Bosch Rexroth IndraDyn L Technical manual

The Drive & Control Company
Rexroth IndraDyn L
Ironless Linear Motors MCL
Edition 05
Project Planning Manual
R911330592

Rexroth IndraDyn L
Ironless Linear Motors MCL
Project Planning Manual
DOK-MOTOR*-MCL********-PR05-EN-P
RS-82551fe8ab5f14650a6846a001697ff3-8-en-US-10
Edition Release Date Notes
DOK-MOTOR*-MCL********-PR01-EN-P 2011-01-11 Edition 01
DOK-MOTOR*-MCL********-PR01-EN-P 2011-06-24 Edition 01.1 (Frame size
MCL030 added)
DOK-MOTOR*-MCL********-PR01-EN-P 2011-07-13 Edition 01.2 (Technical
data updated)
DOK-MOTOR*-MCL********-PR02-EN-P 2012-07-10 Edition 02 (revision and
amendment MCP070M)
DOK-MOTOR*-MCL********-PR03-EN-P 2014-04-11 Edition 03 (revision)
DOK-MOTOR*-MCL********-PR04-EN-P 2014-06-06 Edition 04 (details about
commutation adjustment
Chapter 14.6 amended)
DOK-MOTOR*-MCL********-PR05-EN-P 2015-02-02 Edition 05 (details about
parallel arrangement
added)
Copyright © Bosch Rexroth AG 2015
This document, as well as the data, specifications and other information set
forth in it, are the exclusive property of Bosch Rexroth AG. It may not be re‐
produced or given to third parties without its consent.
Liability The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated
in the contract. All rights are reserved with respect to the content of this docu‐
mentation and the availability of the product.
Note This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Record of Revision
Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P
Rexroth IndraDyn L Ironless Linear Motors MCL

Table of Contents
Page
1 Rexroth MCL - Product presentation............................................................................. 7
1.1 Fields of application ironless linear motors............................................................................................. 7
1.2 Construction ironless linear motors........................................................................................................ 8
1.3 Comparison ironless with ferreous linear motors.................................................................................... 8
1.4 Power spectrum of MCL motors............................................................................................................. 9
1.5 About this documentation..................................................................................................................... 10
1.5.1 Document structure........................................................................................................................... 10
1.5.2 Additional documentation.................................................................................................................. 10
1.5.3 Standards.......................................................................................................................................... 11
1.5.4 Additional components...................................................................................................................... 11
1.5.5 Your feedback................................................................................................................................... 11
2 Important instructions on use....................................................................................... 13
2.1 Appropriate use.................................................................................................................................... 13
2.1.1 Introduction........................................................................................................................................ 13
2.1.2 Areas of use and application............................................................................................................. 13
2.2 Inappropriate use.................................................................................................................................. 14
3 Safety Instructions for Electric Drives and Controls..................................................... 15
3.1 Definitions of Terms.............................................................................................................................. 15
3.2 General information.............................................................................................................................. 16
3.2.1 Using the Safety instructions and passing them on to others............................................................ 16
3.2.2 Requirements for safe use................................................................................................................ 16
3.2.3 Hazards by improper use.................................................................................................................. 17
3.3 Instructions with Regard to Specific Dangers....................................................................................... 18
3.3.1 Protection Against Contact with Electrical Parts and Housings......................................................... 18
3.3.2 Protective extra-low voltage as protection against electric shock .................................................... 19
3.3.3 Protection against dangerous movements........................................................................................ 20
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 21
3.3.5 Protection against contact with hot parts........................................................................................... 22
3.3.6 Protection during handling and mounting.......................................................................................... 22
3.3.7 Battery safety..................................................................................................................................... 22
3.3.8 Protection Against Pressurized Systems........................................................................................... 23
3.4 Explanation of signal words and the Safety alert symbol..................................................................... 23
4 Technical data.............................................................................................................. 25
4.1 Explanations about technical data........................................................................................................ 25
4.1.1 Introduction........................................................................................................................................ 25
4.1.2 Operating behavior............................................................................................................................ 25
4.1.3 Description of specified sizes............................................................................................................ 27
4.2 General technical data.......................................................................................................................... 29
4.3 Technical data - frame size MCL015.................................................................................................... 30
4.3.1 Data sheet MCP015.......................................................................................................................... 30
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Page
4.3.2 Data sheet MCS015.......................................................................................................................... 30
4.3.3 Motor characteristic curve frame size 015......................................................................................... 31
4.4 Technical data - frame size MCL020.................................................................................................... 32
4.4.1 Data sheet MCP020.......................................................................................................................... 32
4.4.2 Data sheet MCS020.......................................................................................................................... 32
4.4.3 Motor characteristic curves frame size 020....................................................................................... 33
4.5 Technical Data - frame size MCL030................................................................................................... 35
4.5.1 Data sheet MCP030.......................................................................................................................... 35
4.5.2 Data sheet MCS030.......................................................................................................................... 35
4.5.3 Motor characteristic curve frame size 030......................................................................................... 36
4.6 Technical data - frame size MCL040.................................................................................................... 38
4.6.1 Data sheet MCP040.......................................................................................................................... 38
4.6.2 Data sheet MCS040.......................................................................................................................... 39
4.6.3 Motor characteristic curves frame size 040....................................................................................... 40
4.7 Technical data - frame size MCL070.................................................................................................... 42
4.7.1 Data sheet MCP070.......................................................................................................................... 42
4.7.2 Data sheet MCS070.......................................................................................................................... 43
4.7.3 Motor characteristic curve frame size 070......................................................................................... 44
5 Dimension sheets........................................................................................................ 47
5.1 Installation tolerances........................................................................................................................... 47
5.1.1 General information........................................................................................................................... 47
5.1.2 Frame size MCL015.......................................................................................................................... 48
5.1.3 Frame size MCL020 ... 070............................................................................................................... 49
5.1.4 Parallelism and symmetry of machine parts...................................................................................... 50
5.2 Dimension sheets MCL015................................................................................................................... 52
5.3 Dimension sheets MCL020................................................................................................................... 54
5.4 Dimension sheets MCL030................................................................................................................... 56
5.5 Dimension sheets MCL040................................................................................................................... 58
5.6 Dimension sheets MCL070................................................................................................................... 60
6 Type codes.................................................................................................................. 63
6.1 Type code structure and description .................................................................................................... 63
6.1.1 General information........................................................................................................................... 63
6.1.2 Type code primary part MCP............................................................................................................. 63
6.1.3 Type code secondary part MCS........................................................................................................ 65
6.2 Type code frame size 015.................................................................................................................... 66
6.3 Type code frame size 020.................................................................................................................... 68
6.4 Type code frame size 030.................................................................................................................... 70
6.5 Type code frame size 040.................................................................................................................... 72
6.6 Type code frame size 070.................................................................................................................... 74
7 Accessories and options.............................................................................................. 77
7.1 Hall unit ................................................................................................................................................ 77
7.1.1 General information........................................................................................................................... 77
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Page
7.1.2 Hall unit functional princple................................................................................................................ 77
7.1.3 Hall unit assembly/disassembly......................................................................................................... 80
7.1.4 Ordering designation separate Hall unit............................................................................................ 81
7.2 Hall unit adapter box SHL03.1.............................................................................................................. 81
7.2.1 General functional principle............................................................................................................... 81
7.2.2 Order designation Hall unit adapter box ........................................................................................... 81
8 Connection technique.................................................................................................. 83
8.1 Power connection ................................................................................................................................ 83
8.1.1 Connection cable on primary part...................................................................................................... 83
8.1.2 Assembly connection cable on primary part...................................................................................... 85
8.1.3 Connection Power ............................................................................................................................ 86
8.1.4 Installation of power connection........................................................................................................ 88
8.2 Sensors................................................................................................................................................. 90
8.2.1 Connection temperature sensor........................................................................................................ 90
8.2.2 Connection Hall unit.......................................................................................................................... 90
8.2.3 Assembly Hall unit connection cable................................................................................................. 92
8.2.4 Connect digital Hall unit..................................................................................................................... 93
8.2.5 Connect analog Hall unit................................................................................................................... 94
8.3 Length measuring system .................................................................................................................... 94
9 Application and construction instructions..................................................................... 97
9.1 Mode of functioning.............................................................................................................................. 97
9.2 Motor design......................................................................................................................................... 97
9.2.1 Design primary part .......................................................................................................................... 97
9.2.2 Design secondary part ...................................................................................................................... 98
9.2.3 Frame size and frame length............................................................................................................. 99
9.3 Setup elevation and ambient conditions............................................................................................. 100
9.4 Ambient conditions............................................................................................................................. 101
9.5 Degree of protection........................................................................................................................... 102
9.6 Acceptances and approvals................................................................................................................ 102
9.6.1 CE-Sign........................................................................................................................................... 102
9.6.2 RoHS conformity............................................................................................................................. 102
9.7 Magnet fields...................................................................................................................................... 103
9.8 Noise emission................................................................................................................................... 104
9.9 Thermal behavior................................................................................................................................ 104
9.10 Motor temperature monitoring............................................................................................................ 107
9.11 Feed force at reduced covering between primary and secondary part.............................................. 108
9.12 Requirements on the machine design................................................................................................ 110
9.12.1 General............................................................................................................................................ 110
9.12.2 Mass reduction................................................................................................................................ 110
9.12.3 Mechanical rigidity........................................................................................................................... 110
9.12.4 Protection of the motor installation space........................................................................................ 112
9.12.5 Thermal motor connection............................................................................................................... 112
9.13 Arrangement of motor components.................................................................................................... 112
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Page
9.13.1 Single arrangement......................................................................................................................... 112
9.13.2 Several motors per axis................................................................................................................... 113
9.13.3 Arrangement of secondary parts..................................................................................................... 118
9.13.4 Vertical axis .................................................................................................................................... 119
9.14 Length measuring system................................................................................................................... 119
9.14.1 General............................................................................................................................................ 119
9.14.2 Selection criteria for length measuring system ............................................................................... 119
9.15 Linear guiding systems....................................................................................................................... 121
9.16 Manufacturers of linear guiding systems............................................................................................ 121
9.17 Braking systems and holding devices................................................................................................. 122
9.18 End position shock absorber ............................................................................................................. 122
9.19 Axis cover systems............................................................................................................................. 122
9.20 Drive and control of IndraDyn L motors.............................................................................................. 123
9.20.1 General............................................................................................................................................ 123
9.20.2 Drive controllers............................................................................................................................... 123
9.20.3 Control systems............................................................................................................................... 123
9.21 Deactivation upon EMERGENCY STOPand in the event of a malfunction ....................................... 124
9.21.1 General............................................................................................................................................ 124
9.21.2 Deactivation by the drive................................................................................................................. 124
9.21.3 Deactivation by a master control..................................................................................................... 125
9.21.4 Deactivation via mechanical braking device.................................................................................... 125
9.21.5 Response to a mains ...................................................................................................................... 125
9.21.6 Short-circuit of DC bus.................................................................................................................... 127
9.22 Position and velocity resolution.......................................................................................................... 127
9.22.1 Drive internal position resolution and position accuracy ................................................................. 127
9.22.2 Velocity resolution........................................................................................................................... 128
10 Motor-controller-combinations................................................................................... 129
10.1 General information............................................................................................................................ 129
10.2 Motor-controller-combinations with NYCe 4000................................................................................. 129
10.3 Motor-controller-combinations with IndraDrive Cs.............................................................................. 130
11 Motor dimensioning ................................................................................................... 131
11.1 General procedure.............................................................................................................................. 131
11.2 Basic formulae.................................................................................................................................... 132
11.2.1 General movement equations ........................................................................................................ 132
11.2.2 Feed forces...................................................................................................................................... 133
11.2.3 Average velocity.............................................................................................................................. 136
11.2.4 Trapezoidal velocity profile.............................................................................................................. 137
11.2.5 Triangle-shaped velocity profile....................................................................................................... 141
11.2.6 Sinusoidal velocity profile ............................................................................................................... 142
11.3 Duty cycle and feed force................................................................................................................... 145
11.3.1 General information......................................................................................................................... 145
11.3.2 Determining the duty cycle.............................................................................................................. 145
11.4 Determining the drive power............................................................................................................... 146
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Rexroth IndraDyn L Ironless Linear Motors MCL
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Page
11.4.1 General information......................................................................................................................... 146
11.4.2 Rated output ................................................................................................................................... 146
11.4.3 Maximum output.............................................................................................................................. 147
11.4.4 Power loss ...................................................................................................................................... 148
11.5 Energy regeneration .......................................................................................................................... 148
11.6 Efficiency............................................................................................................................................ 149
11.7 Thermal connection of MCL motors on the machine.......................................................................... 149
11.8 Operation at or near motor standstill.................................................................................................. 152
12 Handling, transport and storage................................................................................. 153
12.1 Identification of the motor components............................................................................................... 153
12.1.1 Primary part..................................................................................................................................... 153
12.1.2 Secondary part................................................................................................................................ 154
12.2 Delivery status and packaging............................................................................................................ 155
12.2.1 Primary parts................................................................................................................................... 155
12.2.2 Secondary parts.............................................................................................................................. 155
12.3 Checking the motor components........................................................................................................ 155
12.3.1 Factory checks of the motor components ....................................................................................... 155
12.4 Transport and storage........................................................................................................................ 156
12.4.1 Notes about transport...................................................................................................................... 156
12.4.2 Notes about storage........................................................................................................................ 157
13 Installation.................................................................................................................. 159
13.1 Basic precondition.............................................................................................................................. 159
13.2 Arrangement of motor components.................................................................................................... 159
13.3 Installation of motor components........................................................................................................ 160
13.4 Air-gap, parallelism and symmetry of the motor components............................................................. 160
13.5 Fastening secondary part................................................................................................................... 161
13.6 Fastening the primary part.................................................................................................................. 163
13.7 Electrical connection .......................................................................................................................... 164
14 Commissioning, operation and maintenance............................................................. 165
14.1 General information for startup of ironless IndraDyn L motors........................................................... 165
14.2 General requirements ........................................................................................................................ 165
14.2.1 General information......................................................................................................................... 165
14.2.2 Checking all electrical and mechanical components....................................................................... 165
14.2.3 Tools................................................................................................................................................ 166
14.3 General start-up procedure................................................................................................................. 166
14.4 Parameterization................................................................................................................................. 168
14.4.1 General information......................................................................................................................... 168
14.4.2 Entering motor parameters.............................................................................................................. 168
14.4.3 Entering length measuring system parameter................................................................................. 168
14.4.4 Entering drive limitations and application-related parameters......................................................... 169
14.5 Determining the polarity of the linear scale......................................................................................... 170
14.6 Commutation adjustment.................................................................................................................... 171
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14.6.1 General information......................................................................................................................... 171
14.6.2 Sinusoidal procedure....................................................................................................................... 173
14.6.3 Hall sensor procedure..................................................................................................................... 173
14.6.4 Measuring procedure: Measuring the reference between primary and secondary part.................. 174
14.7 Setting and optimizing the control loop............................................................................................... 176
14.7.1 General procedure........................................................................................................................... 176
14.7.2 Parameterization and optimization of Gantry axes.......................................................................... 179
14.7.3 Estimating the moved mass using a velocity ramp ......................................................................... 180
14.8 Maintenance and check of motor components................................................................................... 182
14.8.1 General information......................................................................................................................... 182
14.8.2 Check of motor and auxiliary components ..................................................................................... 182
14.8.3 Electrical check of motor components............................................................................................. 182
14.9 Operation with third-party controllers.................................................................................................. 183
14.10 Environmental protection and disposal .............................................................................................. 183
14.10.1 Environmental protection................................................................................................................. 183
14.10.2 Disposal........................................................................................................................................... 183
15 Service and support................................................................................................... 185
Index.......................................................................................................................... 187
Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-PVI/193
Rexroth IndraDyn L Ironless Linear Motors MCL
Table of Contents

1 Rexroth MCL - Product presentation
1.1 Fields of application ironless linear motors
Continuously increasing demands on economic benefit of electric machines
require new problem-solving approaches to fulfill the requirements on dynam‐
ic, accuracy and synchronization. Conventional NC-drives, consisting of a ro‐
tary electrical motor and mechanical transmission elements like gearboxes,
belt transmissions or gear rack pinions, cannot fulfill these demands or, if on‐
ly with high effort.
Ironless linear direct drive technique is an extension of the IndraDyn L prod‐
uct family with innovative product characteristics. Due to the wide application
range of ironless linear motors, medium to midget mass can be moved and
positioned high-dynamically and high-precisely.
Based on the above-mentioned advantages, typical applications result for ex‐
ample in:
● Electronic, placement technology and manufacturing technology
● Solid state technology (e.g. wafer-inspection and bonding)
● Medicine technology (e.g. transport of pipettes)
● Solar technology (e.g. for laser structuring)
● Precision and ultra-precision machining
Even in other areas, for example, in machine tool industry, printing industry
and especially in measuring technology, the advantages of this technology
becomes important.
The ironless drive technology offers a lot of significant advantages in oppo‐
site to a ferrous motor, without accepting disturbing ancillary effects like cog‐
ging. For this reason, it is the optimum option for many applications.
Significant advantages of ironless linear motors are:
● Highest dynamic
● Excellent control quality and synchronization
● No magnetic attractive force, no detent torque
● High-precision positioning behavior
● Direct power transfer – no mechanical transmission elements like ball
srew, toothed belt, gear rack, etc.
● High efficiency - low overhead
● Maintenance-free drive (no wearing parts at the motor)
● Simplified machine structure
For a comprehensive overview of all product families of Bosch
Rexroth Electric Drives and Controls, please refer to the following
link in our online product catalog: http://www.boschrexroth.com/
indradyn.
DOK-MOTOR*-MCL********-PR05-EN-P Bosch Rexroth AG 7/193
Rexroth IndraDyn L Ironless Linear Motors MCL
Rexroth MCL - Product presentation

1.2 Construction ironless linear motors
Ironless linear motors MCL consist of the components primary and secondary
part and have an optional Hall unit .
The ironless primary part bears the electrically active part of the linear motor
with a winding, cast in plastics. The primary part carrier made of aluminum
serves to assemble the primary part and for heat dissipation out of the pri‐
mary part. A fastening of an optional Hall unit for position recording is pre‐
pared on the primary part. Additionally, a temperature sensor is placed in the
winding. Hall unit and temperature sensor are available for all MCL, except
for the smalles frame size.
The secondary part consists of an u-shaped iron yoke. The legs of the yoke
bear permanent magnets and surround the primary part. The line is built with
the secondary parts and can be realized as long as required.
The motor designation depends on the ironless primary part. The designation
is as follows:
●MCL: Motor Coreless Linear
●MCL: Motor Coreless Primary part
●MCS: Motor Coreless Secondary part
Fig. 1-1: Rexroth MCL example
1.3 Comparison ironless with ferreous linear motors
Ferreous linear motors use the iron, in which the winding is inserted to bundle
the magnetic flow. Therewith, a very high force density is reached. Act up to
a principle, very high magnetic attractive forces exist among the motor com‐
ponents (primary and secondary part). These lead to detent force and due to
saturation effecst to other parasitic effects, such as e.g. winding influences
for ripple of the operation force.
No attractive forces exist among primary and secondary part towards ferre‐
ous linear motors. Detent forces due to a slotting, existing for ferreous linear
motors are also not created. These aspects and the relatively small moved
mass of the primary part allow a vergy high dynamic with high precision at
the same time.
Additionally wearing mechanical components are not necessary due to direct
installation into the machine. Due to not existing mechanical elements, a
backlash free, with minimum or without hysteresis afflicted drive train, is
available.
Bosch Rexroth AG DOK-MOTOR*-MCL********-PR05-EN-P8/193
Rexroth IndraDyn L Ironless Linear Motors MCL
Rexroth MCL - Product presentation