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404LXR Series Product Manual

Appendix A – Understanding Linear Motors

43

Appendix A – Understanding Linear Motors

The Linear Motor Concept

Linear Motors are basically a conventional rotary servo motor unwrapped. So now what
was the stator is now called a forcer and the rotor becomes a magnet rail. With this
design, the load is connected directly to the motor. No more need for a rotary to linear
transmission device.

Linear Motor Benefits

•

High speeds:

Only the bus voltage and the speed of the control electronics limit the maximum

speed of a linear motor. Typical speeds for linear motors are 3 meters per second with 1 micron
resolution and over 5 meters per second with courser resolution.

Note: Motors must be sized for specific loading conditions.

•

High Precision:

The feedback device controls the accuracy, resolution, and repeatability of a

linear motor driven device. And with the wide range of linear feedback devices available today,
resolution and accuracy are primarily limited to budget and control system bandwidth.

•

Fast Response:

The response rate of a linear motor driven device can be over 100 times

faster than some mechanical transmissions. This is simply because there is no mechanical
linkage. This means faster accelerations and settling times, thus more throughput.

•

Stiffness:

Because there is no mechanical linkage in a linear motor, increasing the stiffness is

simply a matter of gain and current. Thus the spring rate of a linear motor driven system can be
many times that of a ball screw driven device. However it must be noted that this is limited by
the motor’s peak force, the current available, and the resolution of the feedback.

•

Zero Backlash:

Since there are no mechanical components there is no backlash. There are

however, resolution considerations which effect the repeatability of the positioner (See Chapter
2,

General Table Specifications

, Chapter 3,

Setting Home Sensor

and

Z Channel Position

Reference

)

•

Maintenance Free Drive Train:

Because linear motors of today have no contacting parts, in

contrast with screw and belt driven positioners, there is no wear on the drive mechanism.

Slotless Linear Motor Design

The Linear Motor inside the 404LXR is a Slotless Linear Motor. The following will give a
brief description of the motor design and construction:

•

Construction:

Designed by the Compumotor and Daedal Divisions of Parker Hannifin, the

motor takes its operating principle from Parker’s slotless rotary motors which have grown
popular over the past few years. The magnetic rail is simply a flat iron plate with magnets
bonded to it. The forcer is unique. It begins with a coil and a “backiron” plate, which is placed
behind the coil. This assembly is placed inside an aluminum housing with an open bottom. The
housing is then filled with epoxy, securing the winding and “backiron” into the housing. The
thermal sensors and hall effect sensors are mounted to the housing.

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Содержание Daedal 400LXR Series

Страница 1: ...Manual No 100 5319 01 Rev 3 404LXR Series Product Manual Effective April 11 2003 Supersedes Electromechanical Positioning Systems Automation Daedal ...

Страница 2: ...d or used for any purpose not expressly authorized by the owner thereof Since Parker Hannifin Corporation Daedal Division constantly strives to improve all of its products we reserve the right to change this product manual and equipment mentioned therein at any time without notice For assistance contact Parker Hannifin Corporation Daedal Division 1140 Sandy Hill Road Irwin PA 15642 Phone 724 861 8...

Страница 3: ...24 MOUNTING METHODS 24 SIDE AND INVERTED MOUNTING CONCERNS 25 SETTING TRAVEL LIMIT SENSORS 25 SETTING HOME SENSOR 26 Z CHANNEL POSITION REFERENCE 26 GROUNDING SHIELDING 26 CABLING 27 CHAPTER 4 PERFORMANCE 28 ACCELERATION LIMITS 28 SPEED LIMITS 29 ENCODER ACCURACY AND SLOPE CORRECTION 29 THERMAL EFFECTS ON ACCURACY 31 THERMAL EFFECTS ON REPEATABILITY 32 CAUSES OF TEMPERATURE INCREASES 32 COMPENSATI...

Страница 4: ...404LXR Series Product Manual Revision Notes 4 Revision Notes Rev 3 April 11 2003 Correction for Motor Wire 4 Pin Mat N Lok p 21 Limit and Home Sensor Module Adjustment Switch positions corrected p 41 ...

Страница 5: ...ve the following guidelines for handling and mounting of your new positioner DO NOT allow the positioner to drop onto the mounting surface Dropping the positioner can generate impact loads that may result in flat spots on bearing surfaces or misalignment of drive components DO NOT drill holes into the positioner Drilling holes into the positioner can generate particles and machining forces that ma...

Страница 6: ...e too HOT to handle Electrical Shock DO NOT take apart or touch any internal components of the positioner while unit is plugged into an electrical outlet SHUT OFF power before replacing components to avoid electrical shock High Magnetic Field Unit may be HAZARDOUS to people with Pace Makers or any other magnetically sensitive medical devices Unit may have an effect on magnetically sensitive applic...

Страница 7: ...on of a standard unit before failure is 5 40 Degrees C Specifications are Mounting Surface Dependent Catalog specifications are obtained and measured when the positioner is fully supported bolted down to eliminate any extrusion deviation and is mounted to a work surface that has a maximum flatness error of 0 013mm 300mm 0 0005 ft Specifications are Point of Measurement Dependent Catalog specificat...

Страница 8: ...404LXR Series Product Manual Chapter 1 Introduction 8 Assembly Diagrams Strip Seal Version ...

Страница 9: ...404LXR Series Product Manual Chapter 1 Introduction 9 Hardcover Version ...

Страница 10: ...404LXR Series Product Manual Chapter 2 404LXR Series Table Specifications 10 Chapter 2 404LXR Series Table Specifications Order Number Nomenclature ...

Страница 11: ...404LXR Series Product Manual Chapter 2 404LXR Series Table Specifications 11 Dimensional Drawings ...

Страница 12: ... Continuous 50 N 11 lb Carriage Weight 1 4 kg Travel Dependent Specifications Accuracy Positional Travel mm 0 1 0 5 1 0 resolution um 5 0 resolution um Straightline Accuracy um Strip Seal Version Unit Weight kg Hard Cover Version Unit Weight kg 50 6 16 6 4 4 4 4 100 7 17 7 4 8 4 9 150 8 18 9 5 2 5 4 200 10 20 11 5 6 5 8 250 12 22 14 6 0 6 3 300 14 24 17 6 4 6 7 350 16 26 19 6 8 7 2 400 18 28 22 7 ...

Страница 13: ...IAGE LIFE VS LOAD 1000 10000 100000 1 3 5 7 9 11 13 15 17 19 21 23 25 28 30 32 34 36 38 40 42 44 46 48 50 LOAD KG LIFE KM NORMAL LOAD CONTINOUS 55 N NORMAL LOAD CONTINUOS 28 N SIDE LOAD CONTINUOS 55 N SIDE LOAD CONTINUOUS 28 N BEARING LIFE NORMAL LOAD 1000 10000 100000 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 NORMAL LOAD PER BEARING N BEARING LIFE KM 55 N CONTINOUS 28 N CONTINUOS Table L...

Страница 14: ... life if only 28 Newtons RMS is used d1 d2 da Strip Seal Model 108 5 60 0 48 5 Hardcover Model 108 5 60 0 53 5 BEARING LIFE SIDE LOAD 1000 10000 100000 10 20 30 40 50 60 70 80 SIDE LOAD PER BEARING N LIFE PER BEARING KM 55 N CONTINUOS 28 N CONTINOUS Side Bearing Load Chart The Side Bearing Load chart is to be used in conjunction with the corresponding formulas on the following pages to establish t...

Страница 15: ...404LXR Series Product Manual Chapter 2 404LXR Series Table Specifications 15 ...

Страница 16: ...5 mm db 130 mm d2 60 0 mm d3 50 mm da 48 5 mm d4 da db 178 5 9 14 2 2 4 4 3 d d L P P compression Kgf 8 4 2 4 1 3 3 1 d d L L P P s s 2 0 2 4 1 3 4 2 d d L L P P s s The normal and side force components on each bearing block are computed from the equations as shown Life for each bearing needs to be evaluated independently For bearings with a side load refer to the combined equivalent loading facto...

Страница 17: ...ns 17 404LXR Series Technical Data Force Speed Charts The chart on this page illustrates the characteristics of the 404LXR linear motor The force speed chart shows the characteristics of the motor with either a 170 VDC or 340 VDC bus voltage Peak Peak Continuous Continuous ...

Страница 18: ... which utilizes ULPA filters to produce an environment having a cleanliness of class 1 prior to testing Tables were tested in a variety of orientations with sampling both below the table and at the carriage mounting surface Laminar flow rate is 0 65 inches W C Standard Clean Room Preparation Stringent cleaning and handling measures Clean room rated lubricant Strip seal replaced with hard shell cov...

Страница 19: ...s applied 7 DC current through a pair of motor phases of a trapezoidal six state commutated motor 8 Peak of the sinusoidal current in any phase for a sinusoidal commutated motor 9 Total motor force per peak of the sinusoidal amps measured in any phase 10 10 Maximum time duration with 2 times rated current applied with initial winding temperature at 60 o C 11 Maximum time duration with 3 times rate...

Страница 20: ...en collector 300 mA sink capability 10V scalable 8 bit not to be used as control functions Normally open dry contact Communications Type Baud Rate Daisy Chain RS232 RS485 4 wire Fixed at 9600 Up to 98 Environmental Temperature Humidity Shock Vibration Still air 32o F 0o C 113o F 46o C moving air 32o F 0o C 122o F 50o C 0 95 non condensing Shock 15G half sign 11 msec vibration 2G 10 2000 Hz Protect...

Страница 21: ...404LXR Series Product Manual Chapter 2 404LXR Series Table Specifications 21 Cabling and Wiring Diagrams Connector Pin Out and Extension Cable Wire Color Codes ...

Страница 22: ...een Yellow 4 Shield Shield Shield Case Encoder Connections Function Cable Wire Color 404LXR High Density 15 Pin D Connector 5VDC Red 1 Ch A White 2 Ch A Yellow 3 Ch B Green 4 Ch B Blue 5 Ch Z Orange 6 Ch Z Brown 7 Ground Black 8 5 VDC Hall White Blue 9 Hall 1 White Brown 10 Hall 2 White Orange 11 Hall 3 White Violet 12 Temp Yellow Orange 13 Temp Yellow Orange 14 Ground White Green 15 Shield Green ...

Страница 23: ...D Ground Black E Shield Shield Shield Case Auxiliary Connections Function Cable Wire Color 404LXR Connector Female 9 Pin D Connector User Defined Red 1 User Defined Blue 2 User Defined White 3 User Defined Yellow 4 User Defined Orange 5 User Defined Green 6 User Defined Purple 7 User Defined Brown 8 User Defined Black 9 User Defined Shield Shield Cover Available only on Cable Transport Module Opti...

Страница 24: ...ace does not met these specifications the surface can be shimmed to comply with these requirements If mounting conditions require that the table base is overhung table specifications will not be met over that portion of the table Additionally in X Y Systems the overhung portion of the Y axis may not met specifications due to the additional error caused by deflection and non support of the base Con...

Страница 25: ... known from your application requirements Velocity limits should be set in your program or in your amplifier to cause a fault if the speed exceeds this value The maximum deceleration is a factor of load and available peak force of the table Using F ma calculate maximum acceleration and then required deceleration distance See the following example for calculating maximum deceleration for an applica...

Страница 26: ...oward the positive side of the table See Chapter 2 Dimensional Drawing for positive direction definition The repeatability of the Z channel is equal to 2 resolution counts of the encoder except for 0 1 micron scales which have a repeatability of 1 microns Thus the repeatability of the Z channel equals Encoder Resolution Z Channel Repeatability 5 micron 10 micron 1 micron 2 micron 0 5 micron 1 micr...

Страница 27: ...odule Replacement for replacement P N s and a detailed procedure of the replacement process Un harnessed OEM Cable System This option provides high flex round cables directly from the carriage This option is provided for applications where the design of the machine already has a cable management system Four cables come from the carriage connector motor encoder Hall effect and limit home sensor cab...

Страница 28: ...ting factor unless loading is significantly cantilevered causing high moment loads during accelerations Chapter 2 404LXR Series Technical Data to determine bearing load life for your application Available Motor Force This is the primary factor that reduces acceleration This is simply the amount of motor force available to produce acceleration The larger the inertial and or frictional load the lowe...

Страница 29: ...d increases Chapter 2 404LXR Series Technical Data Encoder Accuracy and Slope Correction Encoder Accuracy The 404LXR Series makes use of an optical linear tape encoder for positional feedback This device consists of a readhead which is connected to the carriage and a steel tape scale which is mounted inside the base of the 404LXR The linearity of this scale is 3 microns per meter however the absol...

Страница 30: ...LETE SLCORR PROGRAM DEF SLCORR DEFINE SLCORR PROGRAM VAR2 VAR1 1000 0 085 VAR2 EQUALS DESIRED DISTANCE IN METERS TIMES THE SLOPE FACTOR mm meter Step 3 VAR3 VAR1 VAR2 SUBTRACT SLOPE ERROR FROM DESIRED DISTANCE Step 4 D VAR3 SET DISTANCE AS VAR3 END END SUBROUTINE In the example above the required move distance is 880 mm But the LXR has a slope error of 0 085mm per meter This is a positive slope er...

Страница 31: ...mm Accuracy microns Travel mm Accuracy microns 50 6 400 18 100 7 500 21 150 8 600 25 200 10 700 28 250 12 800 31 300 14 900 33 350 16 1000 35 Thermal Effects on Accuracy All specifications for the 404LXR are taken at 20 C Variation from this temperature will cause additional positional errors If the base of the 404LXR varies from this temperature the encoder scale will expand or contract thus chan...

Страница 32: ...ent Temperature This is the air temperature that surrounds the 404LXR Application or Environment Sources These are mounting surfaces or other items which produce a thermal change that effect the temperature of the 404LXR base i e Machine base with motors or other heat generating devices that heat the mounting surface and thus thermally effect the 404LXR base Motor heating from 404LXR Since the 404...

Страница 33: ...is case the system must be exercised through its normal operating cycle The temperature of the base should be measured and recorded from the beginning cold until the base becomes thermally stable This base temperature should be used in a compensation equation Below is the fundamental thermal compensation equation Cd Id Id Te T Cd Corrected displacement mm Id Incremental displacement mm Te Thermal ...

Страница 34: ...404LXR Series Product Manual Chapter 5 Connecting the Gemini Amplifier 34 Chapter 5 Connecting the Gemini Amplifier ...

Страница 35: ... Function Wire Color Pin Encoder Wires Ch A White 5 Ch A Yellow 6 Ch B Green 7 Ch B Blue 8 Ch Z Orange 9 Ch Z Brown 10 Ground Black 3 4 5 VDC Red 1 2 Shield Green Yellow Shield Cover Hall Signal Wires Hall Gnd White Green 15 Hall 5V White Blue 14 Hall 1 White Brown 16 Hall 2 White Orange 17 Hall 3 White Violet 18 Shield Green Yellow Shield Cover Temperature Switch Temp Switch Yellow 12 Temp Switch...

Страница 36: ...l even pins are connected to logic ground Function Wire Color LXR Pin 5 to 24VDC Red A Limit Blue B Limit Orange C Home Green D Ground Black E LXR Limit Home Cable P N 006 1742 0X VM25 Module Color scheme of the flying leads from the Limit Home Cable P N 006 1742 0X Axes 1 4 use the first 25 pin limits home connector and axes 5 8 use the second limits home connector on the 6K External 24 VDC Suppl...

Страница 37: ...the steps required to access the interior of the positioner Remove carriage end caps by removing four 4 M3 Socket Head Cap Screws 2pc carriage side using a 2 5 mm Allen wrench Pull carriage end caps off Carriage end caps on both sides of carriage must be removed Remove the two 2 strip seals clamps by removing four 4 Phillips Head Screws Remove strip seal cover plate ...

Страница 38: ...Chapter 6 Maintenance and Lubrication 38 Carefully pull the strip seal through the carriage Caution The strip seal ends are VERY SHARP Remove both wear bars that are located on the carriage Reassemble positioner by reversing steps ...

Страница 39: ...ation chips etc and replenish according to inspection results Lubricant Application Wipe the rails down the entire length with a clean cloth Apply lubrication on the rails allowing a film of fresh grease to pass under the wipers and into the recirculating bearings After bearings are relubricated clean encoder tape scale located on inside wall of table Clean with lint free cloth removing all dirt a...

Страница 40: ...ng a 2 5 mm Allen wrench Pull the carriage connector off taking care to pull straight off to avoid bending the connectors Remove the strip seal clamp on the connector end by removing two 2 Phillips Head Screws Remove two 2 M3 Button Head Screws from connector end by using a 2 5 mm Allen wrench Replacement modules are mounted by reversing steps ...

Страница 41: ...Home Option Switch 1 Position Switch 2 Position Switch 3 Position Limit and Home Option Switch 1 Position Switch 2 Position Switch 3 Position H2L2 404LXR 1 1 1 H4L2 404LXR 1 2 1 H2L3 404LXR 3 1 3 H4L3 404LXR 3 2 3 H2L4 404LXR 2 1 2 H4L4 404LXR 2 2 2 H2L5 404LXR 4 1 4 H4L5 404LXR 4 2 4 H3L2 404LXR 1 3 1 H5L2 404LXR 1 4 1 H3L3 404LXR 3 3 3 H5L3 404LXR 3 4 3 H3L4 404LXR 2 3 2 H5L4 404LXR 2 4 2 H3L5 4...

Страница 42: ...ing a 2 5 mm Allen wrench Pull the carriage connector off taking care to pull straight off to avoid bending the connectors Locate the limit home wire connection Press on the release tab to disengage the connector Remove the two 2 M2 Flat Head Screws that attach the limit home switch to the cable carrier using a 1 5 mm Allen wrench Replacement switches are mounted by reversing steps ...

Страница 43: ...tor increasing the stiffness is simply a matter of gain and current Thus the spring rate of a linear motor driven system can be many times that of a ball screw driven device However it must be noted that this is limited by the motor s peak force the current available and the resolution of the feedback Zero Backlash Since there are no mechanical components there is no backlash There are however res...

Страница 44: ...or fatigue failures Light Weight Forcer Because of its aluminum body construction the slotless linear motor forcer weight is approximately 2 3 that of an equivalent iron core linear motor Thus resulting in higher throughput in light load applications Lower Attractive Forces The slotless design has a backiron causing attractive forces between the forcer and the rail However this attractive force is...

Страница 45: ...n objects of 12 5 mm diameter and larger 3 Protection against access to hazardous parts with a tool and protection against solid foreign objects of 2 5 mm diameter and larger Second Number The second number indicates protection of internal equipment against harmful ingress of water 0 No special protection provided Note Number Indicators above represent only a partial list of IP Rating specificatio...

Страница 46: ... as follows Using the supplied aluminum foil disks cover all counter bored base mounting holes that are not covered by your mounting surface The disks should be installed from the outside of the unit Depending on the travel length some disks will not be used Using the supplied aluminum foil disks plug all unused carriage mounting holes that are not covered by the load or load plate Using the suppl...

Страница 47: ...l Effect 26 34 43 Signal Wires 34 Specifications 18 Home Sensor Connections 22 Replacement 40 41 Setting 25 Specifications 19 Home Switch 9 Horizontal Translation 15 Ingress Protection Rating 44 Internal Access Procedure 36 Internal Protection 44 Limit Sensor Connections 22 Replacement 40 41 Specifications 19 Limit Switch 9 Linear Motor 42 Specifications 18 Lubrication 36 38 Maintenance 36 Maximum...

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