Bosch rexroth MCL Technical manual

MCL
Ironless Linear Motors
Project Planning Manual
R911330592
Edition 06

MCL
Ironless Linear Motors
Project Planning Manual
DOK-MOTOR*-MCL********-PR06-EN-P
RS-82551fe8ab5f14650a6846a001697ff3-9-en-US-3
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Title
Type of Documentation
Document Typecode
Internal File Reference
MCL Ironless Linear Motors

Table of Contents
Page
1 Introduction to the product............................................................................................. 1
1.1 Fields of application................................................................................................................................ 1
1.2 Basic features......................................................................................................................................... 2
1.3 Setup...................................................................................................................................................... 2
1.4 Comparison ironless with ferreous linear motors.................................................................................... 3
1.5 Motor power spectrum............................................................................................................................ 4
1.6 About this documentation....................................................................................................................... 4
1.6.1 Editions of this documentation............................................................................................................. 4
1.6.2 Document structure............................................................................................................................. 5
1.6.3 Information presentation...................................................................................................................... 5
1.6.4 Further documentation........................................................................................................................ 6
1.6.5 Standards............................................................................................................................................ 7
1.6.6 Additional components........................................................................................................................ 7
1.6.7 Your feedback..................................................................................................................................... 7
2 Important instructions on use......................................................................................... 9
2.1 Appropriate use...................................................................................................................................... 9
2.1.1 Introduction.......................................................................................................................................... 9
2.1.2 Areas of use and application............................................................................................................... 9
2.2 Inappropriate use.................................................................................................................................. 10
3 Safety instructions for electric drives and controls....................................................... 11
3.1 Definitions of terms............................................................................................................................... 11
3.2 General information.............................................................................................................................. 12
3.2.1 Using the Safety instructions and passing them on to others............................................................ 12
3.2.2 Requirements for safe use................................................................................................................ 12
3.2.3 Hazards by improper use.................................................................................................................. 13
3.3 Instructions with regard to specific dangers.......................................................................................... 14
3.3.1 Protection against contact with electrical parts and housings........................................................... 14
3.3.2 Protective extra-low voltage as protection against electric shock .................................................... 15
3.3.3 Protection against dangerous movements........................................................................................ 16
3.3.4 Protection against electromagnetic and magnetic fields during operation and mounting.................. 17
3.3.5 Protection against contact with hot parts........................................................................................... 18
3.3.6 Protection during handling and mounting.......................................................................................... 18
3.3.7 Battery safety..................................................................................................................................... 18
3.3.8 Protection against pressurized systems............................................................................................ 19
3.4 Explanation of signal words and the Safety alert symbol..................................................................... 20
4 Technical data.............................................................................................................. 21
4.1 Explanations about technical data........................................................................................................ 21
4.1.1 Introduction........................................................................................................................................ 21
4.1.2 Operating behavior............................................................................................................................ 21
4.1.3 Description of specified sizes............................................................................................................ 25
MCL Ironless Linear Motors I
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Page
4.2 IndraSize............................................................................................................................................... 26
4.3 General technical data.......................................................................................................................... 27
4.4 Frame size 015..................................................................................................................................... 28
4.4.1 Data sheet MCP015.......................................................................................................................... 28
4.4.2 Data sheet MCS015.......................................................................................................................... 28
4.4.3 Motor characteristic curve frame size 015......................................................................................... 29
4.5 Frame size 020..................................................................................................................................... 30
4.5.1 Data sheet MCP020.......................................................................................................................... 30
4.5.2 Data sheet MCS020.......................................................................................................................... 30
4.5.3 Motor characteristic curves frame size 020....................................................................................... 31
4.6 Frame size 030..................................................................................................................................... 33
4.6.1 Data Sheet MCP030.......................................................................................................................... 33
4.6.2 Data sheet MCS030.......................................................................................................................... 33
4.6.3 Motor characteristic curve frame size 030......................................................................................... 34
4.7 Frame size 040..................................................................................................................................... 36
4.7.1 Data sheet MCP040.......................................................................................................................... 36
4.7.2 Data sheet MCS040.......................................................................................................................... 37
4.7.3 Motor characteristic curves frame size 040....................................................................................... 37
4.8 Frame size 070..................................................................................................................................... 40
4.8.1 Data sheet MCP070.......................................................................................................................... 40
4.8.2 Data sheet MCS070.......................................................................................................................... 41
4.8.3 Motor characteristic curve frame size 070......................................................................................... 41
5 Dimension sheets........................................................................................................ 45
5.1 Specifications........................................................................................................................................ 45
5.1.1 Air gap and installation height........................................................................................................... 45
5.1.2 Installation dimensions MCL015........................................................................................................ 46
5.1.3 Installation dimensions MCL020 ... 070............................................................................................. 47
5.1.4 Parallelism and symmetry of machine parts...................................................................................... 48
5.2 Dimensional sheets for MCL015........................................................................................................... 50
5.3 Dimensional sheets MCL020................................................................................................................ 52
5.4 Dimensional sheets for MCL030........................................................................................................... 54
5.5 Dimensional sheets MCL040................................................................................................................ 56
5.6 Dimensional sheets MCL070................................................................................................................ 58
6 Identification................................................................................................................. 61
6.1 Type codes .......................................................................................................................................... 61
6.1.1 General.............................................................................................................................................. 61
6.1.2 Type codes primary part MCP........................................................................................................... 61
6.1.3 Type code MCS secondary part........................................................................................................ 63
6.1.4 Type code frame size 015................................................................................................................. 64
6.1.5 Type code frame size 020................................................................................................................. 66
6.1.6 Type code frame size 030................................................................................................................. 68
6.1.7 Type code frame size 040................................................................................................................. 70
6.1.8 Type code frame size 070................................................................................................................. 72
II
Table of Contents
MCL Ironless Linear Motors
Bosch Rexroth AG R911330592_Edition 06

Page
6.2 Identification.......................................................................................................................................... 74
6.2.1 Identification MCP primary part ........................................................................................................ 74
6.2.2 Identification MCS secondary part..................................................................................................... 75
6.2.3 Certification mark............................................................................................................................... 76
7 Accessories and options.............................................................................................. 77
7.1 Hall unit................................................................................................................................................. 77
7.1.1 General.............................................................................................................................................. 77
7.1.2 Hall unit function................................................................................................................................ 77
7.1.3 Hall unit assembly/Disassembly........................................................................................................ 80
7.1.4 Ordering code separate Hall unit....................................................................................................... 81
7.2 Hall unit adapter box SHL03.1 for digital Hall unit................................................................................ 81
7.2.1 General mode of functioning............................................................................................................. 81
7.2.2 Ordering code.................................................................................................................................... 81
8 Connection technique.................................................................................................. 83
8.1 Notes.................................................................................................................................................... 83
8.2 Power connection ................................................................................................................................ 83
8.2.1 Connection cable on primary part...................................................................................................... 83
8.2.2 Assembly Connection cable on primary part..................................................................................... 85
8.2.3 Connection power ............................................................................................................................. 86
8.2.4 Installation of power connection........................................................................................................ 88
8.3 Sensors................................................................................................................................................. 90
8.3.1 Connection temperature sensor........................................................................................................ 90
8.3.2 Connection Hall unit.......................................................................................................................... 90
8.3.3 Assembly Hall unit connection cable................................................................................................. 92
8.3.4 Connect digital Hall unit..................................................................................................................... 93
8.3.5 Connect analog Hall unit................................................................................................................... 94
8.4 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 Installation altitude and ambient conditions........................................................................................ 100
9.4 Environmental conditions during operation......................................................................................... 101
9.5 Type of protection............................................................................................................................... 102
9.6 Acceptances and approvals................................................................................................................ 102
9.6.1 CE.................................................................................................................................................... 102
9.6.2 EAC................................................................................................................................................. 102
9.6.3 RoHS............................................................................................................................................... 103
9.6.4 China RoHS 2.................................................................................................................................. 103
9.7 Magnetic fields.................................................................................................................................... 103
MCL Ironless Linear Motors III
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R911330592_Edition 06 Bosch Rexroth AG

Page
9.8 Noise emission................................................................................................................................... 104
9.9 Thermal behavior................................................................................................................................ 105
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
9.13 Arrangement of motor components.................................................................................................... 112
9.13.1 Single arrangement......................................................................................................................... 112
9.13.2 Several motors per axis................................................................................................................... 113
9.13.3 Arrangement of secondary parts..................................................................................................... 119
9.13.4 Vertical axis .................................................................................................................................... 119
9.14 Length measuring system................................................................................................................... 120
9.14.1 General............................................................................................................................................ 120
9.14.2 Selection criteria for length measuring system ............................................................................... 120
9.15 Linear guiding systems....................................................................................................................... 121
9.16 Braking systems and holding devices................................................................................................. 122
9.17 End position shock absorber ............................................................................................................. 123
9.18 Axis cover systems............................................................................................................................. 123
9.19 Motor control and regulation............................................................................................................... 123
9.19.1 General............................................................................................................................................ 123
9.19.2 Drive controllers............................................................................................................................... 124
9.19.3 Control systems............................................................................................................................... 124
9.20 Deactivation upon EMERGENCY STOP and in the event of a malfunction ...................................... 125
9.20.1 General............................................................................................................................................ 125
9.20.2 Deactivation by the drive................................................................................................................. 125
9.20.3 Deactivation by a master control..................................................................................................... 126
9.20.4 Deactivation via mechanical braking device.................................................................................... 126
9.20.5 Response to a power outage .......................................................................................................... 126
9.20.6 Short-circuit of DC bus.................................................................................................................... 128
9.21 Position and velocity resolution.......................................................................................................... 128
9.21.1 Drive internal position resolution and position accuracy ................................................................. 128
9.21.2 Velocity resolution........................................................................................................................... 129
9.22 Thermal connection - Installation modes............................................................................................ 129
9.23 Operation at or near motor standstill.................................................................................................. 132
10 Motor-control combinations........................................................................................ 133
10.1 General............................................................................................................................................... 133
10.2 Motor-control combinations with NYCe 4000..................................................................................... 133
10.3 Motor-control combinations with IndraDrive Cs.................................................................................. 134
11 Motor dimensioning.................................................................................................... 135
11.1 General procedure.............................................................................................................................. 135
IV
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MCL Ironless Linear Motors
Bosch Rexroth AG R911330592_Edition 06

Page
11.2 Basic formulae.................................................................................................................................... 136
11.2.1 General movement equations ........................................................................................................ 136
11.2.2 Feed forces...................................................................................................................................... 137
11.2.3 Average velocity.............................................................................................................................. 140
11.2.4 Trapezoidal velocity profile.............................................................................................................. 141
11.2.5 Trapezoidal velocity profile.............................................................................................................. 145
11.2.6 Sinusoidal velocity profile ............................................................................................................... 146
11.3 Duty cycle and feed force................................................................................................................... 149
11.3.1 General............................................................................................................................................ 149
11.3.2 Determining the duty cycle.............................................................................................................. 149
11.4 Determining the drive power............................................................................................................... 150
11.4.1 General............................................................................................................................................ 150
11.4.2 Continuous power ........................................................................................................................... 150
11.4.3 Maximum output.............................................................................................................................. 151
11.4.4 Power loss ...................................................................................................................................... 152
11.5 Energy regeneration .......................................................................................................................... 152
11.6 Efficiency............................................................................................................................................ 153
12 Handling, transport and storage................................................................................. 155
12.1 Delivery status and packaging............................................................................................................ 155
12.1.1 Primary parts................................................................................................................................... 155
12.1.2 Secondary parts.............................................................................................................................. 155
12.2 Testing of motor components............................................................................................................. 155
12.2.1 Factory checks of the motor components ....................................................................................... 155
12.3 Transport and storage........................................................................................................................ 156
12.3.1 Notes about transport...................................................................................................................... 156
12.3.2 Information on storage..................................................................................................................... 157
13 Assembly................................................................................................................... 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 .......................................................................................................................... 165
14 Commissioning, operation and maintenance............................................................. 167
14.1 General............................................................................................................................................... 167
14.2 General requirements ........................................................................................................................ 167
14.2.1 General............................................................................................................................................ 167
14.2.2 Checking all electrical and mechanical components....................................................................... 167
14.2.3 Tools................................................................................................................................................ 168
14.3 General commissioning procedure..................................................................................................... 168
14.4 Parameterization................................................................................................................................. 170
MCL Ironless Linear Motors V
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R911330592_Edition 06 Bosch Rexroth AG

Page
14.4.1 General............................................................................................................................................ 170
14.4.2 Entering motor parameters.............................................................................................................. 170
14.4.3 Motor parameter at parallal arrangement........................................................................................ 170
14.4.4 Entering length measuring system parameter................................................................................. 171
14.4.5 Entering drive limitations and application-related parameters......................................................... 172
14.5 Determining the polarity of the linear scale......................................................................................... 173
14.6 Commutation adjustment.................................................................................................................... 174
14.6.1 General............................................................................................................................................ 174
14.6.2 Sinusoidal procedure....................................................................................................................... 176
14.6.3 Hall sensor procedure..................................................................................................................... 176
14.6.4 Measuring procedure: Measuring of the relation between primary and secondary part.................. 177
14.7 Setting and optimizing the control loop............................................................................................... 179
14.7.1 General procedure........................................................................................................................... 179
14.7.2 Parameter value assignments and optimization of Gantry axes..................................................... 182
14.7.3 Estimating the moved mass using a velocity ramp ......................................................................... 183
14.8 Maintenance and checking of motor components.............................................................................. 185
14.8.1 General............................................................................................................................................ 185
14.8.2 Checking of motor and additional components .............................................................................. 185
14.8.3 Electrical check of motor components............................................................................................. 185
14.9 Operation with third-party controllers.................................................................................................. 186
14.10 Environmental protection and disposal .............................................................................................. 186
14.10.1 Environmental protection................................................................................................................. 186
14.10.2 Disposal........................................................................................................................................... 186
15 Service and support................................................................................................... 189
Index.......................................................................................................................... 191
VI/197
Table of Contents
MCL Ironless Linear Motors
Bosch Rexroth AG R911330592_Edition 06

1 Introduction to the product
1.1 Fields of application
Continuously increasing demands on the economic benefit of electric ma‐
chines require new problem-solving approaches to fulfill the requirements on
dynamic, accuracy and synchronization. Conventional NC-drives, consisting
of a rotary electrical motor and mechanical transmission elements like gear‐
boxes, belt transmissions or gear rack pinions, cannot fulfill these demands
or, only with high effort.
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
● Semi-conductor technology (z.B. wafer inspection and bonding)
● Medical technology (e.g. transport of pipettes)
● Solar technology (e.g. 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
screw, 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 groups of Bosch
Rexroth Electric Drives and Controls, please refer to the online
product catalog: http://www.boschrexroth.com/indradyn.
MCL Ironless Linear Motors 1/197
Introduction to the product
R911330592_Edition 06 Bosch Rexroth AG

1.2 Basic features
Product 3~ PM motor
Type MCL consist of MCP and MCS
Ambient temperature during oper‐
ation 0 … 40 °C
Protection class (EN 60034-5) IP00 (IP20)
Cooling mode (EN 60034-6) IC410, Self-cooling
Installation altitude 0 ... 1000 m above MSL (without derating)
Thermal class (EN 60034-1) 130 (B)
Encoder system Hall sensor digital
SUP-E01-D15-MCP020
SUP-E01-D30-MCP030/040/070
Hall sensor analog
SUP-E01-A15-MCP020
SUP-E01-A30-MCP030/040/070
Electrical connection Connection cable with open cable ends
shielded cable (3x power + 1x PE, 2x KTY)
Mechanical protection Primary part moulded with synthetic resin
Magnets of the secondary part coated with synthetic resin
Motor ends
1.3 Setup
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 you want.
The motor type designation depends on the ironless primary part. The desig‐
nation is as follows:
●MCL: Motor Coreless Linear
●MCL: Motor Coreless Primary part
●MCS: Motor Coreless Secondary part
2/197
Introduction to the product
MCL Ironless Linear Motors
Bosch Rexroth AG R911330592_Edition 06