Bosch DOK-MOTOR-MCL Series Project Planning Manual Download Page 26

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WARNING

In case of non-compliance with this safety instruction, death or serious injury

could occur.

CAUTION

In case of non-compliance with this safety instruction, minor or moderate in‐

jury could occur.

NOTICE

In case of non-compliance with this safety instruction, property damage could

occur.

Bosch Rexroth AG

DOK-MOTOR*-MCL********-PR05-EN-P

24/193

Rexroth IndraDyn L Ironless Linear Motors MCL

Safety Instructions for Electric Drives and Controls

Summary of Contents for DOK-MOTOR-MCL Series

Page 1: ...The Drive Control Company Rexroth IndraDyn L Ironless Linear Motors MCL Edition 05 Project Planning Manual R911330592 ...

Page 2: ...2 Edition 05 details about parallel arrangement added Copyright Bosch Rexroth AG 2015 This document as well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth AG It may not be re produced or given to third parties without its consent Liability The specified data is intended for product description purposes only and shall not be deemed to be...

Page 3: ...6 3 2 3 Hazards by improper use 17 3 3 Instructions with Regard to Specific Dangers 18 3 3 1 Protection Against Contact with Electrical Parts and Housings 18 3 3 2 Protective extra low voltage as protection against electric shock 19 3 3 3 Protection against dangerous movements 20 3 3 4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting 21 3 3 5 Protection against ...

Page 4: ...70 44 5 Dimension sheets 47 5 1 Installation tolerances 47 5 1 1 General information 47 5 1 2 Frame size MCL015 48 5 1 3 Frame size MCL020 070 49 5 1 4 Parallelism and symmetry of machine parts 50 5 2 Dimension sheets MCL015 52 5 3 Dimension sheets MCL020 54 5 4 Dimension sheets MCL030 56 5 5 Dimension sheets MCL040 58 5 6 Dimension sheets MCL070 60 6 Type codes 63 6 1 Type code structure and desc...

Page 5: ...ion and construction instructions 97 9 1 Mode of functioning 97 9 2 Motor design 97 9 2 1 Design primary part 97 9 2 2 Design secondary part 98 9 2 3 Frame size and frame length 99 9 3 Setup elevation and ambient conditions 100 9 4 Ambient conditions 101 9 5 Degree of protection 102 9 6 Acceptances and approvals 102 9 6 1 CE Sign 102 9 6 2 RoHS conformity 102 9 7 Magnet fields 103 9 8 Noise emissi...

Page 6: ...ia mechanical braking device 125 9 21 5 Response to a mains 125 9 21 6 Short circuit of DC bus 127 9 22 Position and velocity resolution 127 9 22 1 Drive internal position resolution and position accuracy 127 9 22 2 Velocity resolution 128 10 Motor controller combinations 129 10 1 General information 129 10 2 Motor controller combinations with NYCe 4000 129 10 3 Motor controller combinations with ...

Page 7: ... motor components 159 13 3 Installation of motor components 160 13 4 Air gap parallelism and symmetry of the motor components 160 13 5 Fastening secondary part 161 13 6 Fastening the primary part 163 13 7 Electrical connection 164 14 Commissioning operation and maintenance 165 14 1 General information for startup of ironless IndraDyn L motors 165 14 2 General requirements 165 14 2 1 General inform...

Page 8: ... Estimating the moved mass using a velocity ramp 180 14 8 Maintenance and check of motor components 182 14 8 1 General information 182 14 8 2 Check of motor and auxiliary components 182 14 8 3 Electrical check of motor components 182 14 9 Operation with third party controllers 183 14 10 Environmental protection and disposal 183 14 10 1 Environmental protection 183 14 10 2 Disposal 183 15 Service a...

Page 9: ...lar technology e g for laser structuring Precision and ultra precision machining Even in other areas for example in machine tool industry printing industry and especially in measuring technology the advantages of this technology becomes important The ironless drive technology offers a lot of significant advantages in oppo site to a ferrous motor without accepting disturbing ancillary effects like ...

Page 10: ...CS Motor Coreless Secondary part Fig 1 1 Rexroth MCL example 1 3 Comparison ironless with ferreous linear motors Ferreous linear motors use the iron in which the winding is inserted to bundle the magnetic flow Therewith a very high force density is reached Act up to a principle very high magnetic attractive forces exist among the motor com ponents primary and secondary part These lead to detent fo...

Page 11: ...ctrum of ironless linear drive technique of Bosch Rexroth realized drives with feed forces of 10 N up to 3 300 N acceleration up to 250 m s and maximum velocity up to 1 400 m min The following dia gram gives an overview of the performance spectrum Fig 1 2 Perfomance spectrum Rexroth MCL DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 9 193 Rexroth IndraDyn L Ironless Linear Motors MCL Rexroth MCL Product...

Page 12: ...ection technique 9 Operating condition and application instructions 10 Motor Control Combination 11 Motor dimensioning 12 Handling transport and storage 13 Installation 14 Startup operation and mainte nance 15 Service Support Additional information 16 Index Tab 1 1 Chapter structure 1 5 2 Additional documentation To plan the drive systems with MCL motors it is possible that you need addi tional do...

Page 13: ...tmaster beuth de 1 5 4 Additional components Documentation for external systems which are connected to Bosch Rexroth components are not included in the scope of delivery and must be ordered directly from the corresponding manufacturers 1 5 5 Your feedback Your experiences are an essential part of the process of improving both the product and the documentation Please send your remarks to Bosch Rexr...

Page 14: ...Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 12 193 Rexroth IndraDyn L Ironless Linear Motors MCL ...

Page 15: ...t be ensured that the products are installed according to the regu lations specified in the documentation 2 1 2 Areas of use and application Coreless linear motors MCL of the IndraDyn L series by Bosch Rexroth are determined to be used as linear servo drive motors There are drive controllers with different ratings different DC bus voltages and different interfaces to allow application specific use...

Page 16: ...ditions which do not comply with the ambient conditions described above for example operation under wa ter under extreme variations in temperature or extreme maximum tem peratures is not permitted the intended fields of application have not been expressly released for the motors by Bosch Rexroth MCL motors are not suited to be operated directly on the power supply system Bosch Rexroth AG DOK MOTOR...

Page 17: ...lines and ca bles Installation An installation consists of several devices or systems interconnected for a defined purpose and on a defined site which however are not intended to be placed on the market as a single functional unit Machine A machine is the entirety of interconnected parts or units at least one of which is movable Thus a machine consists of the appropriate machine drive elements as ...

Page 18: ...ic shock or even death 3 2 2 Requirements for safe use Read the following instructions before initial commissioning of the compo nents of the electric drive and control system in order to eliminate the risk of injury and or property damage You must follow these safety instructions Bosch Rexroth is not liable for damages resulting from failure to observe the safety instructions Read the operating m...

Page 19: ... the respective application docu mentation The machine or installation manufacturer is responsible for compliance with the limit values as prescribed in the national regulations The technical data connection and installation conditions of the compo nents are specified in the respective application documentations and must be followed at all times National regulations which the user has to comply wi...

Page 20: ...ectric components in accordance with the connection diagram Even for brief measurements or tests operation is only allowed if the equipment grounding conductor has been permanently connected to the points of the components provided for this purpose Before accessing electrical parts with voltage potentials higher than 50 V you must disconnect electric components from the mains or from the power sup...

Page 21: ...on outer con ductor Minimum cross section equipment grounding conductor Leakage current 3 5 mA 1 equipment grounding conductor 2 equipment grounding conductors 1 5 mm2 16 AWG 10 mm2 8 AWG 2 1 5 mm2 16 AWG 2 5 mm2 14 AWG 2 2 5 mm2 14 AWG 4 mm2 12 AWG 2 4 mm2 12 AWG 6 mm2 10 AWG 2 6 mm2 10 AWG 10 mm2 8 AWG 16 mm2 6 AWG 16 mm2 6 AWG 25 mm2 4 AWG 35 mm2 2 AWG 50 mm2 1 0 AWG 25 mm2 4 AWG 70 mm2 2 0 AWG...

Page 22: ...ve movements will occur The extent of faulty drive movements depends upon the type of control and the state of opera tion Dangerous movements Danger to life risk of injury serious injury or property damage A risk assessment must be prepared for the installation or machine with its specific conditions in which the components of the electric drive and control system are installed As a result of the ...

Page 23: ...ric drive and control system for possible malfunctions when operating such high fre quency remote control and radio equipment in its possible positions of normal use It might possibly be necessary to perform a special electro magnetic compatibility EMC test 3 3 4 Protection Against Magnetic and Electromagnetic Fields During Oper ation and Mounting Magnetic and electromagnetic fields generated by c...

Page 24: ...ine or in stallation guards shieldings or barriers or safety instructions in the ap plication documentation 3 3 6 Protection during handling and mounting Risk of injury by improper handling Injury by crushing shearing cutting hit ting Observe the relevant statutory regulations of accident prevention Use suitable equipment for mounting and transport Avoid jamming and crushing by appropriate measure...

Page 25: ... Before dismounting lines relieve pressure and empty medium Use suitable protective equipment safety goggles safety shoes safety gloves for example Immediately clean up any spilled liquids from the floor due to the risk of falling Environmental protection and disposal The agents e g fluids used to operate the product might not be environmentally friendly Dispose of agents harmful to the environmen...

Page 26: ... non compliance with this safety instruction minor or moderate in jury could occur NOTICE In case of non compliance with this safety instruction property damage could occur Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 24 193 Rexroth IndraDyn L Ironless Linear Motors MCL Safety Instructions for Electric Drives and Controls ...

Page 27: ...temperatures acc to chapter 9 3 Setup elevation and ambient conditions on page 100 Motor winding temperature 110 C Specified values in the data sheet are effective values according to DIN EN 60034 1 Reference value is the maximum intermedi ate circuit voltage of 420 VDC at MCP020 070 or 48 VDC at MCP015 4 1 2 Operating behavior The characteristic curve force over speed is specified as a characteri...

Page 28: ...lication dependent and can be calculated via the duty factor ED Refer to Relative duty factor on page 28 The continuous nominal force FN is available up to nominal velocity vN The maximum velocity vmax is the maximum reachable motor velocity at ap propriate UDC up to approximately FN 0 N The reachable motor data are significantly dependent from the thermal coupling of the motor onto the machine po...

Page 29: ...or voltage depending from the travel velocity relating on velocity 1 m s Unit Vs m Winding resistance R12 at 20 C Measured winding resistance among two strands Unit Ω Winding inductivity L12 Measured winding inductivity among strand 1 and 2 This details are typical values which are determined with a measuring cur rent of 1 mA at a measuring frequency of 1 kHz Unit mH Winding inductivity L23 31 Mea...

Page 30: ...only then available if the continuous voltage of the drive controller is higher than the continuous nominal voltage of the motor Allowed ambient temperature TUM during operation Allowed ambient temperature Unit C Degree of protection Degree of protection according to DIN EN 60034 5 Temperature class Temperature class according to DIN EN 60034 1 RoHS conformity RoHS conformity according to EC guide...

Page 31: ...rt temperature See chapter 12 4 1 Notes about transport on page 156 TT C 20 80 Allowed storage temperature See chapter 12 4 2 Notes about storage on page 157 TL C 20 60 Temperature class according to DIN EN 60034 1 130 B Warning temperature winding See chapter 9 10 Motor temperature monitor ing on page 107 Twarn C 110 Shutdown temperature winding See chapter 9 10 Motor temperature monitor ing on p...

Page 32: ... vN m min 430 480 Force constant KFN N A 6 0 5 6 Voltage constant KEMK Vs m 3 6 3 2 Winding resistance at 20 C R12 Ohm 5 3 2 7 Winding inductivity L12 mH 0 56 0 25 Winding inductivity L23 31 mH 0 56 0 25 Rated power loss PVN W 23 9 55 2 Pole width tp mm 8 25 Thermal time constant Tth min 0 6 Primary part mass mP kg 0 050 0 075 Latest amendment 2014 08 19 Tab 4 2 MCP015 Technical data 4 3 2 Data sh...

Page 33: ...ame size 015 Fig 4 4 Motor characteristic curve MCP015A L040 at 48 VDC Fig 4 5 Motor characteristic curve MCP015B L040 at 48 VDC DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 31 193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data ...

Page 34: ...410 Force constant KFN N A 32 5 18 6 32 0 17 8 30 1 16 0 Voltage constant KEMK Vs m 18 8 10 7 18 5 10 3 17 4 9 2 Winding resistance at 20 C R12 Ohm 40 5 13 3 28 8 8 18 5 5 Winding inductivity L12 mH 4 4 1 5 2 9 0 9 1 9 0 6 Winding inductivity L23 31 mH 6 6 2 2 4 3 1 3 2 7 0 9 Rated power loss PVN W 51 8 52 1 94 5 85 1 129 8 134 6 Pole width tp mm 15 00 Thermal time constant Tth min 1 7 1 9 2 1 Pri...

Page 35: ... frame size 020 Fig 4 6 Motor characteristic curves MCP020B at 300 VDC Fig 4 7 Motor characteristic curves MCP020C at 300 VDC DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 33 193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data ...

Page 36: ...Fig 4 8 Motor characteristic curves MCP020D at 300 VDC Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 34 193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data ...

Page 37: ...rce constant KFN N A 36 9 30 0 41 1 30 8 42 0 30 0 Voltage constant KEMK Vs m 21 3 17 3 23 7 17 8 24 2 17 3 Winding resistance at 20 C R12 Ohm 27 14 6 20 10 6 14 7 9 Winding inductivity L12 mH 10 1 5 6 7 5 4 19 5 56 2 9 Winding inductivity L23 31 mH 16 2 9 1 11 6 6 16 8 17 4 7 Rated power loss PVN W 91 1 74 6 129 4 121 9 174 8 193 3 Pole width tp mm 30 00 Thermal time constant Tth min 2 2 2 4 2 6 ...

Page 38: ... frame size 030 Fig 4 9 Motor characteristic curve MCP030B at 300 VDC Fig 4 10 Motor characteristic curve MCP030C at 300 VDC Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 36 193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data ...

Page 39: ...Fig 4 11 Motor characteristic curve MCP030D at 300 VDC DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 37 193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data ...

Page 40: ...constant KEMK Vs m 35 1 22 2 36 7 21 5 Winding resistance at 20 C R12 Ohm 30 11 4 22 7 4 Winding inductivity L12 mH 14 6 5 6 10 8 3 7 Winding inductivity L23 31 mH 22 6 8 9 15 9 5 6 Rated power loss PVN W 86 3 82 2 127 0 124 3 Pole width tp mm 30 00 Thermal time constant Tth min 2 3 2 4 Primary part mass mP kg 0 56 0 81 Latest amendment 2013 07 03 Tab 4 8 MCP040B C Technical data Parameter Symbol ...

Page 41: ...1 6 Winding inductivity L23 31 mH 9 5 3 5 7 2 4 Rated power loss PVN W 213 3 220 6 294 7 287 1 Pole width tp mm 30 00 Thermal time constant Tth min 2 6 2 8 Primary part mass mP kg 1 26 1 71 Latest amendment 2013 07 03 Tab 4 9 MCP040E G Technical data 4 6 2 Data sheet MCS040 Designation Symbol Unit MCS040 __ 0120 MCS040 __ 0180 MCS040 __ 0300 Secondary part mass mS kg 1 3 1 9 3 2 Latest amendment 2...

Page 42: ... frame size 040 Fig 4 12 Motor characteristic curve MCP040B at 300 VDC Fig 4 13 Motor characteristic curve MCP040C at 300 VDC Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 40 193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data ...

Page 43: ... Motor characteristic curve MCP040E at 300 VDC Fig 4 15 Motor characteristic curve MCP040G at 300 VDC DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 41 193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data ...

Page 44: ...tage constant KEMK Vs m 56 4 24 3 59 0 25 8 Winding resistance at 20 C R12 Ohm 15 7 3 03 13 2 2 94 Winding inductivity L12 mH 12 2 3 10 2 Winding inductivity L23 31 mH 17 1 3 3 14 1 2 9 Rated power loss PVN W 151 8 157 4 206 7 240 5 Pole width tp mm 30 00 Thermal time constant Tth min 3 0 4 0 Primary part mass mP kg 1 50 1 95 Latest amendment 2013 07 03 Tab 4 11 MCP070C D Technical data Parameter ...

Page 45: ...2 Winding inductivity L23 31 mH 7 8 1 94 3 92 1 23 Rated power loss PVN W 317 0 355 9 614 8 615 4 Pole width tp mm 30 00 Thermal time constant Tth min 5 0 3 1 3 3 Primary part mass mP kg 2 85 5 9 Latest amendment 2014 10 22 Tab 4 12 MCP070F M Technical data 4 7 2 Data sheet MCS070 Designation Symbol Unit MCS070 __ 0120 MCS070 __ 0180 MCS070 __ 0300 Secondary part mass mS kg 3 0 4 5 7 4 Latest amen...

Page 46: ... frame size 070 Fig 4 16 Motor characteristic curve MCP070C at 300 VDC Fig 4 17 Motor characteristic curve MCP070D at 300 VDC Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 44 193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data ...

Page 47: ... Motor characteristic curve MCP070F at 300 VDC Fig 4 19 Motor characteristic curve MCP070M at 300 VDC DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 45 193 Rexroth IndraDyn L Ironless Linear Motors MCL Technical data ...

Page 48: ...Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 46 193 Rexroth IndraDyn L Ironless Linear Motors MCL ...

Page 49: ...from weight attractive forces and process forces must be taken into account The specified installation dimensions with the corresponding toler ances must be kept by the user over the complete travel path Due to an undersized air gap the primary part can have contact with the secondary part and can therewith damage or destroy mo tor components For the installation of the motors into the machine str...

Page 50: ... Motor width MCP B MCS C 015 51 mm 13 5 mm 14 8 mm Tolerance details see motor dimension sheet Tab 5 1 Mounting sizes and tolerances MCL0150 Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 48 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 51: ...m 070 124 0 mm 49 2 mm 49 5 mm Tolerance details see motor dimension sheet Tab 5 2 Mounting sizes and tolerances MCL020 070 The specified installation dimensions with the corresponding toler ances must be kept by the user over the complete travel path DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 49 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 52: ... the primary part and the secondary part in the machine are strictly done according to the dimensions of the particular dimension sheet The alignment of the motor components must be done according to fig 5 1 Parallelism and symmetry between primary and secondary parts on page 50 You will find further notes regarding assembly of primary and secondary parts in the chapter chapter 13 Installation on ...

Page 53: ...DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 51 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 54: ...5 2 Dimension sheets MCL015 Fig 5 2 Dimension sheet primary part MCP015 Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 52 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 55: ...Fig 5 3 Dimension sheet secondary part MCP015 DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 53 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 56: ...5 3 Dimension sheets MCL020 Fig 5 4 Dimension sheet primary part MCP020 Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 54 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 57: ...Fig 5 5 Dimension sheet secondary part MCS020 DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 55 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 58: ...5 4 Dimension sheets MCL030 Fig 5 6 Dimension sheet primary part MCP030 Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 56 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 59: ...Fig 5 7 Dimension sheet secondary part MCS030 DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 57 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 60: ...5 5 Dimension sheets MCL040 Fig 5 8 Dimension sheet primary part MCP040 Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 58 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 61: ...Fig 5 9 Dimension sheet secondary part MCS040 DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 59 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 62: ...5 6 Dimension sheets MCL070 Fig 5 10 Dimension sheet primary part MCP040 Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 60 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 63: ...Fig 5 11 Dimension sheet secondary part MCS070 DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 61 193 Rexroth IndraDyn L Ironless Linear Motors MCL Dimension sheets ...

Page 64: ...Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 62 193 Rexroth IndraDyn L Ironless Linear Motors MCL ...

Page 65: ...ponents e g for orders is made possible The following description gives an overview over the separate columns of the type code abbrev column and its meaning When selecting a product always consider the detailed specifica tions in the chapter chapter 4 Technical data on page 25 and chapter chapter 9 Application and construction instructions on page 97 6 1 2 Type code primary part MCP General inform...

Page 66: ... is described by the letters T and I Hall unit Short text columns 1718 Primary parts of size 020 up to 070 can be optionally fitted with a Hall unit for position detection Depending from the frame size the following Hall units with different output signals are available L1 analog L0 digital N0 none The cable output direction of the Hall unit is performed to the same front side as for the power con...

Page 67: ... fastening of the secondry part with screws Mechanical Protection Short text column 9 To ensure the best possible operational reliability the permanent magnets of the secondary part are protected against outer influences like corrosion by coating Therefore no additional cover for specified environmental conditions is necessary Segment Length Abbrev column 11 12 13 14 Depending from the motor frame...

Page 68: ...6 2 Type code frame size 015 Fig 6 3 Type code MCP015 primary part Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 66 193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes ...

Page 69: ...Fig 6 4 Type code MCS015 secondary part DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 67 193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes ...

Page 70: ...6 3 Type code frame size 020 Fig 6 5 Type code MCP020 primary part Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 68 193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes ...

Page 71: ...Fig 6 6 Type code MCS020 secondary part DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 69 193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes ...

Page 72: ...6 4 Type code frame size 030 Fig 6 7 Type code MCP030 primary part Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 70 193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes ...

Page 73: ...Fig 6 8 Type code MCS030 secondary part DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 71 193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes ...

Page 74: ...6 5 Type code frame size 040 Fig 6 9 Type code MCP040 primary part Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 72 193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes ...

Page 75: ...Fig 6 10 Type code MCS040 secondary part DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 73 193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes ...

Page 76: ...6 6 Type code frame size 070 Fig 6 11 Type code MCP070 primary part Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 74 193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes ...

Page 77: ...Fig 6 12 Type code MCS070 secondary part DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 75 193 Rexroth IndraDyn L Ironless Linear Motors MCL Type codes ...

Page 78: ...Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 76 193 Rexroth IndraDyn L Ironless Linear Motors MCL ...

Page 79: ...nt is necessary The Hall unit offers special advantages for example at commutation of linear motors in Gantry arrangement on vertical axes in mechanical safe state which are not allowed to be driven during the commutation process for safety reasons 7 1 2 Hall unit functional princple The Hall unit analog or digital serves for motionless commutation of ironless linear motors in connection with an i...

Page 80: ...e secondary parts and is prepared on the lines according to Fig 7 1 The voltage supply is 7 20 V The voltage supply must ensure a current consumption of the Hall unit of minimum 40 mA Fig 7 1 Signal curve of an analog Hall unit Bosch Rexroth controllers use a voltage supply of 12 V for analog Hall units Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 78 193 Rexroth IndraDyn L Ironless Linear Motors MCL A...

Page 81: ... supply is 3 24 V The voltage supply must ensure a current consumption of the Hall unit of minimum 40 mA Fig 7 2 Signal curve of a digital Hall unit The signal height of the digital Hall unit is depending on the volt age supply of open collector switch Bosch Rexroth contoller use a voltage supply of 5 V DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 79 193 Rexroth IndraDyn L Ironless Linear Motors MCL A...

Page 82: ...ightening torque can damage the fastening thread of the Hall unit and can make it useless then Fig 7 3 Hall unit assembly disassembly 1 Loosen both fastening screws Store them until the new Hall unit must be fastened When loosing the fastening screws only use screws of the same design see Fig 7 1 2 Press the dummy or the Hall unit with the tool out of the installation space and remove it 3 Assembl...

Page 83: ...Drive Cs using a Hall unit adapter box SHL03 1 makes the use of a dig ital Hall unit and an incremental length measuring system possible at the same time The SHL03 1 adapter box joins signals of both components and merges them with the provided interface on the IndraDrive Cs A possible cabling with Rexroth cables is described under chapter 8 2 4 Connect digital Hall unit on page 93 7 2 2 Order des...

Page 84: ...Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 82 193 Rexroth IndraDyn L Ironless Linear Motors MCL ...

Page 85: ...able power on the primary part MCP Wire designation on power connection cable Designation MCP015 1 MCP020 070 1 U BN YE 1 BN YE V BK GN 2 BK GN W GY BU 3 GY BU PE not applicable GNYE TP not applicable 7 PK TP not applicable 8 WH GY Shield Shield Shield 1 Colors in brackets can be transitionally available Tab 8 1 Wire designation power on MCP primary parts Exceeding of voltage limits DANGER Prepare...

Page 86: ...es Basically we recommend to lead the con nection cable in fix installation to a junction provided by the customer like e g flange sockets or terminal boxes Flange socket or terminal boxes must also be fixed with the machine construction From this junction a suitable ad ditional power cable can be laid to supply power through the energy chains or the machine construction Avoid bending pulling and ...

Page 87: ...sembly connection cable on primary part Bosch Rexroth offers ready made power cables to connect MCP primary part on Rexroth controllers See also chapter 8 1 3 Connection Power on page 86 Mount the connection cable on the flange socket RLS1704 to connect the primary part with the power cable Available ready made power cables of Rexroth can be connected on these flange sockets The assignment of the ...

Page 88: ... adjusted to our products and their most different demands Please observe that ready made cables or cable systems of other manufacturers may not fulfill these demands completely Rexroth shall not be held responsible for resulting malfunction states or damage You can find additional information on the selection of power and encoder cables for Rexroth motors in documentation Rexroth Connection Cable...

Page 89: ...ower connection on drive controller Connection power cable in de pendence from primary part at parallel arrangement At parallel arrangement of primary parts the connection of the power wires of the connection cable on the drive controller depends from the direction of the cable output Observe the notes about connecting power wires under chapter Parallel arrangement on page 114 DOK MOTOR MCL PR05 E...

Page 90: ...on a drive controller the following possibili ties exist to assembly the motor cable Installation with two separate power cables Installation with a collective power cable with bigger cross section The power cables are described in the documentation Rexroth Connection Cables MNR R911322948 DE or R911322949 EN R911322948 DE or R911322949 EN Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 88 193 Rexroth In...

Page 91: ...cable If this installation method collective power cable is used bigger power wire cross section can be necessary Observe the current rating dependent from the nominal current of the motor when se lecting the power cable Drive controller Energy chain Junction Terminal boxes Motor 1 Motor 2 Fig 8 7 Parallel arrangement collective power cable DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 89 193 Rexroth I...

Page 92: ...res of the sen sor are protected by a protective foil at the connection cable Before connecting the sensor take measures regarding ESD protection ESD electrostatic discharge The used temperature sensors are double or reinforced in sulated according to DIN EN 50178 so separation exists ac cording to DIN EN 61800 5 1 8 2 2 Connection Hall unit Motors with Hall unit have an additional cable to connec...

Page 93: ... the Hall unit can be connected with the power cable via cable ties if the power cable is provided with a strain relief If a fixed in stallation is not possible provide the connection cable of the Hall unit with a strain relief for example see Fig 8 2 to protect the cable and the primary part from any damage e g cable break The Hall unit is a component that might by damaged by ESD For this reason ...

Page 94: ...ent of the connector depends on the Hall unit used digital or analog Connection cable Hall unit analog digital 1 12 V BN 12 V BN 2 A GY S1 YE 3 A YE 4 0V WH S2 GN 5 B PK 0V WH 6 B GN 7 8 S3 PK 9 Connector housing Outer shield Outer shield Tab 8 4 Connection assignment RGS0005 for Hall unit connection Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 92 193 Rexroth IndraDyn L Ironless Linear Motors MCL Conn...

Page 95: ... power cables max cable length 75 m RKG0049 Adapter box encoder evaluation on drive controller max ca ble length 75 m RKG0050 Digital Hall unit adapter box max cable length 30 m RKG0051 Length measuring system adapter box max cable lengths 75 m Fig 8 9 Connection overview MCP with digital Hall unit The total distance between drive controller and the head of the length measuring system and or the H...

Page 96: ...bserve further notes about the SHL03 1 adapter box in the documentaion DOK INDRV HCS01 PRxx xx P MNR R911322210 and under chapter 7 2 Hall unit adapter box SHL03 1 on page 81 8 3 Length measuring system The length measuring system is not in the scope of delivery of the motor and must be prepared and assembled by the maschine manufacturer see chapter 9 14 Length measuring system on page 119 Setting...

Page 97: ...k A negative 4 GND_Encoder Reference potential voltage supplies 5 B Track B positive 6 B Track B negative 7 n c 8 n c 9 R Reference track positive 10 R Reference track negative 11 VCC_Encoder 12 V Encoder supply 12 V 12 VCC_Encoder 5 V Envoder supply 5 V 13 n c 14 n c 15 Sense Feedback of reference potential Sense line Connector housing Outer shield Tab 8 5 Connection assignment to be done on RGS0...

Page 98: ...Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 96 193 Rexroth IndraDyn L Ironless Linear Motors MCL ...

Page 99: ...ction For force multiplication can be two or more primary parts mechanically cou pled arranged in line For further information see chapter 9 13 2 Several motors per axis on page 113 Only the primary and the secondary part s belong to the scope of delivery of the motor Linear guide and length scale as well as fur ther additional components have to be made available by the user 9 2 Motor design 9 2 ...

Page 100: ...condary part are nickel plated and the permanent magnets are coated with epoxy Permanent magnets Screwed secondary part body Fig 9 2 Secondary part MCS040 Available lengths secondary parts Secondary parts are available in different lengths Please also refer to the da ta in the type code underchapter Segment Length on page 65 Required length of the secondary parts The required length L of the secon...

Page 101: ...MCS020 MCP030 MCS030 MCP040 MCS040 MCP070 MCS070 Frame lengths Primary and secondary parts of one size are graduated additionally to differ net frame sizes The length designation of the primary part in the type code is done via code letters like A B C The length designation of the secondary part in the type code is given directly by the length in mm For detailed information about available frame s...

Page 102: ...s Celsius fH Height utilization factor h Installation altitude in meters Fig 9 5 Derating of ambient temperature installation altitude in operation Calculation of performance data in case the limits specified are exceeded Ambient temperature 40 C M0_red M0 fT Installation altitude 1 000 m M0_red M0 fH Ambient temperature 40 C and setup elevation 1 000 m M0_red M0 fT fH The details for the utilizat...

Page 103: ...hich our products are allowed to be used during operation Ob serve the detailed description of the classifications to take all of the factors which are specified in the particular class into account Allowed operation conditions Environmental factor Unit Value Air temperature C 5 401 Air humidity relative 5 95 Air humidity absolute g m 1 29 Max temperature change rate C min 0 5 Occurrence of salt m...

Page 104: ...tion of the motor may damage or destroy the motor components or result in personal in jury CAUTION The motors or components may only be used in environments where the de gree of protection specified is adequate 9 6 Acceptances and approvals 9 6 1 CE Sign Declaration of conformity Certificate of conformity certifying the structure of and the compliance with the valid EN standards and EC guidelines ...

Page 105: ...metallic implants must keep away from these motor parts Access to areas in which such drive components are moun ted and operated is not allowed for the named persons It is allowed after consulting a doctor only Keep magnetic data carriers credit cards check cards and identity cards with magnetic strips and all ferromagnetic parts away from magnetic fields It if forbidden to wear jewelry made of fe...

Page 106: ...rial necessary III 4 6 m 0 525 µT 5 25 mG Shipping only with pre approval of the responsible national au thority of the state of departure and the state of the airline Tab 9 4 Limit values of magnetic flow density for air freight 9 8 Noise emission The noise emission of synchronous linear drives can be compared with con ventional inverter operated feed drives Empirically it is dependent from the f...

Page 107: ...actor fT 1 39 Thermal time constant The temperature variation vs the time is determined by the produced power loss and the heat dissipation and storage capability of the motor The heat dissipation and storage capability of an electrical machine is combined in one variable specified as the thermal time constant The following figure Fig 9 8 shows a typical heating and cooling process of an electrica...

Page 108: ...er temperature ϑe can be estimated according to Pce Continuous power loss or average power loss over cycle dura tion in W see chapter 11 4 Determining the drive power on page 146 PvN Nominal power loss of the motor in W ϑemax Maximum final over temperature of the motor in K Feff Effective force in N from application Fdn Continuous nominal force of motor in N see motor data sheet Fig 9 10 Expected ...

Page 109: ... thermally overloaded despite the KTY only displays measuring values 110 C The exclusive use of the KTY for temperature monitoring means no sufficient motor protection for the primary parts A possible form of an additional motor protection is to limit the motor current to 87 of the nominal current at low velocity 1 m min or at movement via a short traverse path 2 tP The Rexroth IndraDrive control ...

Page 110: ... in the end position range of an axis it can be necessary that the primary part moves beyond the end of the secondary part This results in a partial coverage between primary and secondary part If primary and secondary part are only partially covered a reduced feed force and attractive force results Inserted force reduction Outside the beginning and end areas sR1 or sR2 the force is reduced linearl...

Page 111: ...hich is normally without analysis of the Hall unit the primary part can be operated as described under with out Hall unit Tab 9 6 Partial coverage vs installation position The partial coverage of primary and secondary parts must not be used in continuous operation since there is an increased current consumption of the motor due to control strategies Instabilities in the control loop can be expec t...

Page 112: ... required higher mechanical natural frequencies of the machine structure in order to avoid the excitation of vibrations To ensure a sufficient control quality the lowest natural frequency that occurs inside the axis should not be less than approximately 200 Hz The natural fre quencies of axes with masses that are not constantly moving e g due to work pieces that must be machined differently change...

Page 113: ...the machine base in N µm Fig 9 15 Calculation example of the machine base deformation Integrating the linear scale The rigidity of the length measuring system integration is particularly impor tant For explanations refer to chapter 9 14 Length measuring system on page 119 DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 111 193 Rexroth IndraDyn L Ironless Linear Motors MCL Application and construction ins...

Page 114: ...es can arise which can cause a motor dam age Grinding traces and or scratch formation on the motor components can lead for example to destroying of casting compound on the primary part to motor breakdown due to high mechanical force effect Please observe that dirt can also be brought indirectly into via preasure air or due to other machine parts e g grease of the guides This must be preven ted Mak...

Page 115: ...zed utilization of available installation space Fig 9 18 Arrangement of several motors per axis Depending on the application the motors can be controlled in two different ways Two motors at one drive controller and one linear scale parallel ar rangement Two motors at two drive controllers and two linear scales Gantry ar rangement DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 113 193 Rexroth IndraDyn L ...

Page 116: ...ry parts 1 mm in feed direction Position offset between the secondary parts 1 mm in feed direction If possible load stationary and arranged symmetrically with respect to the motors The determination of the distance that must be adhered depends on the di rection of the cable entry and the permissible bending radius of the power ca ble Cable outlet in the same direction If the primary parts are arra...

Page 117: ...chnical data on page 25 Fig 9 21 Determining the distance between the primary parts with cable entries in the same direction Minimum distances between pri mary parts According to Fig 9 20 and Fig 9 21 result size related minimum distances between the primary parts at a motor arrangement with cable output into the same direction xp Required grid spacing between the primary parts in mm n Integer fac...

Page 118: ...primary part 1 according to Fig 9 23 is always the reference motor that is used for determining the encoder polarity and for commutation setting xP Required disctance between the front faces of the primary parts in mm n Integer factor depends on mounting distance τP Pole width see chapter 4 Technical data on page 25 xpmin Smallest allowed distance between the primary parts Fig 9 24 Determining the...

Page 119: ... part 1 according to Fig 9 25 is always the reference motor that is used for determining the sensor polarity and for commutation setting xP Required grid spacing between the primary parts in mm n Integer factor depends on mounting distance τP Pole width see chapter 4 Technical data on page 25 xpmin Smallest allowed distance between the primary parts Fig 9 26 Determining the grid distance between p...

Page 120: ...er and by a drive internal axis error com pensation Arrangement of primary parts in a row Gantry Primary parts can be arranged in feed direction even in a row mechanically coupled Control unit Controller 2 pcs Length measuring system 2 pcs Fig 9 28 Gantry arrangement primary parts in a row 9 13 3 Arrangement of secondary parts During assembly you must not heed the arrangement of the secondary part...

Page 121: ... requirements are placed upon the linear scale and its mechanical connection The linear scale serves for high resolution position sensing and to determine the current speed The necessary length measuring system is not in the scope of de livery of Bosch Rexroth and has to be provided and mounted from the machine manufacturer himself tab 9 10 Manufacturers of length measuring systems on page 120 Fig...

Page 122: ...Pliezhausen Germany http www renishaw de SIKO GmbH Weihermattenweg 2 79256 Buchenbach Germany info siko de http www siko de NUMERIK JENA GmbH Ilmstraße 4 07743 Jena Deutschland applikation numerikjena de http www numerikjena de SICK AG Erwin Sick Straße 1 79183 Waldkirch Germany http www sick com AMO Automatisierung Mes stechnik Optik GmbH NÖFING 4 A 4963 ST PETER AM HART office amo at http www am...

Page 123: ...iding systems Linear guiding systems are not in the scope of delivery of the mo tor and must be ordered separately The selection of a suitable linear guiding system is in the sole responibility of the machine manufacturer When selecting linear measuring systems please observe that this system uses sinusoidal instead of rectangular output signals With sinusoidal output signals a significantly high ...

Page 124: ...g of motor components Using a suitable end stop shock absorber the maximum permissible deceleration for moving against an end stop must be limited to 250 m s The necessary spring excursion of the shock absorbers must be taken into account when the end position shock ab sorber are integrated into the machine in particular when the total travel path is determined 9 19 Axis cover systems Depending on...

Page 125: ...Dyn L motors different digital drive controllers and power supply modules are available see chapter 10 Motor controller combina tions on page 129 9 20 3 Control systems A master control is required for generating defined movements Depending on the functionality of the whole machine and the used control systems Bosch Rexroth offers different control systems DOK MOTOR MCL PR05 EN P Bosch Rexroth AG ...

Page 126: ...eath serious injuries or damage to equip ment may result from an uncontrolled coast ing of a switched off linear drive WARNING Construction and design according to the safety standards Protection of people by suitable barriers and enclosures Using external mechanical braking facilities Use suitable energy absorbing end position shock absorber The parameter values of the drive response to interface...

Page 127: ...r With an undelayed power shutdown the drive coasts in an uncontrolled way once the DC bus energy has been used up 9 21 4 Deactivation via mechanical braking device Shutdown by mechanical braking devices should be activated simultaneously with switching off the power at the power supply module Integration into the holding brake control of the drive controllers is possible too The following must be...

Page 128: ...dd Required additional DC bus capacitor in mF m Moved mass in kg vmax Maximum velocity in m s UDCmax Maximum DC bus voltage in V UDCmin Minimum DC bus voltage in V Fmax Maximum braking force of the motor in N kiF Motor constant force constant in N A R12 Winding resistance at 20 C FR Frictional force in N Fig 9 31 Determining the required additional DC bus capacitor Prerequisites final velocity 0 v...

Page 129: ...output signals The length of such a sine signal is known as the signal period It is mainly specified in mm or µm With the drive controllers from Bosch Rexroth the sine signals are amplified again in the drive see Fig 9 33 The drive internal amplification also de pends on the maximum travel area and the signal period of the length meas uring system It always employs 2n vertices e g 2048 or 4096 fin...

Page 130: ...ernal position resolution Δxabs Position accuracy Fig 9 35 Estimating the reachable position accuracy Prerequisites Optimum controller setting The expected position accuracy cannot be better than the small est position command increment of the superordinate control 9 22 2 Velocity resolution The resolution of the velocity is proportional to the position resolution see fig 9 34 Drive internal posit...

Page 131: ...eeding of voltage limits DANGER Prepare a suitable connection with a protective switch via the primary part carrier when using AC voltage 50 V or DC 120 V DIN IEC 60364 4 41 10 2 Motor controller combinations with NYCe 4000 NYCe 4120 NYCe 4140 48 V 72 V 150 V MCP015A L040 MCP015B L040 MCP020x Vxxx x x MCP030x Vxxx x x MCP040x Vxxx x x MCP070x Vxxx x x Optimal combination x Allowed combination redu...

Page 132: ... x 030C V180 030C V390 x 030D V180 030D V390 x MCP040 040B V070 040B V300 040C V070 x 040C V300 040E V070 040E V300 x x 040G V070 040G V300 MCP070 070C V050 x 070C V300 x x 070D V050 070D V300 070F V050 x x 070F V300 x 070M V050 x 070M V230 x optimal combination allowed combination x allowed combination but maximum force reduces as control ler is under dimensioned Tab 10 2 Motor controller combina...

Page 133: ...y the application related profiles of velocity feed force and the thermal connection The basic sequence of sizing linear drives is shown in the figure below Fig 11 1 Basic procedure of sizing linear drives DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 131 193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning ...

Page 134: ...ss or machining force in N Feff Effective force in N vavg Average velocity in m s t Time in s T Total time in s Fig 11 2 General equations of motion In most cases the mathematical description of the required positions vs the time is known NC program electronic cam disk Using the preparatory func tion velocity acceleration and forces can be calculated Standard software such as MS Excel or MathCad c...

Page 135: ...N FP Processing force in N l Acceleration in m s m Moved mass in kg g Gravitational acceleration 9 81 m s α Axis angel in degrees 0 horizontal axis 90 C vertical axis fCB Weight compensation in tall Total duty cycle time in s FATT Attractive force between primary and secondary part in N µ Friction coefficient Fig 11 4 Determining the feed forces DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 133 193 Rex...

Page 136: ...he moved mass is only noted after successfull motor selection Thus first make assump tions for these variables and verify these values after the motor has been selected Fig 11 5 Determining the resulting feed forces according to motion type and di rection Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 134 193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning ...

Page 137: ... Determining the resulting feed forces according to motion type and di rection With horizontal axis arrangement the weight is FW 0 Further directional base and process forces must be taken into account DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 135 193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning ...

Page 138: ...pezoidal velocity profile vavgi Average velocity for a velocity segment of the duration ti in m s va Initial velocity of the velocity segment in m s ve Final velocity of the velocity segment in m s vavg Average velocity over total duty cycle time in m s ti Duration of velocity segment in s tall Total duty cycle time including breaks and or standstill time in s Fig 11 8 Determining the average velo...

Page 139: ...Trapezoidal velocity profile To determine the respective parameters acceleration a velocity v path s and time t for the trapezoidal drive do a case differentiation regarding velocity Initial velocity va 0 or va 0 Final velocity ve 0 or ve 0 Acceleration initial velocity va 0 Velocity v constant Initial velocity va 0 Acceleration a constant and positive DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 137 ...

Page 140: ...11 10 Constantly accelerated movement initial velocity va 0 for trapezoidal velocity profile Acceleration initial velocity va 0 Velocity v constant Initial velocity va 0 Acceleration a constant and positive Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 138 193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning ...

Page 141: ...Constant velocity Velocity v constant Acceleration a 0 vc Average velocity in m s tc Time during constant velocity in s sc Travel covered constant velocity in m Fig 11 12 Constant velocity for trapezoidal velocity profile Braking final velocity ve 0 Velocity v constant Final velocity ve 0 Acceleration a constant and negative DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 139 193 Rexroth IndraDyn L Ironl...

Page 142: ...g 11 13 Constantly accelerated movement initial velocity ve 0 for trapezoidal velocity profile Braking final velocity ve 0 Velocity v constant Final velocity ve 0 Acceleration a constant and negative Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 140 193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning ...

Page 143: ...shaped velocity profile In contrast to the trapezoidal characteristic this velocity profile does not have a phase of constant velocity The acceleration phase is immediately followed by the deceleration phase This characteristic can frequently be found in con junction with movements of short strokes Fig 11 15 Triangular velocity profile DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 141 193 Rexroth Indra...

Page 144: ...ts for example from the circular interplation of two axes circular movement or the oscillating movement of one axis grinding for example The specified variables are chiefly the motion travel s or the circle diameter 2r and the period T Fig 11 17 Insert motion profiles of an axis at sinusoidal velocity Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 142 193 Rexroth IndraDyn L Ironless Linear Motors MCL Mo...

Page 145: ...rmula for motion profiles of an axis at sinusoidal velocity The following calculation bases on fig 11 17 Insert motion profiles of an axis at sinusoidal velocity on page 142 and fig 11 18 Calculation formula for motion profiles of an axis at sinusoidal velocity on page 143 DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 143 193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensioning ...

Page 146: ...in N FEFFv Effektive force at vertical or inclined axis arrangement in N F0 Base force e g frictional force in N FW Force due to weight in N Fig 11 19 Calculation formulae for sinusoidal velocity profile Further directional base and process forces must additionally be taken into account Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 144 193 Rexroth IndraDyn L Ironless Linear Motors MCL Motor dimensionin...

Page 147: ...e duty cycle Due to the linear correlation of force and current the detection of relative duty cycle EDideal happens via the correlation EDideal Cyclic duration factor in FEFF Effective force or rated force in N FMAX Maximum feed force Fig 11 21 Approximate determination of duty cycle ED Use fig 11 22 Determining the duty cycle ED on page 145 to determine the possible relative duty cycle EDreal Po...

Page 148: ...cal and electrical motor power Pc Rated power in W Pcm Mechanical rated output in W PV Electrical continuous power loss of motor in W Feff Effective force in N from application vavg Average velocity in m s FN Rated force of the motor in N see Chapter 4 Technical data PVN Rated power loss of the motor in W see Chapter 4 Technical data Fig 11 23 Rated power of the linear motor The rated electrical o...

Page 149: ...r of the linear motor When the maximum feed force is reduced against the achievable maximum force of the motor the electrical maximum output Pmaxe is reduced too To determine the reduced electrical maximum output Pmaxe use fig 11 25 Diagram used for determining the re duced electrical power loss on page 147 Fmax Maximum force of the motor in N F Maximum force application in N Pvmax Maximum power l...

Page 150: ...inear drive results from the ener gy balance during the deceleration process To size additional brake resistors or power supply units with feedback capability it can be estimated as follows PR Regeneration energy during a deceleration phase in W PRavg Average regeneration energy over total duty cycle time in W m Moved mass in kg v Maximum velocity in m s tb Braking time in s FR Frictional force in...

Page 151: ...icantely defined by the utilization capacity of the motor The motor performance depends from as good as or as fast as the power loss can be dissipated If the existing power loss of the motor cannot be sufficiently dissipated via the natural convection the heat introduction via the screw on surfaces into the machine construction increases A very good heat dissipation is reached if the screw on surf...

Page 152: ...ossibility of the motor components when dimensioning the machine Only then a pow er loss of the motor via adjacent machine parts can be guaren teed optimally The following details should help to estimate the reachable motor power data in dependence of the thermal connection of the motor The figured installation modes can be selected and observed at motor controller dimensioning in In draSize and a...

Page 153: ... the machine Technical data for this installation mode are specified in chapter 4 Technical data on page 25 C Installation mode C assumes that a motor component either primary or secondary part is thermally isolated and other components must be well dissipating connected onto the machine In this case reckon with a re duced output of the motor due to moderate possibility of heat dissipation of this...

Page 154: ...ed and thermally damaged Also refer to chapter 9 10 Motor temperature monitoring on page 107 The peak value of the instan taneous current is equal with the amplitude of the sinusoidal assumed phase current Its value is higher by root 2 than the effective value of the continuous current IN The power loss PV created in the coil is calculated with Δθ Temperature difference between operation temperatu...

Page 155: ...part and can be fixed on the machine or used be used elsewhere by the user 1 Motor type 2 Type designation 3 Designation of origin 4 UL sign 5 Factory number 6 Mass of primary part 7 CE sign 8 Rated power 9 Maximum input voltage 10 Company address 11 Insulation system 12 Thermal temperature class 13 Protection class by housing 14 Production date 15 Pole graduation 16 Rated current 17 Serial number...

Page 156: ...and can be fixed on the machine or used be used elsewhere by the user 1 Motor type 2 Type designation 3 Designation of origin 4 UL mark 5 Factory number 6 Secundary part mass 7 CE sign 8 Maximum input voltage 9 Company address 10 Insulation system 11 Thermal temperature class 12 Protection class by housing 13 Production date 14 Serial number 15 Rexroth bar code 16 Part number Fig 12 4 Example of a...

Page 157: ... secondary parts The self sticking warning label sizes approx 110 mm x 150 mm can be ordered from Rexroth MNR R911278745 12 3 Checking the motor components 12 3 1 Factory checks of the motor components Electrical inspections The Bosch Rexroth linear motors undergo the following electrical checks at the factory HIgh voltage test according to DIN EN 60034 1 Insulation resistance test acc to DIN EN 6...

Page 158: ... 3 2 the tables below specify classifications and lim it values which are allowed for our products while they are transported by land sea or air Observe the detailed description of the classifications to take all of the factors which are specified in the particular class into account Allowed classes of ambient conditions during transport acc to DIN EN 60721 3 2 Classification type Allowed class Cl...

Page 159: ... 3 1 the tables below specify classifications and lim it values which are allowed for our products while they are stored Observe the detailed description of the classifications to take all of the factors which are specified in the particular classification into account Allowed classes of ambient conditions during transport acc to DIN EN 60721 3 1 Classification type Class Classification of climati...

Page 160: ...nty claims Motors Storage time Measures for commissioning 1 year Visual inspection of all parts to be damage free Check the electric contacts to verify that they are free from corrosion 1 5 years 5 years Tab 12 5 Measures before commissioning motors that have been stored over a prolonged period of time Cables and connectors Storage time Measures before commissioning 1 year None 1 5 years Check the...

Page 161: ...for assembly of the motor components Basically is no limitation regarding motor component arrangement It can be an advantage to mount the secondary part sidewards seefig 13 1 Arrange ment of motor components in pre finished compact module CKL of Rexroth on page 159 or to the bottom that no dirt procedding residues a s o can fall from above into the air gap between primary and secondary part In thi...

Page 162: ...First assemble the primary part and then the secondary part s 13 4 Air gap parallelism and symmetry of the motor components Parallelism and symmetry When mounting primary and secondary parts their position is specified by the holes or threads within the machine slide and within the machine bed see Due to the clearance which exists within the holes of the screw connections the motor components must...

Page 163: ...dies in this area could damage the primary or secon dary part at the first traverse of the motor components For safety reasons the user or machine manufacturer is NOT allowed to dismount the secondary part in its separate parts To fasten the secondary parts it is only allowed to use new unused screws All screws must be tightened with the specified tigthening torque after adjusting the secondary pa...

Page 164: ...m 040 6 4 mm M6 10 4 Nm 070 8 5 mm M8 25 Nm Tab 13 1 Fastening mode variant 1 with tightening torques for MCS Fastening type variant 2 Secondary part MCS Thread di ameter with in secondary part Maximum screw in depth Bolt size ISO grade DIN EN ISO 4762 Property class Tightening torque 10 Variant 2 015 M4 9 mm M4 8 8 3 1 Nm 020 M5 9 mm M5 6 1 Nm 030 M5 9 mm M5 6 1 Nm 040 M6 11 mm M6 10 4 Nm 070 M8 ...

Page 165: ...CP Bolt size ISO grade DIN EN ISO 4762 Screw in depth Property class Tightening torque 10 Variant 1 Variant 2 015 M3 see chapter chapter 5 Dimension sheets on page 47 8 8 1 3 Nm 020 M4 3 1 Nm 030 040 070 M6 10 4 Nm Tab 13 3 Tightening torque for the fastening screws of the primary parts The screw on surfaces and stop faces must be cleaned and be free of grease before the primary parts can be screw...

Page 166: ...ion technique on page 83 Observe the references to supplementary documentation When using self manufactured cables ensure EMC compli ant design and installation Where applicable ensure that connectors and lines are fas tened for strain relief purposes The connection diagrams of the product documentation serve to create system circuit diagrams The drive compo nents must be connected in the machine ...

Page 167: ...not available for direct drives with linear motors The moved foreign mass is independent from the motor self mass Encoder polarity The polarity of the actual speed length measuring system must agree with the force polarity of the motor This connection has to be established before commutation adjustment Commutation adjustment It is necessary at synchronous linear motors to receive the position of t...

Page 168: ...l commissioning software The IndraWorks commissioning software al lows menu driven custom designed and motor specific parameterization and optimization PC When commissioning IndraWorks requires a commercial Windows PC Commissioning via NC Commissioning via the NC control unit requires access to all drive parame ters and functionalities Multimeter At troubleshooting and check of the components can ...

Page 169: ...Fig 14 1 General start up procedure at synchronous linear motors DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 167 193 Rexroth IndraDyn L Ironless Linear Motors MCL Commissioning operation and maintenance ...

Page 170: ...d WARNING Enter the parameters for the linear scale Check and adjust the measuring system polarity Adjust the commutation The motor parameters can be entered in the following way Use IndraWorks to load all the motor parameters Enter the individual parameters manually via the controller With series machines load a complete parameter record via the control ler or IndraWorks 14 4 3 Entering length me...

Page 171: ...etails of the measuring system manufacturer regarding resolution of encoder signals 14 4 4 Entering drive limitations and application related parameters Drive limitations The possible selectable drive limitations include Current limitation Force limitation Velocity limitations Travel range limitations Application related parameters Application related drive parameters include for example parameter...

Page 172: ...ive direction of motor force To set the correct sensor polarity The effective direction of the motor force is always positive in the direction of the cable connection of the primary part Force direction Fig 14 2 Effective direction of motor force Effective direction motor force linear scale count direction When the primary part is moved in the direction of the cable connection the count direction ...

Page 173: ...and constant force development of the synchronous linear motor Commutation adjustment must always be performed in the follow ing cases Initial start up After the mechanical attachment of the length measuring sys tem has been modified Replacement of the linear scale Modification of the mechanical attachment of the primary and or secondary part This procedure ensures that the angle between the curre...

Page 174: ...velocity control loops Correctly connect the motor power cable Ensure protection against uncontrolled movements Errors in commutation adjustment may result in malfunctions and or uncontrolled move ments of the motor DANGER Do the commuation adjustment very carefully Please observe the detailed notes about commutation in the documentation under chapter 14 4 3 Enter ing length measuring system param...

Page 175: ... MPx xx Funktionsbeschreibung MNR R911328670 Rexroth IndraDrive MPx xx Parameter description MNR R911326767 14 6 3 Hall sensor procedure The Hall sensor procedure is used when an incremental measuring system in connection with a Hall unit within the primary part is operated Please also observe the information about the Hall unit provided in chapter 7 1 Hall unit on page 77 Commutation via analog H...

Page 176: ...y an exactness of 30 is electrically reached Thereby reckon with a maximum power loss of 14 The Reference point optimal commutation offset must be prepared that the maximum motor force is available Procedure on IndraDrive Cs 1 Activate initial commissioning mode P 0 0522 Bit 15 2 Do the commutation adjustment via sinusoidal procedure 3 Switch axis in AF 4 Start fine commutation 5 Activate referenc...

Page 177: ...The input value for P 0 0523 that is required for calculating the commutation offset is determined from the measured relativce position of the primary part with respect to the secondary part Fig 14 5 distance d e f or g depending on accessibility and a motor related constant kmx see Fig 14 6 und Fig 14 5 P 0 0523 Commutation adjustment measured value in mm l Relative position reference point in mm...

Page 178: ...fset is calculated in this step If the drive is in command start AB drive ready for operation the commuation offset with the selected procedure saturation or sinuisoidal procedure is determined for automatic commutation The command must subsequently be cleared 14 7 Setting and optimizing the control loop 14 7 1 General procedure The control loop settings in a digital drive controller have an essen...

Page 179: ...brations Digital drives from Rexroth are able to provide a narrow band suppression of vibrations that are produced due to the power train between motor and me chanical axis system This results in increased drive dynamics with good sta bility The position or velocity feedback in the closed control loop excites the me chanical system of the slide that is moved by the linear drive to perform me chani...

Page 180: ...h closed loop operation without rejection filter This leads to an increased profile accuracy and shorter cycle times for posi tioning processes at a sufficient distance to the stability limit Rejection frequency and bandwidth of the filter can be selected The highest attenuation takes effect on the rejection frequency The bandwith defines the frequency range at which the attenuation is less than 3...

Page 181: ...ive controller for a description of the operational principle and the parameter settings Fig 14 9 Possible misalignment with the linear scale of a Gantry axes Parameter settings When using Gantry axes your must ensure that the parameter settings of the following parameters are identical Motor parameter Polarity parameters for force velocity and position Control loop parameters We have kv Position ...

Page 182: ...n and velocity control loop Tab 14 6 Parameterization of the velocity controller integral time S 0 0101 for Gantry axes Optimization The previously described procedure must be followed for optimizing the posi tion and velocity loop Any parameter modifications that are made during the optimiza tion of Gantry axes must always be made in both axes simultane ously If this is not possible the parameter...

Page 183: ...he moved axis mass on the basis of a recorded velocity ramp Prerequisites 1 Correct parameter settings of the rated motor current basis of representa tion S 0 0080 2 Frictional force not directional 3 Recording of Δv and Δt at constant acceleration 4 Do measuring with a motor force between FN and Fmax Due to possible direction related force variations this procedure cannot or only conditionally be...

Page 184: ...d by measuring electrical characteristics The following variables are relevant Resistance between motor connecting wires 1 2 2 3 and 1 3 Inductance between motor connecting wires 1 2 2 3 and 1 3 Insulation resistance between motor connecting wired and guides Resistance and inductance The measured values of resistance and inductance can be compared with the values specified in Chapter Technical Dat...

Page 185: ...e We regularly try to replace pollutant loaded raw materials and supplies by more environ ment friendly alternatives No release of hazardous substan ces Our products do not contain any hazardous substances which may be re leased in the case of appropriate use Normally our products will not have any negativ influences on the environment Significant components Basically our products contain the foll...

Page 186: ...e the batteries or accumulators contained in Rexroth products have to be properly disposed of according to the country specific collection Recycling Most of the products can be recycled due to their high content of metal In order to recycle the metal in the best possible way the products must be dis assembled into individual modules Metals contained in electric and electronic modules can also be r...

Page 187: ... Additional information on service repair e g delivery addresses and training can be found on our internet sites Service worldwide Outside Germany please contact your local service office first For hotline numbers refer to the sales office addresses on the internet Preparing information To be able to help you more quickly and efficiently please have the following information ready Detailed descrip...

Page 188: ...Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 186 193 Rexroth IndraDyn L Ironless Linear Motors MCL ...

Page 189: ...ter 168 Motor parameter 168 Requirements 165 Tools 166 Commutation 77 Commutation adjustment 165 171 Hall sensor procedure 173 Measuring principle 174 Sinusoidal procedure 173 Commutation offset angle 77 Connect Length measuring system 94 Connection 164 Analog Hall unit 94 Digital Hall unit 93 Hall unit 90 Power 86 Power connection 83 Temperature sensor 90 Connection assignment Connection cable Ha...

Page 190: ...orce density 8 Force generation 97 Force reduction 109 Forces Reactive forces 110 Foreign bodies 97 Frame length 64 99 Frame size 64 65 99 Friction 112 G Gantry arrangement 77 113 Gantry axes Parameterization and optimization 179 Gantry structure 110 Gantry arrangement 129 Grinding traces 112 Grounding 85 H Hall unit 8 64 77 90 Assembly 80 Disassembly 80 ESD protection 80 Installation space 80 Hal...

Page 191: ...ponent arrangement 159 Motor coupling 110 Motor damage 112 Motor design Primary part 97 Secondary part 98 Motor dimensioning 131 Average velocity 136 Feed forces 133 Movement equations 132 Sinusoidal velocity profile 142 Trapezoidal velocity profile 137 Triangle shaped velocity profile 141 Motor installation space 112 Motor parameter 168 Motor temperature monitoring 107 Motor variants 63 Motor win...

Page 192: ...nt length 65 Serial number MCP 153 Serial number MCS 154 Service hotline 185 Setting and optimizing the control loop 176 Setup elevation 100 SHL03 1 93 SHL03 1 adapter box 93 Shock absorber 122 Short circuit loss 104 Shutdown temperature 29 Significant components 183 Skeleton structures 110 Skilled personnel 159 Spare parts 63 Speed 26 Standards 11 Standstill operation 152 Start up Procedure 166 S...

Page 193: ...tical axes 77 Vertical axis 119 Vibrations 110 Voltage constant 27 W Warning temperature 29 Warnings 155 Weight compensation 119 Winding 64 Winding inductivity 27 Winding protection 90 Winding resistance 27 Winding temperature 104 107 Wire designation 83 Wire end ferrules 84 DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 191 193 Rexroth IndraDyn L Ironless Linear Motors MCL Index ...

Page 194: ...Notes Bosch Rexroth AG DOK MOTOR MCL PR05 EN P 192 193 Rexroth IndraDyn L Ironless Linear Motors MCL ...

Page 195: ...Notes DOK MOTOR MCL PR05 EN P Bosch Rexroth AG 193 193 Rexroth IndraDyn L Ironless Linear Motors MCL ...

Page 196: ...l Company Bosch Rexroth AG Electric Drives and Controls P O Box 13 57 97803 Lohr Germany Bgm Dr Nebel Str 2 97816 Lohr Germany Tel 49 9352 18 0 Fax 49 9352 18 8400 www boschrexroth com electrics DOK MOTOR MCL PR05 EN P ...

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