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ServoWeld System

Product catalog summary

Overview of GSWA System
The GSWA is an integrated actuator system designed for industrial resistance spot welding applications. It combines a servo motor, actuator, and feedback mechanisms into a compact and durable package, offering high force output and efficiency without the need for forced cooling.

Key Features

Compact and lightweight design
High force repeatability and output
Over 10 million cycles of durability
Manual override option
Compatibility with various systems
Low inertia and no forced cooling required

Design and Integration
The GSWA integrates a hollow core servo motor with a mechanical design that eliminates the need for couplers, adapters, belts, and gears, reducing assembly labor and cooling requirements. It is suitable for robotic installations and can be integrated with any robot manufacturer.

Performance and Efficiency

Provides consistent weld quality with force repeatability
Soft-touch position and speed control for reduced wear
Programmable for different models and tools
Faster welding cycles with immediate welding capability

Screw Selection

Roller Screw: High load capacity, 10+ million welds, ±3% force repeatability
Ball Screw: Moderate load capacity, 5+ million welds, ±5% force repeatability

Advantages Over Pneumatic Systems

Longer service life and zero maintenance
Energy efficiency improved by over 80%
Reduced environmental impact with less noise and contamination

Additional Features

High thrust bearing and manual override for power-off situations
Multiple motor windings and feedback options
Corrosion-resistant construction with salt bath nitride treatment

Specifications:

Ball and Roller Nuts: Ball nuts offer positioning accuracy and repeatability, while roller nuts provide the highest thrust and life ratings.
Screw Technologies: Options include digital encoders, multi-turn absolute encoders, resolvers, and customer-specified solutions.
Motor Windings: Available in 460V or 230V, with skewed motor windings for minimal torque ripple and smooth motion.
Construction: Features include a hex thrust rod for anti-rotation, bumpers for protection, and a black anodized extrusion design for rigidity and heat dissipation.

Testing Procedures:

High Potential Test: Verifies the insulation system of the assembly.
Electronic Phasing: Aligns feedback devices with the ServoWeld motor.
Functional Testing: Quantifies stroke length, torque, and input current using data acquisition equipment.
Tolomatic System Test: Ensures feedback device alignment with motor poles.

Performance & Mechanical Specifications:

Peak Thrust: Ranges from 1,700 to 3,300 lbf depending on the model.
Maximum Velocity: Up to 11.5 in/sec.
Ambient Temperature Range: 50 to 122°F.
IP Rating: Standard IP65.

Application Guidelines:

Side Loading: Recommendations to limit side loading for extended service life.
Thrust Rod Wiper/Scraper: Field replaceable to prevent contamination.
Cables: Shielded power and feedback cables recommended to minimize electrical noise.
RSW Servo System Calibration: Includes low weld force and tip dress force for optimal performance.

Dimensions: Detailed dimensions for various GSWA models are provided, ensuring compatibility with different applications.

Conclusion: The GSWA actuator is designed for high performance and reliability, with extensive testing and application guidelines to ensure optimal use in industrial settings.

Specifications and Recommendations:
The document discusses the installation and maintenance of ServoWeld units in pedestal RSW (Resistance Spot Welding) gun applications. It emphasizes the importance of minimizing water exposure to extend the service life of the ServoWeld units. Key recommendations include:

Mounting the ServoWeld vertical with the thrust rod down or at an angle of 10-15% to prevent water pooling.
Utilizing water channels on mounting components and external deflectors or thrust rod boots to protect against water exposure.
Incorporating a manual shut-off valve in the water saver circuit to reduce water exposure during weld cap changes.
Ensuring electrical connectors are positioned to prevent water ingress and allowing adequate cable length to avoid tension.

Company Information:
Tolomatic is highlighted as an industry leader known for excellent customer service, fast delivery of standard and custom products, and innovative solutions. They offer online sizing and selection software for actuators, and provide easy access to 3D models and 2D drawings.

Product Offerings:
Tolomatic's product range includes power transmission products, electric and pneumatic products, rodless cylinders, guided rod cylinder slides, high thrust actuators, motors, drives, controllers, gearboxes, clutches, and brakes. They provide detailed brochures for their various product lines.

Catalog excerpts

SERVOWELD® SYSTEM ENDURANCE TECHNOLOGY INTEGRAL MOTOR HIGH THRUST ACTUATOR

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What is the GSWA? The GSWA is a compact, durable, high force rod-style actuator designed specifically for resistance spot welding as well as other welding applications. The GSWA integrates a hollow core servo motor with a proven mechanical design to provide efficient, repeatable high force in a compact lightweight design envelope. Tolomatic has over 50 years of experience manufacturing rodless and rod-style electric and pneumatic actuators. The GSWA combines this experience and the power of servo motor technology into one actuator. The result: reliable, affordable power in a compact package....

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The GSWA in a Typical Robotic ServoWeld Installation ROBOT MANUFACTURER 7TH AXIS FEEDBACK DEVICE ENCLOSED WITHIN PROTECTIVE HOUSING (EXAMPLE: RESOLVER, ENCODER: INCREMENTAL/ ABSOLUTE) ROBOT CABLE ELECTRICAL DRESS PACKAGE CONNECTORS FOR MOTOR POWER & FEEDBACK DEVICE TEACH PENDANT ROBOT CONTROLLER TRANSFORMER GSWA SERVOWELD® ACTUATOR ACTUATOR ROBOT WELD CONTROLLER This illustration shows a typical robot carried weld installation utilizing a Tolomatic GSWA actuator with a 7th axis feedback device enclosed within the actuator. In this pinch-gun application the GSWA33 provides accurate, repeatable...

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Resistance Spot Welding (RSW) With ServoWeld® Gswa Tolomatic’s ServoWeld® Products Offer RSW Users a Higher Level of Performance complete manufacturing flexibility • Using weld or robot controls, the GSWA can be easily programmed to accommodate model or tool changes. • Existing 6-axis robots can be retrofitted with multiple GSWA actuators to achieve all the advantages that servo welding offers. • Operation can be coordinated with robot axis movement. HIGHER QUALITY WELDS • Force repeatability for consistent welds • “Soft-touch” position and speed control for high repeatability and eliminates...

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Superior Quality Welds with GSWA The ServoWeld GSWA Integrated Motor Actuator Design Offers Superior Quality Welds in a Compact Package GSWA integrated motor actuator uses an 8 pole, hollow core rotor with skewed stator laminations. This allows the magnets to remain over multiple windings throughout the weld cycle for maximum torque efficiency and consistent force output at any location along the actuator stroke. The result: • Low cogging torque for better repeatability • Better repeatability independent of position Skewed Stators • Higher quality welds The GSWA has skewed stator laminations...

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GSWA - Screw Selection Roller Screw Roller Screw and Ball Screw Performance Comparisons Capable of handling heavy loads. Force is transmitted via multithreaded helical roller assemblies engaged with a fine threaded roller screw. Roller screws have exceptional loading capability based on many points of contact. Roller Screw Load ratings Very High Ball Screw High Very long, • ± 3% force repeatability • Up to 3,300 lbf. (14,680 N) • Speeds to 11.5” (292 mm) per sec. Helical Roller Screw Speed Moderate Accel. Very high Stiffness Very high • 10+ million welds at high force repeatability many Lifetime...

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Improved Technology, Better Performance Air cylinders, and competing servo actuator designs can’t compare to ServoWeld® SERVO: Reverse-parallel motor configuration, belt driven SERVO: - Integrated motor segmented laminations • Poor repeatability, reduced weld quality • Size and weight create payload challenge (increase of 10% to 30% compared with an integrated design) • Segmented stator design does not offer the performance of skewed windings • “Bang-bang” welds - greater tooling wear • Mechanical linkage of belt is not as responsive as direct drive • Limited adaptability • Transmission belt...

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GSWA - Integrated Motor Actuator GSWA33 integrated motor Actuator Endurance Technology features are designed for maximum durability to provide extended service life. MULTIPLE SCREW TECHNOLOGIES • Ball nuts offer positioning accuracy and repeatability • Roller nuts provide the highest thrust and life ratings available internal bumpers • Bumpers protect the screw and nut assembly from damage at end of stroke INTEGRAL MOUNTING •Four threaded holes on front face are available for direct mounting or addition of customized options Rod Wiper with Scraper • Prevents contaminants from entering...

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GSWA - Integrated Motor Actuator … MAXIMUM DURABILITY Connectors YouR choice: • For integration with many robot / drive manufacturers • Staggered connectors for more convenient installation • Connectors and feedback manufacturers include: + ABB + Motoman/Yaskawa + Fanuc + Allen Bradley + Kawasaki + Bosch-Rexroth + Kuka + WTC-Medar + Nachi +Comau & more HIGH RESOLUTION FEEDBACK You can choose: high thrust bearing • Digital encoder • Multi-turn absolute encoder • Resolver • Customer specified • Provides complete support of screw and protects the feedback device from linear forces • Provides...

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GSWA - Integrated Motor Actuator GSWA33, Guided integrated motor Actuator Endurance Technology features are designed for maximum durability to provide extended service life. •Large bushings provide additional side loading support for the thrust tube protecting the screw assembly • Eliminates external guide on RSW chassis • Protects guided mechanism in RSW environment • Steel thrust tube supports extremely high force capabilities • Salt bath nitride treatment provides excellent corrosion resistance, surface hardness and is very resistant to adherence of weld slag, water and other potential contaminants...

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GSWA - Integrated Motor Actuator … MAXIMUM DURABILITY Connectors MULTIPLE MOTOR WINDINGS • Connectors and feedback manufacturers include: + ABB + Fanuc + Kawasaki + Kuka + Motoman/Yaskawa + Nachi + Allen Bradley + Bosch-Rexroth + WTC-Medar +Comau & more YouR choice: YOU CAN CHOOSE: • 230V or 460V rated windings potted directly into actuator housing • Skewed motor windings provide minimal torque ripple for force repeatability and smooth linear motion • Integral thermal switch for over temperature protection • For integration with many robot / drive manufacturers HIGH RESOLUTION FEEDBACK...

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ServoWeld System

ServoWeld System

Catalog excerpts

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