Linear Motion and Assembly Technologies X4 X3 X1 X2 X30 Indramat AC-CONTROLLER DANGER! High voltage Danger of electrical shock Do not touch electrical connnections for 5 minutes after switching power off. Read and follow Safety instructions for Electrical Drives´ manual DOK-GENERAL-DRIVE******* SVS before operating S2 S3 S1 8.8 X8 RE 82 430/2001-01 STAR – Linear Modules MKL closed type
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Linear Motion andAssembly Technologies
X4
12
34
56
12
39
10
11
4 12
5 13
6 14
7 15
8 16
X3
X1
X2
X30
Indramat
AC-CONTROLLER
DANGER!
High voltageDanger of electrical shock
Do not touch electrical connnections for
5 minutes after switching power off.
Read and follow Safety instructions for
Electrical Drives´ manual
DOK-GENERAL-DRIVE******* SVS
before operating
S2
S3
S1
8.8
X8
RE 82 430/2001-01
STAR – Linear Modules MKLclosed type
RE 82 430/2001-012
STAR – Linear Motion Technology
Ball Rail Systems Standard Ball Rail Systems
Ball Rail Systems with Aluminum Runner Blocks
Super Ball Rail Systems
Wide Ball Rail Systems
Accessories
Miniature Ball Rail Systems
Cam Roller Guides
Roller Rail Systems
Linear Bushings and Shafts Linear Bushings
Linear Sets
Shafts
Shaft Support Rails
Shaft Support Blocks
Ball Transfer Units
Other Engineering Components
Screw Drives
Linear Motion Systems Linear Motion Slides • Ball Screw Drive• Toothed Belt Drive
Linear Modules • Linear Motor
• Toothed Belt Drive• Rack and Pinion Drive• Pneumatic Drive• Ball Screw Drive
Compact Modules • Ball Screw Drive
Precision Modules • Ball Screw Drive
Ball Rail Tables • Ball Screw Drive• Linear Motor
ALU-STAR Profile System
Controllers, Motors, Electrical Accessories
Linear Actuators
RE 82 430/2001-01 3
Linear Modules MKL, closed type
Product Overview 4The Drive Unit 6
The Control System 7
Type Designation with Load Capacities 8
Technical Data 10
Linear Module MKL 20-110, closed type 16Components and Ordering Data 14
Dimension Drawings 16
Linear Encoder 18
Power Cable Chain 19
Switch Mounting 20
Mounting Instructions 22
Documentation 24
4 RE 82 430/2001-01
STAR – Linear Modules MKL, closed type
X4
12
34
56
12
39
10
11
4 12
5 13
6 14
7 15
8 16
X3
X1
X2
X30
Indramat
AC-CONTROLLER
DANGER!
High voltageDanger of electrical shock
Do not touch electrical connnections for
5 minutes after switching power off.
Read and follow Safety instructions for
Electrical Drives´ manual
DOK-GENERAL-DRIVE******* SVS
before operating
S2
S3
S1
8.8
X8
Linear Modules MKL will help you to solve linear motion tasks rapidly andcost-effectively in a wide variety of different applications – from simplesingle-axis systems to complex multi-axis configurations for horizontaloperation.
The combination of synchronous linear motor, ball rail system and carriagesubstantially reduces the complexity of mechanical structures usuallyneeded for a linear motion axis.
The system is controlled via a standard servo controller DKC**.3.
This controller is available with
– analog, stepping motor, and positioning interfaces
or
– SERCOS interface
or
– fieldbus interfaces.
As an option, linear modules MKL can besupplied with an incremental linear encoder.
Product Overview
Cost savings throughshorter cycle times
Take the direct route to success:our Linear Modules with Linear Motor!
Application examples:(preferably for horizontal operation)
– Factory automation systems
– Medical and biomedical equipment
– Scanning and printing systems
– Electronics and the packaging industry
Not suitable for machining of ferrous materials.
Supplied as a complete “plug inand go” linear module withmatching servo amplifier
Mounting instructions: See RDEFI 82 476(in preparation)
Convenient Drive Topstart-up software
Control signals via astandard servo controller
Fan-cooled motor
5RE 82 430/2001-01
Linear Module MKL
Silent operation
Thrust generated directlyat the payload
High positional accuracyand repeatability
Ball rail system unaffected bymagnetic forces
One-point lubrication forball rail system
High speed range,high dynamic response
Constant thrust evenat low speed
Rapid implementation
6 RE 82 430/2001-01
STAR – Linear Modules MKL, closed type
Motor windingThrust rod housingpermanent magnets
CarriageThrust rodmagnetic field
Current directionproduced by motorwinding
Direction of thrustalong the thrust rod
Product Overview
Basic principleThe key mechanical components of LinearModules MKL are the “carriage” (primarypart) and the permanently magnetized“thrust rod” (secondary part). A Ball RailSystem supports and guides the carriageand its payload. The result is a remarkablysimple mechanical arrangement.
The Drive Unit
Easy to install and use
Complete linear unit. No need to sourceindividual components.
Commutation is determined via Hall effectsensors during the cut-in stage.Consequently there is no need for a com-mutation cycle and the reference cycle canbe initiated immediately after powering up.
High speed range
Unbroken linear thrust over the entirespeed range.
The advantagesPermits higher load cycle rates
Excellent heat dissipation.
Maintenance free
No internal moving parts, no wear andno motor maintenance.
Only the Ball Rail System requires main-tenance.
Precise motion and high dynamicresponse for life
Thrust generated directly at the payload.All motor forces are in the direction oftravel only.No need for rotary to linear conversionmechanisms, no gears and thus no back-lash. Non critical alignment.
Ultra low EMI generation
3-phase primary part with low inductance.No open coils.
The carriage and the thrust rod do notcome into contact with each other, theweight of the payload being transmittedto the Ball Rail System only.
Unlike rotary drive systems, the linearmotor comprises no moving parts and isconsequently wear and maintenance free.
The drive system is therefore ideal for 24-hour operation. It also eliminates the needfor additional rotary to linear conversionmechanisms. Because there is no backlash,positional repeatability is outstanding andis maintained for life.
Danger for people with pacemakers!The drive unit generates strong magneticfields (even when switched off!) whichcan under certain circumstances affectthe functioning of pacemakers.This could cause health problems. Wetherefore advise people with pacemakersto keep clear of the drive unit. We alsorecommend to mark hazard zones witha warning sign .
Safety Notes
Risk of injury or damage to the driveunit through improper handling or non-specialist installation!• Mounting or dismounting only by
expert personnel and using suitabletools. Please note that the use offerromagnetic materials can giverise to extremely high forces ofattraction. Wrong handling couldresult in crushed hands or limbs.
• Provide additional external hydraulicshock absorbers in the end positions.
Interference with on-board electronicsystems in transportation (e.g. aircraft)due to strong magnetic fields! It istherefore vital to observe the relevantrules and regulations when transportingdrive units.
Warning Caution Caution
7RE 82 430/2001-01
Linear Module MKL Servo controller DKC Control system, e.g. CLM
Basic principle
Interface
The following interfaces are available forthe DKC servo controller:
DKC 11.3/DKC 01.3• Analog interface• With stepping motor interface• With positioning interface
for 64 positions
DKC 02.3• With SERCOS interface
DKC 03.3• With PROFIBUS-DP interface
for 64 positions
DKC 04.3• With INTERBUS interface
for 64 positions
DKC 05.3• With CANopen interface
for 64 positions
DKC 06.3• With DeviceNET interface
for64 positions
The advantages
The Control SystemRexroth Star offers a matching servocontroller for the Linear Module MKL.This powers the linear motor as well asconstituting the interface to a mastercontrol system.
An incremental linear encoder systemintegrated in the mechanical structuresignals the carriage’s actual position tothe control system position loop.
Optional: Incremental linear encoder
Ready for connection to the linear measur-ing inputs in your control unit.
Matching servo controller DKC**.3
Designed for easy connection to max.230V and easy installation.Diagnostic interface as standard.Convenient Drive Top start-up software.
Motor signal
Position feedback signal
Control signal
Linear encoder
End block Carriage Thrust rod
Linear
guideway
8 RE 82 430/2001-01
STAR – Linear Modules MKL, closed type
Product OverviewType designation (size)Linear Modules are designated accordingto type and size.
M K L 20 – 110
Type Guideway Drive Unit Linear Module
STAR –Linear Modules MKL
Ball RailSystem Linear Motor
Linear Module MKL (example) =
System = Linear module, closed type (M)
Guideway = Ball Rail System (K)
Drive unit = Linear motor (L)
Dimensionsof guideway =
Framedimensions =
Type Size
9RE 82 430/2001-01
Linear module overviewwith permissible loads
Suitable load Linear Modules MKL are particularly suit-able for highly dynamic positioning oflight, evenly distributed loads. Especiallyin manufacturing chains they can usuallyreduce cycle times and therefore consid-
A
C
C
C
C
H
Linear Module Dimensions A x H
(mm)
- Dyn. load capacity C
(N)
110 x 129MKL 20 - 110
Max. thrust
(N)
erably increase productivity. In contrast toplanar linear actuators, this system offersthe special advantage that the rail systemis not subjected to additional magneticloads.
Application conditions Preferably for horizontal operation
990 30540
10 RE 82 430/2001-01
STAR – Linear Modules MKL, closed type
General technical data
The dynamic load capacities and momentsare based on 100,000 m travel.
However, a travel of just 50,000 m is oftentaken as a basis.
If this is the case, for comparisonpurposes:
Multiply values C, Mt and ML from theSTAR table by 1.26.
For controller and servo amplifier see catalog “Controllers, Motors, Electrical Accessories”1) Specify length of cable set in increments of 0.5 m measured from the cable exit on the frame,
Part number Type .... Guideway .. Drive unit .. Carriage ..(and dimension
drawing)1155-200-00, .... mm
Length of cable set .... mm1)
without drive unit (OA)
Part number1140-260-10
For data, see MKR 25-110/STAR – Linear Modules catalog
02 02
03 03
04 04
15RE 82 430/2001-01
Frictionaldrag
Posi-tioning
accuracy
02
05
Please check that the selected combination is a permissibleone (load capacities and moments, motor data, etc.)!
2) Supplied unmounted along with the module3) The cover is mandatory4) To power the fan, the socket and plug must be mounted at the same end of the module (cable length approx. 250 mm)
Calculating the linear module length LLength L = (stroke + 2 · excess travel) + carriage length LT + 170 mm
See dimension drawing for effective stroke,excess travel, carriage length LT.
If the linear module is to operate reliably,the excess travel must be greater than thebraking distance.
The braking distance can be assumed tobe equal to the acceleration distance.
Power input Cover .. 3) Linear encoder .. 1st, 2nd switch .. Documentation ..cable ..
with Socket/plug .. Standard Measure- sealing Switching cam .. report ment
strip Cable duct .. report
We recommend that customers mountshock absorbers at the mass center ofgravity to reduce excess travel.
without 00
Switches2):
PNP NC 11
PNP NO 13
Mechanical switch 15
Cable duct2) Length = L 20
Socket/plug4) 17
Switching cam 16
without 00
with 01
01
without 00
magnetic 01
16 RE 82 430/2001-01
STAR – Linear Modules MKL, closed type
L/2
LT35 35
L20
35 35
5
20 57
1515
Dimension Drawings
Lube nippleDIN3405 AM6
Cable exit
Max. travel2
Max. travel2
Effective stroke2
Effective stroke2
11.25.10 11.25.11
Standard mountingType MA01
Overhead mountingType MA02
Cable exit at back
Cable exit at back
Excess
travel
Excess
travel
17RE 82 430/2001-01
For mounting of power cable chain, see chapter “Power Cable Chain”
11.25.12 11.25.13
Cable exit at back
Cable exit at back
B
8.2
5.2
4.8
2.5
A
8
14.5
4.9
12
6.2
B
85
129
110
60
4120
25
A
A
85
110
32
approx. 250 mm
Left-hand mountingType MA03
Right-hand mountingType MA04
18 RE 82 430/2001-01
STAR – Linear Modules MKL, closed type
Linear Encoders, incremental
A
B
ø 5
≈33
LS100-XXXX
XX XXXX
C
B
A: Magnetized strip MB 100
Width 5 mm
Pole spacing 1 mm
Temperature coefficient (11±1) x 10-6 / K
Operating temperature -20°C to +70°C
Accuracy (measuring system only) (±0.01 + 0.01 x L) mm
[L in m]; at Tamb = 20°C
Reference mark none
C: Plug with amplifier electronics
Power supply 5±5% V DC
Output signals analog sine/cosine similar
Amplitude/level typically 1Vpp (load independent) – differential,
with connection resistance R = 120 Ω to 1 kΩtolerance 10% (±0.1 V)
Amplitude ratio ±10% (±0.1 V)sine/cosine
Offset sine/cosine ±0.5% (±5 mV)
El. connection DSUB connector, 15 pins, female
Immunity class 3, to IEC 801
Certification CE
Signal period 1000 µm
Travel speed max. 50 m/s
Reversal range U, to VDI 3441 20 µm(repeatability)
Working temperature of connector 0°C to +60°C
The total system accuracy of LinearModule MKL is influenced by the
linear encoder system, by the reproduc-ibility of the reference switch, by thestraightness of the frame, and by themounting base.
B: Magnetic sensor Type A
Operating temperature -20°C to +70°C
Protection IP 67
Cable length equal to length of motor cable (max. 18 m)
Storage temperature -20°C to +85°C
Air humidity 100% dewing permissible
Protection of housing IP 67
Type of cable PUR (polyurethane), oil-resistant
Vibration resistance [5...2000 Hz] 20 g
Shock resistance 200 g at 11 ms
19RE 82 430/2001-01
Power Cable Chain
The power cable chain is firmly secured tothe carriage by means of an angle bracket.For ease of alignment this bracket can beslid along the frame when the set screwshave been loosened.
Required mounting space
In the case of cantilever mounting of thepower cable chain, “pre-tensioning” re-sults in a cambered top half of the chainloop (1). Dimension HF indicates therequired mounting height necessitatedby this pre-tensioning. The pre-tensioningallows for greater cantilever lengths andincreases service life and operationalreliability.
The power cable chains are suitable forcantilever operation.If however the bottom half of the chainloop (2) rests upon a supporting surface,this surface has to be completely smooth(no webs).
In dirty environments, make sure that nodirt accumulates in the path of the powercable chain.
70
24
36
5
96
7
110
129
148 16
8
12
HF =
R48
20 RE 82 430/2001-01
STAR – Linear Modules MKL, closed type
Switching system overview1 Socket/plug
2 Proximity switches(with mounting accessories)
2a Reference switch/proximity switch
3 Cable duct (aluminum alloy)
4 Switching cam
SwitchesMounting instructions:
The switches are supplied loose.
Switches may only be mounted on oneside of the linear module (opposite thepower input cable). Do not mount theswitches until the linear module hasbeen fixed to its base.
Insert the plate-mounted switches in theT-slots in the frame and fix them with twoset screws.
Adjust the switching gap from 0.1to 0.2 mm on mounting.
0.1+
0.1
20
Switch Mounting
30
1710
50
22
19
29 7.5
Cabl
e le
ngth
: 3 m
Proximity switch with mounting plate
2
2a3
4
2
1
Miniature switch with potted cable(3 x 0.14 mm2 Unitronic)Switch housing type = NOMini sensor = Type A DIN 41635Operating voltage = 10 to 30 V DCResidual ripple factor = ≤ 10%Load = 200 mAIdling current = ≤ 20 mASwitching frequency = max. 1500 HzTemperature sensitivityof cut-in point = ≤ 4 µm/KSlope ofoutput signal = ≥ 1V/µs
Reproducibility ofcut-in point to EN 50008 = ≤ 0.1 mm
Proximity switch (technical data)
21RE 82 430/2001-01
50 30
35
12.6
PG 1
6
51
Cable duct– Clip the duct into the T-slot in the
frame and fix it in place with mount-ing screws.
– Mounting screws and cable grommetsare provided.
17
20
16-pin plug
Socket and plug– Fix the socket to the side with the
switches.
– To power the fan, the socket and plugmust be mounted at the same end ofthe module.
The socket and plug have 16 pins each.
The socket and switches are not wired.The switch activation points can thus beoptimized during start-up.
A plug is provided.
The plug can be mounted in only onedirection (see figure).
General informationWhen mounting the linear modules,observe the maximum tightening torquesas indicated in the table.
Mounting with clamping fixtures
Do not fix the linear module bythe end blocks!
The frame is the main stress-bearingstructure!Wherever possible, it has to be sup-ported along its entire length.
The flatness of the supporting surfacemust be of the required accuracy.
16.5
132±0.1
150 85
27.5
Part number
1175-290-26
9
1929
70 108
16.5
27.5
Tightening torques for mountingscrews
with friction factor 0.125strength class 8.8
8.8 M4 M5 M6 M8
Nm 2.7 5.5 9.5 23
Mounting with T-nuts
Recommended number of clampingfixtures:
3 per meter and side
23RE 82 430/2001-01
Part number
8447-001-01
Part number
0391-750-03
8
6 10
M6
13
13M6
8
106
209
(2x)
Part number
8442-003-01
13M8
4
Part numberM4: 8447-005-02M5: 8447-006-02M6: 8447-007-02
M
12
8
14 1
Mounting accessories forcarriage superstructure
T-nutsto DIN 508
Square nutsto DIN 562
Spring nutsFor light loads only
100
65
LT
Do not fix any attachments withinthis area.
24 RE 82 430/2001-01
STAR – Linear Modules MKL, closed type
Documentation
Positioning accuracyOption 05
to VDI/DGQ 3441
Measurement points are selected atirregular intervals along the travel. Thisallows even periodical deviations to bedetected during positioning.
Each measurement point is approachedseveral times from both sides.
This gives the following parameters:
Positioning accuracy P
The positioning accuracy corresponds tothe total deviation.
It encompasses all the systematic andrandom deviations during positioning.
The positioning accuracy takes thefollowing characteristic values intoconsideration:
– position deviation– reversal range– position variation range
Reversal range U
Position variation range PSPosition deviation Pa
The position deviation corresponds to themaximum difference arising in the meanvalues of all the measurement points. Itdescribes systematic deviations.
The reversal range corresponds to thedifference in mean values of the twoapproach directions. The reversal rangeis determined at every measurement point.It describes systematic deviations.
The position variation range describesthe effects of random deviations. It isdetermined at every measurement point.
Standard reportOption 01
The standard report serves to confirm thatthe checks listed in the report have beencarried out and that the measured valueslie within the permissible tolerances.
Checks listed in the standard report:
– functional checks of mechanicalcomponents
– functional checks of electricalcomponents
– design is in accordance with orderconfirmation
Frictional dragOption 02
The moment of friction is measured overthe entire travel range.
Devi
atio
n (µ
m)
Example
Set position (mm)
175 252.5 350 612.5 700
25
0
-25
-50
-75
-1000 87.5 437.5 525
P a
P
P /2
sU
P /2
s
25RE 82 430/2001-01
To be completed by customer: Inquiry / OrderLinear Module
(Part number): 1155 - 200 - 00, length ________________ mmLength of cable set = __________ mmType =
Great care has been taken during the compilation of thispublication to ensure all the information contained isaccurate. We accept no responsibility however for anydamage resulting from incorrect or incomplete infor-mation contained.
For deliveries and other services in the course of com-mercial business, the general terms and conditions forsupplies and services contained in the valid price listsand the confirmations of order apply.
As our products are constantly in the process of furtherdevelopment, they are subject to alteration withoutnotice.
STAR, Ball Rail and are trademarks registeredfor Rexroth Star GmbH, Germany.
Roller Rail is a trademark ofRexroth Star GmbH, Germany.
This publication or any part thereof may not bereproduced without our written permission.