Systec DriveSets, Maintenance Manual

Page 1: ...DriveSets Maintenance for DriveSets Notes for preventive maintenance of kinematics and Xemo controllers Elektronik und Software GmbH ...

Page 2: ...the right to make technical changes You can download this document from the Systec website free of charge For this document Systec GmbH grants you the simple charge free right unlimited in space and time for all known and not yet known types of use All rights with respect to patent grants or industrial design registration and further rights remain unaffected You may duplicate this document Distrib...

Page 3: ... information 9 3 Life expectancy 10 3 1 Kinematics 10 3 2 Motors 10 3 3 Hybrid cables 10 3 4 Xemo controllers 10 4 Regular checks 11 4 1 Wiring 11 4 2 Dust deposits 11 5 Preventive maintenance 12 5 1 Linear axes 12 5 2 Guide shafts 12 5 3 Castors 12 5 4 Spindles 12 5 5 Motors 12 5 6 Xemo controllers 12 5 6 1 General comments 12 5 6 2 Xemo R S Compact Controllers 13 5 6 3 Xemo P Controllers 13 6 Ma...

Page 4: ...6 7 8 Lubrication leading nut axis type DLT und DLK 27 6 7 9 Lubrication Axis type MZK 28 6 7 10 Lubrication axis type DuoLine 29 6 7 11 Lubrication Axis type PLS II 30 6 8 Maintenance of axes with carriages 33 6 8 1 Lubrication leading nut axis type DSK and DST QS_ 33 6 8 2 Lubrication runner blocks axis type DS_ und QS_ 36 6 8 3 Lubrication carriage axis type LS_ 37 6 8 4 Lubrication Axis type K...

Page 5: ...he linear axes or rotary modules constitute the mechanical structure with which corresponding motions can be carried out The linear axes can be driven either by a spindle or a cogged V belt In addition linear motors are also used Rotary modules designed as turntables consist in as a rule of a plate and a gearbox with motor Inductive proximity switches or roll switches for trajectory limitation and...

Page 6: ...bles which meet EMF requirements The cables are cropped to specific lengths The cables are attached to the motors by means of plug connect ors On the switching cabinet end the attachment varies according to model In most cases the motor cables are LED directly to the power electronics In individual cases an adapter plug system can be used As a rule the cables of the end and reference switches are ...

Page 7: ...linear axes They are fitted with the appropriate power electronics for the specific axis and motor types The Xemo P Controller is offered in the variants comfort and eco In the comfort version the controller is built into a switch cabinet At the cabinet s front operational elements are attached As a rule the control ler is ready for connection to the power supply and then ready for oper ation In t...

Page 8: ...ous injury indicates a hazardous situation which if not avoided could result in death or serious injury indicates a hazardous situation which if not avoided may result in minor or moderate injury indicates a property damage message Remark Please read passages which are marked with this symbol definitely Get important information about dealing with these instructions and condi tions or limits for t...

Page 9: ...ure that the connection plugs for the power supply of all the power supplies to your application have been unplugged Danger from flying away of parts Ensure that no tools or other materials are lying in the trajectory area or on the axes Malfunctions or even destruction of the Xemo controller or the con nected components Do not plug or unplug cable connections within the DriveSets when the attache...

Page 10: ... fold size of the cable diameter 8 mm amounts to more than 2 million cycles Smaller bending radii minimum 5 fold size of the cable diameter this amount declines In the case of non moving hybrid cables bending radii which are smaller than the 2 fold size of the cable diameter are not permissible 3 4 Xemo controllers The Xemo controllers have a life expectancy of about 8 years Once this period is ex...

Page 11: ... lines etc 4 2 Dust deposits At least once per year Xemo controllers should be checked for dust de posits which can occur through normal convection If there are obvious dust deposits these must be removed by blowing out or vacuuming the unit If a pressed air pistol is used for this purpose the pressed air stream should not be directed at the system from close proximity otherwise some parts might b...

Page 12: ...or this purpose the normal trajectory paths should be traversed at reg ular intervals in order to spread accumulations of lubricant into the tra jectory area Re lubrication of the spindles should be done every 500 to 1000 operating hours According to axle type this is done by way of the lubrication points or in the case of EL30 and EL40 axes with trapeze spindles by lubrication with a brush 5 5 Mo...

Page 13: ...d Never install Xemo R Controllers directly on the floor of a control cabinet or directly over heat emitting drawers Otherwise the necessary cooling is not assured The air taken in should be dust free Xemo S Controllers require no preventive maintenance 5 6 3 Xemo P Controllers Xemo P Controllers in the comfort version require no preventive maintenance If you are using the eco version i e the cont...

Page 14: ...ck the material and can dam age it Do not use cleaning agent containing solvent 6 2 Exchanging cover bands EL_ 100 125 Remove the cylinder screws 1 on one side of the carriage Shove the pull back cap 4 to the side Unscrew the set screws 2 shove the carriage 5 to the side Loosed the set screws 3 on both bearings Pull the cover band 6 out Insert a new cover band and clamp it to the bearing 7 with a ...

Page 15: ...amaged masking tape Kinks cracks or waves in the cover band require an exchange The band of your linear drive unit is defined by its length on your linear unit A faultless functioning can only be guaranteed by an optimal length of cover band 6 3 Belt exchange 6 3 1 Axis type ELZ Fig 3 Belt exchange ...

Page 16: ...th bearing blocks for inserting the new belt The reconstruction of the unit takes place in opposite order Shorten the new belt to the length of the old one Insert the toothed belt with the toothed side to the profile 11 into the not dismounted pulley block A rotate the toothed pul ley 13 until the toothed belt 9 appears at the end of the profile 11 and pull the belt through the dismounted pulley b...

Page 17: ... the carriage to check belt tension Shove the carriage 5 in front of a bearing 7 so that the maxi mum belt length is freed up at the other side Exert the prescribed force see table a tension spring balance in the middle of belt Compare the resulting sag f with the slackened belt Once you have ascertained the sag please compare your measured value with the recommended value which you obtain from th...

Page 18: ...he value with the diagram and if necessary stretch or slacken the belt Adjust the stud screws 2 with a hex socket screw wrench The stud screws 2 must be bonded with the locking device Both screws 2 must be screwed in equally deep Check with a steel tape Screw on the pull back cap 4 again Axis scale spring balance applied force ELZ 30 20 N ELZ 40 20 N ELZ 60 30 N ELZ 80 50 N ELZ 100 50 N ELZ 125 50...

Page 19: ...ads to be moved and can be queried with RK Rose Krieger GmbH for special cases Tension the toothed belt with the belt tensioning kit Tension the toothed belt 1 by steadily tightening the tensioning screw 2 on the front of the slide 3 clockwise Fig 6 Screws to adjust the belt tension Remark The toothed belt of the linear unit must be replaced every 8 years irre spective of the amount of use and the...

Page 20: ...pe LLZ60 Fig 8 Adjusting the roller castor for axis type LLZ60 1 Eccentric key for tightening the 2 hole counternut 2 Hexagon socket for adjusting the eccentric 3 Adjustable roller castors 4 Non adjustable roller castors Loose the 2 hole counter nut with the eccentric key 1 Try to turn the eccentric with the hexagon socket 2 The eccen tric must be movable Turn the eccentric with the hexagon socket...

Page 21: ...just the carriage free of play without initial tension Ensure that the eccentric bolts are adjusted to the right 6 6 Lubrication amounts Bearing grease based on DIN 51825 K2K KP2K Consistency class based on DIN 51818 NLGI 2 Type Gew inde Pitch N a chfettung Regrea sing Type Gew inde Pitch N a chfettung Regrea sing 3 0 Kg 08 x 2 5 0 01 g 6 0 Kg 20 x 05 3 00 g 4 0 Kg 16 x 05 1 33 g 8 0 Kg 25 x 25 3 ...

Page 22: ... 6 7 1 Trapeze spindle scale EL 30 40 Fig 10 Linear axis ELT 30 40 Run the carriage on one side Loosen the set screws 3 remove the cover band 6 Lubricate the spindle with a thin brush Lubricants see chap 6 6 6 7 2 Ball screw spindle scale EL 30 40 Fig 11 Linear axis ELK30 ELK40 ...

Page 23: ... 3 pull out and remove the cover band 6 lubrication hole is now visible in the slide nut recess 9 Lubricate it with a grease gun Lubricants see chap 6 6 6 7 3 Spindle scale EL 60 80 100 125 Fig 12 Linear axis EL_ 60 80 100 125 Lubricate the spindle every 500 1000 operating hours The lubrication point is located in the protective cap 4 on one side of the carriage 5 Lubricant see chap 6 6 ...

Page 24: ... from the un derside of the carriage at the eccentrics Lubricants see chap 6 6 6 7 5 Lubrication roller castors axis type LLZ 60 Fig 14 Lubrication of roller castors Rods will be greased by the strippers of carriage There are 2 oil nipples 1 in the carriage 2 where the tanks for the strippers can be filled with an oil gun Lubricant Viscosity of oil 200 mm s T 40 C ...

Page 25: ...icated felt inserts which are located in the pull back cap 4 of the carriage The felt inserts can be saturated through their lubrication points 8 We recommend the use of lubricants with a viscosity of about 200 mm s at T 40 C The necessary lubrication interval is dependent on the en vironmental influences use once a month as a guide To guarantee suf ficient lubrication of the guide shaft the minim...

Page 26: ...ed laterally to the ends of the roller packs Dismount cover cap 1 Drive the carriage through the service position until you can see the first lubricating nipple 2 in the lubrication hole Re oiled felt now with an oil gun Move the carriage to the second lubricating nipple and re oiled here as well Lubricant Viscosity of oil 200 mm s T 40 C Lubrication interval Interval of greasing depends on enviro...

Page 27: ... 4 and unscrew set screws 5 Push carriage 6 to the side Release the set screw 7 and remove it using the sliding nut Pull out and lift the cover band 8 now the lubrication hole is visible in the leading nut receptacle 9 Regrease with grease gun For the quantity of grease see table in Chap 6 7 8 3 6 7 8 2 Axis type DLT DLK 160 Fig 18 Lubrication leading nut Drive the carriage to the service position...

Page 28: ...king hours Axis type Pitch Lubricant quantities in g 120 16 x 05 1 33 120 16 x 10 0 84 120 16 x 16 1 00 120 160 20 x 20 3 00 120 160 25 x 05 2 00 120 160 25 x 10 3 00 120 160 25 x 25 3 00 200 32 x 05 3 00 200 32 x 10 4 00 200 32 x 20 4 00 200 32 x 32 4 00 6 7 9 Lubrication Axis type MZK Fig 19 Structure linear axis MKZ Grease nipples 3 are attached to both sides of the slide Perform lubri cation w...

Page 29: ...y of approximately 200 mm2 s at T 40 C E g SAE 90 transmission oil 6 7 10 2Spindle lubrication Spindle lubrication Clean grease and oil from the lubrication point before lubricating Ensure that the grease gun is axially aligned with the flow direction of the funnel type lubricating nipple A high pressure grease gun with a needle extrusion tip must be used to lubricate the RK DuoLine 50x50 80x80 an...

Page 30: ...the lubrication points for different axis types for the guide shaft 3 and for the spindle 5 6 7 11 Lubrication Axis type PLS II All linear units are provided in the factory with the required lubricant quantities Servicing intervals are dependent on the hours run the stress ing and environmental factors Lubrication occurs directly via the grease nipple Before lubricating clean grease and oil from t...

Page 31: ...e To do this the guidance slot is driven out from the drive side to the rear end position The grease is fed via the grease nipple 1 to the grease nut 2 and distributed in small quantities on the spindle Grease in two stages After the first stage drive the guide slides through two slide lengths and then top up with the second stage Fig 23 Lubrication point to the spindle lubrication 1 nipples 2 lub...

Page 32: ...Maintenance for DriveSets 32 699 41 20 1 For use in max range Grease in accordance with DIN 51818 Viscosity class NLGI class 2 Lubricant quantities 2 sub quantities for each 2 0 cm3 ...

Page 33: ...ews 8 Cover band 9 Leading nut receptacle Drive the carriage to the service position 1 Remove the fillister head screws 2 and dismount cover cap 3 Remove the middle slider 4 and unscrew set screws 5 Push carriage 6 to the side Release the set screw 7 and remove it using the sliding nut Pull out and lift the cover band 8 now the lubrication hole is visible in the leading nut receptacle 9 Regrease w...

Page 34: ...he middle slider 4 Insert the regreasing adapter A into the lubrication hole of the leading nut receptacle 9 Regrease now with grease gun For the quantity of grease see ta ble below Attach the dissolved components in reverse order 6 8 1 3 Lubrication amounts for the regreasing axis type DSK DST Spindle greasing every 500 1000 working hours Axis size Pitch Regreasing g 120 16 x 05 1 33 120 16 x 10 ...

Page 35: ...e the carriage to the second greasing nipple and re grease here as well Lubricant Bearing grease based on DIN 51825 see Chap 6 6 Lubrication interval The required regreasing intervals depend on environmental conditions the standardrecommendation is once per 1 000 km 6 8 1 5 Lubrication amounts for the regreasing axis type QS_ Axis size Pitch Regreasing g 60 KG 16 x 05 1 33 60 KG 16 x 10 0 84 60 KG...

Page 36: ...tion hole Re greasing with grease gun Move the carriage to the second greasing nipple and re grease here as well Remount the cover cap Lubricant Bearing grease based on DIN 51825 see Chap 6 6 Lubrication interval The required regreasing intervals depend on environmental conditions the standardrecommendation is once per 1 000 km Lubrication amounts Axis type DS_ Axis type QS_ Quantity ml DS_120 0 3...

Page 37: ... based on DIN 51825 see Chap 6 6 Lubrication interval The required regreasing intervals depend on environmental conditions the standardrecommendation is once per 1 000 km To ensure the func tion of the seal a cleaning hub over the entire travel range should be performed after a maximum of 8 hours Lubricant quantities Axis type LSZ_ Lubricant quantities ml LSZ60 0 4 LSZE60 0 4 6 8 4 Lubrication Axi...

Page 38: ... 6 8 5 1 Lubrication of the section slide Lubrication of the section slide The guide slides are lubricated directly via the grease nipples Clean grease and oil from the lubrication point before lubricating Ensure that the grease gun is axially aligned with the flow direction of the funnel type lubricating nipple A high pressure grease gun with a needle extrusion tip must be used to lubricate the R...

Page 39: ...ine Z S 160 Fig 31 View of the lubrication points for different axis types for the section slide 4 and for the spindle 5 Lubrication of spindle For lubricating the spindle see Chap 6 7 10 2 6 9 Maintenance of axes with bush bearings 6 9 1 Linear axis ZLW Linear glide polymer slide bearings are deployed on the guides for the cogged belt axis ZLW These bearings are 100 maintenance and lubri cation f...

Page 40: ...g the ten sion First screw a side cover 1 Then expose practicing a drawbar pull of the Newton meter in the mid dle of the toothed belt 5 and measure the deflection from the rest po sition 1 Screws side cover 2 Screws motor adapter 3 Clamping screws 4 Motor 5 Toothed belt Fig 32 Overview of a rotary module with toothed belt drive Target value When applying a force of 20N the deflection should be 4 ...

Page 41: ...Maintenance for DriveSets 699 41 20 1 41 Fig 33 Clarification of the seat of the clamping screws Step 3 Tighten screws from the motor adapter again Finally screw again the side cover ...

Page 42: ... 14 15 Toothed belt 15 Guide shafts DuoLine 29 Guiding rods DL_ 26 QL_ 26 Linear axis ZLW 39 LLZ 20 24 LSZ 37 Lubricant 35 36 37 Lubricant interval 37 Lubricant quantities DuoLine Spindle 29 38 Leading nut 28 Lubrication 22 amounts 21 leading nut 34 Axis type LLZ 24 DuoLine Roller castor 29 Section slide 38 interval 35 36 PLS II 30 Lubrication points DuoLine Roller castor 30 maintenance and servic...