Bosch rexroth MCL, Project Planning Manual

Page 1: ...MCL Ironless Linear Motors Project Planning Manual R911330592 Edition 06 ...

Page 2: ... as well as in the event of applications for industrial prop erty rights Liability The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed characteristic unless expressly stipulated in the contract All rights are reserved with respect to the content of this docu mentation and the availability of the product Note This document has been printed...

Page 3: ...s and passing them on to others 12 3 2 2 Requirements for safe use 12 3 2 3 Hazards by improper use 13 3 3 Instructions with regard to specific dangers 14 3 3 1 Protection against contact with electrical parts and housings 14 3 3 2 Protective extra low voltage as protection against electric shock 15 3 3 3 Protection against dangerous movements 16 3 3 4 Protection against electromagnetic and magnet...

Page 4: ...0 41 4 8 3 Motor characteristic curve frame size 070 41 5 Dimension sheets 45 5 1 Specifications 45 5 1 1 Air gap and installation height 45 5 1 2 Installation dimensions MCL015 46 5 1 3 Installation dimensions MCL020 070 47 5 1 4 Parallelism and symmetry of machine parts 48 5 2 Dimensional sheets for MCL015 50 5 3 Dimensional sheets MCL020 52 5 4 Dimensional sheets for MCL030 54 5 5 Dimensional s...

Page 5: ...er 86 8 2 4 Installation of power connection 88 8 3 Sensors 90 8 3 1 Connection temperature sensor 90 8 3 2 Connection Hall unit 90 8 3 3 Assembly Hall unit connection cable 92 8 3 4 Connect digital Hall unit 93 8 3 5 Connect analog Hall unit 94 8 4 Length measuring system 94 9 Application and construction instructions 97 9 1 Mode of functioning 97 9 2 Motor design 97 9 2 1 Design primary part 97 ...

Page 6: ...stems 123 9 19 Motor control and regulation 123 9 19 1 General 123 9 19 2 Drive controllers 124 9 19 3 Control systems 124 9 20 Deactivation upon EMERGENCY STOP and in the event of a malfunction 125 9 20 1 General 125 9 20 2 Deactivation by the drive 125 9 20 3 Deactivation by a master control 126 9 20 4 Deactivation via mechanical braking device 126 9 20 5 Response to a power outage 126 9 20 6 Sh...

Page 7: ...arts 155 12 2 Testing of motor components 155 12 2 1 Factory checks of the motor components 155 12 3 Transport and storage 156 12 3 1 Notes about transport 156 12 3 2 Information on storage 157 13 Assembly 159 13 1 Basic precondition 159 13 2 Arrangement of motor components 159 13 3 Installation of motor components 160 13 4 Air gap parallelism and symmetry of the motor components 160 13 5 Fastenin...

Page 8: ...secondary part 177 14 7 Setting and optimizing the control loop 179 14 7 1 General procedure 179 14 7 2 Parameter value assignments and optimization of Gantry axes 182 14 7 3 Estimating the moved mass using a velocity ramp 183 14 8 Maintenance and checking of motor components 185 14 8 1 General 185 14 8 2 Checking of motor and additional components 185 14 8 3 Electrical check of motor components 1...

Page 9: ...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 cog ging For this reason it is the optimum option for m...

Page 10: ... The ironless primary part bears the electrically active part of the linear motor with a winding cast in plastics The primary part carrier made of aluminum serves to assemble the primary part and for heat dissipation out of the pri mary part A fastening of an optional Hall unit for position recording is pre pared on the primary part Additionally a temperature sensor is placed in the winding Hall u...

Page 11: ...e of the operation force No attractive forces exist among primary and secondary part towards ferre ous linear motors Detent forces due to a slotting existing for ferreous linear motors are also not created These aspects and the relatively small moved mass of the primary part allow a vergy high dynamic with high precision at the same time Additionally wearing mechanical components are not necessary...

Page 12: ...nd 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 1 6 About this documentation 1 6 1 Editions of this documentation Edition Release date Notes 06 2020 06 Revision supplement 05 2015 02 Ddetails about parallel arrangement added 04 2014 06 Details about commutation adjustment Chapter 14 6 amended 01 2011...

Page 13: ...dling transport and storage 13 Installation 14 Startup operation and mainte nance 15 Service Support Additional information 16 Index Tab 1 2 Chapter structure 1 6 3 Information presentation Safety instructions The safety instructions in this documentation include signal words danger warning caution note and a signal symbol acc to ANSI Z535 6 2006 The signal word is intended to draw your attention ...

Page 14: ...of safety signs Markup The following markups are used for a user friendly text information represen tation Reference to supplementary documentation This note gives important information which must be observed Listings on the first level contain a bullet point Listings on the second level contain a dash 1 Handling instructions are specified in numbered lists Please comply with the order of the hand...

Page 15: ...e beuth E Mail postmaster beuth de 1 6 6 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 6 7 Your feedback Your experiences are an essential part of the improvement process of prod uct and documentation Please send your feedback to B...

Page 16: ...8 197 MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 17: ...ducts must not be installed or put into opera tion It must be ensured that products are installed in compliance with all reg ulations specified in the documentation 2 1 2 Areas of use and application Ironless linear motors MCL of Bosch Rexroth are intended for use as linear servo drive motors For application specific use of motors drive controllers with various levels of power DC bus voltage and d...

Page 18: ...nded use MCL motors may not be used if they are exposed to operating conditions that do not meet the specified ambient conditions For example they may not be operated under wa ter under extreme temperature fluctuations or extreme maximum tem peratures the intended application range is not explicitly approved for Bosch Rexroth motors MCL motors are not suited to be operated directly on the power su...

Page 19: ...esponding 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 el...

Page 20: ...ent is resold rented and or passed on to others in any other form these safety instructions must be delivered with the component in the official language of the user s country Improper use of these components failure to follow the safety instructions in this document or tampering with the product including disabling of safety de vices could result in property damage injury electric shock or even d...

Page 21: ... that the machine or installation in which the components are instal led complies with the national regulations safety specifications and standards of the application Operation is only allowed if the national EMC regulations for the applica tion are met The instructions for installation in accordance with EMC requirements can be found in the section on EMC in the respective application docu mentat...

Page 22: ...wed to operate maintain and or repair the components of the electric drive and control system Follow the general installation and safety regulations when working on power installations Before switching on the equipment grounding conductor must have been permanently connected to all electric components in accordance with the connection diagram Even for brief measurements or tests operation is only ...

Page 23: ...able below With an outer conductor cross sec tion smaller than 10 mm2 8 AWG the alternative connection of two equipment grounding conductors is allowed each having the same cross section as the outer conductors Cross section 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 ...

Page 24: ...fety especially the danger of injury and or property damage this alone cannot be relied upon to ensure complete safety Until the integrated monitoring functions become effective it must be as sumed in any case that faulty drive 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 ser...

Page 25: ...inued equipment use Prevent the operation of high frequency remote control and radio equip ment near components of the electric drive and control system and their supply leads If the use of these devices cannot be avoided check the machine or installation at initial commissioning of the electric drive and control system for possible malfunctions when operating such high fre quency remote control a...

Page 26: ...t the machine 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 appropria...

Page 27: ...uids and cooling lubricants Improper handling of the connected supply systems supply lines or connections can cause injuries or property damage Risk of injury by improper handling of pressurized lines Do not attempt to disconnect open or cut pressurized lines risk of ex plosion Observe the respective manufacturer s operating instructions Before dismounting lines relieve pressure and empty medium U...

Page 28: ...ion point which pre cedes the signal words DANGER WARNING and CAUTION is used to alert the reader to personal injury hazards DANGER In case of non compliance with this safety instruction death or serious injury will occur 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 moderat...

Page 29: ...is a maximum DC bus voltage of 300 VDC at MCP020 070 or 48VDC for MCP015 Re sulting data from special motor controller combinations may differ from this specified data All relationships and data described in the following sections may only apply if exclusively primary and secondary parts of the same size are combined e g MCP015 with MCS015 4 1 2 Operating behavior The characteristic curve force ov...

Page 30: ...the motor increases This leads to a ve locity dependend reduced maximum force as the motor control voltage will be reduced due to the constant DC bus voltage 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 ...

Page 31: ... the case of same current in each primary part it not limited by the drive controller Ftotal 2 x FMotor Doublication of the voltage within the drive controller if not limited by it IInverter 2 x IMotor Velocity vFmax vN and vmax as for single arrangement vFmax total vFmax Motor vN total vN Motor vmax total vmax Motor Same motor and voltage constant KFN KEMK KFN total KFN Motor KEMK total KEMK Moto...

Page 32: ...primary parts at one drive control ler relevant motor parameters for start up are specified in this documentation see Kapitel 14 4 3 on page 170 24 197 Technical data MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 33: ...ependent Voltage constant at 20 C KEMK Vs m 5 Induced motor voltage depending from the travel velocity relating on ve locity 1 m s at 20 C Winding resistance at 20 C R12 Ω Measured winding resistance among two strands at 20 C Winding inductivity L12 mH Measured winding inductivity between two strands The defined measur ing values are fluctuating due to boundary effects These details are typi cal v...

Page 34: ...IndraSize By using the IndraSize software drive controllers motors and mechanic gearboxes can be easily sized The engineering tool covers the entire range of Rexroth drives and motors Calculate the characteristic curves for your ap plication by using the sizing and calculation tool IndraSize www boschrex roth com IndraSize 26 197 Technical data MCL Ironless Linear Motors Bosch Rexroth AG R91133059...

Page 35: ... about trans port on page 156 TT C 20 80 Allowed storage temperature see also chapter 12 3 2 Information on stor age on page 157 TL C 25 55 Thermal class acc to DIN EN 60034 1 130 B Warning temperature winding See auch chapter 9 10 Motor temperature monitoring on page 107 Twarn C 110 Shutdown temperature winding see also chapter 9 10 Motor temperature monitoring on page 107 Tabst C 130 Degree of p...

Page 36: ...nding resistance at 20 C R12 Ohm 5 3 2 7 Winding inductance 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 τp mm 8 25 Thermal time constant Tth min 0 6 Primary part mass mP kg 0 050 0 075 Latest amendment 2018 04 04 Tab 4 2 MCP015 Technical data 4 4 2 Data sheet MCS015 Designation Symbol Unit MCS015 __ 0066 MCS015 __ 0099 Secondary part mass mS...

Page 37: ...c curve frame size 015 Fig 4 4 Motor characteristic curve MCP015A L040 at 48 VDC Fig 4 5 Motor characteristic curve MCP015B L040 at 48 VDC MCL Ironless Linear Motors 29 197 Technical data R911330592_Edition 06 Bosch Rexroth AG ...

Page 38: ... 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 τp mm 15 Thermal time constant Tth min 1 7 1 9 2 1 Primary part mass mP kg 0 18 0 28 0 38 Latest amendment 2019 04 09 Tab 4 4 MCP020 Technical da...

Page 39: ...stic curves frame size 020 Fig 4 6 Motor characteristic curves MCP020B at 300 VDC Fig 4 7 Motor characteristic curves MCP020C at 300 VDC MCL Ironless Linear Motors 31 197 Technical data R911330592_Edition 06 Bosch Rexroth AG ...

Page 40: ...Fig 4 8 Motor characteristic curves MCP020D at 300 VDC 32 197 Technical data MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 41: ... 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 τp mm 30 Thermal time constant Tth min 2 2 2 4 2 6 Primary part mass mP kg 0 34 0 52 0 70 Latest amendment 2018 04 04 Tab 4 6 MCP030 Technica...

Page 42: ...istic curve frame size 030 Fig 4 9 Motor characteristic curve MCP030B at 300 VDC Fig 4 10 Motor characteristic curve MCP030C at 300 VDC 34 197 Technical data MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 43: ...Fig 4 11 Motor characteristic curve MCP030D at 300 VDC MCL Ironless Linear Motors 35 197 Technical data R911330592_Edition 06 Bosch Rexroth AG ...

Page 44: ...nductivity 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 τp mm 30 Thermal time constant Tth min 2 3 2 4 Primary part mass mP kg 0 56 0 81 Latest amendment 2018 04 04 Tab 4 8 MCP040B C Technical data Designation Symbol Unit MCP040 E G V070 V300 V070 V300 Maximum force Fmax N 732 1032 Continuous nominal force FN N 183...

Page 45: ...hermal time constant Tth min 2 6 2 8 Primary part mass mP kg 1 26 1 71 Latest amendment 2018 04 04 Tab 4 9 MCP040E G Technical data 4 7 2 Data sheet MCS040 Designation Symbol Unit MCS040 __ 0120 MCS040 __ 0180 MCS040 __ 0300 Secondary part mass mS kg 1 3 1 9 3 2 Mass secondary part relative mS_rel kg m 10 7 Latest amendment 2012 03 29 Tab 4 10 MCS040 Technical data 4 7 3 Motor characteristic curve...

Page 46: ...Fig 4 13 Motor characteristic curve MCP040C at 300 VDC Fig 4 14 Motor characteristic curve MCP040E at 300 VDC 38 197 Technical data MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 47: ...Fig 4 15 Motor characteristic curve MCP040G at 300 VDC MCL Ironless Linear Motors 39 197 Technical data R911330592_Edition 06 Bosch Rexroth AG ...

Page 48: ... 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 τp mm 30 Thermal time constant Tth min 3 0 4 0 Primary part mass mP kg 1 50 1 95 Latest amendment 2018 04 04 Tab 4 11 MCP070C D Technical data Designation Symbol Unit MCP070 F M V050 V300 V050 V230 Maximum force Fmax N 1712 3320 Continuous nominal force ...

Page 49: ...30 Thermal time constant Tth min 5 0 3 1 3 3 Primary part mass mP kg 2 85 5 9 Latest amendment 2018 04 04 Tab 4 12 MCP070F M Technical data 4 8 2 Data sheet MCS070 Designation Symbol Unit MCS070 __ 0120 MCS070 __ 0180 MCS070 __ 0300 Secondary part mass mS kg 3 0 4 5 7 4 Mass secondary part relative mS_rel kg m 24 8 Latest amendment 2012 03 29 Tab 4 13 MCS070 Technical data 4 8 3 Motor characterist...

Page 50: ...Fig 4 17 Motor characteristic curve MCP070D at 300 VDC Fig 4 18 Motor characteristic curve MCP070F at 300 VDC 42 197 Technical data MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 51: ...Fig 4 19 Motor characteristic curve MCP070M at 300 VDC MCL Ironless Linear Motors 43 197 Technical data R911330592_Edition 06 Bosch Rexroth AG ...

Page 52: ...44 197 MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 53: ...travel length Any deformations that result from weight attractive forces and process forces must be taken into account The specified installation dimensions with respective toleran ces must always be complied with over the entire travel length An insufficient air gap may lead to contact between the primary part and the secondary part and thus to dam aged and destroyed motor components Long distanc...

Page 54: ...eight Motor width MCL MCP MCS A B C 015 51 mm 13 5 mm 14 8 mm For tolerance details refer to the dimension sheet Tab 5 1 MCL015 Installation dimensions and tolerances 46 197 Dimension sheets MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 55: ... mm 34 3 mm 070 124 0 mm 49 2 mm 49 5 mm For tolerance details refer to the dimension sheet Tab 5 2 Installation dimensions and tolerances MCL020 070 The specified installation dimensions with respective tolerances must always be complied with over the entire travel length MCL Ironless Linear Motors 47 197 Dimension sheets R911330592_Edition 06 Bosch Rexroth AG ...

Page 56: ...the fastening holes for the pri mary part and the threaded holes for the primary and secondary part in the machine are strictly realized according to the dimensions of the particular di mension sheets The alignment of the motor components must be done ac cording to Fig 5 1 You will find further notes regarding assembly of primary and secondary parts in chapter 13 on page 159 Secondary part Primary...

Page 57: ...MCL Ironless Linear Motors 49 197 Dimension sheets R911330592_Edition 06 Bosch Rexroth AG ...

Page 58: ...5 2 Dimensional sheets for MCL015 Fig 5 2 Dimensional sheets primary part MCP015 50 197 Dimension sheets MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 59: ...Fig 5 3 Dimensional sheets secondary part MCS015 MCL Ironless Linear Motors 51 197 Dimension sheets R911330592_Edition 06 Bosch Rexroth AG ...

Page 60: ...5 3 Dimensional sheets MCL020 Fig 5 4 Dimensional sheets primary part MCP020 52 197 Dimension sheets MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 61: ...Fig 5 5 Dimensional sheets secondary part MCS020 MCL Ironless Linear Motors 53 197 Dimension sheets R911330592_Edition 06 Bosch Rexroth AG ...

Page 62: ...5 4 Dimensional sheets for MCL030 Fig 5 6 Dimensional sheets primary part MCP030 54 197 Dimension sheets MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 63: ...Fig 5 7 Dimensional sheets secondary part MCS030 MCL Ironless Linear Motors 55 197 Dimension sheets R911330592_Edition 06 Bosch Rexroth AG ...

Page 64: ...5 5 Dimensional sheets MCL040 Fig 5 8 Dimensional sheets primary part MCP040 56 197 Dimension sheets MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 65: ...Fig 5 9 Dimensional sheets secondary part MCS040 MCL Ironless Linear Motors 57 197 Dimension sheets R911330592_Edition 06 Bosch Rexroth AG ...

Page 66: ...5 6 Dimensional sheets MCL070 Fig 5 10 Dimensional sheets primary part MCP070 58 197 Dimension sheets MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 67: ...Fig 5 11 Dimensional sheets secondary part MCS070 MCL Ironless Linear Motors 59 197 Dimension sheets R911330592_Edition 06 Bosch Rexroth AG ...

Page 68: ...60 197 MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 69: ...on of the single components e g for orders is 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 chapter 4 Technical data on page 21 and chapter 9 Application and construction instructions on page 97 6 1 2 Type codes primary part MCP General Fig 6 1 Ex...

Page 70: ...ary part and is described by the letters T and I Hall unit Abbrev column 17 18 Primary parts in frame sizes 020 up to 070 can be optionally fitted with a Hall unit for position acquisition Depended 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 done to the same front side as for th...

Page 71: ...r fastening of the secondary part with screws Mechanical protection Abbrev column 9 To ensure the optimal operation reliability the permanent magnets of the secondary part are protected against outside influences like corrosion by coating Hence no additional cover is necessary for this specified environ mental conditions Segment lengths Abbrev column 11 12 13 14 Depending from the motor frame size...

Page 72: ...6 1 4 Type code frame size 015 Fig 6 3 Type code primary part MCP015 64 197 Identification MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 73: ...Fig 6 4 Type code secondary part MCS015 MCL Ironless Linear Motors 65 197 Identification R911330592_Edition 06 Bosch Rexroth AG ...

Page 74: ...6 1 5 Type code frame size 020 Fig 6 5 Type code primary part MCP020 66 197 Identification MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 75: ...Fig 6 6 Type code secondary part MCS020 MCL Ironless Linear Motors 67 197 Identification R911330592_Edition 06 Bosch Rexroth AG ...

Page 76: ...6 1 6 Type code frame size 030 Fig 6 7 Type code primary part MCP030 68 197 Identification MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 77: ...Fig 6 8 Type code secondary part MCS030 MCL Ironless Linear Motors 69 197 Identification R911330592_Edition 06 Bosch Rexroth AG ...

Page 78: ...6 1 7 Type code frame size 040 Fig 6 9 Type code primary part MCP040 70 197 Identification MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 79: ...Fig 6 10 Type code secondary part MCS040 MCL Ironless Linear Motors 71 197 Identification R911330592_Edition 06 Bosch Rexroth AG ...

Page 80: ...6 1 8 Type code frame size 070 Fig 6 11 Type code primary part MCP070 72 197 Identification MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 81: ...Fig 6 12 Type code secondary part MCS070 MCL Ironless Linear Motors 73 197 Identification R911330592_Edition 06 Bosch Rexroth AG ...

Page 82: ...the machine or used be used elsewhere by the user 1 Motor type 2 Type designation 3 Designation of origin 4 Factory number 5 Mass of primary part 6 EC declaration of conformity 7 Rated power 8 Maximum input voltage 9 Company address 10 Insulation system 11 Thermal class 12 Degree of protection by housing 13 Manufacturing date 14 Pole pitch 15 Rated current 16 Serial number 17 Change status 18 Rexr...

Page 83: ...econdary 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 Factory number 5 Mass secondary part 6 EC declaration of conformity 7 Maximum input voltage 8 Company address 9 Thermal class 10 Degree of protection by housing 11 Manufacturing date 12 Serial number 13 Change status 14 Rexroth barcode 15 Material number 16 ...

Page 84: ...ce Conformity with applicable EC Directives EAC stands for Eurasian Conformity 25 Conformity according to RoHS and China RoHS2 Tab 6 1 Certification mark at type plate 76 197 Identification MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 85: ... is neces sary no motor movement The Hall unit offers special advantages for commutation of linear motors for example in gantry arrangement at vertical axes in mechanically secured state that must not be moved for safety reasons during commutation 7 1 2 Hall unit function The Hall unit analog or digital serves for motionless commutation of the line ar motor in connection with an incremental measur...

Page 86: ...gnets of the secondary part and is provided at the lines according to 7 1 The voltage supply is 7 20V A minimum current consumption of 40 mA to the Hall unit must be ensured Fig 7 1 Signal process of an analog Hall unit Bosch Rexroth controllers use a supply voltage of 12 V for the an alog Hall unit 78 197 Accessories and options MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 87: ...2 The voltage supply is 3 24V A minimum cur rent consumption of 40 mA to the Hall unit must be ensured Fig 7 2 Signal course of digital Hall unit The signal amplitude of the digital Hall unit depends on the supply voltage of the open collector circuit Bosch Rexroth controllers use a supply voltage of 5 V MCL Ironless Linear Motors 79 197 Accessories and options R911330592_Edition 06 Bosch Rexroth ...

Page 88: ...tening torque can damage the fasten ing thread of the Hall unit and can therewith make them useless Fig 7 3 Hall unit assembly disassembly 1 Untighten both fastening screws Store them to fasten a new Hall unit When the fastening screws are lost only use screws of the same design see Fig 7 1 2 Press the dummy or the Hall unit by means of an auxiliary device out of the installation space and remove ...

Page 89: ...e operated at IndraDrive Cs the Hall unit SHL03 1 adapter box enables simultaneous use of a digital Hall unit with an incremental length measuring system By means of the SHL03 1 adapter box the signals of these two components are connected and forwarded to the dedicated interface at the IndraDrive Cs A possible circuitry with Rexroth cables is described underchapter 8 3 4 Connect digital Hall unit...

Page 90: ...82 197 MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 91: ...tems of other manu factures possibly do not meet these requirements Rexroth shall not be held responsible for resulting malfunction states or dam age 8 2 Power connection 8 2 1 Connection cable on primary part Primary parts of MCL motors are fitted with a flexible and totally shielded con nection cable This 1100 mm long connection cable is connected with the pri mary part Primary part MCP Connecti...

Page 92: ... C01 R911388339 MCP030 MCP040 REL0012 8 3 0 2 4 x 0 75 RLS1722 CM07 R911373943 RLS1703 C01 R911388339 MCP070C D F MCP070M INK0650 12 2 0 5 4 x 1 5 4 x 0 75 only 2 wires are necessary and lead out from the temperature sensor RLS1712 CM01 R911381140 RLS2303 C02 R911381141 1 Max permitted bending radius R for fix installation 5 x D for flexible installation 7 5 x D Tab 8 2 Connection cable power on M...

Page 93: ...elief of connection cable Ground connection If the grounding of the secondary parts cannot be ensured with mounting into the customer s machine construction connect it ac cording to DIN VDE 0100 410 with the potential of the protective conductor 8 2 2 Assembly Connection cable on primary part Bosch Rexroth offers ready made power cables to connect MCP primary part on Rexroth controllers Also refer...

Page 94: ... optimally 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 Connec...

Page 95: ...ge Fig 8 4 Power connection on drive controller Connection power cable in de pendence from primary part at parallel arrangement At parallel arrangement of two primary parts the connection phase se quence of the power wires of the connection cable on the drive controller de pends from the direction of the cable output Observe the notes about con necting power wires inchapter on page 115 MCL Ironles...

Page 96: ...g a motor parallel 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 description of the power cables is done in the documentation Rexroth Connection Cables MNR R911322948 DE or R911322949 EN 88 197 Connection technique MCL Ironless Linear Motors Bo...

Page 97: ...tive power 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 rated current of the motor when select ing the power cable Drive controller Energy chain Junction terminal boxes Motor 1 Motor 2 Fig 8 7 Parallel connection collective power cable MCL Ironless Linear Motors 89 197 Connection tech...

Page 98: ...son the wires 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 3 2 Connection Hall unit Motors with Hall unit have an additional cable...

Page 99: ...tion cable of 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 equip the connection cable of the Hall unit with 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 may by damaged by ESD For this ...

Page 100: ...9 pole D sub connec tor RGS0005 The assignment 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 92 197 Connection technique MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 101: ... 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 102: ...f the motor and must be prepared and assembled by the maschine manufacturer see chapter 9 14 Length measuring system on page 120 Setting the encoder polarity depends on the direction of rotation of the pri mary part and must be parameterized at start up of the controller Also ob serve the manufacturer s instruction of the length measuring system To connect an incremental length measuring system on...

Page 103: ...e 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 RGS0006 to connect the length measuring system on the customer side MCL Ironless Linear Motors 95 197 Connection technique R911330592_...

Page 104: ...96 197 MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 105: ... machine construction 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 M...

Page 106: ...ection the iron parts of the secondary 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 underType code Required length of the secondary parts The required length L of the secondary part ...

Page 107: ... MCP015 MCS015 MCP020 MCS020 MCP030 MCS030 MCP040 MCS040 MCP070 MCS070 Frame lengths Primary and secondary parts of one size are graduated additionally to differ ent 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 detailled information ...

Page 108: ...ure in degrees 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 FN_red FN fT Installation altitude 1 000 m FN_red FN fH Ambient temperature 40 C and setup elevation 1 000 m FN_red FN fT fH The details for...

Page 109: ...s of environmental conditions during operation Based on DIN EN 60721 3 3 some limit values are partially defined in the following which our products are allowed to be exposed to during operation Observe 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 ...

Page 110: ...tion modes Any failure to observe the degree of protec 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 Certificate of conformity certifying the structure of and the compliance with the valid EN stan...

Page 111: ... not cause any inadmissible hazards As of a distance of approx 100 mm to the surface of open perma nent magnet parts there is practically no effective magnetic attraction of fer romagnetic parts However for people with implants a minimum safety dis tance of 1 meter 1000 mm is recommended Depending on the operating location transport ways and storage of the ma chine and its components local regulat...

Page 112: ... motion range of mo tors during operation Prevent any contamination chips and dirt in the motion range of motors Notes on transport For shipping by air freight of magnetic components the limit values for mag netic flux density in all directions in accordance with IATA953 must be com plied with All rotors of Bosch Rexroth synchronous motors comply with cate gory I according to the figure below Depe...

Page 113: ...f cupper in 1 K Fig 9 6 Power loss of synchronous linear motors When you determine the power loss according to Fig 9 6 you must take the temperature related rise of the electrical resistance into account At a temperature rise of 100 K from 20 C up to 120 C for example the electrical resistance goes up by the fac tor fT 1 39 Thermal time constant The temperature variation vs the time is determined ...

Page 114: ...pec ted final over 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 150 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 Fi...

Page 115: ...Y 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 rated current at low velocity 1 m min or at movement via a short traverse path 2 tP The Rexroth IndraDrive control devices monitor the functionality of t...

Page 116: ...he 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 reduction of the force is lin...

Page 117: ...peration which 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 ...

Page 118: ...dth of linear drives 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 machine...

Page 119: ...igidity of the machine base body in N µm Fig 9 14 Calculation example of the machine base body 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 120 MCL Ironless Linear Motors 111 197 Application and construction instructions R911330592_Edition 06 Bosch R...

Page 120: ...een the motor compo nents Thereby temperatures can arise which can cause a motor dam age Due to the high mechanical force effectgrinding traces and or scratch formation on the motor components can result in the destroying of cast ing compounds on the primary part to motor breakdown among oth ers Please note that dirt can also enter indirectly into via compressed air or due to other machine parts e...

Page 121: ...ed forces Optimized utilization of available installation space Fig 9 17 Examples for arrangement Depending on the application the motors can be controlled in two different ways Two or more motors at one drive controller and one linear scale parallel connection Two motors at two drive controllers and two linear scales Gantry ar rangement MCL Ironless Linear Motors 113 197 Application and construct...

Page 122: ...conditions must be fulfilled Use identical primary parts MCP and same line length MCS Stiff motor coupling within the axis Position offset between the primary 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 ...

Page 123: ...y parts in mm n Freely selectable integer factor 0 τp Pole width see Chapter Technical data xPmin smallest allowed distance between the primary parts see Tab 9 7 R Allowed bending radius of the connection cable see Tab 8 2 Fig 9 20 Determining the distance xP between the primary parts with cable outlet in the same direction The grid dimension ΔxP acc to Fig 9 19 must be a integer multiple of the d...

Page 124: ...s in opposite directions to Fig 9 22 a defined distance xP must be kept between the primary parts Fig 9 22 Variant 1 Arrangement of primary parts behind each other with ca ble outlets in opposite directions xP Distance between the front faces of the primary parts in mm n Freely selectable integer factor 0 τp Pole width see Chapter Technical data xPmin smallest allowed distance between the primary ...

Page 125: ...ned distance xP must be kept between the primary parts Fig 9 24 Variant 2 Arrangement of primary parts behind each other with ca ble outlets in opposite directions xP Distance between the front faces of the primary parts in mm n Freely selectable integer factor 0 τp Pole width see Chapter Technical data xPmin smallest allowed distance between the primary parts see Tab 9 9 R Allowed bending radius ...

Page 126: ... linear scales and drive controllers Gantry ar rangement This is frequently the case with axis in a Gantry structure for ex ample Within a Gantry arrangement even parallel connected motors can be used Double comb arrangement Gantry Within a Gantry arrangement the primary parts in feed direction can be me chanically coupled and arranged in the form of a double comb arrangement Control unit Controll...

Page 127: ...otor components on page 160 and chapter 13 5 Fastening secon dary part on page 161 about alignment and fastening of secondary parts 9 13 4 Vertical axis Uncontrolled movements Risk of injuries CAUTION Motors in vertical axes are not self locking when de energize Prevent a sink ing of the axis with appropriate holding devices On vertical axis the use of an absolute measuring system is recommended I...

Page 128: ...condary part by return after start or after a mal function pole position recognition Using an absolute linear scale is the opti mum solution here 9 14 2 Selection criteria for length measuring system General Depending on the operating conditions open or encapsulated linear scales with different measuring principles and signal periods can be used The se lection of a suitable linear scale mainly dep...

Page 129: ...rs of length measuring systems To ensure maximum interference immunity Rexroth recom mends the voltage interface with 1 VSS Please refer to the documents from the corresponding man ufacturer for detailed and updated information Measuring system cables Ready made cables of Rexroth are in preparation for the electrical connec tion between the output of the linear scale and the input of the scale int...

Page 130: ... will find an incomplete list of manufacturers of suitable length measuring systems for linear motors Furthermore other manufactur ers are available which cannot be listed all Bosch Rexroth AG Linear and assembly techni que Maria Theresien Straße 23 97816 Lohr am Main Germany info boschrexroth de http www boschrexroth com business_units brl de Integrated measuring system for profiled rail guide Ta...

Page 131: ...ed 9 18 Axis cover systems Depending on the application design operational principle and features of synchronous linear motors the following requirements on axis cover systems apply High dynamic properties no overshoot little masses Accuracy and smooth run Protection of motor components against chips dust and foreign objects in particular ferromagnetic parts Resistance to oil and coolant lubricant...

Page 132: ...Motor control combinations on page 133 9 19 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 124 197 Application and construction instructions MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 133: ...h 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 fa...

Page 134: ...ive controller With an undelayed power shutdown the drive coasts in an uncontrolled way once the DC bus energy has been used up 9 20 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 foll...

Page 135: ...s follows Cadd 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 kFN Motor constant force constant in N A R12 Winding resistance at 20 C FR Friction force in N Fig 9 30 Determining the required additional DC bus capacitor Prerequisites final ve...

Page 136: ... supply sinusoidal 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 32 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 grid point...

Page 137: ... 2 Velocity resolution The resolution of the velocity is proportional to the position resolution see fig 9 33 Drive internal position resolution on page 129 and inversely propor tional to the cycle rate tAD from Δvd Velocity resolution in m s Δxd Drive internal position resolution tAD Cycle rate in s IndraDrive Basic performance 250 µs Advanced 125 µs Fig 9 35 Velocity resolution 9 22 Thermal conn...

Page 138: ...tor performance has to be expec ted In general the heat dissipation must be increased proportionally with the size and frame length and the respectively higher power loss of the motor if the same utilization capacity of the motor is to be achieved For this reason observe maximum heat dissipation of motor com ponents when designing the machine Only this way optimum dis sipation of the emitted heat ...

Page 139: ...hnical data for this installation mode is specified in chapter 4 Technical data on page 21 C Installation mode C assumes that a motor component primary or secon dary part is thermally isolated and the other components must be well conductively connected to the machine In this case reckon with a per formance reduction of the motor due to moderate heat dissipation D Installation mode D assumes that ...

Page 140: ...inuously the motor will overheat and be thermally damaged Also refer to chapter 9 10 Motor temperature monitoring on page 107 The peak value of the instantaneous current is equal with the amplitude of the si nusoidal assumed phase current Its value is higher by root 2 than the effec tive value of the continuous current IN The power loss PV created in the coil is calculated using Δθ Temperature dif...

Page 141: ... Exceeding 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 for MCP015 10 2 Motor control 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 optimum combination x permitted co...

Page 142: ...0B V390 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 optimum combination permitted combination x permitted combination maximum force however reduced as the controller is under dimensioned Tab 10 2 Motor ...

Page 143: ...ent char acteristics of velocity and feed force and from the thermal connection The sequence of dimensioning of linear drives is illustrated by the following figure Fig 11 1 General procedure of linear drives dimension MCL Ironless Linear Motors 135 197 Motor dimensioning R911330592_Edition 06 Bosch Rexroth AG ...

Page 144: ... FP t Processing force or operation 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 By means of path function the calculation of velocity acceleration and force can be done Standard soft ware su...

Page 145: ...ctive force in N FP Processing force in N a Acceleration in m s m Moved mass in kg g Final velocity 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 feed forces MCL Ironless Linear Motors 137 197 Motor dimensioning...

Page 146: ...er the moving mass is only known after the motor has been selected For this reason an assumption must first be made and checked again after the motor has been selected Fig 11 5 Determining resulting feed forces dependend from the mode of mo tion and direction 138 197 Motor dimensioning MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 147: ...termining resulting feed forces dependend from the mode of mo tion and direction With horizontal axis arrangement the weight is FW 0 Further di rection dependend base and process forces must be additionally observed MCL Ironless Linear Motors 139 197 Motor dimensioning R911330592_Edition 06 Bosch Rexroth AG ...

Page 148: ...1 7 Triangular or trapezoidal velocity profile vavgi Average velocity for a velocity segment with a 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 cycle duration in m s ti Duration velocity segment in s tall Total duty cycle time including breaks and or standstill time in s Fig 11 8 Determining...

Page 149: ...ocity profile When determining the respective parameters acceleration a velocity v dis placement s and time t for trapezoidal travel a case distinction must be made with regard to 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 MCL Ironless Linear Motors 141 197 Moto...

Page 150: ... m Fig 11 10 Constantly accelerated movement initial velocity va 0 for trapezoi dal velocity profile Acceleration initial velocity va 0 Velocity v constant Initial velocity va 0 Acceleration a constant and positive 142 197 Motor dimensioning MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 151: ...profile Constant velocity Velocity v constant Acceleration a 0 vc Constant velocity in m s tc Time during constant velocity in s sc Distance during constant velocity in m Fig 11 12 Constant velocity for trapezoidal velocity profile Brakes final velocity ve 0 Velocity v constant Final velocity ve 0 Acceleration a constant and negative MCL Ironless Linear Motors 143 197 Motor dimensioning R911330592...

Page 152: ...n in m Fig 11 13 Constantly decelerated movement final velocity ve 0 for trapezoi dal velocity profile Brakes final velocity ve 0 Velocity v constant Final velocity ve 0 Acceleration a constant and negative 144 197 Motor dimensioning MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 153: ...city profile 11 2 5 Trapezoidal velocity profile This velocity profile has no phase of constant velocity in contrast to trapezoi dal profiles The acceleration phase is immediately followed by the decelera tion phase This process is frequently encountered with short stroke move ments Fig 11 15 Trapezoidal velocity profile MCL Ironless Linear Motors 145 197 Motor dimensioning R911330592_Edition 06 B...

Page 154: ...eristic results for example from circular interpolation of two axes circular movement or from the oscillating movement of one axis e g during grinding The specified variables are chiefly the motion travel s or the circle diameter 2r and the period duration T Fig 11 17 Insert distance and velocity of an axis at sinusoidal velocity 146 197 Motor dimensioning MCL Ironless Linear Motors Bosch Rexroth ...

Page 155: ...istance and velocity of an axis for sinusoi dal velocity By means of fig 11 17 Insert distance and velocity of an axis at sinusoidal velocity on page 146 and fig 11 18 Calculation formular for distance and velocity of an axis for sinusoidal velocity on page 147 results in the following calculation base MCL Ironless Linear Motors 147 197 Motor dimensioning R911330592_Edition 06 Bosch Rexroth AG ...

Page 156: ...FEFF Effective force in N FEFFv Effective force at vertical or inclined axis arrangement in N F0 Base force e g friction in N FW Weight force in N Fig 11 19 Calculation formula for sinusoidal velocity profile Further direction dependend base and process forces must be additionally observed 148 197 Motor dimensioning MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 157: ...between duty cycle and feed force on page 149 Fig 11 20 Correlation between duty cycle and feed force 11 3 2 Determining the duty cycle Due to the linear correlation of force and current the approximate determina tion of the relative duty cycle EDideal is performed via the correlation EDideal Cyclic duration factor in FEFF Effective force or continuous force in N FMAX Maximum feed force Fig 11 21 ...

Page 158: ... are connected to a single power supply module 11 4 2 Continuous power The continuous power corresponds to the sum of the mechanical and electri cal motor power Pc Continuous power in W Pcm Mechanical continuous power 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 Technica...

Page 159: ... Maximum power of the linear motor If the maximum feed force is reduced in relation to the achievable maximum force of the motor the maximum electrical power is al so reduced Pmaxe To determine the reduced electrical maximum output Pmaxe use fig 11 25 Diagram used for determining the re duced electrical power loss on page 151 Fmax Maximum force motor in N F Maximum force application in N PVmax Max...

Page 160: ...r The regenerative power of a synchronous linear drive results from the energy balance during braking and can be estimated as follows for dimensioning ad ditional braking resistors or regenerative supply units PR Energy regeneration during a braking phase in W PRavg Average energy regeneration over total cycle duration in W m Moved mass in kg v Maximum velocity in m s tb Braking time in s FR Frict...

Page 161: ...ase of linear motors is determined by the application de pendent travel speeds and forces and the corresponding motor losses The motor efficiency can be determined or estimated with the help of fig 11 28 Efficiency determination for linear motors on page 153 η Efficiency Pmech Mechanical power in W PV Power loss in W F Feed force in N v Velocity in m s Fig 11 28 Efficiency determination for linear...

Page 162: ...154 197 MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 163: ...ning about danger after opening the package and resulting handling of the secondary parts Fig 12 1 Warning label on the package of secondary parts The self adhesive warning label dimensions approx 110 mm x 150 mm can be ordered from Rexroth MNR R911278745 for the user s own purposes 12 2 Testing of motor components 12 2 1 Factory checks of the motor components Electrical testing During manufacturi...

Page 164: ...crews get into contact with the air gap Also observe the warning notes in fig 12 1 Warning label on the package of secondary parts on page 155 Based on DIN EN 60721 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 Refer to the detailed description of the classifications to take all of the factors which a...

Page 165: ...s until shortly before assembly Based on DIN EN 60721 3 1 the tables below specify classifications and lim it values which are allowed for our products while they are stored Refer to 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 storage acc to DIN EN 60721 3 1...

Page 166: ...isual 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 Cable and plug connector Storage time Measures prior to commissioning 1 year None 1 5 years Check the electric contacts to verify that they are free from corrosio...

Page 167: ...on of the motor components Basically no limitations about arrangement of the motor components exists It can be an advantage to mount the secondary part sidewards see fig 13 1 Arrangement of motor components within ready to mount compact module CKL of Rexroth on page 159 or downwards toppled that dirt residues a s o can drop into the air gap between primary and secondary part from above In this con...

Page 168: ...e primary part and afterwards the secondary part 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 Due to the clearance which exists within the holes of the screw connections the motor components must be adjusted corr...

Page 169: ...nd of foreign bodies 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 After aligning tighten all screws with the specified tightening torque seeChapter ...

Page 170: ...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 Screw size DIN EN ISO 4762 Fastening 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 12 mm M8 25 Nm Tab 13 2 Faste...

Page 171: ...MCP Screw size DIN EN ISO 4762 Screw in depth Fastening class Tightening torque 10 Variant 1 Variant 2 015 M3 see chapter 5 Dimen sion sheets on page 45 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 screwed on the mach...

Page 172: ...oints to fasten the primary part The effect of liquid screw lock Loctite 243 is damaged by loosening or re tightening of screws e g due to torque tests and must be renewed 164 197 Assembly MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 173: ... 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 Only the machine manufacturer s system wiring diagrams are relevant for the connection of the drive components in the machine MCL Ironless Linear Motors 165 197 A...

Page 174: ...166 197 MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 175: ...ot apply for direct drives with linear motors The moved external load depends on load of the motor itself Encoder polarity The polarity of the actual velocity length measuring system must comply with the force polarity of the motor Before commutation adjustment this rela tion must be established Commutation adjustment It is necessary at synchronous linear motors to receive the position of the pri ...

Page 176: ...ning software The IndraWorks commissioning software al lows menu driven custom designed and motor specific parameterization and optimization PC For commissioning by means of IndraWorks a conventional Windows PC is required Commissioning via NC Commissioning via the NC control unit requires access to all drive parame ters and functionalities Multimeter Troubleshooting and component checks can be fa...

Page 177: ...Fig 14 1 General commissioning procedure for synchronous linear drives MCL Ironless Linear Motors 169 197 Commissioning operation and maintenance R911330592_Edition 06 Bosch Rexroth AG ...

Page 178: ... to load all motor parameters Enter the individual parameters manually via the controller Load a complete parameter set at serial machines via the controller or IndraWorks 14 4 3 Motor parameter at parallal arrangement Are two linear motors operated in a control device the following parameters have to be adjusted when commissioning Parameter Designation Adjustment factor P 0 4016 Direct axis induc...

Page 179: ...roller used Rexroth IndraDrive MPx xx Parameter Description MNR R911328651 Rexroth IndraDrive MPx xx Parameter description MNR R911328651 Rexroth IndraDrive Firmware MPx xx Functional Description MNR R911328670 Rexroth IndraDrive MPx xx Application Manual MNR R911326767 Signal period Linear scale for linear motors generate and interpret sinusoid signals The sine signal period has to be entered in ...

Page 180: ...tion related parameters Application related drive parameters include for example parameterization of the drive fault reaction Detailed descriptions can be found in the firmware or parameter description of the drive controller used See also chapter 14 4 4 Entering length measuring system parameter on page 171 172 197 Commissioning operation and maintenance MCL Ironless Linear Motors Bosch Rexroth A...

Page 181: ...r force The following applies for setting of the correct encoder 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 of the motor force Counting direction of the length measuring system In case of motion of the primary part in the direction...

Page 182: ...aximum and constant degree if the commutation angle is set correctly Commutation adjustment always has to be performed in the fol lowing cases Initial commissioning Modification of the mechanical attachment of the linear scale Length measuring system replacement Modification of the mechanical attachment of the primary and or secondary part This procedure ensures that the angle between the current ...

Page 183: ...zation of current and velocity control loops Correct connection of motor power cable Protection against uncontrolled movements Errors in commutation adjustment can result in malfunctions and or uncontrolled move ments of the motor DANGER Take care when carrying out the commutation adjustment For commutation observe the detailed information in the documentation under chapter 14 4 4 Entering length ...

Page 184: ...ve Firmware MPx xx Functional Description MNR R911328670 Rexroth IndraDrive MPx xx Application Manual MNR R911326767 14 6 3 Hall sensor procedure The Hall sensor procedure is applied if an incremental measuring system is used in combination with a Hall unit in the primary part Also observe the in formation on the Hall unit in chapter 7 1 Hall unit on page 77 Commutation by means of analog Hall uni...

Page 185: ...ing of an electrical accuracy of 30 In this respect a maximum power loss of 14 is to be expected Hence the maximum motor force is available a Reference point optimum commutation offset must be stored on the reference point Procedure at IndraDrive Cs 1 Activate initial commissioning mode P 0 0522 bit 15 2 Carry out commutation adjustment using the sinusoidal procedure 3 Switch axis to AF 4 Start fi...

Page 186: ...ting the commutation offset is determined from the measured relative position of the primary part with respect to the secondary part Fig 14 5 distance a or b depending on accessibility and a motor related constant kmx Fig 14 6 and Fig 14 6 P 0 0523 Commutation adjustment measured value in mm a Relative position reference point in mm Fig 14 5 b Relative position reference point in mm Fig 14 5 kmx M...

Page 187: ...n command start AB drive ready for operation the commutation offset with the selected procedure saturation or sinusoidal procedure is determined for automatic commutation Afterwards the command is to 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 essential impor tance for the properties of the servo a...

Page 188: ...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 mechanical system of the slide that is moved by the linear drive is stimu lated to vibrate mechanically due to the position and or velocity return within the closed control loop This behavior known as Two mass vibrational sys...

Page 189: ...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 rejection frequency is the frequency with the highest attenuation The bandwidth de fines the frequency range in which the attenuation is less than 3 dB A high er bandwidth leads to less attenuation of the r...

Page 190: ...n of functions of the drive controller for a de scription of the operational principle and the parameter settings Fig 14 9 Possible alignment errors at length measuring systems of Gantry ax es Parametrization For operation of Gantry axes identical parameterization of the following pa rameters must be ensured Motor parameter Polarity parameter for force velocity and position Control loop parameter ...

Page 191: ...elocity con trol loop Tab 14 7 Parametrization of the velocity loop integral action time S 0 0101 at Gantry axes Optimization For optimization of velocity and position control loop the above described procedure must be observed Parameter changes during optimization of Gantry axes must al ways be carried out at both axes If this is not possible the pa rameter changes during optimization should be c...

Page 192: ...ved axis mass according to recording of a 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 Measuring with a motor force between FN and Fmax The procedure is not suitable or suitable only to a limited extend for vertical axes due to potential di...

Page 193: ...eas uring the 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 inductivity The measured values of resistance and inductance can be compared to the values specified in chapter Technical data ...

Page 194: ...hich allow re using and recycling the resulting waste We regularly try to replace pollutant loaded raw materials and supplies by more environment friendly alternatives No release of hazardous substan ces Our products do not contain any hazardous substances which may be re leased in case of appropriate use Normally our products will not have any negative influences on the environment Significant co...

Page 195: ...sposed of After use the batteries or accumulators contained in Rexroth products must be properly disposed of according to the country specific collection systems 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 assemblies Metals contained in electric and electr...

Page 196: ...188 197 MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 197: ...rexroth com 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 Detai...

Page 198: ...190 197 MCL Ironless Linear Motors Bosch Rexroth AG R911330592_Edition 06 ...

Page 199: ...body 97 Commissioning Drive limitations 172 Length measuring system parameter 171 Motor parameters 170 Procedure 168 Requirements 167 Tools 168 Commutation 77 Commutation adjustment 167 174 Hall sensor procedure 176 Measuring procedure 177 Sinusoidal procedure 176 Commutation offset angle 77 Connect Length measuring system 94 Connection 165 Analog Hall unit 94 Digital Hall unit 93 Hall unit 90 Pow...

Page 200: ... Flange socket power 85 Force constant 21 25 Force density 3 Force generation 97 Force reduction 109 Forces Reactive forces 110 Foreign bodies 97 Frame length 99 Frame lengths 62 Frame shape 62 Frame size 62 63 99 Frame sizes 99 Friction 112 G Gantry arrangement 77 113 133 Gantry axes Parameter value assignments and opti mization 182 Gantry structure 110 Grinding traces 112 Grounding 85 H Half tim...

Page 201: ... Modular system 99 Mold 97 Motor breakdown 112 Motor characteristic curve 22 Characteristic curve 21 Motor coupling 110 Motor damage 112 Motor design Primary part 97 Secondary part 98 Motor dimension Trapezoidal velocity profile 145 Motor dimensioning 135 Average velocity 140 Feed forces 137 Movement equations 136 Sinusoidal velocity profile 146 Trapezoidal velocity profile 141 Motor installation ...

Page 202: ... optimizing the control loop 179 SHL03 1 93 SHL03 1 adapter box 93 Shock absorber 123 Short circuit loss 105 Shutdown temperature 27 Significant components 186 Skilled personnel 159 Spare parts 61 Specifications 45 Speed 22 Standards 7 Standstill operation 132 Start up Parameterization 170 Start Up Mass definition 183 Storage 157 Storage temperature 27 Storage time 158 Strain relief 85 Support 189...

Page 203: ...W Warning notes 155 Warning temperature 27 Weight compensation 119 Winding 62 Winding inductivity 25 Winding protection 90 Winding resistance 25 Winding temperature 105 107 Wire designation 84 Wire end ferrules 84 MCL Ironless Linear Motors 195 197 Index ...

Page 204: ...Notes 196 197 MCL Ironless Linear Motors ...

Page 205: ...Notes MCL Ironless Linear Motors 197 197 ...

Page 206: ...xroth AG P O Box 13 57 97803 Lohr a Main Germany Bgm Dr Nebel Str 2 97816 Lohr a Main Germany Phone 49 9352 18 0 Fax 49 9352 18 8400 www boschrexroth com electrics R911330592 R911330592 DOK MOTOR MCL PR06 EN P ...