technical product information no. 940 en ......ortlinghaus-werke gmbh tpi 940 en 3 about the product...

Edition: 02.2007

Technical Product Information No. 940 EN

Electromagnetically released linear brakeProduct line 801Energy-saving circuit 0085-698-04-001000

Contents

About this Technical Product Information (TPI) 2

The Ortlinghaus numbering system 2

About the product 3

General installation information: 4

Condition on delivery 5

Initial assembly and commissioning 6

Maintenance 8

Remedying malfunctions 9

Spare parts 10

Application / technical data 11

Energy-saving circuit (ESS) 13

Ortlinghaus-Werke GmbHPostfach 14 4042907 Wermelskirchen Kenkhauser Str. 12542929 WermelskirchenDeutschlandTel. +49 2196 85-0Fax +49 2196 855-444E-Mail [email protected] www.ortlinghaus.com

Ortlinghaus-Werke GmbH TPI 940 EN

2

About this Technical Product Information (TPI)

Who is this TPI directed at?This TPI is directed at qualified personnel who

are entrusted with the assembly, commissioning and operation of the product and whohave obtained the necessary qualifications by reading and understand-ing the instructions by training or instruction

It is intended forFitters at the manufacturer of the machine / plantMaintenance fitters at the machine users.

What will you find in the TPI?The TPI provides all the necessary information for the assembly and maintenance of the product described on the title page

Notes on the symbols used in the textOn the pages which follow, important sections of text are highlighted with the following symbols.

This symbol means:There is a risk of injury during the activity described or in operational running!

This symbol means:There is a risk of material damage during the activity described or in operational running!

This symbol indicates sections of text to which particular attention must be paid.

The Ortlinghaus numbering system

Example: 0 111 - 222 - 33 - 444 555

0 = Code for productsCode number for the model rageCode number for design featuresSizeSequence numberOther design features

Please pass on this product information to your customers! If required you can download our TPIs via the Internet from www.ortlinghaus.com in the directory ‚Service‘. However you may also duplicate the copy you have.

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3

About the product

Application for linear brakeThe Ortlinghaus linear brake is a holding and brake device for linear motor drives in clean environments (free from oil and grease).

The brake can support the holding load of the linear motor or assume the holding load in the absence of current. The brake forces are generated using a spring thus the brake assumes safety functions on switch-off or voltage loss.

A redundant brake system can be created using two parallel brakes.

Fig. 1: Structure of the linear brake

The linear brake comprises the brake module which is generally connected to the moved section of the drive (carriage, table) and a band tensioned at each end in special holders. The band runs parallel to the direction of movement of the drive. The two sides of the band form the frictional surfaces at which the friction linings of the brake module act.

The force to generate a frictionally engaged connection between the band and the brake module is applied by pressure springs and released again electromagnetically. Up to three brake modules may be positioned in sequence per band.

The holders are attached to the base plate of the drive or to the machine frame and also serve to align and pre-tension the band.

Brake module Strap Band

Current supply by use of SW4 screw for manual energy-saving circuit releasing of the brake

Holder B Holder A

Thread to keep the screw for manual releasing


4

General installation information:The Ortlinghaus linear brake is modular and thus permits adaption to various applications and mountings with few components:

Fig. 2: Examples

Brake module 0801-000-10-002000The brake module may be attached to the drive assembly to be held or braked at the side using a pivoted bracket.Attachment must permit access to the manual release screw. Each brake module is to be connected via the coil to one energy-saving circuit (observe conductor cross-section and max. cable length!). Care must be taken during assembly and operation that the brake linings are clean (free from oil and grease).

Band 0800-000-10-990000The band can be adapted to the stroke length required, i.e. shortened appropriately. After shortening, the drill hole ø12.5 mm must be placed to push through the attachment screw 7 (see Fig.4). The maximum stroke length of the drive including all the buffer distances for the end cushioning or other safety distances as well as the manner of attachment is to be taken into consideration in specifying the band length as well as the posi-tion of the holders. Damage to the band surface and plastic deformation must be avoided!Deformation from the condition at delivery is eliminated once the pre-tension is applied! (Coil) The band surface must be clean as well as free from oil and grease prior to contact with the brake module linings.

Holder 0800-000-10-0980000The holders for the band permit exact alignment of the band parallel to the direction of movement of the drive. The holders have adjustment screws 5 (see Fig.4) to align the band. These are to remain easily accessible.

Band

Motor

Brake moduleBracketLevelling piece


5

Condition on delivery

Brake module: The mechanical emergency release is activated, i.e. the emergency release screw is screwed in completely. Only loosen or remove this screw once assembly of the band and brake module have been completed!

The attachment screws M6 for the bracket are not tightened; they are only loosely pre-assembled! After brake module assembly and alignment, these screws are to be tightened at a torque Ma = 11 ...13 Nm.

Band: Length corresponding to delivery note or confirmation of order,coiled from 2000 mm (coil Ø approx. 600 mm).

Holder:The spring set (see Fig.4) is not tensioned.

Fig. 3: Determining the band length, position of attachment drill holes

C= Hub- + Modul- + Sicherheits- länge breite abstand

C + 127

15

51,5

1214

15

51,5

12 14

Minimum distance of brake module at end of travel

* The distance between holes A in the unten-sioned band is:

A= C+22 (the elastic extension of the band is to be taken into consideration).

C = stroke + width of + safety length module distance


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Initial assembly and commissioningThe linear brake, comprising brake module(s) and band with holders, is attached in four steps:

1. Pre-assembly of the brake band with the holders

2. Pre-assembly of the brake module

3. Final assembly of the brake band with fine adjustment

4. Final assembly of the brake module

Fig. 4: Holder for brake band

1. Pre-assembly of the band with holdersCheck band length, shorten if necessary and make drill holes 12.5 mm; see Fig. 3 for determining band length.Fix holder A with screws 6 , only tighten fingertight! Fix holder B (disk spring set is not tensioned!) with screws 6 , only tighten fingertight!Insert band, clamp with screws 7 , tightening torque MA = 125 Nm. Slightly pretension band with screw 8 , observe minimum distance 2.5 mm between holder 1 and shim 3 . Apply gauge, compensate major deviations by moving the holder. As soon as deviation is < 0.2 mm at the band ends at the clamping, tighten screws 6 with torque MA = 72 Nm.

2. Pre-assembly of the brake moduleThe standard bracket is positioned for attachment and is pre-assembled fingertight. Screw M5 for manual release must be tightened (condition on delivery). The screw must be accessible in the brake module attachment

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8 4 (12 x) 7 7 94 (2 x)

2 1 6 35 1 3 5 6

0,1 ... 0,2

Ma = 125 Nm

Ma = 72 Nm

2,5 min

Holder B Holder A


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position! Observe the position of the cable outlet of the coil! Clean and degrease the brake band using a suitable cleaning agent. Demount the brake band on one side. To do so, release screw 8 and re-move an attachment screw 7 . Loosen the second attachment screw. Lift the band out of the clamp slit and thread the the brake module onto the band in the correct direction. Remount the brake band and screws 7 and screw in 8 according to the pre-assembly of the band. Pre-assemble, attach and align the brake module with bracket at the position provided for (tighten screws fingertight).

3. Final assembly of the brake moduleFine adjustment of the parallelism of the band using screw 5, permissible deviation 0.05 mm at the band ends. To do so, first loosen one screw and tighten the opposite screw with MA = 11 Nm (gradually approach). The pre-assembly brake module is to be used as an aid to alignment by applying the band end to the brake lining at the pressure plate side and between film 0.05 - 0.1 mm during adjustment. Increase the band pre-tension by tightening the screw 8 until sleeve 2 shows a residual gap at the holder of 0.1 - 0.2 mm. Check the parallelism of the band over the entire stroke length (parallel-ism and residual waviness < 0.1 mm).

4. Final assembly of the brake moduleHold film 0.05 - 0.1 mm on the side of the pressure plate (the side away from the armature disk) between the band and friction lining and thus align the brake module parallel to the brake band.Remove film. Check that the friction linings have not contacted to the brake band at any point. If this has occurred, all the bracket screws are to be tighted with MA = 15 Nm and the bracket is to be pinned. Connect the brake module coil to the energy-saving circuit (ESS terminal 7 and 8). Connect ESS to suitable power supply (24 V DC) (terminal 3 to GND, terminal 4 to 24 V DC). Remove manual release screw, brake is activated with currentless coil. Retain the manual release screw by screwing it into the tapped hole in the holder bracket (see Fig. 1).

Caution! Do not tighten screw for manual release if the axes are inclined or vertical before the load has been safety supported or moved to the lower position. Danger of injury!

Completely remove the screw for manual release after complete loosening and tighten it into the tapped hole in the holder bracket (park).

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Activation, voltage supplyThe linear brake is spring-activated and electromagnetically released. Apply 24 V DC (terminal 3 (-) terminal 4 (+)) to the energy-saving circuit (ESS) to release the brake.

Electric activation of the energy-saving circuit:The motor must assume the load acting on the brake before the ESS is activated.Supply connection voltage to valve coil prior to start of motor movement (approx. 100 ms pilot actuation).The switching module voltage must be switched off on switching off or loss of motor voltage. Delay approx. 40 ms until complete braking force is achieved. If the brake is to assist or assume the holding force of the motor in posi-tioning operation, then the „position reached“ signal from the positioning control system is used to activate the brake. The brake holds the position reached without backlash. Loading results in elastic deformation of the brake module and band. The elastic defor-mation of the module is approx. 0.02 mm. The elastic deformation of the band depends on the length of the band, the position of the module on the band, the force acting on the module and the direction of force. For example, a band length of 1000 mm, a force of 700 N and central posi-tioning of the brake module result in a theoretical elastic deformation of 0.06 mm.However the actual and target values must correspond to prevent the motor working against the closed brake.

Maintenance

Checking during machine operationRegular monitoring of the holding force using the motor control system is recommended with high safety requirements e.g. with vertical axes with linear motor drive.If the holding force decreases, then the complete brake module is to be replaced and the brake band surface examined for the required minimum surface roughness (Ra = 1.5 - 2.5 µm corresponding to Rz ≈ 5 - 12 µm). If the brake band is too smooth, it must be replaced.

Check on wearThe armature disk air gap is to be determined at all four corners (feeler gauges) and the geometric mean established with activated brake. The value must be 0.4 mm; otherwise the brake module is to be replaced.

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Remedying malfunctions

Malfunction Cause Remedy

Holding force too low Friction linings worn (maximum permissi-ble wear reached)

Fit replacement mod-ule, examine brake band for smoothing of surface, replace if necessary (Ra = 1.5 - 2.5 µm)

Lubricants, dirt on brake band and friction linings

Clean band and degrease, fit replace-ment module

Contact between brake band and brake lining in released state

Brake band not par-allel to direction of movement

Align brake band parallel to movement, see initial assembly and commissioning

Brake blocks not par-allel to brake band

Align brake band parallel to movement, see initial assembly and commissioning

Brake module does not release

Power supply inter-rupted

Repair power supply

Defective coil winding Disconnect brake module from elec-tricity, measure coil resistance (approx. 8.3 Ohm at 20°C and 10.3 Ohm at 80°C) if measurement result deviates, replace brake module

Brake linings worn, thus large air gap

Measure air gap of armature disk at the four corners, deter-mine geometric mean; replace brake module if greater than 0.4 mm


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Ensure loads are secured during replacement work on vertical and inclined axes (brake module). Always move the unit to the lower position prior to commencing work!

Spare partsPlease state the serial number of the brake when ordering spare parts. The serial number is located on the outside of the brake module.

The serial number comprises a two-digit year number and a consecutive number, e.g. 00/12345. Please also state the linear brake article number if possible.

Please note that warranty claims are only recognised if original spare parts are used.

Fig. 5: Serial number

00/12345

Malfunction Cause Remedy

Brake module does not release

Coil too warm Measure tempera-ture of magnet body, switch currentless if above 60° C and ensure cooling. Sub-sequently operate with fewer releases per minute. Check the electrical operating parameters for con-formity to the manu-facturer‘s specifica-tions.


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Application / technical dataStatic holding force ≥ 700 NPick-up voltage 24 V DC (for max. 500 ms)Holding voltage 6 . . . 10 V DCPick-up current 2.5 AHolding current 0,6 . . . 1.0 A

We recommend energy-saving circuit 0085-698-04-0010000 to wire the brake.Dynamic braking is permissible is special cases. The graphs in the diagram show the maximum values for the respective application.

A check for wear must be performed after dynamic braking and the brake module is to be replaced once the wear limit is reached.

The resulting brake path and delay are to be taken into consideration.

Fig. 6: Permissible total carriage mass per module for emergency braking depending on slope and intial speed.

1 kg

10 kg

100 kg

1000 kg

011

0°

30°

60°

90°

Caution! Brake path at limit approx. 0.5 m

v in m/s

Total permissible mass

Slo

pe o

f lin

ear a

xis


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Drawing 080142,5

25

56,5

42,5

50

31

12,5 50

6 94

31

ø6,6

44 15

77,7

12,7

41

75

80

40

≥16,

8≥4

2,7

≥59,

5

1

20

63

M10

41

63

M10

100

15 12,5

Con

nect

ion

cabl

e

Mec

hani

cal e

mer

genc

y re

leas

e


13

24 V DC

F 4 8

3 7

Energy-saving circuit (ESS)

General descriptionThe fully electronic energy-saving circuit works on the principle of pulse-width modulation. This type of wiring only causes slight losses. The modulation frequency is approx. 16 kHz. The coil current is adjusted via the time-pause ratio.The energy-saving circuit is suitable for the simultaneous activation of two parallel-switched linear brakes 801 product line (see Fig. 7).

FunctionThe maximum current (corresponds to the input voltage of 24 V DC) is applied to the attached coil for approx. 300 ms to effect release of the brake. A clocked output signal is then switched to in order to prevent increased heating of the coil.

AdvantagesBrake energy requirement is reduced by approx. 90%.Greatly reduced heating of the coil.No additional supply requiredEasy assembly

Technical data:On-load voltage 24 V DC +/- 10%Residual ripple 10% (smoothed)Load current max. 4 AStarting current max. 6 A (400 ms per operation)Max. switching rate 12 operations / minMax. cable length betweenenergy-saving circuit - brake 20mAmbient temperature 0° - 40° C

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Fig. 7: Schematic circuit diagram

Energy-saving circuit (ESS)

Spring pressure brake(Linear brake 801)


14

107,5

75

22,5

Energy-saving circuit0085-698-04-001000

Caution! The energy-saving circuit output is not short-circuit-proof. A fuse protection (4 A / MT) is to be provided at the input.

Information for electrical connection:The energy-saving circuit is designed to activate electromagnetic brakes. It may only be operated with a voltage of 24 V DC. Direct voltage must be smoothed to a residual ripple of 10% (under load). The energy-saving circuit does not have a separate control input.

The ESS switches the voltage through to the coil as soon as it is applied.All cables are to have a minimum conductor cross-section of 1 mm² to prevent voltage loss.

The energy-saving circuit is intended for installation in a switch cabinet. It is attached using a mounting rail (TS 35). The ESS casing has two plugs which can be stripped to facilitate wiring. The maximum connectable conductor cross-section is 2.5 mm².

Drawing: 0085-698-04-001000

About this Technical Product Information (TPI)The Ortlinghaus numbering systemAbout the productGeneral installation information:Condition on deliveryInitial assembly and commissioningMaintenanceRemedying malfunctionsSpare partsApplication / technical dataEnergy-saving circuit (ESS)

technical product information no. 940 en ......ortlinghaus-werke gmbh tpi 940 en 3 about the product...

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