING

Always use drivers under followings conditions:

-Mount in a vertical position keeping sufficient distance to other devices to let heat generated by the driver radiate freely.

-Ambient temperature: 0˚C to 50˚C

-Ambient humidity: less than 95% RH (Non condensation)

-No contamination by water, oil or foreign matters

-No corrosive, inflammable or explosive gas

Pay attention to negative torque by inverse load. –Inverse load may cause damages of drivers.

-Please consult our sales office, if you intent to apply products for inverse load.

Use sufficient noise suppressing means and safe grounding.

-Keep signal and power leads separated.

-Keep leads as short as possible.

-Ground actuator and driver at one single point, minimum ground resistance class: D (less than 100 ohms)

-Do not use a power line filter in the motor circuit.

Use a fast-response type ground-fault detector designed for PWM inverters.

-Do not use a time-delay-type ground-fault detector.

CAUTION FOR DRIVERS IN OPERATIONS

WARNIN

Never change wiring while power is active.

-Make sure of power non-active before servicing the products.

-Failure to observe this caution may result in electric shock or personal injury.

Do not make a voltage resistance test.

-Failure to observe this caution may result in damage of the control unit.

-Please consult our sales office, if you intent to make a

voltage resistance test.

Do not touch terminals or inspect products at least 5 minutes after turning OFF power.

-Otherwise residual electric charges may result in electric shock.

-Make installation of products not easy to touch their inner electric components.

Do not operate control units by means of power ON/OFF switching.

-Start/stop operation should be performed via input signals.

Failure to observe this caution may result in deterioration of electronic parts.

DISPOSAL OF AN ACTUATOR, A MOTOR, A CONTROL UNIT AND/OR THEIR PARTS

All products or parts have to be disposed of as industrial waste.

-Since the case or the box of drivers have a material indication, classify parts and dispose them separately.

RSF supermini series AC servo actuator manual

Contents

Chapter 1 Overview of the RSF supermini series ................................................................................... 1

1-1 Major characteristics................................................................................................................... 1

1-2 Ordering information ................................................................................................................... 2

1-3 Combinations with drivers .......................................................................................................... 2

1-4 Specifications of RSF supermini actuators................................................................................. 3

1-5 External dimensions of actuators ............................................................................................... 4

1-6 One-way positioning accuracy....................................................................................................6

1-7 Torsional stiffness ....................................................................................................................... 7

1-8 Detector resolution...................................................................................................................... 8

1-9 Mechanical accuracy .................................................................................................................. 8

1-10 Allowable load............................................................................................................................. 9

1-10-1 Allowable radial load and allowable thrust load ............................................................. 9

1-10-2 Radial load when the operating point is different........................................................... 9

1-11 Rotary direction......................................................................................................................... 10

1-12 Impact resistance...................................................................................................................... 10

1-13 Vibration resistance .................................................................................................................. 10

1-14 Torque-speed characteristics.....................................................................................................11

1-15 Cable specifications.................................................................................................................. 13

Chapter 2 Selection of the RSF supermini Series.................................................................................14

2-1 Allowable load moment of inertia.............................................................................................. 14

2-2 Variable load inertia .................................................................................................................. 14

2-3 Verifying loads .......................................................................................................................... 14

2-4 Duty cycles ............................................................................................................................... 15

2-4-1 Actuator speed................................................................................................................ 15

2-4-2 Load moment of inertia ................................................................................................... 15

2-4-3 Load torque.....................................................................................................................15

2-4-4 Acceleration time and deceleration time......................................................................... 16

2-4-5 Calculating equivalent duty............................................................................................. 17

2-4-6 Effective torque and average speed............................................................................... 21

2-4-7 Permissible overloaded time .......................................................................................... 22

Chapter 3 Installing the actuator......................................................................................................... 23

3-1 Receiving Inspection................................................................................................................. 23

3-2 Notice on handling .................................................................................................................... 24

RSF-super_V1_01 - contents 1 -

RSF supermini series AC servo actuator manual

3-3 Location and installation ........................................................................................................... 25

3-3-1 Environment of location .................................................................................................. 25

3-3-2 Considerations into External Noise ................................................................................ 25

3-3-2

Installation....................................................................................................................... 26

Chapter 4 Motor shaft retention brake(RSF-5A) ...................................................................................27

4-1 Motor shaft retention brake specifications ................................................................................ 27

4-2 Controlling the brake power supply .......................................................................................... 27

4-2-1 Using a relay cable (Recommended method) ................................................................ 27

4-2-2 Not using a relay cable ................................................................................................... 28

Chapter 5 Options ................................................................................................................................. 29

5-1 Relay cables ............................................................................................................................. 29

5-2 Relay cable wire bound specifications...................................................................................... 30

5-3 Connectors ............................................................................................................................... 31

Appendix 1 Conversion of Unit ...................................................................................................App. 1-1

Appendix 2 Moment of inertia .....................................................................................................App. 2-1

1. Calculation of mass and moment of inertia .................................................................App. 2-1

2. Moment of inertia of circular cylinder...........................................................................App. 2-3

RSF-super_V1_01 - contents 2 -

Chapter 1 Overview of the RSF supermini series

The RSF supermini series are ultra-small AC servo actuators combining ultra-precision control deceleration device Harmonic Drive® that provides precision rotation operation at a high torque with ultra-small AC servo motor developed to make use of the performance of the decelerator.

Actuators with an electromagnetic brake are also included in the lineup. They can meet fail-safe requirements of equipment to prevent accidents upon power supply failure.

The dedicated servo driver HA-680 is an AC servo driver for 24VDC power supply. The small and multi-functional HA-680 driver is equipped with position control, speed control, and torque control as standard to control operation of the RSF supermini series correctly and precisely.

The RSF supermini series can contribute to downsizing of driving of robot joints, semiconductor/LCD panel manufacturing equipment, machine tools, and other FA equipment. By utilizing its small and high-torque characteristics, it can also be used for small equipment and for research.

1-1 Major characteristics

◆ Small, lightweight, and high-torque

The RSF supermini series with the precision-control deceleration device Harmonic Drive® realizes a high torque and has a very high output torque for the outer dimensions compared to the direct driving method with a high-capacity motor alone.

Also, combination with the dedicated AC servo motor realizes size and weight reduction that are never possible before.

◆ Standard lineup of actuators with a brake (only RSF-5A)

The standard lineup of AC servo actuators includes the deenergisation operation type actuators with an electromagnetic brake for the first time for this size of actuators.

Fail-safe requirements of equipment can be met to prevent accidents upon power failure without providing any external brake or changing the equipment structure to install a brake.

◆ Superior positioning precision

The characteristics of the control deceleration device Harmonic Drive® such as non-backlash and superior positioning precision realize high-precision mechanisms.

◆ Stable controllability

The high deceleration gear ratio of the control deceleration device Harmonic Drive® provides stable controllability for large variations of load moment of inertia.

RSF-Super_V1_02 - 1 -

Chapter 1 Overview of the RSF supermini series

1-2 Ordering information

Model codes for the RSF supermini series actuators are as follows:

RSF-5 A-50-E 050-C

Model: AC servo actuator

RSF series: Output shaft is of the shaft type.

Frame size: 3 or 5

Design version

Reduction ratio of gearing

30: 1/30 50: 1/50 100: 1/100

Encoder specifications US: 14 wire incremental encoder (standard) E: 4 wire incremental encoder (optional)

Encoder pulses on motor shaft

020: 200p/rev (Model 3) 050: 500p/rev (Model 5)

Specifications C: Standard item（with connector） BC: With brake（with connector） SP* Special specification

1-3 Combinations with drivers

The RSF supermini series actuators are used in combination with the HA-680-4B-24 driver.

The HA-680 driver can perform position control, speed control, and torque control.

For details of the driver, refer to “AC Servo Driver for 24VDC Power Supply HA-680 Series Technical Data.”

The optional relay cable is required for connection between the actuator and the driver.

RSF-Super_V1_02 - 2 -

Chapter 1 Overview of the RSF supermini series

1-4 Specifications of RSF supermini actuators

Specifications of actuators are as follows:

Time rating: Continuous Service temperature:

0~40˚C

Excitation method: Permanent magnet type Storage temperature:

-20~+60˚C

ts /ecivreS B :ssalc noitalusnI orage humidity: 20~80%RH (no condensation)

Withstanding voltage: AC500V/min Vibration resistance: 49m/s

Insulation resistance: DC500V 100MΩor more Lubricant: Grease (Harmonic Grease) Structure: Totally enclosed self cooling

type

Item

Chapter 1 Overview of the RSF supermini series

1-4 Specifications of RSF supermini actuators

Specifications of actuators are as follows:

Time rating: Continuous Service temperature:

0~40˚C

Excitation method: Permanent magnet type Storage temperature:

-20~+60˚C

ts /ecivreS B :ssalc noitalusnI orage humidity: 20~80%RH (no condensation)

Withstanding voltage: AC500V/min Vibration resistance: 49m/s

Insulation resistance: DC500V 100MΩor more Lubricant: Grease (Harmonic Grease) Structure: Totally enclosed self cooling

type

Note 1: The table shows typical output values of actuators. Note 2: The values in the table above are obtained when it is combined with the combined driver (HA-680-4B-24). Note 3: All values are typical. Note 4: The moment of inertia is the total value of the motor shaft and Harmonic Drive moment of inertia values

converted to the output side. The values in parentheses are for equipment with a brake.

Note 5: The encoder resolution is (motor shaft encoder resolution when multiplied by 4) x (gear ratio).

Power Supply Voltage V DC24 DC24

Allowable Continuous Current A 0.68 0.63 0.49 1.11 0.92 0.76

Allowable Continuous Torque (during operation at allowable continuous rotation speed)

Allowable Continuous Rotation Speed (output shaft)

Allowable Continuous Stall Torque

Instantaneous Maximum Current A 1.2 1.1 0.8 2.3 2.2 1.7

Maximum Torque

Maximum Speed r/min 333 200 100 333 200 100

Torque Constant

MEF constant V/(r/min) 0.015 0.025 0.050 0.04 0.07 0.13

Phase Resistance (at 20˚C)

Phase Inductance mH 0.18 0.27

Moment of Inertia Note 4

Gear ratio 30 50 100 30 50 100

Allowable Radial Load (output shaft central value)

Allowable Thrust Load

Encoder Pulses (motor shaft) Pulse 200 500

Encoder Resolution (Output shaft: when multiplied by 4) Note 5

Motor Shaft Brake

Mass

Combined Driver HA-680-4B-24 HA-680-4B-24

GD2/4 kg•m

J kgf•cm•s21.07x10

Input

Power

Supply

Voltage

Retention

Torque

w/o brake g

w/ brake g 86.0 (except clamp ﬁlter)

Model

30 50 100 30 50 100

N•m 0.03 0.06 0.08 0.18 0.29 0.44

Kgf•cm 0.31 0.61 0.82 1.83 2.95 4.48

r/min 150 90 45 150 90 45

N•m 0.04 0.08 0.12 0.28 0.44 0.65

kgf•cm 0.41 0.82 1.22 2.85 4.48 6.62

N•m 0.09 0.15 0.21 0.5 0.9 1.4

kgf•cm 0.92 1.53 2.14 5.10 9.17 14.3

N•m/A 0.11 0.18 0.40 0.30 0.54 1.1

kgf•cm/A 1.12 1.84 4.08 3.06 5.51 11.22

Ω

0.11x10

N 40 90

kgf 4.0 9.1

N 130 270

kgf 13.2 27.5

Pulse/

Rotation

V — — — DC24

N•m — — — 0.18 0.29 0.44

kgf•cm — — — 1.83 2.95 4.48

24,000 40,000 80,000 60,000 100,000 200,000

RSF-3A RSF-5A

1.34 0.82

-4

31.0 (except clamp ﬁlter)

0.29x10

2.98x10

-4

1.17x10

11.90x10

0.66x10

-4

(0.11x10-3)

0.67x10

-4

(1.13x10-3)

-4

-3

66.0 (except clamp ﬁlter)

1.83x10

(0.31x10-3)

1.87x10

(3.15x10-3)

-4

7.31x10

(1.23x10-3)

7.45x10

(12.6x10-3)

-4

-3

-3-

Chapter 1 Overview of the RSF supermini series

1-5 External dimensions of actuators

The external drawings are shown as follows:

■ RSF-3

B-XXX-E020-C

4-M1.6 tap 3.2 evenly spaced

Maximum diameter of rotation part

-0.018

φ12 h7

-0.008

φ3.5 h6

Motor lead wire

Encoder lead wire

Line locating range of Encoder cable wire

Clamp filter(2) ZCAT1518-0730(TDK)

Note) For detailed outside dimensions, check the delivery specification drawing issued by us.

RSF-Super_V1_02 - 4 -

■ RSF-5A-XXX-E050-C

Chapter 1 Overview of the RSF supermini series

3-M2x3 evenly spaced

2-φ2.3 evenly spaced

3-φ2x2.5 evenly spaced

■ RSF-5A-XXX-E050-BC

■ RSF-5A-XXX-E050-BC(with brake)

3-M2x3 evenly spaced

3-φ2x2.5 evenly spaced

2-φ2.3 evenly spaced

Maximum diameter of rotation part

Motor lead wire

Encoder lead wire

Clamp filter ZCAT1518-0730(TDK)

FG line

Motor lead wire

FG line

Brake lead wire

Motor and Brake lead wire

Encoder lead wire

Note) For detailed outside dimensions, check the delivery specification drawing issued by us.

Clamp filter ZCAT1518-0730(TDK)

RSF-Super_V1_02 - 5 -

Chapter 1 Overview of the RSF supermini series

1-6 One-way positioning accuracy

The following table shows the “one-way positioning accuracy” and “repeated positioning accuracy.” The following table contains representing values. (JIS B 6201:1987)

The one-way positioning accuracy of RSF supermini actuators is almost equal to the angular positioning accuracy of the Harmonic® drive gearing, because the effect on the positioning error of the built-in motor is reducted to its 1/30 or 1/50 or 1/100 by the gearing.

The accuracy for each gear ratio is shown below.

Mode RSF-3B RSF-5A

Gear ratio

Item

30 50 100 30 50 100

One-way positioning accuracy

arc min 10 4 3 3

-3

rad 2.9×10

1.20×10

■ Reference

(Accuracy display and measurement method according to JIS B 6201: 1987)

● One-way positioning of rotation shaft motion

First, perform positioning at any one position in a fixed direction. This position is the reference position. Next,

One-way positioning

accuracy

perform positioning in succession in the same direction, and measure the difference between the angle actually rotated from the reference position and the desired angle at each position. The maximum difference in one rotation among these values is taken as the measurement value. Measurement of equipment with the continuous positioning function for rotational motion shall be done once per 30 degrees or 12 positions throughout the entire rotation range as a rule.

Start position

-3

0.87×10-3 0.87×10

Positional difference

-3

Actual position

RSF-Super_V1_02 - 6 -

Chapter 1 Overview of the RSF supermini series

1-7 Torsional stiffness

When a torque is applied to the output flange of the actuator with the motor locked, the resulting torsional wind up is near proportional to the torque.

The upper right figure shows the torsional stiffness characteristics of the output flange applying torque starting from zero to plus side [+T trajectory is called torque-torsion characteristics which typically follows a loop 0→A→B→A’→B’→A as illustrated. The torsional stiffness of the RSF supermini actuator is expressed by the slope of the curve that is a spring rate (wind-up) (unit:N･m/rad).

The torsional stiffness may be evaluated by dividing torque-torsion characteristics curve into three major regions. The spring rate of each region is expressed K respectively.

1: spring rate for torque region 0-T1 2: spring rate for torque region T1-T2

3: spring rate for torque region over T2

0] and minus side [–T0]. This

1, K2, and K3

The wind-up for each region is expressed as follows:

◆ wind-up for torque region 0-T

◆ wind-up for torque region T

◆ wind-up for torque region over T

1-T2:

The following table shows average values of T different gear ratios.

Model RSF-3B RSF-5A

Symbol

Nm 0.016 0.016 0.016 0.075 0.075 0.075

Kgf m 0.0016 0.0016 0.0016 0.0077 0.0077 0.0077 Nm/rad 27 30 34 90 110 150

Kgf m/arc min 0.0008 0.0009 0.0010 0.003 0.003 0.004 x10-4 rad 5.9 5.3 4.7 8.7 6.9 5

θ1

arc min 2.0 1.8 1.6 3 2.4 1.7 Nm 0.05 0.05 0.05 0.22 0.22 0.22

Kgf m 0.005 0.005 0.005 0.022 0.022 0.022 Nm/rad 40 47 54 110 140 180

Kgf m/arc min 0.0012 0.0014 0.0016 0.003 0.004 0.005 x10-4 rad 12.5 10.6 9.3 22 18 13

θ2

arc min 4.2 3.6 3.1 7.5 6 4.4 Nm/rad 51 57 67 120 170 200

Kgf m/arc min 0.0015 0.0017 0.0020 0.004 0.005 0.006

Gear ratio

30 50 100 30 50 100

=ϕ

TT −

+θ=ϕ

TT −

+θ=ϕ

1 through T3, K1 through K3, and θ1 through θ2 for

RSF-Super_V1_02 - 7 -

Chapter 1 Overview of the RSF supermini series

1-8 Detector resolution

An encoder with 500 pulses per rotation is incorporated in the motor unit of the RSF supermini series actuators, and the motor output is decelerated by 1/30, 1/50, or 1/100 by the precision control decelerator Harmonic Drive®. Therefore, the resolution per one rotation of the actuator output shaft is 30, 50, or 100 times of the actual encoder resolution. In addition, the encoder signal is electrically multiplied by 4.

The following table shows the resolution at the output shaft for different gear ratios.

Model RSF-3B RSF-5A

Item Detector resolution

(when multiplied by 4)

Angle per one pulse

Gear ratio

Pulse/Rotation 24,000 40,000 80,000 60,000 100,000 200,000

Angle second

(arc sec)

30 50 100 30 50 100

54 32.4 16.2 21.6 12.96 6.48

1-9 Mechanical accuracy

The machining accuracy of the output flange and the mounting flange of RSF supermini actuators are indicated in the table below.

RSF－3B RSF－5A

Machined accuracy of the output flange * T.I.R. unit: mm

Symbol Accuracy value

Model

a Runout of the tip of the output shaft b Concentricity of installed spigot joint c Squareness of installation surface d Output flange surface contact

Parallelism of installation surface

and output flange

*) T.I.R(Total Indicator Reading): Indicates the total amount of dial gage reading when the measurement unit is

rotated once.

Machined parts

RSF－3B RSF－5A

0.03 0.03

0.02 0.04

0.02 0.02

0.005 0.005

0.015 0.015

RSF-Super_V1_02 - 8 -

Chapter 1 Overview of the RSF supermini series

1-10 Allowable load

1-10-1 Allowable radial load and allowable thrust load

The gear head used in the RSF supermini series incorporates the high-precision 4-point contact ball bearing for direct support of external load (output part).

The allowable radial load and thrust load of the output shaft are shown below.

The allowable radial load F

is obtained with

respect to the center (L/2) 0 point of the output shaft.

The values in the following table are designed by considering the life of the bearing.

0 point

The allowable values must not be exceeded.

L/2

Model Unit RSF-3B RSF-5A

Allowable radial load (Fr)

Allowable thrust load (FS)

kgf

36 90

3.6 9.1

130 270

13 27

1-10-2 Radial load when the operating point is different

If the operating point of radial load is different, the allowable radial load value is also different.

The relation between radial load position L following formula.

The allowable values must not be exceeded.

F+=

: Allowable radial load at distance L

: Allowable radial load at the 0 point [N]

: Distance from the bearing starting point to the 0 point [mm]

: Distance from the position where radial load is exerted to the 0 point [mm]

L : Shaft length [mm]

Model RSF-3B RSF-5A

Allowable radial load (Fr)

La mm 8.6 9.85 L mm 7 10

N 36 90 kgf 3.6 9.1

and allowable radial value FR is obtained from the

from the 0 point [N]

RSF-Super_V1_02 - 9 -

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Harmonic Drive RSF, RSF-3A, RSF-5A, RSF-3B Series Manual

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