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LSA Control S.L. - Bosch Rexroth Sales PartnerRonda Narciso Monturiol y Estarriol, 7-9Edificio TecnoParQ Planta 1ª Derecha, Oficina 14(Parque Tecnológico de Paterna)46980 Paterna (Valencia)Telf. (+34) 960 62 43 01 [email protected] www.lsa-control.com www.boschrexroth.es

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Built-On Absolute Encoderfor 2AD Main Spindle Motors

DOK-ENCODR-2AD*ABSOLUT-PRJ1-EN-P

Project Planning Manual

mannesmannRexroth

engineering

Indramat266927

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

2• DOK-ENCODR-2AD*ABSOLUT-PRJ1-EN-E1,44 • 07.97



Table of Contents

Section

About this documentation__________________________________________________________________________

Table of contents__________________________________________________________________

Summary 1_________________________________________________________________

Technical data 2__________________________________________________________________

Mechanical dimensions 3______________________________________________________________________

Electrical connections 4_________________________________________________________________

Order information 5__________________________________________________________________

Procedures for setting home 6________________________________________________________________

Replacing the encoder 7________________________________________________________________



About this documentation

Danger:Information on guidelines and prohibitions to prevent injuryto personnel and damage to property.

Guidelines:Texts marked with this symbol indicate special information.

Mounted Absolute Encoder for 2AD Main Spindle Motors

Project Planning Manual

DOK-ENCODR-2AD*ABSOLUT-PRJ1-EN-E1,44

• 9.568.020.4-00

This electronic document is based on the hardcopy document with documentdesig.: 9.568.020.4-00 EN/06.93

– To supply electrical data and mechanical dimensions of the mountedabsolute encoder for 2AD main spindle motors of the 2AD 132, 2AD 160 and2AD 180 series.

– To assist in the selection of the correct connectors and ready-made cables.

– To assist with type codes for ordering 2AD main spindle motors with mountedabsolute encoders or absolute encoder mounting sets.

– It supplies steps on the correct procedures for replacing an absolute encoder.

Titel

Type of documentation:

Documenttype

Internal file reference

Reference

This documentationis used:

© INDRAMAT GmbH, 1994Copying 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 (MR, FS)

Copyright

Validity

Publisher

Designation of documentation Release- Comentsup to present edition date

9.568.020.4-00 EN/06.93 Jun/93 First Edition

DOK-ENCODR-2AD*ABSOLUT-PRJ1-EN-E1,44 Jul./97 First E-Dok

Change procedures

Definition of thesymbols used in this

document



Documentation summary

Selection data- overview of the AC main drive system- power ratings- technical functions of the AC main spindle drive- selection protocols and order lists- product availability

AC main spindle driveswith controlled

asynchronous motor

2AD

AC main spindle drive with controlled 2ADasynchronous motorS

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AC main spindle drivewith controlled

asynchrous motor orframeless spindle motor

AC main spindle drive with controlledasynchrous motor or frameless spindle motor

Applications- commissioning the AC spindle drives- using the drive- the functions of the drive- diagnostics and fault clearance- overview of parameters and interfacesM

ain

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dle

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Main spindle drives

Project planning- constructing the control cabinet- AS programming module- delivery, storage, transportation- mounting and installation guidelines

Main spindle motor

Project planning- planning the machine- delivery, storage, transportation- mounting and installation guidelines

Electrical connections

Project planning- general guidelines on the electrical connections- feedback circuits and NC terminals of all main spindle drives- power connection circuits of all main spindle drives

RAC4RAC3

RAC2TDA1

Drive KDA3

Asynchronmotor

200Asynchronmotor

180Asynchronmotor

160Asynchronmotor

132Asynchronmotor

101Asynchronous motor

2AD100

Electricalconnections

for mainspindle drives

AC main spindle drives with 2AD main spindle motors ...

Figure 1: Documentation summary of "AC main spindle drives with 2AD mainspindle motors and 1MB frameless spindle motor"



Documentation summary

AC - main spindle drives withcontrolled 2AD asynchronous motorsand 2K planetary gearboxes

Selection data- overview of the AC main drive system- power ratings- order lists

AC main spindledrives with 2K

gearboxces

AC main spindle driveswith controlled frameless

spindle motor

1MB

AC main spindle drives with controlled framelessspindle motor 1MBSelection data- overview of the AC main drive system- power ratings- technical functions of the AC main spindle drive- selection protocols and order lists- product availability

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... and 1MB frameless spindle motors

Frameless spindle motor

Project planning- planning the machine- integrating the cooling system- electrical and coolant connections- delivery

Mounting guidelines- delivery, handling, transport- mounting- cooling guidelines

Supplementary documentation- High-resolution main spindle position encoder- incremental encoder output IGS- high-resolution encoder junction HGV- mounted absolute encoder for 2AD main spindle motors

Bausatzspindel-motor

1MB 375Bausatzspindel-

motor


motor


motor

1MB 2001MB

- RotorFrameless spindle

motor

1MB 160

1MB- Stator

HGV

IGS

High-resolutionmain spindle

position encoder

Absoluteencoder for

2AD

You have this document ...



Table of Contents

Table of Contents

1. Summary 11

2. Technical data 12

3. Mechanical dimensions 13

3.1. Built-on absolute encoder mounted to 2AD mainspindle motor

Mounting set AM 174 SG ........................................................ 13

4. Electrical connections 14

4.1. Terminal diagrams .................................................................. 14

4.2. Ready-made cable .................................................................. 15

4.3. Installation guidelines ............................................................. 16

5. Order details 17

5.1. Order details for 2AD main spindle motors withbuilt-on absolute encoder ....................................................... 17

5.2. Ordering replacement parts for an absoluteencoder mounting set ............................................................. 17

6. Procedures for setting home 18

7. Replacing the encoder 19



While incremental encoders calculate changes in position by addingor subtracting increments in the control, absolute encoders supply anunequivocal (absolute) position value. These values are availableeven after an emergency stop or if the power is switched off. Thiseliminates the need for costly homing procedures of each individualaxis. The current actual position value is immediately available evenafter an axis has been moved while no power was applied.

There are two different types of rotary absolute encoders:

1. Summary

1. Summary

Every angular position between 00 and 3600 is assigned an absolutevalue.

Multiturn encoder In addition to the absolute position in terms of the 3600, a multiturnencoder breaks up a definite number of revolutions assigning abso-lute values.

Figure 1.1: 2AD main spindle motor with mounted absolute encoder

INDRAMAT 2AD main spindle motors are available in Design 3 (motortype code field "motor feedback") with mounted absolute encoder.This is the type most commonly ordered. Mounting sets are alsoavailable. A mounting set makes it possible to equip a 2AD mainspindle motor with second shaft end with an absolute encoder. Forreasons of dimensional precision, the encoders are completelyassembled as a set with the flange needed for that motor size. In theevent a replacement is necessary, the entire set must be replaced.

Primary features – Multiturn encoder with a resolution of 24 bits, gray code,4096 increments / 3600 x 4096 revolutions

– synchronous serial interface

– fully insulated, robust construction

– plug connections, 12 pin

– complete protection against contact; protection against a jet of water(protection category is IP 65 after mounting)

2ADmit Absolgeber

2AD main spindle motor withmounted absolute encoder

Single-turn encoder



2. Technical data

2. Technical data

Figure 2.1: Mounted absolute encoder - technical data

Supply voltage range: DC 10 V...32 V, prot. against polarity reversalPower consumption: ≤ 3 W

Sampling code: gray codeClockwise counting directionlooking towards shaft: risingTransmission of data: synchronous, serialSerial data output: driver as per EIA RS 422 protected against short-circuitMono stable output time tm: 15 µs < tm < 25 µsClock frequency: 200 kHzMinimum clock brush: 30 µsData format: 24 bitProtection categorywhen mounted: IP 65

PFB = power failure bitT = duration of the clock signaltm = mono stable output

Power failure bit:If breaks in the supply voltage (< 5 V) occur over a period longer than 100 µsthen the encoder data could be corrupted.The power failure bit (PFB) indicates this error. A comparator is used in the event of a voltage break to set the PFB in the serial information to logical 1.

Delay time Tv: max. 300ns (clock (+) to data (+) or data (-), measured at the coder).

clock input circuit data output circuit

as per EIA RS 422, short-circuit proof

data +

data -22 pF

22pF

clock +

clock -

100 Ohm

1nF

1nF

100 Ohm

91Ohm

91Ohm

LED2V

clock

serialdata

Tv

tm

G23 G22 G0 PFB

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

G23 G22G21G20 G19G18 G17G16G15 G14G13G12 G11 G10 G9 G8 G7 G6 G5 G4 G3 G2 G1 G0 PFB11

CLOCK +tm - T/2

T

10

TDAbsol



3. Mechanical dimensions

3. Mechanical dimensions

3.1. Mounted absolute encodermounted to a 2AD main spindlemotor Mounting set AM 174 SG

Figure 3.1: Absolute encoder mounting set AM 174 SG mounted to a 2ADasynchronous motor

105

C

motor type

2AD 1322AD 1602AD 180

dim."C"in mm

7934

129

103

22.5° ±5°37.5° ±5° *

*

Dim "A" is outlined in the relevant motor documentation.

*) These tolerances indicate the exterior contours. They are not setting tolerances!

A

AbsolAnbau



4. Electrical connections


Figure 4.1: Absolute encoder terminal diagram

AP2ADGeber

line IN 209(color coding as per

INDRAMAT standard)

red

bk

gn

br

gr

pk

bl

vio

wh

br

0.25 mm2

0.25 mm2

0.25 mm2

0.25 mm2

0.25 mm2

0.25 mm2

0.25 mm2

0.25 mm2

1.0 mm2

1.0 mm2

11

3

10

2

4

5

7

9

8

1

12

6

absolute encoder(mounted to motorwith electrical insulation)

plug-in connector (12 pin)

IN 326

not available ready-made

available ready-made52

26

plug-in connector (12 pin)

IN 92

54

line IN 234 or other

clock (-)

clock (+)

data (-)

data (+)

not assigned

not assigned

not assigned

not assigned

supply voltage

0V

not assigned

shield

26

To maintain protection category IP 65, plug-in connector IN326 may only be connected to line IN 209!

With other line types, protection category IP 65 is onlypossible if plug-in connector IN 92 is used.

4.1. Terminal diagram




Order designation ofthe ready-made position

feedback cable

Type designations of theplug-in connector

IN 326

IN 327

IN 292

IN 209

IN 209

IN 209

IKS 801/ . . .

IKS 806/ . . .

IKS 724/ . . .

Cable enddesign

with ferrulesfor connectionto modular terminal

for connectionto CLM

Line

with coupling unitfor connection toplug-in connectorIN 326 orIKS 801

Figure 4.2: Available ready-made position feedback cables for the built-onabsolute encoder

IN 209 - data

4.2. Ready-made cables

Cable diameter 8.8 mm

Bending radius, fixed routing 40 mm

Bending radius, flexible routing

(more than 500,000 bending loads) 90 mm

Specific weight 0.102 kg/m

Chemical characteristics absolute resistance to

mineral oils and greases,

hydrolysis resistant,

silicone and halogen free

Permissible ambient temperature

for operation and storage -300C to +800C

Cable surface poor adhesion, prevents

sticking in drag chains

Maximum cable length 75 meters

Figure 4.3: IN 209 - technical data



4.3. Installation guidelines


Figure 4.4: Examples of separate and shielded routing of motor power andfeedback cables

Experiences with various industrial applications have demonstratedthat installation is a significant factor. Please note the followingguidelines to avoid emitting interference into feedback lines:

– Always use shielded lines for feedback lines. This is guaranteed, ifINDRAMAT lines are used.

– Apply shield of feedback line in the plug-in connector to the NC!

– Do not apply the shield to the motor housing. (To avoid earth loops,the encoders are insulated, in contrast to the motors.)

– Maintain a minimum clearance of 100 mm if feedback and powercables are routed parallel, or use a metallic partition in the powercable (Figure 4.4).

– Do not remove or insert connectors with power on.

– Do not route the feedback lines in close proximity to high-frequencyequipment, power transformers, chokes, motors and other machineswith strong magnetic fields. Also do not route near high-voltagelines, otherwise interference could be coupled in.

metallic cable channel

MZKabKan

2 - 4 mm>=100 mm

synthetic cable channel



5. Order information

5. Order information

5.1. Order information for a2AD main spindle motor withbuilt-on absolute encoder

Order 2AD main spindle motors with absolute encoders as follows:

Ordering a 2AD main spindle motor with a second shaft end and aradial blower.

the text of the order

Example: 2AD132C-B05RB3-AS03-A 3 N1

Ordering the absolute encoder


Example: AM 174 SG

Ordering the absolute encoder set for the 2AD asynchronous motor


Example: mounting set AM 174 SG for2AD132C-B05RB3-AS03-A3N1

Feedback connector and line or ready-made cable


Example: IN 326 and IN 209/(length)(see section 4.2) or IKS 801

Item 1

Item4

Item 2

Item 3

5.2. Ordering replacementsparts for an absoluteencoder mounting set

The mounting set of the absolute encoder can be ordered individually.


order designation: AM 174 SG

A special tool is offered for mounting and setting (INDRAMAT part no.243 044) see Figure 7.1. The tool must be ordered separately.


order designation EW1



6. Procedures forsetting home

6. Homing procedure

Various procedures can be used to set the homing point.

Set the zero point of the absolute encoder to the mechanical homingpoint.

– set the main spindle drive to the homing point (jog mode)

– connect the control unit to the absolute encoder

– remove the absolute encoder - motor shaft connection (specialsetting tool, part no.: 243 044)

– turn the absolute encoder to the zero point; evaluation by the controlunit

– test run

2nd procedure Set the end of the measuring range of the absolute encoder to themechanical axis end position.

– run the mechanics to the end position

– connect the absolute encoder to the control unit

– remove the absolute encoder - motor shaft connection (setting tool,part no.: 243 044)

– turn the absolute encoder to the relevant end position

– re-connect absolute encoder - motor shaft

– test run

3rd procedure Electronic shifting of the zero point in the control unit (depends on thecontrol unit)

– the absolute encoder remains clamped to the motor

– the drive is connnected to the mechanics

– drive is moved to homing point (jog mode)

– the absolute value of the encoder is read in and interpreted by thecontrol unit as a zero point

1st procedure



7. Encoder replacement


The absolute encoders which INDRAMAT mounts are high-quality measuring systems developed for rugged operationson production machines. The careful mounting of the completemounting set will guarantee trouble-free and continuousoperation.

The encoders are replaced on site as one complete unit.

Do not use harsh cleansers for cleaning the units.The encoder may only be operated if the filler plugs are firmlyscrewed into place (10) (any contamination by dirt can causethe encoder to break down).

Required tools Hexagon socket key, angular, SW 3Hexagon socket key, straight, SW 4Torque key 0 to 5 NmScrewdriverSetting tool, part no. 243 044 (11)

Risk of accident from uncontroll axis movements!Switch servo motor off before working on the absoluteencoder.Pull or insert encoder connector only when power is off.




Removing the absoluteencoder

1. Screw filler plug (10) out of the encoder housing.

2. Place setting tool (11) on expanding mandrel (8) and hold firmly inthis position.

3. Using a hexagon socket screw (SW4) pull the expanding mandrel(9) out with approximately six revolutions!

Do not twist the setting tool during this procedure!The coupling and the encoder expanding mandrel are now

separated.

4. Remove the four screws (4) (SW3) and carefully pull the entireencoder set out. The coupling remains firmly clamped to the motorshaft.

5. If necessary when replacing the coupling, remove the couplingclamped onto the motor shaft after the cylindrical screw has beenremoved (13).

1. Carefully remove the replacement unit out of its packaging.

2. Remove filler plugs (10) on the encoder housing.

3. Check to see whether the expanding shaft (8) is unloaded.

4. It must be possible to slightly move the coupling on the expandingshaft (9). If not, place and hold firmly the setting tool onto thehexagon socket of the expanding shaft. Now, turn the expandingmandrel (9) with a hexagon socket screw (SW4) to the left for six fullrotations. The expanding shaft is now unloaded.

These are the pre-requisites for a correct mounting of the replacementunit.

Figure 7.1: Cross-section drawing of absolute encoder mounting set AM 174 SG

6

1

Shaft end of the motor on side B. Permissible concentricity deviation of the motor shaft equals 0.04 mm

cylindrical screw with hexagon socket SW 3 3.4 Nm

7

8

11 12

SW 4 expanding mandrell

adjustment tool

torque key

13

max. 37 mmmin. 35.5 mm

cylindrical screw with hexagon socket SW 4 5.7 Nm

SchnittBausatz

9

10

23

4

5

A

AG 100 MSSI

ma

x.

torq

ue

3.4

Nm

Preparing the encoder formounting




cover

mit2temWellende

Mounting the new encoder 1. Remove the cover on shaft end of side B (if one is mounted)

2. Push coupling (1) onto the second shaft end

3. Dimension "A" (set distance of flange surface to the end of thecoupling, see Figure 7.1)

4. Tighten screw (13) with 3.4 Nm

5. Check whether O ring (2) is mounted to unit

6. Set the mounting set carefully, and without tipping, onto themotor. Feed the expanding shaft (8) into the coupling at the sametime.

7. Turn connector (6) so that the angle as depicted Figure 3.1 isgiven

8. Fix mounting set into place using the four screws with sealingrings (4). Tightening torque: 5.7 Nm.

9. Place setting tool (11) onto expanding shaft (8).Hold the setting tool firmly in this position.

10. Tighten expanding mandrel (9) using torque key.Tightening torque: 3.4 Nm

11. Screw filler plug (10) into encoder housing

12. Insert connector

13. Switch power on

14. Switch drive on and check encoder function

15. Run a homing procedure

Figure 7.2: 2AD main spindle motor with second shaft end


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

Catálogos Levante Sistemas de Automatización y Control S.L.€¦ · Delay time Tv: max. 300ns...

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