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Rexroth IndraControl VCP 20

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Electric Drivesand Controls

Linear Motion and Assembly Technologies Pneumatics

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MobileHydraulics

Rexroth IndraDyn LSynchronous Linear Motors

R911293635Edition 01

Project Planning Manual

About this documentation Rexroth IndraDyn L

DOK-MOTOR*-MLF********-PR01-EN-P

Rexroth IndraDyn L

Synchronous Linear Motors

Project Planning Manual


• R91129363501_Book.doc

• Document Number, 120-1500-B319-01-EN

This documentation ....

• explains product features and applications, technical data as well as

conditions and limits for operation

• provides guidlines for product selection, application, handling andoperation.

Description ReleaseDate

Notes

DOK-MOTOR*-MLF********-PR01-EN-P June04 1st edition

Bosch Rexroth AG, 2004

Copying this document, giving it to others and the use or communicationof the contents thereof without express authority, are forbidden.Offenders are liable for the payment of damages. All rights are reservedin the event of the grand of a patent or the registration of a utility modelor design (DIN 34-1).

The specified data is for product description purposes only and may notbe deemed to be guaranteed unless expressly confirmed in the contract.All rights are reserved with respect to the content of this documentationand the availability of the product.

Bosch Rexroth AGBgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main

Tel +49 (0)93 52 / 40-0 • Tx 68 94 21 • Fax +49 (0)93 52 / 40-48 85

http://www.boschrexroth.com/

Dept. BRC/EDM1 (FS)

This document has been printed on chlorine-free bleached paper.

Title

Type of Documentation

Document Typecode

Internal File Reference

Purpose of Documentation

Record of Revisions

Copyright

Validity

Published by

Note

Rexroth IndraDyn L Contents I


Contents

1 Introduction to the Product 1

1.1 Application range of linear direct drives .......................................................................................1

1.2 About this Documentation............................................................................................................3

Additional components ...........................................................................................................4

Feedback ...............................................................................................................................4

Standards...............................................................................................................................4

2 Important directions for use 2-1

2.1 Appropriate use........................................................................................................................2-1

Introduction .........................................................................................................................2-1

Areas of use and application................................................................................................2-2

2.2 Inappropriate use .....................................................................................................................2-2

3 Safety Instructions for Electric Drives and Controls 3-1

3.1 Introduction ..............................................................................................................................3-1

3.2 Explanations ............................................................................................................................3-1

3.3 Hazards by Improper Use.........................................................................................................3-2

3.4 General Information..................................................................................................................3-3

3.5 Protection Against Contact with Electrical Parts ........................................................................3-4

3.6 Protection Against Electric Shock by Protective Low Voltage (PELV)........................................3-6

3.7 Protection Against Dangerous Movements ...............................................................................3-7

3.8 Protection Against Magnetic and Electromagnetic Fields During Operation andMounting ..................................................................................................................................3-9

3.9 Protection Against Contact with Hot Parts...............................................................................3-10

3.10 Protection During Handling and Mounting...............................................................................3-10

3.11 Battery Safety.........................................................................................................................3-10

3.12 Protection Against Pressurized Systems.................................................................................3-11

4 Technical Data IndraDyn L 1

4.1 Explanation to technical data.......................................................................................................1

4.2 Technical data – size 040............................................................................................................4





4.7 Technical data – size 300..........................................................................................................10

5 Dimensions, installation dimension and - tolerances 5-1

5.1 Installation tolerances...............................................................................................................5-1

II Contents Rexroth IndraDyn L


5.2 Mounting Sizes.........................................................................................................................5-3

Size 040, primary in standard encapsulation........................................................................5-3

Size 040, primary in thermal encapsulation..........................................................................5-4

Size 040, secondary............................................................................................................5-5


Size 070, primary in thermal encapsulation..........................................................................5-7

Size 070, secondary............................................................................................................5-8


Size 100, primary in thermal encapsulation........................................................................5-10

Size 100, secondary..........................................................................................................5-11

Size 140, primary in standard encapsulation......................................................................5-12


Size 140, secondary..........................................................................................................5-14



Size 200, secondary..........................................................................................................5-17



Size 300, secondary..........................................................................................................5-20

6 Type codes for the IndraDyn L 1

6.1 Description..................................................................................................................................1

Type code of the Primary – The MLP......................................................................................2

Type code of the Secondary – The MLS .................................................................................4

6.2 Type code for IndraDyn L 040 .....................................................................................................6

6.3 Type code IndraDyn L 070 ..........................................................................................................8

6.4 Type code for IndraDyn L 100 ...................................................................................................10




7 Accessories and Options 7-1

7.1 Hall sensor box ........................................................................................................................7-1

Schematic assembly............................................................................................................7-2

8 Electrical connection 8-1

8.1 Power connection.....................................................................................................................8-1

Connection cable on the primary .........................................................................................8-1

Power Cable Connection .....................................................................................................8-3

Connection of IndraDrive Drive Controller ............................................................................8-6

Connection of DIAX04 and EcoDrive Drive-Controllers ........................................................8-8

8.2 Connection of linear feedback devices....................................................................................8-10

9 Application and Construction Instructions 9-1

9.1 Functional principle ..................................................................................................................9-1

9.2 Motor Design............................................................................................................................9-2

Rexroth IndraDyn L Inhaltsverzeichnis III


Primary in standard encapsulation.......................................................................................9-3

Primary in thermal encapsulation.........................................................................................9-4

Design secondary part.........................................................................................................9-5

Motor Sizes .........................................................................................................................9-6

9.3 Requirements on the Machine Design ......................................................................................9-7

Mass reduction....................................................................................................................9-7

Mechanical rigidity...............................................................................................................9-7

9.4 Arrangement of Motor Components..........................................................................................9-9

Single arrangement .............................................................................................................9-9

Several motors per axis .....................................................................................................9-10

Vertical axes......................................................................................................................9-17

9.5 Feed and Attractive Forces.....................................................................................................9-18

Attractive forces between the primary and the secondary...................................................9-18

Air-gap-related attractive forces between the primary and the secondary ...........................9-19

Air-gap-related attractive forces vs. power supply ..............................................................9-19

Air-gap-related feed force ..................................................................................................9-20

Reduced overlapping between the primary and the secondary...........................................9-20

9.6 Motor cooling .........................................................................................................................9-22

Thermal behavior of linear motors......................................................................................9-22

Cooling concept of IndraDyn L synchronous linear motors .................................................9-24

Coolant..............................................................................................................................9-26

Sizing the cooling circuit ....................................................................................................9-29

Liquid cooling system ........................................................................................................9-33

9.7 Motor temperature Monitoring Circuit......................................................................................9-38

9.8 Setup Elevation and Ambient Conditions ................................................................................9-41

9.9 Protection Class .....................................................................................................................9-42

9.10 Compatibility ..........................................................................................................................9-42

9.11 Magnetic Fields ......................................................................................................................9-43

9.12 Vibration and Shock ...............................................................................................................9-44

9.13 Enclosure surface ..................................................................................................................9-45

9.14 Noise emission.......................................................................................................................9-45

9.15 Length Measuring System......................................................................................................9-46

Selection criteria for linear scales.......................................................................................9-46

Mounting Linear scales......................................................................................................9-52

9.16 Linear Guides.........................................................................................................................9-53

9.17 Braking Systems and Holding Devices ...................................................................................9-53

9.18 End Position shock absorber ..................................................................................................9-54

9.19 Axis Cover System.................................................................................................................9-55

9.20 Wipers ...................................................................................................................................9-56

9.21 Drive and Control of IndraDyn L motors..................................................................................9-57

Drive controller and power supply modules........................................................................9-57

Control systems.................................................................................................................9-57

9.22 Shutdown upon EMERGENCY STOP and in the Event of a Malfunction.................................9-58

Shutdown by the drive .......................................................................................................9-58

Shutdown by a master control............................................................................................9-59

Shutdown via mechanical braking device...........................................................................9-59

IV Inhaltsverzeichnis Rexroth IndraDyn L


Response to a mains failure ..............................................................................................9-60

Short-circuit of DC bus ......................................................................................................9-60

9.23 Maximum Acceleration Changes (Jerk Limitation)...................................................................9-61

9.24 Position and Velocity Resolution.............................................................................................9-63

9.25 Load Rigidity ..........................................................................................................................9-64

Static load rigidity ..............................................................................................................9-65

Dynamic load rigidity .........................................................................................................9-65

10 Motor-Controller-Combinations 10-1

10.1 General explanation ...............................................................................................................10-1

Explanation of the variables...............................................................................................10-2

10.2 Motor/Controller Combinations; one primary per drive ............................................................10-3

Controlled DC Bus Voltage, mains supply voltage - 3 x 480 VAC.......................................10-3

10.3 Motor/Controller Combinations; parallel primaries on single drive controllers...........................10-6

Controlled DC Bus Voltage, mains supply voltage - 3 x 480 VAC.......................................10-6

11 Motor Sizing 1

11.1 General Procedure ......................................................................................................................1

11.2 Basic formulae ............................................................................................................................2

General equations of motion...................................................................................................2

Feed forces ............................................................................................................................3

Average velocity .....................................................................................................................5

Trapezoidal velocity................................................................................................................6

Triangular velocity ................................................................................................................10

Sinusoidal velocity................................................................................................................11

11.3 Duty cycle and Feed Force........................................................................................................13

Determining the duty cycle....................................................................................................13

11.4 Determining the Drive Power .....................................................................................................15

Continuous Output ...............................................................................................................15

Maximum Output ..................................................................................................................16

Cooling capacity ...................................................................................................................17

Regeneration energy ............................................................................................................17

11.5 Efficiency ..................................................................................................................................18

11.6 Sizing Examples........................................................................................................................19

Handling axis........................................................................................................................19

Machine tool feed axis; sizing via duty cycle .........................................................................28

12 Handling, transportion and storage of the units 12-1

12.1 Identification of the motor components ...................................................................................12-1

Primary .............................................................................................................................12-1

Secondary.........................................................................................................................12-1

12.2 Delivery status and Packaging................................................................................................12-2

12.3 Transportation and Storage ....................................................................................................12-3

Specifics for transporting secondaries of synchronous linear motors..................................12-4

12.4 Checking the motor components ............................................................................................12-5

Factory checks ..................................................................................................................12-5

Rexroth IndraDyn L Inhaltsverzeichnis V


Customer’s receiving inspection ........................................................................................12-5

13 Mounting Instructions 13-1

13.1 Basic precondition..................................................................................................................13-1

13.2 General procedure at mounting of the motor components.......................................................13-1

Installation at spanned secondary parts over the entire traverse path.................................13-1

Installation at whole secondary over the entire traverse path .............................................13-3

13.3 Installation of the secondary segments ...................................................................................13-5

13.4 Installation of the primary........................................................................................................13-7

13.5 Connection liquid cooling........................................................................................................13-7

13.6 Screw locking.........................................................................................................................13-8

14 Startup, Operation and Maintenance 14-1

14.1 General information for startup of IndraDyn L motors..............................................................14-1

14.2 General precondition ..............................................................................................................14-2

Adherence of all electrically and mechanically components ...............................................14-2

Implements .......................................................................................................................14-3

14.3 General start-up procedure.....................................................................................................14-4

14.4 Parametrization ......................................................................................................................14-5

Entering motor parameters ................................................................................................14-5

Input of linear scale parameters.........................................................................................14-6

Input of drive limitations and application-related parameters ..............................................14-6

14.5 Determining the Polarity of the linear scale .............................................................................14-7

14.6 Commutation adjustment........................................................................................................14-9

Method 1: Measuring the reference between the primary and the secondary ...................14-11

Method 2: Current flow method manually activated ..........................................................14-14

Method 3: Current flow method automatically activated....................................................14-15

14.7 Setting and Optimizing the Control Loop...............................................................................14-16

General sequence ...........................................................................................................14-16

Parameter value assignments and optimization of Gantry axes........................................14-18

Estimating the moved mass using a velocity ramp ...........................................................14-19

14.8 Maintenance and check of Motor components ......................................................................14-21

Check of Motor and Auxiliary Components ......................................................................14-21

Electrical check of motor components..............................................................................14-21

15 Service & Support 15-1

15.1 Helpdesk................................................................................................................................15-1

15.2 Service-Hotline.......................................................................................................................15-1

15.3 Internet...................................................................................................................................15-1

15.4 Vor der Kontaktaufnahme... - Before contacting us... ..............................................................15-1

15.5 Kundenbetreuungsstellen - Sales & Service Facilities.............................................................15-2

16 Appendix 16-1

16.1 Recommended suppliers of additional components ................................................................16-1

Length Measuring System .................................................................................................16-1

Linear Guide......................................................................................................................16-1

VI Inhaltsverzeichnis Rexroth IndraDyn L


Energy Chains...................................................................................................................16-1

Heat-exchanger Unit..........................................................................................................16-2

Coolant Additives ..............................................................................................................16-2

Coolant Tubes...................................................................................................................16-2

Axis Cover System ............................................................................................................16-2

End Position Shock Absorbers...........................................................................................16-3

Clamping Elements for Linear Guideways..........................................................................16-3

External Mechanical Brakes ..............................................................................................16-4

Weight Compensation Systems.........................................................................................16-4

Wipers...............................................................................................................................16-4

16.2 Enquiry form for Linear Drives ................................................................................................16-5

17 Index 17-1

Rexroth IndraDyn L Introduction to the Product 1


1 Introduction to the Product

1.1 Application range of linear direct drives

New technologies found in high-production equipment, demand moreand more numerically driven movements with extreme requirements onacceleration, speed and exactness.

Conventional NC-drives consisting of a rotating electrical motor andmechanical transmission elements, i.e. gearboxes, belt transmissions orgear rack pinions, can only fulfill these demands with great effort.

In many cases, linear direct drive technology is an optimal alternativeproviding significant benefits including:

• High velocity and acceleration

• Excellent control quality and positioning behavior

• Direct power transfer – no mechanical transmission elements like ballsrews, toothed belts or gear racks.

• Maintenance-free drive (no wearing parts on the motor)

• Simplified machine structure

• High static and dynamic load rigidity

IndraDyn_L.jpg

Fig. 1-1: Illustration of an IndraDyn L

Due to the direct installation into the machine, there are no wearingmechanical components. This produces a power train with no or minimalbacklash and permits very high control qualities with gains in the positioncontrol loop (Kv factor) of more than 20 m/min/mm.

In conventional electromagnetic systems, positioning tasks with highfeed rates or highly-accelerated, short-stroke movements in quicksuccession lead to premature wear of mechanical parts and thus tofailures and significant costs. In these applications linear direct drivesoffer decisive advantages.

2 Introduction to the Product Rexroth IndraDyn L


Considering the above-mentioned benefits, the following application arewell-suited for linear synchronous direct drives:

• High-speed cutting in transfer lines and machining centers

• Grinding of camshafts and crankshafts

• Laser machining

• Precision and ultra-precision machining

• Sheet-metal working

• Material handling, textile and packaging machines

• Free-form surface machining

• Wood wooking,

• Machining of printed circuit boards

• ......

Due to a practice-oriented combination of motor technology andintelligent digital drive controllers, the linear direct drive technique offersnew solutions with significantly improved performance.

The development status of the synchronous linear technique of BoschRexroth permits a very high force density.

The spectrum of Bosch Rexroth synchronous linear drive technology,which is described below, permits feed drive systems of 250 N up to21,000 N per motor and speeds over 600 m/min.

The following diagram gives an overview of the performance spectrum ofthe Bosch Rexroth motors type IndraDyn L.

Fig. 1-2: Performance spectrum of IndraDyn L motors

Performance Overview

17750

5560

21500

6720

14250

4460

10000

3150

7150

23103800

1200

16300

5150

10900

3465

7650

2415

5600

17852600

820 1150370

11000

3520

7450

2415

5200

1680

3750

11802000

630 800 250M

RMMM

NMMMM

NRMMM

OMMMM

ORMMM

Vo

rsch

ub

kraf

t in

NF

eed

Fo

rces

in N

4070100140200300

AB

CD

Dauernennkraft FdN

Continuos Force F dN

Maximalkraft FMax

Maximum Force F Max

BaugrößeSize KRAFTSPEKTRUM MLF.XLS

Rexroth IndraDyn L Introduction to the Product 3


1.2 About this Documentation

Document StructureThis documentation includes safety instructions, technical data andoperating instructions. The following setup provides an overview of thecontents of this documentation.

Sect. Title Content

1 Introduction General information

2 Important Instructions on Use

3 SafetyImportant safety instructions

4 Technical data

5 Dimensional Details

6 Type Code

7 Accessories

8 Connection System

9Operating condition and applicationinstructions

10 Motor-Controller-Combinations

11 Motordimensionierung

Pro

du

ct d

escr

ipti

on

s

for

plan

ners

and

pro

ject

man

ager

s

12 Handling, Transport and Storage

13 Installation

14 Startup, Operation and

15 Service & Support

Pra

ctic

al in

form

atio

n

for

oper

atin

g an

d m

aint

enan

cepe

rson

nel

16 Appendix

17 IndexAdditional information

Fig. 1-3: Chapter structure

Additional documentationTo plan your project using an IndraDyn L motor, you may need additionaldocumentation depending on the complexity of your system. BoschRexroth provides all product documentation on CD in a PDF-format. Toplan your project, you will not necessary use all the documentationincluded on the CD.

Note: All documentation on the CD are also available in print. Youcan order the required product documentation through yourBosch Rexroth sales office.

Material no.: Title / description

R911281882 -Produktdokumentation Electric Drives and Controls Version xx 1)

DOK-GENRL-CONTR*DRIVE-GNxx-DE-D650

R911281883 -Product documentation Electric Drives and Controls Version xx 1)

DOK-GENRL-CONTR*DRIVE-GNxx-EN-D650

1) The index (e.g. ..02-...) identifies the version of the CD.

Fig. 1-4: Additional documentation

4 Introduction to the Product Rexroth IndraDyn L


Additional componentsDocumentation for external systems which are connected to BoschRexroth components are not included in the scope of delivery and mustbe ordered directly from the particular manufacturers.

For information about the manufacturers see chapter 16 “Appendix”

FeedbackYour experiences are an essential part of the process of improving bothproduct and documentation.

Please do not hesitate to inform us of any mistakes you detect in thisdocumentation or of any modifications you might desire. We wouldappreciate your feedback.

Please send your remarks to:

Bosch Rexroth AGDept. BRC/EDM1Bürgermeister-Dr.-Nebel-Strasse 2D-97816 Lohr, Germany

Fax +49 (0) 93 52 / 40-43 80

StandardsThis documentation refers to German, European and internationaltechnical standards. Documents and sheets on standards are subject tothe protection by copyright and may not be passed on to third parties byBOSCH REXROTH AG. If necessary, please address the authorizedsales outlets or, in Germany, directly to:

BEUTH Verlag GmbHBurggrafenstrasse 610787 Berlin

Phone +49-(0)30-26 01-22 60, Fax +49-(0)30-26 01-12 60Internet: http://www.din.de/beuth [email protected]

Rexroth IndraDyn L Important directions for use 2-1


2 Important directions for use

2.1 Appropriate use

IntroductionBosch Rexroth products represent state-of-the-art developments andmanufacturing. They are tested prior to delivery to ensure operatingsafety and reliability.

The products may only be used in the manner that is defined asappropriate. If they are used in an inappropriate manner, then situationscan develop that may lead to property damage or injury to personnel.

Note: Bosch Rexroth, as manufacturer, is not liable for anydamages resulting from inappropriate use. In such cases, theguarantee and the right to payment of damages resultingfrom inappropriate use are forfeited. The user alone carriesall responsibility of the risks.

Before using Rexroth products, make sure that all the pre-requisites forappropriate use of the products are satisfied:

• Personnel that in any way, shape or form uses our products must firstread and understand the relevant safety instructions and be familiarwith appropriate use.

• If the product takes the form of hardware, then they must remain intheir original state, in other words, no structural changes arepermitted. It is not permitted to decompile software products or altersource codes.

• Do not mount damaged or faulty products or use them in operation.

• Make sure that the products have been installed in the mannerdescribed in the relevant documentation.

2-2 Important directions for use Rexroth IndraDyn L


Areas of use and applicationRexroth IndraDyn L motors are designed to be used as linear servo drivemotors.

Available for an application-specific use of the motors are unit types withdiffering drive power and different interfaces.

Control and monitoring of the motors may require additional sensors andactors.

Note: The motors may only be used with the accessories and partsspecified in this document. If a component has not beenspecifically named, then it may not be either mounted orconnected. The same applies to cables and lines.

Operation is only permitted in the specified configurationsand combinations of components using the software andfirmware as specified in the relevant function descriptions.

Every drive controller has to be programmed before starting it up,making it possible for the motor to execute the specific functions of anapplication.

The motors may only be operated under the assembly, installation andambient conditions as described here (temperature, protectioncategories, humidity, EMC requirements, etc.) and in the positionspecified.

2.2 Inappropriate use

Using the motors outside of the above-referenced areas of application orunder operating conditions other than described in the document and thetechnical data specified is defined as “inappropriate use".

IndraDyn L motors may not be used if

• they are subject to operating conditions that do not meet the abovespecified ambient conditions. This includes, for example, operationunder water, in the case of extreme temperature fluctuations orextremely high maximum temperatures or if

• Bosch Rexroth has not specifically released them for that intendedpurpose. Please note the specifications outlined in the generalSafety Instructions!

Rexroth IndraDyn L Safety Instructions for Electric Drives and Controls 3-1


3 Safety Instructions for Electric Drives and Controls

3.1 Introduction

Read these instructions before the initial startup of the equipment inorder to eliminate the risk of bodily harm or material damage. Followthese safety instructions at all times.

Do not attempt to install or start up this equipment without first readingall documentation provided with the product. Read and understand thesesafety instructions and all user documentation of the equipment prior toworking with the equipment at any time. If you do not have the userdocumentation for your equipment, contact your local Bosch Rexrothrepresentative to send this documentation immediately to the person orpersons responsible for the safe operation of this equipment.

If the equipment is resold, rented or transferred or passed on to others,then these safety instructions must be delivered with the equipment.

WARNING

Improper use of this equipment, failure to followthe safety instructions in this document ortampering with the product, including disablingof safety devices, may result in materialdamage, bodily harm, electric shock or evendeath!

3.2 Explanations

The safety instructions describe the following degrees of hazardseriousness in compliance with ANSI Z535. The degree of hazardseriousness informs about the consequences resulting from non-compliance with the safety instructions.

Warning symbol with signalword

Degree of hazard seriousness accordingto ANSI

DANGER

Death or severe bodily harm will occur.

WARNING

Death or severe bodily harm may occur.

CAUTION

Bodily harm or material damage may occur.

Fig. 3-1: Hazard classification (according to ANSI Z535)

3-2 Safety Instructions for Electric Drives and Controls Rexroth IndraDyn L


3.3 Hazards by Improper Use

DANGER

High voltage and high discharge current!Danger to life or severe bodily harm by electricshock!

DANGER

Dangerous movements! Danger to life, severebodily harm or material damage by unintentionalmotor movements!

WARNING

High electrical voltage due to wrongconnections! Danger to life or bodily harm byelectric shock!

WARNING

Health hazard for persons with heartpacemakers, metal implants and hearing aids inproximity to electrical equipment!

CAUTION

Surface of machine housing could be extremelyhot! Danger of injury! Danger of burns!

CAUTION

Risk of injury due to improper handling! Bodilyharm caused by crushing, shearing, cutting andmechanical shock or incorrect handling ofpressurized systems!

CAUTION

Risk of injury due to incorrect handling ofbatteries!



3.4 General Information

• Bosch Rexroth AG is not liable for damages resulting from failure toobserve the warnings provided in this documentation.

• Read the operating, maintenance and safety instructions in yourlanguage before starting up the machine. If you find that you cannotcompletely understand the documentation for your product, pleaseask your supplier to clarify.

• Proper and correct transport, storage, assembly and installation aswell as care in operation and maintenance are prerequisites foroptimal and safe operation of this equipment.

• Only persons who are trained and qualified for the use and operationof the equipment may work on this equipment or within its proximity.

• The persons are qualified if they have sufficient knowledge of theassembly, installation and operation of the equipment as well asan understanding of all warnings and precautionary measuresnoted in these instructions.

• Furthermore, they must be trained, instructed and qualified toswitch electrical circuits and equipment on and off in accordancewith technical safety regulations, to ground them and to mark themaccording to the requirements of safe work practices. They musthave adequate safety equipment and be trained in first aid.

• Only use spare parts and accessories approved by the manufacturer.

• Follow all safety regulations and requirements for the specificapplication as practiced in the country of use.

• The equipment is designed for installation in industrial machinery.

• The ambient conditions given in the product documentation must beobserved.

• Use only safety features and applications that are clearly andexplicitly approved in the Project Planning Manual.For example, the following areas of use are not permitted:construction cranes, elevators used for people or freight, devices andvehicles to transport people, medical applications, refinery plants,transport of hazardous goods, nuclear applications, applicationssensitive to high frequency, mining, food processing, control ofprotection equipment (also in a machine).

• The information given in the documentation of the product withregard to the use of the delivered components contains onlyexamples of applications and suggestions.The machine and installation manufacturer must

• make sure that the delivered components are suited for hisindividual application and check the information given in thisdocumentation with regard to the use of the components,

• make sure that his application complies with the applicable safetyregulations and standards and carry out the required measures,modifications and complements.

• Startup of the delivered components is only permitted once it is surethat the machine or installation in which they are installed complieswith the national regulations, safety specifications and standards ofthe application.



• Operation is only permitted if the national EMC regulations for theapplication are met.The instructions for installation in accordance with EMC requirementscan be found in the documentation "EMC in Drive and ControlSystems".The machine or installation manufacturer is responsible forcompliance with the limiting values as prescribed in the nationalregulations.

• Technical data, connections and operational conditions are specifiedin the product documentation and must be followed at all times.

3.5 Protection Against Contact with Electrical Parts

Note: This section refers to equipment and drive components withvoltages above 50 Volts.

Touching live parts with voltages of 50 Volts and more with bare handsor conductive tools or touching ungrounded housings can be dangerousand cause electric shock. In order to operate electrical equipment,certain parts must unavoidably have dangerous voltages applied tothem.



DANGER

High electrical voltage! Danger to life, severebodily harm by electric shock!⇒ Only those trained and qualified to work with or on

electrical equipment are permitted to operate, maintainor repair this equipment.

⇒ Follow general construction and safety regulationswhen working on high voltage installations.

⇒ Before switching on power the ground wire must bepermanently connected to all electrical units accordingto the connection diagram.

⇒ Do not operate electrical equipment at any time, evenfor brief measurements or tests, if the ground wire isnot permanently connected to the points of thecomponents provided for this purpose.

⇒ Before working with electrical parts with voltage higherthan 50 V, the equipment must be disconnected fromthe mains voltage or power supply. Make sure theequipment cannot be switched on again unintended.

⇒ The following should be observed with electrical driveand filter components:

⇒ Wait five (5) minutes after switching off power to allowcapacitors to discharge before beginning to work.Measure the voltage on the capacitors beforebeginning to work to make sure that the equipment issafe to touch.

⇒ Never touch the electrical connection points of acomponent while power is turned on.

⇒ Install the covers and guards provided with theequipment properly before switching the equipment on.Prevent contact with live parts at any time.

⇒ A residual-current-operated protective device (RCD)must not be used on electric drives! Indirect contactmust be prevented by other means, for example, by anovercurrent protective device.

⇒ Electrical components with exposed live parts anduncovered high voltage terminals must be installed in aprotective housing, for example, in a control cabinet.



To be observed with electrical drive and filter components:

DANGER

High electrical voltage on the housing!High leakage current! Danger to life, danger ofinjury by electric shock!⇒ Connect the electrical equipment, the housings of all

electrical units and motors permanently with thesafety conductor at the ground points before power isswitched on. Look at the connection diagram. This iseven necessary for brief tests.

⇒ Connect the safety conductor of the electricalequipment always permanently and firmly to thesupply mains. Leakage current exceeds 3.5 mA innormal operation.

⇒ Use a copper conductor with at least 10 mm² crosssection over its entire course for this safety conductorconnection!

⇒ Prior to startups, even for brief tests, always connectthe protective conductor or connect with ground wire.Otherwise, high voltages can occur on the housingthat lead to electric shock.

3.6 Protection Against Electric Shock by Protective LowVoltage (PELV)

All connections and terminals with voltages between 0 and 50 Volts onRexroth products are protective low voltages designed in accordancewith international standards on electrical safety.

WARNING

High electrical voltage due to wrongconnections! Danger to life, bodily harm byelectric shock!⇒ Only connect equipment, electrical components and

cables of the protective low voltage type (PELV =Protective Extra Low Voltage) to all terminals andclamps with voltages of 0 to 50 Volts.

⇒ Only electrical circuits may be connected which aresafely isolated against high voltage circuits. Safeisolation is achieved, for example, with an isolatingtransformer, an opto-electronic coupler or whenbattery-operated.



3.7 Protection Against Dangerous Movements

Dangerous movements can be caused by faulty control of the connectedmotors. Some common examples are:

• improper or wrong wiring of cable connections

• incorrect operation of the equipment components

• wrong input of parameters before operation

• malfunction of sensors, encoders and monitoring devices

• defective components

• software or firmware errors

Dangerous movements can occur immediately after equipment isswitched on or even after an unspecified time of trouble-free operation.

The monitoring in the drive components will normally be sufficient toavoid faulty operation in the connected drives. Regarding personalsafety, especially the danger of bodily injury and material damage, thisalone cannot be relied upon to ensure complete safety. Until theintegrated monitoring functions become effective, it must be assumed inany case that faulty drive movements will occur. The extent of faultydrive movements depends upon the type of control and the state ofoperation.



DANGER

Dangerous movements! Danger to life, risk ofinjury, severe bodily harm or material damage!⇒ Ensure personal safety by means of qualified and

tested higher-level monitoring devices or measuresintegrated in the installation. Unintended machinemotion is possible if monitoring devices are disabled,bypassed or not activated.

⇒ Pay attention to unintended machine motion or othermalfunction in any mode of operation.

⇒ Keep free and clear of the machine’s range of motionand moving parts. Possible measures to preventpeople from accidentally entering the machine’srange of motion:- use safety fences

- use safety guards

- use protective coverings

- install light curtains or light barriers

⇒ Fences and coverings must be strong enough toresist maximum possible momentum, especially ifthere is a possibility of loose parts flying off.

⇒ Mount the emergency stop switch in the immediatereach of the operator. Verify that the emergency stopworks before startup. Don’t operate the machine ifthe emergency stop is not working.

⇒ Isolate the drive power connection by means of anemergency stop circuit or use a starting lockout toprevent unintentional start.

⇒ Make sure that the drives are brought to a safestandstill before accessing or entering the dangerzone. Safe standstill can be achieved by switching offthe power supply contactor or by safe mechanicallocking of moving parts.

⇒ Secure vertical axes against falling or dropping afterswitching off the motor power by, for example:- mechanically securing the vertical axes

- adding an external braking/ arrester/ clampingmechanism

- ensuring sufficient equilibration of the verticalaxes

The standard equipment motor brake or an externalbrake controlled directly by the drive controller arenot sufficient to guarantee personal safety!



⇒ Disconnect electrical power to the equipment using amaster switch and secure the switch againstreconnection for:- maintenance and repair work

- cleaning of equipment

- long periods of discontinued equipment use

⇒ Prevent the operation of high-frequency, remotecontrol and radio equipment near electronics circuitsand supply leads. If the use of such equipmentcannot be avoided, verify the system and theinstallation for possible malfunctions in all possiblepositions of normal use before initial startup. Ifnecessary, perform a special electromagneticcompatibility (EMC) test on the installation.

3.8 Protection Against Magnetic and Electromagnetic FieldsDuring Operation and Mounting

Magnetic and electromagnetic fields generated near current-carryingconductors and permanent magnets in motors represent a serious healthhazard to persons with heart pacemakers, metal implants and hearingaids.

WARNING

Health hazard for persons with heartpacemakers, metal implants and hearing aids inproximity to electrical equipment!⇒ Persons with heart pacemakers, hearing aids and

metal implants are not permitted to enter thefollowing areas:- Areas in which electrical equipment and parts are

mounted, being operated or started up.

- Areas in which parts of motors with permanentmagnets are being stored, operated, repaired ormounted.

⇒ If it is necessary for a person with a heart pacemakerto enter such an area, then a doctor must beconsulted prior to doing so. Heart pacemakers thatare already implanted or will be implanted in thefuture, have a considerable variation in their electricalnoise immunity. Therefore there are no rules withgeneral validity.

⇒ Persons with hearing aids, metal implants or metalpieces must consult a doctor before they enter theareas described above. Otherwise, health hazardswill occur.



3.9 Protection Against Contact with Hot Parts

CAUTION

Housing surfaces could be extremely hot!Danger of injury! Danger of burns!⇒ Do not touch housing surfaces near sources of heat!

Danger of burns!⇒ After switching the equipment off, wait at least ten

(10) minutes to allow it to cool down before touchingit.

⇒ Do not touch hot parts of the equipment, such ashousings with integrated heat sinks and resistors.Danger of burns!

3.10 Protection During Handling and Mounting

Under certain conditions, incorrect handling and mounting of parts andcomponents may cause injuries.

CAUTION

Risk of injury by incorrect handling! Bodily harmcaused by crushing, shearing, cutting andmechanical shock!⇒ Observe general installation and safety instructions

with regard to handling and mounting.⇒ Use appropriate mounting and transport equipment.⇒ Take precautions to avoid pinching and crushing.⇒ Use only appropriate tools. If specified by the product

documentation, special tools must be used.⇒ Use lifting devices and tools correctly and safely.⇒ For safe protection wear appropriate protective

clothing, e.g. safety glasses, safety shoes and safetygloves.

⇒ Never stand under suspended loads.⇒ Clean up liquids from the floor immediately to prevent

slipping.

3.11 Battery Safety

Batteries contain reactive chemicals in a solid housing. Inappropriatehandling may result in injuries or material damage.



CAUTION

Risk of injury by incorrect handling!⇒ Do not attempt to reactivate discharged batteries by

heating or other methods (danger of explosion andcauterization).

⇒ Never charge non-chargeable batteries (danger ofleakage and explosion).

⇒ Never throw batteries into a fire.⇒ Do not dismantle batteries.⇒ Do not damage electrical components installed in the

equipment.

Note: Be aware of environmental protection and disposal! Thebatteries contained in the product should be considered ashazardous material for land, air and sea transport in thesense of the legal requirements (danger of explosion).Dispose batteries separately from other waste. Observe thelegal requirements in the country of installation.

3.12 Protection Against Pressurized Systems

Certain motors and drive controllers, corresponding to the information inthe respective Project Planning Manual, must be provided withpressurized media, such as compressed air, hydraulic oil, cooling fluidand cooling lubricant supplied by external systems. Incorrect handling ofthe supply and connections of pressurized systems can lead to injuriesor accidents. In these cases, improper handling of external supplysystems, supply lines or connections can cause injuries or materialdamage.

CAUTION

Danger of injury by incorrect handling ofpressurized systems !⇒ Do not attempt to disassemble, to open or to cut a

pressurized system (danger of explosion).⇒ Observe the operation instructions of the respective

manufacturer.⇒ Before disassembling pressurized systems, release

pressure and drain off the fluid or gas.⇒ Use suitable protective clothing (for example safety

glasses, safety shoes and safety gloves)⇒ Remove any fluid that has leaked out onto the floor

immediately.

Note: Environmental protection and disposal! The media used inthe operation of the pressurized system equipment may notbe environmentally compatible. Media that are damaging theenvironment must be disposed separately from normal waste.Observe the legal requirements in the country of installation.



Notes

Rexroth IndraDyn L Technical Data IndraDyn L 1


4 Technical Data IndraDyn L

4.1 Explanation to technical data

All relevant technical motor data as well as the functional principle ofthese motors are given on the following pages in terms of tables andcharacteristic curves. The following parameters will be taken intoconsideration :

• Size and length of the primary

• Type of winding of the primary

• Available power supply or DC link voltage

Note: Unless otherwise noted, all data and characteristic curves arebased on the following conditions:

• Motor-winding temperature of 135°C.

• Nominal air gap

• Cooling with water with a supply temperature of 30°C

Note: Resulting data from certain motor-controller combinations candiffer from the given data. See Chapter 10 “Motor-controllercombinations”.

Characteristic force/speed curveThe characteristic force vs. speed curve is given shows the limitingcurve. The shapes of these characteristic curves are defined by the DCbus voltage and the relevant motor-specific data, e.g. inductivity,resistance and the motor constants. Varying the DC bus voltage (usingdifferent drives, power supplies or supply voltages) and/or using differentmotor windings will result in different characteristic curves (see Fig. 4-1).

2 Technical Data IndraDyn L Rexroth IndraDyn L


FVKENNLIN-MLF-EN.EPS

[1]: 3 x 400V providing an unregulated DC bus voltage, UDC = 540V(Possible with an HCS compact drive controller or with an HMS orHMD drive controller in combination with an HMV power supply)



[4]: 3 x 480V providing an regulated DC bus voltage, UDC = 650V(Possible with an HMS or HMD drive controller in combination withan HMV power supply)

[5]: 3 x 400....480V providing an regulated DC bus voltage, UDC = 750V(Possible with an HMS or HMD drive controller in combination withan HMV power supply)

Fig. 4-1: Characteristic force vs. Speed curve

The maximum force, FMAX, is available up to a limited velocity, vFMAX.When the velocity rises, the available DC bus voltage is reduced by thevelocity-dependent Back EMF of the motor. This leads to a reduction ofthe maximum feed force at higher velocities. The characteristic curvesare specified up to the continuous nominal force. The velocity thatbelongs to the continuous nominal force is known as nominal velocity,vN.

Note: If the connection voltages or mains voltages are different, thespecified characteristic curves can be converted linearlyaccording to the existing voltages.

Where power supply modules with unregulated DC busvoltage are concerned, voltage drops – from simultaneousacceleration of several axes, for example - must be taken intoconsideration.



The following interrelations exist for the parallel connection of twoprimaries on one drive controller:

• Doubling of currents and feed forces(unless limited by the drive controller)

• Velocities vFMAX and vNENN as in single arrangement

• Same motor and voltage constants (kiF, kE)

• Halved motor resistances and inductances.

FVKENNLIN1-MLF-EN.EPS

Fig. 4-2: Characteristic force vs. Speed curves for single and parallelconnection of primaries to one drive controller

Note: To facilitate the commissioning of parallel connection of twoprimaries to one drive controller, this document hascorresponding selection data for motor – controllercombinations and the motor parameters (see chapter 10“Motor – Controller Combinations” and Chapter 14“Commissioning”)

Parallel connection of twoprimaries on one drive controller



4.2 Technical data – size 040

Description Symbol Unit MLP040

Motor data 1)

Frame length A B

Winding code 0300 0150 0250 0300

Corresponding secondaries MLS040S-3A-****-NNNN

Maximum force 2) Fmax N 800 1150

Continuous nominal force FdN N 250 370

Max. current imax A 20 20 27 35

Continuous current idN A 4.2 4.2 5.3 6

Maximum speed with Fmax 3) vFmax m/min 300 150 250 300

Nominal velocity 3) vN m/min 500 300 400 500

Force constant KiFN N/A 60 88 70 62

Voltage constant 4) KEMF Vs/m in preparation

Winding resistance at 20°C R12 Ohm 8.6 i.p. i.p. 5.1

Winding inductivety L12 mH 54.2 i.p. i.p. 33.2

Minimum cross-section of connection cable 5) APL mm² 1

Rated power loss PvN W 400 550

Nominal air gap δ mm 1.0 ±0.4

Attractive force 6) FATT N 1200 1700

Mass of primary - standard encapsulation mPS kg 4.7 6.1

Mass of primary - thermal encapsulation mPT kg 6.1 8.1

Unit mass if secondary mS kg/m 5.4

Required coolant flow ∆ϑN 10) Qmin l/min 0.57 0.79

standard encapsulation 0.16 0.16Pressure loss constant 7)

thermal encapsulationkdp

0.16 0.16standard encapsulation 0.06 0.10

Pressure loss at QNthermal encapsulation

∆p bar0.06 0.11

Coolant inlet temperature 8) ϑin °C +15...+40

Temperature rise at PvN 9) ∆ϑN K 10

Thermal time constant Tth min in preparation

Permissible temperature of secondary TSmax °C 70

Permissible ambient temperature Tum °C 0...+45

Permissible storage and transport temperature TL °C -10...+60

Protection class IP65

Insulation class acc. to DIN VDE 0530-1 F

Housing surface of primary-FT-: Priming black (RAL 9005)-FS-: stainless steel blank / priming black (RAL 9005)

1) The measured values are effective values acc. to IEC 60034-1, unless other values are given. Reference value is 540 VDC.2) The maximum obtainable force depends on the drive controller.3) The obtain velocity depends on the DC bus voltage.4) EMF=Electromagnetic force. Effective value refer to 1 min-1.5) Dimensioned to EN 60204-1(1993), laying system B2 and conversion factor for Bosch Rexroth cable at 40°C environmental

temperature. When using other cables, other cross-sections may be required. For additional notes to connection and power cablessee Chapter 8.1.

6) Nominal air gap between primary and secondary, No voltage applied to primary, see Chapter 9.5.7) Coolant medium is water. Actual pressure loss is dependent on the coolant flow, see Chapter 9.6.8) The coolant inlet temperature may be max. 5°K under the ambient temperature due to danger of condensation!9) Operation with liquid cooling using water as coolant with a supply temperature of 30°C.10) For further notes see Chapter 9.6 “Motor coolant, flow rate“.

Fig. 4-3: Data sheet motor size 040




Description Symbol Unit MLP070Motor data 1)

Frame length A B

Winding code 0150 0220 0300 0100 0120 0150 0250 0300


Maximum force 2) Fmax N 2000 2600

Continuous nominal force FdN N 630 820

Max. current imax A 27 35 55 28 42 48 55 70

Continuous current idN A 5.3 6.3 10.5 5.5 5.8 6.2 10 12

Maximum speed with Fmax 3) vFmax m/mi 150 220 300 100 120 150 250 300

Nominal velocity 3) vN m/mi 250 360 450 200 220 260 400 450

Force constant KiFN N/A 119 100 60 149 141 132 82 68

Voltage constant 4) KEMF Vs/ i.p. i.p. 20 i.p. 80 i.p. i.p. i.p.

Winding resistance at 20°C R12 Ohm i.p. i.p. 2.8 i.p. 9.2 i.p. i.p. i.p.

Winding inductivety L12 mH i.p. i.p. 14.3 i.p. 51.6 i.p. i.p. i.p.

Minimum cross-section of connection cable 5) APL mm² 1

Rated power loss PvN W 780 900


Attractive force 6) FATT N 2900 3750

Mass of primary - standard encapsulation mPS kg 8.4 10.4

Mass of primary - thermal encapsulation mPT kg 10.9 13.4


Required coolant flow ∆ϑN 10) Qmin l/min 1.12 1.29

standard encapsulation 0.18 0.18Pressure loss constant 7)


0.18 0.18standard encapsulation 0.22 0.28


∆p bar0.22 0.29



Thermal time constant Tth min 6 5.7










Fig. 4-4: Data sheet motor size 070(1/2)




Motor data 1)

Frame length C

Winding code 0120 0150 0240 0300


Maximum force 2) Fmax N 3800

Continuous nominal force FdN N 1200

Max. current imax A 55 62 70 110

Continuous current idN A 8.9 10 13 19

Maximum speed with Fmax 3) vFmax m/min 120 150 240 300

Nominal velocity 3) vN m/min 180 250 350 450

Force constant KiFN N/A 135 120 92 63

Voltage constant 4) KEMF Vs/m 78 i.p. i.p. i.p.

Winding resistance at 20°C R12 Ohm 5.7 i.p. i.p. 1.5

Winding inductivety L12 mH 33.9 i.p. i.p. 12.3

Minimum cross-section of connection cable 5) APL mm² 1 2.5

Rated power loss PvN W 1100


Attractive force 6) FATT N 5500

Mass of primary - standard encapsulation mPS kg 14.5

Mass of primary - thermal encapsulation mPT kg 18.4


Required coolant flow ∆ϑN 10) Qmin l/min 1.58

standard encapsulation 0.19Pressure loss constant 7)


0.19standard encapsulation 0.43


∆p bar0.43



Thermal time constant Tth min 7.5










Fig. 4-5: Data sheet motor size 070(2/2)





Motor data 1)

Frame length A B C

Winding code 0090 0120 0150 0190 0120 0250 0090 0120 0190


Maximum force 2) Fmax N 3750 5600 7150

Continuous nominal force FdN N 1180 1785 2310

Max. current imax A 38 44 55 70 70 130 70 85 140

Continuous current idN A 6.6 8 10 12 12 22 13 15 23

Maximum speed with Fmax 3) vFmax m/mi 90 120 150 190 120 250 90 120 190

Nominal velocity 3) vN m/mi 150 190 220 290 190 350 170 190 290

Force constant KiFN N/A 169 148 118 98 149 81 178 154 100

Voltage constant 4) KEMF Vs/ i.p. i.p. i.p. i.p. 87 i.p. i.p. 89 i.p.

Winding resistance at 20°C R12 Ohm 8.8 8 i.p. i.p. 4.45 i.p. i.p. 3.8 i.p.

Winding inductivety L12 mH 55 49 i.p. i.p. 25 i.p. i.p. 21.1 i.p.

Minimum cross-section of connection cable 5) APL mm² 1 2.5 1 1.5 4

Rated power loss PvN W 900 1300 1600


Attractive force 6) FATT N 5400 8000 10400

Mass of primary - standard encapsulation mPS kg 13.5 18.7 24

Mass of primary - thermal encapsulation mPT kg 17 23.3 29.7


Required coolant flow ∆ϑN 10) Qmin l/min 1.29 1.87 2.3

standard encapsulation 0.19 0.18 0.19Pressure loss constant 7)


0.19 0.18 0.19standard encapsulation 0.29 0.52 0.8


∆p bar0.3 0.54 0.82



Thermal time constant Tth min i.p. 7 6.8










Fig. 4-6: Data sheet size 100





Motor data 1)

Frame length A B C

Winding code 0120 0090 0120 0050 0120 0170




Max. current imax A 70 70 105 70 125 140

Continuous current idN A 12 13 18 13 21 29

Maximum speed with Fmax 3) vFmax m/min 120 90 120 50 120 170

Nominal velocity 3) vN m/min 190 160 190 110 190 250

Force constant KiFN N/A 140 186 134 242 150 109

Voltage constant 4) KEMF Vs/m i.p. i.p. i.p. i.p. i.p. i.p.

Winding resistance at 20°C R12 Ohm 4 i.p. 2.6 i.p. 2.6 i.p.

Winding inductivety L12 mH 28.2 i.p. 19.8 i.p. 12.3 i.p.

Minimum cross-section of connection cable 5) APL mm² 1 2.5 1 2.5 4




Mass of primary - standard encapsulation mPS kg 17 24.5 32

Mass of primary - thermal encapsulation mPT kg 21.2 30.1 38.9







∆p bar0.56 0.89 1.18


















Motor data 1)

Frame length A B C D

Winding code 0090 0120 0040 0120 0090 0120 0170 0060 0100 0120


Maximum force 2) Fmax N 7450 10900 14250 17750

Continuous nominal force FdN N 2415 3465 4460 5560

Max. current imax A 70 88 70 130 140 175 210 140 210 225

Continuous current idN A 13 16 13 22 29 30 46 28 46 53

Maximum speed with Fmax 3) vFmax m/mi 90 120 40 120 90 120 170 60 100 120

Nominal velocity 3) vN m/mi 170 190 100 190 170 190 220 140 180 190

Force constant KiFN N/A 186 151 267 158 147 142 92 199 121 105

Voltage constant 4) KEMF Vs/ in preparation

Winding resistance at 20°C R12 Ohm i.p. 2.3 i.p. 1.7 i.p. 2.7 i.p. i.p. i.p. 1.3

Winding inductivety L12 mH i.p. 10.9 i.p. 16.4 i.p. 13.1 i.p. i.p. i.p. 12.4

Minimum cross-section of connection cable 5) APL mm² 1 2.5 1 2.5 4 6 10 4 10 10

Rated power loss PvN W 1700 2200 2700 3000


Attractive force 6) FATT N 10700 15600 20500 25400

Mass of primary - standard encapsulation mPS kg 23 33 42 51

Mass of primary - thermal encapsulation mPT kg 28.3 40 50.7 61.3


Required coolant flow ∆ϑN 10) Qmin l/min 2.44 3.16 3.88 4.31

standard encapsulation 0.18 0.18 0.19 0.19Pressure loss constant 7)


0.19 0.19 0.19 0.19standard encapsulation 0.88 1.38 1.99 2.4


∆p bar0.9 1.41 2.04 2.45


















Motordaten 1)

Frame length A B C

Winding code 0090 0120 0070 0120 0060 0090




Max. current imax A 110 138 140 205 140 212

Continuous current idN A 19 23 28 35 29 37

Maximum speed with Fmax 3) vFmax m/min 90 120 70 120 60 90

Nominal velocity 3) vN m/min 160 190 140 190 110 150

Force constant KiFN N/A 176 146 184 147 232 182

Voltage constant 4) KEMF Vs/m i.p. i.p. i.p. i.p. i.p. i.p.

Winding resistance at 20°C R12 Ohm i.p. 2 i.p. 1.3 i.p. 1

Winding inductivety L12 mH i.p. 20.8 i.p. 13.6 i.p. 9.9

Minimum cross-section of connection cable 5) APL mm² 2.5 4 4 6 4 6




Mass of primary - standard encapsulation mPS kg 33 48 62

Mass of primary - thermal encapsulation mPT kg 40.8 58.3 74.9







∆p bar1.44 2.34 2.78






Permissible storage and transport temperatur TL °C -10...+60








Rexroth IndraDyn L Dimensions, installation dimension and - tolerances 5-1


5 Dimensions, installation dimension and -tolerances

5.1 Installation tolerances

In order to ensure a constant force along the entire travel length, adefined air gap height must be guaranteed. For this purpose, theindividual parts of the motor (primary and secondary) are toleratedaccordingly. The distance of the mounting surface, the parallelism andthe symmetry of the primary and secondary of the linear motor in themachine must be within a certain tolerance above the entire travellength. Any deformations that result from weight, attractive forces andprocess forces must be taken into account. A deviation of the specifiednominal air gap may lead

• to a reduction or modification of the specified performance data,

• to a contact between the primary and the secondary and thus todamaged and destroyed motor components.

For the installation of the motors into the machine structure, BoschRexroth specifies a defined installation height including tolerances (seeinstallation size L1 in Fig. 5-1). Thus, the specified size and tolerances ofthe air gap are maintained automatically – even if individual motorcomponents are replaced.

Size Primary Design Primary DesignSecondary

InstallationHeight

L1

MeasurableAir Gap L2

40, 070, 100, 140, 200 standardencapsulation

61,4 +0,1

300 standardencapsulation

63,4 +0,1

040, 070, 100, 140, 200 thermalencapsulation

73,9 +0,1

300 thermalencapsulation

MLSxxxS-*

77,9 +0,1

1,0 ± 0,4

Fig. 5-1: Mounting Sizes and Tolerances

5-2 Dimensions, installation dimension and - tolerances Rexroth IndraDyn L


Figure 5-2 defines the parallelism and symmetry between primary andsecondary to be kept.

PARALSYSM-MLF-EN.EPS

Fig. 5-2: Parallelism and symmetry between primary and secondary

Note: The specified installation height with the correspondingtolerances has to be observed absolutely.

Parallelism and symmetrybetween primary and secondary



5.2 Mounting Sizes

Size 040, primary in standard encapsulation

mlp040-standard.tif

Fig. 5-3: Size 040, primary in standard encapsulation



Size 040, primary in thermal encapsulation

mlp040-thermo.tif

Fig. 5-4: Size 040, primary in thermal encapsulation



Size 040, secondary

mls040.tif

Fig. 5-5: Size 040, secondary




mlp070-standard.tif





mlp070-thermo.tif




Size 070, secondary

mls070.tif





mlp100-standard.tif





mlp100-thermo.tif




Size 100, secondary

mls100.tif





mlp140-standard.tif





mlp140-thermo.tif




Size 140, secondary

mls140.tif





mlp200-fs.tif





mlp200-ft.tif




Size 200, secondary

mls200.tif





mlp300-standard.tif





mlp300-thermo.tif




Size 300, secondary

mls300.tif


Rexroth IndraDyn L Type codes for the IndraDyn L 1


6 Type codes for the IndraDyn L

6.1 Description

The type code describes the available motor variations. It is the basis forselecting and ordering products from BOSCH REXROTH. This applies toboth new products as well as spare parts and repairs.

IndraDyn L is the overall product designation for synchronous linearmotors. This designation describes the whole system, which consists ofa primary and a secondary. As linear motors are kit motors, theprimaries and secondaries each have their own additional, unambiguousthree-letter abbreviations: MLP and MLS, respectively.

IndraDynL_Bausatz_EN.EPS

Fig. 6-1: Abbreviations for IndraDyn L motor and components

The following figures give an example of motor type codes for theprimary and secondary. The type code allows you to exactly define theindividual parts, e.g. for orders.

The following description gives an overview of the separate positions ofthe type code and their meanings.

Note: When selecting a product, always consider the detailedspecifications in Chapter 4 “Technical Data” and Chapter 9“Notes Regarding Applications”.

2 Type codes for the IndraDyn L Rexroth IndraDyn L


Type code of the Primary – The MLP

!""#"$" ! %#&'"$" %

( )# *

+ ,## -#-$#&"#.$"# *

! " ****

# $%

( + ( +

( +

( +

/0"&$1

&''(

' ' ! ' * * ' * * * *

)

&

*

!"#.$"#!#&"#.$"#2!""#"$"#%#&'"$"3/#"!#)& 2-#&"453

)&

*

/0"&$1

INN-41-43-Muster2.EPS

Fig. 6-2: Example of a type code for an MLP100 primary



Subcomponent MLPMLP is the designation of the primary part of an IndraDyn L motor.

2. Motor Frame SizeThe motor frame size is derived from the active magnet width of thesecondary and represents different power ranges.

3. Motor Frame LengthWithin a frame size, the graduation of increasing motor frame length isindicated by ID letters in alphabetic order.

Frame lengths are, for example, A, B, or C.

4. Winding CodeThe numbers of the winding code describe the obtainable maximumspeed, Fmax in m/min.

5. CoolingIn general, the primary of the IndraDyn L motors are provided with liquidcooling for operation and thus only available with liquid cooling.

6. Encapselation• S = standard encapsulation stainless steel encapsulation with the

liquid cooling integrated into the back of the motor to dissipate thelost heat.

• T = thermal encapsulation: stainless steel encapsulation withadditional liquid cooling on the back of the motor and additionalconductive plates for optimal thermal decoupling from the machineframe.

7. Motor encoderThe feedback system is not in the scope of delivery of Bosch Rexrothand has to be provided and mounted by the machine manufacturerhimself.

8. Electric connectionThe primaries of IndraDyn L synchronous linear motors are fitted with ahighly-flexible shielded cable. The power cable is brought out throughthe front of the primary and is fixed to it.

9. Other typesThese fields for future use.

Positions 1 2 3

Positions 4 5 6

Positions 7

Positions 9 10 11 12

Position 14

Position 15

Positions 17 18

Positions 19 20




Type code of the Secondary – The MLS

! "# $#$

# %$

& '" & '" ! !& '" & &

! "(

#$%

! & ( ) * ! & ( ) *

! & ( ) *

! & ( ) *

!

+',

&''(

- - -

. $/' 0-$/' 1# #/ ".23%1

! &

',

RNC-41431-Muster2.EPS

Fig. 6-3: Example of a type code for an MLS100 secondary



Subcomponents MLSMLS is the designation of the secondary part of an IndraDyn L motor.

2. Motor Frame SizeThe motor frame size is derived from the active magnet width of thesecondary and represents different power ranges.

3. TypeS = secondary

4. Mechanical designThe number 3 indicates that the secondary will be bolted along the outeredge of the secondary.

5. Mechanical protectionTo ensure the utmost operation reliability, the permanent magnets of thesecondary are protected against corrosion, coolants, oil and mechanicaldamage by an integrated, stainless-steel cover plate.

6. Segment lengthSecondary segments are available in 150mm, 450mm and 600mmlengths.

7. Other typesThese fields for future use.

Positions 1 2 3

Positions 4 5 6

Position 7

Position 9

Position 10





6.2 Type code for IndraDyn L 040

! " #$

! $ %#%#!

% &"

! "#'

$ ( ) *

% "+ ,"-- .*

& '/ ****

( #)

( + ( +

( +

( +

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6.3 Type code IndraDyn L 070

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Rexroth IndraDyn L Accessories and Options 7-1


7 Accessories and Options

7.1 Hall sensor box

The SHL01.1 hall sensor box is an optional component for drivecontrollers with incremental measuring systems and Bosch RexrothIndraDyn L motors.

When using an incremental measuring system without an SHL box, theaxis must be commutated every time the drive is powered up. This isdue to a drive-internal procedure. Without determining the propercommutation, the motor cannot be operated. An SHL box eliminates thisnecessity.

Note: The commutation is determined automatically during thephase step up by the SHL-Box. Therefore, no power switch-on is necessary.

Possible applications are, for example

• Commutation of motors on vertically axes,

• Commutation of motors which should not move for safety reasonsduring the commutation process .

• Gantry-arrangement of the motors.

SHL hall-effect-sensor boxes can be delivered

• ex works, as accessory of an IndraDyn L motor,

• as a spare part for retrofitting existing machines with IndraDyn Lmotors and IndraDyn or Ecodrive drive controllers.

Note: With the appropriate firmware, DIAX04-type controllers arealso compatible with the SHL hall-effect-sensor boxes.

Hallbox10.EPS

Fig. 7-1: Accessory SHL01.1

7-2 Accessories and Options Rexroth IndraDyn L


Schematic assembly

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1: Control 4: Secondary2: Control unit 5: Primary3: Linear scale 6: SHL Hall-effect-sensor box

with cableFig. 7-2: Schematic assembly of IndraDyn L and SHL box

Note: Notice the notes within the “SHL01.1, Functional description”documentation, part-No. R911292537.

Rexroth IndraDyn L Electrical connection 8-1


8 Electrical connection

8.1 Power connection

Connection cable on the primaryIndraDyn L motor primaries are fitted with a two-meter, flexible, shieldedpower cable.

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Fig. 8-1: Design of power cable for the primary of the IndraDyn L, the MLP

The following overview gives the technical data of the power cables foreach motor size.

Motor FrameSize

Power cable onthe primary

Cross-section ofpower

conductors

Cross-section ofcontroller

conductors

Cross-section ofcable

Bending radiusof cable

MLP040x-xxxx INK653 1.0 mm² 0.75 mm² 12 mm 72 mm

MLP070x-xxxx INK603 4.0 mm² 16.3 mm 100 mm

MLP100x-xxxxMLP140x-xxxxMLP200A-xxxxMLP200B-xxxxMLP200C-0090MLP200C-0120MLP200D-0060

INK604 6.0 mm² 18.5 mm 110 mm

MLP200C-0170MLP200D-0100MLP200D-0120MLP300x-xxxx

INK605 10.0 mm²

1.0 or 1.5 mm²

22.2 mm 130 mm

Fig. 8-2: Power cable data for IndraDyn L primaries

8-2 Electrical connection Rexroth IndraDyn L


The power cable which is connected to the primary has flying leadsterminated with ferrules (see Fig. 8-1). This power cable may not beexposed to dynamic bending forces (repeated flexing). The power cableon the primary should therefore never be laid in a moving cable track.

We recommend ridgidly laying the cable and terminating it with

• a flange socket

• a connection coupling or

• a terminal box (not in the scope of delivery of Bosch Rexroth)

From this junction, the main power cable can be laid in a cable track orin the machine construction. Ready-made connection cables areavailable from Bosch Rexroth.

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Fig. 8-3: Laying of the connection cable attached to the primary

WARNING

Damage of the connection cable (and, thus, themotor) through repeated flexing!⇒ Do not lay the power cable of the primary in a cable

track.⇒ Lay the connecting cable, after the junction, in a

cable track.

Note: The connection cables of the primaries are designed for thehighest current of a given motor size, so, in certaincircumstances, the cross-section of the power cable after thejunction could be smaller.

Laying the primary power cable



Power Cable ConnectionThe following diagrams show the power cable connection plans for therespective connection types.

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Fig. 8-5: Electric connection when using a terminal box.

Laying of cable and cable cross-sectional areasWhen connecting two or more motors parallel onto one drive controller,the following connection possibilities exist for connection cable:

• Lay a common cable with a higher cross-section (Fig. 8-8)

• Lay two separate parallel cables (Fig. 8-7)

The latter possibility gives a possible advantage of a lower bendingradius. The summation of the cross-section of the cables layed in parallelmust correspond to the increased requirement of the combination ofmotors installed in parallel.

Connection via flange socket orconnection coupling

Terminal box connection

Parallel motor connection



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Fig. 8-6: Power connection with a single motor arrangement

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Fig. 8-7: Power connection with a parallel motor arrangement, and separatepower cables

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Fig. 8-8: Power connection with a parallel motor arrangement and a commonpower cable with increased cross-sectional area

Power connection with a singlemotor arrangement

Power connection with a parallelmotor arrangement and separate

power cables

Power connection with a parallelmotor arrangement and a

common power cable with anincreased cross-sectional area



The selection of the correct cable cross-sectional area depends on theway the cable is laid. The decision should be made according to thefollowing table:

IndraDyn L

Motor Type

RMS Motorphase-current [A]

Power cable arrangementacc. to Figs. 8-6 and 8-7

Power cable arrangementaccording to Fig. 8-8

MLP040A-0300 4

MLP040B-0150 4

MLP040B-0250 5

MLP040B-0300 6

MLP070A-0150 5

MLP 070A-0220 6

1.0 mm² (INK653)

MLP 070A-0300 10 2.5 mm² (INK602)

MLP 070B-0100 5.2

MLP 070B-0120 5.8

MLP 070B-0150 6.2

1.0 mm² (INK653)

MLP 070B-0250 10 2.5 mm² (INK602)

MLP 070B-0300 12 4 mm² (INK603)

MLP 070C-0120 8.9

MLP 070C-0150 102.5 mm² (INK602)

MLP 070C-0240 13

1.0 mm² (INK653)

4 mm² (INK603)

MLP 070C-0300 19 2.5 mm² (INK602) 6 mm² (INK604)

MLP 100A-0090 6.6

MLP 100A-0120 8

MLP 100A-0150 10

2.5 mm² (INK602)

MLP 100A-0190 12

MLP100B-0120 12

1.0 mm² (INK653)

4 mm² (INK603)

MLP100B-0250 22 2.5 mm² (INK602) 10 mm² (INK605)

MLP100C-0090 13 1.0 mm² (INK653) 4 mm² (INK603)

MLP100C-0120 16 2.5 mm² (INK602) 6 mm² (INK604)

MLP100C-0190 23 4 mm² (INK603) 10 mm² (INK605)

MLP140A-0120 12

MLP140B-0090 131.0 mm² (INK653) 4 mm² (INK603)

MLP140B-0120 18 2.5 mm² (INK602) 6 mm² (INK604)

MLP140C-0050 13 1.0 mm² (INK653) 4 mm² (INK603)

MLP140C-0120 21 2.5 mm² (INK602) 10 mm² (INK605)

MLP140C-0170 29 4 mm² (INK603) 16 mm² (INK606)

MLP200A-0090 13 1.0 mm² (INK653) 4 mm² (INK603)

MLP200A-0120 16 2.5 mm² (INK602) 6 mm² (INK604)

MLP200B-0040 13 1.0 mm² (INK653) 4 mm² (INK603)

MLP200B-0120 22 2.5 mm² (INK602) 10 mm² (INK605)

MLP200C-0090 29 4 mm² (INK603)

MLP200C-0120 30 6 mm² (INK604)16 mm² (INK606)

MLP200C-0170 46 10 mm² (INK605) 25 mm² (INK607)

MLP200D-0060 28 4 mm² (INK603) 16 mm² (INK606)

MLP200D-0100 46 25 mm² (INK607)

MLP200D-0120 5310 mm² (INK605)

-----

MLP300A-0090 19 2.5 mm² (INK602) 6 mm² (INK604)

MLP300A-0120 23 10 mm² (INK605)

MLP300B-0070 284 mm² (INK603)

MLP300B-0120 35 6 mm² (INK604)

MLP300C-0060 29 4 mm² (INK603)

16 mm² (INK606)

MLP300C-0090 37 6 mm² (INK604) 25 mm² (INK607)

Fig. 8-9: Required cross-sectional areas of the conductors in the power cabledepending on the motor type, the way the cables are laid and theway the motors are arranged

Power Cable (after the junctionwith the primaries connection

cable)



Note: For additional descriptions of the power cables on theprimaries and the power connection cables, see thedocumentation entitled “Connection Cable” Selection Data,Mat-No.: R911280894.

Connection of IndraDrive Drive ControllerThe following overview shows the connection and terminationdesignations for the motor power conductors and the motor temperaturesensors.

Note: For additional information about motor temperaturemonitoring, see Chapter 9-7.

Drive device Terminal blockpower connection

Terminationdesignation of thepower connection

Terminal blockdesignation of themotor temperature

sensors

Terminationdesignation of themotor temperature

sensors

HMS0x.x

HMD0x.xX5 1, 2, 3 X6 1, 2

Fig. 8-10: Termination designation at the drive-controller( +

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Fig. 8-11: Connection to the drive-controller – one primary per drive controller

Separate arrangement



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Fig. 8-12: Sample connection to the drive controller – parallel arrangement ofprimaries on one drive controller.

The way the power conductors are connected to the drive controllerwhen you have a parallel arrangement of the primaries depends on thedirection(s) of the connection cable outputs from the primaries.

Connection with an arrangement according to Fig. 9-8Cable outputs in the same direction

Drive controller X5 1 2 3

Primary 1 1 2 3

Primary 2 1 2 3

Connection with an arrangement according to Fig. 9-12Cable outputs in the OPPOSITE direction

Drive controller X5 1 2 3

Primary 1 1 2 3

Primary 2 1 3 2

Fig. 8-13: Connection to the drive controller of the power conductors of parallelmotors to a single drive controller – dependent on layout ofprimaries

Parallel arrangement

Power cable connection of theprimary using a parallel

arrangement of the motors



Connection of DIAX04 and EcoDrive Drive-ControllersThe following describes the connection of the power supply and thetemperature sensors to DIAX04 and EcoDrive (DKCx.3) drive-controllers.

The following overview shows the connection and terminationdesignations for the power connection and the motor temperaturesensors.

Note: For additional information about motor temperaturemonitoring, see Chapter 9-7.

Drive device Terminal blockpower connection

Terminationdesignation of thepower conductors

Terminal blockdesignation for themotor temperature

sensors

Terminationdesignation of the

motor-temperature-sensor conductors

HDS0x.x

DKCxx.xX5 A1, A2, A3 X6 1, 2

Fig. 8-14: Termination designations of the drive-controller

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Fig. 8-15: Connection to the drive-controller – separate primary

Single Connection



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Fig. 8-16: Connection on the drive-controller – parallel arrangement ofprimaries

The way the power conductors are connected to the drive controllerwhen you have a parallel arrangement of the primaries depends on thedirection(s) of the connection cable outputs from the primaries.

Connection with an arrangement according to Fig. 9-8Cable outputs in the same direction

Drive-controller X5 A1 A2 A3

Primary 1 1 2 3

Primary 2 1 2 3

Connection with an arrangement according to Fig. 9-12Cable outputs in the OPPOSITE direction

Drive-controller X5 A1 A2 A3

Primary 1 1 2 3

Primary 2 1 3 2

Fig. 8-17: Connection to the drive controller of the power conductors of parallelmotors to a single drive controller – dependent on layout of primaries

Parallel arrangement

Connection of the powerconductors of parallel-arranged

primaries



8.2 Connection of linear feedback devices

The connection of linear feedback devices is made via ready-madecables.

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ELCON05-MLF-EN.EPS

Fig. 8-18: Connection example of a linear feedback device

The following table shows an overview of the ready-made cables forlinear feedback devices.

Measuring system type Absolut, ENDAT Incremental

Output variable Voltage Voltage

Signal flow line Sine Sine

Signal amplitude 1Vp-p 1Vp-p

Position interface DAG DLF

Bosch Rexroth ready-made cables – designed with

Connector for DIAX04

Connector for DKCxx.3

Connector forIndraDrive

RKG 4142

RKG 4001

RKG 4038

RKG 4384

RKG 4002

RKG 4041

Coupling for DIAX04

Coupling for DKCxx.3

Coupling for IndraDrive

-

-

-

RKG 4383

RKG 4389

RKG 4040

Fig. 8-19: Connection components for linear feedback devices

Note: For additional descriptions, see documentation “ConnectionCable” Selection Data, Mat-Nr. R911280894.

Rexroth IndraDyn L Application and Construction Instructions 9-1


9 Application and Construction Instructions

9.1 Functional principle

The following figure shows the principal design of IndraDyn L motors.

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AUFBAU-MLF-EN.EPS

Fig. 9-1: General construction of an IndraDyn L motor

The force generation of the IndraDyn L motor, a synchronous-linearmotor, is the same as the torque generation at rotative synchronousmotors. The primary (active part) has a three-phase winding; thesecondary (passive part) has permanent magnets (see Fig. 9-1).

Both, the primary and the secondary can be moved.

Realization of any traverse path length can be done by stringing togetherseveral secondaries.

The IndraDyn L motor is a kit motor. The components primary andsecondary are delivered separately and completed by the user via linearguide and the linear measuring system.

The construction of an axis fitted with an IndraDyn L motor (see Fig. 9-2)normally consists of

• Primary with three-phase winding,

• one or more secondaries with permanent magnets,

• Linear scale

• linear guide,

• energy flow as well as

• slide or machine construction

Axis installation

9-2 Application and Construction Instructions Rexroth IndraDyn L


1

)'9

ACHSAUFBAU-MLF-EN.EPS

Fig. 9-2: General construction of an axis with an IndraDyn L

For force multiplication can be two or more primaries mechanicallycoupled, arranged parallel or in-line. For further information see chapter9.4 “Arrangement of Motor Components”.

Note: Only the primary and the secondary belong to the scope ofdelivery of the motor.

Linear guide and length scale as well as further additionalcomponents have to be made available by the user. Forrecommendations to tested additional components seechapter 16 “Recommended suppliers of additionalcomponents”

9.2 Motor Design

IndraDyn L motors of Bosch Rexroth are tested drive components. Theyhave the following characters:

• Modular system with different motor sizes and lengths for feed forcesup to 21.500 N per motor and speeds over 600 m/min

• Different winding constructions at any motor size for optimumadjustment to different speed demands.

• All motor components are completely encapsulated, i.e. crackinitiation within casting compounds, damage or corrosion of magnetsa.s.o. are excluded.

• Different designs regarding cooling and encapsulation of the primary(see below: “standard and thermal encapsulation”)

• Protection class IP65 (all motor components)

• High operation safety for DC-link voltage up to 750V.

• No mechanical wastage

• Protection of the motor winding against thermal overstress byintegrated temperature sensors

• Flexible, shielded and strain-bearing power lead wire



To make the optimum motor for the different uses, regarding technicaldemands and costs available, are primary parts in different designs incooling and encapsulation available.

• Standard encapsulation: stainless steel encapsulation with a liquidcooling integrated into the back of the motor to dissipate the lost heat.

• Thermal encapsulation: stainless steel encapsulation with anadditional liquid cooling on the back of the motor and heat conductiveplates for optimum thermal decoupling to the machine construction.

Primary in standard encapsulationAt use with less thermal demands on the exactness of the machine,primaries in standard encapsulation present an economy solution.Primaries with standard encapsulation are mainly used in the generalautomation sector. There, the electrical motor components are protectedby a stainless steel encapsulation. The cooling system of this motordesign is integrated into the motor and can only be used to dischargelost heat or keeping the specified continuous feedrate. It offers noadditional thermal decoupling on the motor side to the machine.

2" "

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Fig. 9-3: Primary with standard encapsulation (see fig. with secondary)

Note: For further information to liquid cooling see Chapter 9.6“Motor cooling”.

The main application areas of this design of the primary can be found inthe sectors:

• General automation

• Handling

Design of cooling andencapsulation

Main application area



Primary in thermal encapsulationPrimaries in thermal encapsulation reach an high constant temperatureon the mounting surface due to an additional – into the encapsulationintegrated liquid coolant for thermal encapsulation to the machineconstruction. At design “Thermal encapsulation”, a maximumtemperature rise on the screw-on surface in opposite to the coolant inlettemperature of 2 K can be reached.

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THERMOKAPSELUNG-MLP-EN.EPS

Fig. 9-4: Primary with thermal encapsulation (see fig. with secondary)

The primary is not completely connected with the mounting surface onthe machine side, but only lays on increased bearing points. This offersthe following advantages:

• Additional thermal encapsulation and therewith further minimization ofthe possible heat-flow into the machine

• Processing of the screw-on surface on the machine side makes iteasier to keep the necessary mounting tolerances.

Note: For further information to liquid cooling see Chapter 9.6“Motor cooling”.

Main application areas of this primary design are, e.g.

• Machine tools

• Precision applications

Main application area



Design secondary partThe secondary consists of a steel base plate with fitted permanentmagnets. The fastening holes are located on the outer edge along thesecondary.

To ensure the utmost operation reliability, the permanent magnets of thesecondary are always protected against corrosion, action of outerinfluences (e.g. coolants and oil) and against mechanical damage, dueto an integrated rustless cover plate.

It is possible to use a scraper direct on the secondary (see also Chapter9.20 “Scraper”).

MLS.tif

Fig. 9-5: MLS-secondary

Note: The design of the secondary is independent from the designof the primary.

Secondaries are available in the following lengths (see also Chapter 5“Specification)

• 150mm

• 450mm

• 600mm

The required length L of the secondary can be defined as follows:

partimaryPrpathTraversepartSecondary LLL +≥

Fig. 9-6: Defining the required length of the secondary

Available length of thesecondaries

Required length of thesecondary



Motor SizesFor adjusting on different feed force requirements, Bosch Rexroth offersIndraDyn L motors in a modular system with different sizes and lengths.

The active breadth of the primary and the secondary at linear motorsserve to define the size. A linear motor with e.g. size 100 has alaminated core and magnet breadth of 100 mm. The IndraDyn L modularsystem contains the following motor sizes:

( ! !

Baugrösse_Breite_MLF.EPS

Fig. 9-7: Sizes of IndraDyn L synchronous linear motors

Every primary is graduated in different motor lengths. The designation ofthe length of the primary is done by the letters A, B, C, D.

67 8

Baugrösse_Länge_MLF.EPS

Fig. 9-8: Different lengths of the primaries

Note: For detailed information to sizes and length see Chapter 5“Specification”.

Sizes



9.3 Requirements on the Machine Design

Derived from design and properties of linear direct drives, the machinedesign must meet various requirements. For example, the movedmasses should be minimized whilst the rigidity is kept at a high level.

Mass reductionTo ensure a high acceleration capability, the mass of the movedmachine elements must be reduced to a minimum. This can be done byusing materials of a low specific weight (e.g. aluminum or compoundmaterials) and by design measures (e.g. skeleton structures).

If there are no requirements for extreme acceleration, masses up toseveral tons can be moved without any problems. There is no control-engineering correlation between the moved slide mass and the motor´smass, as this is the case with rotary drives.

Precondition therefore is, a very stiff coupling of the motor to the weight.

Mechanical rigidityIn conjunction with the mass and the resulting resonant frequency, therigidity of the individual mechanical components within a machine chieflydetermines the quality a machine can reach. The rigidity of a motion axisis determined by the overall mechanical structure. The goal of theconstruction must be to obtain an axis structure that is as compact aspossible.

The increased loop bandwidth of linear drives required highermechanical natural frequencies of the machine structure in order toavoid the excitation of vibrations.

To ensure an adequate control quality, the lowest natural frequency thatoccurs inside the axis should not be less than approximately 200 Hz.The natural frequencies of axes with masses that are not constantlymoving (e.g. due to workpieces that must be machined differently)change, so that the natural frequency is reduced with m/1f ≈ as themass increases.

The elasticity´s of the axes (both, the mechanical and the control-engineering component) add up. This must be taken into account withrespect to the rigidity of cinematically coupled axes.

If several axes must cinematically be coupled in order to produce pathmotions (e.g. cross-table or gantry structure), the mutual effects of theindividual axes on each other should be minimized. Thus, cinematicchains should be avoided in machines with several axes. Axisconfigurations with long projections that change during operation areparticularly critical.

Natural frequencies

Mechanically linked axes



Initiated by acceleration, deceleration or process forces of the movedaxis, reactive forces can deform the stationary machine base or cause itto vibrate.

$

STEIFIGKEIT01-MLF-EN.EPS

Fig. 9-9: Deformation of the machine base caused by the reactive forceduring the acceleration process

m 5mN/ 1000m/s² 10kg500

cam

splate base

µµ

=⋅=⋅=∆

∆s: Deformation of displacement of the machine base in µmm: Mass in kga: Acceleration in m/s²c: Rigidity of the machine base in N/µm

Fig. 9-10: Typical calculation of the machine base deformation

The rigidity of the length measuring system integration is particularlyimportant. Please refer to Chapter 9.15 for explanations.

Reactive forces

Integrating the linear scale



9.4 Arrangement of Motor Components

Single arrangementThe single arrangement of the primary is the most commonarrangement.

Fig. 9-11: Single arrangement of the primaries

The independent operation of two or more primaries on a secondary ispossible too (see Fig. 9-11 right-hand sight). In such an arrangement,the length measuring system can also be equipped with two or morescanning heads.

Note: Due to the higher sealing lip friction, the number of scanningheads in encapsulated linear scales is usually limited to two.Please contact the scale manufacturer for details.

5

EINZELANORDNUNG01-MLF-EN.EPS

Fig. 9-12: Controlling a linear motor with single arrangement of the motorcomponents



Several motors per axisThe arrangement of several motors per axis provides the followingbenefits:

• Multiplied feed forces

• With corresponding arrangement, compensation of the attractiveforces “outwards”

Fig. 9-13: Arrangement of several motors per axis

Depending on the application, the motors can be controlled in twodifferent ways:

• Two motors at one drive controller and one linear scale (parallelarrangement)

• Two motors at two drive controllers and two linear scales (Gantryarrangement)

Parallel arrangementThe arrangement of two or more primaries on one drive controller inconjunction with a linear scale is known as parallel arrangement. Parallelarrangement is possible if the coupling between the motors can be veryrigid.

5

PARALLELANORDNUNG01-MLF-EN.EPS

Fig. 9-14: Parallel arrangement of two primaries on one drive controller inconjunction with a length measuring system



To ensure successful operation, the axis must fulfill the followingrequirements in parallel arrangement:

• Identical primary and secondary parts

• Very rigid coupling of the motors 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

• Same pole sequence of the secondaries

• If possible, load stationary and arranged symmetrically with respect tothe motors

$' 2 2 $ $ $.$'$9/1

$ 22$ 3 # $,

$ 22$ 3 # $ $

)

3

3


Fig. 9-15: Alignment of motor components in parallel arrangement

Note: The mounting holes of the primaries are used for defining thecorrect position of the paralleled motors. In the grid, you mustalways use the same hole in either primary (see Fig. 9-15).An offset of the hole grid between the primaries is onlypermitted in the structures shown in Fig. 9-9 or Fig. 9-21.

The face ends of the primary parts may alternatively be used if themounting holes cannot be employed as position reference. The motorparts have the corresponding tolerances.

Parallel arrangement: Double comb arrangementIn a parallel arrangment – within a Gantry arrangement, too – theprimaries in feed direction can mechanically be coupled and be arrangedin the form of a “double comb arrangement” (see Fig. 9-13 right-handside). In addition to the force multiplication, the attractive forces betweenprimary and secondary are compensated towards the outside. With thecorresponding arrangement, the linear guides are not stressedadditionally, and may even be sized smaller.

Note: Double comb arrangement (to Fig. 9-13 right-hand side) doesnot require a minimum distance to be kept between the twosecondary mounting surfaces.



Parallel arrangement: Arrangement of primaries insuccessionIn a parallel arrangement – within a Gantry arrangement, too – theprimaries in feed direction can mechanically be coupled and be arrangedin succession (see Fig. 9-5 center).

To ensure successful operation, the primaries must be arranged in aspecific grid. The determination of the grid sizes that must be adhered todepends on the direction of the cable entry and the permissible bendingradius of the power cable.

If the primaries are arranged behind each other with the cable entries inthe same direction (see Fig. 9-9), an integer multiple of twice theelectrical pole pitch must be adhered to:

3


Fig. 9-16: Arrangement of the primaries behind each other and cable entry inthe same direction

Note: When you determine the correct primary distance with cableentries in the same direction acc. to Fig. 9-8, you mustalways use the same reference point for both primaries (e.g.the same mounting hole).

pP 2nx τ∆ ⋅⋅=∆xP: Required grid spacing between the primaries in mmτP: Electrical pole pitch in IndraDyn L motors in mm (all sizes 37.5 mm)n: Integer factor (depends on mounting distance)

Fig. 9-17: Determining the grid distance between the primaries with cableentries in the same direction

Cable entry in the same direction



According to Fig. 9-9 and 9-10, the following minimum distancesbetween the primaries result at a motor arrangement with the cableentries in the same direction:

Motor version Xpmin in mm

Standard encapsulationsizes (all) p2nmm 15 τ⋅⋅+

Thermal encapsulationsizes (all) p2nmm 65 τ⋅⋅+

n: The integer factor n must be chosen in that way, so that the followingconditions can be kept.

τP: Electrical pole pitch in IndraDyn L motors in mm (all sizes 37.5 mm)Fig. 9-18: Distance xpmin to be kept between the two primaries with cable

entries in the same direction

cablemotorradiusbendingepermissiblx minp >Fig. 9-19: Distance xpmin to be kept between the two primaries with cable

entries in the same direction

Option 1:

If the primaries are arranged behind each other and with cable entries inopposite directions to Fig. 9-20 a defined distance must be kept betweenthe primaries according to Fig. 9-21.

3


Fig. 9-20: Option 1: Arrangement of primaries behind each other with cableentries in opposite directions

Note: When you determine the correct primary distance with cableentries in opposite directions according to Fig. 9-20, you canuse the distance between the primary end faces xp asreference point.

minppP x2nx +⋅⋅= τxP: Required grid spacing between the primaries in mmτP: Electrical pole pitch in IndraDyn L motors in mm (all sizes 37.5 mm)n: Integer factor (depends on mounting distance)

Fig. 9-21: Determining the grid distance between the primaries with cableentries in opposite directions

Minimum distances between theprimaries

Requirement

Cable entry in opposite direction



For a motor arrangement with cable entries at opposite directions, thefollowing size-related minimum distances between the primaries resultfrom:


Standard encapsulationsizes (all)

mm65

Thermal encapsulationsizes (all)

mm59

Fig. 9-22: Distance xpmin to be kept between the two primaries with cableentries in opposite direction

Option 2:

If the primaries are arranged behind each other and with cable entries inopposite directions to Fig. 9-20 a defined distance must be kept betweenthe primaries according to Fig. 9-21.

3

3


Fig. 9-23: Option 2: Arrangement of the primaries behind each other with cableentries in opposite directions

Note: When you determine the correct primary distance with cableentries in opposite directions according to Fig. 9-20, you canuse the distance between the primary end faces xp asreference point.

minppP x2nx +⋅⋅= τxP: Required grid spacing between the primaries in mmτP: Electrical pole pitch in IndraDyn L motors in mm (all sizes 37.5 mm)n: Integer factor (depends on mounting distance)

Fig. 9-24: Determining the grid distance between the primaries with cableentries in opposite directions

Minimum distance between theprimaries (Option 1)

Cable entry in opposite direction



For a motor arrangement with cable entries at opposite directions, thefollowing size-related minimum distances between the primaries resultfrom:


Standard encapsulationsizes (all) p2nmm40 τ⋅⋅+

Thermal encapsulationsizes (all) p2nmm71 τ⋅⋅+

n: The integer factor n must be chosen in that way, so that the followingconditions can be kept.

τP: Electrical pole pitch in IndraDyn L motors in mm (all sizes 37.5 mm)Fig. 9-25: Distance xpmin to be kept between the two primaries with cable

entries in opposite direction

cablemotorradiusbendingepermissiblx minp >Fig. 9-26: Distance xpmin to be kept between the two primaries with cable

entries in opposite direction

The connection of the power wires of the connection cable on the drivecontroller at parallel arrangement of the primaries with outgoing cable inthe cross-direction depend on the direction of the outgoing cable.

Connection at arrangement acc. to Fig. 9-9Outgoing cable in the same direction

Drive-controller X5 1 2 3

Primary 1 1 2 3

Primary 2 1 2 3

Connection at arrangement acc. to Fig. 9-20Outgoing cable in the same direction

Drive-controller X5 1 2 3

Primary 1 1 2 3

Primary 2 1 3 2

Fig. 9-27: Connection of the power wires at parallel arrangement of theprimaries on a drive-controller

Note: For detailed information to electrical connection please referto Chapter 8 Connection system.

Note: The primary 1 according to Fig. 9-20 is always the referencemotor that is used for determining the sensor polarity and forcommutation setting. See also Chapter 14 “Commissioning”.Ensure that the secondary is correctly aligned.

Minimum distance between theprimaries (Option 2)

Requirement

Power cable connection



Gantry ArrangementOperation with two linear scales and drive controllers (Gantryarrangement) should be planned if there are load conditions that aredifferent with respect to place and time, and sufficient rigidity betweenthe motors cannot be ensured. This is frequently the case with axis in aGantry structure, for example.

Note: Parallel motors may also be used with a Gantry arrangement.

5

GANTRYANORDNUNG01-MLF-EN.EPS

Fig. 9-28: Gantry arrangement

With Gantry arrangements it must be remembered that the motors maybe stressed unsymmetrically, although the position offset is minimized.As a consequence, this permanently existing bas load may lead to agenerally higher stress than in a single arrangement. This must be takeninto account when the drive is selected.

Note: The asymmetric stress can be reduced to a minimum byexactly aligning the length measuring system and the primaryand secondary parts to each other, and by a drive-internalaxis error compensation.



Vertical axes

WARNING

Uncontrolled movements⇒ When linear motors are used in vertical axes, it

must be taken into account that the motor is notself-locking when power is switched off. Loweringthe axis can only be secured by an appropriateholding brake (see also Chapter 9.17 “BrakingSystems and Holding Devices”).

Suitable holding devices must be used for preventing the axis fromsinking after the power has been switched off. These holding devicescan be actuated electrically, pneumatically or hydraulically.

Note:

• Adequate holding devices are integrated in most of today´s weightcompensation systems.

• On vertical axis, the use of an absolute measuring system isrecommended. Alternatively, also an incremental measuring system,in connection with a hall sensor box (see Chapter 7 “Accessories”)can be used.

An additionally used weight compensation ensures that the motor is notexposed to an unnecessary thermal stress that is caused by the holdingforces and the acceleration capability of the axis is independent of themotion direction. The weight compensation can be pneumatic orhydraulic.

Weight compensation with a counterweight is not suitable since thecounterweight must also be accelerated.

Weight compensation



9.5 Feed and Attractive Forces

Attractive forces between the primary and the secondaryWhen it is installed, a synchronous linear motor has a permanentlyeffective attractive force between the primary and the secondary thatresults from its principle. With synchronous linear motors, this attractiveforce also exists when the motor is switched off.

%2:

ANZKRAFT01-MLF-EN.EPS

Fig. 9-29: Attractive force between the primary and the secondary

These attractive forced must always be taken into account in themechanical design of the system.

Depending on the motor arrangement, the attractive forces must beaccommodated by linear guides and the slide and machine structure.

With an unfavorable arrangement of the motors, the attractive forcescan cause deformations (deflection) in the machine structure andunacceptable transverse stress on the linear guides. The following pointsshould therefore be taken into account during the design integration ofthe motors:

• Arrange the linear guides as close to the motor as possible.

• To compensate the attractive forces, you can use the parallelarrangement shown at the right-hand side in Fig. 9-13.

Note: When installed, the attractive force must not reduce the airgap between the primary and the secondary. The mechanicaldesign must provide sufficient rigidity.

Note: The attractive forces at the nominal air gap are specified ineach data sheet of a motor in Chapter 4 “Technical Data”.

Considering the attractive forcein motor installation



Air-gap-related attractive forces between the primary and the secondaryThe attractive force rises as the distance between the primary and thesecondary is reduce.

When lowering the primary on the secondary, result by reducing the airgap increasing attractive forces.

The curve in the following diagram shows the attractive force as afunction of the air gap.

0%

20%

40%

60%

80%

100%

120%

140%

160%

0 mm 5 mm 10 mm 15 mm 20 mm 25 mm 30 mmmeasurable air gap

attr

acti

re f

orc

e re

l. T

o n

orm

inal

air

gap

nominal air gap

ANZIEHUNGSKRAFT.XLS

Fig. 9-30: Attractive force vs. distance between the primary and the secondary

Air-gap-related attractive forces vs. power supplyThe attractive force decreases with rising power supply of the primary.

The curve in the following diagram shows the attractive force vs. thepower supply.

00

-&(:

ANZIEH_BESTROM-MLF.EPS

FATT: Attractive forceimax: Max. voltage

Fig. 9-31: Attractive force vs. power supply



Air-gap-related feed force

The feed force detailed in the specifications are related to the specifiedrated air gap. The tolerances permissible for the measurable air gaphave a slight effect on the feed forces that can be achieved. Thefollowing diagram shows this relationship:

97%

98%

99%

100%

101%

102%

103%

0,7 mm 0,8 mm 0,9 mm 1,0 mm 1,1 mm 1,2 mm 1,3 mm

measurable air gap

feed

fo

rce,

rel

. to

no

min

al a

ir g

ap

nominal air gap

LUFTSPALTABHÄNGIGE VORSCHUBKRAFT MLF_EN.XLS

Fig. 9-32: Feed force within the air gap tolerance of synchronous linear motorsIndraDyn L

Note: Sizes in Fig. 9-32 are only valid for IndraDyn L synchronouslinear motors; there is no general correlation for other motortypes.

Reduced overlapping between the primary and the secondaryWhen moving in the end position range of an axis, it can be necessarythat the primary moves beyond the end of the secondary. This results ina partial coverage between the primary and the secondary.

If the primary and the secondary are only partially covered, follows areduced feed force and attractive force.

The force reduction does not start immediately. It differs according to theencapsulation types and the installation position of the primary.

Outside the beginning and end areas, the force is reduced linearly as afunction of the reduced coverage area.

The following diagram illustrates the correlation between the coveragebetween the primary and the secondary and the resulting forcereduction.

Air gap tolerances

Inception of the force reduction



:

:

:

:

!:

:

&:

(:

):

*:

:

%'''" 2

2

%

2

$

2/

2

%

"2

3

#

$

$;

$;

PRIMPARTOVSEC02-MLF-EN.EPS

Fig. 9-33: Force reduction with partial coverage of the primary and thesecondary

;

$

"+3#3/" ##"3

;

$

"+3#3/" ##"3

;

$

;

$

PRIMPARTOVSEC04-MLF-EN.EPS

Fig. 9-34: Presentation of force reduction with regard to Fig. 9-33

Installation position 1Motor version

SR1 [mm] SR2 [mm]

Standard encapsulation 30 5

Thermal encapsulation 52 8

Installation position 2

Standard encapsulation 5 30

Thermal encapsulation 8 52

Fig. 9-35: Partial coverage vs. installation position

The partial coverage of the primary and the secondary must not be usedin continuous operation since there is an increased current consumptionof the motor. Instabilities in the control loop can be expected from acertain reduction of the degree of coverage onwards.

WARNING

Malfunctions and uncontrolled motormovements due to partial coverage of theprimary and the secondary!⇒ Partial coverage of the primary and the secondary

only when moving to the end position during a driveerror

⇒ Minimum coverage factor 75%



9.6 Motor cooling

Thermal behavior of linear motorsThe rated feed force of a synchronous linear motor can be achieved ismainly determined by the power loss PV that is produced during theenergy conversion process. The power loss fully dissipates in form ofheat. Due to the limited permissible winding temperature it must notexceed a specific value.

Note: The maximum winding temperature of IndraDyn L motors is155°C. This corresponds to insulation class F.

The total losses of synchronous linear motors are chiefly determined bythe direct load loss of the primary due to the low relative velocitiesbetween the primary and the secondary:

T122

ViV fRi43

P P ⋅⋅⋅=≈

PV: Total loss in WPVi: Direct load losses in Wi: Current in motor cable in AR12: Electrical resistance of the motor at 20°C in Ohm

(see Chapter 5 “Technical Data)fT: Factor temperature-related resistance raise

Fig. 9-36: Power loss of synchronous linear motors

Note: When you determine the power loss according to Figure 9-36, you must take the temperature-related rise of theelectrical resistance into account. At a temperature rise of115 K (from 20°C up to 135°C), for example, the electricalresistance goes up by the factor fT = 1.45.

The temperature variation vs. the time is determined by the producedpower loss and the heat-dissipation and –storage capability of the motor.The heat-dissipation and –storage capability of an electrical machine is(combined in one variable) specified as the thermal time constant.

Note: With liquid cooling systems, the thermal time constant isbetween 5...10 min (depending on size).

The following Figure 9-37 shows a typical heating and cooling process ofan electrical machine. The thermal time constant is the period withinwhich 63% of the final over temperature is reached. With liquid cooling,the cooling time constant corresponds to the heating time constant.Thus, the heating process and the cooling process can both be specifiedwith the specified thermal time constant (heating time constant) of themotor.

In conjunction with the duty cycle, the correlation to Fig. 9-38 and Fig. 9-40 are used for defining the duty type, e.g. acc. to DIN VDE 0530.

Power loss

Thermal time constant



Time

Ove

rtem

per

atu

re

heating up with final overtemperature = 0

heating up with initial overtemperature > 0

cooling

ERWAERMUNG MLF_EN.XLS

final overtemperture

tth

63 %

Fig. 9-37: Heating up and cooling down of an electrical machine

thth tt

att

e ee1)t(−−

⋅+

−⋅= ϑϑϑ

ϑe: Final over temperature in Kϑa: Initial over temperature in Kt: Time in mintth: Thermal time constant in min (see Chapter 4 “Technical Data)

Fig. 9-38: Heating up (over temperature) of an electrical machine comparedwith coolant

Since the final over temperature is proportional to the power loss, theexpected final over temperature ϑe can be estimated according to Fig.9-39:

maxe2dN

2eff

maxevN

cee

F

F

PP ϑϑϑ ⋅=⋅=

Pce: Permanent power loss or average power loss vs. duty cycle time inW (see Chapter 11.4 “Determining the Drive Power)

PVN: Nominal power loss of the motor in Wϑemax: Maximum final over temperature of the motor in KFeff: Effective force in N (from application)FdN: Rated force of the motor in N (see Chapter 4 “Technical data”)tth: Thermal time constant in min (see Chapter 4 “Technical Data)

Fig. 9-39: Expected final over temperature of the motor

thtt

e e)t(−

⋅= ϑϑϑe: Final over temperature or shutdown temperature in Kt: Time in mintth: Thermal time constant in min (see Chapter 4 “Technical Data)

Fig. 9-40: Cooling down of an electrical machine

Heating up

Final over temperature

Cooling



Cooling concept of IndraDyn L synchronous linear motorsThe request for highest feed forces and minimum installation volumeusually requires linear motors to be equipped with a liquid cooling. Theliquid cooling ensures:

• that the power loss is removed and, consequently, rated feed forcesare maintained;

• that a certain temperature level is maintained at the machine

The cooling and encapsulation concept of IndraDyn L motors includestwo different solutions:

Primaries with standard encapsulation are mainly used in the generalautomation sector. The cooling system of this motor design is integratedinto the motor and can only be used to discharge lost heat or keepingthe specified continuous feedrate. It offers no additional thermaldecoupling on the motor side to the machine. The maximumtemperature of the contact surface can locally rise up to 60°C. Thesemaximum temperature gradients can occur independently of the coolantinlet temperature.

For an optimum thermal decoupling between the motor and the machinestructure, the primary parts of the thermal encapsulation version have anadditional liquid cooling system at the back of the motor and atlongitudinal and frond ends. The constant temperature that can easily beattained and the minimum heat transfer into the machine make theprimary parts of the thermal encapsulation version particularly suitablefor the utilization in machine tools and in other precision applications.Inside the motor there is already an optimum connection between theinternal cooling circulation used for removing the power loss and thecooling ducts of the thermal encapsulation.

The primary is not completely connected with the mounting surface onthe machine side, but only lays on increased bearing points. Thisprovides an additional thermal decoupling and, consequently, furtherminimization of the possible heat transfer into the machine (see Fig. 9-41).

Note: Using the thermal encapsulation does not provide anyimproved performance date, e.g. for the continuous feedforce. The power ratings are identical for both versions.

Standard encapsulation

Thermal encapsulation



;

.

. 1

67. ' '/'"1

/$2 $/2"$ ' ' /

. 2 $1

THERMOKAPSELUNG02-MLF-EN.EPS

Fig. 9-41: Cooling concept for thermal encapsulation

The secondary version is identical for both primary part versions. Thesecondary does not develop any power loss. With inadvertent conditions(extended standstill or slow velocity of the primary together with asimultaneously acting high continuous force), there can be a heattransfer by the primary due to radiation or convection.

Note: The secondary does not develop any power loss. Themaximum heat infiltration possible of the primary at standstilland continuous nominal force is approximately 3% of themotor´s nominal power loss.

The heat transfer depends on the ambient temperature and on theinstallation conditions in the machine.

To maintain a constant temperature level in the machine, cooling can bedone at the machine side (e.g. via two cooling pipes). See Fig. 9-41.

Secondaries



CoolantThe specified motor data and the characteristics of the motor coolingsystem (e.g. continuous feed forces, pressure losses, and flowcharacteristics), and all the other specifications in this Chapter arerelated to liquid cooling with coolant water. Most cooling devices usewater, too.

The following coolants can be used:

• Water

• Oil

• Air

Note: The specified motor data and the characteristics of the motorcooling system (e.g. continuous feed forces, pressure losses,and flow characteristics), and all the other specifications inthis Chapter are related to liquid cooling with coolant water.

This data is no longer valid and must again be calculated or determinedempirically if coolants with different material characteristics are used.

An impairment of the thermal decoupling may also have to be taken intoaccount, if necessary.

WARNING

Impairing the cooling effect of damaging thecooling system!⇒ Adjust coolant and flow to the required motor

performance data⇒ With coolant water use anticorrosion agent and

observe the specified mixture and the pH-value.⇒ Use approved anticorrosion agents, only⇒ Do not use cooling lubricants from machining

process⇒ Filter the coolant⇒ Do not use flowing water⇒ Use a closed cooling circuit⇒ Adhere to the specified inlet temperatures⇒ Do not exceed the maximum pressure⇒ Motor operation not without liquid cooling

Coolant additivesCorrosion protection and chemical stabilization required a suitableadditive to be added to the cooling water. The corrosion protectionagent must be suitable for a mixed installation (steel or iron, aluminum,copper and brass). The required mix (acc. to the manufacturer´sspecifications) must be adhered to and/or verified. Larger differencescan lead to changes in the stability of the emulsion, the behavior towardssealant, and the corrosion protection capability.



Watery solutions ensure a reliable corrosion protection withoutsignificant changes of the physical property of the water. Therecommended additives do not contain any water-endangeringsubstances, according to the water endangering classes (WGK).

Corrosion protection oils for coolant systems contain emulsifiers whichensure a fine allocation of the oil in the water. The oily components ofthe emulsion protect the metal surface of the coolant duct againstcorrosion and cavitation. Herewith, an oil content of 0.5 – 2 volumepercent has proved itself. Does the corrosion protection oil comparedwith the corrosion protection has also the coolant pumping lubricant,then the oil content of 5 volume percent is necessary. (observe therequirements of the pump manufacturers!)

Description Manufacturer

1%...3% emulsions

Aquaplus 22 Petrofer, Hildesheim

Varidos 1+1 Schilling Chemie, Freiburg

33%-emulsions

Glycoshell Deutsche Shell Chemie GmbH, Eschborn

Tyfocor L Tyforop Chemie GmbH, Hamburg

OZO Frostschutz Deutsche Total GmbH, Düsseldorf

Aral Kühler-Frostschutz A ARAL AG, Bochum

BP antifrost X 2270 A Deutsche BP AG, Hamburg

Emulsifiable mineral oil concentrate

Shell Donax CC (WGK: 3) Shell, Hamburg

Fig. 9-42: Recommended coolant additives

Note: The specified coolant additives are only a recommendation ofBOSCH REXROTH. Please contact your responsible salesrepresentative when using another coolant additive.

Not only the mixture, but also the pH-value of the used coolant must bechecked in suitable distances. The coolant should be chemically neutral.Larger differences can lead to changes in the stability of the emulsion,the behavior towards sealant, and the corrosion protection capability.

Note: Keep the pH-value of the used coolant controlled in 6-8 pH!

Watery solutions

Emulsion with corrosionprotection oil

pH-value coolant



Coolant temperatureThe recommended temperature range of the coolant is 15...40°C. Thecoolant temperature must never be outside this range. The adjustedcoolant inlet temperature must be chosen with regard to the actualexisting environmental temperature and should be max. 5°C lower thanthe measured environmental temperature.

An overstepping of the recommended temperature range leads to astronger reduction of the continuous feed force.

Note: The coolant inlet temperature should be maximum 5k lowerthan the actual existing room temperature to avoidcondensation.

WARNING

Reduction of the continuous feed force ofdestruction of the motor!⇒ Keep coolant within permissible temperature range

The specification of the rated feed force in the technical motorspecifications is related to a coolant inlet temperature of 30°C.

If the inlet temperature is different, there is a minor change of thecontinuous feed force according to Fig. 9-43:

95%

100%

105%

15 °C 20 °C 25 °C 30 °C 35 °C 40 °C

Cooling water inlet temperature

Co

nfi

nu

ou

s fe

ed f

orc

e

KMTEMPERATUR LSF.XLS

Fig. 9-43: Continuous feed force vs. coolant flow temperature

Maximum pressureWith all motor versions, the maximum system pressure via the internalsystem circulation of the motor is 10 bar.

Pressure fluctuations within the cooling circuit should not exceed ± 1 barduring motor operation. Beyond pressure fluctuations or pressure peaksare not permitted!

WARNING

Motor destruction!⇒ Keep coolant within permissible inlet pressure.⇒ Incorrect pressure fluctuations and pressure peaks

have to be excluded via constructive measures.

Temperature range

Continuous feed force vs.coolant temperature



Operation of IndraDyn L synchronous linear motorswithout liquid coolingIn certain exceptions it can be necessary or possible, to do without aliquid cooling. Depending on the size, this results in a reduction of thecontinuous nominal force to approximately 40...45%. It does not reducethe maximum force of the motors.

Depending on the load, the temperature at the contact surface of theprimary may rise up to 140%C without liquid cooling.

WARNING

Drastic reduction of the rated feed force andsignificant heating and stress of the machinestructure if synchronous linear motors are usedwithout liquid cooling!⇒ Provide liquid cooling⇒ The reduction of the rated force and the heating of

the machine structure (stress due to expansion)must be included in the sizing and design of axesthat are used without liquid cooling.

Sizing the cooling circuit

D

0< 0 <

3

KUEHLUNG01-MLF-EN.EPS

Q: Flow quantityT1: Coolant inlet temperatureT2: Coolant outlet temperaturep1: Inlet pressurep2: Outlet pressure

Fig. 9-44: Liquid-cooled component

12 TTT −=∆T1: Coolant inlet temperature in KT2: Coolant outlet temperature in K∆T: Coolant temperature rise in K

Fig. 9-45: Coolant temperature rise in K

21 ppp −=∆p1: Inlet pressurep2: Outlet pressure∆p: Pressure drop

Fig. 9-46: Pressure drop across traversed component

Coolant temperature rise

Pressure drop



Related to the motor, two basic application-related requirements must bedistinguished when the cooling circuit of synchronous linear motors issized.

1. Liquid cooling is only used for removing the power loss and thus formaintaining the specified rated forces (e.g. for standardencapsulation motor version)

2. At the same time, liquid cooling shall ensure a defined temperaturelevel at the contact surface (e.g. for the thermal encapsulation motorversion).

Flow quantityRexroth recommends to dimension the coolant flow for motors up to size070 to ~ 5l/min, for size 100 to ~ 6l/min.

The minimum coolant flow required to maintain the rated feed force isdefined in Chapter 4 “Technical Data”.

The specification of this value is based on a rise of the coolanttemperature by 10 K.

Figures 9-47 and 9-48 are used to determine the necessary coolant flowat different temperature rises and / or different coolants:

Tc60000P

Q co

∆ρ ⋅⋅⋅=

Q: Rated coolant flow in l/minPro: Removed power loss in Wc: Specific heat capacity of the coolant in J / kg - Kρ: Density of the coolant in kg/m³∆T: Coolant temperature rise in K

Fig. 9-47: Coolant flow required for removing a given power loss.

Coolant Specific heat capacity c in J / kg -K

Density ρρρρ in kg/m³

Water 4183 998,3

Thermal oil(example)

1000 887

Air 1007 1,188

Fig. 9-48: Substance values of different coolants at 20°C

If you want to ensure a defined temperature level at the contact surfaceof the primary of the thermal encapsulation motor version, you must usethe formula acc. to Fig. 9-49 to determine the coolant flow that isnecessary for maintaining a maximum coolant temperature rise. It is tobe taken into account that only a part of the power loss remains to beremoved via the thermal encapsulation. ∆Tm is the temperature at thecontact surface of the primary.

Note: A defined temperature level at the contact surface can onlybe maintained with the thermal encapsulation motor version.

Design criteria

Coolant flow to maintain therated feed force

Maintaining a constanttemperature level at thermal

encapsulation



m

co

Tc25200P

Q∆ρ ⋅⋅

⋅=

Q: Rated coolant flow in l/minPco: Removed power loss in Wc: Specific heat capacity of the coolant in J / kg - Kρ: Density of the coolant in kg/m³∆Tm: Temperature rise on contact surface in K

Fig. 9-49: Coolant flow required for maintaining a constant temperature level atthe motor contact surface in the case of thermal encapsulation

Prerequisites: Q ≥ Qmin (see chapter 4 “Technical Data”)

Pressure dropThe flow resistance at the pipe walls, curves, and changes of the cross-section produces a pressure drop along the traversed components (seeFig. 9-44).

The pressure drop ∆p rises as the flow quantity rises (see Fig. 9-50).

-)&DKUEHLUNG02-MLF-EN.EPS

Fig. 9-50: Pressure drop vs. flow quantity; general representation

On the basis of the constant for determining the pressure drop kdp that isexplained in Chapter 4 “Technical Data”, the pressure drop across theinternal motor cooling circuit can be determined as follows:

75.1dpm Qkp ⋅=∆

pm: Pressure drop across the internal motor cooling circuit in barQ: Flow quantity in l/minkdp: Constant for determining the pressure drop (see Chapter 4

“Technical data”)Fig. 9-51: Determining the pressure drop vs. the flow quantity

Pressure drop across the motorcooling system



The pressure drop across the overall system is determined by the sumof a series of partial pressure drop (see Fig. 9-52). Usually, the pressuredrop across the internal motor cooling system is relatively small.

33

- 4"

-

)

D

KUEHLUNG03-MLF-DE.EPS

Fig. 9-52: General arrangement of a liquid cooled motor with heat removalfacility

Note: The overall pressure drop of the cooling system is determinedby various partial pressure drops (motor, feeders, connectors,etc.). This must be taken into account when the cooling circuitis sized.

Note: With all motor versions, the maximum system pressure viathe internal system circulation of the motor is 10 bar.

Cooling capacityThe specifications that are needed for determining the cooling capacitywhich is required for a synchronous linear motor can be found in Chapter11.4 “Determining the Drive Power”.

Overall pressure drop



Liquid cooling systemMachines and systems can require liquid cooling for one or moreworking components. If several liquid-cooled drive components exist,they are connected to the heat removal device via a distribution unit.

!

33

33

2

2

2

2


Fig. 9-53: General arrangement of cooling systems with one and more drivecomponents

The heat removal device carries off the total heat that was fed into theliquid into a higher-level coolant. It provides a temperature-controlledcoolant and thus maintains a required temperature level at thecomponents that are to be cooled.

There are three different types of heat removal devices (see Fig. 9-54).They are identified by the type of the heat exchanger between thedifferent media:

1. Air-to liquid cooling unit

2. Liquid-to-liquid cooling unit

3. Cooling unit

A heat removal device includes a heat exchanger, a coolant pumpcontainer and a coolant container (see Fig. 9-52).

Heat removal device



&&4"

%

'

!

% '

(

&" &&"

"

!&4"

(3 E


Fig. 9-54: Heat removal devices

Air-to liquidcooling unit

Liquid-to-liquid coolingunit

Cooling unit

Coolant temperature control accuracy Low (±5 K) Low (±5 K) Good (±1 K)

Upstream coolant circuit required No Yes No

Heating of ambient air Yes No Yes

Power loss recovery No Yes No

Size of the cooling unit Small Small Large

Dependent of ambient temperature Yes No No

Environment-damaging coolant No No Yes

Comments on utilization criteria Particularlysuitable forstand-alonemachines thatdo not have anupstreamcoolant circuitavailable anddo not have tofulfill highrequirementson the stabilityof the coolanttemperature.

This cooling type isparticularly suitable forsystems with existingcentral feedback cooler. Iddoes fulfill highrequirements on thestability of the coolanttemperature.

Particularly suitable for highrequirements on the thermalstability (high-precisionapplications, for example).

Fig. 9-55: Overview of the heat removal devices according to utilization criteria

Coolant linesThe coolant lines are a major part of the cooling system. They have agreat influence on the system´s operational safety and pressure drop.The lines can be made up as hoses or pipes.



The coolant lines of linear motor drives with moved primaries must belaid within a flexible energy chain.

The continuous bending strain of the coolant lines must always be takeninto account when they are sized and selected.

Further optional components• Distributions

• Coolant temperature controller

• Flow monitorA message is output when the flow drops below a selectableminimum flow quantity.

• Level monitorChiefly minimum-maximum level monitor to check the coolant level inthe coolant container

• Overflow valve

• Safety valveOpens a connection between the coolant inlet and the containedwhen a certain pressure is reached

• Coolant filter (100 µm)

• Coolant heatingsTo provide coolant of a correct temperature, in particular for coolanttemperature control

• Restrictor and shut-off valves

Circuit typesThe two possible ways of connecting hydraulic components(series/parallel connection) show significant differences with respect to:

• Pressure drop of the entire cooling system

• Capacity of the coolant pump

• Temperature level and controllability of the individual componentsthat are to be cooled

D

D

D D

!

D!

A

A

A!


Fig. 9-56: Parallel connection of liquid-cooled drive components

The parallel connection is characterized by nodes in the hydraulicsystem. The sum of the coolant streams flowing into a node is equal tothe sum of the coolant streams flowing out of this node. Between twonodes, the pressure difference (pressure drop) is the same for allintermediate cooling system branches.

Laying flexible coolant lineswithin the energy chain

Parallel connection



n21

n21

pppp

Q... QQQ

∆∆∆∆ ===

++=

∆p: Pressure dropQ: Flow quantity

Fig. 9-57: Pressure drop and flow quantity in the parallel connection ofhydraulic components

When several working components are cooled, a parallel connection isadvantageous for the following reasons:

• The individual components that are to be cooled can be cooled at theindividual required flow quantity. This means a high thermaloperational reliability.

• Same temperature level at the coolant entry of all components (equalmachine heating)

• Same pressure difference between coolant entry and outlet of allcomponents (no high overall pressure required)

D# !

# # !#!

FFF!

A A A!


Fig. 9-58: Series connection of liquid-cooled drive components

In series connection, the same coolant stream flows through allcomponents that are to be cooled. Each component has a pressuredrop between coolant inlet and coolant outlet. The individual pressuredrops add up to the overall pressure drop of the drive components.

Series connection does not permit any individual selection of the flowquantity required for the individual components to be made. It is onlyexpedient if the individual components that are to be cooled needapproximately the same flow quantity and bring about only a smallpressure drop or if they are installed very far away from the heat removaldevice.

n21

n21

p ... ppp

QQQQ

∆∆∆∆ ++=

===

∆p: Pressure dropQ: Flow quantity

Fig. 9-59: Pressure drop and flow quantity in the parallel connection ofhydraulic components

The following disadvantages of series connection must always be takeninto account:

Series connection



• The required system pressure corresponds to the sum of all pressuredrops of the individual components. This means a reduced hydraulicoperational safety due to a high system pressure.

• The temperature level of the coolant rises from one component to thenext. Each power loss contribution to the coolant rises its temperature(inhomogeneous machine heating)

• Some components may not be cooled as required since the flowquantity cannot be selected individually.

Combining series and parallel connections of the drive components thatare to be cooled permits the benefits of both connection types to beused.

D

D

D D

!D!

D % '

A

A

A!

A%A A'


Fig. 9-60: Combination of series and parallel connection

Combination of series andparallel connection



9.7 Motor temperature Monitoring Circuit

In their standard configuration, the primaries of IndraDyn L motors areequipped with built-in motor protection temperature sensors. Everymotor phase contains of one out of three switched in a row ceramicPTC´s, so that a sure thermical control of the motor in every operationphase is possible. These thermistors (furthermore: thermistor motorprotection) have a switching character (see Fig. 9-64) and becomeevaluated on all Bosch Rexroth control devices.

Furthermore all primaries are fitted with an additional thermistor forexternal temperature measurement. These sensors (furthermore: sensortemperature measurement) has nearly a linear characteristic curve (seeFig. 9-65).

5

/340

.6*7

!687

(

(

( 3 <=;>>> / $$ % ''

#

' 2

;4.*<$$ ' /$/ % ''

TEMPSENS01-MLF-EN.EPS

Fig. 9-61: Arrangement of temperature sensors at IndraDyn L motors

Type PTC SNM.150.DK.***

Rated response temperature ϑNAT 150 °C

Resistor at 25°C ≈ 100...250 Ohm

Fig. 9-62: Temperature sensor motor protection

Note: For the parallel arrangement of two or more primary parts, themotor protection temperature sensors of all primary parts areconnected in series. For further details, please see Chapter 8“Electrical Connection”.

Type KTY84-130

Resistor at 25°C 577 Ohm

Resistor at 100°C 1000 Ohm

Continuous current at 100°C 2 mA

Fig. 9-63: Temperature measurement sensor

Note: Notice the correct polarity when using the sensor fortemperature measurement external.

Temperature sensor motorprotection

Sensors temperaturemeasurement external



Motor protection temperature sensorsconnecting cores 5 and 6

norminal responce temperature 150°C

100

1000

10000

100000

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170

motor winding temperature in °C

tem

per

atu

re s

enso

r re

sist

ance

in o

hm

s

N=íÉãéÉê~íìêÉ=ëÉåëçê=EN=éêáã~êóF=

O=éêáã~êáÉë=áå=ëÉêáÉë

=Q=éêáã~êáÉë=áå=ëÉêáÉë=

TEMPERATURSENSOREN LSF.XLS

Fig. 9-64: Characteristik of temperature sensors motor protection (PTC)

temperature measuring sensor KTY84-130connecting cores 7 (+) und 8 (-)

500

600

700

800

900

1000

1100

1200

1300

1400

1500

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170

motor winding temperature in °C

tem

per

atu

re s

enso

r re

sist

ance

in o

hm

s

Fig. 9-65: Characteristik sensor temperature measurement KTY84-130 (PTC)

A polynomial of degree 3 proves sufficient for describing the resistancecharacteristic of the sensor used for temperature measurement (KTY84-130). Below, this is specified for determining a temperature from a givenresistance, and vice versa.



DRCRBRAT KTY2

KTY3

KTYw +⋅+⋅+⋅=Tw: Winding temperature of the motor in °CRKTY: Resistance of the temperature sensor in OhmsA: 3.039 ·10-8

B: -1.44 ·10-4

C: 0.358D: -143.78

Fig. 9-66: Polynomial used for determining the temperature with a knownsensor resistance (KTY84)

DTCTBTAR w2

w3

wKTY +⋅+⋅+⋅=Tw: Winding temperature of the motor in °CRKTY: Resistance of the temperature sensor in OhmsA: 1.065 ·10-6

B: 0.011C: 3.93D: 492.78

Fig. 9-67: Polynomial used for determining the sensor resistance (KTY84) witha known temperature

Temperature vs. resistance

Resistance vs. temperature



9.8 Setup Elevation and Ambient Conditions

The performance data specified for the motors apply in the followingconditions:

• Ambient temperature + 0 bis + 40° C

• Setup heights of 0 m up to 1000 m above MSL

Different conditions lead to a departing of the data according to thefollowing diagrams. Do occur deviating ambient temperatures and highersetup elevations at the same time, both utilization factors must bemultiplied.

-

GH.I ! %

#'

#+

% % %%

-7

GI

#

#'

#+

#

UMGEBHOE-MLF-DE.EPS

(1): Utilization depending on the ambient temperature(2): Utilization depending on the site altitudefT: Temperature utilization factortA: Ambient temperature in degrees CelsiusfH: Height utilization factorh: Site altitude in meters

Fig. 9-68: IndraDyn L height utilization

If either the ambient temperature or the site altitude exceeds thenominal data:

1. Multiply the motor data provided in the selection data with thecalculated utilization factor.

2. Ensure that the reduced torque data are not exceeded by yourapplication.

If both the ambient temperature and the site altitude exceed the nominaldata:

1. Multiply the determined utilization factors fT and fH by each other.2. Multiply the value obtained by the motor data specified in the

selection data.Ensure that the reduced motor data are not exceeded by yourapplication.

Note: The details for the utilization against the site altitude andenvironmental temperature do not apply to the defined liquidcoolant on the motor, but on the whole drive system,consisting of motor, drive controller and mains supply.



9.9 Protection Class

The design of the IndraDyn L synchronous linear motors complies withthe following degrees of protection according to DIN VDE 0470, Part 1,ed. 11/1992 (EN 60 529):

Motor components Protection class

Primary in standard encapsulation

Primary in thermal encapsulation

Secondary segment

IP 65

Fig. 9-69: Protection class of IndraDyn L motors

The type of protection is defined by the identification symbol IP(International Protection) and two code numbers specifying the degree ofprotection.

The first code number defines the degree of protection against contactand penetration of foreign particles. The second code number definesthe degree of protection against water.

First figure Degree of protection

6Protection against penetration of dust (dust-proof);complete shock protection

Second figure Degree of protection

5Protection against a water jet from a nozzle directedagainst the housing from all directions (jet water)

Fig. 9-70: IP degrees of protection

Note: Tests regarding the second characteristic numeral must beperformed using fresh water. If cleaning is effected using highpressure and/or solvents, coolants, or penetrating oils, itmight be necessary to select a higher degree of protection.

WARNING

Personal injuries, damaging or destroying motorcomponents!⇒ Use IndraDyn L synchronous linear motors only in

environments for which the specified class ofprotection proves sufficient.

9.10 Compatibility

All Rexroth controls and drives are developed and tested according tothe state-of-the-art.

However, as it is impossible to follow up the permanent newdevelopment of all material which may come into contact with ourcontrollers and drives (e.g. lubricants for machine tools), we cannotgenerally exclude any reaction with the materials used in our systems.

For this reason, you will have to carry out a test on compatibility amongnew lubricants, detergents, etc. and our housing and device materials.



9.11 Magnetic Fields

The secondaries of synchronous linear motors are equipped withpermanent magnets, which are not magnetic shielded.

To be able to assess EMC problems (e.g. the influence on inductiveswitches or inductive measuring systems), chip attraction, and forhuman protection, the values of the magnetic induction as a function ofthe distance to the secondary are specified below.

The representation distinguishes between ferromagnetic materials (e.g.steel) and non-ferromagnetic materials (e.g. air), and between differentdirections.

0,0 T

0,1 T

0,2 T

0,3 T

0,4 T

0,5 T

0,6 T

0,7 T

0,8 T

0 mm 10 mm 20 mm 30 mm 40 mm 50 mm 60 mm 70 mm 80 mm 90 mm

distance to the secondary

ind

uct

ion

B

1: direction 1, ferromagnetic material2: direction 1, non-ferromagnetic material3: direction 2 and 3, areas of both materials

1

2

INDUKTIONSVERTEILUNG M

Fig. 9-71: Magnetic induction in ferromagnetic and non-ferromagnetic materialsvs. the distance to the secondary

Note: Secondaries of IndraDyn L motors generate a static magneticfield.

Ferromagnetic chips are not attracted at a distance of approximately 100mm from the surface of the secondary.

Note: It must be ensured that the secondary is not located in theimmediate chip area of the machine. Suitable covers must beprovided.

Chip attraction



9.12 Vibration and Shock

According to IEC 721-3-3 Issue 1987 or EN 60721-3-3 Issue 06/1994,IndraDyn L motors are approved for the utilization in areas that areexposed to vibration and/or shock as given in Fig. 9-72 and 9-73.IndraDyn L motors may be used in stationary weather-proof operationcorresponding to class 3M5.

Influencing quantity Unit Maximumvalue

Amplitude of the excursion at 2 to 9 Hz mm 0,3

Amplitude of the acceleration at 9 to 200Hz

m/s² 1

Fig. 9-72: Limit data for sinusoidal vibrations

Influencing quantity Unit Maximumvalue

Total shock-response spectrum(according to IEC721-1, :1990; Table 1,Section 6)

Type II

Reference acceleration,in IEC 721: Peak acceleration

m/s² 250

Duration ms 6

Fig. 9-73: Limits for shock load

WARNING

Motor damage and loss of warranty!⇒ A motor, used outside of specified operating

conditions can be damaged. In addition, anywarranty claim will expire.

⇒ Ensure that the maximum values specified in Fig. 9-72 and Fig. 9-73 for storage, transport, andoperation of the motors are not exceeded.



9.13 Enclosure surface

The following table shows the condition of the enclosure surface whendelivered.

Motor component Layout of enclosure / enclosuresurface

Remarks

Primary in standard encapsulationStainless steel V4Ablack printing (RAL 9005)

Varnish resistant to weather,yellowing, chalking, thinned acidsand thinned lyes

Primary in thermal encapsulationStainless steel V4Ablack printing (RAL 9005); front sidealuminium blank

Varnish resistant to weather,yellowing, chalking, thinned acidsand thinned lyes

SecondaryCover plate V4Amagnet base carrier C45, chromatic

Fig. 9-74: Layout of enclosure surface

Note: The surface of the motor components may be painted withadditional varnish.

9.14 Noise emission

The noise emission of synchronous linear drives can be compared withconventional inverter-operated feed drives.

Experience has shown that the noise generation chiefly depends on

• the employed linear guides (velocity-related travel noise),

• The mechanical design (following cover, etc.), and

• the settings of drive and controller (e.g. switching frequency)

A generally valid specification is therefore not possible.



9.15 Length Measuring System

A linear scale is required for measuring the position and the velocity.Particularly high requirements are placed upon the linear scale and itsmechanical connection. The linear scale serves for high-resolutionposition sensing and to determine the current speed.

Note: The necessary length measuring system is not in the scopeof delivery of Bosch Rexroth and has to be provided andmounted from the machine manufacturer himself. (see Fig. 9-80).

model

open systemsensapsulated

systems

measuringprinciple

incrementalincremental,

distance-encodedreference marks

absolutelinear scale

integrated intolinear guides

Fig. 9-75: Classification of linear scales

It is necessary at synchronous linear motors to receive the position ofthe primary relating on the secondary by return after start or after amalfunction (pole position recognition). Using an absolute linear scale isthe optimum solution here.

Selection criteria for linear scalesDepending on the operating conditions, open or encapsulated linearscales with different measuring principles and signal periods can beused. The selection of a suitable linear scales mainly depends on:

• the maximum feed rate (model, signal period)

• the maximum travel (measuring length, model)

• if applicable, utilization of coolant lubricants (model)

• produced dirt, chips etc. (model)

• the accuracy requirements (signal period)

Peculiarities of synchronouslinear motors



Models

Open model Encapsulated model Measuring system,integrated in rail guides

Advantages:

- High traverse rates

- No friction

- High accuracy

- Easy installation

- High protection rating

- Incremental and absolute

measurement available

- Combined guidance and

measurement

- No additional installation required

- Highest protection rating

- High traverse rates

- Little space required

Disadvantage:

- Low protection mode

- Currently no absolute measurement

systems available

- More complicated mounting and

adjustment

- Maximum velocity

currently 120m/min

- No absolute measurement systems

available

Fig. 9-76: Advantages and disadvantages of different linear scales models

If there are no dirt, chips, etc. in a machine or system and if coolantlubricants will never be used, employing an open linear scale isrecommended. Thus open linear scale are frequently used for handlingaxes, precision and measuring machines, and in the semiconductorindustry.

Encapsulated systems should be employed if chips are produced and/orcoolant lubricants are used. To achieve highest operational reliability, anencapsulated system can have additional sealing air. Encapsulatedlinear scales are chiefly used at chip-producing machine tools.

The ball and roller rail guides from Rexroth are available with anintegrated inductive linear scales. The system consists of a separatescanner (read head) and a material measure that is integrated into therail. The material measure is accommodated in a groove of the guiderail, and is protected by a tightly welded stainless steel type. The readhead is attached directly to the guide carriage.

The system is insensitive against soiling (e.g. dust, chips, coolant, etc.)and magnetic fields. Due to the little space required, the compact androbust device (measuring system and guides) permits simplifiedstructures compared with an externally attached measuring system.There are no costs for material and installation of external systems.

Open model

Encapsulated model

Measuring system,integrated in rail guides



Measuring principle

The advantages of an absolute linear scale result from the fact that ahigh availability and operational reliability of the axis of motion and,consequently, of the entire system is guaranteed.

Advantage

• Monitoring and diagnosis functions of the electronic drive system arepossible without any additional wiring

• No axis travel limit switches required

• The maximum available motor force is available at any point of thetravel immediately after power-up.

• No referencing required

• Easy commissioning of horizontal and vertical axes

• pole position recognition only required for initial commissioning

Disadvantage:

• Maximum measuring length is limited (3040mm)

• Only encapsulated systems available

Note: An ENDAT interface is required if absolute linear scales areused.

Using an absolute linear scales makes it possible that the pole positionrecognition of the motor need only be performed once for initialcommissioning. This drive-internal procedure is possible withoutactivating the power. This provides advantages when commissioningvertical axes, in particular.

Rexroth recommends the absolute linear scale LS181 and LC481 fromHeidenhain. Both systems are equipped with an ENDAT interface.

LC181_1.TIF

Fig. 9-77: Absolute encapsulated length measuring system LC181

Absolute scales



When an incremental linear scale is used together with a synchronouslinear motor, the pole position must be measured upon each power-up.This is done, using a drive-internal procedure that must be executedwhenever the axis is switched on. After this, a force processing of themotor is possible.

Note: With incremental linear scales, the drive-internal pole positionrecognition procedure must be executed upon each power-up. Pole position recognition required the primary part to bemoved!

Advantage

• Depending on the model, travels up to 30 m (or unlimited distance)possible

• high feed rate possible

• Different signal periods and, consequently, different positionresolutions possible.

Disadvantage:

• Pole position must be measured upon each power-up.

• Pole position recognition required the primary part to be moved

• Pole position recognition is not possible for vertical axes

• Pole position recognition is not possible for securely braked axes orfor axes at the hard stop

• Pole position recognition of Gantry axes may cause problems

• Reference point interpretation and homing switch are required

• Safety limit switch is required

Incremental linear scales with distance-encoded reference marks offerthe benefit of a simplified and, even more important, shortenedreferencing. With such a system, referencing requires the axis merely tobe moved by several centimeters (depends on the model).

Note: Distance-encoded scales do not perform absolutemeasurement. Pole position recognition must also beperformed upon each power-up (like incremental systems thatare not distance encoded).

lida185.tif

Fig. 9-78: Open incremental linear scales LIDA185C with distance-encodedreference marks

Incremental scales

Incremental linear scales withdistance-encoded reference

marks



Maximum permissible velocity and accelerationOne limitation factor of the maximum permissible feed rate of a lengthmeasuring system are the sealing lips and the guides of the scancarriage on the glass rule. Currently, the velocity of an encapsulatedsystem is limited to 120 m/min.

The other limitation factor of the maximum permissible feed rate is thefrequency limit of the output signals (manufacturer´s specifications) orthe maximum permissible input frequency of subsequent circuits (drivecontroller).

60periodSignalfv maxmax ⋅⋅=vmax: Maximum feed rate in m/minSignal period: Signal period of linear scale in mmfMAX: Maximum input frequency of scale interface

DAG 1 VSS: 500kHzDLF 1 VSS: 500kHz

Fig. 9-79: Maximum traverse rate of linear scale related to the maximum inputfrequency of the scale interface

The very rigid internal structure of open linear scales permits maximumacceleration values in the measuring direction of up to 200m/s². Topermit relatively high attachment tolerances, the scan carriage ofencapsulated linear scales cannot rigidly be connected with the mountingfoot. Encapsulated linear scales systems for linear motors, however, arecomparatively rigid and may be used for maximum accelerations in themeasuring direction between 50 m/s² and 100 m/s² (depending on thelength measuring system employed).

Note: Please refer to the documents from the correspondingmanufacturer for detailed and updated information.

Position resolution and positioning accuracyTo reach a high resolution of the linear scale, an interpolation of thesinusoidal input signal of the linear scale is performed in the drivecontroller (see Fig. 10-9). Depending on the maximum travel range andon the signal period, a drive-internal position resolution of less than 1mm is possible. (See also Chapter 10.4 Position and Velocity Resolution)

Note: The drive-internal position resolution does not correspond tothe positioning accuracy! The absolute positioning accuracyis depending on the entire drive system, including mechanicalsystems.

Measuring system cablesReady-made cables of Rexroth are available for the electrical connectionbetween the output of the linear scale and the input of the scaleinterface. To ensure maximum transmission and scale interferencesafety, you should preferably use these ready-made cables.

Maximum permissible feed rate

Maximum permissibleacceleration in the measuring

direction



Recommended linear scales for linear motorsManufacturer

typeSignal period

in mm(S-0-0116)

Model Outputsignals

Measuringprinciple

Maximummeasuring

length in mm

Maximumvelocity in

m/min

P-0-0074 Reference marks

HeidenhainLC 181 0.016 Encapsulated Sine 1 Vss

absoluteENDAT 3040 120 8 None

(absolute)

HeidenhainLC 481 0.016 Encapsulated Sine 1 Vss

absoluteENDAT 2040 120 8 None

(absolute)

HeidenhainLS 486 0.02 Encapsulated Sine 1 Vss Incremental 2040 120 2

one(Center meas.

length)

HeidenhainLS 486C 0.02 Encapsulated Sine 1 Vss Incremental 2040 120 2 Distance-encoded

HeidenhainLS 186 0.02 Encapsulated Sine 1 Vss Incremental 3040 120 2

one(Center meas.

length)HeidenhainLS 186C 0.02 Encapsulated Sine 1 Vss Incremental 3040 120 2 Distance-encoded

HeidenhainLB 382 0.04 Encapsulated Sine 1 Vss Incremental 30040 120 2 Selectable by

masks

HeidenhainLB 382C 0.04 Encapsulated Sine 1 Vss Incremental 30040 120 2 Distance-encoded

HeidenhainLF 183 0.004 Encapsulated Sine 1 Vss Incremental 3040 60 2 Selectable by

magnets

HeidenhainLF 183C 0.004 Encapsulated Sine 1 Vss Incremental 3040 60 2 Distance-encoded

HeidenhainLF 481 0.004 Encapsulated Sine 1 Vss Incremental 1220 60 2

one(Center meas.

length)HeidenhainLF 481C 0.004 Encapsulated Sine 1 Vss Incremental 1220 60 2 Distance-encoded

HeidenhainLIDA 185 0.04 Open Sine 1 Vss Incremental 30040 480 2 Selectable by

magnets

HeidenhainLIDA 185C 0.04 Open Sine 1 Vss Incremental 30040 480 2 Distance-encoded

HeidenhainLIDA 187 0.04 Open Sine 1 Vss Incremental 6040 480 2 Selectable by

magnets

HeidenhainLIDA 187C 0.04 Open Sine 1 Vss Incremental 6040 480 2 Distance-encoded

RenishawRG 2 0.02 Open Sine 1 Vss Incremental 30040 500 2 Selectable by

magnets

HeidenhainLIF 181R 0.004 Open Sine 1 Vss Incremental 3040 120 2

one(Center meas.

length)HeidenhainLIF 181C 0.004 Open Sine 1 Vss Incremental 3040 120 2 Distance-encoded

Heidenhain LIP481R 0.002 Open Sine 1 Vss Incremental 420 60 2

one(Center meas.

length)

RexrothIML 1.000 Integrated in

rail guides Sine 1 Vss Incremental 4000 600 2One

(Position tocustomer request)

P-0-0074: Drive parameter “Encoder type 1”S-0-0116: Drive parameter “Encoder 1 resolution”

Fig. 9-80: Recommended linear scales for linear motors

Note:

• To ensure maximum interference immunity, Rexroth recommends thevoltage interface with 1Vpp.

• Please refer to the documents from the corresponding manufacturerfor detailed and possibly updated information.



Mounting Linear scales

With linear drives, the mounting of the measuring system to the machinecan limit the bandwidth of the position control loop. As a consequencefor the design, this means that the coupling between the scan unit andthe rule of an open linear scale, or between the rule enclosure of anencapsulated linear scale, and the machine – with respect to the naturalfrequency – must be significantly higher than the one of the linear scale.The natural frequencies of today´s encapsulated linear scales are 2kHzand higher.

It must also be ensured that the linear scales is not attached to vibratingmachine components. In particular, attaching the system in the vicinity ofvibration maximal must be avoided.

In order to minimize the moved masses and to obtain the highest rigidityin the measuring direction, the scanner unit should always be moved ifpossible.

The user should provide an encapsulation if an open linear scale isemployed despite adverse conditions (chips, dust, etc.). It must also benoted that the scanning head must be adjusted when the open linearscale is installed. Corresponding adjustment possibilities must beprovided in the design (please heed the specifications of themanufacturer).

To obtain relatively high installation tolerances, the scan carriage ofencapsulated linear scale is connected with the mounting base viacoupling that is very rigid in the measuring direction and slightly flexibleperpendicularly to the measuring direction. If the rigidity of this couplingin the measuring direction is too weak, there are low natural frequenciesin the feedback of the position and velocity control loop that can limit thebandwidth. The encapsulated linear scales that are recommended forlinear motors usually possess a natural frequency in the measuringdirection that is above 2 kHz. Thus, the natural frequency of the linearscale in the measuring direction can be neglected with respect to themechanical natural frequencies of the machine.

If several motors on an axis are used with a single linear scale, themotors should be positioned as symmetrically as possible.

With a Gantry axis, where each motor of pair of motors is assigned to alinear scale system, the distance between motor and linear scale shouldbe as small as possible. The accuracy of the linear scale as such andwith respect to each other should be less than 5 µm/m. Drive-internalaxis error compensations can minimize remaining misalignmentsbetween the linear scales.

Elasticity of the coupling to themachine

Mounting method

Open linear scales systems

Encapsulated linear scalessystems

Parallel arrangement of motorswith one linear scale system

Gantry axes



9.16 Linear Guides

Depending on the motor arrangement, the attractive, feed and processforces and the velocities of more than 600 m/min that can be reachedtoday stress the linear guides. The employed linear guides must theable to handle

• Attractive force between the primary and the secondary and

• Machining and acceleration forces

Depending on the application, the following linear guides are employed:

• Ball or roll rail guides

• Slideways

• Hydrostatic guides

• Aerostatic guides

The following requirements should be taken into account when a suitablelinear guide system is selected:

• High accuracy and no backlash

• Low friction and no stick-slip effect

• High rigidity

• Steady run, even at high velocities

• Easy mounting and adjustment

9.17 Braking Systems and Holding Devices

The following systems can be used as braking systems and/or holdingdevices for linear motors:

• External braking devices

• Clamping elements for linear guides

• Holding brakes integrated in the weight compensation

See also Chapter 16 “Recommended suppliers of additionalcomponents”.

Note: Additional information about stopping linear motors can befound in the Chapters 9.18 End Position and 9.21 Stopping atEMERGENCY STOP and in the event of malfunction and inthe appropriate documentation of the used drive-controller.



9.18 End Position shock absorber

Where linear drives with frequently high traverse rates and accelerationsare concerned, uncontrolled movements (such as coasting after a mainsfailure) cannot always safely be avoided.Suitable energy-absorbing end position shock absorber must beprovided in order to protect the machine during uncontrolled coasting ofan axis.

WARNING

Damage on machine or motor componentswhen driving against hard stop!⇒ Use suitable energy-absorbing end position shock

absorber⇒ Adhere to the specified maximum decelerations

Note: The necessary spring excursion of the shock absorbers mustbe taken into account when the end position shock absorberare integrated into the machine (in particular when the totaltravel path is determined).

Given by the type of attachment and by the type of the primary (numberof mounting screws, attractive force, mass, etc.), there is a maximumdeceleration in the movement onto an end stop.If this maximum deceleration is exceeded, this can lead to loosening theprimary and to damaging of motor components.The maximum permissible deceleration upon moving against end stop is300 m/s².

Note: Using a suitable end stop shock absorber, the maximumpermissible deceleration for moving against an end stop mustbe limited to 300 m/s².

With the known maximum deceleration of 300 m/s² and the maximumpossible velocity, the minimum spring excursion can be calculated asfollwos:

2158v

s2max

min =

smin : Minimum braking distance in mmvmax: Maximum possible velocity in m/min

Fig. 9-81: Braking distance to be kept when driving against end stop

Maximum deceleration whendriving against end stop

Braking distance to be keptwhen driving against end stop



9.19 Axis Cover System

Depending on the application, design, operational principle and featuresof synchronous linear motors the following requirements on axis coversystems apply:

• High dynamic properties (no overshoot, little masses)

• Accuracy and smooth run

• Protection of motor components against chips, dust andcontamination (in particular ferromagnetic parts),

• Resistance to oil and coolant lubricants

• Robustness and wear resistance

The following axis cover systems can be used:

• Bellow covers

• Telescopic covers

• Roller covers

A suitable axis cover system should be configured, if possible, during theearly development process of the machine or system – supportet by thecorresponding specialized supplier (see Chapter “Recommendedsuppliers of additional components”).



9.20 Wipers

It is generally possible, to use a wiper for removing chips directly fromthe secondary. The following points must be taken into account when asuitable wiper system is selected and used.

If possible, a wiper should be used on a whole secondary. If more thanone secondary is used, joints between the secondaries must be takeninto account (destruction of wiper or of secondaries). In these cases, adefined distance – smaller than the air gap among the primary and thesecondary – between wiper and the secondary or a wiper in the form of ahard brush can help.

The secondary attracts ferromagnetic chips at a distance of approx. 100mm. These attractive forces must be taken into account whenferromagnetic chips are removed.

If the utilization of the wiper causes a significant rise of the temperatureon the secondary surface, it must be ensured that this temperature doesnot exceed the limit of 70°C.

The wiper should be mounted to the superordinated machineconstruction. Mounting the wiper in additional holes directly on theprimary is not permitted.

WARNING

Damage or destruction of motor components byinappropriate utilization of a wiper on thesecondary part!⇒ If possible, utilization only on whole secondaries⇒ Take slightly height differences of the secondaries

into account⇒ Take temperature rises due to friction into account⇒ Mounting the wiper in additional holes directly on

the primary is not permitted

Secondary part segments

Ferromagnetic chips

Temperature produced byfriction

Mounting the wiper



9.21 Drive and Control of IndraDyn L motors

The following figures shows a complete linear direct drive, consisting of asynchronous linear motor, length scale system, drive controller andsuperordinate control.

=

$%'/$</

#<$$$"'$

3$'/ +60 '$ -

/ '%' '$ '2 '

ANTRSYST01-MLF-EN.EPS

Fig. 9-82: Linear direct drive

Drive controller and power supply modulesTo control IndraDyn L motors, different digital drive controllers and powersupply modules are available. These drive systems are configurable andof a modular or compact structure.

Note: The drive controllers and the related firmware for theIndraDyn L motors are the same as for the rotary drives fromBosch Rexroth.

Control systemsA master control is required for generating defined movements.Depending on the functionality of the whole machine and the usedcontrol systems, Bosch Rexroth offers different control systems.



9.22 Shutdown upon EMERGENCY STOP and in the Event of aMalfunction

The shutdown of an axis, equipped with an IndraDyn L motor, can beinitiated by

• EMERGENCY STOP,

• drive fault (e.g. response of the encoder monitoring function) or

• mains failure

For the options of shutting down an IndraDyn L motor in the event of amalfunction, distinction must be made between

• Shutdown by the drive,

• Shutdown by a master control and

• Shutdown by a mechanical braking device.

Shutdown by the driveAs long as there is no fault or malfunction in the drive system, shutdownby the drive is possible. The shutdown possibilities depend on theoccurred drive error and on the selected error response of the drive.Certain faults (interface faults or fatal faults) lead to a forcedisconnection of the drive.

WARNING

Death, serious injuries or damage to equipmentmay result from an uncontrolled coasting of aswitched-off linear drive!⇒ 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 faults and non-fatal faults can be selected. The drive switches off at the end of eachfault response.

The following fault responses can be selected:

0 – Setting velocity command value to zero

Setting force command value to zero

Setting velocity command value to zero with command value ramp andfilter

3 - Retraction

Note: Please refer to the corresponding firmware functiondescription for additional information about the reaction tofaults and the related parameter value assignments.



Shutdown by a master control

Shutdown by control functionsShutdown by the master control should be performed in the followingsteps:

1. The machine PLC or the machine I/O level reports the fault to theCNC control

2. The CNC control shuts down the drives via a ramp in the fastestpossible way

3. The CNC control causes the power at the power supply module to beshut down.

Drive initiated by the control shutdownShutdown by the master control should be performed in the followingsteps:

1. The machine I/O level reports the fault to the CNC control and SPS

2. The CNC control or the PLC resets the drive enabling signal of thedrives. If SERCOS interface is used, it deactivates the “E-STOP”input at the SERCOS interface module.

3. The drive responds with the selected error response.

4. The power at the power supply module must be switched off 500 msafter the drive enabling signal has been reset or the “E-STOP” inputhas been deactivated.

Note: The delayed power shutdown ensures the safe shutdown ofthe drive by the drive controller. With an undelayed powershutdown, the drive coasts in an uncontrolled way once theDC bus energy has been used up.

Shutdown via mechanical braking deviceShutdown by mechanical braking devices should be activatedsimultaneously with switching off the power at the power supply module.Integration into the holding brake control of the drive controllers ispossible, too. The following must be observed:

• Braking devices with electrical 24V DC control (electrically un-locking)and currents < 2 A can directly be triggered.

• Braking devices with electrical 24V DC control and currents > 2 A canbe triggered via a suitable contractor.

Once the drive enabling signal has been removed, the holding brakecontrol has the following effect:

• Fault reaction “0”, “1” and “3”.The holding brake control drops to 0 V once the velocity is less than10 mm/min or a time of 400 ms has elapsed.

• Fault reaction “2”The holding brake control drops to 0 V immediately after the driveenabling signal has been removed.



Response to a mains failureIn order to be able to shut down the linear drive as fast as possible in theevent of a mains failure,

• either an uninterruptible power supply or

• additional DC bus capacities (condensers), and /or

• mechanical braking facilities

must be provided.

Additional capacities in the DC bus represent an additional energy storethat can supply the brake energy required in the event of a mains failure.

Note: Internal control circuits are also supplied by the DC bus;external backup is not necessary.

The additional capacity required for a shutdown upon a mains failure canbe determined as follows:

+⋅−⋅⋅⋅

−⋅= 3.0

FF

vRk

F5,3

UU

vmC

max

Rmax122

iF

max2

minDC

2

maxDC

maxadd

Cadd: Required additional DC bus capacitor in mFm: Moved mass in kgvmax: Maximum velocity in m/sUDCmax: Maximum DC bus voltage in VUDCmin: Minimum DC bus voltage in VFMAX: Maximum braking force of the motor in NkiF: Motor constant (force constant) in N/AR12: Winding resistance at 20°CFR: Frictional force in N

Fig. 9-83: Determining the required additional DC bus capacitor

Prerequisites: - final velocity = 0- velocity-independent friction –constant deceleration – winding temperature 135°C

Note: The maximum possible DC bus capacity of the employedpower supply module must be taken into account whenadditional capacities are used in the DC bus. Do not initiate aDC voltage short-circuit when additional capacitors areemployed.

Short-circuit of DC busMost of the power supply modules of Bosch Rexroth permit the DC busto be shortened when the power is switched off, which also establishes ashort-circuit between the motor phases. When the motor moves, thiscauses a braking effect according to the principle of the induction;thereby the motor phases are shorted. The reachable braking force isnot very high and velocity-dependend. The DC bus short-circuit cantherefore only be used to support existing mechanical braking devices.

Determining the requiredadditional DC bus capacitor



9.23 Maximum Acceleration Changes (Jerk Limitation)

The maximum rate of current and force rise is determined by theavailable DC bus voltage and the motor inductance. As shown in Fig. 9-84, with highly dynamic movements and short strokes, the motorinductance should be low and the DC bus voltage as high as possible.

iF12

DC

12

DC

kLU

dtdF

LU

dtdi

⋅=

=

UDC: DC bus voltage in VL12: Winding inductance in HkiF: Motor constant (force constant) in N/Ai: Current in At: Time in s

Fig. 9-84: Maximum rate of current and force rise

The acceleration change per time unit (derivative of the acceleration) isknown as jerk (see Fig. 9-87).

?

RUCKBEGR01-MLF-EN.EPS

Fig. 9-85: Acceleration and velocity without jerk limitation

Note: The drive controller or the master control must delimit themaximum jerk when direct drives are employed. (accelerationramp with da/dt ≠ ∞, Fig. 9-86.

Rate of current and force rise



RUCKBEGR02-MLF-EN.EPS

Fig. 9-86: Acceleration and velocity with jerk limitation

The maximum jerk is determined by the maximum rate of current rise, bythe moved mass and by the motor constant:

mLkU

dtda

r12

iFDCmax ⋅

⋅==

m: Moved mass in kgUDC: DC bus voltage in VkiF: Motor constant (force constant) in N/AL12: Winding inductance in Ha: Acceleration in m/s²t: Time in s

Fig. 9-87: Maximum jerk (acceleration change)

Maximum jerk



9.24 Position and Velocity Resolution

Drive-internal position resolution and positioningaccuracyIn linear direct drives, a linear scale is used for measuring the position.The linear scale for linear motors supply sinusoidal output signals. Thelength of such a sine signal is known as the signal period. It is mainlyspecified in mm or µm.

With the drive controllers from Bosch Rexroth, the sine signals areamplified again in the drive (see Fig. 9-89). The drive-internalamplification also depends on the maximum travel area and the signalperiod of the length measuring system. It always employs 2n vertices(e.g. 2048 or 4096).

n

max

31int 2 torounding 2

x

sf p⋅=

fint: Multiplication factor (S-0-0256, Multiplication 1)sp: Linear scale system signal period in mm (S-0-0116 resolution of

encoder 1)xmax: Maximum travel (S-0-0278, maximum travel)

Fig. 9-88: Multiplication factor

$"'

INTPOLSIN-MLF-EN.EPS

Fig. 9-89: Drive-internal multiplication and/or interpolation of the measuringsystem signals

With a known signal period and a drive-internal multiplication, the drive-internal position resolution results as:

int

pd f

sx =∆

∆xd: Drive-internal position resolutionsp: Linear scale system signal period (S-0-0116 resolution of encoder 1)fint: Multiplication factor (S-0-0256, Multiplication 1)

Fig. 9-90: Drive-internal position resolution

Note: The drive-internal position resolution is not identical to thereachable positioning accuracy.



The reachable position accuracy depends on the mechanical andcontrol-engineering overall system and is not identical to the drive-internal position resolution. .

The reachable position accuracy can be estimated as follows (usingempirical values):

50...30xx dabs ⋅= ∆∆∆xd: Drive-internal position resolution∆xabs: Position accuracy

Fig. 9-91: Estimating the reachable position accuracy

Prerequisites: Optimum controller setting

Note: The expected position accuracy cannot be better than thesmallest position command increment of the master control.

Velocity resolutionThe resolution of the velocity (velocity quantization) is proportional to theposition resolution (see Fig. 9-88) and inversely proportional to thesample time tAD from:

AD

dd t

xv

∆∆ =

∆vd: Velocity resolution in m/s∆xd: Drive-internal position resolution (see Fig. 9-90)tAD: Sample time in s (DIAX04: 250µs, ECODRIVE03: 500µs, IndraDrive:

Standard Performance 250µs / High Performance 125µs)Fig. 9-92: Velocity resolution

9.25 Load Rigidity

The elastic deformability resistance of a structure against an externalforce is known as rigidity (usually specified in N/µm). The reciprocalvalue of the rigidity is known as elasticity.

Influence of disturbing factors on a controlled electric drive is called loadrigidity. It is distinguished between static and dynamic load rigidity.

Reachable positioning accuracy



Static load rigidityThe static load rigidity of a linear direct drive only depends on themaximum motor force and the drive-internal position resolution:

D

maxstat x

Fc

∆=

cstat: Static load rigidity in N/µmFMAX: Maximum force of the motor in N∆xD: Drive-internal position resolution in µm (see Fig. 9-90)

Fig. 9-93: Static load rigidity of linear direct drives

Note: The rigidity of the machine structure must be taken intoaccount when the static load rigidity of a linear direct drive israted.

max

Dstat F

xd

∆=

dstat: Static elasticity in N/µmFMAX: Maximum force of the motor in N∆xD: Drive-internal position resolution in µm (see Fig. 9-90)

Fig. 9-94: Static elasticity of linear direct drives

Dynamic load rigidityDynamic load rigidity and elasticity are frequency-dependent variables.The dynamic load rigidity of a linear direct drive only depends on thecontroller settings (current, velocity and position controller) and on themoved masses (see Fig. 9-96). The maximum elasticity (or the minimumrigidity) is in the area of the natural frequency of the control loop.

In a simplified form, the following figure shows a typical elasticityfrequency response.

1 10 100 1 .1031 .10 4

1 .10 3

0.01

0.1

G S ω( )

µm

N

ω2 π.

.

Fig. 9-95: Example elasticity frequency response of a linear direct drive



Despite the frequency sensitivity, a sufficiently exact estimate of thedynamic rigidity can be made for the area below the natural frequency ofthe control loop:

( )

( )nv

niFp

2

D1D

n

nviFpdyn

Tk0167.01m

Tkk06.0

21

D

mit

D1

e1T

Tk0167.01kk06.0c

2

⋅⋅+⋅⋅⋅⋅

⋅=

−+⋅

⋅⋅+⋅⋅⋅=

−⋅− π

cdyn: Dynamic load rigidity in N/µmD: AttenuationkiF: Motor constant (force constant) in N/Akp: Proportional gain of velocity controller in A min/mkv: Proportional gain of position controller (Kv-factor) in m/min mmTn: Integral time of velocity controller in msm: Moved mass in kg

Fig. 9-96: Estimating the dynamic load rigidity

dyndyn c

1d =

cdyn: Dynamic load rigidity in N/µmddyn: Dynamic elasticity in N/µm

Fig. 9-97: Determining of the dynamic elasticity

( )n

nviFp0 Tm

Tk60kk1000

21

⋅⋅+⋅⋅⋅

⋅⋅

=π

ω

ω0: Natural frequency in HzkiF: Motor constant (force constant) in N/Akp: Proportional gain of velocity controller in A min/mkv: Proportional gain of position controller (Kv-factor) in m/min mmTn: Integral time of velocity controller in msm: Moved mass in kg

Fig. 9-98: Determining the controller´s natural frequency

Estimating the dynamic loadrigidity

Rexroth IndraDyn L Motor-Controller-Combinations 10-1


10 Motor-Controller-Combinations

10.1 General explanation

This chapter contains selection data for different motor/controllercombinations using the IndraDrive family of motor controllers.

The structure of the selection data for the IndraDyn L synchronous,linear motors depends on:

• The motor controller used

• The power supply used and the corresponding supply voltage

• The physical arrangement of the primaries (individual or parallel)

The selection data are sorted by the following criteria:

1. Motor type

2. Maximum force, FMAX

3. Maximum speed with maximum force, vFMAX

Both the standard- and thermally-encapsulated versions of the samesize motors have identical specifications, so the specifications of themotor/controller combinations for both designs have been combined.

Note: The specifications for motor/controller combinations forstandard- and thermally-encapsulated motors are identical.

Motor/controller combinations are also given for motors installed inparallel arrangement on one drive controller.

Note: The specifications for the parallel arrangements of motorsassume they are being powered by one drive controller.Motors mounted parallel in a gantry style and driven byseparate drive controllers should be considered as individual,i.e. non-parrallel, motors.

The PWM frequency of the drive controller affects the motor data. Alldata in this documentation is based on a 4 kHz PWM frequency.

Structure of the selection data

Sorting of the lists

Design of the primary

Parallel motor arrangement

PWM frequency of the DriveController

10-2 Motor-Controller-Combinations Rexroth IndraDyn L


Explanation of the variables

Maximum force of the motor. This is available for up to 400 ms (see Fig.4-1).

Maximum speed with maximum force, FMAX. This is the speed availableat the maximum force of the motor. (see Fig. 4-1)

Maximum electrical loss of the motor. This is calculated using themaximum current of a motor and a motor winding temperature of 135°C.

Nominal force of the motor (see Fig. 4-1) assuming:

- liquid cooling with a coolant inlet temperature of 30°C

- a motor winding temperature of 135°C, and

- motor at stand still

Nominal speed (see Fig. 4-1)

This is the speed available when the motor is delivering it’s nominalforce, FdN.

Nominal power loss of the motor at FdN

Relative duty cycle in %. This is given with reference to the specifiedmaximum and continuous forces. (see Fig. 11-16)

Intermittent force

The intermittent force depends on the ratio between motor’s nominalcurrent and the nominal current of the drive controller. This intermittentforce can be used intermittently in S6 operation with a duty cycle ofEDFKB. The maximum cycle duration corresponds to the thermal timeconstant of the motor (see chapter 4 “Technical Data”).

%100FF

ED2

KB

dNFKB

⋅

≈

FdN: Nominal force of the motor in NFKB: Potential intermittent force in N

Fig. 10-1: Calculation of the potential duty cycle as related to FKB

An intermittent force higher than the nominal force of the motor is onlythen available when the nominal current of the drive-controller is higherthan the nominal current of the motor.

Nominal current of the motor at nominal force, FdN

Maximum current of the motor at FMAX.

Note: The specification of the current is always given in peakvalues unless otherwise noted.

FMAX

vFMAX

PVMAX

FdN

VN

PvN

EDFMAX

FKB

idN

imax



10.2 Motor/Controller Combinations; one primary per drive

Controlled DC Bus Voltage, mains supply voltage - 3 x 480 VAC

FMAX [N]

vFmax

[m/min]PVMAX

[kW]FdN [N]

vN [m/min]

PvN [kW]

EDFMAX

[%]FKB [N]

idN [A]

iMAX

[A]Primary MLP...

Standard- / Thermal encapsulation Controller

800 360 6,6 250 600 0,33 5 352 5,9 28 040A-0300 HMS01.1N-W0020800 360 6,6 250 600 0,33 5 375 5,9 28 040A-0300 HMS01.1N-W0036394 537 1,1 127 654 0,08 7 127 3 12 040A-0300 HCS02.1E-W0012800 360 6,6 250 600 0,33 5 375 5,9 28 040A-0300 HCS02.1E-W0028800 360 6,6 250 600 0,33 5 375 5,9 28 040A-0300 HCS02.1E-W00541150 180 7,8 370 360 0,39 5 515 5,9 28 040B-0150 HMS01.1N-W00201150 180 7,8 370 360 0,39 5 555 5,9 28 040B-0150 HMS01.1N-W0036575 313 1,4 188 402 0,1 7 188 3 12 040B-0150 HCS02.1E-W00121150 180 7,8 370 360 0,39 5 555 5,9 28 040B-0150 HCS02.1E-W00281150 180 7,8 370 360 0,39 5 555 5,9 28 040B-0150 HCS02.1E-W0054902 357 5,5 370 480 0,43 8 429 7,5 28 040B-0250 HMS01.1N-W00201150 300 10 370 480 0,43 4 555 7,5 38 040B-0250 HMS01.1N-W0036477 455 0,9 148 532 0,07 7 148 3 12 040B-0250 HCS02.1E-W00121140 303 9,8 370 480 0,43 4 416 7,5 38 040B-0250 HCS02.1E-W00281150 300 10 370 480 0,43 4 555 7,5 38 040B-0250 HCS02.1E-W0054751 483 4 370 600 0,4 10 395 8,5 28 040B-0300 HMS01.1N-W00201150 360 11,9 370 600 0,4 3 555 8,5 49 040B-0300 HMS01.1N-W00361150 360 11,9 370 600 0,4 3 555 8,5 49 040B-0300 HMS01.1N-W00541150 360 11,9 370 600 0,4 3 555 8,5 49 040B-0300 HMS01.1N-W0070432 581 0,7 131 674 0,05 7 131 3 12 040B-0300 HCS02.1E-W0012930 428 7 370 600 0,4 6 385 8,5 38 040B-0300 HCS02.1E-W00281150 360 11,9 370 600 0,4 3 555 8,5 49 040B-0300 HCS02.1E-W00541150 360 11,9 370 600 0,4 3 555 8,5 49 040B-0300 HCS02.1E-W00701150 360 11,9 370 600 0,4 3 555 8,5 49 040B-0300 HCS03.1E-W00701564 256 4,4 630 420 0,34 8 733 7,5 28 070A-0150 HMS01.1N-W00202000 180 7,9 630 420 0,34 4 945 7,5 38 070A-0150 HMS01.1N-W0036819 387 0,7 252 487 0,05 7 252 3 12 070A-0150 HCS02.1E-W00121982 183 7,7 630 420 0,34 4 711 7,5 38 070A-0150 HCS02.1E-W00282000 180 7,9 630 420 0,34 4 945 7,5 38 070A-0150 HCS02.1E-W00541293 351 2,6 630 432 0,28 11 661 8,9 28 070A-0220 HMS01.1N-W00202000 264 7,7 630 432 0,28 4 945 8,9 49 070A-0220 HMS01.1N-W00362000 264 7,7 630 432 0,28 4 945 8,9 49 070A-0220 HMS01.1N-W00542000 264 7,7 630 432 0,28 4 945 8,9 49 070A-0220 HMS01.1N-W0070726 421 0,4 212 484 0,03 7 212 3 12 070A-0220 HCS02.1E-W00121611 312 4,5 630 432 0,28 6 644 8,9 38 070A-0220 HCS02.1E-W00282000 264 7,7 630 432 0,28 4 945 8,9 49 070A-0220 HCS02.1E-W00542000 264 7,7 630 432 0,28 4 945 8,9 49 070A-0220 HCS02.1E-W00702000 264 7,7 630 432 0,28 4 945 8,9 49 070A-0220 HCS03.1E-W00701965 365 15,9 630 540 0,67 4 945 14,8 76 070A-0300 HMS01.1N-W00542000 360 16,6 630 540 0,67 4 945 14,8 78 070A-0300 HMS01.1N-W00702000 360 16,6 630 540 0,67 4 757 14,8 78 070A-0300 HCS02.1E-W00702000 360 16,6 630 540 0,67 4 945 14,8 78 070A-0300 HCS03.1E-W00701953 164 8,6 820 240 0,73 8 931 7,8 28 070B-0100 HMS01.1N-W00202600 120 17,2 820 240 0,73 4 1230 7,8 40 070B-0100 HMS01.1N-W00361036 226 1,5 315 274 0,11 7 315 3 12 070B-0100 HCS02.1E-W00122467 129 15,2 820 240 0,73 5 903 7,8 38 070B-0100 HCS02.1E-W00282600 120 17,2 820 240 0,73 4 1230 7,8 40 070B-0100 HCS02.1E-W00541524 217 7,2 820 264 0,67 9 876 8,2 28 070B-0120 HMS01.1N-W00202316 163 23,2 820 264 0,67 3 1170 8,2 51 070B-0120 HMS01.1N-W00362600 144 31,2 820 264 0,67 2 1230 8,2 59 070B-0120 HMS01.1N-W00542600 144 31,2 820 264 0,67 2 1230 8,2 59 070B-0120 HMS01.1N-W0070943 256 1,2 300 299 0,09 7 300 3 12 070B-0120 HCS02.1E-W00121850 195 12,7 820 264 0,67 5 859 8,2 38 070B-0120 HCS02.1E-W00282516 150 28,7 820 264 0,67 2 1044 8,2 57 070B-0120 HCS02.1E-W00542600 144 31,2 820 264 0,67 2 1230 8,2 59 070B-0120 HCS02.1E-W00702600 144 31,2 820 264 0,67 2 1230 8,2 59 070B-0120 HCS03.1E-W0070

Further information – see next page



FMAX [N]

vFmax

[m/min]PVMAX

[kW]FdN [N]

vN [m/min]

PvN [kW]

EDFMAX

[%]FKB [N]

idN [A]

iMAX

[A]Primary MLP...


1406 269 10,9 820 312 1,18 11 850 8,8 28 070B-0150 HMS01.1N-W00202086 218 35,4 820 312 1,18 3 1103 8,8 51 070B-0150 HMS01.1N-W00362600 180 63,1 820 312 1,18 2 1230 8,8 68 070B-0150 HMS01.1N-W00542600 180 63,1 820 312 1,18 2 1230 8,8 68 070B-0150 HMS01.1N-W0070907 306 1,9 280 352 0,14 7 280 3 12 070B-0150 HCS02.1E-W00121686 248 19,3 820 312 1,18 6 835 8,8 38 070B-0150 HCS02.1E-W00282257 206 43,7 820 312 1,18 3 994 8,8 57 070B-0150 HCS02.1E-W00542600 180 63,1 820 312 1,18 2 1230 8,8 68 070B-0150 HCS02.1E-W00702600 180 63,1 820 312 1,18 2 1230 8,8 68 070B-0150 HCS03.1E-W00702555 305 51,2 820 480 1,95 4 1230 14,1 76 070B-0250 HMS01.1N-W00542600 300 53,4 820 480 1,95 4 1230 14,1 78 070B-0250 HMS01.1N-W00702600 300 53,4 820 480 1,95 4 1002 14,1 78 070B-0250 HCS02.1E-W00702600 300 53,4 820 480 1,95 4 1230 14,1 78 070B-0250 HCS03.1E-W00702109 410 39,8 820 540 2,2 6 1230 17 76 070B-0300 HMS01.1N-W00542600 360 66,9 820 540 2,2 3 1193 17 99 070B-0300 HMS01.1N-W00702170 404 42,8 820 540 2,2 5 883 17 79 070B-0300 HCS02.1E-W00702600 360 66,9 820 540 2,2 3 1230 17 99 070B-0300 HCS03.1E-W00703736 146 32,4 1200 216 0,98 3 1800 12,6 76 070C-0120 HMS01.1N-W00543800 144 33,8 1200 216 0,98 3 1800 12,6 78 070C-0120 HMS01.1N-W00703800 144 33,8 1200 216 0,98 3 1520 12,6 78 070C-0120 HCS02.1E-W00703800 144 33,8 1200 216 0,98 3 1800 12,6 78 070C-0120 HCS03.1E-W00703392 199 27,9 1200 300 1,06 4 1800 14,1 76 070C-0150 HMS01.1N-W00543800 180 37 1200 300 1,06 3 1800 14,1 88 070C-0150 HMS01.1N-W00703490 194 30 1200 300 1,06 4 1404 14,1 79 070C-0150 HCS02.1E-W00703800 180 37 1200 300 1,06 3 1800 14,1 88 070C-0150 HCS03.1E-W00703071 325 14,2 1200 420 0,92 6 1797 18,4 76 070C-0240 HMS01.1N-W00543800 288 23,9 1200 420 0,92 4 1710 18,4 99 070C-0240 HMS01.1N-W00703161 321 15,3 1200 420 0,92 6 1248 18,4 79 070C-0240 HCS02.1E-W00703800 288 23,9 1200 420 0,92 4 1800 18,4 99 070C-0240 HCS03.1E-W00703506 381 29,2 1200 540 1,18 4 1800 26,9 141 070C-0300 HCS03.1E-W01002252 150 9,7 1168 180 1,3 13 1168 9,8 28 100A-0090 HMS01.1N-W00203569 113 31,3 1180 180 1,32 4 1664 9,9 51 100A-0090 HMS01.1N-W00363750 108 35,3 1180 180 1,32 4 1770 9,9 54 100A-0090 HMS01.1N-W00543750 108 35,3 1180 180 1,32 4 1770 9,9 54 100A-0090 HMS01.1N-W00701285 177 1,7 358 203 0,12 7 358 3 12 100A-0090 HCS02.1E-W00122794 135 17,1 1108 182 1,17 7 1108 9,3 38 100A-0090 HCS02.1E-W00283750 108 35,3 1180 180 1,32 4 1548 9,9 54 100A-0090 HCS02.1E-W00543750 108 35,3 1180 180 1,32 4 1770 9,9 54 100A-0090 HCS02.1E-W00703750 108 35,3 1180 180 1,32 4 1770 9,9 54 100A-0090 HCS03.1E-W00702042 200 6,2 1023 233 0,84 13 1023 9,8 28 100A-0120 HMS01.1N-W00203187 162 20,2 1180 228 1,11 5 1530 11,3 51 100A-0120 HMS01.1N-W00363750 144 30 1180 228 1,11 4 1770 11,3 62 100A-0120 HMS01.1N-W00543750 144 30 1180 228 1,11 4 1770 11,3 62 100A-0120 HMS01.1N-W00701200 227 1,1 313 256 0,08 7 313 3 12 100A-0120 HCS02.1E-W00122513 185 11 971 235 0,75 7 971 9,3 38 100A-0120 HCS02.1E-W00283476 153 25 1180 228 1,11 4 1347 11,3 57 100A-0120 HCS02.1E-W00543750 144 30 1180 228 1,11 4 1770 11,3 62 100A-0120 HCS02.1E-W00703750 144 30 1180 228 1,11 4 1770 11,3 62 100A-0120 HCS03.1E-W00703686 182 39,3 1180 264 1,49 4 1770 14,1 76 100A-0150 HMS01.1N-W00543750 180 40,9 1180 264 1,49 4 1770 14,1 78 100A-0150 HMS01.1N-W00703750 180 40,9 1180 264 1,49 4 1443 14,1 78 100A-0150 HCS02.1E-W00703750 180 40,9 1180 264 1,49 4 1770 14,1 78 100A-0150 HCS03.1E-W00703042 261 50,7 1180 348 2,8 6 1770 17 76 100A-0190 HMS01.1N-W00543750 228 85 1180 348 2,8 3 1719 17 99 100A-0190 HMS01.1N-W00703129 257 54,4 1180 348 2,8 5 1271 17 79 100A-0190 HCS02.1E-W00703750 228 85 1180 348 2,8 3 1770 17 99 100A-0190 HCS03.1E-W00704549 167 25,3 1785 228 1,4 6 2678 17 76 100B-0120 HMS01.1N-W00545600 144 42,5 1785 228 1,4 3 2585 17 99 100B-0120 HMS01.1N-W00704679 164 27,2 1785 228 1,4 5 1920 17 79 100B-0120 HCS02.1E-W00705600 144 42,5 1785 228 1,4 3 2678 17 99 100B-0120 HCS03.1E-W00704537 334 39 1785 420 2,1 5 2678 31,1 141 100B-0250 HCS03.1E-W01004895 153 29 2310 204 1,88 6 3134 18,4 76 100C-0090 HMS01.1N-W00545902 133 48,7 2310 204 1,88 4 3014 18,4 99 100C-0090 HMS01.1N-W00705020 150 31,2 2310 204 1,88 6 2377 18,4 79 100C-0090 HCS02.1E-W00705902 133 48,7 2310 204 1,88 4 3465 18,4 99 100C-0090 HCS03.1E-W0070




FMAX [N]

vFmax

[m/min]PVMAX

[kW]FdN [N]

vN [m/min]

PvN [kW]

EDFMAX

[%]FKB [N]

idN [A]

iMAX

[A]Primary MLP...


5014 181 21,6 2310 228 1,86 9 3079 21,2 76 100C-0120 HMS01.1N-W00546121 162 36,3 2310 228 1,86 5 2947 21,2 99 100C-0120 HMS01.1N-W00705151 179 23,2 2168 231 1,64 7 2168 19,9 79 100C-0120 HCS02.1E-W00706121 162 36,3 2310 228 1,86 5 3465 21,2 99 100C-0120 HCS03.1E-W00705495 269 39 2310 348 2,3 6 3465 32,5 141 100C-0190 HCS03.1E-W01004230 167 22,8 1680 228 1,26 6 2520 17 76 140A-0120 HMS01.1N-W00545200 144 38,2 1680 228 1,26 3 2418 17 99 140A-0120 HMS01.1N-W00704350 164 24,5 1680 228 1,26 5 1804 17 79 140A-0120 HCS02.1E-W00705200 144 38,2 1680 228 1,26 3 2520 17 99 140A-0120 HCS03.1E-W00706182 132 22,8 2415 192 1,47 6 3617 18,4 76 140B-0090 HMS01.1N-W00547650 108 38,2 2415 192 1,47 4 3441 18,4 99 140B-0090 HMS01.1N-W00706364 129 24,5 2415 192 1,47 6 2512 18,4 79 140B-0090 HCS02.1E-W00707650 108 38,2 2415 192 1,47 4 3622 18,4 99 140B-0090 HCS03.1E-W00704590 193 14,8 2415 228 1,84 12 2902 25,5 76 140B-0120 HMS01.1N-W00545556 178 24,8 2415 228 1,84 7 2787 25,5 99 140B-0120 HMS01.1N-W00704710 191 15,9 1885 237 1,12 7 1885 19,9 79 140B-0120 HCS02.1E-W00705556 178 24,8 2415 228 1,84 7 3475 25,5 99 140B-0120 HCS03.1E-W00708079 80 45,5 3150 132 2,95 6 4722 18,4 76 140C-0050 HMS01.1N-W0054

10000 60 76,4 3150 132 2,95 4 4493 18,4 99 140C-0050 HMS01.1N-W00708317 78 48,9 3150 132 2,95 6 3277 18,4 79 140C-0050 HCS02.1E-W0070

10000 60 76,4 3150 132 2,95 4 4725 18,4 99 140C-0050 HCS03.1E-W00708344 164 50,7 3150 228 2,49 5 4725 29,7 141 140C-0120 HCS03.1E-W01007531 239 29,2 3150 300 2,74 9 4708 41 141 140C-0170 HCS03.1E-W01006038 135 17,1 2415 204 1,1 6 3571 18,4 76 200A-0090 HMS01.1N-W00547450 108 28,7 2415 204 1,1 4 3402 18,4 99 200A-0090 HMS01.1N-W00706213 132 18,3 2415 204 1,1 6 2509 18,4 79 200A-0090 HCS02.1E-W00707450 108 28,7 2415 204 1,1 4 3622 18,4 99 200A-0090 HCS03.1E-W00705086 184 13,1 2415 228 1,28 10 3125 22,6 76 200A-0120 HMS01.1N-W00546209 165 22 2415 228 1,28 6 2991 22,6 99 200A-0120 HMS01.1N-W00705225 181 14,1 2126 233 0,99 7 2126 19,9 79 200A-0120 HCS02.1E-W00706209 165 22 2415 228 1,28 6 3622 22,6 99 200A-0120 HCS03.1E-W00708815 68 33 3465 120 2,14 6 5172 18,4 76 200B-0040 HMS01.1N-W0054

10900 48 55,4 3465 120 2,14 4 4922 18,4 99 200B-0040 HMS01.1N-W00709074 66 35,5 3465 120 2,14 6 3603 18,4 79 200B-0040 HCS02.1E-W0070

10900 48 55,4 3465 120 2,14 4 5198 18,4 99 200B-0040 HCS03.1E-W00708829 168 33,1 3465 228 1,79 5 5198 31,1 141 200B-0120 HCS03.1E-W0100

10645 143 78 4250 204 7,31 9 6375 41 141 200C-0090 HCS03.1E-W010012544 158 118,4 4250 228 5,28 4 6375 42,4 212 200C-0120 HMS01.1N-W015010589 226 83,3 4250 264 8,76 11 5406 65,1 212 200C-0170 HMS01.1N-W015010589 226 83,3 4250 264 8,76 11 5548 65,1 212 200C-0170 HCS03.1E-W015013394 106 52,6 5560 168 4,6 9 8340 39,6 141 200D-0060 HCS03.1E-W010013287 155 70,2 5560 216 7,37 11 6969 65,1 212 200D-0100 HMS01.1N-W015013287 155 70,2 5560 216 7,37 11 7142 65,1 212 200D-0100 HCS03.1E-W015010135 118 50,7 3350 192 2,05 4 5025 26,9 141 300A-0090 HCS03.1E-W01008477 172 39 3350 228 2,3 6 5025 32,5 141 300A-0120 HCS03.1E-W0100

12316 114 52,6 5150 168 4,6 9 7725 39,6 141 300B-0070 HCS03.1E-W010012688 171 57 5150 228 3,46 6 7116 49,5 212 300B-0120 HMS01.1N-W015012688 171 57 5150 228 3,46 6 7269 49,5 212 300B-0120 HCS03.1E-W015016172 94 27,3 6720 132 2,56 9 10080 41 141 300C-0060 HCS03.1E-W010016255 134 43,9 6720 180 2,97 7 9083 52,3 212 300C-0090 HMS01.1N-W015016255 134 43,9 6720 180 2,97 7 9280 52,3 212 300C-0090 HCS03.1E-W0150

Fig. 10-2: Possible combinations of single motors on single controllers



10.3 Motor/Controller Combinations; parallel primaries onsingle drive controllers

Controlled DC Bus Voltage, mains supply voltage - 3 x 480 VAC

FMAX [N]

vFmax

[m/min]PVMAX

[kW]FdN [N]

vN [m/min]

PvN [kW]

EDFMAX

[%]FKB [N]

idN [A]

iMAX

[A]Primary MLP...


911 511 3,4 415 619 0,45 13 415 9,8 28 040A-0300 HMS01.1N-W00201473 388 10,9 500 600 0,65 6 659 11,8 51 040A-0300 HMS01.1N-W00361600 360 13,1 500 600 0,65 5 750 11,8 56 040A-0300 HMS01.1N-W00541600 360 13,1 500 600 0,65 5 750 11,8 56 040A-0300 HMS01.1N-W00701142 460 5,9 394 624 0,4 7 394 9,3 38 040A-0300 HCS02.1E-W00281600 360 13,1 500 600 0,65 5 579 11,8 56 040A-0300 HCS02.1E-W00541600 360 13,1 500 600 0,65 5 750 11,8 56 040A-0300 HCS02.1E-W00701600 360 13,1 500 600 0,65 5 750 11,8 56 040A-0300 HCS03.1E-W00701322 293 4 615 375 0,53 13 615 9,8 28 040B-0150 HMS01.1N-W00202120 201 12,9 740 360 0,77 6 966 11,8 51 040B-0150 HMS01.1N-W00362300 180 15,6 740 360 0,77 5 1110 11,8 56 040B-0150 HMS01.1N-W00542300 180 15,6 740 360 0,77 5 1110 11,8 56 040B-0150 HMS01.1N-W00701651 255 7 583 378 0,48 7 583 9,3 38 040B-0150 HCS02.1E-W00282300 180 15,6 740 360 0,77 5 852 11,8 56 040B-0150 HCS02.1E-W00542300 180 15,6 740 360 0,77 5 1110 11,8 56 040B-0150 HCS02.1E-W00702300 180 15,6 740 360 0,77 5 1110 11,8 56 040B-0150 HCS03.1E-W00702300 300 20 740 480 0,87 4 1110 15 76 040B-0250 HMS01.1N-W00542300 300 20 740 480 0,87 4 1110 15 76 040B-0250 HMS01.1N-W00702300 300 20 740 480 0,87 4 916 15 76 040B-0250 HCS02.1E-W00702300 300 20 740 480 0,87 4 1110 15 76 040B-0250 HCS03.1E-W00701884 424 14,5 740 600 0,8 6 1110 17 76 040B-0300 HMS01.1N-W00542300 360 23,9 740 600 0,8 3 1084 17 98 040B-0300 HMS01.1N-W00701938 416 15,6 740 600 0,8 5 796 17 79 040B-0300 HCS02.1E-W00702300 360 23,9 740 600 0,8 3 1110 17 98 040B-0300 HCS03.1E-W00704000 180 15,8 1260 420 0,69 4 1890 15 76 070A-0150 HMS01.1N-W00544000 180 15,8 1260 420 0,69 4 1890 15 76 070A-0150 HMS01.1N-W00704000 180 15,8 1260 420 0,69 4 1569 15 76 070A-0150 HCS02.1E-W00704000 180 15,8 1260 420 0,69 4 1890 15 76 070A-0150 HCS03.1E-W00703262 309 9,4 1260 432 0,57 6 1890 17,8 76 070A-0220 HMS01.1N-W00544000 264 15,5 1260 432 0,57 4 1843 17,8 98 070A-0220 HMS01.1N-W00703358 304 10,1 1260 432 0,57 6 1332 17,8 79 070A-0220 HCS02.1E-W00704000 264 15,5 1260 432 0,57 4 1890 17,8 98 070A-0220 HCS03.1E-W00703684 381 27,3 1260 540 1,33 5 1890 29,6 141 070A-0300 HCS03.1E-W01005001 127 31,3 1640 240 1,46 5 2460 15,6 76 070B-0100 HMS01.1N-W00545200 120 34,3 1640 240 1,46 4 2460 15,6 80 070B-0100 HMS01.1N-W00705156 122 33,6 1640 240 1,46 4 1878 15,6 79 070B-0100 HCS02.1E-W00705200 120 34,3 1640 240 1,46 4 2460 15,6 80 070B-0100 HCS03.1E-W00703742 193 26,2 1640 264 1,35 5 2358 16,4 76 070B-0120 HMS01.1N-W00544534 167 44 1640 264 1,35 3 2264 16,4 99 070B-0120 HMS01.1N-W00703840 190 28,1 1640 264 1,35 5 1763 16,4 79 070B-0120 HCS02.1E-W00704534 167 44 1640 264 1,35 3 2460 16,4 99 070B-0120 HCS03.1E-W00703408 247 39,8 1640 312 2,36 6 2220 17,6 76 070A-0300 HMS01.1N-W00544088 241 66,9 1640 312 2,36 4 2139 17,6 99 070B-0150 HMS01.1N-W00703492 243 42,8 1640 312 2,36 6 1709 17,6 79 070B-0150 HCS02.1E-W00704088 221 66,9 1640 312 2,36 4 2460 17,6 99 070B-0150 HCS03.1E-W00704793 321 87,7 1640 480 3,89 4 2460 28,2 141 070B-0250 HCS03.1E-W01003971 422 68,2 1640 540 4,4 6 2460 34 141 070B-0300 HCS03.1E-W01006383 208 47,8 2400 300 2,12 4 3600 28,2 141 070C-0150 HCS03.1E-W01005774 335 24,4 2400 420 1,84 8 3600 36,8 141 070C-0240 HCS03.1E-W01005658 134 35,3 2360 180 2,64 7 3357 19,8 76 100A-0090 HMS01.1N-W00546976 115 59,2 2360 180 2,64 4 3199 19,8 99 100A-0090 HMS01.1N-W00705822 132 37,9 2360 180 2,64 7 2366 19,8 79 100A-0090 HCS02.1E-W00706976 115 59,2 2360 180 2,64 4 3540 19,8 99 100A-0090 HCS03.1E-W00705087 184 22,8 2360 228 2,22 10 3085 22,6 76 100A-0120 HMS01.1N-W00546233 165 38,2 2360 228 2,22 6 2984 22,6 99 100A-0120 HMS01.1N-W0070




FMAX [N]

vFmax

[m/min]PVMAX

[kW]FdN [N]

vN [m/min]

PvN [kW]

EDFMAX

[%]FKB [N]

idN [A]

iMAX

[A]Primary MLP...


5229 181 24,5 2078 233 1,72 7 2078 19,9 79 100A-0120 HCS02.1E-W00706233 165 38,2 2360 228 2,22 6 3540 22,6 99 100A-0120 HCS03.1E-W00706913 190 67,3 2360 264 2,98 4 3540 28,2 141 100A-0150 HCS03.1E-W01005726 270 86,7 2360 348 5,59 6 3540 34 141 100A-0190 HCS03.1E-W01008567 173 43,4 3570 228 2,8 6 5355 34 141 100B-0120 HCS03.1E-W0100

12933 156 83,3 4620 228 3,71 4 6930 42,4 212 100C-0120 HMS01.1N-W01507970 173 39 3360 228 2,51 6 5040 34 141 140A-0120 HCS03.1E-W0100

11624 138 39 4830 192 2,95 8 7245 36,8 68 140B-0090 HCS03.1E-W010011715 173 57 4830 228 3,68 6 6578 51 212 140B-0120 HMS01.1N-W015011715 173 57 4830 228 3,68 6 6719 51 212 140B-0120 HCS03.1E-W015015190 85 78 6300 132 5,89 8 9450 36,8 141 140C-0050 HCS03.1E-W010011364 142 29,2 4830 204 2,21 8 7245 36,8 141 200A-0090 HCS03.1E-W010013117 159 50,4 4830 228 2,56 5 7149 45,2 212 200A-0120 HMS01.1N-W015013117 159 50,4 4830 228 2,56 5 7245 45,2 212 200A-0120 HCS03.1E-W015016579 73 56,5 6930 120 4,27 8 10395 36,8 141 200B-0040 HCS03.1E-W0100

Fig. 10-3: Possible combinations of parallel motors on single controllers

Rexroth IndraDyn L Motor Sizing 1


11 Motor Sizing

11.1 General Procedure

The sizing of linear drives is mainly determined by the application-relatedcharacteristics of velocity and feed force. The basic sequence of sizinglinear drives is shown in the figure below.

: )9

:?67

:

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< -

>+3//> $" .$"'<'''5 1>'">3 $.' '/3 $<$< 1>'" $/"$$$ >'"/#$

-

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@( . ( <.:+;

-%$$$- %2$-/ "$-"

-'" $/"$$ -3'$-'"/#$-$43$3$<34$<#" $ <

( #.#=##

-#- %' "-683/$%' "

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:+;:+;>

:":::0>

.+;.+;>

.:+;.:+;>

.##0"# "#1

::?67

)9:?67

DIMALLGEMEIN-MLF-EN.EPS

Fig. 11-1: Basic procedure of sizing linear drives

2 Motor Sizing Rexroth IndraDyn L


11.2 Basic formulae

General equations of motionThe variables required for sizing and selecting the motor are calculatedusing the equations shown in Figure 11-2.

Note: When linear direct drives are configured, the process-relatedfeed forces and velocities are used directly and withoutconversion for selecting the drive.

∫

∫

⋅=

⋅=

++⋅=

=

=

T

0avg

T

0

2eff

P0

dt )t(vT1

v:velocity Average

dt)t(FT1

F :force Effective

)t(F)t(Fm)t(a)t(F:Force

dt)t(v

)t(a :onAccelerati

dt)t(s

)t(vVelocity

v(t): Velocity profile vs. time in m/ss(t): Path profile vs. time in ma(t): Acceleration profile vs. time in m/s²F(t): Force profile vs. time in Nm: Moved mass in kgF0(t): Base force in NFP(t): Process or machining force in NFeff: Effective force in Nvavg: Average velocity in m/st: Time in sT: Total time in s

Fig. 11-2: General equations of motion

In most cases the mathematical description of the required positions vs.the time is known (NC-program, electronic cam disk). Using thepreparatory function, velocity, acceleration and forces can be calculated.Standard software (such as MS Excel or MathCad) can be used forcalculating the required variables, even with complex motion profiles.

Note: The following Chapter provides a more detailed correlation fortrapezoidal, triangular or sinusoidal velocity characteristics.



Feed forces

all

2221

21

EFF

PWFACCMAX

0ATTF

cbW

ACC

t...tFtF

F :force Effective

FFFFF :force Maximum

F)Fsing(mF :force Frictional

)100f

1(singmF : weightto due Force

amF :force onAccelerati

+⋅+⋅=

+++=

++⋅⋅⋅=

−⋅⋅⋅=

⋅=

αµ

α

:

BJ*7

:

:

FACC: Acceleration force in NFW: Force due to weight in NFF: Frictional force in NF0: Additional frictional or base force in N (e.g. by seals of linear guides)FMAX: Maximum force in NFEFF: Effective force in NFP: Machining force in Na: Acceleration in m/s²m: Moved mass in kgg: Gravitational acceleration (9.81 m/s²)α: Axis angel in degrees (0°: horizontal axis; 90°C: vertical axis)fCB: Weight compensation in %tall: Total duty cycle time in sFATT: Attractive force between primary and secondary in Nµ: Friction coefficient

Fig. 11-3: Determining the feed forces

Note: For sizing calculations of linear motor drives, the movedmass of the motor component must be taken into account (inparticular, if the slide masses are relatively small). However,the moved mass and the attractive force between the primaryand secondary are only known after the motor has beenselected. Thus, first make assumptions for these variablesand verify these values after the motor has been selected.



W

WFACC

WF

WFACC

WFACC

WF

WFACC

F F:time Idle )7(

FFFF :(down) onDecelerati (6)

FFF:(down)velocity Const. (5)

FFF F:(down) tion Accelera(4)

FFFF:(up) onDecelerati (3)

F FF:(up)velocity Const. (2)

FFF F :(up) tion Accelera(1)

=−+−=

−=−+=

++−=+=

++=

1

$%

ABJ*7

FACC: Acceleration force in NFW: Force due to weight in NFF: Frictional force in N

Fig. 11-4: Determining the resulting feed forces according to motion type anddirection

Note: With horizontal axis arrangement, the weight is FW = 0.

Further directional base and process forces must be takeninto account.



Average velocityThe average velocity is required for determining the mechanicalcontinuous output of the drive. Figure 11-2 shows the general way ofdetermining the average velocity. The following calculation can be usedfor a simple determination in trapezoidal or triangular velocity profiles:

%

5--+@

%

% %%

%%%"

%%"

%%"

all

ii avgavg

eaavgi

t

tvv

2

vvv

∑ ⋅=

−=

vavgi: Average velocity for a velocity segment of the duration ti in m/sva: Initial velocity of the velocity segment in m/sve: Final velocity of the velocity segment in m/svavg: Average velocity over total duty cycle time in m/sti: Duration of velocity segment in stall: Total duty cycle time, including breaks and/or downtime, in s

Fig. 11-5: Determining the average velocity with triangular or trapezoidalvelocity profile



Trapezoidal velocityThis mode of operation is characteristic for the most applications. Anacceleration phase is followed by a movement of constant velocity up tothe deceleration phase.

%

%

?%

3

VTRAPEZ01-MLF-EN.EPS

Fig. 11-6: Trapezoidal velocity profile

Acceleration, initial velocity = 0

• Velocity v ≠ constant

• Initial velocity va = 0

• Acceleration a = constant and positive

as2

vs2

av

t:Time

2ta

a2v

t2v

s:Travel

ts2

sa2tav:velocity Final

s2v

ts2

tv

a:onAccelerati

c

ca

2a

2c

ac

a

ac

2c

2aa

c

⋅=⋅==

⋅=⋅

=⋅=

⋅=⋅⋅=⋅=

⋅=⋅==

a: Acceleration in m/s²vc: Final velocity in m/sta: Acceleration time in ss: Travel covered during acceleration in m

Fig. 11-7: Constantly accelerated movement, initial velocity = 0 (acc. to Fig.11-6)



Acceleration, initial velocity ≠≠≠≠ 0


• Initial velocity va ≠ 0

• Acceleration a = constant and positive

a

vvsa2

vvs2

avv

t:Time

2ta

tva2vv

t2

vvs:Travel

vt

s2vsa2tavv:Velocity

s2vv

tv2

ts2

tvv

a:onAccelerati

a2a

ac

aca

2a

aa

2a

2c

aac

a

a

2aaac

2a

2c

a

a2aa

ac

−+⋅⋅=

+⋅=−=

⋅+⋅=⋅−=⋅+=

−⋅=+⋅⋅=⋅+=

⋅−=⋅−⋅=−=

a: Acceleration in m/s²vc: Final velocity in m/sva: Initial velocity in m/sta: Acceleration time in ss: Travel covered during acceleration in m

Fig. 11-8: Constantly accelerated movement, initial velocity ≠ 0 (acc. to Fig.

11-6)

Constant velocity

• Velocity v = constant

• Acceleration a = 0

c

cc

ccc

c

cc

vs

t:Time

tvs:Travel

ts

v:onAccelerati

=

⋅=

=

vc: Average velocity in m/stC: Time during constant velocity in ssc: Travel covered constant velocity in m

Fig. 11-9: Constant velocity (acc. to Fig. 11-6)



Decelerating, Final velocity = 0


• Final velocity ve = 0

• Acceleration a = constant and negative

as2

vs2

av

t :Time

2ta

a2v

t2v

s :Travel

ts2

sa2tav :Velocity

s2v

ts2

tv

a :onAccelerati

c

cb

2b

2c

bc

b

bc

2c

2bb

c

⋅=⋅==

⋅=⋅

=⋅=

⋅=⋅⋅=⋅=

⋅=⋅==

a: Acceleration in m/s²vc: Final velocity in m/stb: Deceleration time in ss: Travel covered during acceleration in m

Fig. 11-10: Constantly decelerated movement, final velocity = 0 (acc. to Fig. 11-6)



Decelerating, Final velocity ≠≠≠≠ 0


• Final velocity ve ≠ 0

• Acceleration a = constant and negative

a

sa2vv

vvs2

avv

t:Time

2ta

tva2vv

t2

vvs:Travel

vt

s2sa2vtavv:Velocity

s2vv

ts2

tv2

tvv

a:onAccelerati

2cc

ec

eca

2b

bc

2e

2c

bec

c

b

2cbce

2e

2c

2bb

c

b

ec

⋅⋅−−=

+⋅=

−=

⋅+⋅=⋅−=⋅+=

−⋅=⋅⋅−=⋅−=

⋅−=⋅−⋅=−=

a: Acceleration in m/s²vc: Initial velocity in m/sve: Final velocity in m/stb: Deceleration time in ss: Travel covered during acceleration in m

Fig. 16-11: Constantly decelerated movement, final velocity ≠ 0 (acc. to Fig. 11-

6)



Triangular velocityIn contrast to the trapezoidal characteristic, this velocity profile does nothave a phase of constant velocity. The acceleration phase isimmediately followed by the deceleration phase. This characteristic canfrequently be found in conjunction with movements of short strokes.

%

VDREIECK01-MLF-EN.EPS

Fig. 11-12: Triangular velocity profile

as4

vs4

av2

t :Time

4ta

a4v

2tv

s :Travel

ts2

sa2

tav:Velocity

sv

ts4

tv2

a :onAccelerati

all

max

allmax

22maxmax

all

allallmax

2max

2allmax

⋅=⋅=⋅=

⋅=⋅

=⋅=

⋅=⋅=⋅=

=⋅=⋅=

vmax: Maximum velocity in m/sa: Acceleration in m/s²sall: Total motion travel in mt: Positioning time in s

Fig. 11-13: Calculation of triangular velocity profile (acc. to Fig. 11-12)



Sinusoidal velocityThis velocity profile results, for example, from the circular interpolation oftwo axes (circular movement) or the oscillating movement of one axis(grinding, for example).

The specified variables are chiefly the motion travel or the circlediameter and the period T.

( ) ( )

( ) ( )f2

T2

tcosrtr:profile Jerk

tsinrta:profile onAccelerati

)tcos(r)t(v:profile Velocity

)tsin(r)t(s :profile Travel

3

2

⋅⋅=⋅=

⋅⋅=

⋅⋅=

⋅⋅⋅=

⋅⋅=

ππω

ωω

ωω

ωω

ω

0

s(t): Travel profile vs. time in mv(t): Velocity profile vs. time in m/sa(t): Acceleration profile vs. time in m/sr(t): Jerk profile over time t m/s³r: Motion travel in one direction (circle radius) in mω: Angular frequency in s-1

T: Period in s (time for circular motion or complete stroke)t: Time in sf: Stroke frequency in Hz

Fig. 11-14: Motion profiles of an axis at sinusoidal velocity.



The following calculation bases on Fig. 11-14.

w0down 0

w0up 0

2down 0

2up 0

2acc

EFFv

20

2

accEFF

maxACC

maxavg

max

2

max

FFF :movement down force Base

FF F:movement up force Base

2

FFFF

:tarrangemen axis Vertical

F2

FF :force ffectiveE

maF :force ncceleratioA

Tr4v2

v:velocity Average

T2

rv:velocity Maximum

T2

ra:ionaccerlat aximumM

−=

+=

++=

+=

⋅=

⋅=⋅=

⋅⋅=

⋅⋅=

π

π

π

amax: Maximum acceleration in m/s²vmax: Maximum velocity in m/sr: Motion travel in one direction (or circle radius) in mT: Period in sm: Moved mass in kgFACC: Acceleration force in NFEFF: Effective force in NFEFFv: Effektive force at vertical or inclined axis arrangement in NF0: Base force, e.g. frictional force in NFW: Force due to weight in N (acc. to Fig. 11-3)

Fig. 11-15: Calculation formulae for sinusoidal velocity profile

Note: Further directional base and process forces must additionallybe taken into account.



11.3 Duty cycle and Feed Force

The relative duty cycle ED specifies the duty cycle percentage of theload with respect to a total duty cycle time, including idle time. Thethermal load capacity of the motor limits the duty cycle. Stressing themotor with rated force is possible over the entire duty cycle time. Theduty cycle must be reduced at F > FdN (see Fig. 11-16) in order to notthermally overload the motor at higher feed forces.

+6

22

A :

+6:

$:$

:$

:3

+6

EDKENNLIN01-MLF-EN.EPS

Fig. 11-16: Correlation between duty cycle and feed force

Determining the duty cycleThe approximate determination of the relative duty cycle EDideal isperformed via the correlation:

100FF

ED2MAX

2EFF

ideal ⋅

=

ED: Cyclic duration factor in %FEFF: Effective force or rated force in NFMAX: Maximum feed force

Fig. 11-17: Approximate determination of duty cycle ED

Prerequisites: Linear correlation between feed force and current.

For IndraDyn L motors to Fig. 11-17, only an approximate duty cyclecalculation is possible since there is a non-linear correlation betweenforce and current.

This calculation remains valid for a rough determination of possible dutycycle at short-time duty forces with FKB ≤ 1.5 FdN.

Note: You must check with Figure 11-18 or Figure 11-19 to exactlydetermine the relative duty cycle of IndraDyn L linear motors.



The non-linearity of the characteristic curve force vs. current ofsynchronous linear motor leads to an increased rise of power loss athigher feed forces. This increased power loss leads – in particular at ahigh percentage of acceleration and deceleration processes – to apossible duty cycle that is reduced with respect to Fig. 11-17.

Use Fig. 11-18 or Fig. 11-19 to determine exactly the possible relativeduty cycle.

100PP

EDa AVG

vNreal ⋅=

EDreal: Possible relative duty cycle in %PvN Maximum removable power loss of the motor in W

(continuous power loss see Chapter 5 “Technical Data”)PAVG a: Average motor power loss in application over a duty cycle time

including idle time in WFig. 11-18: Determining the duty cycle ED

Prerequisites: Duty cycle time ≤ Thermal time constant of motor

Fig. 11-19: Duty cycle vs. force for IndraDyn L synchronous linear motors

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,6 2,8 3,0

F / FdN

ED

ideal

NORMIERTE KENNLINIEN MLF.XLS

real



11.4 Determining the Drive Power

To size the power supply module or the mains rating, you mustdetermine the rated (continuous) and maximum power of the lineardrive.

Note: Take the corresponding simultaneity factor into account whendetermine the total power of several drives that areconnected to a single power supply module.

Continuous OutputThe rated output corresponds to the sum of the mechanical andelectrical motor power.

dneffvn

2

dn

effce

avgeffcm

cecmc

F F mit PFF

P :output electrical Rated

v FP :output rated Mechanical

PPP :output rated Total

≤⋅

=

⋅=

+=

Pc: Rated power in WPcm: Mechanical rated output in WPce: Electrical rated power loss of motor in WFeff: Effective force in N (from application)vavg: Average velocity in m/sFdN: Rated force of the motor in N (see Chapter 4 “Technical data”)PvN Rated power loss of the motor in W (see Chapter 4 “Technical data”)

Fig. 11-20: Rated power of the linear motor

Note: The rated electrical output (see Fig. 11-20) is reduced whenthe rated force is reduced.



Maximum OutputThe maximum output is also the sum of the mechanical and electricalmaximum output. It must be made available to the drive duringacceleration and deceleration phase or for very high machining forces,for example.

Fmaxmaxmaxm

maxemaxmmax

vFP :output maximum Mechanical

PPP :output maximum Total

⋅=

+=

Pmax: Total maximum power in WPmaxm: Mechanical maximum power in WPmaxe: Electrical maximum power in W (see Fig. 11-22)FMAX: Maximum feed force in NvFmax: Maximum velocity with Fmax in N

Fig. 11-21: Maximum power of the linear motor

Note: When the maximum feed force is reduced against theachievable maximum force of the motor, the electricalmaximum output Pmaxe is reduced too. To determine thereduced electrical maximum output Pmaxe use Fig. 11-22.

FMAX: Maximum force of the motor in NF: Maximum force application in NPvmax: Maximum power loss of the motor in WPV: Power loss of the motor application in W

Fig. 11-22: Diagram used for determining the reduced electrical power loss

Note: The maximum power loss is specified in Chapter 10 “Motor-Controller-Combinations”.

0,0

0,2

0,4

0,6

0,8

1,0

0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0

F / Fmax

Pv

/ Pvm

ax

NORMIERTE KENNLINIEN MLF.XLS



Cooling capacityThe necessary cooling capacity nearly corresponds to the motor´selectrical continuous power loss.

dneffvn

2

dn

effceco F F th wiP

FF

PP :capacity Cooling ≤⋅

==

Pco: Required cooling capacity in WPce: Electrical power loss of motor in WFeff: Effective force in NFdN: Rated force of the motor in N (see Chapter 4 “Technical data”)PvN Rated power loss of the motor in W (see Chapter 4 “Technical data”)

Fig. 11-23: Required cooling capacity of the linear motor

Regeneration energyCompared with rotary servo motors, the energy of a linear motor duringdeceleration is lower. The translatory velocity of a linear motor is usuallymuch lower than the circumferential speed of a rotary servo motor.

The regeneration energy of a synchronous linear drive results from theenergy balance during the deceleration process. To size additional brakeresistors or power supply units with feedback capability, it can beestimated as follows.

∫ ∑ ⋅=⋅=

⋅⋅⋅−

⋅−

⋅⋅

=

T

0 all

bii RRRavg

2

iFN

max12

2R

b

2

R

ttP

dt )t(PT1

P

ka

Rm5,12Fv

t2vm

P

PR: Regeneration energy during a deceleration phase in WPRavg: Average regeneration energy over total duty cycle time in Wm: Moved mass in kgv: Maximum velocity in m/stb: Deceleration time in sFR: Frictional force in NR12: Winding resistance of the motor at 20°C in ohms

(see Chapter 4 “Technical Data”)amax: Braking deceleration (negative acceleration) in m/s²kiFN: Motor constant in N/Atall: Total duty cycle time in s

Fig. 11-24: Regeneration energy of the linear motor

Prerequisites: Velocity-independent friction

Constant deceleration

Final velocity = 0

Note: If the regeneration energy that is determined according toFig. 11-24 is negative, energy is not fed back. This meansthat energy must be supplied to the motor during thedeceleration process.



11.5 Efficiency

The efficiency of electrical machines is the ration between the motoroutput and the power fed to the motor. With linear motors, it isdetermined by the application-related traverse rates and forces, and thecorresponding motor losses.

Fig. 11-25 and Fig. 11-26 can be used for determining and/or estimatingthe motor efficiency.

vFP

1

1P)vF(

vFPP

P

velel Vel Vmech

mech

⋅+

=+⋅⋅=

+=η

η: EfficiencyPmech: Mechanical output in WPVel: Electrical power loss in WF: Feed force in Nv: Velocity in m/s

Fig. 11-25: Determining the efficiency of linear motors

Fig. 11-26: Efficiency vs. velocity for IndraDyn L synchronous linear motors.

0,0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1,0

0 m/min 100 m/min 200 m/min 300 m/min 400 m/min 500 m/min 600 m/min

Velocity

effeciency vs.maximum force Fmax

effeciency vs. continuousnorminal force FdN

WIRKUNGSGRAD MLF.XLS



11.6 Sizing Examples

Handling axisThe example of a simple handling axis is used for describing the basicprocedure of sizing a linear drive.

SpecificationsThe following data is specified:

Slide mass: mS = 65 kg

Maximum velocity possible: 300 m/min

Maximum acceleration possible: 50 m/s²

Axis arrangement: horizontally, primary moved

Base force through energy chain,seals, linear guides, etc.: Fzus = 150 N (constant)

Additional process forces: none

Friction coefficient of linear guides: µ = 0.005

Mains connection voltage: 3 x AC 400V

Coolant temperature (water): ϑcoolant = 25°C

Required positioning movements:

No.: Stroke Positioningtime

Idle time after stroke Remark

1 600 mm 0.32 s 0.20 s Moving from startposition to part

pickup

2 -1,300 mm 0.50 s 0.20 s Parts transport anddeposit

3 700 mm 0.35 s 0.45 s Moving back tostart position

Fig. 11-27: Required positioning movements of the handling axis

The mass of the primary must be taken into account when the feedforces are determined. The attractive force between the primary andsecondary is required additionally when the frictional force is determined.The following assumptions are made to start with:

Primary mass: mP = 19 kg

Attractive force: FATT = 8000 N

Check the calculations again when you have selected the motor.



Calculation

The following velocity and acceleration values are selected in order tomaintain the required position times and specified limitations.

No.: Stroke Positioningtime

Feed rate Acceleration

1 600 mm 0.32 s 180 m/min 25 m/s²

2 -1,300 mm 0.50 s 220 m/min 25 m/s²

3 700 mm 0.35 s 185 m/min 25 m/s²

Fig. 11-28: Selected velocities and accelerations of the handling axes

Note: When you select the position velocity and positioningacceleration, you should try to find an optimum ration for themotor selection (to reach a minimum effective force, forexample).

kg 84m

kg 19kg 65m

mmm

ges

ges

PSges

=

+=

+=

N 194F

N 150N) 8000m/s² 9.81kg (840.005F

F)Fg(mF

FFF

0

0

zusATTges0

zusF0

=++⋅⋅=

++⋅⋅=+=

µ

N 0FW = (horizontal axis)

N 2100F

m/s² 52kg) (84F

amF

acc

acc

pgesacc

=⋅=

⋅=

N 2294F

N194N 2100F

FFF

max

max

0accmax

=+=

+=

s 2.02t

s 0.45s 0.35s 0.2s 0.5s 0.2s 0.32t

ges

ges

=

+++++=

Moved total mass

Base force

Force due to weight

Acceleration force:

Maximum force:

Total time or duty cycle time



The selected velocities and the determined forces provide the followingvelocity and force profile:

%'

%

2

)

)

*! *! *!

*! *!

-*& -*& -*&

*!

$

)$

$

$

!($

&$

!($

$

$

!$

$

!$

DIMBSPHDL01-MLF-EN.EPS

Fig. 11-29: Velocity and force profile of handling axis

The effective force and the average velocity are determined on the basisof the force profile:

No.: Time tin s

Force Fi

in NAverage velocity vavg i

in m/min

1 0.120 2294 Fi = Facc+F0 90

2 0.080 194 Fi = F0 180

3 0.120 -1906 Fi = -Facc+F0 90

4 0.200 0 0

5 0.147 2294 Fi = Facc+F0 110

6 0.206 194 Fi = F0 220

7 0.147 -1906 Fi = -Facc+F0 110

8 0.2 0 0

9 0.123 2294 Fi = Facc+F0 92.5

10 0.104 194 Fi = F0 185

11 0.123 -1906 Fi = -Facc+F0 92.5

12 0.45 0 N 0

Fig. 11-30: Force profile vs. time to determine the effective force

N 1313F

t

)tF(F

eff

ges

i2i

eff

=

⋅= ∑

min/m 1.77v

t

tvv

avg

ges

ii avgavg

=

⋅= ∑

Velocity and force profile

Effective force and averagevelocity



Selection of motor – controller combinationOnce the application data has been calculated, an appropriate motor-controller combination can be selected.

The standard encapsulation and the IndraDrive controller family areselected. Using the calculated data, the following combination is chosenfrom the selection data for motor-controller combinations (see Chapter10 “Motor-Controller Combinations”):

Motor: MLP140C-0170-FS-xxxx

Drive device: HMS01.1N-W150

The mass of the selected primary MLP140C-0170-FS is slightly smallerthan the previous mass. The same applies to the attractive force. Theselected motor is retained within the scope of this example.

Using the profiles of velocity and force (Fig. 11-29), the operating pointsof the required feed forces and the necessary velocities can bedetermined. These operating points and the characteristics are shown inthe Figure below.

(

(

!

&

! !

1

3

-% /% #4" $'

DIMBSPHDL02-MLF-EN.EPS

Fig. 11-31: Force-velocity diagram of handling axis(operating points and motor characteristic)

Note: All operating points that are related to force and velocity ofthe application must be inside the characteristic curve of theselected motor – controller combination.

Verification of mass andattractive force

Operation points andcharacteristic curve of the motor



Selecting the secondary segmentsBased on the motion profile, the effective total motion path and,consequently, the required number and/or length of the secondarysegments can be determined. The effective total travel is 1300 mm; thelength of the selected primary is 510 mm.

mm 1810L

mm 510mm 1300L

LLL

econdarys

condaryse

rimaryptravel totalondarysec

=

+=

+≥

Secondary segments for IndraDyn L synchronous linear motors areavailable in a length of 150 mm, 450 mm and 600 mm. Threesecondaries of 600 mm each (total length of 1800 mm) are selected forthe handling axes.

Required length of thesecondary parts

Selecting the secondary partsegments



Power calculation

W 1687P60

min/m 1.77N 1313P

v FP

cm

cm

avgeffcm

=

⋅=

⋅=

W 703P

W 0013N 1785N 1313

P

PF

FP

ce

2

ce

vN

2

n_motor

effce

=

⋅

=

⋅

=

W 2390P

W 703W 1687P

PPP

c

c

cecmc

=+=

+=

W8412P60

min/m 220N 2294P

vFP

maxm

maxm

Fmaxmaxmaxm

=

⋅=

⋅=

Figure 11-22 is used for determining the maximum electrical power loss.The ratio of required maximum force and maximum force of the motor is2294 N / 5600 N = 0.41.

Thus, Figure 11-22 shows a reduction factor of 0.095 for the maximumpower loss. Together with the specification of the maximum motor powerloss from the selection charts for the motor-controller combination, themaximum electrical power loss results as

kW 78.5P

kW 84.60095.0P

P095.0P

maxe

maxe

motor maxmaxe

=⋅=⋅=

Wk 14.19 P

kW 78.5Wk 41.8P

PPP

max

max

maxemaxmmax

=+=

+=

W 704PP ceco ==

Rated mechanical power

Rated electrical power loss

Total rated power

Maximum output mechanical

Maximum output electrical

Total maximum output

Cooling capacity



Figure 11-24 and the motor data in Chapter 4 “Technical data” are usedfor determining the regeneration energy for all deceleration phases.

2

iFN

max12

2R

bi

2

Ri ka

Rm5,12Fv

t2vm

P

⋅⋅⋅−

⋅−

⋅⋅

=

No.: Deceleration time tbi Feed rate Acceleration Regeneration energyPRi

1 0.120 s 180 m/min -25 m/s² 1678 W

2 0.147 s 220 m/min -25 m/s² 2305 W

3 0.123 s 185 m/min -25 m/s² 1767 W

Fig. 11-32: Regeneration energy during the deceleration phases

The average regeneration energy over the entire duty cycle timeamounts to:

W 375P

t

tPP

Ravg

all

bii RRavg

=

⋅= ∑

Additional DC bus capacities (capacitors) shall ensure that the axis issafely stopped in the event of a power failure. Figure 9-77 is used fordetermining the required additional capacities in the DC bus. The motordecelerates at maximum feed force; the minimum DC bus voltage shouldbe 50V. The maximum velocity is 220 m/min is considered as worstcase.

( ) ( )

mF 4.2F 00242.0C

3.0N 5600

N 194sm

17.4 2.1

AN

82

N 56005,3

V 50V 540sm

17.4kg 84C

3.0F

FvR

k

F5,3

UU

vmC

add

222add

motormax_

Rmax122

iF

motormax_

2minDC

2maxDC

maxgesadd

==

+⋅−⋅

⋅⋅−

⋅=

+⋅−⋅⋅⋅

−

⋅=

Ω

Note: The maximum possible DC bus capacity of the employedpower supply module must be taken into account whenadditional capacities are used in the DC bus.

Regeneration energy

Additional capacities forstopping the axis upon a power

failure



Selection of linear scaleThe linear scale can be selected when the effective total travel is known.

An open incremental linear scale of the LIDA187C type is selected forthe handling axis. The selected system has distance-encoded referencemarks.

Motor efficiencyThe motor efficiency, related on the continuous output, results as follows:

706.0

W703 W1687W 1687

PPP

c

eccm

cmc

=

+=

+=

η

η



Final overtemperature of the motor

K 130

K 25K 155

wg

wg

coolantmaxwwg

=

−=

−=

ϑϑ

ϑϑϑ

K 70

K130N 1785N 1313

F

F

w

2

w

wg

2

n_motor

effw

=

⋅

=

⋅

=

ϑ

ϑ

ϑϑ

C 95

K 25K 70

wabs

wabs

coolantwwabs

°=+=

+=

ϑϑ

ϑϑϑ

The thermal time constant of the selected motor is Tth = 7 min. 98% ofthe final temperature is reached after approximately 4 thermal timeconstants (i.e. after 28 minutes).

Note: Additional explanations of the thermal behavior of linearmotors can be found in Chapter 9.4 “Motor Cooling”.

Limit overtemperature of themotor winding

Final overtemperature of themotor winding

Absolute final temperature of themotor winding

Reaching the final temperature



Machine tool feed axis; sizing via duty cycleDetailed information of the motion cycle are sometimes not available orare not exact. In the case of, e.g. small batch production and frequentlychanging port programs. Sizing of the drives is performed on the basisof the relative duty cycle of different operating phases, and based onempirical values from machine manufacturers and/or machine users.

The following example explains this procedure.

SpecificationsThe following data is specified:

Slide mass including motor: mS = 580 kg

Velocity rapid travers: 120 m/min

Velocity machining 15 m/min

Maximum acceleration possible: 15 m/s²

Axis arrangement: horizontally, primary moved

Motion path 0.95 ... 800 mm

Base force: F0 = 600 N (constant)

Maximum machining force: FP = 1200 N

Friction coefficient of linear guides: µ = 0.005

Mains connection voltage: 3 x AC 400V

Type of machining/movement ShareAcceleration and declaration 10 %

Rapid traverse 20 %

Machining process 30 %

Standstill with machining 20 %

Standstill without machining 20 %

Total: 100 %

Fig. 11-33: Percentage of individual machining processes and movements

Fig. 11-34: Graphical presentation of the individual operating phases

machining30%

Standstill withmachining

20%

Standstill withoutmachining

20%

Acceleration/deceleration

10%

Rapid traverse20%



Calculation

N 8700F

m/s² 51kg 580F

amF

acc

acc

gesacc

=⋅=

⋅=

N 9300F

N 600N 8700F

FFF

max

max

0accmax

=+=

+=

The effective force and the average velocity are determined on the basisof the specifications for the individual operating phases.

Type of machining/movement EDi Force Fi Averagevelocity vavgi

Acceleration and declaration 10 % 8700 N Fi = Facc ± F0 60 m/min

Rapid traverse 20 % 600 N Fi = F0 120 m/min

Machining process 30 % 1800 N Fi = FP + F0 15 m/min

Standstill with machining 20 % 1200 N Fi = FP 0 m/min

Standstill without machining 20 % 0 N 0 m/min

Fig. 11-35: Percentage of individual machining processes and movements

N 2983F

)100ED

F(F

eff

i2ieff

=

⋅= ∑

min/m 5.34v

)100ED

v(v

avg

iavgiavg

=

⋅= ∑

Drive selectionThe determined data can be used for selecting a motor-controllercombination. The primary with thermal encapsulation is selected formachine tool applications.

Primary MLP140C-0170-FS-N0CN-NNNNFmax_motor: 10000 N Fn_motor: 3150 NvFmax 750V:170 m/min vNENN 750V: 250 m/min

Secondary segments MLS140A-3A-xxxx-NNNNTotal travel + Primary ~1,500 mm

Drive device HMS01.1N-W0150

Power supply module HMV ( UDC=750V, with feedback capability)

Linear scale Heidenhain LC481encapsulated, absolute, ENDAT interface

Acceleration force:

Maximum force:

Effective force and averagevelocity



Determining the cooling capacity

W 3050P

W 3400N 3150N 2983

P

PF

FPP

co

2

co

vN_motor

2

n_motor

effceco

=

⋅

=

⋅

==

The maximum temperature rise at the contact surface of the primaryshould not exceed 3 K. The necessary coolant flow in L/min isdetermined according to Fig. 9-43:

minl

2.6Q

K 3mkg

3,988Kkg

J4183

25200W 3050Q

Tc25200P

Q

3

m

co

=

⋅⋅⋅

⋅=

⋅⋅⋅=

∆ρ

Note: The way of determining the drive power and other moredetailed data are not discussed within the scope of thisexample.

Rated electrical power loss

Required coolant flow

Rexroth IndraDyn L Handling, transportion and storage of the units 12-1


12 Handling, transportion and storage of the units

12.1 Identification of the motor components

PrimaryA name plate is attached to the front face of the primary where thepower cable and coolant connections are located. The name plateunambiguously identifies the individual primary. An additional name plateis attached to the primary. This additional name plate can be attached tothe machine or can be used otherwise as the customer sees fit. Thename plate contains the following data:

67686%99%96

%81(''%'**'****!*1('

:1,

2*3 *72*3

*616(+

7 7

";#&".

$ ( &&

& <

( &

Name_Plate_Primary.EPS

(1): Rated force (N) (2): Rated voltage (A)(3): Insulation class (4): Protection class(5): Pole pitch (mm)

Fig. 12-1: Name plate of the primary

SecondaryDue to lack of space on the secondary, no name plates are permanentlyattached. Two identical name plates are, however, delivered with thesecondary. To ensure a safe and permanent identification of thesecondary in the future, the type designation and the serial numbers arestamped directly into the secondary.

The type designation and serial numbers are located between the firsttwo mounting holes starting from the side stamped “S” to signify thesouth pole.

A << *&*<$$$ 3%<

::K:: ::

:::

!

%

MLS_KENNZ_EN.EPS

(1): Type designation and serial number(2): Manufacturing date (mm/yy)(3): Supplier(4): Number of test protocol(5): Pole designation “S” (for south pole)

Fig. 12-2: Positions of the identification marks on the secondary

12-2 Handling, transportion and storage of the units Rexroth IndraDyn L


Note: Independent of the length, each secondary has a magneticnorth pole on one end and a magnetic south pole on theother. To indicate which end is which, the south pole ismarked with an “S”.

The type plate of the secondary contains the following data:

!/9*:686%99%96

%81!(!'''****!*1!('

*616(

7

";#&".

& <

( &

:1,

Name_Plate_Secondary.EPS

(1): Protection class (IP rating)(2): Mass of the secondary (kg)

Fig. 12-3: Name plate of the secondary

12.2 Delivery status and Packaging

PrimaryThe primaries are individually packed in wooden boxes which aremarked with the type designation of the primary contained inside; thisallows for easy identification of the contents.

SecondaryThe secondaries are individually packed in cardboard boxes which arealso marked with the type designation of the secondary inside.

CAUTION

Risk of injuries and/or damage when handlingsecondaries of synchronous linear motors!⇒ Strictly observe and adhere to the warnings and

safety instructions

Name plate



The boxes containing the secondaries carry the following warnings:

.C8L* ALB8.77E3 M

9 )##-)" #" -"0#?#21)-"

C#9?#??)"-)-")#*?.23"-

JN""- -M

,B*8*@7E ) ?# ") 4 M

""- "M

) ?# "

8-3#) "

,B*C*@

7E#8 7N"OP-O"

$*)"?-P#EO#E33EE

@"--P7E#8 7N"O2C"2"M

?"-"M

.C8L* ALB8.77E-""3-- "M

""- "M

7) 3"3M7)4

*E-A"2

D"-3"7?E"?O-"M

?"-"M

*

WARNMAGN_MLF_EN.EPS

Fig. 12-4: Warning label on the MLS secondary boxes

Note: Self-adhesive warning labels, as shown in Fig. 12-4, can beordered from Bosch Rexroth (Mat-Nr. R911278745). Theapproximate size is 110 mm x 150 mm.

12.3 Transportation and Storage

The primaries and secondaries of synchronous linear motors must bestored on flat surfaces and supported along the entire bottom – see Fig.12-5. This must be ensured even for storage of a short duration.

The permissible storage and transport temperature is from –10 to +60°C(14 - 140°F). Large or periodic temperature variations during transportand storage are not permitted.

8<B(

*<B(

LAGKOMP_MLF_EN.EPS

Fig. 12-5: Storage of linear motor components

Warnings on the packaging ofthe secondaries



CAUTION

Inappropriate handling during storage ortransport can damage or destroy the motorcomponents!⇒ Use the original packaging for permanent storage.⇒ Store for short periods according to Fig. 12-5⇒ Do not throw parts⇒ Adhere to permissible transportation and storage

temperatures ranges.⇒ Remove the transportation and installation

protection only during or after the installation intothe machine.

Specifics for transporting secondaries of synchronous linear motorsThe secondaries of synchronous linear motors have unshieldedpermanent magnets. Strictly adhere to the safety notes in chapter 3!

CAUTION

Magnetic fields can influence a plane’selectronics!⇒ Heed the packaging and transportation instructions

(IATA 902)

Air freight



12.4 Checking the motor components

Factory checks

All Bosch Rexroth linear motors undergo the following electrical checksat the factory:

• High-voltage test acc. to EN 60034-1/2.95 (VDE 0530 Part 1)

• Insulation resistance test acc. to EN 60204-1

• Verification of the specified electrical characteristics

All Bosch Rexroth linear motors undergo the following mechanical tests:

• Shape and location tolerances acc. to ISO 1101

• Structure and fits acc. to DIN 7157

• Surface characteristics acc. to DIN ISO1302

• Thread test acc. to DIN 13, Part 20

• Leak tests of the cooling system

Note: Each motor is accompanied by a corresponding testcertificate.

The linear motor components of Bosch Rexroth have been subjected toEMV tests and have been certified as compliant to:

EN 55011 Limit Class B, VDE 0875 Part 11

Customer’s receiving inspection

If you wish to perform an additional high-voltage receiving inspection,you must contact Bosch Rexroth.

CAUTION

Destruction of motor components byimproperly-executed high-voltage inspection!⇒ Contact Bosch Rexroth before carrying out such

tests!

Electrical inspections

Mechanical inspections

EMV radia interferencesuppression

Rexroth IndraDyn L Mounting Instructions 13-1


13 Mounting Instructions

13.1 Basic precondition

Basic precondition for mounting the IndraDyn L components is thekeeping of the following basic preconditions:

• Precondition of the necessary installation sizes (Fig. 5-1)

• Machine construction fulfills the requests for mounting (stiffness,attractive force, feed force and acceleration force, etc.)

• Machine construction is prepared for mounting of all components

• Mounting is done by trained personal

• Compliance of danger and safety notes is guaranteed.

13.2 General procedure at mounting of the motor components

The installation of the motor into the machine construction depends onthe arrangement of the secondary and can be done in different ways.

• Installation at spanned secondaries over the entire traverse path

• Installation at whole secondary over the entire traverse path

Note: The described procedures are only suggestions and can bedone user-specific in other forms.

Installation at spanned secondary parts over the entire traverse pathInstallation for a spanned secondary can be done, as shown in Fig. 13-1.Thereby, only a part of the secondary is installed, so that the primary canbe laid on the machine bed.

WARNING

Do not lay the primary directly on the secondary!⇒ Lift-off of the primary from the secondary is difficult

because of high attractive forces (apparatusnecessary).

The assembly of the primary into the installed slide can be done now.Afterwards, the slide with installed primary can be pushed over theinstalled secondaries. Then, all the remaining secondaries can beinstalled.

13-2 Mounting Instructions Rexroth IndraDyn L


3

$$"

$'

'

3

$$"

$'

'

$$"

0

0

MOTEINBAU01-MLF-EN.EPS

Fig. 13-1: Assembly of the components of linear motors at spanned secondarypart

CAUTION

Uncontrolled movement of the slide!⇒ Safety against uncontrolled movements by partial

covering of primary and secondary (force intraverse direction).



Installation at whole secondary over the entire traverse pathAt whole secondary over the entire traverse path can the primary beinstalled into the prepared slide. After mounting the secondary, the slidewith prepared primary can be lowered on the machine bed via a suitedapparatus

3

$

$'

'

"/" '#"/$"%

MOTEINBAU02MLF-EN.EPS

Fig. 13-2: Installation of the linear motor components at whole secondary overthe entire traverse path

CAUTION

When lowering the primary on the secondary,result by reducing the air gap increasingattractive forces!⇒ Heed the specifications in chapter 9.5 feeding and

attractive forces⇒ Do not lower the primary on the secondary with a

crane (elasticity / attractive force).

Note: The apparatus for lowering the primary and the slide is not inthe scope of delivery of Bosch Rexroth.

Another possibility is, to lay the primary on the installed secondary – witha suited apparatus – and to screw it with fastening screws on the slide.Thereby, a non-ferromagnetic distance plate (made of plastic or wood)has to be laid among the primary and secondary so that the primarydoes not bear on the secondary directly. The thickness of the distanceplate should be measured according to nominal air gap. After thefastening of the primary on the slide a moving of the slide should bepossible.

The thickness of the distance plate must be measured in such a way thatthe primary with the fastening screws can preferably not or onlyexiguously be lifted.

Measurable air gap: 1.0 mm

Thickness of the distance plate: 0.95 ... 0.99 mm

Example



The tightening of the fastening screws for the primary has to be made asdescribed in chapter 13.4 “Mounting of the primary”.

3

$

$'

'

3

$$'

'

0

0-2"

$ '

3

$$'

'

0-2"

$ '

'#"/$"%


Fig. 13-3: Installation of the linear motor components at whole secondary overthe entire traverse path

CAUTION

When lowering the primary on the secondary,result by reducing the air gap increasingattractive forces!⇒ Heed the specifications in chapter 9.5 feeding and

attractive forces⇒ Do not lower the primary on the secondary with a

crane (elasticity / attractive force).



13.3 Installation of the secondary segments

WARNING

Personal injury and / or damage of motorcomponents!⇒ Remove the transport and installation protection of

the secondary only after mounting of the secondary.

The secondaries have to be bolt together with the machine construction.The tightening torque of the fastening screws are given as follows:

Size secondaryBolt size-ISO-grade

Tightening torque

MLS040MLS070MLS100MLS140MLS200MLS300

M6 10 Nm

Fig. 13-4: Tightening torque for the secondaries fastening screws.

Using several arranged secondaries over the entire traverse path, thepole series must be kept according to the following figure.

- !&

'*

'*

- !&

- !&

- !&

- !&

- !&


Fig. 13-5: Arrangement of several secondaries

WARNING

Malefunction and / or uncontrolled movement ofthe motor result in danger of damage or risk ofinjury!⇒ Correct arrangement of the secondaries.

Spanned secondary



WARNING

Risk of injury or damage by attractive force orrepulsive force when arranging the secondaries!⇒ Safety against uncontrolled movement⇒ Remove the transportation and installation

protection only during or after the installation intothe machine.

Attractive or repulsive forces can be approx. 300N differing from thesize, when arranging the secondaries.

- !&

)'*

)'*

- !&

- !&

- !&

- !&

- !&


Fig. 13-6: Attractive or repulsive force when arranging the secondaries



13.4 Installation of the primary

)

&

!

(

2"$#$

$'

MOTEINBAU06_MLF_EN.EPS

Fig. 13-7: Order of tightening the fixing screws of the primary

Mounting instructions:

1. Prepare the threaded holes acc. to Chapter 13.6.2. Fasten the primary with screws 1, 2, 3...n until the primary lais on the

slide.3. Fasten screws 1, 2, 3 ...n with nominal tightening torque:

Primary size DesignsBolt size-ISO-grade

Nominaltightening

torque

MLP040

MLP070

MLP100

MLP140

MLP200

MLP300

Standard and

Thermal encapsulationM6 10 Nm

Fig. 13-8: Nominal tightening torque for the fixing screws of the primaries

Note: The screw-on surface among the primary and machineconstruction must be oil free and free of grease.

13.5 Connection liquid cooling

Connection of the liquid cooling is made by standard threads directly onthe primary. Fittings and pipes are not in the scope of delivery of thelinear motor.

The following connection data have to be kept. Excursion of tighteningtorque or depth of engagement can lead to irreversible machinedamage.

Primary with... ThreadMax. tightening

torqueMax. depth ofengagement

standard encapsulation

thermal encapsulationG1/4 30 Nm 12 mm

Fig. 13-9: Connection liquid cooling



13.6 Screw locking

LOCTITE is a plastic adhesive, which is applied to the installation partsin liquid form. The adhesive remains liquid as long as it is in contact withoxygen. Only after the parts have been mounted, it converts from itsliquid state into hard plastic. This chemical conversion takes placeunder exclusion of air and the produced metallic contact. The result is aform-locking connection that is impact- and vibration-resistant. Thehardening accelerator Activator 7649 reduces the hardening time of theadhesive.

Proceed as follows:

1. Clean metal chips and coarse dirt from threaded hole and screw orgrub screw.

2. Use LOCTITE rapid cleanser 7061 to clean oil, grease and dirtparticles from threaded hole and screw/grub screw. The threadshave to be absolutely restless.

3. Spray LOCTITE activator into the threaded hole and let it dry.

4. Use LOCTITE adhesive to moisten the same threaded hole in itsentire thread length thinly and evenly.

5. Screw in the matching screw/grub screw.

6. Allow join to harden. Hardening times see Fig. 13-10.

Securing screwed connections using LOCTITE in tappedblind holesThe adhesive must always be dosed into the tapped hole, never on thescrew. This prevents that the compressed air extrudes the adhesivewhen the screw or grub screw is screwed in.

Hardened Hard to thetouch without

activator

Hard to thetouch with

activator 7649

LOCTITE 243 ≈ 12 h 15 to 30 min 10 bis 20 min

LOCTITE 620 ≈ 24 h 1 to 2 h 15 to 30 min

NOTE: All values refer to the hardening time at room temperature. The times are shorterwhen heat is added.

Fig. 13-10: Hardening times LOCTITE adhesive

Note: LOCTITE 620 is heat-resistant up to 200°C, LOCTITE 243 upto 150°C.

To detach the connection, use a wrench for unscrewing the screw orgrub screw in the traditional way. The breakaway torque of LOCTITE620 is 20-45 Nm, the one of LOCTITE 243 is 14-34 Nm (acc. to DIN 54454). Blowing hot air on the screw connection reduces the breakawaytorque.

Is the screw/grub screw removed, the residuals of the adhesive must beremoved from the threaded hole (e.g. re-cutting the thread).

NOTE: The German version of the chapter was checked by LOCTITE Germany forcorrectness and was approved for publication.

General

Gluing

Detach the connection

Rexroth IndraDyn L Startup, Operation and Maintenance 14-1


14 Startup, Operation and Maintenance

14.1 General information for startup of IndraDyn L motors

The startup of linear motors is different to the rotative servo motors.

Note: Use the functional description of the drive controller for moredetailed information.

The following points have to be especially noticed when startupsynchronous-linear motors.

Synchronous-linear motors are kit motors whose single components are– completed by an encoder system – directly installed into the machineby the manufacturer. As a result of this, kit motors have no data memoryto supply motor parameters or standard controller adjustment. At startup,all parameters have to be manually entered or loaded into the drive. Thestartup-program DriveTop makes all motor parameters of Bosch Rexrothavailable.

The procedure at controller optimization (voltage, acceleration andposition controller) of linear direct drives is the same as at rotative servodrives. At linear drives are only the adjustment limits higher. At lineardirect drives compared with rotative servo drives can be, for example, a10-fold higher kv-factor adjusted. Precondition therefore is anappropriate machine construction (see chapter 9.3 “Request for amachine construction”.

At controlled rotative servo drives are automatic-control engineeringmodifications at the rate of motor-moment of inertia to demand-momentof inertia. Such a modification is not available for direct drives with linearmotors. The moved foreign mass is independent from the motor self-mass.

The polarity of the actual-speed (length measuring system) must agreewith the force polarity of the motor. This connection has to beestablished before commutation-adjustment.

It is necessary at synchronous linear motors to receive the position ofthe primary relating on the secondary by return after start or after amalfunction. This is called identification of pole position or commutationadjustment. The commutation adjustment-process is the establishmentof a position reference to the electrical or magnetic model of the motor.The commutation adjustment can be done after installation of the motorcomponents and length measuring system. The way of doing thecommutation adjustment complies with the measuring principle of thelength measuring system.

Parameter

Controller optimization

Moving masses

Encoder polarity

Commutation adjustment

14-2 Startup, Operation and Maintenance Rexroth IndraDyn L


14.2 General precondition

The following preconditions have to be created for a successful start-up.

• Adherence of the safety instructions and notes.

• Check of electrical and mechanical components on a safe function.

• Availability and supply of required implements.

• Adherence of the following described start-up

Adherence of all electrically and mechanically components

Do a check of all electrically and mechanically components before start-up. Heed the following points in particular:

• Safety warranty of personnel and machine

• Proper installation of the motor

• Correct power connection of the motor

• Correct connection of the length measuring system

• Function of available limit switch, door switch, a.s.o.

• Proper function of the emergency stop circuit and emergency stop.

• Machine construction (mechanical installation) in proper andcomplete condition.

• Availability and function of suitable end-of-stroke damper.

• Correct connection and function of the motor cooling.

• Proper connection and function of the drive controller unit.

WARNING

Danger to life, heavy injury or damage by failureor malfunction on mechanical or electricalcomponents!⇒ Troubleshooting at mechanical or electrical

components before continue with the start-up.

WARNING

Risk of injury or danger to life, as well asdamage due to non-adherence of warning andsafety notes!⇒ Adherence of the warning and safety notes.⇒ Start-up must to be done by skilled personnel⇒ Adherence of the following described start-up



Implements

The start-up can be made directly via a NC-terminal or via a specialsoftware. The start-up software DriveTop makes a menu-driven, custom-designed and motor specific parameterizing and optimization possible.

For start-up with DriveTop is a usual Windows-PC needed.

For start-up via NC-control, access to all drive parameters andfunctionalities must be guaranteed.

An oscilloscope is needed for drive optimization. It serves to display thesignals, which can be shown via the adjustable analog output of the drivecontroller. Viewable signals are, e.g. nominal and actual values of thespeed, position or voltage, position lag, intermediate circuit a.s.o.

At troubleshooting and check of the components can be a multimeterwith the possibility to voltage metering and resistor measuring helpful.

Start-up software DriveTop

PC

Start-up via NC

Oscilloscope

Multimeter



14.3 General start-up procedure

In the following flow-chart is the general start-up procedure atsynchronous linear motors MLF shown. In the following chapters arethese points explained in detail.

parameter value assignments

Verification:

- power connection - safety end switch- measuring system connection - motor cooling- mechanical system - controller function- end position dampers - drive control function- E STOP function

No

determine sensorpolarity

commutation setting

position sensor typeparameter S-0-0277 Bit 3 = 1

............1001

Necessary information,parameters and aids

- motor parameters- constant focommutation setting kmx

set and optimizecontrol loop

error ?

polarityFsoll = vist?

eliminate errorYes

system is operational!

No

load drive parameterdefault values

enter/load motorparameters

enteapplication-relatedparameters

enter drive limitation

enter parameters forlength measuring

system

Yes

initialcommissioning

Yes

No

Fig. 14-1: General start-up procedure at synchronous linear motors



14.4 Parametrization

With DriveTop, entering or editing certain parameters and executingcommands during the commissioning process is done inside menu-driven dialogs or in list representations. Optionally, it can also beperformed via the control terminal.

Entering motor parameters

Note: The motor parameters are specified by Rexroth and must notbe changed by the user. Commissioning is not possible, ifthese parameters are not available. In this case, please getinto contact with your Rexroth Sales and Service Facility.

WARNING

Injuries and mechanical damage, if the motor isswitched on immediately after the motorparameters have been entered! Entering themotor parameters does not make the motoroperational!⇒ Do not switch on the motor immediately after the

motor parameters have been entered.⇒ Enter the parameters for the linear scale.⇒ Check and adjust the measuring system polarity.⇒ Perform commutation setting.

The motor parameters can be entered in the following way:

• Use DriveTop to load all the motor parameters.

• Enter the individual parameters manually via the controller.

• With series machines, load a complete parameter recordvia the controller or DriveTop.



Input of linear scale parameters

The type of the linear scale must be defined. The parameter P-0-0074,encoder type 1 (see also Fig. 9-83).

Encoder type P-0-0074

Incremental measuring system, e.g.LS486 in conjunction with high-resolution DLF position interface

2

Absolute encoder with ENDATinterface, e.g. LC181 in conjunctionwith high-resolution DAG positioninterface

8

Fig. 14-2: Encoder type definition

Linear scale for linear motors generate and interpret sinusoid signals.The sine signal period must be entered in the parameter S-0-0116,sensor 1 resolution.

Note: The values that must be enterd for parameter S-0-0116,sonsor resolution, are specified in Fig. 9-66. The values forlinear scale that are not shown in this figure must be obtaineddirectly from the manufacturer.

Input of drive limitations and application-related parameters

The possible selectable drive limitations include:

• Current limitation

• Force limitation

• Velocity limitations

• Travel range limits

The application-related drive parameters include, for example, theparameters of the drive fault reaction.

Note: Detailed information can be found in the description offunction of the employed drive controller and/or Firmware.

Encoder type

Signal period

Drive limitations

Application-related parameters



14.5 Determining the Polarity of the linear scale

In order to avoid direct feedback in the velocity control loop, the effectivedirection of the motor force and the count direction of the linear scalesmust be the same.

WARNING

Different effective directions of motor force andcount direction of linear scale causeuncontrolled movements of the motor uponpower-up!⇒ Safety against uncontrolled movement⇒ Adjust effective direction of motor force equal to

linear scale count direction.

To set the correct sensor polarity:

The effective direction of the motor force is always positive in thedirection of the cable connection of the primary.

)

8

GEBPOL01-MLF-EN.EPS

Fig. 14-3: Effective direction of motor force

Effective direction of motorforce



When the primary is moved in the direction of the cable connection, thecount direction of the linear scale must consequently be positive:

)

8

8

GEBPOL02-MLF-EN.EPS

Fig. 14-4: Effective direction motor force = linear scale count direction

Note: The encoder polarity is selected via the primary (cableconnection). The installation direction or the pole sequence ofthe secondary does not have any influence on the selection ofthe sensor polarity.

The encoder polarity is selected via the parameter

S-0-0277, position encoder type 1 (Bit 3)

Position, velocity and force data must not be inverted when the linearscale count direction is set:

S-0-0085, Force polarity parameter 0000000000000000

S-0-0085, Velocity polarity parameter 0000000000000000

S-0-0085, Position polarities 0000000000000000

The process-related axis count direction is set as required after sensorpolarity and commutation have been set.

Effective direction motor force =linear scale count direction



14.6 Commutation adjustment

Setting the correct commutation angle is a prerequisite for maximum andconstant force development of the synchronous linear motor.

This procedure ensures that the angle between the current vector of theprimary and the flux vector of the secondary is always 90°. The motorsupplies the maximum force in this state.

Three different commutation adjustment procedures have beenimplemented in the firmware. The figure below shows the correlationbetween the employed linear scale and the method that is to be use.

incremental

Only for initialcommissioning and sensor

replacement

measuringprinciple of linear scale

absoluteENDAT

initialcommissioning

NoYes

Commutation setting ofsynchronous linear motors

Procedure 1

Measuring the refernecebetween primary and secondarypart and starting the P-0-0524

command

no controller enabling signal no axis movment

always after power-up

Procedure 3

Current flow methodAutomatic execution after

controller enabling signal is set

Only for initialcommissioning and sensor

replacement

Procedure 2

Current flow methode bystarting the P-0-0524 command

with controller enabling signal axis movement

with controller anabling signal axis movement

Fig. 14-5: Commutation adjustment method for synchronous linear motors

Note: The three methods are described subsequently.

Note: Method 2 and 3 cannot be employed for:

• vertical axes without weight compensation

• jammed or blocking axes

Adjustment procedure



DANGER

Malfunction due to errors in activating motorsand moving elements!Commutation adjustment must always beperformed in the following cases:⇒ Initial commissioning⇒ Modification of the mechanical attachment of the

linear scale⇒ Replacement of the linear scale⇒ Modification of the mechanical attachment of the

primary and/or secondary

WARNING

Malfunction and/or uncontrolled motormovement due to error in commutationadjustment!⇒ Effective direction motor force = linear scale count

direction⇒ Adhering to the described setting procedures⇒ Correct motor and encoder parameterization⇒ Expedient parameter values must be assigned for

current and velocity control loop.⇒ Correct connection of motor power cable⇒ Protection against uncontrolled movements

The individual phases of the motor power connection must correctly beassigned. See also Chapter 8 “Electrical Connection”.

To ensure a correct commutation adjustment, the following parametersshould be checked again and, if necessary, set to the values specifiedbelow:

Identitynumber

Description Value

S-0-0085 Torque/force polarity parameter 0000000000000000

S-0-0043 Velocity polarity parameter 0000000000000000

S-0-0055 Position polarity 0000000000000000

P-0-4014 Motor type 3 (synchronous linearmotor)

P-0-0018 Number of pole pairs/pole pairwidth

75

S-0-0116 S-0-0016, Encoder 1 resolution Fig. 9-83

Fig. 14-6: Parameters that must be checked prior to commutation adjustment

Motor connection

Parameter verification



Method 1: Measuring the reference between the primary and thesecondary

If this procedure is used for commutation adjustment, the relativeposition of the primary with respect to the secondary must bedetermined. The benefit of this procedure is that the commuationadjustment requires neither the power to be switched on nor the axes tobe moved. Commutation adjustment need only be performed during thefirst-time commissioning.

Note: This procedure requires an absolute linear scale with ENDATinterface.

Depending on the accessibility of the primary and the secondary in themachine or system, the relative position between primary and secondarycan be measured in different ways.

)

2

"

'

KOMMUT01-MLF-EN.EPS

Fig. 14-7: Measuring the relative position between primary and secondary

Note: From now on, the position of the primary must not bechanged until the commutation adjustment procedure isterminated!

The input value for P-0-0523 that is required for calculating thecommutation offset, is determined from the measured relativce positionof the primary with respect to the secondary (Fig. 14-10, distance d, e, for g, depending on accessibility), and a motor-related constant kmx (seeFig 14-11 and Fig. 14-13).

Measuring the relative positionbetween the primary and the

secondary

Calculation of P-0-0523,commutation adjustment

measured value



mxp

mxp

mx

mx

klgmmP

klfP

mmkeP

kdP

−−−=−−

−−−=−−

−−=−−

−=−−

5.3705230 :4point Reference

05230 :3point Reference

5.3705230 :2point Reference

05230 :1point Reference

P-0-0523: Commutation adjustment measured value in mmd: Relative position, reference position 1 in mm (see Fig. 14-7) )e: Relative position, reference position 2 in mm (see Fig. 14-7) f:

Relative position, reference position 3 in mm (see Fig. 14-7)g: Relative position, reference position 4 in mm (see Fig. 14-7)kmx: Motor constant for commutation adjustment in mmlp: Length of the primary in mm

Fig. 14-8: Calculation of P-0-0523, commutation adjustment measured value

Note: Ensure that the sign is correct when you determine P-0-0523,commutation adjustment measured value.If P-0-0523 is determined with a negative sign, this must beentered when the setup procedure is started.

The motor constants for adjusting the commutation offset kmx depend onthe orientation of primary and secondary:

)

&

)

C

3

3

3

3

KOMMUT02-MLF-EN.EPS

Fig. 14-9: Possible arrangements between primary and secondary

Motor constant for commutationadjustment kmx



Arrangement A(acc. to Fig. 14-9)

kmx in mm

Arrangement B(acc. to Fig. 14-9)

kmx in mm

Standard encapsulationSize 040...300

68 105.5

Thermal encapsulationSize 040 300

65 102.5

Fig. 14-10: Motor constants for commutation adjustment kmx

Example 1, reference point (see Fig. 14-7):

d = 100 mm , kmx = 38.0 mm

P-0-0523 = d - kmx = 100 mm - 38.0 mm = 62 mm


d = 0 mm, kmx = 38.0 mm

P-0-0523 = d - kmx = 0 mm - 38.0 mm = - 38.0 mm


g = 180 mm , kmx = 38.0 mm , lp = 540 mm

P-0-0523 = 37.5 mm - g - lp - kmx = 37.5 mm -180 mm - 540 mm - 38mm

P-0-0523 = 720.5 mm

Prerequisites:

1. The drive must be in the A0-13 state during the subsequentadjustment procedure (ready for power connection).

2. The position of the primary part and/or the slide must not havechanged since the relative position of the primary part with respect to thesecondary part has been measured.

Once the determined value P-0-0523, commutation setting measuredvalue, has been entered, the command P-0-0524, D300 commutationsetting command must be started. The commutation offset is calculatedin this step. The commutation offset is calculated in this step.

Note: If the drive is in control mode when the command is started,the commutation offset is determined using the current flowmethod (see method 2).

The command must subsequently be cleared.

Activation of commutationadjustment command



Method 2: Current flow method manually activated

This method is used for the following configurations:

• Synchronous linear motors with absolute linear scale. Infirst-time commissioning, as an alternative of method 1.

1. Adjust the operation mode “Torque-force control”2. Bring the drive into control (AF).3. Start the commando via P-0-0524

WARNING

Injuries due to errors in activating motors andmoving elements!⇒ Is the drive not accordingly commutated, then the

drive must only be switched in operation mode“Torque-force control” in AF.

⇒ Is the drive switched in velocity control or in positioncontrol in AF, an uncontrolled axis movementcannot be excepted.

Note: The parameter P-0-0560, commutation adjustment voltage,P-0-0562 and cycle duration can individually be adjusted atinitial start-up by the user.



Method 3: Current flow method automatically activated


• Synchronous linear motor with incremental length scale inconnection with controllers Ecodrive and Diax04

At initial start-up of the axis, the parameter P-0-0560,commutation adjustment voltage, P-0-0562 andcommutation adjustment are automatically determinatedand recorded in the drive.At every re-start of the axis, the commutation adjustmentis made new to method 3. The parameter values for P-0-0560 and P-0-0562 of the initial start-up serve as initialvalue for the procedure.

Note: The parameter P-0-0560, commutation adjustment voltage,P-0-0562 and cycle duration can individually be adjusted atinitial start-up by the user.


• Synchronous linear motors with incremental length scale inconnection with IndraDrive controllers.

At initial start-up of the axis, the parameters P-0-0506,peak value for angle-survey and P-0-0507, test frequencyfor angle-survey are automatically determinated, if in P-0-506 “0” is entered. Subsequently, the determinedparameters are recorded in the drive-device.At every re-start of the axis, the commutation adjustmentis made new to method 3. The parameter values for P0-0506 and P0-0507 of the initial start-up serve as initialvalue for the procedure.

Note: The parameters P-0-0506, peak value for angle-survey andP-0-507, test frequency for angle-survey can individually beadjusted at initial start-up by the user.

Controllers ECODRIVE andDIAX04

Controller IndraDrive



14.7 Setting and Optimizing the Control Loop

General sequenceThe control loop settings in a digital drive controller are significant to thecharacteristics of the servo axis. The control loop structure consists of acascaded position, velocity and current controller. The correspondingmode defines the active controllers.

Note: Defining the control loop settings requires the correspondingexpertise.

The procedure used for optimizing the control loops (current, velocityand position controllers) of linear direct drives corresponds to the oneused for rotary servo drives. At linear drives are only the adjustmentlimits higher.

filtering mechanicalresonance vibrations

no

yes

setting and optimizing control loop ofsynchronous linear drives

set current controller (part of motor parameter)

optimize velocity controller

set rejection frequency

re-optimize velocity controller

optimize position controller

set and optimize accelerationprecontrol

Fig. 14-11: Setting and optimizing the control loop of synchronous linear drives.



Note: Use the functional description of the drive controller for moredetailed information.

Drive controllers of the EcoDrive03 series are able to perform automaticcontrol loop adjustment.

Digital drives from Rexroth are able to provide a narrow-bandsuppression of vibrations that are produced due to the power trainbetween motor and mechanical axis system. This results in increaseddrive dynamic at a good stability.

The position or velocity feedback in the closed control loop excites themechanical system of the slide that is moved by the linear drive toperform mechanical vibrations. This behavior, known as “Two-massesvibration”, is mainly in the frequency range between 400 and 800 Hz. Itdepends on the rigidity of the mechanical system and the spatialexpansion of the system.

In most cases, this “Two-masses vibration” has a clear resonantfrequency that can selectively be suppressed by a rejection filter in thedrive.

When the mechanical resonant frequency is suppressed, improving thedynamic properties of the velocity control loop and of the position controlloop with may be possible, compared with close-loop operation withoutthe rejection filter.

This leads to an increased profile accuracy and to smaller cycle times forpositioning processes at a sufficient distance to the stability limit.

Rejection frequency and bandwidth of the filter can be selected. Thehighest attenuation takes effect on the rejection frequency. The bandwithdefines the frequency range at which the attenuation is less than –3dB.A higher bandwidth leads to less attenuation of the rejection frequency!

B 29/2$

-

"7 29/23#

SPERRFILTER-MLF-EN.EPS

Fig. 14-12: Amplitude frequency curve rejection filter vs. bandwidth, qualitative

Automatic control loop setting

Filtering mechanical resonancevibrations



Parameter value assignments and optimization of Gantry axes

Prerequisites:

• The parameter settings of the axes are identical

• Parallelism of the guides of the Gantry axes

• Parallelism of the linear scale

• In the controller, the axes are registered as individual axes

Note: Drive-internal axis error compensation procedures can beused for compensating the misalignments between two linearscales as or the mechanical system. Please refer to thecorresponding description of functions of the drive controllerfor a description of the operational principle and theparameter settings.

'" $$$

'" $$$

/'$ %'/ /'$ %'/

ACHSKOMP-MLF-EN.EPS

Fig. 14-13: Possible misalignment with the linear scale of a Gantry axes

Parameter settingsWhen using Gantry axes, your must ensure that the parameter settingsof the following parameters are identical:

• Motor parameters

• Polarity parameters for force, velocity and position

• Control loop parameters

We have:

2p1p

2v1v

kk

kk

=

=

kv: Position controller kv-factor S-0-0104kp: Velocity controller proportional gain S-0-0100

Fig. 14-14: Proportional gains in the position and velocity control loop of bothaxes.



The following possibilities must be taken into account for the velocitycontroller integral time (integral part):

Possibility 1 Possibility 2 Possibility 3 Possibility 4

Alignment of lengthlinear scale and

guidesideal not ideal not ideal not ideal

Integral Part in both axes in both axes in one axis only in no axis

Behaviour of the axes Since both motorsfollow the positioncommand value

ideally, there will notbe a distortion of themechanical system

Both axes workagainst each other

until there is anequalization via themechanical couplingor until the maximumcurrent of one or bothdrive controller(s) hasbeen reached and acontrol effect is nolonger possible.

The axis withoutintegral-part permits a

continuous positionoffset. The magnitudeof the position offset

depends on therigidity of the

mechanical couplingof both axes and of

the proportional gainsin the position and

velocity control loop.

Both axes permit acontinuous position

offset. The magnitudeof the position offset

depends on theproportional gains in

the position andvelocity control loop.

Fig. 14-15: Parameterization of the velocity controller integral time S-0-0101 forGantry-axes.

The previously described procedure must be followed for optimizing theposition and velocity loop.

Note: Any parameter modifications that are made during theoptimization of Gantry axes must always be made in bothaxes simultaneously. If this is not possible, the parameterchanges should be made during optimization in smallersubsequent steps in both axes.

Estimating the moved mass using a velocity rampOften, the exact moving mass of the machine slide is not known.Determining this mass can be made difficult by moving parts, additionallymounted parts, etc.

The procedure explained below permits the moving axes mass to beestimated on the basis of a recorded velocity ramp. This permits, forexample, the acceleration capability of the axis to be estimated.

This procedure requires the oscillographic recording of the followingparameters:

• S-0-0040, actual velocity value

• S-0-0080, torque/force command value

You can either use an oscilloscope or the oscilloscope function of thedrive in conjunction with DriveTop or NC.

Velocity controller integral time(integral part)

Optimization

Preparation



*<*<<.<D

:

:

*<*<<<D

ERMITTLGMASSE-MLF-EN.EPS

Fig. 14-16: Oscillogram of velocity and force

vt

%100FF

F30m DECACCdN ∆

∆⋅

+⋅⋅=

m: Moved axis mass in kgFdN: Continuous nominal force of the motor in NFACC: Force command value during acceleration in %FDEC: Force command value during braking in %

v: Velocity change during constant acceleration in m/mint: Time change during constant acceleration in s

Fig. 14-17: Determining the moved axis mass on the basis of a recorded velocityramp

Prerequisites: 1. Correct parameter settings of the rated motorcurrent (basis of representation S-0-0080)

2. Frictional force not directional

3. Recording of v and t at constant acceleration

4. Do not perform at maximum motor force to avoidnon-linearities

Note: Due to possible direction-related force variations, thisprocedure cannot or only conditionally be used for verticalaxes.



14.8 Maintenance and check of Motor components

The motor components of IndraDyn L do not need any maintenance.Due to external influence, the motor components can be damagedduring operation. There should be a preventive maintenance of thelinear motor components within the service intervals of the machine orsystem.

Check of Motor and Auxiliary ComponentsThe following points should be observed during the preventive check ofmotor and auxiliary components:

• Scratches on primary and secondary

• Chips in the air gap between primary and secondary

• Tightness of liquid cooling, hoses and connections

• State of power and encoder cables in a drag chain.

• State of linear scale (e.g. soiled)

• State of guides (e.g. wear of linear guides)

Electrical check of motor componentsThe electrical defect of a primary can be checked by measuring electricalcharacteristics. 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

The measured values of resistance and inductance can be comparedwith the values specified in Chapter 5 “Technical Data”. The individualvalues of resistance and inductance measured between the connections1-2, 2-3 and 1-3 should be identical – within a tolerance of ± 5 %. Therecan be a phase short circuit, a fault between windings, or a short circuitto ground if one or more values differ significantly.

The insulation resistance – measured between the motor connectingleads and ground – should be at least 1 MΩ. The primary must bereplaced in this case.

Note: If there are and doubts during the electrical verification,please consult your Rexroth Service.

Resistance and inductance

Insulation resistance

Rexroth IndraDyn L Service & Support 15-1


15 Service & Support

15.1 Helpdesk

Unser Kundendienst-Helpdesk im Hauptwerk Lohram Main steht Ihnen mit Rat und Tat zur Seite.Sie erreichen uns

Our service helpdesk at our headquarters in Lohr amMain, Germany can assist you in all kinds of inquiries.Contact us

- telefonisch - by phone: 49 (0) 9352 40 50 60über Service Call Entry Center Mo-Fr 07:00-18:00- via Service Call Entry Center Mo-Fr 7:00 am - 6:00 pm

- per Fax - by fax: +49 (0) 9352 40 49 41

- per e-Mail - by e-mail: [email protected]

15.2 Service-Hotline

Außerhalb der Helpdesk-Zeiten ist der Servicedirekt ansprechbar unter

After helpdesk hours, contact our servicedepartment directly at

+49 (0) 171 333 88 26oder - or +49 (0) 172 660 04 06

15.3 Internet

Unter www.boschrexroth.com finden Sieergänzende Hinweise zu Service, Reparatur undTraining sowie die aktuellen Adressen *) unsererauf den folgenden Seiten aufgeführten Vertriebs-und Servicebüros.

Verkaufsniederlassungen

Niederlassungen mit Kundendienst

Außerhalb Deutschlands nehmen Sie bitte zuerst Kontakt mitunserem für Sie nächstgelegenen Ansprechpartner auf.

*) Die Angaben in der vorliegenden Dokumentation könnenseit Drucklegung überholt sein.

At www.boschrexroth.com you may findadditional notes about service, repairs and trainingin the Internet, as well as the actual addresses *)of our sales- and service facilities figuring on thefollowing pages.

sales agencies

offices providing service

Please contact our sales / service office in your area first.

*) Data in the present documentation may have becomeobsolete since printing.

15.4 Vor der Kontaktaufnahme... - Before contacting us...

Wir können Ihnen schnell und effizient helfen wennSie folgende Informationen bereithalten:

1. detaillierte Beschreibung der Störung und derUmstände.

2. Angaben auf dem Typenschild derbetreffenden Produkte, insbesondereTypenschlüssel und Seriennummern.

3. Tel.-/Faxnummern und e-Mail-Adresse, unterdenen Sie für Rückfragen zu erreichen sind.

For quick and efficient help, please have thefollowing information ready:

1. Detailed description of the failure andcircumstances.

2. Information on the type plate of the affectedproducts, especially type codes and serialnumbers.

3. Your phone/fax numbers and e-mail address,so we can contact you in case of questions.

15-2 Service & Support Rexroth IndraDyn L


15.5 Kundenbetreuungsstellen - Sales & Service Facilities

Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen!from abroad: don’t dial (0) after country code!

Vertriebsgebiet Mitte Germany Centre

Rexroth Indramat GmbHBgm.-Dr.-Nebel-Str. 2 / Postf. 135797816 Lohr am Main / 97803 Lohr

Kompetenz-Zentrum Europa

Tel.: +49 (0)9352 40-0Fax: +49 (0)9352 40-4885

S E R V I C E

C A L L E N T R Y C E N T E RMO – FR

von 07:00 - 18:00 Uhr

from 7 am – 6 pm

Tel. +49 (0) 9352 40 50 [email protected]

S E R V I C E

H O TLI N EMO – FR

von 17:00 - 07:00 Uhrfrom 5 pm - 7 am

+ SA / SOTel.: +49 (0)172 660 04 06

o der / o rTel.: +49 (0)171 333 88 26

S E R V I C E

ERSATZTEILE / SPARESverlängerte Ansprechzeit- extended office time -

♦ nur an Werktagen- only on working days -

♦ von 07:00 - 18:00 Uhr- from 7 am - 6 pm -

Tel. +49 (0) 9352 40 42 22

Vertriebsgebiet Süd Germany South

Bosch Rexroth AGLandshuter Allee 8-1080637 München

Tel.: +49 (0)89 127 14-0Fax: +49 (0)89 127 14-490

Vertriebsgebiet West Germany West

Bosch Rexroth AGRegionalzentrum WestBorsigstrasse 1540880 Ratingen

Tel.: +49 (0)2102 409-0Fax: +49 (0)2102 409-406

+49 (0)2102 409-430

Gebiet Südwest Germany South-West

Bosch Rexroth AGService-Regionalzentrum Süd-WestSiemensstr.170736 Fellbach

Tel.: +49 (0)711 51046–0Fax: +49 (0)711 51046–248

Vertriebsgebiet Nord Germany North

Bosch Rexroth AGWalsroder Str. 9330853 Langenhagen

Tel.: +49 (0) 511 72 66 57-0Service: +49 (0) 511 72 66 57-256Fax: +49 (0) 511 72 66 57-93Service: +49 (0) 511 72 66 57-783

Vertriebsgebiet Mitte Germany Centre

Bosch Rexroth AGRegionalzentrum MitteWaldecker Straße 1364546 Mörfelden-Walldorf

Tel.: +49 (0) 61 05 702-3Fax: +49 (0) 61 05 702-444

Vertriebsgebiet Ost Germany East

Bosch Rexroth AGBeckerstraße 3109120 Chemnitz

Tel.: +49 (0)371 35 55-0Fax: +49 (0)371 35 55-333

Vertriebsgebiet Ost Germany East

Bosch Rexroth AGRegionalzentrum OstWalter-Köhn-Str. 4d04356 Leipzig

Tel.: +49 (0)341 25 61-0Fax: +49 (0)341 25 61-111



Europa (West) - Europe (West)

vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählenfrom abroad: don’t dial (0) after country code, Italy: dial 0 after country code

Austria - Österreich

Bosch Rexroth GmbHElectric Drives & ControlsStachegasse 131120 WienTel.: +43 (0)1 985 25 40Fax: +43 (0)1 985 25 40-93

Austria – Österreich

Bosch Rexroth GmbHElectric Drives & ControlsIndustriepark 184061 PaschingTel.: +43 (0)7221 605-0Fax: +43 (0)7221 605-21

Belgium - Belgien

Bosch Rexroth NV/SAHenri Genessestraat 11070 Bruxelles

Tel: +32 (0) 2 582 31 80Fax: +32 (0) 2 582 43 10 [email protected] [email protected]

Denmark - Dänemark

BEC A/SZinkvej 68900 Randers

Tel.: +45 (0)87 11 90 60Fax: +45 (0)87 11 90 61

Great Britain – Großbritannien

Bosch Rexroth Ltd.Electric Drives & ControlsBroadway Lane, South CerneyCirencester, Glos GL7 5UH

Tel.: +44 (0)1285 863000Fax: +44 (0)1285 863030 [email protected] [email protected]

Finland - Finnland

Bosch Rexroth OyElectric Drives & ControlsAnsatie 6017 40 Vantaa

Tel.: +358 (0)9 84 91-11Fax: +358 (0)9 84 91-13 60

France - Frankreich

Bosch Rexroth SASElectric Drives & ControlsAvenue de la Trentaine(BP. 74)77503 Chelles CedexTel.: +33 (0)164 72-70 00Fax: +33 (0)164 72-63 00Hotline: +33 (0)608 33 43 28

France - Frankreich

Bosch Rexroth SASElectric Drives & ControlsZI de Thibaud, 20 bd. Thibaud(BP. 1751)31084 ToulouseTel.: +33 (0)5 61 43 61 87Fax: +33 (0)5 61 43 94 12

France – Frankreich

Bosch Rexroth SASElectric Drives & Controls91, Bd. Irène Joliot-Curie69634 Vénissieux – CedexTel.: +33 (0)4 78 78 53 65Fax: +33 (0)4 78 78 53 62

Italy - Italien

Bosch Rexroth S.p.A.Via G. Di Vittorio, 120063 Cernusco S/N.MIHotline: +39 02 92 365 563Tel.: +39 02 92 365 1Service: +39 02 92 365 326Fax: +39 02 92 365 500Service: +39 02 92 365 503

Italy - Italien

Bosch Rexroth S.p.A.Via Paolo Veronesi, 25010148 Torino

Tel.: +39 011 224 88 11Fax: +39 011 224 88 30

Italy - Italien

Bosch Rexroth S.p.A.Via Mascia, 180053 Castellamare di Stabia NA

Tel.: +39 081 8 71 57 00Fax: +39 081 8 71 68 85

Italy - Italien

Bosch Rexroth S.p.A.Via del Progresso, 16 (Zona Ind.)35020 Padova

Tel.: +39 049 8 70 13 70Fax: +39 049 8 70 13 77

Italy - Italien

Bosch Rexroth S.p.A.Via Isonzo, 6140033 Casalecchio di Reno (Bo)

Tel.: +39 051 29 86 430Fax: +39 051 29 86 490

Netherlands - Niederlande/Holland

Bosch Rexroth Services B.V.Technical ServicesKruisbroeksestraat 1(P.O. Box 32)5281 RV Boxtel

Tel.: +31 (0) 411 65 16 40+31 (0) 411 65 17 27

Fax: +31 (0) 411 67 78 14+31 (0) 411 68 28 60

[email protected]

Netherlands – Niederlande/Holland

Bosch Rexroth B.V.Kruisbroeksestraat 1(P.O. Box 32)5281 RV Boxtel

Tel.: +31 (0) 411 65 19 51Fax: +31 (0) 411 65 14 83 www.boschrexroth.nl

Norway - Norwegen

Bosch Rexroth ASElectric Drives & ControlsBerghagan 1 or: Box 30071405 Ski-Langhus 1402 Ski

Tel.: +47 (0) 64 86 41 00

Fax: +47 (0) 64 86 90 62

Hotline: +47 (0)64 86 94 82 [email protected]

Spain - Spanien

Bosch Rexroth S.A.Electric Drives & ControlsCentro Industrial SantigaObradors s/n08130 Santa Perpetua de MogodaBarcelona

Tel.: +34 9 37 47 94 00Fax: +34 9 37 47 94 01

Spain – Spanien

Goimendi S.A.Electric Drives & ControlsParque Empresarial ZuatzuC/ Francisco Grandmontagne no.220018 San Sebastian

Tel.: +34 9 43 31 84 21- service: +34 9 43 31 84 56Fax: +34 9 43 31 84 27- service: +34 9 43 31 84 60 [email protected]

Sweden - Schweden

Bosch Rexroth ABElectric Drives & Controls- Varuvägen 7(Service: Konsumentvägen 4, Älfsjö)125 81 Stockholm

Tel.: +46 (0)8 727 92 00Fax: +46 (0)8 647 32 77

Sweden - Schweden

Bosch Rexroth ABElectric Drives & ControlsEkvändan 7254 67 HelsingborgTel.: +46 (0) 42 38 88 -50Fax: +46 (0) 42 38 88 -74

Switzerland East - Schweiz Ost

Bosch Rexroth Schweiz AGElectric Drives & ControlsHemrietstrasse 28863 ButtikonTel. +41 (0) 55 46 46 111Fax +41 (0) 55 46 46 222

Switzerland West - Schweiz West

Bosch Rexroth Suisse SAAv. Général Guisan 261800 Vevey 1

Tel.: +41 (0)21 632 84 20Fax: +41 (0)21 632 84 21



Europa (Ost) - Europe (East)

vom Ausland: (0) nach Landeskennziffer weglassen from abroad: don’t dial (0) after country code

Czech Republic - Tschechien

Bosch -Rexroth, spol.s.r.o.Hviezdoslavova 5627 00 BrnoTel.: +420 (0)5 48 126 358Fax: +420 (0)5 48 126 112

Czech Republic - Tschechien

DEL a.s.Strojírenská 38591 01 Zdar nad SázavouTel.: +420 566 64 3144Fax: +420 566 62 1657

Hungary - Ungarn

Bosch Rexroth Kft.Angol utca 341149 BudapestTel.: +36 (1) 422 3200Fax: +36 (1) 422 3201

Poland – Polen

Bosch Rexroth Sp.zo.o.ul. Staszica 105-800 PruszkówTel.: +48 22 738 18 00– service: +48 22 738 18 46Fax: +48 22 758 87 35– service: +48 22 738 18 42

Poland – Polen

Bosch Rexroth Sp.zo.o.Biuro Poznanul. Dabrowskiego 81/8560-529 PoznanTel.: +48 061 847 64 62 /-63Fax: +48 061 847 64 02

Romania - Rumänien

East Electric S.R.L.Bdul Basarabia no.250, sector 373429 BucurestiTel./Fax:: +40 (0)21 255 35 07

+40 (0)21 255 77 13Fax: +40 (0)21 725 61 21 [email protected]

Romania - Rumänien

Bosch Rexroth Sp.zo.o.Str. Drobety nr. 4-10, app. 1470258 Bucuresti, Sector 2Tel.: +40 (0)1 210 48 25

+40 (0)1 210 29 50Fax: +40 (0)1 210 29 52

Russia - Russland

Bosch Rexroth OOOWjatskaja ul. 27/15127015 MoskauTel.: +7-095-785 74 78

+7-095 785 74 79Fax: +7 095 785 74 77 [email protected]

Russia - Russland

ELMIS10, Internationalnaya246640 Gomel, BelarusTel.: +375/ 232 53 42 70

+375/ 232 53 21 69Fax: +375/ 232 53 37 69 [email protected]

Turkey - Türkei

Bosch Rexroth OtomasyonSan & Tic. A..S.Fevzi Cakmak Cad No. 334630 Sefaköy Istanbul

Tel.: +90 212 413 34 00Fax: +90 212 413 34 17 www.boschrexroth.com.tr

Turkey - Türkei

Servo Kontrol Ltd. Sti.Perpa Ticaret Merkezi B BlokKat: 11 No: 160980270 Okmeydani-Istanbul

Tel: +90 212 320 30 80Fax: +90 212 320 30 81 [email protected] www.servokontrol.com

Slowenia - Slowenien

DOMELOtoki 2164 228 Zelezniki

Tel.: +386 5 5117 152Fax: +386 5 5117 225 [email protected]



Africa, Asia, Australia – incl. Pacific Rim

Australia - Australien

AIMS - Australian IndustrialMachinery Services Pty. Ltd.28 Westside DriveLaverton North Vic 3026Melbourne

Tel.: +61 3 93 14 3321Fax: +61 3 93 14 3329Hotlines: +61 3 93 14 3321

+61 4 19 369 195 [email protected]

Australia - Australien

Bosch Rexroth Pty. Ltd.No. 7, Endeavour WayBraeside Victoria, 31 95Melbourne

Tel.: +61 3 95 80 39 33Fax: +61 3 95 80 17 33 [email protected]

China

Shanghai Bosch RexrothHydraulics & Automation Ltd.Waigaoqiao, Free Trade ZoneNo.122, Fu Te Dong Yi RoadShanghai 200131 - P.R.China

Tel.: +86 21 58 66 30 30Fax: +86 21 58 66 55 [email protected][email protected]

China

Shanghai Bosch RexrothHydraulics & Automation Ltd.4/f, Marine TowerNo.1, Pudong AvenueShanghai 200120 - P.R.China

Tel: +86 21 68 86 15 88Fax: +86 21 58 40 65 77

China

Bosch Rexroth China Ltd.15/F China World Trade Center1, Jianguomenwai AvenueBeijing 100004, P.R.China

Tel.: +86 10 65 05 03 80Fax: +86 10 65 05 03 79

China

Bosch Rexroth China Ltd.Guangzhou Repres. OfficeRoom 1014-1016, Metro Plaza,Tian He District, 183 Tian He Bei RdGuangzhou 510075, P.R.China

Tel.: +86 20 8755-0030+86 20 8755-0011

Fax: +86 20 8755-2387

China

Bosch Rexroth (China) Ltd.A-5F., 123 Lian Shan StreetSha He Kou DistrictDalian 116 023, P.R.China

Tel.: +86 411 46 78 930Fax: +86 411 46 78 932

China

Melchers GmbHBRC-SE, Tightening & Press-fit13 Floor Est Ocean CentreNo.588 Yanan Rd. East65 Yanan Rd. WestShanghai 200001

Tel.: +86 21 6352 8848Fax: +86 21 6351 3138

Hongkong

Bosch Rexroth (China) Ltd.6th Floor,Yeung Yiu Chung No.6 Ind Bldg.19 Cheung Shun StreetCheung Sha Wan,Kowloon, Hongkong

Tel.: +852 22 62 51 00Fax: +852 27 41 33 44

[email protected]

India - Indien

Bosch Rexroth (India) Ltd.Electric Drives & ControlsPlot. No.96, Phase IIIPeenya Industrial AreaBangalore – 560058

Tel.: +91 80 51 17 0-211...-218Fax: +91 80 83 94 345

+91 80 83 97 374

[email protected]

India - Indien

Bosch Rexroth (India) Ltd.Electric Drives & ControlsAdvance House, II FloorArk Industrial CompoundNarol Naka, Makwana RoadAndheri (East), Mumbai - 400 059

Tel.: +91 22 28 56 32 90+91 22 28 56 33 18

Fax: +91 22 28 56 32 93

[email protected]

India - Indien

Bosch Rexroth (India) Ltd.S-10, Green Park ExtensionNew Delhi – 110016

Tel.: +91 11 26 56 65 25+91 11 26 56 65 27

Fax: +91 11 26 56 68 87

[email protected]

Indonesia - Indonesien

PT. Bosch RexrothBuilding # 202, CilandakCommercial EstateJl. Cilandak KKO, Jakarta 12560

Tel.: +62 21 7891169 (5 lines)Fax: +62 21 7891170 - [email protected]

Japan

Bosch Rexroth Automation Corp.Service Center JapanYutakagaoka 1810, Meito-ku,NAGOYA 465-0035, Japan

Tel.: +81 52 777 88 41+81 52 777 88 53+81 52 777 88 79

Fax: +81 52 777 89 01

Japan

Bosch Rexroth Automation Corp.Electric Drives & Controls2F, I.R. BuildingNakamachidai 4-26-44, Tsuzuki-kuYOKOHAMA 224-0041, Japan

Tel.: +81 45 942 72 10Fax: +81 45 942 03 41

Korea

Bosch Rexroth-Korea Ltd.Electric Drives and ControlsBongwoo Bldg. 7FL, 31-7, 1GaJangchoong-dong, Jung-guSeoul, 100-391

Tel.: +82 234 061 813Fax: +82 222 641 295

Korea

Bosch Rexroth-Korea Ltd.1515-14 Dadae-Dong, Saha-guElectric Drives & ControlsPusan Metropolitan City, 604-050

Tel.: +82 51 26 00 741Fax: +82 51 26 00 747 [email protected]

Malaysia

Bosch Rexroth Sdn.Bhd.11, Jalan U8/82, Seksyen U840150 Shah AlamSelangor, Malaysia

Tel.: +60 3 78 44 80 00Fax: +60 3 78 45 48 00 [email protected] [email protected]

Singapore - Singapur

Bosch Rexroth Pte Ltd15D Tuas RoadSingapore 638520

Tel.: +65 68 61 87 33Fax: +65 68 61 18 25 sanjay.nemade

@boschrexroth.com.sg

South Africa - Südafrika

TECTRA Automation (Pty) Ltd.71 Watt Street, MeadowdaleEdenvale 1609

Tel.: +27 11 971 94 00Fax: +27 11 971 94 40Hotline: +27 82 903 29 23 [email protected]

Taiwan

Bosch Rexroth Co., Ltd.Taichung Branch1F., No. 29, Fu-Ann 5th Street,Xi-Tun Area, Taichung CityTaiwan, R.O.C.

Tel : +886 - 4 -23580400Fax: +886 - 4 -23580402 [email protected] [email protected]

Taiwan

Bosch Rexroth Co., Ltd.Tainan BranchNo. 17, Alley 24, Lane 737Chung Cheng N.Rd. YungkangTainan Hsien, Taiwan, R.O.C.

Tel : +886 - 6 –253 6565Fax: +886 - 6 –253 4754 [email protected]

Thailand

NC Advance Technology Co. Ltd.59/76 Moo 9Ramintra road 34Tharang, Bangkhen,Bangkok 10230

Tel.: +66 2 943 70 62 +66 2 943 71 21Fax: +66 2 509 23 62Hotline +66 1 984 61 52 [email protected]



Nordamerika – North AmericaUSAHeadquarters - Hauptniederlassung

Bosch Rexroth CorporationElectric Drives & Controls5150 Prairie Stone ParkwayHoffman Estates, IL 60192-3707

Tel.: +1 847 6 45 36 00Fax: +1 847 6 45 62 [email protected] [email protected]

USA Central Region - Mitte

Bosch Rexroth CorporationElectric Drives & ControlsCentral Region Technical Center1701 Harmon RoadAuburn Hills, MI 48326

Tel.: +1 248 3 93 33 30Fax: +1 248 3 93 29 06

USA Southeast Region - Südwest

Bosch Rexroth CorporationElectric Drives & ControlsSoutheastern Technical Center3625 Swiftwater Park DriveSuwanee, Georgia 30124

Tel.: +1 770 9 32 32 00Fax: +1 770 9 32 19 03

USA SERVICE-HOTLINE

- 7 days x 24hrs -

+1-800-REX-ROTH+1 800 739 7684

USA East Region – Ost

Bosch Rexroth CorporationElectric Drives & ControlsCharlotte Regional Sales Office14001 South Lakes DriveCharlotte, North Carolina 28273

Tel.: +1 704 5 83 97 62+1 704 5 83 14 86

USA Northeast Region – Nordost

Bosch Rexroth CorporationElectric Drives & ControlsNortheastern Technical Center99 Rainbow RoadEast Granby, Connecticut 06026

Tel.: +1 860 8 44 83 77Fax: +1 860 8 44 85 95

USA West Region – West

Bosch Rexroth Corporation7901 Stoneridge Drive, Suite 220Pleasant Hill, California 94588

Tel.: +1 925 227 10 84Fax: +1 925 227 10 81

Canada East - Kanada Ost

Bosch Rexroth Canada CorporationBurlington Division3426 Mainway DriveBurlington, OntarioCanada L7M 1A8

Tel.: +1 905 335 5511Fax: +1 905 335 4184Hotline: +1 905 335 5511 [email protected]

Canada West - Kanada West

Bosch Rexroth Canada Corporation5345 Goring St.Burnaby, British ColumbiaCanada V7J 1R1

Tel. +1 604 205 5777Fax +1 604 205 6944Hotline: +1 604 205 5777 [email protected]

Mexico

Bosch Rexroth Mexico S.A. de C.V.Calle Neptuno 72Unidad Ind. Vallejo07700 Mexico, D.F.

Tel.: +52 55 57 54 17 11Fax: +52 55 57 54 50 [email protected]

Mexico

Bosch Rexroth S.A. de C.V.Calle Argentina No 3913Fracc. las Torres64930 Monterrey, N.L.

Tel.: +52 81 83 65 22 53+52 81 83 65 89 11+52 81 83 49 80 91

Fax: +52 81 83 65 52 [email protected]

Südamerika – South AmericaArgentina - Argentinien

Bosch Rexroth S.A.I.C."The Drive & Control Company"Rosario 2302B1606DLD CarapachayProvincia de Buenos Aires

Tel.: +54 11 4756 01 40+54 11 4756 02 40+54 11 4756 03 40+54 11 4756 04 40

Fax: +54 11 4756 01 36+54 11 4721 91 53

[email protected]

Argentina - Argentinien

NAKASEServicio Tecnico CNCCalle 49, No. 5764/66B1653AOX Villa BalesterProvincia de Buenos Aires

Tel.: +54 11 4768 36 43Fax: +54 11 4768 24 13Hotline: +54 11 155 307 6781 [email protected] [email protected] [email protected] (Service)

Brazil - Brasilien

Bosch Rexroth Ltda.Av. Tégula, 888Ponte Alta, Atibaia SPCEP 12942-440

Tel.: +55 11 4414 56 92+55 11 4414 56 84

Fax sales: +55 11 4414 57 07Fax serv.: +55 11 4414 56 86 [email protected]

Brazil - Brasilien

Bosch Rexroth Ltda.R. Dr.Humberto Pinheiro Vieira, 100Distrito Industrial [Caixa Postal 1273]89220-390 Joinville - SC

Tel./Fax: +55 47 473 58 33Mobil: +55 47 9974 6645 [email protected]

Columbia - Kolumbien

Reflutec de Colombia Ltda.Calle 37 No. 22-31Santafé de Bogotá, D.C.Colombia

Tel.: +57 1 368 82 67+57 1 368 02 59

Fax: +57 1 268 97 [email protected]@007mundo.com

Rexroth IndraDyn L Appendix 16-1


16 Appendix

16.1 Recommended suppliers of additional components

Length Measuring SystemDR. JOHANNES HEIDENHAIN GmbHDr.-Johannes-Heidenhain-Straße 5 • D-83301 TraunreutTel.: +49 (0) 8669 31 0Fax: +49 (0) 8669 50 61E-Mail: [email protected]: http://www.heidenhain.de/

Renishaw GmbHKarl-Benz Strasse 12 • D-72124 PliezhausenTel.: +49 (0) 712 797 960Fax: +49 (0) 712 788 237E-Mail: [email protected]: http://www.renishaw.com/encoder/

RexrothErnst-Sachs-Str. 90 • D-97419 SchweinfurtTel.: +49 (0) 9721 937 0Fax: +49 (0) 9721 937 350E-Mail: [email protected]: http://www.rexroth.com/rexrothstar

Linear GuideRexrothErnst-Sachs-Str. 90 • D-97419 SchweinfurtTel.: +49 (0) 9721 937 0Fax: +49 (0) 9721 937 350E-Mail: [email protected]: http://www.rexroth.com/rexrothstar

Energy Chainsigus GmbHSpicher Straße 1a • D-51147 KölnTel.: +49 (0) 2203 9649 0Fax: +49 (0) 2203 9649 222E-Mail: [email protected]: http://www.igus.de/

KABELSCHLEPP GMBHMarienborner Straße 75 • 57074 SiegenTel.: +49 (0) 271 5801 0Fax: +49 (0) 271 5801 220E-Mail: [email protected]: http://www.kabelschlepp.de/

16-2 Appendix Rexroth IndraDyn L


Heat-exchanger UnitSCHWÄMMLE GmbH & Co KGDieselstraße 12-14 • D-71546 AspachTel.: +49 (0) 7191 9242 0Fax: +49 (0) 7191 225 10E-Mail: [email protected]: http://www.schwaemmle-gmbh.de/

Universal Hydraulik GmbHSiemensstrasse 33 • D-61267 Neu-AnspachTel.: +49 (0) 6081 9418 0Fax: +49 (0) 6081 9602 20E-Mail:Internet: http://www.universalhydraulik.com/

Coolant AdditivesSee Fig. 9-27

Coolant TubesPolyflex AGDorfstasse 49 • CH-5430 WettingenTel.: +44 (0) 56-4241088Fax: +44 (0) 56-4241114E-Mail:Internet: http://www.polyflex.ch/

igus GmbHSpicher Straße 1a • D-51147 KölnTel.: +49 (0) 2203 9649 0Fax: +49 (0) 2203 9649 222E-Mail: [email protected]: http://www.igus.de/

RexrothPostfach 910762 • D-30427 HannoverTel.: +49 (0) 511 2136 0Fax: +49 (0) 511 2136 269E-Mail: [email protected]: http://www.rexroth.com/rexrothmecman

Axis Cover SystemMöller Werke GmbHMöller BalgKupferhammer • D-33649 BielefeldTel.: +49 (0) 521 4477 0Fax: +49 (0) 521 4477 333E-Mail: [email protected]: http://www.moellerflex.de/



HCR-Heinrich Cremer GmbHOppelner Str. 37 • D-41199 MönchengladbachTel.: +49 (0) 2166 964900Fax: +49 (0) 2166 609157E-Mail: [email protected]: http://www.hcr.de/

Gebr. HENNIG GmbHPostfach 1137 • 85729 IsmaningTel.: +49 (0) 89 96096 0Fax: +49 (0) 89 96096 120E-Mail: [email protected]: http://www.hennig-gmbh.de/

End Position Shock AbsorbersACE Stoßdämpfer GmbHPostfach 1510 • D-40740 LangenfeldHerzogstraße 28 • D-40764 LangenfeldTel.: +49 (0) 2173 92 26 10Fax: +49 (0) 2173 92 26 19E-Mail: [email protected]: http://www.ace-ace.de/

RexrothPostfach 910762 • D-30427 HannoverTel.: +49 (0) 511 2136 0Fax: +49 (0) 511 2136 269E-Mail: [email protected]: http://www.rexroth.com/rexrothmecman

Rhodius GmbHTreuchlinger Str. 23 • D-91781 WeißenburgTel.: +49 (0) 9141 919 0Fax: +49 (0) 9141 919 45E-Mail: [email protected]: http://www.rhodius.com/

Clamping Elements for Linear GuidewaysRexrothErnst-Sachs-Str. 90 • D-97419 SchweinfurtTel.: +49 (0) 9721 937 0Fax: +49 (0) 9721 937 350E-Mail: [email protected]: http://www.rexroth.com/rexrothstar

Metal Braid Shock Absorbers



External Mechanical BrakesKendrion Binder Magnete GmbHMönchweilerstr. 1 • D-78048 Villingen-SchwenningenTel.: +49 (0) 7721 877 455Fax: +49 (0) 7721 877 462E-Mail:Internet: http://www.binder-magnete.de/

Ortlinghaus-Werke GmbH

Kenkhauser Str. 125 • D-42929 Wermelskirchen

Tel.: +49 (0) 2196 85-0Fax: +49 (0) 2196 855-444E-Mail: [email protected]: http://www.ortlinghaus.com/

Weight Compensation SystemsRoss Europa GmbHRobert-Bosch-Str. 2 • D-63225 LangenTel.: +49 (0) 6103 7597 0Fax: +49 (0) 6103 7469 40 E-Mail:Internet:

RexrothJahnstr. 3-5 • D-97816 Lohr am MainTel.: +49 (0) 9352 18 0Fax: +49 (0) 9352 18 2598E_Mail:Internet: http://www.rexroth.com/

WipersHunger DFE GmbHDichtungs- und Führungselemente

Alfred-Nobel Str. 26 • D-97080 WürzburgTel.: +49 (0) 931 900 97 0Fax: +49 (0) 931 900 97 30E-Mail: [email protected]: http://www.hunger-dichtungen.de/

HME DichtungssystemeRichthofenstr. 31 • D - 86343 KönigsbrunnTel.: +49 (0) 8231 9623 0Fax: +49 (0) 8231 865 16E-Mail: [email protected]: http://www.hme-seals.de/

Pneumatic

Hydraulic



16.2 Enquiry form for Linear Drives

Rexroth Indramat

Fax:

Contact person:

..............................................................

..............................................................

Date: ..........................

1. Information for the user

Company ..................................................... Name ...........................................................

Street ..................................................... Department ...........................................................

Zip Code ..................................................... Phone ...........................................................

Place ..................................................... Fax ...........................................................

Email ...........................................................

Requesting to: O Recall O Drive dimensioning O Offer O ..................................................

2. General information on use

Sector O Machine Tools O Automation O Packaging O Printing

O ........................................................................................................

Type of use ............................................................................................................

............................................................................................................

Designation of theAxis

............................................................................................................

Axis Grouping O Single axis O Grouping of ............ axis within the machine

O only linear drives O rotative and linear drives

Quantity ........................... per year

3. Mechanical and cinematic requirements

Installation position O Horizontal O Vertical O Slant, axis angle: ............degrees

Moved motorcomponent O Primary part moves O Secondary part moves

Moved mass ....................... kg (incl. guides, power feeders, etc.)

Maximum velocity ..................... m/min Maximum acceleration ....................... m/s²

Base force ....................... N (friction, energy supply, etc. )

Machining force ....................... N (detailed specifications see point 5)



4. Ambient conditions

Ambient temperature ....................... °C

Machined material O Steel / cast iron O Light metal O Plastic O Wood

O Other:......................................... O None(only handling)

Dirt and aggressive media O Chips O Dust

O Oil or lubricants: .........................................................................

O Other: .........................................................................................

Protection ofmotor components

O Bellows O Telescopic cover O Wiper on secondary

O Other:................................................................................................

5. Thermal conditions and cooling

Liquid cooling Coolant and additives: .............................................................................

Inlet temperature, minimum: .............°C maximum: ...............°C

Max. flow quantity: .........l/min Max. system pressure: .........bar

Maximum heating of the machine structure: ........... K O Not relevant

Maximum coolant temperature rise: ....................... K O Not relevant

Additional cooling at machine O Yes O No

O Air cooling, natural convection (Reducing the continuous forces to approximately 25 %)

6. Drive and Control

Drive series O ECODRIVE03 O DIAX04 O IndraDrive

Mainvoltage

O 1 x 230 V O 3 x 400 V O 3 x 480 V O ................................

Driveinterface /bus system

O SERCOS interface O ANALOG ±10V O Parallel interface

O Profibus O Interbus O CANopen O DeviceNet O PWM

O .....................................................................................................................

ControlO ..................................................:..................................................................

7. Linear scale

Measuring principleand interface

O absolut ENDAT

O incremental, sine signals 1 VSS

O incremental, sine signals 1 VSS, distance-encoded reference marks

Model O open O encapsulated O integradted in linearbuides

Positioning accurary ......................... µm



8. Motion profile

Specification ofmotion profile

O Not required, drive selection data exist (see 8.1)

O Strokes, positioning and idle times, maximum velocity and acceleration asspecified under item 3 (see 8.2)

O Sketch of velocity profile v(t) and process forces FP(t) (see 8.2 and 8.3)

O Operating phases and duty cycles (see 8.4)

O Equation of motion for s(t) and / or v(t) (see 8.5)

O s(t) and / or v(t) can ve specified in digital form: O MathCad O Excel O ASCII O ...........................

8.1 Data for motion selection exists:

Fmax: .............. N FEFF / FdN: .............. N vFmax: ............. m/min vmax: ............. m/min

8.2 Specification of strokes, position and idle times

Stroke Travel Positioning time Idle time Stroke Travel Positioning time Idle time

1 82 93 104 115 126 137 14

8.3 Sketch of velocity profile and process forces

wÉáí==áå=KKK KKK

wÉáí==áå=KKKKKK



8.4 Specification of operating phases and related duty cycle

EDi Force Fi

Acceleration, deceleration at .............m/s² ............. % .............. N

Acceleration, deceleration at .............m/s² and machining ............. % .............. N

Rapid traverse at v = constant = ............ m/min ............. % .............. N

Machining at v = ............ m/min ............. % .............. N

Standstill with machining ............. % .............. N

Standstill without machining ............. % .............. N

................................................................................ ............. % .............. N

Total: 100 %

8.5 Equation of motion for s(t) or v(t)

Equation of motion,

e.g.: )tsin(r)t(s ⋅ω⋅=

Explanation:

9. Miscellaneous/comments/sketches

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

Rexroth IndraDyn L Index 17-1


17 Index

AAir gap 9-19Appropriate use

Introduction 2-1Uses 2-2

Attractive forces 9-18Average velocity 5

BBraking Systems 9-53

CCommutation adjustment 14-9Connection cable 8-1Connection of DIAX04 and EcoDrive Drive-Controllers 8-8Connection of IndraDrive Drive Controller 8-6Connection of linear feedback devices 8-10Continuous Output 15Coolant temperature 9-28Cooling capacity 9-32, 17Customer’s receiving inspection 12-5

DDelivery status 12-2different motor/controller combinations 10-1Dimensions 5-1Duty cycle 13

EEnclosure surface 9-45

FFactory checks 12-5feed forces 3Flow quantity 9-30Frame length 3

GGantry Arrangement 9-16General construction 9-2General equations of motion 2General start-up procedure 14-4

HHolding Devices 9-53

IIdentification 12-1Inappropriate use 2-2

Consequences, Discharge of liability 2-1Installation 13-1Integrating the linear scale 9-8

17-2 Index Rexroth IndraDyn L


LLoad Rigidity

Dynamic load rigidity 9-65Static load rigidity 9-65

MMagnetic Fields 9-43Maintenance 14-21Mass reduction 9-7Maximum Acceleration Changes 9-61Maximum Output 16maximum system pressure 9-28Measuring principle 9-48Mechanical rigidity 9-7Mechanically linked axes 9-7Motor cooling

Coolants 9-26Standard encapsulation 9-24Thermal encapsulation 9-24Thermal time constant 9-22

Motor coolingPower loss 9-22

Motor cooling 9-22Motor Design 9-2Mounting 13-1Mounting Sizes

size 070 5-6size 100 5-9size 140 5-12size 200 5-15size 300 5-18

Mounting Sizes 5-3size 040 5-3

NNatural frequencies 9-7Noise emission 9-45

Oon axis cover system 9-55Operation without liquid cooling 9-29

PPackaging 12-2parallel arrangement 9-10Parameter settings 14-18Performance Overview 2pH-value coolant 9-27Position and Velocity Resolution 9-63Pressure drop 9-29, 9-31Protection class 9-42

RReactive forces 9-8Reduced overlapping 9-20Regeneration energy 17

SSafety Instructions for Electric Drives and Controls 3-1Sensors temperature measurement external 9-38

Rexroth IndraDyn L Index 17-3


Shock 9-44shock absorber 9-54Shutdown by a master control 9-59Shutdown by the drive 9-58Shutdown upon EMERGENCY STOP 9-58Shutdown via mechanical braking device 9-59single arrangement 9-9Sinusoidal velocity 11Sizing the cooling circuit 9-29Specifics for transporting 12-4Standard encapsulation 9-3Standards 4Storage 12-3Symmetry 5-2

TTemperature sensor motor protection 9-38Thermal encapsulation 9-3Tolerances 5-1Transportation 12-3Trapezoidal velocity 6Triangular velocity 10type code 1

UUse See appropriate use and inappropriate useUtilization factor 9-41

VVertical axes 9-17Vibration 9-44

WWeight compensation 9-17Winding 3Wipers 9-56

Bosch Rexroth AGElectric Drives and ControlsP.O. Box 13 5797803 Lohr, GermanyBgm.-Dr.-Nebel-Str. 297816 Lohr, GermanyPhone +49 (0)93 52-40-50 60Fax +49 (0)93 52-40-49 [email protected]

Printed in GermanyDOK-MOTOR*-MLF********-PR01-EN-PR911293635