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LAF050 - 121Linear Motors

DOK-MOTOR*-LAF********-AWP1-EN-P

Selection and Project Planning

mannesmannRexroth

engineering

Indramat266416

LSA Control S.L. www.lsa-control.com [email protected] (+34) 960 62 43 01

• DOK-MOTOR*-LAF********-AWP1-EN-E1,44 • 02.97 2

About this documentation

LAF050 - 121Linear motors

Selection and project planning

DOK-MOTOR*-LAF********-AWP1-EN-E1,44

• Mappe 16• LAF-AP.pdf• 209-0069-4387-00

This electronic document is based on the hardcopy document with documentdesig.: 209-0069-4387-00 EN/07.95

The purpose of this documentation is:

• Dimensioning of linear motors

• Selection of linear motors and related drive control units

• Clarification of technical data

• Mechanical integration of linear motor in machine

• Electrical integration of linear motor in machine

• Specification of ordering information for linear motor and its electricalconnection accessories

Titel

Type of documentation:

Documenttype

Internal file reference

Reference

This documentationis used:

© INDRAMAT GmbH, 1995Copying of this document, and giving it to others and the use or communicationof the contents thereof, are forbidden without express authority. Offenders areliable to the payment of damages.All rights are reserved in the event of the grant of a patent or the registrationof a utility model or design. (DIN 34-1)

The electronic documentation (E-doc) may be copied as often as needed ifsuch are to be used by the consumer for the purpose intended.

All rights reserved with respect to the content of this documentation and theavailability of the products.

INDRAMAT GmbH • Bgm.-Dr.-Nebel-Straße 2 • D-97816 LohrTelefon 0 93 52 / 40-0 • Tx 689421 • Fax 0 93 52 / 40-48 85

Dept ENA (BS, UW, FS)

Copyright

Validity

Publisher

Designation of documentation Release- Comentsup to present edition date

209-0069-4387-00 EN/07.95 Jul./95 First Edition

DOK-MOTOR*-LAF********-AWP1-EN-E1,44 Feb./97 First Edition E-Doc

Change procedures



Table of Contents

PageTable of Contents

1. Applications 7

2. General information 8

2.1. Operating principle ...........................................................................8

2.2. Design of linear motors ....................................................................8

2.3. Installation in machine .....................................................................9

2.4. Properties and characteristics..........................................................9

3. Integration of linear direct drives in control systems 11

3.1. General servo applications ............................................................ 113.1.1. ANALOG interface ......................................................................... 113.1.2. SERCOS interface .........................................................................12

3.2. Servo application with electronic synchronization .........................13

3.3. System configurations ....................................................................14

4. Dimensioning and selection of linear direct drives 15

4.1. Dimensioning .................................................................................15

4.2. Triangular speed curve ..................................................................164.2.1. Calculation equations for triangular speed curve ...........................174.2.2. Calculation example for triangular speed curve .............................19

4.3. Trapezoidal speed curve ................................................................214.3.1. Calculation equations for trapezoidal speed curve: .......................214.3.2. Calculation example for trapezoidal speed curve ..........................23

4.4. Sinusoidal speed curve ..................................................................254.4.1. Calculation equations for sinusoidal speed curve ..........................254.4.2. Calculation example for sinusoidal speed curve ............................27

4.5. Calculation during switch-on duration ............................................284.5.1. Calculation equations for given switch-on durations......................28

5. Selection lists 30

5.1. Explanations for selection lists .......................................................30

5.2. Selection lists .................................................................................33



Table of Contents

6. Combination possibilities for linearmotor, drive control unit and measuring system 37

7. Measuring systems 42

7.1. General information ........................................................................42

7.2. Selection ........................................................................................42

7.3. Transducer signal distribution for operation of several driveson one linear scale .........................................................................45

7.4. Transducer signal amplification for long cable lengths ..................46

8. Design information 47

8.1. Motor arrangement .........................................................................47

8.2. Basic mechanical conditions ..........................................................508.2.1. Machine kinematics ........................................................................508.2.2. Mechanical rigidity..........................................................................508.2.3. Motors arranged in parallel ............................................................518.2.4. Forces of attraction between primary and secondary part ............538.2.5. Seals ..............................................................................................54

8.3. Installation dimensions and production tolerances ........................55

8.4. Guides ............................................................................................56

8.5. Length measuring system ..............................................................568.5.1. Attaching length measuring system ...............................................568.5.2. Reference switch and reference cam ............................................588.5.3. Minimum distance from end windings ............................................58

8.6. Vertical axes ...................................................................................59

8.7. Motor cooling..................................................................................598.7.1. General information ........................................................................598.7.2. Cooling plates ................................................................................60

8.8. Behavior in case of EMERGENCY-STOP ......................................618.8.1. EMERGENCY-STOP due to drive error .........................................618.8.2. EMERGENCY-STOP due to machine-dependent error .................63

8.9. Behavior in case of mains failure ...................................................64

8.10. Information on protection of personnel ..........................................65

8.11. Information on protection of machinery .........................................65

8.12. Set-up altitude and environmental conditions ................................66

8.13. Behavior of linear motors during operation ....................................66



Table of Contents

9. Technical data 67

9.1. Motor data ......................................................................................67

9.2. Installation drawing ........................................................................69

9.3. Dimension sheets for linear motor LAF 050 ..................................70



9.6. Electrical power connection ...........................................................79

9.7. Electrical connection of measuring system ....................................86

10. Product line 92

11. Assembly 96

11.1. Safety notes ...................................................................................96

11.2. Mounting of primary and secondary part on the machine..............97

11.3. Connecting electrical lines of primary part .....................................98

12. Storage, handling and transport 102

13. Shipped state 103

13.1. Shipping .......................................................................................103

13.2. Scope of delivery..........................................................................103

14. Product identification 105

15. Index 107



1. Applications

1. Applications

New technologies with high economic utility increasingly require numericallycontrolled movements with extremely demanding requirements for pathspeed and path precision.

These requirements can be met with linear direct drives. Particularly onmachine tools with limited load forces, such as laser machining, beam-cuttingand high-speed cutting machines, textile, packaging and thermal moldingmachines, considerable performance increases can be achieved compared tocommon NC drive technology characterized by mechanical transmissionelements.

Linear direct drives offer new solutions and clearly improved performancedata by combining asynchronous linear motors with digital, intelligent drivecontrol units with the use of a SERCOS interface as the interface to thecontroller.



2. General information


Linear direct drives consist of:

• LAF asynchronous linear motors

• digital, intelligent drive control units

• measuring systems and

• guides

2.1. Operating principleLAF asynchronous linear motors are created by unfolding a rotary asynchro-nous motor. The basic characteristics of the LAF motor largely correspond tothose of a rotary asynchronous motor. As a result, the drive control units, whichhave been proven on rotary drives in numerous applications, are used for theiractivation and control.

2.2. Design of linear motors

LAF asynchronous linear motors are modular motors. The motor consists ofa primary part with a 3-phase a.c. winding and a secondary part with a squirrel-cage winding. The primary and secondary parts are supplied as separate partsand integrated in the machine design by the machine manufacturer.

The primary part has fixed dimensions dependent on the size and is usuallyintegrated in the moving part of the machine. The total length of the secondarypart is dependent on the traverse distance. It is put together from a freelyselectable number of separate elements with a predefined length.

The optimal use of the LAF asynchronous linear motor requires liquid coolingof the primary and secondary parts. Appropriate cooling plates are availablefor this purpose. The cooling plates can be supplied as part of the motor orseparately.

Fig. 2.1: Schematic design of an LAF asynchronous linear motor

EXLAF01

Cooling platefor primary part

Cooling platefor secondary part

Machine carriage

Primary part

Secondary part

Linear positionmeasuring system




2.3. Installation in machine

It is the task of the machine manufacturer to integrate the LAF asynchronouslinear motors in the machine. In addition to the LAF asynchronous linearmotors, measuring systems and guides must also be mounted. The advan-tages of a linear direct drive can only be ensured in operation with suitabledesign measures which take the interaction of the various separate compo-nents into consideration.

Fig. 2.2: Decisive influencing variables of a linear direct drive

2.4. Properties and characteristics

When LAF asynchronous linear motors are used, the mechanical transmis-sion elements used for common linear movements, such as ball screw drives,rack-and-pinion units, transmissions or clutches, are eliminated. This results,in conjunction with digital, intelligent drive control units and controllerscompatible to the SERCOS interface, in the following major advantages:

• high acceleration capacity with simultaneously high contour and positioningexactness due to the lack of mechanical transmission elements

• high control quality

• no transmission faults as the result of backlash on reversal and play in thedrive train

• good synchronous operation properties

• high load stiffness

• high operating reliability due to the lack of wearing components, i.e.,maintenance-free operation

• prevention of overload damage by monitoring the motor temperature withthe temperature sensor in the drive control unit integrated in the motorwinding

In contrast to conventional electro-mechanical drive systems, in which aspatial separation between the electric motor and the linearly moved part(support) is given, there is no spatial separation of the motor from the movingpart of the mechanical system in a linear direct drive.

FSLAF01

Linear direct drive

Mechanicaldesign

CNC control

LAF asyn-chronous

linear motor

Drive control unit

Advantages

Disadvantages




This results in the following disadvantages:

• The thermal losses occur directly in the motor, i.e., also within the machine.As a result, suitable motor cooling must be provided. To guarantee themaximum performance data, and thus particularly the maximum availablepower of the drive, and to ensure that no thermal energy is given off to theremaining machine elements, cooling plates are required for the primaryand secondary parts.

• The feed forces per motor are considerably lower than for comparable,conventional electro-mechanical systems.

An increase in the permanent, maximum power within a linear direct drive isachieved with

• a parallel arrangement or

• a series arrangement

of the individual motors. The dynamic characteristics (e.g., the maximumacceleration capacity) result under consideration of the total weight to beaccelerated in the drive train.

Power increase



3. Integration of linear direct drives in control systems

3. Integration of linear direct drives incontrol systems

Linear direct drives can be used for various applications. The main uses aredivided into the areas:

• General servo applications with higher-level CNC control and

• Servo applications with electronic drive synchronization

3.1. General servo applicationsFor the general servo application range, servo applications can be furtherdistinguished in accordance with the type of interface to the CNC control

• ANALOG interface or

• SERCOS interface

3.1.1. ANALOG interface

When the ANALOG interface is used, it is possible to use conventionalcontrollers.

Main applications

Fig. 3.1: Linear direct drive with ANALOG interface

The position sensor signals detected by the measuring system are madeavailable as an incremental sensor signal with a freely programmable resolu-tion.

The programming and diagnosis of the drive are carried out with a VT 100terminal.

Due to the insufficiently fast setpoint specification by the controller, the contourexactness lies below the possibilities which would apply if the SERCOSinterface were used.

D AA D

+W

-X

Primarypart 3 a.c.

Kv

Secondary part

Field-orientedstator currentcontrol

Speedcontrol

Speedsetpointanalog± 10 V

Actualposition value

CNC control(position control)

DDS digital control modulewith analog interface

Asynchronouslinear motor

Linear scale

Drive computer

FSANINT

VT 100

Parameterdiagnostics

Positioninterface

High-resolutionposition interface

Advantages

Disadvantages




The speed range (range between the slowest and fastest speed) is generallylimited to + 11 bits (vmin = vmax/2048).

The resolution of the sensor signals used for position control is clearly lowerthan is possible with the SERCOS interface.

3.1.2. SERCOS interface

A full utilization of all possibilities and advantages of linear direct drives ismade possible with the SERCOS interface.

The following operating modes can be used:

• Position control, either with or without lag distance

• Speed control

• Current control (force)

The following advantages result

• High contour exactness with high path speeds through fine interpolation anddrive-internal, contouring-error-free position control with a 250 µs cycle time

• High surface quality through low force ripple, high position resolution andshort position-control cycle time

• Linear scale measuring steps are divided by 2048

• Simple realization of gantry axes, i.e., without compensation control viacontroller

• Start-up and diagnosis directly via the NC terminal

• NC-independent start-up via PC with graphic support

• Fast initial start-up and easy duplication for a series of machines by loadingcomplete parameter sets

Fig. 3.2: Linear direct drive with SERCOS interface

High-resolutionposition interface

Field-orientedstator currentcontrol

Speed control

CNC control DDS digital control module with SERCOS interface Asynchronouslinear motor

SERCOSinterface

Drive computer

Position control

Fine interpolationSERCOSinterface

FSSERINT

ParametersDiagnosticsOperating data

Primarypart 3 a.c.

Secondary part

Linear scale

Advantages




3.2. Servo application with electronic synchronization

Electronically synchronized drives contain the following system components

• synchronized drives

• higher-level controllers (master computer, SPC)

• I/O modules

• local operating units

Here electronic synchronization is realized in the drive control units by usingthe SERCOS-interface bus system between the drives. A control card is usedto coordinate data exchange between the drives, I/O modules, mastercomputer, SPC and local operating units. This control card can be plugged intoeither the drive control units, the PCs or the VME bus systems.

Therefore, the drives are divided into systems

• with an integrated control card

• without an integrated control card

The following operating modes are realized within the drive control units:

• Position synchronization

• Speed synchronization

• Free synchronization (e.g., simulation of a cam disk)

When the control card is used, the

• parameterization

• referencing

• and set-up

of the axes is also supported.

In this case both a virtual and an actual guide axis are used as a guide axis.

• Replacement of complex mechanical cam drives

• Increased exactness and speed

• Free change of the synchronization parameters, e.g., of the speed ratios

• Guide axis transducer directly connectable

• Inputs/outputs can be directly connected

Operating modes

Advantages




3.3. System configurations

The individual systems described in Section 3.1 and 3.2 are designated assystem configurations and each marked with an abbreviation. This abbrevia-tion must be indicated when ordering drive control units, as they specify theplug-in modules for the drive control units required for the special systemconfiguration. Please see the documentation "Digital Intelligent Drive-SystemConfigurations" for details.

Selection diagram

Fig. 3.3: Selection diagram for function-oriented selection of linear direct drive

Applicationrange

Controller orinterfacefor controller

Extras Configurationcode

SERCOSinterface

DA 06

DS 13

General servoapplication

DS 08Separatecontrol

Connection ofguide axis

transducer GDS

I/O card with15 inputs/16 outputs


+Connection of

guide axistransducer GDS

Servo applicationwith drive

synchronization

DS 15

DS 22

DS 07or

DS 28

DS 21

DS 06Integrated

CLCcontrol card


DS 14

ANALOGinterface

FSAUSLINDIR

Connection ofguide axis

transducer GDS



4. Dimensioning and selection of linear direct drives

4. Dimensioning and selection of lineardirect drives

4.1. DimensioningApplications for which linear direct drives can be used advantageously aredivided into the following characteristic speed/time graphs:

• Triangular speed curve with idle time

• Operation with trapezoidal speed curve and idle time

• Sinusoidal speed curve

These characteristic speed/time graphs determine the design criteria inconjunction with the forces resulting during these time segments.

The basic procedure for dimensioning is as follows:

Fig. 4.1: Dimensioning procedure

FPdimLAF

1. Determination of mechanical conditions

• Moved weight• Friction, counter-force• Motor installation position• Axis traverse path• Machining force

2. Specification of kinematic requirements

• Maximum speed• Acceleration

3. Determination of forces • Friction force• Force of weight• Basic force• Load force• Acceleration force• Maximum force

4. Determination of effective force Feff

Define representative movement sequence

Movement sequence known?

Estimation of relative switch-on duration

Calculate Feff(4.10, 4.11, 4.12)

yes

no

Specify movement profile of a cycle (traverse path, speed,

acceleration) by individual time segments (speed/time graph)

Assign forces (determined from Step 3) to individual time

segments (force/time graph)

5. Selection of motor type and combination of LAF motor and drive control unit from selection list under consideration of design criteria

(4.1)(4.2)(4.3)

(4.4, 4.5)(4.6, 4.7)(4.8, 4.9)




The linear direct drive must meet the following conditions:

• Adherence to the required speed,i.e., vmax > vmax,req

• Adherence to the required maximum force,i.e., Fmax > Fmax,req

• Adherence to the required load force,i.e., FKB > FLoad

• Adherence to the required continuous nominal force,i.e., FpN > Feff

If these conditions cannot be adhered to, an increase in the forces of an axiscan be realized by mechanically connecting several linear direct drives inparallel.

4.2. Triangular speed curve

This operating mode is characteristic of all highly dynamic advance move-ments, such as those which can frequently be found in the sheet-metal, paper,plastic or packaging industries.

Design criteria

Fig. 4.2: Speed/time curve for triangular operation

The design for this operating mode is mainly carried out in accordance with therequired maximum force Fmax,req, composed of the acceleration and brakingforce, and the effective force Feff.

DGverlLAF

Speed v

Time t

vmax




4.2.1. Calculation equations for triangular speed curve

In the following the basic calculation equations are shown.

FR = (m • g + FAtt ) • µ + FAdd

FG = m • g • (1-fg ) • sin( α)

100

FO = FR + FG

FAtt

Force of attraction between primary and secondarypart of asynchronous liner motor

FO

Basic force in NF

RFriction force in N

FG

Force of weight in Nm Moved weight in kg (under consideration of moved

weight of motor)g Acceleration due to gravity in m/s2

µ Friction coefficientF

AddAdditional friction force (e.g., bellows) in N

fg

Counterbalance in %α Axis angle to horizontal plane in degrees

FLoad = FMach + FO(upward motion with sloped axis)

FLoad = FMach + FO - 2 • FG(downward motion with sloped axis)

FAcc

= m • a

(for uniform acceleration)

Fmax, req = FAcc + FLoad(for simultaneous acceleration and machining)

Fmax, req = FAcc + FO(for acceleration)

FLoad Load force in NFMach Machining force in NFO Basic force in NFG Force of weight in NFAcc Acceleration force in Nm Moved weight in kga Acceleration in m/s2

Fmax, req Required maximum force of drive in N

Friction force

Force of weight

Basic force

Load force

Acceleration force

(4.1)

(4.2)

(4.3)

(4.4)

(4.5)

(4.6)

(4.8)

(4.9)

Maximum force



Effective force


Feff =Σ ( Fi2 • ti )

(for uniform forces in knowΣ ti time segments)

Feff Effective force in NFi Force occurring within a time segment in Nti Time segment in sec.

(4.10)



4.2.2. Calculation example for triangular speed curve

Cycle


Given data

Fig. 4.3: Speed/time graph of calculation example

Moved weight m = 400 kg (incl. primary-part weight)

Friction coefficient µ = 0.05

Force of attraction betweenprimary and secondary partof linear motor FAtt = 0 N

Additional friction force FAdd = 50 N

Vertical counterbalance fG = 90 %

Machining force FMach = 0 N

The following applies:

a =

a = = 10 m/s2

FR = (m • g + F

Att) • µ + F

Add

FR = (400 kg • 9.81 m/s2 + 0 N) • 0.05 + 50 N = 246 N

FG = m • g • ( 1 – ) • sin (α)

FG = (400 kg • 9.81 m/s2 • (1 – ) • sin (90°) = 392 N

FO = F

R + F

G

FO = 246 N + 392 N = 638 N

FAcc

= m • a

FAcc

= 400 kg • 10 m/s2 = 4000 N

Fmax, req

= FAcc

+ FO

Fmax, req

= 4000 N + 638 N = 4638 N

Calculation procedure

Acceleration

Friction force

Force of weight

Basic force

Acceleration force

Maximum force

vtAcc

1m/s0.1 s

fg100 90

100

DGGEZE1

v

t in ms

in m/s

100 200 300 400 500 600

-1

700 800

+1

Cycle time



Effective force Feff

=

The force/time graph is as follows:

Fig. 4.4: Force/time graph of calculation example

Selecting lineardirect drive

This results in:

Feff

=

Feff

= 2883 N

Asynchronous linear motor 2 x LAF 121 C-CDrive control unit 2 x DDS 2.1-W100

with following data: vmax = 60 m/min.FpN = 4.000 NFmax = 5.260 N


Σ (Fi2 • t

i)

Σ ti

100 200 300 400 500 600 700 800

DGKRZE1

t in ms

F in N

FAcc + FR + FG = 4638 N

– FAcc + FR + FG = – 3362 N

– FAcc – FR + FG = – 3854 N

FAcc - FR + FG = 4146 N

FO = 638 N FO = 638 N

(46382 N2 • 0.1 s + 33622 N2 • 0.1 s) + (6382 N2 • 0.2 s)+ (38542 N2 • 0.1 s + 41462 N2 • 0.1 s) + (6382 N2 • 0.2 s)

0.8 s




4.3. Trapezoidal speed curveThis operating mode is characteristic of most applications in machine toolengineering. It can also be found frequently in handling systems.

DGtrapLAF

Speed v

Time t

Fig. 4.5: Speed/time curve for trapezoidal operation

The design for this operating mode is mainly based on the required maximumforce Fmax,eff in the acceleration phases and the effective force Feff during thetotal cycle time.

4.3.1. Calculation equations for trapezoidal speed curve:

FR = (m • g + FAtt) • µ + FAdd

FG = m • g • (1-fg ) • sin( α)

100

FO = FR + FG

FAtt

Force of attraction between primary and secondarypart of asynchronous liner motor

FO

Basic force in NF


FG





fg

Counterbalance in %α Axis angle to horizontal plane in degrees

Friction force

Force of weight

Basic force

(4.1)

(4.2)

(4.3)



Load force

Acceleration force

(4.4)

(4.5)

(4.6)

(4.8)

(4.9)



FAcc

= m • a

(for uniform acceleration)


Fmax, req

= FAcc

+ FO

(for acceleration)




Effective force

Feff =Σ ( Fi

2 • t i )(for uniform forces in know

Σ ti time segments)

Feff Effective force in NFi Force occurring within a time segment in Nti Time segment in sec.

(4.10)

Maximum force



4.3.2. Calculation example for trapezoidal speed curve

Cycle:


Given data


Friction force

Force of weight

Basic force

Acceleration force

Load force

Maximum force

Fig. 4.6: Speed/time graph of calculation example

Moved weight m = 400 kg(with primary-part weightestimated at 50 kg)


Force of attraction between primaryand secondary part FAtt = 15.000 N (estimated)


Horizontal arrangement ofmachining force FMach = 1.500 N

Acceleration a = 6 m/s2


FR = (m • g + FAtt) • µ + FAddFR = (400 kg • 9.81 m/s2 + 15 000 N) • 0.02 + 50 N = 428 N

FG = 0 N, as horizontal axis

FO = FR + FGFO = 428 N

FAcc = m • a

FAcc = 400 kg • 6 m/s2 = 2400 N

FLoad = FMach + FOFLoad = 1500 N + 428 N = 1928 N

Fmax, req = FAcc + FLoadFmax, req = 2400 N + 1928 N = 4328 N

0.5 1.0 1.5 2.0 2.5 3.0

0.6

0.3

-0.6

DGGEZE2

t in s

v in m/s

Cycle time

MachiningF = 1500 N

Rapid-traversetool ap-proachmotion

Rapid-traversereturn motion

Idle



This results in:

Feff

=

Feff

= 1542 N

A.) Asynchronous linear motor LAF 121 C-CDrive control unit DDS 2.1-W200

with following data: vmax = 60 m/min.FpN = 2000 NFmax = 4800 N

or

B.) Asynchronous linear motor 2 x LAF 121 A-EDrive control unit 1 x DDS 2.1-W200

with following data: vmax = 60 m/min.FpN = 2000 NFmax = 4800 N

Fig. 4.7: Force/time graph of calculation example:

(28282 N2 • 0.1 s) + (4282 N2 • 0.3 s) + (19722 N2 • 0.1 s)+ (43282 N2 • 0.05 s)+ (19282 N2 • 0.95 s)+ (4722 N2 • 0.05 s) + (28282 N2 • 0.1 s) + (4282 N2 • 0.65 s)+ (19722 N2 • 0.1 s) + (4282 N2 • 0.65 s)

3.0 s


Feff =

The force/time graph is as follows:


Σ (Fi2 • t

i)

Σ ti

– FAcc – FO= – 2828 N

– FAcc + FLast= – 472 N– FAcc + FO

= – 1972 N

0.5 1.0 1.5 2.0 2.5 3.0

2000

4000

-2000

-4000DGKRZE2

t in s

F in N

FAcc + FO= 2828 N

FO = 428 N

Fmax, req = 4328 N

FLoad = 1928 N

– FO = – 428 N

FAcc – FO = 1972 N

Effective force



4.4. Sinusoidal speed curve

This operating mode can frequently be found in applications in the textile andpackaging industry


DGsinLAF

Speed v

Time t

Fig. 4.8: Speed/time curve for sinusoidal speed curve

The design for this operating mode is carried out primarily in accordance withthe maximum force Fmax,req in the acceleration phases and the force Feff over theperiod duration.

4.4.1. Calculation equations for sinusoidal speed curve

FR = (m • g + FAtt) • µ + FAdd

FG = m • g • (1-

fg ) • sin( α)100

FO = F

R + F

G

FAtt Force of attraction between primary and secondarypart of asynchronous liner motor

FO Basic force in NFR Friction force in NFG Force of weight in Nm Moved weight in kg (under consideration of moved


µ Friction coefficientFAdd Additional friction force (e.g., bellows) in Nfg Counterbalance in %α Axis angle to horizontal plane in degrees

Friction force

Force of weight

Basic force

(4.1)

(4.2)

(4.3)




(4.7)

(4.9)

Acceleration force

Maximum force

FAcc =m • vmax • 2 • π

T(for sinusoidal speed/time graph)

Fmax, req = FAcc + FO (for acceleration)

FO Basic force in NFAcc Acceleration force in Nm Moved weight in kgvmax Moved weight in kgT Period duration in sec.Fmax, req Required maximum force of drive in N

Effective force

Feff

= FO

2 +F

Acc2

2

(for sinusoidal speed/time graph with constantbasic force)

Feff Effective force in NFO Basic force in NFAcc Acceleration force in N

(4.11)




4.4.2. Calculation example for sinusoidal speed curve

CycleGiven data


Friction force

Force of weight

Basic force

Acceleration force

Maximum force

Effective force



FR = (m • g + FAtt) • µ + FAddFR = (100 kg • 9.81 m/s2 + 10 000 N) • 0.02 + 50 N = 269 N

FG = 0 N, as horizontal axis

FO = FR + FGFO = 269 N + 0 N = 269 N

FAcc = m • vmax •

FAcc = 100 kg • 0.6 m/s2 • = 943 N

Fmax, req = FAcc + FOFmax, req = 943 N + 269 N = 1212 N

Feff = FO2 +

Feff = 2692 + = 898 N

Asynchronous linear motor LAF 121 A-FDrive control unit DDS 2.1-W050

with following data: vmax = 45 m/min

FpN = 1000 N

Fmax = 2140 N

2 • π T

2 • π 0.4 s

FAcc2

2

1212 2

2

Fig. 4.9: Speed/time chart of calculation example

Moved weight m = 100 kg (incl. primary part weight)


Force of attraction betweenprimary and secondarypart of linear motor FAtt = 10 000 N (estimated)


Machining force for FMach = 0 Nhorizontal arrangement

0.6

-0.6

0.2 0.4

DGGEZE3

t in s

v in m/s

Period duration T




4.5. Calculation during switch-on durationIf the speed/time curve is not exactly known, the calculation can take placeduring the switch-on duration.

Fig. 4.10: Time shares/switch on duration for various operating phases

The design is carried out in accordance with the required forces in theindividual operating phases and the effective force Feff during the switch-ondurations.

4.5.1. Calculation equations for given switch-on durations

FSedantLAF

Rapidtraverse

Machining

Break/acceleration

Standstill

FR = (m • g + F

Att) • µ + F

Add

FG = m • g • (1-fg ) • sin( α)

100

FO = FR + FG

FAtt

Force of attraction between primary and secondarypart of asynchronous linear motor

FO

Basic force in NF


FG





fg

in %α Axis angle to horizontal plane in degrees

Friction force

Force of weight

Basic force

(4.1)

(4.2)

(4.3)




Load force

Acceleration force

(4.4)

(4.5)

(4.6)

(4.8)

(4.9)



FAcc

= m • a(for uniform acceleration)


Fmax, req

= FAcc

+ FO

(for acceleration)



Effective force(approx. calculation) Feff = Σ (Fi

2 • EDi) (for uniform forces with known switch-on duration)

Feff Effective force in NEDi Switch-on duration within an operating phase in %Fi Force within an operating phase in N

100

(4.12)

Maximum force



5. Selection lists

5. Selection lists

5.1. Explanations for selection listsThe performance data of the motor/drive control unit combinations are listedin the selection lists per drive control unit. Up to a maximum of two LAF motorscan be connected. These combinations were included in the selection lists. Inaddition, linear motors can be arranged mechanically in series or parallel. Thecorresponding combination possibilities are contained in Section 6. The forcescan then be added together accordingly.

The variables listed in the selection lists have the following meaning:

Usable maximum speed vmax for standard applications in a closed positioncontrol circuit with an NC control.The speed at which the linear motor can be operated with the nominal forceover the entire speed range is used as a basis.

This force can be output by the linear motor for an unlimited time.

The maximum force can be output by the motor briefly for a maximum switch-on duration of 400 ms. Then this force is reduced to the short-term operatingforce FKB in dependency on the current limitation in the drive control unit. Themaximum force is available for acceleration up to the critical speed vFmax.

This force is available at maximum speed.

This force can be used in the intermittent mode for the specified switch-onduration percentage (operating mode S6 as per DIN 57530/VDE 0530). Themaximum play duration corresponds to the thermal time constant of the motor.For lower short-term operating force the switch-on duration is determinedapproximately as follows:

(1) vmaxMaximum speed

(2) FpNContinuous nominal

force

(3) Fmax – vFmaxMaximum force-

Critical speed

(4) FvmaxMaximum force at vmax

(5) FSO – EDShort-term operating

force switch-onduration

ED Switch-on duration in %FpN Continuous nominal force in NFSO Short-term operating force in N

ED = ( )2 • 100 %F

dN

FKB

(5.1)



(6) tAAcceleration/braking

time

(7) mMMotor weight of

primary part

(8) PDCIntermediate-circuit

continuous output

(9) LAF motor

(10) DDS drivecontrol unit

5. Selection lists

Acceleration time of motor from standstill to maximum speed or braking timefrom maximum speed to standstill.

• without load weights

• without load forces

under consideration of the characteristic F = f(v).

Weight of the linear-motor primary part

Continuous output which must be constantly made available by the supplysystem if the motor is operating in the continuous nominal mode.

The indicated motor code specifies the motor-related drive data. To determinethe ordering data, proceed as described in Section 10.

The model designations of the drive control unit are indicated to the degreethat they help determine the data in the selection list.

Fig. 5.1: Part of drive control unit model decisive for drive data

Please specify the remaining ordering information in accordance with theproject planning documentation. Here the configuration designation as perSection 3.3 will also be required.

This factor is to be entered during the programming of the drives to achievethe desired drive data.

When other values are entered, the selection data are changed.

The overload factor indicates the ratio of the continuous amplifier current to thecontinuous motor current. The operating range within the amplifier character-istic is defined with this factor. Several operating ranges are possible for somemotor/drive control-unit combinations.

These are distinguished as follows:

• Operating range with high maximum force and low short-term operatingforce

• Operating range with high short-term operating force and low maximumforce

Example: DDS 2.1 – W 015

Code for:Drive control unitSeriesDesignCooling typeModel current

(11) OF:Overload factor



Fig. 5.2: Schematic representation of the characteristic data from the selection lists

The length of the secondary part is dependent on the required total traversepath and the length of the secondary part.

The following standard lengths are available

• LAF050, 070, 1,000 mm parts

• LAF 121, 500 mm and 200 mm parts

Any desired traverse length can be achieved by connecting several secondaryparts in series. The length of the secondary part is calculated as follows:

Characteristic data

5. Selection lists

DGKENNDA

F

v

Fmax

FSO

FdN

vFmax

Fvmax

vmax

Secondary part

Example

Selection

Lpath = 1300 mm, Lprimary = 650 mm

Lsecondary = 1300 mm + 650 mm = 1950 mm

4 secondary parts of the type LFS 121 with a length of 500 mm each

When specifying the secondary part length, the following points must beobserved:

• When using a secondary-side cooling plate, the maximum length is limitedby the pressure drop within the cooling plate (see Section 8.7).

• For long traverse paths, corresponding measuring systems with at least thelength of the available traverse path (see Section 7) are required.

• The specified production tolerances of the machine elements must beadhered to over the entire traverse path to ensure a defined air gap height.

Lsecondary > Lpath + Lprimary

Lsecondary Length of secondary part in mmLpath Traverse path in mmLprimary Length of primary part in mm

(5.2)



5. Selection lists

5.2. Selection lists

Vmax

FdN

Fmax

vFmax

Fvmax

FSO

ED tA m

M P

DC Motor type Controller OF

m/min N N m/min N N % ms kg kW LAF type DDS %

150 170 340 96 170 300 32 35/24 3.2 1.7 050A-H 2.1-W050-D 267150 170 460 56 170 330 27 30/17 3.2 1.6 050A-H 2.1-W100-D 317150 170 450 59 170 340 25 30/18 3.2 1.6 050A-H 2.1-W100-D 333150 170 460 56 170 340 25 30/17 3.2 1.6 050A-H 2.1-W150-D 333

150 340 440 136 340 380 80 48/36 6.4 3.6 2 x050A-H 2.1-W050-D 133150 340 690 94 340 380 80 35/23 6.4 3.3 2 x050A-H 2.1-W100-D 133150 340 500 126 340 500 46 43/32 6.4 3.5 2 x050A-H 2.1-W100-D 200150 340 870 64 340 520 43 31/18 6.4 3.2 2 x050A-H 2.1-W150-D 217150 340 600 109 340 600 32 38/27 6.4 3.4 2 x050A-H 2.1-W150-D 267150 340 920 55 340 560 37 30/17 6.4 3.1 2 x050A-H 2.1-W200-D 240150 340 650 101 340 650 27 36/25 6.4 3.4 2 x050A-H 2.1-W200-D 300150 340 690 94 340 600 32 35/23 6.4 3.3 2 x050A-H 2.1-A100-D 267150 340 650 101 340 650 27 36/25 6.4 3.4 2 x050A-H 2.1-A100-D 300150 340 870 64 340 690 24 31/18 6.4 3.2 2 x050A-H 2.1-A150-D 333150 340 920 55 340 690 24 30/17 6.4 3.1 2 x050A-H 2.1-A200-D 333150 340 690 94 340 690 24 35/23 6.4 3.3 2 x050A-H 2.1-F100-D 333150 340 870 64 340 690 24 31/18 6.4 3.2 2 x050A-H 2.1-F150-D 333150 340 920 55 340 690 24 30/17 6.4 3.1 2 x050A-H 2.1-F200-D 333

150 340 440 136 340 380 80 49/37 6.5 3.6 050C-H 2.1-W050-D 133150 340 690 94 340 380 80 35/24 6.5 3.3 050C-H 2.1-W100-D 133150 340 500 126 340 500 46 44/33 6.5 3.5 050C-H 2.1-W100-D 200150 340 870 64 340 520 43 31/19 6.5 3.2 050C-H 2.1-W150-D 217150 340 600 109 340 600 32 39/27 6.5 3.4 050C-H 2.1-W150-D 267150 340 920 55 340 560 37 31/18 6.5 3.1 050C-H 2.1-W200-D 240150 340 650 101 340 650 27 37/25 6.5 3.4 050C-H 2.1-W200-D 300150 340 690 94 340 600 32 35/24 6.5 3.3 050C-H 2.1-A100-D 267150 340 650 101 340 650 27 37/25 6.5 3.4 050C-H 2.1-A100-D 300150 340 870 64 340 690 24 31/19 6.5 3.2 050C-H 2.1-A150-D 333150 340 920 55 340 690 24 31/18 6.5 3.1 050C-H 2.1-A200-D 333150 340 690 94 340 690 24 35/24 6.5 3.3 050C-H 2.1-F100-D 333150 340 870 64 340 690 24 31/19 6.5 3.2 050C-H 2.1-F150-D 333150 340 920 55 340 690 24 31/18 6.5 3.1 050C-H 2.1-F200-D 333

150 680 1030 123 680 690 97 43/32 13.0 7.0 2 x050C-H 2.1-W150-D 117150 680 760 146 680 760 80 56/43 13.0 7.3 2 x050C-H 2.1-W150-D 133150 680 1270 103 680 690 97 37/26 13.0 6.8 2 x050C-H 2.1-W200-D 117150 680 820 141 680 820 69 52/40 13.0 7.2 2 x050C-H 2.1-W200-D 150150 680 890 135 680 760 80 49/37 13.0 7.1 2 x050C-H 2.1-A100-D 133150 680 820 141 680 820 69 52/40 13.0 7.2 2 x050C-H 2.1-A100-D 150150 680 1160 113 680 910 56 39/28 13.0 6.9 2 x050C-H 2.1-A150-D 175150 680 1380 94 680 790 74 35/24 13.0 6.7 2 x050C-H 2.1-A200-D 142150 680 1200 109 680 910 56 39/27 13.0 6.8 2 x050C-H 2.1-A200-D 175150 680 890 135 680 890 58 49/37 13.0 7.1 2 x050C-H 2.1-F100-D 167150 680 1160 113 680 910 56 39/28 13.0 6.9 2 x050C-H 2.1-F150-D 175150 680 1380 94 680 910 56 35/24 13.0 6.7 2 x050C-H 2.1-F200-D 175

Fig. 5.3: Selection list with LAF050



5. Selection lists

Vmax

FdN

Fmax

vFmax

Fvmax

FSO

ED tA m

M P

peak P


m/min N N m/min N N % ms kg KW kW LAF type DDS %

120 350 610 83 350 520 45 26/18 5,6 3,0 2,7 070A-P 2.1-W050-D 235120 350 790 58 350 520 45 23/14 5,6 3,0 2,5 070A-P 2.1-W100-D 235120 350 680 73 350 680 26 24/16 5,6 3,0 2,6 070A-P 2.1-W100-D 353120 350 790 58 350 700 25 23/14 5,6 3,0 2,5 070A-P 2.1-W150-D 371120 350 610 83 350 610 33 26/18 5,6 3,0 2,7 070A-P 2.1-A050-D 294120 350 790 58 350 700 25 23/14 5,6 3,0 2,5 070A-P 2.1-A100-D 371120 350 610 83 350 610 33 26/18 5,6 3,0 2,7 070A-P 2.1-F050-D 294120 350 790 58 350 700 25 23/14 5,6 3,0 2,5 070A-P 2.1-F100-D 371

120 700 860 109 700 860 66 34/26 11,2 6,0 5,7 2 x070A-P 2.1-W100-D 176120 700 1540 60 700 910 59 23/15 11,2 6,0 5,1 2 x070A-P 2.1-W150-D 191120 700 1050 95 700 1050 44 29/21 11,2 6,1 5,5 2 x070A-P 2.1-W150-D 235120 700 1590 57 700 1010 48 22/14 11,2 5,9 5,1 2 x070A-P 2.1-W200-D 221120 700 1140 89 700 1140 38 27/20 11,2 6,1 5,4 2 x070A-P 2.1-W200-D 265120 700 1220 83 700 1050 44 26/18 11,2 6,1 5,4 2 x070A-P 2.1-A100-D 235120 700 1140 89 700 1140 38 27/20 11,2 6,1 5,4 2 x070A-P 2.1-A100-D 265120 700 1540 60 700 1250 31 23/15 11,2 6,0 5,1 2 x070A-P 2.1-A150-D 309120 700 1590 57 700 1250 31 22/14 11,2 5,9 5,1 2 x070A-P 2.1-A200-D 309120 700 1220 83 700 1220 33 26/18 11,2 6,1 5,4 2 x070A-P 2.1-F100-D 294120 700 1540 60 700 1250 31 23/15 11,2 6,0 5,1 2 x070A-P 2.1-F150-D 309120 700 1590 57 700 1250 31 22/14 11,2 5,9 5,1 2 x070A-P 2.1-F200-D 309

120 700 860 109 700 860 66 35/27 11,5 6,0 5,7 070C-P 2.1-W100-D 176120 700 1540 60 700 910 59 23/15 11,5 6,0 5,1 070C-P 2.1-W150-D 191120 700 1050 95 700 1050 44 30/22 11,5 6,1 5,5 070C-P 2.1-W150-D 235120 700 1590 57 700 1010 48 23/14 11,5 5,9 5,1 070C-P 2.1-W200-D 221120 700 1140 89 700 1140 38 28/20 11,5 6,1 5,4 070C-P 2.1-W200-D 265120 700 1220 83 700 1050 44 27/19 11,5 6,1 5,4 070C-P 2.1-A100-D 235120 700 1140 89 700 1140 38 28/20 11,5 6,1 5,4 070C-P 2.1-A100-D 265120 700 1540 60 700 1250 31 23/15 11,5 6,0 5,1 070C-P 2.1-A150-D 309120 700 1590 57 700 1250 31 23/14 11,5 5,9 5,1 070C-P 2.1-A200-D 309120 700 1220 83 700 1220 33 27/19 11,5 6,1 5,4 070C-P 2.1-F100-D 294120 700 1540 60 700 1250 31 23/15 11,5 6,0 5,1 070C-P 2.1-F150-D 309120 700 1590 57 700 1250 31 23/14 11,5 5,9 5,1 070C-P 2.1-F200-D 309

120 1380 1380 120 1380 1380 100 43/33 23,0 11,6 11,6 2 x070C-P 2.1-W200-D 132120 1380 1380 120 1380 1380 100 43/33 23,0 11,6 11,6 2 x070C-P 2.1-A100-D 132120 1400 2020 98 1400 1570 80 31/23 23,0 12,1 11,1 2 x070C-P 2.1-A150-D 154120 1380 2360 86 1380 1380 100 28/19 23,0 12,2 10,8 2 x070C-P 2.1-A200-D 132120 1400 2110 95 1400 1570 80 30/22 23,0 12,1 11,0 2 x070C-P 2.1-A200-D 154120 1400 1510 116 1400 1510 86 40/30 23,0 11,7 11,5 2 x070C-P 2.1-F100-D 147120 1400 2020 98 1400 1570 80 31/23 23,0 12,1 11,1 2 x070C-P 2.1-F150-D 154120 1400 2440 83 1400 1570 80 27/19 23,0 12,2 10,7 2 x070C-P 2.1-F200-D 154

Fig. 5.4: Selection list with LAF071

in preparation



5. Selection lists

Vmax FdN Fmax vFmax Fvmax FSO ED tA mM PDC Motor type Controller OFm/min N N m/min N N % ms kg kW LAF type DDS %

45 1000 2140 31 1000 1780 32 9/7 19.0 3.1 121A-F 2.1-W050-D 16945 1000 2200 30 1000 2000 25 9/6 19.0 3.1 121A-F 2.1-W100-D 19445 1000 2140 31 1000 2000 25 9/7 19.0 3.1 121A-F 2.1-A050-D 19445 1000 2200 30 1000 2000 25 9/6 19.0 3.1 121A-F 2.1-A100-D 19445 1000 2140 31 1000 2000 25 9/7 19.0 3.1 121A-F 2.1-F050-D 19445 1000 2200 30 1000 2000 25 9/6 19.0 3.1 121A-F 2.1-F100-D 194

45 2000 3570 35 2000 2240 80 10/8 38.0 6.4 2 x121A-F 2.1-W100-D 10645 2000 2950 39 2000 2950 46 12/10 38.0 6.5 2 x121A-F 2.1-W100-D 13845 2000 4400 30 2000 3370 35 9/6 38.0 6.2 2 x121A-F 2.1-W150-D 15945 2000 3570 35 2000 3570 31 10/8 38.0 6.4 2 x121A-F 2.1-W150-D 16945 2000 4400 30 2000 3830 27 9/6 38.0 6.2 2 x121A-F 2.1-W200-D 18445 2000 3940 33 2000 3940 26 10/7 38.0 6.3 2 x121A-F 2.1-W200-D 19145 2000 4280 31 2000 3570 31 9/7 38.0 6.2 2 x121A-F 2.1-A100-D 16945 2000 3940 33 2000 3940 26 10/7 38.0 6.3 2 x121A-F 2.1-A100-D 19145 2000 4400 30 2000 4000 25 9/6 38.0 6.2 2 x121A-F 2.1-A150-D 19445 2000 4400 30 2000 4000 25 9/6 38.0 6.2 2 x121A-F 2.1-A200-D 19445 2000 4280 31 2000 4000 25 9/7 38.0 6.2 2 x121A-F 2.1-F100-D 19445 2000 4400 30 2000 4000 25 9/6 38.0 6.2 2 x121A-F 2.1-F150-D 194

60 1000 1770 48 1000 1460 47 14/11 19.0 3.4 121A-E 2.1-W050-D 14960 1000 2400 39 1000 1820 30 11/8 19.0 3.2 121A-E 2.1-W100-D 19360 1000 2110 43 1000 2000 25 12/9 19.0 3.3 121A-E 2.1-W100-D 21760 1000 2400 39 1000 2000 25 11/8 19.0 3.2 121A-E 2.1-W150-D 21760 1000 1770 48 1000 1770 32 14/11 19.0 3.4 121A-E 2.1-A050-D 18660 1000 2400 39 1000 2000 25 11/8 19.0 3.2 121A-E 2.1-A100-D 21760 1000 1770 48 1000 1770 32 14/11 19.0 3.4 121A-E 2.1-F050-D 18660 1000 2400 39 1000 2000 25 11/8 19.0 3.2 121A-E 2.1-F100-D 217

60 2000 4770 39 2000 2410 69 11/8 38.0 6.5 2 x121A-E 2.1-W150-D 12160 2000 2920 53 2000 2920 47 16/13 38.0 7.0 2 x121A-E 2.1-W150-D 14960 2000 4800 39 2000 2760 53 11/8 38.0 6.5 2 x121A-E 2.1-W200-D 13960 2000 3240 51 2000 3240 38 14/12 38.0 6.9 2 x121A-E 2.1-W200-D 16760 2000 3540 48 2000 2920 47 14/11 38.0 6.8 2 x121A-E 2.1-A100-D 14960 2000 3240 51 2000 3240 38 14/12 38.0 6.9 2 x121A-E 2.1-A100-D 16760 2000 4770 39 2000 3680 30 11/8 38.0 6.5 2 x121A-E 2.1-A150-D 19560 2000 4800 39 2000 3680 30 11/8 38.0 6.5 2 x121A-E 2.1-A200-D 19560 2000 3540 48 2000 3540 32 14/11 38.0 6.8 2 x121A-E 2.1-F100-D 18660 2000 4770 39 2000 3680 30 11/8 38.0 6.5 2 x121A-E 2.1-F150-D 19560 2000 4800 39 2000 3680 30 11/8 38.0 6.5 2 x121A-E 2.1-F200-D 195

100 1000 2440 57 1000 1170 73 19/13 19.0 3.5 121A-D 2.1-W100-D 122100 1000 1690 79 1000 1690 35 24/19 19.0 3.9 121A-D 2.1-W100-D 183100 1000 2700 49 1000 1910 27 18/12 19.0 3.4 121A-D 2.1-W150-D 214100 1000 2440 57 1000 2000 25 19/13 19.0 3.5 121A-D 2.1-W150-D 228100 1000 2700 49 1000 2000 25 18/12 19.0 3.4 121A-D 2.1-W200-D 228100 1000 2440 57 1000 2000 25 19/13 19.0 3.5 121A-D 2.1-A100-D 228100 1000 2700 49 1000 2000 25 18/12 19.0 3.4 121A-D 2.1-A150-D 228100 1000 2440 57 1000 2000 25 19/13 19.0 3.5 121A-D 2.1-F100-D 228100 1000 2700 49 1000 2000 25 18/12 19.0 3.4 121A-D 2.1-F150-D 228

100 2000 4570 61 2000 2060 94 20/14 38.0 7.2 2 x121A-D 2.1-W200-D 107100 2000 2630 91 2000 2630 58 30/24 38.0 8.2 2 x121A-D 2.1-W200-D 138100 2000 2900 86 2000 2350 72 27/22 38.0 8.1 2 x121A-D 2.1-A100-D 122100 2000 2630 91 2000 2630 58 30/24 38.0 8.2 2 x121A-D 2.1-A100-D 138100 2000 4030 70 2000 3020 44 21/16 38.0 7.5 2 x121A-D 2.1-A150-D 161100 2000 4880 57 2000 2490 65 19/13 38.0 7.1 2 x121A-D 2.1-A200-D 130100 2000 4220 67 2000 3020 44 21/15 38.0 7.4 2 x121A-D 2.1-A200-D 161100 2000 2900 86 2000 2900 48 27/22 38.0 8.1 2 x121A-D 2.1-F100-D 153100 2000 4030 70 2000 3020 44 21/16 38.0 7.5 2 x121A-D 2.1-F150-D 161100 2000 4880 57 2000 3020 44 19/13 38.0 7.1 2 x121A-D 2.1-F200-D 161

Fig. 5.5: Selection list with LAF121A



5. Selection lists

Vmax

FdN

Fmax

vFmax

Fvmax

FSO

ED tA m

M P


m/min N N m/min N N % ms kg kW LAF type DDS %

45 2000 2780 37 2000 2230 80 13/9 35.0 5.1 121C-B 2.1-W050-D 11045 2000 4830 17 2000 2230 80 9/5 35.0 4.5 121C-B 2.1-W100-D 11045 2000 3270 32 2000 3270 37 11/8 35.0 5.0 121C-B 2.1-W100-D 16545 2000 4830 17 2000 3930 26 9/5 35.0 4.5 121C-B 2.1-W150-D 20745 2000 4130 24 2000 4130 23 10/6 35.0 4.7 121C-B 2.1-W150-D 22045 2000 5000 6 2000 4000 25 9/4 35.0 4.1 121C-B 2.1-W200-D 21245 2000 4500 20 2000 4500 20 9/6 35.0 4.6 121C-B 2.1-W200-D 24845 2000 2780 37 2000 2780 52 13/9 35.0 5.1 121C-B 2.1-A050-D 13845 2000 4830 17 2000 4000 25 9/5 35.0 4.5 121C-B 2.1-A100-D 21245 2000 5000 15 2000 4000 25 9/5 35.0 4.4 121C-B 2.1-A150-D 21245 2000 2780 37 2000 2780 52 13/9 35.0 5.1 121C-B 2.1-F050-D 13845 2000 4830 17 2000 4000 25 9/5 35.0 4.5 121C-B 2.1-F100-D 21245 2000 5000 15 2000 4000 25 9/5 35.0 4.4 121C-B 2.1-F150-D 212

45 4000 5560 37 4000 4170 92 13/9 70.0 10.3 2 x121C-B 2.1-W150-D 10345 4000 4460 43 4000 4460 80 16/12 70.0 10.6 2 x121C-B 2.1-W150-D 11045 4000 8070 25 4000 4170 92 10/7 70.0 9.4 2 x121C-B 2.1-W200-D 10345 4000 5020 40 4000 5020 63 14/10 70.0 10.5 2 x121C-B 2.1-W200-D 12445 4000 5560 37 4000 4460 80 13/9 70.0 10.3 2 x121C-B 2.1-A100-D 11045 4000 5020 40 4000 5020 63 14/10 70.0 10.5 2 x121C-B 2.1-A100-D 12445 4000 7860 26 4000 5810 47 10/7 70.0 9.5 2 x121C-B 2.1-A150-D 14545 4000 9660 17 4000 4750 71 9/5 70.0 8.9 2 x121C-B 2.1-A200-D 11745 4000 8260 24 4000 5810 47 10/6 70.0 9.4 2 x121C-B 2.1-A200-D 14545 4000 5560 37 4000 5560 52 13/9 70.0 10.3 2 x121C-B 2.1-F100-D 13845 4000 7860 26 4000 5810 47 10/7 70.0 9.5 2 x121C-B 2.1-F150-D 14545 4000 9660 17 4000 5810 47 9/5 70.0 8.9 2 x121C-B 2.1-F200-D 145

60 2000 3550 41 2000 2100 91 14/10 35.0 5.3 121C-C 2.1-W100-D 10460 2000 2630 52 2000 2630 58 18/13 35.0 5.6 121C-C 2.1-W100-D 13260 2000 5000 23 2000 2940 46 12/7 35.0 4.7 121C-C 2.1-W150-D 14960 2000 3380 43 2000 3380 35 15/10 35.0 5.3 121C-C 2.1-W150-D 17660 2000 5000 23 2000 3350 36 12/7 35.0 4.7 121C-C 2.1-W200-D 17460 2000 3720 39 2000 3720 29 14/9 35.0 5.2 121C-C 2.1-W200-D 19860 2000 4040 35 2000 3380 35 13/9 35.0 5.1 121C-C 2.1-A100-D 17660 2000 3720 39 2000 3720 29 14/9 35.0 5.2 121C-C 2.1-A100-D 19860 2000 5000 23 2000 4000 25 12/7 35.0 4.7 121C-C 2.1-A150-D 21760 2000 4040 35 2000 4000 25 13/9 35.0 5.1 121C-C 2.1-F100-D 21760 2000 5000 23 2000 4000 25 12/7 35.0 4.7 121C-C 2.1-F150-D 217

60 3990 3990 60 3990 3990 100 22/18 70.0 11.8 2 x121C-C 2.1-W200-D 9960 3990 3990 60 3990 3990 100 22/18 70.0 11.8 2 x121C-C 2.1-A100-D 9960 4000 6410 45 4000 4640 74 15/11 70.0 10.8 2 x121C-C 2.1-A150-D 11560 3990 7770 37 3990 3990 100 13/9 70.0 10.3 2 x121C-C 2.1-A200-D 9960 4000 6770 43 4000 4640 74 14/10 70.0 10.7 2 x121C-C 2.1-A200-D 11560 4000 4430 57 4000 4430 82 20/16 70.0 11.6 2 x121C-C 2.1-F100-D 11060 4000 6410 45 4000 4640 74 15/11 70.0 10.8 2 x121C-C 2.1-F150-D 11560 4000 8080 35 4000 4640 74 13/9 70.0 10.1 2 x121C-C 2.1-F200-D 115

100 2000 4350 44 2000 2080 92 22/13 35.0 5.4 121C-A 2.1-W150-D 104100 2000 2570 86 2000 2570 61 31/23 35.0 6.8 121C-A 2.1-W150-D 128100 2000 5000 29 2000 2180 84 21/12 35.0 4.9 121C-A 2.1-W200-D 109100 2000 2870 79 2000 2870 49 28/20 35.0 6.5 121C-A 2.1-W200-D 144100 2000 3150 73 2000 2570 61 27/19 35.0 6.3 121C-A 2.1-A100-D 128100 2000 2870 79 2000 2870 49 28/20 35.0 6.5 121C-A 2.1-A100-D 144100 2000 4350 44 2000 3280 37 22/13 35.0 5.4 121C-A 2.1-A150-D 168100 2000 5000 29 2000 2920 47 21/12 35.0 4.9 121C-A 2.1-A200-D 147100 2000 4550 39 2000 3280 37 21/13 35.0 5.2 121C-A 2.1-A200-D 168100 2000 3150 73 2000 3150 40 27/19 35.0 6.3 121C-A 2.1-F100-D 160100 2000 4350 44 2000 3280 37 22/13 35.0 5.4 121C-A 2.1-F150-D 168100 2000 5000 29 2000 3280 37 21/12 35.0 4.9 121C-A 2.1-F200-D 168

100 3290 5140 86 3290 3290 100 34/23 70.0 12.5 2 x121C-A 2.1-A200-D 84100 3290 4830 90 3290 3290 100 35/24 70.0 12.7 2 x121C-A 2.1-F150-D 84100 3290 6300 73 3290 3290 100 29/19 70.0 11.8 2 x121C-A 2.1-F200-D 84

Fig. 5.6: Selection list with LAF121C



Basic combination A)

6. Combination possibilities

Fig. 6.1: Combination with one LAF motor, one drive control unit and one measuring system

One LAF motor, one drive control unit, one measuring systemCombination A) is characterized by the following:

• Number of linear motors: 1

• Number of drive control units: 1

• Number of measuring systems: 1 scale / 1 scanning head

• Transducer signal distribution: no

The following basic combinations apply to control with a SERCOSinterface. For control with an ANALOG interface, only the basiccombinations A or B are possible.

6. Combination possibilities for linearmotor, drive control unit and measuringsystem

Based on the required performance data, a suitable number of linear motorsand drive control units can be combined as specified in Sections 4 and 5.

Several motors can be arranged mechanically in parallel or in series per axis.With a mechanically rigid coupling of the individual motors, only one measur-ing system is required per axis. If several drive control units are used with onlyone measuring system, the output signal of the measuring system is distrib-uted to the individual drive control units. A transducer signal distribution of thetype DGA 1.2 (voltage output signals) is used for this purpose.

The maximum number of motors and drive control units per axis is limited asfollows:

• max. number of LAF motors per drive control unit: 2

• max. number of drive control units per measuring system: 4

Various combination possibilities result in interdependence on measuringsystems depending on the number of linear motors and drive control units peraxis. The optimal combination results in close coordination with the overallmechanical design. The possible basic combinations are described in thefollowing. The individual basic combinations can be varied accordingly.

FSLAF1A1M1

Primary part

Linear scale

Secondary part

DDS 2 configured drive control unit

LAFlinear motor

CNC control

SERCOS interface




Basic combination B) Two LAF motors, one drive control unit, one measuring systemCombination B) is characterized by the following:




• Mechanical motor connection: rigidly coupled


Fig. 6.2: Combination with two LAF motors, one drive control unit and one measuringsystem

The following advantages result:

• Good power input with larger guide width

• Power increase compared to basic combination A) possible

The following disadvantages result:

• Different asymmetrical loads cannot be specifically fully stabilized

• Rigid mechanics required

• Only limited spacing between motors possible

FSLAF2A1M1

Primary part

Linear scale

Secondary part

DDS 2 configured drive contr ol units

Mechanically rigid coupling of LAF

linear motor sCNC contr ol

SERCOS interface

Advantages

Disadvantages



Basic combination C)


Two LAF motors, two drive control units, one measuring systemCombination C) is characterized by the following:





• Transducer signal distribution: yes

Fig. 6.3: Combination with two LAF motors, two drive control units and one measuringsystem



• Power increase compared to basic combination B)

• Only one measuring system required


• Different asymmetrical loads cannot be specifically fully stabilized

• Rigid mechanics required

• Only limited spacing between motors possible

FSLAF2A2M1DGA transducersignal distribution

Primary part

Linear scale

Secondary part

DDS 2 configured drive control units

Mechanically rigid coupling of LAF


SERCOS interface

Advantages

Disadvantages



Basic combination D)


Two LAF motors, two drive control units, two measuring systems (gantry axis)

Combination D) is characterized by the following:



• Number of measuring systems: 2 scales / 2 scanning heads

• Mechanical motor connection: non-rigidly coupled


FSLAF2A2M2

Primarypart

Linear scale

Secondarypart


Mechanically non-rigidcoupling of LAF


SERCOS interface

Linear scale

Fig. 6.4: Combination with two LAF motors, two drive control units and two measuringsystems


• Asymmetrical loads are fully stabilized independently of each other

• Larger spacing between motors possible


• Power increase compared to basic combination B)

• No rigid mechanics required


• High precision of measuring systems themselves and to each other re-quired (max. 5 µm/m)

• Two measuring systems required

• Increased costs for wiring

Advantages

Disadvantages



Basic combination E)


Combination E) is characterized by the following:

• Number of linear motors: >2

• Number of drive control units: >2



• Transducer signal distribution: yes

FSLAFxAxM1

Max. 4amplifier

Addl. digital drivers

Max. 4 x 2LAF Linear

motors

DGAtransducer

signal distribution

Primary part

Linear scale

Secondarypart

DDS 2 configured drive control unitsMechanically rigidcoupling of LAF

linear motorsCNC control

SERCOS interface

Fig. 6.5: Combination with several LAF motors, several drive control units and onemeasuring system



7. Measuring systems


7.1. General informationA measuring system is required for position and speed detection. Linear scaleson the basis of photo-electric scanning are available from various manufactur-ers for this purpose.

These incrementally operating systems provide two signals shifted by 90° withthe corresponding signal period. These are read into the evaluation electronicsin the drive control unit and intermediately interpolated to achieve a higheraccuracy and resolution.

An absolute dimensional reference is produced for an incremental measuringsystem by evaluating a reference mark on the scale. Therefore, the referencemark must be approached first after switching on the machine.

To avoid long approach paths with only one reference mark on the scale, linearscales are offered with distance-coded reference marks.

INDRAMAT drive control units are currently unable to evaluatedistance-coded reference marks when operated with linear motors.

Absolute measuring linear scales are currently being tested and will begenerally available from 1/96.

The measuring system is not available from INDRAMAT. It must be providedand installed by the machine manufacturer itself.

7.2. Selection

Depending on the respective application, linear scales are offered

• in encapsulated and open designs, and

• in various precision classes and

• with different signal periods.

Open measuring systems are recommended for applications requiring maxi-mum precision and control quality. In contrast to encapsulated systems, openlinear scales are characterized by contactless operation.

This results in the following advantages:

• no additional guidance by the measuring system is present in the axis

• no friction in the measuring system seals

These are opposed by the following disadvantages:

• sealing may need to be carried out by the machine manufacturer

• adjustment of the scanning device must be carried out by the machinemanufacturer during mounting on the machine.

For applications in the field of machine tools (MT), e.g., high-speed machining(HSC) and grinding machining, encapsulated measuring systems with thecorresponding rigid coupling are completely adequate.

Evaluation

Reference mark

Distance-codedreference marks

Open measuringsystems

Encapsulatedmeasuring systems

Absolute measuringsystems

Delivery status




The condition for the compatibility of the linear scale with the INDRAMAT drivecontrol units is an interface with a sinusoidal output signal with 11 µAss or 1 Vss.

Compatibility

Designation Unit min. typ. max.

Supply voltage V 4.75 5.0 5.25

Supply current mA 150

Ie1 ; Ie2 µAss 7 16

Ie0 µA 2 8

Ie1 ° el. 0

Ie2 ° el. 90

Signal shape Approx. sinusoidal

Max. input frequency kHz 150

Interpolation of signal periods 2048 fold

Mea

surin

gsy

stem

sup

ply

Incr

emen

tal o

utpu

t sig

nals

Phase angle

Signal current

Fig. 7.1: Specification of the interface for linear scales with sinusoidal current outputsignals 11 µAss

Designation Unit min. typ. max.

Supply voltage V 4.75 5.0 5.25

Supply current mA 150

A, B Vss

1

R V 0,4

A °el. 0

B °el. 90

Signal shape Approx. sinusoidal

Max. input frequency kHz 400

Interpolation of signal periods 2048 fold

Mea

surin

gsy

stem

sup

ply

Incr

emen

tal o

utpu

t sig

nals

Fig. 7.2: Specification of the interface for linear scales with sinusoidal voltage outputsignals 1 Vss

Phase angle

Signal current



To achieve a high linear scale resolution, an interpolation of the sinusoidalinput signal is carried out in the drive control unit with a factor of 2.048. In thisway, a resolution (measuring step) of up to approximately 2 nm can be realizeddepending on the signal period of the linear scale. However, this resolutiondoes not match the positioning exactness achievable with the measuringsystem!

The measuring system resolution does not match the positioningexactness achievable with the measuring system.

Measuring systems are selected under observance of the following criteria:

• Maximum traverse range (this determines the required measuring length)

• Maximum installation length

• Positioning exactness

• Maximum traversing speed (limited by the mechanically permissible speedor permissible input frequency of the evaluation electronics in the drivecontrol unit)

• Required protection type

• Observance of external influences, such as vibration or shock loading

Please use the special documentation of the linear scale supplier to make aselection.

The positioning exactness can be approximately determined from the scaleincrement or signal period of the linear scale as follows:


Max. speed(maximum input

frequency ofevaluation electronics)

vmax ≤ fin • tp • 0.06

vmax Maximum traversing speed in m/minfin Maximum input frequency of the evaluation

electronics in kHzfor linear scales with– current output signals: 150 kHz– voltage output signals: 400 kHz

tp Signal period in µm

Appropriate cables are available from INDRAMAT for the electrical connectionbetween the scale output and the evaluation electronics input. See Section 9.6for information.

tp

Signal period in µm∆s Positioning exactness in µm

(7.1)

(7.2)

∆s ≤ tp 20

Positioning exactness(absolute exactness)

Selection information

Measuring systemresolution




The following measuring systems from the firm Heidenhain are recom-mended:

Model designation for linear scale with

Designation: Current output signals Voltage output signals

11 µASS 1VSS

Open measuring system LIF 101 LIF 181(Tp=4 µm, vmax=36 m/min) (Tp=4 µm, vmax=96 m/min)

Encapsulated measuring LS 406 LS 486system (Tp=20 µm, vmax=120 m/min) (Tp=20 µm, vmax=120 m/min)

Recommendations

Linear scale with Transducer signal distribution

Voltage output signals 1 VSS DGA 1.2

7.3. Transducer signal distribution for operation ofseveral drives on one linear scale

For axes with several linear motors, several drive control units and only onecommon length measuring system, the output signals of the measuringsystem are distributed. Transducer signal distribution cards are available forthis purpose.

Up to 4 drive control units can be connected per transducer signal distribution.

APVERLINSPAN

~ Output signals to drive control unit

~ Output signals to drive control unit

Voltage input signals from linear scalePower supply DGA

(in a transducer cable)

~ Output signals todrive control unit + DGA 1.2

X4 X3

X2

X5 X6

X1

Output signals for monitoring purposes

Fig. 7.3: Transducer signal distribution for linear scales with voltage output signals (1 Vss)

Pre-fabricated INDRAMAT cables are available for the connections

• from the measuring system to the transducer signal distribution and

• from the transducer signal distribution to the drive control unit.




7.4. Transducer signal amplification for long cablelengths

When using linear scales with current output signals, a transducer signalamplification box DVG 1.1 must be used for cable lengths greater than 30 m.With this transducer signal amplification a maximum total cable length of 80m can be realized.

When using linear scales with voltage output signals, a maximum cable lengthof 50 m can be realized without transducer signal amplification. A transducersignal amplification to increase the cable length is currently only available inthe form of the transducer signal distribution box DGA 1.2. The maximumcable length is then 150 m.

Linear scales withcurrent output signals

Linear scales withvoltage output signals



8. Design information

LAF asynchronous linear motors are modular motors. They consist of aprimary and secondary part, which are to be integrated in the machine by themachine manufacturer (OEM).

Due to the fact that the motors must be an integral part of the entire machine,a few important points must be observed with regard to the design incomparison to conventional electromechanical linear axes (e.g., ball screwdrives). The following section provides information on:

• Possibilities of mechanical motor integration

• Installation dimensions and production tolerances

• Guides

• Mounting measuring system

• Sealing off against dirt

• Operation of vertical axes

• Motor cooling

• Braking of an axis in case of EMERGENCY STOP

• Set-up height and environmental conditions

8.1. Motor arrangementAfter specifying

• the type and number of the primary parts

• the type and length of the secondary parts

• the type and number of drive control units and

• the suitable system configuration

as described in Chapters 3, 4, 5 and 6, different possibilities for motorarrangement within the machine design result, particularly for axes withseveral motors mechanically connected in parallel. Possible arrangementsare shown in the following.


Possible motorarrangement on an

axis of motion

Fig. 8.1: One motor per axis

MZM1H

Measur-ingsystem

Carriage Cooling plate for primary part

Primary part

Machine bedSecondary partCooling plate for secondary part



Fig. 8.2: Two motors per axis


Fig. 8.3: Two motors per axis, vertical arrangement

MZM2V1

Carriage

Cooling plate for primary part

Primary partSecondary part

Cooling plate for secondary part

Machine bed

Measuring system

Advantage:

Disadvantage:

• Low deflection

• High installation height

MZM2H

Advantage:

Disadvantage:

Measuringsystem

Carriage Cooling plate for primary part

Primary part

Machine bed Secondary partCooling plate for secondary part

• Low installation height

• Rigid design required• Measuring system arrangement closest to center as possible difficult• Deflection due to force of attraction






MZM2V2

Carriage

Machine bedCooling platefor secondary part

Secondary part

Cooling platefor primary part Primary part

Measuringsystem

Advantage:

Disadvantages:

• High rigidity• No tipping torque on guide

• High installation space• Measuring system arrangement among motors difficult

MZM2V3

Carriage Cooling platefor primary part

Primary part

Measuringsystem

Machine bedCooling platefor secondary part Secondary part

Advantage:

Disadvantage:

• High rigidity

• High installation space• Tipping torque on guide• Mounting of primary part difficult



8.2. Basic mechanical conditions

8.2.1. Machine kinematics

To ensure a high acceleration capacity, the weight of the moved machineelements must be reduced to a minimum. This can be achieved by usingmaterials with a low specific weight (e.g., aluminum or compound materials)and through design measures (e.g., framework design).

If it is necessary to double several axes kinematically to produce pathmovements (e.g., compound table), then the reactions of the individual axesto each other must be minimized. Therefore, kinematic chains are to beavoided on machines with several axes. Here axis configurations with longprojection lengths that change during operation are particularly critical.

8.2.2. Mechanical rigidity

The rigidity of the individual mechanical components within a machine largelydetermines, in conjunction with the weight and the resulting resonancefrequency, the achievable quality of the machine. Here a differentiation ismade between the rigidity

• of the machine baseframe

• of axes located mechanically downstream in the case of kinematic couplingof axes

• of the axis of motion.

Due to reaction forces, consisting of acceleration, braking and process forces,from moving axes, the machine baseframe is stimulated to oscillate and issubjected to a deformation.


Machine baseframer

m • a cbaseframe

Example

a

∆s m

FBVERFOR

Fig. 8.6: Deformation of machine baseframe as a result of the reaction force duringacceleration

cbaseframe = 1000 N/µmm = 500 kga = 10 m/s2

Deformation of the machine frame:

∆s =

∆s = 5 µm




Rigidity ofkinematicallycoupled axes

Rigidity of theaxis of motion

With regard to the rigidity of kinematically coupled axes, it must be noted thatthe flexibility of the axes (both the mechanical flexibility and the componentresulting from the control technique) are added together.

The rigidity of an axis of motion is determined by the overall mechanicaldesign. The goal during the design process must be to design of axis ascompactly as possible. To ensure sufficient control quality, the lowest naturalfrequency occurring within the axis should not exceed approx. 200 Hz. Foraxes with non-constant forces of weight (e.g., workpieces to be machineddifferently), the natural frequencies also change so that a reduction in thefrequency f ~ 1/m occurs as the force of weight increases.

8.2.3. Motors arranged in parallel

If motors arranged in parallel are used with an axis of motion, then this can beoperated with

• a common measuring system (Fig. 8.7) or

• with two separate measuring systems (Fig. 8.8: gantry axis).

Which of the arrangements represents a reasonable technical and economi-cal solution is largely dependent on the rigidity of the connecting elementsbetween the individual motors and their installation symmetry with the axis.

Fig. 8.7: Axis with one measuring system

Axis with onemeasuring system

FSLAF2A2M1

DGA trans-ducer signaldistribution

Primary part

Linear scale

Secondarypart


CNC contr ol

SERCOS interface

Mechanicall y rigidcoupling of LAF

linear motors

Effect of non-symmetrical loads

If the control of both motors is supplied with the same actual position value (i.e.,only one common measuring system) and the control and axis parameters inthe drive control units are identical, then both motors are subjected to the sameforce. In the case of a non-symmetrical load (e.g., non-symmetrical weightdistribution

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Catálogos Levante Sistemas de Automatización y Control S.L. · 2019. 5. 28. · Distribuidor oficial Bosch Rexroth, Indramat, Bosch y Aventics. LSA Control S.L. - Bosch Rexroth